Eaton Transmission CL-450 Service Manual

Service Manual

Fuller Mid Range Transmissions
TRSM0196

October 2007

For parts or service call us

Pro Gear & Transmission, Inc.

1 [phone]

[phone]

[e-mail]

906 W. Gore St.

Orlando, FL 32805

Caution -

Before towing the vehicle, be sure to lift the rear wheels off the ground or disconnect the

driveline to avoid damage to the transmission during towing.

FOREWARD

This manual has been prepared to provide the customer and the maintenance personnel with information and instruc­tions on the maintenance and repair of the CLARK® Transmission.
Extreme care has been exercised in the design, selection of materials and manufacturing of these units. The slight out­lay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and
such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service.
In order to become familiar with the various parts of the transmission, its principle of operation, troubleshooting and
adjustments, it is urged that the service person study the instructions in this manual carefully and use it as a reference
when performing maintenance and repair operations.
Whenever repair or replacement of components parts is required, only Clark-approved parts as listed in the applicable
parts manual should be used. Use of “will-fit” or non-approved parts may endanger proper operation and performance
of the equipment. The Clark Equipment Company does not warrant repair or replacement parts, nor failures resulting
from the use thereof, which are not supplied by or approved by the Clark Equipment Company.

IMPORTANT: Always furnish the Distributor with the transmission serial and model number when ordering parts.

The CL455 is our “soft fourth” transmission, with the 28 percent step from fourth to fifth. The soft fourth allows the use
of a two speed axle without the confusing swap shift in fourth and fifth speeds.

The CL457 is the conventional short fourth 5-speed, for those that still prefer it.

And the CL450 is a straight 5-speed with an 8 to 1 low and reverse ratio . . . a real benefit when a steep grade must be
negotiated.

MODELS

CL455

Speed

Fifth Direct Direct Direct

Fourth 1.28 1.17 1.48

Third 2.13 2.13 2.48

Second 3.78 3.78 4.35

First 6.99 6.99 8.05

Reverse 6.99 6.99 8.05

Nomenclature-CL Stands for Clark. 1st number stands for nominal torque capacity (nom. 400/lb./ft.). 2nd number
is number of forward speeds. 3rd number denotes specific gear set.

Constant mesh in all gears, including low and reverse, is a CL450 feature as is helical gearing throughout, including low
and reverse.

The Clark split-pin synchronizer is used in 2nd, 3rd 4th and 5th gears. Greater bearing capacity in the CL450 is achieved
by the use of numerous needle roller bearings, and tapered roller bearings at main support locations.

Shift forks have replaceable bronze inserts. The shift pattern is of the standard progression type with all shifts having
the same throw at the lever.

(Soft 4th)

CL457

(Short 4th)

CL450

(Straight 5-speed

A

CL 450 SERIES

ASSEMBLY INSTRUCTIONS

Unless otherwise specified:
Tighten all capscrews 20 to 25 lbs. ft. [27,2 - 33,8 N.m].

Use a Grade #2 Multi-Purpose Grease to retain needle
rollers in reverse idler gear bore during assembly.

Apply a thin coat of Loctite 510 Gasket Eliminator to the
O.D. of all oil seals and countershaft front bore plug
before assembly.

Hand-spin idler gear and countershaft assemblies after
each is installed on their bearings in trans. case. Both
must spin freely and smoothly.

Check all mainshaft constant-mesh gears to make sure
they rotate freely on mainshaft.

Fasteners that are removed and reused, apply Locktite
262 Adhesive/Sealant.

B

THE CLARK SYNCHRONIZER

AND HOW IT WORKS FOR YOU

The Clark split-pin synchronizer prevents the clashing of the gears and increase the speed of shifting.

In a conventional transmission which does not have synchronizers the absence of gear clashing is dependent entirely
on the skill of the truck driver. By double-clutching and split second timing of engine speeds with the gear shifting
movement, a driver can synchronize the speeds of the engaging gears and thereby prevent the damage to gears by
clashing when a fast shift. The splint-pin sychronzier performs the same function with or without the “double-clutching”
operating even though the driver does not accurately time his gear shifting movements. It also mechanically prevents
the driver from completing the shift to the point of gear engagement until the engaging gears have reached the same or
synchronous speeds. This is known as the blocking action of the synchronizer and it is this action that makes the oper­ation of shifting a transmission having synchronizers different from one which does not have synchronizers.

Upon shifting gears in these synchronized transmissions the first part of the gear shift lever movement brings the
blockers into contact. The blockers momentarily prevent further movement of the shift lever and the pressure exerted
by the driver to complete the movement, is transferred by the blockers to the synchronizer providing the force neces­sary to synchronize the gears being engaged. When the engaging gears have reached the same speed, the blockers
automatically disengage, permitting the gear shift lever movement to be completed. Therefore, to properly shift a syn­chronized transmission a steady and continuous pressure must be applied by the driver to the shift lever until the shift
is completed. Under normal conditions this action is instantaneous.

Sometimes difficulty is experienced in shifting a synchronizer when the vehicle is standing still. This is caused by the
fact that the disengagement of the blockers requires relative rotation and with the vehicle at rest and with the engine
clutch released, there may be at times, no relative rotation of the engaging gears. Under these conditions, the same con­tinuous pressure should be applied to the shift lever and at the same time, the clutch should be engaged slightly. This
will give sufficient rotation to unblock the synchronizer and allow the shift to be completed without difficulty.

C

RECOMMENDED LUBRICANTS FOR CLARK

MANUALLY SHIFTED TRANSMISSIONS

*Mil-L-2105C Extreme Pressure Lubricant (or API classification GL-5)
of the SAE viscosity recommended in the chart at the right is pre­ferred. All lubricants should be backed by the reputation of a well­know supplier. It is important to specify EP lubricants of the MIL-L­2105C type only, or of a API classification GL-5.

*Do not use extreme pressure lubricants other than MIL-L-2105C or
of a API classification GL-5.

Many EP lubricants contain highly-active chemical compounds that
have been formulated to perform satisfactorily in specific types of
applications. Severe corrosion, residual deposits, and inadequate
lubrication may result from improper application. Use of EP lubricants
other that MIL-L-2105C or of a API classification GL-5 may result in
failure and/or impaired operation.

DRAINING ECONOMY - The object in draining the transmission oil
periodically is to eliminate possible bearing surface abrasion and
attendant wear. Minute particles of metal, the product of normal wear
in service, are deposited in and circulate with the transmission oil. The
oil changes chemically, due to its repeated heating and cooling, also
the terrific churning it undergoes in the presence of air. It is desirable
to drain out this used oil after the first 1,000 miles (1609,0 Km) of
service (regardless of type of service). Subsequent drains should be

made every 24,000 miles (38616,0 Km) or six (6) months (whichever
comes first) for highway service, and every 8,000 to 10,000 miles [12872,0-16090,0 Km] or six (6) months (whichever
comes first) “on-off” highway and “pick-up and delivery” types of service. Do this only when the transmission is thor­oughly warm.

FLUSHING - After draining, flushing is desirable. Replace the drain plug and fill the transmission to the proper level with
a light flushing oil. Drive the transmission for a short period at fast idle in such a manner that the gears in the transmis­sion are rotating without load. This washes out the old oil clinging to the interior of the gear case, covers and shifter
rails. BE SURE TO DRAIN OUT ALL of the flushing oil before attempting to refill with new oil. This flushing procedure is
most important after first drain.

REFILL - First, removal all dirt around the filler plug, Then refill with new oil of a grade recommended for the existing
season and prevailing service. Fill to the bottom of the level testing plug positioned on the side of the transmission. DO
NOT OVERFILL, as the excess quantity will serve no useful purpose. If the oil level is too high, it will cause excessive oil
churning and high oil temperature and possible leakage.

INSPECTION - Oil level inspection should be made every 6,000 miles [9654,0 Km] which usually coincides with the
vehicle manufacturers chassis lube procedure. Always clean around filler plug before inspection. Add sufficient oil to
maintain correct level.

D

CLARK

E

CL450 -SERIES TRANSMISSION

ITEM DESCRIPTION QTY.

1 Control Cover Assembly ..........................................................1

2 Control Cover Screw Lockwasher ..........................................13

3 Control Cover Screw..............................................................13

4 Control Cover Gasket ..............................................................1

5 Mainshaft 2nd Gear..................................................................1

6 Mainshaft 2nd Gear Roller Bearing ..........................................1

7 Split Washer Retainer Ring......................................................1

8 Mainshaft 2nd Gear Split Washer.............................................2

9 Split Washer Lock Ball .............................................................1

10 Mainshaft 1st Gear .................................................................1

11 Mainshaft 1st Gear Bearing......................................................1

12 Mainshaft 1st & Reverse Shift Hub..........................................1

13 Mainshaft.................................................................................1

14 Mainshaft Reverse Gear Roller Bearing....................................1

15 Mainshaft Reverse Gear...........................................................1

16 Mainshaft Rear Bearing Thrust Washer ...................................1

17 Mainshaft Rear Bearing Cone...................................................1

18 2nd & 3rd Gear Shift Hub Sleeve .............................................1

19 2nd Gear Shift Hub Sleeve Retainer Ring.................................1

20 2nd & 3rd Gear Synchronizer Assembly ..................................1

21 3rd Gear Synchronizer Cup......................................................1

22 Mainshaft 3rd Gear Bearing ....................................................1

23 Mainshaft 3rd Gear..................................................................1

24 Mainshaft 3rd Gear Locating Washer Ball................................1

25 Mainshaft 3rd Gear Locating Washer.......................................1

26 3rd Gear Locating Washer Retaining Ring ...............................1

27 Mainshaft 4th Gear Bearing ....................................................1

28 Mainshaft 4th Gear ..................................................................1

29 4th & 5th Synchronizer Cup.....................................................1

30 4th & 5th Synchronizer Assembly............................................1

31 4th & 5th Synchronizer Cup.....................................................1

32 4th & 5th Shift Hub Sleeve ......................................................1

33 4th & 5th Shift Hub Thrust Bearing.........................................1

34 4th & 5th Shift Hub Thrust Bearing Race.................................1

35 Countershaft Front Bearing Cone.............................................1

36 Countershaft Drive Gear Retainer Ring ....................................1

37 Countershaft Drive Gear...........................................................1

38 Countershaft 4th Gear..............................................................1

39 Countershaft Gear Key.............................................................2

40 Countershaft 3rd Gear..............................................................1

41 Countershaft 2nd Gear.............................................................1

42 Countershaft............................................................................1

43 Countershaft Rear Bearing Cone..............................................1

44 Reverse Idler Gear Thrust Washer ...........................................1

45 Reverse Idler Gear ..................................................................1

ITEM DESCRIPTION QTY.

46 Reverse Idler Gear Bearing ....................................................26

47 Reverse Idler Gear Bearing Spacer...........................................1

48 Reverse Idler Gear Bearing ....................................................26

49 Reverse Idler Thrust Washer....................................................1

50 Mainshaft Rear Bearing Cap Nut..............................................4

51 Mainshaft Rear Bearing Cap Washer........................................4

52 Mainshaft Rear Bearing Cap .................................................... 1

53 Mainshaft Rear Bearing Cap Shim........................................ AR

54 Speedometer Driven Gear ......................................................1

55 Mainshaft Rear Bearing Cap Stud............................................4

56 Mainshaft Rear Bearing Cup....................................................1

57 Mainshaft Flange Nut............................................................... 1

58 Output Flange..........................................................................1

59 Mainshaft Rear Bearing Cap Oil Seal....................................... 1

60 Speedometer Drive Gear Tube Nut ..........................................1

61 Speedometer Driven Gear ....................................................... 1

62 Mainshaft Rear Bearing Cap Bolt............................................. 4

63 Mainshaft Rear Bearing Cap Bolt Washer................................ 4

64 Countershaft Rear Bearing Capscrew......................................4

65 Countershaft Rear Bearing Cap ............................................... 1

66 Countershaft Rear Bearing Cap Shim ................................... AR

67 Countershaft Rear Bearing Cup ...............................................1

68 Reverse Idler Shaft..................................................................1

69 Reverse Tab Lock Screw .........................................................1

70 Reverse Idler Shaft Lock ........................................................ 1

71 Mainshaft Roller Bearing Washer Retainer Ring......................1

72 Mainshaft Roller Bearing Washer............................................ 1

73 Mainshaft Roller Bearing ...................................................... 14

74 Main Drive Gear ......................................................................1

75 Main Drive Gear Bearing Cone ................................................1

76 Main Drive Gear Bearing Cup ................................................. 1

77 Main Drive Gear Bearing Cap Oil Seal......................................1

78 Main Drive Gear Bearing Cap Gasket....................................... 1

79 Main Drive Gear Bearing Cap...................................................1

80 Main Drive Gear Bearing Capscrews .......................................4

81 Transmission Case .................................................................. 1

82 Countershaft Front Bearing Cup.............................................. 1

83 Countershaft Front Bearing Race Locator Ring .......................1

84 Countershaft Front Bore Plug ..................................................1

85 Clutch Shaft Grease Fitting ...................................................... 2

86 Clutch Housing Cover .............................................................1

87 Clutch Housing Cover Screw Lockwasher............................... 2

88 Clutch Housing Cover Screw................................................... 2

89 Clutch Housing........................................................................1

90 Clutch Pedal Shaft Bushing ....................................................4

ITEM DESCRIPTION QTY.

91 Clutch Housing to Case Screw ................................................ 4

92 Clutch Housing to Case Screw Lockwasher ............................4

93 P.T.O. Cover Lockscrew.........................................................12

94 P.T.O. Cover Plate....................................................................2

95 P.T.O. Cover Plate Gasket.........................................................2

96 Magnetic Drain Plug................................................................1

97 Filter Plug................................................................................1

98 Name Plate Screw ...................................................................2

99 Name Plate..............................................................................1

AR = As Required

F

CLARK

F

CL450 CONTROL ASSEMBLY (With Round Rails)

ITEM Description QTY

1 Gear Shift Lever Dust Cover.....................................................1

2 Gear Shift Lever Pivot Pin........................................................2

3 Control Top ..............................................................................1

4 Gear Shift Lever.......................................................................1

5 Gear Shift Lever Support Washer.............................................1

6 Support Spring ........................................................................1

7 Control Top Gasket...................................................................1

8 Shift Rail Housing....................................................................1

9 Shift Fork Lock Pin...................................................................4

10 1st & Reverse Shift Fork ..........................................................1

11 2nd & 3rd Shift Fork Assembly................................................1

12 4th & 5th Shift Fork Assembly .................................................1

13 Shift Fork Bushing ...................................................................4

14 4th & 5th Shift Rail ..................................................................1

15 Support Screw.........................................................................8

16 Front and Rear Rail Support ....................................................2

17 2nd & 3rd Shift Rail .................................................................1

18 Interlock Cross Pin .................................................................1

19 1st & Reverse Shift Lug...........................................................1

20 1st & Reverse Shift Rail...........................................................1

21 Mesh and Interlock Ball ...........................................................7

22 Mesh Lock Spring....................................................................3

23 Back Up Light Plug Washer .....................................................1

24 Back Up Light Plug ..................................................................1

25 1st & Reverse Latch Plunger Spring Plug................................1

26 1st & Reverse Latch Plunger Spring Plug Gasket....................1

27 1st & Reverse Latch Plunger Stop...........................................1

28 1st & Reverse Latch Plunger Spring........................................1

29 1st & Reverse Latch Plunger ...................................................1

30 Control Top Capscrew Washer.................................................4

31 Control Top Capscrew..............................................................4

Remote Control Assembly *

1. Shaft and lever assembly

2. Boot

3. Oil Seal

4. Bushing

5. Breather

6. Housing

7. Plug

8. Spring

9. Set screw

10. Shift finger

11. Gasket
*Right-hand remote is pictured. Left-hand remote uses identical components, but all are installed on reverse side of
control housing, with exception of 8, 9 and 10, which remain the same.

G

CLARK

H

OVERHAUL OF TRANSMISSION ASSEMBLY

The instructions contained herein cover the disassembly
and reassembly of the transmission in a sequence that
would normally be followed after the unit has been
removed from the machine and is to be completely over­hauled.

DISASSEMBLY OF THE TRANSMISSION:

Figure 1 - Remove shift lever control top or remote con­trol assembly. Remove control cover capscrews.

CAUTION: Cleanliness is of extreme importance and an
absolute must in the repair and overhaul of this unit.
Before attempting any repairs, the exterior of the unit
must be thoroughly cleaned to prevent the possibility of
dirt and foreign matter entering the mechanism

Figure 4 - Remove bearing cap and shims.

Figure 2 - Remove control cover assembly.

Figure 3 - Remove rear mainshaft bearing cap bolts

Figure 5 - Remove main drive gear bearing cap bolts.

Figure 6 - Remove bearing cap.

1

Figure 7 - Remove main drive gear and bearing assembly.

Figure 8 - Using a hoist (if available) and a heavy rope, lift
mainshaft assembly from transmission case. Mainshaft
can be removed by hand, but is quite difficult to handle.

Figure 10 -Remove bearing cap and shims.

Figure 11 - Remove countershaft rear taper bearing cup.

Figure 9 -Remove countershaft bearing cap bolts.

Figure 12 - Remove countershaft assembly.

2

Figure 13 - Using a suitable puller, remove reverse idler
shaft.

Figure 14 - Remove reverse idler gear and thrust wash­ers. NOTE: Idler gear has loose needle rollers in it. DO
NOT lose these rollers.

Figure 15 -If the countershaft is to be disassembled for
any reason, the front bearing must be destroyed. Split the
front bearing cage. Remove cage and taper rollers.

Figure 16 - Using snap ring pliers and screwdriver,
remove drive gear retaining ring from ring groove. NOTE:
Be sure snap ring is completely out of snap ring groove.
(See illustration A and B)

Figure 17 - With drive gear, snap ring out of groove,
press countershaft drive gear and front taper bearing
inner race from shaft. Press 4th gear from shaft. Remove
gear keys from countershaft. 3rd speed and 2nd speed
gears are splined on the countershaft and may be
pressed from shaft, if replacement is necessary.

MAINSHAFT DISASSEMBLY

Position mainshaft assembly in a suitable stand. A vise
may be used, if soft jaws are utilized.

Figure A Figure B

Figure 18 - Remove 5th-Speed synchronizer cup.

3

Figure19 - Remove shift hub thrust bearing and bearing
race.

Figure 22 - Remove 4th speed gear.

Figure 20 - Remove 4th & 5th speed synchronizer
assembly/

Figure 21 -Remove the 4th & 5th shift hub sleeve.

Figure 23 - Remove 4th gear bearing.

Figure 24 - Remove 3rd gear locating washer retaining
ring.

4

Figure 25 - Remove washer and lock ball.

Figure 28 - Remove 2nd & 3rd speed synchronizer.

Figure 26 - Remove 3rd speed gear.

Figure 27 -Remove 3rd gear bearing.

Figure 29 - Remove 2nd & 3rd shift hub sleeve retaining
ring.

Figure 30 - Remove 2md & 3rd shift hub sleeve.

5

Figure 31 - Remove 2nd speed gear and bearing.

Figure 32 - Remove split ring retainer ring.

Figure 34 - Remove 1st gear.

Figure 35 - Remove first gear bearing.

Figure 33 -Separate split ring from groove in mainshaft.
Remove split ring halves and lock ball.

Figure 36 - Remove mainshaft 1st & Reverse shift hub.

6

Figure 37 - Remove Reverse speed gear and rear bearing
from mainshaft.

See Cleaning and Inspection Section on Page 20.

MAINSHAFT ASSEMBLY

NOTE: All parts must be lubricated with Clark recom­mended transmission lubricant when reassembling. No
part should be reassembled dry.

Figure 38 - Position the mainshaft in a suitable stand with
the threaded end up. Install the Reverse speed gear roller
bearing on shaft.

Figure 40 - Install mainshaft rear bearing thrust washer.

Figure 41 - Using a suitable bearing driver and a soft
hammer, install mainshaft rear taper bearing. Be certain
bearing race is tight against the thrust washer.

Figure 39 -Position Reverse speed gear on bearing with
clutching teeth down

Figure 42 - Turn mainshaft over. Locate 1st & Reverse
shift hub on shaft.

7

Figure 43 - Install 1st gear roller bearing on shaft.

Figure 44 - Position 1st gear on bearing with clutching
teeth down.

Figure 46 - Position split washer retainer ring over split
washer.

Figure 47 - Install 2nd gear roller bearing on shaft.

Figure 45 -Position 1st gear split washer locating ball in
shaft. Install split washer in washer groove with ends of
washer together at locating ball.

Figure 48 - Position 2nd speed gear on bearing with
clutching teeth up.

8

Figure 49 - Install 2nd & 3rd speed shift hub sleeve.
NOTE: Counter bore in sleeve must go up or sleeve
retaining ring will not fit in ring groove.

Figure 50 - Install shift hub sleeve retaining ring.

Figure 52 - Install 3rd speed gear roller bearing.

Figure 53 - Position 3rd gear on bearing with clutching
teeth down.

Figure 51 -Install 2nd & 3rd speed synchronizer assem­bly and 3rd speed synchronizer cup.

Figure 54 - Position 3rd gear locating washer lock ball in
mainshaft. Install locating washer on shaft with notch in
washer on lock ball.

9

Figure 55 - Install locating washer retaining ring.

Figure 58 - Install 4th & 5th shift hub sleeve. NOTE:
machine ground surface must be up.

Figure 56 - Install 4th speed gear roller bearing.

Figure 57 -Position 4th gear on bearing with clutching
teeth up.

Figure 59 - Position 4th speed synchronizer cup and 4th
& 5th synchronizer on shift hub sleeve.

Figure 60 - Position shift hub thrust bearing and thrust
bearing race on mainshaft.

10

Figure 61 - Install 5th speed synchronizer cup on the syn­chronizer assembly.

Figure 64 - Install 4th speed gear key in countershaft key
slot. With hub of gear as shown, align 4th gear keyway
with key in countershaft. Press gear on shaft.

Figure 61-A

COUNTERSHAFT REASSEMBLY

Figure 62 -Press 2nd speed gear on countershaft with
hub of gear as shown.

Figure 63 - Press 3rd speed gear on countershaft with
hub of gear as shown.

Figure 65 - Install drive gear key in countershaft key slot.
With hub of gear as shown, align drive gear keyway with
key in countershaft. Press gear on shaft.

Figure 66 - Install drive gear retaining ring. NOTE: Make
sure retaining ring is in full position in ring groove.

11

Figure 67 - Install countershaft front and rear taper bear­ings.

Figure 70 - Remove front and rear rail supports.

Figure 68 - Overall view of countershaft assembly.

Figure 69 -Remove front and rear rail support capscrews.

Figure 71 - Remove the 4th & 5th shift fork and rail
assembly.

Figure 72 - Remove 2nd & 3rd shift fork and rail assem­bly. CAUTION: Do not lose interlock cross pin.

12

Figure 73 - Remove 1st & Reverse shift fork, rail and lug
assembly.

Figure 76 - Remove Reverse latch plunger, pin and
spring.

See Cleaning and Inspection Section Page 20.

SHIFT CONTROL REASSEMBLY

Figure 74 - Remove mesh lock spring and lock ball, 3
each. Remove crossover interlock balls, 4 each.

Figure 75 - If the 2nd, 3rd, 4th or 5th shift fork bushing is
to be replaced, remove worn bushings from fork. Install
new bushing and bend bushing tab over top and bottom
of fork.

Figure 77 - Install Reverse latch plunger, spring, pin and
plunger spring plug.

Figure 78 - Position crossover interlock balls in cover
cross bores. 2 balls in cover cross between 1st &
Reverse rail groove, and 2nd & 3rd rail groove and 2 balls
in cover cross bore between 2nd & 3rd rail groove, and
4th & 5th rail groove. (See cross section Figure 78-A)

13

Figure 78-A

Figure 81 - Install interlock cross pin in 2nd & 3rd shift
rail. Position 2nd & 3rd shift rail and fork assembly in rail
groove over mesh lock ball and spring. Make certain
cross pin is in position in rail. (See Figure 78-A).

Figure 79 - Position the mesh lock spring and ball, 3
each, in spring pockets. (See cross section Figure 78-A).

Figure 80 -Position the 1st & Reverse shift fork, rail and
lug assembly in rail groove over mesh lock ball and
spring.

Figure 82 - Position the 4th & 5th shift rail and fork
assembly in rail groove over mesh lock ball and spring.

Figure 83 - Position front rail support over shift rails and
install capscrews. Position rear support over rails and
install capscrews.

14

Figure 84 - Tighten support capscrews 20 to 25 ft. lbs.
torque.

Test cover for double shift.

Pry 4th & 5th shift fork and rail out of neutral position.
Try to pry 1st & Reverse shift fork and rail out of neutral
position. 1st & Reverse fork should NOT shift, if it does,
interlock cross pin or interlock cross over balls were NOT
assembled correctly. Disassemble cover and correct
cross over. (See Figure 78-A).

MAIN DRIVE GEAR DISASSEMBLY

Figure 87 - Press new taper bearing on drive gear. Turn
gear over. Using a high quality heavy grease, coat roller
bearing surface. Place rollers in grease as shown.

Figure 88 - Install roller bearing washer and retainer ring.

REASSEMBLY OF TRANSMISSION

Figure 85 - If main drive gear taper bearing is to be
removed, a split puller, as shown, is recommended.

Figure 86 -Remove pilot bearing washer retainer ring.
Remove bearing washer. Use caution as not to lose roller
bearings.

Figure 89 - If the transmission case or countershaft front
taper bearing cup was replaced, install bearing cup locat­ing ring. From inside of case, install bearing cup. Coat
outer diameter of bore plug with Loctite 510 and install
bore plug in case.

15

Figure 90 - Use heavy grease on reverse idler thrust
washer to hold in place. Position tang of washers in
groove in housing.

Figure 91 - Coat inside diameter of reverse idler gear with
a high quality heavy grease. This will hold needle rollers
in position while assembling. (See illustration for position
of rollers and spacer).

Figure 93 - Turn transmission case on end as shown.
Position countershaft assembly into front bearing cup.
Install rear bearing cup over rear taper bearing, tap cup
into place.

Figure 94 - Position the same shims that were removed
at disassembly over countershaft rear bearing cup. Install
bearing cap. Apply a band of Loctite 262 Thread Lock to
bearing capscrews .125 from end of thread .375 long.
(Do not dip capscrews).

Figure 92 - Carefully position reverse idler gear in hous­ing. Use caution as not to disrupt needle rollers. Insert
idler shaft through case and idler gear needle rollers.
NOTE: Idler shaft lock groove MUST line up with lock­screw hole. Drive shaft into position. Install shaft lock
and capscrew.

Figure 95 - Tighten capscrews 20-25 Ft. Lbs. Torque.

16

Figure 96 - Roll countershaft to be certain bearings and
bearing cups are seated. Position a dial indicator as
shown. Pry countershaft to get countershaft end play.
End play must be between .002-.008 [0,05 -0,20mm].
Add shims for more end play or remove shims for less
end play. NOTE: Each time a change is made, retorque
capscrews and roll countershaft. At final assembly, coat
both sides of each shim with Loctite 510.

Figure 97 - Position mainshaft assembly in transmission
as shown.

Figure 99 - Coat outer diameter of main drive bearing cap
oil seal with Loctite 510. Press seal into drive gear bear­ing cap with lip of seal up. Install main drive gear taper
bearing cup in bearing cap.

Figure 100 - Position main drive gear bearing cap gasket
on bearing cap. Install bearing cap on main drive gear.
Apply a band of Loctite 262 Thread Lock to bearing cap­screws. .125 [3,1mm] from end of thread .375[9,5mm]
long. (Do not dip capscrews).

Figure 98 - With main drive gear needle rollers in place
and greased, position main drive gear in housing bore.
Align clutching teeth on main drive gear with teeth in 5th
speed synchronizer cup.

Figure 101 - Torque bearing capscrews 15 - 20 Ft. Lbs.
Torque [20,4 - 27,1 N,m].

Figure 102 - Coat outer diameter of mainshaft rear oil
seal with Loctite 510. Press seal into bearing cap with lip
of seal down (in). Install mainshaft rear taper bearing cup
in bearing cap.

Figure 105 - Place transmission in vertical position, with
main drive gear pointing down. Install transmission out­put flange and nut. Roll main drive gear and mainshaft to
seat front and rear taper bearings. Position a dial indica­tor as shown. Pry on output flange to get mainshaft and
play. End play must be between .002 - .008. Add shims
for more end play or remove shims for less end play.
NOTE: Each time a change is made, retorque stud nuts
and roll mainshaft. Apply Loctite 510 to both sides of
each shim during final assembly.

Figure 103 - Position the same shims that were removed
at disassembly over mainshaft rear bearing cap studs.
Install bearing cap. Install bearing cap lockwashers and
stud nuts.

Figure 104 - Tighten bearing cap stud nuts 35 -45 Ft. Lbs.
Torque [47,5 - 61,0 N.m].

Figure 106 - Locate control cover gasket on transmission
case. With transmission in neutral, position control cover
over gears aligning shift forks in shift cover with gear
shift hubs. If control cover is in neutral and transmission
is in neutral, transmission drive gear should turn without
output shaft turning.

18

Figure 107 - Install two control cover capscrews in the
locations shown. These are special alignment holes.

Figure 108 - Tighten screws in alignment holes 20 - 25 Ft.
Lbs. Torque. Install remaining control cover capscrews
and tighten to the same torque as the alignment screws.

19

CLEANING AND INSPECTION

CLEANING

Cleaning all parts thoroughly using solvent type cleaning
fluid. It is recommended that parts be immersed in clean­ing fluid and moved up and down slowly until all old
lubricant and foreign material is dissolved and parts are
thoroughly cleaned.

CAUTION: Care should be exercised to avoid skin rashes,
fire hazards, and inhalation of vapors when using solvent
type cleaners.

Bearings:

Remove bearings from cleaning fluid and strike against a
block of wood to dislodge solidified particles of lubricant.
Immerse again in cleaning fluid to flush out particles.
Repeat above operation until bearings are thoroughly
clean. Dry bearings using moisture-free compressed air.
Be careful to direct air stream across bearing to avoid
spinning. Do not spin bearings when drying. Bearing say
be rotated slowly by hand to facilitate drying process.

Housings:

Clean interior and exterior of housings, bearing caps, etc.
thoroughly. Cast parts may be cleaned in hot solution
tanks with mild alkali solutions providing these parts do
not have ground or polished surfaces. Parts should
remain in solution long enough to be thoroughly cleaned
and heated. This will aid the evaporation of the cleaning
solution and rinse water. Parts cleaned in solution tanks
must be thoroughly rinsed with clean water to remove all
traces of alkali. Cast parts may also be cleaned with
steam cleaner.

CAUTION: Care should be exercised to avoid inhalation of
vapors and skin rashes when using alkali cleaners.

Gears and Shafts:

If magno-flux process is available, use process to check
parts. Examine teeth on all gears carefully for wear, pit­ting, chipping, nicks, cracks, or scores. If gear teeth
show spots where case hardening is worn through or
cracked, replace with new gear. Small nicks may be
removed with suitable hone. Inspect shafts to make cer­tain they are not sprung, bent, or splines twisted, and that
shaft are true.

Housing, Covers, Etc.:

Inspect housings, covers, and bearing caps to be certain
they are thoroughly cleaned and that mating surfaces,
bearing bores, etc., are free from nicks or burrs. Check all
parts carefully for evidence of cracks or condition which
would cause subsequent oil leaks or failures.

Bearings:

Carefully inspect all rollers and balls for wear, chipping or
nicks to determine fitness of bearings for further use.
After inspection, dip bearings in clean oil and wrap in
clean lintless cloth or paper to protect them until
installed.

Oil Seals, Gaskets, Etc.:

Replacement of spring load oil seals. “O”- rings, metal
sealing rings, gaskets and snap rings is more economical
when unit is disassembled than premature overhaul to
replace these parts at a future time. Further, loss of lubri­cant through a worn seal may result in failure of other
more expensive parts of the assembly. Sealing members
should be handled carefully, particularly when being
installed. Cutting, scratching, or curling under of lip of
seal seriously impairs its efficiency.

All parts cleaned must be thoroughly dried immediately
by using moisture-free compressed air or soft, lintless
absorbent wiping rages free of abrasive materials such as
metal filings, contaminated oil or lapping compound.

INSPECTION

The importance of careful and thorough inspection of all
parts cannot be overstressed. Replacement of all parts
showing indication of wear or stress will eliminate costly
and avoidable failures at a later date.

20

TROUBLESHOOTER’S TRANSMISSION CHECKLIST

1. NOISE ARISING IN NEUTRAL

Misalignment of transmission
Worn transmission bearings
Scuffed gear tooth contact surfaces on gears
Worn mainshaft gear bushings
Worn or rough reverse idler gear
Sprung or work countershaft
Excessive backlash in constant mesh gear
Work mainshaft pilot bearing
Incorrect lubricant
Low lubricant level
Noisy main drive gear bearing

2. NOISE ARISING IN GEAR

Worn or rough mainshaft rear bearing
Excessive end play on mainshaft gears
Noisy speedometer gears
(See Conditions under #1)

3. NOISE ARISING OUTSIDE

Out-of-balance fan
Defective torsional dampener
Out-of-balance crankshaft
Out-of-balance flywheel
Out-of-balance clutch assembly
Loose engine mountings
Worn universal joints
U-joints improperly installed (Out of phase)
Misaligned or sprung driveshaft
Incorrect driveshaft assembly
Out-of-balance driveshaft
Out-of-balance parking brake drum

4. DIFFICULT SHIFTING

Improperly operating clutch (Does not release
properly
Shift hubs tight on Shift hub sleeve splines
Damaged pointing on clutching teeth
Misaligned mainshaft
Damaged or worn synchronizer assembly
Improper linkage adjustment
Worn or sprung shift fork

6. SLIPPING OUT OF DIRECT

Misaligned of transmission on engine
Worn drive gear teeth
Worn clutching teeth on shift hub or drive gear
Insufficient tension on detent balls
Improper linkage adjustment
Excessive shift lever whip action
Worn torque lock on shift hub sleeve

7. SLIPPING OUT OF OTHER SPEEDS

Excessive clearance between mainshaft gear and
mainshaft, or worn needle bearings
Excessive end play of mainshaft gear on mainshaft
Worn clutching teeth
Weak detent ball springs
Improper linkage adjustment
Worn torque lock on shift hub sleeve.

8. LOSS OF LUBRICANT

Lubricant level too high
Damaged gaskets
Damaged or worn oil seals
Cracked transmission housing
Use of incorrect lubricant
Oil return holes under bearing caps plugged

9. BEARING FAILURES

Use of incorrect lubricants
Improper bearing adjustment
Improper reassembly in unit overhaul
Lack of cleanliness in unit overhaul
Foreign particles in transmission

5. STICKING IN GEAR

Improperly operating clutch
Shift hubs tight on shift hub splines
Misaligned mainshaft
Improper linkage adjustment

21

Copyright Eaton Corporation, 2012.
Eaton hereby grant their customers,
vendors, or distributors permission
to freely copy, reproduce and/or
distribute this document in printed
format. It may be copied only in
its entirety without any changes or
modifications. THIS INFORMATION
IS NOT INTENDED FOR SALE OR
RESALE, AND THIS NOTICE MUST
REMAIN ON ALL COPIES.

Note: Features and specifications
listed in this document are subject to
change without notice and represent
the maximum capabilities of the
software and products with all options
installed. Although every attempt has
been made to ensure the accuracy of
information contained within, Eaton
makes no representation about the
completeness, correctness or accuracy
and assumes no responsibility for
any errors or omissions. Features and
functionality may vary depending on
selected options.

For spec’ing or service assistance,
call 1-800-826-HELP (4357) or visit
www.eaton.com/roadranger.
In Mexico, call 001-800-826-4357.

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

Eaton Corporation

Vehicle Group
P.O. Box 4013
Kalamazoo, MI 49003 USA
800-826-HELP (4357)
www.eaton.com/roadranger

Printed in USA

For parts or service call us

Pro Gear & Transmission, Inc.

1 [phone]

[phone]

[e-mail]

906 W. Gore St.

Orlando, FL 32805