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
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.
4
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.
5
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.
6
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.
7
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
8
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
9
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.
10
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
734.1
734.1
734.1
734.1
734.1
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
606 /
275
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
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.
11
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.
12
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
13
Lubrication
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.
14
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
15
Tool Information
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
16
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.
17
To support and locate the front
section countershafts during
bearing removal and installation.
tapered bearings.
tapered bearings.
chassis. Can use slide hammer.
G200 Kit T-101 Kit
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.
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
18
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.
19
Preventative Maintenance
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
1
2
8
9
7
4
10
6
Note: Transmission appearance may differ, the procedure is the same.
5
20
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.
21
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
22
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.
23
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.
24
Power Flow
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)
25
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
26
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.
27
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
Timing
28
Loading...