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

[phone] [e-mail]

906 W. Gore St. Orlando, FL 32805

Warnings and Precautions

Warnings and Precautions

! WARNING

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: 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		Output Yoke/Companion Flange
	Purpose and Scope of Manual . . . . . . . . . . . . . . . . . .	. 4
	Disassemble Precautions . . . . . . . . . . . . . . . . . . . . . . .	4	How to Remove the Output Yoke/
	Serial Tag and Model Nomenclature	8
			Companion Flange and Nut	51
	Model Options	9
			How to Install the Output Yoke/
	Gear Ratios - XX709, 1X710	11
			Companion Flange and Nut	54
	Torque Ratings	12
			How to Remove the Output Yoke/
	Lubrication	14
			Flange and Retaining Capscrews	55
	Tool Information	16
			How to Install the Output Yoke/
	Preventative Maintenance	20
			Flange and Retaining Capscrews	56
	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

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

Contents of Table

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

Introduction

Purpose and Scope of Manual

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 Proce- dures—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.

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

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

Introduction

Gray Iron Parts

•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.

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

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!

Designations Model

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.

R T - 1 2 6 0 9 A

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

Ratio Set

Forward Speed

5 = "Spur" Gearing

6 = "Multi-Mesh" Gearing

7 = Helical Auxilary Gearing and

"Multi-Mesh" Front Gearing

This (x) 100 = Nominal Torque Capacity

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®.

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.

Designations Model

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			Length	Weight	Oil Cap.
																						PTO Gear To			In / mm	Lbs/ Kgs	Pints /
																						Input R.P.M.			*	**	Liters
																											***
	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/	.696		.696	28.90 /	606 /	25.5 / 12
																					13.89				734.1	275
RT-11710B	14.78		11.00		8.17		6.00		4.46		3.31		2.46		1.83		1.34		1.00		3.38/	.788		.788	28.9 /	604 /	26 /
																					14.78				734.1	274	12
RT-12709H	13.29		9.16		6.53		4.80		3.57		2.56		1.83		1.34		-		-		3.89/	.696		.696	28.90 /	606 /	25.5 / 12
																					13.89				734.1	275
RT-12710B	14.78		11.00		8.17		6.00		4.46		3.31		2.46		1.83		1.34		1.00		3.38/	.788		.788	28.9 /	606 /	26 /
																					14.78				734.1	275	12
RT-13709H	13.29		9.16		6.53		4.80		3.57		2.56		1.83		1.34		-		-		3.89/	.696		.696	28.90 /	606 /	25.5 / 12
																					13.89				734.1	275
RT-13710B	14.78		11.00		8.17		6.00		4.46		3.31		2.46		1.83		1.34		1.00		3.38/	.788		.788	28.9 /	611 /	26 /
																					14.78				734.1	277	12
RT-14709H	13.29		9.16		6.53		4.80		3.57		2.56		1.83		1.34		-		-		3.89/	.696		.696	28.90 /	606 /	25.5 / 12
																					13.89				734.1	275
RT-14710B	14.78		11.00		8.17		6.00		4.46		3.31		2.46		1.83		1.34		1.00		3.38/	.788		.788	29.5 /	624 /	26 /
																					14.78				749.3	283	12
RTX-11709H	10.55		7.41		5.23		3.79		2.77		1.95		1.38		1.00		-		-		2.99/	.788		.788	28.91 /	664 /	25.5 / 12
																					11.33				743.3	301
RTX-11710B	10.99		8.18		6.07		4.46		3.32		2.46		1.83		1.36		1.00		.74		2.52/	.788		.788	28.9 /	604 /	26 /
																					11.23				734.1	274	12
RTX-12709H	10.55		7.41		5.23		3.79		2.77		1.95		1.38		1.00		-		-		2.99/	.788		.788	28.91 /	664 /	25.5 / 12
																					11.33				743.3	301
RTX-12710B	10.99		8.18		6.07		4.46		3.32		2.46		1.83		1.36		1.00		.74		2.52/	.788		.788	28.9 /	606 /	26 /
																					11.23				734.1	275	12
RTX-13709H	10.55		7.41		5.23		3.79		2.77		1.95		1.38		1.00		-		-		2.99/	.788		.788	28.91 /	664 /	25.5 / 12
																					11.33				743.3	301
RTX-13710B	10.99		8.18		6.07		4.46		3.32		2.46		1.83		1.36		1.00		.74		2.52/	.788		.788	28.9 /	611 /	26 /
																					11.23				734.1	277	12
RTX-14709H	10.55		7.41		5.23		3.79		2.77		1.95		1.38		1.00		-		-		2.99/	.788		.788	28.91 /	664 /	25.5 / 12
																					11.33				743.3	301
RTX-14710B	10.99		8.18		6.07		4.46		3.32		2.46		1.83		1.36		1.00		.74		2.52/	.788		.788	29.5 /	624 /	26 /
																					11.23				749.3	283	12
RTX-16709H	10.55		7.41		5.23		3.79		2.77		1.95		1.38		1.00		-		-		2.99/	.788		.788	28.91 /	664 /	25.5 / 12
																					11.33				743.3	301
RTX-16709B	12.46		7.41		5.23		3.79		2.77		1.95		1.38		1.00		-		-		3.43/	.788		.788	29.50 /	693 /	25.5 / 12
																					13.03				749.3	314

*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 assembly, 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	Thread	Additional Comments
		lbs. ft.	Size
1	Main Drive Gear Bearing Nut	250-300		Apply Loctite grade 277 sealant.
				Stake to input shaft.
6	Front Bearing Cover Capscrews	35-45	3/8" - 16	Apply Loctite 242 to threads.		Specifications
6	Clutch Housing Nuts	Aluminum housing:	5/8" - 18	Use lockwashers.
		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		35-45	3/8" - 16	Apply Loctite 242 to threads.
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
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:	1/2" - 13	Use lockwashers.
		70-75
		Cast Iron Housing:
		90-100

12

Specifications

Torque - Auxiliary Section

Description		Torque Value	Thread	Additional Comments
		lbs. ft.	Size
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.

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

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.	TOOL	PURPOSE	G & W TOOL	GREAT LAKES	OTC TOOL
NO.			NO.	TOOL NO.	NO.
T1	Output Yoke Puller	May be required to remove a rusted	SP-450		7075
		output yoke.
T2	Auxiliary Section Hanger	To support, or hang, the auxiliary sec-	G-40	T-125	5061
		tion in the horizontal position.
T3	Auxiliary	To hold the auxiliary countershafts in	G-250	T-311	5062
	Countershaft	position while installing the auxiliary
	Support and Shim Tool	section in the horizontal position. Also
		to simplify the
		checking and setting of the auxiliary
		countershaft bearing endplay.
T4	Shift Lever Spring	To install the shift tower tension	G-116	T-170
	Installation Tool	spring.
	(Tension Spring Driver)
T5	Slide Hammer	To remove the output seal and reverse	G-70	T-150	1155 Slide
		idler shafts. Requires 1/2"-13 threads.			Hammer /
		(Optional, idler shaft can be driven out			8007 1/2" -13
		from front.)			Adapter
T6	Bearing Puller	To remove front section countershaft	G-10 or G-15	T-100	7070A Kit
		bearings.
T7	Bearing Driver	To install front section countershaft	G200 Kit	T-101 Kit
		bearings (3.97" OD, 1.78" ID).
T8	Bearing Driver	To install the front countershaft rear	G200 Kit	T-101 Kit
		bearings (3.5" OD, 1.6" ID)
T9	Countershaft	To support and locate the front	G-50 / G-51 /	T-145S	7109
	Support Tools (2)	section countershafts during	G-58
		bearing removal and installation.
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	G-247A /		1123 / 927
		tapered bearings.	G-247G
T12	Bearing Driver	To install the auxiliary countershaft	G200 Kit	T-101 Kit
		tapered bearings.
T13	Output Seal Removal Tool	To remove the output seal in			Use 27315
		chassis. Can use slide hammer.			hook with 1155
					slide hammer
* Tool numbers are referenced in the service procedures.

17

Tool Information

REF.	TOOL	PURPOSE	G & W TOOL	GREAT LAKES	OTC TOOL
NO.			NO.	TOOL NO.	NO.
T14	Auxiliary Section Removal	To attach transmission jack to	G-115		49611
	Adapter Plate	auxiliary section for auxiliary			(Used with OTC
		section removal in chassis.			transmission
					jack P/N 5019.)
T15	Mainshaft Hook	To assist in lifting of mainshaft from	G-225	T-165
		front section.
T16	Input Bearing Puller	To remove input bearing.	G-38		7070A Kit
T17	Bearing Race Puller	To remove the auxiliary countershaft	G-247B	T-157 with	7136 puller
		tapered bearing outer races.	attached to G-	T-150	attached to
			70 impact		1155 slide
			puller		hammer
T18	Bearing Race Installer	To install the auxiliary countershaft	G-200 Kit	T-101 Kit	27524/27530
		tapered bearing outer races.			discs used with
					27488 handle
					and 10020
					screw.
* Tool numbers are referenced in the service procedures.

Shop Equipment

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

Information Tool

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	P/N 4301157 included in kit K-2394.
	push-to-connect fittings.
Air Line Cutting Tool	To cut plastic air lines smoothly	P/N 4301158 included in kit K-2394.
	and squarely.
Output Seal Driver	To install output seal.	For 7 series: Eaton P/N 5564501 driver.
		For 9 series: Use Eaton P/N 5564509 adapter with 5564501
		driver. Both parts included in Complete Eaton Seal Kit P/N K-
		3651.
Output Seal Slinger Driver	To install output seal slinger.	For 7 series: Eaton P/N 71223.
		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

Maintenance Preventative

1

8

2	9	7

4

10

6 5

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

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.

Maintenance Preventative

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

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.

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

Leak

Step 1

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.

Step 2

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...

Step 3

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.

23

	Preventative Maintenance
Inspection
Part to Inspect	What to Check For	Action to be Done
Speedometer Connections	Speedometer cables should not be	Applied hydraulic thread sealant #71208
	loose.	to threads.
		Torque speedometer sleeve to
		35-50 lbs. ft.
	Should be an O-ring or gasket between	Replace the O-ring/gasket if damaged or
	the mating speedometer sleeve and the	missing.
	rear bearing cover.
Rear Bearing Cover Capscrews, Gasket,	Check retaining capscrews for tightness.	Apply Eaton Sealant #71205 to the cap-
and Nylon Collar		screw threads.
		Torque capscrews to 35-45 lbs. ft.
	Verify nylon collar and gasket are	Use new parts if need to replace.
	installed at the chamfered hole, aligned	Apply Eaton Sealant #71205 to the cap-
	near the mechanical speedometer open-	screw threads.
	ing.	Torque capscrews to 35-45 lbs. ft.
	Verify that a rear bearing cover gasket is	Install a new gasket if rear bearing cover
	in place.	was removed.
Output Yoke Retaining Nut	Check the output yoke retaining nut for	Torque the output yoke retaining nut to
	tightness.	450-500 lbs. ft. Do not over torque the
		output nut.
PTO Covers and Openings	Check the capscrews for tightness.	Apply Eaton Sealant #71205 to the cap-
		screw threads.
		Tighten 6 bolt PTO capscrews to
		35-45 lbs. ft.
		Tighten 8 bolt PTO capscrews to
		50-65 lbs. ft.
Gray Iron Parts	Check front bearing cover, front case,	Replace parts found to be damaged.
	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
		shaft.
	Check the capscrews for tightness.	Tighten the capscrews to 35-45 lbs. ft.
Oil Cooler and Oil Filter	Check all connectors, fittings, hoses,	Tighten any loose fittings.
	and filter element for tightness.
Oil Drain Plug, Oil Fill Plug	Check the oil drain plug and the oil fill	Torque the oil drain plug to 45-55 lbs. ft.
	plug for leakage.	Torque the oil fill plug to 60-70 lbs. ft.

Maintenance Preventative

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)

Flow Power

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

Timing

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

28