Troubleshooting Guide
Fuller Transmissions
TRTS0920
July 2011
Warnings and Precautions
Warnings and Precautions
! WARNING
Before starting a vehicle always be seated in the driver’s seat, place the transmission in neutral, set the parking brakes and disengage the clutch.
Before working on a vehicle place the transmission in neutral, set the parking brakes and block the wheels.
Before towing the vehicle place the transmission in neutral, and lift the rear wheels off the ground, remove the axle shafts, or disconnect the driveline to avoid damage to the transmission during towing.
The description and specifications contained in this service publication are current at the time of printing.
Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice.
Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents may be used.
This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and/or component damage.
Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technican or vehicle operator.
Warning: Failure to follow indicated procedures creates a high risk of personal injury to the service technician.
Caution: Failure to follow indicated procedures may cause component damage or malfunction.
Note: Additional service information not covered in the service procedures.
Tip: Helpful removal and installation procedures to aid in the service of this unit.
Always use genuine Eaton replacement parts.
Table of Contents
General Information |
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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 |
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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 |
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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 |
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(with Dash Mounted Valve) ................................ |
71 |
RT, RTO, & RTX xx607LL, |
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xx608LL, and xx615 models .............................. |
72 |
Deep Reduction Air System |
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(with A-6915 Roadranger Valve) ........................ |
75 |
RT, RTO, & RTX xx607LL, |
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xx608LL, and xx615 Models .............................. |
76 |
9 and 13-Speed Air Systems |
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(Top 2 & Convertible) and 18-Speed (Top-2) .... 79 |
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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 |
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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 |
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(with 2 Position Shift Valve) ............................. |
134 |
AT-1202 Auxiliary Housing (3 Position Valve) ......... |
135 |
System Components |
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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 |
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613 and 6613, 3-Position Selector Valve .......... |
164 |
Intermediate Shift Cylinder Assembly |
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613 and 6613, A-5015 Roadranger Valve ......... |
166 |
Combination Cylinder Assembly .............................. |
168 |
Splitter Cylinder Assembly ....................................... |
171 |
RTLO-xx610 Model Splitter Cylinder Assembly |
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(Old Design) .................................................... |
173 |
RTLO-xx610 Model Splitter Cylinder Assembly |
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(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 |
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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 - |
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6610,8609, and 6609 ....................................... |
191 |
Basic Air System Drawings - |
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07L, 08, 08L, 09, and 10-Speed Models .......... |
192 |
Basic Air System Drawings - |
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07LL, 08LL, and 15 Speed Models .................. |
193 |
Basic Air System Drawings - 707LL, 7/908LL, 7/909LL, |
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and 7/915 Speed Models ................................. |
194 |
Basic Air System Drawings - 11613, 14613, and 15613 |
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Speed Models .................................................. |
195 |
Basic Air System Drawings - 6613, and 7608LL Speed |
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Models ............................................................. |
196 |
Basic Air System Drawings - |
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18 Speed Models Left-Hand Drive ................... |
197 |
Basic Air System Drawings - |
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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.
Information General
1
For parts or service call us Pro Gear & Transmission, Inc.
1(877) 776-4600
(407)872-1901 parts@eprogear.com
906 W. Gore St. Orlando, FL 32805
General Information
Transmission Identification
2-Speed Auxiliary/3-Speed and 2x2 Auxiliary
Roadranger
Valve
Air Lines
Slave
Valve
Air Hoses
Roadranger
Valve
Air Lines
Slave
Valve
Air Hoses
Range Cylinder
Air Filter/
Regulator
2-Speed Auxiliary
Range Cylinder
Air Filter/
Regulator
3-Speed
&
2X2 Auxiliary
Deep Reduction or
Splitter Cylinder
2
General Information
Combination Cylinder / RTLO-10 Speeds
Roadranger
Valve
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Combination |
Air Lines |
Combination |
Cylinder |
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Cylinder |
Air Filter/ |
Slave |
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Regulator |
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Valve |
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Air Hoses
Roadranger
Valve
RTLO-10 Speeds
Air Lines |
Range Cylinder |
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Range |
Air Filter/ |
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Actuator |
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Regulator |
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Valve |
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ON |
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LY |
CN |
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C |
Air Hose
Splitter Cylinder
Information General
3
General Information
Component Identification
Air Filter/ Regulators
Control Valves - Old Production
A-3546 |
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Two Position Selector |
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Three Position Selector |
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LOW- |
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H |
DOWN |
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IGH- |
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UP |
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Deep Reduction Valve |
A-5010 |
A-5015 |
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14651 |
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REDU |
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P |
C |
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T |
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E |
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O |
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D |
E |
SHIFT ONLY |
I |
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N |
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WHEN IN LOW |
IN |
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OUT |
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RANGE |
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DO NOT |
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PRE-SELECT |
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Blue
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8, 9, and 10 Speeds |
8LL, 15, 6613 Speeds |
A-5510 |
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A-4900 |
A-5013 |
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Gray |
Red |
Gray |
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RTLO-10 Speeds |
RT/RTLO 13 Speeds |
RTLO-18 Speeds |
4
Control Valves - Current Production
A-6909 |
A-6915 |
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Blue |
8, 9, and 10 Speeds |
8LL, 15, 6613 Speeds |
A-6910 |
A-6913 |
Gray |
Red |
RTLO-10 Speeds |
RT/RTLO 13 Speeds |
Slave Valves
19470 - Obsolete |
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A-4688 - Old |
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Range Valves
23545 |
23545 - old design |
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NO |
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S |
CYL |
NC |
P |
EXH |
General Information
A-6918
Gray |
General |
RTLO-18 Speeds |
Information |
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A-5000 - Current
4303110 - latest design
S
S
EXH
P
5
General Information
Lubricants and Sealants
The use of improper sealants and lubricants during air system assembly can cause improper component operation and severe transmission damage.
The following are the recommended sealants and lubricants to be used when assembling air system components:
Name: |
Eaton® Fuller® Silicone Lubricant |
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Part #: |
71203 (8 oz. container)—Fleet size |
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Part #: |
71206 (4 cc container)—Single application |
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Where Used: |
All O-rings and mating surfaces |
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Name: |
Eaton® Fuller® Sealant |
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Part #: |
71205 (2 cc container)—Single application |
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Part #: |
71206 (4 cc container)—Single application |
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Where Used: |
Air fittings and threads |
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6
General Information
Suggested Test Fixtures
Note: For the Automated transmission models, refer to their Troubleshooting Guides for air system diagnostics.
Test Fixture for Range Cylinder
5/32" Air Line
0-100 PSI Gauge
84006 - 5/32" Push-To-Connect
to 1/8" NPTF
12881 - 1/8" Tee |
12769 - 1/8" Nipple |
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Test fixture for 1/8" Air lines |
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0-100 PSI Gauge |
5/32" Air Line |
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84006 - 5/32" Push-To-Connect |
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to 1/8" NPTF |
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84502 - Elbow |
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85002 - Elbow Assembly |
12881 - 1/8" Tee |
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1/8" Air Line |
83501 - Grip Nut |
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83001 - Compression Sleeve |
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Test Fixture For 5/32" Air Line
0-100 PSI Gauge
5/32" Air Line
84006 - 5/32" Push-To-Connect 
to 1/8" NPTF
85003 - Elbow
85003 - Elbow
12881 - 1/8" Tee
5/32" Air Line
Information General
7
Air System Troubleshooting
8, 9, 10, 11, 13, 15, and 18-Speed Troubleshooting
Symptom
•Air Leak at Shift Knob
•Air Leak at Slave Valve
•Air Leak from Transmission Breather or Transmission Case is Pressurized
•Air Leak at Splitter Cylinder Cover Exhaust Port
•No or Slow Range Shift into Low
•No or Slow Range Shift into High
•Range Shifts with Shift Lever in Gear
WARNING: Use care when removing air lines or checking for air flow from disconnected lines. High pressure air may exhaust suddenly. Wear safety glasses. Exhaust all air pressure from system before removing air filter/regulator or combination cylinder cover.
Note: During all testing, the vehicle air pressure must be greater than 90 PSI (620 kPa). If during testing the pressure falls below 90 PSI (620 kPa), make sure the transmission is in neutral, start the engine, and let the pressure build to governor cutoff. After the pressure reaches the governor cutoff, continue testing. The pressure is critical if the vehicle is equipped with a Pressure Protection Valve that would shut off the air supply to certain air circuits if the system pressure dropped below a preset level.
IMPORTANT: Use the following air system troubleshooting procedures for part replacement only if the symptom can be duplicated. If the problem is intermittent, parts that are not defective could be replaced.
Instructions
1.Start at “Procedures” for Step A.
2.Based on the “Result” of the procedure, go to the corresponding “What To Do Next”.
8
Air System Troubleshooting
Procedure 1: Symptom - Air Leak at Shift Knob
Normal Operation:
•A burst of air will be exhausted from the shift knob when moving the range selector from low to high. This is the air being exhausted from the “P” air line.
•A burst of air will be exhausted from the shift knob when moving the splitter button rearward (shifting to low split). This is the air being exhausted from the “SP” air line.
Possible Causes:
•Incorrectly attached air lines
•Internal leak in slave valve
•Internal leak at insert valve
•Internal leak at shift knob
Table 10 Air Leak at Shift Knob
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Procedure |
Result |
What to do next |
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Step A |
Remove lower skirt on shift knob. |
Leak found. |
Repair leaking fitting or air line. |
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Check for leaking fitting at the shift |
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knob. |
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No leak found. |
Go to Step B. |
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Step B |
Check air lines to make sure all lines |
Air lines are not connected to the |
Connect lines properly. |
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are connected to the proper ports on |
proper ports. |
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the shift knob. |
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A.) Reversal of “S” and “P” lines will |
Air lines are connected to the proper |
Go to Step C. |
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result in a constant leak from the ex- |
ports. |
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haust when high range is selected. |
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B.) Reversal of the H/L and “SP” |
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lines will result in a constant leak |
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when the splitter button is rearward. |
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Step C |
Move the range selector lever down |
Constant air flow from the “E” port. |
Replace knob. |
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to low range. Check for constant air |
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flow from the exhaust “E” port. |
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No air flow from “E” port. |
Go to Step D. |
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Step D |
Move the range selector up to high |
Constant air is leaking from the “P” |
Repair or replace the shift knob. |
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range. Disconnect the small air line |
port or the “E” port. |
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connected to the “P” port of the shift |
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knob. Check for air flow from the |
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port and air line. |
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Air is coming out of the disconnect- |
1. Verify that the air line is connected |
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ed air line. |
to the slave valve “p” port. |
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2. If properly connected, replace the |
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slave valve. |
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Air is not leaking from either port or |
Go to Step E. |
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disconnected air line. |
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Troubleshooting System Air
9
Air System Troubleshooting
Table 10 Air Leak at Shift Knob
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Procedure |
Result |
What to do next |
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Step E |
Reattach the air line to the “P” port. |
Air is flowing from the SP line. |
1. Check to make sure the “SP” line |
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Move the range selector down to low |
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is connected to the splitter cylinder |
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range and move the splitter button |
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cover. |
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rearward. Disconnect line from the |
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“SP” port. Check for air flowing from |
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the SP port on the shift knob. |
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2. If the line is properly attached, |
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check that the insert valve (old style) |
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is properly installed (stem facing in- |
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ward) and that the insert valve bore |
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is not defective. |
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3. Replace the insert valve. |
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Air is not flowing from the line. |
Repair or replace the shift knob. |
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10
Air System Troubleshooting
Procedure 2: Symptom - Air Leak at Slave Valve
Normal Operation:
A momentary exhaust of air at the slave valve occurs during a range shift. The air from the low side of the range cylinder is exhausted as air pressure is applied to the high range side. Likewise, air from the high range side of the piston is exhausted as air pressure is applied to the low range side. The exhaust port is located at the slave valve to transmission mounting interface.
Possible Causes:
•Internal leak in range cylinder.
•Internal leak in slave valve.
Table 11 Air Leak at Slave Valve
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Procedure |
Result |
What to do next |
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Air |
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Step A |
Confirm that air is leaking from the ex- |
Air is leaking from fitting or air line. |
Repair or replace fitting or air line. |
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haust port on the slave valve and not a |
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System |
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fitting or air line. |
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Air is definitely leaking from slave |
Go to Step B. |
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Troubleshooting |
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valve exhaust port. |
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Step B |
Move range selector down to select low |
Air is flowing from high range sup- |
Remove range cylinder cover and |
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range. |
ply port on range cylinder. |
repair leaking range piston or pis- |
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Remove the 1/4" I.D. rubber air line at |
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ton seal. After repair, check for |
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the high range supply port on the range |
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proper range operation. |
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cylinder. |
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Feel for air flow from the open port on |
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the range cylinder. |
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Notice if the air leak at the slave valve |
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only occurs when the transmission is in |
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high range. |
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Repeat the above test but remove the |
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low range air hose and check with high |
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range selected. |
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No air flow from high range port. |
Repair or replace slave valve. |
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11
Air System Troubleshooting
Procedure 3: Symptom - Air Leak from Transmission Breather or Transmission Case is Pressurized
Normal Operation:
There should be no measurable air flow from the transmission breather.
Possible Causes:
•Leak at range yoke bar O-ring
•Leak at splitter yoke bar O-ring
Table 12 Air Leak from Transmission Breather or Transmission Case is Pressurized
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Procedure |
Result |
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What to do next |
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Step A |
Listen for the air leak with the trans- |
Leak is only in low range. |
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Remove range cylinder and inspect for |
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mission shifted to both low and |
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damaged range yoke bar, yoke bar O- |
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high range. |
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ring, or range cylinder. Repair as neces- |
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sary. |
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Leak is in both low |
and Remove splitter cylinder. Inspect for |
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high range. |
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damaged splitter yoke bar, O-ring, or cyl- |
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inder. Repair as necessary. |
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12
Air System Troubleshooting
Procedure 4: Symptom - Air Leak at Splitter Cylinder Cover Exhaust Port
Normal Operation:
A burst of air will exhaust from this port when shifting into low split (the splitter button is moved rearward while in low range).
Possible Causes:
•Damaged/defective insert valve
•Leak past insert valve external O-rings
•Leak past splitter cylinder piston
Table 13 Air Leak at Splitter Cylinder Cover Exhaust Port
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Procedure |
Result |
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What to do next |
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Step A (old |
Remove insert valve. Check for contamination, dam- |
Contamination |
or |
damage |
Repair or replace as neces- |
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Air |
style) |
aged seals, or sticky movement. Check the insert |
found. |
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sary. |
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System |
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valve bore in the splitter cylinder cover for contami- |
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nation or damage which would result in leakage past |
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the insert valve O-rings. |
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Troubleshooting |
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No contamination or damage |
Go to Step B. |
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found. |
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Step B |
Remove the splitter cylinder cover and piston. |
Contamination |
or |
damage |
Repair or replace as neces- |
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|
|
Check the piston bore for contamination or damage. |
found. |
|
|
sary. |
|
|
|
Check the piston seals for damage. |
|
|
|
|
|
|
|
NOTE: Early production transmissions used a paper |
|
|
|
|
|
|
|
gasket to seal the splitter cover to cylinder, if neces- |
|
|
|
|
|
|
|
sary, replace this configuration with the spool valve |
|
|
|
|
|
|
|
design which uses an O-ring. |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
13
Air System Troubleshooting
Procedure 5: Symptom - No or Slow Range Shift into Low
Normal Operation:
When the range selector on the shift knob is moved down to select low range, air pressure will flow through the shift knob to the "P" port on the slave valve. The slave valve will direct air pressure through the low range 1/4" rubber hose to the range cylinder to shift the range. There will be a brief burst of air at the slave valve as the high range side of the range piston exhausts. Likewise, when high range is selected, the air pressure in the "P" will be exhausted at the shift knob. This will cause the slave valve to direct air to the rear side of the range cylinder piston. The air pressure on the low range side will be exhausted at the slave valve.
Possible Causes:
•Incorrect air line hook up
•Insufficient air supply to transmission
•Damaged or defective air filter / regulator assembly
•Damaged or defective shift knob master valve
•Damaged or defective slave valve
•Damaged or defective range cylinder
•Damaged or defective range yoke or yoke bar
•Damaged or defective range synchronizer
•Damaged or defective gearing in auxiliary section of transmission
Table 14 No or Slow Range Shift into Low
|
Procedure |
Result |
What to do next |
|
|
|
|
|
|
|
|
Step A |
Place the shift lever in neutral. |
Constant air leak is detected. |
Go to the other corresponding symp- |
|
Check for constant air leakage at the shift |
|
tom first. See beginning of Air System |
|
knob, slave valve, and transmission case |
|
Troubleshooting section. |
|
breather when both low and high range |
|
|
|
have been selected. |
|
|
|
|
No constant leak is detected. |
Go to Step B. |
|
|
|
|
Step B |
Place shift lever in neutral. |
Air flows from the low range |
Remove range cylinder cover and re- |
|
Move range selector up to high range |
port. |
pair leaking range piston or piston seal. |
|
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. |
|
|
|
|
No air flow from low range |
Go to step C. |
|
|
port. |
|
|
|
|
|
Step C |
Check for air flow from the disconnected |
Air flows from disconnected |
Go to step F. |
|
air line. |
air line. |
|
|
|
No air flow from disconnect- |
Go to step D. |
|
|
ed line. |
|
|
|
|
|
14
Air System Troubleshooting
Table 14 No or Slow Range Shift into Low
|
Procedure |
Result |
What to do next |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Step D |
Install a 100 PSI air gauge in the discon- |
The gauge read 0 PSI. |
Go to step F. |
|
|
|
nected air line end. With the shift lever in |
|
|
|
|
|
neutral, move the range selector down to |
|
|
|
|
|
select low range. Observe the gauge. |
|
|
|
|
|
|
The gauge reads pressure but |
Replace the filter/regulator and check |
|
|
|
|
is lower than 58 PSI or higher |
for proper range operation. |
|
|
|
|
than 63 PSI. |
|
|
|
|
|
The gauge reads between 58 - |
Go to step E. |
|
|
|
|
63 PSI. |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Step E |
Confirm that shift lever is still in neutral. |
Pressure rapidly changes be- |
Air system appears to be operating |
|
Air |
|
Have an assistant move the range selec- |
tween 58-63 PSI and 0 at the |
satisfactory. Go to step R. |
|
|
|
|
System |
|||
|
range. Does the pressure measured at |
gauge. |
|
|
|
|
tor up and down between low and high |
|
|
|
|
|
the gauge respond rapidly when going |
|
|
|
Troubleshooting |
|
from high to low? |
|
|
|
|
|
|
|
|
|
|
|
|
Pressure does not change |
1. Check for a plugged or dirty filter in |
|
|
|
|
rapidly at gauge. |
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. |
|
|
|
|
|
4. If all are satisfactory, go to step F. |
|
|
|
|
|
|
|
|
Step F |
Place shift lever in neutral. |
Air flows from the discon- |
1. Confirm that the air lines are con- |
|
|
|
At the shift knob, move the range selec- |
nected line. |
nected to the correct ports at the shift |
|
|
|
tion lever up to select high range. |
|
knob. |
|
|
|
At the slave valve, remove the air line |
|
|
|
|
|
from the "P" port. (should be a black |
|
|
|
|
|
line). Check for air flow from the discon- |
|
|
|
|
|
nected line. |
|
|
|
|
|
|
|
2. If the lines are correct, replace the |
|
|
|
|
|
shift knob. |
|
|
|
|
No air flow from the discon- |
Go to step G. |
|
|
|
|
nected line. |
|
|
|
|
|
|
|
|
|
Step G |
Check for air flow from the "P" port on |
Air flows from this port. |
Replace the slave valve. |
|
|
|
the slave valve. |
|
|
|
|
|
|
No air flow from this port. |
Go to step H. |
|
|
|
|
|
|
|
|
15
Air System Troubleshooting
Table 14 No or Slow Range Shift into Low
|
Procedure |
Result |
What to do next |
|
|
|
|
|
|
|
|
Step H |
Place the shift lever in neutral. Install a |
The gauge responds slowly. |
1. Check for a restricted line between |
|
100 PSI pressure gauge in line with the |
|
the shift knob and slave valve. |
|
"P" line. Move the range selector back |
|
|
|
and forth from low to high range. The |
|
|
|
gauge should show rapid pressure |
|
|
|
change. |
|
|
|
|
|
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 be- |
Go to step I. |
|
|
tween 58-63 PSI and 0 PSI. |
|
|
|
|
|
Step I |
If possible, leave air lines attached to |
Actuating plunger pin does |
1. Remove actuating plunger pin and |
|
slave valve. Unbolt the slave valve from |
not move freely. |
check for damage. |
|
transmission side. Check for free move- |
|
|
|
ment 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. |
|
|
|
|
|
2. Check for missing or broken spring. |
|
|
Actuating plunger pin moves |
Repair or replace slave valve and check |
|
|
freely. |
for proper range operation. |
|
|
|
|
16
Air System Troubleshooting
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
Troubleshooting System Air
17
Air System Troubleshooting
Procedure 6: Symptom - No or Slow Range Shift into High
Normal Operation:
When the range selector on the shift knob is moved down to select low range, air pressure will flow through the shift knob to the 'P" port on the slave valve. The slave valve will direct air pressure through the low range 1/4" rubber supply hose to the range cylinder to shift the range. There will be a brief burst of air at the slave valve as the high range side of the range piston exhausts.
Likewise, when high range is selected, the air pressure in the "P" will be exhausted at the shift knob. This will cause the slave valve to direct air to the rear side of the range cylinder piston. The air pressure on the low range side will be exhausted at the slave valve.
Possible Causes:
•Incorrect air line hook up
•Insufficient air supply to transmission
•Plugged filter
•Incorrect regulator pressure
•Damaged or defective shift knob master valve
•Damaged or defective slave valve
•Damaged or defective range cylinder
•Damaged or defective range yoke or yoke bar
•Damaged or defective range synchronizer
•Damaged or defective gearing in auxiliary section of transmission
Table 15 No or Slow Range Shift into High
|
Procedure |
Result |
What to do next |
|
|
|
|
|
|
|
|
Step A |
Place the shift lever in neutral. |
Constant air leak is detected. |
Go to the other corresponding symp- |
|
Check for constant air leakage at the shift |
|
tom first. See beginning of Air System |
|
knob, slave valve, and transmission case |
|
Troubleshooting section. |
|
breather when both low and high range |
|
|
|
have been selected. |
|
|
|
|
No constant leak is detected. |
Go to Step B. |
|
|
|
|
Step B |
Place shift lever in neutral. |
Air flows from the high range |
Remove range cylinder cover and re- |
|
Move range selector down to low range |
port. |
pair leaking range piston or piston seal. |
|
position. |
|
After repair, check for proper range op- |
|
At the transmission rear, disconnect the |
|
eration. |
|
1/4" rubber air line from the range cylin- |
|
|
|
der high range supply port. |
|
|
|
Check for air flow from the cylinder high |
|
|
|
range port. |
|
|
|
|
No air flow from high range |
Go to step C. |
|
|
port. |
|
|
|
|
|
Step C |
Check for air flow from the disconnected |
Air flows from disconnected |
Go to step F. |
|
air line. |
air line. |
|
|
|
No air flow from disconnect- |
Go to step D. |
|
|
ed line. |
|
|
|
|
|
18
Air System Troubleshooting
Table 15 No or Slow Range Shift into High
|
Procedure |
Result |
What to do next |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Step D |
Install a 100 PSI air gauge in the discon- |
The gauge reads 0 PSI. |
Go to step F. |
|
|
|
nected air line end. With the shift lever in |
|
|
|
|
|
neutral, move the range selector up to |
|
|
|
|
|
select high range. Observe the gauge. |
|
|
|
|
|
|
The gauge reads pressure but |
Replace the filter/regulator and check |
|
|
|
|
is lower than 58 PSI or higher |
for proper range operation. |
|
|
|
|
than 63 PSI. |
|
|
|
|
|
The gauge reads between 58 - |
Go to step E. |
|
|
|
|
63 PSI. |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Step E |
Confirm that shift lever is still in neutral. |
Pressure rapidly changes be- |
Air system appears to be operating |
|
Air |
|
Have an assistant move the range selec- |
tween 58-63 PSI and 0 at the |
satisfactory. Go to step R. |
|
|
|
|
System |
|||
|
range. Does the pressure measured at |
gauge. |
|
|
|
|
tor up and down between low and high |
|
|
|
|
|
the gauge respond rapidly when going |
|
|
|
Troubleshooting |
|
from high to low. |
|
|
|
|
|
|
|
|
|
|
|
|
Pressure does not change |
1. Check for a plugged or dirty filter in |
|
|
|
|
rapidly at gauge. |
the filter/regulator assembly. |
|
|
|
|
|
2. Check for a pinched or obstructed 1/ |
|
|
|
|
|
4" rubber air line between the filter/reg- |
|
|
|
|
|
ulator and 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. |
|
|
|
|
|
|
|
|
Step F |
Place shift lever in neutral. |
Air flows from the discon- |
1. Confirm that the air lines are con- |
|
|
|
At the shift knob, move the range selec- |
nected line. |
nected to the correct ports at the shift |
|
|
|
tion lever up to select high range. |
|
knob. |
|
|
|
At the slave valve, remove the air line |
|
|
|
|
|
from the "P" port. (should be black line). |
|
|
|
|
|
Check for air flow from the disconnected |
|
|
|
|
|
line. |
|
|
|
|
|
|
|
2. If the lines are correct, replace the |
|
|
|
|
|
shift knob. |
|
|
|
|
No air flow from the discon- |
Go to step G. |
|
|
|
|
nected line. |
|
|
|
|
|
|
|
|
|
Step G |
Check for air coming out of the slave |
Air flows from this port. |
Replace the slave valve. |
|
|
|
valve "P" port. |
|
|
|
|
|
|
No air flow from this port. |
Go to step H. |
|
|
|
|
|
|
|
|
19
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 |
The gauge responds slowly. |
1. Check for a restricted line between |
|
100 PSI pressure gauge in line with the |
|
the shift knob and slave valve. |
|
"P" line. Move the range selector back |
|
|
|
and forth from low to high range. The |
|
|
|
gauge should show rapid pressure |
|
|
|
change. |
|
|
|
|
|
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 be- |
Go to step I. |
|
|
tween 58-63 PSI and 0 PSI. |
|
|
|
|
|
Step I |
If possible, leave air lines attached to |
Actuating plunger pin does |
1. Remove actuating plunger pin and |
|
slave valve. |
not move freely. |
check for damage. |
|
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 actuat- |
|
|
|
ed and tested while unbolted from the |
|
|
|
transmission case. The air lines, of |
|
|
|
course, must remain attached. |
|
|
|
|
|
2. Check for missing or broken spring. |
|
|
Actuating plunger pin moves |
Repair or replace slave valve and check |
|
|
freely. |
for proper range operation. |
|
|
|
|
20
Air System Troubleshooting
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
Troubleshooting System Air
21
Air System Troubleshooting
Procedure 8: Symptom - Range Shifts with Shift Lever in Gear
Normal Operation:
Range shifts should only occur when the shift lever is in neutral. The range selector can be moved up or down while the shift lever is in a gear position, but the shift will not occur until the shift lever is moved to neutral.
Possible Causes:
•Worn or missing actuating pin or air valve shaft
•Worn shift rail
Procedure:
If the range has been confirmed to shift with the shift lever in gear, unbolt the slave valve from the side of the transmission. Confirm that the actuating pin is present and that it is the proper part number for the corresponding slave valve. If correct, remove the shift bar housing assembly and check for a worn or damaged air valve shaft or worn shift rails. Replace necessary parts.
22
Air System Troubleshooting
RTLO 10-Speed Troubleshooting
Confirm Correct Components and Plumbing
•A-5454 Air Filter/Regulator on the range cylinder cover.
•1/4 inch air hose from the air filter/regulator to the splitter cylinder cover (iron port).
•A red air line from the air filter/regulator to the tee in the range actuator valve "S" port on the shift bar housing.
•A red air line from the tee to the A-5510/A-6910 Roadranger valve "S" port.
•A black air line from the range actuator valve "P" port to the range cylinder.
•A blue air line from the Roadranger A-5510/A-6910 valve "SP" port to the splitter cylinder cover (brass port.)
WARNING: Prior to removing the air module, exhaust the air from it. Failure to exhaust the air module may result in personal injury or damage to parts from the sudden release of air.
WARNING: Use care when removing the test port pipe plugs. If air pressure is present on the plug, it can become a projectile during removal. When removing the “L” plug or “H” plug, pressure can be shut off by selecting the opposite range mode. If removing the “F” plug, exhaust the air to the module inlet.
Red Air Line
Red Air Line
Black Air Line
|
ON |
LY |
CN |
C |
A-5454
Air Filter/
Regulator
Blue Air Line
Air Hose
Troubleshooting System Air
23
Air System Troubleshooting
Air Filter/ Regulator Test
Figure 1 |
Figure 2 |
|
|
Table 1 Air Filter/Regulator Test
Step |
Procedure |
Result |
What to do next |
|
|
|
|
|
|
|
|
A |
Place the transmission shift lever |
|
|
|
in neutral. |
|
|
|
|
|
|
B |
Start the engine and wait for the |
|
|
|
air system pressure to reach gov- |
|
|
|
ernor 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 pres- |
|
|
|
sure, turn the engine off, and con- |
|
|
|
tinue testing. |
|
|
|
|
|
|
D |
Make sure the splitter control but- |
|
|
|
ton is rearward. |
|
|
|
|
|
|
E |
Remove the two (2) screws on the |
|
|
|
Roadranger valve cover and pull |
|
|
|
the cover down. |
|
|
|
|
|
|
F |
Disconnect the blue air line from |
|
|
|
the "SP" port. |
|
|
|
|
|
|
G |
Install the correct test fixture for |
|
|
|
your air line size in the "SP" line. |
|
|
|
|
|
|
24
Air System Troubleshooting
Table 1 Air Filter/Regulator Test
Step |
Procedure |
Result |
What to do next |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
H |
Move the splitter control button |
Air pressure is outside the 58 to |
Replace the A-5454 Filter/Regulator. |
|
|
|
forward to overdrive. The air pres- |
63 PSI range and the truck's air |
|
|
|
|
sure gauge should read between |
system pressure is 90 to 125 PSI. |
|
|
|
|
58 and 63 PSI. |
|
|
|
|
|
|
Air pressure slowly comes up to |
Inspect the red air line from the filter/regulator |
|
|
|
|
|
|||
|
|
between 58 and 63 PSI. |
to the range actuator valve and the red air line |
|
Air |
R |
Remove the test fixture. Assemble |
|
from the range actuator valve to the A-5510/A- |
|
|
|
6910 Roadranger valve for restrictions |
|
System |
||
|
|
|
|
|
|
|
|
|
|
|
|
|
the Roadranger valve. |
|
|
|
Troubleshooting |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
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25
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