Eaton Transmission FRO-16210C Service Manual

Fuller® Heavy-Duty FR/FRO Transmissions

More time on the road®

Service Manual

Fuller Heavy-Duty FR/FRO Transmissions

TRSM2400

January 2010

FR-11210B

FR-12210B

FR-13210B

FR-14210B

FR-15210B

FR-9210B

FRF-11210B

FRF-12210B

FRF-13210B

FRF-14210B

FRF-15210B

FRF-9210B

FRO-11210B

FRO-11210C

FRO-12210B

FRO-12210C

FRO-13210B

FRO-13210C

FRO-14210B

FRO-14210C FRO-15210B FRO-15210C FRO-16210B FRO-16210C FRO-17210C FRO-18210C FROF-11210B FROF-11210C FROF-12210B FROF-12210C FROF-13210B FROF-13210C FROF-14210B FROF-14210C FROF-15210B FROF-15210C FROF-16210B FROF-16210C

Warnings and Precautions

Warnings and Precautions

! WARNING

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

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

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

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

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

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

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

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

WARNING

Failure to follow indicated procedures creates a high risk of personal injury to the service technician.

CAUTION

Failure to follow indicated procedures may cause component damage or malfunction.

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

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

Always use genuine Eaton replacement parts.

Table of Contents

General Information
Purpose and Scope of Manual ....................................	1
Serial Tag Information and Model Nomenclature ........	5
Lubrication Specifications ...........................................	8
Oil Leak Inspection Process .......................................	10
Transmission Operation ............................................	11
Tool Specifications ....................................................	15
Torque Specifications ................................................	19
Power Flow Diagrams ...............................................	21
Air System Troubleshooting ......................................	31
General Troubleshooting Chart .................................	42
Air System Overview .................................................	45
Timing Procedures ....................................................	60

In-Vehicle Service Procedures

How to Disassemble the Roadranger Valve ...............	62
How to Assemble the Roadranger Valve ...................	64
How to Remove Compression Type Fittings ..............	66
How to Install Compression Type Fittings .................	67
How to Remove Push-To-Connect Type Fittings ......	68
How to Install Push-To-Connect Type Fittings ..........	69
How to Remove a Roadranger Valve .........................	70
How to Install a Roadranger Valve ............................	71
How to Remove the Gear Shift Lever/Remote
Shift Control .......................................................	72
How to Install the Gear Shift Lever/Remote
Shift Control .......................................................	73
How to Adjust the Remote Shift Control (LRC Type) . 74
How to Remove the Detent Spring ............................	76
How to Install the Detent Spring ...............................	77
Neutral Switch Operation and Testing .......................	78
How to Remove the Neutral Switch ...........................	79
How to Install the Neutral Switch ..............................	80
Reverse Switch Operation and Testing ......................	81
How to Remove the Reverse Switch .........................	82
How to Install the Reverse Switch .............................	83
How to Install the Shift Bar Housing .........................	84
How to Remove the Shift Bar Housing ......................	85
Ho to Remove the Oil Seal Mechanical/Magnetic
Speedometer ......................................................	86
How to Install the Oil Seal Mechanical/Magnetic
Speedometer ......................................................	88
How to Remove the Auxiliary Section in Chassis ......	90
How to Install the Auxiliary Section in Chassis ..........	92
How to Disassemble the Integral Oil Cooler ..............	96
How to Assemble the Integral Oil Cooler ...................	98
How to Remove the Air Module ................................	99
How to Install the Air Module ..................................	101

Transmission Overhaul
Procedures-Bench Service
How to Disassemble the Gear Shift Lever ................	102
How to Assemble the Gear Shift Lever ....................	104
How to Remove the Shift Bar Housing ....................	106
How to Install the Shift Bar Housing ........................	107
How to Disassemble the Shift Bar Housing .............	108
How to Disassemble the Range Cylinder .................	111
How Assemble the Range Cylinder ..........................	112
How to Assemble the Shift Bar Housing ..................	114
How to Remove the Input Shaft Assembly
(without main case disassembly) .....................	118
How to Install the Input Shaft Assembly
(without main case disassembly) .....................	120
How to Remove the Auxiliary Section ......................	122
How to Disassemble the Auxiliary Section ...............	124
How to Disassemble the Range Yoke ......................	127
How to Disassemble the Output Shaft .....................	128
How to Disassemble the Synchronizer Assembly ....	129
How to Assemble the Synchronizer Assembly .........	130
How to Remove the Clutch Housing ........................	132
How to Assemble the Output Shaft ..........................	133
How to Assemble the Range Yoke ...........................	135
How to Disassemble the Auxiliary Countershaft ......	136
How to Remove the Auxiliary Countershaft
Bearing Races ..................................................	137
How to Install the Auxiliary Countershaft
Bearing Races ..................................................	138
How to Assemble the Auxiliary Countershaft ...........	139
How to Remove the Auxiliary Drive
Gear Assembly .................................................	140
How to Disassemble the Upper and Lower
Reverse Idler Gear Assembly ............................	141
How to Remove the Upper and Lower
Countershaft Bearings ......................................	144
How to Remove the Mainshaft Assembly ................	146
How to Remove the Countershaft Assemblies .........	149
How to Disassemble the
Countershaft Assemblies ..................................	151
How to Remove the Input Shaft and
Main Drive Gear ................................................	153
How to Prepare the Main Case for Reassembly .......	155
How to Disassemble the Mainshaft Assembly .........	156
How to Assemble the Mainshaft Assembly with
Non-Selective (Non-Adjustable)
Tolerance Washers ...........................................	158
How to Install the Mainshaft Assembly ....................	161
How to Assemble the Countershaft Assemblies .......	163
How to Assemble the Lower Reverse Idler
Gear Assembly .................................................	165
How to Install Countershaft Assemblies ..................	167

Table of Contents

How to Install the Lower Countershaft Bearings .....	168
How to Install the Input Shaft and Main
Drive Gear ........................................................	170
How to Install the Input Bearing Cover ....................	172
How to Install the Upper Countershaft Bearings .....	173
How to Install the Upper Reverse Idler
Gear Assembly .................................................	175
How to Install the Auxiliary Drive Gear Assembly ....	177
How to Install the Clutch Housing ...........................	178
How to Remove the Oil Pump .................................	180
How to Install the Oil Pump ....................................	181
How to Install the Oil Seal .......................................	182
How to Assemble the Auxiliary Section ...................	183
How to Install the Auxiliary Section .........................	187
Shim Procedure without a Shim Tool for
Tapered Bearings ............................................	189

Introduction

Purpose and Scope of Manual

This manual is designed to provide information necessary to service and repair the Eaton Fuller transmissions listed on the front.

How to use this Manual

The service procedures have been divided into two sections: In-Vehicle Service Procedures and Transmission Overhaul Proce- dures—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 followed by more specific headings and the procedures. To find the information you need in these sections, first go to the section that contains the procedure you need. Then look at the heading at the top and outside edge of each page until you find the one that contains the procedure you need.

Transmission Overhaul Procedures follow the general steps for complete disassembly and then assembly of the transmission.

Note: In some instances the transmission appearance may be different from the illustrations, but the procedure is the same.

Disassemble Precautions

It is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission, the necessary linkage and vehicle air lines disconnected and the transmission has been removed from vehicle chassis. Removal of the gear shift lever housing assembly (or remote control assembly) is included in the detailed instructions (How to Remove the Gear Shift Lever). This assembly MUST be detached from the shift bar housing before the transmission can be removed.

Follow closely each procedure in the detailed instructions, make use of the text, illustrations, and photographs provided.

Assemblies

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

Bearings

•Carefully wash and lubricate all usable bearings as removed and protectively wrap until ready for use. Remove bearings planned to be reused with pullers designed for this purpose.

Cleanliness

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

Input Shaft

•The input shaft can be removed from the transmission without removing the countershafts, mainshaft, or main drive gear. Special procedures are required and provided in this manual.

Snap Rings

•Remove snap rings with pliers designed for this purpose. Snap rings removed in this manner can be reused, if they are not sprung or loose.

Introduction

1

Introduction

When Using Tools to Move Parts

•Always apply force to shafts, housings, etc., with restraint. Movement of some parts is restricted. Never apply force to driven parts after they stop solidly. The use of soft hammers, soft bars, and mauls for all disassembly work is recommended.

Inspection Precautions

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

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

Recommended inspection procedures are provided in the following checklist.

Bearings

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

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

•Replace bearings with excessive clearances.

•Check bearing fit. Bearing inner races should be tight to shaft; outer races slightly tight to slightly loose in case bore. If the bearing spins freely in the bore the case should be replaced.

Bearing Covers

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

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

Clutch Release Parts

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

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

Gears

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

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

•Check axial clearance of gears.

Gear Shift Lever Housing Assembly

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

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

2

Introduction

Gray Iron Parts

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

Oil Return Threads and Seals

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

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

O-Rings

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

Reverse Idler Gear Assemblies

•Check for excessive wear from action of roller bearings.

Shift Bar Housing Assembly

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

•Check yokes for correct alignment. Replace sprung yokes.

•If housing has been disassembled, check shift shaft and all related parts for wear.

Sliding Clutches

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

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

Splines

•Check splines on all shafts for abnormal wear. If sliding clutch gears, companion flange, or clutch hub has wear marks in the spline sides, replace the specific shaft effected.

Synchronizer Assembly

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

•Check blocker pins for excessive wear or looseness.

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

Washers

•Check surfaces of all washers. Washers scored or reduced in thickness should be replaced.

Assembly Precautions

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

Bearings

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

Introduction

3

Introduction

Capscrews

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

Gaskets

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

Initial Lubrication

•Coat all limit washers and shaft splines with Lubricant during assembly to prevent scoring and galling of such parts.

O-Rings

•Lubricate all O-rings with silicon lubricant.

Universal Joint Companion Flange or Yoke

•Pull the companion flange or yoke tightly into place with the output shaft nut, using 450-500 lb. ft. of torque. Make sure the speedometer drive gear or a replacement spacer of the same width has been installed. Failure to pull the companion flange or yoke tightly into place can result in damage to the mainshaft rear bearing.

IMPORTANT

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

4

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 the tag which is located 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!

PTO Code

Eaton Fuller

Transmissions

Model Serial

FRO-14210-C

Eaton Corporation	Made
Transmission Div
	In
Kalamazoo, MI 49003

Fig 1-1

Transmission Tag and Location

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.

F R -

1 4 2 1 0 C

Eaton Fuller Model Designation Prefix

See options below:

Prefix

Definition

Ratio Set

FR

Fuller Roadranger Twin Countershaft

Forward Speeds

FRF

w/ Forward Shift Bar Housing

FRO

w/ Overdrive

FROF

w/ Overdrive and Forward Shift Bar Housing

2 = Helical Auxilary Gearing and

"Multi-Mesh" Front Gearing

This (x) 100 = Nominal Torque Capacity

Serial Number

The serial number is the sequential identification number of the transmission. Before calling for service assistance, write the number down as it may be needed.

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®.

Designations Model

5

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 the Roadranger Help Desk at 1-800-826-HELP (4357).

Two types of shift bar housings are available for this transmission. Both are described and shown below.

Shift Bar housings

Standard: The standard shift bar housing has a gear shift lever opening that is located toward the rear of the transmission. The housing is shown in figure 1-2.

Fig 1-2

6

Model Designations

Forward Opening: The forward opening shift bar housing 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 in indicated by an “F” in the model number. The housing is shown in figure1-3.

Designations Model

Fig 1-3

Lubrication Pumps

Two types of lubrication pumps are available for use on this transmission and are described below:

PTO Driven: A PTO driven pump is externally mounted on the 6 or 8 bolt PTO openings and driven off the PTO gear.

Auxiliary Countershaft: An auxiliary countershaft pump is mounted on the rear of the transmission and driven off the auxiliary countershaft.

Power Take Off (PTO) Usage

PTO’s can be mounted in the following ways:

6 or 8 Bolt: The 6 or 8 bolt openings are standard with the transmission. The PTO is mounted to the opening and driven from the PTO gear on the front countershaft.

Thru-Shaft: The thru-shaft PTO mounts on the rear of the transmission. It requires a special auxiliary housing and main case countershaft with internal splines.

7

Lubrication

Lubrication Specifications

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

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

Note: Additives and friction modifiers must not be introduced. Never mix engine oils and gear oils in the same transmission.

IMPORTANT

Transmission filters should be changed during regular lube intervals. Inspection of the transmission filter should be conducted during preventive maintenance checks for damage or corrosion. Replace as necessary.

Buy from a reputable dealer

For a complete list of approved and reputable dealers, write to: Eaton Corporation, Worldwide Marketing Services, P.O. Box 4013, Kalamazoo, MI 49003

Transmission Operating Angles

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

Operating Temperatures with Oil Coolers

The transmission must not be operated consistently at temperatures above 250° F. Operation at temperatures above 250°F [121°C] causes loaded gear tooth temperatures to exceed 350°F [177°C] which will ultimately destroy the heat treatment of the gears. If the elevated temperature is associated with an unusual operating condition that will reoccur, a cooler should be added, or the capacity of the existing cooling system increased.

The following conditions in any combination can cause operating temperatures of over 250° F [121°C]:

•Operating consistently at slow speed.

•High ambient temperatures.

•Restricted air flow around transmission.

•Use of engine retarder.

•High horsepower operation.

Note: Transmission coolers must be used to reduce the operating temperatures when the above conditions are encountered.

Oil Cooler Chart

Table 4

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 1500 lb. ft. and above

8

Lubrication

Table 4

Transmission Oil Coolers are:

18-speed AutoShift transmissions require use of an Eaton supplied oil-to-water cooler or approved equivalent.

• With engines 450 H.P. and above.

Lubrication

9

Lubrication

Oil Leak Inspection Process

Inspect for Oil Leak

Determine if it is a Weep or a Leak

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

Leak: Extremely wet or dripping of oil in the contaminated area.

Gasket

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.

Rear Seal

1.Do not repair: Rear seal is designed to allow minimal seepage (refer to Roadranger TCSM-0912 Seal Maintance Guide).

2.Ensure lube is to proper level.

Leak

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 area. Use of a high pressure spray may force contamination into the area of concern and temporarily disrupt the leak path.

i.Clean area with a clean dry cloth or mild soluble degreaser and fill the transmission to the proper lube level.

OR

ii.Clean the area as noted above and insert tracer dye into the transmission lube and fill transmission to proper lube level.

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 inspecting for the origin of the leak(s) make sure the assumed leak area is not being contaminated by a source either forward or above the identified area such as the engine, shift tower, shift bar housing, top mounted oil cooler, etc...

Step 3

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

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.

10

Transmission Operation and Theory

Transmission Operation

Transmission Operation

This Eaton® Fuller® Roadranger® transmission model contains ten forward speeds and two and reverse speeds. The gear shift lever mechanically engages and disengages five forward gears and one reverse gear in the transmission front section. The range lever on the shift knob allows the operator to control an air shifted auxiliary section to provide a low and high “range”. The five forward gears selected in low range are used again in high range to provide the remaining 5 progressive forward gear ratios.

Once the highest shift lever position (5th gear) is obtained in low range, the operator preselects the range shift lever for high range. The range shift occurs in neutral as the shift lever is moved from 5th gear position to 6th gear position.

When downshifting, the operator preselects the range lever for low range and the range shift occurs automatically as the shift lever is moved to the next gear position. Refer to the illustrations in the “Power Flow” portion of this section.

Shift Patterns

A Shift pattern decal that explains how to properly shift the transmission should be in your vehicle. The decal is shown in Figure 2-1. If it has been lost, a replacement may be obtained from any Eaton® parts distributor.

			10
	7	9
	2	4
			1-2-3-4-5 RAISE RANGE SELECTOR
6	8	10	6-7-8-9-10
			10-9-8-7-6 MOVE RANGE SELECTOR DOWN
1	3	5	5-4-3-2-1

and Operation Transmission

Theory

Figure 2-1 Shift Pattern Decal

11

Transmission Operation and Theory

Operating Instructions

Initial Start - Up

WARNING

Before starting a vehicle always be seated in the driver’s seat, move the shift lever to neutral, and set the parking brakes.

CAUTION

Before moving a vehicle, make sure you understand the shift pattern configuration.

1.Make sure the shift lever is in neutral and the parking brakes are set.

2.Turn on the key switch, and start the engine.

3.Allow the vehicle air pressure to build to the correct level. Refer to your “Operator and Service Manual” supplied with the truck.

4.Apply the service brakes.

5.Release the parking brakes on the vehicle.

6.Make sure the Range Selector is down in the low range position as shown below in Figure 2-2.

Figure 2-2

7.Depress the clutch pedal to the floor.

8.Move the shift lever to the desired initial gear.

9.Slowly release the clutch pedal and apply the accelerator.

12

Transmission Operation and Theory

Upshifting

CAUTION: Never move the Range Selector with the shift lever in neutral while the vehicle is moving.

1.Move the shift lever, double-clutching, to the next desired gear position in low range.

Range shift - low to high Range (5th to 6th)

2.When in last gear position for low range and ready for the next upshift, pull up the Range Selector and move the shift lever, double-clutching, to the next higher speed position according to your shift pattern. As the shift lever passes through neutral, the transmission will automatically shift from low to high range.

Note: If after attempting a range shift to high, the transmission remains in neutral with the shift lever in gear, the range synchronizer protection device may deactivated. Move the shift lever into neutral to allow the range shift to complete, and then move the shift lever back into gear.

3.Continue upshifting, double-clutching, to the next desired gear position in high range

Downshifting

1.Move the shift lever, double-clutching, to the next desired gear position in high range

Range shift from High Range to Low Range (6th to 5th)

2.While in 6th and ready for the next downshift, preselect low range, and push the Range Selector down.

3.Move the shift lever, double-clutching, to the next desired gear position in low range. As the shift lever passes through neutral, the transmission automatically shifts from high range to low range.

4.Continue downshifting, double-clutching, to the next desired gear position in low range

Double - Clutching Procedure

1.Depress the pedal to disengage the clutch.

2.Move the shift lever to neutral.

3.Release the pedal to engage the clutch.*

a.Upshifts-decelerate engine until engine RPM and road speed match.

b.Downshifts-accelerate engine until engine RPM and road speed match.

4.Quickly depress the pedal to disengage the clutch and move the shift lever to the next gear speed position.

5.Release the pedal to engage the clutch.

Note: * By engaging the clutch with the shift lever in the neutral position, the operator is able to control the mainshaft gear RPM since it is regulated by engine RPM. This procedure allows the operator to speed up or slow down the mainshaft gearing to properly match the desired gear speed and output shaft speed.

and Operation Transmission

Theory

13

Transmission Operation and Theory

Additional Operating Information

Preselect

IMPORTANT: Always preselect all range shifts when upshifting or downshifting. Preselection requires that the Range Selector is moved to the needed position before starting the lever shift.

Preselected range shifts are completed automatically as the lever is moved through neutral and into the next gear. Preselecting all range shifts prevents damage to the transmission and provides for smoother shifts.

SynchroSaver™

The transmission contains a range synchronizer protection device to prevent damage to the high range synchronizer. If the shift lever engages a front section gear prior to completion of the air shift into high range, the range synchronizer remains in neutral, preventing damage to the range synchronizer. If this neutral condition occurs, the operator must shift the lever to neutral and then back into gear to complete the range shift.

Clutch Brake (Used with pull-type clutches)

The Clutch Brake is applied by fully depressing the clutch pedal to the floor board. When applied, the brake slows down and can stop the transmission front box gearing. It is a disc-type brake incorporated into the clutch and transmission drive gear assemblies. Never use the Clutch Brake when upshifting or downshifting. Use only for initial gear engagement when the vehicle is standing still.

Countershaft Brake (Used with push-type clutches)

The control button is mounted on the shift lever just below the shift knob. To operate the brake, disengage the clutch, press down the control button, and shift into 1st or reverse. This is an air operated mechanical brake which slows down the transmission gearing by forcing a piston against the countershaft PTO gear.

Note: Never use the Countershaft Brake when upshifting or downshifting. Use only for initial gear engagement when the vehicle is standing still.

Driver Instruction Booklet

Complete operation instruction can be found in the Drive Instruction Booklet TRDR-0515.

14

Tools

Tool Specifications

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.

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 the only tools needed to successfully disassemble and reassemble any Eaton®Fuller® transmission.

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.

Table 5 General Tools

TOOL		PURPOSE
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	- 50lb. in. 3/8" drive Torque Wrench	General torquing of fasteners
0	- 30lb. in. 1/4" drive Torque Wrench	Torquing of capscrews to 7 lb. in. during auxiliary countershaft
		bearing endplay setting procedure
70 MM or 2 2/4" Socket - Standard Depth		To remove the output yoke nut
Large Brass Drift		Used to protect shafts and bearings during removal
Large Dead Blow Hammer or Maul		To provide force for shaft and bearing removal
Snap Ring Pliers - Large Standard External		To remove the snap rings at the auxiliary drive gear, input shaft
		bearing, and countershaft bearings
Feeler Gauges		To set mainshaft washer endplay and auxiliary tapered bearing
		endplay
Rolling Head (Crow's Foot) Prybar		To remove the auxiliary drive gear bearing
(2) Air Pressure Gauges 0-100 PSI (0-1034 kPa)		To troubleshoot and verify correct operation of air system
Universal Bushing Driver		To remove and install clutch housing bushings. Bushing OD =
		1.125", ID = 1.000"

Tools

15

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.

REF.	TOOL	PURPOSE	G & W TOOL	GREAT LAKES			OTC TOOL
NO.			NO.	TOOL NO.				NO.
T1	Output Yoke Puller	May be required to remove a rusted	SP-450				7075
		output yoke.
T2	Auxiliary Section Hanger	To support, or hang, the auxiliary sec-	G-40	T-125			5061
		tion in the horizontal position.
T3	Auxiliary	To hold the auxiliary countershafts in	G-250	T-311			5062
	Countershaft	position while installing the auxiliary	(can also use
	Support and Shim Tool	section in the horizontal position. Also	G-251)
		to simplify the
		checking and setting of the auxiliary
		countershaft bearing endplay.
T4	Shift Lever Spring	To install the shift tower tension	G-116	T-170
	Installation Tool	spring.
	(Tension Spring Driver)
T5	Slide Hammer	To remove the output seal and reverse	G-70 (with g-	T-150 (with T-			1155 Slide
		idler shafts. Requires 1/2"-13 threads.	247D for Rev.	151	metric		Hammer /
		(Optional, idler shaft can be driven out	Idler removal)	adapter)			8007	1/2" -13
		from front.)					Adapter
T6	Bearing Puller	To remove front section countershaft	G-246	T-2			7070A Kit
		bearings.
T7	Bearing Driver	To install front section countershaft	G-230	T-101	Kit	or
		bearings		T-120 with		T-
				120A adapter
T8	Bearing Driver	To install the front countershaft rear	G-230	T-101 Kit
		bearings
T9	Countershaft	To support and locate the front	G-54	T-132			7109
	Support Tools (2)	section countershafts during
		bearing removal and installation.
T10	Input Bearing Driver	To install input bearing on input shaft.	G-35	T-120			5066 (2" shaft)
T11	Bearing Puller	To remove the auxiliary countershaft	G-247 or				1123 / 927
		tapered bearings.	G-247A
T12	Bearing Driver	To install the auxiliary countershaft ta-	G-230	T-101 Kit
		pered bearings.
T13	Output Seal Removal Tool	To remove the output seal in					Use	27315
		chassis. Can use slide hammer.					hook with 1155
							slide hammer
* Tool numbers are referenced in the service procedures.

16

Tools

REF.	TOOL	PURPOSE	G & W TOOL		GREAT LAKES	OTC TOOL
NO.			NO.		TOOL NO.		NO.
T14	Auxiliary Section Removal	To attach transmission jack to	G-115			49611
	Adapter Plate	auxiliary section for auxiliary				(Used with OTC
		section removal in chassis.				transmission
						jack P/N 5019.)
T15	Mainshaft Hook	To assist in lifting of mainshaft from	G-225		T-165
		front section.							Tools
T16	Input Bearing Puller	To remove input bearing.	G-38		T-3	7070A Kit
T17	Bearing Race Puller	To remove the auxiliary countershaft	G-247B	(used	T-157 with	7136	puller at-
		tapered bearing outer races.	with	G-70	T-150	tached to 1155
			slide hammer)			slide hammer
T18	Bearing Race Installer	To install the auxiliary countershaft ta-	G-247C	(used	T-101 Kit	27524/27530
		pered bearing outer races.	with G-230)			discs used with
						27488 handle
						and	10020
						screw.
* Tool numbers are referenced in the service procedures.

Table 7 Shop Equipment

20 Ton capacity press	To press countershaft gears from countershaft.

Special Tools Manufacturers

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

G & W Tool Company	Great Lakes Tool	O.T.C.
907 S. Dewey Ave	8530 M-89	655 Eisenhower Dr.
Wagoner, OK 74467	Richland, MI 49083	Owatonna, MN 55060-1171
800-247-5882	800-877-9618	800-533-6127
www.gwtoolco.com	269-629-9628
	www.greatlakestools.com

17

Tools

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.

TOOL	PURPOSE	EATON PART NUMBER
5/32" Air Line Release Tool	To remove 5/32" air lines from	P/N 4301157 included in kit K-2394.
	push-to-connect fittings.
Air Line Cutting Tool	To cut plastic air lines smoothly	P/N 4301158 included in kit K-2394.
	and squarely.
Output Seal Driver	To install output seal.	For 7 series: Eaton P/N 5564501 driver.
		For 9 series: Use Eaton P/N 5564509 adapter with 5564501 driv-
		er. Both parts included in Complete Eaton Seal Kit P/N K-3651.
Output Seal Slinger Driver	To install output seal slinger.	For 7 series: Eaton P/N 71223.
		For 9 series: Eaton P/N 4303829.

18

Transmission Overhaul Procedures-Bench Service

Torque Specifications

SHIFT BLOCK TO SHIFT ROD CAPSCREW 54-61 N.m [40-45 lb.ft.]

M10x1.5 THREAD

FRONT BEARING COVER CAPSCREWS 54-61 N.m [40-45 lb.ft.]

M10x1.5 THREAD

	CLUTCH HOUSING NUTS
	ALUMINUM HOUSING
CLUTCH HOUSING STUDS	CAST IRON HOUSING	SHIFT LEVER HOUSING CAPSCREWS
	244-271 N.m [180-200 lb.ft.]
81 N.m [60 lb.ft.] MIN	M16x1.5 THREAD	54-61 N.m [40-45 lb.ft.]
M16x2 THREAD		M10x1.5 THREAD
DRIVEN UNTIL BOTTOMED
		AUX DRIVE GEAR
		BEARING RETAINER CAPSCREWS
		54-61 N.m [40-45 lb.ft.]
		M10x1.5 THREAD

OUTPUT SHAFT NUT 610-677 N.m [450-500 lb.ft.] M48x2 THREAD

USE NYLON LOCKING INSERT (OILED AT YOKE INSTALLATION)

	COUNTERSHAFT FRONT BEARING
CLUTCH HOUSING CAPSCREWS	RETAINER CAPSCREWS
	122-162 N.m [90-120 lb.ft.]
ALUMINUM HOUSING	.625-18-THREAD
CAST IRON HOUSING
97-108 N.m [72-80 lb.ft.]
M12x1.75 THREAD

Service Bench-Procedures	Overhaul Transmission

19

Transmission Overhaul Procedures-Bench Service

PIPE THREAD TORQUE SPECIFICATIONS. UNLESS OTHERWISE SPECIFIED:

PIPE THREAD SIZE	HYDRAULIC LINE SEALANT
.0625 - 27	6.8-9.5 N.m [60-84 lb.in]
.125 - 27	9.5-13.6 N.m [84-120 lb.in]
.250 - 18	20.3-27.1 N.m [180-240 lb.in]
.375 - 18	33.9-47.5 N.m [300-420 lb.in]

MASTER VALVE JAM NUT 48-61 N.m [35-45 lb.ft.]

.500-13 THREAD

RANGE COVER TO SBH

RANGE CYL CAPSCREWS 27-31 N.m [20-23 lb.ft.] M8x1.25 THREAD

AUX C'SHAFT REAR BEARING COVER CAPSCREWS 54-61 N.m [40-45 lb.ft.]

M10x1.5

AUX HOUSING CAPSCREWS 54-61 N.m [40-45 lb.ft.] M10x1.5 THREAD

OIL FILL PLUG

47-67 N.m [35-50 lb.ft.]

1.0625-12 THREAD

LARGE PTO COVER CAPSCREWS 77-88 N.m [57-65 lb.ft.] M12x1.75 THREAD

REAR BEARING COVER CAPSCREWS 54-61 N.m [40-45 lb.ft.]

M10x1.5 THREAD

SHIFT LEVER SHOULDER BOLT AND NUT 14-16 N.m [10-12 lb.ft.]

.3125-18 THREAD

SUPPORT STUDS 81 N.m [60 lb. ft.] M16x2 THREAD

DRIVE UNTIL BOTTOMED

SUPPORT STUD NUTS 230-257 N.m [170-190 lb.ft.] M16x1.5 THREAD

CAPTIVATED LIFTING EYE CAPSCREWS 54-61 N.m [40-45 lb.ft.]

M10x1.5 THREAD

HAND HOLE COVER CAPSCREWS 19-24 N.m [14-18 lb .ft.]

.3125-18 THREAD

SPEEDO SENSOR CAPSCREW 27-31 N.m [20-23 lb.ft] M8x1.25 THREAD

SMALL PTO COVER CAPSCREWS 54-61 N.m [40-45 lb.ft.] M10x1.5 THREAD

OIL DRAIN PLUG 61-74 N.m [45-55 lb.ft.]

.750 PIPE THREAD

THERMOCOUPLE PLUG 54-67 N.m [40-50 lb.ft.]

.500 PIPE THREAD

20

Power Flow

Power Flow Diagrams

An understanding of the engine’s power flow through a transmission in each particular gear will assist the technician in troubleshooting and servicing a transmission.

The Eaton Fuller Roadranger transmission can be thought of as two separate “transmissions” combined into one unit. The first “transmission” or front section contains six gear sets which are shifted with the gear shift lever. The second “transmission” called the auxiliary section, contains two gear sets and is shifted with air pressure.

Note: This transmission is referred to as a constant mesh type transmission. When in operation, all gears are turning even though only some of them are transferring power.

Figure 2-3 below shows the transmission with the main components called out. Note that the transmission is in the neutral position because the sliding clutches are all in their center positions and not engaged is any gears.

Front Section

Auxiliary Section

Auxiliary Drive Gear

Output Shaft

(Auxiliary Mainshaft)

	Auxiliary Mainshaft
Input Shaft	Reduction Gear
	Range Sliding Clutch
	Auxiliary Countershaft
Main Drive Gear	Mainshaft Gear
Sliding Clutch	Countershaft

Figure 2-3. Transmission Components Important for Understanding Power Flow

Information General

21

Power Flow

Front Section Power Flow

Note: The heavy lines in Figure 2-4 outline the power flow description below. For help in understanding the transmission components, refer to Figure 2-3.

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

2.The input shaft rotates the main drive gear through internal splines in the hub of the gear.

3.The main drive gear meshes with both countershaft driven gears and the torque is split between both countershafts.

4.Because the countershaft gears are in constant mesh with the mainshaft gears, all the front section gearing rotates. However, only the engaged mainshaft gear will have torque. External clutching teeth on the sliding clutch will engage internal clutching teeth on the selected mainshaft gear. Torque will now be provided from both opposing countershaft gears, into the engaged mainshaft gear, and through the sliding clutch to the front section mainshaft.

5.The rear of the front section mainshaft is spined into the auxiliary drive gear and torque is now delivered to the auxiliary section.

Sliding Clutch Back

Sliding Clutch Forward

Figure 2-4 Front Section Torque (1st Gear)

22

Power Flow

Front Section Power Flow - Direct gear

In direct gear (5th/10th for FR model, 4th/9th for FRO model), the front sliding clutch is moved forward and engages into the back of the main drive gear. Torque will flow from the input shaft to the main drive gear, main drive gear to sliding clutch, sliding clutch straight into the front section mainshaft which delivers the torque to the auxiliary drive gear.

Note: All countershaft and mainshaft gears will rotate, but the gears will not be loaded.

Information General

Sliding Clutch Forward

Sliding Clutch Back

Figure 2-5 5th Gear FR, 4th Gear FRO

Sliding Clutch Forward

Sliding Clutch Forward

Figure 2-6 10th Gear FR, 9th Gear FRO

23

Power Flow

Front Section Power Flow - Reverse Gear

Torque will flow from the countershafts to the reverse idler gears. Torque will then flow from the reverse idler gears to the mainshaft reverse gear. Torque will now travel through the mainshaft reverse gear, the sliding clutch in the reverse position and then to the mainshaft and auxiliary drive gear.

Note: The idler gears cause the reversal of rotation.

Sliding Clutch Back

Sliding Clutch Back

Figure 2-7 Reverse Gear - Low Range

24

Power Flow

Auxiliary Section Power Flow - Low Range

The auxiliary drive gear transfers torque to both auxiliary countershafts.

If the auxiliary section is in low range, the range sliding clutch is rearward and engaged into the auxiliary mainshaft reduction gear. Torque will flow from the auxiliary countershafts, into the auxiliary mainshaft reduction gear, through the range sliding clutch and then into the output shaft (auxiliary mainshaft).

Information General

Sliding Clutch Back

Sliding Clutch Forward

Figure 2-8 Low Range (Sliding Clutch Back)

25

Power Flow

Auxiliary Section Power Flow - High Range

If the auxillairy section is in high range, the range sliding clutch is forward and engaged into the back of the auxiliary drive gear. Torque will flow from the auxillairy drive gear to the range sliding clutch. Because the range sliding clutch has internal splines which connect to the output shaft, torque will flow straight through the auxiliary section.

Note: The auxiliary gearing will still turn, but the gears will not be loaded.

Sliding Clutch Forward

Sliding Clutch Forward

Figure 2-9 High Range Selected (Sliding Clutch Forward)

26