Eaton Transmission FRLO-16410C-T2 Service Manual
Service Manual
Fuller Heavy Duty Transmissions
TRSM0580
October 2007
FRLO-14410C-T2
FRLO-15410C
FRLO-15410C-T2
FRLO-16410C
FRLO-16410C-T2
FRLOF-14410C
FRLOF-14410C-T2
FRLOF-15410C
FRLOF-15410C-T2
FRLOF-16410C
FRLOF-16410C-T2
For parts or service call us
Pro Gear & Transmission, Inc.
1 (877) 776-4600
(407) 872-1901
parts@eprogear.com
906 W. Gore St.
Orlando, FL 32805
Warnings and Precautions
Introduction
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.
Always use genuine Eaton replacement parts.
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
inj ury to t he servici ng technici an.
CAUTION: Failure to follow indicated
procedures may cause component
damage or malfunction.
IMPORTANT: Highly recommended
procedures for proper service of this unit.
Note: Additional service information not
cover ed in the servic e proce dures .
Service Procedure
Tip: Helpful removal and installation
procedures to aid in the service of this unit.
0
Lightning Breakdown
Overview
Control Unit:
Electronic Control Unit:
ECU
Auxiliary Components:
Rear Bearing Cover
Control Unit:
Shift Knob
Control Unit:
Levers/Housings
& Isolators
Auxiliary Components:
Range Cylinder
Auxiliary Components:
Countershaft & Brgs
Front Section:
Reverse Idler
Auxiliary Components:
Mainshaft & Synchro
Air System:
Air Filter/Regulator
Front Section:
Case Assembly
Front Section:
Case Assembly
Auxiliary Components:
Splitter Cylinder
Front Section:
Integral Oil Cooler
Auxiliary Components:
Countershaft & Brgs
Front Section:
Countershaft Assy
106008-7-99
Control Unit:
Shift Shaft Assy
Front Section:
Reverse Idler
Front Section:
Countershaft Assy
Front Section:
Mainshaft Assy
Front Section:
Input Shaft & Drive Gear
Table of Contents
Introduction
Warnings and Precautions ........................................... i
Overview ..................................................................... ii
General Service Practices and Part Inspection ............ 1
Purpose and Scope of Manual .................................... 5
Serial Tag Information and Model Nomenclature ........ 6
Torque Chart ............................................................... 9
Lubrication Information ............................................ 11
Recommended Tools ................................................14
Preventive Maintenance ............................................ 17
Oil Leak Inspection Process ...................................... 19
RTV Sealant Application Procedures ......................... 20
Power Flow ............................................................... 22
Gear Sets to be Timed ............................................... 27
Timing Procedures .................................................... 28
In-Vehicle Service Procedures
How to Remove the ECU ........................................... 31
How to Install the ECU .............................................. 32
How to Remove the Air Filter/Regulator .................... 33
How to Install the Air Filter/Regulator ....................... 34
How to Remove the Shift Knob ................................. 35
How to Install the Shift Knob .................................... 36
How to Remove the Gear Shift Lever/Remote
Shift Control ....................................................... 37
How to Install the Gear Shift Lever/Remote
Shift Control ....................................................... 38
How to Adjust the Remote Shift
Control (LRC Type) ............................................ 39
Neutral Switch Operation and Testing .......................41
How to Remove the Neutral Switch ........................... 42
How to Install the Neutral Switch .............................. 43
Reverse Switch Operation and Testing ...................... 44
How to Remove the Reverse Switch ......................... 45
How to Install the Reverse Switch ............................. 46
How to Remove the Shift Shaft Seal ......................... 47
How to Install the Shift Shaft Seal ............................. 48
How to Remove the Oil Seal -
Magnetic Speedometer ...................................... 50
How to Install the Output Shaft Oil Seal -
Magnetic Speedometer ...................................... 52
How to Remove the Output Bearing Cover ................ 54
How to Install the Output Bearing Cover ................... 56
How to Remove the Oil Cooler Fitting ....................... 58
How to Install the Oil Cooler Fitting ........................... 59
How to Remove the Auxiliary Countershaft
Bearing Cover .................................................... 60
How to Install the Auxiliary Countershaft
Bearing Cover .................................................... 61
How to Remove the Range Piston and
Range Bar O-Ring .............................................. 62
How to Install the Range Piston and
Range Bar O-Ring .............................................. 64
How to Remove the Splitter Piston ............................66
How to Install the Splitter Piston ...............................68
How to Remove the Clutch Access Cover ..................70
How to Install the Clutch Access Cover .....................71
Transmission Overhaul
Procedures-Bench Service
How to Disassemble the Gear Shift Lever ..................72
How to Assemble the Gear Shift Lever ......................74
How to Remove Output Yoke .....................................76
How to Remove the ECU ............................................77
How to Remove the Auxiliary Countershaft
Bearing Cover .....................................................78
How to Orient Transmission for Overhaul ..................79
How to Remove and Disassemble
Input Shaft and Oil Pump ...................................80
How to Remove and Disassemble Clutch
Housing/Front Cover ..........................................83
How to Remove Output Bearing Cover ......................85
How to Remove and Disassemble Front
Countershaft .......................................................86
How to Remove and Disassemble Mainshaft .............88
How to Remove and Disassemble the Shift Shaft ......91
How to Remove and Disassemble Reverse Idler ........94
How to Disassemble Splitter System .........................96
How to Remove and Disassemble Auxiliary
Countershaft .......................................................99
How to Remove and Disassemble Range System ....102
How to Remove and Disassemble Auxiliary
Mainshaft Assembly .........................................104
How to Remove Cooler and Fittings .........................106
How to Install Cooler and Fittings ............................107
How to Assemble and Install Auxiliary
Mainshaft Assembly .........................................108
How to Assemble and Install Range System ............111
How to Assemble and Install Auxiliary
Countershaft .....................................................114
How to Assemble Splitter System ............................117
How to Assemble and Install Reverse Idler ..............119
How to Assemble and Install the Shift Shaft ............121
How to Assemble and Install the Mainshaft .............123
How to Assemble and Install Front
Countershaft Assembly ....................................127
How to Install Output Bearing Cover ........................128
How to Assemble Clutch Housing / Front Cover ......129
How to Assemble Input Shaft and Oil Pump ............131
How to Install the Auxiliary Countershaft
Bearing Cover ...................................................134
How to Install the ECU .............................................135
How to Install Output Yoke ......................................136
M/S Endplay Shimming Procedure ..........................137
Introduction
General Service Practices and Part Inspection
Safety
Always keep personal safety in mind when working on heavy truck transmissions. Do not ignore common sense.
Use appropriate safety equipment including:
• Safety glasses
• Safety shoes
• Gloves
• Proper transmission jack or lift with safety chains
• Guards and protective devices for presses, pullers, and drivers.
• Wheel chocks
Disassembly Tips
Cleanliness
The workplace must be clean to prevent dirt or other foreign material from contaminating the transmission during repairs. Dirt is
abrasive and can damage bearings. Eaton® recommends cleaning the outside of the unit before beginning disassembly.
Disassembling Assemblies
As components are removed from assemblies, lay the parts on a clean bench in the order in which they are removed. By laying the
parts out in order, they are less likely to be lost, and reassembly will be easier.
If bearings are to be reused, they must be removed with the proper bearing pullers, or they can be damaged. After removing bearings, carefully wash and lubricate them, and wrap them protectively in clean shop rags or towels until they are to be installed in
the transmission.
Input Shaft Removal
The input shaft assembly contains the transmission lube pump. The special procedure for removal and disassembly is located in
the “Transmission Overhaul Procedures” section.
Snap Ring Removal
Snap rings should be removed with snap ring pliers to avoid overstretching or deforming them.
Removing Parts Using Tools
Use care when removing parts with pullers or drivers to prevent damage to components. Never apply force to driven parts after
they stop solidly. Eaton® recommends using only soft hammers, soft bars, mauls, and the special tools indicated in the procedures for all disassembly work.
Marking Parts
To aid in reassembly and prevent unnecessary work, use a toolmaker’s die to mark the countershaft parts and rear bearing cover
to indicate position. Mark the countershaft parts, including the countershaft, gears, bearings, and shims, as “upper” or “lower”.
Mark the rear bearing cover to indicate the original position to the cover.
Parts Cleaning
WARNING
DO NOT USE GASOLINE TO CLEAN PARTS AS IT IS HIGHLY EXPLOSIVE.
Clean bearings and ground or polished parts in a cleaning solvent. To prevent corrosion, DO NOT clean ground or polished parts
in a hot solution tank, with water, or in alkaline solutions.
Housings can be cleaned with a cleaning solvent or in a hot solution tank with a mild alkaline solution. Dry and oil parts immedi-
ately after removal to prevent machined surfaces from corroding. Be careful cleaning aluminum parts; some cleaning solutions
may damage them.
1
Introduction
Inspection
Gears
Inspect gear teeth for frosting, pitting, spalling, or other damage. Gears with frosting can usually be reused. Often, frosting on
gears heals with continuous use of the transmission and more serious pitting does not occur. Gears with light pitting can have
considerable life left and can also be reused. For gears with severe pitting, spalling, damage, or confirmed noise issues, the complete gear set (mainshaft gear and both countershaft gears) must be replaced.
Inspect the internal clutching teeth for excessive wear or rounding. Replace the gear and sliding clutch if necessary.
For additional information on wear of gear teeth, including full color photographs, refer to Eaton® Fuller® publication TRSM0913, Understanding Spur Gear Life.
Bearings
Inspect balls, rollers, races, and thrust surfaces for pitting, spalling, or discoloration. Check for excessive axial (up and down) or
radial (side-to- side) play. Replace the bearings as necessary.
Lubricate bearings with clean oil and rotate them to check for tightness or roughness. Replace the bearings as necessary.
Splined Shafts
Inspect splines for twisting, cracking, or wear. Replace splined shafts as necessary.
Note: Worn splines may indicate excessive torsional vibration. Make sure the vehicle system is corrected to prevent recurring
damage to the transmission.
Thrust Washers
Inspect thrust washers for wear or scoring, and replace them as necessary.
Snap Rings
Inspect snap rings for wear, twisting, stretching, or other damage. Snap rings must fit tightly in their grooves. Replace them as
necessary.
Housings
Inspect housings for cracks. Replace any cracked housings.
Inspect threaded holes for damage, and repair them as necessary.
Inspect bearing bores for wear. Light wear is acceptable. Housings with moderate to heavy wear in the bearing bores must be
replaced.
Introduction
Sliding Clutches
Inspect the clutching teeth for excessive wear or rounding. Light wear or rounding is acceptable. Replace clutches with moderate
to heavy tooth wear.
Inspect the yoke slots of the clutches for excessive wear. Replace worn clutches.
Range Synchronizer
Inspect the friction material for excessive wear of damage. Replace the synchronizer as necessary.
Inspect the blocker pins for excessive wear on the chamfered corners, looseness, or torsional vibration damage. If the blocker
pins are damaged, replace the range synchronizer.
Fit the low and high range synchronizers in their respective gears. Check for synchronizer bottoming on or in the gears. If bottoming occurs, replace the synchronizer assembly.
Inspect the synchronizer mating surface on the gears for signs of excessive heat. If signs of excessive heat are present, replace
the synchronizer assembly.
2
Introduction
Clutch Housing
Inspect the pilot diameter where the clutch housing mates with the engine. Replace the clutch housing if the pilot diameter is
excessively worn.
Inspect the bushings for the clutch release linkage. Replace the bushings if they are worn.
O-Rings and Seals
Inspect o-rings and seals for wear, gouges, or permanent set, and replace them as necessary.
Shifting Mechanism
Inspect the shift yokes for excessive wear in the fork area. Light wear is acceptable. Replace any moderately or heavily worn shift
yokes.
Inspect the shift shaft for burrs or raised metal, and check the notches for excessive wear. Repair or replace parts as necessary.
Inspect the shift shaft, shift block, bias plate, shift key, detent key, plungers, and actuator parts for excessive wear or scoring.
Replace any of these parts as necessary.
Range Cylinder Assembly
Inspect the O-rings and piston seal for wear, damage, or permanent set, and replace them as necessary.
Inspect the piston bar, piston bores, and cylinder bores for wear or scoring. Replace any of these parts as necessary.
Shift Lever
Inspect the shift lever tip and spade pin groove for wear. Replace the parts as necessary.
Inspect the spade pin bore in the shift lever housing for excessive wear. Replace the housing as necessary
Input Shaft Seal
The input shaft seal is a lip type seal. Inspect the input shaft grooves and the inside of the front bearing cover for damage.
Replace any damaged parts.
Front Bearing Cover
If an input-shaft-mounted clutch brake is used on the transmission, inspect the clutch brake mating surface on the front bearing
cover for excessive wear. Replace the front bearing cover if the mating surface is excessively worn.
Gasket Surfaces
Inspect flanges and gasket surfaces for burrs, nicks, and scratches. Repair or replace parts as necessary.
Output Seal System
Inspect the output seal mating surface for wear, scratches, burrs, or other damage. Replace the seal surface if it is worn or damaged. Do not attempt to salvage the seal surfaces with crocus cloth, filing, etc.
For additional information, refer to the Eaton/Fuller® brochure TCSM-0912 “Seal Maintenance Guide”.
Reassembly Tips
Cleanliness
Make sure that parts are kept clean during reassembly. Prevent dirt or other foreign material from contaminating the transmisssion. Dirt is abrasive and can damage bearings.
Use lint-free shop rags when handling and cleaning parts. Too much lint inside the transmission can clog the oil pump pickup
screen.
Bearing Installation
To avoid damaging bearings, use a driver that contacts both the inner and outer race of the bearing. If the bearing balls/rollers or
bearing cage is damaged, the bearing must be replaced.
3
Introduction
Capscrews
Make sure the threaded holes are clean and free of debris. If necessary, use a tap to clean the threads.
Make sure the capscrew threads are in good condition. If necessary, replace the capscrew.
Use a thread seal/locker compound on all capscrews. Use Eaton® Fuller® P/N 71295 thread sealant of equivalent.
Torque all capscrews to the recommended tightness.
Initial Lubrication
Unless stated specifically, lubricate all mating or sliding parts with transmission oil.
Lubricate all bearings with transmission oil.
Air System Lubrication
Lubricate all air system O-rings, seals, and cylinders with a light coating of silicone lubricant such as Eaton® Fuller® P/N 71203
(8fl.oz.) or P/N 71206 (0.14 fl.oz/).
Snap rings
Eaton® recommends using new snap rings for reassembly. A properly installed snap ring fits tightly in its groove and cannot be
easily rotated. All loose or overstretched snap rings must be replaced.
Introduction
4
Introduction
Purpose and Scope of Manual
This manual is designed to provide detailed information necessary to service and repair the Eaton® Fuller® transmissions listed
on the front cover.
How to Use This Manual
The service procedures have been divided into two sections: In-Vehicle Service Procedures and Transmission Overhaul Procedures-Bench Service. In-Vehicle Service Procedures contain procedures that can be performed while the transmission is still
installed in the vehicle. Transmission Overhaul Procedures contain procedures that are performed after the transmission has
been removed from the vehicle.
The procedure sections are laid out with a general heading at the top outside edge of each page, along with more specific headings on the top left of the page and the specific procedures below. To find the information you need, first go to the section that
contains the correct procedure (In-Vehicle Service Procedures, Transmission Overhaul Procedures-Bench Service). Then look for
the correct heading at the top left of each page and follow the steps.
The sections located in front of the repair procedures are intended to give you information that is not included in the Service
Repair Procedures.
5
Model Designations
Serial Tag Information and Model Nomenclature
Transmission model designation and other transmission identification information are stamped on the serial tag. To identify the
transmission model and serial number, locate the tag on the transmission and then locate the numbers as shown. Figure 1-1
below shows a tag and the tag location on the transmission.
When calling for service assistance or parts, have the model and serial numbers handy
Do not remove or destroy the transmission identification tag!
Model Designations
Model Number
The model number gives basic information about the transmission and is explained below. Use this number when calling for service assistance or replacement parts.
Serial Number
The serial number is the sequential identification number of the transmission. Before calling for service assistance, write the
number down.
Bill of material or Customer number
This number may be located below the model and serial numbers. It is a reference number used by Eaton®.
6
Model Designations
Model Options
Torque Rating
The torque rating of the transmission specified in the model number is the input torque capacity in lb-ft. Various torque ratings
are available. For more information, call your Eaton Fuller regional sales and service office at 1-800-826-HELP (4357).
Shift System
Two types of shift systems are available for this transmission. Both are described and shown below.
Standard
The standard shift system has a gear shift lever opening located toward the rear of the transmission.
Forward Opening
The forward opening shift system has a gear shift lever opening located three inches closer to the front of the transmission than
the standard opening. This forward design allows greater flexibility in mounting the transmission and is indicated by an “F” in the
model number.
Standard Opening
Lubrication Pumps
Standard internal pump
Power Take Off (PTO) Usage
The 6 bolt openings are standard with the transmission. The PTO is mounted to the opening on either side and driven from the
countershaft gear.
Rear Mount
The thru-shaft PTO mounts are on the rear of the transmission. The thru-shaft PTO configuration is standard on the Lightning
transmission.
7
Forward Opening
Contact Information for Lightning compatible PTO’s
Chelsea Power Take-Off Products
Dana Corporation
Model Designations
P.O. Box 321
Toledo, OH 43697-0321
Phone 1-800-729-3262
www.chelseapower.com
Muncie Power Products
P.O. Box 548
Muncie, IN 47308-0548
Phone 1-800-FOR-PTOS (1-800-367-7867) or 1-765-284-7721
www.munciepower.com
Model Designations
8
Specifications
Torque Chart
The chart below lists the torque values for all the fasteners used on this model transmission. The torque values are also given in
the procedures any time a fastener must be tightened.
Table
Description Torque Value lb·ft
(Nm)
Shift Knob Jam Nut 35–45 (48–61) 1/2” X 13
Shift Lever Housing Capscrews 47–52 (63–70) M10 X 1.5
Remote Shift Control Mounting Capscrews
Clutch Release Yoke Capscrews 35–45 (48–61) 3/8” X 24
Clutch Release Adjusting Arm Capscrews
Clutch Housing Flange Capscrews See engine manufacturer recommendations
Rear Support Studs 60 Minimum (81) M16 X 2.0 Drive until bottomed (When using plugs apply
Rear Support Stud Nuts 170-190 (230-
Speed Sensor Retaining Capscrews 20-23 (27-31) M8 X 1.25
PTO Cover Capscrews/Studs 47-52 (63-70) M10 X 1.5
47–52 (63–70) M10 X 1.5
35–45 (48–61) 3/8” X 24
257)
Thread Size
X30MM
X30MM
for type, size, and assembly torque.
71206 sealant)
M16 X 1.5
X20MM
External Attachment Stud Nuts 20-23 (27-31) M8 X 1.25
Thermocouple Plug 47-52 (63-70) 1/2" NPT Use thread sealant
Oil Fill Plug 35-50 (47-67) 1 1/16" X 12 O-ring plug
Oil Drain Plug 35-50 (47-67) 1 1/16" X 12 O-ring plug
Air System Diagnostic Port Plugs 84-120 lb. in. 1/16"-27 Use thread sealant
Oil Level Site Glass 60-70 (81-95) 1 5/8" X 12 O-ring fitting
Air Filter/Regulator Capscrews 9-10 (12-14) M6 X 1.0 X
55MM
Neutral Switch 15-20 (20-27) M16 X 1.5 O-ring seal
Reverse Switch 15-20 (20-27) M16 X 1.5 O-ring seal
Splitter Detent Plug 15-20 (20-27) M16 X 1.5 O-ring seal
Output Shaft Nut 450-500 (610-
677)
Cooler Inlet & Outlet Fittings 40-50 (54-67) 7/8" UNF O-ring fitting
Main Case Breather 15-20 (20-27) 1/4" X 18 Use thread sealant
M48 X 2.0 Oil at yoke installation
9
Table
Specifications
Description Torque Value lb·ft
(Nm)
ECU Breather 84-120 lb-in (9.5-
13.6)
Clutch Housing / Front Cover Capscrews
Front Bearing Cover Capscrews 35-40 (48-55) M10 X 1.5 X
Front Cover Oil Dam Plate Capscrew 20-23 (27-31) M8 X 1.25 X
Oil Trough Capscrews 20-23 (27-31) M8 X 1.25 X
Rear Countershaft Bearing CoverCapscrews
Output Shaft Bearing Cover Capscrews
Vehicle Wiring Harness Connector
Retaining Screw at ECU
ECU Mounting Capscrews 20-23 (27-31) M8 X 1.25 X
47-52 (63-70) M10 X 1.5
47-52 (63-70) M10 X 1.5 X
47-52 (63-70) M10 X 1.5 X
7-13 lb-in (.8-1.5) 10 X 24 Part of connector assembly
Thread Size
1/8" X 27 Use thread sealant
35MM
12MM
12MM
30MM
45MM
70MM
Specifications
ECU Position Sensor Capscrews 22-28 lb-in (2.4-
3.2)
ECU Solenoid Pack Capscrews 22-28 lb-in (2.4-
3.2)
Range Piston Retaining Nut 25-35 (34-47) M10 X 1.5
Eccentric Pump Setscrew 3 Maximum (4)
maximum
Shift Shaft Neutral Detent Plunger
Plug
Shift Shaft Reverse Bias Detent Plug 15-20 (20-27) M18 X 1.75
Reverse Idler Retaining Capscrews 47-52 (63-70) M10 X 1.5 X
Cooler Retaining Capscrews 20-23 (27-31) M8 X 1.25 X
15-20 (20-27) M16 X 1.5
M4 X.75 X
16MM
M4 X.75 X
16MM
M4 X.75 X
25MM
30MM
12MM
Drive until the setscrew bottoms into pump
eccentric
10
Lubrication Information
Lubrication Information
Proper lubrication procedures are the key to a good all-around maintenance program.
Eaton® Fuller® Transmissions are designed so internal parts operate in an oil circulating bath created by the motion of the gears
and shafts.
All parts will be properly lubricated if these procedures are closely followed:
a. Maintain oil level and inspect regularly.
b. Follow maintenance interval chart.
c. Use the correct grade and type of oil.
d. Buy from a reputable dealer.
Maintain Proper Oil Level
Make sure the oil is level with the filler opening. Being able to reach the oil with your finger does not mean the oil is at The proper
level. (One inch of oil level is about one gallon of oil.)
IMPORTANT
When adding oil, never mix engine and gear oils in the same transmission.
Hole
Improper Oil Level
Hole
Proper Oil Level
11
Lubrication Information
Oil Capacity is 27 pints
Maintenance Interval Chart
Eaton® Roadranger® CD50 Transmission Fluid
HIGHWAY USE-Heavy duty and Mid-Range initial Fill with Eaton® Roadranger® CD50 E500 (PS-164)
HIGHWAY
Every 10,000 miles Check fluid level. Check for leaks.
Every 500,000 miles Change transmission lubricant.
OFF-HIGHWAY USE
First 30 hours Change transmission lubricant on new units.
Every 40 hours Inspect lubricant level. Check for leaks.
Every 1,000 hours Change transmission fluid where severe dirt conditions exist.
Every 2,000 hours Change transmission fluid (Normal off-highway use).
If your vehicle has a transmission oil filter, you must change the filter when fluid or lubricant is changed.
The use of lubricants not meeting these requirements will affect warranty coverage.
For a list of Eaton Approved Synthetic Lubricants, see TRSM-0911 or call 1-800-826-HELP (4357).
Buy from a Reputable Dealer
For a complete list of approved and reputable dealers, write to:
Eaton Corporation
Global Marketing Services
P.O. Box 4013
Kalamazoo, MI 49003
Lubrication Information
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.
12
Lubrication Information
Operating Temperatures with Oil Coolers
The transmission must not be operated consistently at temperatures above 250°F. However, intermittent operating temperatures
to 300°F do not harm the transmission. Operating temperatures above 250°F increase the lubricant’s oxidation rate and shortens
its effective life. When the average operating temperature is above 250°F, the transmission can require more frequent oil changes
or external cooling.
Oil coolers are standard on Lightning transmissions.
The following conditions in any combination can cause operating temperatures of over 250°F:
a. Operating consistently at slow speed.
b. High ambient temperatures.
c. Restricted air flow around transmission or engine radiator.
d. Exhaust system too close to transmission.
e. High horsepower operation.
f. Restricted engine coolant flow to transmission cooler.
Oil coolers are effective in reducing operating temperatures when the above conditions are encountered.
Oil Cooler Chart
Transmission Oil Coolers are:
Recommended
With engines of 350 H.P. and above.
Required
With engines 399 H.P. and above and GCW’s over 90,000 lbs.
With engines 399 H.P. and above and 1400 lb-ft or greater torque.
With engines 450 H.P. and above.
13
Tools
Recommended Tools
Some repair procedures pictured in this manual show the use of specialized tools. Their actual use is recommended as they
make transmission repair easier, faster, and prevent costly damage to critical parts.
But for the most part, ordinary mechanic’s tools such as socket wrenches, screwdrivers, etc., and other standard shop items
such as a press, mauls and soft bars are all that is needed to successfully disassemble and assemble any Eaton Fuller Transmission.
Recommended Tools
The following tables list and describe the typical tools required to properly service this model transmission above and beyond the
necessary basic wrenches, sockets, screwdrivers, and prybars.
General Tools
The following tools are available from several tool manufacturers such as Snap-On, Mac, Craftsman, OTC, and many others.
General Tools
Tools
TOOL PUPOSE
0 - 100 lb·ft 1/2" drive Torque Wrench. General torquing of fasteners. (Typically 15-80 lb·ft.)
0 - 600 lb·ft 3/4" or 1" drive Torque Wrench. Torquing of output nut to 500 lb·ft.
0 - 150 lb·in 3/8" drive Torque Wrench. Torquing of pipe plugs 60-120 lb·in.
70 MM or 2 3/4" Socket - Standard Depth To remove/install the output yoke nut
5/64” Allen Wrench Driver To remove/install eccentric pump set screw
Snap Ring Pliers - small external To remove/install snap ring at input shaft thrust washer
Snap Ring Pliers - medium external To remove/install snap ring at rear of mainshaft
Snap Ring Pliers - small internal To remove/install snap ring at range cylinder
Dial Indicator and Magnetic Base To check mainshaft endplay
(2) Rolling Head (Crow's Foot) Prybars To remove the rear auxiliary countershaft bearings
Air Pressure Gauge 0 - 100 PSI (0-1034 kPa) To troubleshoot and verify correct air system operation
14
Tools
Eaton Fuller Model Special Tools
The following special tools are designed for this Eaton® Fuller® transmission. The addresses and phone numbers of the tool
suppliers are listed after the table. This list is provided as a convenience to our customers. These tools are manufactured by independent companies with no relationship to Eaton Fuller. Eaton Fuller does not warrant the fit or function of the listed tools. To
obtain the tools, contact the tool supplier directly.
Special Tools
REFERENCE
NUMBER
T1 Output Yoke Puller Required to remove an output yoke. 7075**
T2 Transmission Jack Adapter
T3 Transmission Service
T4 Bearing Puller To remove front countershaft bearings
T5 Bearing Race Puller To remove input shaft bearing race J-44077
T6 Bearing Race Puller To remove front countershaft bearing
T7 Bearing Race Puller To remove auxiliary countershaft front
T8 Bearing Puller To remove auxiliary countershaft front
T9 Bearing Race Puller To remove shift shaft bushing from
T10 Bearing, Race, & Bushing
TOOL PURPOSE KENT MOORE
TOOL NUMBER
Plate
Mounting Plate
Installer Kit
Provides stable base for removing the
transmission from the truck
Allows for correct orientation of transmission during bench service
from clutch housing
races
bearing races from front countershafts
roller bearings
front cover
To install all bearings, bearing races,
and bushings
J-44076
J-44075
J-44096
J-44352
J-44353
J-44354
J-44098
J-44751
OTC TOOL NUMBER
T11 Seal Puller/Installer To remove and install the rear shift
shaft seal
T12 Seal Puller To remove output shaft seal J-44355
T13 Transmission/Engine Stand Supports transmission service mount-
ing plate during bench service
** OTC 7070A kit includes 7075 yoke puller
15
J-44099
1726
Tools
Tool Suppliers
The following vendor makes tools specifically for Eaton® Fuller® Lightning transmissions:
SPX / Kent-Moore
28635 Mound Road
Warren, MI 48092–3499
Phone: 800-328–6657
Fax: 800–578–7375
The specialized tools can be obtained from a tool supplier or made from tool prints as required by the individual user. Detailed
Eaton Fuller Transmission Tool Prints are available upon request by writing to:
Eaton Corporation
Truck Components Operations
Technical Service
P.O. Box 4013
Kalamazoo, Michigan 49003
Eaton Aftermarket Parts
The following tools are available through Eaton Aftermarket Parts. To obtain any of the tools listed, contact your local Eaton®
parts distributor.
Aftermarket Parts
TOOL PURPOSE EATON PART NUMBER
Output Seal Driver To Install Output Seal 5564509 adapter with 5564501 driver - both parts included in complete
Eaton Seal Kit P/N TCMT-0912
Tension Spring Driver Install Shift Lever Spring T-11938 Eaton Transmission Print
Tools
16
Preventive Maintenance
Preventive Maintenance
The preventive maintenance items below are necessary to prevent costly transmission failures that may not be covered by warranty. Parts of the transmission to be checked or accessed for preventive maintenance are shown.
2
1
7
8
3
4
5
6
1. Clutch Release Bushings
2. Oil Fill Plug
3. Shift Tower
4. Air filter/Regulator
5. Output Seal
6. Oil Drain Plug
7. Oil fill Sight Glass
8. Clutch Inspection Cover
ECU
• Avoid any heat source close to the transmission. The exhaust system or any other source of heat must be at least four
(4) inches from the transmission ECU.
• Maintain vehicle electrical system in proper working condition.
• Check for clogged or plugged vents on ECU.
Transmission Oil
• Check transmission weekly for oil leaks. Repair promptly to prevent oil loss and subsequent transmission failure.
• Check transmission oil level at every engine oil change interval. Add transmission oil as necessary.
• Drain and replace transmission oil as recommended by the schedule in the lubrication interval chart.
17
Preventive Maintenance
Air System
• Drain moisture from the vehicle air system daily.
• Listen for air leaks daily, and repair them promptly.
• This model requires an air dryer. Confirm the air dryer system is working properly. Repair as necessary.
• Service the vehicle air compressor as required to prevent oil from entering the vehicle air system.
Master Clutch System
• Have the clutch checked and adjusted if any of the following occurs:
Clutch does not disengage completely.
Clutch brake does not function.
Clutch pedal free-play is less than 1/2".
• When replacing the clutch, use a high quality spring damped replacement unit without free travel.
Drivetrain
• Inspect the driveshaft for loose or worn U-joints weekly. Repair promptly to prevent excessive driveline vibration.
• Inspect air ride suspension ride height per OEM requirements.
Overall Inspection
• Inspect the transmission at the chassis lubrication interval for loose or missing capscrews and fasteners.
• Pay particular attention to the capscrews that attach the transmission to the engine.
Preventative Maintenance
18
Preventive Maintenance
Oil Leak Inspection Process
Inspect for Oil Leak
Determine if it is a Weep or a Leak
Weep: Stained, damp, no drips, light oil film,
dirt adhered to the contaminated area.
Gasket Rear Seal Leak
1. Clean suspected oil weep
area with a clean dry cloth
or mild soluble degreaser.
2. Ensure lube is to proper
level.
3. Notify the customer that it
is only a weep and it is not
considered to be detrimental
to the life of the transmission.
4. Repair is complete.
1. Do not repair: Rear seal is
designed to allow min
seepage (refer to Roadranger
TCSM-0912 Seal Maintance
Guide).
2. Ensure lube is to proper
level.
imal
Leak: Extremely wet or dripping of oil in the
contaminated area.
Step 1
1. Determine the origin of the leak path.
2. If origin of leak is obvious skip to Step 3.
3. If the origin of the oil leak is not obvious then
use either of the two following steps to determine
the oil leak:
Note: Do not use a high pressure spray washer to
clean the ar
force contamination into the area of concern and
temporarily disrupt the leak path.
i. Clean area with a clean dry cloth or mild
soluble degreaser and fill the transmission to
the proper lube level.
OR
ii. Clean the area as noted above and insert tracer
dye into the tr
transmission to proper lube level.
ea. Use of a high pressure spray may
ansmission lube and fill
Step 2
Operate vehicle to normal transmission operating
temperature and inspect the area for oil leak(s)
visually or if tracer dye was introduced use an UVL
(Ultraviolet Light) to detect the tracer dye’s point
of origin.
Note: When i
make sure the assumed leak area is not being
contaminated by a source either forward or above
the identified area such as the engine, shift tower,
shift bar housing, top mounted oil cooler, etc...
nspecting for the origin of the leak(s)
Step 3
Once the origin of the leak is identified, repair the
oil leak using proper repair proced
designated model service manual.
ures from the
Step 4
After the repair is completed, verify the leak is
repaired and operate the vehicle to normal
transmission operating temperature.
Inspect repaired area to ensure oil leak has been
eliminated. If the leak(s) still occurs, repeat steps
or contact the Roadranger Call Center at
1-800-826-4357.
19
Sealant Application
RTV Sealant Application Procedures
1. Clean and remove all foreign material from surfaces to be sealed.
2. Use solvent to prep surface before application.
3. Use the precut applicator nozzle to apply a continuous and even 1/8” bead to one of the surfaces to be assembled.
4. Apply the sealant bead inboard of all capscrew holes.
5. Parts must be assembled with 10 minutes of application, maximum RTV cure is achieved after 90 minutes.
6. Reference bead paths shown below for exact location for applying sealant.
7. Follow assembly instructions and torque specifications shown in the Lightning Series Manual. Eaton literature # TRSM0580
Sealant Bead Pattern for Main Case to Front Cover
Sealant Application
20
Sealant Application
Sealant Bead Pattern for Main Case Rear Bearing Covers
Sealant Bead Pattern for Main Case PTO Covers
21
Transmission Power Flow
Power Flow
An understanding of the engine’s power flow through a transmission in each particular gear assists the technician in troubleshooting and servicing a transmission.
The Eaton Fuller Lightning series transmission is really two transmissions combined into one unit. The first transmission or front
section contains three sets of forward gears and one reverse gear controlled by the driver’s movement of the shift lever. The second transmission called the auxiliary, or back box contains three sets of gears with two air shift cylinders. However, unlike other
Eaton Fuller Roadranger products, you cannot separate the front section from the auxiliary of the transmission for servicing.
Troubleshooting of the mechanical subsystem is similar to current Eaton Fuller mechanical products, although transmission disassembly may now be necessary to inspect the internal components.
The unique design of the Lightning transmission uses concentric countershafts. The front box countershaft fits through the hollow center of the auxiliary countershaft providing support for the auxiliary countershaft. The illustration shows the transmission
gearing with a cross sectional view of how the front section countershaft fits through the auxiliary countershaft.
The Lightning transmission uses constant mesh helical gearing throughout. When in operation, all gears rotate together even
though a few transfer power to the driveline at any one time.
Transmission Power Flow
1 2
1. Front Section
2. Auxiliary Section
22
Transmission Power Flow
Understanding power flow can help to isolate the individual gear set when diagnosing noise or shift complaints. However, complete knowledge of truck systems benefits the technician when diagnosing either of these complaints.
The figure illustrates the transmission with the main components called out. Note specifically, the sectional view of the auxiliary
countershaft showing how the front box countershaft supports the auxiliary countershaft. Left out of the picture is the clutch
housing. The clutch housing pilots into the transmission case with dowel pins and supports the transmission’s front section
gearing and input shaft.
11
12
12
10
9
8
7
6
3
Component Nomenclature and Auxiliary Countershaft Sectional View
1. Input Shaft
2. Main Drive Gear
3. Front Section Countershaft
4. Auxiliary Countershaft
5. Shaft Splined For PTO
6. Synchronizer Assembly
23
7. Output Shaft (Auxiliary Mainshaft)
8. Auxiliary Splitter Gear (Auxiliary Mainshaft)
9. Auxiliary Drive Gear
10. Auxiliary Countershaft Support Bearings
11. Sliding Clutches
12. Countershaft Drive Gear
13. Reverse Gear
13
5
4
Transmission Power Flow
Power Flow by Gear
Note: The heavy lines in all figures represent the power flow path.
All the gearing in the transmission is constantly rotating because the transmission uses constant mesh gearing. However, only
the engaged gears have power (torque) transmitted across the gear set. Sliding clutches located on the front section and auxiliary section mainshafts slide forward or rearward to engage into a selected gear. Torque comes through the gear set only after
the sliding clutch engages the gear.
a. Power (torque) from the vehicle’s engine is transferred to the transmission’s input shaft.
b. The input shaft rotates the main drive gear through internal splines in the hub of the gear.
c. The main drive gear meshes with both countershaft drive gears splitting the engine torque equally across both gears.
d. Only those gears selected by the sliding clutches have torque across them even though all gears in the transmission
turn all the time.
e. The following illustrations show the torque path in all ten (10) gears and both reverse gears.
Transmission Power Flow
Low Reverse Gear
1. Sliding Clutch Rearward
2. Splitter Clutch Rearward
3. Synchronizer in Low Range
1
1st Gear
1. Sliding Clutch Forward
2. Splitter Clutch Rearward
3. Synchronizer in Low Range
231
2
1
3
High Reverse Gear
1. Sliding Clutch Rearward
2. Splitter Clutch Forward
3. Synchronizer in Low Range
3
2
2
1
3
2nd Gear
1. Sliding Clutch Forward
2. Splitter Clutch Forward
3. Synchronizer in Low Range
24
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