Page 1
Service Manual
Fuller Automated Transmissions
TRSM0050
October 2007
RTAO-11710B-AC
RTAO-11710C-AC
RTAO-12710B-AC
RTAO-12710C-AC
RTAO-13710B-AC
RTAO-13710C-AC
RTAO-14710B-AC
RTAO-14710B-AS
RTAO-14710C-AC
RTAO-14710C-AS
RTAO-15710B-AC
RTAO-15710C-AC
RTAO-16710B-AC
RTAO-16710B-AS
RTAO-16710C-AC
RTAO-16710C-AS
RTLO-14918B-AS
RTLO-16918B-AS
RTLO-18918B-AS
RTLO-20918B-AS
Page 2
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
Page 3
Introduction
Warnings and Cautions
WARNING: Follow the specified procedures in the indicated order to avoid personal injury
CAUTION: Follow the specified procedures in the indicated order to avoid equipment malfunction or damage.
Note: Additional relevant information not covered in the service procedure.
WARNING: Before starting a vehicle:
• Sit in the driver's seat
• Place shift lever in neutral
• Set the parking brake
WARNING: Before working on a vehicle or leaving the cab with engine running:
• Place shift lever in neutral
• Set the parking brake
• Block the wheels
WARNING: When parking the vehicle or leaving the cab:
• Place shift lever in neutral
• Set the parking brake
CAUTION: Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level.
CAUTION: To avoid damage to the transmission during towing:
• Place shift lever in neutral
• Lift the drive wheels off of the ground or disconnect the driveline
CAUTION: Do not operate vehicle if alternator lamp is lit or if gauges indicate low voltage.
Every effort has been made to ensure the accuracy of all information in this manual. However, Eaton Truck Component Operations makes no expressed
or implied warranty or representation based on the enclosed information. Any errors or omissions may be reported to Marketing Services, Eaton Truck Component Operations, P.O. Box 4013, Kalamazoo, MI 49003.
Copyright Eaton Corporation, 2001. All rights reserved.
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Introduction
Purpose .......................................................................1
Identification Tag ........................................................ 2
Model Designations .................................................... 3
Lubrication Information .............................................. 4
Maintenance/Lubricant Change Intervals ....................5
Preventive Maintenance Overview ............................... 7
Repair Warnings .......................................................10
Service Procedures
Reverse Ball Switch - Overview ................................. 12
How to Remove the Reverse Ball Switch ................... 13
How to Install the Reverse Ball Switch ...................... 15
Rail Select Sensor - Overview ................................... 18
How to Remove the Rail Select Sensor ..................... 19
How to Install the Rail Select Sensor ........................ 21
Gear Select Sensor - Overview .................................. 24
How to Remove the Gear Select Sensor .................... 25
How to Install the Gear Select Sensor ....................... 27
Input/Main Shaft Speed Sensors - Overview ............. 30
How to Remove the Input/Main Shaft
Speed Sensors .................................................. 31
How to Install the Input/Main Shaft
Speed Sensor ..................................................... 33
Output Shaft Speed Sensor - Overview ..................... 36
How to Remove the Output Shaft Speed Sensor ....... 37
How to Install the Output Shaft Speed Sensor .......... 39
Range Valve - Overview ............................................ 42
How to Remove the Range Valve ..............................43
How to Install the Range Valve ..................................45
Splitter Valve - Overview ........................................... 48
How to Remove the Splitter Valve .............................49
How to Install the Splitter Valve ................................ 51
Air Filter/Regulator - Overview ..................................54
How to Remove the Air Filter/Regulator .................... 55
How to Install the Air Filter/Regulator ....................... 57
Inertia Brake Solenoid - Overview ............................. 60
How to Remove the Inertia Brake Solenoid ............... 61
How to Install the Inertia Brake Solenoid .................. 63
Inertia Brake - Overview ............................................ 66
How to Remove the Inertia Brake .............................. 67
How to Install the Inertia Brake ................................. 69
Power Module - Overview ......................................... 72
How to Remove the Power Module ........................... 73
How to Install the Power Module .............................. 75
Electric Shifter - Overview ......................................... 78
How to Remove the Electric Shifter ........................... 79
How to Install the Electric Shifter .............................. 81
Table of Contents
Transmission ECU - Overview ...................................84
How to Remove the Transmission ECU .....................85
How to Install the Transmission ECU .........................87
Transmission Harness - Overview .............................90
How to Remove the Transmission Harness ...............91
How to Install the Transmission Harness ..................93
Shift Lever - Overview ...............................................96
How to Remove the Shift Lever .................................97
How to Install the Shift Lever .....................................99
Power Relay - Overview ...........................................102
How to Remove the Power Relay .............................103
How to Install the Power Relay ................................105
System Manager - Overview ....................................108
How to Remove the System Manager ......................109
How to Install the System Manager .........................111
Tower Harness - Overview .......................................114
How to Remove the Tower Harness .........................115
How to Install the Tower Harness ............................117
Gear Display - Overview ...........................................120
How to Remove the Gear Display ............................121
How to Install the Gear Display ................................123
Table of Contents
Page 5
Introduction
Purpose
This manual is designed to provide detailed information necessary to service and repair the Automation of Eaton® Fuller® transmissions listed on the front.
How to Use This Manual
The service procedures in this manual are for transmission automation components only. To locate the information you need,
simply locate the procedure in the table of contents, turn to the page specified, and follow the procedure.
To service the mechanical portion of the transmission system, refer to the model specific transmission service manual.
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Introduction
Identification Tag
PTO Code
Eaton Fuller
Transmissions
Model
Eaton Corporation
Transmission Div
Kalamazoo, MI 49003
All Eaton® Fuller® Transmissions are identified by the model and serial number. This information is stamped on the transmission identification tag and affixed to the case.
DO NOT REMOVE OR DESTROY THE TRANSMISSION IDENTIFICATION TAG.
Have reference numbers handy when ordering replacement parts or requesting service repairs.
Made
In
Serial
Introduction
2
Page 7
Model Designations
AutoSelect Nomenclature
RTA O -14710B-AC
Introduction
Roadranger
Twin Countershaft
Automated
Overdrive
AutoShift Nomenclature
RTA O -14710B-AS
Roadranger
Twin Countershaft
Automated
Overdrive
RTL O -20918B-AS
Roadranger
Twin Countershaft
Low-Inertia
O = Overdrive w/Direct Shift Pattern
AutoSelect
Gear Ratio
Forward Speeds
Design Level
This (x) 100 = Nominal Torque Capacity
AutoShift
Gear Ratio
Forward Speeds
Design Level
This (x) 100 = Nominal Torque Capacity
AutoSelect
Ratio Set
Forward Speeds
9 = Improved Seal System
This (x) 100 = Nominal Torque Capacity
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Page 8
Introduction
Lubrication Information
Recommended Lubricants
Where transmissions are concerned, lubrication is possibly the most important part of keeping a vehicle operating.
Lubricants which meet the Eaton (PS-164) specification are required in AutoSelect/AutoShift transmissions. Lubricants must be
approved by Eaton Corporation to qualify for the 5/750,000 warranty. For a list of Eaton® Roadranger® approved lubricants,
order item number TCMT-0021.
Type Grade (SAE) Ambient Temperature Drain Interval Note
Eaton® Roadranger®
CD-50 E500 (PS-164)
*The first lube change may be extended to 500,000 miles (800,000 km) when a new transmission has been factory filled with
a lube that is Eaton approved for 500,000 miles (800,000 km) (E-500, PS-164).
50 All 250,000*
(400,000)/1000 Hrs
Approved for
Oil Coolers
Introduction
4
Page 9
Introduction
Maintenance/Lubricant Change Intervals
Transmission inspections and lubricant changes depend on the type of lubricant used and whether the vehicle is used On- or OffHighway.
On-Highway Lubricant - Vehicles operated on paved roads, interstate highways, and turnpikes are designated as onhighway vehicles. Lubricant change and inspection intervals are the most generous for on-highway vehicles using synthetic
lubricants.
Off-Highway Lubricant - When operating vehicles with AutoSelect/AutoShift transmissions in off-highway applications such as
coal trucks or mining vehicles, it is more important to use time rather than mileage to keep the transmission within its proper
preventive maintenance schedule. Off-highway applications are divided into two categories, severe and normal. 'Severe off-highway' is the designation used when there is excessive dust and dirt. 'Normal off-highway' is for applications where dust and dirt
are minimal.
PM Interval - The PM interval in off-highway vehicles with AutoSelect or AutoShift transmissions is every 40 hours.
Lubricant Change Interval - The lubricant must be changed in AutoSelect/AutoShift transmissions in off-highway vehicles every
500 hours in severe applications, and every 1000 hours for vehicles in normal applications.
Type Grade (SAE) Ambient Temperature Drain Interval Note
Eaton® Roadranger®
CD-50 E500 cm
(PS-164)
*The first lube change may be extended to 500,000 miles (800,000 km) when a new transmission has been factory filled with
a lube that is Eaton approved for 500,000 miles (800,000 km) (E-500, PS-164).
50 All 250,000*
(400,000)/1000 Hrs
Approved for
Oil Coolers
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Page 10
Introduction
Oil Level
Hole
When checking the transmission lubricant there are two important points to know: where to check the lubricant and what the
proper lubricant level is. Always be cautious when checking the transmission lubricant as it may be hot.
• Checking Location - Check the lubricant at the lubricant fill plug located on the left side of the main transmission case.
• Proper Lubricant Level - The lubricant is at the proper level when it is even with the bottom of the fill hole. When you
remove the plug to check the lubricant level, lubricant should actually seep out. Do not use your finger to feel for the
lubricant. Even if you can touch the lubricant, it may not be at the proper level. In a transmission one inch of lubricant
level equals about one gallon of lubricant.
Proper Oil Level
Hole
Improper Oil Level
Recommended Lubricant
Eaton requires the use of Eaton approved lubes meeting the E-500 performance requirements (PS-164) for these transmissions.
A current list of approved lubes is available from Eaton Roadranger Field Marketing, call 1-800-826-4357. Failure to use a
required lube may affect AutoSelect/AutoShift performance and warranty coverage.
Introduction
Buy from a reputable dealer
For a complete list of approved and reputable dealers, write to:
Eaton Corporation
Truck Components Operations
Global Marketing Services
P.O. Box 4013
Kalamazoo, MI 49003
http://truck.eaton.com/na/service_products/lubricant_requirements/
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Introduction
Preventive Maintenance Overview
To keep a vehicle running properly, it is important to perform preventive maintenance on the vehicle components. This insures
the vehicle and its subassemblies will operate properly throughout their useful life. To cover preventive maintenance completely,
you must review the following subjects in detail.
• Inspecting the Transmission
• Changing the Fluid
• Vehicle System Effects
Transmission Inspections
When performing preventive maintenance (PM) inspections, several items must be checked. It is important to perform every
step to ensure the transmission meets its life expectancy. Proper PM consists of the following steps:
• Check the transmission oil level
• Inspect under the vehicle for loose/missing bolts
• Check the transmission for air leaks
• Check the transmission for lubricant leaks
Loose or Missing Bolts
While you are under the vehicle checking the lubricant, make a quick check for loose or missing bolts. Check all bolts on the back
box, PTO covers, shift bar housing, clutch housing and transmission controller. Replace any missing or broken bolt with the
proper bolt as called out in the illustrated parts listing. Follow the procedure defined in the manual transmission service manual
when tightening any bolts.
Air Leaks
While you are under the vehicle, check for air leaks as well. The two steps when checking for an air leak are inspection and repair.
• Audible Inspection for Leaks - To find air leaks, make sure the vehicle air system has at least 90 PSI air pressure. Then,
listen for leaks, making sure a vehicle leak is not mistaken for a transmission air leak.
• Refer to Troubleshooting Procedures for Repair - Once you find an air leak, use the troubleshooting guide to isolate
the air leak to the faulty component.
Lubricant Leaks
Oil leak repair is very important. An lubricant leak could cause a catastrophic transmission failure. Check for leaks first at the gasket surfaces, the rear seal, and the transmission cooler.
Visual Check for Leaks at Gaskets
A visual check at each gasket to ensure that no leak is present. Typically a moist spot is acceptable; however drips or larger wet
areas are not. Check for leaks at the rear housing, PTO, shift bar housing, shift tower, and clutch housing gasket surfaces. It is
also Important to ensure that the leak is indeed coming from the transmission. Make sure the lubricant is not being blown back
from the engine or another vehicle component.
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Introduction
Check for Leaks Around the Input Shaft
Check for leaks around the input shaft. Leaks in this area could be caused by a faulty gasket, the input shaft, or pressurization of
the main transmission case by the air system. If you find a leak at the input shaft, make sure the air system is not leaking into the
case before looking for leaking gaskets.
Rear Seal
The rear seal is very important in maintaining lubricant in the transmission. If the seal is improperly installed or has failed, the
transmission may experience a catastrophic failure. Check the rear seal by performing the following steps:
• Visual Check For Leak - Visually inspect the rear seal for a leak. If a rear seal leak is suspected, proper isolation is nec-
essary.
• Verify the Leak Path - Other leaks may give the impression the rear seal is leaking. One possible cause is the vehicle
speed sensor. Any lubricant leak above and in front of the rear seal could cause lubricant to collect around the seal.
Wipe the seal with a clean rag, operate the vehicle, and recheck to verify the leak path. More information can be found in
the rear seal maintenance guide (TRSM-0912).
Transmission Cooler Leaks
If the vehicle is equipped with a transmission lubricant cooler, make sure there are no leaks at the lubricant cooler, hoses, and fitting of the cooler circuit. Repair any cooler leaks as necessary.
Introduction
Transmission Fluid Change
When it is time to change the transmission lubricant, there are only a few steps to follow: draining and filling the transmission,
draining and filling the cooler (if equipped), and changing the oil filter (if equipped). Remember to be careful when changing the
transmission lubricant, as it may be hot.
• Transmission Drain - Draining the transmission consists of removing the drain plug located on the bottom of the trans-
mission case. Put a drain pan in place under the drain plug before removing it. Once the oil has finished draining, install
the drain plug and torque to 45-55 Lb f ·ft. No sealant is required on the drain plug.
• Cooler Drain - If the vehicle is equipped with a transmission cooler, you must drain the cooler as well. To drain the
cooler, remove both cooler lines at the transmission and pressurize one line with 30 PSI of air pressure. This will force
the oil out of the cooler. Once the cooler has drained, reconnect the coolant lines to the transmission, making sure the
lines are not crossed.
• Transmission Fill - Remove the transmission fill plug and fill the transmission with the desired approved oil. The trans-
mission is full once oil starts flowing out of the fill hole. Replace the fill plug and torque to 60-70 Lb f ·ft.
• Cooler Fill - If the transmission is equipped with a cooler, the best way to fill the cooler is to place the transmission in
neutral, start the vehicle, then release the clutch pedal so the input shaft of the transmission can rotate. This allows the
pump to fill the cooler. Once the vehicle has run for about one minute, shut it off and recheck the transmission oil level.
• Filter Change - If the transmission is equipped with a spin-on oil filter, remove and replace the filter as you would any
spin-on filter. It is also necessary to remove the filter when draining the oil from the cooler. As you unscrew the filter,
catch the oil that seeps out between the filter opening and the "spin-on" casting.
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Page 13
Introduction
Vehicle System Effects
Some vehicle systems can affect transmission operation and possibly cause a failure. The major system that can affect AutoSelect or AutoShift is the air system.
Air System
If the air system is not given recommended preventive maintenance, it can cause transmission system problems. Although the
transmission has an air filter regulator it cannot protect the transmission from contaminants indefinitely. This is why it is important to follow OEM recommendations for air system PM. It is important to regularly drain the air tanks and insure that oil is not
being pumped by the air compressor into the vehicle air system. If moisture enters the transmission system, it may cause corrosion. Also, in cold climates it may freeze, preventing the shift mechanisms from operating. If allowed into the system, oil could fill
the air system components causing them to lose valuable air volume, slowing or preventing movement.
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Introduction
Repair Warnings
When disassembling various assemblies, lay all parts on a clean bench in the same sequence as removed to simplify assembly
and reduce the possibility of losing parts.
Provide a clean work area. Make sure no dirt or foreign material enter the unit during repair and assembly.
Disconnect the vehicle's battery before removing or installing electronic parts.
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
that could lead to additional repairs and expense.
Use of other than recommended tools, parts, and instructions listed in this manual may place the safety of the service technician
or vehicle driver in jeopardy.
The location of some components may vary with each O.E.M.
The removal and installation procedure described for each component may vary for your vehicle.
Always use genuine Eaton replacement parts. For a complete list of approved and reputable dealers, write to:
Eaton Corporation
Truck Components Operations
Global Marketing Services
P.O. Box 4013
Kalamazoo, MI 49003
http://truck.eaton.com/na/service_products/lubricant_requirements/
Introduction
10
Page 15
Introduction
11
Page 16
Reverse Ball Switch - Overview
Service Procedure
Special Instructions
None.
Required Tools
• Torque Wrench with 25 lb.ft. capacity.
Essential Steps
Install a new fiber washer.
Service Procedure
Reverse Ball Switch
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Page 17
Service Procedure
How to Remove the Reverse Ball Switch
Procedure-
1. Disconnect the Transmission Harness from the Reverse
Ball Switch.
2. Using a 7/8" wrench, Loosen the Reverse Ball Switch.
3. Remove the Reverse Ball Switch and Fiber Washer from
the Shift Bar Housing.
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1
Disconnect
Transmission Harness
from Reverse Ball Switch
Service Procedure
2
3
Remove Reverse Ball
Switch and Fiber Washer
Transmission Harness
Reverse Ball Switch
Loosen Reverse
Ball Switch
Reverse Ball Switch
Service Procedure
7/8" Wrench
Fiber Washer
Reverse Ball Switch Removal
Reverse Ball Switch
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Service Procedure
How to Install the Reverse Ball Switch
Procedure-
1. Install a new fiber washer (included in the Reverse Ball
Switch service kit) on the Reverse Ball Switch.
2. Using a 7/8" wrench, install and tighten the Reverse Ball
Switch to 20-25 lbs. ft. (27.1-33.9 N•m).
3. Connect the Transmission Harness to the Reverse Ball
Switch.
Final Check
Verify Harness is locked.
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1
Install reverse ball
Switch and Fiber Washer
Fiber Washer
Service Procedure
2
Tighten Reverse
Ball Switch
Reverse Ball Switch
3
Connect
Transmission Harness to
Reverse Ball Switch
Reverse Ball Switch
Service Procedure
7/8" Wrench
Transmission Harness
Reverse Ball Switch
Reverse Ball Switch Installation
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Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
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Rail Select Sensor - Overview
Service Procedure
Special Instructions
Install the sensor with the connector on top.
While removing or installing the capscrews, hold the sensor
in place. Don't allow it to snap out of position.
Required Tools
• Basic Hand Tools
Essential Steps
The shifter module must be calibrated before the vehicle is
placed into operation.
Service Procedure
Rail Select Sensor
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Page 23
Service Procedure
How to Remove the Rail Select Sensor
Procedure-
1. Disconnect the Transmission Harness from the Rail
Select Sensor.
2. Using a 5/16" wrench, remove the two (2) sensor capscrews.
3. Carefully allow the sensor to rotate (not snap) to a
relaxed position. Then remove the sensor, steel sleeves
and O-rings from the housing.
4. Insert your finger into the sensor bore and push the arm
slightly.
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g
1
Disconnect
Transmission Harness
from Sensor
Service Procedure
2
Remove Mounting
Capscrews
Select Sensor
Remove Rail
Select Sensor
Sensor Connector
Service Procedure
3
Sleeve O-Rin
Sensor O-Ring
Rail Select Sensor Removal
Select
Sensor
Sleeve
Capscrew
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Page 25
Service Procedure
How to Install the Rail Select Sensor
Procedure-
1. Align the sensor's tab with the slot in the shifter housing.
Then position the Sensor O-ring and insert the Rail Sensor into its mounting location.
2. Insert the new sleeve O-rings, new steel sleeves and capscrews into the sensor mounting holes.
3. Using a 5/16" wrench, install and tighten the capscrews
to 21-27 lbs. in. (2.4-3.1 N•m).
4. Reconnect the Transmission Harness to the Rail Select
Sensor.
Final Check
Make sure that the capscrews are tightened to specification.
Make sure that the sensor connections are secure.
Calibration
To operate properly, the system must be calibrated as follows:
a. Turn the ignition switch to ON and allow the trans-
mission to power up.
b. Turn the ignition switch to OFF and wait two minutes.
IMPORTANT: The shifter module must be calibrated before
the vehicle is placed into operation.
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g
1
Insert Rail
Select Sensor
Sensor O-Ring
Sensor
Select
Sleeve
Service Procedure
Sleeve O-Rin
Capscrew
2
Attach Mounting
Capscrews
3
Reconnect Transmission
Harness to Sensor
Select Sensor
2
Service Procedure
5/16" Wrench
Mounting Capscrew
Sensor Connector
Rail Select Sensor Installation
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Page 27
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
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Page 28
Gear Select Sensor - Overview
Service Procedure
Special Instructions
Install the sensor with the connector on top.
While removing the capscrews, hold the sensor in place.
Don't allow it to snap out of position.
Required Tools
• Basic Hand Tools.
Essential Steps
The shifter module must be calibrated before the vehicle is
placed into operation.
Service Procedure
Gear Select Sensor
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Service Procedure
How to Remove the Gear Select Sensor
Procedure-
1. Remove nylon cable ties from motor wires.
2. Disconnect the Transmission Harness from the Gear
Select Sensor and Rail Select Sensor.
3. Disconnect the Gear Select Motor and Rail Select Motor
from the Transmission ECU.
4. Using a 5/16" wrench, remove the four (4) Electric Shifter
capscrews.
5. Remove the Electric Shifter and gasket.
6. Turn the shifter over (upsidedown).
7. Using a 5/16" wrench, remove the two (2) Gear Select
Sensor capscrews.
8. Carefully allow the sensor to rotate (not snap) to a
relaxed position, then remove the sensor, steel sleeves
and O-ring from the housing.
9. Insert your finger into the sensor bore and push the arm
slightly.
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Service Procedure
1
9/16" Wrench
Disconnect
Transmission Harness
from Rail and Gear
Select Sensor
Sensor Connectors
3
Remove Mounting
Capscrews
2
Disconnect Rail Motor
and Gear Motor from
Transmission ECU
Motor Connectors
4
Remove Electric
Shifter and Gasket
Electric Shifter
T
Service Procedure
5
Remove Gear
Select Sensor
Gear Select Sensor Removal
Capscrew
Sleeve
Sleeve
O-Ring
Gasket
Position
Sensor
Sensor
O-Ring
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Page 31
How to Install the Gear Select Sensor
Procedure-
Service Procedure
1. Using a screwdriver, push and hold the Gear Select bushing inside the Shift Bar Housing toward the outside of the
housing.
2. While holding the bushing in place, align the sensor tab
with the slot and insert the Gear Select Sensor into the
shift shaft.
Note: Install the sensor with the connector toward the
top of the Shifter Housing
3. Insert the new steel sleeves, O-rings and capscrews into
the sensor mounting holes.
4. Using a 5/16" wrench, install and tighten the two (2) capscrews to 21-27 lbs. in. (2.4-3.1 N•m).
5. Clean and remove old gasket material from the Shift Bar
Housing.
6. Position a new gasket at the Shift Bar Housing mounting
location.
Note: Check to make sure that the shift blocks are in the
neutral position.
Final Check
Make sure the capscrews are tightened to specification.
Make sure all connections are tight.
Calibration
To operate properly, the system must be calibrated as follows:
a. Turn the ignition switch to ON and allow the trans-
mission to power up.
b. Turn the ignition switch to OFF and wait two minutes.
IMPORTANTThe shifter module must be calibrated before the
vehicle is placed into operation.
7. Move the shift finger in the Electric Shifter to the center
(Neutral) position.
Note: If the shift finger is not properly aligned, the Elec-
tric Shifter will not fit properly at its mounting
location.
8. Position the Electric Shifter on the Shift Bar Housing.
9. Using a 9/16" wrench, install and tighten the four (4) capscrews to 35-45 lbs. ft. (47.5-61.0 N•m).
10. Reconnect the Rail Select Motor to the Transmission
ECU.
11. Reconnect the Gear Select Motor to the Transmission
ECU.
12. Reconnect the Transmission Harness to the Rail Select
Sensor and Gear Select Sensor.
13. Use nylon cable ties to secure the motor wires to the
transmission.
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1
Install Gear
Select Sensor
Service Procedure
2
Install Electric
Shifter
Electric Shifter
3
Install Mounting
Capscrews
9/16" Wrench
5
Reconnect Transmission Harness
to Rail and Gear Select Sensors
Sensor Connectors
3
Gasket
4
Reconnect Rail
and Gear Select Motors to
Transmission ECU
Motor Connectors
Shift Finger
Service Procedure
Gear Select Sensor Installation
T
28
Page 33
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
29
Page 34
Service Procedure
Input/Main Shaft Speed Sensors - Overview
Special Instructions
Use care when installing the O-ring.
Lubricate the O-ring with Eaton/fuller silicone #71214 or
equivalent.
Required Tools
• Basic Hand tools.
Service Procedure
Input Shaft
Speed Sensor
Mainshaft Speed Sensor
Output Shaft
Speed Sensor
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Service Procedure
How to Remove the Input/Main Shaft Speed Sensors
Procedure-
1. Disconnect the Transmission Harness from the Speed
Sensor.
2. Remove the rubber cap from the retaining bolt.
Note: This cap is installed during manufacturing. It is
NOT necessary to replace it.
3. Using a 9/16" wrench, remove the sensor retaining bolt.
4. Remove the spring clip.
5. Remove the Speed Sensor, with O-ring, from the transmission housing.
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1
Disconnect
Transmission Harness
and Sensor Cap
Service Procedure
Transmission Harness
Connector
2
Remove Speed
Sensor Retaining Bolt,
Spring Clip, Speed Sensor
and O-Ring
Rubber Cap
Service Procedure
O-Ring
Use a
9/16" Wrench
Spring Clip
Input/Main Shaft Speed Sensor Removal
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Service Procedure
How to Install the Input/Main Shaft Speed Sensor
Procedure-
1. Using a smooth, twisting motion, fully insert the Speed
Sensor in the transmission housing opening.
2. Install the spring clip.
3. Using a 9/16" wrench, install and tighten the retaining
bolt to 35-45 lbs. ft. (47.5-61.0 N•m).
4. Reconnect the Transmission Harness to the Speed Sensor.
Final Check
Make sure the retaining bolt is properly tightened.
Make sure the Transmission Harness is properly connected to
the Speed Sensor.
Calibration
None.
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1
Install O-ring, Speed
Sensor, Spring Clip,
and Retaining Bolt
Service Procedure
2
Reconnect
Transmission Harness
Use a
9/16" Wrench
Spring Clip
O-Ring
Rubber Cap
Transmission Harness
Connector
Service Procedure
Input/Main Shaft Speed Sensor Installation
34
Page 39
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
35
Page 40
Service Procedure
Output Shaft Speed Sensor - Overview
Special Instructions
Use extra care when installing the O-ring.
Lubricate the O-ring with Eaton/Fuller silicone #71214 or
equivalent.
Required Tools
• Basic Hand Tools.
Essential Steps
Make sure the retaining bolt is properly tightened.
Make sure the Transmission harness is properly connected to
the Speed Sensor.
Service Procedure
Input Shaft
Speed Sensor
Mainshaft Speed Sensor
Output Shaft
Speed Sensor
36
Page 41
Service Procedure
How to Remove the Output Shaft Speed Sensor
Procedure-
1. Disconnect the Transmission Harness from the Speed
Sensor.
2. Using a 9/16" wrench, remove the sensor retaining bolt.
3. Remove the Speed Sensor, with O-ring, from the transmission housing.
37
Page 42
1
Disconnect
Transmissin Harness
Service Procedure
2
Transmission Harness
Output Shaft
Speed Sensor
Remove Retaining Bolt,
Speed Sensor
and O-ring
Output Shaft
Speed Sensor
O-Ring
Transmission Harness
9/16"
Wrench
Service Procedure
Output Shaft Speed Sensor Removal
38
Page 43
Service Procedure
How to Install the Output Shaft Speed Sensor
Procedure-
1. Using a smooth, twisting motion, fully insert the Speed
Sensor in the transmission housing opening.
2. Using a 9/16" wrench, install and tighten the retaining
bolt to 35-45 lbs. ft. (47.5-61.0 N•m).
3. Reconnect the Transmission Harness to the Speed Sensor.
Final Check
Make sure the retaining bolt is properly tightened.
Make sure the Transmission Harness is properly connected to
the Speed Sensor.
Calibration
None.
39
Page 44
Output Shaft
Speed Sensor
O-Ring
1
Install O-ring,
Speed Sensor
and Retaining Bolt
9/16"
Wrench
Service Procedure
2
Reconnect
Transmission Harness
Transmission Harness
Service Procedure
Output Shaft
Speed Sensor
Transmission Harness
Output Shaft Speed Sensor Installation
40
Page 45
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
41
Page 46
Range Valve - Overview
Service Procedure
Special Instructions
Do not use a hammer to loosen the Range Valve in the housing.
Use caution when installing O-rings.
Lubricate O-rings with Eaton/Fuller silicone #71214 or equivalent.
Required Tools
• Basic Hand Tools.
Essential Steps
None.
Service Procedure
Range Valve
42
Page 47
Service Procedure
How to Remove the Range Valve
Procedure-
1. Relieve system air pressure by disconnecting vehicle air
supply from the Air Filter/Regulator.
2. Disconnect the Transmission Harness from the Range
Valve assembly.
3. Using a 5/16" wrench, remove the four (4) Range Valve
capscrews.
4. Lift and remove the Range Valve from the transmission
housing.
43
Page 48
v
Transmission
Harness
Connector
Service Procedure
1
Disconnect
Transmission
Harness
2
Remove Mounting
Capscrews
Ring
3
Remove
Range Valve
from Housing
Mounting Capscrew
Service Procedure
5/16" Wrench
2
Range Val
Range Valve Removal
44
Page 49
Service Procedure
How to Install the Range Valve
Procedure-
1. Install and push the Range Valve down into the transmission housing.
Note: The valve is keyed to fit its mounting location. Take
care to align the slot in the valve with the slot in
the transmission housing.
2. Using a 5/16" wrench, install and tighten the our (4) capscrews to 21-27 lbs. in. (2.4-3.1 N•m).
3. Reconnect the Transmission Harness to the Range Valve.
4. Reconnect the air supply to the Air Filter/Regulator.
Final Check
Make sure that the capscrews are tightened to specification.
Make sure the Transmission Harness is connected and locked.
Calibration
None.
45
Page 50
O-Ring
1
Install
Range Valve
Service Procedure
Range Valve
2
Install Mounting
Capscrews
Mounting Capscrew
Transmission
Harness
Connector
3
Reconnect
Transmission
Harness
5/16" Wrench
Service Procedure
2
Range Valve Installation
46
Page 51
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
47
Page 52
Splitter Valve - Overview
Service Procedure
Special Instructions
Do not use a hammer to loosen the Splitter Valve in the housing.
Use caution when installing O-rings.
Lubricate O-rings with Eaton/Fuller silicone #71214 or equivalent.
Required Tools
• Basic Hand Tools.
Essential Steps
None.
Service Procedure
Splitter
Valve
48
Page 53
Service Procedure
How to Remove the Splitter Valve
Procedure-
1. Relieve system air pressure by disconnecting vehicle air
supply from the Air Filter/Regulator.
2. Disconnect the Transmission Harness from the Splitter
Valve.
3. Using a 5/16" wrench, remove the four (4) Splitter Valve
capscrews.
4. Lift and remove the Splitter Valve from the transmission
housing.
49
Page 54
1
Disconnect
Transmission
Harness
Service Procedure
2
Remove Mounting
Capscrews
Mounting Capscrew
Transmission Harness
Connector
O-Ring
Service Procedure
2
5/16" Wrench
3
Remove
Splitter Valve
from Housing
Splitter Valve Removal
Splitter Valve
50
Page 55
Service Procedure
How to Install the Splitter Valve
Procedure-
1. Install and push the Splitter Valve down into the transmission housing.
Note: The valve is keyed to fit its mounting location. Take
care to align the slot in the valve with the slot in
the transmission housing.
2. Using a 5/16" wrench, install and tighten the four (4) capscrews to 21-27 lbs. in. (2.4-3.1 N•m).
3. Reconnect the Transmission Harness to the Splitter
Valve.
4. Reconnect the air supply to the Air Filter/Regulator.
Final Check
Make sure the capscrews are properly tightened.
Make sure the Transmission Harness is connected and locked.
Calibration
None.
51
Page 56
1
Install
Splitter Valve
Service Procedure
2
O-Ring
3
Reconnect
Transmission
Harness
Install Mounting
Capscrews
Mounting Capscrew
Splitter Valve
Service Procedure
2
5/16" Wrench
1
Transmission Harness
Connector
Splitter Valve Installation
52
Page 57
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
53
Page 58
Air Filter/Regulator - Overview
r
Service Procedure
Special Instructions
The Air Filter/Regulator has two (2) O-rings located between
the filter/regulator and the Range Cylinder Cover..
Lubricate the O-rings with Eaton/Fuller Silicone #71214 or
equivalent
Required Tools
• Basic Hand Tools.
Essential Steps
None.
Service Procedure
Air Filter/Regulato
54
Page 59
Service Procedure
How to Remove the Air Filter/Regulator
Procedure-
1. Relieve system air pressure by disconnecting vehicle air
supply from the Air Filter/Regulator.
2. Using a 7/16" wrench, remove the two (2) capscrews.
3. Remove the Air Filter/Regulator assembly.
4. Remove the two (2) O-rings from the recesses in the
Range Cylinder Cover.
55
Page 60
1
Remove Capscrews
Air Filter/Regulator
Service Procedure
2
Remove O-Rings
7/16" Wrench
Service Procedure
Capscrews
O-Rings
Air Filter/Regulator Removal
56
Page 61
Service Procedure
How to Install the Air Filter/Regulator
Procedure-
1. Press the O-rings into the recesses in the Range Cylinder
Cover.
2. Apply Eaton/Fuller sealant #71205 or equivalent to the
two (2) retaining capscrews.
3. Insert the capscrews into the Air Filter/Regulator mounting holes.
4. Position the Air Filter/Regulator over the o-rings.
5. Using a 7/16" wrench, install and tighten the two (2) capscrews to 8-12 lbs. ft. (10.8-16.3 N•m).
6. Reconnect the air supply to the Air Filter/Regulator.
Final Check
Make sure that the capscrews are properly tightened.
Make sure that all air supply fittings are tight.
Calibration
None.
57
Page 62
1
Position O-Rings
Service Procedure
2
Tighten Capscrews
O-Rings
Air Filter/Regulator
Service Procedure
7/16" Wrench
Capscrews
Air Filter/Regulator Installation
58
Page 63
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
59
Page 64
Inertia Brake Solenoid - Overview
e
Service Procedure
Special Instructions
The Air Filter/Regulator must be removed before removing the
Inertia Brake Solenoid. See “Air Filter/Regulator - Overview”
on page 54.
Make sure the two (2) O-rings between the Air Filter/Regulator
and the Range Cylinder Cover are properly positioned during
reassembly.
Apply the thread sealer (Eaton #71205) to all air connections
before assembly.
Required Tools
• Basic Hand Tools.
Essential Steps
None.
Service Procedure
Inertia Brak
Solenoid
60
Page 65
Service Procedure
How to Remove the Inertia Brake Solenoid
Procedure-
1. Relive system air pressure by disconnecting vehicle air
supply from the Air filter/Regulator.
2. Disconnect the Transmission Harness from the Inertia
Brake Solenoid.
3. Using a 5/8" wrench, disconnect the air from the Inertia
Brake end (swivel end).
4. Using a 3/4" wrench, disconnect the air line at the solenoid.
5. Using a 7/16" wrench, remove the Air filter/Regulator,
with the solenoid attached from the Range Cylinder
Cover.
Note: Remove and Inspect the two (2) O-rings from the
recesses in the Range Cylinder Cover.
6. Remove the Inertia Brake Solenoid from the Air filter/
Regulator.
7. Using a 9/16" wrench, remove the 1/8" 90° elbow from
the Inertia Brake Solenoid and save it for installation on
the new solenoid.
8. Using a 7/16" wrench, remove the 1/8" pipe nipple from
the Inertia Brake Solenoid and save for installation on the
solenoid.
61
Page 66
1
r
w
Disconnect
Transmission Harness
Transmission
Harness
Solenoid Connecto
Service Procedure
Inertia Brake
2
Disconnect Air Line
at Inertia Brake End
2
Inertia Brake
Air Line
Solenoid Elbow
Non-Swivel
End
Inertia Brake
3
Disconnect Air Line
at Solenoid End
3/4"
Wrench
Air Line
5
Remove 90° Elbow
and 1/8" Pipe Nipple
Inertia Brake
4
Remove Air
Filter/Regulator
Inertia Brake
Elbow
O-Rings
5/8" Wrench
Service Procedure
Inertia
Brake
Solenoid
Inertia
Brake
Solenoid
1/8" Nipple
Air Filter/Regulator
Inertia Brake Solenoid Removal
1/8" 90 Solenoid Elbo
9/16" Wrench
Filter/Regulator
7/16"
Wrench
Mounting
Bolts
62
Page 67
Service Procedure
How to Install the Inertia Brake Solenoid
Procedure-
1. Using a 9/16" wrench, install the 90° elbow onto the Inertia Brake Solenoid and tighten.
Note: Align the elbow to face the front of the transmis-
sion.
2. Using a 9/16" wrench, install the Inertia Brake Solenoid
onto the Air Filter/Regulator with a pipe nipple and
tighten.
3. Press the O-rings into the recesses in the Range Cylinder
Cover.
4. Apply Eaton/Fuller sealant #71205 or equivalent to the
two (2) retaining capscrews.
5. Insert the capscrews into the Air Filter/Regulator mounting holes.
6. Position the Air Filter/Regulator over the o-rings.
7. Using a 7/16" wrench, install and tighten the two (2) capscrews to 8-12 lbs. ft. (10.8-16.3 N•m).
8. Using a 3/4" wrench, reconnect the non-swivel end of the
air line to the solenoid elbow fitting and tighten.
9. Using a 5/8" wrench, reconnect the swivel end of the air
line to the Inertia Brake elbow fitting and tighten.
10. Reconnect the Transmission Harness to the Inertia Brake
Solenoid.
11. Secure the air line and electrical harness as required with
nylon cable ties.
12. Reconnect the air supply to the Air Filter/Regulator.
Final Check
Make sure the capscrews are properly tightened.
Make sure the air connections are tight.
Make sure the solenoid connector is properly connected to
the Transmission Harness.
Calibration
None.
63
Page 68
w
1
r
Install 90° Elbow,
pipe Nipple,
and Solenoid
Inertia
Brake
Solenoid
1/8" Nipple
Service Procedure
1/8" 90 Solenoid Elbo
9/16" Wrench
2
Install Air
Filter/Regulator
O-Rings
Inertia
Brake
Solenoid
Air Filter/Regulator
Solenoid Elbow
Reconnect Air Line
at Solenoid End
Non-Swivel
End
Inertia Brake
Air Line
Reconnect
Transmission Harness
Transmission
Harness
3
Mounting
Filter/Regulator
Bolts
7/16"
Wrench
Service Procedure
4
Reconnect Air Line
at Inertia Brake End
2
3/4"
Wrench
5
tia Brake
Inertia Brake
Elbow
Inertia Brake
Air Line
5/8" Wre
Inertia Brake Solenoid Installation
Inertia Brake
Solenoid Connecto
64
Page 69
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
65
Page 70
Inertia Brake - Overview
Service Procedure
Special Instructions
Be sure to use sealing type washers on the mounting bolts.
Apply Eaton #71205 thread sealer to all air connections before
assembly.
The Inertia Brake is mounted with two (2) longer mounting
bolts (ends) and four (4) shorter mounting bolts (sides).
Required Tools
• Basic Hand Tools.
Service Procedure
Inertia Brake
66
Page 71
Service Procedure
How to Remove the Inertia Brake
Procedure-
1. Drain the lubricant from the transmission.
Note: The Inertia Brake will still contain some lubricant.
2. Using a 5/8" wrench, disconnect the Inertia Brake air line
from the 90 elbow.
3. Using a 9/16" wrench, remove the six (6) mounting bolts,
with sealing washers, from the Inertia Brake.
4. Remove the Inertia Brake and gasket from the transmission.
5. Using a 9/16" wrench, remove the 90 elbow from the
Inertia Brake.
67
Page 72
(2)
1
Drain Transmission
Lubricant
Service Procedure
2
Disconnect Inertia
Brake Air Line
Inertia Brake
Air Line
Transmission
Eight to Six
Bolt Adapter
Inertia Brake
Transmission
Drain Plug
3
Remove Mounting
Bolts, Inertia Brake,
Gasket, and 90° Elbow
5/8" Wrench
90 Elbow
Service Procedure
Inertia Brake
Inertia Brake Gasket
Washer With
Rubber Seal
Inertia Brake Removal
Longer
Mounting
Bolt
90 Elbow
Shorter Mounting
Bolt (4)
68
Page 73
Service Procedure
How to Install the Inertia Brake
Procedure-
1. Clean and remove all old gasket material from the mating
surfaces of the Inertia Brake and the transmission.
2. Using a 9/16" wrench, install the 90 elbow to the Inertia
Brake and tighten.
3. Install the Inertia Brake being careful to align the Inertia
Brake gear with the 47-tooth PTO drive gear.
4. Using a 9/16" wrench, install the four (4) shorter mounting bolts with sealing washers and two (2) longer mounting bolts with the sealing washers. Tighten mounting
bolts to 35-45 lbs. ft. (47.5-61.0 N•m).
Note: The longer mounting bolts go on the ends of the
Inertia Brake. The shorter bolts go on the sides of
the Inertia Brake.
5. Using a 5/8" wrench, reconnect the air line to the 90
elbow on the Inertia Brake and tighten.
6. Using nylon cable ties, secure the air line as required.
7. Fill the transmission with lubricant.
Final Check
Make sure the mounting bolts are properly tightened.
Make sure the air fittings are properly tightened.
Make sure the transmission is properly filled with lubricant.
Check for lubricant leaks after operating the vehicle.
Calibration
None.
69
Page 74
Service Procedure
(2)
1
Install 90° Elbow,
Inertia Brake, Gasket
and Mounting bolts
2
Transmission
Eight to Six
Bolt Adapter
Inertia Brake
Washer With
Rubber Seal
Longer
Mounting
Bolt
Reconnect Inertia
Brake Air Line
Inertia Brake Gasket
5/8" Wrench
Service Procedure
90 Elbow
Shorter Mounting
Bolt (4)
3
Inertia Brake Installation
Fill Transmission
with Lubricant
Transmission
Fill Plug
70
Page 75
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
71
Page 76
Power Module - Overview
Service Procedure
Special Instructions
Disconnect Batteries before performing this procedure.
Required Tools
• Basic Hand Tools.
Service Procedure
Power Module
(Behind ECU)
72
Page 77
Service Procedure
How to Remove the Power Module
Procedure-
1. Remove the two (2) 1/2" ring terminals from the starter
(in the engine compartment).
2. Use a small flat-blade screwdriver to pry and disconnect
the Motor Power connector from the Transmission ECU.
3. Disconnect the Logic Power connector from the Transmission Harness.
4. Using a phillips head or torx head screwdriver, remove
the two (2) Power Module mounting screws.
5. Lift the Power Module assembly up and away from the
transmission.
73
Page 78
Service Procedure
1
Disconnect Ring Terminals
at Engine Starter and Disconnect
Power Connectors
Logic Power
Connector
Motor Power
Connector
Small Flat-Blade
Screwdriver
2
Remove
Mounting Screws
To Engine Starter
Service Procedure
Use a
Torx Head or
Phillips Head
Power Module Removal
Power Module
74
Page 79
Service Procedure
How to Install the Power Module
Procedure-
1. Position the Power Module at its mounting location.
2. Use a phillips head or torx head screwdriver to install and
tighten the two (2) mounting screws.
3. Reconnect the Motor Power connector to the Transmission ECU.
4. Reconnect the Logic Power connector to the Transmission Harness.
5. Reconnect the two (2) 1/2" ring terminals to the engine
starter.
Note: Observe proper polarity when connecting the ter-
minals to the starter (red for positive and black for
negative).
Final Check
Verify mounting screws are properly tightened.
Calibration
None.
75
Page 80
1
Position
Power Module
Service Procedure
Power Module
ECU
Connector
Transmission
Harness Connector
2
Reconnect Power Module
Connections and Ring
Terminals to Starter
Ring Terminals
Length Depends
on Application
Power Module
Service Procedure
Power Module Installation
Motor Power
Connector
Logic Power
Connector
76
Page 81
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
77
Page 82
Electric Shifter - Overview
Service Procedure
Special Instructions
Make sure the three (3) sets of detent balls and springs are
installed properly in the Shift Bar Housing.
Required Tools
• Basic Hand Tools.
Essential Steps
IMPORTANT: The shifter module must be calibrated before
the vehicle is placed into operation.
Service Procedure
Electric Shifter
78
Page 83
Service Procedure
How to Remove the Electric Shifter
Procedure-
1. Remove nylon cable ties from the motor wires.
2. Disconnect the Transmission Harness from the Rail
Select Sensor and the Gear Select Sensor.
3. Disconnect the Rail Select Motor from the Transmission
ECU.
4. Disconnect the Gear Select Motor from the Transmission
ECU.
5. Using a 9/16" wrench, remove the four (4) capscrews.
6. Remove the Electric Shifter and gasket.
79
Page 84
1
Disconnect
Transmission Harness
from Rail and Gear
Select Sensors
Sensor Connectors
Service Procedure
2
Disconnect Rail Motor
and Gear Motor from
Transmission ECU
Motor Connectors
9/16" Wrench
Service Procedure
3
Remove Mounting
Capscrews
4
Remove Electric
Shifter and Gasket
Possible Pinch Point- Make sure
battery is disconnected before
removal of XY shifter.
Electric Shifter
Electric Shifter Removal
Gasket
80
Page 85
Service Procedure
How to Install the Electric Shifter
Procedure-
1. Clean and remove old gasket material from the Shift Bar
Housing.
2. Position a new gasket at the Electric Shifter mounting
location.
3. Check to ensure that the shift blocks are in the Neutral
position.
4. Move the shift finger to the center (NEUTRAL) location.
Note: If the shift finger is not properly aligned, the Elec-
tric Shifter will not fit properly at its mounting
location.
5. Position the Electric Shifter on the Shift Bar Housing.
6. Using a 9/16" wrench, install and tighten the capscrews
to 35-45 lbs. ft. (47.5-61.0 N•m).
7. Reconnect the Transmission Harness to the Rail Select
Sensor and Gear Select Sensor.
8. Reconnect the Rail Select Motor to the Transmission
ECU.
9. Reconnect the Gear Select Motor to the Transmission
ECU.
10. Using nylon cable ties, secure the motor wires to the
transmission in their previous position.
Final Check
Make sure that the capscrews are tightened to specification.
Make sure all Electric Shifter connectors are securely
attached.
Calibration
To operate properly, the system must be calibrated as follows:
a. Turn the ignition switch to ON and allow the trans-
mission to power up.
b. Turn the ignition switch to OFF and wait two minutes.
IMPORTANT: The shifter module must be calibrated before
the vehicle is placed into operation.
81
Page 86
Gasket
1
Position New Gasket
on Mounting Surface
3
Service Procedure
2
Position Electric Shifter
on Transmission
9/16" Wrench
Install and Tighten
Mounting Capscrews
5
Reconnect Rail Select Motor
and Gear Select Motor to
Transmission ECU
Motor Connectors
Service Procedure
Shift Finger
4
Reconnect Transmission
Harness to Rail and Gear
Select Sensors
Sensor Connectors
Electric Shifter Installation
82
Page 87
Service Procedure
83
Page 88
Transmission ECU - Overview
Service Procedure
Special Instructions
Install the Power Module on the Transmission ECU before
installing the Transmission ECU.
Apply lubricant to the ECU mounting bracket locating studs on
the main case top.
Make sure the three (3) 2-pin packard connectors are properly
located on the Transmission ECU top.
Required Tools
• Basic Hand Tools.
Service Procedure
Transmission ECU
84
Page 89
Service Procedure
How to Remove the Transmission ECU
Procedure-
1. Disconnect the negative battery cable.
2. Remove nylon cable ties from ECU 24-way and 32-way
connectors.
3. Disconnect the Gear Select Motor from the Transmission
ECU.
4. Disconnect the Rail Select Motor from the Transmission
ECU.
5. Use a small flat-blade screwdriver to unlock and disconnect the Motor Power connector.
6. Unlock and disconnect the Transmission ECU 32-way
connector.
7. Unlock and disconnect the Transmission ECU 24-way
connector.
8. Using a 1/2" wrench, remove the two (2) Transmission
ECU mounting bolts.
9. Remove the Transmission ECU assembly from the locating studs.
CAUTION: When removing the Transmission
ECU, take care not to bend the ECU locating
bracket.
10. Using a phillips head or torx head screwdriver, remove
the Power Module mounting screws.
11. Remove the Power Module and lay it on the transmission.
85
Page 90
Transmission ECU
Transmission ECU Connectors
Service Procedure
1
Disconnect Five
connectors
2
Remove Mounting
Capscrews
3
Remove
Transmission ECU
Service Procedure
1/2" Wrench
4
Remove
Power Module
Locating Studs
Transmission ECU Removal
Power Module Screws
86
Page 91
Service Procedure
How to Install the Transmission ECU
Procedure-
1. Position the Power Module on the Transmission ECU.
2. Use a phillips head or torx head screwdriver to install and
tighten the two (2) mounting screws.
3. Position the Transmission ECU on the locating studs.
CAUTION: When attaching the Transmission ECU,
take care not to bend the ECU locating bracket.
4. Using a 1/2" wrench, install and tighten the two (2) Transmission ECU mounting bolts.
5. Reconnect the Transmission ECU 24-way connector.
6. Reconnect the Transmission ECU 32-way connector.
7. Install nylon cable ties around 24-way and 32-way connectors.
8. Reconnect the Motor Power connector.
9. Reconnect the Transmission ECU to the Rail Select
Motor.
10. Reconnect the Transmission ECU to the Gear Select
Motor.
11. Reconnect the negative battery cable.
Final Check
Make sure the retaining capscrews are properly tightened.
Make sure all Transmission ECU connectors are properly connected and locked.
Make sure the shifter module harness connectors are properly
connected.
Calibration
None.
87
Page 92
Service Procedure
1
Install
Power Module
Power Module Screws
2
Install
Transmission ECU
1/2" Wrench
3
Install and Tighten
Mounting Bolts
Service Procedure
Locating Studs
4
Reconnect Five
Harness Connectors
Transmission ECU Connectors
Transmission ECU Installation
88
Page 93
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
89
Page 94
Transmission Harness - Overview
Service Procedure
Special Instructions
Make sure the three (3) two pin packard connectors are properly located on the Transmission ECU top.
Required Tools
• Basic Hand Tools.
Service Procedure
Transmission Harness
90
Page 95
Service Procedure
How to Remove the Transmission Harness
Procedure-
1. Remove nylon cable ties holding the harness and connectors in place.
2. Disconnect 32-way and 24-way ECU connectors from the
ECU
3. Disconnect Input and Main Shaft Speed Sensors
4. Disconnect Gear Select Sensor and Rail Select Sensor
5. Disconnect Reverse Ball Switch
6. Disconnect Logic Power from the Transmission Harness
7. Disconnect Output Shaft Speed Sensor
8. Disconnect Range Solenoid Valve
9. Disconnect Transmission Interface connector
10. If required, disconnect the Splitter Solenoid and Inertia
Brake Solenoid.
11. Remove the Transmission Harness.
91
Page 96
Service Procedure
1
24-Way and 32-Way
Connectors
Disconnect 24-Way and
32-way Connector from
Transmission ECU
3
Disconnect Output
Speed Sensor Connector
2
Disconnect
Harness Connectors from
Speed and Position Senors
Harness Connectors
Service Procedure
Output Speed
Sensor
5
Disconnect Transmission
Interface Connector
4
Disconnect Range
Valve Solenoid Connector
Range Solenoid
Connector
Transmission Harness Installation
92
Page 97
Service Procedure
How to Install the Transmission Harness
Procedure-
1. Route the pigtail harness that comes off the 32-way connector behind the Transmission ECU and up to the top of
the transmission.
2. If required, reconnect the Splitter Solenoid and Inertia
Brake Solenoid.
3. Reconnect the Transmission Interface connector
4. Reconnect the Range Solenoid Valve
5. Reconnect the Output Shaft Speed Sensor
6. Reconnect the Logic Power from the Transmission Harness
7. Reconnect the Reverse Ball Switch
8. Reconnect the Gear Select Sensor and Rail Select Sensor
9. Reconnect the Input and Main Shaft Speed Sensors
10. Reconnect the 32-way and 24-way ECU connectors to the
Transmission ECU
11. Replace all nylon cable ties to hold the Transmission Harness and connectors in place.
Final Check
Double-check all connections to make sure they are secure.
Calibration
None.
93
Page 98
1
Reconnect Transmission
Interface harness
3
Reconnect Output
Speed Sensor
Service Procedure
2
Reconnect Range
Valve Solenoid
Range Solenoid
Connector
3
Reconnect 24-Way and 32-Way
Connectors to Transmission ECU
24-Way and 32-Way
Connectors
Service Procedure
4
Reconnect Harness Connectors
to Speed and Position Sensors
Harness Connectors
5
Transmission Harness Installation
94
Page 99
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
95
Page 100
Shift Lever - Overview
Service Procedure
Special Instructions
None.
Required Tools
• Basic Hand Tools.
Service Procedure
96
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