5/01
1/7
It is assumed in the detailed disassembly instructions
that the lubricant has been drained and the necessary
linkage and air lines (if fitted) have been removed from
the chassis.
Removal of the gear shift remote control housing
assembly is included in the detailed instructions; howev-
er, this assembly may also be removed from the trans-
mission before removing unit from vehicle.
Follow each procedure closely in each section, making
use of both the text and the pictures.
1.
Bearings
Carefully wash and relubricate all
bearings as removed and protectively wrap until ready
for use. Remove bearings with pullers designed for this
purpose.
2.
Assemblies
When disassembling the various
assemblies, such as the mainshaft, layshaft and remote
control housing, lay all parts on a clean bench in the
same sequence as removed. This procedure will simpli-
fy reassembly and reduce the possibility of losing parts.
When pulling off synchroniser hubs follow the proce-
dures detailed in Disassembly using a suitable puller of
adequate capacity. Failure to adhere to the recom-
mended procedures may cause irreparable damage.
3.
Snap rings
Remove snap rings with pliers
designed for this purpose. New selective fit snap rings
must be fitted as specified in Reassembly .
4.
Cleanliness
Provide a clean place to work.
It is important that no dirt or foreign material enters the
unit during repairs. The outside of the unit should be
carefully cleaned before starting the disassembly. Dirt is
abrasive and can damage bearings.
5.
When Pressing
Apply force to shafts, hous-
ings etc. with restraint. Movement of some parts is
restricted. Do not apply force 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.
Inspection of Expendable
General
Disassembly Precautions
Before reassembling the transmission, the individual
parts should be carefully checked to eliminate those
damaged. They should be renewed. This inspection
procedure should be carefully followed to ensure the
maximum wear life from the rebuilt unit.
The cost of a new part is generally a small fraction of
the total cost of downtime and labour, should the use of
a questionable part make additional repairs necessary
before the next regularly scheduled overhaul.
Recommended inspection procedures are set forth in
the following check list.
A. Bearings
1.
Wash all bearings in clean solvent. Check rollers
and races for pits and spalled areas. Renew damaged
bearings.
2
.
Lubricate undamaged bearings and check for axial
and radial clearances. Renew bearings with excessive
clearances.
3.
Check fits of bearings in housing bores. If outer
races turn too freely in the bores, the housing should be
renewed. Check housing bores for signs of wear prior
to taking this action. Only replace housing if wear is
seen as a result of bearing spin.
B.
Gears
1.
Check gear teeth for pitting of the tooth faces.
Gears with pitted teeth should be renewed. Check the
reverse gear dog engagement teeth for freedom from
damage.
2.
Check the internal bearing surfaces for wear of the
effects of overheating.
3.
Check axial clearances of gears. Where excessive
clearance is found, check gear and hub for excessive
wear.
Maintain the specified axial clearance on mainshaft for-
ward gears.
C.
Bearing Sleeve Mainshaft
1.
Sleeves with groove formation, pits or which have
either been overheated or worn out must be renewed.
Summary of Contents for Roadranger TRSM4106
Page 1: ...Service Manual Fuller Mid Range Transmissions TRSM4106 October 2007...
Page 3: ......
Page 6: ...5 01 Section 2 General...
Page 22: ...5 01 Section 2 General Description...
Page 25: ...5 01 3 1 Section 3 Shifting Controls 6 Speed MK 4...
Page 35: ...5 01 3 11 10 Refit the rubber gaiter and breather...
Page 36: ...5 01 4 1 Section 4 Transmission Overhaul...
Page 88: ......