Eaton Transmission Clark 280V Service Manual

Service Manual

Fuller Mid Range Transmissions
TRSM0194

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 dis-

connect 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 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.

A

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 well-know supplier. It is important to specify
EP lubricants of the MIL-L-2105C type only, or of a API clas­sification GL-5.

*Do not use extreme pressure lubricants other than MIL-L­2105C 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-L­2105C 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.

B

CLARK

C

280V-Series Transmission

Item Description QTY

1 Shift Rod Cover Screw...........................................................14

2 Shift Rod Cover Screw Lockwasher.......................................14

3 Control Cover (Stamped version).............................................1

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

5 Mainshaft 5th Speed Synchronizer Cup ...................................1

6 Mainshaft 4th & 5th Synchronizer Assembly...........................1

7 Mainshaft 4th Speed Synchronizer Cup ...................................1

8 Mainshaft 4th & 5th Shift Hub Sleeve Retainer Ring................1

9 Mainshaft 4th & 5th Shift Hub Sleeve......................................1

10 Mainshaft 4th Speed Gear........................................................1

11 Mainshaft 3rd Gear Retainer Ring............................................1

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

13 Mainshaft 3rd Speed Gear .......................................................1

14 Mainshaft 3rd Speed Synchronizer Cup...................................1

15 Mainshaft 2nd & 3rd Synchronizer Assembly..........................1

16 Mainshaft 2nd & 3rd Shift Hub Sleeve Retainer Ring ..............1

17 Mainshaft 2nd & 3rd Shift Hub Sleeve.....................................1

18 Mainshaft 2nd & 3rd Shift Hub Sleeve Retainer Ring ..............1

19 Mainshaft 2nd Speed Gear.......................................................1

20 Mainshaft 2nd Speed Gear Locating Washer ...........................1

21 Mainshaft 2nd Speed Gear Retainer Ring ................................1

22 Mainshaft ................................................................................1

23 Mainshaft 1st & Reverse Gear .................................................1

24 Countershaft Rear Bearing capscrew .......................................4

25 Countershaft Rear Bearing Cap Lockwasher ............................4

26 Countershaft Rear Bearing Cap ...............................................1

27 Countershaft Rear Bearing Cap Gasket....................................1

28 Countershaft Rear Bearing Cap Retainer Ring .........................1

29 Countershaft Rear Bearing ......................................................1

30 Countershaft Rear Bearing Oil Slinger......................................1

31 Countershaft............................................................................1

32 Countershaft Gear Key.............................................................1

33 Countershaft 4th Speed Gear ...................................................2

34 Countershaft Drive Gear...........................................................1

35 Countershaft Drive Gear Retainer Ring ....................................1

36 Filler Plug.................................................................................1

37 Magnetic Drain Plug ................................................................1

38 Flange Nut................................................................................1

39 Flange to Drum Bolt Nut ..........................................................4

40 Flange to Drum Bolt Lockwasher .............................................4

41 Companion Flange...................................................................1

42 Brake Assembly .......................................................................1

Item Description QTY

43 Brake Drum to Flange Bolt....................................................... 4

44 Mainshaft Rear Oil Seal...........................................................1

45 Mainshaft Rear Bearing capscrew ...........................................3

46 Mainshaft Rear Bearing capscrew Lockwasher....................... 3

47 Mainshaft Rear Bearing Cap .................................................... 1

48 Mainshaft Rear Bearing Cap Gasket ........................................ 2

49 Speedometer Drive Gear ......................................................... 1

50 Mainshaft Rear Bearing ........................................................... 1

51 Transmission Case .................................................................. 1

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

53 P.T.O. Cover Plate....................................................................2

54 P.T.O. Cover Plate Screw .......................................................12

55 Mainshaft Rear Bearing capscrew Lockwasher....................... 1

56 Mainshaft Rear Bearing capscrew ...........................................1

57 Speedometer Driven Gear ....................................................... 1

58 Speedometer Tube Nut............................................................1

59 Reverse Idler Shaft Lock Screw...............................................1

60 Reverse Idler Shaft Lock ......................................................... 1

61 Reverse Idler Shaft..................................................................1

62 Reverse Idler Thrust Washer ................................................... 2

63 Reverse Idler Bearing.............................................................. 2

64 Reverse Idler Gear...................................................................1

65 Mainshaft Spigot Bearing ........................................................ 1

66 Main Drive Gear.......................................................................1

67 Main Drive Gear Bearing Oil Slinger ........................................1

68 Main Drive Gear Bearing ......................................................... 1

69 Main Drive Gear Bearing Retainer Ring...................................1

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

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

72 Main Drive Gear Bearing Cap...................................................1

73 Main Drive Gear Bearing capscrew..........................................4

74 Clutch Housing Stud Nut......................................................... 4

75 Clutch Housing Stud Nut Lockwasher.....................................4

76 Clutch Housing Stud ............................................................... 4

77 Countershaft Pilot Bearing.......................................................1

78 Pedal Shaft Grease Fitting .......................................................2

79 Clutch Housing Inspection Plate Bolt ...................................... 2

80 Clutch Housing Inspection Plate Lockwasher.......................... 2

81 Clutch Housing Inspection Plate.............................................. 1

82 Clutch Pedal Shaft Bushing .....................................................4

83 Clutch Housing........................................................................1

D

CLARK

E

280V-SERIES CONTROL PARTS GROUP (Stamped Cover)

ITEM Description QTY

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 Rod Cover....................................................1

9 Shift Rod Cover Gasket........................................1

10 Shift Rod Support Screw and Lockwasher...........4

11 Shift Rod Support................................................1

12 1st & Reverse Shift Fork Lockscrew....................1

13 1st & Reverse Shift Fork......................................1

14 Shift Fork Lock Pin...............................................1

15 4th & 5th Shift Fork Assembly (Inc. Items 16 & 17)1

16 Shift Fork Bushing ...............................................2

32 Reverse Latch Plunger.........................................1

33 Reverse Latch Plunger Retainer Washer..............1

34 Reverse Latch Plunger Spring.............................1

35 1st & Reverse Rocker..........................................1

36 Reverse Latch Plunger Nut..................................1

37 Reverse Latch Plunger Nut Cotter........................1

38 Backup Switch Hole Plug.....................................1

39 Backup Switch Hole Plug Gasket.........................1

40 Welch Plug ..........................................................1

41 Control Top Screw & Lockwasher ...........................................4

17 Shift Fork Bushing ...............................................2

18 Shift Fork Bushing ...............................................2

19 Shift Fork Bushing ...............................................2

20 Shift Fork Lock Pin...............................................1

21 2nd & 3rd Fork Assembly (Inc. Items 18 & 19) ...1

22 2nd Speed Overshift Spacer.................................1

23 Reverse Shift Lug Lock Screw.............................1

24 Reverse Shift Lug ................................................1

25 4th & 5th Shift Rod..............................................1

26 Mesh Lock Ball ....................................................4

27 Interlock Cross Pin ..............................................1

28 2nd & 3rd Shift Rod.............................................1

29 1st & Reverse Shift Rod ......................................1

30 Mesh Lock Spring................................................3

31 Mesh Lock Spring................................................3

F

CLARK

G

280V-SERIES CONTROL PARTS GROUP (Diecast Cover - Fabricate Rails)

ITEM Description QTY

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

ITEM Description QTY

16 Front Rail Support................................................................... 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 or Remote Control Gasket ....................................1

8 Control Cover...........................................................................1

9 1st & Reverse Rocker Arm ......................................................1

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

11 Rear Rail Support ....................................................................1

12 Rear Rail Support Capscrew Lockwasher ................................2

13 Rear Rail Support Capscrew ....................................................4

14 Front Rail Support Capscrew ...................................................4

15 Front Rail Support Capscrew Lockwasher ...............................4

17 2nd & 3rd, 4th & 5th Shift Fork Bushing.................................4

18 4th & 5th Shift Fork & Rail Ass’y (Includes Item #17)............. 1

19 2nd & 3rd Shift Fork & Rail Ass’y (Includes Item #17) ........... 1

20 Interlock Cross Pin..................................................................1

21 Interlock Tapered Pin Support.................................................2

22 Interlock Tapered Pin...............................................................2

23 1st & Reverse Shift Rail ..........................................................1

24 Mesh Lock Poppet Rails..........................................................4

25 Poppet Springs........................................................................ 4

26 Reverse Latch Plunger ............................................................ 1

27 Plunger Spring ........................................................................1

28 Plunger Spring Retaining Plug ................................................ 1

Control Top or Remote Control Capscrew4

H

CLARK

I

280V-SERIES CONTROL PARTS GROUP (Diecast Cover - Round Rails)

ITEM Description QTY

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 or Remote Control Gasket......... 1

8 Welch Plug................................................... 1

9 Shift Rail Housing ........................................ 1

10 1st & Reverse Rocker Lug ........................... 1

11 Shift Fork Lock Pin....................................... 4

12 1st & Reverse Rocker Arm........................... 1

13 4th & 5th Shift Fork...................................... 1

14 2nd & 3rd Shift Fork..................................... 1

15 Mesh Lock Ball............................................. 1

16 1st & Reverse Mesh Lock Spring................. 1

17 1st & Reverse Shift Fork ............................. 1

23 Rear Rail Support .........................................1

24 Rail Support Screw.......................................6

25 Front Rail Support ........................................1

26 2nd & 3rd Shift Rail......................................1

27 Inter-Lock Cross Pin.....................................1

28 1st Gear Shift Stop Space (wide)..................1

29 1st & Gear Shift Lug.....................................1

30 1st & Gear Shift Stop Spacer (narrow) .........1

31 1st & Reverse Shift Rail................................1

32 Mesh & Inter-Lock Ball .................................7

33 Mesh Lock Spring.........................................3

34 Back-up Switch Hole Plug Gasket.................1

35 Back-up Switch Hole Plug ............................1

36 1st & Reverse Latch Plunger Springer Plug .1

37 1st & Reverse Latch Plunger Plug Gasket ....1

38 1st & Reverse Latch Plunger Stop................1

39 1st & Reverse Latch Plunger Spring............1

18 1st & Reverse Shift Fork Rail Lock Pin......... 1

19 1st & Reverse Shift Fork Rail ...................... 1

20 Shift Fork Bushing........................................ 2

21 Shift Fork Bushing........................................ 2

22 4th & 5th Shift Rail....................................... 1

40 1st & Reverse Latch Plunger........................1

41 Control Top Lockwasher...............................4

42 Control Top Screw ........................................4

J

CLARK

K

280V-SERIES BRAKE PARTS GROUP

ITEM Description QTY

ITEM Description QTY

1 Brake Support Capscrew.........................2

2 Brake Support Capscrew.........................2

3 Brake Locating Bracket ...........................1

4 Brake Band Locating Screw Nut..............2

5 Brake Release Spring..............................2

6 Brake Spacer Link Clevis Pin...................2

7 Brake Draw Rod Clevis Pin .....................1

8 Brake Cam Lever.....................................2

9 Brake Adjusting End................................1

10 Brake Draw Rod Clevis Pin Cotter...........1

11 Brake Spacer Link ...................................2

12 Spacer Link Clevis Pin Cotter..................2

13 Adjusting Bolt .........................................1

14 Brake Cam Lever Shoe............................1

15 Brake Band & Facing Assembly (Inc. items

30 & 31)1

18 Companion Flange to Brake Drum Bolt Nut4

19 Anchor Clip Screw ..................................1

20 Brake Compression Spring Washer ........1

21 Brake Adjusting Bolt Nut.........................2

22 Brake Adjusting Bolt Nut Lockwasher .....1

23 Brake Anchor Support Bar ......................1

24 Brake Anchor Clip Spring........................1

25 Brake Support Stud Nut..........................2

26 Brake Support Stud Nut Lockwasher ......2

27 Brake Support Stud.................................1

28 Brake Band Locating Screw ....................1

29 Compression Spring ...............................1

30 Brake Band Facing Rivet .......................26

31 Brake Band Facing .............1Brake Drum1

32 Brake Drum to Flange Bolt ......................4

16 Companion Flange ..................................1

17 Companion Flange to Brake Drum Lock-

washer4

L

280V-SERIES

ASSEMBLY INSTRUCTIONS

When screws with pre-applied thread locking compound
are removed after initial assembly, clean thread locking
compound are removed after initial assembly, clean
threads thoroughly and apply Loctite 262 Thread Lock
before re-installation.

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

Check mainshaft 1st & Reverse sliding gear to make sure
it slides freely on mainshaft.

Hand-spin idler gear and countershaft assemblies after

each is installed on their bearings in trans. case. Both

must spin freely and smoothly.

Unless otherwise specified:

Tighten all capscrews 20-25 Lbs. Ft. [27,2-33,8N.m]

Apply a thin coat of Loctite 510

Gasket Eliminator to the O.D. of all oil seals before

assembly.

M

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:

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 1-Remove control top or remote control assembly.

Figure 2-Remove shift rod cover capscrews.
NOTE: See Page 23 for Diecast Cover Disassembly

Figure 3-Remove shift rod cover.

Figure 4-Remove shift rod support assembly.

1

Figure 5-Remove anchor clip screw lockwire and clip
screw.

Figure 7-Remove adjusting bolt, nuts, and washer.

Remove adjusting bolt.

Figure 6-Remove jam nuts and brake band locating
screw.

Figure 8-Remove brake release springs and cam lever

shoe.

2

Figure 9-Remove brake band and anchor clip spring.

Figure 11-Remove brake drum.

Figure 10-Lock transmission in two gears and remove

brake drum.

Figure 12-Remove mainshaft rear bearing cap and

speedometer drive gear.

3

Figure 13-Remove countershaft rear bearing cap.

Figure 15-Remove main drive gear bearing cap.

Figure 14-Remove countershaft rear bearing retainer

ring.

Figure 16-Remove main drive gear. Use caution as not to

drop mainshaft spigot bearing rollers in transmission

case.

4

Figure 17-Pry mainshaft to the rear to expose rear bear­ing. Remove bearing.

Figure 19-Remove reverse idler shaft lockscrew and

lock. Using a suitable puller remove reverse idler shaft.

Figure 18-Remove mainshaft assembly

Figure 20-Remove reverse idler gear, bearings, and two

thrust washers.

5

Figure 21-Pry countershaft to the rear to expose rear
bearing.

Figure 23-Remove countershaft assembly.

Figure 22-Remove countershaft rear bearing and oil

slinger.

Figure 24-Remove mainshaft 1st & reverse sliding gear.

Set mainshaft up as shown and remove 4th & 5th syn-

chronizer assembly. NOTE: Bottom synchronizer cup may

stay on mainshaft.

6

Figure 25 - Remove 4th & 5th shift hub sleeve retainer
ring.

Figure 27 - Remove 3rd speed gear retainer ring.

Figure 26 - Remove 4th & 5th shift hub sleeve and 4th

speed gear.

Figure 28 - Remove 3rd speed gear and locating washer.

7

Figure 29 - Remove 2nd & 3rd synchronizer assembly.

Figure 31 - Remove 2nd & 3rd shift hub sleeve.

Figure 30 - Remove 2nd & 3rd shift hub sleeve retainer

ring.

Figure 32 - Remove 2nd gear retainer ring.

8

Figure 33 - Remove 2nd gear and locating washer.

STAMPED CONTROL DISASSEMBLY
See Page 23 for Diecast Cover - Fabricated Rails
See Page 31 for Diecast Cover - Round Rails

Figure 35 - Remove 1st & Reverse shift fork, rod and lug

from shift rod support.

Figure 34 - Remove 1st & Reverse shift lug lockscrew.

Figure 36 - Using a small pin or drift, remove 2nd & 3rd

shift fork roll pin.

9

Figure 37 - Remove 2nd & 3rd shift rod. CAUTION: Do
not lose interlock cross pin or 2nd speed overdrive
spacer.

Figure 34 - Remove 4th & 5th shift fork roll pin.

Figure 39 - Remove 4th & 5th shift rod and fork.

CLEANING AND INSPECTION

CLEANING

Cleaning all parts thoroughly using solvent type cleaning

fluid. It is recommended that parts be immersed in clean-

ing 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.

10

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.

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.

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.

MAIN DRIVE GEAR DISASSEMBLY AND REASSEMBLY

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, gaskets and snap
rings is more economical when unit is disassembled that
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.

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.

Figure 40 - Remove main drive gear bearing retainer

ring. Press bearing and oil slinger from main drive gear.

Replace gear or bearing and install as shown. Install

retainer ring.

11

CLUTCH HOUSING OR COUNTERSHAFT
FRONT BEARING REPLACEMENT

STAMPED CONTROL REASSEMBLY

Figure 41 - If countershaft front bearing is to be replaced,

remove clutch housing and drive front bearing from
transmission case. Apply a light coat of permatex No. 2
on the outher diameter of the new bearing. Install in
transmission case as shown with end of bearing .001 to
.007 below the face of case. Install main drive gear
andearing assembly in transmission case. Install main
drive gear bearing cap on drive gear.

Figure 43 - Install 4th & 5th shift rod through support

and into 4th & 5th shift fork.

Figure 44 - Install 4th & 5th shift fork to shift rod roll pin,

move rod to neutral.

Figure 42 - Install clutch housing and tighten stud nuts
60 to 80 ft. lbs. torque. Remove drive gear bearing cap
and main drive gear.

12

Figure 45 - Install two interlock balls between 4th & 5th,
and 2nd & 3rd shift rods.

Figure 47 - Install 2nd & 3rd shift fork to shift rod roll

pin. Move rod to neutral.

Figure 46 - Install 2nd & 3rd shift rod through shift sup­port. Install over shift spacer, shift fork and interlock
cross pin.

Figure 48 - Install two interlock balls between the 2nd &

3rd, and 1st & Reverse shift rods.

13

MAINSHAFT REASSEMBLY

Figure 49 - Install 1st & reverse rod through support and

into lug

Figure 50 - Install 1st & reverse lug lockscrew and lock­wire to prevent loosening.

Figure 51 - Install 2nd speed gear retainer ring, locating

washer, and 2nd speed gear on mainshaft. (NOTE: clutch-

ing teeth are up.)

Figure 52 - Install 2nd gear retainer ring.

14

Figure 53 - Install 2nd & 3rd shift hub sleeve and sleeve
retainer ring.

Figure 55 - Install 3rd speed gear with clutching teeth

down. Install 3rd gear locating washer.

Figure 54 - Install 2nd & 3rd synchronizer assembly.

Figure 52 - Install 3rd gear retainer ring.

15

Figure 57 - Install 4th gear with clutching teeth up. Note
chamfer on 4th & 5th shift hub sleeve. Chamfer must go
down. Install bottom cup of 4th & 5th synchronizer on
4th speed gear clutching teeth before installing 4th & 5th
shift hub sleeve. Install sleeve retainer ring.

Figure 59 - Turn mainshaft assembly over and install 1st

& reverse sliding gear with shift fork slot down.

REASSEMBLY OF TRANSMISSION

Figure 58 - Install 4th & 5th synchronizer on shift hub

sleeve.

Figure 60 - Coat countershaft pilot bearing needles with

heavy grease to hold in place until countershaft is

installed.

16

Figure 61 - Tip rear of countershaft down and into trans­mission case. Feed rear of countershaft through rear
countershaft bearing bore. Move countershaft forward
and into pilot bearing. CAUTION: Do not disrupt counter­shaft needle bearing.

Figure 63 - Drive rear bearing on countershaft and rear

bearing bore. NOTE: Countershaft drive gear must be

supported on each side with a ¼” flat bar to prevent dam-

age to countershaft pilot bearing.

Figure 62 - Position rear bearing oil slinger as shown and
start rear bearing.

Figure 64 - Install countershaft rear bearing retainer ring.

17

Figure 65 - Coat a new gasket on both sides with a grade
#2 multi-purpose grease. Position

Figure 67 - Insert two reverse idler gear bearings in idler

gear.

Figure 66 - Use heavy grease on reverse idler thrust
washers to hold in place.

Figure 68 - Install reverse idler gear as shown. Insert

idler shaft through case and idler gear. NOTE: Idler shaft

lock groove must line up with lock bolt hole. Drive shaft

into position. Install shaft lock and bolt. Tighten bolt 20 to

25 ft. lbs. torque [27,2 - 33,8 N.m].

18

Figure 69 - Install mainshaft assembly into transmission
case as shown.

Figure 70 - Assemble the pilot bearing in the main drive
gear as follows:

1. If a new pilot bearing is used it comes from the fac-

tory with a plastic sleeve. Stand drive gear on end.
Set bearing and sleeve over bearing pocket in drive
gear. Slide bearing rollers and cage from plastic
sleeve into bearing pocket.

2. If old pilot bearing is used, set rollers in bearing cage

and hold in place with a rubber band. Slide bearing
rollers and cage from rubber band into bearing
pocket.

Figure 71 - Install main drive gear assembly in transmis-

sion case. Clutching teeth on main drive gear must enter

5th speed synchronizer cup without binding.

Figure 72- Press oil seal into drive gear bearing cap with

lip of seal up. Coat a new gasket on both sides with a

grade #2 multi-purpose grease. Position gasket on drive

gear bearing cap. Use caution as not to cover oil return

groove in bearing cap.

19

Figure 73 - With bearing cap oil return groove lined up
with oil hole in transmission case, install bearing cap and
bolts. Tighten bolts 15 to 20 ft. lbs. torque [20,4 - 27,1
N,m]

Figure 75 - Install speedometer drive gear.

Figure 74 - Install mainshaft rear bearing.

Figure 76 - Press a new oil seal in mainshaft rear bearing

cap with lip of seal down. Coat a new gasket on both

sides with a grade #2 multi-purpose grease. Position

gasket on mainshaft rear bearing cap, use caution as not

to cover oil return grooves in bearing cap. Install bearing

cap with oil grooves lined up with oil holes in case.

Tighten bolts 35 to 45 ft. lbs. torque [47,5 - 61,0 N,m].

20

Figure 77 - Install drum and flange assembly, brake
locating bracket, and anchor support bar.

Figure 79 - Install anchor clip spring and brake band on

anchor support bar.

Figure 78 - Install companion flange nut and tighten 400
to 500 ft. lbs. torque [542,3 - 610,0 N,m].

Figure 80 - Install brake release springs and cam lever

shoe as shown.

21

Figure 81 - With spacer link and cam lever in position,
install adjusting bolt washer and nut.

Figure Install band locating screw as shown with
threaded end up; install nut.

Figure 83 - Install anchor clip screw.

BRAKE BAND ADJUSTMENT

Adjust brake band anchor screw to give clearance of.010

between brake drum and band. Adjust brake band locat-

ing screw and adjusting bolt to give a .010 clearance

around the entire drum. After adjustment, lockwire

anchor clip screw.

Figure 84 - With transmission shifted into neutral, install

shift control assembly. 2nd & 3rd and 4th & 5th shift

forks set over shift hubs, 1st & reverse fork enters slot on

1st & reverse gear. Tighten bolts 20 to 25 ft. lbs. torque

[27,2 - 33,8 N.m]. Position three mesh lock balls and

springs in support housing.

22

Figure 87 - Install remove control or shift control top,

tighten bolts 20 to 25 ft. lbs. torque [27,2 - 33,8 N.m.].

Figure 85 - Install shift support cover.

Figure 86 - Tighten shift support cover bolts 20 to 25 ft.

lbs. torque [27,3 - 33,8 N.m.].

USE FOLLOWING PROCEDURE FOR DIECAST COVER

DISASSEMBLY AND REASSEMBLY (Fabricated Rails)

Figure 88 - Remove remote control or shift tower from

control cover. Remove control cover capscrew and lock-

washers.

23

Figure 89 - Remove control cover assembly from trans­mission. Remove backup switch.

Figure 92 - Remove front rail support.

Figure 90 - With control cover in neutral, pry 4th & 5th

shift fork to 4th speed position (toward the rear of cover).

Figure 91 - Remove front rail support capscrews.

Figure 93 - Remove interlock tapered pin supports

Figure 94 - Note position of interlock tapered pins for

reassembly.

24

Figure 95 - Remove rear rail support capscrews.

Figure 96 - Remove rear rail support

Figure 98 - Remover 4th, 5th 2nd & 3rd shift fork and rail

assembly. (See Caution in Figure 99).

Figure 99 - Use caution as not to lose interlock cross pin,

interlock tapered pins or mesh lock poppet balls.

Figure 97 - Remove 1st & reverse shift fork and rail
assembly.

Figure 100 - Remove 1st & reverse shift rail.

25

Figure 101 - Remove mesh lock poppet balls, quantity 4.

Figure 102 - Remove poppet springs, quantity 4.

Figure 104 - Remove reverse latch plunger spring retain-

ing plug.

Figure 103 - Remove 1st & reverse rocker arm.

Figure 105 - Remove reverse latch plunger spring and

plunger.

SEE CLEANING AND INSPECTION PROCEDURE, PAGES

10-11.

26

DIECAST CONTROL REASSEMBLY

Figure - 106 - If fork bushings are worn, secure fork in a

vise equipped with soft jaws and remove worn bushings
with a drift. Install new bushings in fork. Turn fork over
on anvil of vise and secure bushing in fork using a prick
punch and upsetting bushing metal on outside of fork.

Figure 109 - Install poppet springs, quantity 4.

Figure 107 - Install reverse latch plunger, spring and

retaining plug. Tighten plug securely.

Figure 108 - Position 1st & reverse rocker arm on pivot
pin as shown.

Figure 110 - Install mesh lock poppet balls, quantity 4.

Note 1st & reverse shift fork rail poppet ball in pocket.

Figure 111 - Align one tapered interlock cross pin with

hole in 1st & reverse shift rail. Position rail on poppet ball

with rail in neutral position.

27

Figure 112 - Note position of tapered interlock cross pin
in relation to rail.

Figure 113 - Install interlock cross pin in 2nd & 3rd shift
rail.

Figure 115 - Install 2nd interlock tapered pin. Align pin

with interlock cross pin hole.

Figure 116 - Position 4th & 5th shift fork and rail on pop-

pet ball in neutral.

Figure 114 - Position 2nd & 3rd shift rail on poppet ball
in neutral position with interlock pin aligned with 1st
interlock tapered pin.

Figure 117 - Slightly raise rear of 4th & 5th shift rail and

align 2nd interlock tapered pin with cross hole in 4th &

5th shift rail.

28

Figure 118 - Note position of tapered interlock pins and
shift rails.

Figure 119 - Install 1st & reverse shift fork and rail
assembly on poppet ball in a neutral position. Align 1st &
reverse rocker arm in notch at rear of rail as shown.

Figure 121 - Install rail support capscrews and washers.

Tighten capscrews slightly.

Figure 122 - Install interlock tapered pin supports. Tap

4th & 5th shift fork to the rear. (4th speed position).

Figure 120 - Position rear rail support

Figure 123 - Position front rail support and install cap-

screws and washers.

29

Figure 124 - Tighten front and rear support capscrews 20
to 25 ft. lbs. torque [27,2 - 33,8 N,m]. Tap 4th & 5th shift
fork and rail assembly forward to a neutral position.

Figure 125 - 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 brake drum or output shaft turning.

Figure 126 - Install center rear capscrews first and

tighten 20 to 25 ft. lbs. torque [27,2 - 33,8 N,m]. Install

center front screw second and tighten 20 to 25 ft. lbs

torque [27,2 - 33,8 N,m]. Tighten remaining capscrews

20 to 25 ft. lbs torque [27,2 - 33,8 N,m].

30

SHIFT CONTROL DISASSEMBLY (Round Rails)

Figure 1- Remove front and rear rail support capscrews.

Figure 2 - Remove front and rear rail supports

Figure 4 - Remove 2nd & 3rd shift fork and rail assembly.

CAUTION: Do not loss interlock cross pin.

Figure 5 - Remove 1st & reverse shift fork, rail and lug

assembly.

Figure 3 - Remove the 4th and 5th shift fork and rail
assembly.

Figure 6 - Using a small magnet remove the 1st and

reverse shift fork rod lock pin.

31

Figure 7 - Remove first & reverse shift fork and rail
assembly.

Figure 10 - If the second, third, fourth or fifth shift fork

bushing is to be replaced, remove worn bushings from

fork. Install new bushing and bend bushings tab over top

and bottom of fork.

Figure 8 - Remove 1st & reverse rocker arm.

Figure 9 - Remove mesh lock spring and lock ball - 3

each. Remove crossover interlock balls - 4 each.

Figure 11 - Remove reverse latch plunger, pin and

spring.

See Cleaning and Inspection Section, Page 10.

REASSEMBLY

Figure 12 - Install reverse latch plunger, spring, pin and

plunger spring plug.

32

Figure 13 - Position crossover interlock balls in cover
cross bores. Two balls in cover cross bore between 1st
& reverse rail groove, and 2nd & 3rd rail groove and two
balls in cover cross bore between 2nd & 3rd rail groove,
and 4th & 5th rail groove. (See cross-section illustration
Figure 13-A).

Figure 13-A

Figure 15 - Position 1st & reverse rocker arm on pivot

pin.

Figure 16 - Install 1st & reverse shift fork and rail assem-

bly in control housing. Install shift rail lock pin to position

rail in control housing.

Figure 14 - Position the mesh lock spring and ball, three
each, in spring pockets. (See cross-section illustration
Figure 13-A).

Figure 17 - Install 1st & reverse shift lug, rocker lug, shift

rail and spacers in rail groove over mesh lock ball and

spring. NOTE: Position widest spacer between shift lug

and front support. The narrower spacer between the shift

lug and center support.

33

Figure 18 - 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 13-A).

Figure 20 - Position front rail support shift rails and

install capscrews. Position rear support over rails and

install capscrews.

Figure 19 - Position 4th & 5th shift rail and fork assem­bly in rail groove over mesh lock ball and spring.

Figure 21 - Tighten support capscrews 20 to 25 ft. lbs.

torque [27,2 - 33,8 N.m].

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 neutral pos-

itoin. 1st & reverse fork should not shift. If it does, inter-

lock cross pin or interlock cross over balls were not

assembled correctly. Disassemble cover and correct

cross over. (See illustration Figure 13-A).

NOTE: Install control cover capscrews in sequence

explained in Figure 126.

34

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
Sliding gear teeth rough, chipped, tapered
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
Misaligned or sprung driveshaft
Incorrect driveshaft assembly
Out-of-balance driveshaft

5. STICKING IN GEAR

Improperly operating clutch
Sliding gear or shift hubs tight on mainshaft splines
Misaligned mainshaft
Improper linkage adjustment

6. SLIPPING OUT OF DIRECT

Misaligned of transmission on engine
Worn pinion gear teeth
Worn clutching teeth on shift hub
Insufficient tension on detent balls
Improper linkage adjustment
Excessive shift lever whip action

7. SLIPPING OUT OF FIRST OR REVERSE

First or reverse sliding gear splines worn
Sliding gear teeth worn or tapered
Worn mainshaft splines
Worn countershaft first speed gear
Partial engagement
Improper linkage adjustment

8. SLIPPING OUT OF OTHER SPEEDS

Excessive clearance between mainshaft gear and
mainshaft
Excessive end play of mainshaft gear on mainshaft
Worn clutching teeth
Weak detent ball springs
Improper linkage adjustment

4. DIFFICULT SHIFTING

Improperly operating clutch
Sliding gear or shift hubs tight on mainshaft splines
Damaged chamfer on sliding gear teeth
Burred mainshaft splines
Misaligned mainshaft
Damaged or worn synchronizer assembly
Improper linkage adjustment
Worn or sprung shift fork

35

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