Eaton Transmission FS-6106 Service Manual

Service Manual

Fuller Mid Range Transmissions
TRSM0171

October 2007

For parts or service call us

Pro Gear & Transmission, Inc.

1 [phone]

[phone]

[e-mail]

906 W. Gore St.

Orlando, FL 32805

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

Note: The

Housing.

sembly
the drawings to the shift bar housing.

A. Removal

BAR

HOUSING

ASSEMBLY

Cut

6229A-4/87

BAR HOUSING ASSEMBLIES

FS-6106

To

and reassembly refer

transmission can

identify which type

and

CAPSCREW'

LIFTING~

EYE

CONTROLS

be

of

shift bar housing the transmission is equipped with and the procedure for disas·

to

pages

Disassembly

REVERSE
LIGHT

SWITCH~-

.

I

L-------

---

Appendix

equipped with either a Flat Rail Shift Bar Housing or a Round Rall Shift Bar

19,

12

in the

FS-6106

Round Rall

Service Manual and the following illustrations

Design

GASKET

to

match

:._.::;;;;:::.-:;;:::.~~~~>~":~:.

~,......,:::.:;;;;:;.;..;..-~

NEUTRAL
LIGHT SWITCH

-

YOKES

ANO

BARS

Cut

62268-3/87

1

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

1.

Turn
case. sion springs (inset)

BAR HOUSING ASSEMBLY (con't.)

out capscrews

CONTROLS

and

lift shift bar housing from

3.

Tilt the assembly and remove the four sets
shift bar housing.

and

balls from bores

in

of

top

ten·

of

2.

Remove
S!)ring cover

the two tension plate capscrews,

and

gasket (inset). move nine capscrews and three retaining plates

and

the

2

4.

Lay

shift

(inset).

bar housing on work bench as shown,

re-

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

5.

Remove the reverse yoke assembly from the shift

bar housing.

BAR HOUSING ASSEMBLY

CONTROLS

(con't.)

7.

Remove the third-fourth yoke assembly, and in­terlock pin (inset).

6.

Remove the first-second yoke assembly from the
shift bar housing and remove the first-second in­terlock pin (inset),

as

shown.

8.

Remove the

terlock pin (inset).

3

fifth-sixth

yoke assembly, and in-

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

9.

Remove the six interlock balls from the cross­bores

BAR HOUSING ASSEMBLY (con't.)

of

the

shift

CONTROLS

bar housing.

11. If necessary the shift yoke bushings can
moved. Use
straight then
(inset).

12.

Loosen the neutral light
the

neutral light switch or plug and gasket from

the housing (inset).

pliers

pull the bushings from the yoke slot

to

bend

switch/or

the

bushing

plug. Remove

be

tabs

re-

10.

If it is necessary
secure shift rail in a vice equipped with brass
jaws

or

wood blocks. Drive the retension/roll pin

from yoke and yoke bar

to

replace yoke

as

or

shown.

shift

blocks,

4

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

13. Remove the pin from the neutral
bore. Note: The neutral
reverse

BAR HOUSING ASSEMBLY

light switch pin are not interchangeable.

CONTROLS

light

switch pin and the

light

switch

(con't.)

15. Remove the pin from the reverse
bore.

light

switch

14. Loosen the reverse light

light

the
housing (inset).

switch/or

plug and gasket from the

switch/or

plug. Remove

16. If the removal

cure the

I

ACAUTION

Depress the reverse plunger spring and remove the
snap ring.

5

of

reverse plunger is ncessary,

shift

rail and yoke in

I THE SNAP RING AND

PLATE

TENSION.

ARE

UNDER

an

Arbor press.

RETAINER

SPRING

se-

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

17. Remove the retaining plate.

BAR HOUSING ASSEMBLY

CONTROLS

(con't.)

19. Remove the reverse plunger washer.

18. Remove the inner reverse plunger spring, then
move the outer plunger spring (inset). Note: The
reverse and
changeable.

neutral plunger springs are not inter-

Keep them separated.

re-

6

20.

Remove the reverse plunger.

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

21.

If

the removal
cure the fifth-sixth
bor press.

I

ACAUTION

BAR HOUSING ASSEMBLY (con't.)

of

neutral plunger is necessary, se-

shift

I THE SNAP RING AND RETAINER

PLATE

TENSION.

CONTROLS

yoke assembly in

ARE

UNDER

an

Ar-

SPRING

23. Remove the neutral
neutral and reverse plunger springs are not
changeable. Keep them separate.

plunger

spring. Note: The

inter-

Depress the neutral plunger spring and remove the
snap ring.

22.

Remove the retaining plate.

24.

Remove the neutral plunger.

7

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

B.

Reassembly

BAR HOUSING ASSEMBLY (con't.)

Round Rail

CONTROLS

Shift

Bar

Housing.

3.

If
plunger

neutral

in fifth-sixth

plunger

was removed,

shift

yoke.

install

neutral

1.

If previously removed install yoke

bar.

yoke
or

wood blocks. Align holes in
block and insert lock pin. Drive lock pin flush with
shift yoke (inset).

Secure assembly in a vise with

or

shift

shift

yoke

block on

soft

or

jaws
shift

4.

Install neutral plunger spring in

shift

yoke.

2.

If

previously removed install new
ings in
sixth
bushing tabs over

slot

of

first-second, third-fourth

shift

yoke. Seat bushing in slot and bend

to

secure (inset).

shift

yoke bush-

or

fifth-

8

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

5.

Install neutral retaining washer.

IACAUTION

BAR HOUSING ASSEMBLY (con't.)

THE SNAP RING AND
WILL
SION AS INSTALLED.

CONTROLS

BE UNDER SPRING TEN·

RETAINER

7.

If

reverse plunger was removed, install reverse

plunger in reverse shift yoke.

6.

Place shift yoke in hand press. Depress retaining

and

washer

spring

and

install the snap ring.

8.

Install reverse plunger washer.

9

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

BAR HOUSING ASSEMBLY (con't.)

CONTROLS

9.

Install outer reverse plunger spring. Install inner
reverse plunger spring (inset).

10.

Install reverse plunger retaining washer.

11.

Place the
taining washer and spring and install the snap
ring.

IA.CAUTION

12.

Install the reverse light switch pin in the shift bar
housing.

shift

yoke in a hand press. Depress

THE SNAP RING AND
WILL
SION AS INSTALLED.

BE UNDER SPRING TEN·

RETAINER

re-

10

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

13.

Install reverse
shift
plug (inset).

BAR HOUSING ASSEMBLY (con't.)

light

bar housing. Tighten reverse

CONTROLS

switch

or

plug and gasket in

light

switch

or

15. Install the neutral light switch
shift

in
or

bar housing. Tighten neutral

plug in

shift

bar housing (inset).

or

plug and gasket

light

switch

14.

Install the neutral light switch pin in the
housing.

shift

bar

11

Install interlock balls in the

16.
the following sequence: position

in the first-second crossbore; third-fourth

balls
crossbore; and the fifth-sixth crossbore.

shift

bar housing

two

interlock

in

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

17. Place
shown, and
position

BAR HOUSING ASSEMBLY (con't.)

shift

bar

housing

install the reverse yoke assembly in

as

shown.

CONTROLS

on a

work

bench as

19. Install interlock pin in the third-fourth yoke
rail assembly (inset). Position the assembly in
shift

bar housing.

and

18.

Install interlock pin in the first-second yoke
sembly (inset). Position first-second yoke and rail

in

shift

assembly

bar housing.

as-

12

20.

Install interlock pin in the fifth-sixth yoke

sembly (inset). Position the assembly in shift bar

housing.

as-

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

.

SHIFT

BAR HOUSING ASSEMBLY (con't.)

CONTROLS

23.

Install nine capscrews in
shown and tighten to the recommended torque.

shift

bar housing as

21.

Make sure all yoke assemblies
position

aligned to interlock ball crossbores.

22.

Position the three retainer plates in
housing.

as

shown (inset) and interlock pins

are

in the neutral

shift

are

bar

24.

Position shift bar housing
four interlock balls.

as

shown and install

13

DISASSEMBLY

AND

REASSEMBLY

SHIFTING

SHIFT

25.

Install the four interlock springs.

BAR HOUSING ASSEMBLY (con't.)

CONTROLS

27.

Install

mended torque.

two

capscrews

and

tighten

to

recom·

26.

Install gasket (inset) and retainer plate.

14

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