fuller heavy duty transmissions trsm0310 - eprogear every 40 hours inspect oil level. check for...

Service Manual

Fuller Heavy Duty TransmissionsTRSM0310October 2007

For parts or service call us Pro Gear & Transmission, Inc.

1 (877) 776-4600

(407) 872-1901

[email protected]

906 W. Gore St.

Orlando, FL 32805

TABLE OF CONTENTS

FOREWORDMODEL DESIGNATIONS AND SPECIFICATIONS LUBRICATIONOPERATIONPOWER FLOW TIMINGTORQUE RECOMMENDATIONS TOOL REFERENCE PREVENTIVE MAINTENANCEPRECAUTIONS

DISASSEMBLYINSPECTIONREASSEMBLY

CHANGING INPUT SHAFTAIR SYSTEM

RANGE SHIFT AIR SYSTEMAIR SYSTEM SCHEMATICS

DISASSEMBLY AND REASSEMBLY–SHIFTING CONTROLSAIR SYSTEM GEAR SHIFT LEVER HOUSING ASSEMBLY SHIFT BAR HOUSING ASSEMBLY

REMOVAL – COMPANION FLANGE, AUXILIARY SECTION AND CLUTCH HOUSINGDISASSEMBLY – AUXILIARY SECTIONREASSEMBLY – AUXILIARY SECTIONDISASSEMBLY – FRONT SECTION REASSEMBLY – FRONT SECTION INSTALLATION–COMPANION FLANGE, AUXILIARY SECTION AND CLUTCH HOUSINGINSTALLATION–SHIFTING CONTROLS

SHIFT BAR HOUSING ASSEMBLY GEAR SHIFT LEVER HOUSING ASSEMBLYAIR SYSTEM

FOREWORD

This manual is designed to provide detailed infor-mation necessary to service and repair the Fuller®

Transmissions listed on the cover.As outlined in the Table of Contents, the manual

is divided into 3 main sections:a. Technical information and referenceb. Removal, disassembly, reassembly and

installationc. Options

The format of the manual is designed to befollowed in its entirety if complete disassembly andreassembly of the transmission is necessary. But ifonly one component of the transmission needs tobe repaired, refer to the Table of Contents for thepage numbers showing that component. For exam-ple, if you need to work on the Shift Bar Housing,you will find instructions for removal, disassemblyand reassembly on page 34. Instructions for installa-tion are on page 100. Service Manuals, IllustratedParts Lists, Drivers Instructions, Driver Training

Programs and other forms of product service infor-mation for these and other Fuller Transmissions areavailable upon request. A Technical Literature OrderForm may be found in the back of this manual*. Youmay also obtain Service Bulletins, detailing informa-tion on product improvements, repair proceduresand other service-related subjects by writing to thefollowing address:

EATON CORPORATIONTRANSMISSION DIVISIONTechnical Service DepartmentP.O. Box 4013Kalamazoo, Michigan 49003(61 6) 342-3344

MODEL DESIGNATIONSAND SPECIFICATIONS

Nomenclature:

RTF-11608

8 Speed Series Transmissions

(Note 1)Relative Speed

PTO Gear (Note 2) (Note 3) (Note 4)Gear Ratios To Input R PM

No. In Lbs PintsModels Spds 1 st 2nd 3rd 4th 5th 6th 7th 8th Reverse Right Bottom mm kg Liters

RT-11608 8 1023 7 2 3 5 2 4 3 8 2 2 6 7 1 89 1 37 1 00 3 33/12 74 575 575 2 8 9 578 26734 262 12

RT-14608 8 1023 7 2 3 5 2 4 3 8 2 2 6 7 1 89 1 37 1 00 3 33/12 74 575 575 2 9 5 604 28 —

749 274 13

See Chart Notes.

CHART NOTES:1 Lengths measured from face of clutch housing to front bottoming surface of companion flange or yoke.2 Weights include SAE No. 1 cast iron clutch housing and standard controls (control valve, gear shift lever and

housing assembly, and air lines), less clutch release parts. For information on available clutch housings, re-fer to Publication FUL-140 —” Clutch Housing Chart.” All weights are approximate.

3 Oil Capacities are approximate, depending on inclination of engine and transmission. Always fill transmis-sion with proper grade and type of lubricant to level of filler opening. See LUBRICATION.

LUBRICATION

Proper Lubrication...

the Key to long

transmission life

Proper lubrication procedures are the key to a goodall-around maintenance program. If the oil is not do-ing its job, or if the oil level is ignored, all the main-tenance procedures in the world are not going tokeep the transmission running or assure long trans-mission life.

Fuller Transmissions are designed so that the in-ternal parts operate in a bath of oil circulated by themotion of gears and shafts. Grey iron parts havebuilt-in channels where needed, to help lubricatebearings and shafts.

Thus, all parts will be amply lubricated if theseprocedures are closely followed:

1. Maintain oil level. Inspect regularly.2. Change oil regularly.3. Use the correct grade and type of oil.4. Buy from a reputable dealer.

Lubrication Change and Inspection

HIGHWAY USE

I First 3,000 to Change transmission oil5,000 miles (4827 to 8045 Km) on new units

Every 10,000 miles (16090 Km) Inspect oil level.Check for leaks.

I Every 50,000 miles (80450 Km) Change transmission oil. I

I OFF-HIGHWAY USE II First 30 hours Change transmission oil on new units. II Every 40 hours Inspect oil level. Check for leaks. I

Every 500 hours Change transmission oil where severedirt conditions exist.

Every 1,000 hours Change transmission oil(Normal off-highway use).

Change oil filter element, if so equipped, at each oil change

Oil is Important...Here are some of the functions oil must perform:

● Provide a protective film—To protect surface ofheavily loaded parts such as gear teeth andbearings, thus preventing metal to metal contactwhich causes scoring, scuffing and seizure.

● Act as a coolant—To dissipate heat and reduceheat by reducing friction.

● Afford suff icient f luidity—To follow, coat andcushion all loaded surfaces.

● Be chemically stable—To withstand heat and agita-tion without separation, gumming-up, oxidizing orcorroding.

• Be non-foaming —To prevent excessive foam and in-creased volume under severe conditions.

• Be free of sediment and water—To prevent sludgeand rust.

Recommended LubricantsFahrenheit(Celsius)

Grade AmbientType (SAE) Temperature

Heavy Duty Engine OilMIL-L-2104B or MIL-L-2104C 50 Above 10°F.(-12°C.)or API-SF or API-CD 40 Above 10°F.(-12°C.)

(Previous API designations 30 Below 10°F.(-12°C.)acceptable)

Mineral Gear Oil with rust 90 Above 10°F.(-12°C.)and oxidation inhibitor 80W Below 10°F.(-12°C.)API-GL-1

‘Mild EP Gear Oil 90 10°F.(-12°C.) to 100°F.(38°C.)MIL-L-2105 or API-GL-4 80W -15°F.(-26°C.) to 70°F.(21°C.)

‘Multipurpose Gear Oil 85W140 Above 10°F.(-12°C.)MIL-L-2105B or MIL-L-2105C 80W140 Above -15°F.(-26°C.)

or API-G L-5 90 10°F.(-12°C.) to 100°F.(38”C.)80W90 -15°F.(-26°C.) to 100°F.(38°C.)80W -15°F.(-26°C.) to 70°F.(21°C.)75W -40°F.(-40°C.) to -15°F.(-26°C.)

Additives, friction modifiers or synthetic lubricants are not recommendedfor use in Fuller Transmissions. -

*Mild EP Gear Oil or Multi-Purpose Gear Oil are not recommended when lubri-cant operating temperatures are above 230°F (110°C).

LUBRICATION

Proper Oil Level

Make sure oil is level with filler opening. Becauseyou can reach oil with your finger does not mean oilis at proper level. One inch of oil level is about onegallon of oil.

Draining Oil

Drain transmission while oil is warm. To drain oil re-move the drain plug at bottom of case. Clean thedrain plug before reinstalling.

Refilling

Clean case around filler plug and remove plug fromside of case. Fill transmission to the level of the filleropening. If transmission has two filler openings, fillto level of both openings on twin countershaftmodels.

The exact amount of oil will depend on the trans-mission inclination and model. In every instance, fillto the level of the filler opening.

Do not over fill—this will cause oil to be forced outof the case through front bearing cover.

When adding oil, types and brands of oil should notbe intermixed because of possible incompatibility.

Operating Temperatures

The transmission should not be operated consis-tently at temperatures above 250°F (120°C). However,intermittent operating temperatures to 300°F (149°C)will not harm the transmission. Operating tempera-tures above 250°F increase the lubricant’s rate of ox-idation and shorten its effective life. When thetransmission is operated intermittently above 250°,heavy duty engine oil provides the best oxidation re-sistance. When the average operating temperature isabove 250°F, the transmission may require more fre-quent oil changes or external cooling.

The following conditions in any combination cancause operating temperatures of over 250°F: (1)operating consistently at slow speeds, (2) high am-bient temperatures, (3) restricted air flow aroundtransmission, (4) exhaust system too close to trans-mission, (5) high horsepower, overdrive operation.

External oil coolers are available to reduce operat-ing temperatures when the above conditions areencountered.

Proper Lubrication Levels

as Related to Operating Angles

If the transmission operating angle is more than 12degrees, improper lubrication can occur. The operat-ing angle is the transmission mounting angle in thechassis plus the percent of upgrade (expressed indegrees).

The chart below illustrates the safe percent of up-grade on which the transmission can be used withvarious chassis mounting angles. For example: if youhave a 4 degree transmission mounting angle, then 8degrees (or 14 percent of grade) is equal to the limitof 12 degrees. If you have a O degree mounting angle,the transmission can be operated on a 12 degree (21percent) grade.

Anytime the transmission operating angle of 12 de-grees is exceeded for an extended period of time thetransmission should be equipped with an oil pump orcooler kit to insure proper lubrication.

Note on the chart the effect low oil levels can haveon safe operating angles. Allowing the oil level to fall1/2” below the filler plug hole reduces the degree ofgrade by approximately 3 degrees (5.5 percent).

Proper Lubrication Levels are Essential!22

20

18

16

14

12

10

8

6

4

2

00° 1“ 2° 3“ 4° 5° 6° 7°

Transmission Mounting Angle

12°

1 0 ° 1 9 ’

1 0 ° 1 3 ’

9 ° 1 6 ’

8 °

6 ° 5 1 '

5 ° 4 8 ’

4 ° 3 5 ’

3 ° 2 6 ’

2 ° 1 8 ’

1 “ 8 ’

0 °

OPERATION

8-Speed Transmissions

Shift Lever Patterns and Shifting Controls

RT (Direct) Models

Shift 1-2=3-4 in LOW RANGE.Range Shift . . .And shift 5-6-7-8 in HIGH RANGE.

Range Control Valve(A-3546)

Range Control Valve(A-5010)

UP forHIGH RANGE

Range Preelection Lever

DOWN forLOW RANGE

POWER FLOW

The transmission must efficiently transfer the engine's power, in terms of torque, to the vehicle's rear wheels.Knowledge of what takes place in the transmission during torque transfer is essential when trouble-shootingand making repairs become necessary.

Front Section Power Flow

1.

2.

3.

4.

5.

6.

Power (torque) from the vehicle's engine is trans-ferred to the transmission's input shaft.Splines of input shaft engage internal splines inhub of main drive gear.Torque is split between the two countershaftdrive gears.Torque is delivered along both countershaft tomating countershaft gears of "engaged" main-shaft gear. The following cross section views(Figures 1-3) illustrate a 1st/5th speed gearengagement.Internal clutching teeth in hub of engaged main-shaft gear transfers torque to mainshaft throughsliding clutch.Mainshaft transfers torque directly to auxiliarydrive gear.

POWER FLOW

Auxiliary Section Power Flow:

LOW RANGE

7.

8.

The auxiliary drive gear splits torque between the 9. Torque is transferred to range mainshaft or out-two auxiliary countershaft drive gears. put shaft through sliding clutch.Torque is delivered along both countershaft to 10. Torque is delivered to driveline as LOW RANGEthe "engages" low range gear on range main- 1st.shaft or output shaft.

LOW RANGE POWER FLOW

Auxiliary Section Power Flow:

HIGH RANGE

7. The auxiliary drive gear transfers torque directly 8. Torque is delivered through range mainshaft and/to the range mainshaft or output shaft through or output shaft to driveline as HIGH RANGE 5th."engaged" sliding clutch.

HIGH RANGE POWER FLOW

TIMING

Timing Procedures: All Models

All Fuller twin countershaft transmissions are“timed” at assembly. It is important that proper tim-ing procedures are followed when reassembling thetransmission. Timing assures that the countershaftgears will contact the mating mainshaft gears at thesame time, allowing mainshaft gears to center on themainshaft and equally divide the load.

Timing is a simple procedure of marking the appro-priate teeth of a gear set prior to installation andplacing them in proper mesh while in the transmis-sion. In the front section, it is necessary to time onlythe drive gear set. And depending on the model, onlythe low range or deep reduction gear set is timed inthe auxiliary section.

Front Section

A. Marking countershaft drive gear teeth.1. Prior to placing each countershaft assembly

into case, clearly mark the tooth locateddirectly over the keyway of drive gear asshown. This tooth is stamped with an “O” toaid identification.

A. TOOTH MARKED ON EACHCOUNTERSHAFT DRIVE GEARFOR TIMING PURPOSES

Cut 7300

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 drivegear. As shown below, there should be anequal number of unmarked gear teeth on eachside between the marked sets.

B. TEETH MARKED ON MAINDRIVE GEAR FOR TIMINGPURPOSES

C. Meshing marked countershaft drive gear teethwith marked main drive gear teeth.(After placing the mainshaft assembly into case,the countershaft bearings are installed to com-plete installation of the countershaft assemblies.)1.

2.

When installing the bearings on left counter:shaft, mesh the marked tooth of countershaftdrive gear with either set or two marked teethon the main drive gear.Repeat the procedure when installing thebearings on right countershaft, making use ofthe remaining set of two marked teeth on themain drive gear to time assembly.

C. DRIVE GEAR SET PROPERLYCut 7300B TIMED

Auxiliary Section

A. Timing the low range gear set.1.

2.

3.

4.

5.

6.

Mark any two adjacent teeth on the mainshaftgear of set to be timed. Then mark the two ad-jacent teeth located directly opposite the firstset marked as shown in Illustration B.Prior to placing each auxiliary countershaft as-sembly into housing, mark the tooth stampedwith an “O” on gear to mate with timed main-shaft gear as shown in Illustration A.Install the mainshaft gear in position on rangemainshaft OR output shaft.Partially seat the countershaft rear bearings inhousing bores.Place the auxiliary countershaft assembliesinto position and mesh the marked teeth ofmating countershaft gears with the markedteeth of mainshaft gear as shown in lllustrationC.Fully seat the rear bearings on each counter-shaft to complete installation.

C u t 7 3 0 0 A

TORQUE RECOMMENDATIONS

Correct torque application is extremely important to assure low transmission life and dependable Performance”Over-tightening or under-tightening can result in a loose installation and, in many instances, eventually causedamage to transmission gears, shafts, and/or bearings. Use a torque wrench whenever possible to attain recom-mended lbs./ft. ratings. Do not torque capscrews dry.

FRONT SECTION: ALL MODELS

TORQUE RECOMMENDATIONS

AUXILIARY

TOOL REFERENCE

Some repair procedures pictured in this manual show The specialized tools listed below can be obtainedthe use of specialized tools. Their actual use is rec- from a tool supplier or made from dimensions as re-ommended as they make transmission repair easier, quired by the individual user. Detailed Fuller Transmis-faster, and prevent costly damage to critical parts. sion Tool Prints are available upon request by writing.

But for the most part, ordinary mechanic’s tools Eaton Corporationsuch as socket wrenches, screwdrivers, etc., and Transmission Divisionother standard shop items such as a press, mauls and Technical Service Dept.soft bars are all that is needed to successfully disas- P.O. Box 4013semble and reassemble any Fuller Transmission. Kalamazoo, Michigan 49003

PAGE T O O L HOW OBTAINED

4 0 Auxiliary Section Hanger Bracket Made from Fuller TransmissionPrint T-22823

4 0 Output Shaft Hanger Bracket Made from Stop Nut andflat steel stock

3 3 Tension Spring Driver Made from Fuller TransmissionPrint T-11938

4 5 Snap Ring Pliers Tool Supplier

46 Bearing Puller (Jaw Type) Tool Supplier

6 3 Impact Puller (1/2-1 3 Threaded End) Tool Supplier

5 3 Bearing Drivers (Flanged-End) Made from Fuller TransmissionPrint Series T-10842*

5 3 Oil Seal Driver Made from Fuller TransmissionPrint T-18088=23

7 9 Countershaft Support Tool Made from Fuller TransmissionPrint T-22247

99 Torque Wrench, 1000 Lbs./Ft. Capacity Tool Supplier

59 Input Shaft Nut Installer Made from Fuller TransmissionPrint T-22553-A

*Dimensions necessary to determine specific tool number required.

PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE CHECK CHART

CHECKS WITHOUT PARTIAL

DISASSEMBLY OF CHASSIS OR CAB

1.

2.

3.

4.

5.

6.

7.

8.

Air System and Connectionsa. Check for leaks, worn air lines, loose con-

nections and capscrews. See AIR SYSTEM.

Clutch Housing Mountinga. Check all capscrews of clutch housing

flange for looseness.

Clutch Release Bearing (Not Shown)a. Remove hand hole cover and check radial

and axial clearance in release bearing.b. Check relative position of thrust surface of

release bearing with thrust sleeve on push-type clutches.

Clutch Pedal Shaft and Boresa. Pry upward on shafts to check wear.

b. If excessive movement is found, removeclutch release mechanism and check bush-ings in bores and wear on shafts.

Lubricanta. Change at specified service intervals.b. Use only the types and grades as recom-

mended. See LUBRICATION.

Filler and Drain Plugsa. Remove filler plugs and check level of lubri-

cant at specified intervals. Tighten filler anddrain plugs securely.

Capscrews and Gasketsa. Check all capscrews, especially those on

PTO covers and rear bearing covers forlooseness which would cause oil leakage.See TORQUE RECOMMENDATIONS.

b. Check PTO opening and rear bearing coversfor oil leakage due to faulty gasket.

Gear Shift Levera. Check for looseness and free play in hous-

ing. If lever is loose in housing, proceedwith Check No. 9.

9 . Gear Shift Lever Housing Assemblya. Remove air lines at slave valve and remove

the gear shift lever housing assembly fromtransmission.

b. Check tension spring and washer for setand wear.

c. Check the gear shift lever spade pin andspade in slot for wear.

d. Check bottom end of gear shift lever forwear and check slot of yokes and blocks inshift bar housing for wear at contact pointswith shift lever.

CHECKS WITH DRIVE LINE DROPPED

10. Universal Joint Companion Flangeor Yoke Nuta. Check for tightness. Tighten to recom-

mended torque.

11. Output Shaft (Not Shown)a. 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 toclean sealing surface of companion flange oryoke. DO NOT USE CROCUS CLOTH, EMERYPAPER OR OTHER ABRASIVE MATERIALSTHAT WILL MAR SURFACE FINISH.

12. Splines on Output Shaft(Not Shown)a. Check for wear from movement and chuck-

ing action of the universal joint companionflange or yoke.

13. Mainshaft Rear Bearing Covera. Check oil seal for wear.

PRECAUTIONS

Disassembly

It is assumed in the detailed assembly instructions that the lubricant has been drained from transmission, thenecessary linkage and air lines disconnected and the transmission has been removed from vehicle chassis. Re-moval of the gear shift lever housing assembly (or remote control assembly) is included in the detailed instruc-tions (Disassembly and Reassembly—Shifting Controls); however, this assembly MUST be detached from shiftbar housing before transmission can be removed.

FOLLOW CLOSELY EACH PROCEDURE IN THE DETAILED INSTRUCTIONS, MAKING USE OF THE TEXT, iLLUS-TRATIONS AND PHOTOGRAPHS PROVIDED.

1

2.

3.

4.

BEARINGS — Carefully wash and relubricate allreusable bearings as removed and protectivelywrap until ready for use. Remove bearings plannedto be reused with pullers designed for this pur-pose.

ASSEMBLIES — When disassembling the variousassemblies, such as the mainshaft, countershaft,and shift bar housing, lay all parts on a cleanbench in the same sequence as removed. This pro-cedure will simplify reassembly and reduce thepossibility of losing parts.

SNAP RINGS — Remove snap rings with pliers de-signed for this purpose. Snap rings removed in thismanner can be reused, if they are not sprung orloose.

INPUT SHAFT—The input shaft can be removed

tershafts, mainshaft, or main drive gear. Specialprocedures are required and provided in this man-ual.

5. CLEANLINESS — Provide a clean place to work. It

6

is important that no dirt or foreign material entersthe unit during repairs. Dirt is an abrasive and candamage bearings. It is always good practice toclean the outside of the unit before starting theplanned disassembly.

WHEN USING TOOLS TO MOVE PARTS — Alwaysapply force to shafts, housings, etc, with restraint.Movement of some parts is restricted. Never applyforce to the part being driven after it stops solidly.The use of soft hammers, bars and mauls for alldisassembly work is recommended.

from transmission without removing the coun-

Inspection

Before reassembling the transmission, check each part carefully for abnormal or excessive wear and damage todetermine reuse or replacement. When replacement is necessary, use only genuine Fuller Transmission parts toassure continued performance 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 reus-ing a questionable part which could lead to additional repairs and expense soon after initial reassembly. To aidin determining the reuse or replacement of any transmission part, consideration should also be given to the un-it’s history, mileage, application, etc.

Recommended inspection procedures are provided in the following checklist.

A. BEARINGS B. GEARS1.

2.

3.

Wash all bearings in clean solvent. Check 1.balls, rollers and raceways for pitting, discol-oration, and spalled areas. Replace bearingsthat are pitted, discolored, or spalled.

Lubricate bearings that are not pitted, discol-ored, or spalled and check for axial and radialclearances.

Replace bearings with excessive clearances.

Check bearing f i ts. Bearing inner races 2.should be tight to shaft; outer races slightlytight to slightly loose in case bore. If bearingspins freely in bore, however, case should bereplaced.

Check gear teeth for frosting and pitting.Frosting of gear tooth faces present no threatof transmission failure. Often in continuedoperation of the unit, frosted gears will “heal”and not progress to the pitting stage. And inmost cases, gears with light to moderate pit-ted teeth have considerable gear life remain-ing and can be reused. But gears withadvanced stage pitting should be replaced.

Check for gears with clutching teeth abnor-mally worn, tapered, or reduced in lengthfrom clashing in shifting, Replace gearsfound in any of these conditions.

PRECAUTIONS

Inspection (cont’d.)

3. Check axial clearance of gears. Where exces-sive clearance is found, check gear snap ring,washer, spacer, and gear hub for excessivewear. Maintain .005” to .012” axial clearancebetween mainshaft gears.

C. SPLINES1. Check splines on all shafts for abnormal wear.

If sliding clutch gears, companion flange, orclutch hub have worn into the sides of thesplines, replace the specific shaft affected.

D. TOLERANCE/LIMIT WASHERS1. Check surfaces of all limit washers. Washers

scored or reduced in thickness should bereplaced.

E. REVERSE IDLER GEAR ASSEMBLIES1. Check for excessive wear from action of roller

bearings.

F. GRAY IRON PARTS1. Check all gray iron parts for cracks and breaks.

Replace or repair parts found to be damaged.Heavy castings may be welded or brazed pro-vided the cracks do not extend into bearingbores or bolting surfaces. When welding, how-ever, never place the ground so as to allow cur-rent to pass through the transmission.

G. CLUTCH RELEASE PARTS1. Check clutch release parts. Replace yokes

worn at cam surfaces and bearing carrierworn at contact pads.

2. Check pedal shafts. Replace those worn atbearing surfaces.

H. SHIFT BAR HOUSING ASSEMBLY1. Check for wear on shift yokes and blocks at

pads and lever slot. Replace excessively wornparts.

2. Check yokes for correct alignment. Replacesprung yokes.

3. Check Iockscrews in yokes and blocks.Tighten and rewire those found loose.

4. If housing has been disassembled, checkneutral notches of shift bars for wear from in-terlock balls.

I.

J.

K.

L.

GEAR SHIFT LEVER HOUSINGASSEMBLY1. Check spring tension on shift lever. Replace

tension spring and washer if lever moves toofreely.

2. If housing is disassembled, check spade pinand corresponding slot in lever for wear. Re-place both parts if excessively worn.

BEARING COVERS1. Check covers for wear from thrust of adjacent

bearing. Replace covers damaged from thrustof bearing outer race.

2. Check bores of covers for wear. Replacethose worn oversize.

OIL RETURN THREADSAND SEALS1. Check oil return threads in front bearing

cover. If sealing action of threads has beendestroyed by contact with input shaft, replacebearing cover.

2. Check oil seal in mainshaft rear bearing cover.If sealing action of lip has been destroyed, re-place seal.

SLIDING CLUTCHES1. Check all shift yokes and yoke slots in sliding

clutches for extreme wear or discolorationfrom heat.

2. Check engaging teeth of sliding clutches forpartial engagement pattern.

M. SYNCHRONIZER ASSEMBLY1. Check synchronizer for burrs, uneven and ex-

cessive wear at contact surface, and metalparticles.

2. Check blocker pins for excessive wear orlooseness.

3. Check synchronizer contact surfaces on theauxiliary drive and low range gears for exces-sive wear.

N. O-RINGS1. Check all O-rings for cracks or distortion. Re-

place if worn.

PRECAUTIONS

Reassembly

Make sure that interiors of case and housings are clean. It is important that dirt and other foreign materials bekept out of the transmission during reassembly. Dirt is an abrasive and can damage polished surfaces ofbearings and washers. Use certain precautions, as listed below, during reassembly.

1.

2.

3.

4.

5.

GASKETS — Use new gaskets throughout thetransmission as it is being rebuilt. Make sure allgaskets are installed. An omission of any gasketcan result in oil leakage or misalignment ofbearing covers.

CAPSCREWS — TO prevent oil leakage, use Loctite242 thread sealant on all capscrews. For torqueratings, see TORQUE RECOMMENDATIONS.

O-RINGS — Lubricate all O-rings with silicone lubri-cant.

ASSEMBLY — Refer to the illustrations provided inthe detailed disassembly instructions as a guideto reassembly.

INITIAL LUBRICATION — Coat all limit washersand splines of shafts with Lubriplate during reas-sembly to prevent scoring and galling of suchparts.

6.

7.

8.

AXIAL CLEARANCES — Maintain original axialclearances of .005” to .012” for mainshaft gears.

BEARINGS — Use of flanged-end bearing drivers isrecommended for the installation of bearings.These special drivers apply equal force to bothbearing races, preventing damage to balls/rollersand races while maintaining correct bearing align-ment with bore and shaft. Avoid using a tubular orsleeve-type driver, whenever possible, as force isapplied to only one of the bearing races. SeeTOOL REFERENCE.

UNIVERSAL JOINT COMPANION FLANGE ORYOKE — Pull the companion flange or yoke tightlyinto place with the output shaft nut, using 450-500foot-pounds of torque. Make sure the speedome-ter drive gear or a replacement spacer of the samewidth has been installed. Failure to pull the com-panion flange or yoke tightly into place will permitthe output shaft to move axially with resultantdamage to the rear bearing.

IMPORTANT: REFER TO THE APPROPRIATE ILLUSTRATED PARTS LIST (SPECI-FIED BY MODEL SERIES) TO ENSURE THAT PROPER PARTS AREUSED DURING REASSEMBLY OF THE TRANSMISSION.

CHANGING INPUT SHAFT

Special Procedure

In some cases, it may become necessary to replace the input shaft due to excessive clutch wear on the splines.Except for removal of the shift bar housing assembly, the input shaft can be removed without further disas-sembly of the transmission. Removal of the clutch housing is optional.

NOTE: The following illustration and instructions pertain to changing the input shaft ONLY. To change the maindrive gear, disassembly of the front section is required.

Disassembly 5. Using a flanged-end drive, install the drive gear

1.

2.

3.

4.

5.

6.

7.

Remove the gear shift lever housing assembly (orremote control assembly) from shift bar housing,if necessary, and the shift bar housing assemblyfrom transmission case.

Remove the front bearing cover and gasket. If nec-essary, remove the oil seal from cover of modelsso equipped.

Remove the drive gear bearing nut (left handthreads) or snap ring from input shaft.Suggestion: For removal of nut ONLY, engage twomainshaft sliding clutches into gear to prevent themainshaft from rotating.

Move the main drive gear assembly as far forwardas possible and remove the drive gear bearing.

Remove the spacer from input shaft.

From the front of transmission, remove the snapring from I.D. of main drive gear using two smallscrewdrivers. If mainshaft was previously locked

bearing on shaft and into case bore. When apply-ing force to driver, use caution so as not to dam-age bearing shield.Suggestion: Engaging the sliding clutch intomain drive gear and blocking it forward will holdthe input shaft forward.

6. When drive gear bearing nut is used, degreasethe threads of input shaft and new nut. DO NOTREUSE OLD NUT. When snap ring is used, installthe snap ring in groove of input shaft and pro-ceed to #10.

7. Apply Fuller Transmission adhesive sealant#71204 or equivalent to the cleaned threads of in-put shaft and nut, using caution so as not to con-taminate bearing with sealant.

8. Engage two mainshaft sliding clutches into gearto prevent the mainshaft from rotating and installthe new drive gear bearing nut, left-hand threads,on input shaft. Tighten nut with 250-300 Lbs./Ft.of torque.

in two gears, it may become necessary to place Suggestion: To avoid damaging the O.D. of nut,sliding clutches in the neutral position to rotate use the tool specifically designed for this pur-input shaft and mainshaft for removal of snap ring. pose. See TOOL REFERENCE.Pull the inputdrive gear.

Reassembly

1. If necessary,shaft.

shaft forward and from splines of 9. With a punch and maul, peen the nut into the twomilled slots of input shaft, using caution so asnot to distort O.D. of nut.

10. To facilitate proper reinstallation of the shift barinstall bushing in pocket of input housing assembly on case, make sure mainshaft

sliding clutches are placed in the neutral posi-2. Install new input shaft into splines of main drive tion.

gear just far enough to expose snap ring groove 11. Reinstall the shift bar housing assembly, thein I.D. of drive gear. front bearing cover and all other parts and as-

3. Install snap ring in groove of drive gear. semblies previously removed, making sure to re-

4. Install spacer on input shaft.place the gaskets used.

AIR SYSTEM

AIR SYSTEM

RANGE SHIFT AIR SYSTEM—ALL MODELS

Operation

The Range Shift Air System consists of the air filter/regulator, slave valve, a Range Control Valve, rangecylinder, fittings and connecting air lines. See AirSystem Schematics.

CONSTANT AIR from the air filter/regulator is sup-plied to the “S” or Supply Port of slave valve andpassed through to the INLET or “S” Port of controlvalve.

WHILE IN LOW RANGE, the control valve is OPENand AIR is returned to slave valve at the “P” or EndPort. This signals the valve to supply AIR in line be-tween the Low Range or “L” Port of slave valve andthe Low Range Port of range cylinder housing. AIRreceived at this port moves the range piston to therear and causes the auxiliary low range gear to be-come engaged.

WHILE IN HIGH RANGE, the control valve isCLOSED and NO AIR is returned to the slave valve.This signals the slave valve to supply AIR in line be-tween the High Range or “H” Port of valve and theHigh Range Port of range cylinder cover. AIR re-ceived at this port moves the range piston forward toengage the auxiliary drive gear with sliding clutchand bypass the low range gear set.

Range shifts can be made ONLY when the gearshift lever is in, or passing through, neutral. Thus, therange desired can be PRESELECTED while the shiftlever is in a gear position. As the lever is movedthrough neutral, the actuating plunger in the shift barhousing releases the slave valve piston, allowing it tomove to the selected range position.

Trouble Shooting

If the transmission fails to make a range shift orshifts too slowly, the fault may be in the Range ShiftAir System or actuating components of the shift barhousing assembly.

To locate the trouble, the following checks shouldbe made with normal vehicle air pressure applied tothe system, but with the engine off.

CAUTION: NEVER WORK UNDER A VEHICLEWHILE ENGINE IS RUNNING as personal injury mayresult from the sudden and unintended movement ofvehicle under power.

1. INCORRECT AIR LINE HOOK-UPS(See Air System Schematics)With the gear shift lever in neutral, move the con-trol that provides range selection UP and DOWN.A. If the air lines are crossed between control

valve and slave valve, there will be CON-STANT AIR flowing from the exhaust port ofcontrol valve WHILE IN HIGH RANGE.

2.

3.

4.

B. If the air lines are crossed between the slavevalve and range cylinder, the transmissiongearing will not correspond with the range se-lection. A LOW RANGE selection will result ina HIGH RANGE engagement and vice versa.

AIR LEAKSWith the gear shift lever in neutral, coat all airlines and fittings with soapy water and check forleaks, moving the control that provides range se-lection UP and DOWN.

A.

B.

C.

D.

If there is a steady leak from the exhaust portof control valve, O-rings and/or related partsof the control valve are defective.

If there is a steady leak from breather of slavevalve: an O-ring in valve is defective, or thereis a leak past O-rings of range cylinder piston.

If transmission fails to shift into LOW RANGEor is slow to make the range shift and thecase is pressurized, see Check No. 7 of thissection.

Tighten all loose connections and replace de-fective O-rings and parts.

AIR FILTER/REGULATOR(See illustration, .)With the gear shift lever in neutral, check thebreather of air filter/regulator assembly. Thereshould be NO AIR leaking from this port. Thecomplete assembly should be replaced if asteady leak is found.

Cut off the vehicle air supply to the air filter/regulator assembly, disconnect the air line at fit-ting in Supply OUTLET and install an air gage inopened port. Bring the vehicle air pressure to nor-mal. Regulated air pressure should be 57.5 to 62.5Psi.

DO NOT ADJUST SCREW AT BOTTOM OF REGU-LATOR TO OBTAIN CORRECT READINGS. Theair regulator has been PREADJUSTED within thecorrect operating limits. Any deviation from theselimits, especially with regulators that have beenin operation for some time, is likely to be causedby dirt or worn parts. If replacement or cleaningof the filter element does nothing to correct theair pressure readings, replace the complete as-sembly, as the air regulator is nonserviceable.

RANGE CONTROL VALVE (See Pages 23 and 24.)With the gear shift lever in neutral, select HIGHRANGE and disconnect the l/8” O.D. air line atthe OUTLET or “P” Port of control valve.

AIR SYSTEM

A.

B.

When LOW RANGE is selected, a steady blastof air will flow from opened port. Select HIGHRANGE to shut off air flow. This indicates thecontrol valve is operating properly. Reconnectair line.

If control valve does not operate properly,check for restrictions and air” leaks. Leaks in-dicate defective or worn O-rings.

5. HIGH RANGE OPERATIONWith the gear shift lever in neutral, select LOWRANGE and disconnect the 1/4” I.D. air line at theport of range cylinder cover. Make sure this lineleads from the High Range or “H” Port of slavevalve.

A.

B.

C.

When HIGH RANGE is selected, a steadyblast of air should flow from disconnectedline. Select LOW RANGE to shut off air flow.

Move the shift lever to a gear position and se-lect HIGH RANGE. There should be NO AIRflowing from disconnected line. Return thegear shift lever to the neutral position. Thereshould now be a steady flow of air from dis-connected line. Select LOW RANGE to shutoff air flow and reconnect air line.

If the air system does not operate accord-ingly, the slave valve or actuating componentsof the shift bar housing assembly are defec-tive.

IMPORTANT: RANGE PRESELECTIONThe plunger pin, located in case bore betweenthe slave valve and actuating plunger of shift barhousing, prevents the slave valve from operatingwhile the shift lever is in a gear position. Whenthe lever is moved to or through the neutral po-sition, the pin is released and the slave valve be-comes operational.

6. LOW RANGE OPERATIONWith the gear shift lever in neutral, select HIGHRANGE and disconnect the 1/4" I.D. air line at thefitting on range cylinder housing. Make sure thisline leads from the Low Range or “L” Port ofslave valve.

A. When LOW RANGE is selected, a steady blastof air should flow from disconnected line. Se-lect HIGH RANGE to shut off air flow.

B. Move the shift lever to a gear position and se-lect LOW RANGE. There should be NO AIRflowing from disconnected line. Return thegear shift lever to the neutral position. Thereshould now be a steady flow of air from dis-connected line. Select HIGH RANGE to shutoff air flow and reconnect air line.

C. If the air system does not operate accord-ingly, the slave valve or actuating componentsof the shift bar housing assembly are defec-tive.

7. RANGE CYLINDER (Refer to the followingillustration.)If any of the seals in the range cylinder assemblyare defective, the range shift will be affected.

A.

B.

c.

Leak at either O-ring A results in completefailure to make a range shift; steady flow ofair from breather of slave valve in bothranges.

Leak at gasket B results in a steady flow of airto atmosphere while in HIGH RANGE.

Leak at O-ring C results in a slow shift toLOW RANGE; pressurizing of transmissioncase.

Cut 7420 4/84

Range Cylinder Assembly

AIR SYSTEM

AIR FILTER/REGULATOR ASSEMBLY

The air filter contains a replaceable filter element which can be removed by turning out the end cap. This ele-ment should be cleaned at each oil change, or more often under high humidity conditions. Replace if necessary.

SLAVE VALVES

Refer to the drawing for disassembly and reassembly of the piston-type slave valve assemblies. Should the pop-pet-type slave valve assembly prove to be defective, replace the complete assembly, as it is non-serviceable.The actuating components used with these valve assemblies are non-interchangeable. Failure to use the correctplunger pin, spring, and alignment sleeve during installation on the transmission will cause hard shifting in LowRange gears.

AIR SYSTEM

RANGE CONTROL VALVE A-3546

Reassembly and Installation

1.

2.

3.

4.

Removal and Disassembly

Disconnect the air lines and loosen clamp se-curing the valve to gear shift lever. Remove valve.

Remove the four screws to separate the front andrear housings and remove the slide and two setsof position springs and balls.

Remove the seal, insert valve O-ring and spring 2.from rear housing.

If necessary, remove the two felt seals. Punch out 3.the roll pin to remove the control knob from slide.

4.

1. Refer to the drawing for proper reassembly. Use aVERY SMALL amount of silicone lubricant on theO-rings to avoid clogging ports. A small amount ofgrease on the position springs and balls will helpto hold them in place during reassembly.

Install the air lines with their sheathing and O-rings on the gear shift lever.

Secure the valve on gear shift lever with mountingclamp. The control knob should face to the frontand be approximately 6“ below the centerline ofball grip.

Attach the air lines.

AIR SYSTEM

RANGE CONTROL VALVE A-5010

1.

2.

3.

4.

5.

6.

7.

8.

Removal and Disassembly Reassembly and Installation

Refer to the drawing for proper reassembly. Use aRemove two screws holding bottom cover to valve 1.and slide cover down gearshift lever to expose airline fittings. Disconnect air lines.

Loosen jam nut and turn control valve from gearshift lever.

Pry medallion from recess in top cover.2.

Turn out the two screws to remove the top coverfrom valve housing.

.

Turn out the two screws in side of valve housing toseparate the housing.

Remove the Range Preelection Lever from lefthousing and the position balls and guide fromlever.

If necessary, remove spring and O-ring from boresin left housing.

If necessary, remove springs, O-ring and sleevefrom bores in right housing.

VERY SMALL amount of silicone lubricant on theO-rings to avoid clogging ports. A small amount ofgrease on the position springs and balls will helpto hold them in place during reassembly.

Reinstall control valve on gear shift lever andtighten jam nut.

Attach air lines and reinstall bottom cover.3.

Schematic

For all questionsconcerningremoval andreplacement,refer to EatonService and PartsLiterature.

Range—LO

Air Filter/RegulatorAssembly

Range CylinderAssembly

Air fromVehicleSource

Constant Air

HI

No Air

Air to HousingPort

A-3546 RangeValve

P S

A-5010 RoadrangerValve

DownOR

SP

Slave ValveIdentification

A-4688 Valve

A-5000 Valve

19470 Valve

7L: 8: 9: and 10 Speed (2-Speed Auxiliary)

A-4688 Slave Valve 19470 or A-5000Slave Valve

OR

PS

PS

LO

Down

Outlet

HILO

LO

HI

Schematic

For all questionsconcerningremoval andreplacement,refer to EatonService and PartsLiterature.

Air fromVehicle Source

Constant Air

HI

Up

Outlet

P S

UpOR

SP

Slave ValveIdentification

19470 Valve

A-5000 Valve

A-4688 Valve

No Air

Air to CoverPort

Air Filter/RegulatorAssembly

Range CylinderAssembly

A-5010 RoadrangerValve

Range—HI

OR

S

PS

A-4688 Slave Valve 19470 or A-5000Slave Valve

LO

7L: 8: 9: and 10 Speed (2-Speed Auxiliary)

HILO

HI

LO

P

A-3546 RangeValve

DISASSEMBLY AND REASSEMBLYSHIFTING CONTROLS

AIR SYSTEM

RANGECONTROL

VALVEA-501O(2) PORT

CONNECTORS

RANGECONTROL

VALVEA-3546(2) PORT

CONNECTORS

Cut 702011/84

A. Removal of Control ValveNOTE: For removal and disassembly of modelsalso equipped with the Countershaft Brake Con-trol, see Page 106.

3.3

1. Disconnect two 1/8" O.D. air lines at the "S" orSupply Port and the "P" or End Port of slave valveon transmission case.


3. Disconnect two 1/8" O.D. air lines at Range Con-trol Valve of models so equipped (left). Removeball grip, loosen valve mounting clamp and re-move valve, mounting clamp, air lines, sheathingand O-rings from gear shift lever (right).NOTE: For disassembly and reassembly of RangeControl Valve, see Page 23.

4. For models equipped with an A-5010 Valve, turnout two mounting screws in valve cover.

5. Slide cover down shift lever to expose valve portsand disconnect two 1/8" O.D. air lines at valve.

6. Loosen jam nut and turn the A-5010 Valve and nutfrom gear shift lever. Remove valve cover, airlines, sheathing and O-rings from lever.NOTE: For disassembly and reassembly of A-5010Valve, see Page 24.


C. Removal of Slave Valve19470 Slave Valve shown. For other slave valve com-binations see Air System Schematics page 25.

B. Removal of Air Filter

Regulator Assembly

1. Disconnect and remove 1/4" I.D. air line between 1. Disconnect and remove 1/4" I.D. air line betweenthe slave valve and air filter/regulator assembly.the slave valve and High Range Port in housing ofrange cylinder.

2. Turn out capscrews and remove air filter/regulatorassembly.NOTE: For disassembly and reassembly of Air Fil-ter/Regulator Assembly, see Page 22.

2. Disconnect and remove l/4" I.D. air line betweenthe slave valve and Low Range Port in cover ofrange cylinder.


5. Remove spring and plunger pin from bore in case.3. Turn out four retaining capscrews and remove

slave valve from transmission.

4. Remove hat-type alignment sleeve from bore inslave valve.

6. If necessary, remove air line fittings from slavevalve.NOTE: For disassembly and reassembly of pis-ton-type Slave Valve Assembly ONLY, see Page22.

30


GEAR SHIFT LEVER HOUSING ASSEMBLY

A. Removal and Disassembly

1.

4-2

Turn out four capscrews, jar lightly to breakgasket seal and remove gear shift lever housingfrom shift bar housing.NOTE: Remote control housings are removedfrom shift bar housing in the same manner. Fordisassembly and reassembly of LRC Assemblies,see Illustrated Parts List No. P-541. For disas-sembly and reassembly of SRC Assemblies, seeIllustrated Parts List No. P-515.

2. Remove boot from gear shift lever and secure as-sembly in vise with bottom of housing up. Use alarge screwdriver to twist between spring andhousing, forcing spring from under lugs in hous-ing. Do one coil at a time.

31


3. Remove tension spring, washer and gear shiftlever from housing.

4. Remove spade pin from bore in housing tower. Ifnecessary, remove the O-ring from groove insidetower.

B. Reassembly of Gear Shift Lever

Housing Assembly

1. With gear shift lever housing secured in vise asduring disassembly, install spade pin in bore ofhousing tower. If previously removed, install O-ring in tower groove.

2. Position gear shift lever in housing with spadepin in lever ball slot and install tension springwasher over ball, dished-side up.

32


4. Remove assembly from vise and install rubberagainst housing.

3. Install tension spring under lugs in housing, seat-ing one coil at a time. Use of a spring driving toolis recommended.


A. Removal and DisassemblyNOTE: For models equipped with an Oil Pumpand/or Cooler Assemblies, make sure to discon-nect the lube line at fitting on shift bar housingprior to proceeding with the following instruc-tions.

1. Turn out capscrews, jar to break gasket seal andlift shift bar housing from case.NOTE: During disassembly, lay all parts on aclean bench in order of removal from housing tofacilitate reassembly. Shift bars not being re-moved MUST be kept in the neutral position or in-terlock parts will lock bars. For disassembly andreassembly of "X" and "F" model assemblies,see Illustrated Parts List.

2. Tilt assembly and remove three tension springsand balls from housing.


3. Mount assembly in a vise with plunger-side upand secure on housing flange. For models soequipped, cut lockwire and turn out the retainingcapscrews to remove oil trough from housing.NOTE: Starting with the upper shift bar, move allbars to the right and out bore of rear boss. Cutlockwire and remove Iockscrews from each barjust prior to their removal from housing.

5. Move 1st-2nd speed shift bar to rear of housing,removing yoke and block from bar. As notch inbar clears rear boss, remove small interlock pinfrom bore at notch.

6. Remove actuating plunger from bore at top ofcenter boss.

4. Move 3rd-4th speed shift bar to rear of housing,removing yoke and block from bar.


7. Move Reverse speed shift bar to rear of housing,removing yoke and spacer from bar.

8. As shift bar is removed from housing, two 3/4Ò in-terlock balls will drop from bottom bore of rearboss.

9. If necessary, remove plug, spring and plungerfrom bore in Reverse shift yoke.

B. Reassembly of Shift Bar

Housing Assembly

1. If previously removed, install plunger in Reverseshift yoke, making sure plunger is fully seated inbore at yoke slot.

2. Install spring in bore of yoke and onto shank ofplunger.


3. Install plug and tighten to compress spring (left).Back plug out 1 - 1 1/2 turns and stake plug throughsmall hole in yoke (right).

4. With shift bar housing secured in vise as shown,hold notched-end of Reverse shift bar and installin lower bore of housing bosses, positioning spa-cer and yoke on bar between the bosses. Installyoke Iockscrew, torque to 35-45 lbs./ft. and wiresecurely.NOTE: Keep bars in neutral position during instal-lation. DO NOT EXCEED recommended torqueratings for yoke Iockscrews.

5. Install actuating plunger in bore at top of centerboss as shown.

6. Install one 3/4" interlock ball in bore at top of rearboss.


7. Install 1st-2nd speed shift bar in middle bore, po-sitioning the shift block and yoke on bar asshown. Just prior to pushing notched end of barin boss, install the interlock pin VERTICALLY inbore at neutral notch. Install the block and yokeIockscrews, torque to 35-45 lbs./ft. and wire se-curely.

9. Install the 3rd-4th speed shift bar in upper bore,positioning the shift block and yoke as shown. In-stall the block and yoke lockscrews, torque to 35-45 lbs./ft. and wire securely.

8. Install second 3/4" interlock ball in bore.

10. For models so equipped, install the oil trough onhousing. Tighten capscrews and wire securely.

11. Remove assembly from vise and install three ten-sion balls, one in each bore and three tensionsprings, one over each ball in housing bores (in-set).

REMOVAL-COMPANION FLANGE,AUXILIARY SECTION AND CLUTCH HOUSING

COMPANION FLANGE, AUXILIARY SECTIONAND CLUTCH HOUSING

A. Removal of Universal Joint

Companion Flange or Yoke

2. Pull companion flange or yoke from splines of1. Lock transmission by engaging two mainshaft output shaft. Remove speedometer drive gear or

gears with sliding clutches (inset). Use a large replacement spacer from hub of flange/yoke orbreaker bar to turn nut from output shaft and re- from inside rear bearing cover remaining on out-move washer if so equipped. put shaft.


B. Removal of Auxiliary Section

3. Remove puller screws and attach a chain hoist toauxiliary section. Move assembly to rear until freeof front section and remove gasket.

1. Turn out capscrews in auxiliary housing flange.

2. Insert three puller screws in tapped holes ofhousing flange. Tighten evenly to move auxiliarysection to rear and just far enough from front sec-tion to break gasket seal.

4. The auxiliary section can also be removed withtransmission set in vertical position. Block underclutch housing to prevent damage to input shaft,remove capscrews in housing flange and lift as-sembly evenly from front section.

40


C.

1.

Removal of Clutch Housing

For models so equipped, remove the clutch re-lease mechanism and/or clutch brake assembly.See OPTIONS page 104.

2. Turn out and remove four capscrews (left) and re-move six nuts and lockwashers from studs (right)securing the clutch housing to transmissioncase.

3. Jar clutch housing with a rubber mallet to breakgasket seal and pull from transmission case.

41

DISASSEMBLY-AUXILIARY SECTION

AUXILIARY SECTION

*NOTE: Use lockwire at these positions during reassembly.

Cut 6427 5/83

A. Removal and Disassembly of

Range Cylinder Assembly

1. For ease of disassembly, mount auxiliary sectionupright in vise as shown. Turn out capscrews and

2. Remove nut from end of yoke bar.

remove range cylinder cover.


5. Remove range yoke from sliding clutch of syn-3. Cut lockwire and remove two yoke Iockscrews.

4. Pull yoke bar from bore of cylinder housing.

6. Remove range piston from cylinder bore.If necessary, remove the O-rings from piston I.D.and O.D. (inset).


7. Turn out capscrews and remove range cylinderhousing. If necessary, remove small O-ring fromgroove in housing bore (inset).


. Cut 6485 9/80

B. Removal of Auxiliary

Countershaft Assemblies

1. Turn out capscrews and remove both counter-shaft rear bearing covers and gaskets.

2. Remove snap ring from groove at rear of eachcountershaft.


3. Use a soft bar and maul to drive countershaftforward and from rear bearings.

5. If necessary, secure assembly in a vise and re-move bearing inner race from front of counter-shaft with jaw pullers.NOTE: The vise used should be equipped withbrass jaws or wood blocks to prevent damage tocountershaft.

4. Remove bearings from bores in auxiliary plate bytapping lightly and evenly to rear with a soft bar.

.


Cut 6480B 3/84

C. Removal and Disassembly of

Synchronizer Assembly

2. Place larger low range synchronizer ring onbench and pull high range synchronizer fromblocker pins. However, before doing so, cover theassembly with a shop rag to prevent losing thethree springs released from high range synchroni-zer at pin locations.

1. Pull synchronizer assembly from splines of out-put shaft.

3. Remove sliding clutch from pins of low rangesynchronizer ring.

DISASSEMBLY—AUXILIARY SECTION

Cut 6551A 4/84

48


D. Removal and Disassembly of

Output Shaft and Rear BearingAssemblies

1. Use a soft bar and maul to drive output shaftforward and through rear bearing assembly.

2. Remove bearing inner spacer from output shaft.

3. Using front face of low range gear as a base,press the output shaft through gear and bearing.Remove bearing and washer from hub of lowrange gear.

4. If necessary, remove snap ring from low rangegear of models so equipped.


5. Remove splined spacer from output shaft.

6. Remove stepped washer from shaft of models soequipped.

7. Turn out capscrews and remove rear bearingcover. Rear bearing cone will drop from bore inauxiliary plate when cover is removed. If neces-sary, remove oil seaI from cover (inset).

8. Remove two bearing cups and outer spacer frombore in auxiliary plate.

REASSEMBLY-AUXILIARY SECTION

AUXILIARY SECTIONA. Reassembly and Installation of

Output Shaft and Rear Bearing

Assemblies

1. Secure output shaft in a vise with threaded endup. For 11608 models, install stepped washer onshaft large diameter down (arrow), then installsplined spacer.

2. For 14608 models, install spacer with largediameter splines down.

IMPORTANT: Mark any two adjacent teeth on lowrange gear and repeat procedure for two adjacentteeth directly opposite first set marked. A highlyvisible color-of toolmakers' dye is recommended.

4. If previously removed, install snap ring in lowrange gear of models so equipped (inset). Installthe gear on output shaft, clutching teeth downand engaged with splines of spacer.

3.


5. Install washer on shaft; 11608 models flat side ofwasher facing up, 14608 models flat side ofwasher facing down.

6. Heat front bearing cone and install on shaftagainst washer, bearing taper up.NOTE: DO NOT HEAT BEARING ABOVE 275oF(136oC). If possible, use heat lamps as source.

7. Install bearing inner spacer on output shaft.

8. Install front bearing cup in bore of auxiliary plate,taper to the inside. Use a soft bar to start cupinto bore.


9. Place bearing outer spacer against cup and use asoft bar or flanged-end driver to move both partsevenly into bore.

10.

11. Install auxiliary plate over end of output shaft as-sembly. Heat rear bearing cone and install onshaft, taper down and inside bearing cup.NOTE: DO NOT HEAT BEARING ABOVE 275oF(136oC).

Place rear bearing cup against spacer. Use a12. If previously removed, install oil seal in rearflanged-end driver to move all three parts evenly

bearing cover with a flanged driver (inset). Sealinto bore until lip of rear bearing cup seats onshould be installed so the spring is to front ofauxiliary plate.transmission.


13.

B.

1.

Remount the assembly upright in vise and secureon flange of auxiliary plate. Position correspond-ing new gasket on cover mounting surface and in-stall the rear bearing cover. Use the nylon collarand brass washer with capscrew at the cham-fered hole which intersects speedometer bore (in-set). Secure cover to auxiliary plate.NOTE: Because collar becomes distorted whencompressed, DO NOT RE-USE OLD NYLON COL-LAR.

2. Install three springs in bores of high range syn-chronizer ring.

Reassembly and Installation

of Synchronizer Assembly

Place larger low range synchronizer ring onbench and install sliding clutch on blocker pins,recessed side up.

3. Place high range synchronizer ring over blockerpins of low range synchronizer, seating springsagainst pins.


4. Apply downward pressure to high range syn-chronizer ring WHILE TWISTING COUNTER-CLOCKWISE to compress springs and fully seatring on blocker pins of low range synchronizer.

5. Install synchronizer assembly on splines of out-put shaft, low range ring in recess of low rangegear.

C. Timing and Installation of

Auxiliary Countershaft Assemblies

1. If previously removed, install bearing inner raceon front of each countershaft.

2. IMPORTANT: On low range gear of each auxiliarycountershaft assembly, use a highly visible colorof toolmaker's dye to mark the tooth stampedwith an "O" for timing purposes.

REASSEMBLY-AUXILIARYSECTION (10-SPEED MODELS)

4. Install snap ring in groove at rear of each counter-shaft.

3. Place one countershaft assembly into position inrear plate, meshing the marked tooth of counter-shaft low range gear with either set of twomarked teeth of low range gear on output shaft(inset). Center rear of countershaft in bearingbore, start rear bearing in bore and complete in-stallation with a flanged-end driver and maul. Re-pea t t he p rocedure w i th o the r aux i l i a r ycountershaft assembly, making sure the lowrange gear set remains in time during bearing in-stallation.NOTE: Check synchronizer assembly for springsthat may have been released from bores in highrange ring during bearing installation.

5. Position corresponding new gasket on covermounting surface and install both rear bearingcovers.


D. Reassembly and Installation ofRange Cylinder Assembly

1. If previously removed, install O-ring in bore ofrange cylinder housing.

inder housing, aligning notches in bar with yokeIockscrew holes (inset).

2. Position corresponding new gasket on housingmounting surface and install cylinder housing inrear bore of auxiliary plate, air fitting to the upperleft. Secure housing to plate.

3. Place range yoke into position with sliding clutchof synchronizer assembly, long hub of yoke to thefront (RT-11608 Series); long hub of yoke to therear (RT-14608 Series). Insert threaded-end ofyoke bar through yoke and into bore of range cyl-

4. Install two yoke lockscrews, tighten and wire securely.


5. If previously removed, install O-rings in I.D. and0.0. of range piston.

7. Position corresponding new gasket on covermounting surface and install range cylinder coveron housing, open port to the upper left. Tightencapscrews to secure cover to housing.

6. In cylinder housing bore, install range piston onyoke bar, flat side to the rear. Secure with nuttightened to recommended torque ratings (Inset).

DISASSEMBLY„ FRONT SECTION

A. Removal of Front Bearing Cover

and Input Shaft Nut

1. Turn out retaining capscrews and remove drivegear bearing cover and gasket.

3. Engage two mainshaft sliding clutches into gear(inset), this prevents transmission from rotating.Remove nut (left hand thread) with drive gear nutremoving tool.

2. If necessary remove oil seal from cover of modelsso equipped.

DISASSEMBLY - FRONT SECTION

CASE ASSEMBLIES

B. Removal and Disassembly of

Auxiliary Drive Gear Assembly

1. Remove snap ring from groove at rear of main-shaft.

2. Cut lockwire and remove capscrews from bearingretainer ring.

DISASSEMBLYÑFRONT SECTION

3. Insert three puller screws in the specially tappedholes of retainer ring. Tighten screws evenly topull auxiliary drive gear assembly from case bore.

4. Remove snap ring from hub of auxiliary drivegear.

5. Using rear face of retainer ring as a base, pressdrive gear through bearing.

6. If necessary, remove O-rings from hub O.D. ofauxiliary drive gear.

DISASSEMBLY-FRONT SECTION

C. Removal and Disassembly of LeftReverse Idler Gear Assembly

1. Move mainshaft reverse gear as far to rear as pos-sible and remove snap ring from I.D. of gear.

2. Move reverse gear forward and against spacer,engaging splines of mainshaft sliding clutch.


3. Using impact puller, remove auxiliary counter-shaft front bearing from left reverse idler gearbore. If necessary, repeat procedure for removingauxiliary countershaft front bearing from right re-verse idler gear bore.

.

4. Turn out stop nut from front of idler shaft and re-move washer.

5. Remove plug from rear of idler shaft and use animpact puller, 1/2-13 threaded end, to remove shaftfrom case bore (inset).

6. As idler shaft and idler plate is moved to the rear,remove the thrust washer, and gear from case.

7. If necessary, remove inner race from bearing andpress needle bearing from idler gear.

DISASSEMBLY– FRONT SECTION

D. Removal of Countershaft BearingsNOTE: In the following instructions, the front andrear bearings from BOTH countershaft are re-moved. For removal of the mainshaft assemblyfrom case, it is necessary to remove the bearingsfrom right countershaft ONLY.

1. Remove snap ring from groove at rear of eachcountershaft.

2. From inside case, use a soft punch and maul todrive the countershaft rear bearings to the rearand from case bores.NOTE: This procedure will damage bearings andshould not be attempted unless replacement ofbearings is planned.


3. Turn out capscrew and remove front bearing re-tainer plate from right countershaft.

„

4. Use a soft bar and maul to drive countershaft tothe rear as far as possible. This will partially un-seat the front bearing.NOTE: The soft bar used should have a flattenedend that is large enough so as not to damageholes for roll pin and capscrew.

5. From the rear of case, use a soft bar and maul todrive right countershaft forward to unseat frontbearing from case bore and expose the bearingsnap ring.

6. Use a bearing puller to remove the countershaftfront bearing.N O T E : The bearing inner race of modelsequipped with roller-type front bearings will re-main pressed on countershaft.

DISASSEMBLY—FRONT SECTION

E. Removal and Disassembly of

Mainshaft Assembly

1. Block right countershaft assembly against case2. Remove 3rd-4th speed sliding clutch from front of

wall and pull mainshaft assembly to the rear tomainshaft.

free pilot from pocket of input shaft. Tilt front ofmainshaft up and lift assembly from case (inset).Use caution. Reverse gear is free and can fallfrom shaft.

66


3. Remove snap ring from groove at rear of main-shaft.

4. Remove reverse gear and spacer from rear ofmainshaft.

5. From rear of mainshaft, pull the key from main-shaft keyway.NOTE: When removing limit washers, spacersand gears, note their location on mainshaft to fa-cilitate reassembly. There is ONLY one limitwasher and one spacer belonging to each gear.

6. Turn reverse gear limit washer to align its splineswith those of mainshaft and remove washer.


7. Remove Reverse speed sliding clutch from main-shaft.

8. Using a small screwdriver, turn limit washeralign its splines with those of mainshaft andmove from rear of mainshaft.

9. Remove spacer from mainshaft.

10. Remove 1st speed gear from rear of mainshaft. Ifnecessary, remove the snap ring from I.D. of gear(inset).


11. Remove spacer (left), rotate limit and limit washer(right) and remove from rear of mainshaft.

12. Remove 1st-2nd speed sliding clutch.

13. Using a small screwdriver, turn limit washer inhub of 2nd speed gear to align its splines withthose of the mainshaft.

14. Lift 2nd speed gear from rear of mainshaft to re-move limit washer, spacer, and gear. If necessaryremove snap ring from I.D. of gear.


15. Remove 3rd gear, spacer, and limit washer. If nec-essary remove snap ring from I.D. of gear.

DISASSEMBLY - FRONT SECTION

F. Removal and Disassembly ofMain Drive Gear Assembly

2. Move upper countershaft to right and removedrive gear and spacer from case.

1. Drive the input shaft back through bearing with asoft bar and maul. Remove input shaft from case(inset).


3. Drive the input shaft bearing out the front ofcase.

4. If necessary, remove the snap ring from drivegear.

5. Check the bushing in pocket of input shaft andreplace if worn or damaged.

6. Remove the front and rear bearings from leftcountershaft as described in Part D of this sec-tion.


G. Removal and Disassembly ofCountershaft AssembliesNOTE: Refer to the illustration provided at Part Dof this section. Except for the PTO gears, the leftand right countershaft assemblies are identicaland disassembled in the same manner.

1. Move the right countershaft assembly to the rearas far as possible so front of shaft can be re-moved from case bore and moved to the center ofcase. Lift the assembly from case and repeat theprocedure for left countershaft assembly.NOTE: The left and right reverse idler gear as-semblies are identical and disassembled in thesame manner. If removal and disassembly of thisassembly is necessary, refer to Part B of this sec.tion.

3. Remove the drive gear retaining snap ring fromfront of each countershaft.

3. Using the rear face of 4th speed gear as a base,press the drive gear, PTO gear and 4th speed (oroverdrive) gear from each countershaft (left). Thiswill also remove the front bearing inner race fromcountershaft of models so equipped (right).IMPORTANT: NEVER USE THE PTO GEAR AS APRESSING BASE. The narrow face width of thisgear makes it very susceptible to breakage.

4. Using the rear face of 2nd speed gear as a base,press the 3rd speed and 2nd speed gears fromeach countershaft.NOTE: Always use caution when pressing a clus-ter of gears from countershaft. It is necessary topress these gears off in a cluster of three and,then, in a cluster of two.


5. I f necessary, remove key f rom countershaf t . 6. If necessary, remove spacer.

REASSEMBLY-FRONT SECTION

CASE ASSEMBLIESNOTE: Before starting reassembly, make sure thethree magnetic discs are solidly in place at bottom ofcase. These can be secured to disc mounting sur-faces with Scotch Grip Rubber Adhesive or equiva-lent adhesive.

A. Reassembly and Installation ofRight Reverse Idler Gear Assembly

1. If previously removed, thread pipe plug in rear ofreverse idler shaft and tighten. Install the washeron shaft, flat side to the front (inset).

2. If previously removed, press the needle bearinginto bore of reverse idler gear.

3. Install the bearing inner race on idler shaft and in-sert shaft into case bore, threaded-end of shaft tothe front. As the idler shaft is moved forward, in-stall the reverse idler gear on shaft, long hub tothe front and seating on bearing inner race. Posi-tion the thrust washer on shaft between the gearand support boss in case and continue withmovement of idler shaft forward into bore of sup-port boss.


5.

B.

1.

Install OUTER RACE of auxiliary countershaftfront bearing into case bore and against retainingwasher.NOTE: The bearing INNER RACE is installed onfront of auxiliary countershaft and never withouter race.

Reassembly of Countershaft

Assemblies

NOTE: Except for PTO gears, the left and rightcountershaft assemblies are identical and reas-sembled in the same manner.

If previously removed, install the spacer (left) andkey in keyway of countershaft (right).

2. Align keyway of gear with key in countershaft andpress the 1st speed gear on shaft, long hub ofgear to the front of countershaft.

3. Press 2nd speed gear on countershaft, long hubof gear against 1st speed gear hub.


4. Press 3rd speed gear on countershaft, long hubof gear to front of shaft.

5. Start the PTO gear onto countershaft, bullet-noseside of teeth facing up and toward rear of shaft.Align keyway of drive gear with key in counter-shaft and press BOTH gears onto shaft, long hubof drive gear against PTO gear.NOTE: The left countershaft assembly has a 47-tooth PTO gear; the right countershaft assemblyhas a 45-tooth PTO gear.

6. To avoid confusion during installation, mark endof left countershaft with an "L"; the end of rightcountershaft with an "R".

7. Install drive gear retaining snap ring in groove onfront of each countershaft.


8. For models equipped with rol ler- type frontbearings, use a rubber mallet or flanged-enddriver to install bearing inner race on shaft,shoulder of race against shoulder of coun-tershaft.

IMPORTANT: Mark the countershaft drive gear fortiming purposes. On the drive gear of each coun-tershaft assembly, mark the tooth aligned with key-way of gear and stamped with an "O" for easyidentification. A highly visible color of toolmakers'dye is recommended for making timing marks.

. -

C. Partial Installation ofCountershaft Assemblies

1. Place the left countershaft assembly into posi-tion in case, making sure that the "L"-marked as-sembly has the larger 47-tooth PTO gear.

2. Place the right countershaft assembly into posi-tion in case, making sure that the "R"-marked as-sembly has the smaller 45-tooth PTO gear.


D. Bearing Installation of LeftCountershaft Assembly

3. Center the front of left countershaft in bearingand move the assembly forward.

1. Move the left countershaft assembly to the rearand insert countershaft support tool or blockingto center shaft in rear case bore.

4. Use a flanged-end bearing driver to completelyseat front bearing or bearing outer race in casebore.

2. Use a flanged-end bearing driver to start thebearing in case bore.NOTE: The inner race of roller-type front bearingis pressed on front of countershaft.


5. Position the retainer plate on front of left counter-shaft, roll pin in hole at end of shaft, and securewith capscrew tightening to recommended tor-que ratings.

6. Remove countershaft support tool or blocking.

from rear case bore and install the left counter-shaft rear bearing with larger I.D. lead chamfer tothe front of shaft and install the snap ring ingroove at rear of left countershaft.


E. Reassembly, Installation and Timing

of Main Drive Gear Assembly

3. Mesh the marked tooth of left countershaft drivegear with either set of two marked teeth on maindrive gear. Slide the input shaft through the maindrive gear (inset).

1. If previously removed, install the snap ring in I.D.of main drive gear and the bushing in pocket ofinput shaft (inset).

4. Install spacer (inset) and bearing on the inputshaft with external snap ring to the outside.

2. Mark the main drive gear for timing purposes.Mark any two adjacent teeth on drive gear and re-peat the procedure for the two adjacent teethdirectly opposite the first set marked. A highlyvisible color of toolmakers' dye is recommendedfor making timing marks.

REASSEMBLY-FRONT SECTIONã

5. Tap the bearing into position in the bore with asoft mallet.

7. Use a soft bar and maul to drive the input shaftthrough bearing. Remove front bearing cover.

F. Reassembly of AuxiliaryDrive Gear Assembly

NOTE: Because the auxiliary drive gear assembly

and centering mainshaft in rear bearing boreis used in checking reverse gear axial clearances

during Reassembly and Partial Installation ofMainshaft Assembly, it is necessary to completethe following instructions BEFORE proceeding toPart G.

6. Temporarily install the front bearing cover.

1. If previously removed, install the O-rings on ex-tended front hub of auxiliary drive gear.

REASSEMBLY - FRONT SECTION

2.

3.

Install the retainer ring on auxiliary drive gear,snap ring groove facing front hub and away fromgear teeth.

Start the auxiliary drive gear bearing on front hub,bearing snap ring facing groove in retainer ring.Using both the inner and outer race of bearing asa base, press the bearing on gear with snap ringin groove of retainer ring or use a bearing driver(inset).

4.

G.

1 .

Install the snap ring in groove of front gear hub toretain bearing.

Reassembly and Partial Installationof Mainshaft Assembly

If previously removed, install the correspondingsnap rings in I.D. of mainshaft gears.


FC1.89

2. Secure the mainshaft in a vise equipped withbrass jaws or wood blocks, pilot-end of shaftdown. If previously removed, install the roll pin inkeyway.

3. Install the 4th speed gear limit washer on main-shaft, flat side of washer up. Rotate washer in the1st or bottom groove of mainshaft to align thesplines of washer with those of the mainshaft. in-stall the key in mainshaft keyway to lock washerin place.

4. Install the spacer on shaft against washer.

5. Install the 4th speed (or Overdrive) gear on main-shaft, clutching teeth down and engaged with ex-ternal splines of spacer.NOTE: Gear limit washers are internally splinedand locked to mainshaft by the key. Gear spacersare externally splined to engage with clutchingteeth in gear hubs. There is one limit washer andone spacer for each gear in the mainshaft as-sembly.


6. Install the 3rd speed gear on shaft against 4thspeed (or Overdrive) gear, clutching teeth up.

8. Remove the key from keyway and install the 3rdspeed gear limit washer on mainshaft, flat side ofwasher down and against spacer. Rotate washerin the 2nd groove of mainshaft to align thesplines of washer with those of the mainshaftand reinsert key in keyway to lock washer inplace (inset).

7. Install the spacer in 3rd speed gear, engaging theexternal splines of spacer with clutching teeth ofgear.

121


10. Install the 2nd-3rd speed sliding clutch, aligningthe missing internal spline of sliding clutch withkey in mainshaft.

9. Insert two large screwdrivers between the 3rdand 4th speed (or Overdrive) gears to check axialclearances. Apply slight downward pressure onscrewdriver handles to spread gears evenly. Mak-ing sure the gear hubs are parallel, insert a feelergage between hubs. Correct axial clearanceshould be from .005" to .012". If the clearance isless than the minimum .005" tolerance, the limitwasher in the 3rd speed gear should be replacedby a thinner limit washer. This will increase theaxial clearance between the gears. If the clear-ance checked is greater than the maximum .012"tolerance, a thicker limit washer should be in-stalled in the 3rd speed gear. This would de-crease the axial clearance between the gears.

11. Remove the key from keyway and install the 2ndspeed gear limit washer on mainshaft, flat side ofwasher up. Rotate washer in the 3rd groove ofmainshaft to align the splines of washer withthose of the mainshaft and reinsert key in keywayto lock washer in place.

122

REASSEMBLY—FRONT SECTION

SETTING CORRECT AXIALCLEARANCES FORMAINSHAFT GEARSAxial Clearance (End-Play) Limits Are:

.005’’-,012” for all mainshaft gears

Washers are used to obtain the correct limits; sixthicknesses are available as follows:

LIMITS (INCH) COLOR CODE.248 -.250 WHITE.253 -.255 GREEN.258-.260 ORANGE.263 -.265 PURPLE.268-.270 YELLOW.273 -.275 BLACK

* “PLUS RED”

*NOTE: New style limit washers come in a full rangeof tolerances as corresponding colors listed above“plus red. ” (Example: “Orange plus red” limitwasher has an inch limit thickness of .258-.260.)

Refer to Illustrated Parts Lists for washer part num-bers.

Always use the .248-.250” low limit washer ("White"or “white plus red”) in the 1st and 3rd speed gear po-sitions as shown at right.

Cut 7324A 11/84


12. Install spacer on shaft against washer.

13. Install 1st speed gear on mainshaft, clutchingteeth down and engaged with external splines ofspacer.

14. Install spacer on shaft against 1st speed gear.

15. Remove key from keyway and install spacer limitwasher on mainshaft, flat side of washer downand against spacer. Rotate washer in 4th grooveof mainshaft to align splines of washer withthose of mainshaft and reinsert key in keyway tolock washer in place (inset).


16. Pull up evenly on spacer and check axial clear-ance between 1st speed gear and spacer. If nec-essary make adjustments as described in No. 9 ofthis section.

17. Install Reverse speed sliding clutch, aligningmissing internal spline of sliding clutch with keyin mainshaft.

18. Remove key from keyway and install reverse gearlimit washer on mainshaft, flat side of washer up.Rotate washer in 5th groove of mainshaft to alignsplines of washer with those of mainshaft. Rein-sert key in keyway to lock washer in place.

19. Install spacer on shaft against washer.


20. Install snap ring in 6th groove of mainshaft to re-tain key in keyway.

22. Install reverse gear on mainshaft, clutching teethdown and engaged with external splines of spa-cer.

21. Install snap ring in hub of reverse gear ONLY TOCHECK AXIAL CLEARANCE (END-PLAY) LIMITS.

23 . Install the auxiliary drive gear assembly in itsproper position on rear of mainshaft.


24. Force both the reverse gear and auxiliary drivegear downward on the shaft to flatten their re-spective snap rings. Making sure the gear hubsare parallel, insert a feeler gage between thehubs of the reverse gear and auxiliary drive gear.Correct axial clearance should be from .005" to.012". If clearance is less than the minimum .005"tolerance, the reverse gear limit washer should bereplaced by a thinner limit washer. This will in-crease the axial clearance between the gears. Ifthe clearance checked is greater than the max-imum .012" tolerance, a thicker limit washershould be installed in the reverse gear. Thiswould decrease the axial clearance between thegears.NOTE: THIS CHECK IS MADE WITHOUTSPREADING THE GEARS WITH SCREW-DRIVERS.

25. With the proper reverse gear limit washer in-stalled on mainshaft, remove the auxiliary drivegear assembly and reverse gear.

26. Remove the snap ring from hub of reverse gearand reinstall the gear on mainshaft. Engage theclutching teeth of gear with the splines of spacerand sliding clutch and move the reverse gearagainst the 1st speed gear.


Remove the mainshaft assembly from vise. Alignthe missing internal spline of 3rd-4th speed slid-ing clutch with key in mainshaft and install onfront of shaft, engaging the external splines ofsliding clutch with clutching teeth of 3rd speedgear.

28. Block the right countershaft assembly againstcase wall and lower the mainshaft assembly intoposition with the reverse gear held against spacerand rear of shaft moved into case bore.

29. Move the pilot-end of mainshaft into pocket bush-ing of input shaft.

30. With the reverse gear remaining against spacer,mesh corresponding forward speed gears of leftcountershaft assembly. Check to make sure thatmarked tooth on left countershaft drive gear hasremained in mesh with marked set of teeth onmain drive gear.

27.


31.

H.

Center rear of mainshaft in case bore and installauxiliary drive gear assembly on shaft, partiallyseating bearing in bore. DO NOT COMPLETE IN-STALLATION AT THIS TIME.

Bearing Installation and Timing of

Right Countershaft Assembly

IMPORTANT: The left countershaft assemblyMUST remain in time with main drive gear whentiming right countershaft assembly.

1. Remove blocking from right countershaft as-sembly and place it parallel to mainshaft as-sembly . Mesh the marked too th o f r igh tcountershaft drive gear with remaining set of twomarked teeth on main drive gear.

2. Insert countershaft support tool in rear bearingbore.

3. Install right countershaft bearings in the samemanner described in Part D for left countershaftbearings.

4. With bearing installation complete, install snapring in groove at rear of right countershaft.


1. Reassembly and Installation of

Left Reverse Idler Gear Assembly

NOTE: Since the left and right reverse idler gearassemblies are identical, reassembly and installa-tion of the left reverse idler gear assembly shouldbe performed at this time as described in Part Aof this section.

1. Move reverse gear to the rear on mainshaft andengage sliding clutches with all forward speedgears. A sliding clutch that will not engage with agear indicates the gear set is not in proper mesh.The bearings of the right countershaft would thenneed to be removed and the drive gear set reti-med.NOTE: Do not engage sliding clutches with morethan one gear at the same time. This will lock thegearing and prevent the mainshaft and countershaftassemblies from rotating.

J. Completed Installation of Mainshaft

and Auxiliary Drive Gear Assemblies

1. Remove auxiliary drive gear assembly from main-shaft and rear bearing bore. Do not allow main-shaft to move to rear when removing auxiliarydrive gear.

2. Move reverse gear to the rear as far as possible,meshing teeth of gear with those of the reverseidler gears.


3. Align external splines of spacer with clutchingteeth of reverse gear and move spacer forward onmainshaft and into gear.

6. Align the six capscrew holes in retainer withtapped holes in case and install capscrews.Tighten to 35-45 lbs./ft. and lockwire capscrewsin groups of three as shown.

4. Install snap ring in hub orf hub of reverse gear and movereverse gear forward on mainshaft and intoproper position in case.

5. Reinstall the auxiliary drive gear assembly on rearof mainshaft. Use a flanged-end driver and maulto seat bearing in case bore. 7. Install snap ring in groove at end of mainshaft.


K. Installation of Drive Gear Nut

and Front Bearing Cover

1. Apply Loctite grade 277 sealant to cleanedthreads of new drive gear bearing nut. DO NOTREUSE OLD NUT.NOTE: For models equipped with a snap ring toretain bearing, install snap ring in groove of inputshaft and proceed to No. 4.

4. If previously removed, install the oil seal in drivegear bearing cover of models so equipped.

2. Engage two mainshaft sliding clutches into gearto prevent transmission from rotating.

3. Install nut on shaft (left hand threads). Using adrive gear nut installer, tighten to 250-300 lbs/ft oftorque. Use a punch and maul to peen the nutinto the two milled slots of input shaft.

5. Install drive gear bearing cover and gasket, mak-ing sure to align the oil return hole in case. Se-cure cover on case with retaining capscrews(inset).

INSTALLATION-COMPANION FLANGE,AUXILIARY SECTION AND CLUTCH HOUSING

COMPANION FLANGE AUXILIARY SECTIONAND CLUTCH HOUSINGA. Installation of Clutch Housing

1. Position corresponding new gasket on housingmounting surface and install clutch housing onfront case, piloting on six studs and drive gearbearing cover.

2. Install six nuts with washers or lockwashers on

3. Install four capscrews with lockwashers andtighten to 90-100 lbs./ft. iron housing, 70-75 lbs./ft. aluminum housing.

4. For models so equipped, install the clutch re-lease mechanism and/or clutch brake assembly.See OPTIONS.

studs and tighten to 180-190 lbs./ft. iron housing,170-175 lbs./ft. aluminum housing.


B. Installation of Auxiliary Section

NOTE: Make sure the bearing inner race is in-stalled on front of each auxiliary countershaft BE-FORE proceeding with the following.

1. Attach a chain hoist to auxiliary. Move assemblyevenly into rear of front case, piloting it on thedowel pins. As assembly is moved forward, thecountershaft drive gears will mesh with the aux-iliary drive gear.

3. The auxiliary section can also be installed withtransmission set in the vertical position. Blockunder clutch housing to prevent damage to inputshaft, position corresponding new gasket onhousing mounting surface and lower assemblyonto rear of front case. Install retaining cap-screws and tighten to 35-45 lbs./ft.

2. Install retaining capscrews in flange of auxiliaryhousing and tighten to 35-45 lbs./ft. to secure theauxiliary section to front section.


C. Installation of Universal Joint

Companion Flange or Yoke

1. For models so equipped, install the speedometerdrive gear or replacement spacer in position onhub of companion flange or yoke. Install the com-panion flange or yoke on splines of output shaftand move into rear bearing cover.NOTE: For 14608 models, the speedometer drivegear or replacement spacer is installed on outputshaft prior to installation of rear bearing cover.

2. Lock the transmission by engaging two main-shaft gears with sliding clutches. Install thewasher and/or nut on output shaft and tighten nutusing 450-500 lbs/ft of torque.

INSTALLATION-SHIFTING CONTROLS

SHIFT BAR HOUSING ASSEMBLYA. Installation

1. Place all three mainshaft sliding clutches in theneutral position.

3. Install the capscrews in housing and torque to35-45 lbs./ft.

100

2. With all three shift bars in the neutral position, in-stall shift bar housing assembly on case, fitting the shift yokes into slots of corresponding slid-ing clutches.NOTE: Avoid tilting assembly during installation asthe three sets of tension springs and balls are freeto be released from bores in top of housing.

Install new shift bar housing gasket in positionon case.

lNSTALLATION-SHIFTING CONTROLS

GEAR SHIFT LEVER HOUSING ASSEMBLYA. Installation

NOTE: For models equipped with a LRC or SRCAssembly, the housing is installed in the samemanner described in the following instructions.

1. Check shift bar housing assembly to make sureshift block and yoke notches are aligned in theneutral position.

3. Install retaining capscrews in housing flange andtorque to 35-45 lbs./ft.

2. Install new gear shift lever housing gasket in po-sition on shift bar housing and install the gearshift lever housing assembly on shift bar hous-ing, fitting lever into shift block and yokenotches.

INSTALLATION-SHIFTING CONTROLS

AIR SYSTEMSA. Installation of Slave Valve

NOTE: 19470 slave valve shown, for other

combinations see air systems schematics on

page 25.

1. If previously removed, install air line fittings onslave valve.

4. Position corresponding new gasket on valvemounting surface and install slave valve on case,inserting the end of actuating pin into alignmentsleeve. Secure the valve to case with four retain-ing capscrews tightened evenly to 8-12 lbs./ft.

2. Install spring on shank of actuating pin and insertin bore of transmission case.

3. Install hat-type alignment sleeve in borevalve.

B. Installation of Air Lines

(See Air System Schematics on pages 25-26.)

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.

Eaton CorporationVehicle GroupP.O. Box 4013Kalamazoo, MI 49003 USA800-826-HELP (4357)www.eaton.com/roadranger

Printed in USA

Roadranger: Eaton and trusted partners providing the best products and services in the industry, ensuring more time on the road.

For parts or service call us Pro Gear & Transmission, Inc.

1 (877) 776-4600

(407) 872-1901

[email protected]

906 W. Gore St.

Orlando, FL 32805

fuller heavy duty transmissions trsm0310 - eprogear every 40 hours inspect oil level. check for...

Documents