Eaton Fuller FSO-2405 Service Manual Download

Page: 6 / 163

General Table of Contents

2nd Ed. 02/07

FSO-2405

Section 3

Rear Section ............................................... 89

Output Sleeve, Yoke and 4x4
Transmission Differences ........................ 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

Summary of Contents for Fuller FSO-2405

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

Page 2: ......

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: ...e 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 Speci...

Page 6: ...fferences 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 Countershaf...

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...

Page 8: ...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 Adj...

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

Page 10: ......

Page 11: ...on 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...

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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...

Page 14: ...otograph 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...

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...

Page 16: ...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...

Page 17: ...n 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...

Page 18: ...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 Caps...

Page 19: ...ed 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 Mainsh...

Page 20: ...E 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 synchr...

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 Shif...

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 Bo...

Page 23: ...th 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...

Page 24: ...f 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 recommende...

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 failure...

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 delive...

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

Page 28: ...put 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...

Page 29: ...g 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 t...

Page 30: ...ssembly 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 bea...

Page 31: ...ly 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...

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...

Page 33: ...orque 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...

Page 34: ...ving 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 solv...

Page 35: ...asive 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 pa...

Page 36: ...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 ti...

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...

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 Recommende...

Page 39: ...n or damaged Replace rings Synchronizer synchronizer rings assemblies page 140 Excessively worn Replace synchronizer Synchronizer or damaged assemblies assemblies synchronizer page 140 assemblies spri...

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 l...

Page 41: ...e 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 capscr...

Page 42: ...y 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...

Page 43: ...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 se...

Page 44: ...ft 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 fron...

Page 45: ...ral Information E001013 E001020 E001021 E001010 E001010 Permaglide bushing installer E001010 E001013 Universal handle E001020 Front housing expansion plug installer E001021 Input shaft bearing cover s...

Page 46: ...35 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 Applicat...

Page 47: ...036 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 E...

Page 48: ...r 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...

Page 49: ...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 Po...

Page 50: ...ion 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...

Page 51: ...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...

Page 52: ...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 meas...

Page 53: ...2001 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 pu...

Page 54: ...5 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...

Page 55: ...l 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 adapt...

Page 56: ...6003 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 soc...

Page 57: ...nstalling 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 applicat...

Page 58: ...o be ratio applied FSO2405F 3 481 63 77 N m FSO2405G 4 213 52 64 N m FSO2405H 4 994 44 54 N m FSO2405J 3 716 59 72 N m FSO2405K 4 473 49 60 N m WARNING Check the vehicle s Service Manual for the trans...

Page 59: ...shaft 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...

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: ...SO 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...

Page 81: ...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 spl...

Page 82: ...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...

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 Niss...

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

Page 86: ......

Page 87: ...ars 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 di...

Page 88: ...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 corre...

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...

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Page 91: ...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 C...

Page 92: ...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 NOT...

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 O...

Page 94: ...O 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 FS...

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 FS...

Page 96: ...g 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 syn...

Page 97: ...e 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...

Page 98: ...e 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 wa...

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...

Page 101: ...ion 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 I...

Page 102: ...ll 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...

Page 103: ...stall 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...

Page 104: ...ked 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 Inst...

Page 105: ...9 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 bearin...

Page 106: ...r 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 FS...

Page 107: ...he 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 Tool...

Page 108: ...004 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 mainsh...

Page 109: ...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 th...

Page 110: ......

Page 111: ...sassembly 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 Installa...

Page 112: ...ting 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 Cou...

Page 113: ...able 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 Shim...

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Page 115: ...hreaded 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 ca...

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 re...

Page 117: ...rface 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 gr...

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 WA...

Page 119: ...ed 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...

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 The...

Page 121: ...R 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 spe...

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 remo...

Page 123: ...s 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...

Page 124: ...y 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...

Page 125: ...tall 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...

Page 126: ...emoval 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...

Page 127: ...appens 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 N...

Page 128: ...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 Ea...

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 lubrica...

Page 130: ...e 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...

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 positi...

Page 132: ...erlocking 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 housin...

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 housin...

Page 134: ...meter 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...

Page 135: ...cking 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 bal...

Page 136: ...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 thro...

Page 137: ...port 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 bea...

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 bearin...

Page 139: ...e 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 I...

Page 140: ...nizer 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 a...

Page 141: ...he 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 synchronize...

Page 142: ...atures 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 syn...

Page 143: ...h 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 th...

Page 144: ...lies 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 rev...

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 m...

Page 146: ...ower 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...

Page 147: ...r 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 facin...

Page 148: ...NING 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 sup...

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 counter...

Page 150: ...haft 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 Me...

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 speci...

Page 152: ...cessary 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...

Page 153: ...ply 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 inter...

Page 154: ...alant 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 NO...

Page 155: ...ont 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...

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: ...ase 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 fro...

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 wa...

Page 161: ...all 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 inw...

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 prope...

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

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