Eaton Transmission RTX-16710C Service Manual

Service Manual

Fuller Heavy Duty Transmissions TRSM0440

August 2009

RTX-11709A RTX-11709B RTX-11709H RTX-11710B RTX-11710C RTX-12709A RTX-12709B RTX-12709H RTX-12710B RTX-12710C RTX-13709H RTX-13710B RTX-13710C RTX-14709A RTX-14709B RTX-14709H RTX-14710B RTX-14710C

RTX-15710B RTX-15710C RTX-15715 RTX-16709B RTX-16709H RTX-16710B RTX-16710C RTXF-11709H RTXF-11710B RTXF-11710C RTXF-12709H RTXF-12710B RTXF-12710C RTXF-13709H RTXF-13710B RTXF-13710C RTXF-14709H RTXF-14710B

RTXF-14710C RTXF-15710B RTXF-15710C

For parts or service call us

Pro Gear & Transmission, Inc.

1 (877) 776-4600

(407) 872-1901

parts@eprogear.com

906 W. Gore St.

Orlando, FL 32805

Warnings and Precautions

Before starting a vehicle always be seated in the driver’s seat, place the transmission in neutral, set the parking brakes and disengage the clutch.

Before working on a vehicle place the transmission in neutral, set the parking brakes and block the wheels.

Before towing the vehicle place the transmission in neutral, and lift the rear wheels off the ground, remove the axle shafts, or disconnect the driveline to avoid damage to the transmission during towing.

The description and specifications contained in this service publication are current at the time of printing.

Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice.

Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents may be used.

This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and/or component damage.

Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator.

WARNING

Warning: Failure to follow indicated procedures creates a high risk of personal injury to the service technician.

Caution: Failure to follow indicated procedures may cause component damage or malfunction.

Note: Additional service information not covered in the service procedures.

Tip: Helpful removal and installation procedures to aid in the service of this unit.

Always use genuine Eaton replacement parts.

Table of Contents

General Information

Purpose and Scope of Manual . . . . . . . . . . . . . . . . . . . 4

Disassemble Precautions . . . . . . . . . . . . . . . . . . . . . . . 4

Serial Tag and Model Nomenclature . . . . . . . . . . . . . . 8

Model Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Gear Ratios - XX709, 1X710 . . . . . . . . . . . . . . . . . . . 11

Torque Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Tool Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . 20

Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Timing

Timing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Auxiliary Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

In-Vehicle Service Procedure

Air System

How to Remove Compression Type Fittings . . . . . . . . 29

How to Install Compression Type Fittings . . . . . . . . . 30

How to Remove Push-To-Connect Type Fittings . . . . 31

How to Install Push-To-Connect Type Fittings . . . . . . 32

How to Remove Rubber 1/4" Air Hoses . . . . . . . . . . . 33

How to Install Rubber 1/4" Air Hoses . . . . . . . . . . . . . 34

How to Install the Air Filter/Regulator . . . . . . . . . . . . 35

How to Remove the Air Filter/Regulator . . . . . . . . . . . 36

How to Remove a Roadranger Valve . . . . . . . . . . . . . 37

How to Install a Roadranger Valve . . . . . . . . . . . . . . . 38

How to Remove a Slave Valve . . . . . . . . . . . . . . . . . . 39

How to Install a Slave Valve . . . . . . . . . . . . . . . . . . . . 40

Shift Bar Housing

How to Remove the Gear Shift Lever/Remote

Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

How to Install the Gear Shift Lever/Remote

Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

How to Adjust the Remote Shift Control

(LRC Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Neutral Switch Operation and Testing . . . . . . . . . . . . 45

How to Remove the Neutral Switch . . . . . . . . . . . . . . 46

How to Install the Neutral Switch . . . . . . . . . . . . . . . . 47

Reverse Switch Operation and Testing . . . . . . . . . . . . 48

How to Remove the Reverse Switch . . . . . . . . . . . . . 49

How to Install the Reverse Switch . . . . . . . . . . . . . . . 50

Table of Contents

Output Yoke/Companion Flange

How to Remove the Output Yoke/

Companion Flange and Nut . . . . . . . . . . . . . . . . 51

How to Install the Output Yoke/

Companion Flange and Nut . . . . . . . . . . . . . . . . 54

How to Remove the Output Yoke/

Flange and Retaining Capscrews . . . . . . . . . . . . 55

How to Install the Output Yoke/

Flange and Retaining Capscrews . . . . . . . . . . . . 56

Auxiliary Section

How to Remove the Auxiliary Section with

Tapered Bearings . . . . . . . . . . . . . . . . . . . . . . . . 57

How to Install the Auxiliary Section in Chassis . . . . . 60

Transmission Overhaul Procedures Bench Service

Shift Bar Housing

How to Disassemble the Gear Shift Lever . . . . . . . . . 63

How to Assemble the Gear Shift Lever . . . . . . . . . . . 65

How to Remove the Shift Bar Housing . . . . . . . . . . . 67

How to Install the Shift Bar Housing . . . . . . . . . . . . . 69

How to Disassemble the Shift Bar Housing . . . . . . . . 71

How to Assemble the Shift Bar Housing . . . . . . . . . . 73

Disassemble Auxiliary Section

How to Remove the Auxiliary Section with

Tapered Bearings . . . . . . . . . . . . . . . . . . . . . . . . 77

How to Disassemble the Range Cylinder Assembly . . 80 How to Remove the Auxiliary Countershaft

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

How to Disassemble the Synchronizer Assembly . . . 86

How to Disassemble the Output Shaft Assembly . . . . 87

Assemble Auxiliary Section

How to Assemble the Output Shaft Assembly . . . . . . 92

How to Assemble the Synchronizer Assembly . . . . . . 94

How to Install the Oil Seal . . . . . . . . . . . . . . . . . . . . . 96

How to Assemble the Range Cylinder Assembly . . . . 97

How to Install the Countershaft Assemblies . . . . . . 100

Table of Contents

Disassemble Front Section

How to Remove the Clutch Housing

(with Internal Oil Tube) . . . . . . . . . . . . . . . . . . . 106

How to Install the Clutch Housing

(with Internal Oil Tube) . . . . . . . . . . . . . . . . . . . 108

How to Remove the Standard Torque Auxiliary

Drive Gear Assembly . . . . . . . . . . . . . . . . . . . . . 111

How to Disassemble the Upper and Lower Reverse

Idler Gear Assembly . . . . . . . . . . . . . . . . . . . . . 112

How to Remove the Upper and Lower

Countershaft Bearings . . . . . . . . . . . . . . . . . . . 114

How to Remove the Input Shaft and Main

Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

How to Remove the Mainshaft Assembly . . . . . . . . . 119

How to Disassemble the Mainshaft Assembly . . . . . 121

How to Disassemble the Mainshaft Assembly

with Low Force Gearing . . . . . . . . . . . . . . . . . . 125

How to Remove the Countershaft Assemblies . . . . . 127

How to Disassemble the Countershaft Assemblies . 129 How to Disassemble the Auxiliary Drive

Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 132

Assemble Front Section

How to Prepare the Main Case for Assembly . . . . . . 133

How to Assemble the Auxiliary Drive

Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 134

How to Assemble the Lower Reverse Idler Gear

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

How to Assemble the Mainshaft Assembly

with Low Force Gearing . . . . . . . . . . . . . . . . . . 138

How to Assemble the Countershaft Assemblies . . . . 141

How to Install the Auxiliary

Countershaft Assembly . . . . . . . . . . . . . . . . . . 144

How to Install the Lower Countershaft Bearings . . . 147 How to Install the Input Shaft and Main

Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Mainshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . 152

How to Install the Mainshaft Assembly with Selective

(Adjustable) Thickness Tolerance Washers . . . 153

How to Install the Mainshaft . . . . . . . . . . . . . . . . . . 161

How to Install the Upper Countershaft Bearings . . . 163 How to Assemble the Upper Reverse Idler

Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 166

How to Install the Standard Torque Auxiliary Drive

Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 168

Install Auxiliary Section

How to Install the Auxiliary Section With

Tapered Bearings . . . . . . . . . . . . . . . . . . . . . . . 169

Shim Procedure With A Shim Tool For

Tapered Bearings . . . . . . . . . . . . . . . . . . . . . . . 172

Shim Procedure without a Shim Tool for

Tapered Bearings . . . . . . . . . . . . . . . . . . . . . . . 175

Purpose and Scope of Manual

Introduction

This manual is designed to provide information necessary to service and repair the Eaton Fuller transmissions listed on the front.

How to use this Manual

The service procedures have been divided into two sections: In-Vehicle Service Procedures and Transmission Overhaul Procedures—Bench Service. In-Vehicle Service Procedures contain procedures that can be performed while the transmission is still installed in the vehicle. Transmission Overhaul Procedures contain procedures that are performed after the transmission has been removed from the vehicle.

The procedure sections are laid out with a general heading at the top outside edge of each page followed by more specific headings and the procedures. To find the information you need in these sections, first go to the section that contains the procedure you need. Then look at the heading at the top and outside edge of each page until you find the one that contains the procedure you need.

Transmission Overhaul Procedures follow the general steps for complete disassembly and then assembly of the transmission.

Note: In some instances the transmission appearance may be different from the illustrations, but the procedure is the same.

Disassemble Precautions

It is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission, the necessary linkage and vehicle air lines disconnected and the transmission has been removed from vehicle chassis. Removal of the gear shift lever housing assembly (or remote control assembly) is included in the detailed instructions (How to Remove the Gear Shift Lever). This assembly MUST be detached from the shift bar housing before the transmission can be removed.

Introduction

Follow closely each procedure in the detailed instructions, make use of the text, illustrations, and photographs provided.

Assemblies

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

Bearings

• Carefully wash and lubricate all usable bearings as removed and protectively wrap until ready for use. Remove bearings planned to be reused with pullers designed for this purpose.

Cleanliness

• Provide a clean place to work. It is important that no dirt or foreign material enters the unit during repairs. Dirt is an abrasive and can damage bearings. It is always a good practice to clean the outside of the unit before starting the planned disassembly.

Input Shaft

• The input shaft can be removed from the transmission without removing the countershafts, mainshaft, or main drive gear. Special procedures are required and provided in this manual.

Snap Rings

• Remove snap rings with pliers designed for this purpose. Snap rings removed in this manner can be reused, if they are not sprung or loose.

Introduction

When Using Tools to Move Parts

• Always apply force to shafts, housings, etc., with restraint. Movement of some parts is restricted. Never apply force to driven parts after they stop solidly. The use of soft hammers, soft bars, and mauls for all disassembly work is recommended.

Inspection Precautions

Before assembling the transmission, check each part carefully for abnormal or excessive wear and damage to determine reuse or replacement. When replacement is necessary, use only genuine Eaton® Fuller® Transmission parts to assure continued performance and extended life from your unit.

Since the cost of a new part is generally a small fraction of the total cost of downtime and labor, avoid reusing a questionable part which could lead to additional repairs and expense soon after assembly. To aid in determining the reuse or replacement of any transmission part, consideration should also be given to the unit's history, mileage, application, etc.

Recommended inspection procedures are provided in the following checklist.

Bearings

• 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.

• Lubricate bearings that are not pitted, discolored, or spalled and check for axial and radial clearances.

• Replace bearings with excessive clearances.

• Check bearing fit. Bearing inner races should be tight to shaft; outer races slightly tight to slightly loose in case bore. If the bearing spins freely in the bore the case should be replaced.

Bearing Covers

• Check covers for wear from thrust of adjacent bearing. Replace covers damaged from thrust of bearing outer race.

• Check cover bores for wear. Replace those worn or oversized.

Clutch Release Parts

• Check clutch release parts. Replace yokes worn at cam surfaces and bearing carrier worn at contact pads.

• Check pedal shafts. Replace those worn at bushing surfaces.

Gears

• 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.

• 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.

• Check axial clearance of gears.

Gear Shift Lever Housing Assembly

• Check spring tension on shift lever. Replace tension spring if lever moves too freely.

• If housing is disassembled, check gear shift lever bottom end and shift finger assembly for wear. Replace both gears if excessively worn.

Gray Iron Parts

Introduction

• Check all gray iron parts for cracks and breaks. Replace parts found to be damaged.

Oil Return Threads and Seals

• Check oil return threads on the input shaft. If return action of threads has been destroyed, replace the input shaft.

• Check oil seal in rear bearing cover. If sealing action of lip has been destroyed, replace seal.

O-Rings

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

Reverse Idler Gear Assemblies

• Check for excessive wear from action of roller bearings.

Shift Bar Housing Assembly

• Check for wear on shift yokes and blocks at pads and lever slot. Replace excessively worn parts.

• Check yokes for correct alignment. Replace sprung yokes.

• Check lockscrews in yoke and blocks. Tighten and rewire those found loose.

• If housing has been disassembled, check neutral notches of shift bars for wear from interlock balls.

Sliding Clutches

• Check all shift yokes and yoke slots in sliding clutches for extreme wear or discoloration from heat.

• Check engaging teeth of sliding clutches for partial engagement pattern.

Introduction

Splines

• Check splines on all shafts for abnormal wear. If sliding clutch gears, companion flange, or clutch hub has wear marks in the spline sides, replace the specific shaft effected.

Synchronizer Assembly

• Check synchronizer for burrs, uneven and excessive wear at contact surface, and metal particles.

• Check blocker pins for excessive wear or looseness.

• Check synchronizer contact surfaces on the synchronizer cups for wear.

Washers

• Check surfaces of all washers. Washers scored or reduced in thickness should be replaced.

Assembly Precautions

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 assembly.

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.

Introduction

Capscrews

• To prevent oil leakage and loosening, use Eaton Fuller sealant #71205 on all capscrews.

Gaskets

• Use new gaskets throughout the transmission as it is being rebuilt. Make sure all gaskets are installed. An omission of any gasket can result in oil leakage or misalignment of bearing covers.

Initial Lubrication

• Coat all limit washers and shaft splines with Lubricant 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 lbs. 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 number) to ensure that proper parts are used during assembly of the transmission.

Model Designations

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. Figure 1-1 below shows the tag which is located on the transmission.

When calling for service assistance or parts, have the model and serial numbers handy

Do not remove or destroy the transmission identification tag!

Model Designations

Fig 1-1

Transmission Tag and Location

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.

RT-12609A

RT Roadranger Twin Countershaft RTF w/ Forward Shift Bar Housing RTO w/ Overdrive RTOO w/ Double Overdrive RTOF w/ Overdrive and Forward Shift Bar Housing RTOOF w/ Double Overdrive and Forward Shift Bar Housing RTX w/ Overdrive and Direct Shift Pattern RTXF w/ Overdrive, Direct Shift Pattern and Forward Shift Bar Housing

7 = Helical Auxilary Gearing and

"Multi-Mesh" Front Gearing

This (x) 100 = Nominal Torque Capacity

5 = "Spur" Gearing

6 = "Multi-Mesh" Gearing

Serial Number

The serial number is the sequential identification number of the transmission. Before calling for service assistance, write the number down as it may be needed.

Bill of material or Customer number

This number may be located below the model and serial numbers. It is a reference number used by Eaton®.

Ratio Set

Forward Speed

Model Designations

Model Options

Torque Rating

The torque rating of the transmission specified in the model number is the input torque capacity in lb. ft. Various torque ratings are available. For more information, call the Roadranger Help Desk at 1-800-826-HELP (4357).

Two types of shift bar housings are available for this transmission. Both are described and shown below.

Shift Bar housings Standard: The standard shift bar housing has a gear shift lever opening that is located toward the rear of the transmission. The

housing is shown in figure 1-2.

Fig 1-2

Model Designations

Forward Opening: The forward opening shift bar housing has a gear shift lever opening located three inches closer to the front of the transmission than the standard opening. This forward design allows greater flexibility in mounting the transmission and in indicated by an “F” in the model number. The housing is shown in figure1-3.

Model Designations

Fig 1-3

Lubrication Pumps

Two types of lubrication pumps are available for use on this transmission and are described below:

PTO Driven: A PTO driven pump is externally mounted on the 6 or 8 bolt PTO openings and driven off the PTO gear.

Auxiliary Countershaft: An auxiliary countershaft pump is mounted on the rear of the transmission and driven off the auxiliary

countershaft.

Power Take Off (PTO) Usage

PTOs can be mounted in the following ways:

6 or 8 Bolt: The 6 or 8 bolt openings are standard with the transmission. The PTO is mounted to the opening and driven from the PTO gear on the front countershaft.

Thru-Shaft: The thru-shaft PTO mounts on the rear of the transmission. It requires a special auxiliary housing and main case countershaft with internal splines.

Model Designations

Gear Ratios

Model Speed Gear Ratios Relative Speed

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10 Reverse Right Btm

RT-11709H 13.29 9.16 6.53 4.80 3.57 2.56 1.83 1.34 - - 3.89/

RT-11710B 14.78 11.00 8.17 6.00 4.46 3.31 2.46 1.83 1.34 1.00 3.38/

RT-12709H 13.29 9.16 6.53 4.80 3.57 2.56 1.83 1.34 - - 3.89/

RT-12710B 14.78 11.00 8.17 6.00 4.46 3.31 2.46 1.83 1.34 1.00 3.38/

RT-13709H 13.29 9.16 6.53 4.80 3.57 2.56 1.83 1.34 - - 3.89/

RT-13710B 14.78 11.00 8.17 6.00 4.46 3.31 2.46 1.83 1.34 1.00 3.38/

RT-14709H 13.29 9.16 6.53 4.80 3.57 2.56 1.83 1.34 - - 3.89/

RT-14710B 14.78 11.00 8.17 6.00 4.46 3.31 2.46 1.83 1.34 1.00 3.38/

RTX-11709H 10.55 7.41 5.23 3.79 2.77 1.95 1.38 1.00 - - 2.99/

RTX-11710B 10.99 8.18 6.07 4.46 3.32 2.46 1.83 1.36 1.00 .74 2.52/

RTX-12709H 10.55 7.41 5.23 3.79 2.77 1.95 1.38 1.00 - - 2.99/

RTX-12710B 10.99 8.18 6.07 4.46 3.32 2.46 1.83 1.36 1.00 .74 2.52/

RTX-13709H 10.55 7.41 5.23 3.79 2.77 1.95 1.38 1.00 - - 2.99/

RTX-13710B 10.99 8.18 6.07 4.46 3.32 2.46 1.83 1.36 1.00 .74 2.52/

RTX-14709H 10.55 7.41 5.23 3.79 2.77 1.95 1.38 1.00 - - 2.99/

RTX-14710B 10.99 8.18 6.07 4.46 3.32 2.46 1.83 1.36 1.00 .74 2.52/

RTX-16709H 10.55 7.41 5.23 3.79 2.77 1.95 1.38 1.00 - - 2.99/

RTX-16709B 12.46 7.41 5.23 3.79 2.77 1.95 1.38 1.00 - - 3.43/

13.89

14.78

13.89

14.78

13.89

14.78

13.89

14.78

11.33

11.23

11.33

11.23

11.33

11.23

11.33

11.23

11.33

13.03

.696 .696 28.90 /

.788 .788 28.9 /

.696 .696 28.90 /

.788 .788 28.9 /

.696 .696 28.90 /

.788 .788 28.9 /

.696 .696 28.90 /

.788 .788 29.5 /

.788 .788 28.91 /

.788 .788 28.9 /

.788 .788 28.91 /

.788 .788 28.9 /

.788 .788 28.91 /

.788 .788 28.9 /

.788 .788 28.91 /

.788 .788 29.5 /

.788 .788 28.91 /

.788 .788 29.50 /

PTO Gear To Input R.P.M.

Length

In / mm

734.1

749.3

743.3

734.1

743.3

734.1

743.3

734.1

743.3

749.3

743.3

749.3

Weight

Lbs/ Kgs

606 / 275

604 / 274

606 / 275

611 / 277

606 / 275

624 / 283

664 / 301

604 / 274

664 / 301

606 / 275

664 / 301

611 / 277

664 / 301

624 / 283

664 / 301

693 / 314

Oil Cap.

Pints /

Liters

***

25.5 / 12

26 / 12

25.5 / 12

26 / 12

25.5 / 12

26 / 12

25.5 / 12

26 / 12

25.5 / 12

26 / 12

25.5 / 12

26 / 12

25.5 / 12

26 / 12

25.5 / 12

26 / 12

25.5 / 12

* Lengths measured from face of clutch housing to front bottoming surface of companion flange or yoke. ** Weights include SAE No.1 cast iron clutch housing and standard controls (control valve, gear shift lever and housing assem-

bly, and air lines), less clutch release parts. All weights are approximate. ***Oil Capacities are approximate, depending on inclination of engine and transmission. Always fill transmission with proper grade and type of lubricant to level of filler opening. See “Lubrication” on page 14.

Specifications

Torque Ratings

Correct torque application is extremely important to assure long transmission life and dependable performance. Overtightening or under-tightening can result in a loose installation and, in many instances, eventually cause damage to transmission gears, shafts or bearings. Use of a thread sealer/locking compound is recommended for all capscrews. Do not torque capscrews dry.

Torque - Front Section

Description Torque Value

lbs. ft.

1 Main Drive Gear Bearing Nut 250-300 Apply Loctite grade 277 sealant.

6 Front Bearing Cover Capscrews 35-45 3/8" - 16 Apply Loctite 242 to threads.

6 Clutch Housing Nuts Aluminum housing:

170-175 Cast Iron Housing: 180-190

4 Slave Air Valve Capscrews 8-12 1/4" - 20 Apply Loctite 242 to threads.

1 Neutral Signal Switch Plug 35-50 3/4" - 16

5 Shift Block and Yoke Lockscrews 35-45 7/16" - 20 Secure with lockwire.

16 Shift Bar Housing and 4 Shift Lever Housing Capscrews

1 Reverse Signal Switch Plug 35-50 9/16" - 18

2 Support Stud Nuts 170-185 5/8" - 18 Use lockwashers.

1 Oil Drain Plug 45-55 3/4" Pipe

6 Mainshaft Rear Bearing Retainer Capscrews 35-45 3/8" - 16 Secure with lockwire.

1 Oil Fill Plug 25-35 1-1/4" Pipe

35-45 3/8" - 16 Apply Loctite 242 to threads.

Thread Size

5/8" - 18 Use lockwashers.

Additional Comments

Stake to input shaft.

Specifications

2 Reverse Idler Shaft Nuts 50-60 5/8" - 18

6 Small PTO Cover Capscrews 20-25 3/8" - 16 Apply Loctite 242 to threads.

8 Large PTO Cover Capscrews 50-65 7/16" - 14 Apply Loctite 242 to threads.

4 Hand Hole Cover Capscrews 20-25 5/16" -18

2 Countershaft Front Bearing Retainer Capscrews 90-120 5/8" - 18 Secure with lockwire.

4 Clutch Housing Capscrews Aluminum housing:

70-75 Cast Iron Housing: 90-100

1/2" - 13 Use lockwashers.

Specifications

Torque - Auxiliary Section

Description Torque Value

lbs. ft.

2 Air Filter/Regulator Mounting Capscrews 8-12 1/4" - 20 Apply Loctite 242 to threads.

1 Range Cylinder Shift Bar Nut 70-85 5/8" - 18

2 Range Shift Yoke Capscrews 50-65 1/2" - 20 Secure with lockwire.

6 Mainshaft Rear Bearing Cover Capscrews 35-45 3/8" - 16 Apply Loctite 242 to threads.

4 Range Cylinder Mounting Capscrews 35-45 3/8" - 16 Apply Loctite 242 to threads.

4 Range Cylinder Cover Capscrews 35-45 3/8" - 16 Apply Loctite 242 to threads.

8 Countershaft Rear Bearing Cover Capscrews 35-45 3/8"-16 Apply Loctite 242 to threads.

1 Speedometer Housing Plug 35-50 13/16" - 20 Apply Loctite 242 to threads.

19 Auxiliary Housing Capscrews 35-45 3/8" - 16 Apply Loctite 242 to threads.

1 Output Shaft Nut 450-500 2" - 16 Oiled at vehicle installation.

Thread Size

Additional Comments

Lubrication

Proper lubrication procedures are the key to a good all-around maintenance program.

Fuller

Transmissions are designed so that the internal parts operate in an oil circulating bath created by the motion of the gears

and shafts.

All parts will be properly lubricated if these procedures are closely followed:

• Maintain oil level. Inspect regularly.

• Follow maintenance interval chart.

• Use the correct grade and type of oil.

• Buy from a reputable dealer.

Maintain Proper Oil Level

Make sure oil is level with the filler opening. Being able to reach oil with your finger does not mean oil is at proper level. (One inch of oil level is about one gallon of oil.)

When adding oil, never mix engine oils and gear oils in the same transmission.

Additives and friction modifiers must not be introduced.

Buy from a reputable dealer.

The use of lubricants not meeting requirements will affect warranty coverage.

Lubrication Information

For additional lubrication information and lube intervals, see TCMT0021 or call 1-800-826-HELP (4357).

For a list of approved lubricants, see TCMT0020 or call 1-800-826-HELP (4357).

Oil Level

Hole

Proper Oil Level

Hole

Improper Oil Level

Lubrication

Oil Filter

For transmissions equipped with oil filter, P/N 4304827.

• For highway use - Inspect filter for leaks or damage replace as necessary.

• For off-highway use - Change filter every two years.

Lubrication

If your vehicle has a transmission oil filter, you must change the filter when fluid or lubricant is changed.

Transmission Operating Angles

If the transmission operating angle is more than 12 degrees, improper lubrication will occur. The operating angle is the transmission mounting angle in the chassis plus the percent of upgrade (expressed in degrees). For operating angles over 12 degrees, the transmission must be equipped with an oil pump or cooler kit to insure proper lubrication.

Operating Temperatures with Oil Coolers

The transmission must not be operated consistently at temperatures above 250° F. Operation at temperatures above 250°F [121°C] causes loaded gear tooth temperatures to exceed 350°F [177°C] which will ultimately destroy the heat treatment of the gears. If the elevated temperature is associated with an unusual operating condition that will reoccur, a cooler should be added, or the capacity of the existing cooling system increased.

The following conditions in any combination can cause operating temperatures of over 250° F [121°C]:

• Operating consistently at slow speed.

• High ambient temperatures.

• Restricted air flow around transmission.

• Use of engine retarder.

• High horsepower operation.

Note: Transmission coolers must be used to reduce the operating temperatures when the above conditions are encountered.

Oil Cooler Chart

Transmission Oil Coolers are:

Recommended

• With engines of 350 H.P. and above.

Required

• With engines 399 H.P. and above and GCW’s over 90,000 lbs.

• With engines 399 H.P. and above and 1400 lb. ft. or greater torque.

• With engines 1500 lb. ft. and above

Tool Information

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.

Recommended Tools

The following tables list and describe the typical tools required to properly service this model transmission above and beyond the necessary basic wrenches, sockets, screwdrivers, and prybars.

General Tools

The following tools are available from several tool manufacturers such as Snap-On, Mac, Craftsman, OTC, and many others.

TOOL PURPOSE

0 - 100 lbs. ft. 1/2" drive Torque Wrench. General torquing of fasteners (typically 15-80 lbs. ft.).

0 - 600 lbs. ft. 3/4" or 1" drive Torque Wrench. Torquing of output nut to 500 lbs. ft.

0 - 50 lbs. in. 3/8" drive Torque Wrench. General torquing of fasteners.

0 - 30 lbs. in. 1/4" drive Torque Wrench. Torquing of capscrews to 7 lbs. in. during auxiliary countershaft bearing

endplay setting procedure.

70 MM or 2-2/4" Socket - Standard Depth To remove the output yoke nut.

Large Brass Drift Used to protect shafts and bearings during removal.

Large Dead Blow Hammer or Maul To provide force for shaft and bearing removal.

Snap Ring Pliers - Large Standard External To remove the snap rings at the auxiliary drive gear, input shaft bearing,

and countershaft bearings.

Feeler Gauges To set mainshaft washer endplay and auxiliary tapered bearing endplay.

Rolling Head (Crow's Foot) Prybar To remove the auxiliary drive gear bearing.

(2) Air Pressure Gauges 0-100 PSI (0-1034 kPa) To troubleshoot and verify correct operation of air system.

Universal Bushing Driver To remove and install clutch housing bushings. Bushing OD = 1.125",

ID = 1.000"

Tool Information

Eaton Fuller Model Special Tools

The following special tools are designed for this Eaton® Fuller® transmission. The addresses and phone numbers of the tool suppliers are listed after the table. This list is provided as a convenience to our customers. These tools are manufactured by independent companies with no relationship to Eaton® Fuller®. Eaton® Fuller® does not warrant the fit or function of the listed

tools. To obtain the tools, contact the tool supplier directly.

REF.

NO.

T1 Output Yoke Puller May be required to remove a rusted

T2 Auxiliary Section Hanger To support, or hang, the auxiliary sec-

T3 Auxiliary

Countershaft Support and Shim Tool

T4 Shift Lever Spring

Installation Tool (Tension Spring Driver)

T5 Slide Hammer To remove the output seal and reverse

T6 Bearing Puller To remove front section countershaft

TOOL PURPOSE G & W TOOL

output yoke.

tion in the horizontal position.

To hold the auxiliary countershafts in position while installing the auxiliary section in the horizontal position. Also to simplify the checking and setting of the auxiliary countershaft bearing endplay.

To install the shift tower tension spring.

idler shafts. Requires 1/2"-13 threads. (Optional, idler shaft can be driven out from front.)

bearings.

GREAT LAKES

NO.

SP-450 7075

G-40 T-125 5061

G-250 T-311 5062

G-116 T-170

G-70 T-150 1155 Slide

G-10 or G-15 T-100 7070A Kit

TOOL NO.

OTC TOOL

NO.

Hammer / 8007 1/2" -13 Adapter

T7 Bearing Driver To install front section countershaft

bearings (3.97" OD, 1.78" ID).

T8 Bearing Driver To install the front countershaft rear

bearings (3.5" OD, 1.6" ID)

T9 Countershaft

Support Tools (2)

T10 Input Bearing Driver To install input bearing on input shaft. G-35 T-120 5066 (2" shaft)

T11 Bearing Puller To remove the auxiliary countershaft

T12 Bearing Driver To install the auxiliary countershaft

T13 Output Seal Removal Tool To remove the output seal in

* Tool numbers are referenced in the service procedures.

To support and locate the front section countershafts during bearing removal and installation.

tapered bearings.

chassis. Can use slide hammer.

G200 Kit T-101 Kit

G-50 / G-51 / G-58

G-247A / G-247G

G200 Kit T-101 Kit

T-145S 7109

1123 / 927

Use 27315 hook with 1155 slide hammer

Tool Information

REF.

NO.

T14 Auxiliary Section Removal

Adapter Plate

T15 Mainshaft Hook To assist in lifting of mainshaft from

T16 Input Bearing Puller To remove input bearing. G-38 7070A Kit

T17 Bearing Race Puller To remove the auxiliary countershaft

T18 Bearing Race Installer To install the auxiliary countershaft

* Tool numbers are referenced in the service procedures.

TOOL PURPOSE G & W TOOL

NO.

To attach transmission jack to auxiliary section for auxiliary section removal in chassis.

front section.

tapered bearing outer races.

G-115 49611

G-225 T-165

G-247B attached to G70 impact puller

G-200 Kit T-101 Kit 27524/27530

GREAT LAKES

TOOL NO.

T-157 with T-150

OTC TOOL

(Used with OTC transmission jack P/N 5019.)

7136 puller attached to 1155 slide hammer

discs used with 27488 handle and 10020 screw.

Shop Equipment

NO.

20 Ton capacity press To press countershaft gears from countershaft.

Special Tools Manufacturers

Below are the addresses and phone numbers of the companies that make tools specifically for Eaton® Fuller® transmissions.

G and W Tool Company Great Lakes Tool O.T.C.

1105 E. Louisville 8530 M-89 655 Eisenhower Dr.

Broken Arrow, OK 74012-5724 Richland, MI 49083 Owatonna, MN 55060-1171

800-247-5882 800-877-9618 800-533-6127

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

Truck Components Operations

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

Tool Information

Eaton Aftermarket Parts

The following tools are available through Eaton Aftermarket Parts. To obtain any of the tools listed, contact your local Eaton® parts distributor.

TOOL PURPOSE EATON PART NUMBER

5/32" Air Line Release Tool To remove 5/32" air lines from

push-to-connect fittings.

Air Line Cutting Tool To cut plastic air lines smoothly

and squarely.

Output Seal Driver To install output seal. For 7 series: Eaton P/N 5564501 driver.

Output Seal Slinger Driver To install output seal slinger. For 7 series: Eaton P/N 71223.

P/N 4301157 included in kit K-2394.

P/N 4301158 included in kit K-2394.

For 9 series: Use Eaton P/N 5564509 adapter with 5564501 driver. Both parts included in Complete Eaton Seal Kit P/N K-

3651.

For 9 series: Eaton P/N 4303829.

Preventative Maintenance

Everyday there are countless vehicles operating over the highways with transmissions in such a neglected mechanical condition, they can be referred to as failures looking for a place to break down. They lack a proper and organized preventive maintenance program.

Preventive maintenance is a general term which applies to all procedures necessary to have maximum life and satisfactory service at the lowest possible cost, short of removing and repairing the unit.

A number of conditions contrary to good preventive maintenance can generally be pointed to when inspecting a failed transmission. Taking a few minutes every so many hours or miles to do a few simple checks could help avoid eventual breakdown or reduce the repair cost. If the transmission is not cared for, it will breakdown.

Preventative Maintenance Check Points

Preventative Maintenance

Note: Transmission appearance may differ, the procedure is the same.

Preventative Maintenance

Air System and Connections (1)

• Check for leaks, worn air lines, loose connections and capscrews.

Clutch Housing Mounting (2)

• Check all capscrews of clutch housing flange for looseness.

Clutch Release Bearing (Not Shown)

• Remove hand hole cover and check radial and axial clearance in release bearing.

• Check relative position of thrust surface of release bearing with thrust sleeve on push-type clutches.

Clutch Pedal Shaft and Bores (4)

• Pry upward on shafts to check wear.

• If excessive movement is found, remove clutch release mechanism and check bushings on bores and wear on shafts. See OEM literature.

Lubricant (5)

• Change at specified service intervals.

• Use only the types and grades as recommended. See "Recommended Lubrication Chart".

Filler and Drain Plugs (6)

• Remove filler plugs and check level of lubricant at specified intervals. Tighten fill and drain plugs securely.

Capscrews and Gaskets (7)

• For applicable models, check all capscrews, especially those on PTO covers and rear bearing covers for looseness which would cause oil leakage.

• Check PTO opening and rear bearing covers for oil leakage due to faulty gasket.

Gear Shift Lever (8)

• Check for looseness and free play in housing. If lever is loose in housing, proceed with Check No. 9.

Gear Shift Lever Housing Assembly (9)

• If present, remove air lines at air valve or slave valve. Remove the gear shift lever housing assembly from the transmission.

• Check the tension spring and washer for set and wear.

• Check the gear shift lever spade pin and slot for wear.

• Check bottom end of gear shift lever for wear and check slot of yokes and blocks in shift bar housing for wear at contact points with shift lever.

Checks With Drive Line Dropped

Universal Joint Companion Flange or Yoke Nut (10)

• Check for tightness. Tighten to recommended torque.

Output Shaft (Not Shown)

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

Preventative Maintenance

Checks With Universal Joint Companion Flange or Yoke Removed

Note: If necessary, use solvent and shop rag to clean sealing surface of companion flange or yoke. Do not use crocus cloth,

emery paper, or other abrasive materials that will mar surface finish.

Splines on Output Shaft (Not Shown)

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

Mainshaft Rear Bearing Cover (13)

• Check oil seal for wear.

Preventative Maintenance

Oil Leak Inspection Process

Inspect for Oil Leak

Determine if it is a Weep or a Leak

Weep: Stained, damp, no drips, light oil film, dirt adhered to the contaminated area.

Gasket Rear Seal Leak

Leak: Extremely wet or dripping of oil in the contaminated area.

Step 1

1. Clean suspected oil weep area with a clean dry cloth or mild soluble degreaser.

2. Ensure lube is to proper level.

3. Notify the customer that it is only a weep and it is not considered to be detrimental to the life of the transmission.

4. Repair is complete.

1. Do not repair: Rear seal is designed to allow minimal seepage (refer to Roadranger TCSM-0912 Seal Maintance Guide).

2. Ensure lube is to proper level.

Step 2

Step 3

1. 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 area. Use of a high pressure spray may force contamination into the area of concern and temporarily disrupt the leak path.

i. Clean area with a clean dry cloth or mild soluble degreaser and fill the transmission to the proper lube level. OR ii. Clean the area as noted above and insert tracer dye into the transmission lube and fill transmission to proper lube level.

Operate vehicle to normal transmission operating temperature and inspect the area for oil leak(s) visually or if tracer dye was introduced use an UVL (Ultraviolet Light) to detect the tracer dye’s point of origin. Note: When inspecting for the origin of the leak(s) make sure the assumed leak area is not being contaminated by a source either forward or above the identified area such as the engine, shift tower, shift bar housing, top mounted oil cooler, etc...

Once the origin of the leak is identified, repair the oil leak using proper repair procedures from the designated model service manual.

Step 4

After the repair is completed, verify the leak is repaired and operate the vehicle to normal transmission operating temperature. Inspect repaired area to ensure oil leak has been eliminated. If the leak(s) still occurs, repeat steps or contact the Roadranger Call Center at 1-800-826-4357.

Preventative Maintenance

Inspection

Part to Inspect What to Check For Action to be Done

Speedometer Connections Speedometer cables should not be

loose.

Should be an O-ring or gasket between the mating speedometer sleeve and the rear bearing cover.

Rear Bearing Cover Capscrews, Gasket, and Nylon Collar

Check retaining capscrews for tightness. Apply Eaton Sealant #71205 to the cap-

Verify nylon collar and gasket are installed at the chamfered hole, aligned near the mechanical speedometer opening.

Verify that a rear bearing cover gasket is in place.

Applied hydraulic thread sealant #71208 to threads.

Torque speedometer sleeve to 35-50 lbs. ft.

Replace the O-ring/gasket if damaged or missing.

screw threads.

Torque capscrews to 35-45 lbs. ft.

Use new parts if need to replace. Apply Eaton Sealant #71205 to the capscrew threads. Torque capscrews to 35-45 lbs. ft.

Install a new gasket if rear bearing cover was removed.

Preventative Maintenance

Output Yoke Retaining Nut Check the output yoke retaining nut for

tightness.

PTO Covers and Openings Check the capscrews for tightness. Apply Eaton Sealant #71205 to the cap-

Gray Iron Parts Check front bearing cover, front case,

shift bar housing, rear bearing cover, and clutch housing for cracks or breaks.

Front Bearing Cover Check return threads for damage. If threads damaged, replace the input

Check the capscrews for tightness. Tighten the capscrews to 35-45 lbs. ft.

Oil Cooler and Oil Filter Check all connectors, fittings, hoses,

and filter element for tightness.

Oil Drain Plug, Oil Fill Plug Check the oil drain plug and the oil fill

plug for leakage.

Torque the output yoke retaining nut to 450-500 lbs. ft. Do not over torque the output nut.

screw threads.

Tighten 6 bolt PTO capscrews to 35-45 lbs. ft.

Tighten 8 bolt PTO capscrews to 50-65 lbs. ft.

Replace parts found to be damaged.

shaft.

Tighten any loose fittings.

Torque the oil drain plug to 45-55 lbs. ft.

Torque the oil fill plug to 60-70 lbs. ft.

Power Flow

The transmission must efficiently transfer the engine's power, in terms of torque, to the vehicle's rear wheels. Knowledge of what takes place in the transmission during torque transfer is essential when troubleshooting and making repairs.

Front Section Power Flow (All Models)

• Power (torque) from the vehicle's engine is transferred to the transmission's input shaft. (1)

• Splines of input shaft engage internal splines in hub of main drive gear. (2)

• Torque is split between the two countershaft drive gears. (3)

• Torque is delivered along both countershafts to mating countershaft gears of "engaged" mainshaft gear. The cross section views illustrate 1st/6th speed gear engagement. (4)

• Internal clutching teeth in hub of engaged mainshaft gear transfers torque to mainshaft through sliding clutch. (5)

• Mainshaft transfers torque directly to rear auxiliary drive gear. (6)

Auxiliary Section Power Flow: LO RANGE (All Models)

• The auxiliary drive gear splits torque between the two auxiliary countershaft drive gears. (7)

• Torque is delivered along both auxiliary countershafts to the "engaged" LO RANGE gear on range mainshaft or output shaft. (8)

• Torque is transferred to range mainshaft or output shaft through sliding clutch. (9)

• Torque is delivered to driveline as LO RANGE 1st. (10)

Power Flow

Auxiliary Section Power Flow HI RANGE (All Models)

• The auxiliary drive gear transfers torque directly to the range mainshaft or output shaft through "engaged" sliding clutch. (7)

• Torque is delivered through the range mainshaft and/or output shaft to driveline as HI RANGE 6th. (8)

Power Flow

Timing

Timing Procedures

Special Instructions

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.

Procedure - Front Section

1. Marking countershaft drive gear teeth: 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.

2. Marking main drive gear teeth: Mark any two adjacent

teeth on the main drive gear.

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.

3. 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.

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.

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.

Procedure - Auxiliary Section

4. Marking the helical auxiliary countershafts: Mark any two

teeth on the LO range gear. Then mark two teeth located directly opposite the first marked.

Prior to placing each auxiliary countershaft assembly into housing, mark the tooth on each auxiliary countershaft assembly LO range gear stamped with the two "O"s. Repeat the procedure on each auxiliary countershaft reduction gear.

Follow the assembly procedures in the “How to Install the Auxiliary Section With Tapered Bearings” on page 165.

Timing

Air System

How to Remove Compression Type Fittings

Special Instructions

WARNING

A sudden release of air pressure can cause personal injury or damage to equipment. To prevent injury or equipment damage, exhaust the vehicle air tanks.

CAUTION

Small air lines are available in 1/8" or 5/32" sizes. Make sure 1/8" air lines are used with 1/8" fittings and 5/32" air lines are used with 5/32" fittings. Mixing sizes can cause air leaks or damage to fittings.

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

Special Tools

Typical service tools

Procedure -

1. Exhaust the vehicle air tanks before continuing.

2. Loosen the nut on the fitting, and slide it back out of the way.

3. Pull the air line and attached collet from the fitting.

4. Inspect the fitting, air line, collet, and nut for damage or wear. Replace as necessary.

1342

1. Connector

2. Collet

3. Nut

4. Air Line

Air System

How to Install Compression Type Fittings

Special Instructions

WARNING

A sudden release of air pressure can cause personal injury or damage to equipment. To prevent injury or equipment damage, exhaust the vehicle air tanks.

CAUTION

Special Tools

Typical service tools

Procedure -

1. Check the threads of the fitting for thread sealant. If no sealant is present, apply Eaton

or equivalent.

2. Install the fitting.

Note: Do not overtighten the nut. Overtightening can com-

press the collet too much and cause an air line restriction.

3. Install the air line, collet, and nut. If installing a new fitting, place the collet in the fitting and loosely install the nut. (Do not tighten the nut yet.) Insert the air line through the nut and into the collet. Tighten the nut as usual.

Fuller® thread sealant #71205

Air System

1342

1. Connector

2. Collet

3. Nut

4. Air Line

4. Enable the vehicle air system. Allow the air tanks to pressurize, and check for leaks. Repair as necessary.

Air System

How to Remove Push-To-Connect Type Fittings

Special Instructions

WARNING

A sudden release of air pressure can cause personal injury or damage to equipment. To prevent injury or equipment damage, exhaust the vehicle air tanks.

CAUTION

Make sure only 5/32" air lines are used with push-to-connect fittings. Using sizes other than 5/32" can cause air leaks or damage to fittings.

Before removing the air lines and hose, label or record their location.

Special Tools

See “Tool Information”.

For 'push-to-connect' fittings, the Eaton service tool kit K-2394 is recommended.

The kit contains the release tool and the tubing cutter.

Procedure -

1. Exhaust the vehicle air tanks before continuing.

2. Use the air line release tool from kit K-2394 to press the release sleeve down while pulling the air line from the fitting.

ase Tool

Eaton Fuller

Air Fitting Rele

4301157

3. Inspect the fitting for damage or wear. Remove and replace as necessary.

Air System

How to Install Push-To-Connect Type Fittings

Special Instructions

WARNING

A sudden release of air pressure can cause personal injury or damage to equipment. To prevent injury or equipment damage, exhaust the vehicle air tanks.

CAUTION

Make sure only 5/32" air lines are used with push-to-connect fittings. Using sizes other than 5/32" can cause air leaks or damage to fittings.

Special Tools

See “Tool Information”

For 'push-to-connect' fittings, we recommend Eaton service tool kit K-2394. The kit contains the release tool and the tubing cutter.

Procedure -

1. Check the threads of the fitting for thread sealant. If no sealant is present, apply Eaton® Fuller® thread sealant #71205 or equivalent.

2. Install the fitting.

3. Inspect the air line for burrs or deformed areas. Trim the air line if necessary using a sharp razor blade or the air line cutting tool from kit K-2394. The cut must be smooth and square. If the tubing end is deformed or burred, the internal O-ring in the fitting will be damaged when the air line is inserted.

4. Push the air line into the fitting. It should insert approximately 3/4". If it does not insert far enough or is difficult to insert, the fitting may be damaged and should be replaced. After inserting, give the air line a slight tug to make sure the line stays in place. If line does not stay in place, replace the fitting.

Air System

5. Enable the vehicle air system. Allow the air tanks to pressurize, and check for leaks.

Air System

How to Remove Rubber 1/4" Air Hoses

Special Instructions

For the 1/4" I.D. air hoses, install the fixed nut end first.

Special Tools

Typical service tools

Procedure -

1. Remove all air line brackets and ties.

2. Remove swivel end.

3. Remove fixed end.

How to Install Rubber 1/4" Air Hoses

Special Instructions

For the 1/4" I.D. air hoses, install the fixed nut end first.

Special Tools

Typical service tools

Procedure -

1. If necessary, apply Eaton Fuller thread sealant # 71205 or equivalent to threads.

2. Install and tighten fixed end first, then install and tighten swivel end.

3. Replace all air line brackets and ties.

Air System

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 range cylinder cover.

Special Tools

Typical service tools

Procedure -

1. Position the air filter/regulator.

2. Apply Eaton/Fuller Sealant #71205 or equivalent to the two (2) retaining capscrews.

3. Install the two (2) retaining capscrews, tighten to 8-12 lbs. ft. of torque.

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 auxiliary section.

Special Tools

Typical service tools

Procedure -

1. Remove the air lines from the air filter regulator.

Air System

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

Air System

How to Remove a Roadranger Valve

Special Instructions

WARNING

A sudden release of air pressure can injure you or damage equipment. To prevent injury or equipment damage, the vehicle air tanks must be exhausted.

Special Tools

Typical service tools

Procedure -

1. From the Roadranger valve cover, remove the two (2) mounting screws.

2. Slide the Roadranger valve cover down.

3. From the air fittings, disconnect the air lines.

4. From the Roadranger base, loosen the jam nut. Rotate the Roadranger valve until the valve is removed.

5. Inspect the parts: nut, valve cover, air lines, sheathing, and O-rings from the lever shaft.

6. In the Roadranger valve, inspect the air fittings, and remove if damaged.

Air System

How to Install a Roadranger Valve

Special Instructions

To position the Roadranger valve, the range lever must be to the front or the splitter button to the left when facing forward.

Special Tools

Typical service tools

Procedure -

1. Make sure the nut, valve cover, air lines, sheathing, and Orings are in position on the lever shaft.

2. If previously removed, replace the air fittings and torque to 84-120 lbs. in.

3. Place the Roadranger valve on the lever shaft and rotate so the range selector faces the vehicle front.

Air System

4. From the Roadranger valve bottom, tighten the jam nut to 35-45 lbs. ft. of torque.

5. Connect the air lines to the air fittings.

6. Slide the cover into position on the Roadranger valve.

7. Install the Roadranger valve cover mounting screws.

Note: Make sure the air lines are seated fully.

Air System

How to Remove a Slave Valve

Special Instructions

WARNING

A sudden release of air pressure can injure you or damage equipment. To prevent injury or equipment damage, the vehicle air tanks must be exhausted.

Special Tools

Typical service tools

Procedure -

1. Record or mark air line locations.

2. Remove all air lines.

Note: Remove three 1/4" ID air hoses at swivel fitting at

range cylinder location. Remove air line bracket at rear of transmission. Remove slave valve with air hoses still attached.

3. Remove the retaining capscrews around valve perimeter.

4. Remove slave valve and gasket.

5. From the transmission case, remove the sleeve, spring, and plunger pin.

6. Inspect the air fittings, replace if damaged.

How to Install a Slave Valve

Special Instructions

None

Special Tools

Typical service tools

Procedure -

1. Clean gasket surface and install air fittings.

Air System

2. Lightly lubricate and install plunger pin, spring, and sleeve into case.

3. Install any necessary air hoses at this time.

4. Install new gasket.

5. Apply Eaton/Fuller Sealant #71205 or equivalent to the retaining capscrews.

6. Install the retaining capscrews. Tighten to 8-12 lbs. ft. of torque.

Note: Make sure the retaining capscrews are properly

torqued.

Air System

In-Vehicle Service Procedure

How to Remove the Gear Shift Lever/Remote Shift Control

Special Instructions

The air lines must be disconnected from the transmission or from the Roadranger valve.

Different detent springs are available to increase or decrease shifting effort. Note and record specific locations for specific springs. In some cases, a stiffer spring is installed in the top rail position.

Remote control housings are removed the same way as gear shift levers.

Special Tools

Typical service tools

Procedure -

1. From the gear shift lever base/shift control housing, remove the four (4) retaining capscrews.

1. Housing

2. Capscrew

3. Gasket

2. To break the gasket seal, lightly jar the gear shift/shift control housing.

3. Remove the gear shift lever housing.

CAUTION

Make sure the detent springs do not fall into the transmission.

4. Remove detent springs as needed.

5. Remove the gasket and clean the area the replacement gasket will contact.

In-Vehicle Service Procedure

How to Install the Gear Shift Lever/Remote Shift Control

Special Instructions

Remote control housings are installed the same way as gear shift levers.

For standard and forward shift bar housings, make sure the detent springs and balls are in the shift bar housing top bores.

Make sure the shift block and yoke notches are aligned in the neutral position.

Special Tools

Typical service tools

Procedure -

1. Thoroughly clean mounting surface.

2. Position a new gear shift lever/shift control housing gasket on the gear shift lever mounting surface.

3. Install the detent springs.

4. Install the shift lever/shift control housing. Make sure the tip (finger) of the gear shift lever fits into the slots in the shift block.

5. Apply Eaton/Fuller Sealant #71205 or equivalent to the retaining capscrews.

In-Vehicle Service Procedure

6. Install the retaining capscrews, tighten to 35-45 lbs. ft. of torque.

Note: Make sure the capscrews are properly torqued.

Note: Make sure you can shift the transmission.

1. Housing

2. Capscrew

3. Gasket

In-Vehicle Service Procedure

How to Adjust the Remote Shift Control (LRC Type)

Special Instructions

The following is a typical adjustment procedure for an LRC type slave control. It is recommended that the OEM Chassis Service Manual be consulted first.

Special Tools

Typical service tools

Procedure -

1. Reach Rod

2. Turnbuckle

3. Selection Lever

4. Inner Shift Finger

Figure A

Figure B

1. Selection Lever

2. Shift Arm

5. Shift Arm

6. Pivot Link Assembly

7. Inner Shift Shaft

1. Move the gear shift lever forward or backward to the neutral position.

2. Move the gear shift lever sideways, toward reverse, until you feel resistance from the reverse plunger spring. DO NOT shift to reverse. The shift finger must remain in this position while you are making all the adjustments.

3. Remove the cotter pin, castle nut and ball joint A (see figure A) from the selection lever. Do not remove the ball joint from the pivot link.

4. Loosen the capscrew B (see figure A) and remove the shift arm from the inner shift shaft. Do not disconnect the selection lever from the shift arm.

5. Turn the shift arm until it is at a right angle (90°) to the selection lever as viewed from the side (see figure B).

Note: Ideally, the shift arm should be adjusted 90° to the

selection lever as described, but in some chassis configurations it may be necessary to index the shift arm in the vertical position. Indexing the shift lever is done to prevent shift lever jump out. This type of

6. Install the shift arm on the splines of the inner shift shaft.

adjustment will cause an unequal amount of gear shift lever travel between neutral and a forward lever position as compared to neutral and a rearward lever position.

You may have to move the shift arm 4° or 5° to align the splines of the two parts. Disregard any movement of the gear shift lever at this point. The gear shift lever will be

adjusted later.

7. Tighten the capscrew B (see figure A) on the shift arm.

8. Connect the pivot link assembly ball joint to the selection lever. Secure it with the castle nut and cotter pin.

In-Vehicle Service Procedure

Figure C

9. Loosen the jam nuts C (see figure C) on the pivot link.

10. Check to be sure the inner shift finger is still in place.

11. Rotate the pivot link until the curved end of the selection lever is parallel with the shift arm as viewed from the rear (see figure C).

12. Tighten the pivot link jam nuts C (see figure C).

13. Loosen both capscrews on the turnbuckle D (see figure A).

14. Check to be sure inner shift finger is still in place.

15. Rotate the turnbuckle to obtain the proper forward-backward neutral position of the gear shift lever in the cab.

16. Tighten one turnbuckle D capscrew (see figure A).

17. Move the gear shift lever to the desired position.

18. Turn the second turnbuckle D capscrew.

19. Check for linkage obstructions in all gear positions.

1. Selection Lever

2. L.H. Thread

3. R.H. Thread

4. Shift Arm

5. Parallel

In-Vehicle Service Procedure

Neutral Switch Operation and Testing

Special Instructions

The neutral switch is a normally closed switch. An electrical current flows through it when the transmission shifter is in the neutral position. When the transmission shifter is in gear, the switch is open and no current flows through it. Likewise, the switch is open when the ball is depressed. The switch is actuated by the air valve shaft.

Special Tools

Typical service tools

Volt/Ohm meter

Procedure -

1. Disconnect the wiring from the switch.

2. Connect an ohm meter to check for continuity or a small reading.

3. Place the transmission shift lever in the neutral position. The ohm meter should register continuity or a small reading. If it does, go to the next step. If it does not, remove the switch and replace it.

4. Shift the transmission into all gear positions. The ohm meter should read open or infinity. If it does not, remove the switch. Then, depress the switch ball and check for continuity. The ohm meter should read open or infinity when the ball is depressed.

5. Look into the neutral switch hole and verify that the air valve shaft moves as the transmission is shifted from neutral into gear.

• If it does, replace the switch.

• If not, remove the shift bar housing and check the air

valve and shift rails for excessive wear. Also, check the slave valve plunger and spring for free movement.

How to Remove the Neutral Switch

Special Instructions

None

Special Tools

Typical service tools

Procedure -

1. Remove 2 screws retaining wire terminals.

In-Vehicle Service Procedure

2. Remove the switch using a 7/8" deep well socket or box end wrench.

1. Neutral Light Switch

2. Gasket

3. Shift Bar Housing

4. Gasket

5. Air Valve Shaft

3 4

In-Vehicle Service Procedure

How to Install the Neutral Switch

Special Instructions

None

Special Tools

Typical service tools

Procedure -

1. Neutral Light Switch

2. Gasket

3. Shift Bar Housing

4. Gasket

5. Air Valve Shaft

1. Install a new gasket.

2. Install the neutral switch. Tighten it to 15-20 lbs. ft. (20-27 N•m) of torque.

3 4

3. Connect the wiring to the switch.

In-Vehicle Service Procedure

Reverse Switch Operation and Testing

Special Instructions

The reverse switch is a normally open ball switch. When the transmission is shifted into reverse, a ramp on the reverse yoke bar contacts and raises a pin. The pin depresses the ball on the switch, which closes the switch contact, allowing current to flow through the switch and light up the vehicle's backup lights.

Special Tools

Typical service tools

Volt/Ohm meter

Procedure -

1. Disconnect the wiring from the switch.

2. Connect an ohm meter to check for continuity.

3. Place the transmission shift lever in any position except reverse. If the switch is working properly, the ohm meter should read open or infinity. If it is not, remove the switch and recheck it for continuity. Replace as necessary.

4. Place the transmission shift lever in the reverse position. If the switch is working properly, the ohm meter should register continuity, or a small reading. If it does not, remove the switch and recheck it for continuity. Replace it as necessary. Also, check for sticking or excessive wear of the reverse pin.

In-Vehicle Service Procedure

How to Remove the Reverse Switch

Special Instructions

None

Special Tools

Typical service tools

Procedure -

1. Reverse Light Switch

2. Gasket

3. Pin

4. Shift Bar Housing

5. Gasket

2 3

1. Remove 2 screws retaining wire terminals.

2. Remove the switch using a 7/8" deep well socket or box end wrench.

How to Install the Reverse Switch

Special Instructions

None

Special Tools

Typical service tools

Procedure -

In-Vehicle Service Procedure

1. Insert the reverse pin in the reverse switch bore.

2. Install new gasket on switch.

3. Install the reverse switch. Tighten it to 15-20 lbs. ft. (20-27 N•m) of torque.

4. Connect the wiring to the switch.

1. Reverse Light Switch

2. Gasket

3. Pin

4. Shift Bar Housing

5. Gasket

2 3

In-Vehicle Service Procedure

How to Remove the Output Yoke/Companion Flange and Nut

Special Instructions

You must remove the shift bar housing in order to lock the transmission.

For proper cleaning and maintenance, see TRSM0912 "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

See Tool Information.

A large breaker bar or air impact wrench

Procedure -

1. Engage two (2) mainshaft sliding clutches into two (2) mainshaft gears to lock the transmission or use a yoke holding tool if available.

2. Use a large breaker bar or air impact wrench to remove the output shaft nut.

3. Remove the output yoke. Use the output yoke puller (Tool ref. ID T1).

In-Vehicle Service Procedure

How to Install the Output Yoke/Companion Flange and Nut

Special Instructions

You must remove the shift bar housing in order to lock the transmission.

For proper cleaning and maintenance, see TCSM0912 Seal Maintenance Guide.

Special Tools

See Tool Information.

Torque wrench with 0-600 lbs. ft. capacity

Procedure -

1. Engage two (2) mainshaft sliding clutches into two (2) mainshaft gears to lock the transmission, or use a yoke holding tool if available.

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. Install the output yoke over the output shaft. The yoke should slide on and stop before contacting the speedometer rotor. As the output shaft nut is installed, the output yoke will contact the speedometer rotor.

5. Install the output shaft nut, tighten to 450-500 lbs. ft. of torque.

6. Make sure the output shaft nut is properly torqued and unlock the transmission, or remove the yoke holding tool.

In-Vehicle Service Procedure

In-Vehicle Service Procedures

How to Remove the Output Yoke / Flange and Retaining Capscrews

Special Instructions

None

Special Tools

• Typical service tools

Procedure -

1. Remove drive shaft from transmission. Reference OEM removal guidelines.

2. Remove the end yoke retaining capscrews and washer from auxiliary mainshaft.

3. Remove the end yoke/flange.

In-Vehicle Service Procedures

How to Install the Output Yoke / Flange and Retaining Capscrews

Special Instructions

For proper cleaning and maintenance, see TCSM0912 Seal Maintenance Guide.

Special Tools

• Typical service tools

Procedure -

1. Install end yoke, retaining washer, and capscrews. Apply Eaton/Fuller #71205 liquid thread sealant to capscrews and then snug each capscrew to 35 lbs. ft. [47 N·m.]

2. Fully tighten both retaining capscrews to specified torque rating 74-81 lbs. ft. [100-110 N·m.]

Auxiliary Section

Note: This fastening design employs Spiralock

conventional metric thread pitch tap cannot be used for thread restoration on this product.

WARNING

Use only Eaton/Fuller #71205 liquid thread sealant or liquid equivalent on the yoke retaining capscrews. Do not use any type of thread locking tape on the end yoke retaining capscrews. This may cause the capscrews threads to strip and cause the end yoke to loosen.

3. Reinstall driveshaft per OEM guidelines.

threads. A

In-Vehicle Service Procedure

How to Remove the Auxiliary Section with Tapered Bearings

Special Instructions

There can be different capscrew lengths, note their location.

Auxiliary sections can be removed either with the transmission in the horizontal position or the vertical position.

Auxiliary countershaft retaining straps may be installed to hold the countershafts in place. You can make retaining straps from 3" x 1" bar stock. Auxiliary can be removed without straps, use caution.

Special Tools

See Tool Information.

Item T2: 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

Auxiliary countershaft retaining straps

Procedure -

1. To remove the auxiliary section in the horizontal position:

Remove the four (4) capscrews and the auxiliary countershaft rear bearing cover, gasket, and rear bearing shim.

2. Install the auxiliary countershaft retaining straps with 2 - 3/8" NC x 1" and 1 - 3/8" NC x 1-1/2" clean capscrews.

Note: Do not use an air gun. Tighten by hand until the cap-

screws are snug.

In-Vehicle Service Procedure

3. From the auxiliary section housing, remove the retaining capscrews that attach the front section to the auxiliary section.

4. Insert the two (2) longest capscrews in the housing flange tapped holes. Tighten evenly to move the auxiliary section away from the front box. Go far enough to break the gasket seal.

5. Remove the capscrews from the tapped holes.

6. Attach an auxiliary section hanger bracket to the auxiliary section top.

7. Attach a lifting chain to the auxiliary section hanger bracket.

8. Move assembly to the rear until auxiliary section is free.

9. Remove the gasket and clean all mounting surfaces of gasket material.

In-Vehicle Service Procedure

Procedure -

1. To remove the auxiliary section in the vertical position:

With blocks under the clutch housing to prevent input shaft damage, place transmission in the vertical position, clutch housing down.

2. Remove the four (4) capscrews and the auxiliary countershaft rear bearing cover, gasket, and rear bearing shim. Clean the gasket surface area.

3. Install the auxiliary countershaft retaining straps with 2 - 3/8" NC x 1" and 1 - 3/8" NC x 2-1/2" clean capscrews.

Note: Do not use an air gun. Tighten by hand until the cap-

screws are snug.

4. From the auxiliary section housing, remove the retaining capscrews that attach the front box to the auxiliary section.

5. Install a steel bar through the yoke.

6. Attach a lifting chain to the steel bar.

7. Lift assembly from the front section.

How to Install the Auxiliary Section in Chassis

Special Instructions

None

Special Tools

See Tool Information.

Item T3: Countershaft support tools

Item T14: Auxiliary section removal adapter plate

A hoist with lifting chain

Procedure -

In-Vehicle Service Procedure

1. Install the countershaft support tools on the auxiliary section countershafts to center and hold the countershafts in position. Install a 3/8"-16 X 2-1/2" long capscrew into countershaft center.

2. If removed, slide the output yoke over the output shaft. Lightly oil the threads and install the output nut on the output shaft. Torque the nut to 450-500 lbs. ft. (610-677 N•m).

Note: To prevent the output shaft from rotating while

installing the nut, place a clean shop rag in the gear mesh.

Note: Due to chassis interference, it may not be possible to

install the yoke at this step. However, the output shaft must be drawn fully into position to prevent it from sagging when the auxiliary section is installed in the chassis. If the chassis causes interference, the yoke can be temporarily installed to draw up the output shaft and then removed before the auxiliary section is installed.

3. Use crocus cloth or a wire wheel to clean rust and paint from the dowel pins before installing them.

In-Vehicle Service Procedure

CAUTION: If the dowel pins are not installed in the

main case to the proper depth, the auxiliary section will not properly align with the main case and bearing or synchronizer failure may occur.

In-Vehicle Service Procedure

4. Install the dowel pins into the main case so that 3/8"-1/2" of the shoulder is exposed or pin is flush with front of case ear.

5. Clean all rust and paint from the dowel pin holes in the auxiliary section housing, and lightly grease the dowel pins on the main case and the dowel pin holes on the auxiliary section housing.

6. Make sure the auxiliary section is in low range. If not, blow shop air (max 100 PSI) into the low range supply port to shift the range synchronizer to low. If necessary, make sure the deep reduction clutch is engaged into gear.

7. Position the gasket onto the main case mounting surface.

8. Mount the auxiliary section on the lifting device or jack.

9. Tighten the center capscrew on the countershaft support tools to draw the countershafts into a level position. Do not overtighten the capscrews. The output yoke and shaft must be able to rotate.

10. Position the auxiliary section in line with the main case, and slide the housing onto the dowel pins. Mesh the countershafts with the auxiliary drive gear. Rotate the output yoke and shaft slightly to help the gears mesh and slide the auxiliary section forward until it is flush with the main section.

CAUTION: The auxiliary section should slide into place fairly easily. DO NOT force it on or pull it into place with the capscrews. Excessive force may damage the transmission. If excessive force is necessary, the gearing is likely out of time.

11. If the auxiliary section does not install fully, slide it back and check the following:

a. The output yoke and nut should be installed to pull back and center the auxiliary mainshaft assembly.

b. The countershaft support tool center capscrew should be snug to level the countershafts.

c. The dowel pins and auxiliary housing mating holes should be clean and well oiled.

d. The internal gearing on the auxiliary section must have been properly timed during reassembly.

12. Apply Eaton® Fuller® thread sealant #71205 or equivalent to the all the retaining capscrew threads. Install the capscrews to secure the auxiliary section to the main case. Torque the capscrews to 40-45 lbs. ft. (54-61 N•m).

13. If the countershaft, countershaft bearings, or auxiliary housing have been replaced, or if the countershafts, bearings, or shims were not marked and reassembled in the same location, the bearing endplay must be checked and set by shimming. Shim the countershaft bearings using “Shim Procedure Without a Shim Tool for Tapered Bearings” on page 171.

14. If shimming is not required, remove the support tools, and install the proper shim, gasket, and countershaft bearing cover. Secure the bearing covers with the capscrews. Install sealer. Tighten the capscrews to 40-45 lbs. ft. (54-61 N•m).

15. Connect all removed air hoses and lines. Use Eaton® Fuller® thread sealant #71205 or equivalent as necessary.

16. Connect the driveshaft and U-joint, and refill the transmission with the recommended lubricant. For lubrication instructions refer to "Lubrication."

In-Vehicle Service Procedure

Bench Service Procedure

How to Disassemble the Gear Shift Lever

Special Instructions

If total disassembly is needed, the Roadranger valve, must be removed first.

Release the spring one coil at a time.

Special Tools

Vise with brass jaws or wood blocks

1. Pin 8. Capscrew

2. Bushing 9. Gasket

3. Upper Lever 10. O-ring

4. Snap Ring 11. Washer

5. Rubber Boot 12. Lower Lever

6. Spade Pin 13. Stepped Washer

7. Housing 14. Tension Spring

Procedure -

1. On a non-isolated shift lever, remove the Roadranger valve using the “How to Remove a Roadranger Valve” on page 37. If the shift lever is equipped with a lever isolator, remove the snap ring, bushing, and cross pin to disconnect and remove the upper lever.

2. Slide the rubber boot up and off the shift lever shaft.

3. With housing bottom facing up, secure the assembly in a vise.

4. Use large screwdriver to twist between the spring and housing, forcing the spring from under the housing lugs one coil at a time.

5. From inside the housing tower, remove the tension spring, washer, and gear shift lever.

Bench Service Procedure

6. In models so equipped, from the housing bore, remove the nut and washer.

7. From the housing tower spade pin bore, remove and inspect the spade pin, discard if damaged.

8. From the housing tower inside groove, inspect the O-ring, discard if damaged.

Bench Service Procedure

How to Assemble the Gear Shift Lever

Special Instructions

Inspect tension spring and washer for wear. Apply Eaton rust preventative lubricant #71212 or equivalent to the shift lever pivot ball. A rust preventative lubricant film should cover all surfaces between and including the pivot ball. Seat the tension spring one coil at a time.

Special Tools

Vise with brass jaws or wood blocks

Item T4: Tension Spring Driver

1. Pin 8. Capscrew

2. Bushing 9. Gasket

3. Upper Lever 10. O-ring

4. Snap Ring 11. Washer

5. Rubber Boot 12. Lower Lever

6. Spade Pin 13. Stepped Washer

7. Housing 14. Tension Spring

Procedure -

1. With housing bottom facing up, secure the assembly in a vise.

2. If the spade pin is damaged, replace and install the spade pin, in housing tower bore.

3. In models so equipped, install the nut and washer in the housing bore.

4. If the O-ring is damaged, replace; lubricate the O-ring with Eaton/Fuller lubricant #71206 or equivalent. Install the Oring in the housing tower inside groove.

5. Align the lever ball slot with the spade pin and position the gear shift lever in the housing tower.

Bench Service Procedure

6. With dished-side up, install the washer over the ball.

7. Use a tension spring driver to install the tension spring under the housing lugs.

8. Remove the assembly from the vise.

9. Install a rubber boot over the gear shift lever and against the housing.

Note: Make sure the gear shift lever can move.

Bench Service Procedure

How to Remove the Shift Bar Housing

Special Instructions

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

For models equipped with an oil pump and/or cooler assemblies, make sure to disconnect the oil line connected to the shift bar housing.

There are three (3) sizes of capscrews. The 1 1/2" capscrews are used with the lifting eyes. The 1 1/4" are used on all other locations except the left front corner at the roll pin location. This capscrew is 1 3/4".

Be careful when removing the shift bar housing to prevent damaging the oil tube with the shift yokes.

Special Tools

Typical service tools

Procedure -

1. From the shift bar housing, remove the two retaining capscrews securing the oil cooler. Remove oil cooler and set aside.

2. Remove slave valve.

3. Remove interlock parts (pin, spring, and sleeve).

4. From the shift bar housing rim, remove the retaining capscrews.

Bench Service Procedure

5. To break the gasket seal, jar the shift bar housing.

6. Remove the shift bar housing.

7. Inspect the roll pin, replace if damaged.

8. Remove the gasket and clean all mounting surfaces of gasket material.

9. If the three (3) sets of tension springs and balls from the housing top bores are loose, tilt the assembly and remove them.

Bench Service Procedure

How to Install the Shift Bar Housing

Special Instructions

There are three (3) sizes of capscrews. The 1-1/2" capscrews are used with the lifting eyes. The 1-1/4" are used on all other locations except the left front corner at the roll pin location. This capscrew is 1-3/4".

Be careful when removing the shift bar housing to prevent damaging the oil tube with the shift yokes.

The slave valve and interlock parts must be removed prior to installing the shift bar housing.

Special Tools

Typical service tools

Procedure -

1. Place the shift bar housing and shift blocks 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.

Note: The slave valve and interlock assembly must remain

off, until the shift bar housing is installed, to avoid damaging the interlock pin.

4. As you install the shift bar housing make sure the yokes fit into the corresponding sliding clutch slots and the housing aligns with the roll pin.

5. Apply Eaton/Fuller Sealant #71205 or equivalent to the retaining capscrews.

6. Install interlock parts (pin, spring and sleeve).

7. Install slave valve and tighten to specifications.

Bench Service Procedure

How to Disassemble the Shift Bar Housing

Special Instructions

To aid in assembly, mark the location and orientation of all shift yokes and blocks.

Procedure -

1. If installed, remove the oil trough capscrews and oil trough.

2. If present, cut and remove the lockwire on the yoke lockscrews. Remove the yoke lock screws. Slide the yoke bar from the bore.

Note: The remaining yoke bars must be in the neutral posi-

tion so that yoke bars will slide out freely.

3. Remove all yoke lockscrews, yoke bars, yokes, and shift blocks.

4. Remove the two 3/4" interlock balls.

5. Remove the air valve shaft.

Bench Service Procedure

6. For the reverse yoke, unscrew the plug to remove the spring and plunger.

7. If equipped with a yoke activator (x-actuator configuration), remove the nut or snap ring (depending on version) and remove yoke activator.

Note: On version with snap ring, do not remove pivot pin if

parts will not be replaced.

Bench Service Procedure

How to Assemble the Shift Bar Housing

Procedure -

1. Install the plunger in the 1st & reverse shift yoke bore, plunger shank to the outside.

2. Install the spring into the bore over the plunger shank.

3. Install the plug and tighten to compress the spring.

4. After plug bottoms out, back the plug out 1 - 1-1/2 turns.

5. Complete the block assembly process by staking the plug through the small hole in block.

CAUTION: Overtorquing of lockscrew can result in distortion and binding of yoke bar. Make sure yoke bar has free movement. Lockwire lockscrew.

6. Install the reverse yoke bar, reverse yoke and direct/overdrive yoke (on x-actuator versions). The yoke bar neutral notches must be positioned in line with the detent ball bores. Start the lockscrews by hand to assure proper engagement of the cone into the yoke bar hole. Torque the lockscrews to 35-45 lbs. ft.

Bench Service Procedure

7. Install air valve shaft.

Bench Service Procedure

8. Install one 3/4" interlock ball.

9. Insert small pin into middle yoke bar.

Note: The yoke bar and pin must be kept in line with the

interlock ball bore. If the yoke bar is rotated, the pin can slide out and bind in the detent ball bore. Slide yoke bar through shift block and yoke while installing bar into center housing bore. Start the lockscrews by hand to assure proper engagement of the cone into the yoke bar hole. Torque the lockscrews to 3545 lbs. ft.

CAUTION: Overtorquing of lockscrew can result in distortion and binding of yoke bar. Make sure yoke bar has free movement. Lockwire lockscrew.

10. Install the 2nd 3/4" interlock ball.

11. Install the third yoke bar into the housing. Slide through the remaining shift block and shift yoke. Start the lockscrews by hand to assure proper engagement of the cone into the yoke bar hole. Torque the lockscrews to 35-45 lbs. ft.

CAUTION: Overtorquing of lockscrew can result in distortion and binding of yoke bar. Make sure yoke bar has free movement. Lockwire lockscrew.

12. Install the oil trough and oil trough capscrews. Torque the lockscrews to 8-12 lbs. ft. If applicable, lockwire the screws. If lockwire holes are not present, clean threads and use a thread locking compound to retain the capscrews.

13. Insert reverse switch pin. Install gasket and reverse light switch or plug. Torque to 15-20 lbs. ft.

14. Install gasket and neutral switch or plug. Torque to 15-20 lbs. ft.

15. If used, install breather.

16. Install the three (3) detent balls, one in each housing top bore.

Bench Service Procedure

17. Install the three (3) detent springs, one over each detent ball.

Bench Service Procedure

How to Remove the Auxiliary Section with Tapered Bearings

Special Instructions

There can be different capscrew lengths, note their location.

Auxiliary sections can be removed either with the transmission in the horizontal position or the vertical position.

Special Tools

See ’Tool Information’.

Item T2: 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

Auxiliary countershaft retaining straps

Procedure -

1. To remove the auxiliary section in the horizontal position:

Remove the four (4) capscrews and the auxiliary countershaft rear bearing cover, gasket, and rear bearing shim.

2. Install the auxiliary countershaft retaining straps with 2 - 3/8" NC x 1" and 1 - 3/8" NC x 1 - 1/2" clean capscrews.

Note: Do not use an air gun. Tighten by hand until the cap-

screws are snug.

Bench Service Procedure

3. From the auxiliary section housing, remove the retaining capscrews that attach the front section to the auxiliary section.

4. Insert the two (2) longest capscrews in the housing flange tapped holes. Tighten evenly to move the auxiliary section away from the front box. Go far enough to break the gasket seal.

5. Remove the capscrews from the tapped holes.

6. Attach an auxiliary section hanger bracket to the auxiliary section top.

7. Attach a lifting chain to the auxiliary section hanger bracket.

Bench Service Procedure

8. Move assembly to the rear until auxiliary section is free.

9. Remove the gasket and clean all mounting surfaces of gasket material.

Bench Service Procedure

Procedure -

1. To remove the auxiliary section in the vertical position:

With blocks under the clutch housing to prevent input shaft damage, place transmission in the vertical position, clutch housing down.

2. Remove the four (4) capscrews and the auxiliary countershaft rear bearing cover, gasket, and rear bearing shim. Clean the gasket surface area.

3. Install the auxiliary countershaft retaining straps with 2 - 3/ 8" NC x 1" and 1 - 3/8" NC x 2 - 1/2" clean capscrews.

Note: Do not use an air gun. Tighten by hand until the cap-

screws are snug.

4. From the auxiliary section housing, remove the retaining capscrews that attach the front box to the auxiliary section.

5. Install a steel bar through the yoke.

6. Attach a lifting chain to the steel bar.

7. Lift assembly from the front section.

How to Disassemble the Range Cylinder Assembly

Procedure -

1. From the range cylinder cover, remove the capscrews, cover, and gasket.

2. Clean the gasket mounting surfaces of all gasket material.

3. From the range cylinder housing bore, remove the 15/16" nut.

Bench Service Procedure

4. Remove 3/4" bolts from range yoke.

Bench Service Procedure

5. Pull range shaft out of cylinder and remove range yoke from synchronizer.

6. From the cylinder housing bore, remove the range piston.

7. Inspect the range piston O-rings, remove if damaged.

8. From the range cylinder housing, remove the housing and gasket.

9. Clean the gasket mounting surfaces of all gasket material.

10. Inspect the O-ring inside the range cylinder housing bore, remove if damaged.

Bench Service Procedure

How to Remove the Auxiliary Countershaft Assembly

Special Instructions

For ease of disassembly, mount the auxiliary section upright in a vise.

Both countershafts are removed the same.

As the countershaft strap is removed, the countershaft can fall.

Special Tools

See “Tool Information”.

Vise with brass jaws or wood blocks

Item T11: Bearing Puller

Soft bar and maul

Procedure -

1. To hold the auxiliary countershafts from turning, place a shop rag or equivalent between the splitter gear and one countershaft.

2. From the output shaft, loosen the 15/16" capscrew and retainer. Do not remove the capscrew.

3. Install countershaft retaining strap.

4. Use a soft bar and maul to drive the output shaft forward far enough to partially unseat the bearing.

Bench Service Procedure

5. Support the auxiliary countershaft while removing the auxiliary countershaft retaining strap.

6. Remove the auxiliary countershaft.

7. Remove the auxiliary countershaft bearing race from bore.

Bench Service Procedure

8. If necessary, secure the countershaft assemblies in a vise and remove both the front and rear bearings with a bearing separator and jaw pullers.

Bench Service Procedure

How to Disassemble the Synchronizer Assembly

Special Instructions

Place the synchronizer assembly on a clean, flat surface. Cover the synchronizer assembly with a shop rag to prevent losing the three (3) springs under pressure from the HI range synchronizer pin locations.

Special Tools

Typical service tools

1. Spring

2. Synchronizer Hi

3. Sliding Clutch

4. Synchronizer Lo

Procedure -

1. Place the larger LO range synchronizer ring on the bench.

2. Cover the synchronizer with a shop rag to contain the springs.

3. Grab both sides of the HI range synchronizer and pull.

4. From the synchronizer ring LO range pins, remove the sliding clutch.

Bench Service Procedure

How to Disassemble the Output Shaft Assembly

Special Instructions

When using the soft bar and maul on the output shaft, be careful not to damage the threads.

When removing the rear bearing cover, the rear bearing cone drops from the housing bore.

Special Tools

Vise with brass jaws or wood blocks

Press

Soft bar and maul

Bench Service Procedure

OEM supplied

speedometer

adjustable

sensor

(Threaded)

OEM supplied non-adjustable speedometer sensor (Non-Threaded)

Mechanical

Magnetic

Bench Service Procedure

1 - Speedo rotor assembly 2 - O-ring 3 - Oil seal kit 4 - Capscrew 5 - Rear bearing cover assembly 6 - Gasket 7 - Capscrew 8 - Capscrew 9 - Cover 10 - Gasket 11 - Shim Kit 12 - Gasket

13 - Rear housing 14 - Slinger 15 - Lifting eye 16 - Capscrew 19 - Speedo drive gear 20 - Speedo spacer assembly 21 - Oil seal w/slinger 22 - Capscrew 23 - Speed sensor kit 24 - Bushing 25 - O-ring 26 - Rear bearing cover assembly

Bench Service Procedure

Procedure -

1. Use a soft bar and maul to drive the output shaft forward and through the rear bearing assembly.

2. From the auxiliary housing rear, remove the rear bearing retaining capscrews, cover, and gasket.

3. Clean the gasket mounting surface of gasket material.

4. Inspect the rear bearing cover oil seal for damage, remove if damaged.

5. From the auxiliary housing rear, remove the bearing cup and spacer.

6. From the auxiliary housing front, remove the remaining bearing cup.

Bench Service Procedure

7. Some models have a one piece bearing race. Remove it from the bearing bore.

Bench Service Procedure

8. From the output shaft, remove the bearing inner spacer.

9. Use the output shaft assemble gear front face as a base, press the output shaft through the bearing and gear.

Bench Service Procedure

How to Assemble the Output Shaft Assembly

Special Instructions

Make sure the magnetic plugs are installed in the auxiliary housing.

Output shaft stack up should be done on a clean, flat surface.

When heating the bearings, do not heat above 275°F (136°C).

When installing the rear bearing race, the proper depth is when the race shoulder is seated on bearing bore top.

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

Special Tools

See "Tool Information."

Toolmaker’s dye

Heat lamp or hot plate and oil

Oil seal installation tool

Procedure -

1. Use toolmaker's dye and mark the LO range gear for timing purposes.

2. Mark any two (2) adjacent teeth on the LO range gear. Repeat the procedure for the two (2) adjacent teeth directly opposite the first set marked.

Bench Service Procedure

3. With splined washer facing up, place the washer on the output shaft shoulder.

4. With LO range gear clutching teeth down, position LO range gear on the output shaft, engage the washer splines.

5. With chamfer side up, position the LO range gear rear washer on the output shaft against the LO range gear.

6. With tapered side up, use heat or appropriate driver and install the output shaft rear bearing.

7. On the output shaft, position the bearing inner spacer. Set aside.

8. Lay the auxiliary housing front face down on a clean flat surface. Install the bearing race in the bearing bore.

Bench Service Procedure

How to Assemble the Synchronizer Assembly

Special Instructions

Assembly should be done on a clean, flat surface slightly lower than your waist.

Pins on the LO range synchronizer must line up with the chamfered holes on the sliding clutch bottom.

When compressing the HI range synchronizer springs cover with a shop rag. In the event compression is not achieved the first time, this prevents the springs from leaving the bench area.

Special Tools

Typical service tools

1. Spring

2. Synchronizer Hi

3. Sliding Clutch

4. Synchronizer Lo

Procedure -

1. On the bench place the larger LO range synchronizer ring face down with pins up.

2. With the sliding clutch recessed side up, place the sliding clutch on the LO range synchronizer pins.

Bench Service Procedure

3. In the HI range synchronizer bores, install the three (3) springs.

4. Place the HI range synchronizer ring over the LO range synchronizer ring. Rotate the HI range synchronizer until the springs are seated against the pins.

5. Cover the assembly with a shop rag.

6. Apply downward pressure to the HI range synchronizer ring while twisting counterclockwise. This compresses the springs to fully seat HI range on the LO range synchronizer. This should be done with a rapid twist and push motion.

Note: Make sure there are three springs and they are fully

compressed.

Note: Make sure you can move the sliding clutch from HI to

LO range and back.

How to Install the Oil Seal

Special Tools

See Tool Information Eaton Aftermarket Tools for part numbers.

Oil seal driver

Oil seal slinger driver

Procedure -

1. Install the seal into the rear bearing cover using the proper seal driver. The seal is fully installed when the flange on the seal is flush with the shoulder in the bore.

Bench Service Procedure

2. Install a new slinger on the seal sleeve or output yoke using a slinger driver.

Note: Some versions use a sealing ring which is pressed

into a groove on the seal sleeve rear. Make sure this seal is in place on this design level.

Bench Service Procedure

How to Assemble the Range Cylinder Assembly

Special Instructions

Apply Eaton lubricant #71214 or equivalent to shift cylinder assembly and insert valve O-rings so a film covers the entire surface of each O-ring.

Procedure -

1. If previously removed, in the cylinder housing bore, install the small O-ring.

2. If previously removed, on the piston I.D. and O.D., install the piston O-rings.

3. Position a new gasket on the range cylinder housing mounting surface.

4. Install the cylinder housing.

5. Apply Eaton/Fuller sealant #71205 or equivalent to the retaining capscrews.

6. Install the capscrews, tighten to 20-25 lbs. ft. of torque.

7. Lean auxiliary section back with range cylinder upward.

8. Insert the piston. Push it in as far as it will go.

9. Slide range bar through the cylinder and yoke, aligning grooves on range bar with bolt holes in range yoke.

Bench Service Procedure

10. Apply Eaton Fuller sealant #71205 or equivalent to range yoke bolts. Install bolts and torque to 50-65 lbs. ft. of torque.

11. Secure the piston with the retaining nut, tighten to 70-85 lbs. ft. of torque.

12. Position a new gasket on the cylinder housing cover mounting surface.

Bench Service Procedure

Eaton Transmission RTX-16710C Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual