Eaton Transmission RTLO-10 Service Manual

Troubleshooting Guide

Fuller Transmissions TRTS0920

July 2011

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

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

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

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

Air Hose

Splitter Cylinder

General Information

Component Identification

Air Filter/ Regulators

Control Valves - Old Production

A-3546

DOWN-LOW

-H UP

Deep Reduction Valve 14651

SHIFT ONLY WHEN IN LOW

RANGE

DO NOT

PRE-SELECT

OUT

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

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

23545 - old design

EXH

4303110 - latest design

EXH

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

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

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”.

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.

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.

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

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.

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.

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.

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.

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.

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

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.

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.

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.

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

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.

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

Black Air Line

O N

L Y

A-5454 Air Filter/ Regulator

Air Hose

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.

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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