Eaton Transmission FS-6106A Service Manual
Service Manual
Fuller Mid Range Transmissions
TRSM0170
October 2007
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
TABLE
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OF
CONTENTS
MODEL
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . 7
TORQUE RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TOOL REFERENCE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PREVENTIVE
PRECAUTIONS
DISASSEMBLY AND REASSEMBLY-SHIFTING CONTROLS
REMOVAL-REAR
DESIGNATIONS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE....................................................
DISASSEMBLY.
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GEARSHIFT LEVER HOUSING
SHIFT BAR HOUSING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ASSEMBLY...
YOKE AND CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
16
26
DISASSEMBLY-TRANSMISSION.................................................
REASSEMBLY-TRANSMISSION
INSTALLATION-REAR YOKE AND CLUTCH HOUSING
INSTALLATION-SHIFTING CONTROLS
SHIFT BAR HOUSING
GEARSHIFT LEVER HOUSING ASSEMBLY
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..................................................
..............................
ASSEMBLY............................................
.....................................
28
39
54
55
56
57
1
FOREWORD
This manual is designed
tion necessary
to
to
provide detailed informa-
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
of
The format
followed in
reassembly
its
of
only one component
repaired, refer to the
the manual is designed
entirety
if
complete disassembly and
the transmission is necessary. But
of
the transmission needs to be
Table
of
Contents
numbers showing that component. For
you need
find
sembly
on page
Drivers
to
work
on the
instructions
on page
55.
for
removal, disassembly and reas-
19.
Instructions
Service Manuals, Illustrated Parts Lists,
Instructions, and other
Shift
Bar Housing, you
for
forms
installation are
to
for
the page
example,
of product
be
if
if
will
service information
missions are
Literature Order Form may be found in the back
this manual*.
detailing
information on product improvements,
for
these and other Fuller Trans-
available upon request. A Technical
You
may also obtain Service Bulletins,
of
repair procedures and other service-related subjects by
writing
EATON
to
the following address:
CORPORATION
TRANSMISSION DIVISION
Technical Service
P.O.
Box
4013
Department
Kalamazoo, Michigan 49003
(616)
342-3344
Every
effort
has
implied
warranty
Transmission
been
or
representation
Division,
made
P.O.
to
ensure
Box
based
4013,
the
accuracy
on
the
Kalamazoo,
of
all
enclosed
Ml
49003.
information
information.
in
this
Any
2
brochure.
errors
or
However,
omissions
Eaton
may
be
Transmission
reported
to
Division
Training
makes
and
Publications,
no
expressed
or
Eaton
MODEL
DESIGNATIONS
AND
SPECIFICATIONS
Nomenclature:
FS-6106A
~:~::~D-es_i_g_n_a_ti_o_n_s
Synchronized----------~
Specifications:
Models
FS-6106A
See
Chart
Notes.
No.
No.
Spds.
6
_______
1st
9.00
2nd
5.01
_.I
I 1
_ -
Gear
3rd
2.96
4th
1.89
·1
-
_·_1
'----------Design
..____
_________
IMPORTANT: All Fuller Transmissions are identi-
fied by
is stamped on the transmission
and affixed
DO
MISSION IDENTIFICATION
Ratios
5th
1.32
1.00
____
~~:
b;r:::ignations
0
Forward
Speeds
Level
x
100
=Nominal torque
Capacity
model and serial number. This information
identification
to
the case.
NOT
6th
REMOVE
Reverse
8.00
OR
DESTROY THE TRANS-
TAG.
Relative
PTO
To
Input
.454
Speed
Gear
A.PM.
1
Length
In.
(mm)
28.46
(722.9)
2 3
Weight
Lbs.
(Kg.)
418
(189.6)
tag
Oil
Cap.
Pints
(Liters)
19
(9)
CHART NOTES:
1 Lengths measured
2
Weight
shift
weights are approximate.
3
Oil Capacities are approximate, depending on inclination
sion
*For
- Listed
lever housing and gear
with
proper grade and type
information
from
face
weights
on available
are without
of
shift
clutch
clutch
of
housing
clutch
lever. Weight
lubricant
housings refer
to
housing*
of
to
level
to
front
bottoming
and include standard controls,
standard
of
Publication FUL-140 -
controls
of
engine and transmission. Always
filler
surface
opening. See LUBRICATION.
of
is approximately 10 lbs. (4.5
"Clutch
companion flange
which
Housing
consist
fill
Chart".
or
yoke.
of
gear
kg)_
All
transmis-
3
LUBRICATION
Proper Lubrication ...
the
transmission life
Proper lubrication procedures are the key
all-around maintenance program. If the oil is not doing
its
tenance procedures in the
the transmission running
life.
ternal parts operate in a bath
motion
in channels where needed, to help lubricate bearings
and shafts.
cedures are
job,
Key
or
to long
if
the
oil
level
is
ignored, all the main-
world are not going
or
assure long transmission
Fuller®
Thus,
Transmissions are designed so that the in-
of
oil circulated by the
of
gears and shafts. Grey iron parts have built-
all parts will be amply lubricated
closely followed:
1.
Maintain oil level. Inspect regularly.
2.
Change oil regularly.
3.
Use
the correct grade and type
4.
Buy from a reputable dealer.
of
to
if
these pro-
oil.
a good
to
keep
Oil
is
Important.
Here are some
• Provide a
heavily
bearings,
of
protective
loaded
thus
the functions oil must perform:
preventing metal
which causes scoring,
•Act
as a
coolant-
by reducing friction.
•Afford
cushion
•
Be
tion
sufficient
all loaded surfaces.
chemically
without
stable-
separation, gumming-up, oxidizing
corroding.
•
Be
non-foaming-
creased
•
Be
volume under severe conditions.
free of sediment and
and rust.
..
film-
To
protect
parts
such
as
to
scuffing
To
dissipate heat and reduce heat
fluidity-
To
To
prevent excessive foam and in-
and seizure.
To
follow,
withstand heat and agita-
water-
To
surface
gear
teeth
metal
coat
prevent sludge
of
and
contact
and
or
First
5,000
Every
Every
Lubrication Change and Inspection
USE
Change transmission oil
Inspect oil level.
Change transmission oil.
3,000
miles
10,000
50,000
to
(4827
miles
miles
HIGHWAY
to
8045
(16090
(80450
Km)
Km)
Km)
on new units
Check for leaks.
Recommended Lubricants
Grade Ambient
Type
Heavy
Duty
Engine
MIL·L·2104B,
or
APl-SF
(Previous
acceptable)
Mineral
Gear
and
oxidation
APl-GL-1
'Mild
EP
Gear
MIL-L-2105
'Multipurpose
MIL-L-2105B
or
APl-GL-5
Additives, friction modifiers
use in Fuller Transmissions.
'Mild
EP
Gear Oil
cant operating temperatures are above
C,
or
APl-CD
API
designations
Oil
inhibitor
Oil
or
APl·GL-4
Gear
or
MIL-L-2105C
Oil
or
D
with
rust
Oil
or
Multi-Purpose Gear Oil are not recommended when lubri-
(SAE)
85W140
80W140
or
synthetic lubricants are not recommended
50
40
30
90
BOW
90
BOW
90
80W90
sow
75W
230'
Above
Above
Below
Above
Below
10'F.(-12'C.)
-15'F.(-26'C.)
Above
Above
10'F.(-12'C.)
-15'F.(-26'C.)
-15'F.(-26'C.)
-40'F.(-40'C.)
F (110'C).
Fahrenheit
(Celsius)
Temperature
10'F.(-12'C.)
10'F.(-12'C.)
10'F.(-12'C.)
10'F.(-12'C.)
10'F.(-12'C.)
to
100'F.(38'C.)
to
70'F.(21'C.)
10'
F.(-12'C.)
-15'F.(-26'C.)
to
100'F.(38'C.)
to
100'
to
70'F.(21'C.)
to
-15'F.(-26'C.)
F.(38'C.)
for
4
LUBRICATION
Proper
Make sure oil is level with
level. One inch
used to check
Draining
Drain transmission while oil is warm.
before re-installing.
Oil
Oil
Level
of
oil level
oil level.
filler
opening. Because you can reach oil with your finger does not mean oil is at proper
is
about one gallon
To
of
oil. The FS-6106 is equipped with a
drain oil remove the drain plug at
bottom
dip
stick
which may also be
of
case. Clean the drain plug
Refilling
Clean case around filler plug and remove plug from side
The exact amount
of
the
level
Do
When adding
Operating
The transmission should not be operated
operating temperatures to 300°F (149°C) will not harm the transmission. Operating temperatures above 250°F in-
crease the lubricant's rate
tently above 250°, heavy
temperature is above
The following
sistently at
system too
filler
not over
Temperatures
slow
close to transmission,
of
oil will depend on the transmission inclination and model. In every instance,
opening.
fill-this
oil, types and brands
conditions
speeds,
will cause oil to
of
oxidation and shorten
duty
engine oil provides the best oxidation resistance. When the average operating
250°F, the transmission may require more frequent oil changes
in any combination can cause operating temperatures
(2)
high ambient temperatures,
be
forced out
of
oil should not
consistently
(5)
high horsepower, overdrive operation.
of
case. Fill transmission to the level
of
the case through front bearing cover.
be
intermixed because of possible incompatibility.
at temperatures above 250°F (120°C). However,
its
effective life. When the transmission is operated intermit-
of
over 250°F:
(3)
restricted air
flow
around transmission,
of
the
filler
or
external cooling.
(1)
operating con-
opening.
fill
intermittent
(4)
to the
exhaust
5
OPERATION
Gear
Shift
Lever
Follow the simple 6-speed
Pattern
,..
and
Shifting
shift
pattern
,..
1
.....
,..
"
Instructions
...
,.
"II
3
..
.Ill
,..
.,
..,
....
N
.,
.....
,..
"'II
5
.Ill
"
-
"'II
R 2
..
General
FS-6106A transmissions have six forward speeds and
one reverse, and
synchronized
ple 6-speed shift pattern.
Driving
• Always use the
downshifts. Premature synchronizer
sult from not using the clutch.
• Always select
cient reduction for the
• Never downshift at
• Never slam or jerk the
engagement.
• Never coast with the transmission in neutral and
the
Information
are
shifted
manual transmission, following the sim-
Tips
clutch
a starting gear that will provide suffi-
too
clutch dis-engaged.
load and terrain.
high
shift
...
....
as
you would shift any
when making
of
a road speed.
lever to complete gear
upshifts
failure can
..
.Ill
or
re-
4
6
..ii
....
.Ill
6
POWER
FLOW
The transmission must
of
Knowledge
and when making repairs become necessary.
1.
Power (torque) from the engine is transferred to the
2.
Torque is transferred
3.
Torque is delivered along countershaft to all countershaft gears.
4.
Torque is transferred
5.
Internal
sembly.
6.
Mainshaft transfers torque
what takes place in the transmission
clutching
efficiently
to
countershaft drive gear.
to
"engaged" mainshaft gear. The cross section illustrates 1st speed gear position.
teeth
of
transfer
engaged mainshaft gear
directly
the engine's power, in terms
during
to
driveshaft through rear yoke.
torque
input
transfers
of
torque, to the vehicle's rear wheels.
transfer
shaft and drive gear.
torque
is essential when trouble-shooting
to
mainshaft through synchronizer
as-
1.
\
3.
7
TORQUE
RECOMMENDATIONS
Correct torque application is extremely
tightening
transmission.
6
M'SHAFT FRONT BEARING
COVER CAPSCREWS
35-45
3/s-16 THREAD
CLUTCH
6
HOUSING
140-150
USE PLAIN
DRIVE GEAR NUT
250-300
21/s-16 L.H. THREAD
CLEAN THREAD
WITH SOLVASOL
OR
BEFORE APPLYING
FULLER ADHESIVE
SEALANT
STAKE 2 PLACES
of
fasteners can result in a loose installation and, in many instances, eventually cause damage
Use a torque wrench
FT.-LBS.,
NUTS--~
FT.-LBS., (OILED)
FLAT WASHER
FT.-LBS.,
EQUIVALENT
(71204)
2 LIFTING
EYE
CAPSCREWS
35-45
FT.-LBS.,
to
attain recommended torque ratings. Do
important
REVERSE SIGNAL SWITCH PLUG
30-40
USE GASKET
to
assure long transmission life. Over-tightening
FT.-LBS., 9f1s-18 THREAD
or
under-
to
not
torque capscrews dry.
4 SHIFT LEVER HOUSING CAPSCREWS
30·40
FT.
LBS.,
3/s-16
THREAD
14 SHIFT BAR HOUSING
CAPSCREWS
35.45 FT.·LBS.,
6
RETAINING STRAP
.----CAPSCREWS
FT.·LB.,
SECURED WITH
LOCKWIRE
3/s-16
SHIFT BAR
3/s-16
THREAD
25-35
THREAD,
the
INSTALL SEAL
FLUSH WITH
FRONT BEARING
COVER
C'SHAFT FRONT BEARING
RETAINER
90-120
5/a-18 THREAD
Cut
7193A-12185
CAPSCREW
FT.-LBS.,
2 HAND HOLE
COVER CAPSCREWS
20-25
S/1s-18 THREAD
FT.-LBS.,
4 CLUTCH HOUSING
CAPSCREWS
35-45
3/s-16 THREAD
(FRONT OF C'SHAFT)
FT.-LBS.,
INSTALL SEAL
FLUSH WITH
BEARING COVER
THERMOCOUPLE PLUG
40-50 FT.·LBS.,
1h
PIPE THREAD
REAR
8
TORQUE
RECOMMENDATIONS
INSTALL SEAL
FLUSH WITH SHIFT
BAR HOUSING
(BOTH SIDES)
SPEEDOMETER
HOUSING PLUG
35-50
FT.-LBS.,
13/15-20
OIL FILL PLUG
60-75
FT.-LBS.,
11/4
PIPE
-----;.~=ll~f--:::~_.,.J~_)
--+---H----1--+---.11--~
THREAD
__
THREAD
NEUTRAL SHIFT PLUG
30-40
FT.-LBS.,
3/4-16 THREAD
USE GASKET
__:~..:..+--......4~
DETENT SELECTION PLUG
30-40
FT.-LBS.,
3/4-16 THREAD
USE GASKET
4
COVER CAPSCREWS
145-155
s/a-11 THREAD
USE LOCKWASHERS
lltt---tt-t----ttt----+--t-+-----4-l-.l--NvLoN
M'SHAFT
FT.-LBS.,
REAR BEARING
OUTPUT SHAFT
NUT
235-275
FT.·LBS.,
THREAD WITH
INSERT. USE
PLAIN
WASHER (OILED
AT
INSTALLATION)
11/4·18
LOCKING
FLAT
VEHICLE
SMALL
6
COVER CAPSCREWS
35-45
PTO
FT.-LBS.,
---------::lo.,,o-4:'>.\
3/a-16 THREAD
Cut
71938-12/85
OIL DRAIN PLUG
45-55
FT.-LBS.,
3/4
PIPE THREAD
-~-+--:1'-1--+-,~"""--""~--4
C'SHAFT
COVER CAPSCREWS
35-45
REAR BEARING
FT.-LBS.,
3/a-16 THREAD
8 LARGE
COVER CAPSCREWS
50-65
7'1s-14
NOTE: APPLY LOCTITE 242
OF
ALL
PTO
FT.-LBS.
TH
READ
TO
CAPSCREWS BEFORE INSTALLING
THREADS
9
TOOL
REFERENCE
Some repair procedures pictured in
the use
ommended
faster, and prevent
such as
other standard shop items such as a press,
soft bars
semble and reassemble any Fuller Transmission.
of
specialized tools. Their actual use is rec-
as
they make transmission repair easier,
costly damage
But for the most part, ordinary mechanic's
socket
are
wrenches, screwdrivers, etc., and
all that is needed to successfully disas-
PAGE
18
35
38
42
Impact Puller
Countershaft Support Tool Made from Fuller Transmission
this
manual show
to
critical parts.
mauls and
TOOL
Tension Spring Driver
Snap Ring Pliers
(1/2·13
Threaded End)
and Bearing Driver
tools
The specialized
from a
quired by the individual user. Detailed Fuller Transmission
tool supplier
Tool Prints are available upon request by writing.
Eaton Corporation
Transmission Division
Technical Service Dept.
P.O.
Box 4013
Kalamazoo,
tools
listed below can be obtained
or
made from dimensions as
Michigan 49003
re-
HOW OBTAINED
Made from Fuller Transmission
Print T-11938
Tool Supplier
Tool Supplier
Print
T·22913·C
50
51
52
52
53
53
Bearing Guide
Oil Seal Driver, Rear Bearing Cover
Input Shaft
Nut
Installer
Torque Wrench, 1000 Lbs./Ft. Capacity
Oil Seal Driver Made from Fuller Transmission
Front Bearing Cover (push type
clutch)
Oil Seal Driver Made from Fuller Transmission
Front Bearing Cover
(pull type clutch)
Made from
Made from
Fuller Transmission
Print
T-18042·110
Fuller Transmission
Print
T-18088·61
Made from Fuller Transmission
Print T
·22553-A
Tool Supplier
Print T-18088·67
Print T-18088·64
10
PREVENTIVE
MAINTENANCE
11
PREVENTIVE
MAINTENANCE
PREVENTIVE
CHECKS
DISASSEMBLY
1.
Clutch Housing Mounting
a.
2.
Clutch Release Bearing (Not Shown)
a.
b.
3.
Clutch Pedal Shaft and Bores
a.
b.
4.
Lubricant
a.
b.
5.
Filler
a.
WITHOUT
Check all capscrews in bolt circle
housing
Remove hand hole cover and check radial
and axial clearance in release bearing.
Check relative position
release bearing with thrust sleeve on push-
type
Pry upward on shafts to check
If
excessive movement is found, remove
clutch release mechanism and check bushings in bores and wear on shafts.
Change at specified service intervals.
Use only the types and grades as recom-
mended.
Remove
level
Tighten
for
clutches.
See
and
Drain Plugs
filler
of
lubricant
filler
MAINTENANCE
PARTIAL
OF
CHASSIS
looseness.
LUBRICATION.
plug
or
at
and drain plugs securely.
OR
of
thrust surface
dip
stick
specified
CAB
of
clutch
wear.
and check
intervals.
CHECK
8.
CHECKS
of
9.
10. Output Shaft (Not Shown)
CHECKS
COMPANION
REMOVED
NOTE:
CHART
Gear Shift Lever Housing Assembly
a.
Remove the gear
sembly from transmission.
b.
Check tension spring and washer
and wear.
c.
Check
wear
assembly.
bottom
of
slots. Also check
WITH
DRIVE
Universal Joint Companion Flange
or
Yoke
a.
a.
Nut
Check
mended torque.
Pry upward against output shaft to check
radial clearance in mainshaft rear bearing.
for
WITH
tightness.
UNIVERSAL
FLANGE
If
necessary, use
clean sealing surface
yoke.
DO
NOT
USE
PAPER
THAT WILL MAR SURFACE FINISH.
OR
OTHER ABRASIVE MATERIALS
shift
end
lever
of
gear
LINE
Tighten
housing
for
shift
lever
for
wear
of
DROPPED
to
recom-
JOINT
OR
YOKE
solvent
CROCUS CLOTH, EMERY
and
shop
of
companion flange
rag
finger
asset
for
to
or
6.
Capscrews
a.
Check all capscrews, especially those on
PTO covers and rear bearing covers
looseness which would cause oil leakage.
See
b.
Check
for
oil leakage due
7.
Gear Shift Lever
a.
Check
ing.
with Check No.
and
Gaskets
TORQUE RECOMMENDATIONS.
PTO
opening and rear bearing covers
to
faulty gasket.
for
looseness and free play in hous-
If
lever is loose in housing, proceed
8.
for
11. Splines
on
Output Shaft
(Not Shown)
a.
Check
ing action
flange
12.
Mainshaft Rear Bearing Cover
a.
Check oil seal
for
wear from movement and chuck-
of
the universal
or
yoke.
for
wear.
joint
companion
12
PRECAUTIONS
Disassembly
It is assumed in the detailed assembly
necessary
gear
sembly
before transmission can be removed.
FOLLOW CLOSELY EACH PROCEDURE IN THE DETAILED INSTRUCTIONS, MAKING USE OF THE
TRATIONS
1.
BEARINGS-Carefully
reusable
wrap until ready
to
pose.
2.
ASSEMBLIES-When
assemblies, such as the mainshaft, countershafts,
and
bench in the same sequence as removed. This pro-
cedure
possibility
3.
SNAP
signed for this purpose. Snap rings removed in this
manner can
loose.
linkage
shift
lever housing assembly (or remote control assembly) is included in the detailed
and
Reassembly-Shifting
AND PHOTOGRAPHS PROVIDED.
bearings
be reused
shift
will
RINGS-Remove
disconnected
for
with
bar
housing,
simplify
of
losing parts.
be
reused,
and the transmission has been removed from vehicle chassis. Removal
wash and
as removed and
use. Remove bearings planned
pullers designed
disassembling
lay all
reassembly and reduce the
snap rings with pliers de-
if
they are not sprung
instructions
Controls); however,
relubricate
protectively
for
this
the various
parts
on a clean
that the lubricant has been drained from transmission, the
all
pur-
or
instructions
this
assembly
4.
CLEANLINESS-Provide a clean place to work. It is
important that no dirt
unit during repairs. Dirt is
age bearings. It is always good practice
outside of the unit before starting the
sembly.
6.
WHEN USING TOOLS
ply force
Movement of some parts is restricted. Never
force to the part being driven after it stops solidly.
The use of soft hammers, bars and mauls for all disassembly
must
be detached from
or
foreign material enters the
an
abrasive and can dam-
TO
MOVE
to
shafts, housings, etc,
work is recommended.
shift
PARTS-Always
Inspection
of
the
(Disas-
bar housing
TEXT,
ILLUS-
to
clean the
planned disas-
ap-
with
restraint.
apply
Before
termine reuse or replacement. When replacement is necessary, use only genuine Fuller Transmission parts to assure
continued performance and extended
questionable part which could lead to additional repairs and expense soon after initial reassembly.
mining the reuse
mileage, application, etc.
A.
reassembling the transmission, check each part carefully for abnormal
life from your unit.
Since the cost
Recommended inspection procedures are provided in the
BEARINGS
1.
Wash all bearings in clean solvent. Check balls,
rollers
and
pitted, discolored, spalled,
disassembly.
2.
Lubricate bearings that
ored,
clearances.
3.
Replace bearings with excessive clearances.
4.
Check bearing fits. Bearing inner races should
be
tight
slightly loose in case bore. If bearing spins
freely in bore, however, case should be
placed.
of
a new part is generally a small fraction of the total cost of downtime and labor, avoid reusing a
or
replacement
and raceways for pitting, discoloration,
spalled areas. Replace bearings that
or
spalled and check for axial and radial
to
shaft; outer races slightly tight
of
any transmission part, consideration should also
or
damaged during
are
not pitted, discol-
are
to
re-
following checklist.
B.
GEARS
1.
2.
or
excessive wear and damage to de-
To
aid in deter-
be
given
to
the unit's history,
Check gear teeth
ing
of
gear tooth faces present no threat
transmission failure. Often in continued operation
of
the unit, frosted gears will "heal" and
not progress
cases, gears with
have
considerable gear life remaining and can
be
reused. But gears with advanced stage pit-
ting should be replaced.
Check
mally
clashing in shifting. Replace gears found in any
of
for
worn, tapered,
these conditions.
for
frosting and pitting. Frost-
to
the pitting stage. And in most
light to moderate pitted teeth
gears
with
clutching
or
reduced in length from
teeth abnor-
of
13
PRECAUTIONS
Inspection
3.
Check axial clearance
sive
split washer, clutch hub, and gear hub for
cessive
C.
SPLINES
1. Check splines on all shafts for abnormal
If sliding clutch gears, companion flange,
clutch
splines, replace the specific shaft affected.
D.
SPLIT WASHERS
1.
Check surfaces of all washers. Washers scored
or
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
Replace
Heavy castings may be
vided the cracks do not extend into bearing
bores or
ever,
rent to pass through the transmission.
(cont'd.)
of
gears. Where exces-
clearance is found, check gear snap ring,
wear.
hub have worn
reduced in thickness should
or
repair parts found to be damaged.
bolting surfaces. When welding, how-
never place the ground so
into
the sides
welded
be
or
as
ex-
wear.
or
of
the
replaced.
and
breaks.
brazed pro-
to allow cur-
I.
GEAR
SHIFT
LEVER
ASSEMBLY
1.
Check spring tension on
tension spring
2.
If
housing
end
of
sembly
sively worn.
gear
for
if
lever moves
is
disassembled,
shift
wear. Replace both parts
J. BEARING COVERS
1. Check covers
bearing.
of
bearing
2.
Check
those worn oversize.
K.
OIL SEALS
1. Check oil seal in
cover.
stroyed,
L.
CLUTCHING
1. Check all
clutches
from heat.
2.
Check engaging teeth
pattern.
bores
If sealing
for
wear from
Replace covers damaged from
outer
race.
of
covers
input
action
replace seal.
TEETH
shift
yokes and yoke
for
extreme wear
HOUSING
shift
lever. Replace
too
freely.
check
lever and
shaft and rear bearing
for
shift
finger
thrust
for
of
lip
partial engagement
of
wear.
has been de-
slots
or
discoloration
bottom
as-
if
exces-
adjacent
thrust
Replace
in sliding
G. CLUTCH RELEASE PARTS
1.
2.
H.
SHIFT
1. Check
2.
3.
Check
worn
worn at contact pads.
Check pedal shafts. Replace those worn at
bushing surfaces.
sembly at pads and lever slot. Replace excessively worn parts.
Check yokes
sprung yokes.
Check lockscrews in yokes assembly retainer
plates. Tighten and rewire those found loose.
clutch
at cam
BAR
for
release parts. Replace yokes
surfaces
HOUSING
wear on
for
correct alignment. Replace
and
ASSEMBLY
shift
yokes and finger as-
bearing
carrier
M.
SYNCHRONIZER
1. Check synchronizer
cessive wear at
particles.
2.
3.
N.
0-RINGS
1. Check
Check
looseness.
Check synchronizer
synchronizer cups
blocker
0-ring
ASSEMBLY
for
contact
pins
for
contact
for
of
idler
shaft
burrs, uneven and ex-
surface, and metal
excessive
wear.
for
surfaces on the
cracks
wear
or
cuts.
or
14
PRECAUTIONS
Reassembly
Make sure that interiors
kept
out
of the transmission during reassembly. Dirt is
bearings and washers. Use certain precautions, as listed below, during reassembly.
1.
GASKETS-Use
transmission as
gaskets are
can
_result
bearing covers. These drivers apply equal force
2.
CAPSCREWS-To
242
thread sealant on all capscrews.
ratings, see TORQUE RECOMMENDATIONS. bore and shaft. Avoid using a
3.
O·RINGS-Lubricate
cant.
4.
ASSEMBLY-Refer
the
detailed disassembly
to
reassembly.
5.
INITIAL
and
synchronizers
during reassembly
of
such parts.
_inst~lled.
in
LUBRICATION-Coat
IMPORTANT: REFER
of
case and housings are clean. It is
new
gaskets
it
is
being rebuilt. Make sure all clearances
An
omissio~
011
leakage
prevent oil leakage, use
0-rings
to
the
illustrations
instructions
with
transmission
to
prevent scoring and galling
FIED
BY
throughout
or
misalignment
with
all
thrust
TO
THE APPROPRIATE ILLUSTRATED
MODEL SERIES)
the
of. any gasket
of
Loctite
For
torque while maintaining correct bearing alignment
silicone
lubri-
provided in
as a guide
washers
lubricant
important
an
abrasive and can damage polished surfaces
6.
AXIAL
7.
BEARINGS-Use
recommended
races,
type driver, whenever
to
only
ERENCE.
8.
UNIVERSAL
YOKE-Pull
place
foot-pounds
ter
drive gear
stalled.
result in damage
TO
ENSURE THAT PROPER
that
dirt
CLEARANCES-Maintain
for
mainshaft gears.
of
for
preventing
one
of
the bearing races. See TOOL REF-
JOINT
the
companion
with
the
output
of
torque. Make sure the speedome-
or
a replacement spacer has been in-
Failure
to
to
and
other
flanged-end bearing drivers is
the
installation
damage
possible, as force is applied
COMPANION
shaft
properly
the mainshaft rear bearing.
PARTS
USED DURING REASSEMBLY OF THE TRANSMISSION.
foreign materials be
to
rollers
tubular
flange
nut,
torque
original
of
to
both bearing
FLANGE
or
using
the
axial
bearings.
and races
with
or
sleeve-
yoke
235-275
nut
LIST (SPECI·
PARTS
ARE
of
OR
into
can
15
DISASSEMBLY
AND
REASSEMBLY
SHIFTING
CONTROLS
GEARSHIFT LEVER HOUSING ASSEMBLY
LEVER
ASSEMBLY
HOUSING
LEVER
""'U
~CLAMP
SHIFT
LEVER
SHIFT
LEVER-....-...
HOUSING
GASKET
,
iOLL
PIN
i1---~
__
SHIFT
LEVER
LOCKWASHER
STUD
RISER
BLOCK
Cut
6291-12/85
A.
Removal
"O"RING~
-~-~
and
Disassembly
GASKET
SPRING
1.
Turn
out four capscrews and remove tower as·
sembly
from shift bar housing.
16-01
16
2.
Remove boot and
and secure assembly in vise with bottom
ing up. Use a large screwdriver to twist between
spring and housing, forcing spring from under
lugs
in
housing.
shift
Do
ball from gearshift lever
one coil
at
a time.
of
16-02
hous-
DISASSEMBLY
AND
REASSEMBLY
SHIFTING
CONTROLS
GEARSHIFT LEVER HOUSING ASSEMBLY (con't.)
B.
3.
Remove tension spring. Remove washer and gear-
lever from housing.
shift
17-03
Reassembly
Lever
Housing
of
Gearshift
Assembly
4.
If necessary, remove the 0-ring from groove inside
tower.
17-04
1.
Secure gearshift housing in vise as during disassembly. Install
0-ring
in groove of tower.
17-01
17
2.
Position gearshift lever and washer in tower.
17-02
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