Eaton Transmission RTLO-10 Service Manual
Troubleshooting Guide
Fuller Transmissions
TRTS0920
July 2011
Warnings and Precautions
!
Warnings and Precautions
WARNING
Before starting a vehicle always be seated in the driver’s seat, place the transmission in neutral, set the parking brakes and
disengage the clutch.
Before working on a vehicle place the transmission in neutral, set the parking brakes and block the wheels.
Before towing the vehicle place the transmission in neutral, and lift the rear wheels off the ground, remove the axle shafts,
or disconnect the driveline to avoid damage to the transmission during towing.
The description and specifications contained in this service publication are current at the time of printing.
Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any
time without notice.
Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use
and should not be considered an endorsement. Equivalents may be used.
This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow
specific instructions may result in personal injury and/or component damage.
Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize
the personal safety of the service technican or vehicle operator.
Warning: Failure to follow indicated procedures creates a high risk of personal injury to the service technician.
Caution: Failure to follow indicated procedures may cause component damage or malfunction.
Note: Additional service information not covered in the service procedures.
Tip: Helpful removal and installation procedures to aid in the service of this unit.
Always use genuine Eaton replacement parts.
Table of Contents
General Information
How to use this Troubleshooting/Operation Guide ...... 1
Transmission Identification ......................................... 2
Component Identification ............................................ 4
Lubricants and Sealants .............................................. 6
Suggested Test Fixtures .............................................. 7
Air System Troubleshooting
8, 9, 10, 11, 13, 15, and 18-Speed Troubleshooting ... 8
RTLO 10-Speed Troubleshooting .............................. 23
Combination Cylinder Troubleshooting ..................... 33
FR-1X210 Troubleshooting ....................................... 51
Operation
Air Line Color Chart ...................................................64
Slave Valve Preselection System ............................... 65
7,8,9 and 10-Speed Range Air Systems .................... 66
7L,8,9 and 10-Speed (2-Speed auxiliary) .................. 67
RT & RTO-610,6610, 6609, and 8609 Models .......... 69
Deep Reduction Air System
(with Dash Mounted Valve) ................................ 71
RT, RTO, & RTX xx607LL,
xx608LL, and xx615 models .............................. 72
Deep Reduction Air System
(with A-6915 Roadranger Valve) ........................ 75
RT, RTO, & RTX xx607LL,
xx608LL, and xx615 Models .............................. 76
9 and 13-Speed Air Systems
(Top 2 & Convertible) and 18-Speed (Top-2) .... 79
RT, RTO, & RTOO xx613 and xx813 Models ............. 83
RTLO-xx613 Models ................................................. 86
RTLO-xx713 Models ................................................. 89
RTLO-xx913 Models ................................................. 92
RT0-15618 and RTLO-xx618 Models ........................ 95
RTLO-xx718 Models ................................................. 99
RTLO-xx918 Models ............................................... 103
Combination Cylinder Air System ............................ 107
7LL/DLL/MLL, 8LL, 9MLL, and 15-Speed Models .. 108
Unique Air Systems ................................................. 111
RT &RTO 613 and 6613 Models ............................. 112
RT & RTO 613 and 6613 Models
With A-6913 Roadranger Valve ....................... 115
RT & RTO 613 and 6613 Models ............................ 116
7608LL with A-6915 Roadranger Valve ................... 119
7608LL Models ....................................................... 120
RTLO-xx610 Speed Air System ............................... 123
RTLO-xxX610 Models ..............................................125
RTL-xx710 Speed Models ........................................129
RTL-xx710 Models ..................................................130
AT-1202 Auxillairy Transmission
(with 2 Position Shift Valve) .............................134
AT-1202 Auxiliary Housing (3 Position Valve) .........135
System Components
A-4740 Air Filter/Regulator Assembly ......................137
A-5161/A-5454 Air Filter/Regulator Assembly .........138
A-3546 Range Valve ................................................139
A-5010/A-6909 Roadranger Valve ...........................140
14651 Reduction Valve (Dash-Mounted) .................141
A-5015/A-6915 Roadranger Valve ...........................142
Two Position Selector Valve ....................................143
A-4900/A-6913 Roadranger Valve ...........................144
A-5013/A-6913 Roadranger Valve ...........................145
Three Position Selector Valve ..................................147
A-5510/A-6910 Roadranger Valve ...........................148
Range Actuator Valve (Old Design) ..........................150
Range Actuator Valve (Latest Design) .....................151
19470 Poppet-Type Slave Valve ..............................152
A-4688 Slave Valve ..................................................153
A-5000 Slave Valve ..................................................154
Range Cylinder ........................................................155
Range Cylinder for 610, 6610, 6609 and 8609 ........156
Dash-Mounted Deep Reduction Cylinder .................157
Deep Reduction Cylinder with Roadranger Valve .....158
RTLO-xx610 Model Range Cylinder Assembly ........160
RTL-xx710 Model Range Cylinder Assembly ...........162
Intermediate Shift Cylinder Assembly
613 and 6613, 3-Position Selector Valve ..........164
Intermediate Shift Cylinder Assembly
613 and 6613, A-5015 Roadranger Valve .........166
Combination Cylinder Assembly ..............................168
Splitter Cylinder Assembly .......................................171
RTLO-xx610 Model Splitter Cylinder Assembly
(Old Design) ....................................................173
RTLO-xx610 Model Splitter Cylinder Assembly
(Latest Design) .................................................175
RTL-xx710 Model Splitter Cylinder Assembly ..........177
RTLO-xx613 Model Splitter Cylinder Assembly .......179
RTLO-xx713 Model Splitter Cylinder Assembly .......181
RTLO-xx913 Model Splitter Cylinder Assembly .......183
RTO-15618 and RTLO-xx618 Model
Splitter Cylinder Assembly ...............................185
RTLO-xx718 Model Splitter Cylinder Assembly .......187
RTLO-xx918 Model Splitter Cylinder Assembly .......189
Table of Contents
Engineering Reference Drawings
Basic Air System Drawings -
6610,8609, and 6609 ....................................... 191
Basic Air System Drawings -
07L, 08, 08L, 09, and 10-Speed Models .......... 192
Basic Air System Drawings -
07LL, 08LL, and 15 Speed Models .................. 193
Basic Air System Drawings - 707LL, 7/908LL, 7/909LL,
and 7/915 Speed Models ................................. 194
Basic Air System Drawings - 11613, 14613, and 15613
Speed Models .................................................. 195
Basic Air System Drawings - 6613, and 7608LL Speed
Models ............................................................. 196
Basic Air System Drawings -
18 Speed Models Left-Hand Drive ...................197
Basic Air System Drawings -
18 Speed Right-Hand Drive .............................198
General Information
How to use this Troubleshooting/Operation Guide
The purpose of this manual is to assist in the diagnosis and repair of your air system. Use this manual in conjunction with other
service literature produced by Eaton®, including Service Bulletins, Illustrated Parts Lists, Service Manuals, and OEM service material.
This guide provides four functions
• Troubleshooting Guide: Designed to isolate and resolve air system problems.
• System Operation and Schematics: Designed to explain a complete air system's operation.
• System Components: Designed to explain each component's function and operation.
• Engineering Reference Drawings: Detailed drawings with optional parts and part numbers.
General Information
1
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
General Information
Transmission Identification
2-Speed Auxiliary/3-Speed and 2x2 Auxiliary
Roadranger
Valve
Slave
Valve
Air Hoses
Air Lines
Air Lines
Range Cylinder
Air Filter/
Regulator
2-Speed
Auxiliary
RoadrangerRoadranger
Valve
Range Cylinder
Air Filter/
Slave
Valve
Regulator
3-Speed
&
2X2 Auxiliary
Air Hoses
Deep Reduction or
Splitter Cylinder
2
Combination Cylinder / RTLO-10 Speeds
Roadranger
Valve
General Information
Combination
Slave
Valve
Air Hoses
Air Lines
Roadranger
Valve
Combination
Cylinder
Cylinder
Air Filter/
Regulator
General Information
Air Lines
Range
Actuator
Valve
RTLO-10 Speeds
Range Cylinder
Air Filter/
Regulator
O
N
L
Y
C
C
N
Air Hose
Splitter Cylinder
3
General Information
Component Identification
Air Filter/ Regulators
Control Valves - Old Production
A-3546
DOWN-LOW
H
IG
-H
UP
Deep Reduction Valve
14651
D
U
E
C
R
T
P
I
SHIFT ONLY
WHEN IN LOW
RANGE
DO NOT
PRE-SELECT
O
N
IN
OUT
E
E
D
Two Position Selector
A-5010
8, 9, and 10 Speeds 8LL, 15, 6613 Speeds
Three Position Selector
A-5015
Blue
A-5510
Gray
A-4900
Red
RT/RTLO 13 Speeds
A-5013
Gray
RTLO-18 SpeedsRTLO-10 Speeds
4
Control Valves - Current Production
General Information
Slave Valves
A-6909
8, 9, and 10 Speeds 8LL, 15, 6613 Speeds
A-6910
A-6915
A-6913
A-4688 - Old19470 - Obsolete A-5000 - Current
Blue
A-6918
General Information
Red
RT/RTLO 13 Speeds RTLO-18 SpeedsRTLO-10 Speeds
GrayGray
Range Valves
23545
CYL
NO
23545 - old design
S
NC
P
EXH
4303110 - latest design
S
P
S
EXH
5
General Information
Lubricants and Sealants
The use of improper sealants and lubricants during air system assembly can cause improper component operation and severe
transmission damage.
The following are the recommended sealants and lubricants to be used when assembling air system components:
Name: Eaton® Fuller® Silicone Lubricant
Part #: 71203 (8 oz. container)—Fleet size
Part #: 71206 (4 cc container)—Single application
Where Used: All O-rings and mating surfaces
Name: Eaton® Fuller® Sealant
Part #: 71205 (2 cc container)—Single application
Part #: 71206 (4 cc container)—Single application
Where Used: Air fittings and threads
6
General Information
Suggested Test Fixtures
Note: For the Automated transmission models, refer to their Troubleshooting Guides for air system diagnostics.
Test Fixture for Range Cylinder
5/32" Air Line
0-100 PSI Gauge
84006 - 5/32" Push-To-Connect
to 1/8" NPTF
General Information
12881 - 1/8" Tee
Test fixture for 1/8" Air lines
0-100 PSI Gauge
85002 - Elbow Assembly
Test Fixture For 5/32" Air Line
0-100 PSI Gauge
12769 - 1/8" Nipple
5/32" Air Line
84006 - 5/32" Push-To-Connect
to 1/8" NPTF
84502 - Elbow
12881 - 1/8" Tee
1/8" Air Line
5/32" Air Line
83501 - Grip Nut
83001 - Compression Sleeve
85003 - Elbow
84006 - 5/32" Push-To-Connect
to 1/8" NPTF
85003 - Elbow
12881 - 1/8" Tee
5/32" Air Line
7
Air System Troubleshooting
8, 9, 10, 11, 13, 15, and 18-Speed Troubleshooting
Symptom
• Air Leak at Shift Knob
• Air Leak at Slave Valve
• Air Leak from Transmission Breather or Transmission Case is Pressurized
• Air Leak at Splitter Cylinder Cover Exhaust Port
• No or Slow Range Shift into Low
• No or Slow Range Shift into High
• Range Shifts with Shift Lever in Gear
WARNING: Use care when removing air lines or checking for air flow from disconnected lines. High pressure air may
exhaust suddenly. Wear safety glasses. Exhaust all air pressure from system before removing air filter/regulator or combination cylinder cover.
Note: During all testing, the vehicle air pressure must be greater than 90 PSI (620 kPa). If during testing the pressure falls below
90 PSI (620 kPa), make sure the transmission is in neutral, start the engine, and let the pressure build to governor cutoff.
After the pressure reaches the governor cutoff, continue testing. The pressure is critical if the vehicle is equipped with a
Pressure Protection Valve that would shut off the air supply to certain air circuits if the system pressure dropped below a
preset level.
IMPORTANT: Use the following air system troubleshooting procedures for part replacement only if the symptom can be duplicated. If the problem is intermittent, parts that are not defective could be replaced.
Instructions
1. Start at “Procedures” for Step A.
2. Based on the “Result” of the procedure, go to the corresponding “What To Do Next”.
8
Air System Troubleshooting
Procedure 1: Symptom - Air Leak at Shift Knob
Normal Operation:
• A burst of air will be exhausted from the shift knob when moving the range selector from low to high. This is the air being
exhausted from the “P” air line.
• A burst of air will be exhausted from the shift knob when moving the splitter button rearward (shifting to low split). This
is the air being exhausted from the “SP” air line.
Possible Causes:
• Incorrectly attached air lines
• Internal leak in slave valve
• Internal leak at insert valve
• Internal leak at shift knob
Table 10 Air Leak at Shift Knob
Procedure Result What to do next
Step A Remove lower skirt on shift knob.
Check for leaking fitting at the shift
knob.
Step B Check air lines to make sure all lines
are connected to the proper ports on
the shift knob.
A.) Reversal of “S” and “P” lines will
result in a constant leak from the exhaust when high range is selected.
B.) Reversal of the H/L and “SP”
lines will result in a constant leak
when the splitter button is rearward.
Step C Move the range selector lever down
to low range. Check for constant air
flow from the exhaust “E” port.
Leak found. Repair leaking fitting or air line.
No leak found. Go to Step B.
Air lines are not connected to the
proper ports.
Air lines are connected to the proper
ports.
Constant air flow from the “E” port. Replace knob.
Connect lines properly.
Go to Step C.
Air System Troubleshooting
Step D Move the range selector up to high
range. Disconnect the small air line
connected to the “P” port of the shift
knob. Check for air flow from the
port and air line.
No air flow from “E” port. Go to Step D.
Constant air is leaking from the “P”
port or the “E” port.
Air is coming out of the disconnected air line.
Air is not leaking from either port or
disconnected air line.
Repair or replace the shift knob.
1. Verify that the air line is connected
to the slave valve “p” port.
2. If properly connected, replace the
slave valve.
Go to Step E.
9
Air System Troubleshooting
Table 10 Air Leak at Shift Knob
Procedure Result What to do next
Step E Reattach the air line to the “P” port.
Move the range selector down to low
range and move the splitter button
rearward. Disconnect line from the
“SP” port. Check for air flowing from
the SP port on the shift knob.
Air is flowing from the SP line. 1. Check to make sure the “SP” line
is connected to the splitter cylinder
cover.
2. If the line is properly attached,
check that the insert valve (old style)
is properly installed (stem facing inward) and that the insert valve bore
is not defective.
3. Replace the insert valve.
Air is not flowing from the line. Repair or replace the shift knob.
10
Air System Troubleshooting
Procedure 2: Symptom - Air Leak at Slave Valve
Normal Operation:
A momentary exhaust of air at the slave valve occurs during a range shift. The air from the low side of the range cylinder is
exhausted as air pressure is applied to the high range side. Likewise, air from the high range side of the piston is exhausted as air
pressure is applied to the low range side. The exhaust port is located at the slave valve to transmission mounting interface.
Possible Causes:
• Internal leak in range cylinder.
• Internal leak in slave valve.
Table 11 Air Leak at Slave Valve
Procedure Result What to do next
Step A Confirm that air is leaking from the ex-
haust port on the slave valve and not a
fitting or air line.
Step B Move range selector down to select low
range.
Remove the 1/4" I.D. rubber air line at
the high range supply port on the range
cylinder.
Feel for air flow from the open port on
the range cylinder.
Notice if the air leak at the slave valve
only occurs when the transmission is in
high range.
Repeat the above test but remove the
low range air hose and check with high
range selected.
Air is leaking from fitting or air line. Repair or replace fitting or air line.
Air is definitely leaking from slave
valve exhaust port.
Air is flowing from high range supply port on range cylinder.
No air flow from high range port. Repair or replace slave valve.
Go to Step B.
Remove range cylinder cover and
repair leaking range piston or piston seal. After repair, check for
proper range operation.
Air System Troubleshooting
11
Air System Troubleshooting
Procedure 3: Symptom - Air Leak from Transmission Breather or Transmission Case is
Pressurized
Normal Operation:
There should be no measurable air flow from the transmission breather.
Possible Causes:
• Leak at range yoke bar O-ring
• Leak at splitter yoke bar O-ring
Table 12 Air Leak from Transmission Breather or Transmission Case is Pressurized
Procedure Result What to do next
Step A Listen for the air leak with the trans-
mission shifted to both low and
high range.
Leak is only in low range. Remove range cylinder and inspect for
damaged range yoke bar, yoke bar Oring, or range cylinder. Repair as necessary.
Leak is in both low and
high range.
Remove splitter cylinder. Inspect for
damaged splitter yoke bar, O-ring, or cylinder. Repair as necessary.
12
Air System Troubleshooting
Procedure 4: Symptom - Air Leak at Splitter Cylinder Cover Exhaust Port
Normal Operation:
A burst of air will exhaust from this port when shifting into low split (the splitter button is moved rearward while in low range).
Possible Causes:
• Damaged/defective insert valve
• Leak past insert valve external O-rings
• Leak past splitter cylinder piston
Table 13 Air Leak at Splitter Cylinder Cover Exhaust Port
Procedure Result What to do next
Step A (old
style)
Remove insert valve. Check for contamination, damaged seals, or sticky movement. Check the insert
valve bore in the splitter cylinder cover for contamination or damage which would result in leakage past
the insert valve O-rings.
Contamination or damage
found.
Repair or replace as necessary.
Air System Troubleshooting
Step B Remove the splitter cylinder cover and piston.
Check the piston bore for contamination or damage.
Check the piston seals for damage.
NOTE: Early production transmissions used a paper
gasket to seal the splitter cover to cylinder, if necessary, replace this configuration with the spool valve
design which uses an O-ring.
No contamination or damage
found.
Contamination or damage
found.
Go to Step B.
Repair or replace as necessary.
13
Air System Troubleshooting
Procedure 5: Symptom - No or Slow Range Shift into Low
Normal Operation:
When the range selector on the shift knob is moved down to select low range, air pressure will flow through the shift knob to the
"P" port on the slave valve. The slave valve will direct air pressure through the low range 1/4" rubber hose to the range cylinder to
shift the range. There will be a brief burst of air at the slave valve as the high range side of the range piston exhausts. Likewise,
when high range is selected, the air pressure in the "P" will be exhausted at the shift knob. This will cause the slave valve to direct
air to the rear side of the range cylinder piston. The air pressure on the low range side will be exhausted at the slave valve.
Possible Causes:
• Incorrect air line hook up
• Insufficient air supply to transmission
• Damaged or defective air filter / regulator assembly
• Damaged or defective shift knob master valve
• Damaged or defective slave valve
• Damaged or defective range cylinder
• Damaged or defective range yoke or yoke bar
• Damaged or defective range synchronizer
• Damaged or defective gearing in auxiliary section of transmission
Table 14 No or Slow Range Shift into Low
Procedure Result What to do next
Step A Place the shift lever in neutral.
Check for constant air leakage at the shift
knob, slave valve, and transmission case
breather when both low and high range
have been selected.
Step B Place shift lever in neutral.
Move range selector up to high range
position. At the rear of the transmission,
disconnect the 1/4" rubber air line from
the low range supply port on the range
cylinder. Check for air flow from the low
range port.
Step C Check for air flow from the disconnected
air line.
Constant air leak is detected. Go to the other corresponding symp-
No constant leak is detected. Go to Step B.
Air flows from the low range
port.
No air flow from low range
port.
Air flows from disconnected
air line.
tom first. See beginning of Air System
Troubleshooting section.
Remove range cylinder cover and repair leaking range piston or piston seal.
Go to step C.
Go to step F.
14
No air flow from disconnected line.
Go to step D.
Table 14 No or Slow Range Shift into Low
Procedure Result What to do next
Air System Troubleshooting
Step D Install a 100 PSI air gauge in the discon-
nected air line end. With the shift lever in
neutral, move the range selector down to
select low range. Observe the gauge.
Step E Confirm that shift lever is still in neutral.
Have an assistant move the range selector up and down between low and high
range. Does the pressure measured at
the gauge respond rapidly when going
from high to low?
The gauge read 0 PSI. Go to step F.
The gauge reads pressure but
is lower than 58 PSI or higher
than 63 PSI.
The gauge reads between 58 63 PSI.
Pressure rapidly changes between 58-63 PSI and 0 at the
gauge.
Pressure does not change
rapidly at gauge.
Replace the filter/regulator and check
for proper range operation.
Go to step E.
Air system appears to be operating
satisfactory. Go to step R.
1. Check for a plugged or dirty filter in
the filter/regulator assembly.
2. Check for a pinched or obstructed
1/4" rubber air line between the filter/
regulator and slave valve.
3. Check for a pinched or obstructed
1/4" rubber air line between the slave
valve and the test gauge.
Air System Troubleshooting
Step F Place shift lever in neutral.
At the shift knob, move the range selection lever up to select high range.
At the slave valve, remove the air line
from the "P" port. (should be a black
line). Check for air flow from the disconnected line.
Step G Check for air flow from the "P" port on
the slave valve.
4. If all are satisfactory, go to step F.
Air flows from the disconnected line.
No air flow from the disconnected line.
Air flows from this port. Replace the slave valve.
No air flow from this port. Go to step H.
1. Confirm that the air lines are connected to the correct ports at the shift
knob.
2. If the lines are correct, replace the
shift knob.
Go to step G.
15
Air System Troubleshooting
Table 14 No or Slow Range Shift into Low
Procedure Result What to do next
Step H Place the shift lever in neutral. Install a
100 PSI pressure gauge in line with the
"P" line. Move the range selector back
and forth from low to high range. The
gauge should show rapid pressure
change.
Step I If possible, leave air lines attached to
slave valve. Unbolt the slave valve from
transmission side. Check for free movement of the plunger pin protruding from
the case under the slave valve. The pin
should extract when the transmission is
shifted into gear and retract when shifted
into neutral.
NOTE: If desired, the slave valve can be
actuated and tested while unbolted from
the transmission case. The air lines, of
course, must remain attached.
The gauge responds slowly. 1. Check for a restricted line between
the shift knob and slave valve.
2. If the lines are correct, replace the
shift knob.
3. Check for a plugged or dirty filter in
the filter / regulator assembly.
4. Check for a pinched or obstructed
1/4" rubber air line between the filter/
regulator and slave valve.
5. Check for a pinched or obstructed air
line between the slave valve and the "S"
port on the shift knob.
6. If all are good, replace the shift knob.
The gauge rapidly moves between 58-63 PSI and 0 PSI.
Actuating plunger pin does
not move freely.
Go to step I.
1. Remove actuating plunger pin and
check for damage.
16
Actuating plunger pin moves
freely.
2. Check for missing or broken spring.
Repair or replace slave valve and check
for proper range operation.
Table 14 No or Slow Range Shift into Low
Procedure Result What to do next
Step R If air system has been tested and found
to operate satisfactory, the auxiliary section must be removed to inspect for mechanical problem.
Remove auxiliary section and inspect
for:
•Binding of range yoke bar or piston
•Damaged or defective range yoke
•Damaged or defective range synchronizer
•Cracked countershaft weld resulting in
gear turning on shaft
•Damaged or defective range sliding
clutch
•Auxiliary section gearing out of time
Air System Troubleshooting
Air System Troubleshooting
17
Air System Troubleshooting
Procedure 6: Symptom - No or Slow Range Shift into High
Normal Operation:
When the range selector on the shift knob is moved down to select low range, air pressure will flow through the shift knob to the
'P" port on the slave valve. The slave valve will direct air pressure through the low range 1/4" rubber supply hose to the range
cylinder to shift the range. There will be a brief burst of air at the slave valve as the high range side of the range piston exhausts.
Likewise, when high range is selected, the air pressure in the "P" will be exhausted at the shift knob. This will cause the slave valve
to direct air to the rear side of the range cylinder piston. The air pressure on the low range side will be exhausted at the slave valve.
Possible Causes:
• Incorrect air line hook up
• Insufficient air supply to transmission
• Plugged filter
• Incorrect regulator pressure
• Damaged or defective shift knob master valve
• Damaged or defective slave valve
• Damaged or defective range cylinder
• Damaged or defective range yoke or yoke bar
• Damaged or defective range synchronizer
• Damaged or defective gearing in auxiliary section of transmission
Table 15 No or Slow Range Shift into High
Procedure Result What to do next
Step A Place the shift lever in neutral.
Check for constant air leakage at the shift
knob, slave valve, and transmission case
breather when both low and high range
have been selected.
Step B Place shift lever in neutral.
Move range selector down to low range
position.
At the transmission rear, disconnect the
1/4" rubber air line from the range cylinder high range supply port.
Check for air flow from the cylinder high
range port.
Constant air leak is detected. Go to the other corresponding symp-
No constant leak is detected. Go to Step B.
Air flows from the high range
port.
No air flow from high range
port.
tom first. See beginning of Air System
Troubleshooting section.
Remove range cylinder cover and repair leaking range piston or piston seal.
After repair, check for proper range operation.
Go to step C.
Step C Check for air flow from the disconnected
air line.
18
Air flows from disconnected
air line.
No air flow from disconnected line.
Go to step F.
Go to step D.
Table 15 No or Slow Range Shift into High
Procedure Result What to do next
Air System Troubleshooting
Step D Install a 100 PSI air gauge in the discon-
nected air line end. With the shift lever in
neutral, move the range selector up to
select high range. Observe the gauge.
Step E Confirm that shift lever is still in neutral.
Have an assistant move the range selector up and down between low and high
range. Does the pressure measured at
the gauge respond rapidly when going
from high to low.
The gauge reads 0 PSI. Go to step F.
The gauge reads pressure but
is lower than 58 PSI or higher
than 63 PSI.
The gauge reads between 58 63 PSI.
Pressure rapidly changes between 58-63 PSI and 0 at the
gauge.
Pressure does not change
rapidly at gauge.
Replace the filter/regulator and check
for proper range operation.
Go to step E.
Air system appears to be operating
satisfactory. Go to step R.
1. Check for a plugged or dirty filter in
the filter/regulator assembly.
2. Check for a pinched or obstructed 1/
4" rubber air line between the filter/regulator and slave valve.
3. Check for a pinched or obstructed 1/
4" rubber air line between the slave
valve and the test gauge.
Air System Troubleshooting
Step F Place shift lever in neutral.
At the shift knob, move the range selection lever up to select high range.
At the slave valve, remove the air line
from the "P" port. (should be black line).
Check for air flow from the disconnected
line.
Step G Check for air coming out of the slave
valve "P" port.
4. If all are satisfactory, go to step F.
Air flows from the disconnected line.
No air flow from the disconnected line.
Air flows from this port. Replace the slave valve.
No air flow from this port. Go to step H.
1. Confirm that the air lines are connected to the correct ports at the shift
knob.
2. If the lines are correct, replace the
shift knob.
Go to step G.
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Air System Troubleshooting
Table 15 No or Slow Range Shift into High
Procedure Result What to do next
Step H Place the shift lever in neutral. Install a
100 PSI pressure gauge in line with the
"P" line. Move the range selector back
and forth from low to high range. The
gauge should show rapid pressure
change.
Step I If possible, leave air lines attached to
slave valve.
Unbolt the slave valve from transmission
side.
Check for free movement of the plunger
pin protruding from the case under the
slave valve. The pin should extract when
the transmission is shifted into gear and
retract when shifted into neutral.
If desired, the slave valve can be actuated and tested while unbolted from the
transmission case. The air lines, of
course, must remain attached.
The gauge responds slowly. 1. Check for a restricted line between
the shift knob and slave valve.
2. Check for a restricted exhaust port
on the shift knob.
3. Check for a plugged or dirty filter in
the filter/regulator assembly.
4. Check for a pinched or obstructed
1/4" rubber air line between the filter/
regulator and slave valve.
5. Check for a pinched or obstructed air
line between the slave valve and the "S"
port on the shift knob.
6. If all are good, replace the shift knob.
The gauge rapidly moves between 58-63 PSI and 0 PSI.
Actuating plunger pin does
not move freely.
Go to step I.
1. Remove actuating plunger pin and
check for damage.
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Actuating plunger pin moves
freely.
2. Check for missing or broken spring.
Repair or replace slave valve and check
for proper range operation.
Table 15 No or Slow Range Shift into High
Procedure Result What to do next
Step R If air system has been tested and found
to operate satisfactory, the auxiliary section must be removed to inspect for mechanical problem.
Remove auxiliary section and inspect
for:
•Binding of range yoke bar or piston
•Damaged or defective range yoke
•Damaged or defective range synchronizer
•Cracked countershaft weld resulting in
gear turning on shaft
•Damaged or defective range sliding
clutch
•Auxiliary section gearing out of time
Air System Troubleshooting
Air System Troubleshooting
21
Air System Troubleshooting
Procedure 8: Symptom - Range Shifts with Shift Lever in Gear
Normal Operation:
Range shifts should only occur when the shift lever is in neutral. The range selector can be moved up or down while the shift lever
is in a gear position, but the shift will not occur until the shift lever is moved to neutral.
Possible Causes:
• Worn or missing actuating pin or air valve shaft
• Worn shift rail
Procedure:
If the range has been confirmed to shift with the shift lever in gear, unbolt the slave valve from the side of the transmission. Confirm that the actuating pin is present and that it is the proper part number for the corresponding slave valve. If correct, remove the
shift bar housing assembly and check for a worn or damaged air valve shaft or worn shift rails. Replace necessary parts.
22
Air System Troubleshooting
RTLO 10-Speed Troubleshooting
Confirm Correct Components and Plumbing
• A-5454 Air Filter/Regulator on the range cylinder cover.
• 1/4 inch air hose from the air filter/regulator to the splitter cylinder cover (iron port).
• A red air line from the air filter/regulator to the tee in the range actuator valve "S" port on the shift bar housing.
• A red air line from the tee to the A-5510/A-6910 Roadranger valve "S" port.
• A black air line from the range actuator valve "P" port to the range cylinder.
• A blue air line from the Roadranger A-5510/A-6910 valve "SP" port to the splitter cylinder cover (brass port.)
WARNING: Prior to removing the air module, exhaust the air from it. Failure to exhaust the air module may result in
personal injury or damage to parts from the sudden release of air.
WARNING: Use care when removing the test port pipe plugs. If air pressure is present on the plug, it can become a
projectile during removal. When removing the “L” plug or “H” plug, pressure can be shut off by selecting the opposite
range mode. If removing the “F” plug, exhaust the air to the module inlet.
Air System Troubleshooting
Blue Air Line
Red Air Line
Red Air Line
Black Air Line
O
N
L
Y
C
C
N
A-5454
Air Filter/
Regulator
Air Hose
23
Air System Troubleshooting
Air Filter/ Regulator Test
Figure 1
Figure 2
Table 1 Air Filter/Regulator Test
Step Procedure Result What to do next
A Place the transmission shift lever
in neutral.
B Start the engine and wait for the
air system pressure to reach governor cut off (90 to 125 PSI.)
C Turn the engine off.
If at any time during testing the
truck's air pressure falls below 90
PSI; restart the engine, wait for air
pressure to reach governor pressure, turn the engine off, and continue testing.
D Make sure the splitter control but-
ton is rearward.
E Remove the two (2) screws on the
Roadranger valve cover and pull
the cover down.
F Disconnect the blue air line from
the "SP" port.
G Install the correct test fixture for
your air line size in the "SP" line.
24
Air System Troubleshooting
Table 1 Air Filter/Regulator Test
Step Procedure Result What to do next
H Move the splitter control button
forward to overdrive. The air pressure gauge should read between
58 and 63 PSI.
R Remove the test fixture. Assemble
the Roadranger valve.
Air pressure is outside the 58 to
63 PSI range and the truck's air
system pressure is 90 to 125 PSI.
Air pressure slowly comes up to
between 58 and 63 PSI.
Replace the A-5454 Filter/Regulator.
Inspect the red air line from the filter/regulator
to the range actuator valve and the red air line
from the range actuator valve to the A-5510/A6910 Roadranger valve for restrictions
Air System Troubleshooting
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