Eaton Transmission RTLO-16713A Service Manual

Service Manual

Fuller® Heavy-Duty Transmissions

TRSM0670 EN-US

September 2013

RTLO-12713A	RTLO-16918B-T2	RTLOF-12913A	RTLOF-18718B
RTLO-12913A	RTLO-18718B	RTLOF-14713A	RTLOF-18913A
RTLO-14713A	RTLO-18718B-T2	RTLOF-14718B	RTLOF-18913A-T2
RTLO-14718B	RTLO-18913A	RTLOF-14913A	RTLOF-18918B
RTLO-14913A	RTLO-18913A-T2	RTLOF-14918B	RTLOF-18918B-T2
RTLO-14918B	RTLO-18918B	RTLOF-14918B-T2	RTLOF-20913A
RTLO-14918B-T2	RTLO-18918B-T2	RTLOF-16713A	RTLOF-20918B
RTLO-16713A	RTLO-20913A	RTLOF-16713A-T2	RTLOF-20918B-T2
RTLO-16713A-T2	RTLO-20918B	RTLOF-16718B	RTLOF-22918B
RTLO-16718B	RTLO-20918B-T2	RTLOF-16913A	RTLOFC-16909A-T2
RTLO-16913A	RTLO-22918B	RTLOF-16913A-T2
RTLO-16913A-T2	RTLOC-16909A-T2	RTLOF-16918B
RTLO-16918B	RTLOF-12713A	RTLOF-16918B-T2

This Page Intentionally Blank

Warnings

Warnings and Cautions

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® 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	WARNING: Failure to follow indicated
manual to call attention to procedures	procedures creates a high risk of personal
where carelessness or failure to follow	injury to the servicing technician.
specific instructions may result in
personal injury and/or component	CAUTION: Failure to follow indicated
damage.	procedures may cause component
Departure from the instructions, choice	damage or malfunction.
of tools, materials and recommended	IMPORTANT: Highly recommended
parts mentioned in this publication	procedures for proper service of this unit.
may jeopardize the personal safety
of the service technician or vehicle	Note: Additional service information not
operator.	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.

CAUTION

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.

i

Introduction

Transmission Overview

Air System:

Roadranger® Valve

Shift Bar Housing:

Levers/Housings

& Isolators

Shift Bar Housing:

Shiftbar Housing Assembly

Front Section:

Reverse Idler

Front Section:

Clutch Housing / Case Assembly

Front Section:

Input Shaft / Drive Gear

Front Section:

Countershafts

106004-8-94 15 spd trans

Auxiliary Section:

Range Cylinder

Auxiliary Section:
Auxiliary Countershaft
Auxiliary Section:	Air System:
	Air Filter/Regulator
Auxiliary Housing

Auxiliary Section:

Auxiliary Drive Gear

Front Section:

Mainshaft

Auxiliary Section:

Reduction Cylinder

Air System:

Slave Valve

ii

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 Gearing ...........................................	204
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

iv

Introduction

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.

Information General

1

For parts or service call us Pro Gear & Transmission, Inc.

1(877) 776-4600

[phone] [e-mail]

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® Transmission parts to assure continued performance and 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

•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.

2

Introduction

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.

Information General

3

Introduction

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® Sealant #71205 on all Cap Screws.

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.

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.

IMPORTANT

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

4

Model Designations

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.

Information General

R T

L

O

C or F ___ 1 6

7

1 8

A __ MTor T2

Roadranger

Top 2

Multi-Torque

Twin Countershaft

Ratio Set

Low-Inertia

Forward Speeds

O= Overdrive w/ Direct Shift Pattern

6= Multi-Mesh Gearing

7= Helical Auxiliary Gearing and

C= Convertible

Multi-Mesh Front Section Gearing

9= Improved Seal System

F= Forward Opening Shift Housing

This (x) 100 = Nominal Torque Capacity

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.

5

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.

6

Lubrication

Lubrication Specifications

IMPORTANT

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

•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.

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.

Information General

7

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.

8

Recommended Tools

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® Transmission.

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.

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	General torquing of fasteners (Typically 15–80 lb-ft
		[20.34–108.47 N•m])
	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	Torquing of Cap Screws to 7 lb-in (0.79 N•m) during Auxiliary Countershaft
		Bearing endplay setting procedure
	70 MM or 2 2/4" Socket - Standard Depth	To remove the Output Shaft Nut
	Snap Ring Pliers - Large Standard External	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.

Information General

9

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	Used to install Output Seal Protective Slinger on FR & RT-Series
			(Gen 9) Transmission Output Yokes.
	RR1001TR-2	Driver - Output Seal	Used to install Output Seal in Rear Bearing Cover on RT-Series
			(Gen 6 & 7) Transmissions with 2.75" Output Shaft.
	RR1001TR-4	Driver - Output Seal Slinger	Used to install Output Seal Protective Slinger on RT-Series (Gen 6 &
			7) Transmission Output Yokes.
	RR1001TR-8	Driver - Output Seal	Used with Seal Driver RR1001TR-2 to install Output Seal in Rear
			Bearing Cover on FR & RT-Series (Gen 9) Transmissions.
	RR1002TR	Auxiliary Countershaft Support Straps	Used to support the aux-Countershaft Assemblies when servicing the
			aux-section on FR & RT-Series (Gen 7 & 9) Transmissions.
	RR1004TR	Mainshaft Lifting Hook	Used to remove/install Mainshaft Assembly into the Transmission
			Main Case.
	RR1005TR	Driver - Input Bearing	Used to install the Input Bearing on Transmissions with 2" & 1.75"
			Input Shafts.
	RR1006TR	Auxiliary Section Lifting Bracket	Used to lift Transmission Auxiliary Sections.
	RR1007TR	Shimming Gauge - Auxiliary	Used for setting proper Auxiliary Countershaft Bearing clearance on
		Countershaft (0.100")	FR-Series and RT-Series (Gen 7 & 9) Transmissions.
	RR1010TR	Slide Hammer	Used to remove Bearing Races, Reverse Idler Shafts, and Seals.
	RR1011TR-1	Slide Hammer Attachment	Used for removing Output Seals.
	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	Used to install Front Countershaft Bearings on RT-Series
			Transmissions.
	RR1012TR-3	Puller - Countershaft Front Bearings	Used to remove Front Countershaft Bearings on RT-Series
			Transmissions.
	RR1012TR-4	Driver - Countershaft Rear Bearings	Used to install Rear Countershaft Bearings, RT-Series Transmissions.
	RR1012TR-5	Driver - Auxiliary Countershaft	Used to install Auxiliary Countershaft Bearings on FR & RT-Series
		Bearings	Transmissions with Auxiliary Section helical gearing.
	RR1012TR-6	Driver - Auxiliary Countershaft	Used to install Auxiliary Countershaft Bearings on RT-Series
		Bearings	Transmissions with Auxiliary Section spur gearing.
	RR1013TR	Timing Block - RT-Series Countershaft	Used to support the Upper Countershaft during Main Box assembly on
			RT-Series Transmissions.

10

		Recommended Tools
K-Line Part #	Tool	Tool Description		General
RR1015TR	Driver - Countershaft Front/Rear	Used to install Front and Rear Countershaft Bearings on FR-Series
	bearings	Transmissions.
				Information
RR1017TR	Pusher - Countershaft	Used to push the Countershaft Assembly rearward to create clearance
		for Bearing Puller on FR & RT-Series Transmissions.
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	Used to support the Upper Countershaft during Main Box disassembly
		on FR & RT-Series Transmissions.
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.

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	To remove 5/32" Air Lines from Push-to-	P/N 4301157 included in Kit K-2394
		Connect Fittings.
	Air Line Cutting Tool	To cut plastic Air Lines smoothly and	P/N 4301158 included in Kit K-2394.
		squarely.

11

Recommended Tools

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.

(2) Support Stud Nuts

170-185 lb-ft (230.49-250.93 Nm)

5/8 -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 Drain Plug

45-55 lb-ft (61.01-74.57 Nm)

¾Pipe Threads

(1)Oil Fill Plug

35-50 lb-ft (47-68 Nm) 1¼ Pipe Threads

12

Preventive Maintenance

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.

Information General

13

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.

14

Preventive Maintenance

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	Applied hydraulic Thread Sealant #71208 to threads,
			torque Speedometer Sleeve to 35–50 lb-ft
		loose.
			(47.45–67.79 N•m).
	Speedometer Connections
		Should be an O-Ring or gasket between
		the mating Speedometer Sleeve and the	Replace the O-Ring/gasket if damaged or missing.
		Rear Bearing Cover.
		Check Retaining Cap Screws for	Apply Eaton Sealant #71205 to the Cap Screw
		tightness.	threads, torque to 35–45 lb-ft (47.45–61.01 N•m).
	Rear Bearing Cover Cap	Verify Nylon Collar and Gasket are	Use new parts if need to replace. Apply Eaton
		installed at the chamfered hole, aligned
	Screws, Gasket, and Nylon		Sealant #71205 to the Cap Screw threads, torque to
		near the mechanical Speedometer
	Collar		35–45 lb-ft (47.45–61.01 N•m).
		opening.
		Verify that a Rear Bearing Cover gasket	Install a new Gasket if Rear Bearing Cover was
		is in place.	removed.
	Output Shaft Nut	Check the Output Shaft Nut for	Torque the Output Shaft Nut to 650–700 lb-ft
			(881.28–949.07 N•m). Do not over torque the
		tightness.
			Output Nut.
			Apply Eaton Sealant #71205 to the Cap Screw
	PTO Covers and Openings	Check the Cap Screws for tightness.	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).
		Check Front Bearing Cover, Front Case,
	Gray Iron Parts	Shift Bar Housing, Rear Bearing Cover,	Replace parts found to be damaged.
		and Clutch Housing for cracks or
		breaks.
		Check return threads for damage.	If threads damaged, replace the Input Shaft.
	Front Bearing Cover
		Check the Cap Screws for tightness.	Torque the Cap Screws to 35–45 lb-ft
			(47.45–61.01 N•m).
	Oil Cooler and Oil Filter	Check all connectors, Fittings, Hoses,	Tighten any loose Fittings.
		and Filter Element for tightness.
	Oil Drain Plug, Oil Fill Plug	Check the Oil Drain Plug and the Oil Fill	Torque the Oil Drain Plug to 45–55 lb-ft
			(61.01–74.57 N•m), Oil Fill Plug to 60–70 lb-ft
		Plug for leakage.
			(81.35–94.91 N•m).

Information General

15

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.

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

	Gasket				Rear Seal			Leak

Step 1

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.

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.

OR

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.

16

Power Flow

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® Transmission can be thought of as two separate “Transmissions” combined into one unit. The first “Transmission” 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 though only some of them are transferring power.

1

2

Information General

Cross Sectional View

1.Front Section

2.Auxiliary Section

17

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.

12

11

10

9 1

8

2

				7
				6
				5
	3			4
Transmissions Components		7.	Auxiliary Countershaft
1.	Input Shaft	8.	Range Sliding Clutch
2.	Main Drive Gear	9.	Auxiliary Mainshaft Reduction Gear
3.	Sliding Clutch	10.		Output Shaft (Auxiliary Mainshaft)
4.	Countershaft	11.		Splitter Gear
5.	Mainshaft Gear	12.		Auxiliary Drive Gear
6.	Auxiliary Splitter Clutch (slides on Front Section Mainshaft)

18

Power Flow

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.

3

1

2

		RTO			RTX
	R	5	7	R	5	8
		1	3		1	4
		Neutral			Neutral
	LO	6	8	LO	6	7
		2	4		2	3

Front Section Power Flow

1.Sliding Clutch forward

2.Sliding Clutch forward

3.Sliding Clutch rearward

Information General

19

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.

3

			1			2
		RTO			RT	1
	R	5	7	R	5	7
		1	3		1	3
		Neutral
	LO	6	8	LO	6	8
		2	4		2	4

Front Section Power Flow - Direct Gear

1.Sliding Clutch forward

2.Sliding Clutch forward

3.Sliding Clutch rearward

20

Power Flow

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.

	3		3
1	2	1	2

Reverse LO - 9/13 speed; Reverse LO - Low Split - 18 speed		Reverse LO - High Split - 18 Speed
1.	Sliding Clutch rearward	1. Sliding Clutch rearward
2.	Sliding Clutch forward	2. Sliding Clutch rearward
3.	Sliding Clutch rearward	3. Sliding Clutch rearward

	3
1	2

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

1.Sliding Clutch rearward

2.Sliding Clutch forward

3.Sliding Clutch forward

	3
1	2

Reverse HI - High Split - 18 Speed

1.Sliding Clutch rearward

2.Sliding Clutch rearward

3.Sliding Clutch forward

Information General

21

Power Flow

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).

							3					3
	RTO			RTX	1	2					1	2
								RTO			RTX
	5	7
R			R	5	8			5	7	R	5	8
	1	3		1	4		R
								1	3		1	4
				Neutral
	Neutral							Neutral			Neutral
	6	8		6	7
LO			LO					6	8	LO	6	7
	2	4		2	3		LO
								2	4		2	3
LO - 9/13 Speed; LO - Low Split - 18 Speed							LO - High Split - 18 Speed
1. Sliding Clutch forward							1. Sliding Clutch forward
2. Sliding Clutch forward							2. Sliding Clutch rearward
3. Sliding Clutch rearward							3. Sliding Clutch rearward

22

Power Flow

Auxiliary Section Power FlowHigh 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).

							3					3
					1		2			1		2
		RTO			RT			RTO			RTX
	R	5	7		5	7	R	5	7	R	5	8
		1	3	R
					1	3		1	3		1	4
		Neutral						Neutral			Neutral
		6	8								6	7
	LO			LO	6	8	LO	6	8	LO
		2	4
					2	4		2	4		2	3

5th - 9/13–18 speed Low Split		5th - 9/13–18 speed High Split
1.	Sliding Clutch rearward	1.	Sliding Clutch rearward
2.	Sliding Clutch forward	2.	Sliding Clutch rearward
3.	Sliding Clutch forward	3.	Sliding Clutch forward

Information General

23