Eaton Transmission RTLO-10 Service Manual

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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

Range System Test

If water or oil is found in an insert valve, remove both insert valves, the filter/regulator, the range cylinder cover, and the range piston. Clean everything and replace the range piston O-rings and range cylinder cover gasket. Apply silicone grease to the external range piston O-ring and the insert valve O-rings. Assemble and test.

Note: If you replace or repair any parts, return to Step A after completion

Figure 3

Figure 4

Table 2 Range System Test

Step Procedure Result What to do next

A Move the transmission shift lever in

neutral away from the driver to the top gear rail position.

B Remove the black air line from the

range cylinder cover.

C Check for air flow out of the black air

line.

There is no air flow from the black air line.

There is air flow. Check the range actuator valve retain-

Go to step D.

ing bolts. Tighten any loose bolts and check again for air flow. If air flow continues, remove the range actuator valve retaining bracket bolts. Push the button all the way into the valve. If air flow continues, replace the range actuator valve. If air flow stops when the range actuator valve is manually operated, remove the actuating pin (lift it out with a magnet). Check the pin for wear. It should be 1.029 to 1.032 inches long. If it is not, replace the pin. If the pin length is correct, refer to the service manual for shift bar housing inspection.

Air System Troubleshooting

Table 2 Range System Test

Step Procedure Result What to do next

D Check for air flow from the range cyl-

inder port.

E Install the correct test fixture, for your

air line size, in the range cylinder port.

There is no air flow from the port. Go to step E.

There is air flow. Remove the insert valve retaining plug

from the range cylinder cover bottom. The insert valve will be blown out of the cover. Clean the insert valve, using compressed air and apply silicone grease to the external O-rings. Assemble and check for air flow from the port. If air flow persists, replace the insert valve.

Air System Troubleshooting

F Move the transmission shift lever to-

ward the driver (center rail.) The air pressure should rapidly be between 58 and 63 PSI.

Air pressure rapidly comes up to between 58 and 63 PSI.

Air pressure does not rapidly come up to between 58 and 63 PSI.

Remove the test fixture and connect the black air line to the range cylinder. If air pressure does rapidly come up to between 58 and 63 PSI, remove the actuating pin (lift it out with a magnet). The pin should be between 1.029 and

1.032 inches long. If it is not, replace it. If the pin length is correct, refer to the service manual for shift bar housing inspection.

Inspect the black air line from the range actuator valve "CYL" port for restrictions.If there are no restrictions, remove the range actuator valve retaining bolt. Push the button all the way into the valve and release it. If air pressure does not rapidly come up to between 58 and 63 PSI, replace the range actuator valve.

Air System Troubleshooting

Table 2 Range System Test

Step Procedure Result What to do next

G Listen for a range shift while moving

the transmission shift lever from neutral to the top gear rail and back toward the driver into the center rail. If there is no range shift, move the transmission shift lever back and forth again and check for a momentary exhaust from the insert valve retaining plug in the range cylinder cover bottom.

I Move the transmission shift lever in

neutral toward the driver to the center rail. Check both insert valve retaining plugs for continuous air flow from the exhaust port.

There is no range shift and there is momentary exhaust from both insert valves.

There is no momentary exhaust. Remove the insert valve retaining plug

There is momentary exhaust. Move the transmission shift lever in

There is air flow. Remove the insert valve retaining plug.

Remove the range cylinder cover. If the piston is stuck from rust and contamination, remove the piston, clean the cylinder, replace the O-rings, and assemble. Clean the insert valve, use compressed air and apply silicone grease to the external O-rings. Assemble and test.

from the range cylinder cover bottom. The insert valve will be blown out of the cover. Clean the insert valve, use compressed air and apply silicone grease to the external O-rings. Assemble and test. If there is still no momentary exhaust, replace the insert valve.

neutral back and forth again and check for momentary exhaust from the insert valve retaining plug on the range cylinder cover side. Continue to step I.

The insert valve will be blown out of the cover. Clean the insert valve, use compressed air and apply silicone grease to the external O-rings. Assemble and check for air flow. If air flow persists, replace the insert valve. If air flow persists with a new insert valve, remove the range cylinder cover and inspect the range piston O-rings for damage or contamination and the range piston for cracks.

J Move the transmission shift lever in

neutral away from the driver to the top gear rail. Check both insert valve retaining plugs for continuous air flow from the exhaust port.

There is no air flow. Go to step J.

There is air flow. Remove the insert valve retaining plug.

There is no air flow. Go to step K.

Air System Troubleshooting

Table 2 Range System Test

Step Procedure Result What to do next

K With the transmission shift lever in

neutral, toward the driver in the center rail, remove the breather or breather hole plug on the shift bar housing. Check for air flow from the hole in the shift bar housing. If there is airflow move the transmission shift lever in neutral, away from the driver, to the top gear rail.

R If the insert valves were not removed

and cleaned during the test, remove them now (remove the insert valve retaining plugs.) The insert valves will be blown out the cover. Clean the insert valve, use compressed air and apply silicone grease to the external "O" rings. Assemble and test. The range portion of the test is now complete.

Air flow stopped. Refer to the service manual and re-

place the range piston shaft to range cylinder O-ring.

Air System Troubleshooting

Air flow did not stop. Refer to the service manual and re-

place the splitter piston shaft to splitter cylinder O-ring.

Air System Troubleshooting

Splitter System Test

If you replace or repair any parts , return to Step A after completion

Ffigure 1

Figure 3

Figure 2

Table 3 Splitter System Test

Step Procedure Result What to do next

A Wipe off the area around the insert

valve exhaust port.

B Move the control button back and

forth several times to clear the exhaust port.

C Make sure the control button is rear-

ward. Loosen the control air line retaining nut at the splitter cylinder.

Air System Troubleshooting

Table 3 Splitter System Test

Step Procedure Result What to do next

D Remove the loosened control air line

and check for air flow from the cylinder fitting.

E Install, between the control line and

the cylinder fitting, the correct test fixture for your air line size.

F Move the control button forward. Air pressure rapidly changes to be-

G Check the insert valve exhaust port for

leakage.

H Move the control button rearward and

listen for the shift.

There is no air flow. Go to step E.

There is air flow. Remove the insert valve and clean us-

tween 58 and 63 PSI and the truck's air system is 90 to 125 PSI.

Air pressure does not change to between 58 and 63 PSI and the truck's air system is 90 to 125 PSI.

No leakage is detected. Go to next step H.

Leakage is detected. Go to Step L.

There is a shift. Go to next step I.

ing compressed air. Then apply silicone grease to the o-rings and recheck for airflow.

Air System Troubleshooting

Go to next step G.

Inspect the control air line for restrictions.

There is no shift or a delayed shift. Go to Step L.

I Check the exhaust port for leakage. No leakage is detected. Go to next step J.

Leakage is detected. Go to Step L.

J Move the control button forward and

listen for the shift.

K If there is air pressure at the control

line, move the control button rearward and remove the test fixture. Connect the control line to the cylinder.

L Remove the insert valve retaining

plug. The insert valve will be blown out of the cover (note valve orientation.)

M Clean insert valve using compressed

air.

There is a shift. Go to next step K.

There is no shift or a delayed shift. Go to Step L.

There is no water and/or oil blown out. Go to next step M.

Water and/or oil is blown out. Remove the cylinder cover and clean

the cover and cylinder. Replace the cylinder cover gasket with a new gasket. Install cover.

Air System Troubleshooting

Table 3 Splitter System Test

Step Procedure Result What to do next

N Install the insert valve, as noted in

Step L, and replace the retaining plug.

O Check the insert valve exhaust port for

leakage.

P Move the control button forward and

listen for the shift.

Q Check the insert valve exhaust port for

leakage.

R Move the control button rearward and

listen for the shift

S Check the insert valve exhaust port for

leakage.

No leakage is detected. Go to next step P.

Leakage is detected. Replace the insert valve.

There is a shift. Go to next step Q.

There is no shift or a delayed shift. Replace the insert valve.

No leakage is detected. Go to next step R.

Leakage is detected. Replace the insert valve.

There is a shift. Go to next step S.

There is no shift or a delayed shift. Replace the insert valve.

No leakage is detected. Go to next step T.

Leakage is detected. Disassemble (see service manual)

and inspect splitter/reduction piston O-ring and piston to shaft seal.

T Move the control button forward and

listen for the shift.

V The air system test procedure is now

complete and the air system has been confirmed to be operating correctly. If performance irregularities persist, they are not caused by the air system.

There is a shift. Go to next step V.

There is no shift or a delayed shift. Disassemble (see service manual)

and inspect splitter/reduction piston O-ring and piston to shaft seal.

Air System Troubleshooting

Combination Cylinder Troubleshooting

The symptoms listed below are covered on the following pages. Before beginning any of those troubleshooting procedures, place the transmission in neutral and move the range selection lever from low to high. Listen for any constant air leak from the shift knob, air module base (exhaust), or transmission breather. If a constant leak is heard, go to that particular leak troubleshooting procedure first.

If you do not see the symptom you need to correct, refer to the General Troubleshooting chart.

Symptom

• Air Leak from Air Module Base (Exhaust Leak)

• No or Slow Range Shift into High (Shift into low range is good)

• No or Slow Range Shift into Low (Shift into high range is good)

• Constant Air Leak from Shift Knob

• Range Shifts in Gear

• Air Leak from Transmission Breather or Transmission Case is Pressurized

Note: Use the 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.

Air System Troubleshooting

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 vehicle air system Pressure Protection Valve that would shut off the air supply to certain air circuits if the system pressure dropped below a preset level.

Note: A 0-150 PSI (0-1034 kPa) air gauge with a 1/16” male pipe thread fitting attachment is required for some of the test proce-

dures.

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

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 deep reduction button rearward (shifting out of deep reduction).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 1 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. Reversal of “S” and “P” lines will result in a constant leak from the exhaust when high range is selected. Reversal of the H/L and “SP” lines will result in a constant leak when the deep reduction button is rearward.

Step C Move the range selector lever down to

Low range. Check for constant air flow from the exhaust “E” port.

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.

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 proper ports. Go to step C.

Constant air flow from “E” port. Replace knob.

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.

Connect lines properly.

Repair or replace the shift knob.

1. Verify that the air line is connected to the slave valve “p” port.

Air is not leaking from either port or disconnected air line.

2. If properly connected, replace the slave valve.

Go to Step E.

Table 1 Air Leak at Shift Knob

Procedure Result What to do next

Air System Troubleshooting

Step E Reattach the air line to the “P” port. Move

the range selector down to low range and move the deep reduction button rearward. Disconnect the air line from the “SP” port. Check for air flowing from the SP line.

Air is flowing from the SP line. 1. Check to make sure the

“SP” line is connected to the deep reduction cylinder cover.

2. If the line is properly attached, check that the insert valve 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:

Possible Causes:

• Internal leak in range cylinder

• Internal leak in slave valve.

Table 2 Air Leak at Slave Valve

Procedure Result What to do next

Step A Confirm that air is leaking from the

exhaust 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. Note: 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 deep reduction yoke bar O-ring

Table 3 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 O-ring, or range cylinder. Repair as necessary.

Leak is in both low and high range. Remove deep reduction cylinder. In-

spect for damaged deep reduction yoke bar, O-ring, or cylinder. Repair as necessary.

Air System Troubleshooting

Procedure 4: Symptom: Air Leak at Deep Reduction Cylinder Cover Exhaust Port

Normal operation:

A burst of air will exhaust from this port when shifting into deep reduction (the deep reduction button is moved forward while in low range).

Possible causes:

• Damaged/defective insert valve

• Leak past insert valve external O-rings

• Leak past deep reduction cylinder piston

Table 4 Air Leak at Deep Reduction Cylinder Cover Exhaust Port

Procedure Result What to do next

Step A Remove insert valve. Check for con-

tamination, damaged seals, or sticky movement. Check the insert valve bore in the deep reduction cylinder cover for contamination or damage which would result in leakage past the insert valve O-rings.

Step B Remove the deep reduction 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 piston to the yoke bar, if necessary, replace this configuration with the current design which uses an Oring.

Contamination or damage found. Repair or replace as necessary.

No contamination or damage found. Go to step B.

Contamination or damage found. 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 5 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.

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. Remove range cylinder cover and re-

Air System Troubleshooting

tom first. See beginning of Air System Troubleshooting section.

pair leaking range piston or piston seal.

Step C Check for air flow from the discon-

nected air line.

No air flow from low range port. Go to step C.

Air flows from disconnected air line. Go to step F.

No air flow from disconnected line. Go to step D.

Air System Troubleshooting

Table 5 No or Slow Range Shift into Low

Procedure Result What to do next

Step D Install a 100 PSI air gauge in the dis-

connected air line end. With the shift lever in neutral, move the range selector down to select low range and observe the gauge.

Step E Confirm that shift lever is still in neu-

tral. 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.

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 flow from the “P” por-

tion the slave valve.

3. Check for a pinched or obstructed 1/4” rubber air line between the slave valve and the test gauge.

4. If all are satisfactory, go to step F.

Air flows from the disconnected line. 1. Confirm that the air lines are con-

nected to the correct ports at the shift knob.

2. If the lines are correct, replace the shift knob.

No air flow from the disconnected line.

Air flows from this port. Replace the slave valve.

No air flow from this port. Continue to step H.

Go to step G.

Table 5 No or Slow Range Shift into Low

Procedure Result What to do next

Air System Troubleshooting

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

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.

Air System Troubleshooting

2. Check for missing or broken spring.

Actuating plunger pin moves freely. Repair or replace slave valve and

check for proper range operation.

Air System Troubleshooting

Table 5 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 c/s 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 6 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 above corresponding

No constant leak is detected. Go to step B.

Air flows from the high range port. Remove range cylinder cover and re-

Air System Troubleshooting

symptom first. See beginning of Air System Troubleshooting section.

pair leaking range piston or piston seal. After repair, check for proper range operation.

Step C Check for air flow from the discon-

nected air line.

No air flow from high range port. Go to step C.

Air flows from disconnected air line. Go to step F.

No air flows from disconnected line. Go to step D.

Air System Troubleshooting

Table 6 No or Slow Range Shift into High

Procedure Result What to do next

Step D Install a 100 PSI air gauge in the dis-

connected 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 a 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 low to 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. Go to Step E.

Pressure rapidly changes between 58-63 PSI and O at the gauge.

Pressure does not respond rapidly at gauge.

Replace the filter/regulator and check for proper range operation.

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.

Step F Place shift lever in neutral. At the shift

knob, move the range selector 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. 1. Confirm proper air line hook-up at

the shift knob.

2. If correct hook-up, replace the shift knob.

No air flow from the disconnected line.

Air flows from this port. Replace the slave valve.

No air flow from this port. Continue to Step H.

Go to Step G.

Table 6 No or Slow Range Shift into High

Procedure Result What to do next

Air System Troubleshooting

Step H Place the shift lever in neutral. Install

a 100 PSI pressure gauge in line with the "P" line end. Move the range selection lever 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 the 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. 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.

Air System Troubleshooting

2. Check for missing or broken spring.

Actuating plunger pin moves freely. Repair or replace slave valve and

check for proper range operation.

Air System Troubleshooting

Table 6 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 c/s weld resulting in gear turning on shaft

•Damaged or defective range sliding clutch

•Auxiliary section gearing out of time.

Air System Troubleshooting

Procedure 7: Symptom - No or Slow Shift into Deep Reduction

Normal Operation:

When the deep reduction button is moved forward to select deep reduction, air pressure is supplied through the “SP” air line to the insert valve signal port. This air pressure causes the insert valve to exhaust the air pressure on the rear of the deep reduction piston and the piston moves rearward. A burst of air occurs at the deep reduction cylinder exhaust port as this air is exhausted from the piston back side. A burst of air also occurs at the shift knob when the deep reduction button is moved rearward. This is the signal air being exhausted out of the “SP” line.

Possible causes:

• Incorrect air line hook up, Plugged filter.

• Incorrect regulator pressure. Insufficient air supply to transmission.

• Damaged or defective shift knob master valve.

• Damaged or defective deep reduction insert valve.

• Damaged or defective deep reduction piston or cylinder.

• Damaged or defective deep reduction yoke bar or yoke.

• Damaged or defective deep reduction sliding clutch or gearing.

Note: Before completing the following troubleshooting procedure, move the deep reduction button both rearward and forward an

check for constant exhaust air at either the shift knob or deep reduction cylinder exhaust port. If a constant leak is noticed, go to that troubleshooting procedure first. In addition, confirm that the low and high range shifts are occurring properly. If not, go to the appropriate range shift troubleshooting procedure before completing the following procedure.

Table 7 No or Slow Shift into Deep Reduction

Procedure Result What to do next

Step A Move range selector down to select

low range. Move the deep reduction button rearward. At the deep reduction cylinder on the transmission back, remove the small air line which provides the signal to the insert valve (SP line). Make sure this line was connected to the proper port location on the cylinder cover. Check for air flow from the line.

Air flows from the disconnected line. Go to Step K.

Air System Troubleshooting

Step B Connect a 100 PSI pressure gauge to

the disconnected signal port line. Move the deep reduction button forward. Read the pressure on the gauge.

No air flow from disconnected line. Go to Step B.

Gauge reads 0 PSI. Go to Step F.

Gauge reads pressure, but is lower than 58 PSI or higher than 63 PSI.

Gauge reads between 58 PSI and 63 PSI.

Replace filter / regulator assembly.

Go to Step C.

Air System Troubleshooting

Table 7 No or Slow Shift into Deep Reduction

Procedure Result What to do next

Step C Have an assistant move the deep re-

duction button forward and rearward. Observe the pressure gauge.

Step D Remove the insert valve. NOTE: After

the insert valve plug has been removed, cover the opening with a shop rag and apply shop air to the signal line port to blow the insert valve out of it’s bore. Catch the valve with the shop rag. If the vehicle air pressure is still present, constant air flow should be blowing out of the insert valve bore. Inspect the insert valve for contamination or damage. Make sure the small piston inside the valve can freely move 1/32”.

Pressure rapidly changes between 5863 PSI and 0 PSI at the gauge.

Pressure does not respond rapidly at gauge.

Insert valve is contaminated, sticking, or damaged.

Insert valve is clean and small internal piston moves freely.

Go to Step D.

Go to Step F.

Replace insert valve, reconnect air line, and check if deep reduction shifts normally.

Go to step E.

Step E Remove the deep reduction cylinder

cover and deep reduction piston. Inspect piston and bore for contamination or damage.

Deep reduction cylinder bore or piston is contaminated or damaged.

Deep reduction cylinder bore or piston is in good condition.

Repair as necessary, replace insert valve and air line. Check if deep reduction shifts normally

1. Remove deep reduction cylinder assembly. Inspect for contamination or damage causing deep reduction yoke bar to bind in cylinder. Repair as necessary.

2. Remove auxiliary section and inspect deep reduction yoke, sliding clutch, and gearing for damage which would prevent deep reduction shift. Repair as necessary.

Table 7 No or Slow Shift into Deep Reduction

Procedure Result What to do next

Air System Troubleshooting

Step F At the shift knob, remove the two

screws attaching the lower cover, and slide the lower cover down to access the fittings. Confirm that the air lines are connected to the proper ports. Make sure the shift lever is in neutral. Move the range selector down to select low range, and move the deep reduction button rearward. Disconnect the air line connected to the “SP” port. Check for air flow from the “SP” port.

Step G Move deep reduction button forward.

Check for air flow from “SP” port.

Step H Disconnect air line H/L port on shift

knob. Check for air flow from the disconnected line.

Air flows from “SP” port. Replace shift knob.

Air System Troubleshooting

No air flow from “SP” port. Go to Step G.

Air flows from “SP” port. 1. Check for proper air line connec-

tion from “SP” port on shift knob to “SP port on deep reduction cylinder .

2. Check for obstruction in “SP” air line or fittings.

3. If clear, reconnect the air line at the shift knob, go to step A.

No air flow from “SP” port. Go to step H.

Air flows from disconnected line. Replace shift knob.

No air flow from disconnected line.

1. Check to make sure that the shift lever is in neutral, the range selector is down in low range and the “H/ L” line is properly connected to the low range hose at the slave valve.

2. If no air pressure is available on low range hose, perform low range shift troubleshooting procedure to correct this problem.

Air System Troubleshooting

Procedure 8: Symptom - Range Shifts with Shift Lever in Gear

Normal Operation:

Range shift 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 P/N 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

FR-1X210 Troubleshooting

Symptom

• Air leak from Air Module Base (Exhaust leak)

• No or Slow Range Shift into High (Shift into low range is good)

• No or Slow Range Shift into Low (Shift into high range is good)

• Constant Air Leak from Shift Knob

• Range Shifts While Transmission is in Gear

• Air Leak from Transmission Breather or Transmission Case is Pressurized

Note: Use the 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.

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.

Note: A 0-150 PSI (0-1034 kPa) air gauge with a 1/16" male pipe thread fitting attachment is required for some of the test proce-

dures.

Note: Regulated air pressure is 75 to 85 PSI (517-586 kPa).

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.

Air System Troubleshooting

Air System Nomenclature

Figures 4-1 through 4-3 below show the air module, shift knob, and range alignment lock cover (earlier models) with their components labeled. These are the primary components used during troubleshooting. If necessary, refer to these figures while troubleshooting the air system.

Air System Troubleshooting

Figure 4-4 below shows how to isolate the air module. If necessary, refer to this figure when isolating the air module.

Air System Troubleshooting

Figure 4-4 Air Module Isolation

The table below shows which air lines connect to which ports on the shift knob and air module. If necessary, refer to this table when connecting the air lines.

Port on Knob Port on Air Module Air Line Color (Typical)

SSRed

PPBlack

Air System Troubleshooting

Air System Symptom - Air Leak from Module Base (Exhaust)

Short bursts of air leakage from the module base (exhaust) are normal as the range system is shifted. The module base is defined as both the interface of the module cover and module base and the extreme underside of the module. Leakage is a problem when it is audible and constant. Air leakage from the module base may result from either a defective air module or a defective range piston. The following procedure will identify the defective component.

Test Procedure:

1. Check for air leakage from the module base (exhaust) in each of the four following conditions. (Make sure the range is shifted

when the shift lever is in neutral.)

a. Range selection lever in Low and shift lever in neutral.

b. Range selection lever in Low and shift lever in gear.

c. Range selection lever in High and shift lever in neutral.

d. Range selection lever in High and shift lever in gear.

Record the findings (constant leak or no leak) in the following table.

Range Selector in LOW Range Selector in HIGH

Lever in Neutral

Lever in Gear

2. If the information you recorded at step 1 matches one of the following tables, replace the air module. If your table does not match either of the tables, it will be necessary to isolate and test the air module separately, continue to step 3.

Range Selector in LOW Range Selector in HIGH

Lever in Neutral No Leak Constant Leak

Lever in Gear No Leak Constant Leak

Range Selector in LOW Range Selector in HIGH

Lever in Neutral Constant Leak Constant Leak

Lever in Gear Constant Leak Constant Leak

WARNING: Failure to exhaust the air pressure may cause personal injury or damage to parts.

3. Exhaust the air pressure from the air module. To do so, the vehicle’s air tanks may need to be exhausted.

4. Leaving all air lines connected to the module, remove the four capscrews attaching the air module to the shift bar housing. Lift

the air module and tilt it to gain access to the two air holes at the underside on the rear capscrew location. Do not damage or lose the two o-rings used to seal the holes.

5. Block off the air ports on the underside of the module. Use a piece of gasket material or rubber material to seal the bottom of the module as shown in Figure 4-1 under “Air System Nomenclature”.

6. Repressurize the air module with an inlet supply pressure of over 90 PSI (620 kPa). To repressurize the air module, the vehicle may need to be started and air pressure allowed to build up.

7. Check for air leakage in both high and low range. If air continues to leak constantly from the exhaust, the air module is defective. If air does not leak, a range cylinder piston or piston seal failure has occurred. Remove the shift bar housing to gain access to the range shift cylinder.

Air System Troubleshooting

Air System Symptom - No or Slow Range Shift into High (Shift into Low Range is Good)

This transmission contains a SynchroSaver feature to protect the high range synchronizer. When high range is selected and a front section gear is engaged, air pressure is supplied to both sides of the range piston, which reduces synchronizer force. Therefore, if the driver engages a front section gear before the high range synchronizer engages, the high range synchronizer will remain in neutral. When a front section gear engages before the synchronizer shift completes, the driver must shift the lever back to neutral to allow the high range synchronizer to complete its shift. Once the range shift is complete, the driver can complete the front section shift.

If the high range synchronizer hangs up or is slow to synchronize, the front section may engage first. The driver complaint will be that the transmission “neutralizes” on a shift to high range. If this condition occurs, perform the following test of the air system to eliminate the air system as the source of the problem. If the air system performs properly, then the problem is internal to the transmission range synchronizer system.

Note: The driver must preselect all range shifts.

Note: If a capscrew or stud is installed too far into the right side (air module side) rear support hole, the fastener can extend too

far into the transmission. The fastener may contact the range yoke and bind the range synchronizer assembly during the range shift.

Test Procedure

1. Check the shift knob operation.

Air System Troubleshooting

On the shift knob, remove the screws holding the plastic skirt. Slide the skirt down and out of the way. Move the range selection lever up into high range. Disconnect the black line connected to the “P” port on the knob.

Question Result What to do next

Does air come out of the “P” port on the knob?

2. Test the regulator pressure. (Regulator pressure should be between 75 and 85 PSI (517-586 kPa).)

Reconnect the “P” line at the shift knob. Locate the two small pipe plugs on the rear of the air module. One is labeled “H" and the other “L”. (See Figure 4-1 “Air System Nomenclature”). Install a 0-150 PSI (0-1034 kPa) air gauge in the port marked “H.”

Note: Prior to removing the pipe plug, turn off the air flow by flipping the range selector down into the low range position. The

transmission must be in neutral.

Move the range selector up to the high range position and record the pressure on the gauge. Match the pressure to one of those on the chart on the next page, and follow the corresponding instructions.

Question Result What to do Next

What is the air pressure at the “H” port?

75-85 PSI (517-586 kPa) (to specification)

Yes Repair or replace the knob.

No Reconnect the air line to the knob, and con-

tinue to the next step.

Continue to the next step.

Air System Troubleshooting

Question Result What to do Next

Less than 75 PSI (517 kPa)

Greater than 85 PSI (586 kPA)

3. Check the spool valve function.

With the shift lever in neutral, move the range selector from low to high several times. Answer the question on the chart below, and follow the instructions corresponding to the result.

Question Result What to do Next

Does the gauge rapidly go from 7585 PSI (517-586 kPa) in High to 0 PSI in Low?

4. Isolate and test the air module. Refer to Figure 4-1 “Air System Nomenclature” to see an example of an isolated air module.

Yes Air system performs properly. Go to

No Continue to the next step.

On the top of the air module, remove the test port pipe plug for filtered vehicle air. (Marked “F” as shown in Figure 4-1.) Install the test gauge in the “F” port, and check the pressure. If the pressure is less than 90 PSI (620 kPa), repair the vehicle air system to achieve full vehicle air pressure at the air module inlet, and repeat the test. If the pressures greater than 90 PSI (620 kPa) and no external air leaks were detected from the air module, shift knob, or transmission, replace the air module.

Replace the air module.

step 5.

WARNING: Failure to exhaust the air module may cause personal injury or damage to parts due to the rapid release of air.

Exhaust the air pressure from the air module. To do so, the vehicle air tanks may need to be exhausted. Remove the four capscrews attaching the air module to the shift bar housing. Lift the air module and tilt it to gain access to the two air holes at the underside at the rear capscrew location. Do not damage or lose the two O-rings used to seal the holes. Block off the air ports on the underside of the module. Repressurize the air module with an inlet supply pressure of over 90 PSI (620 kPa). To repressurize the air module, the vehicle may need to be started and the air pressure allowed to build. With the shift lever in neutral and the gauge still in the “H” test port, move the range selection lever from high to low (down) position.

Answer the question on the chart below, and follow the instructions corresponding to the result.

Question Result What to do Next

Does the gauge rapidly go from 75-85 PSI (517-586 kPa) in High to) PSI in Low?

5. Install the air module, and remove the range alignment lock cover (Figure 4-3). Then move the range selection lever from the low to high (up) position. If range now shifts properly, inspect and correct the source of binding between lock cover and range yoke bar.

Note: To prevent binding, range alignment lock cover capscrews must be tightened when transmission is in Low Range. If the

transmission does not shift properly, continue to Step 6.

Yes Continue to the next step.

No Replace the air module.

Air System Troubleshooting

6. Remove the auxiliary section and inspect the range synchronizer, range yoke, range yoke bar, range yoke snap ring, range sliding clutch, and mating gears for excessive wear, binding, or damage. Repair as necessary. If these components do not need repair, continue to Step 7.

7. Remove the shift bar housing and inspect the range piston, piston bar, and cylinder for excessive wear, binding, or damage. Repair as necessary.

Air System Troubleshooting

Air System Symptom - No or Slow Range Shift into Low (Shift into High is Good)

Test Procedure:

1. Check the shift knob operation.

On the shift knob, remove the two screws holding the plastic skirt. Slide the skirt down and out of the way. Move the range selector up into high range. Disconnect the black line connected to the “P” port on the knob. Move the range selector down into low. Answer the question on the chart below and follow the instructions corresponding to the result.

Question Result What to do Next

Does air come out of the “P” port on the knob?

2. Check the air supply to the shift knob.

Disconnect the red line from the “S” port on the shift knob. Answer the question on the chart below and follow the instructions corresponding to the result.

Question Result What to do Next

Is air coming out of the red line? Yes Repair or replace the shift knob.

3. Check the black line for obstruction.

Yes Go to Step 3.

No Reconnect the air line to the knob, and con-

tinue to the next step.

No Loosen the air fitting for the line that sup-

plies vehicle air to the module inlet. If no air is available here, repair the vehicle air to the air module. If air is available at the inlet, check the red line going from the air module to the shift knob for obstructions or damage. If the line is clear, replace the air module.

Reconnect the black line at the shift knob. At the air module, disconnect the black air line from the “P” port. Answer the question on the chart below and follow the instructions corresponding to the result.

Question Result What to do Next

Is air available on the line when the range selector is in the Low position?

4. Check the regulator pressure.

Reconnect the “P” line at the air module. Locate the two small pipe plugs on the rear of the air module. One is labeled “H,” and the other is labeled “L”. (See Figure 4-1 “Air System Nomenclature”). Install a 0-150 PSI (0-1034 kPa) air gauge in the port marked “L”.

Note: Prior to removing the pipe plug, turn off the air flow by placing the range selector up into the high range position. The trans-

mission must be in neutral.

Yes Continue to next step.

No Repair the black line for damage or obstruc-

tion.

Air System Troubleshooting

Move the range selector down to the low position and record the pressure on the gauge. Match the air pressure to one of those described on the chart on the next page, and follow the corresponding instructions.

Question Result What to do Next

What is the air pressure at the “L” port? 75-85 PSI (517-586 kPa) (To specifica-

tion.)

Less than 75 PSI (517 kPa) On the top or the air module, remove the

Greater than 85 PSI (586 kPa) Replace the air module.

5. Check the spool valve function.

With the shift lever in neutral, move the range selector from low to high several times. Answer the question on the chart below and follow the instructions corresponding to the result.

Question Result What to do Next

Continue to the next step.

test port pipe plug for filtered vehicle air. (Marked “F” as shown in Figure 4-1 “Air System Nomenclature”) Install the test gauge in the “F” port, and check the pressure. If the pressure is less than 90 PSI (620 kPa), repair the vehicle air system to achieve full vehicle air pressure at the module inlet, and repeat the test. If the pressure is greater than 90 PSI (620spa) and no external air leaks were detected form the air module, shift knob, or transmission, replace the air module.

Air System Troubleshooting

Does the gauge rapidly go from 7585PSI (517-586 kPa) in Low to 0 PSI in High?

6. Isolate the air module from the transmission. Refer to Figure 4-4 “Air System Nomenclature” to see an example of an isolated air module.

WARNING: Failure to exhaust the air module may cause personal injury or damage to parts due to the rapid release of air.

Exhaust the air pressure from the air module. To do so, you may have to exhaust the vehicle air. Remove the four capscrews attaching the air module to the shift bar housing. Lift the air module and tilt it to gain access to the two air holes on the underside at the rear capscrew location. Do not lose or damage the two small O-rings that seal the holes. Block off the air ports at the underside of the module. Repressurize the air module with an inlet supply pressure of over 90 PSI (620 kPa). To repressurize the air module, the vehicle may have to be started and the air pressure allowed to build. With the shift lever in neutral and the gauge still in the “L” test port, move the range selector from low to high (up) position.

Answer the question on the chart below, and follow the corresponding instructions.

Question Result What to do Next

Does the gauge rapidly go from 7585PSI (517-586 kPa) in Low to 0 PSI in High?

Yes Air system performs properly. Go to step 7.

No Continue to the next step.

Yes Continue to next step.

Air System Troubleshooting

Question Result What to do Next

No Replace the air module.

7. Install the air module, and remove range alignment lock cover (Figure 4-3 “Air System Nomenclature”). Then move the range selector from low to high (up) position. If range now shifts properly, inspect and correct the source of binding between lock cover and range yoke bar.

Note: To prevent binding, range alignment lock cover capscrew must be tightened when transmission is in Low Range. If trans-

mission does not shift properly, continue to Step 8

8. Remove the auxiliary section, and inspect range synchronizer, range yoke, range yoke bar, range yoke snap rings, range sliding clutch, and mating gears for excessive wear, binding, or damage. Repair as necessary. If these components do not need repair, continue to step 9.

9. Remove shift bar housing and inspect range piston, piston bar, and cylinder for excessive wear, binding, or damage. Repair as necessary.

Air System Troubleshooting

Air System Symptom - Constant Air Leak from Shift Knob

In normal operation, a burst of air will be exhausted from the shift knob when moving the range selector from low to high range.

If a constant air leak is detected, first check for a leaking fitting. If the leak occurs when both high and low range are selected and the leak is from the exhaust “E” port on the shift knob. Repair or replace the shift knob.

If the leak only occurs in high range, check for reversed hook up of “P” and “S” air lines. If the air lines are connected properly, repair or replace the shift knob.

Air System Troubleshooting

Air System Symptom - Range Shift While Transmission is in Gear

The interlock mechanism allows the driver to move the range selection lever while still in gear (preselect). The range will then shift when the shift lever moves into neutral. If the driver preselects a range shift and the shift occurs while the shift lever is in gear, a problem is present.

Test Procedure:

WARNING: Failure to exhaust the air module may cause personal injury or damage to parts due to the rapid release of air.

1. Exhaust air pressure from the air module. To do so, the vehicle air may need to be exhausted.

2. Remove the four capscrews attaching the air module to the shift bar housing. Lift the air module and tilt it to gain access to the

module interlock finger. Do not lose or damage the two O-rings at the rear mounting capscrew.

3. Inspect the module interlock finger for excessive wear. Replace, if necessary.

4. Shine a bright light into the hole the interlock finger engages. Inspect the chamfer on the shift shaft for excessive wear. To

inspect the chamfer, the transmission may need to be shifted into gear so both the forward and rearward chamfers are visible. If the chamfer is excessively worn, remove the shift bar housing, disassemble, and replace the worn parts.

5. If the shift shaft is not excessively worn, replace the air module.

Air System Troubleshooting

Air System Symptom - Air Leak From Breather or Case is Pressurized

If the air leak occurs when the transmission is in high range, the problem is with the range cylinder in the transmission. Remove the shift bar housing, and disassemble and inspect the range cylinder for worn or missing o-rings. Also, inspect the shift bar housing for cracks or porosity.

If the leak only occurs when the transmission is shifted to low range, the air module may be leaking into the transmission at the interlock finger location. Prior to removing the shift bar housing, perform the following test to determine the problem.

Test Procedure:

WARNING: Failure to exhaust the air module may cause personal injury or damage to parts due to the rapid release of air.

Exhaust the air pressure from the air module. To do so, the vehicle air may need to be exhausted. Remove the four capscrews attaching the air module to the shift bar housing. Lift the air module and tilt it to gain access to the two air holes at the underside at the rear capscrew location. Do not lose or damage the two small o-rings near the rear capscrew location. Block off the air ports on the underside of the module (Figure 4-4 “Air System Nomenclature”). Repressurize the air module with an inlet supply pressure of over 90 PSI (620 kPa). Repressurizing the air module may require starting the vehicle and allowing the air pressure to build. Shift the transmission into low range. Answer the question on the chart below, and follow the instructions corresponding to the result.

Question Result What to do Next

Can any air leakage be detected at the module interlock finger?

Yes Replace the air module.

No Air leak is at the range cylinder. Remove

the shift bar housing, and disassemble and inspect the range cylinder for worn or missing o-rings. Also inspect the shift bar housing for cracks or porosity.

Air System Troubleshooting

Operation

Air Line Color Chart

Eaton® Fuller® 5/32" air lines are color coded for easy identification. Use the follow chart along with the appropriate system schematic when troubleshooting and repairing your air system.

Nomenclature Color

S- Supply Red

P-Pilot Black

H/L- Splitter or Deep reduction Green

A- Supply, Non-regulated Orange

SP- Splitter pilot Blue

B- Brake signal Yellow

E-Exhaust Brown

Operation

Slave Valve Preselection System

An air valve shaft protruding from the shift bar housing prevents the actuating piston in the slave valve from moving while the gear shift lever is in a gear position and releases the piston when the lever is moved to or through neutral.

Operation

7, 8, 9 and 10-Speed Range Air Systems

Air is supplied to the system at the air supply port (1) by the vehicle's air system. The air filter (2) removes foreign matter from the air then allows it to pass through the air regulator (3) where the pressure is adjusted for 58 to 63 PSI (4.0 daN/cm2). From there the air passes through the supply air hose (4) and the slave valve supply port (5) through the supply air line (6) to the range control valve (7). With the range control valve lever or knob down (LO range), air passes through the air line connected to the slave valve "P" port (8). The slave valve then directs air to the LO range hose (9) and exhausts the HI range hose (10). With the range control valve lever or knob up (HI range,) the air line connected to the slave valve "P" port (8) is exhausted. The slave valve then directs air to the HI range hose (10) and exhausts the LO range hose (9).

Range Control

Valve

Slave Valve

Range Cylinder

Air Filter/ Regulator

7L, 8, 9 and 10-Speed (2-Speed Auxiliary)

Operation

Range-HI

A-3546

Range

Valve

A-6909 Valve

Roadranger

Slave

Valve

Identification

A-4688

Valve

(old)

A-4688

Slave

Valve

Tii

p s

19470

A-5000

Slave

Valve

.....___

n:~

A-5000

Valve

(current)

19470

Valve

(obsolete)

Air

Filter/Regulator

Assembly

Air

from

Vehicle

Source

Constant

Air

Range

Cylinder

Assembly

RT & RTO-610, 6610, 6609, and 8609 Models

Operation

nge-HI

A-3546 Valve

A-4688

Range

Slave

Valve

A-6909 Valve

Roadranger

19470

A-5000

Slave

Valve

Slave

Valve

Identification

A-4688

Valve

(old)

n:ro

A-5000

Valve

(current)

19470

Valve

(obsolete)

Air

Filter/Regulator

Assembly

Air

from

Vehicle

,....

Constant

Air

Range Assembly

Cylinder

Operation

Deep Reduction Air System (with Dash Mounted Valve)

In addition to the components of the range air system, the deep reduction air system utilizes a reduction cylinder and a separate dash mounted deep reduction valve. Air is supplied to the system at the air supply port (1) by the vehicle's air system. The air filter (2) removes foreign matter from the air then allows it to pass through the air regulator (3) where the pressure is adjusted for 58 to 63 PSI. From there the air passes through the supply air hose (4) to the slave valve supply port (5) through the supply air hose (6) to the deep reduction valve (7). Depending upon the position of the deep reduction valve lever, if air passes through the air hose (8) connected to the reduction cylinder center port (9) then the deep reduction gearing is disengaged. If there is no air, the constant air from the air filter/regulator assembly (10) moves the reduction piston rearward to engage deep reduction gearing.

Operation

RT, RTO, & RTX xx607LL, xx608LL, and xx615 models

Operation

Range-L

A-3546 Valve

A-4688

Range

Slave

Valve

A-6915 Valve

Roadranger

19470

Slave

Valve

A-5000

Slave

Valve

Identification

A-4688

Valve

(old)

A-5000

Valve

(current)

19470

Valve

(obsolete)

Operation

Air

Filter/Regulator

Assembly

Air

from

Vehicle

Deep

Reduction

Valve

Range

Cylinder

Assembly

Operation

Range-HI

A-3546

Range

Valve

A-6915 Valve

Roadranger

Slave

Valve

Identification

A-4688

Valve

(old)

A-4688

Slave

Valve

it'

p s

19470

A-5000

Slave

Valve

o:tt)

A-5000

Valve

194

Valve

(obsolete)

(current)

Air

Filter/Regulator

Assembly

Deep

Reduction

Valve

nge

Cylinder

Assembly

Operation

Deep Reduction Air System (with A-6915 Roadranger Valve)

In addition to the range air system components, the deep reduction air system uses a reduction cylinder and the Roadranger Valve A-6915.

When the A-6915 Roadranger Valve is used, the deep reduction cover must be equipped with an insert valve.

Air is supplied to the system at the air supply port (1) by the vehicle's air system. The air filter (2) removes foreign matter from the air and allows it to pass through the air regulator (3) where the pressure is adjusted for 58 to 63 PSI. From there, the air passes through the supply air hose (4) to the slave valve supply port (5) through the supply air line to the Roadranger valve (6).

Depending upon the position of the Roadranger valve button (7), if air passes through the air line (8) connected to the reduction cylinder center port (9), then the deep reduction gearing is engaged. If there is no air, the constant air from the air filter/regulator assembly (10) moves the reduction piston rearward to disengage deep reduction gearing.

Operation

RT, RTO, & RTX xx607LL, xx608LL, and xx615 Models

Ran

ge-

A-6915

Roadranger

Valve

Slave

Valve

Identification

Operation

A-4688

Rearward

Down

....

fea~n

Ful

tYi

YYtTI

H/L

Slave

Valve

19470 Slave

A-5000

Valve

A-4688

A-5000

Valve

19470

Valve

(old)

(current)

(obsolete)

Operation

Air

Filter/Regulator

Assembly

Reduction

Assembly

Insert

Valve

Cylinder

Range

Cylinder

Assembly

Operation

Range-HI

A-6915

Roadranger

Valve

Slave

Valve

Identification

A-4688

Slave

Valve

H/L

P S

Rearward

19470 Slave

( i1tr>L

...I.

\_]

"--

Fullef

A-5000

Valve

A-4688

A-5000

19470

Valve

(current)

Valve

(obsolete)

(old)

Air

Filter/Regulator

Assembly

Reduction

Assembly

Insert Valve

Cylinder

Range

Cylinder

Assembly

Operation

9 and 13-Speed Air Systems (Top 2 & Convertible) and 18-Speed (Top-2)

In addition to the range air system components, the splitter air system uses a splitter cylinder and the Roadranger Valve A-4900/ A-6913 or the Two-Position Selector Valve.

Air is supplied to the system at the air supply port (1) by the vehicle’s air system. The air filter (2) removes foreign matter from the air then allows it to pass through the air filter regulator (3) where the pressure is adjusted for 58 to 63 psi. From there, the air passes through the supply air hose (4) to the slave valve supply port (5), through the supply air line (6) to the control valve.

Depending upon the position of the splitter button (7), if air passes through the air line (8) connected to the splitter cylinder center port (9) then the underdrive/overdrive gearing is engaged. If there is no air, the constant air from the air filter/regulator assembly (10) moves the splitter piston forward to disengage underdrive or overdrive gear.

18-Speed

Operation

13-Speed

9-Speed Top 2 Convertible

Operation

9-Speed Non-Top 2 Convertible

RT, RTO, & RTOO xx613 and xx813 Models

Operation

Range-HI

A-3546

Range

Valve

Outlet

P S H

A-4688

Slave

/Splitter-Direct

Selector Valve

Valve

H/L

A-6913

19470

Roadranger

A-5000

Valve

P S

Slave

H/L

Valve

Slave

Valve

Identification

A-4688

Valve

d:©()

A-5000

Valve

(current)

19470

Valve

(obsolete)

(old)

Air

Filter/Regulator

Assembly

Splitter

Cylinder

Assembly

Range

Cylinder

Assembly

Operation

Range-Hl

A-3546

Range

Valve

Outlet

p s

A-4688

Slave

/Sp

litter-Und

U.D./0.0.

Valve

Selector Valve

" 8

H/L

erdrive

Overdrive

A-6913

Roadranger

For

war~P

"-~

'l~l

~~}'

19470

Valve

u '

H/L P S

A-5000

t H

Slave

Slave Identification

A-4688

A-5000

19470

Valve

(old)

Valve

(current)

Valve

(obsolete)

Operation

Air

Filter/Regulator

Assembly

Air

from

Vehicle

Splitter

Cylinder

Assembly

Range

Cylinder

Assembly

Operation

RTLO-xx613 Models

Range

A-6913

Roadranger

Valve

Slave

Valve

Identification

A-5000

Valve

19470

Valve

Operation

(current)

(obsolete)

Operation

Air

Filter/Regulator

Assembly

Air

from

Vehicle

19470

Splitter Assembly

A-5000

Cylinder

Slave

H/L

Valve

Range

Cylinder

Assembly

Operation

Range

A-6913

Roadranger

H/L

Valve

P S

194

A-5000

Slave

Valve

Slave

Identification

A-5000

Valve

194

Valve

(current)

(obsolete)

Air

Filter/Regulator

Assembly

Splitter

Cylinder

Assembly

H/L

_____.

Range

Cylinder

Assembly

RTLO-xx713 Models

Operation

Range

A-6913

Roadranger

Valve

A-5000

Slave

Valve

Slave

Valve

Identification

A-5000

Valve

(current)

Air

Filter/Regulator

Assembly

Air

from

Vehicle

t H

Splitter

Cylinder

Assembly

...

Range

Cylinder

Assemb

HI R

ange

A-6913

Roadranger

H/L

Valve

P S

A-5000

Slave

Valve

Slave

Valve

Identification

A-5000

Valve

Operation

(current)

Operation

Air

Filter/Regulator

Assembly

Splitter

Cylinder

Assembly

H/L

Range

Cylinder

Assembly

Operation

RTLO-xx913 Models

Operation

Range Low

A-6913

Roadranger

Rearwar~P

Split

Valve

Slave

Valve

Identification

A-5000

Valve

(current)

YTI YtTI

H/L

P S

A-5000

Slave

Operation

Valve

H/L

Air

Filter/Regulator

Assembly

Air

from

Vehicle

Splitter

Cylinder

Assembly

N A

.........

Range

Cylinder

Assembly

Air

Operation

HI Range

A-6913

Forward

\ I I

High

Split

Road

ranger

Valve

lUl

H/L

P S

A-5000

Slave

Valve

H/L

Slave

Valve

Identification

A-5000

Valve

(current)

Air

Filter/Regulator

Assembly

Splitter

Cylinder

Assembly

Range

Cylinder

Assembly

Air

RT0-15618 and RTLO-xx618 Models

Operation

Eaton Transmission RTLO-10 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual