Service Manual 9/10 Speed Transmission
Contents
1. g O 082 13345 au S Q oo ob S lt o g MAINTENANCE MODELS Section l PS 9 10 D solvents could damage filter components and affect proper operation N 4 Blow air through the filter inside and outside to dislodge surface Filter Regulator The 9 speed uses a filter regulator preset at 55 6 1Ibs DB Use only petroleum based solvents to clean parts Other types of contaminants Otherwise these contaminants could affect proper filter a 9 operation and lead to equipment damage e Do not disassemble the regulator section 9 it is not field repairable If itis damaged replace it t regulator malfunction is indicated replace the entire unit 1 Clean or replace the filter element 7 every 6 12 months or whenever slow shifting is encountered The element should be replaced after three cleanings If 2 To service the filter section shut off the air pressure Unscrew the bowl 1 and remove the O ring 2 Unscrew the stud 4 Remove the louver 5 upper gasket 6 element 7 and lower gasket 8 from the stud Do not disassemble the regulator section 9 a 3 After cleaning inspect the parts carefully Replace any damaged parts 4 Reassemble the unit by first installing the element 7 on the stud 4 so that the large end of the internal taper thinnest wall section is toward the hex on the stud Torque the stud to 5 10 Ibs inch gt k daarf2. P Fan out of balance or blades bent Defective vibration dampers Crankshaft out of balance Flywheel out of balance Loose flywheel mounting bolts Rough engine idle producing rattle in gear train Clutch assembly out of balance Loose or broken engine mounts Power take off engaged Worn universal joints Driveshaft out of balance Universal joint angles out of phase or at excessive angles Center bearings in driveline dry not mounted properly Wheels out of balance Tire treads humming or vibrating at certain speeds Air leaks on suction side of induction system especially with turbo chargers SPICER TRANSMISSIONS PS 9 10 Mechanics should try to locate and eliminate noise by means other than a transmission removal or an overhaul However if the noise appears to be in the transmission try to determine what position the gear shift lever is in when the noise occurs If the noise is evident in only one gear position the problem is generally traceable to the operating gears Next try to categorize the noise into the following classifications A Growling humming and grinding These noises are caused by worn chipped rough or cracked gears As gears continue to wear the grinding noise will be noticeable particularly in the gear position that throws the greatest load on the worn gear A lack of lubricant or use of improper lubricant can also result in growling and grinding noises This is because ther
3. WASHER CLUTCH DRIVE GEAR BEARING CONE THRUST PLATE BEARING CONE THRUST HIGH RANGE Y LOW RANGE pa DRIVE GEAR OUTPUT NUT OUTPUT SHAFT YOKE WASHER SPACER OR SPEEDOMETER GEAR 16 tech line 800 401 9866 www ttcautomotive com RANGE CASE DISASSEMBLY MODELS Section VI PS 9 10 1 Begin the teardown by setting the transmission on a bench 2 To remove an air line from a fitting like the one shown here push Remove the shift tower and air lines the bushing in with a small screwdriver or your fingernail and pull the tubing 3 Remove the ULG interlock plate retainer and gasket Also remove the 4 Next remove the air control valve and gasket the air lines and the three springs and poppet balls three interlock pins 5 Remove the SPICER backup light switch and pin 17 tech line 800 401 9866 www ttcautomotive com RANGE CASE DISASSEMBLY MODELS Section VI PS 9 10 6 Remove the two clutch housing bolts from the case Also remove 7 Stand the transmission on end on a workbench that all but four clutch housing to case bolts contains a hole for the drive gear Lift the transmission with a hoist 8 Continue by removing the end yoke or flange and the 9 The range piston is removed next Also remove the O ring on the speedometer gear shift rod and oil ring under piston housing 10 Remove the countershaft be
4. b r ih w a 1 SS RE oe 5 Apply a wipe coat of Dow Corning DC7 Silicone Grease or equivalent to the O ring 2 seating surfaces on the regulator 9 and bowl 1 Apply a light even coat of Molykote G or equivalent to the bowl threads Torque the bowl to 5 10 Ibs aii 7 inch If the drain valve 3 was removed reinstall it and torque it to 10 15 Ibs Inch C mai a SPICER TRANSMISSIONS tech line 800 401 9866 www ttcautomotive com MAINTENANCE MODELS Section II Lubrication D CAUTION To ensure proper lubrication and operating temperatures in this unit the proper lubricants must be used Correct oil levels must be maintained Spicer recommends using only lubricants produced by reputable well known suppliers If you want to use a lubricant not specified below please contact your local truck dealer to determine whether the lubricant is suitable for your purposes Recommended Lubricants The lubricants listed below are recommended for use in all Spicer mechanical transmissions auxiliaries and transfer cases Oil Changes Many factors influence oil change periods Changes should be scheduled at three years or 250 000 miles with synthetic engine oil for normal over the highway operations Off highway use usually requires an oil change every 1 000 hours The oil level in the transmission should be checked every 5 000 miles 8 045 km on highway or every 40 hours in off highway operat
5. Bulletin No SPTS0130807 August 2007 SPICER TRANSMISSIONS 9 10 Speed Transmission MODELS PS95 9A PS125 9A PS140 9A PSO125 9A PSO140 9A PSO150 9A Service Manual PSO100 10S PSO125 10S PSO140 10S PS0150 10S SAFETY FIRST Carefully read this service manual General Safety Precautions before beginning any work on your Spicer transmission Use a hoist whenever lifting the transmission or shaft assemblies Using a hoist can help prevent Throughout this literature you will see symbols that warn of muscle strain or other possible injuries potential physical danger or product damage if the accompanying instructions aren t followed Here are the Always wear safety glasses when working on the symbols and their meanings transmissions to help prevent possible eye injury due to small parts such as snap rings or metal Be careful when picking up gears or other sharp This symbol indicates a potentialy hazardous situation If the instructions aren t followed the result could be death or serious injury chips that may fly up unexpectedly during a teardownorrebuild a components If you aren t careful you could cut your ERIS symbo indicates that yi must do some thing in hands Consider wearing heavy cloth gloves or order for the transmission to function properly For covering sharp objects with shop towels before picking example you must use only one gasket underneath them up the shift tower
6. DISASSEMBLY MAIN CASE DISASSEMBLY CASE amp SHIFT FORKS EXPLODED DRAWING CLUTCH HOUSING EXPLODED DRAWING MAIN CASE OPTILUBE EXPLODED DRAWING MAIN CASE GEARS EXPLODED DRAWING DISASSEMBLY COUNTERSHAFT DISASSEMBLY amp REASSEMBLY CLEANING amp INSPECTION PROCEDURES MAIN CASE REASSEMBLY RANGE CASE REASSEMBLY REMOTE CONTROL REASSEMBLY SHIFT TOWER REASSEMBLY TROUBLESHOOTING TABLE OF CONTENTS 11 12 30 31 33 34 38 39 40 41 44 TRANSMISSIONS GENERAL INFORMATION 9 SPEED Gear Ratios O D Ratio 13 95 10 40 6 74 4 85 3 55 2 65 1 89 Aor 1 00 0 74 Pro Shift Nine Speeds Weight Clutch Housing PS95 9A 284 288 kgm 1 or 2 PS140 9A PSO125 9A PSO140 9A PSO150 9A 625 635 Ibs lron SAE 284 288 kgm 1 or 2 weight includes clutch housing SPICER tech line 800 401 9866 General Application Guidelines GVW HP Range RPM Range Engine Types Lube Capacity 8 5 liters 8 5 liters On Highway Use PSO100 80 000 lbs PSO125 110 000lbs PSO140 amp PSO150 140 000 Ibs 250 430 1 600 2 400 8 10 and 14 liter diesel m Simple Shift Patterns w 6 V BN 2 A 7 9 V EY SY Overall Length PTO Speed of engin 4 www ttcautomotive com GENERAL INFORMATION 10 SPEED Gear Rev 1st 2nd 3rd Ath Gear Ratios Ratio 14 02 12 54 9 24 6 68 4 80 3 60 General Application Guidelines O
7. 9866 www ttcautomotive com REMOTE CONTROL DISASSEMBLY Section V 1 Remove the six bolts Separate the remote control from the Transmission 2 Disconnect the tie rod from the housing and the selection lever 3 Disconnect the selection lever from the outer shift lever 4 Remove the bolts from the outer shift lever Tap the lever off the shift rod 5 Cut the tie straps from the boot and remove it SHIFT ROD SELECTION LEVER tech line 800 401 9866 MODELS PS 9 10 6 Remove the shift finger bolts and tap the finger off the rod 7 Pullthe rod from the housing 8 To disassemble the selection lever subassembly first remove the snap ring and retainer plate 9 The bearing race ball stud and a final bearing race are removed next 10 Remove the two springs and the boot BREATHER u a HOUSING lt 14 www ttcautomotive com RANGE CASE DISASSEMBLY MODELS Section VI PS 9 10 Range Case Exploded Drawing De AIR FITTING PISTON i Oo NUT Na e RING5 PLUG WASHER OU 5 BEARING CAP sruo SPACER y RANGE FORK rt BOLT BEARING CAP NG BRACKET AIR VALVE po REG GUAN FITTING 15 tech line 800 401 9866 www ttcautomotive com SPICER MODELS RANGE CASE DISASSEMBLY SPICER PS 9 10 Range Gears Exploded Drawing BEARING RANGE COUNTERSHAFT ASSEMBLY x REVERSE RANGE IDLER GEAR SYNCHRONIZER
8. If it is eliminated or more than one l gasketis used binding can occur This would prevent proper shifting of the transmission and could damage the unit When draining the transmission prior to working on it be careful to let the unit cool down first Otherwise hot transmission fluid could cause burns This symbol indicates that you must NOT do something in order to avoid damaging the transmission For example you mustnotuse sealant underneath the shift tower Using sealant underneath the tower will prevent proper interlock functioning and could damage the unit Be sure you understand all procedures and instructions in this manual before you begin working on your Spicer Transmission If you have any questions contact your Spicer Transmission representative The information in this service manual was current at the time of publication This information is subject to change at any time without notice 2 SPIC SECTION SECTION II SECTION III SECTION IV SECTION V SECTION VI SECTION VII SECTION VIII SECTION IX SECTION X SECTION XI SECTION XII SECTION XIII SECTION XIV GENERAL INFORMATION 9 SPEED SPECIFICATIONS 10 SPEED SPECIFICATIONS TORQUE SPECIFICATIONS DRIVER INSTRUCTIONS MAINTENANCE AIR LINE PIPING DIAGRAM FILTER REGULATOR LUBRICATION GENERAL DISASSEMBLY SHIFT TOWER DISASSEMBLY REMOTE CONTROL DISASSEMBLY RANGE CASE DISASSEMBLY CASE EXPLODED DRAWING GEARS EXPLODED DRAWING
9. it to build to maximum air pressure A With the clutch pedal fully depressed to engage the clutch brake see Clutch Brake B Position the range selector to low range Move the gear shift lever into 1st gear position UP FOR HIGH RANGE DOWN FOR LOW RANGE A Release the tractor parking brakes and trailer parking brakes where applicable Release the clutch pedal gradually to full position Depress the throttle to start the vehicle moving Depress the clutch pedal Move the gear shift lever to neutral See Double Clutching Upshifting D Then move the gear shift lever to 2nd gear B C A After attaining optima speed in 1st gear B C MODELS PS 9 10 A Continue the above procedures through 5th gear position A A To continue upshifting 6th gearthrough 9th gear B Preselect high range on the range selector C Depress the clutch pedal B Move the gear shift lever from the 5th gear position to neutral See Double Clutching Upshifting E Then move the gear shift lever into 6th gear position UP FOR HIGH RANGE DOWN FOR Er LOW RANGE 7 A After attaining optimal speed in 6th gear B Depress the clutch pedal C Move the gear shift lever to neutral see Double Clutching Upshifting D Then move the gear shift lever into 7th gear position 8 A Continue these procedures for 8th 9th gear positions Downshifting Downshifting is actually just the reverse of up
10. overload Dirt More than 90 of all ball bearing failures are caused by dirt which is always abrasive Dirt may enter the bearings during assembly of units or may be carried into the bearing by the lubricant while in service Dirt also may enter bearings through seals the breather or even dirty containers used for addition or change of lubricant Softer material such as dirt or dust usually forms abrasive paste or lapping compounds within the bearings The pressure between the balls and raceways makes a perfect pulverizer The rolling motion tends to entrap and hold the abrasives As the balls and raceways wear the bearings become noisy The lapping action tends to increase rapidly as the fine steel from the balls and rollway adds to the lapping material Hard coarse material such as metal chips may enter the bearings during assembly from tools such as hammers drifts and power chisels It may also be created within the unit during service from raking teeth These chips produce small indentations in balls and races When these hard particles jam between the balls and races it may cause the inner race to turn on the shaft or the outer race to turn in the housing Fatigue All bearings are subject to fatigue and must be replaced eventually Your own operating experience will dictate mileage replacement of bearings showing only normal wear 43 TROUBLESHOOTING MODELS Section XIV Corrosion Water acid and corros
11. FT DISASSEMBLY amp REASSEMBLY MODELS Section VIII PS 9 10 T nii ai Sr Xa rar ku aaa 2 Es Ki _ gc iu u s i ll 2 If a straight edge is placed between the teeth painted to show the timing marks every gear on the countershaft will be in line with the blind spline on the countershaft When the shafts are in time these marks will be directly across from each other 1 This view of the countershaft shows the direction of the gears Thegears are secured with three keys PRESSING DIRECTIONS Overdrive Direct Drive When pressing the gears onto the countershaft it is very important to assemble in the proper direction The bearing gear and shim to the left of the black bar in the photo above are pressed on from one direction all other items are pressed on from the other direction When pressing the gears onto the countershaft it is very important to assemble in the proper direction The bearing gear and shim to the left of the black bar in the photo above are pressed on from one direction all other items are pressed on from the other direction 29 SP CER tech line 800 401 9866 www ttcautomotive com TRANSMISSIONS CLEANING amp INSPECTION PROCEDURES Section IX Cleaning Prior to reassembly wash all parts thoroughly A Do not use water or steam to clean internal components If you do it could cause corro
12. aring retainer caps and the air 11 Remove the output bearing cap and shims regulator valve SPICER Ki tech line 800 401 9866 www ttcautomotive com RANGE CASE DISASSEMBLY MODELS Section VI PS 9 10 12 Remove the range case bolts Using pry bars in the milled slots 13 Use a chain hoist to lift the range case from the unit will make case removal easier 14 The output shaft and low range gear will remain with the range 15 Be aware that separating the synchronizer will suddenly case Remove the range synchronizer and fork assembly release the springs Always wear safety glasses to protect your eyes when servicing transmissions Synchronizer replacement parts may be purchased separately 16 Remove retaining bolt and washer next remove the synchronizer cup and high range clutch gear o 19 RANGE CASE DISASSEMBLY MODELS Section VI PS 9 10 17 Lift high range gear from the case 19 Simultaneously lift both countershafts straight up to 20 Remove the retaining bolt and washer then remove the remove them Now remove the mainshaft reverse gear and rear countershaft reverse gears thrust plate together T i em a a 21 Remove the oil pump housing screws next remove oil pump assembly SPICER 20 tech line 800 401 9866 www ttcautomotive com GEARS amp RELATED PARTS MODELS Section VI PS 9 10 _ 2 L Ka p M i a i s p aa a z 22 Remove the left countershaft re
13. because of improper shifting H Binding or interference of shift lever with other objects or rods inside the cab or near the remote control island J Clutch dragging K Free running gears seized or galled on either the thrust face or diameters A Sticking in Gear A Clutch not releasing Also check remote units such as a hydraulic or air assist Note On some units employing a full air control for clutch release air pressure of approximately 60 Ibs or more must be secured before the clutch can be released Do not leave these vehicles parked in gear B Sliding clutch gears tight on splines C Chips wedged between or under splines of shaft and gear D Improper adjustment excessive wear or lost motion in shifter linkage SPIC PS 9 10 Bearing Failures The service life of most transmissions main and auxiliary is governed by the life of the bearings The majority of bearing failures can be attributed to vibration and dirt Some other prominent reasons for unit bearing failures are A Fatigue of raceways or balls B Wrong type or grade of lubricant C Lack of lubricant D Broken retainers brinelled races and fretting caused by vibration E Bearings set up too tight or too loose F Improper installation resulting in brinelled bearings G Improper fit of shafts or bore H Acid etching due to water in lube I Vehicle overload or too large an engine for the transmission resulting in
14. bly into the range case The tapered bearing and spacer must be pressed onto the shaft diagram OUTPUT BEARING CAP DISTANCE A 15 Continue by applying Loctite 515 or the equivalent to the 16 The output bearing cap is installed next To shim the output bearing cap measure the distance from the end of the case to the housing face then lower the rear case into place Low range gear should be centered between the countershafts Torque the case bearing cup A bolts to 78 98 ft Ibs DISTANCE B m eee o l en BEARING ASSEMBLY gt un a eel I a RANGE CASE 17 Next measure from the face of the bearing cap to the end of the pilot B Subtract the two figures and shim accordingly You can be cap and reinstall it Secure it with bolts tightened to 34 41 ft Ibs within four thousandths of an inch so select the shims that will give you the amount closest to what is required 18 Apply purple Loctite 515 or the equivalent to the output bearing 36 RANGE CAS REASSEMBLY MODELS Section XI PS 9 10 19 Reinstall the countershaft bearings in the case Apply purple 20 Install new O rings on the piston and in the housing Then install Loctite 515 or the equivalent to the bearing caps and install them the piston The counterbore on the piston should face the new O Align the bearing caps with the oil holes in the case to help ensure ring on the rod proper lub
15. cations 9 Check the remote control dimensions shown on the illustrations below 39 www ttcautomotive com SHIFT TOWER REASSEMBLY MODELS Section XIII PS 9 10 SHIFT PATTERN INSERT 1 Place the two opposing springs and the lower socket into the shift tower A ro NUT 2 Place the lever through the tower and supportit in a vise nn ae WASHERS NY 3 Install the upper socket Once the socket clears the groove install the snap ring 4 Seat the boot properly and secure it with two tie down straps SHIFT KNOB O 5 When the tower is installed onto the transmission housing one P single gasket must be in place under the tower assembly for proper gear ee CASTELLATED NUT selection Failure to use any gasket or using more than one gasket under i the tower may cause binding and damage to the unit rm UPPER LEVER Br UPPER SOCKET amp lt LOWER LEVER Cal BREATHER 40 SP CER tech line 800 401 9866 www ttcautomotive com TRANSMISSIONS TROUBLESHOOTING MODELS Section XIV Noisy Operation Noise is usually a very elusive problem and is generally not the fault of the transmission Mechanics should road test the vehicle to determine if the driver s complaint of noise is actually in the transmission In numerous instances where drivers have insisted noise was coming from the transmission investigations revealed it was caused by one ofthe following conditions
16. cautomotive com MAIN CASE DISASSEMBLY MODELS Section VII PS 9 10 11 Remove countershafts 12 Remove mainshaft and 4th 5th clutch collar SPICER a tech line 800 401 9866 www ttcautomotive com MAIN CASE DISASSEMBLY MODELS Section VII PS 9 10 13 If the 4th 5th speed shift fork shoes are worn replace them It is not necessary to remove the fork to replace the fork shoes 15 The 5th speed direct gear or 4th speed overdrive gear is removed next The oil troughs can remain with the case 17 Notice that the fork slot the 4th 5th speed shift collar is wider than the fork slot on the other collars in an overdrive transmission In a direct transmission all collars will be the same 19 To disassemble the input shaft assembly remove the snap ring Press the bearing off the shaft Make sure you wear safety glasses to protect your eyes 14 To remove 4th 5th speed shift fork remove the snap ring Push the pin through the bracket Lift the fork from the unit Pa e 16 Remove countershaft front bearing cups as shown 18 To remove the input shaft and bearing cap remove the four cap retaining bolts Pull the shaft from the housing It may be helpful to place two bolts in the threaded bearing cap holes Tightening the bolts will draw the bearing cap from the housing Tap the input shaft out of the clutch housing toward the front of the transmission 28 COUNTERSHA
17. e is insufficient lubricant to cool and cover the gears which allows metal to metal contact B Hissing thumping and bumping Hissing noises can be caused by bad bearings As bearings wear and retainers start to break up etc the noise could change to a thumping or bumping C Gear whine This is usually caused by lack of backlash between mating gears Improper PTO shimming is the big offender here D Vibration Today s improved highways mean entire power trains are cruising at higher RPM s These higher soeeds mean damage caused by driveline vibration is more obvious than in the past When the maximum RPM of a shaft is reached it begins to bow A resonant hum can be heard and a vibration will be set up This type vibration can cause gear seizures broken synchronizer pins bearing failures brinelling and corrosion During acceleration and deceleration the shaft may pass through half critical vibration half the maximum RPM of the shaft Awhine or boom may be heard at this point E Metallic rattles These noises within the transmission usually result from a variety of conditions Engine torsional vibrations are transmitted to the transmission through the clutch In heavy duty equipment clutch discs with vibration dampers are not used so a rattle particularly in neutral is common with diesel equipment In general engine speeds should be 600 RPM or above to eliminate objectionable rattles and vibration during the idle A def
18. ective or faulty injector would cause a rough or lower idle speed and possibly a rattle in the transmission Arattle can also be caused by excessive backlash between the PTO input gear and the transmission output gear 41 tech line 800 401 9866 www ttcautomotive com TROUBLESHOOTING MODELS Section XIV Noise in Neutral Possible Causes A Misalignment of transmission B Worn flywheel pilot bearing C Worn or scored countershaft bearings D Sprung or worn countershaft E Excessive backlash in gears F Scuffed gear tooth contact surface G Insufficient lubrication Use of incorrect grade of lubricant M AA RG L Noise In Gear Possible Causes A Rough chipped or tapered sliding gear teeth B Noisy speedometer gears C Excessive end play of countershaft gears D Refer to conditions listed under Noise in Neutral Oil Leaks Possible Causes A Oil level too high B Wrong lubricant in unit C Seals defective wrong type or omitted from bearing cap D Transmission breather omitted or plugged internally E Capscrews loose omitted or missing from remote control shifter tower bearing caps PTO or covers F Oil drain back openings in bearing caps or case plugged with varnish or dirt G Gaskets shifted or squeezed out of position broken gaskets with pieces still under the shift tower H Cracks or holesin castings 1 Loose drain plug J Oil leakage from
19. engine K Loose speedometer adaptor or connections SPICER PS 9 10 Walking or Jumping Out of Gear If the units are walking out of gear it could be caused by A External interference such as the floorboard opening preventing full engagement or B An internal malfunction such as worn clutching teeth allowing the transmission to shift out of position If a remote control is being used make sure it is functioning properly before the transmission is blamed for the problem Note whether the unit walks out of gear under drive while pulling a load or on a coast load Also notice whether the gear hop occurs on smooth roads or only on rough roads Items that would prevent full engagement of gears are A Improperly positioned forward remote control which limits full travel forward and backward from the remote neutral position B Improper length shift rails or linkage that limits travel of forward remote from neutral position C Loose bell cranks sloppy ball and socket joints D Shift rails cables etc too spongy or flexible or not secured properly at both ends E Worn or loose engine mounts if forward unit is mounted to frame F Forward remote mount too flimsy or loose on the frame G Setscrews loose at remote control joints on shift forks inside remote H Shift fork pads or groove sliding gear or collar worn excessively 1 Transmission and engine out of alignment either vertically or hori
20. gear with timing marks on countershaft head end gear SPICER tech line 800 401 9866 www ttcautomotive com MAIN CASE REASSEMBLY MODELS Section X PS 9 10 7 Leave countershafts tilted outward as shown 8 Slide 3rd gear clutching teeth up and 4th gear clutch teeth down speed gears over mainshaft 9 Tilt countershafts inward to engage 3rd 4th speed gears Make sure there is equal spacing around the mainshaft and internal teeth LA 11 Slide 2nd speed gear onto mating countershaft gears Make 12 Install 1st speed gear as shown Clutching teeth facing up sure to maintain equal spacing around mainshaft Clutching teeth facing down SPICER tech line 800 401 9866 www ttcautomotive com MAIN CASE REASSEMBLY MODELS Section X PS 9 10 i u N 7 sas h lt 14 Install the 1st reverse shift fork and collar 15 Apply Loctite 515 or the equivalent to the clean housing face The using a hoist lower the main case into position Install the case bolts and torque them to 78 98 ft Ibs 33 RANGE CASE REASSEMBLY MODELS Section XI PS 9 10 1 Install the range countershaft shims thin ones first and 2 Place the oil bypass valve into the opening in the main case retainer plates Make sure the shims are in line with the plate oiling system holes to help ensure proper transmission operation Torque the bolts to 34 41 ft Ibs 3 Install the oil pu
21. haft size there are standard bearings for light medium and heavy duty service Numbers and symbols stamped on inner and outer races of bearings designate size and type Note that the numbering systems of different bearing manufacturers have not been standardized Consult interchangeable tables and use the proper bearings for replacement parts SPIC PS 9 10 Clutch Troubleshooting Faulty clutch operation interferes with proper shifting of gears in any transmissions The two following paragraphs describe the most common problems encountered with clutches A If the clutch slips or does not engage properly first check the internal clutch adjustment If adjustment does not remedy the situation check for weak pressure springs lack of free pedal and worn or oily clutch facings and binding release mechanism B If the clutch drags or does not release properly check the internal clutch adjustment Some other causes for clutch drag are an intermediate plate sticking on drive pins or drive lugs the pressure plate not retracting a distorted or warped driven disc worn splines on the main drive gear of the transmission a damaged clutch release bearing or the bushing in the release sleeve dragging on the trans mission drive gear Backup Lights If the backup lights do not function check the following A Continuity of the switch with the ball fully depressed B Electrical plug connection C Wiring 44 14700 Helm Co
22. ifts and will help ensure proper engagement Downshift through all gear speeds when you are slowing down Chassis and trailer brake life can be increased by doing this Do not force the shift since this can cause damage to clutch collars and clutching teeth Use steady force on the shift lever to complete shifts Do not coast in neutral The vehicle could lose RPM s during coasting and you may not be able to shift back into the proper gear Do not downshift at road speeds that are too fast This could prevent proper gear engagement and could damage clutching teeth Do not tow vehicles without first pulling the axles or disconnecting the driveshaft If you tow the vehicle without doing this you can damage drive train components because the system lubrication is inadequate when the vehicle is towed MODELS PS 9 10 AIR LINE PIPING DIAGRAM Maintenance O S S S gt gt gt LHOd LS WWI ALAN 12551 er NOISIAOHd LNO 4907 OHVOS 40074 AO138 NMOHB AY3HHL N osz TrilN34333I9 HOd 1H0d ONALX3 OL LSNVHX3 OVSYHLL Ld N 082 MOTI ATBW3SSY 3ATVA SSINHYH ONIANL HIY a am a il ia O734HL OY3YHL PS SATWA HLIM Lan ser A E LA N SZL a LSnwHXx3 SONOGdSIYHOD zer Tepe gt IK Wa Moga CU NG Kr Y 7 C gt 5 HMH LHOd 3A1NA HLM SaN dJSIJHHOJ Hd SONY LJIHS O43HH1 Ld N Ose _ _ M Og 13 ONISNOH NOLSId SONVH IH OO 082 Hayag
23. ine or clutch This is especially true of noise complaints Therefore before removing the transmission or related components to locate trouble road test to check the possibility of trouble in other closely associated units Road testing is most effective when the mechanic drives the vehicle However riding with the driver can be very informative Check Functioning Prior to Disassembly If a remote control is used a careful check of the remote and connecting linkages and their adjustment must be made The remote unit must be in good working order if the transmission is expected to shift satisfactorily Many times the answer to the trouble is apparent when the unit is inspected prior to disassembly But this evidence is often lost when the parts are separated If possible check the unit prior to disassembly Bear in mind that a careful inspection of the unit should be made as each disassembly step is performed SPIC PS 9 10 Inspect Thoroughly During Disassembly It is poor practice to disassemble a unit or the complete transmission as quickly as possible without examining the parts The mechanic may completely disassemble a unit and fail to find the cause of the trouble unless he examines the parts After the transmission is disassembled check the lubricant for foreign particles This is a source of trouble often overlooked during the disassembly Repair or Replace Worn Parts Many times the parts or critical adjustmen
24. ion When it is necessary to add oil Spicer recommends that types and brands of oil not be mixed The correct oil level in this transmission is established by the filler plug opening PS 9 10 Refill First remove all dirt around the filler plug Then refill the transmission with new oil Use the grade recommended for the existing season and prevailing service The lubricant should be level with the oil fill plug located on the left side of the transmission case Overfilling CAUTION Do not overfill the transmission This usually results in oil breakdown due to excessive heat and aeration from the churning action of the gears Early breakdown of the oil will result in heavy varnish and sludge deposits that plug up oil ports and build up on splines and bearings Temperature All CD 50 Oil Cooler See standard application requirements Synthetic engine oil meeting MIL L 2104 D or MIL L 46152 B API SF or API CD GENERAL DISASSEMBLY MODELS Section III Important Procedure To locate and correct unit power or auxiliary transmission troubles a systematic procedure should be followed Road test whenever possible Mechanics usually get second or third hand reports of trouble experienced with the unit These reports do not always accurately describe the actual conditions Sometimes symptoms seem to indicate trouble in the transmission while actually the problem is with the axle driveshaft universal joints eng
25. ive materials formed by deterioration of lubricant will produce a reddish brown coating and small etched holes over outer and exposed surfaces of the race Corrosive oxides also act as lapping agents Shaft Fits Bearing fits on rotating shafts are usually specified as tight Excessive looseness even 001 under a load produces a creeping or slipping of the inner race on the rotating shaft The result is that surface metal of the shafts scrub or wear off The force causing the inner race to rotate disappears when the bearing fits properly Installation and Removal of Bearings Improper installation or removal of bearings especially hammering the bearing on the shaft with off center blows can result in brinelling Since such damage is seldom visible it does not become known until after failure or complete disassembly The correct drivers preferably under an arbor press and pullers should be used Removing bearings is more difficult than installing them In most cases it is necessary to remove the bearing by pulling on the outer race which can damage the balls or races Therefore it is a good idea to replace bearings during an overhaul to prevent problems However if a bearing is not going to be replaced avoid removal during low mileage rebuilds Interchangeability All ball bearings whether manufactured here or abroad are interchangeable in regard to standardized dimensions tolerances and fits However for a given s
26. klet Cut lines squarely to ensure a proper connection gear selection If this gasket is eliminated binding may occur Always use arazor sharp edge to cut tubing Never use side cuts because the gasket also acts as a shim O Do not apply sealant to the shift tower or housing It could prevent proper interlock functioning Torque the bolts to 31 45 ft Ibs 38 tech line 800 401 9866 www ttcautomotive com SPICER REMOTE CONTROL REASSEMBLY Section XII 1 After packing the remote control housing cavity with grease install the rod 2 Set the shift finger in place and secure it with a setscrew Torque to 40 50 ft ibs 3 Slide the boot over the rod onto the remote control housing Secure it with two tie down straps 4 Put the outer shift lever onto the splined end of the shift rod Install the setscrew and torque it to 40 50 ft tbs 5 Reassemble the selection lever subassembly and bolt it into place 7 323 tech line 800 401 9866 MODELS PS 9 10 6 Screw the jam nuts turnbuckle and ball joints onto the tie rod Grease the ball joints 7 Place a spacer on the ball joint studs Attach it to the selection lever subassembly and remote control housing Place the interlock inthe rear position and install the interlock 8 Install the remote control gasket and assembly onto the transmission Torque the bolts to 31 45 ft Ibs Then adjust the linkage according to the original equipment manufacturer s specifi
27. loded Drawing OIL DISCHARGE TUBE SCREW MOUNTING PLATE OIL PUMP HOUSING FRONT SCREW olet QI PUMP OIL PUMP SHAFT PUMP HOUSING TUBE fee SNAP RING fe my O RING SPRING PIN MOUNTING PLATE MAIN CASE 24 MAIN CASE DISASSEMBLY MODELS Section VII PS 9 10 Main Case Gears Exploded Drawing THRUST RING COUNTERSHAFT 5TH GEAR N 9TH GEAR Reverse WASHER RETAINER GEAR PLATE p4 THRUST RING 1ST GEAR 2ND GEAR 6TH GEAR MAINSHAFT 4TH 5TH SHIFT COLLAR 8TH 9TH SHIFT COLLAR SNAP RING 3RD GEAR 7TH GEAR K 4TH GEAR 8TH GEAR THRUST RING STH GEAR 9TH GEAR 1ST REVERSE SHIFT COLLAR 1ST GEAR 2ND GEAR 6TH GEAR 3RD GEAR 7TH GEAR 4TH GEAR 8TH GEAR 25 MAIN CASE DISASSEMBLY MODELS Section VII PS 9 10 ni 1 Remove the four remaining case bolts Next use pry bars in the 2 If the auxiliary countershaft front bearings are damaged remove milled slots to help separate the case from the clutch housing and replace them Also remove the rear countershaft bearing cup races before removing the main case This will prevent them from falling into the transmission n ga er F NG a f a Na er Jl u umma ama p SS T N TYYNY 4 Remove mainshaft snap ring ch NEL Ll 5 Removethe 1st reverse clutch collar and fork 6 Separate both countershafts from mainshaft SPICER tech line 800 401 9866 www tt
28. mp mounting plate Torque to 34 41 ft lb D 4 Next check the main box countershaft end play Make sure end play is between 001 and 003 on each countershaft This will help ensure proper transmission functioning s a ae L gt JE aa j A 5 Install the oil pump assembly on the oil pump mounting plate 6 Reinstall the countershaft reverse gears These gears only fit in Secure it with bolts and torque to 34 41 ft Spin the oil pump gear one position because of the blind spine Secure each gear with a to make sure it moves freely washer and bolt Torque the bolts to 78 98 ft Ibs 34 SPICER tech line 800 401 9866 www ttcautomotive com RANGE CASE REASSEMBLY MODELS Section XI PS 9 10 7 Position reverse gear and thrust plate between the range 8 Slide countershaft and reverse gear assembly down over countershaft gears mainshaft 11 Install the high range clutch gear and the synchronizer cup 12 Install the synchronizer and fork with the synchronizer springs Secure them with the washer and bolt Torque to 78 98 ft Ibs facing the output yoke or flange Make sure the synchronizer springs stay in place during installation Place a new lubricated O ring on the fork assembly SPICER 35 tech line 800 401 9866 www ttcautomotive com MODELS PS 9 10 RANGE CASE REASSEMBLY iret serie ate Section XI 13 Synchronizer parts are available separately Refer to the 14 Install the output shaft assem
29. n Highway Use PSO100 80 000 Ibs PSO125 110 000 Ibs PSO140 amp PSO150 140 000 Ibs HP Range 250 430 RPM Range 1 600 2 400 Engine Types 8 10 and 14 iiter diesel Simple Shift Pattern PSO100 10S 1 000 Ibs ft 1 354 nm PSO125 10S 1 250 Ibs ft 1 693 nm PSO140 10S 1 400 Ibs ft 1 896 nm PSO150 10S 1 500 Ibs ft 2 031 nm 17 1 31 clutch housing mounting face to washer seat face 630 Ibs 284 kg SAE No 1 or 2 14 or 15 1 2 Spicer Easy Pedal 2 plate Input Shaft 1 75 or 2 00 x 10 spline Output Shaft 2 5 x 10 spline Lube Capacity 19 pints 10 8 liters Speedometer Provision for mechanical and electronic Power Take Off 6 bolt right side 8 bolt bottom left 45 tooth 6 pitch drive gear both sides 85 of engine RPM 4B GENERAL INFORMATION Section TORQUE SPECIFICATIONS FOR NUTS AND CAP SCREWS Wrench Torque ft Ibs Nom Thread Size PART NAME NON LOCKING TYPE LOCKING TYPE Dia Bonded Nylon Patch Inches in Min Max Cap Screw or Nut PTO Aperture Cover Cap Screws Cap Screw Cap Screw with Gasket 97 324 2 Cap Screw with Gasket 22P22 5 GENERAL INFORMATION 9 SPEED How to Shift the Spicer res Die PS95 9A PS125 9A PS140 9A PSO125 9A PSO140 9A PSO150 9A Starting Vehicle Froma Stop 1 SPICER TRANSMISSIONS A With the gear shift lever in neutral B Clutch pedal depressed C And brakes set D Start the engine Allow
30. nge is driven on the shaft however two conditions can exist A If the bearing fit is tight on the shaft usually the bearings will brinell as they must absorb the pounding force B If the bearing fit is loose the shaft will keep moving inward until it is stopped by the internal parts such as the pilot bearing thrust washers These conditions must be prevented Power Take Offs Refer to your owner s manual installation procedures and safety precaution when installing any PTO on your transmission Push sleeve over end of shaft install bearing cap assembly After red sleeve is in place install seal dry Hydrodynamic Lip Seal must be installed so that Hydrodynamic Lip faces toward inside of transmission Remove seal cardboard shipping tube or plastic installation sleeve just prior installing bearing cap assembly to transmission 12 www ttcautomotive com SHIFT TOWER DISASSEMBLY MODELS Section IV PS 9 10 W SHIFT PATTERN INSERT 1 Cut the tie down straps and lift the boot off the lever age RIO 2 Holding the lever in a vise Remove the tower snap ring I Ra ae WASHERS 3 Pull the lever the upper and lower plastic sockets and the two opposing springs from the tower ze SHIFT KNOB Eia CASTELLATED NUT UPPER LEVER ISOLATOR a v all Yu SNAP RING B UFFER SOCKET lt LOWER LEVER LOWER SOCKET D7 OPPOSING DISK SPRINGS SPICER tech line 800 401
31. rication Torque the bolts to 34 41 ft Ibs Also assemble the two spacers and air regulator The air regulator bolts are longer than the bearing cap bolts 21 Install the retaining nut and torque to 52 62 ft Ibs Lubricate the 22 Next install the range piston housing with the four bolts The air piston O ring inlet should be at the top Torque to 34 41 ft lbs The speedometer gear and end yoke or flange can be installed now Torque to 550 600 ft Ibs 23 Using a chain hoist place the transmission in a horizontal position Install the two clutch housing retainer bolts next Torque to 78 98 ft lbs Bench shift the transmission to make sure it is working correctly 24 Next install the backup light switch and pin 37 SPICER RANGE CASE REASSEMBLY MODELS Section XI PS 9 10 25 Shift all forks into neutral then install the three air control valve 26 Insert the three poppet balls and springs into the case Place the pins interlock into the interlock retaining plate and install the assembly at this time Adjust the interlock to the proper position for a forward or center control Secure the plate with two bolts Torque to 52 62 ft Ibs 27 1nstall the air control valve and gasket Torque the retaining bolts o 28 Reassembly is complete with the installation of the gasket to 52 62 ft Ibs Install the air lines referring to the diagram in this and shift tower The gasket must be in place to ensure proper boo
32. shifting see Double Clutching Downshifting Clutch Brake The clutch brake used with this unit is designed for stopping gear rotation so you can shift into 1st and reverse gears The last one inch of clutch pedal travel activates the clutch brake So on shifts other than 1st or reverse from a stop only depress the clutch pedal enough to release the clutch Depressing the pedal to the floorboard will activate the clutch brake and could cause gear hang up or hard shifting When selecting a starting gear if you have a butt tooth condition gradually release the clutch so the drive gear can rotate to align the gear clutching teeth to complete the shift 6 tech line 800 401 9866 www ttcautomotive com GENERAL INFORMATION 10 SPEED How to Shift the Spicer PSO100 10S PS0125 10S PSO140 10S amp PSO150 10S Transmissions Des Die Starting Vehicle Froma Stop 1 SPICER TRANSMISSIONS A With the gear shift lever in neutral B Clutch pedal depressed C And brakes set D Start the engine Allow it to build to maximum air pressure A With the clutch pedal fully depressed to engage the clutch brake see Clutch Brake B Position the range selector to low range Move the gear shift lever into 1st gear position UP FOR HIGH RANGE DOWN FOR LOW RANGE A Release the tractor parking brakes and trailer parking brakes where applicable Release the clutch pedal gradually to full position Depress the
33. sion of these components Use a petroleum based solvent Refer to the solvent manufacturer s safety precautions to prevent personal injury or transmission damage A Do not use gasoline to clean parts Gasoline can explode causing serious physical injury Dry the parts immediately with compressed air Coat them with lubricant if they are to be reassembled immediately If the parts are to be stored coat them with a rust inhibitor and wrap them to keep contamination out Inspect parts thoroughly for wear or damage Parts damaged or worn from previous service must be replaced to insure maximum rebuild life Suggested inspection procedures include the following Inspection Clutch Collars Both the internal and external teeth must have sharp edges Check for chipped or broken teeth or teeth with rounded corners Also examine fork slots for wear Replace collars if any of these conditions exist Gears Examine for broken or cracked operating and clutching teeth Also check for any unusual wear patterns If any of the preceding exists replace the gear If a gear is replaced also replace the mating gear SPICER MODELS PS 9 10 Thrust Washers Check for flatness or excessive face wear cracks scoring or signs of heat damage Replace if any of these conditions exists Snap Rings New snap rings are recommended with every rebuild Mainshaft Check for signs of twisting or misalignment Also check for worn or damaged
34. splines Replace the shaft if any of these conditions exists Remote Control Check the shift fingers bushing bores and rods for excessive wear or scuffing Replace springs bearing races boots and seals Clean all reusable parts thoroughly and apply a light coat of grease to the pivot points when reassembling Bearings New bearings are recommended with every rebuild See General Disassembly Bearings for further information Housings Inspect the housing sections for cracks If cracks exist replace that section of the housing Also inspect the shift bar support bracket for cracks or worn slots Replace if either of these conditions exists 30 TRANSMISSIONS tech line 800 401 9866 www ttcautomotive com MAIN CASE REASSEMBLY MODELS Section X PS 9 10 1 Install the input shaft Using a protective sleeve slide the bearing cap into place Torque the cap bolts to 34 41 ft Ibs Continue by installing 5th speed in direct or 4th speed overdrive gear with the thrust face toward the input bearing The timing marks should be positioned to align with the countershafts 2 Install the 4th 5th speed fork Secure it with the pin and two snap rings Make sure you wear safety glasses 3 Place the 4th 5th shift collar on the mainshaft and install into fork Set mainshaft in input shaft Al LU mr i Fr ir 5 All gears will align with blind spline except PTO drive gear 6 Align timing marks on hear end
35. taining bolts and retaining 23 Next remove the right countershaft rear bearing retainer plates plates Also remove the oil passage bypass valve and shims 24 Remove the output shaft from the case 25 Remove the output shaft bearings from the case Wearing Asafety glasses press the inner bearing from the shaft O 26 These bearings and spacers are a matched set If it is necessary to replace any of the components the whole set must be replaced Replace them as a set to help ensure proper end play 21 SP CER tech line 800 401 9866 www ttcautomotive com MAIN CASE DISASSEMBLY MODELS Section VII PS 9 10 Main Case amp Shift Forks Exploded Drawing ELBOWS POPPET INSERT af T SPRING INTERLOCK BIETE a POPFET BALL PS FLUGOR aah COOLER OIL k PLUNGER T 3 4TH 5TH OVERDRIVE SHIFT RAIL SNAP RING OVERDRIVE SHIFT FORK 15T REVERSE SHIFT FORK AND RAIL SHIFT FORK AND RAIL 22 tech line 800 401 9866 www ttcautomotive com SPICER TRANSMISSIONS MAIN CASE DISASSEMBLY MODELS Section VII PS 9 10 Clutch Housing Exploded Drawing PLUG OR COOLER OIL RETURN SUPPORT BRACKET COUNTERSHAFT OIL TROUGH LIFT HOOK COUNTERSHAFT OIL TROUGH BUSHINGS INSPECTION PLATE 23 tech line 800 401 9866 www ttcautomotive com SPICER MAIN CASE DISASSEMBLY B MODELS Section VII PS 9 10 Main Case Optilube Exp
36. the clutch brake and could cause gear hang up or hard shifting When selecting a starting gear if you have a butt tooth condition gradually release the clutch so the drive gear can rotate to align the gear clutching teeth to complete the shift 6B tech line 800 401 9866 www ttcautomotive com GENERAL INFORMATION Section Double Clutching Upshifting The normal double clutching technique is suggested When you want to shift depress the clutch and move the lever to neutral Engage the clutch and allow the engine RPM to drop so engine speed and driveline speed match Depress the clutch and move the lever into gear Engage the clutch and accelerate as conditions permit Downshifting Downshitting is the reverse of upshifting As the engine approaches the shift point start the downshift approximately 50 100 RPM above the shift point depress the clutch and move the lever to neutral Engage the clutch and raise the engine RPM until the engine and driveline speeds are equal normally governed speed Depress the clutch then shift into the next lower gear Engage the clutch Skip Shifting Experienced drivers sometimes want to skip some of the ratios This is acceptable However you should do this only when operating conditions allow Your speed the load and The road type and condition should be considered MODELS PS 9 10 Reminders Double clutch when shifting This will help components match speed better during sh
37. throttle to start the vehicle moving Depress the clutch pedal Move the gear shift lever to neutral See Double Clutching Upshifting D Then move the gear shift lever to 2nd gear B C A After attaining optima speed in 1st gear B C MODELS PS 9 10 A Continue the above procedures through 5th gear position A A To continue upshifting 6th gear through 10th gear B Preselect high range on the range selector C Depress the clutch pedal B Move the gear shift lever from the 5th gear position to neutral See Double Clutching Upshifting E Then move the gear shift lever into 6th gear position UP FOR HIGH RANGE DOWN FOR Er LOW RANGE 7 A After attaining optimal speed in 6th gear B Depress the clutch pedal C Move the gear shift lever to neutral see Double Clutching Upshifting D Then move the gear shift lever into 7th gear position 8 A Continue these procedures for 8th 10th gear positions Downshifting Downshifting is actually just the reverse of upshifting see Double Clutching Downshifting Clutch Brake The clutch brake used with this unit is designed for stopping gear rotation so you can shift into 1st and reverse gears The last one inch of clutch pedal travel activates the clutch brake So on shifts other than 1st or reverse from a stop only depress the clutch pedal enough to release the clutch Depressing the pedal to the floorboard will activate
38. ts causing the trouble are not replaced or corrected because the mechanic only inspects and replaces parts that have failed completely All pieces should be carefully examined because broken parts are often just the result not the cause of the problem All parts that are broken or worn and no longer meet specifications should be replaced Also parts that are worn to the extent that they do not have a long service life remaining should be replaced Replacing these parts now will avoid another teardown on the unit in the near future Also at this time make the recommended changes or modifications to bring the transmission up to date and increase the service life of the unit 11 GENERAL DISASSEMBLY MODELS Section III O Read this section before starting the detailed disassembly procedures Follow procedures closely to ensure proper transmission operation Rebuild Facilities A suitable holding fixture or overhaul stand with a hole for the input shaft is desirable For easier working conditions table height should be 28 30 inches A light chain hoist should be used to handle the mainshaft and countershafts during removal and reassembly procedures Cleanliness Transmissions should be steam cleaned prior to disassembly Seal all openings before steam cleaning to prevent entry of dirt and water which can damage serviceable parts Dirt is abrasive and will cause premature wear of bearings and other parts Spicer sugges
39. ts that mechanics have a wash tank available to clean parts just prior to reassembly Bearings When a transmission is removed at relatively low mileage bearings should be removed with pullers designed for this purpose Wrap the bearings to keep out dirt Clean inspect and lubricate all bearings just prior to reassembly If accumulated mileage is over 150 000 miles we suggest that all bearings be replaced If bearings are worn or damaged always replace them regardless of mileage When installing the front bearing retainer and seal in the transmission use the red plastic sleeve to prevent serious damage to the oil seal Failure to use the seal sleeve will void the seal warranty SPICER TRANSMISSIONS tech line 800 401 9866 Front Bearing Retainer amp Seal PS 9 10 Do not hammer on end yokes and flanges to remove or install them It is not only destructive to the yoke or the flange itself but can also cause serious internal transmission damage Hammering destroys or mutilates the pilot diameters and warps or bends the flange Hammering on end yokes will close in the bearing bores or misalign yoke lugs This will resultin early failures of journal needle bearings Serious damage can be done internally to bearings thrust faces and washers by hammering on external parts In most designs when the yoke flange locknuts are tightened and secure the internal bearings and gears are in proper location When the yoke fla
40. urt Plymouth MI 48170 800 401 9866 or 734 456 3770 Ia Fax 734 456 3739 TECHNOLOGIES Corporation www ttcautomotive com mn automotriz Group Company
41. zontally A few items which could move the gear or shaft out of proper position particularly on rough roads are A Use of heavy shift lever extensions B Broken shift rail poppet springs C Worn shift rail poppet notches D Bent or sprung shift rails E Excessive end play in drive gear or countershaft caused by worn bearings or retainers F Worn or missing thrust rings 42 TRANSMISSIONS tech line 800 401 9866 www ttcautomotive com TROUBLESHOOTING MODELS Section XIV Hard Shifting An improperly operating clutch will interfere with the proper shifting of gears in any transmission It is also important that the hydraulic air or similar release mechanism is in proper working order If full and complete clutch release is being made the following could be a few of the possible causes for hard shifting complaints A No lubricant in remote control unit Note The forward remote is isolated and is often overlooked Many remote controls used on transmissions and auxiliaries require separate lubrication B No lubrication in or grease fittings on u joints or swivels of remote controls C Lack of lubricant or wrong lubricant used causing buildup of sticky varnish and sludge deposits on splines of shaft and gears D Badly worn or bent shift forks E Improper adjustment on shifter linkage F Sliding clutch gears tight on splines of shaft G Clutch teeth burred over chipped or badly mutilated
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