Eaton Transmission RTX-11509 Service Manual

Service Manual

Fuller Heavy Duty Transmissions TRSM0507

October 2007

RTX-11509 RTX-12509 RTXF-11509 RTXF-12509

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

Contents

Specifications Lubrication Disassembly Precautions Inspection Reassembly Precautions Shifting Controls

Air Systems Air Valves Filter/Regulator Gear Shift Lever Housing

Shift Bar Housing

Auxiliary Sections

Removal & Installation

RT-12509 Disassembly

RT-12509 Reassembly

RTO-1258LL Disassembly RTO-1258LL Reassembly RT-12513 Disassembly RT-12513 Reassembly

Front Section-All Models

Disassembly

Reassembly Torque Recommendations Changing Input Shaft Tools

Letter and Model Designations

EXAMPLE: RTOF-12513

"R" - Roadranger Transmission "T" - Twin Countershaft

"O" - Overdrive

"F" - Denotes special shift bar housing which has the gear shift lever mounted forward of the normal position "125" - Number x 10 = Torque Capacity: 125 x 10 = 1250 lbs./ft. Torque Capacity "13" - Number of’ Forward Speeds

RTO-1258LL

RT-12509 RTO-12509

RT-12513 RTO-12513

- Roadranger, Twin Countershaft, Overdrive,

Forward Speeds plus a Low Gear and a Low-Low Gear Roadranger, Twin Countershaft, 1250 lbs./ft. Torque Capacity, 9 Forward Speeds

- Same as above but with an Overdrive Ratio

- Roadranger, Twin Countershaft, 1250 lbs./ft. Torque Capacity, 13 Forward Speeds

- Same as above but with an Overdrive Ratio

Order No.

P-539 - Illustrated Parts List - RTO-1258LL P-518 - Illustrated Parts List - RT-12509 Series

P-509 - Illustrated Parts List - RT-12513 Series

102

- Trouble Shooting Guide

121 52059 - Driver Instructions - RTO-1258LL 52067 - Driver Instructions - RT/RTO-12509 52068 - Driver Instructions - RTO-12513 3-position Splitter Knob 52069 - Driver Instructions - RT-12513 2-position Splitter Knob 52070 - Driver Instructions - RTO-12513 2-position Splitter Knob

Lubrication Recommendations

1250 lbs./ft. Torque Capacity, 8 Progressive

Specifications

Specifications RTO-1258LL

Power Take-Off - Right Side, SAE standard 6-bolt regular duty type, short iron. length. Bottom, SAE standard 13-bolt heavy-duty type.

PTO Drive Gear Speeds - Right Side, 45tooth 6/8 pitch gear. Bottom, 47-tooth 6/8 pitch gear. Both turning at .944 engine Oil Capacity - Approximately 28 pints

speed. (13.2 litres).

Clutch Housing Size - SAE No. 1 cast

Installation Dimensions - From face of clutch housing to front (bottoming) face of companion flange hub 33.6" (854mm). Weight - RTO-1258LL, 770 lbs. (350 Kg. )

Specifications RT-12509 Series

Power Take-Off - Two SAE standard Clutch Housing Size - SAE standard No. openings, short length.

Right Side: Regular duty, 6-bolt type. PTO gear is 45-tooth, 6/8 pitch turning at .700 engine speed on RT-12509 models, .944 on RTO 12509 models.

Bottom: Heavy-duty, 8-bolt type. PTO gear is 47-tooth, 6/8 pitch turning at .700 engine speed on RT-12509 models, .944 on RTO-12509 models.

1 cast iron for push or pull type clutches.

Weight - 680 lbs. (308 Kg. )

Installation Dimensions - From face of clutch housing to front (bottoming) face of companion flange hub 29.5" (749mm).

Oil Capacity - 25 pints (12 litres), depending upon inclination of engine and transmission.

Specifications RT-12513 Series

Power Take-Off - Two SAE standard openings for 6/8 pitch gears. Right Side: Regular duty type, 6-bolt, short length with 4.5-tooth PTO gear turning at

.700 engine speed. Bottom: Heavy duty type, 8-bolt, with 47-

tooth PTO gear turning at .700 engine speed.

Clutch Housing Size - For flush or pull type two-plate clutches. SAE NO. 1 cast iron.

Weight - 725 lbs. (329 Kg).

Installation Dimensions - From face of’ clutch housing to front (bottoming) face of’ companion flange hub 32.4" (823mm).

Oil Capacity - Approximately 27 pints

(13 litres), depending upon inclination of’ engine and transmission.

Lubrication

Proper Oil Level

Make sure oil is level with filler opening. Because you

can reach oil with your finger does not mean oil is at proper level.

Draining Oil

Drain transmission while oil is warm. To drain oil remove the drain plug at bottom of case. Clean the drain plug before re-installing.

Refilling

Clean area around filler plug and remove plug from side of case. Fill transmission to the level of the filler opening.

The exact amount of oil will depend on the transmission inclination and model. In every instance, fill to the

level of the filler opening.

Do not over fill - this will cause oil to be forced out

of the case through mainshaft openings.

Operating Temperature

It is important that the transmission operating temperature does not exceed 250 tended period of time. Operating temperatures above

F: will cause breakdown of the oil and shorten

250

transmission life.

The following conditions in any combination can cause operating temperatures of over 250 ating consistently at roadspeeds under 20 MPH, (2) high engine RPM, (3) high ambient temperature, (4) restricted air flow around transmission, (5) exhaust system too close to transmission, (6) high horsepower, overdrive operation. High operating temperatures may require more frequent oil changes.

External cooler kits are available to keep the transmission operating temperature under 250° F. when the conditions described above are encountered.

If the transmission operating angle is more than 12 degrees, improper lubrication can occur. The operating angle is the transmission mounting angle in the chassis plus the percent of upgrade (expressed in degrees ).

Anytime the transmission operating angle of 12 degrees is exceeded for an extended period of time the transmission should be equipped with an oil pump or

cooler kit to insure proper lubrication.

F. ( 120oC.) for an ex-

F: (1) Oper-

Adding Oil

It is recommended that types and brands of oil not

be intermixed because of possible incompatibility.

Type

Heavy Duty Engine Oil MIL-L-2104C, or MIL-L-46152, or AP1-SE, or AP1-CC SAE 30 Below + 10

Mineral Gear Oil R and O Type

Heavy Duty Engine Oil MIL-2104C, or MIL-L-46152, or API-SE, or AP1-CC SAE 30

Special Recommendation - For extreme cold weather

where temperature is consistently below 0

Heavy Duty Engine Oil MIL-L-2104C, or MIL-L-46152, or AP1-SE, or API-CC

Grade Temperature

SAE 50 or SAE 40 Above + 10

SAE 90 Above + 10 SAE 80W

SAE 50 or SAE 40 Above + 10

SAE 20W

(-12.5

Below + 10

Below 0

(-18

C.)

Note the effect low oil levels can have on safe operating angles. Allowing the oil level to fall 1/2" below the filler plug hole reduces the degree of grade by approximately 3 degrees (5.5 percent).

Every 5,000 miles (8045 Km)

Every 50,000 miles (80450 Km)

First 30 hours

Every 40 hours

Every 500 hours

Every 1,000 hours

Change oil filter element, if so equipped,

Change transmission oil (Normal off-highway use).

Inspect oil level. Check for leaks.

Change transmission oil.

Change transmission oil on new units.

Inspect oil level. Check for leaks.

Change transmission oil where severe dirt

conditions exist.

at each

oil change.

I I

Disassembly Precautions

It is assumed in the detailed disassembly instructions that the lubricant has been drained from the transmission, the necessary linkage and air lines removed and the transmission has been removed from the chassis. Removal of the gear shift lever housing assembly is included in the detailed instructions; however, this assembly must also be removed from transmission before

removing unit from vehicle.

Follow each procedure closely in each section,

making use of both the text and pictures.

1. BEARINGS - Carefully wash and relubricate all

bearings as removed and protectively wrap until ready for use. Remove bearings with pullers designed for this purpose.

2. ASSEMBLIES - When disassembling the various assemblies, such as the mainshaft, countershafts and shifting bar housing, lay all parts on a clean bench in the same sequence as removed. This procedure will simplify m-assembly and reduce the possibility of losing parts.

Inspection

3. SNAP RINGS - Remove snap rings with pliers designed for this purpose. Rings removed in this manner

can be reused.

4. INPUT SHAFT - The clutch or input shaft can be removed without removing the countershaft, mainshaft or drive gear.

5. CLEANLINESS - Provide a clean place to work. It is important that no dirt or foreign material enters the unit during repairs. The outside of the unit should be carefully cleaned before starting the disassembly. Dirt is abrasive and can damage bearings.

6. WHEN DRIVING - Apply force to shafts, housings, etc., with restraint. Movement of some parts is restricted. Do not apply force after the part being driven stops solidly. Use soft hammers and bars for all disassembly work.

Before reassembling the transmission, the individual

parts should be carefully checked to eliminate those damaged from previous service. This inspection procedure should be carefully followed to insure the maxi-

mum of wear life from the rebuilt unit.

The cost of a new part is generally a small fraction of

the total cost of downtime and labor, should the use of a questionable part make additional repairs necessary be-

fore the next regularly scheduled overhaul.

Recommended inspection procedures are set forth in the following check list:

A. Bearings

1. Wash all bearings in clean solvent. Check balls, rolls and races for pits and spalled areas. Replace bearings

which are pitted or spalled.

2. Lubricate bearings which are not spalled or pitted and check for axial and radial clearances. Replace bearings with excessive clearances.

3. Check fits of bearings in case bores. If outer races turn freely in the bores, the case should be replaced.

B. Gears

1. Check operating gear teeth for pitting on the tooth

faces. Gears with pitted teeth should be replaced.

2. Check all engaging gear teeth. Gears with teeth worn, tapered or reduced in length from clashing in shifting

should be replaced.

3. Check axial clearances of gears. Where excessive

clearance is found, check gear snap ring, washer, spacer

and gear hub for excessive wear. Maintain .005 to .012 axial clearance of mainshaft forward speed gears, .005

minimum on reverse gear.

C. Splines

1. Check splines on all shafts for wear. If sliding clutch gears, companion flange or clutch hub have worn into the sides of the splines, the shafts in this condition should be replaced.

D. Thrust Washers

1. Check surfaces of all thrust washers. Washers scored

or reduced in thickness should be replaced.

E. Reverse Gear and Shaft

1. Check bearing sleeve for wear from action of roller bearings.

F. Gray Iron Parts

1. Check all gray iron parts for cracks and breaks. Re-

place or repair parts found to be damaged. Heavy castings may be welded or brazed providing the cracks do not extend into bearing bores or bolting surfaces.

G. Clutch Release Parts

1. Check clutch release parts. Replace yokes worn at

cam surfaces and bearing carrier worn at contact pads.

2. Check pedal shafts. Replace those worn at bearing

surfaces.

H. Shifting Bar Housing Assembly

1. Check yokes and blocks for wear at pads and lever slot. Replace worn parts.

2. Check yokes for alignment. Straighten those which arc sprung.

3. Check yokes for excessive wear; replace worn yokes.

4. Check lockscrews in yokes and blocks. Tighten and rewire those found loose.

5. If housing has been dismantled, check neutral notches of shifting bars for wear from interlock balls. Bars indented at points adjacent to the neutral notch should be replaced.

1. Gear Shift Lever Housing Assembly

1. Check spring tension on shift lever. Replace tension

spring and washer if lever moves too freely.

2. If housing is dismantled, check pivot or spade pin and corresponding slot in lever for wear. Replace both parts if worn.

K. Oil Return Threads and Seals

1. Check oil return threads in front bearing cover. If sealing action of threads has been destroyed by contact with input shaft, replace the cover.

2. Check oil seal in mainshaft rear bearing cover. If scaling action of lip has been destroyed, replace seal.

L. Synchronizers

1. Check high and low range synchronizers for burrs, uneven and excessive wear at contact surface, and metal particles.

2. Check blocker pins for excessive wear or looscness.

3. Check synchronizer contact surfaces on the high and low range gears for excessive wear.

M. Sliding Clutches

1. Check all yokes and yoke slots in sliding clutches for

extreme wear or discoloration from heat.

2. Check engaging teeth of sliding clutches for partial

engagement pattern.

J. Bearing Covers

1. Check covers for wear from thrust of adjacent bearing. Replace covers worn and grooved from thrust of bearing outer race.

2. Check bores of covers for wear. Replace those worn oversize.

Reassembly Precautions

Make sure that interiors of case and housings arc clean. It is important that dirt be kept out of transmission during reassembly. Dirt is abrasive and can dam-

age polished surfaces of bearings and washers. Use cer-

tain precautions, as listed below, during reassembly.

1. GASKETS - Use new gaskets throughout the trans- mission as it is being rebuilt. Make sure all gaskets are installed, as omission of gasket can result in oil leakage or misalignment of bearing covers, See "Location of Gaskets" heading.

2. CAPSCREWS - To prevent oil leakage, use thread sealant on all capscrews. See torque rating chart for

recommended torque.

3. O-RINGS - Lubricate all O-rings with silicone

lubricant.

4. ASSEMBLY - Refer to the disassembly illustrations as a guide to reassembly.

5. INITIAL LUBRICATION -

and splints of shafts with Lubriplate during installation

Coat all thrust washers

N. Front Bearing Cover

1. Check inside hub of front bearing cover for wear

caused by backing off of drive gear bearing nut.

O. O-Rings

1. Check all O-rings for cracks or distortion. Replace if

worn.

to provide initial lubrication, preventing scoring and

galling.

6. AXIAL CLEARANCES - Maintain original axial clearances of mainshaft forward speed gears of .005" to

.012". Mainshaft reverse gear clearance is a minimum of

.005".

7. BEARINGS - Use of flanged-end bearing drivers is

recommended for the installation of bearings. These drivers apply equal force to both races of bearing, preventing damage to balls and races and maintaining cor-

rect bearing alignment with shaft and bore. If tubular or

sleeve type driver is used, apply force only to inner race.

8. UNIVERSAL JOINT COMPANION FLANGE - Pull

the companion flange tightly into place with the mainshaft nut, using 450-500 foot-pounds of torque. Make sure the speedometer gear has been installed on yoke. If a speedometer gear is not used, a replaement spacer of the same width must be used. Failure to pull the yoke or flange tightly into place will permits the shaft to move axially with resultant damage to rear bearing.

Shifting Controls

I. Deep Reduction Air Lines -

RTO-1258LL

(Range Shift Air Lines Omitted for Clarity)

A. REMOVAL

1. Disconnect the signal air line (A) and the supply air line (B) from between the transmission and the deep reduction control valve mounted in the cab.

2. Disconnect the 1/4" ID deep reduction shift cylinder supply air line (C) from between the shift cylinder and the tee fitting forward of the regulator.

3. Disconnect the 1/4" ID slave air valve supply line

(D) from between the slave air valve and the tee fitting

forward of the regulator.

B. INSTALLATION

1. Install the 18" 1/4" ID slave air valve supply line (D) between the slave air valve and the tee fitting for-

ward of the regulator.

2. Install the 17" supply air line (C) between the fitting forward of the regulator and the deep reduction shift cylinder.

3. Install the control valve supply air line (B) between the slave air valve and the "IN" port of the control

valve.

4. Install the signal air line (A) between the deep reduction shift cylinder and the "OUT" port of the control valve.

II. Splitter Gear Air Lines -

RT-12513 Series (Two Position Valve)

(Range Shift Air Lines Omitted for Clarity)

A. REMOVAL

1. Disconnect the white 1/8" OD supply air line (A) from between the tee fitting on the slave air valve and the "S" port on the selector valve.

2. Disconnect the black 1/8" OD signal air line (B) from between the splitter shift cylinder and the "D" port of the selector valve.

3. Disconnect the 1/4" ID supply air line (C) from between the tee fitting forward of the regulator and the splitter shift cylinder.

4. Disconnect the 18" 1/4" ID slave air valve supply line (D) from between the air valve and the tee fitting forward of the regulator.

B. INSTALLATION

1. Connect the 18" 1/4" ID supply air line (D) between the slave air valve and the tee fitting forward of the

regulator.

2. Connect the 1/4" ID supply air line (C) between the splitter shift cylinder and the tee fitting forward of the regulator.

3. Connect the black 1/8" OD signal air line (B) between the splitter shift cylinder and the "D" port of the selector valve.

4. Connect the white 1/8" ID supply air line (A) between the tee fitting on the slave air valve and the "S" port on the selector valve.

Shifting Controls - continued

III. Splitter Gear Air Lines -

RT-12513 Series (Three position valve)

(Range Shift Air Lines Omitted for Clarity)

A. REMOVAL

1. Disconnect the white 1/8" OD supply air line (A)

from between

2. Disconnect the black 1/8" OD range shift signal air line (B) from between the slave air valve and the selector valve.

3. Disconnect the black 1/8"

air line (C) from between the selector valve and the

splitter shift cylinder.

Disconnect the "A" OD supply air line (D) from

between the splitter shift cylinder and the tee fitting forward of the regulator.

Disconnect the 1/4" ID slave air valve supply line

(E) from between the slave air valve and the tee fitting

forward of the regulator.

the slave air valve and the selector valve.

OD splitter shift signal

B. INSTALLATION

1. Install the 18" 1/4" ID supply air line (E) between the slave air valve and the tee fitting forward of the

regulator.

2. Install the 17" 1/4" ID supply air line (D) between the splitter shift cylinder and the tee fitting forward of

the regulator.

3. lnstall the 1/8" OD signal air line (C) between the splitter shift cylinder and the "R" port of the selector valve.

4. Install the 1/8" OD signal air line (B) between the slave air valve and the "F" port of the selector valve.

5. Install the 1/8" slave air valve and the "S" port of the selector valve.

OD supply air line (A) between the

IV. Range Shift Air Lines - All Models

—

A. REMOVAL

1. Disconnect the black and white 1/8" OD air lines (A and B) from between the slave air valve and the

range shift control valve.

2. Disconnect the two 1/4" ID air lines from between the slave air valve side cap and the range shift cylinder.

B. INSTALLATION

1. Disconnect the black and white 1/8" OD supply air line between the forward port on the slave air valve and the rear port on the range shift control valve.

2. Install the black 1/8" OD signal air line between the rear port on the slave air valve and the forward port on the range control valve.

3. Use the chart to install the "A" ID air lines between the slave air valve side cap and the range shift cylinder.

Shifting Controls - continued

V. Two and Three Position Selector Valves

A. REMOVAL AND DISASSEMBLY

1. Disconnect all air lines to the valve. Loosen the jam

nut securing the valve to the gear shift lever and turn

the valve from the lever.

2. Remove the three screws on the bottom of the valve and lift the top cover from the body.

3. Remove the actuator from the top cover post and

remove the springs, seals, O-rings and detent parts

from the actuator.

B. REASSEMBLY AND INSTALLATION

1. Refer to the drawing for proper assembly of the

springs, seals, O-ring and detent parts. Use a VERY SMALL amount of silicone lubricant on the O-rings to avoid clogging the valve ports.

2. Install the air lines with their sheathing and O-rings

on the gear shift lever.

3. Install the jam nut on the lever and install the selec-

tor valve. Use the jam nut to lock the valve in position

with the actuator button facing the driver's seat.

4. Install the 1/8" OD air lines.

VI.

Range Control Valve

A. REMOVAL AND DISASSEMBLY

1. Disconnect the air lines and loosen the clamp securing the valve to the gear shift lever. Remove valve.

2. Remove the four screws to separate the front and rear housings and remove the slide and two sets of position springs and balls.

3. Remove the valve plate, insert O-rings and wave

washer from the valve bodies.

4. If necessary, remove the two felt seals. Punch out the roll pin to remove the button from the slide.

B. REASSEMBLY AND INSTALLATION

1. Refer to the drawing for proper reassembly. Use a VERY SMALL amount of silicone lubricant on the

O-rings to avoid clogging the ports. A small amount of grease on the position springs and balls will help to hold them in place during reassembly.

2. Install the air lines with their sheathing and O-rings on the gear shift lever.

3. Secure the valve on the gear shift lever with the

clamp. The control button should face to the front and be approximately 6“ below the centerline of the shift knob or selector valve.

4. Attach the air lines.

Shifting Controls - continued

VII.

Slave Air Valve - All Models

A. REMOVAL AND DISASSEMBLY

1. Turn out the four capscrews, jar lightly to break the gasket seal and remove the air valve from the adapter plate.

2. Remove the alignment sleeve which will be either in the adapter plate bore or on the back of the air valve.

5. Remove the insert spring from the piston.

3. Chuck the valve in a vise by the top and bottom and

remove all brass fittings if necessary. Turn out the two

screws and remove the side cap.

4. Remove the valve insert from the piston and remove the O-ring from the valve insert.

6. Turn the end cap from the valve body and remove the piston from the bore.

7. Remove the two O-rings from the piston.

8. Remove the nylon plug from the piston and remove

the O-ring from the plug.

9. Remove the actuating spring and plunger from the adapter plate or case bore.

10. If so equipped, turn out the two Allen head screws and two capscrews and remove the adapter plate from the transmission side.

Shifting Controls - continued

VII. Slave Air Valve - All Models

B. REASSEMBLY AND INSTALLATION

1. If so equipped, install the adapter plate and gasket

on the transmission with the two Allen head screws and two capscrews. Use the alignment sleeve to make sure that the bore in the adapter plate lines up properly with the case bore.

2. Install the actuating plunger in the plate bore with the small end facing out.

3. Install the actuating spring over the plunger.

4. Install the O-rings on the piston and apply a thin coat of silicone lubricant. Install the piston in the valve body with the large end facing out and the piston bore lined up with the slot in the side cap mounting surface.

5. Install the O-ring on the plug and apply a thin coat of silicone lubricant. Insert the plug into the piston bore with the flat surface facing out.

7. Apply a thin coat of Lubriplate to the machined face of

the side cap and install the side cap on the valve body.

8. Install the end cap on the valve body. DO NOT use more than 40 lbs.-ft. of torque or the end cap will bind

the piston.

6. Install the insert spring in the bore. Install the O-ring

on the valve insert and apply a thin coat of silicone lubricant. Install the valve insert in the bore with the large end facing out.

9. Install the alignment sleeve in the bore in the back of the valve and install the valve and gasket on the adapter plate. If previously removed, install the brass fittings on the valve.

VII. Filter/Regulator Assembly - All Models

* Not used with RT-12509 Series Transmissions

A. REMOVAL AND DISASSEMBLY

1. Turn out the two retaining capscrews and remove

the assembly from the transmission.

2. Turn out the two clamp nuts and remove the filter/ regulator assembly from the bracket.

3. Remove the fittings and if necessary, turn the regu-

lator from the filter.

4. If necessary, turn the end cap from the filter to remove the filter core. Use caution as the end cap is spring loaded.

B. REASSEMBLY AND INSTALLATION

1. Refer to the drawing for reassembly of the air filter.

2. Secure the nipple and regulator to the "OUTLET" port of the filter. Note that the larger of the two bores on the regulator attaches to the filter.

3. Secure the filter to the bracket with the "U" clamp, nuts and lockwashers.

4. Install the two range shift air lines between the slave air valve and the range shift cylinder and secure the filter/regulator assembly to the auxiliary housing with the two capscrews.

Shifting Controls - continued

IX. Gear Shift Lever Housing - All Models

OLD STYLE

NEW STYLE

A. REMOVAL AND DISASSEMBLY

B. REASSEMBLY

AND INSTALLATION

1. Turn out the capscrews, jar lightly to break the gasket seal and remove the gear shift lever housing from

the shift bar housing.

1. Install the spade pin or pivot pin, nut and washer in the bore in the housing. If previously removed, install the O-ring in the groove.

2. Install the gear shift lever in the housing, fitting the slot in the lever ball over the spade pin.

3. Place the tension spring washer over the lever ball

with the dished side up:

2. Secure the housing in a vise and use a large screw-

driver to twist between the spring and side of the hous-

ing, forcing the spring from under the three lugs. Do

one coil at a time. Remove the spring.

3. Remove the washer and gear shift lever.

4. Remove the spade pin or pivot pin, nut and washer from the bore in the housing. If necessary, remove the O-ring from the housing.

4. Seat the tension spring under the lugs in the housing, seating one coil at a time. Use of a spring driving tool

is recommended.

5. Make sure that the three tension springs and balls are in the shift bar housing bores and install the gear

shift lever housing and gasket on the shift bar housing.

Shifting Controls - continued

X. Shift Bar Housing - All Models

A. REMOVAL AND DISASSEMBLY

1. Make sure that the shift bars are in the neutral position. Remove the three tension springs, (arrow ). Turn out the retaining capscrews, jar lightly to break the gasket seal and lift the shift bar housing from the front case. Remove the three tension balls from the housing

bores by tipping the housing slightly.

4. Remove the actuating plunger.

2. Mount the housing in a vise using caution to avoid

marring the machined mounting surface. If so equipped, remove the oil trough. Cut and remove all of lockwires. Turn out the lockscrews and remove the direct speed shift bar, yoke and block.

the

3. Turn out the lockscrews and remove the 2nd speed shift bar, yoke and block. As the notch clears the hous-

ing boss, remove the interlock pin, (arrow).

5. Turn out the lockscrew and remove the reverse speed shift bar and yoke. If necessary, turn out the plug on the yoke and remove the spring and plunger. Use caution as the plug is spring loaded.

6. Remove the two interlock balls from the bore in the housing boss.

Shifting Controls - continued

X. Shift Bar Housing

B. REASSEMBLY AND INSTALLATION

1. If previously removed, install the reverse-stop plunger in the reverse yoke. Make sure that the plunger

is fully seated in the bore.

2. Install the spring in the bore and on the plunger.

4. Install the reverse shift bar and yoke. Install the yoke lockscrew; tighten and wire securely.

5. Install the actuating plunger.

3. Apply adhesive sealant to the plug threads and partially

install the plug. Use the tip of the gear shift lever to push the plunger back into the bore to compress the spring. Tighten the plug fully and then back off 1/2 - 1-1/2 turns. Stake the plug threads in the hole.

6. Install one of the two interlock balls in the housing bore, making sure that the ball goes all the way to the bottom of the bore and rests on the reverse shift bar.

7. Install the 2nd speed shift bar, yoke and block, in-

serting the interlock

pin in the neutral notch of the bar,

(arrow). Install the yoke and block lockscrews; tighten and wire securely. On "F" model transmissions, use the short lockscrew in the shift block.

8. Install the remaining interlock ball,

10. Install the three tension balls; one in each bore.

11. Install the shift bar housing and gasket on the front case, fitting the yoke slots into the mainshaft sliding clutch gears. The shift bars and clutches must be in the neutral position. Install the three tension springs in the bores.

9. Install the direct speed shift bar, yoke and block. Install lockscrews and wire securely. If so equipped, install the oil trough with the two lockscrews and wire securely.

12. Secure the housing with the retaining capscrews. I

Auxiliary Sections

I. Removal and lnstallation -

All Models

A. REMOVAL FROM FRONT CASE

NOTE:

The RT-12513 auxiliary section is shown in the following steps. However, the procedure is the same for RT-12509 series and RTO-

1258LL transmissions.

3. Turn out the capscrews securing the auxiliary section to the front case.

1. If not previously removed, use two clutches in the front case to lock the transmission in two gears and use a large breaker bar to turn the output shaft nut from the output shaft.

2. Remove the stop nut washer and companion flange or yoke from the splines of the output shaft.

4. insert three puller screws in the tapped holes in the auxiliary section flange and tighten evenly to move the auxiliary approximately 1/2" to the rear.

5. Attach a lifting bracket at the top center of the auxiliary section. Move the auxiliary to the rear and off the front case dowel pins. Mount the auxiliary in a vise using caution to avoid damage to the machined surface of the flange.

B. INSTALLATION ON THE FRONT CASE

1. Install the gasket on the front case. Attach a lifting bracket and chain hoist to the top center of the auxiliary section and guide the section on to the front case dowel pins. The two auxiliary countershafts will mesh with the drive gear and the front of each shaft will seat in the two bearings installed in the front section. Move the assembly evenly, rotating the drive gear, if necessary, to properly mesh gears.

3. Install the speedometer drive gear or replacement spacer on the hub of the flange or yoke. Install the flange on the splines of the output shaft.

NOTE:

The auxiliary section can also be installed by setting the front section vertically on wood blocks and lowering the auxiliary section onto the front case with a chain hoist attached to an

output shaft lifting bracket. This procedure is

recommended for installation of the RTO-

1258LL auxiliary section due to the extreme length and weight of the countershaft assemblies.

With

the

auxiliary section fully

into position against the

front case, install the capscrews.

4. Lock the front case by engaging two sliding clutches and secure the flange or yoke with the elastic stop nut, using 450-500 lbs./ft. or torque. The nut should be pre-lubricated.

Auxiliary Sections - continued

II. RT-12509 Auxiliary Section Disassembly

A. REMOVAL AND DISASSEMBLY

OF THE RANGE SHIFT CYLINDER ASSEMBLY

1. Turn out the four capscrews and remove the shift cylinder cover. Remove the nut from the end of the

yoke bar.

2. Cut the lockwire and turn out the two yoke lock-

screws.

3. Pull the yoke bar forward and out of the housing. Re-

move the piston from the cylinder bore and if necessary,

remove the O-rings from the ID and OD of the piston.

4. Remove the shift yoke, turn out the four capscrews and remove the cylinder housing from the auxiliary plate. If necessary, remove the O-ring from the bore in

the housing.

B. REMOVAL OF THE

AUXILIARY COUNTERSHAFTS

1. Turn out the capscrews and remove the two countershaft rear bearing covers. Remove the snap ring from the rear of each countershaft.

C. REMOVAL AND DISASSEMBLY

OF THE SYNCHRONIZER ASSEMBLY

2. Pull the synchronizer assembly forward and from the splines of the output shaft.

2. Use a soft bar and mall to drive the countershafts forward and from the rear bearings. Use a soft bar to tap the bearings to the rear and from the auxiliary plate. Tap on the outer race to avoid damaging the bearings.

2. Pull the direct ring from the blocker pins of the low speed ring; cover the assembly with a cloth during this step to avoid losing the three springs which will be released from the direct ring. Remove the sliding clutch gear from the low speed ring.

Auxiliary Sections - continued

II. RT-12509 Auxiliary Section Disassembly

D. REMOVAL AND DISASSEMBLY

OF THE LOW SPEED GEAR AND OUTPUT SHAFT

1. Use a soft bar and mall to drive the output shaft for-

ward and from the rear bearing.

2. Remove the bearing inner spacer from the shaft.

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