Eaton Transmission RTO-13109B-AT Service Manual
Service Manual
Fuller Automated Transmissions
TRSM0020
October 2007
RT-11109A-AT
RT-11109A-ATR
RT-11109A-ATS
RT-12109A-AT
RT-14109A-ATS
RTO-11109A-AT
RTO-11109A-ATS
RTO-11109B-AT
RTO-11109B-ATE
RTO-11109B-ATR
RTO-11109B-ATS
RTO-12109A-AT
RTO-12109B-AT
RTO-13109A-ATE
RTO-13109B-AT
RTO-13109B-ATE
RTO-14109A-ATE
RTO-14109A-ATS
RTO-14109B-AT
RTO-14109B-ATE
RTO-14109B-ATS
RTO-16109A-AT
RTO-16109A-ATE
RTO-16109B-AT
RTO-16109B-ATE
RTO-9109A-AT
RTO-9109B-AT
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
Warnings & Precautions
General Information
Model/Assembly Reference
External Parts
Shift Bar Housing
Front Section
Auxiliary Section
Options
Section 1: Warnings and Precautions
Warning
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Precautions
Disassemble
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Snap Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
When using Tools to Move Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Warning & Precautions
Inspection
Autoshift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Bearing Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Gray Iron Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Power Synchronizer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Rear Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Reverse Idler Gear Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Shift Bar Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Sliding Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Synchronizer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Assemble
Axial Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Universal Joint Companion Flange or Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
9
WARNING
Before starting a vehicle always be
seated in the drivers seat, place the
transmission in neutral, set the
Warning & Precautions
parking brakes.
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
drive wheels off the ground or
disconnect the driveline to avoid
damage to the transmission during
towing.
11
Precautions
Disassemble
It is assumed in the detailed assembly instructions that the lubricant has
been drained from the transmission, the necessary linkage, cooler lines,
and air lines disconnected, and the transmission has been removed from
vehicle chassis. Removal of the gear shift cable and electrical harness is
included in the detailed instructions; however, they MUST be detached
from the transmission before they can be removed from the chassis. For
in shop disassembly, holding the transmission in the vertical position can
be done securely by fastening a compatible companion flange to a large
base, forming a holder for the output shaft splines. Use extreme caution
when handling heavy equipment.
Follow closely each procedure in the detailed instructions, make use of
the text, illustrations, and photographs provided.
The electronic control unit (ECU is a non-serviceable
component. Follow the instructions in the "External Parts"
section, careful to remove and protect the unit from damage.
Assemblies
When disassembling the various assemblies, such as the reverse
idler, countershafts, and auxiliary section, 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.
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.
12
When Using Tools to Move Parts
Always apply force to shafts, housings, etc., with restraint.
Movement of some parts is restricted. Never apply force to driven
parts after they stop solidly. The use of soft hammers, soft bars,
and mauls for all disassembly work is recommended.
Inspection
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.
Precautions
Warning & Precautions
Recommended inspection procedures are provided in the following
checklist.
Autoshift Assembly
1. Autoshift finger should move side to side, fore and aft with frictional
resistance only.
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.
2. Check cover bores for wear. Replace those worn or oversized.
continued on next page
13
Precautions
Inspection
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.
Gray Iron/Torque Converter Housing Parts
1. Check all gray iron parts for cracks and breaks. Replace parts
found to be damaged.
Hydraulic Valve
1. Should be clean and free of contamination.
O-Rings
1. Check all O-rings for cracks or distortion. Replace if worn.
Oil Pump
1. Free from damage with no apparent leaks.
Power Synchronizer/Inertia Brake Assembly
1. Check the splined shaft and drive gear for free rotation.
2. No visual damage to band or disc and free of contamination.
Rear Oil Seals
1. Check oil seal in rear bearing cover. If sealing action of lip has
been destroyed, replace the seal. Check the mating flange for
damage.
14
Reverse Idler Gear Assemblies
1. Check for excessive wear from action of roller bearings.
continued on next page
Inspection
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.
Precautions
Warning & Precautions
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.
Range 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.
Wiring Harnesses
1. Should have no abrasions, connector pins should be firmly seated.
15
Precautions
Assemble
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
sleeve-type 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
#71211 or equivalant on all capscrews. For torque ratings, use the
torque recommendations through out the service manual.
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.
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.
16
IMPORTANT: See the appropriate Illustrated Parts Lists (specified by
model series) to ensure that proper parts are used during assemby of the
transmission.
Section 2: General Information
How to Use This Manual 3
Model Designation 5
Lubrication
Maintain Proper Oil Level 6
Draining Oil 7
Refilling 7
Flush Procedure 8
Maintenance Interval Chart 9
Recommended Lubricant Chart 9
Transmission Operating Angles 10
Operating Temperatures with Oil Coolers 11
Power Flow
General Information
Torque Converter Mode: LO Range 12
Torque Converter Mode: Lockup Mode 14
Auxiliary Section: HI Range 15
Timing
Front Section 16
Auxiliary Section 17
Tool Reference 18
Preventive Maintenance 19
Checks Before Transmission Removal 20
Checks with Drive Line Dropped 21
Checks With Universal Joint Companion Flange or Yoke Removed 21
Transmission appearance may differ, procedure is the same.
1
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.
How to Use This Manual
General Information
The following is the general layout with descriptions.
1. Heading
Gives a general description of the topic covered.
2. Subhead
Gives a more specific description of the topic covered.
3. Special Instructions
Procedures that need to be done before performing the
topic covered. Hints that will make the procedure
easier to preform.
4. Special Tools
For most procedures typical service mechanic tools are
all that is required, but sometimes a "special" tool is
needed to prevent damaging the transmission.
5. The "How to"
The actual procedure to be performed.
6. Illustrations and pictures
To further help explain and illustrate the procedures.
How to Install the Air Supply Hoses for LO and HI Range
Special Instructions
Make sure air hoses are not damaged.
Install the air hoses at their proper locations.
All externally threaded
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
To install the hoses, the air filter/regulator must be in
position.
Special Tools
Typical service mechanic tools
To Install
1. Connect one air supply hose end to the range
2. Connect the other end to the slave valve HI range
3. Connect one air supply hose end to the range
4. Connect the other end to the slave valve LO range
Final Check
Make sure air lines are not kinked.
3
1
⁄4" air fittings that are not coated
4
1
⁄4" I.D. air hoses, install the fixed nut end first.
5
cylinder HI range supply port.
supply port.
cylinder LO range supply port.
supply port.
7
Air System
1
2
1
6
H/45-4
External Parts
2
H/45-3
3
H/45-2
7. Final Check
Must do's for proper performance.
8. Page Number/Section
Tells what page your on and in what section.
Transmission appearance may differ, procedure is the same.
Transmission appearance may differ, procedure is the same.
4
H/45-1
8
6
3
How to Use This Manual
3
Synchronizer
Assembly
Rear Bearing
Cover
DS/AS-3
1
2
Auxiliary
Section
Range
Cylinder
Assembly
Countershaft
Assemblies
Output
Shaft
Assembly
As mentioned on the previous page, 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 synchronizer
assembly.
Follow the flow chart "How to Disassemble the
Auxiliary Section".
1. Remove the auxiliary section from the front box.
2. Remove the range cylinder assembly.
3. Disassemble the synchronizer.
AS/AS-4
2
3
Output
Shaft
Assembly
Countershaft
Assemblies
Range
Cylinder
Assembly
Auxiliary
Section
1
Assemble
Synchronizer
Assembly
Rear Bearing
Cover
Once the synchronzier parts have been replaced,
assemble the auxiliary section according to the "How
to Assemble the Auxiliary Section".
1. Assemble the synchronizer assembly.
2. Install the countershaft assemblies, if they were
removed.
3. Install the range cylinder assembly.
4
Transmission appearance may differ, procedure is the same.
Transmission model designation and other
transmission identification information are stamped on
the transmission tag. To identify the transmission
model designation and serial number, locate the tag on
the transmission and then locate the numbers as
shown.
Do not remove or destroy the transmission
identification tag.
Model Designation
General Information
Converter
Enhanced
Electronically
Roadranger
Twin Countershaft
Overdrive
X 100 = Nominal
Torque Capacity
Design Level
Forward Speeds
BYPASS
INTERRUPT
MAIN
LUBE
C E E M A T
R T O - 11 1 09 A - A T E
Transmission
Automatic
Managed
S—Special Duty
R—Regular Duty
E—Electronic
Governed Engines
Torque Converter
Automatic
Gear Ratio
Transmission appearance may differ, procedure is the same.
5
Lubrication
Proper lubrication procedures are the key to a good all-around
maintenance program. If the oil is not doing its job, or if the oil level is
ignored, all the maintenance procedures in the world are not going to
keep the transmission running or assure long transmission life.
Eaton Fuller Transmissions are designed so that the internal parts
operate in an oil bath circulated by the motion of the gears and shafts.
Thus, all parts are amply lubricated if these procedures are closely
followed:
1. Maintain oil level. Inspect regularly.
2. Change oil and filters regularly.
• Use the correct grade and type of oil.
• Buy oil from a reputable dealer.
Additives and friction modifiers are not recommended for use in Eaton
Fuller Transmissions.
20053-7/93
1. Maintain Proper Oil Level
Different Views of the Oil Dipstick
Make sure oil is within dipstick marks for the corresponding oil temperature. Oil
should be checked at idle speed in the neutral position using the corresponding
temperature band. Cold checks can be performed when the oil temperature is 60–
120°F. The oil level should be within the dipstick “cold” band. Additional checks can
be made with the transmission at operating temperature by using the “hot” band on
the opposite side of the dipstick. The “hot” band temperature range is 180–220°F.
6
Transmission appearance may differ, procedure is the same.
2. Draining Oil
Drain transmission while oil is at ambient temperature (65°F ± 20). To
drain oil, remove the main case drain plug and the converter housing oil
pan drain plug. Clean the drain plugs and flush the cooler circuit before
re-installing.
A complete hydraulic circuit flush should be completed
when:
• changing oil types and brands.
• changing oil viscosity grades from or to Arctic oil.
• a catastrophic failure has occurred.
3. Refilling
The operational level should always be within the limit marks on the
dipstick. The exact amount of oil depends on the transmission
inclination and model. Insufficient oil damages the pump and other
components, and can affect the function and reduce the life of the
transmission.
Lubrication
General Information
DO NOT OVERFILL! This causes overheating and loss of fuel economy.
When adding oil, types and brands of oil should not be mixed because of
possible incompatibility.
When changing oil viscosity to Arctic oil or alternate viscosity ranges,
follow the recommended transmission oil flush procedure.
Use clean oil and clean containers when filling transmssion. Containers
that have been used for anti-freeze or water should not be used for
transmission oil.
1. Remove the dipstick and slowly add seven (7) gallons of the
prescribed oil through the filltube.
2. Place the transmission in the neutral position and apply the parking
brakes. Start the engine and let it idle for 5 minutes, (this allows oil
to fill the converter, main case, and cooling system), add oil as
needed to obtain a level at the proper temperature range, (cold
band under 120°F, hot band between 180 and 220°F). Total oil
quantity needed at this time should be approximately 10 gallons;
this varies depending on the cooling system.
3. Increase the engine idle slowly to 1500 RPM for two (2) minutes.
Now recheck the oil level at normal idle speed in neutral, again
adding oil to obtain a level at the proper temperature range (cold
band under 100°F, hot band between 180 and 220°F).
4. Replace the dipstick and tighten securely.
Transmission appearance may differ, procedure is the same.
7
Lubrication
4. Flush Procedure
1. Disconnect the transmission cooler supply line between the
transmission outlet and the oil cooler, (not between the cooler and the
transmission oil pan).
2. With clean dry air from a hose and nozzle (20 psi), use a rubber
stopper or clean rag to seal the air hose to the converter outlet hose.
3. Apply air to the converter outlet for approximately 2 minutes to
backflush oil into the transmission oil pan.
4. Connect the hose between the transmission and cooler. Tighten to
vehicle manufacturers specifications.
5. Install the transmission converter housing oil pan drain plug, tighten to
14-20 Lbf·ft of torque.
6. Install the transmission main case drain plug (rear @ bottom), tighten
to 45-50 Lbf·ft of torque.
7. Remove the transmission dipstick and slowly pour 7 gallons of the
appropriate oil into the transmission.
8. Apply the vehicle parking brakes and place the transmission lever in
neutral. Start the engine and let it idle for 5 minutes. Check the
dipstick periodically while the engine is idling, adding oil as needed to
obtain a level that is in the Cold Band on the dipstick. Total quantity
added at this time should be approximately 10 gallons.
9. With the transmission still in neutral, increase the engine idle speed to
1500 rpm and retain at this speed for 5 minutes. Now recheck the oil
level at normal engine idle speed in neutral, again adding oil as required
on the dipstick. Total oil quantity added at this time should be ≈11
gallons.
Transmission Temperature (°F)
180 to 220 Oil level between the add-
hot and full-hot marks.
Below 120 Oil level at the cold fill
mark.
8
Transmission appearance may differ, procedure is the same.
5. Maintenance Interval Chart
Lubrication Change and Inspection
HIGH WAY USE
First 1,000 to 1,500 miles Change transmission oil, filter,
and strainer on new units.
Every 2,500 miles Inspect lubrication level.
Check for leaks.
Every 50,000 miles or 1 year Change transmission lubricant and filter.
Check the strainer for dirt.
OFF-HIGHWAY USE
First 30 hours Change transmission oil, filter,
and strainer on new units.
Every 40 hours Inspect lubrication level.
Check for leaks.
Lubrication
General Information
Every 500 hours Change transmission lubricant and filter
where severe dirt conditions exist.
Every 1,000 hours Change transmission lubricant and filter.
(Normal off-highway use.)
6. Recommended Lubricant Chart
Recommended Lubricant
Type Grade Fahrenheit (Celsius)
(SAE) Ambient
Temperature
C4 Type 10W Above 0°F (-32°C)
Dexron II Above 0°F (-32°C)
MIL-L-2104E
C4Type 10W Above 0°F (-32°C)
Dexron
II Above 0°F (-32°C)
MIL-L-2104E
Arctic Oil 0W-20 Below 0
0°F
-17.78
°C
SAE 10W or Dexron II
°F (-32°C)
-25
°F
-31.67
°C
-50 -40 -30 -20 -10 0 10 20 30 40 50 Above
SAE 0W-20
(Degrees F)
50
Minimum Temperature For Operating Transmission
Transmission appearance may differ, procedure is the same.
9
Lubrication
7. Buy from a reputable dealer
For a complete list of approved and reputable dealers,
write to:
Eaton Corporation
Truck Component Marketing Headquarters
P.O. Box 4013
Kalamazoo, MI 49003
Transmission Operating Angles
If the transmission operating angle is more than 12
degrees, improper lubrication can occur. A special kit
may be required for sustained operation on grades
greater than 12 degrees.
10
Transmission appearance may differ, procedure is the same.
Operating Temperatures with Oil Coolers
An external oil cooler is required on the automatic
transmission in order to maintain proper operating
temperatures*. Transmission oil temperature is sensed
from the torque converter outlet port before the oil
enters the cooler.
Normal operating temperature, when sensed from the
torque converter outlet port, should be below 250°F;
however, intermittent operating temperatures to 300°F
do not harm the transmission.
On vehicles equipped with two transmission oil
temperature gauges, one gauge (required) senses
torque converter oil as mentioned above, while the
other gauge (optional) reads oil temperature from the
transmission sump. The sump temperature represents
oil that has circulated through the cooler. This
temperature is normally below 225°F; however,
intermittent sump temperatures to 250°F do not harm
the transmission.
Lubrication
General Information
When the average temperature of the transmission oil
exceeds the temperature limits as stated above, more
frequent oil changes may be needed.
The following conditions in any combination can cause
the recommended transmission oil temperatures to be
exceeded: (1) operating the transmission in a "stall"
condition; i.e., extended operation while in gear with the
vehicle stopped or slowly moving, (2) high density of
starts and stops at slow operating speed, (3) minimal
cooler capacity and/or restricted air flow to the
transmission oil cooler, (4) exhaust system too close to
the transmission, (5) improper oil level/incorrect oil.
*Engineering approval is required for cooler sizing on
all new CEEMAT
TM
applications.
Transmission appearance may differ, procedure is the same.
11
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
troublshooting and making repairs.
Torque Converter Mode: LO Range
1. Power (torque) from the vehicle's engine is
transferred to the torque converter's splined
cover.
2. The impeller spins directing oil through the
torque converter.
3. The oil flow hits the turbine causing the turbine to
rotate. The power is related to the speed
difference between the impeller and the turbine.
4. The turbine is connected to the interrupt clutch
housing. The interrupt clutch inner hub is
splined directly to the transmission input shaft.
5. When the interrupt clutch is activated, the
housing and the innner hub are connected to
1
3
2
complete the mechanical link and transfers power
to the input shaft.
4
5
12
5004A-8/92
Transmission appearance may differ, procedure is the same.
6. Input shaft splines engage the internal splines in
the main drive gear hub.
7. Torque is split between the two countershaft drive
gears.
8. Torque is delivered along both countershafts to
mating countershaft gear of the "engaged"
mainshaft gear (1st gear in this example).
9. The internal clutching teeth in the engaged
mainshaft gear hub transfers torque to the
mainshaft through the sliding clutch.
10. The mainshaft transfers torque directly to the
auxiliary drive gear.
11. The auxiliary drive gear splits torque between the
two auxiliary countershaft drive gears.
Power Flow
General Information
12. Torque is delivered along both countershafts to
the "engaged" LO range gear on the range
mainshaft or output shaft.
13. Torque is transferred to the output shaft through a
sliding clutch.
14. Torque is delivered to the driveline as LO range
1st.
7
6
8
9
10
13
14
5004A-8/92
Transmission appearance may differ, procedure is the same.
11
12
13
Power Flow
Torque Converter Mode: Lockup Mode
1. Power (torque) from the vehicle's engine is
transferred to the torque converter's splined
cover.
2. The splined cover is connected to the lockup
clutch.
3. The lockup clutch is splined directly to the
interrupt clutch outer hub. When the lockup
clutch is activated, the interrupt clutch is driven
directly from the engine.
4. The interrupt clutch inner hub is splined directly
to the transmission input shaft.
5. When the interrupt clutch is activated, the torque
is transmitted directly from the engine to the
input shaft from the lockup clutch. The losses
from the slippage in the torque converter are
eliminated in this manner.
1
2
3
4
5
5004B-8/92
14
Transmission appearance may differ, procedure is the same.
Auxiliary Section: HI Range
6. Input shaft splines engage the internal splines in
the main drive gear hub.
7. Torque is split between the two countershaft drive
gears.
8. Torque is delivered along both countershafts to
mating countershaft gear of the "engaged"
mainshaft gear.
9. The internal clutching teeth in the engaged
mainshaft gear hub transfers torque to the
mainshaft through the sliding clutch.
10. The mainshaft transfers torque directly to the
auxiliary drive gear.
Power Flow
General Information
11. The auxiliary drive gear transfers torque directly to
the range mainshaft or output shaft through the
"engaged" sliding clutch.
12. Torque is delivered through the output shaft to the
driveline as HI range 6th.
6
7
8
9
10
11
12
5004C-8/92
Transmission appearance may differ, procedure is the same.
15
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 simple 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 gear teeth.
1
1
2
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.
16
Transmission appearance may differ, procedure is the same.
Timing Procedures (cont)
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
Timing
2
1
General Information
Standard Auxiliary Section
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".
Transmission appearance may differ, procedure is the same.
17
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