Page 1
Service Manual
Fuller Mid-Range Transmissions
TRSM0130
October 2007
FS-4005A
FS-4005B
FS-4005C
FS-4205A
FS-4205B
FS-4205C
FS-5005A
FS-5005B
FS-5005C
Page 2
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
Page 3
A WARNING
Before starting a vehicle always be
in
seated
transmission
the drivers seat, place the
in
neutral, set the park-
ing brakes and disengage the
Before working
transmission
ing brakes and block the wheels.
Before towing the vehicle
transmission
rear wheels off the ground or discon-
on
in
neutral, set the park-
in
neutral, and lift the
a vehicle place the
place the
clutch.
nect the
the transmission during towing.
driveline to avoid damage to
Page 4
TABLE
OF
CONTENTS
FOREWORD
MODEL DESIGNATIONS AND SPECIFICATIONS
LUBRICATION
OPERATION
POWER FLOW
TORQUE RECOMMENDATIONS
PREVENTIVE MAINTENANCE
PRECAUTIONS
DISASSEMBLY
INSPECTION
REASSEMBLY
DISASSEMBLY AND REASSEMBLY - SHIFTING CONTROLS
GEARSHIFT LEVER HOUSING ASSEMBLY
SHIFT BAR HOUSING ASSEMBLY
................................................................
..................................
...............................................................
................................................................
...............................................................
................................................
.................................................
............................................................
..............................................................
.............................................................
.......................................
..............................................
2
3
4
6
7
8
10
12
12
14
15
18
REMOVAL - YOKE AND CLUTCH HOUSING
DISASSEMBLY -TRANSMISSION
REASSEMBLY - TRANSMISSION
INSTALLATION-
INSTALLATION - SHIFTING CONTROLS
OPTIONS
..................................................................
CLUTCH HOUSING
..............................................
..............................................
...........................................
........................................
.....................................
27
29
43
57
58
59
Page 5
FOREWORD
This manual is designed to provide detailed information
necessary to service and repair the
Transmission listed
As outlined
divided into 3 main sections:
a.
Technical information and reference
b.
Removal, disassembly, reassembly, and
installation
c.
Options
The format of the manual is designed to be followed
its entirety if complete disassembly and reassembly of
the transmission is necessary. But if only one component of the transmission needs to be repaired, see the
Table of Contents for the page numbers showing that
component. For example, if you need to work
Shifting Controls, you will find instructions for removal,
on
the cover.
in
the Table of Contents, the manual
Eaton@
Fuller@
in
on
the
is
disassembly, and reassembly
for installation are
Illustrated Parts Lists, Drivers Instructions, and other
forms of product service information for these and other
Eaton Fuller Transmissions are available upon request. A Product Literature Order Form, Service
Bulletins (detailing information
ments), repair procedures, and other service-related
subjects can be obtained by writing to the following
address:
EATON CORPORATION
TRANSMISSION DIVISION
Technical Service Department
P.O. Box 4013
Kalamazoo, Michigan 49003
(616) 342-3344
on
on
page 15. Instructions
page 58. Service Manuals,
on
product improve-
Every effort has been made to ensure the accuracy of
sion Division makes no expressed or implied warranty or representation based on the enclosed information.
Any errors or omissions may be reported to Training and Publications, Eaton Transmission Division, P.O. Box 4013,
Kalamazoo, Ml 49003.
all information
2
in
this brochure. However, Eaton Transmis-
Page 6
MODEL DESIGNATIONS
AND
SPECIFICATIONS
Nomenclature:
Letter Designations
Fuller"'
Synchronized----------""""'
F
I
S-
5005A
IMPORTANT: All Eaton Fuller Transmissions are
identified by the model and serial number. This
information
cation tag and affixed to the case.
DO
NOT REMOVE OR DESTROY THE TRANSMIS-
SION IDENTIFICATION TAG.
I
is
stamped
Number
Designations
Ratio Group
Forward Speeds
Design
Level
x 100 = Nominal Torque
Capacity
on
the transmission identifi-
Specifications:
No:c
Reial
ve
Soeed
PTO
Ne.
Model
FS-5005A
FS-50058
FS-5005C
1.
Lengths measured from clutch housing face to speedo gear rear.
2.
Weights include shift bar housing, clutch housing, less tower assembly, and clutch release parts. For more
Speecs 1 st
7.52
5
5 6.82 2.15
6.82
5
2
nc
2.54
1.99
GearRat'os
3
·a
4th
2.54 1.52
2.15 1.28
1.99 1.17
5
'.1
1.00
1.00
1.00
Rf:'ver:;e
6.27
5.30
5.30
3ear:::
lnpc:
R.P.~A.
Rig
rt
Li:/t
.460 .435
.543 .515
.543 .515
information on available clutch housings, see the transmission's Illustrated Parts List or the Super Parts Book.
All weights are approximate.
3. Oil capacities are approximate, depending
with proper grade and type of
lubricant, to level of filler opening. See LUBRICATION.
on
inclination of engine and transmission. Always fill transmission,
·
_e-g111
ir.
'"1:'1)
21.9
(556.0)
21.9
(556.0)
21.9
(556.0)
~ote
2
l//eo':
Los.
:Kg)
280
(127.0)
280
(127.0}
280
(127.0)
Note
Q,I
Caoaci:y
Pi-ts
1Uersi
10.5
(5.0}
10.5
(5.0)
10.5
(5.0}
S
3
Page 7
LUBRICATION
-
Proper
Lubrication .
..
the Key to long
transmission life
Proper lubrication procedures are the key to a good allaround maintenance program.
job, or if the
procedures
oil level
in
is
ignored, all the maintenance
the world are not going to keep the
transmission running or assure
Eaton Fuller Transmissions are designed so that the
internal parts operate
in
motion of the gears and shafts.
all parts are amply lubricated if these procedures
Thus,
are
closely followed:
1.
Maintain oil level. Inspect regularly.
2. Change oil regularly.
3. Use the correct grade and type of oil.
4.
Buy from a reputable dealer.
Lubrication Change and Inspection
Eaton® Roadranger®
HIGHWAY USE
Firs'
3,000
tc
5,000
{4827
Every t 0,000
(;6090
Every
(402336
Firs~
30
Every
Every
500
Every t .:O·J
First
3.000
I
4827
to
Every
10,000
(t6090
Every
50.000
(80450)
First
3·J
Every
40
Every
500
Every
1,00C
miles
to
8045
Km!
miles
Ker)
250,000
m•les
Krr)
OFF-HIGHWAY USE
hour_;
40
hours
hours
oours
Heavy Duty Engine Lubricant or
Mineral Gear Lubricant
HIGHWAY USE
to
5,COO
riiles
8045
Krr
I
-;iles
~rr•
11
les
OFF-HIGHWAY USE
oours
1purs
rours
hoers
If
the oil is not doing its
long transmission life.
an oil circulating bath by the
CDSO
Transmission Fluid
Factory
1rn:ia
o·ai:-:.
Check
flukl
Check
::::r
iea;.;s.
Craoge
t•ans'.'1•sso1
Factory
initial
d·ain.
lnspec:
fluic
eve!.
Creek
fa•
leaks.
Criange
tra."sriission
71uic
dirt
:::onditions
trans11·ss.0°
off-h
ahway
Fac:oryiill
lubrica'lt
C1eck
tra:isr:i1ss1on
transrr:issio-;
en
new
Chee!\
lubr:cant
di~
condit:ons
off-h:ghway
where
exist.
cse."
imtial.
:or
·eal{s.
lubr•car:.
:.inits.
br
1eaks.
where
exist.
lubricant
t.se.]
severe
lr.soect
lubricaPt
c~.a:ige
transmissior.
sevee
Change
Cra1ge
(Norrra:
l'isoec:
Cha1ge
Cnange
lubricant
1
eve~.
'ransmission
(Norma:
fill
level.
llu·d.
f I
lluid
level.
Recommended Lubricants
Fahrenheit
Type
Eaton@Roadranger(<,
CDSO
Transmission
Fluid
Heavy
Duly
E.0.gine
MIL-L-21048, C or
APl-SF
(Pr9ViOJS
acceotab
M
neral
and
oxi:::a~ion
ft.Pl-GL-'.
Oi
Dor
0'
AP:-CD
API
des1gna~io1s
e1
Gear
OI'
w
'.h
rust
i'":hibitor
Grade
(SAE)
50
50
40
30
90
sew
Ambient
Temperature
All
Above
10' F (-t2'C)
Above
10"F
Below
10'F
Abo'e 1
JF i-'.2'·C)
Below
'O'F i-"2'C)
(Celsius)
(·12"C;
:-12''C)
The use of mild EP gear oil or multi-purpose gear oil
is not recommended, but
be sure to adhere to the
Do
not use mild EP gear oil or multi-purpose gear oil
ifthesegearoilsare
used,
following limitations.
when operating temperatures are above 230° F (110"
C).
Many of these gear oils, particularly 85W140,
break down above 230° F and coat seals, bearings, and
gears with deposits that can cause premature
If
these deposits are observed (especially a coating on
seal areas causing oil leakage), change
Roadranger
gine
oil, or mineral gear oil to assure maximum compo-
nent
life and to maintain your warranty with Eaton.
CD50 transmission fluid, heavy duty en-
failures.
to
Eaton
(Also see "Operating Temperatures".)
Additives and friction modifiers are not recommended
in
for use
Eaton Fuller Transmissions.
Proper Oil Level
Proper Oil Level
Make sure oil is level with the filler opening. Because you
can reach
proper
of
oil.)
oil with your finger does not mean oil is at
level. (One inch of oil level is about one gallon
Draining Oil
Drain transmission while oil is warm. To drain oil remove
the drain
plug at case bottom. Clean the drain plug
before re-installing.
Refilling
Clean case around filler plug and remove plug from case
side.
Fill the transmission to the level of the filler opening.
If
the transmission has two filler openings, fill to the level
of both openings.
The exact amount of
inclination and model. Do not over
be forced out of the case through the front bearing cover.
When adding
oil, types and brands of oil should not
be mixed because of
oil depends on the transmission
fill-this
causes oil to
possible incompatibility.
4
Page 8
LUBRICATION
Operating Temperatures
-With
Eaton Roadranger
CDSO
Transmission Fluid
Heavy Duty Engine Oil
and Mineral Oil
The transmission should not be operated consistently
at temperatures above
intermittent operating temperatures to
do not harm the transmission. Operating temperatures
above
and shorten its effective
ating temperature
can require more frequent
cooling.
The following conditions
operating temperatures of over
consistently at
tures,
exhaust system too close to transmission,
horsepower, overdrive operation.
External oil coolers are available to reduce operating
temperatures when the above conditions are encountered.
Transmission
250° F increase the lubricant's oxidation rate
slow speeds,
(3)
restricted air flow around transmission,
Oil
250° F (120° C}. However,
300° F (149°
life. When the average oper-
is
above 250°
in
any combination can cause
Coolers
F,
the transmission
oil changes or external
250°
F:
(2)
high ambient tempera-
are:
(1
)operating
(5)
C}
(4)
high
Proper Lubrication Levels
as Related
Operating
If the transmission operating angle
degrees, improper
ing angle
chassis
degrees).
The chart below
on
which the transmission can be used with various
chassis mounting
4 degree transmission mounting angle, then 8 degrees
(or 14 percent of grade)
degrees.
transmission can be operated on a 12 degree
percent} grade.
Anytime the transmission operating angle or 12 degrees
is
transmission should
cooler kit to insure proper lubrication.
Note
on
safe operating angles.
below the filler plug hole reduces the degree of grade
by approximately 3 degrees (5.5 percent}.
to
Transmission
Angles
is
more than 12
lubrication can occur. The operat-
is
the transmission mounting angle
plus the percent of upgrade (expressed
illustrates the safe percent of upgrade
angles. For example: if you have a
is
equal to the limit of 12
If you have a 0 degree mounting angle, the
exceeded for
the chart the effect
an
extended period of time the
be
equpped with
low
Allowing the oil level to fall 1 /2"
an
oil
levels can have on
oil
pump or
in
the
in
(21
Recommended
-With
Required
-With
-With
-With
With
Mild
EP
recommended when lubricant operating temperatures
are above
coolers are not recommended with these gear oils
since the oil cooler materials can
gear
oils. The
restriction
success
engines of 350 H.P. and above with
overdrive transmissions
engines 399 H.P. and above with over
drive transmissions and GCW's over
90,000 lbs.
engines 399 H.P. and above and 1400
lbs-ft
or greater torque
engines 450 H.P. and above
EP
or
Multipurpose Gear Oil
gear oil and multipurpose gear oil are not
230° F (110°
lower
with
to
milder
C).
temperature
these
gear
applications.
In
addition, transmission oil
be
attacked by these
limit
and
oil
cooler
oils
generally
limit
their
Proper Lubrication Levels are Essential!
2
t---+--l--+--+--l---1---1
0 0
0 2 3 4 5
Transmission Mounting Angle
Dotted line showing "2 Quarts Low"
reference
only. Not recommended
67
is
1 8'
for
5
Page 9
OPERATION
Gear Shift Lever Pattern and
Shifting
Instructions
Follow the simple 5-speed shift pattern.
Simple progressive
shift pattern
-,
(--
R 2
I
/
"-·-1
I
-,
-,\
\,
__
..
__
)
Neutral
I
.,
I
\
,
(
4
____
_/
]
___
i
j
'
\
I
1
··--"
Adobe 0001-2/88
3
J
/
General Information
5
j
\
..
____
J
./
..
R
<__;
-
1
1 H
-
1L , 3L ·
1
\ ____ ) "·-
FS-SOOSB
2H• 4H
2L
i 4L ,
\...
I
./
Ne~tral
.,,
1(-
3H
-,i
: < _
with "soft"
fourth and 2-speed axle.
--j
,--
s
(--\
I
R
.
,;
-,I
_;
\, _ _ )
/-~\
, 1 H , 3H , ,
\,_
I 2L : 4L
\.._.)
~-
Neutral
(--
1L 3L
__/
\
___
I
2H. I 4H'
""-
-1
: -..\
(,,.-
SH
SL
_
.)
,__
-
.\
_)
·-,,
j
!
FS-5005C with "short"
fourth and 2-speed axle.
FS-5005 transmissions have five forward speeds and one reverse, and are shifted as you would shift any synchronized manual transmission, following the simple 5-speed shift pattern.
Driving Tips
• Always use the clutch when making upshifts or downshifts. Premature synchronizer failure can result from not
using the clutch.
• Always select a starting gear that provides sufficient reduction for the load and terrian.
• Never downshift at road speed too high.
• Never slam or jerk the shift lever to complete gear engagement.
• Never coast with the transmission
in
neutral and the clutch dis-engaged.
6
Page 10
POWER FLOW
The transmission must efficiently transfer the engine's power, in terms of torque, to the vehicle's rear wheels. Knowledge of whattakes
1.
Power (torque) from the engine is transferred to the input shaft and drive gear.
2.
Torque is transferred to the countershaft drive gear.
3.
Torque is delivered along the countershaft to all countershaft gears.
4.
Torque
5.
Engaged mainshaft gear internal clutching teeth transfers torque to mainshaft through synchronizer assembly.
6. Mainshaft transfers torque directly to driveshaft through rear yoke.
1.
place
in
the transmission during torque transfer is essential when troubleshooting and making repairs.
is
transferred to "engaged" mains haft gear. The cross section illustrates 1st speed gear position.
5.
3.
4.
7
Page 11
TORQUE RECOMMENDATIONS
Correct torque application is important to assure long transmission life. Over or under tightening of fasteners can
in
a loose installation and,
in
many instances, can eventually cause damage to the transmission. Use a torque wrench
obtain recommended torque ratings. Do not torque capscrews dry.
SHIFT RAIL RETAINER
9
CAPSCREWS
20-25 LBS.-FT.
3/8-16 THREAD
17
SHIFT
CAPSCREWS
20-25 LBS.-FT.
3/8-16 THREAD
BAR
HOUSING
4 FRONT BEARING
COVER CAPSCREWS
15-20 LBS.-FT.
5/16-18 THREAD
SHIFT LEVER HOUSING
4
CAPSCREWS
20-25 LBS.-FT.
3/8-16 THREAD
resul1
to
2 HAND
COVER CAPSCREWS
5 LBS.-FT.
1/4-12 THREAD
HOLE
@
4 CLUTCH HOUSING
CAPSCREWS
145-155 LBS.-FT.
5/8-16 THREAD
OUTPUT SHAFT NUT
300-350
11/4-18 THREAD
NYLON LOCKING INSERT
(OILED
INSTALLATION)
LBS.-FT.
AT
VEHICLE
WITH
Adobe 0002-2/88
8
Page 12
TORQUE
4 MAINSHAFT REAR BEARING
COVER NUTS
LBS.-FT.
60-70
1 /2-32 THREAD
USE LOCKWASHERS
RECOMMENDATIONS
14
CAPSCREWS
10-15 LBS.-FT.
3/8-16 THREADS
Adobe
0003-2/88
PTO
COVER
4 COUTNERSHAFT REAR BEARING
COVER
20-30 LBS.-FT.
3/8-16 THREAD
USE PLAIN
CAPSCREWS
FLAT
WASHERS
OIL FILL PLUG
20-25 LBS.-FT.
3/4
PIPE THREAD
2
COUNTERSHAFT REAR
NOTE:
BEARING
5-10 LBS.-FT.
1/4 THREAD
OIL DRAIN PLUG
20-25 LBS.-FT.
PIPE THREAD
3/4
APPLY
ALL
LOCTITE #262 TO THREADS OF
CAPSCREWS BEFORE INSTALLING.
CAP
SET SCREWS
9
Page 13
PREVENTIVE MAINTENANCE
10
Page 14
PREVENTIVE MAINTENANCE
Preventive Maintenance Check Chart
CHECKS WITHOUT PARTIAL
DISASSEMBLY
1.
Clutch Housing Mounting
a.
Check all capscrews of clutch housing flange
for looseness.
2.
Clutch Release Bearing (Not Shown)
a.
Remove hand hole cover and check radial
and axial clearance
b.
Check relative position of thrust surface of
release bearing with thrust sleeve
type clutches.
3.
Clutch Pedal Shaft and Bores
a.
Pry upward
b.
If excessive movement
clutch release mechanism and check bush-
ings
in
4.
Lubricant
a.
Change at specified service intervals.
b.
Use only the types and grades as recommended. See LUBRICATION.
5.
Filler and Drain Plugs
a.
Remove filler plug and check level of lubricant
at specified intervals. Tighten filler and drain
plugs securely.
6.
Capscrews and Gaskets
a.
Check all capscrews, especially those
PTO covers, front and rear bearing covers for
looseness which can cause
See TORQUE RECOMMENDATIONS.
b.
Check PTO opening and rear bearing covers
for oil leakage.
OF CHASSIS OR CAB
in
release bearing.
on
shafts to check wear.
is
found, remove
bores and wear
on
shafts.
oil
leakage.
on
push-
on
8.
Gear Shift Lever Housing Assembly
a.
Remove the gear shift lever housing assembly from transmission.
b.
Check tension spring and washer for set
and wear.
c.
Check gear shift lever bottom end for wear of
slots. Also check finger assembly for wear.
CHECKS WITH DRIVE LINE DROPPED
9.
Universal Joint Companion Flange or
Yoke Nut
a.
Check for tightness. Tighten to recom-
mended torque rating.
10. Output Shaft (Not Shown)
a.
Pry upward against output shaft
radial clearance
CHECKS WITH UNIVERSAL JOINT COMPANION
NOTE: If necessary, use solvent and shop rag to
FLANGE
clean sealing surface of companion flange or
yoke. DO NOT USE CROCUS CLOTH,
EMERY PAPER,
MATERIALS
FINISH.
11. Splines on Output Shaft (Not Shown)
a.
Check for wear from movement and chucking
action of the universal joint companion flange
or yoke.
to
check
in
mainshaft rear bearing.
OR
YOKE REMOVED
OR OTHER ABRASIVE
THAT WILL MAR SURFACE
7.
Gear Shift Lever
a.
Check for looseness and free play
ing.
If
lever is loose
Check No.
8.
in
hous-
in
housing, proceed with
12. Mainshaft Rear Bearing Cover
a.
Check
11
oil
seal for wear.
Page 15
PRECAUTIONS
Disassembly
It
is
assumed
necessary
lever housing assembly
however, this assembly must be detached from shift bar housing before transmission can
in
the detailed assembly instructions that the lubricant has been drained from the transmission, the
linkage disconnected and the transmission has been removed from vehicle chassis. Removal of the gear shift
is
included in the detailed instructions (Disassembly and Reassembly-Shifting Controls);
be
removed.
-
FOLLOW CLOSELY EACH PROCEDURE
ILLUSTRATIONS, AND PHOTOGRAPHS PROVIDED.
1.
BEARINGS-Carefully
reuseable bearings as removed and protectively
wrapped
planned to be reused with pullers designed for
this purpose.
2.
ASSEMBLIES-When
assemblies, such as the mainshaft, countershafts, and shift bar housing,
clean bench
procedure simplifies reassembly and reduces the
possibility of
3.
SNAP
designed for this purpose. Snap rings removed
in
this manner can
sprung or
until ready for use. Remove bearings
in
the same order as removed. This
losing parts.
RINGS-Remove
loose.
wash and relubricate
disassembling the various
lay all parts
snap rings with pliers
be
reused,
if
they are not
IN
THE DETAILED INSTRUCTIONS, MAKING USE OF THE TEXT,
all
on
a
Inspection
Before
determine reuse or replacement. When
to assure continued performance and extended
Since the cost of a new part
questionable part which
reuse or
application, etc.
Recommended inspection procedures are provided
reassembling the transmission, check each part carefully for abnormal or excessive wear and damage to
replacement
replacement
is
generally a small fraction of the total cost of downtime and labor, avoid reusing a
could lead to additional repairs and expense soon after reassembly. To aid
of
any transmission part, consideration should also be given to the unit's history, mileage,
is
lite from your unit.
in
the following checklist.
4.
CLEANLINESS-Provide
It
is
important that no dirt or foreign material
enters the unit during repairs. Dirt
and can damage bearings.
practice to
starting the
5.
WHEN USING TOOLS TO MOVE
Always apply force to shafts, housings, etc, with
restraint. Movement of some parts
Never
stops
mauls for
necessary, use only genuine Eaton Fuller Transmission parts
clean the outside of the unit before
planned disassembly.
apply force to the part being driven after it
solidly. The use of soft hammers, bar, and
all disassembly work
a clean place to work.
is
an
abrasive
It
is
always good
PARTS-
is
restricted.
is
recommended.
in
determining the
A.
BEARINGS
1. Wash all bearings
rollers,
and
pitted,
disassembly.
2.
Lubricate bearings that are not pitted, discolored, or spalled and check for axial and radial
clearances.
Replace
3.
Check bearing fit. Bearing inner races should
be tight to shaft; outer races slightly tight to
slightly loose
freely
and raceways for pitting, discoloration,
spalled areas. Replace bearings that are
discolored, spalled, or damaged during
bearings with excessive clearances.
in
bore, case should
in
clean solvent. Check balls,
in
case bore. If bearing spins
be
replaced.
12
B.
GEARS
1. Check gear teeth for frosting and pitting. Frost-
ing of gear teeth faces present no threat of
transmission failure.
tion of the unit, frosted gears
progress to the pitting stage.
gears with
considerable gear
reused, but gears with advanced stage pitting
should be replaced.
2.
Check for gears with clutching teeth abnormally
worn, tapered, or reduced
ing
in
these conditions.
light to moderate pitted teeth have
shifting. Replace gears found
Often
in
continued opera-
"heal" and do not
In
most cases,
life remaining and can be
in
length from clash-
in
any of
Page 16
PRECAUTIONS
Inspection
3.
Check axial clearance of gears. Where excessive clearance is found, check gear snap ring,
split washer, clutch hub, and gear hub for excessive wear.
C. SPLINES
1.
Check splines
If sliding clutch gears, companion flange, or
clutch hub have worn into the sides of the
splines, replace the specific shaft affected.
D.
WASHERS
1. Check surfaces of all washers. Washers
scored or reduced
replaced.
E.
REVERSE IDLER GEAR ASSEMBLIES
1.
Check for excessive wear from action of roller
bearings.
F.
GRAY IRON PARTS
1.
Check all gray iron parts tor cracks and breaks.
Replace or repair parts found to be damaged.
Heavy castings may be welded or brazed provided the cracks do not extend into the bearing
bores or bolting surfaces. When welding, never
place the ground so current passes through the
transmission.
(cont.)
on
all shafts for abnormal wear.
in
thickness should be
I.
GEAR SHIFT LEVER HOUSING ASSEMBLY
1.
Check spring tension
tension spring if lever moves too freely.
2.
If
housing is disassembled, check gear shift
lever bottom end and shift finger assembly for
wear. Replace both gears
J.
BEARING COVERS
1. Check covers for wear from thrust of adjacent
bearing. Replace covers damaged from thrust
of bearing outer race.
on
shift lever. Replace
if
excessively worn.
2. Check cover bores for wear. Replace those
worn oversized.
K.
OIL SEALS
1.
Check oil seal
cover.
stroyed, replace seal.
L.
SYNCHRON~ERASSEMBLY
1. Check synchronizer for burrs, uneven and
excessive wear at contact surface, and
particles.
It
in
input shaft and rear bearing
sealing action of lip has been de-
metal
2. Check blocker pins for excessive wear or loose-
ness.
G.
CLUTCH RELEASE PARTS
1. Check clutch release parts. Replace yokes
worn at cam surfaces and bearing carrier worn
at contact pads.
2. Check pedal shafts. Replace those worn at
bushing surfaces.
H.
SHIFT BAR HOUSING ASSEMBLY
1.
Check tor wear on shift yokes and finger as
sembly at pads and lever slot. Replace excessively worn parts.
2. Check yokes for correct
sprung yokes.
3.
Check lockscrews
plates. Tighten those loose.
alignment. Replace
in
yoke assembly retainer
13
3.
Check synchronizer contact surfaces on the
synchronizer cups for wear.
Page 17
PRECAUTIONS
Reassembly
-
Make sure that case interiors and housings are clean.
of the transmission during reassembly. Dirt is
Use certain precautions, as listed below, during reassembly.
1.
GASKETS-Use
transmission as it is being rebuilt. Make sure all
gaskets are installed.
can result
bearing covers.
2.
CAPSCREWS-To
loosening, use Loctite #262 thread sealant
capscrews. For recommended torque ratings,
see TORQUE RECOMMENDATIONS.
3. SHIMS-Apply a light coat of Loctite
sides
leakage.
4.
ASSEMBLY-See
detailed disassembly instructions as a guide to
reassembly.
in
of
shims before final installation to prevent
new gaskets throughout the
An
omission of any gasket
oil
leakage or misalignment of
prevent oil leakage and
the illustrations provided
an
abrasive and can damage polished surfaces of bearings and washers.
on
51
O to both
in
all
the
It
is
important that dirt and other foreign materials are kept out
5.
INITIAL LUBRICATION-Coat all thrust washers,
synchronizers, and bearings with transmission
lubricant during reassembly to prevent damage
during initial start up.
6.
AXIAL CLEARANCES-Maintain original axial
clearances for mainshaft gears.
7.
BEARINGS-Using a sleeve type driver that
contacts the bearing inner race prevents damage
to the rollers and cage.
8.
UNIVERSAL JOINT COMPANION FLANGE OR
YOKE-Pull
place with the output shaft nut, using 300-350
lbs.-ft. (407-475 Nm) of torque. Make sure the
speed ometer drive gear or a replacement spacer
has been installed. Failure to properly torque the
nut can result
bearing.
the companion flange or yoke into
in
damage to the mainshaft rear
IMPORTANT: SEE THE APPROPRIATE ILLUSTRATED PARTS LIST (SPECIFIED
ENSURE
THAT PROPER PARTS ARE USED DURING REASSEMBLY OF THE TRANSMISSION.
BY
MODEL SERIES) TO
14
Page 18
DISASSEMBLY
AND
REASSEMBLY
SHIFTING CONTROLS
Gearshift Lever Housing Assembly
LCV(RGAl=P,---
·
9---
HOUSING
~
,,...,,,,
PIN
WAS"ER~
):t-
~PRING
GAS!<H~
y
ousrcovrR
~CAPSCREVi
_PIN
"SHJFT
LEVE.A
A.
Removal and Disassembly
1. T
wn
ou1
tCMJr
bly
and
gasket from
capsctews
the
arld
shllt bar
remove
hous.ing
the
tower a5Sem-
of
Gearshift Lever Housing
2.
Remove
sorure
a
large
forongthe
a1 a lime
the shifl levergripand
assmbly
scrc·
.
wdriver
Spl'ing
In
a vise
from
to
twisi
under
with
between
the
tne
llovsing
boo1
housing
spnrig
from
bottom
lugs-
...
the
shift
lever,
up.
and
houSJng
. Dooneooi
Use
,
15
Page 19
I a
DISASSEMBLY
AND
REASSEMBLY
SHIFTING CONTROLS
Gearshift Lever Housing Assembly (cont.)
(
3. Rem
-
ovo
tho
ten&1on
spring trom
the
haualng
5.
Remov
e the
spadO
pins lrom housi
ng
bo1e
.
4,
Remove
houM'lg
tne
Remove
wasf'le(
the
and gearshtl\
boot
from
..
ver
trom
die gear 1htfl IGVlf
ttle
16
Page 20
DISASSEMBLY
AND
REASSEMBLY
SHIFTING
CONTROLS
B. Reassembly
1.
Secure
spade
1he
gearshift lever housing In a
pins in housing
bore.
of
Gearshift Lever Housing Assembly
3.
Use
vise,
Install the
under
a spMg
the
housing
driving
lugs,
tool
to
seating
Install
one
ooll
tho
at a
tension
ume
sp<ing
-
2.
POSihon
in
1ho
levor ball slot and
over
tho
ball
gearshlh lever In housing with the
ins1all
the lension spnng washer
. dlslled
side
up
spade
pins
17
4.
Remove
boot
l
nsl.all
ovEK
1he
ass9'mbty
the
gearshlJt
shrf1
lev9I
lrom
gn.p
lhe
klver
.
vise
-and
and
tnstaJI
against
lhe
tt1<I
rubbe<
housing
,
Page 21
DISASSEMBLY
SHIFTING CONTROLS
AND
REASSEMBLY
hift
Bar Housing Assembly
..
Page 22
DISASSEMBLY
AND
REASSEMBLY
SHIFTING
CONTROLS
C. Removal and Disassembly
. -
' ' I
t '
1.
Sh
11100
capscrewa.
11'\c
oate
(1rigtHI.
transmission into
and I It
the
neutral
shift bar
po81hon,
housing
and
remove
OdSklll
the
honl
of
Shift Bar Housing
3.
Rcmo11e
ors.
tile
r8$1
of
1he
capsorewS:
and
tne
two
retain
2.
Uy
MO
capecr9W$
into
.&th
h
""111>11'
speed
~onlhe,......
a.s
showo
position
and
W'trl
shh
4th·~
a
$C~Nvr
_
)'Ok.o
-·
1:111
n:itf
19
Page 23
DISASSEMBLY
AND
REASSEMBLY
SHIFTING CONTROLS
Shift
5. Remove
(Inset).
Bar
Housing Disassembly (cont.)
2nd
-3rd yoke
assembly
and lnteflock pin
7.
If
neoossary
shdt
baf'
remove
tho
front
spacer from
1st-1evetse
6.
Rernove
remove the front spaoer from 1st-reverse shift bar (ln$el).
1SJ
•toverso bar assembly II neoessary
20
8.
RQ1~\ove
shift
yoke
(1nsel).
lhe
1st·reverse
tISsembly
lock
Remove
p10
from
the
1st0reverso
Iha
1st-reverse
shift
yoke
Page 24
DISASSEMBLY
AND
REASSEMBLY
SHIFTING
CONTROLS
Shift Bar Housing Disassembly (cont.)
,
'
r
9.
Remove lhe
tst-~verae
actua1or
11. Remove
from
1he
shift bar housing
1he
revetse
plu:noer
reta.in
tng plug and
ga.Ske:t
1
O.
Remove
100
ltlrce back
trom
the
tile f
up
shltc bar
our
interlockballs.
liQht
swnch
hou-.sing
.
1ha
lhf'eedeten1 balls.
bafls, and the 1.hree springs
12.
Remove
the
reverse plunger spring.
Page 25
DISASSEMBLY
AND
REASSEMBLY
SHIFTING CONTROLS
Shift Bar Housing Disassembly (cont.)
13.
Remove
1he
reverse
p1u~er
s1op
15. II the
trom
sh1t1
bottom
yokej)OO~
yOke
01
yOke
nre tObe repl;ieed, remove worn pnd
1n.s1:ill
now
•
p.'dandbend
tabG.
over
top
and
164 I'
removed
hammer as shown
22
necess.ary
bydr1vi1"1Q
itllft
bll)Cll.S
IOCkp.n
from
and
sh
shift
yokes
f1
bar
with a punch aod
ca..,
be
Page 26
DISASSEMBLY
AND
REASSEMBLY
SHIFTING
CONTROLS
D. Reassembly
1. Pillot
1ns11.1U 1ho
tho
shift bar
rovo1so
housing
plunger.
of
on
Sh
ift Bar Housing
1tr
side
as
shOwn
ond
3.
I
nstaD
r
everse
!he 1
plunge
ev~so
ptungor
r plug 101
gaske1
1101ecommended
ancf
plug
Tighteo
tCKq1,1e
lhO
2.
-
1ns1o1
.,.
""""""
,...,...
-
~"II"'
-
r.-i
ll>d
,,,.
4. If shdt block$
yoke or
klck P'"
NOTE: II
teverse
23
b6ock
p11MOU
sh1h
or
with
1>a1
before
st
1fl
yok•
01.gnment
sly
IQl'l'IOVOd
•nstotllng
were removed ahgn sh
holo 1n the
install
both
shrl't
bar end
two
spacers on
shift
blocks
11
inaer1
1$l·
(inse-11.
Page 27
DISASSEMBLY
AND
REASSEMBLY
SHIFTING CONTROLS
Shift
s. Install
following
swrleh
oore
?OStbOn
Bar
Housing
intoOOck
bails,
deten1
seQUence; position
and instaJl
(2 ) balls
1s1-reversedetentspnngand
In
adjacent
Assembly
balls
and
~
3)
balls
in
the
cross
bore
and
(cont.)
springs in the
reverse
instal
bght
bal
l.
l 2nd·
3rd detent
cross
bore
OT
E: Salls
N
spring
and
insta
and
and
ball Position (2> balls
ll
4th~51h
SJ)llngs
can
deten1
be
used
ui
adjacent
spnr.g
and
ball
lnterohangeabl)'
.
6.
Seal
over
the
1he
actuator
1st
rQVQrse
pll/01
actuatOf
ptn, as
In
the sh1h bar
shown
housing
,
7.
POStbon
housing
assembly
tst·reverse yoke assembly in dle shift
(inset) Install
.
the
1st-reverse
lock pin
in
the
bar
yoke
Page 28
DISASSEMBLY
AND
REASSEMBLY
SHIFTING
Shift
8.
sembty
NOTE:
Bar Housing Assembly (cont.)
Position
151-tev~rse
as
shown.
Position
bat
spacQrs
CONTROLS
assambfy
as
shOwn
in
mo
hous.ng
as·
-
--
1 O.
Position
assembly
-
as
1he
4th· 5th
shown
yoke
assembly
.
in
lhe
hovslng
9.
ln!lalt
POSlbon
bly
as
shown
the
the
2nd·3rct
2nd-3rd
yoke
yoke
assembly
assembly
interlock
ln
the
housing
pin
(1ose1~
ass.em·
.
'
11.
Place
retaine
e.apsaews
as&&mbfy
rs
atld
lhe still!
lhe tout
10100
into 4tll
yokes
an
oou11at
capscrews
recommenced
speed
pos111on
and
Install
as
sllO•llfl
tOtQUB. Shih
.
the
Tigh1on
4th· Sth
1
wo
the
yoke
Page 29
DISASSEMBLY
AND
REASSEMBLY
SHIFTING CONTROLS
Shift Bar Housing Assembly (cont. )
12.
lns1au lhe
capsc1&w1
remaln1ng
10 1
ooommcnded 1orque
rwo
capscrews
nnd
tight
en
Page 30
REMOVAL - YOKE
AND
CLUTCH HOUSING
Yoke and Clutch Housing
....
,,.;_
~
kA~fl
!Of:
0
COVE-A
A.
Removal
1.
Lock
1he
as
Shown
rc1a!n
ng
nul
of
11ansrn.r.s1on
(111&00
.
from
by
Use
a latge
lhe output
Yoke
oogaglng
b<oakCf
shaft
••
~
lwo
mi\lnMnl1geat&
bar
10
tutn
1.0C
~A
1he
w
:z.
Removo
!he
yoko
from
1he
output
shalt.
v
Page 31
REMOVAL - YOKE
AND
CLUTCH HOUSING
B. Removal
1.
Remove
lhe
four
retaining
of
the
bOlts
as
Clutch
sh<>wn.
Housing
2 • .kir
clutch
houslng
transmission
case.
\\/Ith a rubber
mal'6l
and
pul1
lrom
the
28
Page 32
DISASSEMBLY - TRANSMISSION
Input Shatt Assembly
INPUT
SHArT
ANO
DRJVE
BeAfl:lNGCUP
GEAR
A. Removal & Disassembly
1. Remove ltle four capscrews trom lhe front bearing
oover
a.nd
remove
oovershlms
necessary
can
come
remove
1he
cover and
oft
the
oi1
\Vlth
seal
shims
1he
from
The
tront beanng
front bean.ng cover. If
the
cover (inset) .
of
Input Shaft Assembly
2.
Remove
..
..,
I.he
input shaft assembly
from
the
transmls·
29
Page 33
DISASSEMBLY - TRANSMISSION
Input Shaft Disassembly (cont.)
3. It
nectSSatY.
beaung
rtltntion
remDVe
ring
me
ratan!Joo
snap
r.ng
Mel
the
5. use a
Ins.tall
beanng
...,.,.
shalt.
c:hisef
puster
lO
remove
anct
the
remoye
beamg
the
bearing
cage
and rollers
race
lrom N
4,
It
ma.n
neoeuary
drive gear
temove
bearing
the
1.a
poc:f(et
roller
bearings
tron1
tna
30
Page 34
DISASSEMBLY - TRANSMISSION
Malnshaft Assembly
c
tH
!>I
H
ASS£t.•Bl..V
S:YNCl~llfl1
'IMAIA:l
'""""""'"'"'
"""
•ARI~~
'>..
'-...
~ru-
OfAA
...
o
,
~
I
......
"\
ASHER
c..
COii<
"'"""'
....
B. Removal and Disassembly
1. Rffmovt the toor rcta1ntng nuts and
remove
Oii
i;.1181
the
lrom
'9at
covet
beardlQ
("5e!J
rove.-
It
kx:kw~hers
R808INI')'.
t8"T10Y91he
and
of
31
Ma
2.
Remove
tron1
ol
abou! 1
a>d
locoong
inshaft
speedon'lelerdrNe gear
Ille
main
Iha~
10
4"
UM
pry bwa
"""'mg
,,_.
U'8
to
t8"nCri9 lh&
(inset).
ma.nsha~
rear
Tap on
,..._d
beanng
1ne
a.,
Page 35
DISASSEMBLY - TRANSMISSION
Mainshaft Disassembly {cont.)
3.
Wrap
a
S'l1ng
Use a hotst
to
transmtSslon
or
remove
case
rope
around
the
mainsllaft
the
2nd-3
assembly
rd
S)'OChronlzer
from
the
S.
Remove
the
throst
bearing
and
bearing
race.
4. Install
soh
)aws or
51h
speed
the
malnshaft assembly in a vise equipped mlh
wood
,
shah
lronl
synchronizer
and
facing up.
wps.
Remove
!ht!
4th-
32
6.
RemO\l'e 41h-51h
speed
clutch
hub
.
Page 36
DISASSEMBLY - TRANSMISSION
Mainsha
tt Disassembly (cont.)
-
7.
Remove the
4th
spaoo
geaf
9. Rem
ove
3rd speed gear
reta
ini
ng
snap ring.
a. Rem
ove
4ltl
geru
beari
ng
10. A
en1ove
locating ball.
31d speed
gea
1 1hrusl wasllor.
Remo
ve the
Page 37
DISASSEMBLY - TRANSMISSION
Mainshaft Disassembly (cont.)
1
1.
Remove
1he
lid
speQd
g.ear
1
3.
!lizer
Remove
assembly
lhe
,
3rd
gear synchronizer cup and
synehrO
·
12. Remove
the
3rd
gear
beanng
.
14. Reposition
ma.inshalt
In Lhevlse
so
reat beating is
up
Page 38
DISASSEMBLY - TRANSMISSION
Malnshafl Disassembly (cont.)
15
U8'llg • g90r
bW"ll•"-'
ouller.
remove
lhl"'""""""
,..,
17.
RemoYethelll-ip14washer
18
.
Remov&
beanng
rOllors
thO
1
S.I
..-lho
gea1
,.,
Use cavtjon
gear(.,...).
so
n01
10
IDM
Page 39
DISASSEMBLY - TRANSMISSION
Malnshaft Disassembly (cont.)
19.
Remove
1.he
beanng rollers and spacers.
21
. Remove the 1si-1everse sliding cl
u1ch
20. Remove 1s1-
reverse
sluf1
hvbsnap
ring
. 22. R
36
emove
dte
shih hub.
Page 40
DISASSEMBLY - TRANSMISSION
Mainshaft Disassembly (cont.)
23. Remove
the
reverse
gear
25. Remove
2nd gear split washer retainer ring
24
. Rem
ove
the r
BWrSe
gear beanng
37
26. R
jmse1)
emove
lh&
2nd
gear
spl I washer
and
locaung
bail
Page 41
DISASSEMBLY - TRANSMISSION
Mainshaft Disassembly (cont.)
27.
-.
2l'ld
speed
gear
311
Page 42
DISASSEMBLY - TRANSMISSION
ountershaft Assembly
. -
Reverse
CUI
ISJn t111
Idler Assembly
o..EACE.AR
C.
Removal and Disassembly
Idler
1.
Romovt the lour
i.aring
oover
and
gaskel
cac:iwews
and
Lhe
coun
lerthah
rear
of
Countershaft and Reverse
2.
Remove
beanng
NOTE
beanng
:
the 1wo
reta
nor oul
Countllrsl\llft
bolt
t-r
may
RO
I
race.
screws
and
shims
i.hde
to
(1fls&1}.
the
rear
Remove
aoo
ou1
oi
1he
mo
Page 43
DISASSEMBLY - TRANSMISSION
5.
3.
Movo
from
the
the
transmission
coun1ershatt
case
asse
.
mbly to
the
rear
~nd
1111 ti
Using a wedge bar,
remove
the
roverse idler
shaft
.
4.
Remove
retainer
1ho
<averse
l~r
r
etain
ing
capscrew
and
the
6.
Remove
thrust washers.
•o
the tevers&
Idiot
bearings.
spacer.
and
Page 44
DISASSEMBLY - TRANSMISSION
7. It
dnve
and
the
countofShah
ltl&
bofe
dr1ve
1he
plug
race
tront
through
to
the
reartoWard
bearing
the
#ron1
raoe
is
to
of
the
the
case's insrde.
be
replaced
transmlsslson
9.
ring
U$9
a screwdriver
out
ot
snap
and
snap ring pilers to move the snap
rlng
groove and against Iha beanng back.
•
8.
Position gear
shah
bearing
pulAer
and
and
remove
c1a1opb&h1nd
the
beanng.
tho
<ear
coun1er
10.
Use
the
·
then
f)fess
countershaft.
countershaft
the drive
gear,
dove
gear
snap ring
rear
and
face
as a base
bearing
from
,
1he
Page 45
DISASSEMBLY - TRANSMISSION
Countershaft and Reverse
Idler
Disassembly (cont.)
13. Remove 4th
gear
key
ltom
lhe
c:ouotlfl'Shah
12. Remove
eoun1l'!rshatt
.ttli gear
Page 46
REASSEMBLY - TRANSMISSION
A. Reassembly and Installation
Idler
of
Countershaft and Reverse
1.
Install
4th
and
knyways
way toshal1 key
hub
(1ns&t1
to
stlaJt lront
611l
.
Align
Pr~
spoed
gear
key$
in
1he
41h
speed oountorshalt gear key·
4th gear on lhe
ex>OOl9f!>h_.n
countOfshafl
long
3. l
groov
nsta
e.
JI
11nap
ring 111
the
oountersha-ft
1ron1
snap
nng
.
2.
Prvs.s
...
,
S1h
speed
coomor8'latt gear on,
long
hub to stiaft
4.
H&11t
And
CAUTION,
It
PM
l>l""
1nstal11he
Do
not
heat1ne
use a
heat~
front
coun1orshafi
bu>tong
aa
the
above
source
beanno
275 F 1136
~)
Page 47
REASSEMBLY - TRANSMISSION
Reassembly Countershaft and Reverse I
dler
(cont.)
• •
•
5.
Heat
and
CAUTION
If
posstble.
lnstol11he
Do
noll1oat1he
use
a
heal
rear oountersllatt
lamp
bearing
as
the
above
sou1ce
beanng.
275"F ( 136 C).
,
7.
Use
hold
ers
ttle
grease
In
place
In
housing
rea
r
on
. Insta
groove
the
two
ll
reverse
.
w.th
reverse
the
ldJer
idlergearwtfh
small
reverse
thrust
tangs
washers
of wasti·
idler
gear
to
to
6.
UpreVtOusly
front
bearing race {
plug Coat
#510
befo
re
removed,
from
1he
outer diame1er
install
ing,
1nstall
inside of
the
snapnng, oountershaft
case)
and lronl
of
bore plug with loctita
casa
bore
8.
tnsen
1he
gQarneectie
capscrew
lines
1he
(Inset). Make
t1p
wrlh the
tacommended
revtuse
bearings
capsc1ew
1orqua
Idler
lnsi.all
su1e
shaft
through
the
reverse
Ille Idiot shall locking groove
hole.
1he
Tlgtiten
case
and
tdlerretrunOf
100
capsctew
.
Idler
and
to
Page 48
REASSEMBLY - TRANSMISSION
Reassembly Countershaft and Reverse Idler (cont.)
I.
Caretuly lower the counierihafl into the
....
11:31'1$.mission
11.
klstal h
~case
count~'!
asshcM't'I
rear beanng race .n10 the
10.
Pos1t100
PMtllon ttle
.....
100
1raM.m1sa1on
coun1eralio
case
oo
lt
assembly ln10 the
end
front
•
RI
l:M!ating
shown.
t 2.
Teimporanly
(inset)
recomn1ended
lns1at11he
inS:tall
new Shim
reta11"101
lol'QU(j
and I
M'ltO
the beanng
oghtenthe
rat.1
no1
set sorewtto the
Page 49
REASSEMBLY - TRANSMISSION
Reassembly Countershaft
13.
Rota1e
Position
with
be
set
end
NOTE: Once
apply a light coat ot LoctilB #510
and
Coat
recommended
1hecounte1shatt
the
dial
1t1dicator
a
screwdfrl/ertomeasuro
aJ
.00
2-.0
08
(0.05·0.20
play
and
1emove
end play Is cotrecl
the
tataln9f lace
setscrewt~eads
torque
to
as
stllms lor loss
w
1th
Loc11
.
seat
tho
bearings
sOOwn
. lilt
tho.end
mm)
ptny
Add
end
remove
to
each side
1e #262and tighten
and
Reverse Idler (cont.)
and
1aces
the
countershaft
End
play
must
shims
play
the
tor
more
retainet and
of
tho
shims
to
the
1
4.
Install Ille
Coatcapscrewthreads wtlh Loeltle #262 and bghten
recommended
oountersha.ft
torque
.
1earbaa11ng
covoc
and
gas1<e1
co
tho
Page 50
REASSEMBLY - TRANSMISSION
8.
Reassembly and Installation
of
Mainshaft
1
1ns1all
1ht
t:wat1>1W'l
- 2nd
main!ihattreatfacing~
maJO&ha'I
&pOed
9""r bOanng
in a v«Se
eq1J•ppeid
w
1h
wooa
Lubnc:a11tandlnstal
Of
3.
1he
tnsian
loc:allflg ball (lnsu
spin
nngs
JO"
..
Ille
t1and2nc:f
1ocallng
bal
gear
splr1
washer
50
4.
'f'lS.lall
2nd gear aplll
was.hQr
riilaine< nng
Page 51
REASSEMBLY - TRANSMISSION
Reassembly
of
Mainshaft (cont.)
$.
Install
m;:unshalt
nwef'Se
gear
bearing.
7.
Instal
l mwnshaft
1st-reverse
speed clutch
hub.
6.
lnsiau
malnshaft
reverse
gear
••
8. lnstatl
1s1.;eve
rse gear
slidlng
Clutch
Page 52
REASSEMBLY - TRANSMISSION
10. Coatlhiem.,1nlh.l"'
grease
Shah
cM
around
spacOf
beat'll'IQS
44
tNI
1>ear1nos
the
ring
lay
a
ttM
l"lfledle
bean
lay a sec:ond
ma1os.haf'I
ovtK
~
11'\e
11
tt11tall
beat!nQt
calCh
d'l8
111@9ar~tlOnWlUlaf\lghqualrty
l"llKKIB
ns
on
l
baannos
Place a spacer
row ol
top
o1
tNi
op
ol
the
second
around
nng
44
noecfle
spacer
row
over
ring
die
ma1n-
the
beanngs
l
nstatr
of
needle
1op
a
12. ln•t<u O loc0"'1g ball
spoed
10Cf"11
ge;11
ng bad
tnainlhafl 1
wlli
<';ICl"'CJ
~roller beantlQ$
llJl•I
&1
gaar-
-
0<1
washef. so
ovet
!tie mainshofl. Install I
1he
-..
the
SQI•
two
rows
Be
ca'llflJI
nngs Jon
ol
nee<le
"°'
at
10
st
lhe
49
Page 53
REASSEMBLY - TRANSMISSION
Reassembly
of
Mainshaft (cont.)
1
3.
tns1an
lhespli1
washer retainer
1lng
Dvef
lhe
spl
1
rings.
15.
Reposition
malnshaft 3rd
mainshal1
speed
gear
in vise so
synch.tonizer
rronl Is up. Install !he
assel'nbly
.
14.
as
r>hcr.vn
Using
a bearing
.
dmrer.
inslaU
mainshaf1
rear beari
ng
50
16. Install
assho·Nn
Ul&mrunshaft
3rd
speed
gear
syndl
ron12er cup
Page 54
REASSEMBLY - TRANSMISSION
Reassembly
of
Malnshalt (cont.)
t
7.
lnstaD
mrunshott
3rd
gpeed
gear
boar.no
.
1
9.
lns1oll
locating ball and 3ttl epeed gear
ttuus1
wo:.110!'
1
r
l'.
~
,'
..
,
'll!!ll
...,.,
-
<IC;.
..
• . -
.
18. lnsiall maJnshaft
OOvm
31d
$pOOd
gear
ciutcl'wng
100th
tac:lng
SI
20.
tn$1')11mainshah3rd
tt\13
'IMP
ring
groove.
, ,
speed
oear
reuun1ng
Stl8'1nng1n
Page 55
REASSEMBLY - TRANSMISSION
Reassembly
of
Malnshaft (
cont
.)
22. Install malnthaf'I
up
41'1
~&edgoar.
clutching teetn f
acing
24
. Install
shilti
lhru.&t
.c1h-51t1
clu1ch
bearing and
hub
boar1ng
race
on
the
main·
Page 56
REASSEMBLY - TRANSMISSION
Reassembly
of
Mainshaft (cont.)
25.
lns1al'
ma1111shett
4th-5th
4th-5th ciJtCh
speed
syncllfonlzer
hub
end
cups over
1ne
27. II previousty
main drivegeai
mg
and
retenlOl
•
l>gh
quality-
removlil'd
beanng
nng
,
ln&:talt
poc:kal
(
tntot
1'1
lnslall ttie
f,
11.bncaJe
rollerbeafing!.
retenUOtl
sne
beanngs w
in
11'11
lf"l8')
tr'I
26.
Remove
or
rope
the
n1runshnft
!he
around
mainshati
2nd-3ld
synchron1zor.
assembly
from
lh8
in
tranam11slon
w::e
Use
aod
a
hOtSI
case
V'l'ra?
to iflsta•
a
sfi1ig
28..
Hl:!at
tf'le
mput
sriafl beanng
lh•
W1put
stiatL
CAUTION: Oonol nombconngobove 275 F(136
ponlble use a heat
53
lomp
o.s
1he
ancf
inSlal
source-
the
beanrig on
C)
II
Page 57
REASSEMBLY - TRANSMISSION
Installation of Mainshaft (cont.)
31.
Insta
ll
29.
Install
dnve gear
c
up.
the
Input shatl by
with
tee
aligning
th
Jn mainshaft 5th speed synchronl2et
clutching
teeth
on
sctows.
beat the
and lighten 10
NO
TE:
Input shafl
The
f
ront bearing
top
.
Apply
rooom
Bearing
LoctiteD262.tothreads
cover~
bearing
mended torque.
oover
cover lubricat
marked
lor
gaske1, and
ion
oil
groove must
ol
capscsrews
ptopec insta
<:ap·
lla1fo
n
••
ll
30. Coal lhe outer diameter of the input
covar oil seal v.·
fro
nt
be.anng
the input
proper beruing dflver.
ith
coveJ
bearing
Loc1ite
wilh a
race
in
#S10
. I
bearing
the
front
nstall
the
driver as
bearing cover with
shati
oil
seal
shown
be.anng
on the
. l
ns1ell
the
32. Inst.alt the
oulpul shaft
spoo®mete< d
rlvo
gear
or
rotor on
the
54
Page 58
REASSEMBLY - TRANSMISSION
Installa
3
3.
rns1an
Olltpul shaft
tion
1he
main
bearlng
of
Malnshaft (cont.)
shal1
1ear
outer
llEWtng
bore.
'
·~
taco
1n
1119
35. Coal both sides
with
Loctite
bearing
lutxlcatton
N
OTE:
#510, and
cover Install
on
groove
Roar
bflaring cover tS marked
uon
of
a
posffion
the
w!lh
nevi
rear beanng
rear
bearing
case
hole
1he
gasket
oover. position
.
IOI
oover
~ske
on
the
rear
the
proper inslalla·
l
34.
II
a new
driver. Coat the oil
od
seal
1n
iS
required,
seal
ouLor
dt.ameter
Install
with Lociite
using e
llanged
#51
O.
36.
ol
totque. Using
oons,
the
urementsa11d
1
hickn&ss
$hims
above
in$1all
lour
me.nded
55
Tigh1.en
transmlSSiOn
ca1ainmg
the
record
the gap
10
start the end
to
equal
p1ocedure
lhe
shim
lo(que.
lroo1
add
ltlO 101
pack.
ca,pscraws.
beating
1wo
reeler
bB!wQeo
case.
Average
0.016. This
pt.ay
a1
shim
.
Remov&
Reptace
cover
capsctews
gages
at
the
the
fron1
the
two
totatg~vos
measurement Combine
pack
rneasuremen1
the ffonl beating cover
1he
lfon1
tig
ltten
capscrS\.,,S
to
capsaew
bearing
recorded
you a shim
beanng
30
cover
from
cover
10
If! ·
lbs
toca·
and
moos·
pack
1ho
the
and
and
recom·
Page 59
REASSEMBLY· TRANSMISSION
Installation
37. Pl
torqut. Rotato !ht
seal
Install
aoo
1ra
nsmission In a vertlcal
yoke
and nut. Tighten the
the
bonrings
of
Mainshaft (cont.)
posiUon
yoke
nut 10
lnpU1
and
shattstxt1
rsce.s.
mes
ineadl d r0t.1lon
.
o.s
shown
te<:ommendect
to
38.
-•cNllndcalO'as.,_.,onlhe
Pry
on
1119
C>Jtput
.,...
mainst\olrt end
012
(0 20·0.30mm) Addsllims1olhefrontboarlngoaver
more
lor
1he
and
al
oove1
OO\+&r
beanno
Ind
00t1ec1 ond
tlhlms. Coo.I bo
LOCl<le
#610. lnstotl
on
1he
cap1e11W1
oove1
llange
p&ay
play or
remove
p&ay
is
set rem
lh
s.dos
transmission
with
LOCllt
. 8"d
tighten
and
read
End
play
shims
ove
of the &lilms w
tOe
shims
case Coal
& .-262, Install
to
Ole
reoomtnllnded
1l1e
muse
for
lhe
and 1ho
c>aJ
be
less
fro
the
_
_,.,,
bet'ktlen
end
nt
boanng
l11l
hont
fron
1n
_,
to
get
ooe
play, After
cover
a hghl
ooa
boar1
ng
t bearing
1ho tronl
totque
l
Page 60
INSTALLATION - CLUTCH HOUSING
A. Installation
of
Clutch Housing
1.
Position
housing
bol1s
and tighten
the
on
u'e
1ransmission
11ansmlS&On
10
the
as
case I nstatl
1eoommended
shown. Place
1he
rour
1orqoe.
I.he
dutch
retaining
57
Page 61
INSTALLATION - SHIFTING CONTROLS
A.
Installation
of
Shift Bar Housing and Gear
Shift
Lever
1. Pince
Place
make
chrOfllt•rs
2.
capeo..,.,
ngn1en
1he
l1a
.nsm1SStOn
1ho 1h!l1 bot
sure
1hG
and
Atll>'Yloc:<!0l2!;21t>-ol_.,..
Into Ill n
10
1M
housing
shift
shchog
recomm&f'lded
lnflootral and
yak.Gs
allg.n
dutch..
bat
hous>ng
in
nO\ltral
and
wilh
correspoodlng
•'°9""*'' ...,...
~e
•nstnll
ln11au
the gaskol
on
case.
&yn-
lnolallwO
and
3. Install lhe rem[I nlng ca,pscrews and lighten to 1
recommended
4.
Coat
there"'""""capecrewsthreads...,
andWlSla.
IO<que
torqvo
TIQIMnlhocapeo-IO
~e•262
hi~
tie
Page 62
OPTIONS
REMOTE SHIFT ARM
SHIFT FINGER
Cut 727-8/87
REMOTE CONTROL HOUSING ASSEMBLY
CAPSCREW
)
BREATHER
~
Cut 728-6/87
59
Page 63
Page 64
Page 65
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
Page 66
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
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