Eaton Fuller FSO 2405 K Service Manual Download Page 46

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Special Tools

General Information

2nd Ed. 02/07

FSO-2405

E001033

E001034

E001035

E001032

E001032

Input shaft bearing cover oil baffle
installer

NOTE

Used with

E001013

E001032

E001033

Front housing bearing cup installer

NOTE

Used with

E001037

E001034

Rear seal installer

Application

: All 4x4 vehicles

E001035

Mainshaft bearing cup puller

NOTE

Used with

E001037

Summary of Contents for Fuller FSO 2405 K

Page 1: ...Eaton Fuller Light Duty Transmissions 2nd Ed 02 07 FSO 2405 Service Manual Transmission ...

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Page 3: ...FSO 2405 2ndEd 02 07 General Information 3 1 2 3 4 5 Input Shaft Bearing Cover Rear Section Front Section Gear Shift Lever Housing ...

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Page 5: ...se This Manual 14 Identification and Specifications 15 Exploded View 18 Lubrication 23 Operation 25 Power Flow 26 Sealant Application 30 Torque Recommendation 31 Precautions 34 Troubleshooting 38 Special Tools 43 Installation Reference 60 Section 2 Input Shaft Bearing Cover 85 Removal 87 Installation 88 ...

Page 6: ...ifferences 91 Rear Section Disassembly 92 Oil Seal Replacement 100 Rear Section Assembly 101 Section 4 Front Section 111 Front Section Disassembly 115 Mainshaft Disassembly 118 Assembly 119 Countershaft Disassembly 122 Assembly 122 Input Shaft Disassembly 123 Assembly 123 Shift Yoke Bars Disassembly 124 Assembly 124 ...

Page 7: ... 129 Installation 130 Reverse Shifting Interlocking System Description 131 Disassembly 132 Assembly 133 Double Gear Shifting Interlocking System Description 134 Disassembly 135 Assembly 136 Input Shaft Bearing Cup Removal 137 Installation 137 Countershaft Front Bearing Cup Removal 138 Installation 138 Mainshaft and Countershaft Rear Bearing Cups Removal 139 Installation 139 ...

Page 8: ...n 140 Disassembly 140 Assembly 141 Installation 142 Front Section Assembly 145 End Play Adjustment Mainshaft End Play Measurement 148 Countershaft End Play Measurement 149 Determination of End Play Adjusting Shims 150 Section 5 Gear Shift Lever Housing 157 Disassembly 159 Assembly 161 ...

Page 9: ...9 General Table of Contents FSO 2405 2ndEd 02 07 ...

Page 10: ......

Page 11: ...ion Foreword 13 How to Use This Manual 14 Identification and Specifications 15 Exploded View 18 Lubrication 23 Operation 25 Power Flow 26 Sealant Application 30 Torque Recommendation 31 Precautions 34 Troubleshooting 38 Special Tools 43 Installation Reference 60 ...

Page 12: ......

Page 13: ... to another according to its application and serial number In addition it is also assumed that the transmission has been removed from the vehicle and the 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 by its turn divided into sections gathering...

Page 14: ...fotograph illustrating the procedures 5 WARNING Information requiring special attention to avoid personal injury or product damage 6 NOTE Useful information to perform the procedure 7 Manual s section number 8 Manual s section description 9 Page number FSO 2405 40 FSO 2405 38 FSO 2405 39 FSO 2405 41 WARNING Be careful NOT to use mainshaft flange as a pressing base when using the 3rd speed gear 5 T...

Page 15: ... Lb ft FSO 2405 86 FSO 2405 85 Identification Model designation All Eaton transmissions are identified by the model designation and serial number These information are stamped on the identification tag fixed to the transmission case WARNING Do not remove or destroy the transmission identification tag NOTE When ordering parts or consulting service dept please inform identification tag numbers ...

Page 16: ...6 Reverse Speed CE 12 3 795 12 3 238 12 3 457 12 3 457 Reverse Idler Gear 29 29 29 29 EP 32 32 32 32 FSO 2405 A FSO 2405 B FSO 2405 C FSO 2405 D Torque Lb ft 310 310 280 280 N m 420 420 380 380 ND Gear Ratio ND Gear Ratio ND Gear Ratio ND Gear Ratio Input Shaft 26 26 26 26 Countershaft 37 37 37 37 1st Speed CE 15 4 079 15 4 079 14 4 473 14 4 473 EP 43 43 44 44 2nd Speed CE 23 2 289 23 2 289 22 2 4...

Page 17: ...on inclination Always refill the transmission with proper grade and type of lubricant to the level of the filler plug opening see Lubrication FSO 2405 K FSO 2405 M FSO 2405 N Torque Lb ft 280 369 280 N m 380 500 380 ND Gear Ratio ND Gear Ratio ND Gear Ratio Input Shaft 26 25 26 Countershaft 37 38 37 1st Speed CE 14 4 473 14 4 994 14 4 473 EP 44 46 44 2nd Speed CE 23 2 289 22 2 625 23 2 289 EP 37 3...

Page 18: ...l plug 23 Dowel pin 24 Permaglide bushing 25 Spring 26 Reverse shifting interlock assembly 27 Oil drain plug 28 Plug 29 Expansion plug 30 Dowel pin 31 Intermediate housing 32 Permaglide bushing 33 Capscrew 34 Pivot threaded pin 35 Capscrew 36 Actuator 37 Spring 38 Plug 39 Dowel pin 40 Reverse light switch 41 Capscrew 42 Reverse idler gear shaft 43 Ball 44 Needle bearing 45 Reverse idler gear 46 Do...

Page 19: ...eed gear mainshaft 18 2nd speed synchronizer ring 19 1st 2nd speed synchronizer assembly 20 1st speed synchronizer ring 21 Needle bearing 22 1st speed gear mainshaft 23 1st speed gear bushing 24 Mainshaft intermediate bearing cone 25 Mainshaft intermediate bearing cup 26 Mainshaft bearing shim 0 050 Mainshaft bearing shim 0 102 Mainshaft bearing shim 0 178 Mainshaft bearing shim 0 254 Mainshaft be...

Page 20: ...TE Use shim thickness and quantity as required see End Play Adjustment 7 Ball 8 Thrust washer 9 Needle bearing 10 Needle bearing 11 Key 12 Spring 13 5th speed gear countershaft 14 5th speed gear synchronizer ring 15 5th reverse speed synchronizer assembly 16 Reverse speed gear synchronizer ring FSO 2405 180 13 10 9 8 7 6 5 4 3 2 1 14 15 16 17 18 21 22 23 24 11 12 19 20 17 5th reverse speed synchro...

Page 21: ... 7 Nylon pad 8 1st 2nd speed shift yoke 9 Roll pin 10 Roll pin 11 Shift selecting block 12 Roll pin 13 5th reverse speed shift block 14 1st 2nd speed yoke bar 15 Shift selecting bar 16 Roll pin 17 Shift lug 18 5th reverse speed yoke bar 19 5th reverse speed linked shift block 20 Roll pin 21 5th reverse speed swiveled shift yoke 22 Nylon pad holder 23 Nylon pad 1 3 5 6 7 4 2 8 9 14 10 11 15 16 17 1...

Page 22: ... Housing Direct FSO 2405 182 1 Gear shift lever 2 Lower bushing 3 Thrust washer 4 Wave washer 5 Oil baffle 6 Capscrew 7 Pin 8 Gear shift lever end bushing 9 Gear shift lever housing 10 Pin 11 Nut 12 Boot 13 Capscrew 14 Cover 15 Upper bushing 1 2 3 5 6 7 14 15 12 13 11 8 9 10 4 ...

Page 23: ...ath created by the motion of gears and shafts Thus all parts are amply lubricated if these procedures are closely followed 1 Maintain proper oil level by inspecting it regularly 2 Change oil regularly following maintenance interval chart 3 Use the recommended grade and type of oil 4 Buy from a reputable dealer Oil change and level inspection Periodic transmission oil change eliminates possible bea...

Page 24: ...of oil necessary to refill the transmission depends on the transmission angle So refill the 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 out of the case through the front bearing cover the control cover the shift lever housing etc Oil level inspection Everytime the oil level is being checked cl...

Page 25: ... system prevents from accidental transmission shifting from 5th to reverse gear Tips for the driver Always use the clutch to change the gears The incorrect use of the clutch may cause premature failures of the synchronizer assembly Always select a starting gear that will provide sufficient power torque for the vehicle s load and working conditions terrain Never slam or jerk the gear shift lever to...

Page 26: ... to the transmission s input shaft 2 The torque is transferred to the countershaft drive gear In this way input shaft and countershaft allways run together 3 The torque along the countershaft is delivered to all mainshaft gears assembled on bearings These gears rotate free unless one gear is shifted 4 When a gear is shifted the torque is transferred from the corresponding engaged mainshaft gear th...

Page 27: ...27 Power Flow 1 FSO 2405 2ndEd 02 07 General Information FSO 240591 3rd Speed FSO 240590 2nd Speed ...

Page 28: ...nput shaft that despite driving the countershaft at the same time transfers the torque directly to the mainshaft The input shaft clutching teeth engage the clutching teeth of the 4th speed synchronizer unit which transfers the torque to the mainshaft The transmission s noise level in this speed is very reduced since torque is delivered directly from one shaft to another and there is no gears under...

Page 29: ...ng gears on mainshaft are assembled fixed to the mainshaft 1 With the 5th speed gear shifted torque is transferred from countershaft to the mainshaft corresponding gear through the clutching teeth of the synchronizer hub 2 When the reverse speed gear is shifted torque is transferred from countershaft to the reverse idler gear that changes the rotating direction and then from that to the mainshaft ...

Page 30: ...assembly and to avoid leakages Apply Eaton E677 to expansion plugs Apply Eaton E680 or Eaton E679 to mounting surface of gear shift lever housing Apply Eaton E680 to mounting surface of input shaft bearing cover Apply Eaton E680 to mounting surface of rear cover and intermediate housing Apply Eaton E680 to mounting surface of front and intermediate housings ...

Page 31: ...aly apply the recommended sealant to the threads WARNING Allways use a torque wrench to tight to the recommended torque Item Description Thread Torque N m Lb ft Remarks 1 Yoke nut 1 20 UNEF 217 270 160 200 Apply Eaton E677 to threads 2 Gear shift M10 19 25 14 19 housing capscrews Apply Eaton E677 to threads 3 Housing M8 19 25 14 19 capscrews Apply Eaton E677 to threads 4 Input shaft M8 10 16 7 12 ...

Page 32: ... to threads 7 Reverse light M14 14 20 11 15 switch Apply Eaton E680 or Eaton E679 to threads 8 Speedometer 13 16 20 UNEF 10 16 7 12 sensor Apply Eaton E680 or Eaton E679 to threads 9 Mainshaft nut M37 217 270 160 200 Lock 10 Countershaft nut M20 108 122 80 90 Lock 11 Oil drain plug 3 4 14 NPTF 13 20 10 15 Apply Eaton E680 or Eaton E679 to threads 12 5th reverse speed 3 4 14 NPTF 13 20 10 15 shift ...

Page 33: ...Torque Recommendation 1 FSO 2405 2ndEd 02 07 General Information FSO 2405 145 NOTE On clutch housings made of cast iron apply torque of 165 to 185 N m 122 to 136 lb ft to tightening capscrews FSO 2405 146 ...

Page 34: ...oving every part up and down slowly until all the old lubricant and foreign material have been dissolved WARNING Care must be taken to avoid skin rasher fire hazard and vapor inhalation when using solvents Non sealed bearings Immerse the bearings in clean solvent Move them up and down slowly in order to loosen the deposits Dry the bearings by means of moisture free compressed air Repeat the operat...

Page 35: ...rasive material such as metal filings contaminated oil or polishing compounds Inspection A thorough and careful inspection of each part is very important for the transmission life The replacement of parts showing either wear or fatigue will avoid future expensive and foreseen failures Gears shafts and synchronizer assemblies Whenever magna flux is available this process should be used to check the...

Page 36: ...c 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 premature overhaul to replace these parts in a future time An oil leakage through a worn seal may result in failures of other more expensive components of the transmission The sealing elements should be handled carefully particularly during assembly Cuts ...

Page 37: ... or remanufactured parts besides have not the factory s warranty may lead to severe damage of the unit Since the cost of a new part is generally a small fraction of the total cost of downtime and labor do not reuse a questionable part which could lead to additional repairs and expense soon after assembly To aid in determining the reuse or replacement of any transmission part consideration should a...

Page 38: ... gears or bearings instructions Transmission Improper or Replace disc As to vehicle s noise with shifted damaged clutch instruction manual gear disc Low lubricant level Fill with recommended Recommended oil to the proper level lubricant page 23 Worn or damaged Replace As to vehicle s flywheel bushing or instruction manual bearing Vibration from other Verify and repair as to As to vehicle s vehicle...

Page 39: ...rn or damaged Replace rings Synchronizer synchronizer rings assemblies page 140 Excessively worn Replace synchronizer Synchronizer or damaged assemblies assemblies synchronizer page 140 assemblies springs keys sleeve or hub Worn or damaged Replace worn or As to this manual shifting system damaged parts instructions components shift yokes nylon pads bars shift blocks Mainshaft or Adjust end play En...

Page 40: ... end adjustment play improperly page 148 adjusted Gear shift rubbing Malfunction of Verify and adjust As to vehicle s clutch clutch shop manual Malfunction of Verify and adjust As to vehicle s clutch linkage linkage shop manual Worn or damaged Replace As to vehicle s flywheel bushing instruction manual or bearing Worn or damaged Replace rings Synchronizer synchronizer rings assemblies page 140 Shi...

Page 41: ...ve Correct to proper Recommended proper level lubricant level lubricant page 23 Clogged breather Verify an clean breather Worn or damaged Replace As to this manual oil seals instructions Housing capscrews Reassemble aplying As to this manual not properly sealant and torque instructions tightened or lack properly pages 30 and 31 of sealant Cracked housings Replace or repair Requires specifc or dama...

Page 42: ...ay End play continuation countershaft end adjustment play improperly page 148 adjusted Bearings were Replace damaged As to this manual not lubricated parts Reassemble instructions before assembling as to proper procedure Double shifting Double gear shifting Reassemble As to this manual interlocking system properly instructions improperly page 134 assembled ...

Page 43: ...r E001037 Bearing cup puller installer support E001038 Mainshaft bearing cup installer E001039 Countershaft bearing cup installer E001040 Rear seal installer E001041 Rear seal installer E001042 Rear seal installer E001043 Countershaft bearing cone installer E001044 1st 2nd 3rd 4th and 5th Reverse gear yoke bar pin punch E001045 Shift lug pin punch E003001 Slide hammer impact puller E004002 Slide h...

Page 44: ...aft bearing cone puller E007007 Mainshaft bearing cone puller E007008 Countershaft bearing cone puller E008001 Pry bar for measuring end play E009001 Plate for measuring end play E010001 Mainshaft front bearing cone installer E010002 Mainshaft rear bearing cone installer E010003 Input shaft bearing cone installer E012001 2 hook universal puller E012002 Reverse gear puller E012003 Input shaft beari...

Page 45: ...eral Information E001013 E001020 E001021 E001010 E001010 Permaglide bushing installer E001010 E001013 Universal handle E001020 Front housing expansion plug installer E001021 Input shaft bearing cover seal installer NOTE Used with E001013 E001021 ...

Page 46: ...035 E001032 E001032 Input shaft bearing cover oil baffle installer NOTE Used with E001013 E001032 E001033 Front housing bearing cup installer NOTE Used with E001037 E001034 Rear seal installer Application All 4x4 vehicles E001035 Mainshaft bearing cup puller NOTE Used with E001037 ...

Page 47: ...1036 E001036 Countershaft bearing cup puller NOTE Used with E001037 E001038 E001037 E001037 Bearing cup puller installer support E001038 Mainshaft bearing cup installer NOTE Used with E001037 E001039 E001039 Countershaft bearing cup installer NOTE Used with E001037 ...

Page 48: ...ar pin punch E001040 E001043 E001040 Rear seal installer Application Ranger 4x2 Troller 4x2 VM Motori Agrale Daily NOTE Used with E001013 E001041 Rear seal installer Application Frontier 4x2 NOTE Used with E001013 E001042 Rear seal installer Application S10 4x2 NOTE Used with E001013 E001043 Countershaft bearing cone installer ...

Page 49: ...d 02 07 General Information E001045 E004002 E003001 E001045 Shift lug pin punch E004002 Slide hammer end for removing the expansion bushing E003001 Slide hammer impact puller E001045 E005003 E005003 Pocket bearing cone puller E005003 ...

Page 50: ...tion 2ndEd 02 07 FSO 2405 E006003 E005005 E006002 E006003 E005005 Thread cutter E006002 30 mm special socket E006003 54 mm special socket E006004 23 spline input shaft spline socket Application Ranger 4x2 Ranger 4x4 Crosslander E006004 ...

Page 51: ...i Troller 4x4 Jeep Troller 4x2 Pickup E006006 54 mm special wrench E006007 Mainshaft lock 27 splines Application S10 4x2 S10 4x4 Jinbei Crosslander E006008 Mainshaft lock 31 splines Application Ranger 4x2 Troller Pickup 4x2 VM Motori E006009 Mainshaft lock 30 splines Application Frontier 4x2 Frontier 4x4 E006010 Mainshaft lock 25 splines Application Ranger 4x4 L200 RS 4x4 Troller Jeep 4x2 E006005 ...

Page 52: ...7 E007008 E008001 E009001 E007002 E007002 Input shaft bearing cone puller E007002 E007007 Mainshaft bearing cone puller E007007 E007008 Countershaft bearing cone puller E007008 E008001 Pry bar for measuring end play E009001 Plate for measuring end play E008001 E009001 ...

Page 53: ...12001 E010001 E010002 E010001 Mainshaft front bearing cone installer E010002 Mainshaft rear bearing cone installer E010001 E010002 E010003 Input shaft bearing cone installer E012001 2 hook universal puller E010003 E012002 E012002 Reverse gear puller NOTE Used with E012001 ...

Page 54: ...05 E014003 E014003 Transmission stand Option Without reductor with reductor or electric powered E014002 E014002 Transmission stand adapter plate E012004 E012004 Front housing bearing cup puller E012003 E012003 Input shaft bearing puller NOTE Used with E012001 ...

Page 55: ...al Tools 1 FSO 2405 2ndEd 02 07 General Information E014010 E014011 E014010 Base for locking the mainshaft NOTE Used with E006007 E006008 E006009 or E006010 E014011 Support for transmission stand adapter plate ...

Page 56: ...06003 1 Install the 54 mm special socket tool E006003 on the mainshaft nut and rotate the shaft until the two holes on the socket match to the nearest two holes on the housing 2 Tighten the special socket to the housing with two housing s capscrews WARNING Be carefull do not overtighten the capscrews or leave them loose in order to avoid damage to the aluminum housing FSO 2405 147 2 FSO 2405 28 3 ...

Page 57: ...installing mainshaft nut 1 Lock mainshaft as described before using tool E006003 Shift transmission into 1st gear E006004 E006005 2 E006003 1 2 Install tool E006004 or E006005 depending on the application on the input shaft spline 3 Using a ratchet wrench rotate counterclockwise for loosening the nut 3 ...

Page 58: ...to be ratio applied FSO2405F 3 481 63 à 77 N m FSO2405G 4 213 52 à 64 N m FSO2405H 4 994 44 à 54 N m FSO2405J 3 716 59 à 72 N m FSO2405K 4 473 49 à 60 N m WARNING Check the vehicle s Service Manual for the transmission to see if the 1st gear ratio matches to the gear ratio informed in the table above If necessary calculate the torque amount as follows E006003 E006004 E006005 Example Specified torq...

Page 59: ...rshaft nut 1 Lock mainshaft as described before using tool E006003 Shift transmission into 1st gear 2 Remove the nut using the 30 mm special socket tool E006002 directly on the countershaft nut 3 When installing tighten the countershaft nut to the specified torque NOTE Torque 108 122 N m 80 90 lb ft E006002 1 2 3 ...

Page 60: ...60 Installation Reference 1 General Information 2nd Ed 02 07 FSO 2405 GM S10 V6 4x2 GM S10 V6 4x2 01 ...

Page 61: ...61 Installation Reference 1 FSO 2405 2nd Ed 02 07 General Information GM S10 V6 4x2 GM S10 V6 4x2 02 ...

Page 62: ...62 Installation Reference 1 General Information 2nd Ed 02 07 FSO 2405 GM S10 2 8 4x2 GM S10 V6 72 8 01 ...

Page 63: ...63 Installation Reference 1 FSO 2405 2nd Ed 02 07 General Information GM S10 2 8 4x2 GM S10 V6 2 8 02 ...

Page 64: ...64 Installation Reference 1 General Information 2nd Ed 02 07 FSO 2405 Nissan Frontier 4x2 Frontier 4x2 01 ...

Page 65: ...65 Installation Reference 1 FSO 2405 2nd Ed 02 07 General Information Nissan Frontier 4x2 Frontier 4x2 02 ...

Page 66: ...66 Installation Reference 1 General Information 2nd Ed 02 07 FSO 2405 Nissan Frontier 4x4 Frontier 4x4 01 ...

Page 67: ...67 Installation Reference 1 FSO 2405 2nd Ed 02 07 General Information Nissan Frontier 4x4 Frontier 4x4 02 ...

Page 68: ...68 Installation Reference 1 General Information 2nd Ed 02 07 FSO 2405 Ford Ranger 4x2 Ranger 4x2 01 ...

Page 69: ...69 Installation Reference 1 FSO 2405 2nd Ed 02 07 General Information Ford Ranger 4x2 Ranger 4x2 02 ...

Page 70: ...70 Installation Reference 1 General Information 2nd Ed 02 07 FSO 2405 Ford Ranger 4x4 Ranger 4x4 01 ...

Page 71: ...71 Installation Reference 1 FSO 2405 2nd Ed 02 07 General Information Ford Ranger 4x4 Ranger 4x4 02 ...

Page 72: ...72 Installation Reference 1 General Information 2nd Ed 02 07 FSO 2405 GM JinBei 4x4 GM JinBei 4x4 01 ...

Page 73: ...73 Installation Reference 1 FSO 2405 2nd Ed 02 07 General Information GM JinBei 4x4 GM JinBei 4x4 02 ...

Page 74: ...74 Installation Reference 1 General Information 2nd Ed 02 07 FSO 2405 Mitsubishi L200 RS 4x4 L200 RS 01 ...

Page 75: ...75 Installation Reference 1 FSO 2405 2nd Ed 02 07 General Information Cross Lander Crosslander 01 ...

Page 76: ...76 Installation Reference 1 General Information 2nd Ed 02 07 FSO 2405 Cross Lander Crosslander 02 ...

Page 77: ...77 Installation Reference 1 FSO 2405 2nd Ed 02 07 General Information Troller Jeep 4x4 Troller 4x4 ...

Page 78: ...78 Installation Reference 1 General Information 2nd Ed 02 07 FSO 2405 VM Motori VM Motori 01 ...

Page 79: ...79 Installation Reference 1 FSO 2405 2nd Ed 02 07 General Information VM Motori VM Motori 02 ...

Page 80: ...FSO 2405 J 27 Teeth 10 splines 14 9 Input shaft splines and lenghts Ford Ranger 4x2 Ford Ranger 4x4 Cross Lander CL 224 Mx Nissan Frontier 4x2 Nissan Frontier 4x4 248 220 205 23 splines 25 50 14 9 20 0 55 3348808 3348850 FSO 2405 F 28 Teeth 3348808 FSO 2405 B 26 Teeth 3348850 FSO 2405 157 FSO 2405 158 ...

Page 81: ...l Information GM Jinbei Pickup Lw9 VM Motori GM S10 4x2 GM S10 4x4 Mitsubishi L200 RS 4x4 FSO 2405 159 FSO 2405 160 10 splines 28 25 14 9 59 5 212 66 185 24 3348806 FSO 2405 A B E 26 Teeth 62 50 10 splines 28 25 14 9 238 50 210 40 3348870 3348871 B 26 Teeth ...

Page 82: ...e 1 FSO 2405 2ndEd 02 07 General Information Agrale Daily Troller Jeep 4x4 FSO 2405 159 FSO 2405 160 10 splines 28 25 14 9 56 5 204 174 55 3348902 FSO 2405 B 26 Teeth 60 0 10 splines 28 25 14 3 228 64 192 39 3362118 B 26 Teeth ...

Page 83: ... Ref Cross Lander CL 224 MX 218 94 102 96 3348671 31 splines Ref Ranger 4 x 2 99 34 56 3 3348705 25 splines Ref Ranger 4 x 4 Ref Mitsubishi L200RS 4x4 Ref Troller Jeep 4 x 4 3348763 30 splines Ref Nissan Frontier 4 x 4 3348771 30 splines Ref Nissan Frontier 4 x 2 77 44 64 9 135 94 90 14 6 218 94 102 96 14 6 FSO 2405 162 Ref Agrale Daily 3348930 31 splines Ref Ranger 4 x 2 Ref Troller Pickup 4 x 2 ...

Page 84: ......

Page 85: ...85 Table of Contents 2 FSO 2405 2ndEd 02 07 Input Shaft Bearing Cover Removal 87 Installation 88 ...

Page 86: ......

Page 87: ...bars under the input shaft bearing cover by using the existing slots 3 By forcing the pry bars remove the input shaft bearing cover 4 Remove the oil baffle 5 If necessary remove oil seal 6 NOTE When disassembling the transmission remove the capscrew that attach the front housing from inside it to the intermediate housing see Front Section Disassembly FSO 2405 52 2 2 3 FSO 2405 51 2 3 2 6 ...

Page 88: ...4 3 FSO 2405 150 FSO 2405 151 E001013 E001021 1 If previously removed install the new oil seal with the installer NOTE See Special Tools Ref E001021 E001013 2 Install the oil baffle observing its correct position 3 Apply sealant to the mounting surface of input shaft bearing cover NOTE Apply Eaton E680 sealant to the cover 4 Align the lubrication slots of both input shaft cover and front housing a...

Page 89: ...89 Table of Contents 3 FSO 2405 2ndEd 02 07 Rear Section Output Sleeve Yoke and 4x4 Transmission Differences 91 Rear Section Disassembly 92 Oil Seal Replacement 100 Rear Section Assembly 101 ...

Page 90: ......

Page 91: ...r the speedmoter sensor nor the rotor whose functions are not performed by the transmission itself The rear housing is shorter and has a mounting surface with holes for attaching a transfer box 4x4 1 Companion flange for attaching the transfer box Transmission with Universal Joint Yoke This transmission model has an output yoke at the mainshaft end for coupling the drive shaft Both the speedometer...

Page 92: ...y pulling it upwards 5 Remove the speedometer rotor snap ring 6 Remove the speedometer rotor 7 Remove the rotor retaining ball from the mainshaft 8 Place the wrench to loosen the mainshaft rear nut NOTE See Special Tools Ref E006006 NOTE As an option the tool E006004 or E006005 may be used for removing the mainshaft rear nut locking the mainshaft with the tool E006003 See Special Tools Using the E...

Page 93: ... or snap ring NOTE On 2006 the nut was replaced by a snap ring in some applications NOTA See Special Tools Ref E006002 13 Remove the countershaft ball bearing 14 Remove the bearing thrust washer NOTE On countershaft with threadless end which uses a snap ring instead of the nut the thrust washer has a retaining ball see detail which should also be removed 15 Remove the reverse gear and the ball bea...

Page 94: ...SO 2405 16 Remove the reverse gear spacer bushing from the mainshaft 17 Remove the reverse idler gear 18 Remove the reverse idler gear needle bearing 19 Remove the reverse gear from the countershaft FSO 2405 10 FSO 2405 9 16 17 FSO 2405 11 FSO 2405 12 18 19 ...

Page 95: ... updated When servicing the unit if older replace both bearings p n 3342286 and spacer p n 3342287 by the new lone bearing p n 3348906 21 Remove the two pivot threaded pins of 5th reverse shift yoke FSO 2405 13 20 FSO 2405 14 21 21 FSO 2405 155 FSO 2405 154 Old needle bearing New needle bearing Old part 2 two bearings Eaton P N 3342286 1 one spacer Eaton P N 3342287 New part 1 one bearing Eaton P ...

Page 96: ...ng 22 Push the 5th reverse shift yoke towards the synchronizer in order to loosen it from the linked shift block Lift the yoke end and remove by pulling the yoke upwards 23 Remove the reverse speed synchronizer ring 24 Remove the 5th reverse synchronizer hub snap ring from the countershaft FSO 2405 18 FSO 2405 17 25 26 FSO 2405 15 FSO 2405 16 22 23 24 ...

Page 97: ...he countershaft 28 Remove the two needle bearings of 5th speed gear from the countershaft FSO 2405 19 FSO 2405 20 27 28 FSO 2405 22 FSO 2405 21 29 30 29 Remove the 5th speed gear thrust washer from the countershaft 30 Remove the retaining ball of the 5th speed gear thrust washer from the countershaft ...

Page 98: ...se light switch 34 Remove the 5th reverse linked shift block retaining roll pin NOTE Use a 4 mm diameter pin punch 31 Remove the 5th speed gear from the mainshaft 32 Remove the 5th speed gear thrust washer from the mainshaft FSO 2405 26 FSO 2405 25 33 34 FSO 2405 23 FSO 2405 24 31 32 ...

Page 99: ...99 Rear Section Disassembly 3 FSO 2405 2ndEd 02 07 Rear Section 35 Remove the 5th reverse linked shift block FSO 2405 27 35 ...

Page 100: ... remove the oil seal NOTE The removed oil seal should not be reused Installation NOTE If removed allways replace the oil seal 1 Coat the new seal lips with the recommended grease 2 Position the seal on the rear cover and install it in the bore using the proper tool NOTE See Special Tools use the proper device for the transmission ...

Page 101: ...tion facing up 2 Install the 5th reverse linked shift block 3 Install the 5th reverse linked shift block retaining roll pin NOTE Use a 4 mm diameter pin punch NOTE Replace the roll pin by a new one 4 Install the reverse light switch NOTE Apply Eaton E680 or Eaton E679 sealant to the switch threads 5 Install the 5th speed gear thrust washer on the mainshaft ...

Page 102: ...all of the countershaft 5th speed gear thrust washer on the countershaft Apply grease to hold the ball in place 8 Install the 5th speed gear thrust washer on the countershaft Make sure to set correctly the retaining ball into the washer slot NOTE Install the thrust washer counterbore side up facing the needle bearing 9 Install the two needle bearings of 5th speed gear on the countershaft ...

Page 103: ...nstall the 5th reverse synchronizer assembly on the countershaft Make sure it is installed in the proper position WARNING Both the synchronizer sleeve sharp end and the hub anti escape relief should be installed facing the 5th speed gear see Synchronizer Assemblies Make sure to slide the synchronizer ring lugs into the hub key slots 13 Install the 5th reverse synchronizer hub snap ring on the coun...

Page 104: ...nked shift block 17 Install the two pivot threaded pins of 5th reverse shift yoke NOTE Apply Eaton E677 sealant to the pin threads Torque 10 16 N m 7 12 Lb ft NOTE See Special Tools Ref E001044 18 Install the reverse gear spacer and the two needle bearings on the countershaft NOTE The reverse gear needle bearing on the countershaft was updated When servicing the unit if older replace both bearings...

Page 105: ...19 Install the reverse gear on the countershaft 20 Install the reverse idler gear needle bearing on the idler shaft FSO 2405 155 FSO 2405 154 Old needle bearing New needle bearing Old part 2 two bearings Eaton P N 3342286 1 one spacer Eaton P N 3342287 New part 1 one bearing Eaton P N 3348906 ...

Page 106: ...er on the countershaft NOTE On countershaft with threadless end which uses a snap ring instead of the nut the thrust washer has a retaining ball see detail which should also be installed FSO 2405 10 FSO 2405 9 22 21 21 Install the reverse idler gear on the shaft with the prominent side facing the housing outside 22 Install the reverse gear spacer bushing on the mainshaft FSO 2405 8 23 24 FSO 2405 ...

Page 107: ...the mainshaft with the special tool and shift transmission into the 1st gear NOTE See Special Tools Ref E014010 NOTE As an option the tool E006003 may be used for locking the mainshaft See Special Tools Using the Eaton tool E006003 28 Install the rear nut or snap ring on counter shaft and tighten to the proper torque NOTE On 2006 the nut was replaced by a snap ring in some applications NOTA See Sp...

Page 108: ...6004 or E006005 may be used for installing the mainshaft rear nut locking the mainshaft with the tool E006003 See SpecialTools Using the Eaton tool E006003 32 Place the special tool and lock the mainshaft NOTE See Special Tools Ref E014010 33 Tighten the mainshaft rear nut to the proper torque NOTE Torque 217 270 N m 160 200 lb ft 34 Remove the tools 36 Install the retaining ball that locks the sp...

Page 109: ...h the intermediate housing NOTE Apply Eaton E680sealant to the mounting surface 40 Install the rear cover 41 Install the thirteen retaining capscrews of rear case to the intermediate housing Tighten the capscrews crosswise to the proper torque NOTE Apply Eaton E677 sealant to the capscrews Torque 19 25 N m 14 19 lb ft 42 Install the speedometer sensor NOTE Apply Eaton E680 or Eaton E679 sealant to...

Page 110: ......

Page 111: ...isassembly 118 Assembly 119 Countershaft Disassembly 122 Assembly 122 Input Shaft Disassembly 123 Assembly 123 Shift Yoke Bars Disassembly 124 Assembly 124 Reverse Idler Gear Shaft Removal 126 Installation 126 Expansive Plugs Removal 127 Installation 128 Permaglide Bushing Removal 129 Installation 130 ...

Page 112: ...fting Interlocking System Description 134 Disassembly 135 Assembly 136 Input Shaft Bearing Cup Removal 137 Installation 137 Countershaft Front Bearing Cup Removal 138 Installation 138 Mainshaft and Countershaft Rear Bearing Cups Removal 139 Installation 139 Synchronizer Assemblies Description 140 Disassembly 140 Assembly 141 Installation 142 ...

Page 113: ...Table of Contents 4 FSO 2405 2ndEd 02 07 Front Section Assembly 145 End Play Adjustment Mainshaft End Play Measurement 148 Countershaft End Play Measurement 149 Determination of End Play Adjusting Shims 150 ...

Page 114: ......

Page 115: ...threaded actuator of shifting cam 3 Remove the shift lug roll pin by pushing it forward into the housing NOTE Use a 6 mm diameter pin punch 4 Remove the plug spring and spherical actuator pin of the cam threaded actuator 5 Remove the shift positioning plug spring and ball 6 Remove the thirteen capscrews that attach the intermediate housing to the front housing 7 From inside the front housing remov...

Page 116: ... the shift lug NOTE Carefully hit the housing s capscrews area with a rubber or plastic hammer to brake the gasket seal and detach the housing 9 Pull the 5th reverse yoke bar the longest upwards and remove it 10 Rotate the shift selecting bar counterclockwise and remove it pulling the bar upwards 11 Remove the 1st 2nd shift yoke roll pin NOTE Use a 4 mm diameter pin punch ...

Page 117: ...urface see detail remove the bar and shift yoke assembly 13 Simultaneously remove from the housing the remaining assemblies of mainshaft countershaft 3rd 4th bar and shift yoke and input shaft while grasping them all together and pulling them upwards 14 Take the assemblies apart FSO 2405 145 FSO 2405 146 15 On transmissions with clutch housing not integrated remove clutch housing by removing the f...

Page 118: ... synchronizer hub retaining snap ring 3 Place the mainshaft in the press using the 2nd speed gear as a base 4 Press the mainshaft through and remove the set of components up to the rear bearing cone WARNING Be careful NOT to use mainshaft flange as a pressing base when using the 3rd speed gear 5 Turn the mainshaft over in the press and use the 3rd speed gear as a base 6 Press the mainshaft and rem...

Page 119: ...eed have equal synchronizer rings and they are all EFM II coated 4 Install the 1st 2nd speed synchronizer assembly Make sure it is installed in the proper position WARNING Both the 1st 2nd synchronizer sleeve largest chamfer and the hub most prominent side must face the 1st speed gear see Synchronizer Assemblies The 1st 2nd synchronizer hub does not have the anti escape relief see Synchronizer Ass...

Page 120: ... install the 3rd speed gear needle bearing NOTE The 3rd speed gear needle bearing was modified When servicing the unit replace the old needle bearing by the new one Old part 239818 New part 3348857 They are interchangeable 13 Install the 3rd speed gear 14 Install the 3rd speed synchronizer ring NOTE The 1st 2nd 3rd and 4th speed have equal synchronizer rings and they are all EFM II coated 15 Insta...

Page 121: ...ER apply force to the bearing cage NOTE See Special Tools Ref E010001 E010002 17 Make sure the pressing procedure was successfully disengage the synchronizer and position it between the 3rd and 4th speed gears In this condition the gears should run free Manishaft 18 Install the 3rd 4th synchronizer hub retaining snap ring 19 Position the front bearing cone on the mainshaft 20 Press the front beari...

Page 122: ... Turn the countershaft over and use the 1st speed gear teeth as a pressing base by using the special device NOTE See Special Tools Ref E007001 4 Press the countershaft through the rear bearing and remove the bearing Assembly 1 Position both the front and rear bearing cones on the countershaft 2 Use two tubular tools and place the countershaft in the press using the inner races of those two bearing...

Page 123: ...ss the input shaft through the bearing and remove the bearing Assembly 1 Position the bearing cone on the input shaft 2 With the syncronizer side down place the input shaft on a base Be careful not to damage the synchronizer cone 3 Using the bearing inner race as a base press the bearing assembly with the proper tubular tool until the race shoulder be against the shaft face WARNING Apply force to ...

Page 124: ...ly 1 Make sure the shift block is properly positioned regarding the notch at the yoke bar end and install the shift block on the yoke bar 2 Make sure the 3rd 4th speed shift yoke is properly positioned regarding the notch at the yoke bar end and install the shift yoke on the yoke bar 3 Align the shift yoke with the yoke bar matching the roll pin holes and install the retaining roll pin Push the ro...

Page 125: ...stall the retaining roll pin Push the roll pin until it is flush with shift block hub NOTE See Special Tools Ref E001045 NOTE Replace the roll pin by a new one 5th reverse Yoke Bar Assembly 1 Make sure the shift block is properly positioned regarding the notch at the yoke bar end and install the shift block on the yoke bar Notice that the opposite bar end also has a notch shifted 180 from the othe...

Page 126: ...Removal 1 In the intermediate housing locate the reverse idler gear shaft retaining capscrew and remove it 2 Remove the idler shaft Installation 1 Align the shaft hole with the housing hole and install the idler shaft into the shaft bore 2 Tighten the retaining capscrew to the proper torque NOTE Torque 14 19 N m 19 26 Lb ft ...

Page 127: ...happens that those plugs should be removed and reinstalled when servicing the unit Removal 1 In the housing locate the plug that should be removed Use the special device and make a thread in the plug NOTE See Special Tools Ref E005005 2 Use one retaining capscrew removed from the housing and insert it into the plug threading it until it stays firmly in place 3 Use an impact puller to remove the ca...

Page 128: ...d solvent clean the plug hole and remove any remaining sealant compound Do not use sand paper 2 Apply sealant to the new plug and insert it into the hole using the hands to guide the plug NOTE Apply Eaton E677 to plugs 3 Use the proper tool and a hammer to force the plug into the plug bore The proper depth is when the plug is 2 mm below the plug bore top NOTE See Special Tools Ref E001020 FSO 2405...

Page 129: ... worn NOTE Inspect other transmission bushing too The pictures here show only the front housing bushing however the procedure is the same for all other transmission permaglide bushing 2 Use the lubrication hole to place a punch against the bushing outer diameter 3 Hit the punch and deform the bushing as shown 4 Use pliers and pull the bushing out from the bushing bore ...

Page 130: ...he bushing in the bushing bore and install the bushing by hitting the tool until it rest against the housing This condition gives the proper bushing depth 3 Use a punch and lock the bushing by punching the housing material in four positions around the bushing bore WARNING When locking the bushing be careful not to damage the bushing itself 4 Apply a thin coating of recommended grease to the bushin...

Page 131: ... downshifting from 5th to 4th speed 1 Reverse shifting interlocking mechanism The mechanism comprises a lock device working together with the shift selecting bar When the 5th reverse yoke bar is positioned in 5th the lock mechanism is actuated by the spring and then prevents the reverse speed from being straight shifted To deactivate the locking mechanism just gearshift to neutral and then to reve...

Page 132: ...terlocking System Disassembly 1 Remove the expansive plug from housing hole where is located the interlocking mechanism retaining roll pin NOTE See Expansive Plugs for instructions 2 Through the housing hole remove the roll pin NOTE Use a 4 mm diameter pin punch 3 Pull the interlock pin upwards and remove the mechanism assembly ...

Page 133: ... with the housing hole and install the interlocking mechanism into the pin bore 2 Give the spring as much as the tension you can by winding the spring on the pin and then set its free end in the housing hole 3 Install a new roll pin NOTE Use a 4 mm diameter pin punch NOTE Replace the roll pin by a new one 4 Install a new expansive plug in the housing hole NOTE See Expansive Plugs for instructions ...

Page 134: ...ameter A larger ball does not install into the smallest interlock bore When shifting any of the speed gears the yoke bar of this specific speed push away the corresponding ball displacing the remaining balls and locking the other yoke bars into the neutral position 1 Three balls 9 5 mm diameter aligned from the 3rd 4th yoke bar bore 2 One ball 8 0 mm diameter located on the 1st 2nd yoke bar bore 3...

Page 135: ...ocking System Disassembly 1 Remove the expansive plug near to the 5th reverse yoke bar NOTE See Expansive Plugs for instructions 2 Push the interlock pin to the opposite side in order the interlock balls drop from their bores 3 Displace the interlock pin towards the removed expansive plug hole and remove the pin through the housing hole ...

Page 136: ...s in place 2 Install the three interlock balls aligned from the 3rd 4th yoke bar bore and install the smallest ball 8 0 mm diameter located on the 1st 2nd yoke bar bore 3 Install the interlock pin through the housing hole whose expansive plug was removed before 4 Install the interlock ball located on the 5th reverse yoke bar bore 5 Install a new expansive plug in the housing hole NOTE See Expansiv...

Page 137: ...pport properly the front housing with bearing cup installing side up 2 Prior installing the bearing cup carefully clean bearing cup and bore 3 Use the proper tool and drive the bearing cup into the bearing bore just until the cup be guided by the bore NOTE See Special Tools Ref E001033 E001037 E001039 4 Install the input shaft bearing cover and tighten the cover retaining capscrews to the proper t...

Page 138: ... counterbore at the cup bottom and remove the bearing cup NOTE See Special Tools Ref E011001 Installation 1 Support properly the front housing with bearing bore side up 2 Prior to installing the bearing cup carefully clean both bearing bore and cup 3 Use the proper tool and drive the bearing cup into the bearing bore until it is completely seated on the bottom NOTE See Special Tools Ref E001033 E0...

Page 139: ...de up 2 Prior to installing the bearing cup carefully clean both bearing bore and cup WARNING Dirt between the bearing cup and the bearing bore can lead to axial clearance end play adjustment error 3 Install the bearing cups without any shim before adjusting the transmission end play WARNING See topic End Play Adjustment 4 Along with the support use the proper tool to install the mainshaft and cou...

Page 140: ...onizer 5th reverse speed synchronizer NOTE When repairing synchronizer assemblies do not replace a single part only Allways replace the assembly If would be necessary to replace one synchronizer ring allways replace the transmission synchronizer ring set 1 Synchronizer hub 2 Key 3x 3 Spring 3x 4 Synchronizer sleeve 5 Synchronizer ring with EFM II coating 6 Synchronizer ring without EFM II coating ...

Page 141: ...the key hole depress the spring and slide spring and key together into the synchronizer hub Repeat this procedure for the three keys 2 The center of the key must coincide with the center of synchronizer sleeve spline relief in the three positions With that in mind align the synchronizer sleeve with the synchronizer hub 3 To help when assembling position a synchronizer ring at the sleeve opposite s...

Page 142: ...eatures and be able to identify themselves as well 1st 2nd and 3rd 4th Speed Synchronizer 1 They look exactly alike having as the only difference an anti escape relief existing on the 3rd 4th speed synchronizer hub splines not present on the 1st 2nd synchronizer WARNING Identify the anti escape relief on the 3rd 4th speed synchronizer hub in order to prevent from swapping when installing This misa...

Page 143: ...th the sleeve largest chamfer side facing the odd speed gear either 1st or 3rd depending on the assemly 5th reverse Speed Synchronizer 6 The 5th reverse synchronizer hub has an anti escape relief on the splines and must be installed with that relief side facing the 5th speed gear 7 The 5th reverse synchronizer sleeve spline ends have one side rounded and the other side sharp ended Install the 5th ...

Page 144: ...blies Synchronizer Rings 8 The 1st 2nd 3rd and 4th speed synchronizer rings are the same and all coated with EFM II 9 The 5th and reverse speed synchronizer rings are smaller than the others 10 The reverse synchronizer ring is coated with EFM II 11 The 5th speed synchronizer ring is not coated with EFM II ...

Page 145: ... 1st 2nd 3rd and 4th speed synchronizer rings are the same and all coated with EFM II 3 Install the input shaft with the positioned ring in the mainshaft front bearing cone The synchronizer ring lugs must to slide into the synchronizer hub key slots 4 With the input shaft down position the input shaft and mainshaft assembly on the front housing 5 Position the 3rd 4th speed shift yoke and bar and t...

Page 146: ...lower side NOTE Be careful to keep the double shifting interlock balls in place 9 Align the shift yoke with the yoke bar matching the roll pin holes and install the retaining roll pin The 1st 2nd yoke bar notch should be aligned with the 3rd 4th shift block groove formerly installed NOTE Use a 4 mm diameter pin punch 10 Install the shift selecting bar in the bar bore positioning the selecting bloc...

Page 147: ...ar shift control tower opening in the intermediate housing and install the intermediate housing on the front housing The shift lug should be installed on the shift selecting bar with the cam side facing right as shown in the picture NOTE If necessary carefully hit the housing s capscrews area with a plastic hammer to match the housings 13 Install the intermediate housing retaining capscrews Tighte...

Page 148: ...RNING Prior this procedure make sure the input shaft bearing cover is installed see Input Shaft Bearing Cover 15 Choose one from housing threaded holes and install the special plate tool E009001 to support a dial indicator gauge with magnetic base 16 Install the mainshaft rear nut just a few threads to support the pry bar tool E008001 17 Rotate the mainshaft several times in both directions clockw...

Page 149: ... set the dial indicator tip 22 Install the countershaft rear nut just a few threads to support the pry bar tool E008001 23 Rotate the countershaft several times in both directions clockwise and counterclockwise to make sure the countershaft is completely seated on the bearing 24 Set the dial indicator tip against the capscrew head threaded in the countershaft end Set the pointer to zero 25 Place t...

Page 150: ...shaft is seated properly Redo the measurement Yes No Is the measured value greater than the maximum specified Measure the clearance Is the measured value greater than the minimum specified Calculate Measured value minus maximum specified R1 Measured value minus minimum specified R2 Yes No Shims are not necessary Use a shim pack thickness greater than R1 and less than R2 End End Play Adjustment Det...

Page 151: ... adjustment Specified end play 0 010 mm to 0 080 mm Measured end play 0 005 mm In this case it is not possible to calculate the shim thickness since the clearance is already less than the minimum specified This measured value is not a valid value So it is necessary to redo the measurement verifying before if all existing shims were actually removed if the bearing cup is perfectly seated on the bea...

Page 152: ...ecessary shim pack thickness to adjust the mainshaft end play in the mainshaft rear bearing bore and next install the bearing cup NOTE Use the proper drive tool to install the bearing cup see Mainshaft and Countershaft Rear Bearing Cups Removal and Installation 32 Install the necessary shim pack thickness to adjust the countershaft end play in the countershaft rear bearing bore and next install th...

Page 153: ...pply sealant to the front housing mounting surface Spread the sealant properly to prevent leaks NOTE Use Eaton E680sealant 36 Position the shift lug in the gear shift control tower opening in the intermediate housing and install the intermediate housing on the front housing The shift lug should be installed on the shift selecting bar with the cam side facing right as shown in the picture NOTE If n...

Page 154: ...ealant to capscrews Torque 19 25 N m 14 19 Lb ft 38 From inside the front housing install the capscrew that attach the front housing to the intermediate housing Tighten capscrew to the proper torque NOTE Apply Eaton E677 sealant to capscrews Torque 19 25 N m 14 19 Lb ft 39 Align the shift lug with the shift selecting bar matching the roll pin holes and install the retaining roll pin NOTE See Speci...

Page 155: ...ront Section FSO 2405 29 41 41 Install the spherical actuator pin spring and plug of the cam threaded actuator NOTE Apply Eaton E680 or Eaton E679 sealant to plug threads Torque 10 16 N m 7 12 lb ft 42 Assemble the rear section see Rear Section Assembly ...

Page 156: ......

Page 157: ...157 Table of Contents 5 FSO 2405 2ndEd 02 07 Gear Shift Lever Housing Disassembly 159 Assembly 161 ...

Page 158: ......

Page 159: ...case the housing should be replaced get a complete assembly from your dealer 1 Remove the four retaining capscrews from the gear shift lever housing and remove the gear shift lever housing assembly from the transmission 2 Remove the boot 3 From the housing cover remove the three retaining capscrews and the cover 4 Use a screwdriver and remove the gear shift lever end bushing 5 Pull the lever with ...

Page 160: ... 10 8 9 6 Use a pin punch and remove the two spade pins from the housing tower bores by punching the pins from inside outwards 7 Remove the lower bushing 8 Remove the wave washer 9 Remove the thrust washer 10 Turn the housing over and remove the oil baffle from the housing using a screwdriver NOTE Discard and replace the oil baffle ...

Page 161: ...tall the wave washer and next the thrust washer 4 Install the lower bushing 5 Apply sealant to the spade pins and install the pins in the housing tower bores Use a pin punch and push the spade pins inwards until they are seated on the bore bottom 6 Use a center punch and lock the spade pins around the pin bores 7 Install the gear shift lever and the upper bushing 8 Install the housing cover and in...

Page 162: ... any remaining sealant from the mounting surface of both transmission housing and the gear shift lever housing 12 Apply sealant to the gear shift lever housing mounting surface Spread the sealant properly to prevent leaks NOTE Apply Eaton E680 or Eaton E679 sealant to the mounting surface 13 Install the gear shift lever housing assembly on the transmission 14 Install the four retaining capscrews i...

Page 163: ...Eaton Fuller Light Duty Transmissions ...

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