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Eaton FullerLight Duty Transmissions

Ed. 07/04

FSO-4305/4405Service Manual

Transmission

General Information

3

1

2

3

4

5

Input Shaft Bearing Cover

Gear Shift Lever Housing

Main Section

Shifting System

FSO-4305/4405 Ed. 07/04

4 Ed. 07/04 FSO-4305/4405

5

Table of Contents

1

FSO-4305/4405 Ed. 07/04

General Information

Foreword .................................................. 7

How to Use This Manual .......................... 8

Identification and Specifications ............... 9

Exploded View........................................ 11

Housing ............................................ 11

Engagement ..................................... 13

Shifting System................................. 15

Gear Shift Lever Housing ................. 16

Lubrication.............................................. 18

Operation................................................ 20

Power Flow ............................................. 21

Sealant Application ................................ 25

Torque Recommendation ....................... 26

Precautions ............................................ 29

Troubleshooting ...................................... 33

Special Tools .......................................... 39

6 Ed. 07/04 FSO-4305/4405

7

Foreword

1

FSO-4305/4405 Ed. 07/04 General Information

Eaton Ltda. - Transmission DivisionAftermarket and Service

Rua Clark, 2061 - P.O.Box 30413270 - Valinhos - So Paulo - Brazil

Phone: (19) 3881-9590Fax: (19) 3881-9687

This manual is designed to provide detailed information necessary to service and repair theEaton transmission FSO-4305/FSO-4405.

Disassembly and assembly instructions in this manual make use of a typical FSO-4305/FSO-4405 transmission. Illustrations and pictures show parts that may differ from one transmissionmodel to another, according to its application and serial number.

In addition, it is also assumed that the transmission has been removed from the vehicle andthe lubricant has been drained.

The manual has been divided into two main groups as follows:

1. Information and technical references, placed all together into one section.

2. Disassembly and assembly instructions, divided into sections gathering specific componentassemblies.

For more detailed information on product improvement, repair procedures and other subjectsrelated to service, please contact:

8

How to Use This Manual

1

Informaes Gerais Ed. 07/04 FSO-4305/4405

27. Install the rear thrust ring of the 3rdspeed gear rollers.

28. Lubricate and install the rollers of the3rd speed gear, using a light coat ofgrease to keep the rollers in theirposition.

NOTE: Use transmission oil to lubricatethe bearing.

29. Install the front thrust ring of the 3rdspeed gear.

30. Install the 3rd speed gear on therollers, with the cone side facing up(towards the synchronizer ring).

31. Install the 3rd speed synchronizer ring.

WARNING! The 3rd speedsynchronizer ring HAS EFM coating.See Shifting System, SynchronizerAssemblies.

26. Install the 2nd gear snap ring.

Assembly

89

Main Shaft

Ed. 07/04 FSO-4305/4405 Main Section

4

1

2

3

7

8 9

5

6

4FSO-4405A/108

FSO-4405A/132

FSO-4405A/133

FSO-4405A/134

26

2928

27

30

31

To disassemble and assemble the entire transmission, follow the manual in its normal sequence.

However, if the problem involves one specific component, refer to the table of contents of itsrelated section, for the page number showing that component.

Example

Component: Main Shaft End Play

Location: Main Section, Engagement

From the table of contents: Main Shaft End Play Adjustment, page 88.

General page layout description

1. Heading of the topic covered in the section.

2. Subheading with a more specificdescription of the topic covered.

3. Number and description of operations ofthe procedure.

4. Illustration or photograph showing theprocedures. Reference numbers indicatethe respective operations.

5. WARNING! Information requiring specialattention as it represents risks of personalinjury or product damage.

6. NOTE: Useful information to perform theoperation.

7. Manuals section number.

8. Manuals section description.

9. Page number.

9

Identification and Specifications

1


Eaton FullerSynchronizedOverdrive

FSO - 4405AGear ratio

FSO-4405A/152

FSO-4405A/17

FSO - 4305A


Identification

Model designation

Forward synchronizedspeeds

Design level

Nominal torque capacity(x100 lb.ft)

All Eaton transmissions are identified by the modeldesignation and serial number. This information isstamped on the identification tag fixed to thetransmission case.

WARNING! Do not remove or destroy thetransmission identification tag.

NOTE: When ordering parts or consulting forservice assistance, please inform datacontained on the identification tag.

10


1

General Information Ed. 07/04 FSO-4305/4405

FSO-4405A FSO-4405B FSO-4405CFSO-4305A FSO-4305B FSO-4305C

Torque lb.ft 427 427 427

N.m 580 580 580

NT Gear Ratio NT Gear Ratio NT Gear Ratio

Output Shaft 28 28 28

Countershaft 44 44 44

1st Speed (CS) 12 5.762 17 5.084 12 5.762(MS) 44 55 44

2nd Speed (CS) 20 2.829 25 2.640 25 2.640(MS) 36 42 42

3rd Speed (CS) 36 1.528 36 1.528 36 1.528(MS) 35 35 35

4th Speed (CS) 1.000 1.000 1.000(MS)

5th Speed (CS) 49 0.770 49 0.770 49 0.770(MS) 24 24 24

Reverse Speed (CS) 125.238

174.714

125.238Reverse Idler Gear 28 35 28

(MS) 40 51 40

NT = Number of teeth CS = Countershaft MS = Main shaft

Specifications

NOTE: The transmission specifications may be modified at any time. The data on tableis provided for reference purposes only.

Weight

Cable shifting = 92.0 kg

Rod shifting = 73.5 kg

Direct shifting = 79.0 kg

NOTE: Weight includes transmission lubricant filled up to the correct level.

11

Exploded View

1


1 - Capscrew

2 - Input shaft bearing cover

3 - Oil seal

4 - Oil baffle

5 - Bearing cup

6 - Adjusting shim

7 - Plug

8 - Filling plug

9 - PTO cover

10 - Capscrew

11 - Sphere (or spherical pin)

12 - Spring

13 - Cover

14 - Bracket

15 - Capscrew

16 - Dowel pin

17 - Lifting hook

18 - Capscrew

19 - Oil seal

20 - Baffle

21 - Yoke

22 - Nut

23 - Sphere

24 - Countershaft rear cover

25 - Capscrew

26 - Neutral switch

27 - Speedometer sensor

28 - Rear housing

29 - Reverse speed light switch

30 - Washer

31 - Plug

32 - Drain plug

33 - Front housing

34 - Adjusting shim

35 - Countershaft front cover

36 - Capscrew

FSO-4405A/176

Housings

Main Section

12

Exploded View

1


Housings

Clutch

1 - Capscrew

2 - Clutch collar

3 - Clutch housing

4 - Capscrew

5 - Dust protector

6 - Connection

7 - Bleed valve

8 - Connection

9 - Cover

10 - Capscrew

11 - Washer

FSO-4405A/177

13

Exploded View

1


1 - Bearing cone

2 - Input shaft

3 - Oil baffler

4 - Bearing cone

5 - 4th synchronizer ring

6 - Lock ring

7 - Key

8 - 3rd/4th synchronizer hub

9 - 3rd/4th synchronizer sleeve


11 - 3rd/4th synchronizer assy

12 - 3rd speed gear

13 - Spacer washer

14 - Rollers

15 - Spacer washer

16 - Snap ring

17 - Thrust washer

18 - Sphere

19 - 2nd speed gear

20 - Rollers

21 - Spacer washer

22 - Snap ring

23 - 2nd synchronizer ring

24 - Lock ring

25 - Key

26 - Hub insert

27 - Sleeve insert

28 - 1st/2nd synchronizer hub

29 - 1st/2nd synchronizer sleeve

30 - 1st synchronizer ring

31 - 1st/2nd synchronizer assy(Booster)

32 - 1st speed gear

33 - Needle bearing

34 - Snap ring

35 - Thrust washer

36 - Sphere

37 - Reverse speed gear

38 - Needle bearing

39 - Snap ring

40 - Reverse speed synchronizer ring

41 - Lock ring

42 - Key

43 - 5th/reverse synchronizer hub

44 - 5th/reverse synchronizer sleeve


46 - 5th/reverse synchronizer assy

47 - Main shaft

48 - 5th speed gear

49 - Rollers

50 - Thrust washer

51 - Rear bearing cone

52 - Rear bearing cup

53 - Speedometer rotor

FSO-4405A/178

Engagement

Input Shaft and Main Shaft

14

Exploded View

1


Engagement

Countershaft and Reverse Idler Gear

1 - Front bearing cup

2 - Front bearing cone

3 - Snap ring

4 - Driving gear (4th speed)

5 - 3rd speed gear

6 - Key

7 - Countershaft

8 - 5th speed gear

9 - Snap ring

10 - Rear bearing cone

11 - Rear bearing cup

12 - Reverse idler gear shaft

13 - Capscrew

14 - Needle bearing

15 - Reverse speed idler gear

FSO-4405A/179

15

Exploded View

1


Shifting System

Shift Yoke and Bars

FSO-4405A/180

1 - 1st/2nd speed shift yoke

2 - Pad

3 - Roll pin (diam. 5 mm)

4 - 1st/2nd speed shift bar

5 - Sphere

6 - Interlock pin

7 - 3rd/4th speed shift bar

8 - Roll pin (diam. 4 mm)

9 - 3rd/4th speed shift block

10 - 3rd/4th speed shift yoke

11 - 5th/reverse speed shift block

12 - 5th/reverse speed shift yoke

13 - 5th/reverse speed shift bar

16

Exploded View

1



Remote

FSO-4405A/181

1 - Shaft and lever assy

2 - Lever

3 - Boot

4 - Oil seal

5 - Bushing

6 - 5th speed locator plug (offset)

7 - Capscrew

8 - Plug

9 - Breather

10 - Lifting hook

11 - Capscrew

12 - Spring rear plug

13 - Outer spring

14 - Retainer

15 - Inner spring

16 - Thrust washer

17 - Housing

18 - Locating spring (offset)

19 - Locating sphere (offset)

20 - Capscrew

21 - Lock wire

22 - Internal shift selector

23 - Gasket

24 - Retainer

25 - Washer

26 - Lever

27 - Bearing

28 - Shaft

29 - Bracket

30 - Nut

31 - Shaft

32 - Capscrew

33 - Spherical pin

34 - Counterweight

35 - Bushing

36 - Washer

37 - Snap ring

38 - Bracket

17

Exploded View

1



Direct

FSO-4405A/182

1 - Capscrew

2 - Gear shift lever

3 - Pin

4 - Thrust washer

5 - Ball joint

6 - Cover

7 - Boot

8 - Capscrew

9 - Housing

10 - Capscrew

11 - Capscrew

12 - Plunger

13 - Spring

14 - Plug

15 - Torsion spring

16 - Guide pin

17 - Cam plate

18 - Stop pin

19 - Spring

20 - Ball

18

Lubrication

1


Highway use

After first 50,000 km Change transmission oil

Every 25,000 km Inspect oil level and check for leaks

Every 100,000 km Change transmission oil

Off-highway use

After first 25,000 km Change transmission oil

Every 12,500 km Inspect oil level and check for leaks

Every 50,000 km Change transmission oil

Proper lubrication procedure is the key to a good and complete maintenance program. If theoil is not doing its job, or if the oil level is ignored, all the other possible maintenance procedureswill not be enough to keep the transmission running or to assure long transmission life.

Eaton transmissions are designed so that all the internal parts operate in oil circulating bath,created by the motion of gears and shafts. Thus, all parts are correctly lubricated if theseprocedures are closely followed:

1. Maintain proper oil level, inspecting it regularly.

2. Change oil regularly following maintenance interval chart.

3. Use the recommended grade and type of oil.

4. Buy oil from a reputable dealer.

Oil change and level inspection

Periodic transmission oil change eliminates possible bearing failures, ring wear and seizures,since the products of normal wear in service (tiny metal particles), which circulate in thetransmission oil, are harmful to these parts. In addition, the oil changes its chemicalcharacteristics due to the repeated heating and cooling cycles of a transmission in use.

As a general guide, the following chart provides maintenance interval recommendation tolevel inspection and oil change.

WARNING! Always follow the vehicle manufacturer maintenance recommendation,that prevails over this chart.

Recommended lubricant oil: SAE 80W90 API GL3 or API GL4

19

Lubrication

1


FSO-2405/87

Correct Oil Level Incorrect Oil Level

Draining

It is important to drain the transmission while it is warm. To drain the oil, remove the magneticdrain plug. Clean the drain plug before reinstalling it.

Refilling

Clean the case around the oil fill plug, remove the plug and refill the transmission to the levelof the filler opening.

Oil quantify necessary to refill the transmission depends on the transmission angle. So, refillthe transmission with the vehicle on a flat and leveled surface.

Do not fill the transmission above the recommended level. This will cause oil to be forced outof the case through the front bearing cover, the control cover, the shift lever housing, etc.

Lubricant capacity

4.6 liters

NOTE: The supplied oil volume may vary according to engine and transmission operatingangle. Always refill the transmission with proper grade and type of lubricant up to thelevel of the filler plug opening.

Oil level inspection

Every time the oil level is being checked, clean the area around the filler plug and, if necessary,add sufficient oil to maintain the proper oil level.

WARNING! Do not mix oils of different types and brands, as they might not becompatible.

20

Operation

1


FSO-4405A/151

Gear shift lever pattern

FSO-4305/FSO4405 transmissions have 5 forwardspeeds and one reverse, all of them synchronized.

To shift the speeds follow the shift pattern shownby the illustration aside.

A reverse gear shifting interlocking system preventsfrom accidental transmission shifting from 5th toreverse gear.

Tips for the driver

Always use the clutch to change the gears. The incorrect use of the clutch may cause prematurefailures of the synchronizer assembly.

Always select a starting gear that will provide sufficient reduction (torque) for the vehicles loadand working conditions (terrain).

Never slam or jerk the gear shift lever to complete gear engagement.

Never leave the shift lever in the neutral position while going down hill.

21

Power Flow

1


1st Speed

FSO-4405A/162

The transmission must efficiently transfer the engines power or torque to the vehicles driveline.It is essential to know what takes place in the transmission during torque transfer whentroubleshooting or repairs are required.

1st, 2nd, 3rd and 5th Speeds

1. Torque from the engine is transferred to the transmissions input shaft.

2. The torque is transferred from the input shaft to the countershaft, through its drive gear. Inthis way, input shaft and countershaft always run together.

3. The torque from the countershaft is delivered to all main shaft gears, assembled on bearings.These gears rotate free unless one of the gears is shifted.

4. When a gear is shifted, the torque is transferred from the corresponding engaged mainshaft gear to the clutching teeth of the synchronizer assembly and then to the synchronizerhub, that runs together with the main shaft. Torque is, then, delivered along the main shaftto the driveline components through output yoke.

22

Power Flow

1


2nd Speed

FSO-4405A/163

5th Speed

FSO-4405A/165

3rd Speed

FSO-4405A/164

23

Power Flow

1


4th Speed

FSO-4405A/166

4th Speed

The 4th speed gear is also named direct speed gear.

Torque comes from the input shaft, which transfers the torque directly to the main shaft, despiteof moving the counter shaft at the same time. This torque is transferred through the input shaftclutching teeth, which are engaged to the 4th speed synchronizer hub, directly connected tothe main shaft.

The transmissions noise level in this speed is really low, since torque is delivered directly fromone shaft to another and there are no gears under load.

24

Power Flow

1


Reverse Speed

FSO-4405A/167

Reverse Speed

When the reverse speed gear is shifted, torque is transferred from countershaft to the reverseidler gear, that changes the rotating direction, and then, from that gear to the main shaftreverse speed gear.

25

Sealant Application

1


The correct application of sealing compounds is important to assure a suitable assemblyand to avoid leakages.

FSO-4405A/200

Apply Eaton E680 to mounting surfaces of front and rear covers of the countershaft

Apply Eaton E679 to expanded plugs

Apply Eaton E680 to mounting surface of the PTO cover

* Silicone sealant

Apply Eaton E680 to mounting surfaces of front and rear housings

Apply Eaton E679 to gear shift lever housing plugs

Apply Eaton E679 to mounting surfaces of the input shaft bearing cover and adjusting shims

26

Torque Recommendation

1


Tightening capscrews, plugs and nuts to the proper torque is important to prevent oil leakageand loosening of components, assuring a long working life to the transmission. Additionally,always apply sealant to the threads whenever recommended.

WARNING! Always use a torque wrench to tight to the recommended torque.

Item Description Thread Torque N.m (lb.ft) Sealant

1 Reverse light switch 9/16" - 18 UNF 13.6-20.3 (10-15) Eaton E677

2 Neutral light switch 5/8" - 18 UNF 13.6-20.3 (10-15) Eaton E677

3 Speedometer sensor 3/4" - 16 UNF 9.5-16.3 (7-12) Eaton E677

4 Reverse idler gear M8 19-25.7 (14-19) Eaton E677mounting capscrews

5 Countershaft rear M10 19.0-25.7 (14-19) Eaton E677bearing cover capscrews

FSO-4405A/154

1 2 3

54

27


1


FSO-4405A/155


6 Housing capscrews M8

7 Clutch housing M14

19-25.7 (14-19) Eaton E677

108.6-121.7 (80-90) Eaton E677capscrews

8 Input shaft bearing cover M8 9.5-16.3 (7-12) Eaton E677

9 Yoke nut 1-1/4" - 18 UNF 407-475 (300-350) Eaton E677

10 PTO cover capscrews 3/8" - 16 UNC 19-25.7 (14-19) Eaton E677

11 Oil filling plug 3/4" - 14 NPTF 13.6-20.3 (10-15) Eaton E677

12 Clutch inspection M5 1.4-6.8 (1-5) Eaton E677cover capscrews

13 Countershaft front bearing M8 9.5-16.3 (7-12) *1 Eaton E677cover capscrews 24.4-31-2 (18-23) *2

14 Oil drain plug *3 3/4" - 14 NPTF 13.6-20.3 (10-15) Eaton E677

9

*1 Stamped sheet cover *2 Cast iron cover *3 Not shown

6

10 11 12

7 8

13

28


1


FSO-4405A/156


15 Boot retaining M5 2.0-7.0 (1.5-5) Eaton E677cover capscrews *5

16 Internal shift lever 3/8" - 24 UNF 34-41 (25-30) Eaton E677mounting capscrews *4

17 Gear shift lever M10 19.0-25.7 (14-19) Eaton E677housing capscrews

18 5th gear positioning M16 13.6-20.3 (10-15) Eaton E679spring plug (offset) *4

19 Plunger spring M18 10.5-20.3 (8-15) Eaton E679retainer plug *5

20 Gear shift lever M12 9.5-16.3 (7-12) Eaton E677retaining capscrews *5

21 Shift positioning device M8 9.5-16.3 (7-12) Eaton E677cover capscrews

22 Shift shaft spring 1-1/4" - 12 UNF 34-41 (25-30) Eaton E679plugs *4

*4 Remote Gear Shift Lever Housing *5 Direct Gear Shift Lever Housing

20 21 22 21

16 17 18

1917

15

29

Precautions

1


Precautions during disassembly and assembly

WARNING! When assembling the transmission, it is important to lubricate gearbearings, needle bearings, non-sealed bearings and all other parts under frictionconditions, with the same transmission lubricant oil, in order to prevent damageto transmission parts during initial gears movement.

Cleaning and handling

In order to completely clean the parts, wash them into a solvent bath (kerosene, for instance),moving every part slowly up and down until all the old lubricant and foreign material havebeen dissolved.

WARNING! Care must be taken to avoid skin rasher, fire hazard and vaporinhalation when using solvents.

Non-sealed bearings

Immerse the bearings in clean solvent. Move them slowly up and down in order to loosen thedeposits. Dry the bearings with moisture free compressed air, avoiding the direct air flow tothe bearing in order not to rotate it in high speed. Repeat the above mentioned operation untilthe bearings are thoroughly clean.

WARNING! Never drive the air jet directly to bearing in order to rotate it in highspeed. That can damage the bearing.

Synchronizer assemblies

Avoid bad handling of synchronizer assemblies. Either drops or bumps when disassemblingor assembling may lock them.

30

Precautions

1


Housings

Clean thoroughly the interior and exterior of cases, covers, etc. Cast parts may be cleaned inmild alkaline solution baths (a 7% soluble degreasing oil solution is recommended). The partsare to remain in the bath for the time required to become completely clean. The parts cleanedin alkaline solutions should be rinsed with clean water to remove any alkaline trace aftercleaning process.

WARNING! Care must to be taken to avoid vapor inhalation and skin rashes whenusing alkaline solutions. Every cleaned part must be totally dried at once by meansof moisture free compressed air, or else, by means of a lint free soft cloth, free ofany abrasive material such as metal filings, contaminated oil or polishingcompounds.

Inspection

A thorough and careful inspection of every part is very important for the transmission life. Thereplacement of parts showing either wear or fatigue will avoid future expensive and foreseenfailures.

Gears, shafts and synchronizer assemblies

Whenever magna-flux is available, this process should be used to check the parts.

Check carefully gear teeth for wear, pitting, chipping and cracks. If gear teeth show areaswhere the hardening layer is worn out or cracked, the gear should be replaced by a new one.

Check shafts for warping and excessive wear or damaged splines.

Cases, covers, etc.

Make sure cases, covers, etc. are completely clean and that mounting surfaces and bearingbores are free from chips or burrs. Check carefully every part for cracks, excessive wear or forany other condition that may cause oil leak or a future failure.

Needle bearings

Check carefully every needle roller for wear, pitting or cracked areas to determine whetherthey are suitable for reuse or should be replaced. After inspection, dip the needle bearings inan oil bath and then wrap them in a lint free cloth or paper, so as to protect them until they areto be reassembled.

31

Precautions

1


FSO-2405/98

This side out

Oil seals and snap rings

Any oil seal, snap ring, etc. damaged during maintenance, should be replaced by a new one.Replacement of oil seals and snap rings is cheaper when unit is disassembled than a prematureoverhaul to replace these parts in a future time.

An oil leakage through a worn seal may result in failures of other more expensive componentsof the transmission. The sealing elements should be handled carefully, particularly duringassembly. Cuts, scratches or rolled up seal lips decrease the sealing efficiency.

WARNING! Snap rings have proper assembling position due to the angle of theiropening ends. The side with shorter opening should be faced outwards to facilitatethe installation with pliers.

32

Precautions

1


FSO-2405/140

Parts replacement

When it is necessary to replace parts, use only genuine Eaton transmission spare parts toassure continued performance and extended life of the transmission. The use of either nongenuine or remanufactured spare parts, besides not having the factorys warranty, may lead tosevere damage of the unit.

Since the cost of a new part is generally a small fraction of the total cost of downtime andservice labor, do not reuse a questionable part which could lead to additional repairs andexpenses soon after assembly.

To aid in determining the reuse or replacement of any transmission part, considerations shouldalso be given to the units history, mileage, application, etc.

33

Troubleshooting

1


Problem Probable cause Possible solution Reference

Transmission Incorrect idle speed Adjust idle speed Instructions onnoise when in adjustment vehicles manualneutral

Improper or Replace disc Instructions ondamaged clutch vehicles manualdisc

Loose or damaged Replace and/or Instructions onengine or tighten mounts vehicles manualtransmission mounts

Worn or damaged Replace yoke Instructions onyoke vehicles manual

Warped or Repair or replace Requires specificunbalanced drive drive shaft procedureshaft

Low lubricant level Fill with recommended Recommendedoil to the proper level lubricant - page 18

Contaminated Drain and clean Recommendedlubricant transmission and refill lubricant - page 18

with recommended oil

Worn or damaged Replace damaged parts Instructions on thisgears and/or manualbearings

Misalignment due Retighten capscrews Instructions onto loose tightening vehicles manualcapscrews

Transmission Improper or Replace disc Instructions onnoise with damaged clutch vehicles manualshifted gears disc


The following chart presents some transmission malfunctions with their most common causesand possible solutions.

34

Troubleshooting

1



Transmission Worn or damaged Replace damaged parts Instructions onnoise with flywheel bushing vehicles manualshifted gears or bearing(continued)

Vibration from Verify and repair as Instructions onother vehicle per vehicles manual vehicles manualcomponents (driveshaft, mounts, yoke)

Misalignment Realign Instructions onbetween engine vehicles manualand transmission

Worn or Replace damaged parts Instructions on thisdamaged gears manualand/or bearings

Warped main Replace warped shaft Instructions on thisshaft or manualcountershaft

Hard shifting Malfunction of Verify and adjust Instructions onclutch (not clutch driving system vehicles manualreleasing)

Wrong adjustment Adjust pedal stroke Instructions onof clutch pedal vehicles manual

Worn or damaged Replace damaged parts Instructions onflywheel bushing or vehicles manualbearing

Improper lubricant Drain and refill with Recommendedrecommended oil lubricant - page 18


Worn or damaged Replace damaged parts Gear shift levergear shift lever housing - page 49components

35

Troubleshooting

1



Hard shifting Worn or damaged Replace rings Synchronizer(continued) synchronizer rings assemblies -

page 119

Excessively worn Replace synchronizer Synchronizeror damaged assemblies assemblies -synchronizer page 119assemblies (keys,sleeve or hub)

Improper Readjust synchronizer Synchronizeradjustment of assemblies assemblies -synchronizer page 119assemblies sleeveor hub

Worn or damaged Replace damaged parts Instructions on thisshifting system manualcomponents (yokes,nylon pads, bars,shift blocks)

Improper end play Adjust end play Main shaft andon main shaft or countershaft endcountershaft play adjustment -

pages 88 and 85

Gear shift Malfunction of clutch Verify and adjust clutch Instructions onrubbing (not releasing) driving system vehicles manual

Wrong adjustment Adjust pedal stroke Instructions onof clutch pedal vehicles manualstroke

Malfunction of Verify and adjust system Instructions onclutch driving vehicles manualsystem

Worn or damaged Replace damaged parts Instructions onflywheel bushing vehicles manualor bearing

Incorrect idle Adjust idle speed Instructions onspeed adjustment vehicles manual

36

Troubleshooting

1



Gear shift Worn or damaged Replace rings Synchronizerrubbing synchronizer rings assemblies -(continued) page 119

Worn or damaged Replace gear Instructions on thisgear clutching teeth manual

Worn shift yokes Replace nylon pads Shift bars - pagenylon pads 117

Transmission Misalignment Realign Instructions onslips out of between engine vehicles manualgear and transmission

Incomplete gear Shift gear properlyshifting

Excessive vibration Replace and/or Instructions onon gear shift lever tighten mounts vehicles manualdue to loose ordamaged engineor transmissionmounts

Gear shift lever Adjust console Instructions onconsole out of vehicles manualposition, forcingthe lever

Worn or damaged Replace synchronizer Synchronizersynchronizer assemblies assemblies - pageassemblies 119

Excessive axial Adjust clearance Main shaft end playclearance on main adjustment - pageshaft gears 88

Worn or damaged Replace gear Instructions on thisclutching gear teeth manual

Worn or damaged Replace damaged parts Instructions on thisshifting system manual(gear shifting leverhousing, yokes,bars, etc.)

37

Troubleshooting

1



Oil leak Lubricant above Correct to proper level Recommendedproper level lubricant - page 18

Clogged breather Verify and unclogbreather

Worn or damaged Replace damaged Instructions on thisoil seals seals manual

Housing capscrews Reassemble with proper Instructions on thisnot properly sealant and tightening manual - pages 25tightened or lack torque and 26of sealant

Cracked housing Replace or repair Requires specificor covers damaged parts procedure

Warped or Replace or repair Requires specificdamaged mounting damaged parts proceduresurfaces of housingsand covers

Bearings failures Low lubricant level Fill with recommended Recommendedoil to the proper level lubricant - page 18

Contaminated or Drain and clean Recommendednot recommended transmission and lubricant - page 18lubricant refill with

recommended oil

Improper assembly Reassemble transmission Instructions on thisof transmission manualcomponents

Improper end play Adjust end play Main shaft andon main shaft or countershaft end play adjustment - pagescountershaft 88 and 85

Bearings were not Replace damaged parts. Instructions on thislubricated prior to Reassemble following manual - page 29assembly right procedure

38

Troubleshooting

1



Double shifting Double gear Reassemble system Instructions on thisshifting interlock manual - page 76system assembledimproperly

39

Special Tools

1


Ref. Description

To properly service the Eaton FSO-4305/FSO-4405 transmission, the following specializedtools are recommended:

These special tools should be ordered directly from the approved tools supplier:

40 Ed. 07/04 FSO-4305/4405

41

Table of Contents

2

FSO-4305/4405 Ed. 07/04


Removal ................................................. 43

Disassembly ........................................... 45

Assembly ................................................ 46

Installation .............................................. 47

42 Ed. 07/04 FSO-4305/4405

43


2

FSO-4305/4405 Ed. 07/04 Input Shaft Bearing Cover

FSO-4405A/01

1

FSO-4405A/03

4

FSO-4405A/02

2

3

5

Removal

1. Remove bleed plug and inlet connection.

2. Remove the three mounting capscrews of theclutch collar.

3. Remove the clutch collar.

4. Remove the four mounting capscrews of theclutch housing.

5. Remove the clutch housing.

44


2

Input Shaft Bearing Cover Ed. 07/04 FSO-4305/4405

FSO-4405A/06

FSO-4405A/04

6

FSO-4405A/05

7

6

6. Remove the six mounting capscrews (inner orouter hexagon head, depending on thetransmission model) from the input shaftbearing cover.

Removal

7. Placing two pry bars under the slots existenton the input shaft bearing cover, remove thecover and the main shaft end play adjustingshims.

45


2


FSO-4405A/07

FSO-4405A/08

1

2

3

Disassembly

1. Remove the main shaft front bearing cup withthe special puller. See Special Tools, Reference?????.

2. Remove the oil baffle.

3. Remove input shaft bearing cover oil seal.

NOTE: The oil seal removed should not bereused.

46


2


FSO-4405A/09

3

FSO-4405A/08

2

1

Assembly

1. Install the new oil seal, hitting it carefully withthe special installer of the proper diameter. SeeSpecial Tools, Reference ???.

2. Install the oil baffle, observing its correctassembly position.

3. Install the main shaft front bearing cup, hittingit carefully with the special installer until it isproperly seated on the oil baffle. See SpecialTools, Reference ???.

47


2


FSO-2405/77

3

2, 3

FSO-4405A/86

1, 2

FSO-4405A/04

A

3

Installation

NOTE: Thoroughly clean the parts andremove any remaining sealant from themounting surfaces prior to installation.

WARNING! The main shaft end play isadjusted by using a shim pack,positioned under the input shaft bearingcover.

1. Use the same original shim pack if the mainshaft end play is within the specified range, orelse add or remove shims as needed, followingthe main shaft end play measurement. SeeMain Section Assembly, Main Shaft End PlayAdjustment.

NOTE: Main shaft end play = 0.025 mm to0.100 mm (0.01 to 0.04 in)

2. Apply sealant to both sides of shims of theselected pack and to the mounting surface ofthe input shaft bearing cover.

NOTE: Apply Eaton E679 sealant to both sides of shims and cover surface.

3. Install the shim pack and the input shaft bearingcover. Observe the position of the lubricatingslots on both cover and shims. Slots should beturned toward the upper side of thetransmission (A).

WARNING: Lubricant slots on both coverand shims must be turned toward theupper side of the transmission (A).

NOTE: Place shims with highest thicknesson the extremities of the pack.

48


2


Installation

5

FSO-4405A/01

6

FSO-4405A/04

44. Apply sealant to the threads of the six mounting

capscrews of the input shaft bearing cover andtighten them to the proper torque.

NOTE: Apply Eaton E677 sealant to the threads.Torque = 9.5 to 16.3 N.m (7 to 12 lb.ft)

5. Install the clutch housing and collar followingthe inverse order of the removal.

NOTE: Clutch housing, torque = 108.6 to121.7 N.m (80 to 90 lb.ft)Clutch collar, torque = ??? N.m (??? lb.ft)

6. Install the bleed valve and the inlet connection.

49

3

FSO-4305/4405 Ed. 07/04

Table of Contents


Direct Gear Shift Lever Housing............. 51

Removal............................................ 51

Disassembly ..................................... 52

Assembly .......................................... 55

Installation ........................................ 58

Remote Gear Shift Lever Housing ......... 59

Removal............................................ 59

Disassembly ..................................... 60

Assembly .......................................... 62

Installation ........................................ 64

50 Ed. 07/04 FSO-4305/4405

51

3

FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing

Direct Gear Shift Lever Housing

1. Place transmission gear shifting mechanism inNEUTRAL.

2. Remove the four mounting capscrews of thegear shift lever housing to the transmissioncase.

3. Remove the gear shift lever housing from thetransmission case.

Removal

FSO-4405A/183

2

3

52

3

Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405


1. Secure the gear shift lever housing in a vise,with the gear shift lever facing up.

2. From the cover, remove the four retainingcapscrews and remove the cover.

3. Remove the boot.

4. Remove the two gear shift lever retainingcapscrews and remove the lever.

5. Remove the two nylon thrust washers.

Disassembly

FSO-4405A/184

12

FSO-4405A/185

3

4

FSO-4405A/186

5

53

3



Disassembly

6. From the gear shift lever positioning system,remove the two retaining plugs.

A - Plug

B - Plunger spring

C - Plunger

D - Ball

E - Ball Spring

7. Remove the plunger spring, the plunger andthe ball from both sides of the gear shift leverhousing.

8. Using a screw driver, remove the ball springfrom its housing on both gear shift lever housingsides.

9. Using a pin punch, remove the stop pin of the5th/reverse gear shift inhibitor mechanism, frominside to outside of the gear shift lever housing.

FSO-4405A/187

FSO-4405A/188

AB

C

D

E

FSO-4405A/189

8

FSO-4405A/190

9

6

54

3



10. Remove the 5th/reverse gear shift inhibitormechanism.

A - Torsion spring

B - Cam plate

C - Stop pin

Disassembly

11. Remove the pivot pin of the gear shift lever balljoint, the ball joint itself and the two nylon thrustwashers.

FSO-4405A/191

A

B

C

FSO-4405A/192

11

55

3



1. Install the torsion spring of the 5th/reverse gearshift inhibitor mechanism by inserting one endinto the existing gear shift lever housing hole.

2. Position the cam plate on the housing by fittingthe guide pin and the free torsion spring end.Holding the cam plate in place, install the stoppin and press it into place.

3. Place the ball joint on the gear shift lever withthe two nylon thrust washers and install thepivot pin.

Assembly

FSO-4405A/193

FSO-4405A/194

1

2

FSO-4405A/192

3

56

3



4. Insert the gear shift lever with the two nylonthrust washers into the gear shift lever housing,placing the gear shift lever upper end towardthe same side as the 5th/reverse gear shiftinhibitor mechanism.

Assembly

5. Install the two gear shift lever retainingcapscrews.

NOTE: Apply Eaton E677 sealant to the threads.Torque = 9,5 to 16,3 N.m (7 to 12 lb.ft)

6. Install the gear shift lever positioning systemplunger, springs, ball and the retaining plug onboth gear shift lever housing sides. Tighten theplugs to the recommended torque.

A - Plug

B - Plunger spring

C - Plunger

D - Ball

E - Ball Spring

NOTE: Apply Eaton E679 sealant to the plug threads.Torque = 10,5 to 20,3 N.m (8 to 15 lb.ft)

FSO-4405A/195

FSO-4405A/196

FSO-4405A/197

FSO-4405A/188

AB

C

D

E

5

4

4

6

57

3



Assembly

7. Install the boot.

8. Install the cover and the four retainingcapscrews.

NOTE: Apply Eaton E677 sealant to the threads.Torque = 2,0 to 7,0 N.m (1,5 to 5,0 lb.ft)

FSO-4405A/198

7

8

58

3



1. Place transmission gear shifting mechanism inNEUTRAL.

Installation

2. Apply the recommended sealant to gear shiftlever housing contact surface with thetransmission case.

NOTE: Apply Eaton E680 sealant to gear shift lever housing face.

3. Install the gear shift lever housing on thetransmission case with the housing boss facingthe input shaft.

4. Install the four gear shift lever housing retainingcapscrews and tighten to the recommendedtorque.

NOTE: Apply Eaton E677sealant to the threads.Torque = 19,0 to 25,7 N.m (14 to 19 lb.ft)

FSO-4405A/199

FSO-4405A/198

FSO-4405A/183

3

4

1

2

59

3


Remote Gear Shift Lever Housing

FSO-4405A/10

2

3

4

Removal

1. Place the gear shift lever in NEUTRAL.

2. Remove the four mounting capscrews of thegear shift lever housing to the transmissioncase.

3. Depending on the model of the transmission,remove the lateral mounting capscrew of thegear shift lever linkage and remove its bracketto enable removal of the gear shift leverhousing.

4. Remove the gear shift lever housing and itsgasket.

60

3



FSO-4405A/11

FSO-4405A/12

1

5

2

3

FSO-4405A/79

6

7

7

FSO-4405A/158

4

Disassembly

1. Position and hold the gear shift lever housingin a vise, with the lower part facing up.

2. On the front side of the housing, remove the5th speed locator plug (offset) and then removethe spring and the locating ball.

3. Remove the plug from the opposite side.

NOTE: Some transmission models also mayhave a spring and a ball in this side of thegear shift lever housing.

4. Remove the lock wire from the two mountingcapscrews of the internal shift selector.

5. Remove the two mounting capscrews of theinternal shift selector.

WARNING! Springs are assembled underpressure. Be careful while removing theplug and the snap ring that retains thespring.

6. Remove rear plug of the shifting shaft and theouter spring (1st and 2nd speeds shifting).

7. Remove the retainer and the inner spring (5thand reverse speeds shifting) and the thrustwasher.

61

3



FSO-4405A/14

9

FSO-4405A/12

8

Disassembly

8. Remove the shifting shaft, boot and lever bypulling them outwards.

9. Remove the gear shift lever housing oil seal.

NOTE: In case of worn housing bushings,replace the whole gear shift lever housing.

62

3



FSO-4405A/79

4

FSO-4405A/15

2

FSO-4405A/16

3

FSO-4405A/14

1

Assembly

1. Install the new oil seal, hitting it carefully with aspecial device of the proper diameter until itrests against its seat. See Special Tools,Reference ???.

2. Place the boot on the shifting shaft and installthe shaft on the housing, passing it throughthe first hole. Next, position the internal shiftselector and push the shaft until it reaches theother hole.

3. Install the thrust washer and then install theinner spring and the retainer.

4. Install the external spring and the rear plug,after applying a light sealant coat on themounting surface of the plug. DO NOT applysealant to the plugs thread. Press the plugagainst the spring to allow it to be installed.

NOTE: Apply Eaton E679 sealant to the mounting surface of the plug.Torque = 34 to 41 N.m (25 to 30 lb.ft)

63

3



Assembly

5. Align the holes on the internal shift selector withthe holes on the shaft and tighten the twomounting capscrews.

NOTE: Torque = 34 to 41 N.m (25 to 35 lb.ft)

6. Lock the two mounting capscrews with the wire.

FSO-4405A/12

5

FSO-4405A/11

8

7

FSO-4405A/158

6

7. On the rear side of the housing, install the plugopposite to the 5th speed locator (offset).

NOTE: Some transmission models also mayhave a spring and a ball in this side of thegear shift lever housing.

8. On the front side of the housing, install the 5thspeed locating ball, its spring and the plug.

NOTE: Apply Eaton E679 sealant to the mounting surfaces of the plugs. DO NOT apply sealant to the plugs threadsTorque = 13.6 to 20.3 N.m (10 to 15 lb.ft)

64

3



FSO-4405A/10

3

2

11. Place a new gasket and the gear shift lever

housing assembly on the transmission case.

2. Depending on the model of the transmission,install the shift lever linkage bracket and tightenits mounting capscrew.

3. Apply sealant to the threads of the fourmounting capscrews of the gear shaft leverhousing and tighten them to the proper torque.

NOTE: Apply Eaton E677 sealant to the threads.Torque = 19 to 25.7 N.m (14 to 19 lb.ft)

Installation

65

Table of Contents

4

FSO-4305/4405 Ed. 07/04

Main Section

Engagement ........................................... 67

Disassembly ..................................... 67

Assembly .......................................... 75

Countershaft End PlayAdjustment .................................. 85

Main Shaft End PlayAdjustment .................................. 88

Final Assembly............................ 91

Input Shaft .............................................. 93

Disassembly ..................................... 93

Assembly .......................................... 94

Main Shaft .............................................. 95

Disassembly ..................................... 95

Assembly ........................................ 102

Countershaft ......................................... 108

Disassembly ................................... 108

Assembly ........................................ 111

66 Ed. 07/04 FSO-4305/4405

67

Engagement

4

FSO-4305/4405 Ed. 07/04 Main Section

FSO-4405A/17

1

FSO-4405A/19

3

FSO-4405A/18

2

FSO-4405A/80

2

AB

C

D

Disassembly

1. Remove the clutch housing and collar and theinput shaft bearing cover. See Input ShaftBearing Cover, Removal.

2. Remove the cover of the shift bar locatingdevice, by loosing the two mounting capscrews.Depending on the model of the transmission,the cover of the locating device can be arectangular plate or the shifting cable bracketitself, used simultaneously as a cover, as shownon the illustration aside.

3. Remove the three springs and balls (orspherical pins) of the shift locating device.

A = 1st and 2nd speeds locator

B = 3rd and 4th speeds locator

C = 5th and reverse speeds locator

D = Not used

68

Engagement

4

Main Section Ed. 07/04 FSO-4305/4405

FSO-4405A/22

FSO-4405A/10

5

FSO-4405A/21

6

8

9

7

6

FSO-4405A/20

4

4. Remove the reverse speed light switch and thewasher.

Disassembly

5. Remove the gear shift lever housing. See GearShift Lever Housing, Removal.

6. Remove the neutral switch and the two balls.

7. Remove the speedometer sensor.

8. Lock the shaft with a special tool and removethe output yoke nut. See Special Tools,Reference ???.

9. Remove the output yoke. If necessary, removethe yokes baffler.

69

Engagement

4


FSO-4405A/24

FSO-4405A/25

FSO-4405A/23

11

12 13

10

FSO-4405A/160

B

A

Disassembly

10. To replace only the rear oil seal, it is not requiredto disassemble the rear case. It is possible toremove the oil seal at this stage, by pulling itfrom its housing. Install a new seal with theproper special tool. See Special Tools,Reference ?.

11. Remove the eighteen mounting capscrews ofthe rear case.

NOTE: Depending on the transmissionmodel, one capscrew (A) is used also to holdthe bracket of the gear shift lever linkage andother two capscrews (B) are used to holdthe counterweight of that shifting system.These three capscrews are different from theothers and differ one from each other as well.

12. Place the transmission with the input shaftfacing up.

13. Remove the three mounting capscrews of thecountershaft front cover and remove the cover.

NOTE: Depending on the countershaft frontcover type, these three capscrews might beouter or inner hexagon head type.

70

Engagement

4


FSO-4405A/28

FSO-4405A/29

16

17

FSO-4405A/27

15

FSO-4405A/26

1414. Remove the countershaft end play adjusting

shims.

Disassembly

15. Remove the two reverse idler gear mountingcapscrews.

16. Using two pry bars, separate the front case fromthe rear case.

17. Remove the front case by lifting it.

71

Engagement

4


FSO-4405A/32

FSO-4405A/31

19

21

22

20

FSO-4405A/30

18

Disassembly

18. With the recommended special device, removethe countershaft front bearing cup by hitting itcarefully from either inside or outside the case.See Special Tools, Reference ???.

19. Lift and remove the reverse idler gear shaft.

20. Remove the reverse idler gear shaft togetherwith the needle bearing, paying specialattention not to drop the bearing.

21. Move the countershaft slightly and remove theinput shaft.

22. Remove the 4th speed synchronizer ring.

23. Remove the roll pin of the 5th and reversespeed shift yoke, using a pin punch.

NOTE: Use a 5 mm diameter pin punch.

WARNING! To avoid damage to either theshift bar or its bore on the case, or toboth, place a wooden block between thegears and the bar.

24. Make sure that the transmission is onNEUTRAL position and remove the 5th andreverse speed shift bar together with the shiftcontrol block. The 5th and reverse speed shiftyoke will be removed later, together with themain shaft.

FSO-4405A/33

23

24

72

Engagement

4


FSO-4405A/35

FSO-4405A/36

26

28

FSO-4405A/34

25

27

FSO-4405A/37

29

30

25. Remove the roll pin of the 3rd and 4th speedshift yoke, using a pin punch.



Disassembly

26. Lift the 1st and 2nd speed shift yoke and shiftto 2nd speed.

27. Remove the roll pin of the 3rd and 4th speedshift control block, using a pin punch.



28. Disengage the 2nd speed and return the 1stand 2nd speed shift yoke to NEUTRAL. Thenremove the 3rd and 4th speed shift bar togetherwith its yoke and shift control block.

29. Remove the roll pin of the 1st and 2nd speedshift yoke, using a pin punch.



30. Remove the 1st and 2nd speed shift bar andyoke.

73

Engagement

4


FSO-4405A/38

FSO-4405A/39

31

33

FSO-4405A/40

34

FSO-4405A/41

35

32

36

Disassembly

31. Move the countershaft slightly to enableremoval of the main shaft.

32. Remove the main shaft from its housing on therear case, lifting the shaft together with the 5thand reverse speed shift yoke. Next, remove the5th and reverse speed shift yoke from the mainshaft assembly.

33. Remove the countershaft from thetransmission case.

34. Remove the four balls of the double gearshifting interlocking system.

35. Remove the main shaft rear oil seal, by hittingit from the inside to the outside of the case.

NOTE: The oil seal removed should not bereused.

36. Remove the main shaft rear bearing cup, byhitting it with a special device from the outsideto the inside of the case. See Special Tools,Reference ???.

74

Engagement

4


FSO-4405A/42

37

FSO-4405A/43

38

Disassembly

37. Remove the countershaft rear cover, byloosening its four mounting capscrews.

38. Remove the countershaft rear bearing cup, byhitting it with a special device from the outsideto the inside of the case. See Special Tools,Reference ???.

75

Engagement

4


FSO-4405A/44

FSO-4405A/45

1

4

2

3

Assembly

NOTE: Thoroughly clean the parts andremove any remaining sealant from themounting surfaces prior to installation.

1. Properly place the rear case with its internalside facing up.

2. Carefully clean the bearings cups and housingsprior to installation.

3. Install the countershaft rear bearing cup, bypressing it with a special device until it restsproperly against its housing. See Special Tools,Reference ???.

4. Install the main shaft rear bearing cup, bypressing it with a special device until it restsproperly against its housing. See Special Tools,Reference ???.

76

Engagement

4


FSO-4405A/48

10

FSO-4405A/46

FSO-4405A/47

5

7

FSO-4405A/39

9

6

8

5. Turn the rear case over and properly place itwith the internal side facing down.

6. Manually align the rear oil seal and install it onthe case, by hitting it with a special device untilit rests properly against its housing. See SpecialTools, Reference ???.

Assembly

7. Return the rear case to the position with theinternal side facing up.

8. Install the four balls of the double gear shiftinginterlocking system, placing two balls in eachof the housings. Apply a light grease coat tokeep the balls in the housings during assembly.

9. Install the countershaft in its housing on therear case, with the rear bearing cone facingup.

10. Install the speedometer rotor on the rear endof the main shaft, after applying a grease coatto the rotor hole in order to avoid it to fall duringinstallation of the shaft.

77

Engagement

4


FSO-4405A/38

11

12

FSO-4405A/51

16

17

Assembly

11. Place the 5th and reverse speed shift yoke onthe slot of the corresponding synchronizersleeve on the main shaft.

12. Tilt the countershaft slightly and install the mainshaft on its housing on the rear case, with therear bearing cone facing down. Once the mainshaft has been placed, the countershaft willreturn to its correct position.

13. Insert the 5th and reverse speed shift bar withthe shift control block already assembledthrough its respective shift yoke.

14. With a light grease coat, install the neutralswitch driving pin on the 5th and reverse speedshift bar.

15. Push the 5th and reverse shift bar inside itsbore on the case, making sure that the bar isproperly installed on the ball of the double gearshifting interlocking system.

NOTE: Be careful not to misplace the ballsof the double gear shifting interlockingsystem from their housings.

16. Place the 3rd and 4th speed shift yoke on theslot of the corresponding synchronizer sleeveand install the respective shift bar through theyoke.

17. With a light grease coat, install the interlockpin in the 3rd and 4th speed shift bar.

FSO-4405A/49

13

FSO-4405A/50

15

14

78

Engagement

4


FSO-4405A/55

22

FSO-4405A/52

18

FSO-4405A/53

19

FSO-4405A/54

21

20

18. Install the 3rd and 4th speed shift control blockon the shift bar and push the shift bar to itsbore on the case, assuring that the bar isproperly installed on the ball of the double gearshifting interlocking system.


Assembly

19. Place the 1st and 2nd speed shift yoke on theslot of the corresponding synchronizer sleeveand install its shift bar through the yoke.

20. Push the 1st and 2nd speed shift bar to its boreon the case, making sure that the bar is properlyinstalled on the ball of the double gear shiftinginterlocking system.


21. Align the mounting hole on the 3rd and 4thspeed shift bar with the hole on the shift yokeand install a new roll pin.



22. Align the mounting hole on the 3rd and 4thspeed shift control block with the hole on theshift bar and install a new roll pin.



79

Engagement

4


FSO-4405A/57

24

FSO-4405A/58

25

FSO-4405A/59

27

Assembly

23. Align the mounting hole on the 5th and reversespeed shift bar with the hole on the shift yokeand install a new roll pin.



24. Align the mounting hole on the 1st and 2ndspeed shift bar with the hole on the shift yokeand install a new roll pin.



25. At the end of assembling the shift bars, yokesand control blocks, all bars must have theirupper end aligned and the control blocks mustbe aligned in neutral position.

26. Test the functionality of the double shiftinginterlocking system, trying to shift two gears atthe same time: shift to any gear and then tryshifting another one.

27. Install the 4th speed synchronizer ring on themain shaft.

WARNING! The 4th speed synchronizerring DOES NOT have EFM coating. SeeShifting System, SynchronizerAssemblies.

FSO-4405A/56

23

80

Engagement

4


FSO-4405A/83

30

FSO-4405A/32

28

FSO-4405A/82

29

FSO-4405A/60

29

28. Slightly move the countershaft and install theinput shaft assembly.

Assembly

29. Install the reverse idler gear with the needlebearing in its shaft on its housing on the rearcase.

NOTE: Lubricate the needle bearing with thesame recommended lubricating oil of thetransmission.

30. Align the lower hole of the reverse idler gearshaft with the hole on the rear case and installthe mounting capscrew.

NOTE: Apply Eaton E677 sealant to the thread.Torque = 19 to 25.7 N.m (14 to 19 lb.ft)

81

Engagement

4


FSO-4405A/61

31, 33

FSO-4405A/29

34

32

FSO-4405A/62

35

Assembly

31. Remove any residual sealant form the mountingsurfaces on the front and rear transmissioncases.

32. Remove any residual sealant from thecapscrew holes on the cases, using proper tapsor specially prepared capscrews.

33. Apply recommended sealant on the mountingsurface of the rear case with the front case,spreading it homogeneously over all the surfaceto avoid leakages.

NOTE: Apply Eaton E680 sealant to the mounting surface of the cases.

NOTE: Make sure that all shift bars andassemblies are in NEUTRAL position.

34. Place the front case over the rear case,observing the correct positioning of the dowelpins.

35. Apply sealant to the threads of the eighteenrear case mounting capscrews.

NOTE: Apply Eaton E677 sealant to the threads.

82

Engagement

4


FSO-4405A/27

37

FSO-4405A/26

38

FSO-4405A/84

36

FSO-4405A/160

B

A

36. Place the lifting hook and install the eighteenmounting capscrews. Tighten the capscrewscrosswise to the appropriate torque.

NOTE: Torque = 19 to 25.7 N.m (14 to 19lb.ft)

Assembly

NOTE: Depending on the transmissionmodel, one capscrew (A) is used also to holdthe bracket of the gear shift lever linkage andother two capscrews (B) are used to holdthe counterweight of that shifting system.These three capscrews are different from theothers and differ one from each other as well.

37. Install the second mounting capscrew of thereverse idler gear shaft on the front case.

NOTE: Apply Eaton E677 sealant to the thread.Torque = 19 to 25.7 N.m (14 to 19 lb.ft)

38. Install the countershaft end play adjustingshims.

NOTE: Use the same original shim packremoved during disassembly. Place shimswith highest thickness on the extremities ofthe pack.

83

Engagement

4


FSO-4405A/63

39

FSO-4405A/64

40

41

Assembly

NOTE: At this stage, DO NOT apply anysealant to the mounting surface of thecountershaft front cover with thetransmission case or in the threads of thecover mounting capscrews.

39. Temporarily install the countershaft front coverand the three mounting capscrews. Tighten thecapscrews to the appropriate torque.

NOTE: Depending on the countershaft frontcover type, these three capscrews might beouter or inner hexagon head type.Stamped sheet cover, torque = 9.5 to 16.3N.m (7 to 12 lb.ft)Cast iron cover, torque = 24.4 to 31.2 N.m(18 to 23 lb.ft)

40. Install the main shaft end play adjusting shimspack and temporarily install the input shaftcover. Observe the position of the lubricatingslots on both cover and shims. Slots should beturned toward the upper side of thetransmission. See Input Shaft Bearing Cover,Installation.

NOTE: Use the same original shim packremoved during disassembly. Place shimswith highest thickness on the extremities ofthe pack.At this stage, DO NOT apply any sealant tothe mounting surface of the input shaft coveror in the threads of the cover mountingcapscrews.

41. Install the six mounting capscrews of the inputshaft bearing cover and tighten the capscrewsto the appropriate torque.

NOTE: Torque = 9.5 to 16.3 N.m (7 to 12lb.ft)

84

Engagement

4


FSO-4405A/65

42

4344, 45

42. Place the transmission with the rear side facingup.

43. Install the output yoke on the splines of the mainshaft.

NOTE: If necessary, replace the yoke baffler.

44. Apply sealant to the threads of the new yokenut and tighten the nut.

WARNING! The output yoke nut must bereplaced with a new one each time it isdisassembled.

45. Lock the shaft with a special tool and tightenthe yoke nut to the appropriate torque. SeeSpecial Tools, Reference ???.

NOTE: Apply Eaton E677sealant to the yoke nut threads.Torque = 407 to 475 N.m (300 to 350 lb.ft)

46. Check the countershaft end play. SeeCountershaft End Play Adjustment next in thismanual.

Assembly

85

Engagement

4


FSO-4405A/66

47

FSO-4405A/67

50

FSO-4405A/63

52

48

49

51

53

Countershaft End Play Adjustment

NOTE: The transmission must be positionedwith the rear side facing up.

47. Invert the mounting position of the countershaftrear cover in one of the mounting holes anduse the cover itself as a base to support themagnetic base of the dial indicator.

48. Rotate the countershaft several times, bothclockwise and counterclockwise, to guaranteethat it is completely seated on the bearing.

49. Place the tip of the dial indicator on the end ofthe countershaft. Set the pointer to zero.

50. Remove the lateral cover of the power take off(PTO) opening.

51. Insert a pry bar through the PTO opening andforce the countershaft upwards at once. Readthe countershaft end play on the dial indicator.

52. Invert the position of the transmission case,placing it with the input shaft facing up.

53. Remove the countershaft front cover andremove the end play adjusting shims.

86

Engagement

4


FSO-4405A/26

54, 55

FSO-4405A/63

56

57

54. If necessary, add or remove shims to set theend play within the specified range, preferablycloser to the lower limit.

NOTE: Add shims to reduce end play andremove shims to increase end play.Place shims with highest thickness on theextremities of the pack.Countershaft end play = 0.025 mm to 0.100mm (0.01 to 0.04 in)

55. Install the selected shim pack.

NOTE: Apply Eaton E679 sealant to both sides of shims.


56. Apply sealant to mounting surface of thecountershaft front cover with the transmissioncase and install the cover.

NOTE: Apply Eaton E680 sealant to the mounting surface of the countershaft front cover.

57. Apply sealant to the threads of the threemounting capscrews of the countershaft frontcover and tighten them to the proper torque.

NOTE: Depending on the countershaft frontcover type, these three capscrews might beouter or inner hexagon head type.Stamped sheet cover, torque = 9.5 to 16.3N.m (7 to 12 lb.ft)Cast iron cover, torque = 24.4 to 31.2 N.m(18 to 23 lb.ft)

87

Engagement

4


FSO-4405A/85

58

59


58. Install the lateral PTO opening cover.

NOTE: Apply Eaton E680sealant to the mounting surface of the PTO cover.

Apply Eaton E677 sealant to the threads. Torque = 19 to 25.7 N.m (14 to 19 lb.ft)

59. Check the main shaft end play. See Main ShaftEnd Play Adjustment next in this manual.

88

Engagement

4


FSO-4405A/68

60

FSO-4405A/64

64

6162

63

65

Main Shaft End Play Adjustment

NOTE: The transmission must be positionedwith the rear side facing up.

60. Invert the mounting position of the countershaftrear cover in one of the mounting holes anduse the cover itself as a base to support themagnetic base of the dial indicator.

61. Rotate the main shaft several times, bothclockwise and counterclockwise, to guaranteethat it is completely seated on the bearing.

62. Place the tip of the dial indicator on the end ofthe main shaft. Set the pointer to zero.

63. Place two pry bars under the output yoke andforce the main shaft upwards at once. Readthe main shaft end play on the dial indicator.

64. Invert the position of the transmission case,placing it with the input shaft facing up.

65. Remove the input shaft bearing cover andremove the end play adjusting shims.

89

Engagement

4


FSO-4405A/86

66, 67

FSO-4405A/64

69

FSO-2405/77

68

67, 68

FSO-4405A/04

A

68


66. If necessary, add or remove shims to set theend play within the specified range, preferablycloser to the lower limit.

NOTE: Add shims to reduce end play andremove shims to increase end play.Place shims with highest thickness on theextremities of the pack.Main shaft end play = 0.025 mm to 0.100mm (0.01 to 0.04 in)

67. Apply sealant to both sides of shims of theselected pack and to the mounting surface ofthe input shaft bearing cover.

NOTE: Apply Eaton E679 sealant to both sides of shims and cover surface.

68. Install the shim pack and the input shaft bearingcover. Observe the position of the lubricatingslots on both cover and shims. Slots should beturned toward the upper side of thetransmission (A).

WARNING: Lubricant slots on both coverand shims must be turned toward theupper side of the transmission (A).

NOTE: Place shims with highest thicknesson the extremities of the pack.

69. Apply sealant to the threads of the six mountingcapscrews of the bearing cover and tightenthem to the proper torque.

NOTE: Apply Eaton E677sealant to the threads.Torque = 9.5 to 16.3 N.m (7 to 12 lb.ft)

90

Engagement

4


FSO-4405A/87

7071

72

70. Invert the position of the transmission again,placing it with the rear side facing up.

71. Apply sealant to mounting surface of thecountershaft rear cover with the transmissioncase and install the cover.

NOTE: Apply Eaton E680 sealant to the mounting surface of the countershaft rear cover.

72. Apply sealant to the threads of the threemounting capscrews of the countershaft rearcover and tighten them to the proper torque.

NOTE: Apply Eaton E677sealant to the threads.Torque = 19 to 25.7 N.m (14 to 19 lb.ft)


91

Engagement

4


FSO-4405A/20

76

FSO-4405A/19

77AB

C

FSO-4405A/10

75

FSO-4405A/21

74

73

74

D

Final Assembly

73. Install the speedometer sensor.

74. Install the neutral switch and the two balls.

75. Install the gear shift lever housing. See GearShift Lever Housing, Installation.

76. Install the reverse speed light switch and thewasher.

77. Install the three springs and balls (or sphericalpins) of the shift bar locating device.

A = 1st and 2nd speeds locator

B = 3rd and 4th speeds locator

C = 5th and reverse speeds locator

D = Not used

92

Engagement

4


Final Assembly

FSO-4405A/17

79

FSO-4405A/18

78

FSO-4405A/80

78

78. Install the cover of the shift locating device andtighten its two mounting capscrews. Dependingon the model of the transmission, the cover ofthe locating device can be a rectangular plateor the shifting cable support itself, usedsimultaneously as a cover, as shown on theillustration aside.

NOTE: Apply Eaton E677sealant to the threads.Torque = 9.5 to 16.3 N.m (7 to 12 lb.ft)

79. Install the clutch collar and housing. See InputShaft Bearing Cover, Installation.

93

Input Shaft

4


FSO-4405A/168

FSO-4405A/169

Disassembly

1. Remove the input shaft bearing cone with thespecial puller. See Special Tools, Reference???.

2. Hold the input shaft in a vise with the rear sidefacing up. Remove the oil baffler with ascrewdriver.

94

Input Shaft

4


FSO-4405A/170

FSO-4405A/171

Assembly

1. Install the new oil baffler with a special device.See Special Tools, Reference ???.

2. Place the input shaft in a press with the frontend facing up.

WARNING! Place the tubular tool on theinner race of the bearing. NEVER supportit on the bearing cage.

3. Install the front bearing cone using a specialtubular tool. See Special Tools, Reference ???.

95

Main Shaft

4


FSO-4405A/48

1

FSO-4405A/106

2

FSO-4405A/107

3

FSO-4405A/108

4

5

Disassembly

2. From the front end of the shaft, place the specialpuller on the 3rd speed gear and remove thegear together with the 3rd and 4th speedssynchronizer assembly, the 3rd speedsynchronizer ring and the front bearing cone.See Special Tools, Reference ???.

3. Remove front and rear spacer rings of the 3rdspeed gear rollers and then remove the rollers.

4. Place the main shaft in vertical position in avise, with the front end facing up.

5. Remove the 2nd speed gear snap ring.

1. Manually remove the speedometer rotor fromthe end of the main shaft.

96

Main Shaft

4


FSO-4405A/109

6

FSO-4405A/110

7

FSO-4405A/111

8

FSO-4405A/112

9

6. Remove the thrust washer.

Disassembly

7. Remove the thrust washer locating ball.

8. Remove the 2nd speed gear.

9. Remove the 2nd speed gear rollers.

97

Main Shaft

4


FSO-4405A/113

10

FSO-4405A/114

12

FSO-4405A/115

13

FSO-4405A/172

Disassembly

10. Remove the spacer ring of 2nd speed gearrollers.

11. Remove the 2nd speed synchronizer rings(Tricone) (only FSO-4305 transmission).

12. Remove the snap ring of the 1st and 2nd speedsynchronizer assembly.

13. Remove the 1st and 2nd speed synchronizerassembly.

98

Main Shaft

4


FSO-4405A/117

16

FSO-4405A/118

17

18

FSO-4405A/116

15

FSO-4405A/173

14. Remove the 1st speed synchronizer rings(Tricone) (only FSO-4305 transmission).

Disassembly

15. Remove the 1st speed gear.

16. Remove the 1st gear needle bearing.

17. Remove the reverse speed gear snap ring.

18. Remove the reverse speed gear thrust washer.

99

Main Shaft

4


FSO-4405A/119

19

FSO-4405A/120

20

FSO-4405A/121

21

FSO-4405A/122

22

Disassembly

19. Remove the thrust washer locating ball.

20. Remove the reverse speed gear.

21. Remove the two reverse speed needlebearings.

22. Remove the reverse speed synchronizer ring.

100

Main Shaft

4


FSO-4405A/125

25

FSO-4405A/126

27

FSO-4405A/123

23

FSO-4405A/124

24

23. Remove the snap ring of the 5th and reversespeed synchronizer assembly.

Disassembly

24. Remove the 5th and reverse speedsynchronizer assembly.

25. Remove the 5th speed synchronizer ring.

26. Remove the main shaft from the vise.

27. From the rear end of the main shaft, placespecial puller behind the rear bearing thrustwasher and remove the bearing together withthe washer. See Special Tools, Reference ???.

101

Main Shaft

4


FSO-4405A/127

2829

Disassembly

28. Remove the 5th speed gear.

29. Remove the 5th gear rollers.

102

Main Shaft

4


FSO-4405A/128

4

FSO-4405A/127

32

5

6

FSO-4405A/125

8

7

1

FSO-4405A/124

9

1. Place the main shaft in vertical position in avise, with the rear end facing up.

2. Lubricate and position the rollers of the 5thspeed gear on the shaft, using a light coat ofgrease to keep the rollers in their position.

NOTE: Use transmission oil to lubricate therollers.

3. Manually install the 5th speed gear, with thecone side facing down, until it seats on theshaft.

Assembly

4. Place the main shaft in vertical position in apress, with the rear end facing up and supportit properly.

5. Install the thrust ring of the main shaft rearbearing.


6. Use a tubular tool and press the rear bearing,with the smaller side of the cone facing up, untilit seats on the shaft. See Special Tools,Reference ???.

7. Place the main shaft in vertical position in avise, with the front end facing up.

8. Install the 5th speed synchronizer ring, with theflat side facing down (towards the 5th speedgear).

9. Install the 5th and reverse speed synchronizerassembly with its wider side facing up (towardsthe reverse speed gear).

103

Main Shaft

4


FSO-4405A/123

10

FSO-4405A/122

11

FSO-4405A/121

12

FSO-4405A/120

13

Assembly

10. Install the 5th speed gear snap ring.

11. Install the reverse speed synchronizer ring, withthe flat side facing up (towards the reversespeed gear).

12. Lubricate and install the two needle bearingsof the reverse speed gear, using a light coat ofgrease to keep the bearings in their position.

NOTE: Use transmission oil to lubricate thebearings.

13. Install the reverse speed gear with the coneside facing down.

104

Main Shaft

4


FSO-4405A/130

17

FSO-4405A/116

18

FSO-4405A/118

16

FSO-4405A/119

14

15

14. Install the locating ball of the reverse speedgear thrust washer.

Assembly

15. Install the reverse speed gear thrust washer.

16. Install the reverse gear snap ring.

17. Lubricate and install the needle bearing of the1st speed gear, using a light coat of grease tokeep the bearing in its position.

NOTE: Use transmission oil to lubricate thebearing.

18. Install the 1st speed gear with the cone sidefacing up.

105

Main Shaft

4


FSO-4405A/112

2324

FSO-4405A/131

20

21

FSO-4405A/172

FSO-4405A/173

Assembly

19. Install the 1st speed synchronizer rings(Tricone) (only FSO-4305 transmission).

20. Install the 1st and 2nd speed synchronizerassembly.

21. Install the synchronizer assembly snap ring.

22. Install the 2nd speed synchronizer rings(Tricone) (only FSO-4305 transmission).

23. Install the spacer ring of the 2nd speed gearrollers.

24. Lubricate and install the rollers of the 2nd speedgear, using a light coat of grease to keep therollers in their position.


106

Main Shaft

4


FSO-4405A/132

31

FSO-4405A/108

27

28

3029

FSO-4405A/111

25

FSO-4405A/110

26

25. Install the 2nd speed gear on the rollers, withthe cone side facing the synchronizer assembly.

Assembly

26. Install the locating ball of the 2nd speed gearthrust washer.

27. Install the 2nd speed thrust washer.

28. Install the 2nd gear snap ring.

29. Install the rear spacer ring of the 3rd speedgear rollers.

30. Lubricate and install the rollers of the 3rd speedgear, using a light coat of grease to keep therollers in their position.


31. Install the front spacer ring of the 3rd speedgear.

107

Main Shaft

4


FSO-4405A/136

35

FSO-4405A/135

34

36

FSO-4405A/133

32

FSO-4405A/134

33

Assembly

32. Install the 3rd speed gear on the rollers, withthe cone side facing up (towards thesynchronizer ring).

33. Install the 3rd speed synchronizer ring.

WARNING! The 3rd speed synchronizerring HAS EFM coating. See ShiftingSystem, Synchronizer Assemblies.

34. Install the 3rd and 4th speed synchronizerassembly with its hub wider surface facing down(towards the 3rd speed gear).

35. Place the main shaft in a press, with the frontend facing up and support it properly.


36. Using a tubular tool, press the front bearingwith the smaller side of the cone facing up, untilit seats on the shaft. See Special Tools,Reference ???.

108

Countershaft

4


FSO-4405A/137

1

FSO-4405A/138

2

FSO-4405A/139

FSO-4405A/140

5

3, 4

Disassembly

1. Place the countershaft in vertical position in avise, with the front end facing up, and removethe front bearing using a special puller. SeeSpecial Tools, Reference ???.

2. Remove the 4th speed gear snap ring.

3. Place the countershaft in vertical position in apress, with the front end facing up and usingthe 4th speed gear as a base.

4. Press the countershaft and remove the 4thspeed gear.

5. Turn the countershaft over on the press anduse the 3rd speed gear as a base. Then pressthe countershaft and remove the 3rd speedgear.

109

Countershaft

4


6

FSO-4405A/141

6

FSO-4405A/142

7

FSO-4405A/143

Disassembly

8, 9

6. Place the countershaft in vertical position in avise, with the rear end facing up and removethe rear bearing using a special puller. SeeSpecial Tools, Reference ???.

7. Remove the 5th speed gear snap ring.

8. Place the countershaft in vertical position in apress, with the rear end facing up and usingthe 5th speed gear as a base.

9. Press the countershaft and remove the 5thspeed gear.

110

Countershaft

4


FSO-4405A/144

10

FSO-4405A/145

10

10. Using a punch, remove the rear key and thetwo front keys, carefully tapping to not damagethe shaft and keys.

Disassembly

111

Countershaft

4


FSO-4405A/146

2

FSO-4405A/144

1

FSO-4405A/145

1

FSO-4405A/142

4

3

Assembly

1. Using a hammer, install the rear key and thetwo front keys.

2. Place the countershaft in vertical position in apress, with the rear end facing up and usingthe 2nd speed gear as a base.

3. Using a tubular tool, press the 5th speed geardown the countershaft, with the most prominentside of the gear flange facing down. Make sureto keep the correct alignment of the gear slotwith the shaft key prior to pressing the geardown. See Special Tools, Reference ???.

4. Install the 5th speed gear snap ring.

112

Countershaft

4


FSO-4405A/147

5

FSO-4405A/149

8

FSO-4405A/148

7

6

FSO-4405A/138

9


5. Using a tubular tool, press the rear bearing withthe smaller side of the cone facing up, until itseats on the shaft. See Special Tools,Reference ???.

Assembly

6. Turn the countershaft over on the press, so thatits front end will be facing up. Use the 5th speedgear as a base.

7. Using a tubular tool, press the 3rd speed geardown the countershaft with the most prominentside of the gear flange facing up (towards the4th speed gear). Make sure to keep the correctalignment of the gear slot with the two shaftkeys prior to pressing the gear down. SeeSpecial Tools, Reference ???.

8. Using a tubular

sec 1a - eatonpub/@eatonbr/... · periodic transmission oil change eliminates possible bearing...

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