Eaton Transmission RTO-16910B-AS2 Service Manual
Service Manual
Fuller Automated Transmissions
TRSM0062
October 2007
FO-6406A-ASW
FO-6406A-ASX
FO-8406A-ASW
FO-8406A-ASX
RT-14910B-AS2
RTLO-14918A-AS2
RTLO-16918A-AS2
RTLO-18918A-AS2
RTLO-20918A-AS2
RTLO-22918A-AS2
RTO-10710B-AS2
RTO-10910B-AS2
RTO-10910B-DM2
RTO-12710B-AS2
RTO-12910B-AS2
RTO-12910B-DM2
RTO-14710B-AS2
RTO-14710C-AS2
RTO-14910B-AS2
RTO-14910B-DM2
RTO-14910C-AS2
RTO-16710C-AS2
RTO-16910B-AS2
RTO-16910B-DM2
RTO-16910C-AS2
RTO-18910B-AS2
General Information
General Information
Cautions, and Warnings
WARNING
Follow the specified procedures in the indicated order
to avoid personal injury.
CAUTION
Follow the specified procedures in the indicated order
to avoid equipment malfunction or damage
Note: Additional relevant information not covered in the
service procedure.
IMPORTANT
For additional information and assistance, call the
Roadranger Help Desk at 1-800-826-HELP (4357).
Mexico: 01-800-826-HELP (4357). You may also find
more information at www.Roadranger.com.
Operational Warnings
Before starting a vehicle:
When parking the vehicle or leaving the cab:
8. Place the shift lever in neutral.
9. Set the parking brake.
Do not operate the vehicle if the alternator lamp is lit or if
the gauges indicate low voltage.
Repair Warnings
When disassembling various assemblies, lay all parts on
a clean bench in the same sequence as removed to simplify and reduce the possibility of losing parts.
Disconnect the vehicle’s battery before removing or
installing electronic parts.
Since the cost of a new part is generally a small fraction
of the cost of downtime and labor, avoid reusing a questionable part that could lead to additional repairs and
expense.
Use of other than recommended tools, parts, and instructions listed in this manual may place the safety of the service technician or vehicle driver in jeopardy.
1. Sit in the driver’s seat.
2. Place the Shift Lever in neutral.
3. Set the parking brake.
4. Disengage the clutch.
Before working on the vehicle or leaving the cab with the
engine running:
5. Place the shift lever in neutral.
6. Set the parking brake.
7. Block the wheels.
Do not release the parking brake or attempt to select a
gear until the air pressure is at the correct level.
The location of some components may vary with each
OEM.
The removal and installation procedure described for
each component may vary for your vehicle.
Always use genuine Eaton replacement parts. For a complete list of approved and reputable dealers, write to:
Eaton Corporation
Truck Component Marketing Headquarters
P.O. Box 4013
Kalamazoo, MI 49003
Every effort has been made to ensure the accuracy of the
information contained in this manual. However, Eaton
Corporation makes no warranty, expressed or implied,
based on the information provided.
Table of Contents
General Information
Preventive Maintenance
Service Procedures
Cautions, and Warnings ............................................................................................................................................i
How to Use This Manual ......................................................................................................................................... 1
Dry Clutch Models Only .......................................................................................................................................... 3
UltraShift™ HP Models ............................................................................................................................................ 9
Lubricant Filter (UltraShift HP Models Only) – Remove ........................................................................................ 15
Lubricant Filter (UltraShift HP Models Only) – Install ............................................................................................ 17
Rail Select Sensor – Remove ................................................................................................................................ 19
Rail Select Sensor – Install ................................................................................................................................... 21
Gear Select Sensor – Remove ............................................................................................................................... 23
Gear Select Sensor – Install .................................................................................................................................. 25
Input Shaft Speed Sensor – Remove .................................................................................................................... 27
Input Shaft Speed Sensor – Install ........................................................................................................................ 29
Main Shaft Speed Sensor – Remove ..................................................................................................................... 31
Main Shaft Speed Sensor – Install ........................................................................................................................ 33
Output Shaft Speed Sensor – Remove .................................................................................................................. 35
Output Shaft Speed Sensor – Install ..................................................................................................................... 37
Range Valve – Remove ......................................................................................................................................... 39
Range Valve – Install ............................................................................................................................................. 41
Splitter Valve – Remove ........................................................................................................................................ 43
Splitter Valve – Install ........................................................................................................................................... 45
Air Filter/Regulator – Remove ............................................................................................................................... 47
Air Filter/Regulator – Install .................................................................................................................................. 49
Inertia Brake (6-Speed) – Remove ........................................................................................................................ 51
Inertia Brake (6-Speed)– Install ............................................................................................................................ 53
Inertia Brake (7, 10, and 18-Speed) – Remove ..................................................................................................... 55
Inertia Brake (7, 10, and 18 Speed) – Install ......................................................................................................... 57
Inertia Brake Relocation Instructions 8 to 6 Bolt PTO Opening--Remove .............................................................. 59
Inertia Brake Relocation Instructions 8 to 6-Bolt PTO opening--Install ................................................................. 61
Electric Shifter – Remove ...................................................................................................................................... 63
Electric Shifter – Install ......................................................................................................................................... 65
Transmission Controller – Remove ....................................................................................................................... 67
Transmission Controller – Install .......................................................................................................................... 69
Transmission Harness – Remove .......................................................................................................................... 71
Transmission Harness – Install ............................................................................................................................. 73
Gear Display – Remove ......................................................................................................................................... 75
Gear Display – Install ............................................................................................................................................ 77
Shift Control– Remove .......................................................................................................................................... 79
Shift Control – Install ............................................................................................................................................ 81
Transmission – Remove ....................................................................................................................................... 83
Transmission – Install ........................................................................................................................................... 84
Change Control Log .............................................................................................................................................. 85
Table of Contents
ii
General Information
How to Use This Manual
This manual is designed to provide detailed information necessary to service and repair the Automation portion of the
following Fuller transmissions:
1. 6-Speed (Fx-x406x-ASX, Fx-x406x-ASW)
2. 7-Speed (TO-xx607x-ASX)
3. 10-Speed (RTO-xxx10x-AS2, RTO-xxx10x-DM2)
4. 18-Speed (RTLO-xx918x-AS2)
The service procedures in this manual are for transmission automation components only. To locate the information you
need, simply locate the procedure in the index, turn to the page specified, and follow the procedure.
To service the mechanical portion of the transmission system, refer to the specific transmission service manual.
Serial Tag Information and Model Nomenclature
Transmission model designation and other transmission identification information are stamped on the serial tag. To
identify the transmission model and serial number, locate the tag on the transmission and then locate the numbers as
shown.
Model
RTO-14710B-AS2
Fuller
Made In
R
Eaton Corporation
Transmission Div.
Kalamazoo, MI. 49003
Serial
Eaton
Transmissions
R
1
For parts or service call us
Pro Gear & Transmission, Inc.
1 (877) 776-4600
(407) 872-1901
parts@eprogear.com
906 W. Gore St.
Orlando, FL 32805
General Information
Model Number
The model number gives basic information about the transmission and is explained below. Use this number when calling for service assistance or replacement parts.
6-Speed
Fuller
Overdrive
Torque x 100
Design Level
FO 84 6A0- X-XAS
W-WetClutch
X-Inertia Brake
AutoShift
Gear Ratio
Forward Speeds
General Information
7-Speed
Twin Countershaft
Torque x 100
Design Level
10-Speed
Roadranger
Twin Countershaft
Overdrive
Torque x 100
Design Level
18-Speed
Roadranger
Twin Countershaft
Low Inertia
Overdrive
Torque x 100
Design Level
Overdrive
T O 11 076-B-AS
X - Inertia Brake
AutoShift
Gear Ratio
Forward Speeds
TO-
R
T
14 107B-AS
LO-R
18 189A-AS
2
2 - AutoShift II
(Second Generation)
AutoShift
DM-Data Mechanical Clutch
Gear Ratio
Forward Speeds
2
2 - AutoShift II
(Second Generation)
AutoShift
Gear Ratio
Forward Speeds
PREFIX KEY
F = Fuller
L = Low Inertia
O = Overdrive
R = Roadranger
T = Twin Countershaft
AS = AutoShift
X = Inertia Brake
2 = AutoShift II
(Second Generation)
SUFFIX KEY
W=WetClutch
DM=Data
Mechanical
Clutch
Serial Number
The serial number is the sequential identification number of the transmission. Have the serial number available when
calling for service assistance.
Bill of Material or Customer Number
This number may be located below the model and serial numbers. It is a reference number that is used by Eaton.
2
General Information
Dry Clutch Models Only
Preventive Maintenance Overview
To keep the vehicle running properly, it is important to perform preventive maintenance on vehicle components. This
ensures the vehicle and its subassemblies will operate properly throughout their useful life. To cover preventative maintenance completely, you must review the following subjects in detail:
1. Recommended Lubricants
2. Maintenance/Lubricant Change Interval
3. Inspecting the Transmission
4. Changing the Fluid
5. Vehicle System Effects
Recommended Lubricants
Where transmissions are concerned, lubricant is possibly the most important part of keeping a vehicle operating.
Lubricants which meet the Eaton E500 (PS-164) specification are required in the AutoShift transmission. Lubricant
must be approved by Eaton Corporation to qualify for the 5/750,000 warranty. For a list of Eaton Roadranger approved
lubricants, order publication TCMT-0021.
3
General Information
Maintenance/Lubricant Change Intervals
IMPORTANT
Transmission filters should be changed durning regular lube intervals. Inspection of the transmission filter should
be conducted during preventative maintenance checks for damage or corrosion. Replace as necessary.
Transmission inspections and lubricant changes depend on the type of lubricant used and whether the vehicle is used
On or Off-highway.
On-highway Lubricant- Vehicles operated on paved roads, interstate highways, and turnpikes are designated as onhighway vehicles. Lubricant change and inspection intervals are the most generous for on-highway vehicles using synthetic lubricants.
Off-highway Lubricant- Vehicles operated in off-highway applications such as coal trucks or mining vehicles, it is more
important to use time rather than mileage to keep the transmission within its proper preventative maintenance schedule. Off-highway applications are divided into two categories, severe and normal. “Severe off-highway” is the designation used when there is excessive dust and dirt. “Normal off-highway” is for applications where dust and dirt are
minimal.
Table 1: Lubricant Change and Inspection (On-highway)
Change Interval Description
Every 2500 miles Inspect lubricant level. Perform Transmission Inspection
Every 250,000 Change transmission lubricant and filter. (if equipped)
*The first lube change may be extended to 500,000 miles (800,000 km) when a transmission has been factory
filled with a lube that is Eaton approved for 500,000 miles (800,000 km) (E-500, PS-164)
General Information
Table 2: Lubricant Change and Inspection (Off-highway)
Change Interval Description
Every 40 hours Inspect lubricant level. Perform Transmission Inspection
Every 1000 hours Change Transmission lubricant and filter (if equipped) where
severe dirt conditions exist
Every 2500 hours Change Transmission lubricant and filter (if equipped) (Normal
off-highway use.)
4
General Information
Transmission Inspection
When performing preventive maintenance (PM) inspections, several items must be checked. It is important to perform
every step to ensure the transmission will meet its life expectancy. Proper PM consists of the following steps:
1. Check Lubricant Level
2. Inspect for Loose/Missing Bolts
3. Check for Air Leaks
4. Check for Lubricant Leaks
Check Lubricant Level
When checking the transmission lubricant there are two important points to know: where to check the lubricant and
what the proper lubricant level is. Always be cautious when checking the transmission lubricant as it may be hot.
Checking Location- Checking the lubricant at the lubricant fill plug located on the left side of the main transmission
case.
Proper Lubricant Level- The lubricant is at the proper level when it is even with the bottom of the fill hole. When you
remove the plug to check the lubricant level, lubricant should seep out. Do not use your finger to feel for the lubricant.
Even if you can touch the lubricant, it may not be at the proper level. In a transmission, one inch of lubricant level equals
about one gallon of lubricant.
Improper Oil Level
Hole
Proper Oil Level
Hole
Inspect for Loose/Missing Bolts
While you are under the vehicle checking the lubricant, make a quick check for loose or missing bolts. Check all bolts on
the back box, PTO covers, shift bar housing, clutch housing, and transmission controller. Replace any missing or broken bolt with the proper bolt as specified in the Illustrated Parts Listing. Follow the procedure defined in the transmission Service Manual when tightening any bolts.
5
General Information
Check for Air Leaks
Two steps are required when checking for an air leak: inspection and repair.
Audible Inspection for Leaks- To find air leaks, make sure the vehicle air system has at least 90 PSI air pressure. Then,
listen for leaks, making sure a vehicle leak is not mistaken for a transmission air leak.
Refer to Troubleshooting Procedures- Once you find an air leak, use the Troubleshooting Guide to isolate the air leak to
the faulty component.
Check for Lubricant Leaks
A lubricant leak could cause a catastrophic transmission failure. Check for leaks first at the gasket surfaces, then the
input shaft, the rear seal, and the transmission cooler.
Gaskets- Visually check each gasket to insure that no leak is present. Typically a moist spot is acceptable; however drips
or larger wet areas are not. Check for leaks at the rear housing, PTO, shift bar housing, shift tower, and clutch housing
gasket surfaces. It is also important to ensure that the leak is indeed coming from the transmission. Make sure the oil is
not being blown back from the engine or another vehicle component.
Input Shaft- Check for leaks around the input shaft. Leaks in this area could be caused by a faulty gasket, input shaft, or
pressurization of the main transmission case by the air system. If you find a leak at the input shaft, make sure the air
system is not leaking into the case before looking for leaking gaskets.
Rear Seal- The rear seal is very important in maintaining lubricant in the transmission. If the seal is improperly installed
or has failed, the transmission may experience a catastrophic failure. Check the rear seal by performing the following
steps:
General Information
Visual Check for Leak- Visually inspect the rear seal for a leak. If a rear seal leak is suspected, proper isolation is necessary.
Verify the Leak Path- Other leaks may give the impression the rear seal is leaking. One possible cause is the vehicle
speed sensor. Any lubricant leak above and in front of the rear seal could cause lubricant to collect around the seal.
Wipe the seal with a clean rag, operate the vehicle, and recheck to verify the leak path. More information can be found in
the Seal Maintenance Guide (TCSM-0912).
Transmission Cooler Leaks- If the vehicle is equipped with a transmission cooler, make sure there are no leaks at the
lubricant cooler, hoses, and fittings of the cooler circuit.
6
General Information
Changing Lubricant
When it is time to change the transmission lubricant, there are only a few steps to follow: Draining and filling the transmission, draining and filling the cooler (if equipped), and changing the lubricant filter (if equipped). Remember to be
careful when changing the transmission lubricant, as it may be hot.
Drain the Transmission
1. Locate the drain plug on the bottom of the transmission case.
2. Place a drain pan under the drain plug.
3. Remove the drain plug and allow the lubricant to drain completely.
4. Once drained, reinstall the drain plug and tighten to 45-55 lbs.ft. (61.0-74.6 N•m). Sealant is not required on
the drain plug threads.
Drain the Cooler (if equipped)
1. Remove both cooler lines at the transmission.
2. Pressurize one line with 30 PSI of air pressure to force the lubricant out of the cooler.
3. Once drained, reconnect the coolant lines to the transmission. Make sure the lines are not crossed.
Fill the Transmission
1. Remove the transmission fill plug and fill the transmission with approved lubricant.
2. The transmission is full when the lubricant starts to flow out of the fill hole.
3. Replace the fill plug and tighten to 60-70 lbs.ft. (81.3-94.9 N•m).
Fill the Cooler (if equipped)
1. Place the transmission in neutral and start the vehicle.
2. Release the clutch to rotate the input shaft of the transmission, allowing the pump to fill the cooler.
3. Run the vehicle for one minute.
4. Shut off the vehicle, recheck the transmission lubricant level and add lubricant as required.
Change the “Spin-on” Filter (if equipped)
1. Remove the filter from the “spin-on” casting.
2. Catch any lubricant that seeps from the filter.
3. Clean the casting surface.
4. Install a new filter and hand tighten.
7
General Information
Vehicle System Effects
Some vehicle systems can affect the transmission operation and possibly cause a failure. The air system is a major system that can affect the transmission components.
Air System- If the air system is not given recommended preventive maintenance, it can cause problems for the transmission system. Although the transmission has an Air Filter/Regulator, it can only protect the transmission from contaminants for so long. This is why it is important to follow OEM recommendations for air system preventive
maintenance. It is important to regularly drain air tanks and ensure lubricant is not being pumped into the system. It can
cause corrosion or, in cold climates, it could freeze and prevent the shift mechanisms from operating. If lubricant is
allowed into the system, it could fill the air system components and cause them to lose valuable air volume, slowing or
preventing movement.
General Information
8
General Information
UltraShift™ HP Models
Preventive Maintenance Overview
To keep a vehicle running properly, it is very important to perform preventive maintenance on the vehicle components.
This ensures the vehicle and its subassemblies will operate properly. To cover preventive maintenance completely, you
must review the following subjects in detail.
1. Specified Lubricants
2. Maintenance/Lubricant Change Intervals
3. Inspecting the Transmission
4. Changing the Fluid
5. Clutch Calibration
Specified Lubricants
Where transmissions are concerned, lubrication is possibly the most important part of keeping a vehicle operating.
Synthetic Dexron III
Synthetic Dexron III must be used in the WetClutch portion of the transmission.
CD-50
CD-50 must be used in the gearbox portion of the transmission.
Maintenance/Lubricant Change Intervals
Transmission inspections and lubricant changes are outlined below.
For a list of Eaton Roadranger approved lubricants, order publication TCMT-0020.
Table 1: Lubricant Inspection and Change Interval (On-highway)
Interval Description
Every 2,500 miles Inspect lubricant level. Perform Transmission Inspection.
Every 5 years or 500,000 miles, whichever
occurs first
Change transmission lubricants and filters.
For additional lubricant information, see TCMT-0021.
9
General Information
Transmission Inspections
When performing preventive maintenance, several items must be checked. It is important to perform every step to
ensure the transmission will meet its life expectancy. Proper preventative maintenance consists of the following steps:
1. Check WetClutch Lubricant Level
2. Check Gearbox Lubricant Level
3. Inspect for Loose/Missing Bolts
4. Check for Lubricant Leaks
Check Lubricant Level
When checking the WetClutch model, there are three important things to know: where to check the lubricants, what is
the proper lubricant level, and what is the proper lubricant type. Always be cautious when checking the transmission
fluid since it may be hot.
General Information
Checking WetClutch Lubricant
The WetClutch portion is checked using a dipstick located in the engine compartment.
Proper WetClutch Lubricant Level
WetClutch lubricant level should be checked when idling in neutral, with the transmission temperature between 60° F
and 120° F (15.5° C and 48.8° C) and when the vehicle has been idling in neutral for at least two (2) minutes. Proper
lubricant level is obtained when the lubricant is between the cold ADD mark and the cold FULL marks on the dipstick.
Due to thermal expansion of the lubricant, it is not recommended to check the level when the transmission is above
120° F (48.8° C).
ADD COLD FULL
(COLD 60-120
F) SYNTHETIC DEXRON III
Checking Gearbox Lubricant
The gearbox portion is checked at the lubricant fill plug located on the right side of the gear case.
10
General Information
Proper Gearbox Lubricant Level
The gearbox lubricant is at the proper level when it is even with bottom of the fill hole. When you remove the plug to
check the lubricant level, lubricant should seep out. Do not use your finger to feel for the lubricant. Even if you can
touch the lubricant, it may not be at the proper level. In a transmission, one inch of lubricant level equals about one gallon of lubricant.
Improper Oil Level
Hole
Proper Oil Level
Hole
Inspect for Loose/Missing Bolts
While you are under the vehicle checking the lubricant, make a quick check for loose or missing bolts. Check all bolts on
the PTO cover, inertia brake, shift bar housing, clutch housing oil pan, output flange, and transmission controller.
Replace any missing or broken bolt with the proper bolts as called out in the illustrated parts listing. Follow the procedure defined in the transmission service manual when tightening any bolts.
Check for Lubricant Leaks
A lubricant leak could cause a catastrophic transmission failure. Check for leaks at the gasket surfaces, lubricant lines,
flywheel housing, rear seal, and the cooler.
Gaskets
Visually check each gasket to ensure that no leak is present. Typically, a moist spot is acceptable, however, drips or
larger wet areas are not. Check for leaks at the rear housing, PTO cover, shift bar housing, clutch housing to main case,
inertia brake, and clutch oil pan. It is also important to ensure that the leak indeed is coming from the transmission.
Make sure the lubricant is not being blown back from the engine or another vehicle component.
Lubricant Lines
There are three external lines for lubricant on the UltraShift HP transmission. One lubricates the inertia brake and the
other two are for the oil cooler. Check the lines to ensure they are not leaking.
Flywheel Housing/Clutch Housing
Check for leaks around the flywheel housing/clutch housing mating surface. A faulty seal or loose fittings could cause
leaks in the area. The UltraShift HP transmission has what is called a “wet housing” which means that the clutch housing is used as a sump for the WetClutch lubricant. Any leaks here could cause a transmission failure.
Transmission Cooler Leaks
11
General Information
Ensure there are no leaks at the lubricant cooler, hoses, and fittings of the cooler circuit.
Changing the Lubricant
When it is time to change the transmission lubricant, there are only a few steps to follow:
• Draining and Filling the WetClutch portion
• Draining and Filling the Gearbox portion,
• Draining and Filling the Cooler,
• Changing the Lubricant Filters
WARNING
Remember to be careful when changing the transmission lubricant, as it may be hot.
Drain the Transmission Gearbox and WetClutch Housing
1. Locate the drain plugs at the bottom of the transmission gear case and on the clutch housing oil pan.
2. Place a drain pan under each drain plug.
3. Remove both drain plugs and allow the lubricants to drain completely.
4. Disconnect both cooler lines at the WetClutch housing.
5. Pressurize one line with 20 PSI until all lubricant is forced out of the cooler.
General Information
6. Reconnect both cooler lines.
12
General Information
Change WetClutch Filters
Change the lubricant filters when the transmission lubricant is changed. Detailed information can be found on removal
and replacement of the oil filters in this service manual.
Fill the Transmission
1. Install the transmission gearbox drain plug and tighten to 45-55 lbs.ft. (61.0-74 N•m). Sealant is not required
on the drain plug threads.
2. Install the clutch housing oil pan drain plug and torque to 34-48 lbs.ft. (46-65N•m). Sealant is not required on
the drain plug thread.
3. Fill the transmission gearbox with the recommended lubricant until the lubricant seeps out of the fill hole.
4. Install the fill plug and torque to 25-35 lbs.ft. (34-47 N•m).
5. Slowly fill the clutch through the dipstick tube with a maximum of 18 pints (8.5 liters) of the recommended
lubricant.
6. Place the transmission in neutral position and apply the parking brakes. Start the engine and let idle for five (5)
minutes, (this allows oil to fill the WetClutch system and cooling system), add oil as needed to obtain a level at
the proper temperature range. Total oil quantity should be approximately 24 pints: this varies depending on the
cooling system capacity.
7. Increase the engine idle slowly to 1500 RPM for two (2) minutes. Next, recheck the oil level at normal idle
speed in neutral, again adding oil to obtain a level at the proper temperature range.
8. Replace the dipstick and tighten securely.
Clutch Calibration
The UltraShift HP system automatically provides for clutch wear. The system will initiate a clutch calibration once per
vehicle power up, when certain vehicle conditions are right. Of these conditions, the most important ones include: when
the engine is running at idle speed, during normal operating temperature, when the vehicle is stopped, and when neutral
is selected on the Shift Control. During the calibration, the clutch is partially engaged until the engine begins to slightly
lug down. It will then disengage the clutch and repeat this process several times. The calibration process usually takes
as little as thirty seconds but can take as long as two (2) minutes. The calibration will be aborted when any position
other than neutral is selected on the Shift Control.
If it appears that the vehicle is not engaging smoothly from a stop, it is possible that the clutch needs to be re-calibrated. If it has not been previously calibrated during the current power up, stop the vehicle with the engine idling at its
normal operating temperature and place the Shift Control in neutral and wait two (2) minutes. If the calibration is being
performed you should hear the engine slightly lug down and then return to its no load condition several times.
If calibration does not occur a Power Down/Power Up will initiate a calibration.
13
Oil Leak Inspection Process
General Information
Inspect for Oil Leak
General Information
Determine if it is a Weep or a Leak
Weep: Stained, damp, no drips, light oil film,
dirt adhered to the contaminated area.
Gasket Rear Seal Leak
Leak: Extremely wet or dripping of oil in the
contaminated area.
Step 1
1. Clean suspected oil weep
area with a clean dry cloth
or mild soluble degreaser.
2. Ensure lube is to proper
level.
3. Notify the customer that it
is only a weep and it is not
considered to be detrimental
to the life of the transmission.
4. Repair is complete.
1. Do not repair: Rear seal is
designed to allow min
seepage (refer to Roadranger
TCSM-0912 Seal Maintance
Guide).
2. Ensure lube is to proper
level.
imal
Step 2
Step 3
1. Determine the origin of the leak path.
2. If origin of leak is obvious skip to Step 3.
3. If the origin of the oil leak is not obvious then
use either of the two following steps to determine
the oil leak:
Note: Do not use a high pressure spray washer to
clean the ar
force contamination into the area of concern and
temporarily disrupt the leak path.
i. Clean area with a clean dry cloth or mild
soluble degreaser and fill the transmission to
the proper lube level.
OR
ii. Clean the area as noted above and insert tracer
dye into the tr
transmission to proper lube level.
Operate vehicle to normal transmission operating
temperature and inspect the area for oil leak(s)
visually or if tracer dye was introduced use an UVL
(Ultraviolet Light) to detect the tracer dye’s point
of origin.
Note: When i
make sure the assumed leak area is not being
contaminated by a source either forward or above
the identified area such as the engine, shift tower,
shift bar housing, top mounted oil cooler, etc...
ea. Use of a high pressure spray may
ansmission lube and fill
nspecting for the origin of the leak(s)
Once the origin of the leak is identified, repair the
oil leak using proper repair proced
designated model service manual.
ures from the
Step 4
After the repair is completed, verify the leak is
repaired and operate the vehicle to normal
transmission operating temperature.
Inspect repaired area to ensure oil leak has been
eliminated. If the leak(s) still occurs, repeat steps
or contact the Roadranger Call Cen
1-800-826-4357.
ter at
14
Service Procedures
Lubricant Filter (UltraShift HP Models Only) – Remove
Special Instructions
None
Required Tools
2. Using a 15mm wrench, remove the oil pan mounting
bolts. Record location of the long and short bolts.
3. Remove the WetClutch oil pan and gasket.
4. Remove the two (2) WetClutch filters. Make sure filter seals are removed.
• Basic Hand Tools
Removal
1. Remove the drain plug and drain the fluid from the
WetClutch portion of the transmission.
CAUTION
Fluid may be hot.
Note: The filters will contain fluid when they are
removed.
IMPORTANT
Transmission filters should be changed during regular lube intervals. Inspection of the transmission
filter should be conducted during preventative
maintenance checks for damage or corrosion.
Replace as necessary.
Filter Location
15
Low Pressure Filter
High Pressure Filter
1
Remove Drain Plug
Drain Fluid
Service Procedures
2
Remove Oil Pan
Mounting Bolts
Wrench
3
Remove Oil Pan
and Gasket
Service Procedures
15 mm Wrench
4
Remove Filters
Lubricant Filter Removal
Low Pressure Filter
High Pressure Filter
16
Service Procedures
Lubricant Filter (UltraShift HP Models Only) – Install
Special Instructions
5. Using a 15mm wrench install the mounting bolts and
tighten to 30-35 lbs.ft. (41-47 N•m) using a cross
pattern.
Install each filter in its correct location.
Clean filter seal mating surfaces on the transmission.
Clean and remove all old gasket material from the mating
surfaces of the clutch housing and the oil pan.
Required Tools
Basic Hand Tools
Installation
1. Lubricate each filter seal ring with synthetic Dexron
III prior to installation.
2. Install the low-pressure filter and turn until seal
touches. Then tighten 3/4 to 1 full turn.
3. Install the high-pressure filter and tighten to 25-30
lbs.ft. (34-41 N•m).
4. Install a new gasket and the WetClutch oil pan.
Note: Put the long and short bolts back in their
proper location.
6. Install the oil pan drain plug and tighten to 34-48
lbs.ft. (46-65 N•m).
Note: Fill the WetClutch portion with the proper fluid.
Final Check
Make sure the bolts are properly tightened.
Make sure the WetClutch portion is properly filled with
the specified fluid.
Check for fluid leaks during and after operating the vehicle.
IMPORTANT
Transmission filters should be changed during regular
lube intervals. Inspection of the transmission filter
should be conducted during preventative maintenance
checks for damage or corrosion. Replace as necessary.
17
Service Procedures
1
Lubricate Seal
Rings
Seal Ring
3
Install and Torque
High Pressure Filter
2
Install and Tighten
Low Pressure Filter
Low Pressure Filter
4
Install Oil Pan
and Gasket
Service Procedures
High Pressure Filter
Install and Torque
Mounting Bolts
Mouting Bolts
Pan Gasket
5
Oil Pan
Torque Wrench
6
Install and Torque
Drain Plug
Drain Plug
Torque Wrench
Lubricant Filter Installation
18
Rail Select Sensor – Remove
Service Procedures
Special Instructions
While removing the hex key mounting screws, hold the
sensor in place. Do not allow it to snap out of position.
Required Tools
• Basic Hand Tools
Removal
1. Disconnect the Transmission Harness from the Rail
Select Sensor.
2. Using a 5/32” hex key wrench, remove the two (2)
sensor hex key mounting screws.
Note: Carefully allow the sensor to rotate (not snap)
to a relaxed position or the sensor can snap
when the hex key mounting screws are
removed.
3. Remove the sensor and gasket from the housing.
Rail Select
Sensor
Rail Select Sensor Location
19
1
Disconnect
Transmission Harness
from Sensor
Service Procedures
Transmission
Harness
Rail Select Sensor
3
Remove
Sensor and Gasket
Service Procedures
2
Remove Hex Key
Mounting Screws
5/32"
Hex Key
Wrench
Rail Select Sensor
Rotate to
Relaxed Position
Rail Select Sensor Removal
Gasket
Rail Select
Sensor
Hex Key
Mounting
Screw
120RMVRS
20
Rail Select Sensor – Install
Service Procedures
Special Instructions
While installing the hex key mounting screws, hold the
Rail Select Sensor in place. Do not allow it to snap out of
position.
Torques given below are in pound-inches. Use care not to
overtighten.
Required Tools
Basic Hand Tools
Installation
1. Align the sensor’s tab with the slot in the shifter
housing. Then insert the Rail Select Sensor, with
gasket, into its mounting location.
Note: Install the sensor so the connector opening
faces the right side of the transmission.
2. Using a 5/32" hex key wrench, install the hex key
mounting screws and tighten to 21-27 lbs.in. (2.4-
3.1 N•m).
Note: Carefully hold the sensor in position while
installing the hex key mounting screws or the
sensor can snap.
3. Reconnect the Transmission Harness to the Rail
Select Sensor.
Final Check
Make sure the gasket is installed between the sensor and
the shifter housing.
Make sure the screws are tightened to specification.
Make sure all connections are tight.
Make sure the Transmission Harness is properly connected to the Gear Select Sensor.
Be sure to perform the Electric Shifter calibration procedure before operating the transmission.
21
1
Insert Sensor
and Gasket
Service Procedures
Rotate to
Align Mounting
Holes
3
Reconnect
Transmission Harness
to Sensor
Gasket
2
Install Hex Key
Mounting Screws
Hex Key
Mounting Screw
Rail Select
Sensor
Service Procedures
5/32"
Hex Key
Wrench
Rail Select Sensor
Transmission Harness
Rail Select Sensor Installation
Rail Select Sensor
120INSRS
22
Gear Select Sensor – Remove
Service Procedures
Special Instructions
While removing the hex key mounting screws, hold the
sensor in place. Do not allow it to snap out of position.
Required Tools
Basic Hand Tools
Removal
1. Disconnect the Transmission Harness from the Gear
Select Sensor.
2. Using a 5/32” hex key wrench, remove the two (2)
sensor hex key mounting screws.
Note: Carefully allow the sensor to rotate to a relaxed
position, or the sensor can snap when the
hex key mounting screws are removed.
3. Remove the sensor and gasket from the housing.
Gear Select
Sensor
Gear Select Sensor Location
23
1
Disconnect
Transmission Harness
from Sensor
Gear Select
Sensor
Service Procedures
Transmission
Harness
2
Remove Hex Key
Mounting Screws
Service Procedures
Rotate to
Relaxed Position
Hex Key
Mounting
Screw
Gear Select
Sensor
Gasket
5/32"
Hex Key
Wrench
3
Remove
Sensor
and Gasket
Gear Select
Sensor
120RMVGS
Gear Select Sensor Removal
24
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