Caja de Transmision

Service Manual

Fuller Heavy Duty TransmissionsTRSM0550July 2010

RTLO-11610BRTLO-11610B-T2RTLO-12610BRTLO-12610B-T2RTLO-13610BRTLO-13610B-T2RTLO-14610B-T2RTLO-15610BRTLO-15610B-T2RTLO-16610BRTLO-16610B-T2RTLO-17610BRTLO-17610B-T2RTLO-18610BRTLO-18610B-T2RTLO-14610ARTLOF-11610BRTLOF-11610B-T2

RTLOF-12610BRTLOF-12610B-T2RTLOF-13610BRTLOF-13610B-T2RTLOF-14610BRTLOF-14610B-T2RTLOF-15610BRTLOF-15610B-T2RTLOF-16610BRTLOF-16610B-T2RTLOF-17610BRTLOF-17610B-T2RTLOF-18610BRTLO-14610B

Precautions

1

Warnings and Precautions

Before starting a vehicle always be seated in the driver’s seat, place the transmission in neutral, set the parking brakes anddisengage the clutch.

Before working on a vehicle place the transmission in neutral, set the parking brakes and block the wheels.

Before towing the vehicle place the transmission in neutral, and lift the rear wheels off the ground, remove the axle shafts,or disconnect the driveline to avoid damage to the transmission during towing.

The description and specifications contained in this service publication are current at the time of printing.

Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at anytime without notice.

Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for useand should not be considered an endorsement. Equivalents may be used.

This symbol is used throughout this manual to call attention to procedures where carelessness or failure to followspecific instructions may result in personal injury and/or component damage.

Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardizethe personal safety of the service technical or vehicle operator.

Warning: Failure to follow indicated procedures creates a high risk of personal injury to servicing technician.

Caution: Failure to follow indicated procedures amy cause component damage of malfunction.

Note: Additional service information not covered in the service procedures.

Tip: Helpful removal and installation procedures to aid in the service of this unit.

Always use genuine Eaton replacement parts.

Table of Contents

General Information

General Service Practices and Part Inspection ............ 1How to use this Manual ............................................... 5Model Designation ...................................................... 8Power Flow ................................................................. 9Timing Procedures .................................................... 13Tool Reference .......................................................... 15

Preventive Maintenance

Lubrication ................................................................ 16Preventative Maintenance ......................................... 18Inspection ................................................................. 20Rear Seal Maintenance .............................................. 21

External Parts

How to Disassemble the External Parts ..................... 22How to Assemble the External Parts ......................... 23How to Remove the Air Lines and Hose .................... 24How to Install the Air Lines and Hose ....................... 25How to Remove the Air Filter/Regulator .................... 26How to Install the Air Filter/Regulator ....................... 27How to Remove a Roadranger Valve ......................... 28How to Install a Roadranger Valve ............................ 29How to Remove the Range Actuator Valve ................ 30How to Install the Range Actuator Valve ................... 31How to Remove the Top 2 Valve Assembly ............... 33How to Install the Top 2 Valve Assembly .................. 34How to Remove the Gear Shift Lever ........................ 35How to Install the Gear Shift Lever ............................ 36How to Remove the Shift Bar Housing ...................... 37How to Install the Shift Bar Housing ......................... 38How to Remove the Output Yoke/Companion Flange 39How to Install the Output Yoke/Companion Flange ... 40How to Remove the Auxiliary Section Without Tapered Bearings ..................................... 41How to Install the Auxiliary Section Without Tapered Bearings ..................................... 43How to Remove the Auxiliary Section With Tapered Bearings .......................................... 45How to Install the Auxiliary Section With Tapered Bearings .......................................... 48The Shimming Procedure For Tapered Bearings ....... 50How to Remove the Clutch Housing .......................... 53How to Install the Clutch Housing ............................. 54How to Remove the Input Shaft Without Disassembling the Transmission ............. 55

How to Install the Input Shaft Without Disassembling the Transmission .............57

Shift Bar Housing

Shift Bar Housing Identification .................................59How to Disassemble the Gear Shift Lever ..................61How to Assemble the Gear Shift Lever ......................63How to Disassemble the Standard Shift Bar Housing 65How to Assemble the Standard Shift Bar Housing .....68How to Disassemble the Standard Shift Bar Housig (w/Super 10 on cover) ................71How to Assemble the Standard Shift Bar Housing (w/Super 10 on cover) ..............74How to Disassemble the Forward Shift Bar Housing (w/Super 10 on cover) ..............77How to Assemble the Forward Shift Bar Housing(w/Super 10 on cover) ...............80How to Disassemble the New Forward Shift Bar Housing (w/Super 10 on cover) ..............83How to Assemble the New Forward Shift Bar Housing (w/Super 10 on cover) ..............86

Front Section

How to Disassemble the Front Section ......................89How to Remove the Auxiliary Drive Gear Assembly ...90How to Remove the Reverse Idler Gear Assembly .....91How to Remove the Countershaft Bearings ...............93How to Remove the Mainshaft Assembly ..................95How to Remove the Countershaft Assemblies ...........96How to Remove the Input Shaft Assembly ................97How to Assemble the Front Section ...........................99How to Install the Reverse Idler Gear Assembly ......100How to Install the Countershaft Assemblies ............102How to Install the Countershaft Bearings .................103How to Install the Input Shaft Assembly ..................105How to Install the Mainshaft Assembly ....................108How to Install the Auxiliary Drive Gear Assembly ....109How to Disassemble the Auxiliary Drive Gear Assembly

110How to Assemble the Auxiliary Drive Gear Assembly 112How to Disassemble the Countershaft Assembly .....114How to Assemble the Countershaft Assembly .........115How to Disassemble the Mainshaft Assembly .........117How to Assemble the Mainshaft Assembly ..............119

Table of Contents

Auxiliary Section

How to Disassemble the Auxiliary Section .............. 124How to Remove the Front Auxiliary Drive Gear ....... 125How to Remove the Countershaft Assemblies (w/Tapered Bearings) .......................................... 126How to Remove the Countershaft Assemblies (w/Ball Bearings) A Series ................................... 128How to Remove the Rear Auxiliary Drive Gear ........ 130How to Disassemble the Range Cylinder Assembly 131How to Disassemble the Output Shaft Assembly .... 135How to Disassemble the Splitter Cylinder Assembly 137How to Assemble the Auxiliary Section ................... 139How to Assemble the Output Shaft Assembly ......... 140How to Assemble the Output Shaft Assembly (A Series) ........................................................... 143How to Install the Countershaft Assemblies (w/Tapered Bearings) ......................................... 147How to Install the Countershaft Assemblies (w/Ball Bearings) A Series .................................. 150How to Assemble the Range Cylinder Assembly ..... 153How to Install the Rear Auxiliary Drive Gear ............ 157How to Assemble the Splitter Cylinder Assembly .... 158How to Install the Front Auxiliary Drive Gear ........... 161How to Disassemble the Synchronizer Assembly .... 162How to Assemble the Synchronizer Assembly ........ 163

Options

How to Remove the Integral Oil Pump .................... 165How to Install the Integral Oil Pump ....................... 167How to Disassemble the Integral Oil Pump ............. 169How to Assemble the Integral Oil Pump .................. 171

General Information

General Service Practices and Part Inspection

Disassembly

It is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission, the necessary link-age and vehicle air lines disconnected and the transmission has been removed from vehicle chassis. Removal of the gear shiftlever housing assembly (or remote control assembly) is included in the detailed instructions (External Parts/Shift Bar Housing/How to Remove the Gear Shift Lever); however, this assembly MUST be detached from the shift bar housing before transmissioncan be removed.

CAUTION: Follow closely each procedure in the detailed instructions, make use of the text, illustrations, and photographs provid-ed.

AssembliesWhen disassembling the various assemblies, such as the mainshaft, countershafts, and shift bar housing, lay all parts on a cleanbench in the same sequence as removed. This procedure will simplify assembly and reduce the possibility of losing parts.

BearingsCarefully wash and lubricate all usable bearings as removed and protectively wrap until ready for use. Remove bearings plannedto be reused with pullers designed for this purpose.

CleanlinessProvide a clean place to work. It is important that no dirt or foreign material enters the unit during repairs. Dirt is an abrasive andcan damage bearings. It is always good practice to clean the outside of the unit before starting the planned disassembly.

Input ShaftThe input shaft can be removed from the transmission without removing the countershaft, mainshaft, or main drive gear. Specialprocedures are required and provided in this manual.

Snap RingsRemove snap rings with pliers designed for this purpose. Snap rings removed in this manner can be reused, if they are not sprungor loose.

When using Tools to Move PartsAlways apply force to shafts, housings, etc., with restraint. Movement of some parts is restricted. Never apply force to driven partsafter they stop solidly. The use of soft hammers, soft bars, and mauls for all disassembly work is recommended.

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General Information

General Information

Inspection

Before assembling the transmission, check each part carefully for abnormal or excessive wear and damage to determine reuse orreplacement. When replacement is necessary, use only genuine Eaton® Fuller® Transmission parts to assure continued perfor-mance and extended life from your unit.

Since the cost of a new part is generally a small fraction of the total cost of downtime and labor, avoid reusing a questionable partwhich could lead to additional repairs and expense soon after assembly. To aid in determining the reuse or replacement of anytransmission part, consideration should also be given to the unit’s history, mileage, application, etc.

Recommended inspection procedures are provided in the following checklist.

Bearings

1. Wash all bearings in clean solvent. Check balls, rollers, and raceways for pitting, discoloration, and spalled areas. Replacebearings that are pitted, discolored, spalled, or damaged during disassembly.

2. Lubricate bearings that are not pitted, discolored, or spalled and check for axial and radial clearances.

3. Replace bearings with excessive clearances.

4. Check bearing fit. Bearing inner races should be tight to shaft; outer races slightly tight to slightly loose in case bore. Ifbearing spins freely in bore, case should be replaced.

Bearing Covers

1. Check covers for wear from thrust of adjacent bearing. Replace covers damaged from thrust of bearing outer race.

2. Check cover bores for wear. Replace those worn or oversized.

Clutch Release Parts

1. Check clutch release parts. Replace yokes worn at cam surfaces and bearing carrier worn at contact pads.

2. Check pedal shafts. Replace those worn at bushing surfaces.

Gears

1. Check gear teeth for frosting and pitting. Frosting of gear teeth faces presents no threat of transmission failure. Often incontinued operation of the unit, frosted gears “heal” and do not progress to the pitting stage. In most cases, gears withlight to moderate pitted teeth have considerable gear life remaining and can be reused, but gears in the advanced stageof pitting should be replaced.

2. Check for gears with clutching teeth abnormally worn, tapered, or reduced in length from clashing during shifting. Re-place gears found in any of these conditions.

3. Check axial clearance of gears.

Gear Shift Lever Housing Assembly

1. Check spring tension on shift lever. Replace tension spring if lever moves too freely.

2. If housing is disassembled, check gear shift lever bottom end and shift finger assembly for wear. Replace both gears ifexcessively worn.

Gray Iron Parts

1. Check all gray iron parts for cracks and breaks. Replace parts found to be damaged.

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General Information

Oil Return Threads and Seals

1. Check oil return threads on the input shaft. If return action of threads has been destroyed, replace the input shaft.

2. Check oil seal in rear bearing cover. If sealing action of lip has been destroyed, replace seal.

O-Rings

1. Check all O-rings for cracks or distortion. Replace if worn.

Reverse Idler Gear Assemblies

1. Check for excessive wear from action of roller bearings.

Shift Bar Housing Assembly

1. Check for wear on shift yokes and blocks at pads and lever slot. Replace excessively worn parts.

2. Check yokes for correct alignment. Replace sprung yokes.

3. Check lockscrews in yoke and blocks. Tighten and rewire those found loose.

4. If housing has been disassembled, check neutral notches of shift bars for wear from interlock balls.

Sliding Clutches

1. Check all shift yokes and yoke slots in sliding clutches for extreme wear or discoloration from heat.

2. Check engaging teeth of sliding clutches for partial engagement pattern.

Splines

1. Check splines on all shafts for abnormal wear. If sliding clutch gears, companion flange, or clutch hub has worn marksin the spline sides, replace the specific shaft affected.

Synchronizer Assembly

1. Check synchronizer for burrs, uneven and excessive wear at contact surface, and metal particles.

2. Check blocker pins for excessive wear or looseness.

3. Check synchronizer contact surfaces on the synchronizer cups for wear.

Washers

1. Check surfaces of all washers. Washer scored or reduced in thickness should be replaced.

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General Information

General Information

Assembly

Make sure that case interiors and housings are clean. It is important that dirt and other foreign materials are kept out of the trans-mission during assembly. Dirt is an abrasive and can damage polished surfaces of bearings and washers. Use certain precautions,as listed below, during assemble.

Axial ClearancesMaintain original axial clearances of .006" to .015" for mainshaft gears.

BearingsUse a flange-end bearing driver for bearing installation. These special drivers apply equal force to both bearing races, preventingdamage to balls/rollers and races while maintaining correct bearing alignment with bore and shaft. Avoid using a tubular or sleeve-type driver, whenever possible, as force is applied to only one of the bearing races.

CapscrewsTo prevent oil leakage and loosening, use Eaton/Fuller sealant #71205 on all capscrews.

GasketsUse new gaskets throughout the transmission as it is being rebuilt. Make sure all gaskets are installed. An omission of any gasketcan result in oil leakage or misalignment of bearing covers.

Initial LubricationCoat all limit washers and shaft splines with Lubriplate during assembly to prevent scoring and galling of such parts.

O-RingsLubricate all O-rings with silicon lubricant.

Universal Joint Companion Flange or YokePull the companion flange or yoke tightly into place with the output shaft nut, using 450-500 Lbf-ft of torque. Make sure the speed-ometer drive gear or a replacement spacer of the same width has been installed. Failure to pull the companion flange or yoke tightlyinto place can result in damage to the mainshaft rear bearing.

IMPORTANT: See the appropriate Illustrated Parts Lists (specified by model series) to ensure that proper parts are used duringassemble of the transmission.

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General Information

How to use this Manual

This manual is designed to provide detailed information necessary to service and repair the Eaton® Fuller® transmissions listedon the front.

As outlined on the first page, the manual has been divided into its main components: external parts, shift bar housing, front sec-tion, auxiliary section, and options (if applicable). Each component has its own tabbed section. Each tabbed section has its owntable of contents and procedural flow charts. The table of contents lists the procedures. The flow charts represent the order inwhich the transmission should be disassembled or assembled. The procedures have two parts, disassembly or removal and re-assembly or installation.

As mentioned the flow charts represent the order in which the transmission should be disassembled or assembled.

The following is an example of how to disassemble the auxiliary section, specifically the range cylinder assembly.

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General Information

General Information

Follow the flow chart "How to Disassemble the Auxiliary Section".

1. Remove the auxiliary section from the front box.

2. Remove the front auxiliary drive gear and yoke.

3. Remove the countershaft assemblies.

4. Remove the rear auxiliary drive gear.

5. Remove the range cylinder assembly.

1

2

3

4

5

AuxiliarySection

Front Auxiliary DriveGear and Yoke

CountershaftAssemblies

Rear AuxiliaryDrive Gear

RangeCylinder

Assembly

OutputShaft

Assembly

SplitterCylinder

Assembly

DesassembleSynchronizer

Assembly

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General Information

Once the range cylinder parts have been replaced, assemble the auxiliary section according to the "How to Assemble the AuxiliarySection".

1. Assemble the output shaft assembly.

2. Assemble the synchronizer assembly, if it was disassembled.

3. Install the countershaft assemblies.

4. Install the range cylinder assembly.

1

2

3

4

OutputShaft

Assembly

AssembleSynchronizer

Assembly

CountershaftAssemblies

RangeCylinder

Assembly

Rear AuxiliaryDrive Gear

SplitterCylinder

Assembly

Front Auxiliary DriveGear and Yoke

AuxiliarySection

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General Information

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General Information

Model Designation

General Information and other transmission identification information are stamped on the transmission tag. To identify the trans-mission model designation and serial number, locate the tag on the transmission and then locate the numbers as shown.

WARNING: Do not remove or destroy the transmission identification tag.

Eaton FullerTransmissions

PTO Code

Model Serial

MadeIn

Eaton CorporationTransmission DivKalamazoo, MI 49003

RTO-14710-AS2

T

Overdrive

L O -R

Roadranger

Low Inertia

Twin Countershaft

Torque x 100Design Level 6 ="Multi-Mesh" Gearing

Gear Ratio

Forward Speeds

1 4 1 0 A6

General Information

Power Flow

The transmission must efficiently transfer the engine's power to the vehicle's driveline. Knowledge of what takes place in the transmission is helpful when troubleshooting and making repairs.

1st Gear

• Power (torque) from the vehicle's engine is transferred to the transmission's input shaft.(1)

• The input shaft external splines engage the main drive gear internal splines.(2)

• Torque is split between the two countershaft drive gears.(3)

• Torque is delivered along both countershafts to the mating countershaft gears of the "engaged" mainshaft gear. The fol-lowing cross section view illustrates a 1st speed gear engagement.(4)

• The external clutching teeth of the sliding clutch engage with the internal clutching teeth of the mainshaft gear which transfers torque to the mainshaft.(5)

• The mainshaft transfers torque directly to the rear auxiliary drive gear sliding clutch which is in the rearward posi-tion.(6)

• The rear auxiliary drive gear splits torque between the two auxiliary countershaft drive gears.(7)

• Torque is delivered along both countershafts to the LO range gear in the auxiliary section.(8)

• The LO range gear delivers torque to the output shaft through the range synchronizer sliding clutch.(9)

• The output shaft delivers torque to the driveline components.(10)

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General Information

General Information

2nd Gear




• Torque is delivered along both countershafts to the mating countershaft gears of the "engaged" mainshaft gear. The fol-lowing cross section view illustrates a 2nd speed gear engagement.(4)


• The mainshaft transfers torque directly to the auxiliary drive gear sliding clutch which is in the forward position.(6)

• The auxiliary drive gear splits torque between the two auxiliary countershaft drive gears.(7)

• Torque is delivered along both countershafts to the LO range gear in the auxiliary section.(8)

• The LO range gear delivers torque to the output shaft through the range synchronizer sliding clutch.(9)


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General Information

7th gear




• Torque is delivered along both countershafts to the mating countershaft gears of the "engaged" mainshaft gear. The fol-lowing cross section view illustrates a 7th speed gear engagement.(4)


• The mainshaft transfers torque directly to the rear auxiliary drive gear sliding clutch which is in the rearward posi-tion.(6)

• Torque is delivered to the back of the rear auxiliary drive gear. The range synchronizer sliding clutch is in the forward position, transferring torque directly to the output shaft.(7)


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General Information

General Information

8th Gear




• Torque is delivered along both countershafts to the mating countershaft gears of the "engaged" mainshaft gear. The fol-lowing cross section view illustrates a 8th speed gear engagement.(4)


• The mainshaft transfers torque directly to the front auxiliary drive gear sliding clutch which is in the forward position.(6)

• The front auxiliary drive gear splits torque between the two auxiliary countershaft drive gears.(7)

• Torque is delivered along both countershafts to the rear auxiliary drive gear.(8)

• Torque is transferred to the range synchronizer sliding clutch which is in the forward position delivering torque directly to the output shaft.(9)


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Timing

Timing Procedures

It is essential that both countershaft assemblies of the front and auxiliary sections are "timed." This assures proper tooth contact is made between mainshaft gears seeking to center on the mainshaft during torque transfer and mating countershaft gears that distribute the load evenly. If not properly timed, serious damage to the transmission is likely to result from unequal tooth contact causing the mainshaft gears to climb out of equilibrium.

Timing is a simply procedure of marking the appropriate teeth of a gear set prior to installation and placing them in proper mesh while in the transmission. In the front section, it is necessary to time only the drive gear set. And depending on the model, only the LO range, deep reduction, or splitter gear set is timed in the auxiliary section.

Front SectionA. Marking countershaft drive teeth.

1. Prior to placing each countershaft assembly into the case, clearly mark the tooth located directly over the drive gear keyway as shown. This tooth is stamped with an "O" to aid identification.

B. Marking main drive gear teeth.

1. Mark any two adjacent teeth on the main drive gear.

2. Mark the two adjacent teeth located directly opposite the first set marked on the main drive gear. As shown to the left, there should be an equal number of unmarked gear teeth on each side between the marked sets.

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Timing

General Information

C. Meshing marked countershaft drive gear teeth with marked main drive gear teeth.(After placing the mainshaft assembly into the case, the countershaft bearings are installed to complete installation of the coun-tershaft assemblies.)

1. When installing the bearings on the left countershaft, mesh the countershaft drive gear marked tooth with either set of main drive gear two marked teeth.

2. Repeat the procedure when installing the bearings on the right countershaft, make use of the remaining set of main drive gear two marked teeth to time assembly.

Auxiliary SectionA. Timing the auxiliary countershafts.Standard Auxiliary Section

1. Mark any two teeth on the LO range gear. Then mark two teeth located directly opposite the first marked.

2. Prior to placing each auxiliary countershaft assembly into housing, mark the tooth on each auxiliary countershaft assembly LO range gear stamped with the "O".

3. Follow the assembly procedures in the "Auxiliary Section".

Helical Auxiliary Section

1. Mark any tooth on the LO range gear. Then mark a tooth located directly opposite the first marked.

2. Prior to placing each auxiliary countershaft assembly into housing, mark the two teeth on each auxiliary countershaft assembly LO range gear stamped with the two "O"s. Repeat the procedure on each auxiliary countershaft reduction gear.

3. Follow the assembly procedures in the "Auxiliary Section".

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Tool Reference

15

Tool Reference

Some repair procedures pictured in this manual show the use of specialized tools. Their actual use is recommended as they make transmission repair easier, faster, and prevent costly damage to critical parts.

But for the most part, ordinary mechanic's tools such as socket wrenches, screwdrivers, etc., and other standard shop items such as a press, mauls and soft bars are all that is needed to successfully disassemble and reassemble any Eaton Fuller Trans-mission.

The specialized tools can be obtained from a tool supplier or made from tool prints as required by the individual user. Detailed Eaton Fuller Transmission Tool Prints are available upon request by writing to:

Roadranger Literature Services

Attn: Contract 4 / CA#182

1750 Wallace Ave.

St. Charles, IL 60174-3404

Phone: 888-ETN-INFO (386-4636)

Lubrication / Application Information


Lubrication

For a list of Eaton Approved Synthetic Lubricants, see TCMT-0021 or call 1-800-826-HELP (4357)

The use of lubricants not meeting these requirements will affect warranty coverage.

Additives and friction modifiers must not be introduced.

Never mix engine oils and gear oils in the same transmission.

Buy from a reputable dealer

For a list of approved and reputable dealers, write to:

Eaton Corporation

Worldwide Marketing Services

P.O.Box 4013

Kalamazoo MI 49003

Transmission Operating Angles

If the transmission operating angle is more than 12°, improper lubrication will occur. The operating angle is the transmissionmounting angle in the chassis plus the percent of upgrade (expressed in degrees).

For operating angles over 12°, the transmission must be equipped with an oil pump or cooler kit to insure proper lubrication.

Operating Temperatures with Oil Coolers

The transmission must not be operated consistently at temperatures above 250°F. However, intermittent operating temperaturesto 300°F do not harm the transmission. Operating temperatures above 250°F increases the lubricant’s oxidation rate and shortensits effective life. When the average operating temperature is above 250°F, the transmission can require more frequent oil changesor external cooling.

The following conditions in any combination can cause operating temperatures of over 250°F:

a. Operating consistently at slow speeds.

b. High ambient temperatures.

c. Restricted air flow around transmission.

d. Exhaust system too close to transmission.

e. High horsepower operation.

External oil coolers are available to reduce operating temperatures when the above conditions are encountered.

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Lubrication / Application Information

Oil Cooler Chart

Transmission Oil Coolers are:

RecommendedWith engines of 350 H.P. and above

Required-With engines 399 H.P. and above and GCW’s over 90,000 lbs. -With engines 399 H.P. and above and 1400 lb.ft or greater torque.-With engines 450 H.P and above.

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Preventative Maintenance

Everyday there are countless vehicles operating over the highways with transmissions in such a neglected mechanical condition, they can be referred to as failures looking for a place to break down. They lack a proper and organized preventive maintenance program.

Preventive maintenance is a general term which applies to all procedures necessary to have maximum life and satisfactory ser-vice at the lowest possible cost, short of removing and repairing the unit.

A number of conditions contrary to good preventive maintenance can generally be pointed to when inspecting a failed transmis-sion. Taking a few minutes every so many hours or miles to do a few simple checks could help avoid eventual breakdown or reduce the repair cost. If the transmission is not cared for, it will breakdown.

Checks Before Transmission Removal

1. Air System and Connections

Check for leaks, worn air lines, loose connections and capscrews. See SERVICING AIR SYSTEM.

2. Clutch Housing Mounting

Check all capscrews of clutch housing flange for looseness.

3. Clutch Release Bearing (Not Shown)

Remove hand hole cover and check radial and axial clearance in release bearing.

Check relative position of thrust surface of release bearing with thrust sleeve on push-type clutches.

4. Clutch Pedal Shaft and Bores

Pry upward on shafts to check wear.

If excessive movement is found, remove clutch release mechanism and check bushings on bores and wear on shafts. See OEM literature.

5. Lubricant

Change at specified service intervals.

Use only the types and grades as recommended. See LUBRICANTS.

6. Filler and Drain Plugs

Remove filler plugs and check level of lubricant at specified intervals. Tighten fill and drain plugs securely.

7. Capscrews and Gaskets

Check all capscrews, especially those on PTO covers and rear bearing covers for looseness which would cause oil leak-age.

Check PTO opening and rear bearing covers for oil leakage due to faulty gasket.

8. Gear Shift Lever

Check for looseness and free play in housing. If lever is loose in housing, proceed with Check No. 9.

9. Gear Shift Lever Housing Assembly

Remove air lines at slave valve and remove the gear shift lever housing assembly from the transmission.

Check the tension spring and washer for set and wear.

Check the gear shift lever spade pin and slot for wear.

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Check bottom end of gear shift lever for wear and check slot of yokes and blocks in shift bar housing for wear at contact points with shift lever.

Checks With Drive Line Dropped

10. Universal Joint Companion Flange or Yoke Nut

Check for tightness. Tighten to recommended torque.

11. Output Shaft

Pry upward against output shaft to check radial clearance in mainshaft rear bearing.

Checks With Universal Joint Companion Flange or Yoke Removed.

NOTE:If necessary, use solvent and shop rag to clean sealing surface of companion flange or yoke. Do not use crocus cloth, emery paper, or other abrasive materials that will mar surface finish.

12. Splines on Output Shaft

Check for wear from movement and chucking action of the universal joint companion flange or yoke.

13. Mainshaft Rear Bearing Cover

Check oil seal for wear.

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20


Inspection

Table 1:

Part to inspect What to Check For Action to be Done

Speedometer Con-nections

Speedometer cables should not be loose. Shouldbe an O-Ring or gasket between the matingspeedometer sleeve and the rear bearing cover.

Applied hydraulic thread sealant #71208 tothreads. Torque speedometer sleeve to 35-50Lbf-ft. Replace the O-ring/gasket if damaged ormissing.

Rear Bearing Covercapscrews, Gasket,and Nylon Collar

Check retaining capscrews for tightness. Verifynylon collar and gasket are installed at the cham-fered hole, aligned near the mechanical speedom-eter opening. Verify that a rear bearing covergasket is in place.

Apply Eaton Sealant #71205 to the capscrewthreads. Torque capscrews to 35-45 Lbf-ft.Usenew parts if need to replace. Apply Eaton Sealant#71205 to the capscrew threads. Torque cap-screws to 35-45 Lbf-ft. Install a new gasket ifrear bearing cover was removed.

Output Yoke Retain-ing Nut

Check the output yoke retaining nut for tightness. Torque the output yoke retaining nut to 450-500Lbf-ft. Do not over torque nut.

PTO Covers andOpenings

Check the capscrews for tightness. Apply Eaton Sealant #71205 to the capscrewthreads. Tighten 6 bolt PTO capscrews to 35-45Lbf-ft. Tighten 8 bolt PTO capscrews to 50-65Lbf-ft.

Grey Iron Parts Check front bearing cover, front case, shift barhousing, rear bearing cover, and clutch housingfor cracks or breaks.

Replace parts found to be damaged.

Front Bearing Cover Check return threads for damage. Check the cap-screws for tightness.

If threads damaged, replace the input shaft.Tighten the capscrews to 35-45 Lbf-ft.

Oil Cooler and Oil Fil-ter

Check all connections, fittings, hoses, and filter el-ement for tightness.

Tighten any loose fittings.

Oil Drain Plug, Oil FillPlug

Check the oil drain plug and the oil fill plug forleakage.

Torque the drain plug to 45-55 Lbf-ft. Torque theoil fill plug to 60-70 Lbf-ft.


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Oil Leak Inspection Process

Inspect for Oil Leak

Determine if it is a Weep or a Leak

Weep: Stained, damp, no drips, light oil film,dirt adhered to the contaminated area.

Leak: Extremely wet or dripping of oil in thecontaminated area.

Gasket Rear Seal Leak

1. Clean suspected oil weeparea with a clean dry clothor mild soluble degreaser.

2. Ensure lube is to properlevel.

3. Notify the customer that it is only a weep and it is notconsidered to be detrimentalto the life of the transmission.

4. Repair is complete.

1. Do not repair: Rear seal is designed to allow minimalseepage (refer to RoadrangerTCSM-0912 Seal MaintanceGuide).

2. Ensure lube is to properlevel.

1. Determine the origin of the leak path.2. If origin of leak is obvious skip to Step 3.3. If the origin of the oil leak is not obvious then use either of the two following steps to determine the oil leak:

Note: Do not use a high pressure spray washer to clean the area. Use of a high pressure spray may force contamination into the area of concern and temporarily disrupt the leak path. i. Clean area with a clean dry cloth or mild soluble degreaser and fill the transmission to the proper lube level. OR ii. Clean the area as noted above and insert tracer dye into the transmission lube and fill transmission to proper lube level.

Operate vehicle to normal transmission operating temperature and inspect the area for oil leak(s) visually or if tracer dye was introduced use an UVL (Ultraviolet Light) to detect the tracer dye’s point of origin.Note: When inspecting for the origin of the leak(s) make sure the assumed leak area is not being contaminated by a source either forward or above the identified area such as the engine, shift tower, shift bar housing, top mounted oil cooler, etc...

Once the origin of the leak is identified, repair the oil leak using proper repair procedures from the designated model service manual.

After the repair is completed, verify the leak is repaired and operate the vehicle to normaltransmission operating temperature.Inspect repaired area to ensure oil leak has been eliminated. If the leak(s) still occurs, repeat steps or contact the Roadranger Call Center at 1-800-826-4357.

Step 1

Step 2

Step 3

Step 4

How to Disassemble the External Parts

22

External Parts

How to Disassemble the External Parts

EXTERNAL PARTS

AIRSYSTEM

CHANGING THE INPUT SHAFT

AIR LINES AND HOSES

AIR FILTER/REGULATOR

ROADRANGERVALVE

GEAR SHIFTLEVER

SHIFT BAR HOUSING

AUXILIARYSECTION

OUTPUT YOKE/COMPANIONFLANGE

OPTIONAL PATH

TYPICAL PATH

LEGEND

ClutchHousing

How to Assemble the External Parts

23

How to Assemble the External Parts

EXTERNAL PARTS

OPTIONAL PATH

TYPICAL PATH

LEGEND

OUTPUT YOKE/COMPANION

FLANGE

CLUTCHHOUSING

CHANGING THEINPUT SHAFT

AUXILIARYSECTION

SHIFT BARHOUSING

AIRSYSTEM

GEAR SHIFTLEVER

AIR/FILTERREGULATOR

ROADRANGERVALVE

AIR LINESAND HOSE

Air System

24

External Parts

How to Remove the Air Lines and Hose

Special Instructions

Before removing the air lines and hose, label or record their location.

If, after you remove the air lines and hoses, you are unsure of their location, see the Air System “Troubleshooting/Operation Guide” TRTS-0920.

Special Tools

• Typical Service Tools

• For “push-to-connect” fittings, we recommend Eaton service tool kit K-2394. The kit contains the release tool and the tubing cutter.

Procedure -

1. Disconnect all air lines and hose.

2. Inspect the air lines and hose.

3. Inspect air fittings, remove if damaged.

Air System

25

How to Install the Air Lines and Hose


Make sure air lines and hose are not damaged.

Install the air lines and hose at their proper location.

All externally threaded 1/8" or 5/32" air lines and pipe fittings that are not coated with pre-applied thread sealant must be coatedwith Eaton sealing material #71209 or equivalent for at least 5 complete and consecutive threads.

All externally threaded 1/4" air fittings that are not coated with pre-applied thread sealant must be coated with Eaton sealing ma-terial #71209 or equivalent for at least 3 complete and consecutive threads.

For the 1/4" I.D. air hoses, install the fixed nut end first.

To install the air lines and hose, the air filter/regulator must be in position.

If you are unsure of the air lines and hose location, see the Air System “Troubleshooting/Operation Guide” TRTS-0920.

Special Tools


• For ‘push-to-connect’ fittings, we recommend Eaton “Service Tool Kit” K-2394. The kit contains the release tool and atubing cutter.

Procedure -

1. Replace removed air fittings.

2. Connect all removed air lines and hose.

Final Check• Make sure fittings are tight.

• Make sure air lines are not kinked.

Air System

26

External Parts

How to Remove the Air Filter/Regulator


The air filter/regulator has two (2) O-rings located between the filter/regulator and the range cylinder cover.

Special Tools


Procedure -

1. From the air filter/regulator, remove the two (2) capscrews.

2. From the range cylinder cover, remove the two (2) O-rings.

3. Inspect the O-rings for cracks or distortion.

Air System

27

How to Install the Air Filter/Regulator


The air filter/regulator has two (2) o-rings located between the filter/regulator and the auxiliary section.

Special Tools


Procedure -

1. On the range cylinder cover, position the two (2) o-rings.

2. Over the o-rings, position the air filter/regulator.

3. Apply eaton/fuller sealant #71205 or equivalent to the two(2) retaining capscrews.

4. Install the two (2) retaining capscrews, tighten to 8-12 lb-ftof torque.

Final Check

• Make sure the capscrews are properly torqued.

Air System

28

External Parts

How to Remove a Roadranger Valve


The air lines must be depressurized.

Special Tools


Procedure -

1. From the Roadranger valve cover, remove the two (2)mounting screws.

2. Slide the Roadranger valve cover down.

3. From the air fittings, disconnect the air lines.

4. From the Roadranger base, loosen the jam nut. Rotate theRoadranger valve until the valve is removed.

5. Inspect the parts: nut, valve cover, air lines, sheathing, andO-rings from the lever shaft.

6. On the Roadranger valve, inspect the air fittings; remove ifdamaged.

Air System

29

How to Install a Roadranger Valve


To position the Roadranger valve: the range lever must be to the front or the splitter button to the left when facing forward.

Special Tools


Procedure -

1. Make sure the nut, valve cover, air lines, sheathing, and O-rings are in position on the lever shaft.

2. If previously removed, replace the air fittings.

3. Place the Roadranger valve on the lever shaft and rotate intoposition.

4. From the Roadranger valve bottom, tighten the jam nut.

5. Connect the air lines to the air fittings.

6. Slide the cover into position on the Roadranger valve.

7. Install the Roadranger valve cover two (2) mounting screws.

Final Check

• Make sure the air lines are seated fully

Air System

30

External Parts

How to Remove the Range Actuator Valve



Special Tools


Procedure -

1. From the mounting screws, bend the lockwasher retainingtabs down.

2. From the range actuator valve bracket, remove the two (2)mounting screws. The newest design of the range actuatordoes not have the bracket.

3. Remove the range actuator valve lockwasher, bracket, andrange actuator valve.

4. Inspect the air fittings, remove if damaged.

5. From the range actuator valve bore, remove the actuatingpin.

6. Inspect the actuating pin for damage, replace if necessary.

Air System

How to Install the Range Actuator Valve


Apply Eaton lubricant #71214 or equivalent to the O-ring so a film covers the entire surface of each O-ring.

Special Tools


Procedure -

1. Install the actuating pin in the range actuator valve bore.

2. If previously removed, replace the air fittings

3. Install the range actuating valve.

4. Position the range actuating valve bracket and lockwasherover the capscrew openings. The newest design of therange actuator does not have the bracket.

5. Apply Eaton sealant #71205 or equivalent to the retainingcapscrews.

31

Air System

External Parts

6. Install the retaining capscrews, tighten to 8-12 lb-ft oftorque.

7. Bend the retaining tabs on the lockwasher up.

Final Check


32

Air System

33

How to Remove the Top 2 Valve Assembly



Special Tools


Procedure -

1. From the 3-way connector, disconnect the wire harness.

2. From the air fittings, disconnect the air lines.

3. From the Top-2 valve assembly, remove the two (2) cap-screws.

Air System

34

External Parts

How to Install the Top 2 Valve Assembly



Special Tools


Procedure -

1. Install the two (2) retaining capscrews, tighten to 35-45 lb-ft of torque.

2. Connect the air lines to the air fittings.

3. Connect the 3-way connector to the harness.

Shift Bar Housing

35

How to Remove the Gear Shift Lever


The air lines must be disconnected from the transmission or from the Roadranger valve.

Remote control housings are removed the same way as gear shift levers.

Special Tools


Procedure -

1. From the gear shift lever base, remove the four (4) retaining capscrews.

2. To break the gasket seal, lightly jar the gear shift housing.

3. Remove the gear shift lever housing.

4. Remove the gasket and clean all mounting surfaces of gas-ket material.

Shift Bar Housing

36

External Parts

How to Install the Gear Shift Lever


Remote control housings are installed the same way as gear shift levers.

For standard and forward shift bar housings, make sure the two (2) balls and tension springs are in the shift bar housing top bores.

Make sure the shift block and yoke notches are aligned in the neutral position.

Special Tools


Procedure -

1. Position a new gear shift lever gasket on the gear shift levermounting surface.

2. Fit the gear shift lever into the shift block.

3. Apply Eaton/Fuller Sealant #71205 or equivalent to the re-taining capscrews.


Final Check


• Make sure you can shift the transmission.

Shift Bar Housing

37

How to Remove the Shift Bar Housing


Before removing the shift bar housing, the air lines must be disconnected.

For models equipped with an oil pump and/or cooler assemblies, make sure to disconnect the lube line connected to the shift barhousing.

There are two (2) sizes of capscrews. The 1½" capscrews are used with the lifting eyes. Note their location.

Special Tools


Procedure -

1. From the shift bar housing rim, remove the retaining cap-screws.

2. From the alignment stud, remove the nut and washer.

3. To break the gasket seal, jar the shift bar housing.

4. Remove the shift bar housing.


6. If the two (2) sets of tension springs and balls from thehousing top bores are loose, tilt the assembly and removethem. The anti-rotating pin can be removed also. Newer shiftbar housings do not have the anti-rotating pin.

Shift Bar Housing

38

External Parts

How to Install the Shift Bar Housing


There are two (2) sizes of capscrews. The 1½" capscrews are used with the lifting eyes.

Special Tools


Procedure -

1. Place the shift bars in the neutral position.

2. Place the mainshaft sliding clutches in the neutral position.

3. Position a new shift bar housing gasket on the shift barhousing mounting surface.

4. As you install the shift bar housing, make sure the yokes fitinto the corresponding clutch gears slots.



7. Install the washer and nut on the alignment stud.

Final Check


Output Yoke/Companion Flange

39

How to Remove the Output Yoke/Companion Flange


You must remove the shift bar housing in order to lock the transmission.

For proper cleaning and maintenance, see TCSM-0912 “Seal Maintenance Guide”.

After removal of the output yoke/companion flange, temporarily replace the output shaft nut to protect the output shaft threads during auxiliary section disassembly.

Special Tools


• A large breaker bar or air impact wrench

Procedure -

1. Engage two (2) mainshaft sliding clutches into two (2) mainshaft gears to lock the transmission.

2. Use a large breaker bar or air impact wrench to remove the output shaft nut.

3. Pull the yoke or flange straight to the rear and off the output shaft.

Output Yoke/Companion Flange

40

External Parts

How to Install the Output Yoke/Companion Flange


You must remove the shift bar housing in order to lock the transmission.

For proper cleaning and maintenance, see TCSM-0912 “Seal Maintenance Guide”.

Special Tools


• Torque Wrench 500 lb-ft Capacity

Procedure -

1. Engage two (2) mainshaft sliding clutches into two (2) main-shaft gears to lock the transmission.

2. Install the speedometer drive gear rotor or replacementspacer on the output shaft inside the rear bearing cover.

3. If the slinger on the yoke is damaged, replace using a Sling-er/Seal kit.

4. Slide the companion flange or yoke onto the output shaft.

5. Install the output shaft nut, tighten to 450-500 lb-ft oftorque.

Final Check

• Make sure the output shaft nut is properly torqued.

• Unlock the transmission.

Auxiliary Section

How to Remove the Auxiliary Section Without Tapered Bearings


There can be different capscrew lengths, note their location.

Auxiliary sections can be removed either with the transmission in the horizontal position or the vertical position.

Special Tools


• An auxiliary section hanger bracket for horizontal removal

• A steel bar longer than the width of the output yoke for vertical removal

• A hoist with a lifting chain

Procedure - To remove the auxiliary section in the horizontal position.

1. From the auxiliary section housing, remove the retaining capscrews that attach the front section to the auxiliary sec-tion.

2. Insert the two (2) longest capscrews in the housing flange tapped holes. Tighten evenly to move the auxiliary section away from the front box. Go far enough to break the gasket seal.

41

Auxiliary Section

External Parts

3. Remove the capscrews from the tapped holes.

4. Attach an auxiliary section hanger bracket to the auxiliary section top.

5. Attach a lifting chain to the auxiliary section hanger bracket.

6. Move assembly to the rear until auxiliary section is free.


Procedure - To remove the auxiliary section in the vertical position.

1. With blocks under the clutch housing to prevent input shaft damage, place transmission in the vertical position, clutch housing down.

2. From the auxiliary section housing, remove the retaining capscrews that attach the front box to the auxiliary section.

3. Install a steel bar through the yoke.

4. Attach a lifting chain to the steel bar.

5. Lift assembly from the front section.


42

Auxiliary Section

How to Install the Auxiliary Section Without Tapered Bearings


There are different capscrew lengths, install in the correct location.

Auxiliary sections can be installed either with the transmission in the horizontal position or the vertical position.

To install in the vertical position, the clutch housing must be installed.

Special Tools





Procedure - To install the auxiliary section in the hor-izontal position.

1. Position a new gasket on the transmission mounting sur-face.

2. Attach an auxiliary section hanger bracket to the auxiliarysection top.


4. Position the auxiliary section on the two (2) dowel pins.

5. Slide the auxiliary section on until the hanger bracket con-tacts the front case back.

6. Remove the auxiliary section hanger bracket.

7. Slide the auxiliary section the rest of the way into position.



43

Auxiliary Section

External Parts

Procedure - To install the auxiliary section in the ver-tical position.

1. With blocks under the clutch housing to prevent input shaftdamage, place the transmission in the vertical position,clutch housing down.




5. Position the auxiliary section over the two (2) dowel pins.

6. Slide the auxiliary section down the dowels.



9. Remove the steel bar and chain.

Final Check

• Make sure capscrews are properly torqued.

• Make sure the input shaft rotates.

44

Auxiliary Section

How to Remove the Auxiliary Section With Tapered Bearings


There can be different capscrew lengths, note their location.

Auxiliary sections can be removed either with the transmission in the horizontal position or the vertical position.

Auxiliary countershaft retaining straps may be installed to hold the countershafts in place. Auxiliary can be removed without straps,use caution.

Special Tools





• Auxiliary countershaft retaining straps

Procedure - To remove the auxiliary section in thehorizontal position.

1. Remove the four (4) capscrews and the auxiliary counter-shaft rear bearing cover, gasket, and rear bearing shim.

2. Install the auxiliary countershaft retaining straps with 2-3/8"NC x 1" and 1-3/8" NC x 2-1/2" clean cap-screws.

WARNING: Do not use an air gun. Tighten by hand until thecapscrews are snug.

45

Auxiliary Section

External Parts

3. From the auxiliary section housing, remove the retainingcapscrews that attach the front section to the auxiliary sec-tion.

4. Insert the two (2) longest capscrews in the housing flangetapped holes. Tighten evenly to move the auxiliary sectionaway from the front box. Go far enough to break the gasketseal.

5. Remove the capscrews from the tapped holes.



8. Move assembly to the rear until auxiliary section is free.


Procedure - To remove the auxiliary section in the ver-tical position.

1. With blocks under the clutch housing to prevent input shaftdamage, place transmission in the vertical position, clutchhousing down.

2. Remove the four (4) capscrews and the auxiliary counter-shaft rear bearing cover, gasket, and rear bearing shim.

3. Install the auxiliary countershaft retaining straps with 2-3/8"NC x 1" and 1-3/8" NC x 2-1/2" clean capscrews.


46

Auxiliary Section

4. From the auxiliary section housing, remove the retainingcapscrews that attach the front box to the auxiliary section.



7. Lift assembly from the front section.


47

Auxiliary Section

External Parts

How to Install the Auxiliary Section With Tapered Bearings


There are different capscrew lengths, install in the correct location.

Auxiliary sections can be installed either with the transmission in the horizontal position or the vertical position.

To install in the vertical position, the clutch housing must be installed.

Special Tools





Procedure - To install the auxiliary section in the hor-izontal position.




4. Position the auxiliary section on the two (2) dowel pins.

5. Slide the auxiliary section on until the hanger bracket con-tacts the front section back.

6. Remove the auxiliary section hanger bracket.

7. Slide the auxiliary section the rest of the way into position.



10. To finish installation, see "The Shimming Procedure for Ta-pered Bearings".

48

Auxiliary Section

Procedure - To install the auxiliary section in the ver-tical position.

1. With blocks under the clutch housing to prevent input shaftdamage, place the transmission in the vertical position,clutch housing down.




5. Position the auxiliary section over the two (2) dowel pins.

6. Slide the auxiliary section down the dowels.



9. Remove the steel bar and chain.

10. To finish installation, see "The Shimming Procedure for Ta-pered Bearings".

Final Check

• Make sure capscrews are properly torqued.


49

Auxiliary Section

External Parts

The Shimming Procedure For Tapered Bearings


The shimming procedure can be done in the horizontal or vertical position. The procedure is done the same.

Shims must be aligned properly or else the rear bearing cover may be damaged when final torque is applied.

Special Tools


Procedure -

1. Remove the countershaft straps. Make sure a 0.125 coun-tershaft rear bearing shim is installed. Be sure the counter-shaft rear bearing races are seated in the bearing bores.

2. Install two (2) clean 3¦8" x 1" capscrews without washers di-rectly across from each other in each bearing cover. Tappedholes in auxiliary case must be free of thread adhesive.

3. Tighten the capscrews to 7 Lbf·in of torque. Do not installthe countershaft rear bearing cover gasket.

50

Auxiliary Section

4. Rotate the output shaft six (6) times clockwise, then six (6)times counterclockwise to seat the countershaft rear bear-ings. Use a feeler gauge, as close to each capscrew locationas possible, and measure the gap between the countershaftrear bearing cover and the auxiliary case. Record the mea-surements. Using the average measurement, refer to theshimming chart to identify the proper shim.

5. Remove the countershaft rear bearing cover and gaugingshim.

6. Place the selected shim on the rear countershaft bearingrace.

7. Position a new gasket on countershaft rear bearing covermounting surface.

8. Position the countershaft rear bearing cover over the newgasket.



11. Repeat Steps 1-8 for the other countershaft rear bearingcover.

Final Check• Make sure capscrews are properly torqued.


Table 1:

Feeler Gauge Average Gap

Shim Thickness

Standard Shim Part number

Oil Pump Shim Part Number

Color Code

.088-.089 .042-.043 21454 21474 Brown

.085.0875 .045-.046 21455 21475 Tan

51

Auxiliary Section

External Parts

.082-.0845 .048-.049 21456 21476 Orange

.079-.0815 .051-.052 21457 21477 Yellow

.076-.0785 .054-.055 21458 21478 Green

.073-.0755 .057-.058 21459 21479 Light Blue

.070-.0725 .060-.061 21460 21480 Lavender

.067-.0695 .063-.064 21461 21481 White

.064-.0665 .066-.067 21684 21686 Black

.061-.0635 .069-.070 21685 21687 Silver

.058-.0605 .072-.074 21452 + 21452 21472 + 21472 Red + Red

.055-.0575 .075-.077 21452 + 21453 21472 + 21473 Red + Pink

.052-.0545 .078-.080 21452 + 21454 21472 + 21474 Red + Brown

.049-.0515 .081-.083 21452 +21455 21472 + 21475 Red + Tan

.046-.0485 .084-.086 21452 + 21456 21472 + 21476 Red + Orange

.043-.0455 .087-.089 21452 + 21457 21472 + 21477 Red + Yellow

.040-.0425 .090-.092 21452 + 21458 21472 + 21478 Red + Green

.038-.0395 .093-.095 21452 + 21459 21472 + 21479 Red + Lt. Blue

Table 1:

Feeler Gauge Average Gap

Shim Thickness

Standard Shim Part number

Oil Pump Shim Part Number

Color Code

52

Clutch Housing

53

How to Remove the Clutch Housing


Removal of the clutch housing is done in the horizontal position.

Special Tools


Procedure -

1. From inside the clutch housing, remove the nuts and wash-ers.

2. From inside the clutch housing, remove the bolts.

3. Jar clutch housing to break gasket seal.

4. Pull the clutch housing from the studs and transmissioncase.


Clutch Housing

54

External Parts

How to Install the Clutch Housing


Installation of the clutch housing is done in the horizontal position.

Special Tools


Procedure -

1. Position a new gasket on the housing mounting surface.

2. Install the clutch housing on the front box, pilot it on the sixstuds and drive gear bearing cover.

3. Install the nuts with washers or lockwashers on the studs,tighten to 35 lb-ft (47 N.m) + 90° CW rotation or 175 lb-ft(237 N.m) of torque.

4. Install the capscrews with lockwashers, tighten to 115 lb-ft(156 N.m) of torque.

Final Check


Changing The Input Shaft

How to Remove the Input Shaft Without Disassembling the Transmission


Remove the transmission from the vehicle.

Special Tools


Procedure -

1. Remove the front bearing cover and gasket.

2. Remove the input shaft snap ring.

3. Drive the input shaft towards the transmission rear, throughthe bearing as far as possible.

4. Pull the input shaft forward to expose the bearing snap ring.

5. To complete bearing removal, use pry bars.

6. From the drive gear front, remove the drive gear spacer.

55


External Parts

7. Remove the drive gear snap ring.

8. Pull the input shaft forward, out of the drive gear and trans-mission case.

56


How to Install the Input Shaft Without Disassembling the Transmission


Check the bushing in the input shaft pocket, replace if worn.

Special Tools


• Input Shaft Bearing Driver

Procedure -

1. Install the new input shaft into main drive gear splines.

2. Position the input shaft just far enough into the gear to ex-pose the drive gear I.D. snap ring groove.

3. Install the drive gear I.D. snap ring.

4. Install the drive gear spacer on the input shaft.

5. With the external snap ring to the outside, slide the drivegear bearing on the input shaft and position into the casebore.

57


External Parts

6. With the input shaft bearing driver, seat the bearing.

7. Install the bearing retainer snap ring.


9. Position the front bearing cover on the input shaft, align theoil return hole in the cover with the oil return hole on thecase.

10. Apply Eaton/Fuller sealant #71205 or equivalent to the re-taining capscrews.


Final Check

• Make sure the input shaft turns freely.

58

Functions of a Shift Bar Housing

Shift Bar Housing Identification

Shift bar housings are a very important part of the transmission. No matter what kind of shift bar housing your transmission has,they all provide the same functions

• Engage the transmission gearing.

• Prevents the driver from shifting into 2 gears at the same time.

• Prevents shifting into reverse without force.

• Actuates the back up lights.

• Actuates the neutral switches.

Standard Shift Bar housing

Forward Shift Bar Housing w/SUPER 10 on cover

Standard Shift Bar Housing w/SUPER 10 on cover

59

Functions of a Shift Bar Housing

Shift Bar Housing

New Forward Shift Bar Housing w/SUPER 10 on cover

60

Gear Shift Lever

How to Disassemble the Gear Shift Lever


If total disassembly is needed, the Roadranger valve must be removed first.

Release the spring one coil at a time.

Special Tools


• A vise with brass jaws or wood blocks

Procedure -

1. Slide the Boot up the shift lever shaft and remove

2. With housing bottom facing up, secure the assembly in avise.

3. Use large screwdriver to twist between the spring and hous-ing, forcing the spring from under the housing lugs.

4. From inside the housing tower, remove the tension spring,washer, and gear shift lever.

5. In models so equipped, from the housing bore, remove thenut and washer.

61

Gear Shift Lever

Shift Bar Housing

6. From the housing tower spade pin bore, remove and inspectthe spade pin, discard if damaged.

7. From the housing tower inside groove, inspect the O-ring,discard if damaged.

62

Gear Shift Lever

How to Assemble the Gear Shift Lever


Inspect tension spring and washer for wear.

Apply Eaton rust preventative lubricant #71212 or equivalent to the shift lever pivot ball. A rust preventative lubricant film shouldcover all surfaces between and including the pivot ball.

Seat the tension spring one coil at a time.

Special Tools



• Tension Spring Driver

Procedure -

1. With housing bottom facing up, secure the assembly in avise.

2. If the spade pin is damaged, replace and install the spade pinin housing tower bore.

3. In models so equipped, install the nut and washer in thehousing bore.

4. If the O-ring is damaged, replace; lubricate the O-ring withEaton/Fuller lubricant #71206 or equivalent. Install the O-ring in the housing tower inside groove.

5. Align the lever ball slot with the spade pin and position thegear shift lever in the housing tower.

6. With dished-side up, install the washer over the ball.

63

Gear Shift Lever

Shift Bar Housing

7. Use a tension spring driver to install the tension spring un-der the housing lugs.

8. Remove the assembly from the vise.

9. Install a rubber boot over the gear shift lever and against thehousing.

Final Check

• Make sure the gear shift lever can move.

64

Shift Bar Housing

How to Disassemble the Standard Shift Bar Housing


The shift bar housing must be removed from the transmission.

During disassembly, lay all parts on a clean bench in order of removal to facilitate assembly.

Shift bars not being removed must be kept in the neutral position or the interlocking parts lock the bars.

Start with the bottom shift bar.

Cut the lockwire and remove the lockscrews from each bar just before their removal.

Special Tools


Procedure -

1. If the two (2) sets of tension springs and balls from housingbores and the anti-rotating pin have not been removed, placethe shift bar housing on its side to remove them.

2. With the housing rear to the right, lay the assembly on a flatsurface. If installed, remove the oil trough retaining cap-screws and oil trough.

3. While removing the bottom yoke bar, remove the shift yoke.

65

Shift Bar Housing

Shift Bar Housing

4. While removing the top yoke bar, remove the shift yoke as-sembly and block assembly.

5. Remove the interlock pin.

6. From the middle yoke bar, remove the jam nut, plain nut, andwasher.

7. Remove the range interlock bar.

8. From the middle yoke bar, remove the select interlock bar tothe right.

9. Pull the select tube to the left and remove the shift selectblock.

66

Shift Bar Housing

10. Remove the select tube with key to the left.

11. From the 1st & reverse shift yoke, remove the snap ring,washer, spring, and plunger. From the 3rd speed block, re-move the plug, spring, and plunger.

12. Inspect the yoke or block parts, replace the worn parts.

67

Shift Bar Housing

Shift Bar Housing

How to Assemble the Standard Shift Bar Housing


Inspect shift blocks and shift yokes for wear.

Apply Eaton sealant #71208 or equivalent to the shift bar housing plugs which are used to plug oil cooler provision holes. Thesealant should be applied so that at least 5 complete threads are covered.

Apply Eaton lockwire #1819 or equivalent to all shift bar housing assembly set screws in both blocks and yokes. The wire shouldanchor the capscrew at least 2 complete 360° turns. The lockwire ends should be trimmed and bent out of the way of any partinterference.

Keep yoke bars in neutral while assembling.

Special Tools


Procedure -

1. Assemble the 1st & reverse shift yoke assembly:

a. Install the plunger in the 1st & reverse shift yoke bore,plunger shank to the outside.

b. Install the spring into the bore over the plunger shank.

c. Position the washer over the plunger shank.

d. Install the snap ring.

2. Assemble the 3rd speed block assembly:

a. Install the plunger in the 3rd shift block bore, plungershank to the outside.


c. Install the plug and tighten to compress the spring.

d. After plug bottoms out, back the plug out 1-11/2 turns.

e. Complete the block assembly process by staking theplug through the small hole in block.

68

Shift Bar Housing

3. With the housing rear to the right, lay the assembly on a flatsurface.

4. Install the select tube in the middle boss with key in the keyslot.

5. As the select tube passes through the first boss, install theshift select block.

6. From the right, install the select interlock bar.

7. Install the range interlock bar, chamfered end in, notchedside down.

8. At the middle yoke bar front end, install the washer, plainnut, and jam nut.

69

Shift Bar Housing

Shift Bar Housing

9. Install the interlock pin, centered between bosses.

10. While installing the top yoke bar, position the shift yoke as-sembly and block assembly. The block assembly aligns withshift select block ear.

11. Install the lockscrews, tighten to 35-45 lb-ft of torque. Lock-wire securely.

12. While installing the bottom yoke bar, position the shift yoke.The block assembly aligns with shift select block ear.

13. Install the lockscrew, tighten to 35-45 lb-ft of torque. Lock-wire securely.

14. Turn the shift bar housing over, and install the anti-rotatingpin and the two (2) sets of tension springs and balls.

Final Check

• Make sure interlocking system is working – can’t shiftinto 2 gears at the same time.

• Make sure all capscrews are lockwired.

• Make sure the anti-rotating pin and the two (2) sets oftension springs and balls are installed.

70

Shift Bar Housing

How to Disassemble the Standard Shift Bar Housig (w/Super 10 on cover)







Special Tools


Procedure -

1. If the two (2) sets of tension springs and balls from housingbores have not been removed, place the shift bar housing onits side to remove them.

2. If installed, remove the oil trough retaining capscrews andoil trough.



71

Shift Bar Housing

Shift Bar Housing



7. From the middle yoke bar, drive center block roll pin out.

8. Pull the center bar to the right and remove the shift selectblock.

72

Shift Bar Housing



73

Shift Bar Housing

Shift Bar Housing

How to Assemble the Standard Shift Bar Housing (w/Super 10 on cover)






Special Tools


Procedure -












74

Shift Bar Housing


4. Install the center rail in the middle boss.

5. As the center rail passes through the first boss, install theshift block.

6. Drive the center block roll pin through the center bar to holdthe center block in position.




75

Shift Bar Housing

Shift Bar Housing



12. Install the oil trough and oil trough retaining capscrews.

13. Turn the shift bar housing over, and install the two (2) setsof tension springs and balls.

Final Check



• Make sure the two (2) sets of tension springs and ballsare installed.

76

Shift Bar Housing

How to Disassemble the Forward Shift Bar Housing (w/Super 10 on cover)







Special Tools


Procedure -

1. If the two (2) sets of tension springs and balls from housingbores have not been removed, place the shift bar housing onits side to remove them.




77

Shift Bar Housing

Shift Bar Housing





78

Shift Bar Housing



79

Shift Bar Housing

Shift Bar Housing

How to Assemble the Forward Shift Bar Housing(w/Super 10 on cover)






Special Tools


Procedure -












80

Shift Bar Housing








81

Shift Bar Housing

Shift Bar Housing





Final Check




82

Shift Bar Housing

How to Disassemble the New Forward Shift Bar Housing (w/Super 10 on cover)







Special Tools


Procedure -

1. If the two (2) sets of tension springs and balls from housingbores have not been removed, place the shift bar housing onits side to remove them. Check the condition of the align-ment pin, replace if necessary.




83

Shift Bar Housing

Shift Bar Housing





84

Shift Bar Housing



85

Shift Bar Housing

Shift Bar Housing

How to Assemble the New Forward Shift Bar Housing (w/Super 10 on cover)






Special Tools


Procedure -












86

Shift Bar Housing








87

Shift Bar Housing

Shift Bar Housing





Final Check




88

Front Section

89

How to Disassemble the Front Section

REMOVEEXTERNAL

PARTS

FOLLOW THE SOLID LINE,THEN THE DOTTED LINE,THEN THE DASHED LINE

AUXILIARYDRIVE GEARASSEMBLY

DISASSEMBLEAUXILIARY

DRIVE GEAR MOVEREVERSE

GEAR

REVERSEIDLER GEARASSEMBLY

REMOVECOUNTERSHAFT

BEARINGS

MAINSHAFTASSEMBLY

DISASSEMBLEMAINSHAFT

DISASSEMBLECOUNTERSHAFT

COUNTERSHAFT ASSEMBLY

INPUT SHAFTASSEMBLY

UPPER REVERSE IDLER GEAR

LOWER REVERSSE IDLER GEAR

UPPERCOUNTERSHAFT

LOWER COUNTERSHAFT BEARINGS

LOWER COUNTERSHAFT

UPPER COUNTERSHAFTBEARINGS


90

Front Section

How to Remove the Auxiliary Drive Gear Assembly


Before removing the auxiliary drive gear, the auxiliary section must be removed.

Special Tools


• Large pair of snap ring pliers

Procedure -

1. Remove the auxiliary bearing retainer ring capscrews.

2. Remove the mainshaft rear groove snap ring.

3. From inside the auxiliary drive gear assembly, remove thesplined washer.

4. Insert three (3) of the capscrews in the specially tappedholes of the retainer ring.

5. Tighten the capscrews evenly to force the auxiliary drivegear assembly from the case.

6. Remove the auxiliary drive gear from the mainshaft.

7. From the mainshaft, remove the splined washer.


How to Remove the Reverse Idler Gear Assembly


The following instructions are used to remove upper and lower reverse idler gears.

Before the upper reverse idler gear assembly can be removed, mainshaft reverse gear must be positioned forward against thenext gear.

While removing the reverse idler shaft, the thrust washer can drop to the transmission case bottom.

The mainshaft reverse gear must be moved in order to remove the upper reverse idler gear, see “How to Remove the MainshaftAssembly”, steps 1-3.

Special Tools


• Jaw Pullers or Impact Puller

Procedure -

1. From the reverse idler gear bore, use inside jaw pullers or animpact puller to remove the auxiliary countershaft frontbearing.

2. From the idler shaft, remove the loosened lock nut andwasher.

91


Front Section

3. From the idler shaft rear, remove the pipe plug.

4. Install an impact puller, 1¦2"-13 threaded end, and removethe shaft from case bore.

5. As the idler shaft and idler plate are removed, remove thethrust washer and gear.

6. Inspect the reverse gear assembly, remove the inner raceand needle bearing, if damaged.

92


How to Remove the Countershaft Bearings


The following instructions are used to remove the upper and lower countershaft bearings. To remove the mainshaft assembly,only the upper countershaft bearings need to be removed.

Performing the following instructions will damage the bearings and should be not be done unless bearing replacement is planned.

The bearing inner race remains pressed on the countershaft after removal of the front bearings.

Special Tools


• Soft bar and a maul

• Bearing puller or pry bars

Procedure -

1. To keep the mainshaft pilot from falling out of the input shaftpocket, temporarily install the auxiliary drive gear on themainshaft.

2. From each countershaft rear groove, remove the snap ring.

3. From inside the case, use a soft bar and maul to drive thecountershaft rear bearings from the case bores.

93


Front Section

4. From the front of each countershaft, remove the capscrewand front retainer plate.

5. Use the soft bar and maul to drive each countershaft to therear as far as possible. This partially unseats the front bear-ings.

6. Return to the case rear, and drive each countershaft forwardas far as possible. This exposes the bearing snap rings.

7. Use a bearing puller or pry bars to remove the countershaftfront bearings. If a bearing puller is used, the front bearingcover has to be removed.

94


95

How to Remove the Mainshaft Assembly


Be careful when removing the mainshaft assembly, the sliding clutch on the end can slip off the mainshaft.

Reverse gear is also free and can fall off the shaft.

Special Tools


• Large hook or 3 foot piece of rope

Procedure -

1. From the mainshaft, remove the reverse gear retaining snapring.

2. Move the mainshaft reverse gear as far to the rear as possi-ble and remove reverse gear I.D. snap ring.

3. Move the reverse gear forward and against the next gear, en-gaging the mainshaft sliding clutch spline.

WARNING: If not removing the upper reverse idler gear as-sembly, you must remove the upper reverse idler gear as-sembly shaft and roll the gear to the outside, see “How toRemove the Reverse Idler Gear Assembly”, steps 1-4.

4. Use a large screwdriver and block the upper countershaft as-sembly against the case wall.

WARNING: If removing the upper reverse idler gear assem-bly, see “How to Remove the Reverse Idler Gear Assembly”at this time.

5. Position the hook or rope around the mainshaft.

6. Pull the mainshaft to the rear to free the pilot from the inputshaft pocket.

7. Tilt mainshaft front up and lift assembly from the case.


96

Front Section

How to Remove the Countershaft Assemblies


Expect for the PTO gears the upper and lower countershaft assemblies are the same. Make sure and mark each as they are re-moved.

Special Tools


Procedure -

1. Move the upper countershaft assembly to the rear as far aspossible.

2. Swing the countershaft front to middle of the case.

3. Lift the countershaft assembly from the case.


How to Remove the Input Shaft Assembly


None

Special Tools



Procedure -

1. If the front bearing cover is still installed, remove the six (6)retaining capscrews and cover. Remove the any remaininggasket material from the case and cover.

2. From the input shaft groove, remove the bearing retainingsnap ring.

3. Use a soft bar and maul and drive the input shaft toward thecase rear as far as possible. Pull the input shaft forward.

4. Use pry bars or screwdrivers to complete removal of thebearing.

5. From the drive gear front remove drive gear spacer.

6. Remove the drive gear internal snap ring.

97


Front Section

7. Pull the input shaft forward and out of the drive gear.

8. From inside the case, remove the drive gear.

9. Inspect the bushing in the input shaft pocket, remove if dam-aged.

98

Front Section

99

How to Assemble the Front SectionFOLLOW THE SOLID LINE,THEN THE DOTTED LINE,THEN THE DASHED LINE FRONT

BOX

MAINSHAFTASSEMBLY

REVERSEIDLER GEARASSEMBLY

ASSEMBLECOUNTERSHAFTS

COUNTERSHAFTASSEMBLIES

INPUT SHAFTASSEMBLY

AUXILIARYDRIVE GEARASSEMBLY

INSTALLCOUNTERSHAFT

BEARINGS

UPPER COUNTERSHAFT BEARINGS

UPPER REVERSE IDLER GEAR

LOWER COUNTERSHAFTBEARINGS

LOWER REVERSE IDLER GEAR

ASSEMBLEMAINSHAFT

ASSEMBLEAUXILIARY

DRIVE GEAR

How to Assemble the Front Section

Front Section

How to Install the Reverse Idler Gear Assembly


If you install the bottom reverse idler gear assembly, make sure the three (3) magnetic discs are securely in place at case bottom.Use Eaton Adhesive #71210 or equivalent.

Special Tools


Procedure -

1. If reverse gear assembly is disassemble, position the needlebearing and inner race into the reverse idler gear.

2. Thread the pipe plug into the reverse idler shaft and tighten.

3. On the reverse idler shaft, position the idler shaft plate, flatside to the front.

4. Insert the idler shaft into the case bore, threaded-end to thefront. As the shaft passes through the case bore position thereverse idler gear on the shaft, long hub to the front. Insertthe thrust washer between the reverse idler gear and thecase support boss. Finish inserting the idler shaft.

5. Make sure the reverse idler shaft is seated in the supportboss bore.

6. Install the washer and lock nut on shaft front. Tighten thestop nut to 50-60 lb-ft of torque.

100


7. Use a bearing driver and a maul and install the auxiliarycountershaft front bearing outer race against the idler plate.

Final Check

• Make sure the stop nut is properly torqued.

• Make sure the bearing outer race is installed against theidler plate.

101


102

Front Section

How to Install the Countershaft Assemblies


Make sure the countershaft assemblies have been marked for proper position, 47-tooth PTO gear in the lower position.

On the drive gear of each countershaft assembly, mark the tooth aligned with the gear keyway and stamped with an “O” for easyidentification. A highly visible color of toolmaker’s dye is recommended for making timing marks.

Special Tools

• Toolmaker's dye

Procedure -

1. Mark the countershaft drive gear for timing purposes.

2. Place the lower, 47-tooth PTO gear, assembly in the case,the inner bearing race end to the front.

3. Position as far to the left as possible (the opposition side asthe lower reverse idler gear assemble.)

4. Place the upper, 45-tooth PTO gear, assembly in the case,the inner bearing race end to the front.

5. Position as far to the right as possible (the same side as thelower reverse idler gear assemble).

Final Check

• Make sure the upper and lower countershafts are in theright place.

• Make sure the timing marks are visible.


How to Install the Countershaft Bearings


The front bearing inner race must be pressed on the countershaft front.

The flanged-end driver must cover the bearing outer race for proper installation.

Temporarily use the assembled auxiliary drive gear to hold the mainshaft in the input shaft pilot.

Special Tools


• Countershaft support tool

• Flanged-end driver and maul

Procedure -

1. Move the countershaft to the rear and insert the countershaftsupport tool to center shaft in rear case bore.

2. Use a flanged-end driver to start the front bearing in casebore.

103


Front Section

3. Use a screwdriver inserted in the countershaft capscrewbore to help center the countershaft.

4. Move the countershaft forward into the bearing.

5. Use a flanged-end bearing driver and maul to completelyseat the front bearing in case bore.

6. On the countershaft front, position the retainer plate with rollpin in hole at shaft end.

7. Secure with capscrew, tightening to 90-120 lb-ft of torque.

8. From the rear, remove the countershaft support tool.

9. With the larger I.D. lead chamfer to the shaft front, use aflanged-end bearing driver and install the rear bearing.

10. In the countershaft rear groove, install the rear snap ring.

Final Check

• Make sure the front bearing capscrew is properlytorqued.

• Make sure the rear snap ring is in place.

104


How to Install the Input Shaft Assembly


As part of assembling the input shaft assembly, the mainshaft drive gear must be installed and timed.

Replace the pilot bushing, if worn.

Apply Eaton lubricant #71215 or equivalent to the pilot bushing so that a film of lubricant covers the entire internal surface of thebushing.

Special Tools


• Toolmaker’s dye

Procedure -

1. In I.D. of main drive gear, install the snap ring.

2. Use toolmaker’s dye and mark the main drive gear for timingpurposes.

Mark any two (2) adjacent teeth on the drive gear. Repeat theprocedure for the two (2) adjacent teeth directly opposite thefirst set marked.

3. Inside the case, mesh the lower countershaft drive gearmarked tooth with either set of marked teeth on the maindrive gear.

4. Slide the input shaft through the main drive gear.

105


Front Section

5. Over the input shaft, install the drive gear spacer.

6. With the bearing external snap ring to the outside, positionthe bearing on the input shaft.

7. Use a flanged-end driver and maul to seat the input shaftbearing.

8. Temporarily install the front bearing cover.

9. From inside the case, use a soft bar and maul to drive the in-put shaft through the bearing. Remove the front bearingcover.

10. Install the bearing retainer snap ring.

106


11. Position a new gasket on the bearing cover mounting sur-face, making sure to align the gasket oil return hole withcase oil return hole.

12. Position the front bearing cover, making sure to align thecover oil return hole with case oil return hole.

13. Secure the front bearing cover with six (6) capscrews, tight-en to 35-45 lb-ft of torque.

Final Check

• Make sure the drive gear is timed with the lower Coun-tershaft.

• Make sure the front bearing cover capscrews are tight-en properly.

107


108

Front Section

How to Install the Mainshaft Assembly


The lower countershaft bearings and the input shaft must be installed.

Check to make sure the lower countershaft drive gear marked tooth is in time with main drive gear set of marked teeth.

Special Tools


• A large hook or 3' piece of rope

Procedure -

1. Block the upper countershaft against the case wall.

2. With reverse gear forward against the next speed gear, lowerthe mainshaft assembly while pulling the shaft rear throughthe case bore.

3. Move the mainshaft pilot-end into the input shaft pilot bush-ing. Mesh the mainshaft gears with the corresponding for-ward countershaft assembly gears.

4. Center the mainshaft rear in case bore and temporarily posi-tion the auxiliary drive gear on the mainshaft. Partially seatthe bearing in the bore.

WARNING: At this time other components of the front sec-tion must be Installed before the mainshaft installation canbe completed, see “How to Install the Countershaft Bear-ings”.

5. Mesh the reverse gear teeth with the reverse idler gear teethand move the reverse gear to the rear as far as possible.

6. Remove the auxiliary drive gear.

7. Align the reverse gear spacer external splines with the re-verse gear and move the spacer into the reverse gear.

8. Install the reverse gear I.D. snap ring and move the reversegear forward on the mainshaft and against the reverse gearlimit washer.

9. Install the reverse gear retaining snap ring in the mainshaftsecond snap ring groove.


109

How to Install the Auxiliary Drive Gear Assembly


Before installing the auxiliary drive gear, the mainshaft must be completely installed.

Special Tools


• Large pair of snap ring pliers

• Flanged-end driver and maul

Procedure -

1. Install the splined washer on the mainshaft, against the re-verse gear retaining snap ring.

2. Position the auxiliary drive gear assembly on the mainshaft.

3. Use a flanged-end driver and maul to seat the auxiliary drivegear bearing.

4. Align the retainer ring capscrew holes with the tapped holes.



7. Install the splined washer inside the auxiliary drive gear as-sembly.

8. Install the auxiliary drive gear retaining snap ring in themainshaft snap ring groove.

Auxiliary Drive Gear Assembly

Front Section

How to Disassemble the Auxiliary Drive Gear Assembly


To disassemble, the auxiliary drive gear must be removed.

Special Tools


• A large pair of snap ring pliers

Procedure -

1. Lay the front auxiliary drive gear on a clean, flat surface.

2. From the front auxiliary drive gear hub, use a screwdriver topry off the snap ring retainer.

3. From the front auxiliary drive gear hub, remove the snapring.

4. Use the front hub as a base and press the retaining ring andbearing off.

110


5. From the front auxiliary drive gear hub, inspect the O-rings,remove if damaged.

111


Front Section

How to Assemble the Auxiliary Drive Gear Assembly


Inspect the O-rings and replace if damaged.

Apply Eaton Lubricant #71214 or equivalent to the auxiliary drive gear O-rings.

Special Tools


• A flanged-end driver and a maul

Procedure -

1. Lay the front auxiliary drive gear on a clean, flat surface.

2. Install the O-rings on the front auxiliary drive gear hub.

3. With snap ring groove away from gear teeth, install the re-taining ring on the front auxiliary drive gear.

4. With bearing snap ring facing groove in bearing ring, installthe bearing.

112


5. To retain the bearing, install the snap ring in front gear hubgroove.

6. With grooved side down, use a flanged-end driver and installthe outer retainer ring.

Final Check

• Make sure the outer retainer ring is seated.

113

Countershaft Assembly

114

Front Section

How to Disassemble the Countershaft Assembly


Never use the PTO gear as a pressing base. The narrow width of this gear can cause breakage.

Special Tools

• Snap Ring pliers

• Press

Procedure -

1. From each countershaft front remove the drive gear retain-ing snap ring.

2. Using the rear face of 3rd speed gear as a base, press thedrive gear, PTO gear, and 3rd speed gear from each counter-shaft. This removes the front bearing inner race.

3. Inspect the key and roll pin, remove if damaged.


How to Assemble the Countershaft Assembly


Except for the PTO gears, the upper and lower countershaft assemblies are the same. To avoid confusion during installation, markthe upper countershaft (45-tooth PTO gear) with an “U”. The lower countershaft has a 47-tooth PTO gear.

Special Tools

• Snap ring pliers

• Press

Procedure -

1. If previously removed, install the roll pin and key in counter-shaft keyway.

2. Align 3rd speed gear keyway with the countershaft key andpress the gear on the countershaft.

3. Align PTO gear keyway with the countershaft key and pressthe gear on the countershaft.

4. Align drive gear keyway with the countershaft key and pressthe gear on the countershaft.

115


Front Section

5. On each countershaft front, install the drive gear retainingsnap ring in groove.

6. Use a flanged-driver or the press to install the bearing innerrace on the countershaft front against the drive gear.

Final Check

• Make sure all gears are pressed into place.

• Make sure the bearing inner race is installed.

116

Mainshaft Assembly

How to Disassemble the Mainshaft Assembly


During disassembly, lay all parts on a clean bench in order of removal to facilitate reassembly.

When removing limit washers, spacers and gears, note their location. Keep the internal-splined washers and external-splinedspacers with the gear from which they were removed. There is only one limit washer and one spacer belonging to each gear.

Special Tools


Procedure -

1. Remove reverse gear.

2. Remove reverse gear spIine spacer.

3. Tilt the mainshaft up, and from the opposite end, remove thesliding clutch.

4. Place the mainshaft in a vertical position.

5. Remove the mainshaft key snap ring.

6. From the mainshaft rear, pull the mainshaft key from themainshaft key way.

7. Turn the reverse gear limit washer to align its splines withthe mainshaft and remove the washer.

8. Remove the reverse-1st speed sliding clutch.

117

Mainshaft Assembly

Front Section

9. Remove 1st gear and spline spacer.

10. Remove 1st gear spacer.

11. Turn the 1st gear limit washer to align its splines with themainshaft and remove the washer.

12. Turn the 3rd gear limit washer to align its splines with themainshaft and remove the washer.

13. Remove the 3rd gear spacer.

14. Remove 3rd gear.

15. Remove 3rd gear spline spacer.

16. Turn the 3rd gear limit washer to align Its splines with themainshaft and remove the washer.

17. Inspect the roll pin, remove if damaged.

118

Mainshaft Assembly

How to Assemble the Mainshaft Assembly


Each mainshaft gear must have its I.D. snap ring installed before placement on the mainshaft. Do not replace reverse gear I.D.snap ring.

Gear limit washers are internally splined and locked to the mainshaft by the key. Gear spacers are externally splined to engage withgear hub clutching teeth. There is one limit washer and one spacer for each mainshaft gear.

Axial clearance (end-play) limits are .006"-.015" for all mainshaft gears.

If the axial clearance is less than the minimum .006" tolerance, the limit washer should be replaced with a thinner limit washer.This will increase the axial clearance between the gears. If the axial clearance is greater than the maximum .015" tolerance, a thickerlimit washer should be installed. This will decrease the axial clearance between the gears.

Special Tools


• Feeler gauges

• A piece of 5/32" air line, 1' long

Procedure -

1. With mainshaft pilot-end down, secure the mainshaft in avise equipped with brass jaws or wood blocks.

2. If previously removed, install the roll pin in keyway.

3. With the washer flat side up, position the 3rd speed gear lim-it washer (white) in the mainshaft 1st or bottom groove. Ro-tate the washer until the washer splines and mainshaftspIines align.

4. Start at the mainshaft bottom and install the air line in thekeyway to lock the washer in place. As limit washers andgears are installed, continue to push the air line up.

119

Mainshaft Assembly

Front Section

5. Against the 3rd speed gear washer, position the 3rd speedgear spacer.

6. With clutching teeth down and engaged with the spacer ex-ternal splines, position the 3rd speed gear on the mainshaft.

7. Against 3rd speed gear, position a mainshaft spacer.

8. With the washer flat side down, position the limit washeragainst the spacer. Rotate the washer until the washersplines and mainshaft splines align.

9. Push the air line up to lock the washer on the mainshaft.

120

Mainshaft Assembly

10. Between the gear hub and mainshaft spacer, insert .006"feeler gauge and .015" feeler gauge. If out of tolerance,change the limit against the mainshaft spacer. See “SpecialInstructions” for further information.

11. With the flat side up, position the 1st speed gear limit wash-er (white) in the next available groove. Rotate the washer un-til the washer splines and mainshaft splines align.


13. Against the limit washer, position the mainshaft spacer.

14. With clutching teeth up, position the 1st speed gear on themainshaft against the spacer.

15. Position 1st speed gear spacer against 1st speed gear, en-gaging the spacer external splines with gear clutching teeth.

16. With washer flat side down, position the limit washer againstthe spacer. Rotate the washer until the washer splines andmainshaft splines align.


121

Mainshaft Assembly

Front Section

18. Between the gear hub and mainshaft spacer, insert .006"feeler gauge and .015" feeler gauge. If out of tolerance,change the limit against the mainshaft spacer. See ‘SpecialInstructions’ for further information.

19. Align the sliding clutch missing internal spline with themainshaft key and install the 1st-Reverse speed slidingclutch.

20. With the flat side up, position the Reverse speed gear limitwasher (white) in the next available groove. Rotate thewasher until the washer spIines and mainshaft splines align.


22. Against the limit washer, position reverse speed gear spac-er.

122

Mainshaft Assembly

23. Install reverse gear on the mainshaft. Engage the gearclutching teeth with spacer splines and sliding clutch. Movethe reverse gear down against the 1st speed gear.

24. At this time remove the air line and insert the mainshaft key.

WARNING: Be careful not to move the gears while doing thisprocedure, the limit washers are unlocked and can rotatewhich would cause the gears to drop.

25. Install the mainshaft key snap ring.

26. Remove the mainshaft from the vise.

27. On the shaft front, align the sliding clutch missing internalspline with the mainshaft key and install the 3rd-Drive gearsliding clutch. Engage the sliding clutch external splines withthe 3rd speed gear clutching teeth.

Final Check

• Make sure reverse gear is against 1st speed gear.

• Make sure the mainshaft key is in the keyway.

• Make sure the 3rd speed sliding clutch is engaged into3rd speed gear.

123

Auxiliary Section

124

Auxiliary Section

How to Disassemble the Auxiliary Section

AUXILIARYSECTION

FRONT SECTION DRIVEGEAR & YOKE

COUNTERSHAFTASSEMBLIES

REAR AUXILIARYDRIVE GEAR

RANGECYLINDER ASSEMBLY

OUTPUTSHAFT

ASSEMBLY

SPLITTERCYLINDERASSEMBLY

DISASSEMBLESYNCHRONIZER

ASSEMBLY


125

How to Remove the Front Auxiliary Drive Gear

Special Tools



Procedure -

1. From the splitter cylinder shift yoke, remove the lockwireand capscrew.

2. Pull the sliding clutch and shift yoke straight out to removethem.


Auxiliary Section

How to Remove the Countershaft Assemblies (w/Tapered Bearings)


For "A" Series, go to “A” Series Section.

For ease of disassembly, mount the auxiliary section upright in a vise.

Both countershafts are removed the same.

Make sure the countershaft retaining straps are installed.

As the countershaft strap is removed, support the countershaft; it can fall.

Special Tools


• Vise with brass jaws or wood blocks

• Bearing puller


Procedure -

1. On the output shaft, temporarily install a output yoke.

2. To keep the output shaft from turning, insert a breaker bar.

3. From the output shaft, loosen the 15/16" capscrew and re-tainer. Do not remove the capscrew. Remove the bar andoutput yoke.

126


4. Use a sort bar and maul to drive the output shaft forward farenough to partially unseat the bearing.

5. Support the auxiliary countershaft while removing the auxil-iary countershaft retaining strap.

6. Remove the auxiliary countershafts.

7. If necessary, secure the countershaft assemblies in a viseand remove both the front and rear bearings with a bearingseparator and jaw pullers.

127

Countershaft Assembly (A Series Only)

Auxiliary Section

How to Remove the Countershaft Assemblies (w/Ball Bearings) A Series


For ease of disassembly, mount the auxiliary section upright in a vise.

Both countershafts are removed the same.

When driving that countershaft to the rear, be careful not to damage the bearing inner race.

As the rear bearing is removed, the countershaft will fall.

Special Tools



• Bearing puller


Procedure -

1. From the countershaft rear bearing cover, remove the cap-screws, cover, and gasket.

2. Clean the gasket mounting surface of gasket material.

3. From the countershaft rear, remove the snap ring.

128


4. Use a sort bar and maul to drive the countershaft forward farenough to partially unseat the bearing.

5. Use a soft bar and maul to drive the countershaft to the rear.This exposes the bearing snap ring.

6. Use a bearing puller and remove the countershaft bearingand countershaft.

7. Inspect the countershaft bearing inner race, remove if nec-essary.

129


130

Auxiliary Section

How to Remove the Rear Auxiliary Drive Gear


None

Special Tools



Procedure -

1. Retainer rectangular in shape.

From the output shaft, remove the 15/16" capscrew and re-tainer.

Retainer round in shape.

From the output shaft, remove the 15/16" capscrew and re-tainer, and thrust washer.

2. From the output shaft, remove the auxiliary drive gear. If theretainer, from Step 1, is round, there will also be a thrustwasher behind the auxiliary drive gear to remove.


How to Disassemble the Range Cylinder Assembly


When removing the range cylinder cover insert valves, note the direction the insert valve was positioned (nipple in or out).

Special Tools


Procedure -

1. From the range cylinder cover, remove the capscrews, cov-er, and gasket.

2. Clean the gasket mounting surfaces of all gasket material.

3. From the range cylinder housing bore, remove the nut.

4. From the auxiliary section front, remove the two (2) yoke barretaining capscrews.

131


Auxiliary Section

5. From the cylinder housing bore, remove the yoke bar.

6. From the shaft, pull the synchronizer shift yoke and the syn-chronizer assembly.

7. From the cylinder housing bore, remove the range piston.

8. Inspect the range piston O-rings, remove if damaged.

132


9. From the range cylinder housing, remove the housing andgasket.

10. Clean the gasket mounting surfaces of all gasket material.

11. Inspect the O-ring inside the range cylinder housing bore,remove if damaged.

12. Place the range cylinder cover in a vise, remove one insertvalve retaining nut and insert valve.

13. Inspect the insert valve and the cover bore for damage. Re-peat for other insert valve.

For 14610A Models, go to Steps 14 and 15.

14. Place the range cylinder housing in a vise, remove the rollpin.

133


Auxiliary Section

15. Remove the interlock pin. Inspect the pin, replace if dam-aged.

134


How to Disassemble the Output Shaft Assembly


When using the soft bar and maul on the output shaft, be careful not to damage the threads.

When removing the rear bearing cover, the rear bearing cone drops from the housing bore.

Special Tools



• Press


Procedure -

1. Use a soft bar and maul to drive the output shaft forward andthrough the rear bearing assembly.

2. From the auxiliary housing rear, remove the rear bearing re-taining capscrews, cover, and gasket.


4. Inspect the rear bearing cover oil seal for damage, remove ifdamaged.

135


Auxiliary Section

5. From the auxiliary housing rear, remove the bearing cup andspacer.

6. From the auxiliary housing front, remove the remainingbearing cup.

7. From the output shaft, remove the bearing inner spacer.

8. Use the output shaft assemble gear front face as a base,press the output shaft through the bearing and gear.

136


How to Disassemble the Splitter Cylinder Assembly


When removing the splitter cylinder cover insert valve, note the direction the insert valve was positioned (nipple in or out).

Special Tools



Procedure -

1. From the splitter cylinder cover, remove the capscrews, cov-er, and gasket.


3. From the cylinder housing, remove the yoke bar.

4. From the auxiliary housing, remove the splitter cylinderhousing.

137


Auxiliary Section

5. From the splitter cylinder cover, remove the insert valve re-taining nut and insert valve.

6. Inspect the insert valve and the cover bore for damage.

7. Inspect the yoke bar O-ring; remove if necessary.

8. Inside the cylinder housing bore; inspect the small 0-ring,remove if damaged.

138

Auxiliary Section

139

How to Assemble the Auxiliary Section

AUXILIARYSECTION

REAR AUXILIARYDRIVE GEAR

COUNTERSHAFTASSEMBLY

ASSEMBLESYNCHRONIZER

ASSEMBLY

RANGECYLINDERASSEMBLY

SPLITTERCYLINDERASSEMBLY

FRONT AUXILIARY DRIVEGEAR AND YOKE

AUXILIARYSECTION


Auxiliary Section

How to Assemble the Output Shaft Assembly



Make sure the magnetic plugs are installed in the auxiliary housing.

Output shaft stack up should be done on a clean, flat surface.

When heating the bearings, do not heat bearings above 275°F (136°C).

When installing the rear bearing race, the proper depth is when the race shoulder is seated on bearing bore top.

Because the collar becomes distorted when compressed, do not use an old nylon collar in the rear bearing cover.

Special Tools



• Heat lamp or hot plate and oil

• Oil seal installation tool

Procedure -

1. Use toolmaker’s dye and mark the LO range gear for timingpurposes.

Mark any two (2) adjacent teeth on the LO range gear. Re-peat the procedure for the two (2) adjacent teeth directly op-posite the first set marked.

2. With splined washer facing up, place the washer on the out-put shaft shoulder.

140


3. With LO range gear clutching teeth down, position LO rangegear on the output shaft, engage the washer splines.

4. With chamfer side up, position the LO range gear rear wash-er on the output shaft against the LO range gear.

5. With tapered side up, use heat or appropriate driver and in-stall the output shaft front rear bearing.

6. On the output shaft, position the bearing inner spacer. Setaside.

141


Auxiliary Section

7. Lay the auxiliary housing front face up on a clean, flat sur-face. Install the front bearing cup.

8. Turn the auxiliary housing over, install the rear bearing spac-er and rear bearing race in the bearing bore.

142

Output Shaft Assembly (A Series Only)

How to Assemble the Output Shaft Assembly (A Series)


Make sure the magnetic plugs are installed in the auxiliary housing.

Output shaft stack up should be done on a clean, flat surface.

When heating the bearings, do not heat bearings above 275°F (136°C).

When installing the rear bearing race, the proper depth is when the race shoulder is seated on bearing bore top.

Because the collar becomes distorted when compressed, do not use old nylon collar on rear bearing cover.

Special Tools



• Heat lamp or hot plate and oil

• Oil seal installation tool

Procedure -

1. Use toolmaker’s dye and mark the LO range gear for timingpurposes.

Mark any two (2) adjacent teeth on the LO range gear. Re-peat the procedure for the two (2) adjacent teeth directly op-posite the first set marked.

2. With splined washer facing up, place the washer on the out-put shaft shoulder.

143


Auxiliary Section

3. With LO range gear clutching teeth down, position LO rangegear on the output shaft, engage the washer splines.

4. With chamfer side up, position the LO range gear rear wash-er on the output shaft against the LO range gear.

5. With tapered side up, use heat or appropriate driver and in-stall the output shaft front rear bearing.

6. On the output shaft, position the bearing inner spacer. Setaside.

144


7. Lay the auxiliary housing front face up on a clean, flat sur-face. Install the front bearing cup.

8. Turn the auxiliary housing over, install the rear bearing spac-er and rear bearing race in the bearing bore.

9. With the auxiliary housing rear up, set the housing over theoutput shaft.

10. With tapered side down, use heat or appropriate driver andinstall the output shaft rear bearing.

11. Position a new gasket on the rear bearing cover mountingsurface, making sure the gasket oil return holes align withthe case oil return holes.

12. If previously removed, use an oil seal installation tool and in-stall the oil seal in the rear bearing cover.

145


Auxiliary Section

13. Position the rear bearing cover over the new gasket.


15. Install the five (5) retaining capscrews in the non-chamferedhole, tighten to 35-45 lb-ft of torque.

16. Install the nylon collar and brass washer in the chamferedhole, tighten to 35-45 lb-ft of torque.

Final Check

• Make sure the rear bearing is seated.

• Make sure the rear bearing capscrews are properlytorqued.

• Make sure the output shaft rotates freely.

146


How to Install the Countershaft Assemblies (w/Tapered Bearings)



To make auxiliary section assembly easier, you can make an auxiliary section fixture out of a 2" x 12".

Make sure to use an auxiliary drive gear retaining bolt with thread sealant material.

Special Tools


• Auxiliary countershaft retaining straps


Procedure -

1. Place the countershaft assembly vertical on a clean, flat sur-face. If previously removed, use the proper driver and maulto install the countershaft bearings.

2. Mark each countershaft for correct timing. Locate the "O"stamped on the countershaft and mark the tooth with highlyvisible toolmaker's dye or paint.

3. Install the synchronizer assembly on output shaft front.

4. Place the thrust washer, the rear auxiliary drive gear, thethrust washer, the retainer and the 15/16" capscrew on theoutput shaft assembly. Finger tighten the capscrew.

147


Auxiliary Section

5. Place the countershafts in the fixture or on a flat surface forreassembly. Turn the countershafts so that the two teethmarked on each LO range gear are towards the middle.

6. Align the output shaft between the countershafts, match thetiming marks.

7. With range yoke offset side facing down, install into the syn-chronizer sliding slot.

8. Place the auxiliary housing over the countershaft assembliesand the output shaft assemble.

9. Heat the rear output bearing cone and install the bearing, ta-pered side down, on the shaft.

10. Position a new gasket on the rear bearing cover mountingsurface.

148


11. Position the rear bearing cover.


13. Install the five (5) retaining capscrews in the non-chamferedhole, tighten to 35-45 lb-ft of torque.

14. Install the nylon collar and brass washer in the chamferedhole, tighten to 35-45 lb-ft of torque.

15. Install each auxiliary countershaft retaining strap with 2 - 3/8" NC x 1" and 1 - 3/8" NC x 2 -1/2" clean capscrews.


149


Auxiliary Section

How to Install the Countershaft Assemblies (w/Ball Bearings) A Series


For ease of assembly, mount the auxiliary section in a vise.

When Installing the countershaft assemblies into the countershaft bearings, keep the countershaft assemblies straight. Do notcock the countershafts.

If, when the countershaft bearing cover is removed and you can not see the snap ring groove, install the cover and drive the coun-tershaft further until you can see the groove.

Special Tools



• Bearing driver and a maul


• Large snap ring pliers

Procedure -

1. Place the countershaft assembly vertical on a clean, flat sur-face. If previously removed, using the proper driver andmaul install the countershaft bearing race.

2. In the countershaft rear bearing bore, using the proper driv-er and maul, install the countershaft bearing.

150


3. Temporarily install the rear bearing cover, use two (2) cap-screws and no gasket. The cover holds the bearing as thecountershaft is driven into the bearing.

4. Use toolmaker’s dye and mark the smaller LO range geartooth that aligns with countershaft gear marked with an “O”.

5. Position the countershaft in the auxiliary housing. Mesh thecountershaft marked tooth with either set of LO range gearmarked teeth.

6. Use a sort bar and maul and drive the countershaft into thecountershaft bearing.

151


Auxiliary Section

7. From the auxiliary housing rear, remove the countershaftbearing cover and install the rear countershaft snap ring inthe snap ring groove.

8. Position a new gasket on the countershaft bearing covermounting surface.

9. Position the countershaft bearing cover over the gasket.


11. Install the capscrews, tighten to 35-45 lb-ft of torque.

12. Repeat all steps for other countershaft installation.

Final Check

• Check both countershafts for timing; the output shaftshould rotate freely.

• Check capscrews for proper torque.

152


How to Assemble the Range Cylinder Assembly


Apply Eaton lubricant #71214 or equivalent to all shift cylinder assembly and insert valve O-rings so a film covers the entire surfaceof each O-ring.

Apply Eaton rust preventative #71213 or equivalent to all shift cylinder walls and yoke bars, cover the entire yoke bar surface thatcomes in contact with the shift cylinder O-ring.

Apply Eaton lockwire #1619 or equivalent to the shift yoke capscrews. The lockwire should anchor each capscrew head securelyto the yoke or to the second capscrew which fastens to the yoke bar. The lockwire should be twisted together, trimmed, and bentout of the way of other parts.

Special Tools


Procedure -

1. If previously removed, install the interlock pin in the cylinderhousing. ("A" Series Only).

2. If previously removed, install the roll pin. ("A" Series Only).

153


Auxiliary Section

3. If previously removed, in the cylinder housing bore, installthe small O-ring.

4. If previously removed, on the piston I.D. and O.D., install thepiston O-rings.

5. Position a new gasket on the cylinder housing mounting sur-face.

6. From the rear, with the air passage away from the rear bear-ing cover, install the cylinder housing.

7. Place the range shift yoke, with the threaded yoke hub upand HI range synchronizer towards the front, in the slidingclutch slot.

8. Place the range shift yoke and synchronizer assembly on theoutput shaft, engaging the sliding clutch splines.

154


9. With the yoke bar threaded-end, insert the yoke bar into therange cylinder housing bore, through the range shift yokehub. Align the bar notches with range shift yoke lockscrewholes.

10. Install the two (2) yoke bar retaining capscrews, tighten to50-65 lb-ft of torque.

11. From the rear, insert the piston. Push it in as far as it will go.

12. Secure the piston with the retaining nut, tighten to 70-85 lb-ft of torque.

155


Auxiliary Section

13. If previously removed, install, in one of the cylinder coverbores, the insert valve, nipple in the proper direction.

14. If previously removed, install, over the insert valve, the in-sert valve retaining nut. Tighten the retaining nut to 40-50 lb-ft of torque. Repeat for other insert valve.

15. Position a new gasket on the cylinder housing cover mount-ing surface. The gasket air passage must align with thehousing air passage.

16. Over the gasket, position the range cylinder cover.


18. Install the capscrews, tighten to 20-25 lb-ft of torque.

Final Check

• Make sure all capscrews are tighten to their propertorque.

• Make sure gaskets were used at the appropriate posi-tions.

156


157

How to Install the Rear Auxiliary Drive Gear


None

Special Tools



• Output yoke and breaker bar

Procedure -

1. Temporarily install the output yoke.

2. To keep the output shaft from turning, insert and hold thebreaker bar.

3. Tighten the auxiliary drive gear retainer bolt to 90-120 lb-ftof torque. Remove the breaker bar and output yoke.

Final Check• Make sure the auxiliary drive gear retainer bolt is prop-

erly torqued.


Auxiliary Section

How to Assemble the Splitter Cylinder Assembly


Apply Eaton lubricant #71214 or equivalent to all shift cylinder assembly and insert valve O-rings so a film covers the entire surfaceof each O-ring.

Apply Eaton rust preventative #71213 or equivalent to all shift cylinder walls and yoke bars, cover the entire yoke bar surface thatcomes in contact with the shift cylinder O-ring.

Apply Eaton lockwire #1619 or equivalent to the shift yoke capscrews. The lockwire should anchor each capscrew head securelyto the yoke or to the second capscrew which fastens to the yoke bar. The lockwire should be twisted together, trimmed, and bendout of the way of other parts.

Special Tools



Procedure -

1. If previously removed, in the cylinder housing bore, installthe small O-ring.

2. If previously removed, on the piston O.D., install the pistonO-ring.

158


3. Place the auxiliary housing upright in a vise.

4. Position a new gasket on the cylinder housing mounting sur-face.

5. From the rear, with the air passage towards the rear bearingcover, install the cylinder housing.

6. From the rear, insert the piston. Make it flush with the cylin-der housing.

7. If previously removed, install in the cylinder cover bore theinsert valve, nipple in the proper direction.

8. If previously removed, install over the insert valve the insertvalve retaining nut. Tighten the retaining nut to 40-50 lb-ft oftorque.

9. Position a new gasket on the cylinder housing cover mount-ing surface. The gasket air passage must align with thehousing air passage.

159


Auxiliary Section

10. Position the splitter cylinder cover over the gasket.


12. Install and tighten the retaining capscrews to 20-25 lb-ft oftorque.

Final Check

• Make sure the retaining nut and capscrews are tightento proper torque.

• Make sure gaskets were used at appropriate positions.

160


161

How to Install the Front Auxiliary Drive Gear


Make sure the splitter yoke bar lockscrew hole aligns with the yoke lockscrew hole.

Special Tools



Procedure -

1. Place the shift yoke in splitter sliding clutch slot. Install theclutch and yoke on the splitter yoke bar.

2. Install the lockscrew and tighten to 35-45 lb-ft of torque.Lockwire securely.


162

Auxiliary Section

How to Disassemble the Synchronizer Assembly


Place the synchronizer assembly on a clean, flat surface. Cover the synchronizer assembly with a shop rag to prevent losing thethree (3) springs under pressure from the HI range synchronizer pin locations.

Special Tools

• Shop rag

Procedure -

1. Place the larger LO range synchronizer ring on the bench.

2. Grab both sides of the HI range synchronizer and pull.

3. From the synchronizer ring LO range pins, remove the slid-ing clutch.


How to Assemble the Synchronizer Assembly


Assembly should be done on a clean, flat surface slightly lower than your waist.

Pins on the Low range synchronizer must line up with the chamfered holes on the sliding clutch bottom.

When compress the HI range synchronizer springs cover with a shop rag. In the event compression is not achieved the first time,this prevents the springs from leaving the bench area.

Special Tools

• Shop rag

Procedure -

1. On the bench place the larger LO range synchronizer ringface down with pins up.

2. With the sliding clutch recessed side up, place the slidingclutch on the LO range synchronizer pins.

3. In the HI range synchronizer bores, install the three (3)springs.

163


Auxiliary Section

4. Place the HI range synchronizer ring over the LO range syn-chronizer ring. Rotate the HI range synchronizer until thesprings are seated against the pins.

5. With the shop rag, cover the assembly.

6. Apply downward pressure to the HI range synchronizer ringwhile twisting counterclockwise. This compresses thesprings to fully seat HI range on the LO range synchronizer.

Final Check• Make sure there are three springs and are fully com-

pressed.

• Make sure you can move the sliding clutch from HI toLO range and back.

164

Integral Oil Pump

How to Remove the Integral Oil Pump


None

Special Tools


Procedure -

1. Straighten tube lock on suction tube.

2. Remove suction tube from oil pump. If necessary, removeO-ring from suction tube.

3. Remove three (3) allen head capscrews and washers that re-tain the integral oil pump to the case.

4. Remove the integral oil pump assembly from inside thecase.

165

Integral Oil Pump

Options

5. Remove the integral oil pump retainer plate from inside thecase.

6. If necessary, the front case plug can be removed from thecase. To remove, insert a bar from inside the case and tapthe plug out.

7. Inspect the plug O-ring, replace if damaged.

166

Integral Oil Pump

How to Install the Integral Oil Pump


Lubricate the case front plug O-ring with Eaton/Fuller lubricant #71206 or equivalent.

Special Tools


Procedure -

1. If removed, replace the front case pump plug O-ring. lubri-cate the grove of the plug, install the O-ring onto the plug,and then lubricate the outer diameter of the O-ring.

2. Seat the front case pump plug in the case bore by hand. Donot install the pump plug using any type of impact tool (i.e.hammer, maul, etc.).

Note: P/N 4303107 retainer plate, which has a smaller out-side diameter, must be used with maincase machinedafter April 1995. If an older oil pump assembly is in-stalled into a new case, P/N 20510 retainer plate willnot seat properly in the spot face machined in the casewall

3. With the retainer bore facing the case rear, install the integraloil pump over the alignment pin inside the case.

4. Align oil pump with retainer and alignment pin and install theintegral oil pump assembly.

167

Integral Oil Pump

Options

5. Install three (3) allen head capscrews and washers throughthe case front and into the pump housing. Tighten the cap-screws to 8-12 lb-ft of torque.

6. Replace the O-ring on the suction tube.

7. Install the tube under the case rib and into the integral oilpump.

8. Bend the suction tube lock over the case rib.

Final Check

• Make sure the integral oil pump drive gear can turn.

168

Integral Oil Pump

How to Disassemble the Integral Oil Pump


None

Special Tools



Procedure -

1. From the assembly, remove the outer oil pump element.

2. From the drive shaft, remove the drive gear retaining snapring.

3. From the pump drive shaft, remove the drive gear.

4. From the drive shaft keyway, remove the key.

5. From the drive shaft, remove the element snap ring.

6. From the drive shaft, remove the internal oil pump element.

7. From the drive shaft keyways, remove the two (2) keys.

169

Integral Oil Pump

Options

8. From the integral oil pump housing, remove the drive shaft.

9. If damaged, from the drive shaft, remove the rear drive gearretention snap ring.

10. From the pump housing, remove the relief valve roll pin.

11. From the relief valve housing bore, remove the relief valvespring.

12. From the housing bore, remove the relief valve.

13. Inspect all parts for damage, replace damaged parts.

170

Integral Oil Pump

How to Assemble the Integral Oil Pump


When installing the drive shaft keys, the round key goes in the round keyway and the square key in the square keyway.

Special Tools



Procedure -

1. Install the relief valve in the integral oil pump housing.

2. Install the relief valve spring in oil pump housing.

3. Secure the oil pump housing in a vice.

4. Depress the relief valve spring and drive the relief valve re-tention roll pin into the roll pin bore.

5. If removed, replace the drive shaft snap ring on the pumpdrive shaft.

6. Insert the drive shaft through the pump housing bore.

7. Install the two (2) keys on the drive shaft.

8. Align the inner element keyways with the drive shaft keysand install the integral oil pump inner element.

171

Integral Oil Pump

Options

9. Install the inner element retention snap ring in drive shaftsnap ring groove.

10. Install drive gear key in drive shaft keyway.

11. Align drive gear keyway with drive shaft key and install thedrive gear on the drive shaft.

12. Install the outer drive gear retention snap ring in drive shaftgroove.

13. Install the outer integral oil pump element over the inner el-ement.

172

Copyright Eaton Corporation, 2012. Eaton hereby grant their customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. It may be copied only in its entirety without any changes or modifications. THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.

Note: Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed. Although every attempt has been made to ensure the accuracy of information contained within, Eaton makes no representation about the completeness, correctness or accuracy and assumes no responsibility for any errors or omissions. Features and functionality may vary depending on selected options.

For spec’ing or service assistance, call 1-800-826-HELP (4357) or visit www.eaton.com/roadranger.In Mexico, call 001-800-826-4357.

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.

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