Eaton Transmission FS-4205B Service Manual

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

For parts or service call us

Pro Gear & Transmission, Inc.

1 [phone]

[phone]

[e-mail]

906 W. Gore St.

Orlando, FL 32805

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

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

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
[phone]

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-

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

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

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

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

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

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

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

PREVENTIVE MAINTENANCE

10

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.

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

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.

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

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

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

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

,