Eaton Transmission RTLOF-18610B Service Manual
Service Manual
Fuller Heavy Duty Transmissions
TRSM0550
July 2010
RTLO-11610B
RTLO-11610B-T2
RTLO-12610B
RTLO-12610B-T2
RTLO-13610B
RTLO-13610B-T2
RTLO-14610B-T2
RTLO-15610B
RTLO-15610B-T2
RTLO-16610B
RTLO-16610B-T2
RTLO-17610B
RTLO-17610B-T2
RTLO-18610B
RTLO-18610B-T2
RTLO-14610A
RTLOF-11610B
RTLOF-11610B-T2
RTLOF-12610B
RTLOF-12610B-T2
RTLOF-13610B
RTLOF-13610B-T2
RTLOF-14610B
RTLOF-14610B-T2
RTLOF-15610B
RTLOF-15610B-T2
RTLOF-16610B
RTLOF-16610B -T2
RTLOF-17610B
RTLOF-17610B-T2
RTLOF-18610B
RTLO-14610B
Precautions
Warnings and Precautions
Before starting a vehicle always be seated in the driver’s seat, place the transmission in neutral, set the parking brakes and
disengage the clutch.
Before working on a vehicle place the transmission in neutral, set the parking brakes and block the wheels.
Before towing the vehicle place the transmission in neutral, and lift the rear wheels off the ground, remove the axle shafts,
or disconnect the driveline to avoid damage to the transmission during towing.
The description and specifications contained in this service publication are current at the time of printing.
Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any
time without notice.
Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use
and should not be considered an endorsement. Equivalents may be used.
This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow
specific instructions may result in personal injury and/or component damage.
Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize
the personal safety of the service technical or vehicle operator.
Warning: Failure to follow indicated procedures creates a high risk of personal injury to servicing technician.
Caution: Failure to follow indicated procedures amy cause component damage of malfunction.
Note: Additional service information not covered in the service procedures.
Tip: Helpful removal and installation procedures to aid in the service of this unit.
Always use genuine Eaton replacement parts.
1
Table of Contents
General Information
General Service Practices and Part Inspection ............ 1
How to use this Manual ............................................... 5
Model Designation ...................................................... 8
Power Flow ................................................................. 9
Timing Procedures .................................................... 13
Tool Reference .......................................................... 15
Preventive Maintenance
Lubrication ................................................................ 16
Preventative Maintenance ......................................... 18
Inspection ................................................................. 20
Rear Seal Maintenance .............................................. 21
External Parts
How to Disassemble the External Parts ..................... 22
How to Assemble the External Parts ......................... 23
How to Remove the Air Lines and Hose .................... 24
How to Install the Air Lines and Hose ....................... 25
How to Remove the Air Filter/Regulator .................... 26
How to Install the Air Filter/Regulator ....................... 27
How to Remove a Roadranger Valve ......................... 28
How to Install a Roadranger Valve ............................ 29
How to Remove the Range Actuator Valve ................ 30
How to Install the Range Actuator Valve ................... 31
How to Remove the Top 2 Valve Assembly ............... 33
How to Install the Top 2 Valve Assembly .................. 34
How to Remove the Gear Shift Lever ........................ 35
How to Install the Gear Shift Lever ............................ 36
How to Remove the Shift Bar Housing ...................... 37
How to Install the Shift Bar Housing ......................... 38
How to Remove the Output Yoke/Companion Flange 39
How to Install the Output Yoke/Companion Flange ...40
How to Remove the Auxiliary Section
Without Tapered Bearings ..................................... 41
How to Install the Auxiliary Section
Without Tapered Bearings ..................................... 43
How to Remove the Auxiliary Section
With Tapered Bearings .......................................... 45
How to Install the Auxiliary Section
With Tapered Bearings .......................................... 48
The Shimming Procedure For Tapered Bearings ....... 50
How to Remove the Clutch Housing .......................... 53
How to Install the Clutch Housing ............................. 54
How to Remove the Input Shaft
Without Disassembling the Transmission .............55
How to Install the Input Shaft
Without Disassembling the Transmission .............57
Shift Bar Housing
Shift Bar Housing Identification .................................59
How to Disassemble the Gear Shift Lever ..................61
How to Assemble the Gear Shift Lever ......................63
How to Disassemble the Standard Shift Bar Housing 65
How to Assemble the Standard Shift Bar Housing .....68
How to Disassemble the Standard
Shift Bar Housig (w/Super 10 on cover) ................71
How to Assemble the Standard
Shift Bar Housing (w/Super 10 on cover) ..............74
How to Disassemble the Forward
Shift Bar Housing (w/Super 10 on cover) ..............77
How to Assemble the Forward
Shift Bar Housing(w/Super 10 on cover) ...............80
How to Disassemble the New Forward
Shift Bar Housing (w/Super 10 on cover) ..............83
How to Assemble the New Forward
Shift Bar Housing (w/Super 10 on cover) ..............86
Front Section
How to Disassemble the Front Section ......................89
How to Remove the Auxiliary Drive Gear Assembly ...90
How to Remove the Reverse Idler Gear Assembly .....91
How to Remove the Countershaft Bearings ...............93
How to Remove the Mainshaft Assembly ..................95
How to Remove the Countershaft Assemblies ...........96
How to Remove the Input Shaft Assembly ................97
How to Assemble the Front Section ...........................99
How to Install the Reverse Idler Gear Assembly ......100
How to Install the Countershaft Assemblies ............102
How to Install the Countershaft Bearings .................103
How to Install the Input Shaft Assembly ..................105
How to Install the Mainshaft Assembly ....................108
How to Install the Auxiliary Drive Gear Assembly ....109
How to Disassemble the Auxiliary Drive Gear Assembly
110
How to Assemble the Auxiliary Drive Gear Assembly 112
How to Disassemble the Countershaft Assembly .....114
How to Assemble the Countershaft Assembly .........115
How to Disassemble the Mainshaft Assembly .........117
How to Assemble the Mainshaft Assembly ..............119
Table of Contents
Auxiliary Section
How to Disassemble the Auxiliary Section .............. 124
How to Remove the Front Auxiliary Drive Gear ....... 125
How to Remove the Countershaft Assemblies
(w/Tapered Bearings) .......................................... 126
How to Remove the Countershaft Assemblies
(w/Ball Bearings) A Series ................................... 128
How to Remove the Rear Auxiliary Drive Gear ........ 130
How to Disassemble the Range Cylinder Assembly 131
How to Disassemble the Output Shaft Assembly .... 135
How to Disassemble the Splitter Cylinder Assembly 137
How to Assemble the Auxiliary Section ................... 139
How to Assemble the Output Shaft Assembly ......... 140
How to Assemble the Output Shaft Assembly
(A Series) ........................................................... 143
How to Install the Countershaft Assemblies
(w/Tapered Bearings) ......................................... 147
How to Install the Countershaft Assemblies
(w/Ball Bearings) A Series .................................. 150
How to Assemble the Range Cylinder Assembly ..... 153
How to Install the Rear Auxiliary Drive Gear ............ 157
How to Assemble the Splitter Cylinder Assembly .... 158
How to Install the Front Auxiliary Drive Gear ........... 161
How to Disassemble the Synchronizer Assembly .... 162
How to Assemble the Synchronizer Assembly ........ 163
Options
How to Remove the Integral Oil Pump .................... 165
How to Install the Integral Oil Pump ....................... 167
How to Disassemble the Integral Oil Pump ............. 169
How to Assemble the Integral Oil Pump .................. 171
General Information
General Service Practices and Part Inspection
Disassembly
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 (External Parts/Shift Bar Housing/
How to Remove the Gear Shift Lever); however, this assembly MUST be detached from the shift bar housing before transmission
can be removed.
CAUTION: 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 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 countershaft, mainshaft, or main drive gear. Special
procedures are required and provided in this manual.
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.
1
For parts or service call us
Pro Gear & Transmission, Inc.
1 (877) 776-4600
(407) 872-1901
parts@eprogear.com
906 W. Gore St.
Orlando, FL 32805
General Information
Inspection
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 Eaton® 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
1. 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.
2. Lubricate bearings that are not pitted, discolored, or spalled and check for axial and radial clearances.
3. Replace bearings with excessive clearances.
4. Check bearing fit. Bearing inner races should be tight to shaft; outer races slightly tight to slightly loose in case bore. If
bearing spins freely in bore, case should be replaced.
Bearing Covers
1. Check covers for wear from thrust of adjacent bearing. Replace covers damaged from thrust of bearing outer race.
General Information
2. Check cover bores for wear. Replace those worn or oversized.
Clutch Release Parts
1. Check clutch release parts. Replace yokes worn at cam surfaces and bearing carrier worn at contact pads.
2. Check pedal shafts. Replace those worn at bushing surfaces.
Gears
1. 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.
2. 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.
3. Check axial clearance of gears.
Gear Shift Lever Housing Assembly
1. Check spring tension on shift lever. Replace tension spring if lever moves too freely.
2. 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
1. Check all gray iron parts for cracks and breaks. Replace parts found to be damaged.
2
General Information
Oil Return Threads and Seals
1. Check oil return threads on the input shaft. If return action of threads has been destroyed, replace the input shaft.
2. Check oil seal in rear bearing cover. If sealing action of lip has been destroyed, replace seal.
O-Rings
1. Check all O-rings for cracks or distortion. Replace if worn.
Reverse Idler Gear Assemblies
1. Check for excessive wear from action of roller bearings.
Shift Bar Housing Assembly
1. Check for wear on shift yokes and blocks at pads and lever slot. Replace excessively worn parts.
2. Check yokes for correct alignment. Replace sprung yokes.
3. Check lockscrews in yoke and blocks. Tighten and rewire those found loose.
4. If housing has been disassembled, check neutral notches of shift bars for wear from interlock balls.
Sliding Clutches
1. Check all shift yokes and yoke slots in sliding clutches for extreme wear or discoloration from heat.
2. Check engaging teeth of sliding clutches for partial engagement pattern.
Splines
1. Check splines on all shafts for abnormal wear. If sliding clutch gears, companion flange, or clutch hub has worn marks
in the spline sides, replace the specific shaft affected.
Synchronizer Assembly
1. Check synchronizer for burrs, uneven and excessive wear at contact surface, and metal particles.
2. Check blocker pins for excessive wear or looseness.
3. Check synchronizer contact surfaces on the synchronizer cups for wear.
Washers
1. Check surfaces of all washers. Washer scored or reduced in thickness should be replaced.
3
General Information
Assembly
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 assemble.
Axial Clearances
Maintain original axial clearances of .006" to .015" 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 sleevetype driver, whenever possible, as force is applied to only one of the bearing races.
Capscrews
To prevent oil leakage and loosening, use Eaton/Fuller sealant #71205 on all capscrews.
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 Lubriplate during assembly to prevent scoring and galling of such parts.
O-Rings
Lubricate all O-rings with silicon lubricant.
General Information
Universal Joint Companion Flange or Yoke
Pull the companion flange or yoke tightly into place with the output shaft nut, using 450-500 Lbf-ft 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
assemble of the transmission.
4
General Information
How to use this Manual
This manual is designed to provide detailed information necessary to service and repair the Eaton® Fuller® transmissions listed
on the front.
As outlined on the first page, the manual has been divided into its main components: external parts, shift bar housing, front section, auxiliary section, and options (if applicable). Each component has its own tabbed section. Each tabbed section has its own
table of contents and procedural flow charts. The table of contents lists the procedures. The flow charts represent the order in
which the transmission should be disassembled or assembled. The procedures have two parts, disassembly or removal and reassembly or installation.
As mentioned the flow charts represent the order in which the transmission should be disassembled or assembled.
The following is an example of how to disassemble the auxiliary section, specifically the range cylinder assembly.
5
General Information
Follow the flow chart "How to Disassemble the Auxiliary Section".
1. Remove the auxiliary section from the front box.
2. Remove the front auxiliary drive gear and yoke.
3. Remove the countershaft assemblies.
4. Remove the rear auxiliary drive gear.
5. Remove the range cylinder assembly.
1
Front Auxiliary Drive
2
3
General Information
Auxiliary
Section
Gear and Yoke
Countershaft
Assemblies
Desassemble
Synchronizer
Assembly
4
Rear Auxiliary
Drive Gear
Range
Cylinder
Assembly
Output
Shaft
Assembly
Splitter
Cylinder
Assembly
5
6
General Information
Once the range cylinder parts have been replaced, assemble the auxiliary section according to the "How to Assemble the Auxiliary
Section".
1. Assemble the output shaft assembly.
2. Assemble the synchronizer assembly, if it was disassembled.
3. Install the countershaft assemblies.
4. Install the range cylinder assembly.
Output
1
Shaft
Assembly
Assemble
Synchronizer
Assembly
2
3
4
Countershaft
Assemblies
Range
Cylinder
Assembly
Rear Auxiliary
Drive Gear
Splitter
Cylinder
Assembly
Front Auxiliary Drive
Gear and Yoke
Auxiliary
Section
7
General Information
Model Designation
General Information 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.
WARNING: Do not remove or destroy the transmission identification tag.
PTO Code
Eaton Fuller
T
ransmissions
Model
RTO-14710-AS2
Eaton Corporation
Transmission Div
Kalamazoo, MI 49003
Made
In
Serial
General Information
Roadranger
Twin Countershaft
Low Inertia
Overdrive
Torque x 100
T
LO-R
14 10A6
Gear Ratio
Forward Speeds
Design Level 6 ="Multi-Mesh" Gearing
8
General Information
Power Flow
The transmission must efficiently transfer the engine's power to the vehicle's driveline. Knowledge of what takes place in the
transmission is helpful when troubleshooting and making repairs.
1st Gear
• Power (torque) from the vehicle's engine is transferred to the transmission's input shaft.(1)
• The input shaft external splines engage the main drive gear internal splines.(2)
• Torque is split between the two countershaft drive gears.(3)
• Torque is delivered along both countershafts to the mating countershaft gears of the "engaged" mainshaft gear. The following cross section view illustrates a 1st speed gear engagement.(4)
• The external clutching teeth of the sliding clutch engage with the internal clutching teeth of the mainshaft gear which
transfers torque to the mainshaft.(5)
• The mainshaft transfers torque directly to the rear auxiliary drive gear sliding clutch which is in the rearward position.(6)
• The rear auxiliary drive gear splits torque between the two auxiliary countershaft drive gears.(7)
• Torque is delivered along both countershafts to the LO range gear in the auxiliary section.(8)
• The LO range gear delivers torque to the output shaft through the range synchronizer sliding clutch.(9)
• The output shaft delivers torque to the driveline components.(10)
9
General Information
2nd Gear
• Power (torque) from the vehicle's engine is transferred to the transmission's input shaft.(1)
• The input shaft external splines engage the main drive gear internal splines.(2)
• Torque is split between the two countershaft drive gears.(3)
• Torque is delivered along both countershafts to the mating countershaft gears of the "engaged" mainshaft gear. The following cross section view illustrates a 2nd speed gear engagement.(4)
• The external clutching teeth of the sliding clutch engage with the internal clutching teeth of the mainshaft gear which
transfers torque to the mainshaft.(5)
General Information
• The mainshaft transfers torque directly to the auxiliary drive gear sliding clutch which is in the forward position.(6)
• The auxiliary drive gear splits torque between the two auxiliary countershaft drive gears.(7)
• Torque is delivered along both countershafts to the LO range gear in the auxiliary section.(8)
• The LO range gear delivers torque to the output shaft through the range synchronizer sliding clutch.(9)
• The output shaft delivers torque to the driveline components.(10)
10
General Information
7th gear
• Power (torque) from the vehicle's engine is transferred to the transmission's input shaft.(1)
• The input shaft external splines engage the main drive gear internal splines.(2)
• Torque is split between the two countershaft drive gears.(3)
• Torque is delivered along both countershafts to the mating countershaft gears of the "engaged" mainshaft gear. The following cross section view illustrates a 7th speed gear engagement.(4)
• The external clutching teeth of the sliding clutch engage with the internal clutching teeth of the mainshaft gear which
transfers torque to the mainshaft.(5)
• The mainshaft transfers torque directly to the rear auxiliary drive gear sliding clutch which is in the rearward position.(6)
• Torque is delivered to the back of the rear auxiliary drive gear. The range synchronizer sliding clutch is in the forward
position, transferring torque directly to the output shaft.(7)
• The output shaft delivers torque to the driveline components.(8)
11
General Information
8th Gear
• Power (torque) from the vehicle's engine is transferred to the transmission's input shaft.(1)
• The input shaft external splines engage the main drive gear internal splines.(2)
• Torque is split between the two countershaft drive gears.(3)
• Torque is delivered along both countershafts to the mating countershaft gears of the "engaged" mainshaft gear. The following cross section view illustrates a 8th speed gear engagement.(4)
• The external clutching teeth of the sliding clutch engage with the internal clutching teeth of the mainshaft gear which
transfers torque to the mainshaft.(5)
General Information
• The mainshaft transfers torque directly to the front auxiliary drive gear sliding clutch which is in the forward position.(6)
• The front auxiliary drive gear splits torque between the two auxiliary countershaft drive gears.(7)
• Torque is delivered along both countershafts to the rear auxiliary drive gear.(8)
• Torque is transferred to the range synchronizer sliding clutch which is in the forward position delivering torque directly
to the output shaft.(9)
• The output shaft delivers torque to the driveline components.(10)
12
Timing
Timing Procedures
It is essential that both countershaft assemblies of the front and auxiliary sections are "timed." This assures proper tooth contact
is made between mainshaft gears seeking to center on the mainshaft during torque transfer and mating countershaft gears that
distribute the load evenly. If not properly timed, serious damage to the transmission is likely to result from unequal tooth contact
causing the mainshaft gears to climb out of equilibrium.
Timing is a simply procedure of marking the appropriate teeth of a gear set prior to installation and placing them in proper mesh
while in the transmission. In the front section, it is necessary to time only the drive gear set. And depending on the model, only
the LO range, deep reduction, or splitter gear set is timed in the auxiliary section.
Front Section
A. Marking countershaft drive teeth.
1. Prior to placing each countershaft assembly into the case, clearly mark the tooth located directly over the drive gear
keyway as shown. This tooth is stamped with an "O" to aid identification.
B. Marking main drive gear teeth.
1. Mark any two adjacent teeth on the main drive gear.
2. Mark the two adjacent teeth located directly opposite the first set marked on the main drive gear. As shown to the left,
there should be an equal number of unmarked gear teeth on each side between the marked sets.
13
Timing
C. Meshing marked countershaft drive gear teeth with marked main drive gear teeth.
(After placing the mainshaft assembly into the case, the countershaft bearings are installed to complete installation of the countershaft assemblies.)
1. When installing the bearings on the left countershaft, mesh the countershaft drive gear marked tooth with either set of
main drive gear two marked teeth.
2. Repeat the procedure when installing the bearings on the right countershaft, make use of the remaining set of main
drive gear two marked teeth to time assembly.
Auxiliary Section
A. Timing the auxiliary countershafts.
Standard Auxiliary Section
General Information
1. Mark any two teeth on the LO range gear. Then mark two teeth located directly opposite the first marked.
2. Prior to placing each auxiliary countershaft assembly into housing, mark the tooth on each auxiliary countershaft
assembly LO range gear stamped with the "O".
3. Follow the assembly procedures in the "Auxiliary Section".
Helical Auxiliary Section
1. Mark any tooth on the LO range gear. Then mark a tooth located directly opposite the first marked.
2. Prior to placing each auxiliary countershaft assembly into housing, mark the two teeth on each auxiliary countershaft
assembly LO range gear stamped with the two "O"s. Repeat the procedure on each auxiliary countershaft reduction gear.
3. Follow the assembly procedures in the "Auxiliary Section".
14
Tool Reference
Tool Reference
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.
But 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 all that is needed to successfully disassemble and reassemble any Eaton Fuller Transmission.
The specialized tools can be obtained from a tool supplier or made from tool prints as required by the individual user. Detailed
Eaton Fuller Transmission Tool Prints are available upon request by writing to:
Roadranger Literature Services
Attn: Contract 4 / CA#182
1750 Wallace Ave.
St. Charles, IL 60174-3404
Phone: 888-ETN-INFO (386-4636)
15
Lubrication / Application Information
Lubrication
For a list of Eaton Approved Synthetic Lubricants, see TCMT-0021 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.
Buy from a reputable dealer
For a list of approved and reputable dealers, write to:
Eaton Corporation
Worldwide Marketing Services
P.O.Box 4013
Kalamazoo MI 49003
Transmission Operating Angles
If the transmission operating angle is more than 12°, 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°, the transmission must be equipped with an oil pump or cooler kit to insure proper lubrication.
Operating Temperatures with Oil Coolers
Preventive Maintenance
The transmission must not be operated consistently at temperatures above 250°F. However, intermittent operating temperatures
to 300°F do not harm the transmission. Operating temperatures above 250°F increases the lubricant’s oxidation rate and shortens
its effective life. When the average operating temperature is above 250°F, the transmission can require more frequent oil changes
or external cooling.
The following conditions in any combination can cause operating temperatures of over 250°F:
a. Operating consistently at slow speeds.
b. High ambient temperatures.
c. Restricted air flow around transmission.
d. Exhaust system too close to transmission.
e. High horsepower operation.
External oil coolers are available to reduce operating temperatures when the above conditions are encountered.
16
Lubrication / Application Information
Oil Cooler Chart
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 or greater torque.
-With engines 450 H.P and above.
17
Preventive Maintenance
Preventative Maintenance
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.
Checks Before Transmission Removal
1. Air System and Connections
Check for leaks, worn air lines, loose connections and capscrews. See SERVICING AIR SYSTEM.
2. Clutch Housing Mounting
Check all capscrews 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
Preventive Maintenance
Change at specified service intervals.
Use only the types and grades as recommended. See LUBRICANTS.
6. Filler and Drain Plugs
Remove filler plugs and check level of lubricant at specified intervals. Tighten fill and drain plugs securely.
7. Capscrews and Gaskets
Check all capscrews, 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.
8. Gear Shift Lever
Check for looseness and free play in housing. If lever is loose in housing, proceed with Check No. 9.
9. Gear Shift Lever Housing Assembly
Remove air lines at slave valve and 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.
18
Preventive Maintenance
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
10. Universal Joint Companion Flange or Yoke Nut
Check for tightness. Tighten to recommended torque.
11. Output Shaft
Pry upward against output shaft to check radial clearance in mainshaft rear bearing.
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.
12. Splines on Output Shaft
Check for wear from movement and chucking action of the universal joint companion flange or yoke.
13. Mainshaft Rear Bearing Cover
Check oil seal for wear.
19
Preventive Maintenance
Inspection
Table 1:
Part to inspect What to Check For Action to be Done
Speedometer Connections
Rear Bearing Cover
capscrews, Gasket,
and Nylon Collar
Output Yoke Retaining Nut
PTO Covers and
Openings
Grey Iron Parts Check front bearing cover, front case, shift bar
Front Bearing Cover Check return threads for damage. Check the cap-
Speedometer cables should not be loose. Should
be an O-Ring or gasket between the mating
speedometer sleeve and the rear bearing cover.
Check retaining capscrews for tightness. Verify
nylon collar and gasket are installed at the chamfered hole, aligned near the mechanical speedometer opening. Verify that a rear bearing cover
gasket is in place.
Check the output yoke retaining nut for tightness. Torque the output yoke retaining nut to 450-500
Check the capscrews for tightness. Apply Eaton Sealant #71205 to the capscrew
housing, rear bearing cover, and clutch housing
for cracks or breaks.
screws for tightness.
Applied hydraulic thread sealant #71208 to
threads. Torque speedometer sleeve to 35-50
Lbf-ft. Replace the O-ring/gasket if damaged or
missing.
Apply Eaton Sealant #71205 to the capscrew
threads. Torque capscrews to 35-45 Lbf-ft.Use
new parts if need to replace. Apply Eaton Sealant
#71205 to the capscrew threads. Torque capscrews to 35-45 Lbf-ft. Install a new gasket if
rear bearing cover was removed.
Lbf-ft. Do not over torque nut.
threads. Tighten 6 bolt PTO capscrews to 35-45
Lbf-ft. Tighten 8 bolt PTO capscrews to 50-65
Lbf-ft.
Replace parts found to be damaged.
If threads damaged, replace the input shaft.
Tighten the capscrews to 35-45 Lbf-ft.
Preventive Maintenance
Oil Cooler and Oil Filter
Oil Drain Plug, Oil Fill
Plug
Check all connections, fittings, hoses, and filter element for tightness.
Check the oil drain plug and the oil fill plug for
leakage.
Tighten any loose fittings.
Torque the drain plug to 45-55 Lbf-ft. Torque the
oil fill plug to 60-70 Lbf-ft.
20
Preventive Maintenance
Oil Leak Inspection Process
Inspect for Oil Leak
Determine if it is a Weep or a Leak
Weep: Stained, damp, no drips, light oil film,
dirt adhered to the contaminated area.
Gasket Rear Seal Leak
Leak: Extremely wet or dripping of oil in the
contaminated area.
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 (refer to Roadranger
TCSM-0912 Seal Maintance
Guide).
2. Ensure lube is to proper
level.
Step 2
Step 3
1. Determin
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
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.
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 or
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...
e the origin of the leak path.
to
igin.
21
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.
How to Disassemble the External Parts
How to Disassemble the External Parts
EXTERNAL
PARTS
AIR FILTER/
REGULATOR
AIR
SYSTEM
AIR LINES
AND HOSES
ROADRANGER
VALVE
Clutch
Housing
External Parts
CHANGING THE
INPUT SHAFT
AUXILIARY
SECTION
OUTPUT YOKE/
COMPANION
FLANGE
GEAR SHIFT
LEVER
SHIFT BAR
HOUSING
LEGEND
OPTIONAL PATH
TYPICAL PATH
22
How to Assemble the External Parts
How to Assemble the External Parts
EXTERNAL
PARTS
OUTPUT YOKE/
COMPANION
FLANGE
AUXILIARY
SECTION
AIR
SYSTEM
AIR/FILTER
REGULATOR
CLUTCH
HOUSING
CHANGING THE
INPUT SHAFT
SHIFT BAR
HOUSING
GEAR SHIFT
LEVER
ROADRANGER
VALVE
23
AIR LINES
AND HOSE
LEGEND
OPTIONAL PATH
TYPICAL PATH
Air System
How to Remove the Air Lines and Hose
Special Instructions
Before removing the air lines and hose, label or record their location.
If, after you remove the air lines and hoses, you are unsure of their location, see the Air System “Troubleshooting/Operation
Guide” TRTS-0920.
Special Tools
• Typical Service Tools
• For “push-to-connect” fittings, we recommend Eaton service tool kit K-2394. The kit contains the release tool and the
tubing cutter.
Procedure -
1. Disconnect all air lines and hose.
External Parts
2. Inspect the air lines and hose.
3. Inspect air fittings, remove if damaged.
24
Air System
How to Install the Air Lines and Hose
Special Instructions
Make sure air lines and hose are not damaged.
Install the air lines and hose at their proper location.
All externally threaded 1/8" or 5/32" air lines and pipe fittings that are not coated with pre-applied thread sealant must be coated
with Eaton sealing material #71209 or equivalent for at least 5 complete and consecutive threads.
All externally threaded 1/4" air fittings that are not coated with pre-applied thread sealant must be coated with Eaton sealing material #71209 or equivalent for at least 3 complete and consecutive threads.
For the 1/4" I.D. air hoses, install the fixed nut end first.
To install the air lines and hose, the air filter/regulator must be in position.
If you are unsure of the air lines and hose location, see the Air System “Troubleshooting/Operation Guide” TRTS-0920.
Special Tools
• Typical Service Tools
• For ‘push-to-connect’ fittings, we recommend Eaton “Service Tool Kit” K-2394. The kit contains the release tool and a
tubing cutter.
Procedure -
1. Replace removed air fittings.
2. Connect all removed air lines and hose.
Final Check
• Make sure fittings are tight.
• Make sure air lines are not kinked.
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