Eaton Transmission FS-5106A, FS6206A Service Manual

Service Manual

Fuller Mid-Range Transmissions
TRSM0160

October 2007

FS-5106A
FS-6206A

For parts or service call us

Pro Gear & Transmission, Inc.

1 [phone]

[phone]

[e-mail]

906 W. Gore St.

Orlando, FL 32805

Before starting a vehicle always be
seated in the drivers seat, place the
transmission in neutral, set the park-

ing brakes and disengage the clutch.

Before working on a vehicle place the
transmission in neutral, set the park-

ing brakes and block the wheels.

Before towing the vehicle place the
transmission in neutral, and lift the

rear wheels off the ground or discon-

nect the driveline to avoid damage to
the transmission during towing.

cUT 8007k1/88

©1989 Eaton Corporation. All rights reserved.

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

REMOVAL–YOKE AN D CLUTCH HOUSING

DISASSEMBLY–TRANSMISSION

REASSEMBLY–TRANSMISSION

INSTALLATION–CLUTCH HOUSING AN D YOKE

INSTALLATION–SHIFTING CONTROLS

SHIFT BAR HOUSING ASSEMBLY
GEARSHIFT LEVER HOUSING ASSEMBLY

FOREWORD

This manual is designed to provide detailed informa­tion necessary to service and repair the Fuller@
Transmission listed on the cover.

As outlined in the Table of Contents, the manual is

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 in its entirety if complete disassembly and
reassembly of the transmission is necessary. But if

only one component of the transmission needs to be

repaired, refer to the Table of Contents for the page
numbers showing that component. For example, if

you need to work on the Shift Bar Housing, you will

find instructions for removal, disassembly and reas­sembly on page 18. Instructions for installation are
on page 53. Service Manuals, Illustrated Parts Lists,

Drivers Instructions, and other forms of product

Every effort has been made to ensure the accuracy of all information in this brochure. However, Eaton Transmission 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, PO, Box 4013, Kalamazoo, Ml 49003,

service information for these and other Fuller Trans­missions are available upon request. A Technical

Literature Order Form may be found in the back of
this manual. You may also obtain Service Bulletins,
detailing information on product improvements, re­pair procedures and other service-related subjects
by writing to the following address:

EATON CORPORATION
TRANSMISSION DIVISION
Technical Service Department

PO. Box 4013

Kalamazoo, Michigan 49003
(61 6) 342-3344

MODEL DESIGNATIONS

AND SPECIFICATIONS

IMPORTANT: All Fuller Transmissions are identi­fied by model and serial number. This information
is stamped on the transmission identification tag
and affixed to the case.
DO NOT REMOVE OR DESTROY THE TRANS­MISSION IDENTIFICATION TAG.

Specifications:

Note 1
Length

In.

(mm)

25.56
(649)

25.56
(649)

Model

FS-5106

FS-6206

No

Speeds

6

6

1st

9.01 5.271

9.01

2nd

5.271

3rd

3.250

3.250

Gear Ratios

4th 5th 6th

2.040

2.040

1.362

1.362

1.000

1.000

Reverse

8.625

8.625

Relative Speed

PTO Gear to

Input R.P.M.

Left

.522

.522

Right

522

522

See Chart Notes.

CHART NOTES:

1.

Lengths measured from face of clutch housing to center line of yoke.

2.

Weights include shift bar housing and end yoke, less clutch housing, tower assembly and clutch release

parts. For more information on available clutch housings, refer to publication FUL-140 - “Clutch Housing

Chart.” All weights are approximate.
Oil capacities are approximate, depending on inclination of engine and transmission. Always fill transmis-

3.

sion with proper grade and type of lubricant to level of filler opening. See LUBRICATION.

Note 2 Note 3
Weight

Lbs.

(Kg )

358

(162)

358

(162)

/

011 Capacity

Pints

(Liters)

(8.52)

(8.52)

LUBRICATION

Proper

Lubrication . . .
the Key to long
transmission life

Proper lubrication procedures are the key to a good all-

around maintenance program. If the oil is not doing its
job, or if the oil level is ignored, all the maintenance pro­cedures in the world are not going to keep the transmis­sion running or assure long transmission life.

internal parts operate in a bath of oil circulated by the
motion of gears and shafts.

dures are closely followed:

I

I

I

First 30 hours
Every 40 hours

I

First 30 hours Change transmission lubricant on new units.

Every 40 hours

Change the oil filter when fluid or lubricant is changed.

®

Fuller®Transmissions are designed so that the

Eaton

Thus, all parts will be amply lubricated if these proce-

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®CD50 Transmission Fluid

HIGHWAY USE—Heavy Duty and Mid-Range

First 3,000 to 5,000 miles
(4827 to 8045 Km)

Every 10,000 miles
(16090 Km)

Factory fill

Initial drain,

Check fluid level.

Check for leaks.

Heavy Duty Highway Change Interval

Every 250,000 miles
(402336 Km)

Change transmission

fluid.

Mid-Range Highway Change Interval

Every 100,000 miles (160,000 Km)

or every 3 years whichever occurs first.

Change transmission

fluld.

OFF-HIGHWAY USE

Factory fill initial drain,

Inspect fluid level. Check for leaks.

Every 500 hours Change transmission fluld where

Every 1,000 hours

severe dirt conditions exist.

Change transmission fluld

(Normal off-highway use).

Heavy Duty Engine Lubricant or

Mineral Gear Lubricant

HIGHWAY USE

First 3,000 to 5,000 miles Factory fill
(4827 to 8045 Km) initial drain.

Every 10,000 miles Inspect lubricant level.
(16090 Km)

Every 50,000 miles Change transmission
(80450 Km)

OFF-HIGHWAY USE

Inspect lubricant level. Check for leaks.

Every 500 hours

Every 1,000 hours

Change transmission lubricant where

severe dirt conditions exist.

Change transmission lubricant

(Normal off-highway use).

Check for leaks.

lubricant.

I

I

I
I

I

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Recommended Lubricants

Fahrenheit

(Celsius)

Type

Eaton®Roadranger
CD50 Transmission
Fluid

Heavy Duty Engine 011
MIL-L-2104B, C or D or

API-SF or API-CD

(Previous API deslgnations 30

acceptable)

Mineral Gear Oil with rust 90

and oxidation Inhibitor
API-GL-1

The use of mild EP gear oil or multi-purpose gear
oil is not
used, be sure to adhere to the following limitations:

oil 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 may cause premature failures.
If these deposits are observed (especially a coating on
seal areas causing oil leakage), change to Eaton Road­ranger CD50 transmission fluid, heavy duty engine oil
or mineral gear oil to assure maximum component life
and to maintain your warranty with Eaton. (Also see
“Operating Temperatures”.)

mended for use in Eaton Fuller transmissions.

recommended, but if these gear oils are

Do not use mild EP gear oil or multi-purpose gear

Additives and friction modifiers are not recom-

(SAE)

®

50 All

50

40

80W

Grade

Ambient

Temperature

Above 10°F(-12°C.)
Above 10°F(-12°C.)
Below 10°F(-12°C)

Above 10°F(-12°C)
Below 10 °F(-12°C)

Proper Oil Level

Make sure oil is level with filler opening. Because you
can reach oil with your finger does not mean oil is at
proper level. One inch of oil level is about one gallon

of oil.

Draining Oil

Drain transmission while oil is warm. To drain oil re­move the drain plug at bottom of case. Clean the drain
plug before re-installing.

Refilling

Clean case around filler plug and remove plug from
side of case. Fill transmission to the level of the filler
opening. If transmission has two filler openings, fill to
level of both openings.

The exact amount of oil will depend on the trans­mission inclination and model. Do not over fill—this
will cause oil to be forced out of the transmission.

When adding oil, types and brands of oil should not
be mixed because of possible incompatibility.

LUBRICATION

Operating Temperatures

—With Eaton

®

Roadranger

®

CD50 Transmission Fluid

Heavy Duty Engine Oil

and Mineral Oil

The transmission should not be operated con­sistently at temperatures above 250°F (120°C).

However, intermittent operating temperatures

to 300°F (149°C) will not harm the transmis-

sion. Operating temperatures above 250°F

increase the lubricant’s rate of oxidation and
shorten its effective life. When the average
operating temperature is above 250°F, the
transmission may require more frequent oil

changes or external cooling.

The following conditions in any combina­tion can cause operating temperatures of over
250°F: (1) operating consistently at slow
speeds, (2) high ambient temperatures, (3) re­stricted air flow around transmission, (4) ex­haust system too close to transmission, (5)

high horsepower, overdrive operation.

External oil coolers are available to reduce
operating temperatures when the above condi­tions are encountered.

Proper Lubrication Levels
as Related to Transmission
Installation Angles

If the transmission operating angle is more
than 12 degrees, improper lubrication can oc­cur. The operating angle is the transmission
mounting angle in the chassis plus the per­cent of upgrade (expressed in degrees).

The chart below illustrates the safe percent
of upgrade on which the transmission can be
used with various chassis mounting angles.
For example: if you have a 4 degree transmis­sion mounting angle, then 8 degrees (or 14
percent of grade) is equal to the limit of 12
degrees. If you have a O degree mounting
angle, the transmission can be operated on a
12 degree (21 percent) grade.

Anytime the transmission operating angle of
12 degrees is exceeded for an extended
period of time the transmission should be
equipped with an oil pump or cooler kit to

insure proper lubrication.

Note on the chart the effect low oil levels
can have on safe operating angles. Allowing
the oil level to fall 1/2" below the filler plug

hole reduces the degree of grade by approxi­mately 3 degrees (5.5 percent).

Proper Lubrication Levels are Essential!

Transmission Oil Coolers are:

Recommended

—

With engines of 350 H.P. and above
with overdrive transmissions

Required

—

With engines 399 H.P. and above with
overdrive transmissions and GCW’S

over 90,000 lbs.

—

With engines 399 H.P. and above and
1400 Lbs.-Ft. or greater torque

—

With engines 450 H.P. and above

—

With EP or Multipurpose Gear Oil

Mild EP gear oil and multipurpose gear oil are

not recommended when lubricant operating
temperatures are above 230°F (110°C). In addi­tion, transmission oil coolers are not recom-

mended with these gear oils since the oil
cooler materials may be attacked by these
gear oils. The lower temperature limit and oil
cooler restriction with these gear oils gener-

ally limit their success to milder applications.

Transmission Mounting Angle

Dotted line showing “2 Quarts Low” is for
reference only. Not recommended.

OPERATION

Gear Shift Lever Pattern and
Shifting Instructions

Follow the simple 6-speed shift pattern . . .

General Information

These transmissions have six forward speeds and one

reverse, and are shifted as you would shift any syn­chronized manual transmission, following the simple
6-speed shift pattern.

Driving Tips

Ž 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 will provide suffi-

cient reduction for the load and terrain.

● Never downshift at too high of a road speed.

● Never slam or jerk the shift lever to complete gear

engagement.

● Never coast with the transmission in neutral and

the clutch dis-engaged.

POWER FLOW

The transmission must efficiently transfer the engine's power, in terms of torque, to the vehicle's rear wheels.

Knowledge of what takes place in the transmission during torque transfer is essential when trouble-shooting

and making repairs becomes necessary.

1. Power (torque) from the engine is transferred to the input shaft and drive gear.

2. Torque is transferred to countershaft drive gear.

3. Torque is delivered along countershaft to all countershaft gears.

4. Torque is transferred to "engaged" mainshaft gear. The cross section illustrates 1st speed gear position.

5. Internal clutching teeth of engaged mainshaft gear transfers torque to mainshaft through synchronizer as­sembly.

6. Mainshaft transfers torque directly to driveshaft through rear yoke.

TORQUE RECOMMENDATIONS

Correct torque application is important to assure long transmission life, Over or under tightening of fasteners
can result in a loose installation and, in many instances, can eventually cause damage to the transmission. Use
a torque wrench to obtain recommended torque ratings. Do not torque capscrews dry.

TORQUE RECOMMENDATIONS

PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE CHECK CHART

CHECKS WITHOUT PARTIAL
DISASSEMBLY OF CHASSIS OR CAB

1.

Clutch Housing Mounting

Check all capscrews of clutch housing

a.

flange for looseness.

2.

Clutch Release Bearing (Not Shown)

Remove hand hole cover and check radial

a.

and axial clearance in release bearing.

b. Check relative position of thrust surface of

release bearing with thrust sleeve on push­type clutches.

3.

Clutch Pedal Shaft and Bores

Pry upward on shafts to check wear.

a.

b. If excessive movement is found, remove

clutch release mechanism and check bush­ings in bores and wear on shafts.

4.

Lubricant

Change at specified service intervals.

a.

b. Use only the types and grades as recom-

mended. See LUBRICATION.

5.

Filler and Drain Plugs

Remove filler plug and check level of lubri-

a.

cant at specified intervals. Tighten filler
and drain plugs securely.

6.

Capscrews and Gaskets

a.

Check all capscrews, especially those on

PTO covers and rear bearing covers for
looseness which would cause oil leakage.

See TORQUE RECOMMENDATIONS.

b. Check PTO opening and rear bearing cov-

ers for oil leakage due to faulty gasket.

7.

Gear Shift Lever

Check for looseness and free play in hous-

a.

ing. If lever is loose in housing, proceed
with Check No. 8.

8. Gear Shift Lever Housing Assembly

Remove the gear shift lever housing as-

a.

sembly from transmission.

b. Check tension spring and washer for set

and wear.
Check bottom end of gear shift lever for

c.

wear of slots. Also check for wear of finger
assembly.

CHECKS WITH DRIVE LINE DROPPED

9.

Universal Joint Companion Flange

or Yoke Nut

Check for tightness. Tighten to recom-

a.

mended torque.

10. Output Shaft (Not Shown)

Pry upward against output shaft to check

a.

radial clearance in mainshaft rear bearing.

CHECKS WITH UNIVERSAL JOINT
COMPANION FLANGE OR YOKE
REMOVED

NOTE: If necessary, use solvent and shop rag to

clean sealing surface of companion flange or
yoke. DO NOT USE CROCUS CLOTH, EMERY
PAPER OR OTHER ABRASIVE MATERIALS
THAT WILL MAR SURFACE 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.

Mainshaft Rear Bearing Cover

12.

a.

Check oil seal for wear.

PRECAUTIONS

Disassembly

It is assumed in the detailed assembly instructions that the lubricant has been drained from transmission, the
necessary linkage disconnected and the transmission has been removed from vehicle chassis. Removal of the
gear shift lever housing assembly is included in the detailed instructions (Disassembly and Reassembly—Shift­ing Controls); however, this assembly must be detached from shift bar housing before transmission can be re­moved.

FOLLOW CLOSELY EACH PROCEDURE IN THE DETAILED INSTRUCTIONS. MAKING USE OF THE TEXT.
ILLUSTRATIONS AND PHOTOGRAPHS PROVIDED.

1.

BEARINGS — Carefully wash and relubricate all

reusable bearings as removed and protectively

wrap until ready for use. Remove bearings

planned to be reused with pullers designed for

this purpose.

ASSEMBLIES — When disassembling the various

2.

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 reassembly and reduce the
possibility of losing parts.

3.

SNAP RINGS — Remove snap rings with pliers de-

signed for this purpose. Snap rings removed in this
manner can be reused, if they are not sprung or
loose.

4. 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 good practice to clean the
outside of the unit before starting the planned dis­assembly.

5. 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 the part being driven after it stops solidly.
The use of soft hammers, bars and mauls for all dis­assembly work is recommended.

/

Inspection

Before reassembling 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 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 initial reassembly. 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.

,

A. BEARINGS B. GEARS

1. Wash all bearings in clean solvent. Check

balls, rollers and raceways for pitting, discolor-

ation, and spalled areas. Replace bearings that
are pitted, discolored, spalled, or damaged
during disassembly.

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

Replace bearings with excessive clearances.

3. Check bearing fits. Bearing inner races should
be tight to shaft; outer races slightly tight to
slightly loose in case bore. If bearing spins
freely in bore, however, case should be re­placed.

1.

Check gear teeth for frosting and pitting.
Frosting of gear tooth faces present no threat
of transmission failure. Often in continued

operation of the unit, frosted gears will “heal”
and 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 with advanced
stage pitting should be replaced.

2.

Check for gears with clutching teeth abnor­mally worn, tapered, or reduced in length from

clashing in shifting. Replace gears found in
any of these conditions.

PRECAUTIONS

Inspection (cont’d.)

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 on all shafts for abnormal wear.

If sliding clutch gears, companion flange, or
clutch hub have worn into the sides of the
splines, replace the specific shaft affected.

D.

SPLIT WASHERS

1. Check surfaces of all washers. Washers

scored or reduced in thickness should be

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 for 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

bearing bores or bolting surfaces. When weld-

ing, however, never place the ground so as to

allow current to pass through the transmis-

sion.

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 for wear on shift yokes and finger as­sembly at pads and lever slot. Replace exces-

sively worn parts.

2.

Check yokes for correct alignment. Replace
sprung yokes.

3.

Check Iockscrews in yoke assembly retainer
plates. Tighten those found loose.

1. GEAR SHIFT LEVER HOUSING
ASSEMBLY

1. Check spring tension on shift lever. Replace

tension spring if lever moves too freely.

2. If housing is disassembled, check bottom

end of gear shift lever and shift finger as­sembly for wear. Replace both parts if exces­sively worn.

J. BEARING COVERS

1. Check covers for wear from thrust of adja-

cent bearing. Replace covers damaged from
thrust of bearing outer race.

2. Check bores of covers for wear. Replace

those worn oversize.

K. OIL SEALS

1. Check oil seal in input shaft and rear bearing

cover. If sealing action of lip has been de-

stroyed, replace seaI.

L. CLUTCHING TEETH

1. Check all shift yokes and yoke slots in slid-

ing clutches for extreme ‘wear or discolor­ation from heat.

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

M. SYNCHRONIZER ASSEMBLY

1. Check synchronizer for burrs, uneven and ex-

cessive ‘wear at contact surface, and metal
particles.

2. Check blocker pins for excessive wear or
looseness.

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

PRECAUTIONS

Reassembly

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

5.

1.

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. Install PTO and shift bar housing
gaskets dry.

2.

CAPSCREWS — TO prevent oil leakage and loosen-

ing, use Loctite 262 thread sealant on all cap­screws.
RECOMMENDATIONS.

3.

SHIMS — Apply a light coat of Loctite 510 to both

sides of shims before final installation to prevent

leakage.

4.

ASSEMBLY — Refer to the illustrations provided in

the detailed disassembly instructions as a guide
to reassembly.

For torque ratings, see TORQUE

INITIAL LUBRICATION — Coat all thrust washers,
synchronizers, and bearings with transmission lu­bricant during reassembly to prevent damage
during initial start up.

6.

END PLAY — Maintain .006 -.010 end play on coun-

tershaft and mainshaft assemblies.

7.

BEARINGS — Use of a sleeve type driver that con-

tacts the inner race of the bearing is recom­mended to prevent damage to the rollers and
cage.

8.

UNIVERSAL JOINT COMPANION FLANGE OR

YOKE — Pull the companion flange or yoke into

place with the output shaft nut, using 300-350
foot-pounds (407-475 N.m) of torque. Make sure
the speedometer drive gear or a replacement spa­cer has been installed. Failure to properly torque
the nut can result in damage to the mainshaft

rear bearing.

IMPORTANT: REFER TO THE APPROPRIATE ILLUSTRATED PARTS LIST (SPECl-

FIED BY MODEL SERIES) TO ENSURE THAT PROPER PARTS ARE
USED DURING REASSEMBLY OF THE TRANSMISSION.

DISASSEMBLY AND REASSEMBLY

SHIFTING CONTROLS

GEARSHIFT LEVER HOUSING ASSEMBLY

A. Removal and Disassembly

1. Turn out four capscrews and remove tower as­sembly and gasket from shift bar housing.

2. Remove shift lever grip and boot from shift lever,
secure assembly in vise with bottom of housing

up. Use a large screwdriver to twist between
spring and housing, forcing spring from under lugs
in housing. Do one coil at a time.

DISASSEMBLY AND REASSEMBLY

SHIFTING CONTROLS

GEARSHIFT LEVER HOUSING ASSEMBLY (con't.)

3. Remove tension spring, washer and gearshift lever
from housing.

B. Reassembly of Gearshift Lever Housing Assembly

4. Remove spade pins from bore in housing.

2. Position gearshift lever in housing with spade pins

in lever ball slot and install tension spring washer

over ball, dished side up.

16-04

16-02

1. With gearshift lever housing secured in vise as
during disassembly, install spade pins in bore of
housing.

DISASSEMBLY AND REASSEMBLY

SHIFTING CONTROLS

GEARSHIFT LEVER HOUSING ASSEMBLY (con't.)

3. Install tension spring under lugs in housing, seating
one coil at a time. Use of a spring driving tool is rec­ommended.

4. Remove assembly from vise and install rubber boot
over gearshift lever and against housing. Install shift

lever grip.

DISASSEMBLY AND REASSEMBLY
SHIFTING CONTROLS

SHIFT BAR HOUSING ASSEMBLY

Cut 6225-4/

86

Cut 6226A-586

DISASSEMBLY AND REASSEMBLY

SHIFTING CONTROLS

SHIFT BAR HOUSING ASSEMBLY (con't.)

A. Removal and Disassembly

19-01

1. Shift transmission into neutral position, turn out
capscrews, and lift shift bar housing and gasket from
case.

2. Lay shift bar housing on workbench as shown. Slide
5th-6th yoke into 5th position and remove capscrews

and retainers.

Remove reverse yoke assembly.

3.

4.

Remove 1st-2nd yoke assembly and interlock pin.

19-03

19-04

DISASSEMBLY AND REASSEMBLY

SHIFTING CONTROLS

SHIFT BAR HOUSING ASSEMBLY (con't.)

5. Remove 3rd-4th yoke assembly and interlock pin.

6.

Remove 5th-6th yoke.

NOTE: If yoke replacement is required, yoke can be
removed by driving the roll pin through the yoke
and rail. If the yoke pad inserts are to be replaced,
remove worn pad from shift fork, install new pad,
and bend tabs over top and bottom of fork.

7. Remove interlock balls, detent balls, and springs.

DISASSEMBLY AND REASSEMBLY

SHIFTING CONTROLS

SHIFT BAR HOUSING ASSEMBLY (con't.)

Cut 7226-8/86

B. Disassembly of Reverse Plunger

1. Depress reverse plunger springs and retainer as

shown. Remove snap ring and spring retainer.

I

SNAP RING AND RETAINER ARE
UNDER SPRING PRESSURE.

2. Remove reverse plunger springs.
NOTE: Some assemblies may only use two

springs.
Remove washer and plunger (inset).

DISASSEMBLY AND REASSEMBLY
SHIFTING CONTROLS

SHIFT BAR HOUSING ASSEMBLY (conÍ t.)

C. Reassembly of Reverse Plunger Assembly

1. Install plunger and washer as shown and install

22-01

reverse plunger springs (inset).

D. Reassembly of Shift Bar Housing

22-02

2. Depress reverse plunger retainer and springs and
install snap ring in groove of shift block.

Cut 7226A-8/86

1. Install interlock balls, detent balls and springs in
the following sequence; position (3) balls in the re­verse light switch bore and install reverse detent
spring and ball. Position (2) balls in adjacent cross
bore and install 1st and 2nd detent spring and

ball. Position (2) balls in adjacent cross bore and

install 3rd and 4th detent spring and ball. Position
(2) balls in adjacent cross bore and install 5th and
6th detent spring and ball.

NOTE: Balls and springs can be used interchan-

geably.

DISASSEMBLY AND REASSEMBLY
SHIFTING CONTROLS

SHIFT BAR HOUSING ASSEMBLY (conÕt.)

NOTE: All yoke assemblies must be installed in the neutral position.

2.

Position reverse yoke in housing assembly as
shown.

3. Install interlock pin in 1st-2nd yoke assembly and
position as shown.

23-02

23-03

4. Install interlock pin in 3rd-4th yoke assembly and
position as shown.

23-05

5. Position 5th-6th yoke assembly in housing as
shown.

DISASSEMBLY AND REASSEMBLY

SHIFTING CONTROLS

SHIFT BAR HOUSING ASSEMBLY (con't.)

NOTE: The shift yoke retainer capscrew holes are

not tapped on new shift bar housing. The
capscrews that are used are "thread form­ing" and can be reused if the shift bar hous­ing is replaced.

24-06

6. Position shift yokes as shown. Install front re­tainer over shift rails and install front (2) cap­screws.

NOTE: It may be necessary to support rails in
proper position while installing rail supports.

Position rear retainer over shift rails and install

8.

capscrews.

24-08

7. Position shift yokes as shown and install center

24-07

retainer and capscrews.

Slide 5th-6th shift yoke into 5th position (inset)

9.

and install remaining 2 capscrews. Return 5th-6th
yoke to neutral position. Tighten all retainer
capscrews to 20-25 Ibs.-ft. (27-34 N.m).

24-09

REMOVAL - YOKE AND CLUTCH HOUSING

A. Removal of Yoke

1. Lock the transmission by engaging two mainshaft

gears (inset). use a large breaker bar to turn the
nut from the output shaft.

2. Remove yoke from output shaft.

25-02

REMOVAL - YOKE AND CLUTCH HOUSING

B. Removal of Clutch Housing

1. Remove four retaining bolts as shown.

26-01

26-02

2. Jar clutch housing with rubber mallet and pull
from transmission case.

DISASSEMBLY

- TRANSMISSION

A. Removal & Disassembly of Input

Shaft Assembly

Cut 6392-4/86

1.

Turn out six capscrews, jar front bearing cover
with a rubber mallet and remove. If necessary re­move oil seal from cover (inset).

2. Remove input shaft assembly from transmission.

27 02

27-01

3. Using a chisel, remove bearing cage and rollers. in­stall bearing puller and remove bearing race from
input shaft.

27-03

DISASSEMBLY

B. Removal & Disassembly of Mainshaft

- TRANSMISSION

28-01

1. Turn out four retaining nuts and lockwashers. Us­ing screwdrivers in notches, remove rear bearing

cover. If necessary remove oil seal from cover (in­set)

28-02

2. Remove shims and speedometer drive gear or ro­tor.

NOTE: Shims may come off with rear bearing
cover.

DISASSEMBLY

- TRANSMISSION

3. Wrap sling around the 3rd-4th synchronizer (inset).
Use hoist to remove mainshaft assembly from case.

5. Remove snap ring from front of mainshaft front

29-05

bearing (inset). Using a puller mounted behind 5th-6th
shift hub, remove hub and bearing.

4. Install mainshaft assembly in vise equipped with soft
jaws or wood, front of shaft facing up. Remove 5th­6th speed synchronizer and cups.

29-06

6. Remove 5th gear and bearings from mainshaft.

DISASSEMBLY -

TRANSMISSION

7. Remove snap ring (inset), thrust washer, and locat­ing ball.

9. Remove 4th speed synchronizer cup and 3rd-4th

speed synchronizer

8. Remove 4th gear and bearings.

DISASSEMBLY -

TRANSMISSION

10. Remove snap ring (inset) and 3rd-4th shift hub.

12. Remove snap ring (inset), thrust washer and locat-

ing ball.

11. Remove 3rd gear and bearings from mainshaft.

13. Remove 2nd gear and bearings from mainshaft.

DISASSEMBLY

- TRANSMISSION

14. Remove 1st-2nd speed synchronizer.

16. Using a puller (inset), remove reverse gear, spacer,

and rear bearing.

32-15

15. Reposition mainshaft in vise, rear of shaft facing
up.

Remove reverse

sliding clutch.

32-17

gear bearings and reverse gear

DISASSEMBLY

- TRANSMISSION

18. Using a puller (inset) or press remove 1st gear,

clutch hub, and reverse gear bearing race from
mainshaft.

Remove first gear bearing and spacer.

19.

DISASSEMBLY

C. Removal and Disassembly of

Countershaft and Reverse Idler

- TRANSMISSION

1. Turn out four capscrews, remove countershaft rear
bearing cover and gasket.

2.

Turn out two set screws (inset). Remove bearing re­tainer, outer race, and shims (inset).

NOTE: Countershaft may slide to the rear and out

of bearing bore.

DISASSEMBLY -

TRANSMISSION

3. Using a slide hammer remove reverse idler shaft.

Remove locating ball once it is exposed (inset).

4. Remove reverse idler, bearings, spacer and thrust

washers,

5. Move countershaft assembly to the rear and lift it
from the case.

If countershaft front bearing race is to be replaced,

6.

drive bore plug through front of transmission and
drive the race to the rear toward the inside of the
case.

DISASSEMBLY -

TRANSMISSION

7. Position puller jaws behind rear countershaft
bearing and remove bearing.

9.

Remove drive gear retaining snap ring from front

of shaft.

8. Position countershaft in vise, front of shaft facing
up. Position puller jaws into notches behind front
countershaft bearing and remove bearing.

10. Use the rear face of the drive gear as a base, then
press it from the countershaft as shown. Remove

drive gear locating key from shaft (inset).

DISASSEMBLY -

TRANSMISSION

11. Using the rear face of 5th speed gear as a base,
press it from the countershaft. Remove 5th gear
key from shaft (inset).

37-13

13. Using the rear face of 3rd speed gear as a base,
press it from the countershaft.

12. Using the rear face of 4th speed gear as a base,
press it from the countershaft.

NOTE: Be sure that 5th and 6th speed gear keys
have been removed before removing 4th gear
from countershaft.

37-12

REASSEMBLY -

A. Reassembly and Installation of Countershaft and Reverse Idler

TRANSMISSION

Press 3rd gear on countershaft as shown, splined

1.

end of gear hub to front of shaft.

3. Install 5th and 6th speed gear keys on coun­tershaft (inset). Align keyway of 5th speed gear to
key on shaft. Press 5th gear on, long hub of gear
to front of shaft.

2. Press 4th speed gear on countershaft, long hub of
gear to rear of shaft.

4. Align keyway of drive gear to key on countershaft.
Press drive gear on, long hub of gear to rear of
shaft.

REASSEMBLY

- TRANSMISSION

5. Install snap ring in groove at front of coun-

tershaft.

7. Install rear countershaft bearing as shown.

8. If previously removed, install snap ring, coun-

tershaft front bearing race (from inside of case)
and bore plug. Coat outer diameter of bore plug
with Loctite #510 before installing.

6. Install front countershaft bearing as shown.

REASSEMBLY -

9. Carefully lower countershaft into case.

TRANSMISSION

40.09

10. Turn transmission
tion countershaft

race.

40-11

11. Use grease on reverse idler thrust washers to

hold in place. Position tangs of washers in

groove of housing.

case on end as shown. Posi­assembly into front bearing

REASSEMBLY -

TRANSMISSION

12. Install bearings and spacer in reverse idler gear
(inset) and position gear in housing with long

hub of gear toward the front.

14. Install countershaft rear bearing race into case
as shown.

13.

Insert idler shaft through case and idler gear

bearings. Line up notch in shaft with notch in

case, install lock ball, and drive shaft into posi­tion (inset).

14. Temporarily install new shims into bearing re-

tainer (inset). Install retainer. Tighten set screws
to 5-10 lbs. ft. (7-14 Nm)
NOTE: Lube hole in retainer must line up with
lub hole in case.

.

REASSEMBLY

- TRANSMISSION

B. Reassembly and Installation of Mainshaft

1. Install manshaft in vise equipped with wood or
brass jaws, rear of mainshaft facing up. Lubricate

and install first gear bearings with spacer be­tween bearings as shown.

3. Install reverse gear clutch hub with notched teeth
facing down.

2.

Install mainshaft 1st gear, clutching teeth of gear

facing down.

4.

Using heat lamp or hot plate and oil, heat reverse
gear bearing race and install on shaft with
notched end facing down. Race can also be in­stalled using a sleeve type driver.

NOTE: Do not heat reverse bearing race over

o

F (160oC).

320

43-04

REASSEMBLY -

TRANSMISSION

5. Install reverse gear sliding clutch with stepped
shoulder down.

44-07

7. Install reverse gear with clutching teeth facing
down.

44-06

6. Lubricate and install reverse gear bearings on
race.

44-08

8. Install reverse gear washer. Washer can be in­stalled either way.

REASSEMBLY -

TRANSMISSION

45-09

9. Using a sleeve type driver install rear mainshaft
bearing as shown.

11. Lubricate and install 2nd gear bearings (inset).
Install 2nd gear, clutching teeth facing down.

45-1o

Reposition mainshaft in vise with front of main­shaft facing up. Lubricate friction surface with
transmission lube and install 1st-2nd speed syn­chronizer.

45-12

12. Install locating ball and washer. Washer can be

installed either way. Install snap ring as shown

(inset).

E45-12

REASSEMBLY -

TRANSMISSION

46-13

13. Lubricate and install 3rd gear bearings (inset). in­stall 3rd gear, clutching teeth facing up.

46-15

15. Lubricate friction surface with transmission lube
and install 3rd-4th speed synchronizer and 4th
speed synchronizer cup.

14. Install 3rd-4th clutch hub with stepped face of
hub facing up. Install snap ring in groove of
mainshaft (inset).

16. Lubricate and install 4th gear bearings (inset). ln­stall 4th gear, clutching teeth facing down.

REASSEMBLY -

TRANSMISSION

17. Install locating ball and washer. Washer can be
installed either way. Install snap ring as shown
(inset).

19. Install 5th-6th clutch hub with flat surface facing
up.

47-18

18. Lubricate and install 5th gear bearings (inset). in­stall 5th gear, clutching teeth facing up.

20.

Install 5th speed synchronizer cup (inset). Lubri­cate friction surface with transmission lube and
install 5th-6th speed synchronizer assembly and
6th speed synchronizer cup.

REASSEMBLY

- TRANSMISSION

23. Using a sling around the 3rd-4th synchronizer
carefully lower mainshaft into case.

21. Using a sleeve type driver install front
bearing. Install snap ring in groove

shaft (inset).

22.

Remove mainshaft assembly from vise and place

on bench. Shift synchronizer into 4th gear.

on end of

mainshaft

48-24

24. Using a sleeve type driver install bearing on in­put shaft.

REASSEMBLY

- TRANSMISSION

49-25

25. Install input shaft by aligning clutching teeth on
main drive gear with teeth in 5th speed syn­chronizer cup.

Install input shaft bearing cover and gasket. Ap-

27.

ply Loctite 262 to threads of capscrews and tor­que to 15-20 lbs. ft. (20-27 Nm)

49-28

28. Install speedometer drive gear or rotor on output
shaft.

26. Coat outer diameter of input shaft bearing cover
oil seal with Loctite 510. Install seal with flanged
driver as shown. Install input shaft bearing race
(inset).

REASSEMBLY -

TRANSMISSION

16.

Rotate countershaft to seat bearings and races.
Position dial indicator as shown, lift countershaft

to measure end play. End play must be set at

.006-.010 (0.15-0.25 mm). Add shims for more end
play and remove shims for less end play.

NOTE: Once end play is correct remove retainer
and apply a light coat of Loctite 510 to both sides
of shims and face of retainer.

Coat threads of set screws with Loctite 262 and

retorque.

17. Install countershaft rear bearing cover and
gasket. Coat threads of capscrews with Loctite
262 and torque to 20-30 lbs. ft. (27-41 Nm).

Tip transmission to horizontal position to install

mainshaft.

REASSEMBLY

- TRANSMISSION

29. If necessary install rear bearing race (inset). Tem­porarily install shims and rear bearing cover.

Tighten nuts to 60-70 lbs. ft. (81-95 Nm).

NOTE: Top of rear bearing cover is marked for
proper installation.

31. Position dial indicator as shown. Pry up on out­put shaft to measure end play. End play must be
set at .006 -.010 (0.15-0.25 mm rein). Add shims for
more end play, remove shims for less end play.

NOTE: Once end play is correct remove yoke
and rear bearing cover and apply a light coat of

Loctite 510 to both sides of shims.

30. Place transmission in a vertical position as
shown. Install yoke and nut. Torque yoke nut to
300-350 lbs. ft. (407-475 Nm). Rotate input shaft
and mainshaft to seat bearings and races.

32. Install rear seal using a flanged driver.

REASSEMBLY

- TRANSMISSION

33. Install rear bearing cover. Tighten nuts to 60-70
lbs. ft. (81-95 Nm). Top of rear bearing cover is
marked for proper installation.

INSTALLATION-CLUTCH HOUSING

AND YOKE

A. Installation of Clutch Housing

52A-01

1. Position clutch housing on
Install four retaining bolts
lbs. ft. (196-210 Nm).

front of transmission.

and torque to 145-155

B. Installation of Yoke

1. Lock the transmission by engaging two mainshaft
gears (inset). Carefully install yoke and nut.

Tighten nut to 300-350 lbs. ft (407-475 Nm).

INSTALLATION-SHIFTING CONTROLS

A. Shift Bar Housing Assembly

1. Place transmission
gasket on case. Place shift bar housing in neutral
and install on case making sure shift yokes align
with corresponding synchronizers and sliding
clutch.

in neutral (inset) and install

3. Apply Loctite 262 to threads of capscrews. Install
capscrews into housing and torque to 20-25 lbs. ft
(27-34 Nm).

53-03

2. Apply Loctite 262 to threads and install two shift
bar housing capscrews in allignment holes as

shown. Install front capscrew first then rear.

INSTALLATION-SHIFTING CONTROLS

B. Gear Shift Lever Housing Assembly

With the shift bar housing in the neutral position,

install gasket and gear shift lever assembly on the
shift bar housing. Fit gear shift lever in corre­sponding finger assembly in bar housing as lever
is installed.

2. Coat threads of retaining capscrews with Loctite
262 and install. Torque capscrews to 20-25 lbs. ft.

(27-34 Nm).

Copyright Eaton Corporation, 2012.
Eaton hereby grant their customers,
vendors, or distributors permission
to freely copy, reproduce and/or
distribute this document in printed
format. It may be copied only in
its entirety without any changes or
modifications. THIS INFORMATION
IS NOT INTENDED FOR SALE OR
RESALE, AND THIS NOTICE MUST
REMAIN ON ALL COPIES.

Note: Features and specifications
listed in this document are subject to
change without notice and represent
the maximum capabilities of the
software and products with all options
installed. Although every attempt has
been made to ensure the accuracy of
information contained within, Eaton
makes no representation about the
completeness, correctness or accuracy
and assumes no responsibility for
any errors or omissions. Features and
functionality may vary depending on
selected options.

For spec’ing or service assistance,
call 1-800-826-HELP (4357) or visit
www.eaton.com/roadranger.
In Mexico, call 001-800-826-4357.

Roadranger: Eaton and trusted partners
providing the best products and services in the
industry, ensuring more time on the road.

Eaton Corporation

Vehicle Group
P.O. Box 4013
Kalamazoo, MI 49003 USA
800-826-HELP (4357)
www.eaton.com/roadranger

Printed in USA

For parts or service call us

Pro Gear & Transmission, Inc.

1 [phone]

[phone]

[e-mail]

906 W. Gore St.

Orlando, FL 32805