Eaton Transmission RTLO-16713A Service Manual

Service Manual

Fuller® Heavy-Duty Transmissions TRSM0670 EN-US

September 2013

RTLO-12713A RTLO-12913A RTLO-14713A RTLO-14718B RTLO-14913A RTLO-14918B RTLO-14918B-T2 RTLO-16713A RTLO-16713A-T2 RTLO-16718B RTLO-16913A RTLO-16913A-T2 RTLO-16918B

RTLO-16918B-T2 RTLO-18718B RTLO-18718B-T2 RTLO-18913A RTLO-18913A-T2 RTLO-18918B RTLO-18918B-T2 RTLO-20913A RTLO-20918B RTLO-20918B-T2 RTLO-22918B RTLOC-16909A-T2 RTLOF-12713A

RTLOF-12913A RTLOF-14713A RTLOF-14718B RTLOF-14913A RTLOF-14918B RTLOF-14918B-T2 RTLOF-16713A RTLOF-16713A-T2 RTLOF-16718B RTLOF-16913A RTLOF-16913A-T2 RTLOF-16918B RTLOF-16918B-T2

RTLOF-18718B RTLOF-18913A RTLOF-18913A-T2 RTLOF-18918B RTLOF-18918B-T2 RTLOF-20913A RTLOF-20918B RTLOF-20918B-T2 RTLOF-22918B RTLOFC-16909A-T2

This Page Intentionally Blank

Warnings

WARNING

This symbol is used throughout this manual to call att ention to procedures whe re 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 recom m ended parts me ntion

ed in this publication may jeopardize the personal safety of the service tec hnician or vehicle operator.

WARNING: Failure to follow indicated procedures crea tes a high risk of personal injury to the servicing technician.

CAUTION: Failure to follow indicated procedures may cause component damage or mal

function.

IMPORTANT: Highly recommended procedures for proper servic e of this unit.

Note: Additional servic e information not cover ed in the service pr ocedures.

Tip: Helpful r emoval and installation procedures to aid in the service of this unit.

CAUTION

Warnings and Cautions

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

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.

Always use genuine Eaton

Conversion of a 13-Speed to an 18-Speed by simply changing the Air System will invalidate the User’s Warranty and will cause major internal damage to the Auxiliary Section.

replacement parts.

Introduction

Air System:

Roadranger® Valve

Auxiliary Section:

Range Cylinder

Air System:

Air Filter/Regulator

Auxiliary Section:

Auxiliary Countershaft

Auxiliary Section:

Auxiliary Housing

Air System:

Slave Valve

Front Section:

Countershafts

Front Section:

Mainshaft

Front Section:

Input Shaft / Drive Gear

Front Section:

Clutch Housing / Case Assembly

Front Section:

Reverse Idler

Shift Bar Housing:

Shiftbar Housing Assembly

106004-8-94 15 spd trans

Auxiliary Section:

Reduction Cylinder

Auxiliary Section:

Auxiliary Drive Gear

Shift Bar Housing:

Levers/Housings & Isolators

Shift Bar Housing:

Shiftbar Housing Assembly

Shift Bar Housing:

Levers/Housings & Isolators

Transmission Overview

Table of Contents

General Information

Warnings and Cautions ................................................ i

Transmission Overview ............................................... ii

Purpose and Scope of Manual .................................... 1

Serial Tag Information and Model Nomenclature ........ 5

Lubrication Specifications ........................................... 7

Tool Specifications ...................................................... 9

Transmission Torque Specifications ......................... 12

Preventive Maintenance Inspection ........................... 13

Power Flow Diagrams ............................................... 17

Air System Overview ................................................. 36

General Troubleshooting Chart ................................. 42

Air System Troubleshooting ...................................... 44

Timing Procedures .................................................... 57

In-Vehicle Service Procedures

How to Remove Oil Filter Adapter ............................. 61

How to Assemble Oil Filter Adapter ........................... 62

How to Disassemble Roadranger Valve A-5010 ........ 63

How to Assemble Roadranger Valve A-5010 ............. 65

How to Disassemble Roadranger Valve A-4900 ........ 67

How to Assemble Roadranger Valve A-4900 ............. 69

How to Remove the Air Lines and Hoses .................. 71

How to Install the Air Lines and Hoses ...................... 73

How to Remove Compression Type Fittings .............. 75

How to Install Compression Type Fittings ................. 76

How to Remove Push-to-Connect Type Fittings ........ 77

How to Install Push-to-Connect Type Fittings ........... 78

How to Remove Rubber 1/4" Air Hoses ..................... 79

How to Install Rubber 1/4" Air Hoses ........................ 80

How to Remove the Air Filter/Regulator .................... 81

How to Install the Air Filter/Regulator ....................... 82

How to Remove a Roadranger Valve ......................... 83

How to Install a Roadranger Valve ............................ 84

How to Remove a Slave Valve ................................... 85

How to Install a Slave Valve ......................................86

How to Remove the Top-2 Valve Assembly

(Transmissions with Top-2 Option Only) .................. 87

In-Vehicle Service Procedures (cont’d)

How to Install the Top-2 Valve Assembly

(Transmissions with Top-2 Option Only) ...................88

How to Remove the Gear Shift Lever/Remote

Shift Control ..............................................................89

How to Install the Gear Shift Lever/Remote

Shift Control ..............................................................90

How to Adjust the Remote Shift Control (LRC Type) .91

Neutral Switch Operation and Testing ........................93

How to Remove the Neutral Switch ...........................94

How to Install the Neutral Switch ...............................95

Reverse Switch Operation and Testing ......................96

How to Remove the Reverse Switch ..........................97

How to Install the Reverse Switch .............................98

How to Remove the Shift Bar Housing ......................99

How to Install the Shift Bar Housing ........................101

How to Remove the Oil Seal - Mechanical

Speedometer ...........................................................103

How to Install the Oil Seal - Mechanical

Speedometer ...........................................................105

How to Remove the Oil Seal - Magnetic

Speedometer ...........................................................106

How to Install the Oil Seal - Magnetic Speedometer 108

How to Remove the Output Yoke/Companion

Flange and Nut .........................................................110

How to Install the Output Yoke/Companion Flange

and Nut ....................................................................111

How to Remove the Output Yoke / Flange and

Retaining Cap Screws ..............................................112

How to Install the Output Yoke / Flange and

Retaining Cap Screws ..............................................113

How to Remove the Auxiliary Section in Chassis .....114

How to Install the Auxiliary Section in Chassis ........116

How to Remove the Splitter Cylinder Assembly .......119

How to Install Splitter Cylinder Assembly ................121

How to Disassemble the Range Cylinder Assembly

- 7 Series .................................................................124

How to Disassemble the Range Cylinder Assembly

- 9 Series .................................................................125

How to Assemble the Range Cylinder Assembly ......127

iii

Table of Contents

Transmission Overhaul Procedures-Bench Service

How to Disassemble the Gear Shift Lever ............... 130

How to Assemble the Gear Shift Lever .................... 132

How to Remove the Shift Bar Housing .................... 134

How to Install the Shift Bar Housing ....................... 136

How to Disassemble the Standard Shift Bar

Housing ...................................................................138

How to Assemble the Standard Shift Bar Housing ..141

How to Assemble the Forward Shift Bar Housing .... 144

How to Disassemble the Forward Shift Bar Housing 147

How to Remove the Input Shaft Assembly

(without Main Case disassembly) ........................... 150

How to Install the Input Shaft Assembly

(without Main Case disassembly) ........................... 152

How to Remove the Auxiliary Section with

Tapered Bearings .................................................... 154

How to Remove the Splitter Cylinder Assembly ...... 156

How to Remove the Auxiliary Countershaft

Assembly ................................................................ 158

How to Remove the Splitter Gear ............................ 161

How to Disassemble the Range Cylinder Assembly 162

How to Disassemble the Output Shaft Assembly ....164

How to Disassemble the Synchronizer Assembly .... 167

How to Assemble the Synchronizer Assembly ........168

How to Assemble the Output Shaft Assembly ......... 170

How to Install the Splitter Gear ............................... 172

How to Assemble the Range Cylinder Assembly ..... 173

How to Install Splitter Cylinder Assembly ............... 176

How to Install the Auxiliary Countershaft Assembly 179

How to Disassemble the Splitter Gear Bearing

Assembly ................................................................ 182

How to Assemble the Splitter Gear Bearing

Assembly ................................................................ 183

How to Remove the Auxiliary Drive Gear Assembly 184

How to Remove the Clutch Housing

(with Internal Oil Tube) ...........................................186

How to Disassemble the Upper Reverse Idler

Gear Assembly ........................................................ 189

How to Disassemble the Lower Reverse Idler

Gear Assembly ........................................................ 191

How to Remove the Upper and Lower

Countershaft Bearings ............................................. 192

How to Remove the Mainshaft Assembly ................ 194

How to Remove the Countershaft Assemblies ........ 195

How to Disassemble the Countershaft Assemblies ..197

How to Remove the Input Shaft and

Main Drive Gear .......................................................199

How to Disassemble the Mainshaft Assembly .........202

How to Disassemble the Mainshaft Assembly with

Low Force Gear

How to Assemble the Mainshaft Assembly with Selective (Adjustable) Thickness

Tolerance Washers ..................................................206

How to Assemble the Mainshaft Assembly with Non-Selective (Non-Adjustable) Tolerance Washers 212

How to Assemble the Mainshaft Assembly with

Low Force Gearing ...................................................215

How to Prepare the Main Case for Assembly ...........218

How to Assemble the Countershaft Assemblies .......219

How to Assemble the Lower Reverse Idler Gear

Assembly .................................................................221

How to Install Countershaft Assemblies ..................225

How to Remove the Integral Oil Pump .....................226

How to Install the Lower Countershaft Bearings ......228

How to Install the Input Shaft and Main Drive Gear 230

How to Install the Mainshaft Assembly ....................232

How to Install the Upper Countershaft Bearings ......234

How to Assemble the Upper Reverse Idler

Gear Assembly .........................................................237

How to Install the Auxiliary Drive Gear Assembly ....240

How to Install the Clutch Housing

(with Internal Oil Tube) ............................................241

How to Disassemble the Integral Oil Pump without

Auxiliary Oil Tube .....................................................244

How to Assemble the Integral Oil Pump without

Auxiliary Oil Tube .....................................................247

How to Install the Integral Oil Pump ........................250

How to Disassemble the Integral Oil Pump with

Auxiliary Oil Tube .....................................................252

How to Assemble the Integral Oil Pump with

Auxiliary Oil Tube .....................................................256

How to Install the Auxiliary Section .........................260

Shim Procedure without a Shim Tool for

Tapered Bearings .....................................................262

How to Remove the Boosted or Hydraulic Actuator

and Adapter Housing ...............................................266

How to Install the Boosted or Hydraulic Actuator

and Adapter Housing ...............................................268

ing ...........................................204

Introduction

General Information

Purpose and Scope of Manual

This manual is designed to provide information necessary to service and repair the Fuller® Transmissions listed on the front.

How to use this Manual

The service procedures have been divided into two sections: In-Vehicle Service Procedures and Transmission Overhaul Procedures—Bench Service. In-Vehicle Service Procedures contain procedures that can be performed while the Transmission is still installed in the vehicle. Transmission Overhaul Procedures contain procedures that are performed after the Transmission has been removed from the vehicle.

The procedure sections are laid out with a general heading at the top outside edge of each page followed by more specific headings and the procedures. To find the information you need in these sections, first go to the section that contains the procedure you need. Then look at the heading at the top and outside edge of each page until you find the one that contains the procedure you need.

Transmission Overhaul Procedures follow the general steps for complete disassembly and then assembly of the Transmission.

Note: In some instances the Transmission appearance may be different from the illustrations, but the procedure is the same.

Disassemble Precautions

It is assumed in the detailed assembly instructions that the lubricant has been drained from the Transmission, the necessary linkage and vehicle Air Lines disconnected and the Transmission has been removed from vehicle Chassis. Removal of the Gear Shift Lever Housing Assembly (or Remote Control Assembly) is included in the detailed instructions (How to Remove the Gear Shift Lever). This Assembly MUST be detached from the Shift Bar Housing before the Transmission can be removed.

Follow closely each procedure in the detailed instructions, make use of the text, illustrations, and photographs provided.

Assemblies

• When disassembling the various Assemblies, such as the Mainshaft, Countershafts, and Shift Bar Housing, lay all parts on a clean bench in the same sequence as removed. This procedure will simplify assembly and reduce the possibility of losing parts.

Bearings

• Carefully wash and lubricate all usable bearings as removed and protectively wrap until ready for use. Remove bearings planned to be reused with pullers designed for this purpose.

Cleanliness

• Provide a clean place to work. It is important that no dirt or foreign material enters the unit during repairs. Dirt is an abrasive and can damage bearings. It is always a good practice to clean the outside of the unit before starting the planned disassembly.

Input Shaft

• The Input Shaft can be removed from the Transmission without removing the Countershafts, Mainshaft, or Main Drive Gear. Special procedures are required and provided in this manual.

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

Introduction

Snap Rings

• Remove Snap Rings with pliers designed for this purpose. Snap rings removed in this manner can be reused, if they are not sprung or loose.

When Using Tools to Move Parts

• Always apply force to Shafts, Housings, etc., with restraint. Movement of some parts is restricted. Never apply force to driven parts after they stop solidly. The use of soft Hammers, Soft Bars, and Mauls for all disassembly work is recommended.

Inspection Precautions

Before assembling the Transmission, check each part carefully for abnormal or excessive wear and damage to determine reuse or replacement. When replacement is necessary, use only genuine Fuller extended life from your unit.

Since the cost of a new part is generally a small fraction of the total cost of downtime and labor, avoid reusing a questionable part which could lead to additional repairs and expense soon after assembly. To aid in determining the reuse or replacement of any Transmission part, consideration should also be given to the unit's history, mileage, application, etc.

Recommended inspection procedures are provided in the following checklist:

Bearings

• Wash all Bearings in clean solvent. Check Balls, Rollers, and Raceways for pitting, discoloration, and spalled areas. Replace Bearings that are pitted, discolored, spalled, or damaged during disassembly.

• Lubricate Bearings that are not pitted, discolored, or spalled and check for axial and radial clearances.

• Replace bearings with excessive clearances.

• Check bearing fit. Bearing Inner Races should be tight to Shaft; Outer Races slightly tight to slightly loose in Case Bore. If the Bearing spins freely in the Bore the Case should be replaced.

Bearing Covers

• Check Covers for wear from thrust of adjacent Bearing. Replace Covers damaged from thrust of Bearing Outer Race.

• Check Cover Bores for wear. Replace those worn or oversized.

Clutch Release Parts

Transmission parts to assure continued performance and

• Check Clutch Release parts. Replace Yokes worn at Cam surfaces and Bearing Carrier worn at Contact Pads.

• Check Pedal Shafts. Replace those worn at Bushing surfaces.

Gears

• Check gear teeth for frosting and pitting. Frosting of gear teeth faces presents no threat of Transmission failure. Often in continued operation of the unit, frosted gears "heal" and do not progress to the pitting stage. In most cases, gears with light to moderate pitted teeth have considerable gear life remaining and can be reused, but gears in the advanced stage of pitting should be replaced.

• Check for gears with Clutching teeth abnormally worn, tapered, or reduced in length from clashing during shifting. Replace gears found in any of these conditions.

• Check Axial Clearance of gears.

Introduction

General Information

Gear Shift Lever Housing Assembly

• Check spring tension on Shift Lever. Replace Tension Spring if lever moves too freely.

• If Housing is disassembled, check Gear Shift Lever bottom end and Shift Finger Assembly for wear. Replace both gears if excessively worn.

Gray Iron Parts

• Check all gray iron parts for cracks and breaks. Replace parts found to be damaged.

Oil Return Threads and Seals

• Check oil return threads on the Input Shaft. If return action of threads has been destroyed, replace the Input Shaft.

• Check Oil Seal in Rear Bearing Cover. If sealing action of lip has been destroyed, replace Seal.

O-Rings

• Check all O-Rings for cracks or distortion. Replace if worn.

Reverse Idler Gear Assemblies

• Check for excessive wear from action of Roller Bearings.

Shift Bar Housing Assembly

• Check for wear on Shift Yokes and Block at pads and lever slot. Replace excessively worn parts.

• Check Yokes for correct alignment. Replace sprung Yokes.

• Check lock screw in Yoke and Blocks. Tighten and rewire those found loose.

• If Housing has been disassembled, check Neutral Notches of Shift Bars for wear from Interlock Balls.

Sliding Clutches

• Check all Shift Yokes and Yoke slots in Sliding Clutches for extreme wear or discoloration from heat.

• Check engaging teeth of Sliding Clutches for partial engagement pattern.

Splines

• Check Splines on all shafts for abnormal wear. If Sliding Clutch gears, Companion Flange, or Clutch Hub has wear marks in the Spline sides, replace the specific shaft effected.

Synchronizer Assembly

• Check Synchronizer for burrs, uneven and excessive wear at contact surface, and metal particles.

• Check Blocker Pins for excessive wear or looseness.

• Check Synchronizer contact surfaces on the Synchronizer cups for wear.

Washers

• Check surfaces of all washers. Washers scored or reduced in thickness should be replaced.

Introduction

IMPORTANT

Assembly Precautions

Make sure that Case interiors and Housings are clean. It is important that dirt and other foreign materials are kept out of the Transmission during assembly. Dirt is an abrasive and can damage polished surfaces of Bearings and Washers. Use certain precautions, as listed below, during assembly.

Axial Clearances

• Maintain original Axial Clearances of 0.006–0.015 in. for Mainshaft Gears.

Bearings

• Use a Flange-End Bearing Driver for bearing installation. These special drivers apply equal force to both Bearing Races, preventing damage to Balls/Rollers and Races while maintaining correct Bearing alignment with Bore and Shaft. Avoid using a Tubular or Sleeve-Type Driver, whenever possible, as force is applied to only one of the Bearing Races.

Cap Screws

• To prevent oil leakage and loosening, use Fuller

Gaskets

• Use new Gaskets throughout the Transmission as it is being rebuilt. Make sure all Gaskets are installed. An omission of any Gasket can result in oil leakage or misalignment of Bearing Covers.

Sealant #71205 on all Cap Screws.

Initial Lubrication

• Coat all Limit Washers and Shaft Splines with Lubricant during assembly to prevent scoring and galling of such parts.

O-Rings

• Lubricate all O-Rings with silicon lubricant.

Universal Joint Companion Flange or Yoke

• Pull the Companion Flange or Yoke tightly into place with the Output Shaft Nut, using 650–700 lb-ft (881.28–949.07 N•m) of torque. Make sure the Speedometer Drive Gear or a Replacement Spacer of the same width has been installed. Failure to pull the Companion Flange or Yoke tightly into place can result in damage to the Mainshaft Rear Bearing.

See the appropriate Illustrated Parts Lists (specified by model series) to ensure that proper parts are used during assembly of the Transmission.

Model Designations

General Information

Roadranger

Twin Countershaft

Low-Inertia

F= Forward Opening Shift Housing

Ratio Set

Forward Speeds

6= Multi-Mesh Gearing 7= Helical Auxiliary Gearing and Multi-Mesh Front Section Gearing 9= Improved Seal System

This (x) 100 = Nominal Torque Capacity

C= Convertible

1 6 7 1 8

O= Overdrive w/ Direct Shift Pattern

Top 2

Multi-Torque

______

____

Serial Tag Information and Model Nomenclature

Transmission model designation and other Transmission identification information are stamped on the Transmission Tag. To identify the Transmission model designation and Serial Number, locate the Tag on the Transmission and then locate the numbers as shown.

When calling for service assistance or parts, have the Model and Serial Numbers handy.

Do not remove or destroy the Transmission Identification Tag.

The Model Number gives basic information about the Transmission. Use this number when calling for service assistance or replacement parts.

Serial Number

The Serial Number is the sequential identification number of the Transmission. Before calling for service assistance, write the number down. It may be needed.

Bill of Material or Customer Number

This number may be located below the Model and Serial Numbers. It is a reference number used by Eaton.

Model Designations

Model Options

Torque Rating

The torque rating of the Transmission specified in the Model Number is the Input Torque Capacity in lb-ft. Various torque ratings are available. For more information, call your Eaton Regional Sales and Service Office at 1-800-826-HELP (4357).

Shift Bar Housings

Two types of Shift Bar Housings are available for this Transmission. Both are described and shown below.

Standard

The standard Shift Bar Housing has a Gear Shift Lever opening that is located toward the rear of the Transmission.

Forward

The forward Shift Bar Housing has a Gear Shift Lever opening located three inches closer to the Transmission front than the standard opening. This forward design allows greater flexibility in mounting the Transmission and is indicated by an “F” in the Model Number.

Lubrication Pumps

Three types of Lubrication Pumps are available for use on this Transmission and are described below:

Internal: An internal Lubrication Pump is located in the lower front of the Transmission and is driven off the Upper Countershaft. 13-Speed Transmissions rated 1550 lb-ft and above include the Internal Pump standard. All 18-Speed Transmissions contain the Internal Lube Pump.

Auxiliary Countershaft: An Auxiliary Countershaft Pump is mounted on the rear of the Transmission and driven off the Auxiliary Countershaft.

PTO Driven: A PTO driven pump is externally mounted on the 6 or 8 bolt PTO openings and driven off the PTO Gear.

Power Take Off (PTO) Usage

PTOs can be mounted in the following way:

6 or 8 Bolt: The 6 or 8 bolt openings are standard with the Transmission. The PTO is mounted to the opening and driven from the PTO Gear on the Front Countershaft.

Thru-Shaft: The Thru-Shaft PTO mounts on the rear of the Transmission. It requires a special Auxiliary Housing and Main Case Countershaft with Internal Splines.

Lubrication

General Information

IMPORTANT

Lubrication Specifications

Transmission Filters should be changed during regular lube intervals. Inspection of the Transmission Filter should be conducted during preventive maintenance checks for damage or corrosion. Replace as necessary.

• For a list of Eaton

• The use of lubricants not meeting these requirements will affect warranty coverage.

• Additives and friction modifiers must not be introduced. Never mix engine oils and gear oils in the same Transmission.

Transmission Operating Angles

If the Transmission operating angle is more than 12 degrees, improper lubrication will occur. The operating angle is the Transmission mounting angle in the Chassis plus the percent of upgrade (expressed in degrees). For operating angles over 12 degrees, the Transmission must be equipped with an Oil Pump or Cooler kit to insure proper lubrication.

Operating Temperatures with Oil Coolers

The Transmission must not be operated consistently at temperatures above 250 °F. Operation at temperatures above 250 °F [121 °C] causes loaded gear tooth temperatures to exceed 350 °F [177 °C] which will ultimately destroy the heat treatment of the gears. If the elevated temperature is associated with an unusual operating condition that will reoccur, a Cooler should be added, or the capacity of the existing cooling system increased.

Approved Synthetic Lubricants, see TCMT0021 or call 1-800-826-HELP (4357).

The following conditions in any combination can cause operating temperatures of over 250 °F [121 °C]:

• Operating consistently at slow speed.

• High ambient temperatures.

• Restricted air flow around Transmission.

• Use of engine retarder.

• High horsepower operation.

Note: Transmission Coolers must be used to reduce the operating temperatures when the above conditions are encountered.

Lubrication

Oil Cooler Chart

Table 4

Transmission Oil Coolers are:

Recommended

• With engines of 350 H.P. and above.

Required

• With engines 399 H.P. and above and GCW’s over 90,000 lbs.

• With engines 399 H.P. and above and 1400 lb-ft (1898.15 N•m) or greater torque.

• With engines 1500 lb-ft (2033.73 N•m) and above

18-speed AutoShift Transmissions require use of an Eaton® supplied Oil-to-Water Cooler or approved equivalent.

• With engines 450 H.P. and above.

Recommended Tools

General Information

Tool Specifications

Some repair procedures pictured in this Manual show the use of specialized tools. Their actual use is recommended as they make Transmission repair easier, faster, and prevent costly damage to critical parts.

For the most part, ordinary Mechanic's Tools such as Socket Wrenches, Screwdrivers, etc., and other standard shop items such as a Press, Mauls and Soft Bars are the only tools needed to successfully disassemble and reassemble any Fuller

The following tables list and describe the typical tools required to properly service this model Transmission above and beyond the necessary basic Wrenches, Sockets, Screwdrivers, and Pry Bars.

Transmission.

General Tools

The following tools are available from several Tool Manufacturers such as Snap-On, Mac, Craftsman, OTC, and many others:

Tool Purpose

0–100 lb-ft 1/2" drive Torque Wrench

0–700 lb-ft 3/4" or 1" drive Torque Wrench Torquing of Output Nut to 650–700 lb-ft (881.28–949.07 N•m)

0–50 lb-in 3/8" drive Torque Wrench General torquing of fasteners

0–30 lb-in 1/4" drive Torque Wrench

70 MM or 2 2/4" Socket - Standard Depth To remove the Output Shaft Nut

Snap Ring Pliers - Large Standard External

General torquing of fasteners (Typically 15–80 lb-ft [20.34–108.47 N•m])

Torquing of Cap Screws to 7 lb-in (0.79 N•m) during Auxiliary Countershaft Bearing endplay setting procedure

To remove the Snap Rings at the Auxiliary Drive Gear, Input Shaft Bearing, and Countershaft Bearings

Feeler Gauges To set Mainshaft Washer Endplay and Auxiliary Tapered Bearing Endplay

Rolling Head Pry Bar To remove the Auxiliary Drive Gear Bearing

(2) Air Pressure Gauges 0–100 PSI (0–1034 kPa) To troubleshoot and verify correct operation of Air System

Universal Bushing Driver

To remove and install Clutch Housing Bushings. Bushing OD = 1.125 in., ID = 1.000 in.

Recommended Tools

Special Tools

The following Transmission Tools are available directly from K-Line Industries. To obtain any of these tools listed, contact K-Line by phone or visiting the online store.

K-Line Industries, Inc.

315 Garden Avenue Holland, MI 49424

1-800-824-KLINE (5546)

http://www.klineind.com/

K-Line Part # Tool Tool Description

RR1001TR-1 Driver - Output Seal Slinger

RR1001TR-2 Driver - Output Seal

RR1001TR-4 Driver - Output Seal Slinger

RR1001TR-8 Driver - Output Seal

RR1002TR Auxiliary Countershaft Support Straps

RR1004TR Mainshaft Lifting Hook

RR1005TR Driver - Input Bearing

RR1006TR Auxiliary Section Lifting Bracket Used to lift Transmission Auxiliary Sections.

RR1007TR

RR1010TR Slide Hammer Used to remove Bearing Races, Reverse Idler Shafts, and Seals.

RR1011TR-1 Slide Hammer Attachment Used for removing Output Seals.

Shimming Gauge - Auxiliary Countershaft (0.100")

Used to install Output Seal Protective Slinger on FR & RT-Series (Gen 9) Transmission Output Yokes.

Used to install Output Seal in Rear Bearing Cover on RT-Series (Gen 6 & 7) Transmissions with 2.75" Output Shaft.

Used to install Output Seal Protective Slinger on RT-Series (Gen 6 &

7) Transmission Output Yokes.

Used with Seal Driver RR1001TR-2 to install Output Seal in Rear Bearing Cover on FR & RT-Series (Gen 9) Transmissions.

Used to support the aux-Countershaft Assemblies when servicing the aux-section on FR & RT-Series (Gen 7 & 9) Transmissions.

Used to remove/install Mainshaft Assembly into the Transmission Main Case.

Used to install the Input Bearing on Transmissions with 2" & 1.75" Input Shafts.

Used for setting proper Auxiliary Countershaft Bearing clearance on FR-Series and RT-Series (Gen 7 & 9) Transmissions.

RR1011TR-2 Slide Hammer Attachment Used for removing Bearing Races from the Transmission Case.

RR1011TR-3 Slide Hammer attachment Used for removing Bearing Races from the Transmission Case.

RR1012TR-2 Driver - Countershaft Front Bearings

RR1012TR-3 Puller - Countershaft Front Bearings

RR1012TR-4 Driver - Countershaft Rear Bearings Used to install Rear Countershaft Bearings, RT-Series Transmissions.

RR1012TR-5

RR1012TR-6

RR1013TR Timing Block - RT-Series Countershaft

Driver - Auxiliary Countershaft Bearings

Used to install Front Countershaft Bearings on RT-Series Transmissions.

Used to remove Front Countershaft Bearings on RT-Series Transmissions.

Used to install Auxiliary Countershaft Bearings on FR & RT-Series Transmissions with Auxiliary Section helical gearing.

Used to install Auxiliary Countershaft Bearings on RT-Series Transmissions with Auxiliary Section spur gearing.

Used to support the Upper Countershaft during Main Box assembly on RT-Series Transmissions.

Recommended Tools

General Information

K-Line Part # Tool Tool Description

RR1015TR

RR1017TR Pusher - Countershaft

RR1019TR Hand Maul Used with Bearing and Seal Drivers for part installation/removal.

RR1020TR Soft Bar Used with hand Maul to remove parts from the Transmission.

RR1022TR Countershaft Support Tool

RR1023TR Puller - Input Bearing Used to remove the Input Bearing on FR & RT-Series Transmissions.

RR1024TR Driver - Output Bearing Used to install the Output Bearing on FR & RT-Series Transmissions.

Driver - Countershaft Front/Rear bearings

Used to install Front and Rear Countershaft Bearings on FR-Series Transmissions.

Used to push the Countershaft Assembly rearward to create clearance for Bearing Puller on FR & RT-Series Transmissions.

Used to support the Upper Countershaft during Main Box disassembly on FR & RT-Series Transmissions.

Shop Equipment

Tool Purpose

20 Ton capacity Press To press Countershaft Gears from Countershaft.

Eaton Aftermarket Parts

The following tools are available through Eaton Aftermarket Parts. To obtain any of the tools listed, contact your local Eaton Parts Distributor.

Tool Purpose Eaton Part Number

5/32" Air Line Release Tool

Air Line Cutting Tool

To remove 5/32" Air Lines from Push-toConnect Fittings.

To cut plastic Air Lines smoothly and squarely.

P/N 4301157 included in Kit K-2394

P/N 4301158 included in Kit K-2394.

Recommended Tools

(1) Oil Drain Plug 45-55 lb-ft (61.01-74.57 Nm) ¾ Pipe Threads

(2) Support Stud Nuts 170-185 lb-ft (230.49-250.93 Nm)

/8 -18 Threads, Use Lockwashers

(1) Output Nut 650-700 lb-ft (881-949 Nm) Intall output nut onto a clean, oil free shaft.

Note: DO NOT reuse output nut, replace with new if removed from shaft.

(1) Oil Fill Plug 35-50 lb-ft (47-68 Nm) 1¼ Pipe Threads

Transmission Torque Specifications

Correct torque application is extremely important to assure long Transmission life and dependable performance. Over-tightening or under-tightening can result in a loose installation and in many instances, eventually cause damage to Transmission Gears, Shafts, and/or Bearings. Use a Torque Wrench whenever possible to attain recommended lb-ft ratings. Do not torque Cap Screws dry.

Preventive Maintenance

General Information

Preventive Maintenance Inspection

Everyday there are countless vehicles operating over the highways with Transmissions in such a neglected mechanical condition, they can be referred to as failures looking for a place to break down. They lack a proper and organized preventive maintenance program.

Preventive maintenance is a general term which applies to all procedures necessary to have maximum life and satisfactory service at the lowest possible cost, short of removing and repairing the unit.

A number of conditions contrary to good preventive maintenance can generally be pointed to when inspecting a failed Transmission. Taking a few minutes every so many hours or miles to do a few simple checks could help avoid eventual breakdown or reduce the repair cost. If the Transmission is not cared for, it will breakdown.

Preventative Maintenance Check Points

Note: Transmission appearance may differ, however the procedure is the same.

Preventive Maintenance

1. Air System and Connections

• Check for leaks, worn Air Lines, loose connections and Cap Screws.

2. Clutch Housing Mounting

• Check all Cap Screws of Clutch Housing flange for looseness.

3. Clutch Release Bearing (Not Shown)

• Remove Hand Hole Cover and check Radial and Axial Clearance in Release Bearing.

• Check relative position of thrust surface of Release Bearing with Thrust Sleeve on Push-type Clutches.

4. Clutch Pedal Shaft and Bores

• Pry upward on Shafts to check wear.

• If excessive movement is found, remove Clutch Release Mechanism and check Bushings on Bores and wear on

Shafts. See OEM literature.

5. Lubricant

• See Lubrication Manual TCMT0021.

6. Oil Filter

• Oil Filter Inspection (during vehicle PM schedule):

- Inspect Oil Filter for damage or rust. Replace as necessary.

- Inspect Oil Filter Adapter for damage or leakage. Replace as necessary.

• Oil Filter Replacement

- Replace every 100,000 miles and top off fluid.

- Every Transmission fluid change.

7. Filler and Drain Plugs

• Remove Filler Plugs and check level of lubricant at specified intervals. Tighten fill and Drain Plugs securely.

8. Cap Screws and Gaskets

• For applicable models, check all Cap Screws, especially those on PTO Covers and Rear Bearing Covers for

looseness which would cause oil leakage.

• Check PTO opening and Rear Bearing Covers for oil leakage due to faulty Gasket.

9. Gear Shift Lever

• Check for looseness and free play in Housing. If Lever is loose in Housing, proceed with Check No. 10.

10. Gear Shift Lever Housing Assembly

• If present, remove Air Lines at Air Valve or Slave Valve. Remove the Gear Shift Lever Housing Assembly from

the Transmission.

• Check the Tension Spring and Washer for set and wear.

• Check the Gear Shift Lever Spade Pin and slot for wear.

• Check bottom end of Gear Shift Lever for wear and check slot of Yokes and Blocks in Shift Bar Housing for wear

at contact points with Shift Lever.

Checks With Drive Line Dropped

11. Universal Joint Companion Flange or Shaft Nut

• Check for tightness. Tighten to recommended torque.

12. Output Shaft (Not Shown)

• Pry upward against Output Shaft to check radial clearance in Mainshaft Rear Bearing.

Preventive Maintenance

General Information

Checks With Universal Joint Companion Flange or Yoke Removed Note: If necessary, use solvent and shop rag to clean sealing surface of Companion Flange or Yoke. Do not use Crocus Cloth,

Emery Paper, or other abrasive materials that will mar surface finish.

13. Splines on Output Shaft (Not Shown)

• Check for wear from movement and chucking action of the Universal Joint Companion Flange or Yoke.

14. Mainshaft Rear Bearing Cover (Not Shown)

• Check Oil Seal for wear.

Inspection

Part to Inspect What to Check For Action to be Done

Speedometer Cables should not be loose.

Speedometer Connections

Rear Bearing Cover Cap Screws, Gasket, and Nylon Collar

Output Shaft Nut

PTO Covers and Openings Check the Cap Screws for tightness.

Should be an O-Ring or gasket between the mating Speedometer Sleeve and the Rear Bearing Cover.

Check Retaining Cap Screws for tightness.

Verify Nylon Collar and Gasket are installed at the chamfered hole, aligned near the mechanical Speedometer opening.

Verify that a Rear Bearing Cover gasket is in place.

Check the Output Shaft Nut for tightness.

Applied hydraulic Thread Sealant #71208 to threads, torque Speedometer Sleeve to 35–50 lb-ft (47.45–67.79 N•m).

Replace the O-Ring/gasket if damaged or missing.

Apply Eaton Sealant #71205 to the Cap Screw threads, torque to 35–45 lb-ft (47.45–61.01 N•m).

Use new parts if need to replace. Apply Eaton Sealant #71205 to the Cap Screw threads, torque to 35–45 lb-ft (47.45–61.01 N•m).

Install a new Gasket if Rear Bearing Cover was removed.

Torque the Output Shaft Nut to 650–700 lb-ft (881.28–949.07 N•m). Do not over torque the Output Nut.

Apply Eaton Sealant #71205 to the Cap Screw threads. Torque 6 bolt PTO Cap Screws to 35–45 lb-ft (47.45–61.01 N•m), 8 bolt PTO Cap Screws to 50–65 lb-ft (67.79–88.13 N•m).

Gray Iron Parts

Front Bearing Cover

Oil Cooler and Oil Filter

Oil Drain Plug, Oil Fill Plug

Check Front Bearing Cover, Front Case, Shift Bar Housing, Rear Bearing Cover, and Clutch Housing for cracks or breaks.

Check return threads for damage. If threads damaged, replace the Input Shaft.

Check the Cap Screws for tightness.

Check all connectors, Fittings, Hoses, and Filter Element for tightness.

Check the Oil Drain Plug and the Oil Fill Plug for leakage.

Replace parts found to be damaged.

Torque the Cap Screws to 35–45 lb-ft (47.45–61.01 N•m).

Tighten any loose Fittings.

Torque the Oil Drain Plug to 45–55 lb-ft (61.01–74.57 N•m), Oil Fill Plug to 60–70 lb-ft (81.35–94.91 N•m).

Preventive Maintenance

Oil Leak Inspection Process

Inspect for Oil Leak

Determine if it is a Weep or a Leak

Weep: Stained, damp, no drips, light oil film, dirt adhered to the contaminated area.

Gasket Rear Seal Leak

1. Clean suspected oil weep area with a clean dry cloth or mild soluble degreaser.

2. Ensure lube is to proper level.

3. Notify the customer that it is only a weep and it is not considered to be detrimental to the life of the transmission.

4. Repair is complete.

1. Do not repair: Rear seal is designed to allow minimal seepage.

2. Ensure lube is to proper level.

Leak: Extremely wet or dripping of oil in the contaminated area.

Step 1

1. Determine the origin of the leak path.

2. If origin of leak is obvious skip to Step 3.

3. If the origin of the oil leak is not obvious then use either of the two following steps to determine the oil leak:

Note: Do not use a high pressure spray washer to

clean the area. Use of a high pressure spray may force contamination into the area of concern and temporarily disrupt the leak path.

i. Clean area with a clean dry cloth or mild soluble degreaser and fill the transmission to the proper lube level.

ii. Clean the area as noted above and insert tracer dye into the transmission lube and fill transmission to proper lube level.

Step 2

Operate vehicle to normal transmission operating temperature and inspect the area for oil leak(s) visually or if tracer dye was introduced use an UVL (Ultraviolet Light) to detect the tracer dye’s point of origin.

Note: When inspecting for the origin of the leak(s) make sure the assumed leak area is not being contaminated by a source either forward or above the identified area such as the engine, shift tower, shift bar housing, top mounted oil cooler, etc...

Step 3

Once the origin of the leak is identified, repair the oil leak using proper repair procedures from the designated model service manual.

Step 4

After the repair is completed, verify the leak is repaired and operate the vehicle to normal transmission operating temperature. Inspect repaired area to ensure oil leak has been eliminated. If the leak(s) still occurs, repeat steps or contact the Roadranger Call Center at 1-800-826-4357.

Power Flow

General Information

Power Flow Diagrams

An understanding of the engine's Power Flow through a Transmission in each particular gear will assist the Technician in troubleshooting and servicing a Transmission.

The Fuller or Front Section contains six Gear Sets which are shifted with the Gear Shift Lever. The second “Transmission” called the Auxiliary Section, contains three Gear Sets and is shifted with air pressure.

Note: This Transmission is referred to as a Constant Mesh Type Transmission. When in operation, all gears are turning even

Transmission can be thought of as two separate “Transmissions” combined into one unit. The first “Transmission”

though only some of them are transferring power.

Cross Sectional View

1. Front Section

2. Auxiliary Section

Power Flow

The Transmission components in the figure below shows the Transmission with the main components called out. Note that the Transmission is in the Neutral position because the Sliding Clutches are all in their center positions and not engaged in any gears.

Transmissions Components

1. Input Shaft

2. Main Drive Gear

3. Sliding Clutch

4. Countershaft

5. Mainshaft Gear

6. Auxiliary Splitter Clutch (slides on Front Section Mainshaft)

7. Auxiliary Countershaft

8. Range Sliding Clutch

9. Auxiliary Mainshaft Reduction Gear

10. Output Shaft (Auxiliary Mainshaft)

11. Splitter Gear

12. Auxiliary Drive Gear

Power Flow

General Information

153

264

Neutral

RTO

154

263

Neutral

RTX

Front Section Power Flow

Note: The heavy lines in the figure below outline the Power Flow description. For help in understanding the Transmission

components, refer to the figure “Transmission Components” on the previous page.

1. Power (torque) from the vehicle's engine is transferred to the Transmission's Input Shaft.

2. The Input Shaft rotates the Main Drive Gear through internal Splines in the hub of the Gear.

3. The Main Drive Gear meshes with both Countershaft driven gears and the torque is split between both Countershafts.

4. Because the Countershaft Gears are in constant mesh with the Mainshaft Gears, all the Front Section gearing rotates. However, only the engaged or selected Mainshaft Gear will have torque. External Clutching teeth on the Sliding Clutch will engage internal Clutching teeth on the selected Mainshaft Gear. Torque will now be provided from both opposing Countershaft Gears, into the engaged Mainshaft Gear, and through the Sliding Clutch to the Front Section Mainshaft.

5. The rear of the Front Section Mainshaft is splined into the Auxiliary Splitter Clutch and torque is now delivered to the Auxiliary Splitter Clutch.

Front Section Power Flow

1. Sliding Clutch forward

2. Sliding Clutch forward

3. Sliding Clutch rearward

Power Flow

Front Section Power Flow - Direct Gear

In direct gear, the Front Sliding Clutch is moved forward and engages into the back of the Main Drive Gear. Torque will flow from the Input Shaft to the Main Drive Gear, Main Drive Gear to Sliding Clutch, Sliding Clutch straight into the Front Section Mainshaft which delivers the torque to the Auxiliary Splitter Clutch. See figure below.

Note: All Countershaft and Mainshaft Gears will rotate, but the gears will not be loaded.

Front Section Power Flow - Direct Gear

1. Sliding Clutch forward

2. Sliding Clutch forward

3. Sliding Clutch rearward

RTO

153

Neutral

264

Power Flow

General Information

Front Section Power Flow - Reverse Gear

Torque will flow from the Countershafts to the Reverse Idler Gears. Torque will then flow from the Reverse Idler Gears to the Mainshaft Reverse Gear. Torque will now travel through the Mainshaft Reverse Gear, the Sliding Clutch in the Reverse position and then to the Mainshaft and Auxiliary Splitter Clutch. See figures below.

Note: The Idler Gears cause the reversal of rotation.

Reverse LO - 9/13 speed; Reverse LO - Low Split - 18 speed

1. Sliding Clutch rearward

2. Sliding Clutch forward

3. Sliding Clutch rearward

Reverse LO - High Split - 18 Speed

1. Sliding Clutch rearward

2. Sliding Clutch rearward

3. Sliding Clutch rearward

Reverse HI - 9/13 speed; Reverse HI - Low Split - 18 Speed

1. Sliding Clutch rearward

2. Sliding Clutch forward

3. Sliding Clutch forward

Reverse HI - High Split - 18 Speed

1. Sliding Clutch rearward

2. Sliding Clutch rearward

3. Sliding Clutch forward

Power Flow

153

264

Neutral

RTO

154

263

Neutral

RTX

153

264

Neutral

154

263

Neutral

RTO

RTX

Auxiliary Section Power Flow - Low Range

Depending on the position of the Splitter Button (L or H) the Auxiliary Splitter Clutch engages in either the Auxiliary Drive Gear or the Splitter Gear. The selected Auxiliary Gear transfers torque to both Auxiliary Countershafts.

If the Auxiliary Section is in low range, the Range Sliding Clutch is rearward and engaged into the Auxiliary Mainshaft Reduction Gear. Torque flows from the Auxiliary Countershafts, into the Auxiliary Mainshaft Reduction Gear, through the Range Sliding Clutch and then into the Output Shaft (Auxiliary Mainshaft).

LO - 9/13 Speed; LO - Low Split - 18 Speed

1. Sliding Clutch forward

2. Sliding Clutch forward

3. Sliding Clutch rearward

LO - High Split - 18 Speed

1. Sliding Clutch forward

2. Sliding Clutch rearward

3. Sliding Clutch rearward

Power Flow

General Information

153

264

eutra

153

264

Neutral

154

263

Neutral

RTO

RTX

Auxiliary Section Power Flow- High Range

If the Auxiliary Section is in high range, the Range Sliding Clutch is forward and engaged into the back of the Auxiliary Drive Gear. Torque flows through the Auxiliary Section in high range depending on the splitter state selected (L or H). If splitter (L) is selected, torque flows from the Auxiliary Splitter Clutch to the Auxiliary Drive Gear. From the Auxiliary Drive Gear, torque flows to both Countershafts and then to the Splitter Gear. Torque then flows into the Range Sliding Clutch and Output Shaft. (See Figure 1st-13 Speed; 1st-Low Split-18 Speed).

If splitter (H) is selected, torque flows directly through the Auxiliary Section. Torque flows from the Auxiliary Splitter Clutch to the Auxiliary Reduction Gear to the Range Sliding Clutch to the Output Shaft. The Auxiliary gearing still turns, but the gear teeth will not be loaded. (See Figure 1st-High Split-18 Speed).

5th - 9/13–18 speed Low Split

1. Sliding Clutch rearward

2. Sliding Clutch forward

3. Sliding Clutch forward

5th - 9/13–18 speed High Split

1. Sliding Clutch rearward

2. Sliding Clutch rearward

3. Sliding Clutch forward

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