Eaton Transmission 2A-92 Service Manual

Service Manual

Fuller Mechanical Transmissions

TRSM0992

October 2007

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

1(877) 776-4600

[phone] [e-mail]

906 W. Gore St. Orlando, FL 32805

Introduction

Warnings and Precautions

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

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

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

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

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

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

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

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

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

Caution: Failure to follow indicated procedures may cause component damage or 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
Description..................................................................	1
Specifications..............................................................	2
Lubrication ..................................................................	3
Preventative Maintenance Check List ..........................	4
Tool Reference ............................................................	5
Torque Ratings ............................................................	6
Removal and Disassembly
General Instructions for Disassembly .........................	7
How to Remove the Mainshaft Assembly....................	8
How to Remove the Shifting Bar and Yoke................	12
How to Remove and Disassemble the
Drive Gear Assembly ..........................................	13
How to Remove and Disassemble the
Countershaft Assembly Model 2-A-92 Only ......	15
Assembly and Installation
Inspection and General Instructions
for Reassembly ..................................................	18
To Reassemble and Install the
Countershaft Assembly Model 2-A-92 Only .......	20
To Reassemble and Install the
Drive Gear Assembly.........................................	22
How to Install the Shifting Yoke and Bar ...................	23
How to Reassemble and Install the
Mainshaft Assembly ..........................................	24
How to Install the Drive Gear Housing Assembly ......	28
How to Complete Installation of the
Shifting Yoke and Bar ........................................	30

Introduction

Description

The 2-A-92 model is a two-speed auxilliary transmission, designed primarily for use with heavy-duty transmissions.

This transmission contains two sets of gears, thus giving the reduction (low) ratio when power is delivered through the two sets of gears. The other speed is obtained by direct (high) drive through the auxiliary.

A single shift bar in the right side of the case controls the speed changes. When the shift bar is moved 7/8" forward from neutral, the mainshaft sliding gear locks the mainshaft to the drive gear and shaft, thus delivering power directly through the transmission. When the shift bar is moved 7/8" to the rear from neutral, the sliding clutch locks the mainshaft bushed gear to the mainshaft, thus transferring power through the two sets of gears to obtain the reduction ratio.

The 2-A-92 has a solid countershaft with an integral low speed gear and a press-fit drive gear.

Information General

	2				A			9 2
Two speed
Auxiliary									Use for Heavy Duty Transmissions
									800 lbs. ft.

1

Specifications

Specification Information

Gear Ratios	2-A-92
Direct	1.00
Low (Reduction)	2.30

Mountings

Front - One vertical stud in front bearing housing. An optional mounting consists of a nose piece machined for trunnion mounting.

Rear - Four 5/8" studs with nuts and lockwashers in rear face of case.

Control

Single shifting bar in right side of case. Forward position of shifting bar shifts transmission into direct drive, rear position shifts transmission into the reduction gear. A shift lever can be mounted on an extended brake shaft on the main transmission to operate a control rod to the auxiliary transmission shifting bar.

Speedometer Drive

Provision is made in the rear bearing cover for the installation of a speedometer gear and the attachment of a cable. An electronic sensor may also be installed by adding the correct cover and rotor.

Weight	330 pounds
Oil Capacity	12 pints
Installation length	16-3/16 inches

2

Lubrication

Lubrication Specifications

Note: For a list of Eaton Approved Synthetic Lubricants, see TCMT-0021 the list of approved lubricants and TCMT-0021 the list of lube intervals, or call 1-800-826-HELP (4357). Recommended lubricants for the 2-A-92 are currently the E500 and the E250, which list a mileage, a year, and a hour change interval.

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

Note: Additives and friction modifiers must not be introduced.

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

Buy from a reputable dealer

For a complete 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 degrees, improper lubrication will occur. The operating angle is the transmission mounting angle in the chassis plus the percent of upgrade (expressed in degrees). For operating angles over 12 degrees, the transmission must be equipped with an oil pump or cooler kit to insure proper lubrication.

Mixing of Oil Types

CAUTION: Never mix engine oils & gear oils in the same transmission.

Engine oils and gear oils may not be compatible; mixing can cause breakdown of the lubricant and affect component performance. When switching between types of lubricants, all areas of each affected component must be thoroughly flushed.

Information General

3

Maintenance

Preventative Maintenance Check List

The following maintenance checks can be made without removing the transmission from the chassis. Items 1 through 5 can be performed without any prior mechanical work; items 6 through 8 require the dropping of the output driveline and the input driveline where possible.

1.Oil Leaks

•Make visual checks for oil leakage from mainshaft openings, gaskets at bearing covers, top cover, and from front rear shifting bar bores. Check drain plugs for losseness.

2.Gear Lubricant

•Remove filler plug in right side and check oil level at regular service intervals.

•Change oil at specified intervals, using grade and type recommended.

Note: See Lubrication section for inspection, oil type, grade, and oil capacity.

3.Gear Shift Lever and Linkage

•Check the auxiliary gear shift lever for wear at mounting.

•Check shifting linkage for wear and looseness.

•Check to make sure exact neutral position of auxiliary gear shift lever corresponds to neutral position of auxiliary shifting bar.

4.Capscrews and Nuts

•Check capscrews in top cover and bearing covers for looseness which might be the cause of oil leakage.

•Check nuts on rear support bracket or plate for looseness.

5.Mountings

•Check mounting bolts and nuts for looseness.

6.Universal Joint Companion Flange Retaining Nuts

•With output driveline dropped, and front driveline dropped, where possible, check nuts for looseness. Tighten to recommended torque.

7.Splines on Shafts

•Check input and output shafts for wear from movement and chucking action of universal joint companion flange.

8.Mainshaft Rear Bearing

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

4

Tools

Tool Reference

Some illustrations in this manual show the use of specialized maintenance tools. These tools are recommended for transmission repair as they make repair easier, faster, and prevent costly damage to such critical parts as bearings and sleeves.

Listed below are charts

which list these specialized tools, the tool name and how it can be obtained.

General Tools

Tool

Purpose

0-100 lbs.ft. 1/2" drive Torque Wrench

General torquing of fasteners.

0-600 lbs.ft. 3/4" or 1" drive Torque Wrench

Torquing of output nut.

Snap Ring Pliers - large standard external

To remove snap rings at the auxiliary drive gear, input shaft

bearing, and countershaft.

General

Rolling Head (Crow’s foot) prybar

To remove the auxiliary drive gear bearing.

Aftermarket Tools

Information

Tool

Purpose

Eaton Part Number

Seal Driver Kit

To install seal

K-2413

Special Tools

Reference Number

Tool

Purpose

G and W Tool Number

Great Lakes Tool Num-

ber

T-1

Seal Driver

Used to install the oil

G-112

T-101 #2

seals

T-2

Bearing Driver

Used to install the rear

G-810

*

countershaft bearing

T-3

Bearing Driver

Used to install the front

G-200P and G-200H

T-101 #6,10

countershaft bearing

T-4

Bearing Driver

Used

to

install

rear

G-810

*

mainshaft bearing

T-5

Bearing Driver

Used

to

install

input

G-810

*

shaft rear bearing

T-6

Bearing Driver

Used

to

install

inut

G-810

*

shaft front bearing

* Indicates no tool listed at time of publication

Specialty Tool Manufacturers

Below are the addresses and phone numbers of the companies that make tools specifically for Eaton®Fuller® transmissions:

G and W Tool Company

1105 E. Louisville, Broken Arrow, OK 74012-5724, Phone: [phone], or 918-258-6881

Great Lakes Tool

8530 M-89, Richland, MI 49083, Phone: [phone], or 269-629-9628

5

Torque

Torque Ratings

Recommended torque ratings, location, and thread sizes of capscrews and nuts used on 2-A-92 auxiliary transmissions are listed below. Capscrew lengths are given for reference purposes.

Correct torque application is extremely important to assure long transmission life and dependable performance. Over-tightening or under-tightening can result in a loose installation and, in many instances, eventually cause damage to gears, shafts, or bearings.

Capscrews

	Thread Size and	Torque Rating
	Length	LB. FT.
Countershaft front bearing cover	3/8-16 x 1	35-45
Rear bearing cover	3/8-16 x 1-1/2	35-45
	3/8-16 x 2
Top cover	3/8-16 x 1-1/4	35-45
Top cover	1/2-13 x 1-1/4	75-90
Countershaft bearing retainer plate	1/2-20 x 1	100-115

Nuts

	Thread Size and	Torque Rating
	Length	lbs. ft.
Drive gear bearing housing	1/2 - 20	100-115
Companion flange styles:
Elastic stop nut	1-1/2 - 18	400-450
Slotted type nut	1-1/2 - 18	250-300

6

Removal and Disassembly

General Instructions for Disassembly

Important: Read this section before starting the detailed disassembly procedures.

It is assumed in the detailed disassembly instructions that the transmission has been removed from the chassis, the lubricant has been drained, the parking brake removed, if so equipped, and both universal joint companion flanges have been removed.

Follow each procedure closely in each section, making use of both the text and pictures. Use certain precautions, as listed below, during disassembly.

Cleanliness

•Provide a clean place to work. It is important that no dirt or foreign material enters the unit during repairs. The outside of the unit should be carefully cleaned before starting the disassembly. Dirt is abrasive and can damage highly polished parts such as bearings, sleeves, and bushings.

Bearings

•Carefully wash and re-lubricate all bearings as removed and protectively wrap until ready for use. Remove all bearings with pullers designed for this purpose. Do not remove bearings with hammer and punch.

When Driving

•Apply force to shafts, bearings, and housings with restraint. Movement of some parts is restricted. Do not apply force after the part being driven stops solidly. Use soft hammers, soft bars, and mauls for all disassembly work.

Snap Rings

•Remove snap rings with pliers designed for this purpose. Rings removed in this manner may be reused.

Disassembly and Removal

7