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Service Manual

Fuller Heavy Duty TransmissionsTRSM0515October 2007

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TABLE OF CONTENTSTimingDescriptionOperationsLubrication

Preventive Maintenance

Torque RecommendationsAir SystemPrecautions

DisassemblyFront Section DisassemblyAuxiliary Disassembly

Auxiliary ReassemblyFront Section ReassemblyReassemblyTool ReferenceChanging Clutch (Input Shaft)

Eaton CorporationTransmission DivisionKalamazoo, Mich. 49007

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It is essential that the two countershafts are timed.This assures that the countershaft gears will con-tact the mating mainshaft gears at the sameinstant, allowing the mainshaft gears to seek theirequilibrium position. This prohibits the mainshaftgears from climbing out of position and preventsunequal tooth contact.

Timing one set of gears, the drive gear set, is allthat is necessary. It is a simple procedure, consist-ing of marking the proper teeth prior to installationand meshing the teeth so marked.

A. Marking countershaft drive gear teeth.1. Prior to placing each countershaft assem-

bly into case, clearly mark on each drivegear the gear tooth which is directly over thekeyway in gear. (See illustration A.) Thistooth is stamped with an "O" to aid iden-tification.

A. TOOTH ONCOUNTERSHAFTDIRECTLY OVER

KEYWAY MARKEDFOR TIMING

B. Marking drive gear teeth.1. Mark any two adjacent teeth on the drive

gear.

2. Mark the two adjacent teeth on the drivegear which are directly opposite the first set

marked. There should be an equal numberof teeth between the markings on each sideof gear. (See Illustration B.)

B. DRIVE GEAR TEETHCut 7300A CORRECTLY MARKED

FOR TIMING

C. Meshing marked countershaft geteeth with marked drive gear teet(After installing drive gear and maishaft assemblies, the countershabearings are installed to complecountershaft installation.)

1. When instal l ing bearings on the lecountershaft, mesh the marked counteshaft gear tooth between two marked teeon the drive gear. Repeat the proceduwhen installing the right countershaft bea

ings. (See Illustration C.)

C. COUNTERSHAFT GEAR TEETHMESHED WITH DRIVE GEAR TEET

FOR CORRECT TIMING

D. Timing auxiliary section.(In the auxiliary section, the low speed gear sis marked for timing instead of the drive geset.)

1.

2.

3.

4.

5.

6.

Mark any two adjacent teeth on the largmainshaft low speed gear, then mark thtwo adjacent teeth directly oppositethesame procedure as used when marking thfront section drive gear.

On each auxiliary countershaft assembmark the tooth on the small low speed gewhich is stamped with an "O".

Install the low speed gear and tailshaassembly in auxiliary housing.

Partially install outer races of countersharear bearings in case bores.

Place the auxiliary countershaft assemsemblies into position, meshing marketooth on each countershaft gear betweemarked teeth on low speed gear. Counteshafts will be partially seated in rear beaing.

Fully install rear bearings to complete au

iliary countershaft installation.

TIMIMG

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DESCRIPTION

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SHIFTING THE

10 SPEED ROADRANGER TRANSMISSION

RT-661O SERIES

General Instructions

The 10-speed Roadranger Transmissions provideten selective ratios, evenly and progressively spac-ed and shifted with one lever. But you do NOT shiftthe Roadranger as you would a conventionaltransmission with an auxiliary or 2-speed axle,because there is nosplit-shifting.

The shifting of the 10-speed Roadranger Trans-missions is much simpler.. much easier,

ALL SHIFTS ARE MADE WITH ONE LEVER . . .

you use the RANGE CONTROL BUTTON ONETIME ONLY during a sequence of up-shifts . . .andONE TIME ONLY during a down-shift pattern.

Why is the Roadranger different?The Roadranger is a 2-RANGE transmission con-

sisting of a5-speed front section and an automatic2-speed auxiliary section in ONE CASE. The tenforward speeds are secured by using a 5-speedshifting pattern TWICEthe first time with thetransmission engaged in Iow gear or low range; thesecond time engaged in high gear or high range.

By using the same shifting pattern twice, the

shift lever position for 6th speed is the same lst...7th the same as 2nd, 8th the same as 3rd, the same as 4th, and 10th the same as 5th.

Detailed Shifting Instructions

In the following instructions, it is assumed that driver is familiar with motor trucks and tractoand that he can coordinate the necessamovements of the shift lever and clutch pedal make progressive and selective gear engageme

in either direction, up or down.

Upshifting

To get to high rangepull button UP whilein 5th speed, thenmove lever to 6thspeed.

Let's step into the cab.

1. Move the gear shiftlever to the neutral posi-tion.2. Start the engine.3. Wait for air system to reach normal lipressure.4. Now look at the Range Control Button. If it ispush it to the down position. (With the downwamovement of the button, the transmission wshift into low range.) If the button was down whthe truck was last used, the transmission already in low range.5. Now start the vehicle and shift progressivethrough 1st, 2nd, 3rd and 4th to 5th.6. When is 5th and ready for the next upward shPULL the Range Control Button UP and move t

lever to 6th speed. As the Iever passes through neutral position, the transmission will automacally shift from low range to high range.7. With the transmission in high range, you mnow shift progressively through 7th, 8th and 9th 10th.

Driving tip: always start vehicle moving in fispeed gear.

A shift diagram should be in your vehicle. If your shift diagram has been misplaced, writeto Service Department, Eaton Corporation, Transmission Division, Kalamazoo, Michigan,for replacement. Please specify model number of transmission.

OPERATION

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DownshiftingTo get to low rangepush button DOWNwhile in 6th speed,then move lever to5th speed.

1. When shifting down,move the lever from 10ththrough each succes-sive lower speed to 6th.

2. When in 6th, and ready for the next downwardshift, PUSH the Range Control Button DOWN andmove the lever to 5th speed. As the lever passesthrough the neutral position, the transmission willautomatically shift from high range to low range.3. With the transmission in low range, shift downward through each of the four remaining steps.

Use Range Control Button only as describedDon't shift from high range to low range at highspeeds.Don't make range shifts with the vehicle moving inreverse gear.

Skip-shifting is easy, too

Skip-shifting is easy with the Roadranger trans-mission. Depending on the load, the RT-6610 canbe shifted as a 6, 7, 8, 9 or 10 speed transmission.

When you skip-shift going up make sure to pullthe range control "up" to high range before theshift which passes 5th. Skip-shifting down, makesure to push the range control down to low rangebefore the shift which passes 6th.

Following are some suggested skip-shifting pat-terns:

For 6-speed shifting with light loadsshift 3, 5, 7, 8, 9, 10

For 7-speed shifting with medium-heavy loadsshift 2, 4, 6, 7, 8, 9, 10

For 8-speed shifting with heavy loadsshift 2, 4, 5, 6, 7, 8, 9, 10

"Stop" sign or "Slow" sign

When slowing down for a"stop" or "slow" sign, shiftdown through the individualshort steps. By following this procedure the com-pression of the engine will slow the vehicle. Thelife of chassis and trailer brakes can thus be pro-longed.

Shifting theFullerRT & RTO-6610Roadranger Transmissions

Ratios

RatiosModels

1s t 2nd 3rd 4th 5th 6th 7th 8th 9th 10th Rev.

RT-6610 8.94 7.00 5.46 4.26 3.42 2.61 2.05 1.60 1.25 1.00

RTO-6610 7.17 5.61 4.38 3.42 2.74 2.10 1.64 1.28 1.00 .80

9.502.78

7.622.23

OPERATION

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LUBRICATION

Proper Lubrication . . .the Key to long

transmission lifeProper lubrication procedures are the key to agood all-around maintenance program. If theoil is not doing its job, or if the oil level isignored, all the maintenance procedures in theworld are not going to keep the transmissionrunning or assure long transmission life.

EatonFullerTransmissions are designedso that the internal parts operate in a bath ofoil circulated by the motion of gears andshafts.

Thus, all parts will be amply lubricated ifthese procedures are closely followed:

1. Maintain oil level. Inspect regularly.2. Change oil regularly.3. Use the correct grade and type of oil.4. Buy from a reputable dealer.

Lubrication Change and Inspection

EatonRoadranger

CD50 Transmission Fluid

HIGHWAY USE

First 3,000 to 5,000 miles Factory fill(4827 to 8045 Km) Initial drain,

Every 10,000 miles Check fluid level.(16090 Km) Check for leaks.

I

Every 250,000 miles Change transmission

(402336 Km) fluid.

II OFF-HIGHWAY USE I

IFirst 30 hours Factory fill

Initial drain. I

Every 40 hours Inspect fluid level, Check for leaks.

Every 500 hours Change transmission fluid wheresevere dirt conditions exist.

Every 1,000 hours Change transmission fluid(Normal off-highway use).

Heavy Duty Engine Lubricant orMineral Gear Lubricant

I HIGHWAY USE I

First 3,000 to 5,000 milesFactory fill

(4827 to 8045 Km) initial drain.

Every 10,000 miles Inspect lubricant level.(16090 Km) Check for leaks.

Every 50,000 miles Change transmission(80450 Km) lubricant.

I OFF-HIGHWAY USE IFirst 30 hours Change transmission

lubricant on new units. I

Every 40 hours Inspect lubricant level. Check for leaks,I

Every 500 hours Change transmission lubr icant wheresevere dirt conditions exist.

Every 1,000 hours Change transmission lubricant(Normal of highway use), I

Recommended LubricantsFahrenheit(Celsius)

Grade AmbientType (SAE) Temperature

Eaton

Roadranger

CD50 TransmissionFluid 50 All

Heavy Duty Engine 011MIL-L-2104B, C or D or 50 Above 10E(-12C.)API-SF or API-CD 40 Above 10F.(-12C,)

( Pr ew ou s A PI d es ig na ti on s 3 0 Below 1OF,(-12C,)acceptable)

Mineral Gear Oil with rust 90 Above 1OF,(-12C.)and oxidation inhibitor 80W Below IOF.(-12C,)API-GL-1

The use of mild EP gear oil or multi-pur-pose gear oil is not recommended, but ifthese gear oils are used, be sure to adhere tothe following limitations:

Do not use mild EP gear oil or multi-pur-pose gear oil when operating temperatures areabove 230F (110C). Many of these gear oils,particularly 85W140, break down above 230Fand coat seals, bearings and gears with de-posits that may cause premature failures. Ifthese deposits are observed (especially a coat-ing on seal areas causing oil leakage), changeto Eaton Roadranger CD50 transmission fluid,heavy duty engine oil or mineral gear oil toassure maximum component life and to main-tain your warranty with Eaton. (Also seeOperating Temperatures.)

Additives and friction modifiers are not recom-mended for use in Eaton Fuller transmissions.

Proper Oil LevelMake sure oil is level with filler opening. Be-cause you can reach oil with your finger doesnot mean oil is at proper level. One inch of oillevel is about one gallon of oil.

Draining OilDrain transmission while oil is warm. To drainoil remove the drain plug at bottom of case.

Clean the drain plug before re-installing.RefillingClean case around filler plug and remove plugfrom side of case. Fill transmission to thelevel of the filler opening. If transmission hastwo filler openings, fill to level of both open-ings.

The exact amount of oil will depend on thetransmission inclination and model. Do notover fillthis will cause oil to be forced outof the transmission,

When adding oil, types and brands of oilshould not be mixed because of possible in-compatibility.

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LUBRICATION

Operating TemperaturesWith EatonRoadranger

CD50 Transmission Fluid

Heavy Duty Engine Oiland Mineral Oil

The transmission should not be operated con-sistently at temperatures above 250F (120C).However, intermittent operating temperaturesto 300F (149C) will not harm the transmis-sion. Operating temperatures above 250Fincrease the lubricants rate of oxidation andshorten its effective life. When the averageoperating temperature is above 250F, thetransmission may require more frequent oilchanges or external cooling.

The following conditions in any combina-tion can cause operating temperatures of over250F: (1) operating consistently at slowspeeds, (2) high ambient temperatures, (3) re-stricted air flow around transmission, (4) ex-haust system too close to transmission, (5)high horsepower, overdrive operation.

External oil coolers are available to reduceoperating temperatures when the above condi-tions are encountered.

Transmission Oil Coolers are:

Recommended

With engines of 350 H.P. and abovewith overdrive transmissions

Required

With engines 399 H.P. and above withoverdrive transmissions and GCWSover 90,000 lbs.

With engines 399 H.P. and above and1400 Lbs.-Ft. or greater torque

With engines 450 H.P. and above

With EP or Multipurpose Gear OilMild EP gear oil and multipurpose gear oil arenot recommended when lubricant operatingtemperatures are above 230F (110C). In addi-tion, transmission oil coolers are not recom-mended with these gear oils since the oilcooler materials may be attacked by thesegear oils. The lower temperature limit and oilcooler restriction with these gear oils gener-ally limit their success to milder applications.

Proper Lubrication Levelsas Related to TransmissionInstallation AnglesIf the transmission operating angle is morethan 12 degrees, improper lubrication can ocur. The operating angle is the transmissionmounting angle in the chassis plus the percent of upgrade (expressed in degrees).

The chart below illustrates the safe percof upgrade on which the transmission can used with various chassis mounting anglesFor example: if you have a 4 degree transmsion mounting angle, then 8 degrees (or 14percent of grade) is equal to the limit of 12degrees. If you have a O degree mountingangle, the transmission can be operated on12 degree (21 percent) grade.

Anytime the transmission operating angle12 degrees is exceeded for an extendedperiod of time the transmission should beequipped with an oil pump or cooler kit toinsure proper lubrication.

Note on the chart the effect low oil levecan have on safe operating angles. Allowinthe oil level to fall 1/2" below the filler plughole reduces the degree of grade by approxmately 3 degrees (5.5 percent).

Proper Lubrication Levels are Essential!

Transmission Mounting Angle

Dotted line showing 2 Quarts Low is forreference only. Not recommended.

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PREVENTIVE MAINTENANCE CHECK CHART

CHECKS WITHOUT PARTIALDISASSEMBLY

1. Air System and Connectionsa. Check for leaks, worn air lines, loose con-

nections and capscrews. See Air Systemsection.

2. Clutch Housing Mounting

a. Check all capscrews in bolt circleclutch housing for looseness.

3. Clutch Release Bearinga.

b.

Remove hand hole cover and check wear.

and axial clearance in release bearing.

Check relative position of thrust surface ofrelease bearing with thrust sleeve on pushtype clutches.

4. Clutch Pedal Shaft and Bores

a. Pry upward on shafts to check wear.

b. If excessive movement is found, removeclutch release mechanism and checkbushings in bores and wear on shafts.

5. Gear Lubricant

a. Change at specified service intervals.

b. Use only gear oils as recommended. SeeLubrication section.

6. Filler and Drain Plugs

a. Remove filler plugs and check level oflubricant at specified intervals. Tightenfiller and drain plugs securely.

7. Gear Shift Lever

a. Check for looseness and free play in hous-ing. If lever is loose in housing, proceedwith Check No. 8.

8. Gear Shift Lever Housing Assemblya.

b.

c.

d.

Remove air lines at air valve and removethe gear shift lever housing assembly fromtransmission.

Check tension spring and washer for setand wear.

Check the gear shift lever pivot pin andpivot pin slot for wear.

Check bottom end of gear shift lever forwear and check slot of yokes and blocks inshift bar housing for wear at contactpoints with shift lever.

CHECKS WITH DRIVE LINE DROPPED

9. Universal Joint Companion FlangeNut (Not Shown)

a. Check for tightness. Tighten to recom-mended torque.

CHECKS WITH UNIVERSAL JOINTCOMPANION FLANGE REMOVED

10.

11.

12.

Splines on Output Shaft

a. Check for wear from movement and chuck-ing action of the universal joint compan-ion flange.

Mainshaft Rear Bearing Cover

a. Check oil seal for wear.

Output Shafta. Pry upward against output shaft to check

radial clearance in mainshaft rear bearing.

PREVENTATIVE MAINTENANCE

CHECK CHART

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PREVENTATIVE MAINTENANCE

CHECK CHART

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TORQUE RECOMMENDATIONS

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Cut 7191D-7/84

TORQUE RECOMMENDATIONS

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AIR SYSTEM

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NOTE:Basic Installation and Trouble Shooting Guide

If the transmission is equipped with a A-5010 Roadranger valve, see the Air Systems TroubleshootingGuide, TRSM-0920, for operation and assembly instructions .

OperationThe range shift air system consists of an air filter,regulator, air valve, control valve, range air cylinderwhich is built into the auxiliary housing, fittings,

and connecting lines.Range shifts can only be made when the gearshift lever is in, or passing through, neutral. Thus,the range desired can be pre-selected while theshift lever is in a gear position. As the lever ismoved through neutral, an actuating plunger in theshift bar housing releases the inter-lock pistonallowing it to move to the range position selected.

Constant regulated air is supplied to the "S"port of air valve and to the "IN" port of range con-trol valve. With control button down, the controlvalve is open, and air passes through control valveand to the "P" port of slave valve. This permits air

from the constant supply to flow through the low

range port in slave valve to the air cylinder in aux-iliary housing. Air at the cylinder moves the shiftpiston and shaft to the rear to engage the low

range gear.With the control button up, the control valve isclosed, and air is removed from end port of slavevalve. This permits movement of the air valvepoppet; air from the constant supply to flowthrough the high range port of the slave valve andto the high range port of range cylinder cover inauxiliary housing. The shift piston and shaft aremoved forward to engage the high range or directgear.

When the control button is moved from one posi-tion to another, air from the previously chargedIine exhausts through the breather in range control

valve.

AIR SYSTEM

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TROUBLE SHOOTING

RANGE SHIFT AIR SYSTEMIf transmission fails to make a range shift orshifts too slow, the fault may be in the air systemor actuating parts in the shifting bar housing. Tocheck the air system and pin-point the troublearea, the following procedures are recommended,using the check points indicated by letters in thediagram on page 11.

Checks are to be made with the vehicle engineoff, but with normal vehicle air pressure.

1. Incorrect Hook-upWith normal vehicle air pressure and gear shift

lever in the neutral position, move the control but-ton up and down, from one range to another.

a. If lines are crossed between the control valveand the air valve on transmission, there willbe a steady flow of air from the bottom ex-haust in control valve with button in the upposition.

b. If lines are crossed between the air valve ontransmission and the range cylinder, thetransmission gearing will not correspondwith the button position. Low range, downposition of button, will result in high range

gear engagement in the transmission andvice versa.

2. Air LeaksWith normal vehicle air pressure and gear shiftlever in the neutral position, coat all air lines andfittings with soapy water and check for leaks,moving control button to both positions.

a. If there is a steady leak out exhaust of rangecontrol valve, there are defective parts orO-rings in the range control valve.

b. If there is a steady leak out breather on slavevalve: there is a defective O-ring in the slave

valve, or there is a leak past O-rings on therange shift cylinder piston.c. If transmission fails to shift into low range or

is slow to make the shift and the transmis-sion case is pressurized, see Check Point E.

d. Tighten all loose connections and replacedefective parts or O-rings.

3. Check Point A, Air RegulatorWith normal line pressure and gear shift lever inneutral, check exhaust port of air regulator. Thereshould be no leak from this port.

Cut off the vehicle air pressure and install air

gauge in line at output port of air regulator. Bring

vehicle air pressure to normal. Regulated pressushould be 57.5 to 62.5.

Only as a last resort should an adjustment bmade with the screw in bottom of regulator. Thadjustment has been set for correct operatinlimits. Any deviation from these limits, especiaon regulators which have been in operation fosome time, will in most cases be caused by dirt worn parts. Adjustment of screw will give only temporary remedy.

(1) Turning screw in (clockwise) raises air pre

sure.(2) Turning screw out lowers air pressure.Air regulator is not serviceable and should be r

placed if defective.

4. Check Point BWith normal vehicle air pressure and the gear shlever in the neutral position, pull the control buttoup to high range and disconnect the 1/8 nylon line from out port of control valve at the air valve

a. When control button is pushed down a steadblast of air will flow from disconnected lineAir will shut off when button is pulled up. Thi

indicates that control valve is operating corectly. Reconnect air line.

b. If control valve does not operate correctlycheck for restrictions and leaks; leaks indcate bad O-rings.

5. Check Point CWith normal vehicle air pressure and gear shilever in the neutral position, push the control buton down to the low range position and disconnecthe high range air line, either at fitting on shicylinder or at side port or slave valve.

a.

b.

c.

Pull the control button up. There should be steady flow of air from the high range poPush button down to shut off air.Make sure vehicle engine is off and move thgear shift Iever to a gear position. Pull the buton up; there should be no air at high rangport. Move the gear shift lever to neutrathere should now be a steady flow of air fromthe high range port. Push button down to shoff air and reconnect the high range air lineIf air system operates incorrectly, this indicates that the slave valve is defective, othat actuating parts in shifting bar housing

are jammed or defective.

AIR SYSTEM

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6. Check Point DWith normal vehicle air pressure and gear shiftlever in the neutral position, pull the control buttonup to high range and disconnect the low range airline, either at fitting on range cylinder or at bottomport of air valve.

a. Repeat procedures under Check Point C,reversing the position of the control button inorder to check the low range operation.

7. Check Point EIf any of the seals in the range shift cylinder aredefective the range shift will be affected. The de-gree of lost air will govern the degree of failure,from slow shift to complete failure.

a. Leak at seal A or B as shown in diagram re-sults in failure to shift into either low or highrange; steady leak out air valve breather inboth ranges.

b. Leak at seal C results in failure to shift intolow range; pressurizing of transmission.

Check Point E Cross section of range shift cylinder, showinglocation of seals.

Air Valve Pre-Selection

An actuating pin protruding from the shifting the lever is moved to or through neutral. Seebar housing prevents the poppet slave valve detailed installation of air valve for installa-from moving while the gear shift lever is in a tion precaution concerning the actuating pin.gear position and releases the poppet when

AIR SYSTEM

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IV. RANGE SHIFT AIR LINESALL MODELS

Cut 7001 D-7/84

A. Removal1. Disconnect the black and white l/8" OD air lines(A and B) from between the slave air valve and therange shift control valve.

2. Disconnect the two 1/4" ID air lines frombetween the slave air valve and the range shiftcylinder.

B. Installation1. Connect the black and white 1/8" OD supply line between the forward port on the slave air valand the rear port on the range shift control valve

2. Install the black l/8" OD signal air line betwethe rear port on the slave air valve and the forwaport on the range control valve.

3. Use the chart to install the 1/4" ID air linbetween the slave air valve side cap and the ran

shift cylinder.

AIR SYSTEM

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VI. RANGE CONTROL VALVE

A. Removal and Disassembly1. Disconnect the air lines and loosen the clampsecuring the valve to the gear shift lever. Removevalve.

2. Remove the four screws to separate the frontand rear housings and remove the slide and twosets of position springs and balls.

3. Remove the valve plate, insert O-rings andwave washer from the valve bodies.

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

B. Reassembly and Installation1. Refer to the drawing for proper reassembly. Usea VERY SMALL amount of silicone lubricant on theO-rings to avoid clogging the ports. A small amountof grease on the position springs and balls will helpto hold them in place during reassembly.

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

3. Secure the valve on the gear shift lever with theclamp. The control button should face to the frontand be approximately 6" below the centerline of theshift knob or selector valve.

4. Attach the air lines.

AIR SYSTEM

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AIR FILTER AND REGULATOR

The air filter contains a replaceable filter element which can be removed by turning out the end cap andremoving the spring and tension plate. This element should be cleaned at each oil change, or more often

under high humidity conditions.

AIR SYSTEM

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DISASSEMBLYIt is assumed in the detailed disassembly instruc-tions that the lubricant has been drained from thetransmission, the necessary linkage and air linesremoved and the transmission has been removedfrom the chassis. Removal of the gear shift leverhousing assembly is included in the detailed in-structions; however, this assembly must also beremoved from transmission before removing unitfrom vehicle.

Follow each procedure closely in each section,

making use of both the text and pictures.

1. BEARINGS - Carefully wash and relubricate allbearings as removed and protectively wrap untilready for use. Remove bearings with pullers de-signed for this purpose.

2. ASSEMBLIES - When disassembling thevarious assemblies, such as the mains shaft,countershafts and shifting bar housing, lay all partson a clean bench in the same sequence as removed.

This procedure will simplify re-assembly andreduce the possibility of losing parts.

3. SNAP RINGS - Remove snap rings with pliersdesigned for this purpose. Rings removed in thismanner can be reused.

4. INPUT SHAFT - The input shaft can be removedwithout removing the countershafts, mainshaft ordrive gear.

5. CLEANLINESS - Provide a clean place to work.

It is important that no dirt or foreign material entersthe unit during repairs. The outside of the unitshould be carefully cleaned before starting thedisassembly. Dirt is abrasive and can damagebearings.

6. WHEN DRIVING - Apply force to shafts, hous-ings, etc., with restraint. Movement of some parts isrestricted. Do not apply force after the part beingdriven stops solidly. Use soft hammers and bars forall disassembly work.

INSPECTIONBefore reassembling the transmission, the individ-ual parts should be carefully checked to eliminatethose damaged from previous service. This inspec-tion procedure should be carefully followed to in-sure the maximum of wear life from the rebuilt unit.

The cost of a new part is generally a small frac-

tion of the total cost of downtime and labor, shouldthe use of a questionable part make additional re-pairs necessary before the next regularly scheduledoverhaul.

Recommended inspection procedures are setforth in the following check list:

PRECAUTIONS

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A. Bearings1. Wash all bearings in clean solvent. Check balls,rollers and races for pits and spalled areas.Replace bearings which are pitted or spalled.

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

3. Check fit of bearings in case bores. Bearingsshould be tight to shaft, slightly tight to slightlyloose to bearing bore.

B. Gears1. Check operating gear teeth for pitting on thetooth faces. Gears with pitted teeth should bereplaced.

2. Check all engaging gear teeth. Gears with teethworn, tapered or reduced in length from clashing inshifting should be replaced.

3. Check axial clearances of gears. Where exces-sive clearance is found, check gear snap ring,washer, spacer and gear hub for excessive wear.Maintain .005 to .012 axial clearance of mainshaft

forward speed gears, .005 minimum on reverse gear.

C. Splines1. Check splines on all shafts for wear. If slidingclutch gears, companion flange or clutch hub haveworn into the sides of the splines, the shafts in thiscondition should be replaced.

D. Thrust Washers1. Check surfaces of all thrust washers. Washersscored or reduced in thickness should be replaced.

E. Reverse Gear and Shaft

1. Check bearing sleeve for wear from action ofroller bearings.

F. Gray Iron Parts1. Check all gray iron parts for cracks and breaks.Replace or repair parts found to be damaged. Heavycastings may be welded or brazed providing thecracks do not extend into bearing bores or boltingsurfaces.

G. Clutch Release Parts1. Check clutch release parts. Replace yokes woat cam surfaces and bearing carrier worn at contpads.

2. Check pedal shafts. Replace those worn at being surfaces.

H. Shifting Bar Housing Assembly

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

2. Check yokes for alignment. Replace thowhich are sprung.

3. Check yokes for excessive wear; replace wyokes.

4. Check Iockscrews in yokes and blocks. Rtorque and rewire those found loose.

5. If housing has been dismantled, check neunotches of shifting bars for wear from interloballs. Bars indented at points adjacent to tneutral notch should be replaced.

I. Gear Shift Lever Housing Assembly1. Check spring tension on shift lever. Replatension spring and washer if lever moves too free

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

J. Oil Return Threads and Seals1. Check oil return threads in front bearing covIf sealing action of threads has been destroyed contact with input shaft, replace the cover.

2. Check oil seal in mainshaft rear bearing covIf sealing action of lip has been destroyed, replseal.

PRECAUTIONS

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K. Synchronizers1. Check high and low range synchronizers forburrs, uneven and excessive wear at contact sur-face, and metal particles.

2. Check blocker pins for excessive wear or loose-ness.

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

L. Sliding Clutches

1. Check all yokes and yoke slots in slidingclutches for wear or discoloration from heat.

2. Check engaging teeth of sliding clutches forpartial engagement pattern.

M. O-Rings1. Check all O-rings for cuts, cracks or distortion.Replace if worn.

REASSEMBLYMake sure that interiors of case and housings areclean. It is important that dirt be kept out of trans-mission during reassembly. Dirt is abrasive andcan damage polished surfaces of bearings andwashers. Use certain precautions, as listed below,during reassembly.

1. GASKETS - Use new gaskets throughout thetransmission as it is being rebuilt. Make sure allgaskets are installed, as omission of gasket canresult in oil leakage or misalignment of bearingcovers. See "Location of Gaskets" heading.

2. CAPSCREWS - To prevent oil leakage, usethread sealant on all capscrews. See torque ratingchart for recommended torque.

3. O-RINGS - Lubricate all O-Rings with siliconelubricant.

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

5. INITIAL LUBRICATON - Coat all thrust washersand splines of shafts with Lubriplate during instal-lation to provide initial lubrication, preventingscoring and galling.

6. AXIAL CLEARANCES - Maintain original axialclearances of mainshaft forward speed gears of.005" to .012". Mainshaft reverse gear clearance isa minimum of .005".

7. BEARING - Use of flanged-end bearing driversis recommended for the installation of bearings.These drivers apply equal force to both races ofbearing, preventing damage to balls and races andmaintaining correct bearing alignment with shaftand bore. If tubular or sleeve type driver is used,

apply force only to inner race.

8. UNIVERSAL JOINT COMPANION FLANGE -Pull the companion flange tightly into place withthe mainshaft nut, using 400-450 foot-pounds oftorque. Make sure the speedometer gear has beeninstalled on yoke. If a speedometer gear is notused, a replacement spacer of the same widthmust be used. Failure to pull the yoke or flangetightly into place will permit the shaft to moveaxially with resultant damage to rear bearing.

9. TORQUE - As you reassemble transmission,refer to pages 12 and 13 for proper installationtorque of capscrews, nuts and plugs.

PRECAUTIONS

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I. RANGE SHIFT AIR SYSTEM

A. To Remove the Range Shift ControlValve.

1. Disconnect the two nylon air lines at air valve ontransmission.NOTE: If desired, the gear shift lever housinglever and range control valve can now be remov-ed from the transmission as a unit by turningout the four capscrews which attach the hous-

ing to the transmission.

2. Disconnect the two nylon air lines at the contvalve on gear shift lever, and remove the bgrip from gear shift lever.

DISASSEMBLY

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C. To Remove the Slave Valve.

3. Loosen the mounting clamp and remove therange control valve and mounting clamp fromlever.

4 . Remove nylon air lines, sheathing and O-ringclamp from the gear shift lever.

B. To Remove Air Regulatorand Filter Assembly.

1. Disconnect and remove the air line between theslave valve and air regulator.

2.

3.

4.

Remove street ell and reducer from regulator ifnecessary.

Turn the nipple from air regulator.

Turn out capscrews and remove the air regula-tor and filter assembly from transmission.

1.

2.

Remove the two air lines between the slavevalve and range cylinder in auxiliary.

Turn out the four capscrews and remove theslave valve from transmission. Remove sleevefrom slave valve.

3. If necessary, remove fittings from slave valve.

4. Remove the actuating spring and pin from bore

in transmission.

DISASSEMBLY

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IX. GEAR SHIFT LEVER HOUSING

I

SHIFTING CONTROLS

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A. Removal and Disassembly B. Reassembly and Installation1. Turn out the capscrews, jar lightly to break the 1. Install the spade pin or pivot pin, nut andgasket seal and remove the gear shift lever hous- washer in the bore in the housing. If previouslying from the shift bar housing. removed, install the O-ring in the groove.

2. Secure the housing in a vise and use a largescrewdriver to twist between the spring and side ofthe housing, forcing the spring from under the

three lugs. Do one coil at a time. Remove the spring.3. Remove the washer and gear shift lever.

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

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

3. Place the tension spring washer over the lever

ball with the dished side up.4. Seat the tension spring under the lugs in thehousing, seating one coil at a time. Use of a springdriving tool is recommended.

5. Make sure that the three tension springs andballs are in the shift bar housing bores and installthe gear shift lever housing and gasket on the shiftbar housing.

SHIFT CONTROLS

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Ill. SHIFTING BAR HOUSING

A. To Remove and Disassemble theShifting Bar Housing.

1. Turn out the attaching capscrews, jar to break 2. Turn out the two capscrews and remove thegasket seal, and lift the shifting bar housing tension spring cover from top of housing.from transmission. 3. Remove the three tension springs installed

under cover.

DISASSEMBLY

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4. Tilt housing and remove the three tension balls

5.

6.

installed under springs.

Place the housing in a vise with the plunger sideup; front of housing will be to the right.

Starting with the upper bar, move all bars to theright and out front of housing as detailed in thefol lowing instruct ions. Cut lockwire andremove Iockscrews from each bar just prior toits removal.

7. Move top shifting bar to the right and out of

8.

housing, removing shifting yoke-from bar.

Move center bar to the right and out of hous-ing, removing shifting yoke from bar. Asneutral notch in bar clears the front web,remove the interlock pin from bore in neutralnotch.

NOTE: During disassembly, lay all parts on aclean bench in the order of removal to facilitatereassembly. Bars not being removed must bekept in the neutral position or interlock partswill lock bars.

DISASSEMBLY

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9. Remove the actuating plunger from rear web. 11. Remove the two interlock balls from front web

10. Move the lower bar to the right and out of hous-

ing, removing shifting yoke from bar.

DISASSEMBLY

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IV. COMPANION FLANGE, AUXILIARY SECTION AND CLUTCH

HOUSING REMOVAL

1.

A. To Remove the Universal JointCompanion Flange or Yoke.

Lock the transmission by engaging two speeds 2. Pull the flange or yoke straight to the rear andwith the mainshaft sliding clutches. Use a largebreaker bar to turn the output shaft nut from the

off shaft.

output shaft.

DISASSEMBLY

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B. To Remove the Auxiliary Section fromTransmission.

1. Turn out the capscrews that attach the two sec-tions.

3. Break gasket seal and remove clutch housinfrom case.

2.

3.

Insert puller screws in auxiliary housing flange.

Tighten puller screws evenly to move the aux-iliary section straight to the rear and from front

section.

C.

1.

To Remove the Clutch Housing andFront Bearing Cover.

Remove the clutch release mechanism if equipped.

2. Remove nuts from the six studs and turn out thtwo bolts which attach clutch housing to cas

4. Turn out capscrews and remove the front beaing cover. (Tap against drive gear from insidcase to move cover forward to break gask

seal.)

DISASSEMBLY

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V. FRONT SECTION DISASSEMBLY

A. To Remove Bearings from RightCountershaft.

3. Install snap ring in the exposed bearing snapring groove. (Use snap ring which was removedfrom rear bearing bore.)

1. Remove snap ring in rear bearing bore of case.

4. Loosen the capscrews at the bearing retaining

2. Using soft bar and maul against rear of counter- rings on auxiliary drive gear. This will allowshaft, move the assembly forward as far as movement to the rear of the countershaft andpossible until snap ring groove in front bearing mainshaft assemblies.is exposed.NOTE: If front bearing snap ring groove can notbe exposed (due to variances in thickness ofcase), use punch between hub of countershaftdrive gear and inner race of bearing to move thegear forward on shaft.

DISASSEMBLY

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5. Using soft bar and maul against front of 7. Use puller or pry bars to remove front bearing.countershaft, move the countershaft assemblyto the rear as far as possible. This will movefront bearing forward on shaft.

6. Using soft bar and maul against rear of counter-shaft, again move the countershaft as far for-ward as possible to unseat front bearing fromcase bore.

8. Use a maul and punch from inside the case todrive the rear bearing to the rear and from thecase bores.NOTE: Removal procedures will damage thebearings and removal should not be attempted

unless replacement of the bearings is planned.

FRONT SECTION DISASSEMBLY

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B. To Remove the Input Shaft.

1. Move the drive gear and shaft forward as far aspossible.

2.

3. Push down on input shaft to cock bearing inbore. Drive input shaft toward rear of transmiss-ion, through bearing as far as possible. Pull in-put shaft forward to expose snap ring of bear-ing.

Remove the bearing retaining snap ring from 4. Use pry bars to complete removal of bearing.groove in shaft.


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. -

5. Remove the drive gear washer.

6. Remove the snap ring from groove in ID of drivegear.

8. If necessary, remove bushing from pocket clutch shaft.

9. Move the drive gear to the rear and against th4th speed gear, engaging teeth of sliding clutcgear.

7. Pull shaft forward and from splines of drivegear.


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Cut 6421 -2/80

C. To Remove and Disassemble theAuxiliary Drive Gear Assembly.

1. Turn out capscrews and remove the two bearing

retainer rings from case.

2. Remove the snap ring from the rear of main-shaft (located in bore of auxiliary drive gear).

3. Tap against front of mainshaft to move the aux-iliary drive gear bearing to the rear, exposing thebearing snap ring.


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4. Use pry bars to remove the auxiliary drive gearassembly from case bore and from splines ofmainshaft.

6. Press or use driver to remove bearing from auiliary drive gear.

5. Remove snap ring from groove in auxiliary drivegear.


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D. To Remove the Left ReverseIdler Gear.

2.

1. Use curved pry bar to walk bearing from idlerbore in case.

Remove the rear idler washer and retainer frombore. (If necessary, bend holder lugs andremove washer from holder.)


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3. Remove reverse idler gear from case. 5. Remove the front idler washer from case

4. Remove the idler bearing from reverse idlergear.


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E. To Remove and Disassemble theMainshaft Assembly.

1. Block the right countershaft to the right as faras possible-and lift the mainshaft assemblyfrom case.

2. Remove the drive gear and the 4th-5th slidingclutch from mainshaft.

.

3. Inside hub of the 4th speed gear, remove snapring from groove in mainshaft.

4. Remove the 4th speed gear and washer.


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5. Remove the 3rd speed gear and washer.

6. Remove the 2nd-3rd speed sliding clutch.

7. Remove the long key from slot in mainshaft.

8. Remove the 2nd speed gear and washer.


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9. Remove the 1st speed gear and washer. 11. Remove the reverse gear and washer.

10. Remove the 1st-reverse sliding clutch.


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F. To Remove the CountershaftAssemblies.

3. Lift the left countershaft from case.

1.

2.

Lift the right countershaft from case.

Remove bearings from the left countershaft inthe same manner in which bearings wereremoved from right countershaft. (See pages 33and 34.)


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G. To Disassemble the CountershaftAssemblies.

NOTE: Both countershafts are disassembledin the same manner as construction is iden-tical.

1. Remove snap ring from front of countershaft.

2. Press the drive gear from shaft.

3. Press the 4th speed gear from shaft.

4. Using the rear face of the PTO gear as a base

in press, press the 3rd speed gear, and thePTO-2nd speed gear cluster from shaft.5. If necessary, remove woodruff key, long key

and roll pin from shaft.

H. To Remove the Right ReverseIdler Gear.

The right reverse idler gear assembly is identical tothe left and is disassembled in the same manner.


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VI. AUXILIARY DISASSEMBLY

Cut 6482 2/80

A. To Remove the AuxiliaryCountershaft Assemblies.

1. Use pullers to remove bearing from front oftailshaft.

2. Turn out capscrews and remove the rear beaing cover.

3. If necessary remove the rear seal from cover.


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4. Remove the speedometer gear or replacementspacer from tailshaft.

5. Remove the speedometer gear washer.7. Pull the counters shafts forward and out of

housing.

6. From inside housing, use long punch to moveouter races of countershaft rear bearings tothe rear; move races approximately one-halfinch.

8. If necessary pull bearing inner races from frontand rear of countershaft. (Rear race removal isshown.)

AUXILIARY DISASSEMBLY

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I

C. To Remove the Range ShiftAir Cylinder and -

Synchronizer Assemblies.

1. Turn out capscrews and remove the air cylin-der cover.

2.

3. Use air to remove piston. CAUTION - DO nostand in front of cylinder opening.

Remove the nut and Iockwasher from air cylin-

der piston shaft.

4. If necessary remove O-ring from OD of piston


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5. Remove the copper seal from shaft.

.

6. Move the synchronizer assembly, shift yoke,and piston shaft forward and out of housingas a complete assembly.

7.

8.

Remove the shaft and yoke from synchronizerassembly.Cut lockwire, turn out the two Iock screws and

remove yoke from shaft.

9. Place the larger low range synchronizer ringon bench.

10. Pull upward to remove the high range synchro-nizer from pins.

CAUTION. There are three springs located inhousing of high range synchronizer which willbe released as high range synchronizer isremoved from pins. It may be helpful to coverassembly with rag to prevent losing springs.

11.

D.

Remove the sliding clutch from low rangesynchronizer pins. -

To Remove and Disassemble the AirCylinder Assembly.

1. Important: Remove the dust seal, and air portextension from top of housing.


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E. To Remove and Disassemble the LowSpeed Gear and Tailshaft Assembly

2. Remove cylinder from housing.

1. Drive or press against rear of tailshaft to movassembly forward and from rear bearing.

3. Remove O-ring from small bore in cylinder, ifnecessary.

2. Remove the rear washer and the low speedgear from rear of shaft.


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3. Remove spline washer from hub of low speedgear.

4.

5.

Move the mainshaft rear bearing to the rearand out of housing.Use bearing driver to remove the countershaftrear bearings from housing.


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I. AUXILIARY REASSEMBLY

Cut 6549-9/85

A. To Reassemble and Install the LowSpeed Gear and Tailshaft Assembly.

1. Make sure magnetic cleaner is installed inrecess in auxiliary case.

3. Place splined spacer in hub of low speed geashoulder toward rear.

2. IMPORTANT: Mark timing teeth on the reduc-tion gear.a. Mark any two adjacent gear teeth on lowspeed gear.b. Then, mark the two adjacent teeth which aredirectly opposite the first set marked. Thereshould be the same number of teeth betweenthe markings on each side of the gear.

4. Install the low speed gear and spacer over reaof shaft and against shoulder. Clutching teet

down.

AUXILIARY REASSEMBLY

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5. Install the low speed gear rear washer on shaftand against gear, chamfer to the rear.

7. Seat mainshaft rear bearing securely on shaftand in bore.

6. Set the tailshaft with the forward end down andplace auxiliary housing over rear of shaft so thatshaft extends through rear bore.


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B. To Install the Range Shift Air Cylinder.

1. Install O-ring in slot in small bore in cylinder.

Lubricate O-ring with silicone lubricant.

2. Install range cylinder in housing with air port i

cylinder aligned with air port in top of auxiliarhousing.


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3. Install dust cover and airport extension throughhousing and into bore of air cylinder.

C. To Reassemble the SynchronizerAssembly.

3. Install the three springs in bores in high rangesynchronizer ring.

1. Place the larger low range synchronizer ringface down on bench with pins up.

2. Place the sliding clutch, recessed side up, onpins of low range synchronizer.

4. Place the high range synchronizer ring over pinsof the low speed synchronizer ring, seatingsprings against pins.


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5. Seat the direct ring fully on the low speed pinsby pushing down and twisting to compress thesprings.

D. To Install the Synchronizer and RangeShift Air Cylinder Assemblies.

3.

4.

1.

2.

Place the shifting yoke on piston shaft, long hubtowards the rear of the shaft.Align slots in shaft with bores in Yoke hub and

Place yoke in slot of sliding clutch; threadeend of piston shaft is towards the larger lorange synchronizer.

Place the entire assembly into auxiliary houing, exgaging splines or sliding clutch wittai lshaft and inserting piston shaft througcylinder bore.

install the two Iockscrews secure with safety 5. Install copper seal on threaded end of pistowire. shaft.


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6. Install O-ring on OD of piston. Apply light coatof silicone lubricant to O-ring.

- .

7. Install piston on shaft and against copperwasher, flat side of piston out.

8. Install Iockwasher and nut on shaf to secure

piston.

9.

E.

Install gasket and cylinder cover, tighten thefour capscrews securely.

To Reassemble the CountershaftAssemblies.

1. Install bearing inner race on front and rear ofcountershaft.

2. IMPORTANT: To mark countershaft gear teethfor timing.

Mark the tooth on the countershaft low speedgear which is stamped with an "O".


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F. To Install the CountershaftAssemblies.

1. Seat the outer races of the countershaft rearbearings only partially in bores, just far enoughto stay in place.

2. Place countershafts into position in auxiliaryhousing, inserting inner races into the partiallyinstalled outer races.IMPORTANT: Timing countershaft gears withlow speed gears. As the countershafts are in-stalled, mesh the marked low speed gear toothon each countershaft between each set of mark-ed gear teeth on the low speed gear.

3. With countershafts in position, complete thinstallation of the countershaft rear bearings oshaft and into case bore. Seat securely.


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4.

5.

Install the speedometer gear rear washer ontailshaft and against bearing, champh ered IDtowards bearing, and install the speedometergear or replace merit spacer on shaft andagainst washer.

If previously removed, install oil seal in rearbearing cover, lip of seal to the rear. The springin the seal should be toward the inside of thetransmission.

6. Install the rear bearing cover with the speed-ometer bore up and to the left, tighten capscrews securely.

7. Install bearing on front of tailshaft.


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Il. FRONT SECTION REASSEMBLY

A. To Install the Right Reverse Idler GearAssembly.

1. Apply a heavy coat of white grease on thereverse-idler gear front washer and install it onpin in lower right of case.

2. Set reverse gear in position next to washer,machined surface of gear hub to the rear.

3. Install needle bearing through rear bore and into hub of reverse gear.

4. Place rear washer in holder if previously remed, and bend lugs to secure washer.

5. Place washer and holder into reverse gear cbore, holder flange to the rear.

6. Install the auxiliary countershaft front bearinto the reverse gear case bore to hold treverse idler gear assembly in position.NOTE: The front portion of the auxiliary counshaft is used as a journal for the reverse i

gear.

FRONT SECTION REASSEMBLY

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B. To Assemble the CountershaftAssemblies.

NOTE: Countershafts are identical and are assem-bled in the same manner.

1. If previously removed, install roll pin, long key andwoodruff key in slots in countershaft.

3. Press the 3rd speed gear on shaft.

4. Press the 4th speed gear on shaft, long hub tothe front.

2. Press the PTO-2nd speed gear cluster on counter-shaft, PTO gear to the front.


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5. Press drive gear on shaft, long hub to the rear.

C. To Mark Timing Teeth and PositionCountershaft Assemblies.

1.

2.

6. Install snap ring in groove at front of shaft.

3.

On the drive gear of each countershaft mark thgear tooth which is aligned with the keyway shaft. This tooth will be stamped with an "O"

Place the left countershaft into position in cas- install bearings as shown in illustrations 4, 56 and 7.

Place the right countershaft into position i

case--do not install bearings.


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4. Center rear of left countershaft in rear bore ofcase with block.

5. Install front bearing on countershaft and incase bore with flanged driver.

6. Install rear bearing on countershaft and in casebore with flanged driver.

7. Install snap ring in groove in rear bore of case.

D. To Assemble Auxiliary Drive GearAssembly.

1. Press bearing on auxiliary drive gear, snap ringin groove towards gear.

2. Install bearing retaining snap ring in groove of

auxiliary drive gear shoulder.


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E. To Reassemble the MainshaftAssembly.

1. Place the mainshaft in a vise with the pilot enddown. Keep keyway in mainshaft clear for inser-tion of key.NOTE: Each mainshaft gear is held in positionby locking the gear splined washer to the main-shaft with key. There is one splined washer foreach gear. Splined washers for the reverse, 1st,2nd, and 3rd speed gears are the same diame-ter, the 4th speed gear splined washer is ofsmaller diameter.

2. Install reverse gear splined washer in groovenear rear of mainshaft.

NOTE: Make sure long key is positioned withthe word "top" on key to the outside. During re-assembly the long key will be removed and re-in-

stalled to assure that washers stay in position.

3. Install long key, from the bottom, in keywaymainshaft to lock reverse gear splined wasto mainshaft.

4. Install reverse gear on splined washer wclutching teeth facing down.

5. Install auxiliary drive gear on mainshaft w

clutching teeth facing up.


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SETTING CORRECT AXIAL

CLEARANCES FORMAINSHAFT GEARS

Axial Clearance (End Play) Limits Are:Reverse speed gear - Minimum of .005"Forward speed gears - .005" to .012"

Washers are used to obtain the correct limits; Fivethicknesses are available as follows:

LIMITS COLOR CODE

.259 -.261 Orange

.264 -.266 Purple

.269 -.271 Yellow

.274 -.276 Black

.279 -.281 Red

Refer to Illustrated Parts Lists for washer partnumbers.

Always use the low limit washer in the 1st GEARand 3rd SPEED GEAR positions as shown at right.

Refer to the service manual covering mainshaftreassembly for method of assembling parts.

Reverse gear clearance must be set as low aspossible to the minimum .005". Clearance can bemeasured before the mainshaft assembly is in-stalled in the case. This is done by securing thereverse gear in position on mainshaft with thereverse gear snap ring and the front snap ring;then, secure auxiliary drive gear assembly in posi-tion at rear of mainshaft with the rear snap ring.

**On overdrive models, the (4th) speed gear be-

comes (5th) speed gear.


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6. Install snap ring in groove at rear of m/shaft.

7. Insert two large screw drivers between hub ofreverse gear and auxiliary drive gear applyinglight downward pressure on handles of screw-drivers.

9. Install the 1st-reverse clutch over front of mainshaft and against reverse gear splined washeAlign slot in sliding clutch with key.

10. Remove long key from keyway in mainshaft.Install 1st speed gear splined washer on mainshaft at 1st speed gear location and re-instathe long key to lock splined washer to shaft.

8. Check clearance between the two gears withfeeler gauge. Clearance can be adjusted by re-placing reverse gear splined washer with dif-ferent thickness washer. Proper clearance atthis location should be a minimum of .005".After proper reverse gear clearance has beenset, remove snap ring from rear of mainshaft in

vise, place front (pilot end) of mainshaft in vise.


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11. Install 1st speed gear on mainshaft, clutchingteeth down, fitting gear splines on those ofwasher.

13.

14.

12. Install 2nd speed gear on mainshaft, clutchingteeth up, and against 1st speed gear.

Remove the long key from keyway in main-shaft.

Install 2nd speed gear splined washer on main-shaft and into hub of 2nd speed gear.

15. Install long key in keyway in mainshaft to lockwasher to shaft.


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16. Insert 2 large screwdrivers between the 2 18. Install 3rd gear splined washer on mainshaft gears. Apply slight downward pressure then 3rd speed gear location. It will be necessary insert feeler gauge between the hubs of the pull long key upward slightly in order to fgears to check axial clearance. Correct clear- splined washer over key cross pin and to fit keante should be .005" to .012". in keyway. Re-position key so that cross p

rests on top of washer.

17. Install the 2nd-3rd speed sliding clutch, align-ing slot in sliding clutch with key; engage with2nd speed gear.

19. Install the 3rd speed gear on mainshaft, fittingear splines on those of washer.


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20. Install the 4th speed gear on mainshaft 22.(clutching teeth up) and - against 3rd speedgear.

21. Install the 4th speed gear splined washer onmainshaft and in hub of 4th speed gear.

Install snap ring in groove in mainshaft whichwill hold the 4th speed gear in position onshaft.

23. Install the 4th-5th speed sliding clutch onmainshaft, engage clutch with 4th speed gear.The side marked "front" should be facing up.


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24. IMPORTANT: Mark timing teeth on drive gear 26.(5th speed gear).a. Mark two adjacent teeth on drive gear.b. Mark the two adjacent teeth on drive gear

which are directly opposite the first setmarked. There should be the same numberof teeth between markings on each side of F .gear.

Remove the assembly from vise and install thereverse gear on rear of mainshaft, engagingsplines of gear with those of splined washer onmainshaft.

To Install Mainshaft Assembly.

1.

25. Install the drive gear on mainshaft and againstthe 4th speed gear, snap ring groove in drive 2.gear to the front.

Move right countershaft toward case wall as faras possible.

Place mainshaft assembly in position in case.


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3. If previously removed, install bushing in pocketof input shaft, flush with rear of shaft.

5. Center mainshaft in rear bore of case and installauxiliary drive gear on splines of mainshaft.

4. Install input shaft through bore of case and ontomainshaft. This will prevent the mainshaft as-sembly from dropping to bottom of case.

6. Seat auxiliary drive gear bearing in rear bore ofcase.


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7. Install the two bearing retainer plates and lock-ing tabs on case.

8. Tighten capscrews and secure by bending lock-ing tangs over capscrews.

9. With large screwdriver move mainshaft assebly to rear to expose snap ring groove on rearmainshaft. Install snap ring on rear of mashaft.

10. Install the input shaft in the splines of drigear by moving drive gear forward against side wall of case.


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11. Mesh the marked timing tooth of left counter-shaft drive gear with the two marked timingteeth of the main drive gear. 13. Install drive gear spacer on input shaft.

12. Install snap ring in groove in I.D. of drive gear. 14. Install drive gear bearing on input shaft and in-

to case bore.


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15. Install bearing retaining snap ring in groove ofinput shaft.

16. Engage the 4th-5th sliding clutch into the 4th

speed mainshaft gear. This will prevent the 4thspeed from dropping far enough to cause apossible timing error in the 4th speed gear set.

17. Mesh the marked timing tooth of the rigcountershaft drive gear with the two marktiming teeth of the main drive gear makisure the left countershaft remains in time.

18. Hold countershaft in position and partially stall front and rear bearings in case bores aon countershaft.


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19. Shift the mainshaft sliding clutches into all thegear positions with a screwdriver. If a clutchcannot be shifted into a gear it indicates thatthe gear set is out of time. The right counter-shaft bearings would then need to be removedand the countershaft retimed with the main-shaft. The front box is properly timed if thesliding clutches can be shifted into all themainshaft gears. (Note: Do not shift the trans-mission into two gears at the same time. Thiswill prevent the transmission from rotating.)

20. Use a flanged bearing driver to completeseating of both front and rear bearings.

21. Install snap ring in groove in rear bore of case.


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G. To Install the Left Reverse Idler GearAssembly.

3. Set reverse-idler gear in position, machined suface of gear hub to the rear.

4. Place rear washer in holder if previously remov

ed, and bend lugs to secure washer.

1. Apply heavy coat of white grease on washer andon pin in upper left of case.

5. Place washer and holder into reverse gear casbore, holder flange to the rear.

2. Install needle bearing in hub of reverse-idlergear.

6. Install the auxiliary countershaft front bearinginto the reverse-gear case bore to hold threverse idler gear assembly in position.NOTE: The front portion of the auxiliary counteshaft is used as a journal for the reverse idlegear.


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Ill. CLUTCH HOUSING, AUXILIARY SECTION AND COMPANION

FLANGE INSTALLATIONA. To Install the Clutch Housing. B. To Install the Auxiliary Section.

1. Install the drive gear bearing cover.

2. Install the clutch housing, attaching securelywith the six nuts and two bolts.

3. If so equipped, install the clutch release mech-anism

NOTE: The two reverse gears, including thewashers, must be in perfect alignment with centerof case bores as the front of the auxiliary counter-shafts must be inserted in these parts during aux-iliary installation. A heavy grease or Iubriplate willhelp hold washers in place. Also check rear of front

section to make sure all snap rings have been in-stalled.

1. Install auxiliary section on front section, align-ing auxiliary section on dowel pins and the ex-tended portion of auxiliary countershafts withreverse idler gears. It may make assembly eas-ier if someone slowly rotates input shaft duringinstallation.


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2. Secure the auxiliary with attaching capscrew

C. To Install the Companion Flange orYoke.

NOTE: The auxiliary can also be installed withfront section in a vertical position. Place clutchhousing on blocks and use chain hoist to lowerauxiliary section into position.

1. Lock transmission by engaging two gears wi

the mainshaft sliding clutches.


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2. Make sure the speedometer gear washer andthe speedometer gear or replacement spacerare installed on tailshaft.

3. Install the companion flange on splines oftailshaft.

4. Install the companion flange nut., Tightensecurely, using the correct torque rating.


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IV. SHIFTING BAR HOUSINGA. To Reassemble the Shifting Bar

Housing Assembly.

1. Place the housing in a vise with the front ofhousing to the right.

2. Install the 4th-5th speed shift bar in bottom borewith neutral notches to the front, installing yokeon bar, fork towards front. Install yoke lock-screw and safety wire keep bar in neutral posi-tion.

3. Install interlock ball in vertical bore in front web.

4. Install plunger in vertical bore in rear web.

5. Install the 2nd-3rd speed shift bar in centerbore, and install yoke on bar, Iockscrew hole tothe rear of fork; insert interlock pin in bore inneutral notch.Install yoke Iockscrew and safety wire.

6. Install interlock ball in vertical bore in front web.

7. If previously removed, install the reverse-stopplunger in the reverse yoke. Make sure that theplunger is fully seated in the bore.


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8.

9.

10.

Install the spring in the bore and on the plunger.

Partially install the plug. Use the tip of the gearshift lever to push the plunger back into the boreto compress the spring. Tighten the plug fullyand then back off 1/2 -1 1/2 turns. Stake the plugthreads in the hole.

Install first-reverse shift bar in upper bore, neu-tral notches to the front, installing yoke on bar,fork to the rear.

Install yoke Iockscrew and safety wire.

11. Remove assembly from vise and install thethree tensions balls, one in each bore in top ofhousing. Keep bars in neutral.

12. InstalI the three tension springs, one in eachbore in top of housing.

13. Install the tension spring cover. Tighten cap-

screws securely.


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B. To Install the Shifting Bar HousingAssembly.

3. Install the shifting bar housing on transmsion, fitting yokes into yoke slots of corresponing clutch gears.1. Make sure the shift bars are in the neutral posi-

tion.

4. Install the attaching capscrews, tighten secure2. Place the sliding clutches on the mainshaft in

the neutral position.


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VI. RANGE SHIFT AIR SYSTEM

A. To Install the Air Valve

NOTE: If previously removed install fittings onslave valve.

3. Install the slave valve on transmission, tightecapsc rews even ly and secure ly . Ac tua t inplunger in case fits into alignment sleeve in avalve.

1. Install the actuating pin and spring in bore intransmission.

4. Install the high range air line between the airport in the rear cover of the range cylinder andthe "H" port of the slave valve.

2. Make sure the alignment sleeve is installed inair valve.


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5. Install the low range air line from air port in topof cylinder to the street ell in the "L" port of theslave valve.

B. To Reassemble and Install the AirRegulator and Filter Assembly.

6. Install air line between output port of air regultor and the tee in supply port of air valve.

5. Install the air regulator and filter assembly onmounting surface on the range cylinder, tightencapscrews securely.

REASSEMBLY

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c.

1.

2.

3.

4.

5.

To Install the Range Control Valve.

Install O-ring clamp on gear shift lever.

Install the control valve on gear shift lever withclamp, and replace ball grip on gear shift lever.Position top of control valve button at least sixinches below ball grip.

If air lines are to be replaced, measure lines and

6. Install the black nylon air line from the "OUT"port of control valve to the airport marked "P" inhexagonal end cap of air valve.

7. Install the white nylon air line from the "IN" portof control valve to the tee in supply port of airvalve.

sheathing for correct length.Install sheathing on lines and draw under O-ringclamp on lever.Connect the black nylon air line to the portmarked "OUT" on the control valve and connectthe white nylon air line to the port marked "IN"on the control valve.

REASSEMBLY

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TOOL REFERENCE

Very few special tools are needed to repair the Fuller Twin Countershaft Transmis-sions. Ordinary socket wrenches, screwdrivers, etc., which are found in every mechanicstool box can be used. Other standard shop items are necessary, such as a press, bearingpullers, bearing drivers, mauls and soft bars.

Special tools which are needed consist mostly of snap ring pliers. Listed below are theillustrations which show these tools.

PAGE TOOL HOW OBTAINED

38, 45 & 74 Snap ring pliers, large Tool Supplier

37 &69 Snap ring pliers, medium (Needle-point type) Tool Supplier

46 & 47 Bearing pullers, small Tool Supplier

79 Torque Wrench, 1000 ft.-lb. capacity Tool Supplier

Tool print of this can be73 Drive Gear Bearing Driver obtained from Fuller Ser-

vice Dept. No. T-18042-69

59 Bearing and seal driver Ask for tool print #7551

TOOL REFERENCE

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SPECIAL PROCEDURE FOR CHANGING CLUTCH(INPUT) SHAFT

In some cases in field repair it may be necessary toreplace only the input shaft due to clutch wear onthe splines.

In these instances the input shaft can be remov-ed without disassembling the transmission otherthan removing the shifting bar housing. Removalof the clutch housing is optional. Following is thedetailed procedure:

Disassembly

1. Remove gear shift lever housing and shift barhousing from transmission.2. Remove the front bearing cover.3. Remove snap ring from input shaft.4. Move the drive gear assembly as far forward aspossible and remove the drive gear bearing.5. Remove the washer from input shaft.6. From the front, remove the snap ring from ID ofdrive gear.7. Pull the input shaft forward and from splines ofdrive gear.

Reassembly

Install bushing in new input shaft.

1. Install new input shaft into splines of drive gearjust far enough to expose snap ring groove in ID ofdrive gear.2. Install snap ring in ID of drive gear.3. Install washer on shaft.4. Move the fourth-fifth speed sliding clutch gearforward to contact end of input shaft in hub of drivegear. Block between rear of sliding clutch and frontof the fourth speed gear. When installing bearing

this will hold input shaft in position to seat thebearing properly.5. Install drive gear bearing on shaft and into casebore, making sure blocking remains in place.6. Remove blocking from mainshaft and install thesnap ring on input shaft.7. Re-install front bearing cover, shifting bar hous-ing and gear shift lever housing.NOTE: The above instructions are for changing theinput shaft only. To change the drive gear, com-plete disassembly of the front section must bemade.

CHANGING CLUTCH

(INPUT SHAFT)

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Copyright Eaton Corporation, 2012.Eaton hereby grant their customers,vendors, or distributors permissionto freely copy, reproduce and/ordistribute this document in printedformat. It may be copied only inits entirety without any changes ormodifications. THIS INFORMATIONIS NOT INTENDED FOR SALE ORRESALE, AND THIS NOTICE MUSTREMAIN ON ALL COPIES.

Note: Features and specificationslisted in this document are subject tochange without notice and representthe maximum capabilities of thesoftware and products with all optionsinstalled. Although every attempt has

been made to ensure the accuracy ofinformation contained within, Eatonmakes no representation about thecompleteness, correctness or accuracyand assumes no responsibility forany errors or omissions. Features andfunctionality may vary depending onselected options.

For specing or service assistance,call 1-800-826-HELP (4357) or visitwww.eaton.com/roadranger.In Mexico, call 001-800-826-4357.

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