Eaton Roadranger TRSM4106 User Manual Download

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Service Manual

Fuller Mid Range Transmissions

TRSM4106

October 2007

Summary of Contents for Roadranger TRSM4106

Page 1: ...Service Manual Fuller Mid Range Transmissions TRSM4106 October 2007...

Page 2: ...For parts or service call us Pro Gear Transmission Inc 1 877 776 4600 407 872 1901 parts eprogear com 906 W Gore St Orlando FL 32805...

Page 3: ......

Page 4: ...Service Manual 4106 5206 Eaton 6 Speed Synchromesh Transmission Truck Components Operations Europe PO Box 11 Worsley Manchester M28 5GJ England...

Page 5: ...Control Disassembly 3 4 Remote Control Reassembly 3 7 Direct Control Exploded View 3 8 Direct Control Disassembly 3 9 Direct Control Reassembly Section 4 Transmission Overhaul 4 2 Transmission Case E...

Page 6: ...5 01 Section 2 General...

Page 7: ...side of the front case showing 1 Transmission serial number 2 Transmission model 3 Manufacturing data code 4 Transmission specification number The transmission specification number is unique to each...

Page 8: ...ge 3 recommended backlash is from 0 15 to 0 25mm Gear 6 5 4 3 2 1 Reverse FS 4106A FS 5206A 1 00 __ 1 38 __ 2 00 __ 3 10 __ 5 25 __ 9 03 __ 8 07 Step 38 45 55 69 72 FS 4106B FS 5206B 1 00 __ 1 29 __ 1...

Page 9: ...t types and brands of oil are not intermixed because of possible incompatibility Operating Temprature It is important that the transmission operating tempera ture does not exceed 120 C 250 F for an ex...

Page 10: ...highway use General Recommended Lubricants Models Temprature Range Grade Mild EP Gear Oil to Specification MIL L 2105 or API GL 4 Heavy Duty Engine Oil to Specification MIL L 2104C or MIL L 46152 or...

Page 11: ...Locking Insert 11 Remote Control Housing 4 6 8 Capscrews M10 Thread 35 to 39 Nm 25 to 29 lbs ft Plain Washers and Spring Lockwashers 12 Overdrive Selector fork Pivots 2 Capscrews M8 Thread with lockwa...

Page 12: ...m 51 to 58 lbs ft Spring Lockwashers 11 Reverse Lamp Switch M16 Thread 16 to 22 Nm 12 to 17 lbs ft General Torque Tightening Recommedations continued Screws and Nuts 1 Remote Control Shaft Lever 1 Cap...

Page 13: ...ce after the part being driven stops solidly Use soft hammers for all disassembly work Do not use pry bars or chisels to separate casing halves and housings or irreparable damage may be caused Inspect...

Page 14: ...heck pedal shafts Renew worn shafts and bear ings I Gear Selector Shaft Assembly 1 Check forks and keys for wear at contact points Renew worn parts 2 Check forks for excessive and uneven wear renew wo...

Page 15: ...ars as detailed in the chart on the following page 6 Bearings Use of flange end bearing drivers is recommended for the installation of bearings These drivers apply equal force to both races of the bea...

Page 16: ...10 General Gear End Floats All dimensions in mm Gear 4th 5th o d 6th Low Limit High Limit Tolerance 0 35 0 48 0 13 0 31 0 53 0 22 3rd 0 35 0 48 0 13 2nd 0 35 0 48 0 13 1st 0 40 0 57 0 17 Sliding Gear...

Page 17: ...1327 704461 LC 105A Bearing remover E 108 6 Mainshaft rear seal replacer adaptor E 109 7 Input shaft seal installer adaptor E 105 4 Countershaft bearing remover E 109 Driver E 108 Driver E 109 5 Sele...

Page 18: ...ountershaft bearing cone installer Use with E 109 E 114 Rear mainshaft bearing pilot E 115 Flange holding adaptor plate E 116A Gear assembly lifting fixture E 116 2 Adaptor gear assembly lifting fixtu...

Page 19: ...uired distance during removal and installation of the layshaft If the height of the cradle is increasing the thickness of the block should be increased by the same amount Three Legged Puller Series 15...

Page 20: ...ecial Tools continued 1 1 off hole 1 5 inches diameter 16 threads per inch Whitworth form to suit Sykes Picavant hydraulic ram No 150 000 2 8 holes 11 mm diameter Tool for 4 point ball bearing removal...

Page 21: ...nstaller adaptor J 39585 2 E 109 8 Selector shaft bush installer adaptor Use with E109 J 39585 1 E 109 9 Selector shaft plug installer adaptor Use with E109 J 21465 13 E 109 10 Driver extension J 3958...

Page 22: ...5 01 Section 2 General Description...

Page 23: ...s the gear change remote control may be to the right or the left The synchroniser assemblies are of the baulk ring type with the gear ring cones manufactured separately from the gears This allows the...

Page 24: ...5 01 2 2 General Description Gear Change Pattern Simple shift pattern with the mechanism biased in neutral between 3rd and 4th gears Power Flow in the Gears Direct Drive Top Gear Version 1 2 3 4 5 6 R...

Page 25: ...5 01 3 1 Section 3 Shifting Controls 6 Speed MK 4...

Page 26: ...ousing 9 Plug 10 Gasket 11 End cover 12 Spring washer M8 13 Screw M8 14 Bolt M10 x 50 15 Outer lever 16 Washer 17 Nut M10 18 Boot 19 Oil Seal 20 Bush 21 Reverse plunger 22 Reverse detent spring 23 Det...

Page 27: ...neutral switch and pin if fitted Note The position of the lever is marked on the shaft Check before removal 3 Remove the reverse detent cover and pull out the spring and plunger 4 Remove the four sepa...

Page 28: ...in the housing using the special tool The new bushes are prefinished to the correct size 8 Invert the housing align the grooved pin in the lever with the expansion plug hole 2 If necessary renew the...

Page 29: ...inner lever on the shaft and install a new grooved pin Note Inner lever should be supported whilst driv ing pin to prevent damage to bushes 8 Fit the outer circlip onto the shaft 6 Fit the inner circ...

Page 30: ...to 24 Nm 11 Fit the rubber boot onto the housing Align the outer lever with the timing mark on the shaft Fit the pinch bolt and tighten to 35 to 39 Nm 13 Apply Loctite 5900 sealant Fit control assembl...

Page 31: ...on 09 Spring compression 10 Cover 11 Spring washer 12 Screw 13 Plunger 14 Spring 15 Cover Item 16 Spring washer 17 Screw 18 Gaiter 19 Pin 20 Washer 21 Plug 22 End cap 23 Spring washer 24 Screw 25 Bush...

Page 32: ...ver plate spring and plunger 3 Remove the screws washers detent cover plate spring s and plunger 4 Remove the screws washers and end covers from both sides of the housing 5 If necessary the bushes in...

Page 33: ...joint faces Fit the seat ensuring that the slot aligns with the hole in the housing for the pin 2 Apply grease to the seat and then fit the pin 3 Apply a coating of grease to the Selector shaft and t...

Page 34: ...he yoke into the housing 7 Apply a light coating of grease to the bushes in the end covers Apply Loctite 5900 to the joint faces Fit the end caps screws and washers Torque screws to 20 to 24 Nm 8 Refi...

Page 35: ...5 01 3 11 10 Refit the rubber gaiter and breather...

Page 36: ...5 01 4 1 Section 4 Transmission Overhaul...

Page 37: ...tent plunger 18 Screw 19 Spring washer 20 Washer 21 Dowel 22 Bolt M10 23 Washer M10 24 Nut M10 25 Bushing 26 Oil trough 27 Hammer drive screw 28 Oil trough 29 Hammer drive screw 30 Dowel 31 Bushing 32...

Page 38: ...lled units have the remote control on the side of the transmission and alternative filler and drain plug positions 2 Raise the transmission on a hoist and install the unit onto the stand 3 Remove the...

Page 39: ...m then a retaining pin is not fitted therefore the following procedure can be missed 9 Remove the rear PTO cover Using the special tool or an 8 mm punch drive the reverse idler shaft grooved pin INWAR...

Page 40: ...ht horizontally mounted so that the case will not foul the selector block on removal 13 On overdrive models remove the capscrews retaining the two overdrive fork pivot pins and remove the pins 15 Remo...

Page 41: ...er shaft and expansion plug from the case 1 Thrust washer 2 Needle roller bearing 3 Spacer 4 Reverse idler gear 5 Thrust washer 6 Reverse idler shaft old design 7 Pin 8 O ring 9 Reverse idler shaft ne...

Page 42: ...th gear flange Remove the 6th gear synchroniser ring 25 Raise the hoist and lift out the mainshaft and selector shaft and forks as an assembly Carefully lower on to a clean bench and remove the specia...

Page 43: ...haft rear bearing cover and bearing spacer 32 Drift out the layshaft front bearing cup using the special tool Remove the input shaft bearing using the special tool 33 If necessary to renew the selecto...

Page 44: ...ing the front taper roller bear ing 2 Using the special tool remove the bearing cone and roller assembly 3 Invert the shaft and remove the rear taper roller bearing Layshaft Assembly 1 Countershaft as...

Page 45: ...of graded fit circlips select the circlip which fits into the groove with the minimum free play Part No Thickness mm 8870370 2 12 8870371 2 07 8870372 2 02 8871536 1 97 8871537 1 92 8871538 1 87 8871...

Page 46: ...on the input shaft 1 Using a suitable solvent ensure that both parts are clean and free from oil 2 Apply a thin bead of Loctite 648 to the spine teeth of the gear Press on the synchroniser flange ensu...

Page 47: ...ear and record the reading Note All snap rings and circlips on the mainshaft are graded for selective fit Take care not to score the bearing surfaces of the mainshaft when remov ing or fitting the sna...

Page 48: ...e gear 45 Mainshaft bearing 46 Tachograph 47 Dust shield 48 Coupling flange 49 Nut 1 Mainshaft 2 3rd gear needle roller bearing 3 3rd speed gear 4 3rd gear synchroniser ring 4a 3rd gear synchroniser f...

Page 49: ...erse gear fixed hub and 1st speed gear 4 14 Disassembly 1 Mount the mainshaft assembly plain end upper most in a soft jawed vice Remove the synchronis er ring Carefully slide the 5th 6th synchroniser...

Page 50: ...Circlip 11 Invert the mainshaft As the 5th 6th gear syn chroniser hub is not symmetrical identify its orienta tion Using a press or suitable puller remove the 5th 6th gear synchroniser hub synchronis...

Page 51: ...is may result in damage to the mainshaft Press or pull the 4th speed gear bearing sleeve 4th speed needle roller bearing 4th speed gear assembly 3rd 4th speed synchroniser assembly and 3rd speed gear...

Page 52: ...espective pairs for assembly in the same rel ative position Note The synchroniser flanges apart from those fitted to the 1st and 2nd speed gears must be loc tited to the gears c Place the synchroniser...

Page 53: ...nchroniser flange f Remove the synchroniser friction ring g Fit the synchroniser friction ring on to the syn chroniser flange ensuring that the tabs on the syn chroniser friction ring locate into the...

Page 54: ...n of the assembly procedure in the section 1st 2nd speed synchroniser assembly l Invert the synchroniser assembly and repeat the process Note The synchroniser flanges apart from those fitted to the 1s...

Page 55: ...speed gear and synchroniser assembly ensur ing that the splines on the mainshaft engage into the splines of the synchroniser assembly Press the mainshaft into the synchroniser assembly 6 To prevent t...

Page 56: ...nto the synchroniser hub Place the synchroniser sleeve over the synchroniser hub and support it with the internal groove just above the synchronis er hub Position the three rollers as shown resting on...

Page 57: ...hub to 85 Centigrade and then install it boss downwards onto the mainshaft Ensure that the large slots on the synchroniser hub align with the large shoulders on the synchroniser ring Press the synchro...

Page 58: ...t of free play Fit the Circlip into the groove 21 Using feeler gauges check that the 5th gear end float is within the tolerance stated in the chart 22 Invert the mainshaft and then remove the retainin...

Page 59: ...ee play Fit the Circlip into the groove taking care not to damage the mainshaft needle roller bearing surface 24 Check that the 2nd speed gear end float is within the tolerances stated in the chart 25...

Page 60: ...described in paragraph eleven 32 Fit the synchroniser ring ensuring that the three bosses on the synchroniser ring locate into the three slots on the synchroniser hub Lubricate the synchroniser ring...

Page 61: ...rings lift the detent poppets to release the balls Once the balls have been removed it is possible to remove the detent poppets and springs 9 Remove the synchroniser sleeve 4 Remove the synchroniser i...

Page 62: ...not already removed at step eight remove the detent poppets and springs 11 Remove the synchroniser hub 12 Remove the synchroniser ring 13 Remove the synchroniser friction ring 14 Remove the synchroni...

Page 63: ...the synchroniser hub upper most 6 Fit the synchroniser hub ensuring that the nar row slots are in line with the bosses of the synchro niser ring 1 Place the synchroniser flange spigot uppermost onto t...

Page 64: ...ts of the syn chroniser hub 9 Place the detent poppets and springs into the holes of the synchroniser hub 10 Place the detent ball onto the spring and then using a suitable tool push against the deten...

Page 65: ...of the synchroniser fric tion ring Place the synchroniser friction ring tabs uppermost on to the synchroniser hub 14 Place the synchroniser inner ring in to position ensuring that the three tabs alig...

Page 66: ...fit Take care not to score the bearing surfaces of the mainshaft when remov ing or fitting the snap rings or circlips Note The end float of the gears on the mainshaft is established in manufacture by...

Page 67: ...ring 18 Sliding sleeve 19 Fixed hub 20 Synchro flange 21 Mainshaft gear 3rd 22 Needle roller bearing Exploded View 23 Mainshaft 24 Needle roller bearing 25 Gear 2nd 26 Synchro flange 27 Synchro ring 2...

Page 68: ...he 5th gear and 5th gear needle roller bearing On overdrive transmissions this will be 6th gear 5 Carefully remove the 4th gear bearing sleeve retaining snap ring 6 Invert the shaft assembly and using...

Page 69: ...ssemble the puller over the 2nd gear and pull off 2nd gear 2nd gear synchroniser ring and flange the 1st 2nd gear synchroniser hub and the bearing 13 Support the shaft on the press under 3rd gear Note...

Page 70: ...using feeler gauges at several points around the circumference as shown The clearance should be between 0 5 and 1 9mm Renew both parts if the measurement is not within the specified limits Retain the...

Page 71: ...ay 7 Install the snap ring in the groove taking care not to damage the mainshaft bearing surfaces 8 Check that the gear end float is within the toler ances stated in the chart 9 Assemble the three spr...

Page 72: ...aft 13 Use a soft drift or suitable flange driver if nec essary to ensure the hub is fully home against the shoulder 14 From the range of graded snap rings carefully install the thickest one which wil...

Page 73: ...ack should be sufficiently tight on the shaft to retain the reverse gear on the shaft 19 Invert the shaft in the vice Lubricate and install the 3rd bearing and 3rd gear assembly 20 Install the 3rd gea...

Page 74: ...jelly is applied to the outer edge of the bearing this will support the bearing to stand proud of the gear and ease the procedure of aligning the bearing sleeve in the next operation 26 Take the heat...

Page 75: ...gear 32 From the range of graded circlips select the thickest one which fits into the groove with the min imum free play 33 Fit the circlip into the groove in the mainshaft 34 Check the gear end floa...

Page 76: ...Disassembly 1 Place selector assembly on bench with the selector block to the left Mark the front of the shaft and keys to aid reassembly 2 Hold the assembly by the selector block and withdraw the in...

Page 77: ...Shaft Assembly Vertically mounted unit 1 Overdrive shift pad 2 Overdrive fork 3 Overdrive selector 4 Selector keys 5 Selector shaft 6 Interlock key 7 Shift fork 5th 6th 8 Selector block 9 Set screw 1...

Page 78: ...w to 35 to 39 Nm Note If reusing the screw apply Loctite 270 to the threads before fitting 3 Place the forks in their respective positions on the selector shaft 4 Support the selector shaft and slide...

Page 79: ...and install new selector shaft expansion plugs dished side facing inwards into the cases from the inside 3 Using the special tool install the selector shaft bushes into the cases Drive in until fully...

Page 80: ...do housing with two or three capscrews 9 Fit the special guide sleeve over the mainshaft 10 Locate the selector shaft assembly to the main shaft Support the mainshaft using the special tool and hoist...

Page 81: ...niser sleeve 15 Apply Loctite 5900 sealant to the mating flange on the rear case and install the front case Install the capscrews and nuts 16 On overdrive transmissions using a suitable probe as illus...

Page 82: ...e shoulder ensuring the seal is not damaged 21 Lubricate the shaft seal surface and apply Loctite 5900 sealant to the mating face of the front cover Install the front cover and tighten the cap screws...

Page 83: ...he capscrews to the correct torque 69 to 78 Nm Spacer thickness 2 40mm add shim 0 508 2 908 subtract clearance 0 30 2 608 add preload 0 05 2 658 subtract spacer 2 40 0 258 Shim required 0 254 26 Turn...

Page 84: ...ply a light grease to the oil seal lips and install the drive flange Do not hammer the flange yoke onto the shaft or the bearing spacer may be dislodged from its location on the shaft This could cause...

Page 85: ...ft with a new O ring into the case Take care to ensure that the components are not dis lodged as the shaft is driven home with a soft mal let Reverse Idler Gear Assembly Reverse Idler Old Design 1 Thr...

Page 86: ...e cover plate with a new gasket and tighten the capscrews to the correct torque 20 to 24 Nm or install neutral detent assembly 32 to 37 Nm Or install neutral detent assembly 32 to 37 Nm 39 Ensure that...

Page 87: ...witch tighten to the correct torque 16 to 22 Nm 47 Check manually using the shift lever that all gears can be engaged It may be necessary to rotate the input shaft to obtain full gear engage ment 44 A...

Page 88: ......

Page 89: ...ducts with all options installed Although every attempt has been made to ensure the accuracy of information contained within Eaton makes no representation about the completeness correctness or accurac...

Page 90: ...For parts or service call us Pro Gear Transmission Inc 1 877 776 4600 407 872 1901 parts eprogear com 906 W Gore St Orlando FL 32805...

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