Eaton Transmission RTO-13109B-AT Service Manual

Page 1

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

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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

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Page 4

Warnings & Precautions

General Information

Model/Assembly Reference

External Parts

Shift Bar Housing

Front Section

Auxiliary Section

Options

Page 5

Page 6

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

Page 7

Page 8

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.

Page 9

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.

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.

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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

Page 11

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.

Reverse Idler Gear Assemblies

1. Check for excessive wear from action of roller bearings.

continued on next page

Page 12

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.

Page 13

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.

IMPORTANT: See the appropriate Illustrated Parts Lists (specified by

model series) to ensure that proper parts are used during assemby of the transmission.

Page 14

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.

Page 15

Page 16

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.

⁄4" air fittings that are not coated

⁄4" I.D. air hoses, install the fixed nut end first.

cylinder HI range supply port.

supply port.

cylinder LO range supply port.

supply port.

Air System

H/45-4

External Parts

H/45-3

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.

H/45-1

Page 17

How to Use This Manual

Synchronizer

Assembly

Rear Bearing

Cover

DS/AS-3

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

Output

Shaft

Assembly

Countershaft

Assemblies

Range

Cylinder

Assembly

Auxiliary

Section

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.

Transmission appearance may differ, procedure is the same.

Page 18

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.

Page 19

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.

Transmission appearance may differ, procedure is the same.

Page 20

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.

Page 21

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.

Transmission appearance may differ, procedure is the same.

Page 22

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)

Minimum Temperature For Operating Transmission

Transmission appearance may differ, procedure is the same.

Page 23

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.

Transmission appearance may differ, procedure is the same.

Page 24

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

applications.

Transmission appearance may differ, procedure is the same.

Page 25

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

complete the mechanical link and transfers power to the input shaft.

5004A-8/92

Transmission appearance may differ, procedure is the same.

Page 26

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.

5004A-8/92

Transmission appearance may differ, procedure is the same.

Page 27

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.

5004B-8/92

Transmission appearance may differ, procedure is the same.

Page 28

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.

5004C-8/92

Transmission appearance may differ, procedure is the same.

Page 29

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. 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.

Transmission appearance may differ, procedure is the same.

Page 30

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

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.

Page 31

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:

Eaton Corporation

Transmission Division

Technical Service Dept. P.O. Box 4013 Kalamazoo, Michigan 49003

Transmission appearance may differ, procedure is the same.

Page 32

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.

Preventive Maintenance

General Information

Transmission appearance may differ, procedure is the same.

Page 33

Preventive Maintenance

Checks Before Transmission Removal

1 Air System and Connections (not shown)

Annually replace the filter/regulator element. If excessive contamination is present, service vehicle air/dryer system.

2 Lubricant and Filter

Change at specified service intervals. Use only the types and grades as recommended.

See LUBRICANTS. Check lubrication lines and cooling circuit for

leaks.

3 Dipstick (not shown)

Remove dipstick and check level of lubricant at specificed intervals. Check oil in neutral at engine idle.

4 Drain Plugs

Tighten the drain plugs securely. Tighten the main case drain plug to 45-50 Lbf·ft of torque. Tighten oil pan plugs to 14-20 Lbf·ft of torque.

5 Capscrews and Gaskets

Check all capscrews, especially those on PTO covers and rear bearing covers for looseness which would cause oil leakage. Use the torque recommendations identified in this service manual.

Check PTO opening, oil sump/strainer, hose fittings, and rear bearing covers for oil leakage due to faulty gaskets.

Transmission appearance may differ, procedure is the same.

Page 34

Preventive Maintenance

Checks with Drive Line Dropped

6 Universal Joint Companion Flange or Yoke Nut

Check for tightness. Tighten to recommended torque.

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 sur-

face finish.

8 Splines on Output Shaft

Check for wear from movement and chucking action of the universal joint companion flange or yoke.

7 Output Shaft

Pry upward against output shaft to check radial clearance in mainshaft rear bearing.

9 Mainshaft Rear Bearing Cover

Check oil seal for wear.

General Information

Transmission appearance may differ, procedure is the same.

Page 35

Page 36

Section 3: Model/Assembly Reference

CEEMAT-AT 2 CEEMAT-ATR 4 CEEMAT-ATS 6 CEEMAT-ATE 8

Model/Assembly Reference

Page 37

CEEMAT-AT

Remove/ Install/ Disassemble Assemble

(page numbers)

External Parts

Air System

Air Supply Hoses for the Power Synchronizer 4 5 Air Supply Hose for LO and HI Range 8 9 Air Filter/Regulator 10 11 Slave Valve 12 13

Lube System

Lube Supply Hose for the Power Synchronizer 14 15 Oil Pan/Strainer 18 19 Oil Filter 20 21

Synchronizer System

Power Synchronizer 22 23

Shift Bar Housing

Shift Bar Housing Cover 24 25 Autoshift Harness 26 27 Autoshift Assembly 28 29 Shift Bar Housing 30 31

Torque Converter

Torque Converter 32 33 Hydraulic Valve 34 35 Dip Stick 36 37 Torque Converter Housing 38 39 Oil Pump 40 41 Filter Bypass Valve 42 43

HI Pressure Relief Valve 42 43 Output Yoke/Companion Flange 44 45 Auxiliary Section

Auxiliary Section 46 47

Rear Bearing Cover Assembly 48 49

Page 38

Remove/ Install/ Disassemble Assemble

(page numbers)

Shift Bar Housing

Shift Bar Housing 4 6

CEEMAT-AT

Front Section

Auxiliary Drive Gear Assembly 4, 6 5, 7 Reverse Idler Gear Assembly 8 9 Countershaft Assembly

Countershaft Bearings 10 11

Countershaft Assembly 12, 14 13, 15 Mainshaft Assembly (may have 3 grooves) 16, 18 17, 19 Input Shaft Assembly 22 23

Auxiliary Section

Range Cylinder Assembly

Range Cylinder Assembly 4 5

Synchronizer Assembly 6 7 Countershaft Assembly 8 9 Output Shaft Assembly/Rear Bearing 12 13

Model/Assembly Reference

Page 39

CEEMAT-ATE

Remove/ Install/ Disassemble Assemble

(page numbers)

External Parts

Air System

Air Supply Hoses for theInertia Brake 6 7 Air Supply Hose for LO and HI Range 8 9 Air Filter/Regulator 10 11 Slave Valve 12 13

Lube System

Lube Supply Hose for the Inertia Brake 16 17 Oil Pan/Strainer 18 19 Oil Filter 20 21

Synchronizer System

Inertia Brake 22 23

Shift Bar Housing

Shift Bar Housing Cover 24 25 Autoshift Harness 26 27 Autoshift Assembly 28 29 Shift Bar Housing 30 31

Torque Converter

Torque Converter 32 33 Hydraulic Valve 34 35 Dip Stick 36 37 Torque Converter Housing 38 39 Oil Pump 40 41 Filter Bypass Valve 42 43

HI Pressure Relief Valve 42 43 Output Yoke/Companion Flange 44 45 Auxiliary Section

Auxiliary Section 46 47

Rear Bearing Cover Assembly 48 49

Page 40

Remove/ Install/ Disassemble Assemble

(page numbers)

Shift Bar Housing

Shift Bar Housing 4 6

CEEMAT-ATE

Front Section

Auxiliary Drive Gear Assembly 4, 6 5, 7 Reverse Idler Gear Assembly 8 9 Countershaft Assembly

Countershaft Bearings 10 11

Countershaft Assembly 12, 14 13, 15 Mainshaft Assembly (may have 3 grooves) 16, 18 17, 19 Input Shaft Assembly 22 23

Auxiliary Section

Range Cylinder Assembly

Range Cylinder Assembly 4 5

Synchronizer Assembly 6 7 Countershaft Assembly 8 9 Output Shaft Assembly/Rear Bearing 12 13

Model/Assembly Reference

Page 41

Page 42

Section 4: External Parts

Air System

How to Remove the Air Supply Hoses for the Power Synchronizer 4 How to Install the Air Supply Hoses for the Power Synchronizer 5 How to Remove the Air Supply Hose for the Inertia Brake 6 How to Install the Air Supply Hoses for the Inertia Brake 7 How to Remove the Air Supply Hoses for LO and HI Range 8 How to Install the Air Supply Hoses for LO and HI Range 9 How to Remove the Air Filter/Regulator 10 How to Install the Air Filter/Regulator 11 How to Remove a Slave Valve 12 How to Install a Slave Valve 13

Lube System

How to Remove the Lube Supply Hose for the Power Synchronizer 14 How to Install the Lube Supply Hose for the Power Synchronizer 15 How to Remove the Lube Supply Hose for the Inertia Brake 16 How to Install the Lube Supply Hoses for the Inertia Brake 17 How to Remove the Oil Tube and Oil Pan/Strainer 18 How to Install the Oil Tube and Oil Pan/Strainer 19 How to Remove the Oil Filter 20 How to Install the Oil Filter 21

External Parts

Synchronizer Systems

How to Remove the Power Synchronizer 22 How to Install the Power Synchronizer 23 How to Remove the Inertia Brake 22 How to Install the Inertia Brake 23

Transmission appearance may differ, procedure is the same.

Page 43

Shift Bar Housing

How to Remove the Shift Bar Housing Cover 24 How to Install the Shift Bar Housing Cover 25 How to Remove the Autoshift Harness 26 How to Install the Autoshift Harness 27 How to Remove the Autoshift Assembly 28 How to Install the Autoshift Assembly 29 How to Remove the Shift Bar Housing 30 How to Install the Shift Bar Housing 31

Torque Converter

How to Remove the Torque Converter 32 How to Install the Torque Converter 33 How to Remove the Hydraulic Valve 34 How to Install the Hydraulic Valve 35 How to Remove the Dip Stick 36 How to Install the Dip Stick 37 How to Remove the Torque Converter Housing 38 How to Install the Torque Converter Housing 39 How to Remove the Oil Pump 40 How to Install the Oil Pump 41 How to Remove the Filter Bypass Valve 42 How to Install the Filter Bypass Valve 43 How to Remove the HI Pressure Relief Valve 42 How to Install the HI Pressure Relief Valve 43

Output Yoke/Companion Flange

How to Remove the Output Yoke/Companion Flange 44 How to Install the Output Yoke/Companion Flange 45

Auxiliary Section

How to Remove the Auxiliary Section 46 How to Install the Auxiliary Section 47 How to Remove the Rear Bearing Cover Assembly 48 How to Install the Rear Bearing Cover Assembly 49

Transmission appearance may differ, procedure is the same.

Page 44

Page 45

Air System

How to Remove the Air Supply Hoses for the Power Synchronizer

Special Instructions

Before removing the air hoses, label or record their location.

Special Tools

H/49-1

Typical service mechanic tools

To Remove

1. Remove the capscrew holding the air hose clamp

to the auxiliary housing.

2. Disconnect the air hose at the shift bar housing

power synchronizer disc port (labeled Port A).

3. Disconnect the air supply hose connected to the

power synchronizer disc port.

4. Disconnect the air hose at the shift bar housing

port air supply hose (labeled Port B).

5. Disconnect the air supply hose connected to the

power synchronizer band port.

H/45-5

6. Inspect the air supply fittings on the shift bar

housing and the power synchronizer, remove if damaged.

H/49-2

H/45-8

H/45-9

Transmission appearance may differ, procedure is the same.

Page 46

How to Install the Air Supply Hoses for the Power Synchronizer

Special Instructions

Make sure air hoses are not damaged.

Air System

Install the air hoses at their proper locations. 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.

Special Tools

Typical service mechanic tools

To Install

1. If previously removed, install new air fittings.

Tighten to 7-10 Lbf·ft of torque.

2. Connect one air supply hose end to the power

synchronizer band port. Tighten to 7-10 Lbf·ft of torque.

3. Connect the other end to the shift bar housing

cover band port (labeled Port B). Tighten to 7-10 Lbf·ft of torque.

H/45-9

External Parts

H/45-8

4. Connect one air supply hose end to the power

synchronizer disc port. Tighten to 7-10 Lbf·ft of torque.

5. Connect the other end to the shift bar housing

cover supply port (labeled Port A). Tighten to 710 Lbf·ft of torque.

6. Position the two (2) air supply hoses inside the

retaining clamp.

7. Position the clamp on the auxiliary housing by the

range cylinder and install the retaining capscrew. Tighten to 35-45 Lbf·ft of torque.

Final Check

Make sure air lines are not kinked.

H/49-2

Transmission appearance may differ, procedure is the same.

H/45-5 H/49-1

Page 47

Air System

How to Remove the Air Supply Hose for the Inertia Brake

Special Instructions

Before removing the air hose, label or record its location.

Special Tools

Typical service mechanic tools

To Remove

1. If necessary, remove the capscrew holding the air

H/51-3

hose to the auxiliary housing.

2. Disconnect the air hose at the shift bar housing

inertia brake port (labeled Port A).

3. Disconnect the air supply hose connected to the

inertia brake air port.

4. Inspect the air supply fittings on the shift bar

housing and the inertia brake, remove if damaged.

H/51-4

Transmission appearance may differ, procedure is the same.

Page 48

How to Install the Air Supply Hoses for the Inertia Brake

Special Instructions

Make sure air hose is not damaged. Install the air hose at its proper location. 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.

Air System

To install the hose, the air filter/regulator must be in position.

Special Tools

Typical service mechanic tools

To Install

1. If previously removed, install new air fittings.

Tighten to 7-10 Lbf·ft of torque.

2. The pipe plug in Port B is tighten to 7-10 Lbf·ft of

torque.

3. Connect the air supply hose to the inertia brake

air port. Tighten to 7-10 Lbf·ft of torque.

4. Connect the other end to the shift bar houisng

inertia brake port (labeled Port A). Tighten to 7-10 Lbf·ft of torque.

5. When necessary, position the air supply hose

inside the retaining clamp.

H/51-4

External Parts

H/51-3

6. Position the clamp on the 6 bolt PTO cover and

install the retaining capscrew. Tighten to 35-45 Lbf·ft of torque.

Final Check

Make sure air lines are not kinked.

Transmission appearance may differ, procedure is the same.

Page 49

Air System

How to Remove the Air Supply Hoses for LO and HI Range

Special Instructions

Before removing the air hoses, label or record their location.

Special Tools

Typical service mechanic tools

To Remove

1. Disconnect the slave valve LO range supply port

H/45-1

air hose.

2. Disconnect the air supply hose connected to the

range cylinder LO range supply port.

3. Disconnect the slave valve HI range supply port

air hose.

4. Disconnect the air supply hose connected to the

range cylinder HI range supply port.

5. Inspect the air supply fittings on the shift bar

housing and the range cylinder, remove if damaged.

H/45-2

H/45-3

H/45-4

Transmission appearance may differ, procedure is the same.

Page 50

How to Install the Air Supply Hoses for LO and HI Range

Special Instructions

Air System

Make sure air hoses are not damaged. Install the air hoses at their proper locations. 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 hoses, the air filter/regulator must be in

position.

Special Tools

Typical service mechanic tools

To Install

1. If previously removed, install new air supply

fittings. Tighten to 7-10 Lbf·ft of torque.

2. Connect one air supply hose end to the range

cylinder HI range supply port. Tighten to 7-10 Lbf·ft of torque.

3. Connect the other end to the slave valve HI range

supply port. Tighten to 7-10 Lbf·ft of torque.

H/45-4

External Parts

H/45-3

4. Connect one air supply hose end to the range

cylinder LO range supply port. Tighten to 7-10 Lbf·ft of torque.

5. Connect the other end to the slave valve LO range

supply port.

Final Check

Make sure air lines are not kinked.

Transmission appearance may differ, procedure is the same.

H/45-2

H/45-1

Page 51

Air System

How to Remove the Air Filter/Regulator

Special Instructions

The air filter/regulator has two (2) O-rings located between the filter/regulator and the shift bar housing cover.

Special Tools

Typical service mechanic tools needed

To Remove

H/49-3

1. From the air filter/regulator, remove the two (2)

capscrews.

2. From the shift bar cover, remove the two (2) O-

rings.

3. Inspect the O-rings for cracks or distortion.

4. Inspect the air fittings on the air filter/regulator,

remove if damaged.

H/04-4

Transmission appearance may differ, procedure is the same.

Page 52

How to Install the Air Filter/Regulator

Special Instructions

The air filter/regulator has two (2) O-rings located between the filter/regulator and the shift bar housing.

Use a small amount of grease to hold the O-rings in place, if the shift bar housing is installed on the transmission.

Air System

Special Tools

Typical service mechanic tools needed

To Install

1. If previously removed, install new air supply

fittings. Tighten the larger fitting to 14-20 Lbf·ft of torque and the smaller to 7-10 Lbf·ft of torque.

2. On the shift bar cover, position the two (2) O-

rings.

3. Over the O-rings, position the air filter/regulator.

4. Apply Eaton/Fuller Sealant #71205 or equivalent

to the two (2) retaining capscrews.

5. Install the two (2) retaining capscrews, tighten to

8-12 Lbf·ft of torque.

Final Check

Make sure the capscrews are properly torqued.

H/04-4

4, 5

External Parts

H/49-3

Transmission appearance may differ, procedure is the same.

Page 53

Air System

How to Remove a Slave Valve

Special Instructions

The air lines should be removed.

Special Tools

Typical service mechanic tools needed

To Remove

1. Remove the retaining capscrews.

2. From the shift bar cover, remove the slave valve

H/49-4

and gasket. You may need to use a plastic hammer to remove.

3. Thoroughly clean gasket area. Do not get gasket

material or dirt in the shift bar housing ports or valve ports.

4. If the insert valves have been damaged, remove

the plugs and insert valves.

H/49-5

Range Valve

Transmission appearance may differ, procedure is the same.

Page 54

How to Install a Slave Valve

Special Instructions

Make sure gasket mounting areas are clean.

Air System

Special Tools

Typical service mechanic tools needed

To Install

1. If previously removed, install new insert valves.

Tighten to 20-25 Lbf·ft of torque.

2. Position the corresponding new gasket on the

slave valve mounting surface.

3. Position the slave valve over the gasket.

4. Apply Eaton/Fuller Sealant #71205 or equivalent

to the retaining capscrews.

5. Install the retaining capscrews. Tighten to 8-12

Lbf·ft of torque.

Final Check

Make sure the retaining capscrews are properly torqued.

Range Valve

External Parts

H/49-6

Transmission appearance may differ, procedure is the same.

H/49-5

4, 5

H/49-4

Page 55

Lube System

How to Remove the Lube Supply Hose for the Power Synchronizer

Special Instructions

Before removing the lube hose, label or record its location.

Special Tools

Typical service mechanic tools

To Remove

1. Disconnect the lube hose from the power

H/49-7

synchronizer.

2. To ease in removal, remove the capscrew and

clamp holding the hose to the auxiliary section.

3. Disconnect the lube supply line connected to the

converter housing.

4. Inspect the fitting and connector, remove if

damaged.

5. Inspect the oil restrictor behind the connector,

remove if damaged.

H/43-5

Transmission appearance may differ, procedure is the same.

Page 56

How to Install the Lube Supply Hose for the Power Synchronizer

Special Instructions

Lube System

Make sure lube hose is not damaged. Install the lube hose at its proper location.

Special Tools

Typical service mechanic tools

To Install

1. If previously removed, install a new oil restrictor.

Tighten to 20-30 Lbf·in of torque.

2. If previously removed, install a new connector

and/or fitting. Tighten to 14-20 Lbf·ft of torque.

3. Connect one lube supply hose end to the

converter housing lube port. Tighten to 15-20 Lbf·ft of torque.

4. Connect the other end to the power synchronizer

lube port. Tighten to 15-20 Lbf·ft of torque.

5. Install the capscrew and clamp to hold the hose

to the auxiliary section. Tighten to 35-45 Lbf·ft of torque.

2, 3

H/43-5

External Parts

1, 2

H/49-7

Final Check

Make sure air hoses are not kinked or twisted.

Transmission appearance may differ, procedure is the same.

Page 57

Lube System

How to Remove the Lube Supply Hose for the Inertia Brake

Special Instructions

Before removing the lube hose, label or record its location.

Special Tools

Typical service mechanic tools

To Remove

1. Disconnect the lube supply hose connected to the

H/51-5

inertia brake.

2. Disconnect the lube supply hose at the torque

converter housing lube port.

3. Inspect the fittings, remove if damaged.

4. Inspect the oil restrictor behind the torque

converter fitting, remove if damaged.

H/43-5

Transmission appearance may differ, procedure is the same.

Page 58

How to Install the Lube Supply Hoses for the Inertia Brake

Special Instructions

Lube System

Make sure lube hose is not damaged. Install the lube hose at its proper location.

Special Tools

Typical service mechanic tools

To Install

1. If previously removed, install a new oil retrictor.

Tighten to 20-30 Lbf·in of torque.

2. If previously removed, install new connectors.

Tighten to 15-20 Lbf·ft of torque.

3. Connect one lube supply hose end to the

converter housing lube port.

4. Connect the other lube supply hose end to the

inertia brake.

Final Check

Make sure air hoses are not kinked.

1, 2

H/43-5

External Parts

H/51-5

Transmission appearance may differ, procedure is the same.

Page 59

Lube System

How to Remove the Oil Tube and Oil Pan/Strainer

Special Instructions

Special Tools

H/49-8

H/50-1

Typical service mechanic tools

⁄16" - 12 Point socket

To Remove

H/49-9

1. Disconnect the return tube from the oil pan and

transmission.

2. From the oil pan, remove the retaining capscrews.

3. Remove the oil pan.

4. Remove the retaining capscrews, oil transfer tube,

and oil pan gasket.

5. Inspect the oil return adapter tube, remove if

damaged.

6. Inspect the dip stick adaptor fitting, remove if

damaged.

H/50-2

7. Inspect the cooler back pressure valve, if

damaged replace.

8. Clean the oil pan magnet.

9. Clean and inspect the strainer. Replace, if

damaged.

10. Inspect the return tube fitting on the transmission,

remove if damaged.

H/50-4

H/50-3

Transmission appearance may differ, procedure is the same.

Page 60

How to Install the Oil Tube and Oil Pan/Strainer

Special Instructions

If the magnet needs to be replaced, use adhesive #71210 or equivalent and cover the entire mating surface.

Special Tools

Lube System

Typical service mechanic tools

To Install

1. If previously removed, install the strainer

capscrews. Tighten to 5-7 Lbf·ft of torque.

2. Position a new oil pan gasket and the oil transfer

tube.

3. Install the two (2) retaining capscrews. Tighten

the screws to 14-20 Lbf·ft of torque.

4. Position the oil pan.

5. Install the retaining capscrews. Tighten the

screws to 14-20 Lbf·ft of torque.

6. If previously removed, install the dip stick adaptor

O-ring and fitting. Tighten to 34-48 Lbf·ft of torque.

7. If previously removed, install the oil return

adaptor O-ring and adaptor. Tighten to 34-48 Lbf·ft of torque.

8. If previously removed, install a new return tube

fitting on the transmission. Tighten to 60-75 Lbf·ft of torque.

H/50-2

H/50-1

External Parts

9. Install the return tube on the sump pan. Tighten

to 60-75 Lbf·ft of torque.

Final Check

Make sure all connector are properly torqued.

Transmission appearance may differ, procedure is the same.

H/49-9

8, 9

H/49-8

Page 61

Lube System

How to Remove the Oil Filter

Special Instructions

Special Tools

Typical service mechanic tools

To Remove

1. Remove the three (3) retaining capscrews.

2. Remove the oil filter housing and O-ring seal.

H/50-5

3. Remove the oil filter by pulling it straight off.

4. Inspect the oil filter nipple, remove if damaged.

H/50-6

H/50-7

H/50-8

Transmission appearance may differ, procedure is the same.

Page 62

How to Install the Oil Filter

Special Instructions

Depending on the orientation (vertical or horizontal), grease may be needed to hold the seal ring on the filter housing.

Special Tools

Typical service mechanic tools

To Install

Lube System

1. If removed, apply hydraulic sealant and replace

the oil filter nipple. Tighten to 34-48 Lbf·ft of torque.

2. Install the oil filter on the oil filter nipple.

3. Position the O-ring seal on the oil filter housing.

4. Position the oil filter housing over the oil filter.

5. Install the three (3) capscrews. Tighten to 26-32

Lbf·ft of torque.

Final Check

Make sure the capscrews are properly torqued.

H/50-8

External Parts

H/50-7

Transmission appearance may differ, procedure is the same.

H/50-6

4, 5

H/50-5

Page 63

Synchronizer Systems

How to Remove the Power Synchronizer

Special Instructions

There are different capscrew lengths, note their location.

The hoses need to be disconnected.

Special Tools

Typical service mechanic tools

To Remove

H/28-2

1. From the power synchronizer, remove the

mounting capscrews.

2. Remove the power synchronizer and gasket.

3. Inspect the roll pin in the middle mounting

position.

H/28-3

How to Remove the Inertia Brake

Special Instructions

H/51-6

There are different capscrew lengths, note their location.

The hoses need to be disconnected. The removal/replacement procedure is "typical". Your

inertai brake may be installed in a "6 bolt" or "rotated 6 bolt" PTO configuration. The process for the removal/ replacement is the same. Refer to the Illustrated Parts Lists for further pictures.

Special Tools

Typical service mechanic tools

To Remove

1. From the inertia brake, remove the mounting

capscrews.

2. Remove the inertia brake and gasket.

3. Inspect the fittings, remove if damaged.

H/51-7

Transmission appearance may differ, procedure is the same.

Page 64

Special Instructions

Synchronizer Systems

How to Install the Power Synchronizer

There are different capscrew lengths, make sure they are in their proper location.

Special Tools

Typical service mechanic tools

To Install

1. If previously removed, install a new roll pin in the

middle mounting position.

2. Position the power synchronizer and gasket.

3. Install the power synchronizer mounting

capscrews. Tighten to 35-45 Lbf·ft of torque. The middle capscrew uses a washer.

Final Check

Make sure the capscrews are properly torqued.

H/28-3

External Parts

H/28-2

How to Install the Inertia Brake

Special Instructions

There are different capscrew lengths, note their location.

Special Tools

Typical service mechanic tools

To Remove

1. If previously removed, install new fittings.

Tighten the 1/8" elbow to 7-10 Lbf·ft of torque. Tighten the 90° elbow to 14-20 Lbf·ft of torque.

2. Position the inertia brake and gasket with

washers.

3. Install the inertia brake mounting capscrews.

Tighten to 35-45 Lbf·ft of torque.

Final Check

Make sure the capscrews are properly torqued.

Transmission appearance may differ, procedure is the same.

H/51-7

H/51-6

Page 65

Shift Bar Housing

How to Remove the Shift Bar Housing Cover

Special Instructions

Before removing the shift bar housing cover, the air hoses must be disconnected.

Removal of the air filter/regulator and the slave valve can be done before removing the shift bar cover.

There are different capscrew lengths, note their location.

The shift bar housing cover is a non-serviceable assembly.

H/42-8

CAUTION: Do not touch the electronic components.

Cover and set aside in a clean area.

Special Tools

Typical service mechanic tools needed

To Remove

1. Disconnect the torque converter wire harness.

2. Remove the shift bar housing cover capscrews

and shift cable bracket.

H/46-7

3. Lift the shift bar housing cover up vertically past

the alignment pins.

4. Carefully tip the cover on its side.

5. Disconnect the internal autoshift harness

connector.

6. Remove the shift bar housing cover.

7. Remove the shift bar housing cover gasket.

8. On the shift bar housing back side, inspect the

breather, bushing, and pipe plug, remove if

H/51-1

damaged.

Transmission appearance may differ, procedure is the same.

Page 66

How to Install the Shift Bar Housing Cover

Shift Bar Housing

Special Instructions

Be careful when lowering the shift bar housing cover that the harness wires do not get pinched between the cover and housing or autoshifter.

There are different capscrew lengths, install in the correct location.

Special Tools

Typical service mechanic tools needed

To Install

1. Position a new gasket on the shift bar housing.

2. Carefully set the shift bar cover on its side on the

shift bar housing top.

3. Connect the internal autoshifter harness

connector.

4. Use the alignment pins and set the shift bar

housing cover in place.

H/51-1

External Parts

5, 6

5. Apply Eaton/Fuller Sealant #71205 or equivalent

to the retaining capscrews or use dyna sealsTM.

6. Install the retaining capscrews with washers.

Tighten to 23-30 Lbf·ft of torque.

7. Install the shift cable bracket with washers.

Tighten to 23-30 Lbf·ft of torque.

8. If previously remove, install the shift cable lever

nut. Tighten to 23-30 Lbf·ft of torque.

9. Connect the converter wire harness to the shift

bar housing cover.

10. If previously removed, install a new bushing and

breather. Tighten to 5-7 Lbf·ft of torque.

11. If previously removed, install a new pipe plug.

Tighten to 14-20 Lbf·ft of torque.

Final Check

Make sure the converter wire harness is connected.

H/46-7

H/42-8

Transmission appearance may differ, procedure is the same.

Page 67

Shift Bar Housing

How to Remove the Autoshift Harness

Special Instructions

Make sure all labels are in the right place. Note locations and positions of terminals and

connectors. Use the removal tool included on the harness to

disconnect the in-line connectors.

Special Tools

Typical service mechanic tools needed

H/46-9

H/47-1

To Remove

1. Disconnect the 2 pin in-line connector from the

input shaft speed pick-up using the removal tool located on the autoshifter harness. Slide the tool along the wire into the insert cavity until it

engages the contact and resistance is felt. The contact retaining clip will be in the unlocked position.

2. Pull the contact wire assembly out of the

connector.

H/47-2

H/51-2

3. Repeat steps 1 and 2 to disconnect the output

shaft speed pick-up.

4. On the shift bar housing, loosen the four (4) ball

switch screws on the range ball switches and remove the autoshift harness terminals.

5. Remove the four (4) hex head screws retaining

the autoshifter and remove the autoshifter, gasket and O-ring.

6. Remove the four (4) nuts from the four (4)

H/47-6

H/09-1

autoshift solenoids.

7. Remove the brackets, retainers, and coils.

8. Loosen the six (6) screws that hold the harness

on the three (3) autoshifter ball switches and remove the harness terminals.

H/09-2

H/09-3

Transmission appearance may differ, procedure is the same.

Page 68

How to Install the Autoshift Harness

Special Instructions

Make sure all labels are in the right place. Note locations and positions of terminals and

connectors. When connecting the in-line connectors, make sure the

wire locks into position. To check, pull gently on the wires; if the wires resist they are locked.

Special Tools

Typical service mechanic tools needed

To Install

1. Install the three harness (3) ball switch terminals

(labeled S1, S2, and S3) mounted on the autoshift housing end. Tighten to 14-20 Lbf·ft of torque.

2. Install the four (4) brackets (with square end out)

and coils.

3. Install the four (4) nuts on the solenoids. Tighten to

15-20 Lb

4. Install autoshifter gasket and O-ring.

5. Install the autoshifter with four (4) hex head bolts

with washers. Tighten to 20-30 Lb

6. Position the autoshift harness S4 lead ends under

the washers in the HI range ball switch.

·in of torque.

·ft of torque.

Shift Bar Housing

H/09-3

H/09-1

H/09-2

External Parts

H/47-6

7. Tighten the screws to 15-20 Lb

·in of torque.

8. Position the autoshift harness S5 lead ends under

the washers in the LO range ball switch.

9. Tighten the screws to 15-20 Lb

·in of torque.

10. Connect the 2 pin in-line connector for the input

shaft speed pick-up by inserting the contact wire inside the insert cavity. Check that they are locked.

11. Connect the 2 pin in-line connector for the output

shaft speed pick-up by inserting the contact wire inside the insert cavity. Check that they are locked.

Final Check

Make sure the autoshift harness is connected exactly like the line drawing shown for "How to Install the Autoshifter Assembly".

Transmission appearance may differ, procedure is the same.

H/47-5

H/48-4

8, 9

6, 7

H/51-2

H/47-2

Page 69

Shift Bar Housing

How to Remove the Autoshift Assembly

KEEP

WIRES

OUT

OF THIS AREA

S 6

S1 S7 P2

S 3

S 4

TIE WRAP ALL WIRES - EXCEPT S2

S 2

S 1

P3S5

Special Instructions

Make sure all labels are in the right place.

S 5

P 4

P 3

Note locations and positions of terminals and connectors.

Use the removal tool included on the harness to disconnect the in-line connectors.

P 2

S 7

P 1

The air hoses, shift bar cover assembly, and autoshift harness connectors must be disconnected.

Line drawing

Special Tools

Typical service mechanic tools needed

To Remove

1. Disconnect the 2 pin in-line connector from the

input shaft speed pick-up using the removal tool. Slide the tool along the wire into the insert cavity until it engages the conact and resistance is felt. The contact retaining clip will be in the unlocked position.

H/46-9

H/47-1

2. Pull the contact wire assembly with tool out of

the connector.

3. Repeat steps 1 and 2 to disconnect the output

shaft speed pick-up.

4. On the shift bar housing, loosen the two switch

screws on the range switches and remove the

autoshift harness lead ends.

5. Remove the four (4) allen head screws and

washers from the autoshift assembly.

6. Remove the autoshift assembly and harness.

H/47-2

H/51-2

7. Remove the air supply O-ring and gasket.

H/47-5

H/47-6

Transmission appearance may differ, procedure is the same.

Page 70

How to Install the Autoshift Assembly

Shift Bar Housing

Special Instructions

Make sure all labels are in the right place. Note locations and positions of terminals and

connectors. When connecting the in-line connectors, make sure the

wire locks into position. To check, pull gently on the wires; if the wires resist they are locked.

Make sure air supply O-ring and gasket are in position.

Special Tools

Typical service mechanic tools needed

To Install

1. Install the autoshifter air supply O-ring and

gasket.

2. Postion the autoshifter assembly, align shift

finger with transmission and harness.

3. Install the autoshifter with the four (4) hex head

bolts with washers. Tighten to 20-30 Lb

·ft of

torque.

S 3

S 4

TIE WRAP ALL WIRES - EXCEPT S2

S 2

S 1

S 7

KEEP WIRES

OUT

OF

THIS

AREA

S 6

S1 S7 P2

H/08-9

P3S5

S 5

P 4

P 3

P 2

P 1

Line drawing

External Parts

H/08-7

4. Position the autoshift harness S4 lead end under

the washers in the HI range ball switch.

5. Tighten the screws to 15-20 Lbf·in of torque.

6. Position the autoshift harness S5 lead end under

the washers in the LO range ball switch.

7. Tighten the screws to 15-20 Lbf·in of torque.

8. Connect the 2 pin in-line connector for the input

shaft speed pick-up by inserting the contact wire inside the insert cavity. Check that they are locked.

9. Connect the 2 pin in-line connector for the output

shaft speed pick-up by inserting the contact wire inside the insert cavity. Check that they are locked.

Final Check

Make sure the autoshift harness is connected exactly like the line drawing shown at the top.

6, 7

H/47-5

4, 5

H/51-2

Transmission appearance may differ, procedure is the same.

H/48-4

H/47-2

Page 71

Shift Bar Housing

How to Remove the Shift Bar Housing

Special Instructions

Before removing the shift bar housing, the shift bar

housing cover and autoshifter must be removed.

Special Tools

Typical service mechanic tools needed

To Remove

1. Inspect the input and output shaft magnetic

H/47-7

speed sensors, remove if damaged or defective.

2. Inspect the ball switches, remove if defective or

damaged.

3. From the shift bar housing, remove the three (3)

Allen head screws.

4. Remove the shift bar housing.

5. Remove the gasket and clean all mounting

surfaces of gasket material.

6. If the three (3) sets of tension springs and balls

H/47-9

from the housing top bores are loose, tilt the assembly and remove them.

H/11-9

H/12-6

Transmission appearance may differ, procedure is the same.

Page 72

How to Install the Shift Bar Housing

Shift Bar Housing

Special Instructions

When installing the shift bar housing, make sure the auxiliary section is in LO range.

Make sure the shift bar housing yokes are in the neutral position.

Special Tools

Typical service mechanic tools needed

To Install

1. Place the shift bars in the neutral position.

2. Place the mainshaft sliding clutches in the neutral

position.

3. Position a new shift bar housing gasket on the

shift bar housing mounting surface.

4. As you install the shift bar housing, make sure the

yokes fit into the corresponding sliding clutch slots.

H/11-9

External Parts

5. Install the three (3) interlock balls in the housing

bores.

6. Install the three (3) tension springs in the housing

bores.

7. Install the three (3) allen head screws in the shift

bar housing rim. Tighten to 35-45 Lbf·ft of torque.

8. If previously removed, install the two (2)

magnetic speed sensors. Tighten to 14-20 Lbf·ft of torque. The output shaft speed pick-up on RTO-11109B-ATE has a gasket.

9. If previously removed, install the range switches

with gaskets. Tighten to 14-20 Lbf·ft of torque.

Final Check

Make sure the capscrews are properly torqued.

H/12-7

H/12-6

Transmission appearance may differ, procedure is the same.

H/47-9 H/47-7

Page 73

Torque Converter

How to Remove the Torque Converter

Special Instructions

Removal of the torque converter is done with the transmission in the vertical position.

Special Tools

Typical service mechanic tools are needed A hoist with a lifting chain

To Remove

H/15-2

FIXED H/15-1

1. Remove the pilot retaining capscrews.

2. Insert two bolts in the tapped holes and tighten

evenly to work the pilot out.

3. Remove and discard the O-ring on the pilot.

4. Remove the two (2) seal rings on the pilot.

5. Remove the two (2)piston rings from the input

shaft.

6. From the input shaft, remove the torque

converter retaining snap ring.

H/21-7

H/21-8

7. Mark the location of the input shaft lube slots on

the input shaft end.

pilot holes directly across from each other. Lift the torque converter straight up.

9. Remove the seal ring from the torque converter

stator support.

8. Install two (2) lifting eyes in the torque converter

H/15-6

H/51-8

H/15-9

H/52-1

Transmission appearance may differ, procedure is the same.

Page 74

How to Install the Torque Converter

Special Instructions

Installation of the torque converter is done with the transmission in the horizontal position.

When installing the torque converter pilot, do not damage the seal rings, O-ring, or input shaft seal rings.

Special Tools

Torque Converter

Typical service mechanic tools are needed.

To Install

1. Prepare the stator support seal for installation.

Cross seal ends, be careful not to crease seal. Seal ends should touch when relaxed.

2. Apply thin coat of lubriplate to seal ring and install

on stator support.

3. Install two (2) lifting eyes in the torque converter

pilot holes.

4. Align the marked input shaft lube slots, slowly set

the torque converter down the input shaft until the snap ring groove is visible. You may need to wiggle the converter gently.

5. On the input shaft install the torque converter

retaining snap ring in the snap ring groove.

6. Apply a thin coat of lubriplate to the input shaft

piston rings and install on the input shaft. Ring ends need to be interlocked. Ring ends need to be interlocked.

H/51-9

H/15-9

H/52-1

External Parts

H/51-8

7. Prepare the pilot seal rings for installation. Cross

seal ends, be careful not to crease seal. Seal ends should touch when relaxed. Apply thin coat of lubriplate to seal rings and install on pilot.

8. To install a new O-ring, apply thin coat of lubriplate

and place in the O-ring groove.

9. Align torque converter pilot with bolt holes and

gently tap with hammer to seat. Note: You can only use pilot O-ring once. If pilot is

misaligned, install new O-ring.

10. Install the retaining capscrews, tighten to 23-30

·ft of torque.

Final Check

Make sure the retaining capscrews are properly torqued.

Transmission appearance may differ, procedure is the same.

H/15-6

H/21-8

H/21-7

H/15-1

Page 75

Torque Converter

How to Remove the Hydraulic Valve

Special Instructions

H/22-1

Removal of the hydraulic valve can be vertically or horizontally.

Special Tools

Typical service mechanic tools are needed

To Remove

1. Loosen the dip stick tube nut and remove the dip

stick tube.

2. Remove the two (2) retaining nuts from the

magnetic coils.

3. Remove the two (2) magnetic coils from the

hydraulic valve. Check for distortion or cracks, if damaged, replace.

4. Remove the hydraulic valve mounting capscrews

and socket head screws.

5. Remove the hydraulic valve, mounting plate, and

gaskets.

H/22-2

H/22-3

H/22-4

Transmission appearance may differ, procedure is the same.

Page 76

How to Install the Hydraulic Valve

Special Instructions

Installation of the hydraulic valve can be vertically or horizontally.

Liberally apply Eaton Lubricant #71230 or equivalent to the hydraulic valve stems where the magnetic coils sit.

Special Tools

Typical service mechanic tools are needed.

Torque Converter

To Install

1. Install the hydraulic valve gaskets, mounting

plate, and hydraulic valve. Gaskets marked "housing" and "valve" must be installed in their respective locations.

2. Install the hydraulic valve mounting capscrews

and socket headscrews. Tighten to 26-32 Lbf·ft of torque.

3. Install the two (2) magnetic coils on the hydraulic

valve stems, wires towards the front.

4. Install the two (2) retaining nuts on the magnetic

coils. Tighten to 30 Lbf·in of torque.

5. Install the dip stick tube and tighten the dip stick

tube nut. Tighten to 35-45 Lbf·ft of torque.

Final Check

Make sure the capscrews and headscrews are properly torqued.

H/22-4

H/22-3

External Parts

Transmission appearance may differ, procedure is the same.

H/22-2

H/22-1

Page 77

Torque Converter

How to Remove the Dip Stick

Special Instructions

H/21-9

Removal of the dip stick can be done in the vertical or horizontal position.

Special Tools

Typical service mechanic tools are needed

To Remove

1. Loosen the dip stick tube nut and remove the dip

stick tube.

2. Inspect the dip stick connector, remove if

damaged.

H/50-4

Transmission appearance may differ, procedure is the same.

Page 78

Special Instructions

Torque Converter

How to Install the Dip Stick

Installation of the dip stick can be done in the vertical or horizontal position.

Special Tools

Typical service mechanic tools are needed.

To Install

1. If previously removed, install the dip stick

connector O-ring and connector. Tighten to 34-48 Lbf·ft of torque.

2. Install the dip stick tube and tighten the dip stick

tube nut. Tighten to 35-45 Lbf·ft of torque.

Final Check

Make sure the parts are properly torqued.

H/50-4

External Parts

H/21-9

Transmission appearance may differ, procedure is the same.

Page 79

Torque Converter

How to Remove the Torque Converter Housing

Special Instructions

the vertical position. Disconnect the torque converter and harness from

Removal of the torque converter housing is done in

ECU. Disconnect the hydraulic valve. Remove the synchronizer system lube line, the sump

H/52-1

H/25-7

return tube, and the dipstick.

Special Tools

Typical service mechanic tools are needed

To Remove

1. Remove the stator support seal ring.

2. From the stator support, remove the retaining

capscrews.

3. Remove the stator support and gasket.

4. Remove the torque converter housing retaining

capscrews with washers.

H/26-3

H/26-4

5. Remove the torque converter housing nuts with

washers.

6. Remove the torque converter housing and gasket

from the transmission case.

7. Inspect the synchronizer system lube elbow

adaptor, remove if damaged.

8. Inspect the torque converter housing seal,

remove if damaged.

9. Remove the magnetic sensor. Inspect the O-ring,

H/26-5

H/27-4

remove if damaged.

10. Inspect the stator support O-ring, replace if

cracked or distorted. The O-ring is not used on 9109 Models.

11. Remove all piston rings on the input shaft.

H/27-5

H/27-6

Transmission appearance may differ, procedure is the same.

Page 80

How to Install the Torque Converter Housing

Torque Converter

Special Instructions

Installation of the torque converter housing is done in the vertical position.

Apply Eaton Lubricant #71214 to stator support O-ring. Cover entire surface. The O-ring is not used on 9109 Models.

Special Tools

Typical service mechanic tools are needed.

To Install

1. If removed, install a new O-ring and the magnetic

sensor. Tighten to 14-20 Lb

·ft of torque.

2. If removed, replace the torque converter housing

seal.

3. If removed, install the synchronizer system lube O-

ring and elbow. Tighten to 14-20 Lb

·ft of torque.

4. Position the torque converter housing gasket on the

transmission case.

H/27-6

H/27-5

External Parts

5. Install the torque converter housing over the gasket.

6. Install the nuts with washers. Tighten to 130-170

·ft of torque.

7. Install the capscrews with washers. Tighten to 70-

·ft of torque.

80 Lb

8. Install the 3 piston rings in the input shaft base.

Ring ends need to be interlocked.

9. If previously removed, apply lubrication and install

the O-ring in the stator support bottom. The O-ring is not used on 9109 Models.

10. Make sure the stator support pressure ports are

aligned and position the gasket and support.

11. Install the stator support retaining capscrews.

Tighten to 34-45 Lb

·ft of torque.

12. Cross the stator support seal ring ends. Becareful

not to crease the seal. When finished, seal ring ends should touch when relaxed. Apply a thin film of lubriplate and install.

H/27-4

H/26-5

H/26-4

H/26-3

Final Check

Make sure the retaining capscrews are properly torqued.

Transmission appearance may differ, procedure is the same.

H/25-7

H/52-1

Page 81

Torque Converter

H/26-1

How to Remove the Oil Pump

Special Instructions

The oil pump gear can be removed while removing the torque converter housing.

H/26-2

The oil pump is a non-serviceable assembly and should be returned for service.

The converter and converter housing must be removed before removing the oil pump gear.

Special Tools

Typical service mechanic tools are needed

To Remove

1. From the oil pump gear, remove the retaining nut.

Use a screwdriver to keep the gear from moving.

2. Remove the oil pump drive gear.

3. Remove the two (2) pump mounting capscrews.

4. Use the two (2) capscrews previously removed

and insert them into the pump to lift the pump.

H/26-8

H/26-9

5. Remove the oil pump.

6. Remove the oil pump O-ring.

7. Inspect the snap ring, remove if damaged.

8. Remove the O-ring in the torque converter

housing oil pump bore.

H/27-1

H/27-2

H/27-3

Transmission appearance may differ, procedure is the same.

Page 82

How to Install the Oil Pump

Special Instructions

The oil pump gear can be installed during the torque converter housing installation.

When installing the oil pump, do not damage the Orings and use grease.

Special Tools

Torque Converter

Typical service mechanic tools are needed.

To Install

1. Lube and install the oil pump O-ring in the torque

converter housing oil pump bore.

2. If previously removed, install a new snap ring.

3. Lube and install the oil pump O-ring.

4. Lube the oil pump bore.

5. Install the oil pump, tap with soft faced hammer if

necessary.

6. Install the two (2) pump mounting capscrews.

Tighten to 35-45 Lbf·ft of torque.

7. Inside the torque converter housing, install the oil

pump drive gear.

8. On the oil pump gear, install a new retaining nut.

Use a screwdriver to keep the gear from moving. Tighten to 34-48 Lbf·ft of torque.

4, 5

H/27-3

H/27-1

H/27-2

External Parts

H/26-8

Final Check

Make sure the retaining capscrews are properly torqued.

Transmission appearance may differ, procedure is the same.

H/26-2

H/26-1

Page 83

Torque Converter

How to Remove the Filter Bypass Valve

Special Instructions

The hydralic valve must be removed.

Special Tools

Typical service mechanic tools are needed

To Remove

1. Use a hex socket to remove the filter bypass

valve.

H/52-5

2. Inspect the valve for damage, replace if damaged.

H/52-6

How to Remove the HI Pressure Relief Valve

H/52-7

H/50-8

H/52-8

Special Instructions

The oil filter must be removed.

Special Tools

Typical service mechanic tools are needed

To Remove

1. Remove the oil filter adaptor.

2. Use a hex socket to remove the HI pressure relief

valve.

3. Inspect the valve for damage, replace if damaged.

Transmission appearance may differ, procedure is the same.

Page 84

How to Install the Filter Bypass Valve

Special Instructions

The hydralic valve must be removed.

Torque Converter

Special Tools

Typical service mechanic tools are needed

To Install

1. Use a hex socket to install the filter bypass valve.

2. Tighten the valve to 26-32 Lbf·ft of torque.

Final Check

Make sure the valve is properly torqued.

How to Install the HI Pressure Relief Valve

H/52-5

External Parts

Special Instructions

The oil filter must be removed.

Special Tools

Typical service mechanic tools are needed

To Install

1. Use a hex socket to install the HI pressure relief

valve.

2. Tighten the valve to 26-32 Lbf·ft of torque.

3. Install the oil filter adaptor.

Transmission appearance may differ, procedure is the same.

H/52-7

H/50-8

Page 85

Output Yoke/Companion Flange

How to Remove the Output Yoke/Companion Flange

B/07-3

Special Instructions

If no impact or special tools are available, the shift bar housing must be removed in order to lock the transmission.

For proper cleaning and maintenance, see Form 193 “Rear Seal Maintenance Guide”.

After removal of the output yoke/companion flange, temporarily replace the output shaft nut to protect the output shaft threads during auxiliary section disassembly.

Special Tools

Typical service mechanic tools are needed A large breaker bar or air impact wrench

To Remove

1. Engage two (2) mainshaft sliding clutches into

two (2) mainshaft gears to lock the transmission.

2. Use a large breaker bar or air impact wrench to

remove the output shaft nut.

H/46-2

3. Pull the yoke or flange straight to the rear and off

the output shaft.

H/46-5

Transmission appearance may differ, procedure is the same.

Page 86

How to Install the Output Yoke/Companion Flange

Special Instructions

If no impact or special tools are available, the shift bar housing must be removed in order to lock the transmission.

For proper cleaning and maintenance, see Form 193 “Rear Seal Maintenance Guide”.

Special Tools

Typical service mechanic tools are needed

Output Yoke/Companion Flange

A torque wrench with 1000 Lbf·ft capacity

To Install

1. Engage two (2) mainshaft sliding clutches into

two (2) mainshaft gears to lock the transmission.

2. Install the speedometer drive gear rotor or

replacement spacer on the output shaft inside the rear bearing cover.

3. If the slinger on the yoke is damaged, replace

using a Slinger/Seal kit.

4. Slide the companion flange or yoke onto the

output shaft.

5. Install the output shaft nut, tighten to 450-500

Lbf·ft of torque.

Final Check

Make sure the output shaft nut is properly torqued. Unlock the transmission.

B/07-3

H/46-5

External Parts

Transmission appearance may differ, procedure is the same.

H/46-3

Page 87

Auxiliary Section

How to Remove the Auxiliary Section

There are different capscrew lengths, note their location. The auxiliary section should be removed with the

transmission in the horizontal position. The range cylinder housing must be loosened to remove

the auxiliary section.

Special Tools

Typical service mechanic tools are needed

Special Instructions

H/27-7

H/27-8

An auxiliary section hanger bracket for horizontal removal

A steel bar longer than the width of the output yoke for

vertical removal A hoist with a lifting chain

To remove the auxiliary section in the horizontal position.

1. Remove the four (4) capscrews in the range

cylinder housing.

2. Move the range cylinder to the side and down.

3. From the power synchronizer, remove the

H/28-2

H/28-3

mounting capscrews.

4. Remove the power synchronizer and gasket.

5. From the auxiliary section housing, remove the

retaining capscrews that attach the front section to the auxiliary section.

6. From the auxiliary case, remove the two (2) allen

head setscrews.

7. Insert the three (3) capscrews in the housing

flange tapped holes. Tighten evenly to move the auxiliary section away from the front box. Go far

H/28-4

H/28-5

enough to break the gasket seal.

8. Remove the capscrews from the tapped holes.

9. Attach an auxiliary section hanger bracket to the

auxiliary section top.

10. Attach a lifting chain to the auxiliary section

hanger bracket.

11. Move assembly to the rear until auxiliary section

is free.

12. Remove the gasket and clean all mounting

surfaces of gasket material.

H/28-6

H/28-7

Transmission appearance may differ, procedure is the same.

Page 88

How to Install the Auxiliary Section

Special Instructions

There are different capscrew lengths, install in the correct location.

The auxiliary section should be installed with the transmission in the horizontal position.

Auxiliary Section

Special Tools

Typical service mechanic tools are needed An auxiliary section hanger bracket for horizontal removal A steel bar longer than the width of the output yoke for

vertical removal A hoist with a lifting chain

To install the auxiliary section in the horizontal position.

1. Position a new gasket on the transmission

mounting surface.

2. Attach an auxiliary section hanger bracket to the

auxiliary section top.

3. Attach a lifting chain to the auxiliary section

hanger bracket.

4. Position the auxiliary section on the two (2) dowel

pins.

5. Slide the auxiliary section on until the hanger

bracket contacts the front section back.

6. Remove the auxiliary section hanger bracket.

H/28-7

H/28-4

H/28-5

External Parts

H/28-3

7. Install the two (2) allen setscrews. Tighten to 35-

45 Lbf·ft of torque.

8. Apply Eaton/Fuller Sealant #71205 or equivalent

to the retaining capscrews.

9. Install the retaining capscrews, tighten to 35-45

Lbf·ft of torque. On ATE models, tighten the short (1-1/2") to 26-32 Lbf·ft of torque.

10. Position a new power synchronizer gasket and

power synchronizer on the auxiliary case.

11. Install the mounting capscrews. Tighten to 35-45

Lbf·ft of torque. The middle capscrew uses a washer.

12. Move the range cylinder up and forward. Install

the range cylinder housing capscrews, tighten to 35-45 Lbf·ft of torque.

Transmission appearance may differ, procedure is the same.

H/28-2

H/27-7

Page 89

Auxiliary Section

How to Remove the Rear Bearing Cover Assembly

Special Instructions

The rear bearing cover can be removed without

H/46-6

disassembling the auxiliary section.

Special Tools

Typical service mechanic tools are needed

To Remove

1. Remove the retaining capscrews and the rear

bearing cover and gasket.

2. Inspect the oil seal, remove if damaged.

TA/08-7

Transmission appearance may differ, procedure is the same.

Page 90

How to Install the Rear Bearing Cover Assembly

Special Instructions

When installing the rear bearing oil seal, press into the rear bearing cover flush with the machined step. A thin coat of lubrication may be used on the seal O.D.

Because the collar becomes distorted when compressed, do not re-use an old nylon collar in the rear bearing cover.

Apply Eaton Lubricant #71214 or equivalent to speedometer plug O-rings, cover the entire surface. If the electronic sensor hole has a seal, apply lubricant #71214 or equivalent, covering the top surface. Do not

use an O-ring with the seal.

Auxiliary Section

V/08-1

Special Tools

Typical service mechanic tools are needed Bearing driver and maul Oil seal installation tool (K-2091)

To Install

1. If previously removed, install the oil seal in the

rear bearing cover with the proper driver.

2. The seal should be installed so the spring is to the

transmission front.

3. Position a new gasket on the rear bearing cover

mounting surface and the rear bearing cover.

4. Apply Eaton/Fuller Sealant #71205 or equivalent

to the retaining capscrews.

5. On AT/ATR/ATS models, use a new nylon collar

and brass washer with the capscrew at the chamfered hole, the hole that intersects the speedometer bore.

External Parts

T/60-7

3 4, 6

6. Install the retaining capscrews, tighten to 35-45

Lbf·ft of torque.

Final Check

Make sure the capscrews are properly torqued.

Transmission appearance may differ, procedure is the same.

H/46-6

Page 91

Page 92

Section 5: Shift Bar Housing

Functions of a Shift Bar Housing 3

Shift Bar Housing

How to Disassemble the Shift Bar Housing 4 How to Assemble the Shift Bar Housing 6

Shift Bar Housing

Transmission appearance may differ, procedure is the same.

Page 93

Page 94

Shift bar housings are a very important part of the transmission. No matter what kind of shift bar housing your transmission has, they all provide the same functions:

√ Engage the transmission gearing, √ Prevents the driver from shifting into 2 gears at

the same time.

Functions of a Shift Bar Housing

Shift Bar Housing

Transmission appearance may differ, procedure is the same.

Page 95

Shift Bar Housing

How to Disassemble the Shift Bar Housing

Special Instructions

The shift bar housing must be removed from the transmission.

During disassembly, lay all parts on a clean bench in order of removal to facilitate assembly.

neutral position or the interlocking parts lock the bars. Start with the top shift bar. Cut the lockwire and remove the lockscrews from each

Shift bars not being removed must be kept in the

H/13-6H/13-2

bar just before their removal. Use caution when removing the range sensor bar, it is

under spring tension.

Special Tools

Typical service mechanic tools needed Vise with brass jaws or wood blocks

To Disassemble

1. If the three (3) sets of tension springs and balls

H/14-2

H/14-4

from housing bores have not been removed, place the shift bar housing on its side to remove them.

2. With the housing rear to the right, place the

assembly in a vise.

3. While removing the top yoke bar to the right,

remove the shift yoke and shift block.

4. From the second yoke bar, remove the shift yoke

and shift block.

5. From the third yoke bar, remove the shift yoke.

H/14-6

6. Place your hand over the range sensor bar

opening on the shift bar housing backside. From the housing front, remove the range sensor pins.

7. Carefully remove your hand in order to remove

the range sensor bar and spring.

8. Inspect the yoke and block parts, replace the

worn parts.

Transmission appearance may differ, procedure is the same.

Page 96

Page 97

Shift Bar Housing

How to Assemble the Shift Bar Housing

Special Instructions

Inspect shift blocks and shift yokes for wear.

Apply Eaton lockwire #1819 or equivalent to all shift bar housing assembly set screws in both blocks and yokes. The wire should anchor the capscrew at least 2

complete 360° turns. The lockwire ends should be trimmed and bent out of the way of any part interference.

H/14-6

Keep yoke bars in neutral while assembling. Start with the bottom yoke bar.

Special Tools

Typical service mechanic tools needed Vise with brass jaws or wood blocks

To Reassemble

1. With the housing rear to the right, place the

assembly in a vise.

2. Assemble the spring and range sensor bar.

H/14-7

Install the range sensor bar.

3. Install the longer (about 1") range sensor pin.

Make sure the pin are all the way in against the range sensor bar.

4. Install the shorter (about 3⁄4") range sensor pin.

5. Start installation of the second shift bar, as the

bar passes the rear boss, position the shift yoke. Finish installation.

6. Install the shift yoke lockscrew. Tighten to 35-45

H/14-4

Lbf·ft of torque. Lockwire securely.

H/14-2

Transmission appearance may differ, procedure is the same.

Page 98

continued

How to Assemble the Shift Bar Housing

7. Holding the third bar notched-end, start

installation. As the bar passes the rear boss, position the shift block.

8. As the bar passes the center boss, position the

shift yoke on bar, long hub to the housing front.

9. Install the shift block and shift yoke lockscrews.

Tighten to 35-45 Lbf·ft of torque. Lockwire securely.

Shift Bar Housing

10. Holding the top bar notched-end, start installation.

As the bar passes the rear boss, position the shift block.

11. As the bar passes the center boss, position the

shift yoke on bar, long hub to the housing rear.

12. Install the shift block and shift yoke lockscrews.

Tighten to 35-45 Lbf·ft of torque. Lockwire securely.

13. Install the three (3) tension balls, one in each

housing top bore. Install the three (3) detent springs, one over each tension ball.

Final Check

Make sure interlocking system is working – can’t shift into 2 gears at the same time.

Make sure all lockscrews are lockwired.

H/13-6

H/12-6

H/13-2

Shift Bar Housing

Transmission appearance may differ, procedure is the same.

Page 99

Page 100

Section 6: Front Section

How to Disassemble the Front Section 2 How to Assemble the Front Section 3

Auxiliary Drive Gear Assembly

How to Remove the Auxiliary Drive Gear Assembly 4 How to Install the Auxiliary Drive Gear Assembly 5 How To Disassemble the Auxiliary Drive Gear Assembly 6 How To Assemble the Auxiliary Drive Gear Assembly 7

Reverse Idler Gear Assembly

How to Remove the Reverse Idler Gear Assembly 8 How to Install the Reverse Idler Gear Assembly 9

Countershaft Assembly

How to Remove the Countershaft Bearings 10 How to Install the Countershaft Bearings 11 How to Remove the Countershaft Assemblies 12 How to Install the Countershaft Assemblies 13 How to Disassemble the Countershaft Assembly 14 How to Assemble the Countershaft Assembly 15

Mainshaft Assembly

How to Remove the Mainshaft Assembly 16 How to Install the Mainshaft Assembly 17 How to Disassemble the Mainshaft Assembly 18 How to Assemble the Mainshaft Assembly 19

Input Shaft Assembly

How to Remove the Input Shaft Assembly 24 How to Install the Input Shaft Assembly 25

Front Section

Transmission appearance may differ, procedure is the same.

Eaton Transmission RTO-13109B-AT Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General Information

Model/Assembly Reference

External Parts

Front Section