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Eaton TRSM0020, Service Manual

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Service Manual

Fuller Automated Transmissions

TRSM0020

October 2007

RT-11109A-AT

RT-11109A-ATR

RT-11109A-ATS

RT-12109A-AT

RT-14109A-ATS

RTO-11109A-AT

RTO-11109A-ATS

RTO-11109B-AT

RTO-11109B-ATE

RTO-11109B-ATR

RTO-11109B-ATS

RTO-12109A-AT

RTO-12109B-AT

RTO-13109A-ATE

RTO-13109B-AT

RTO-13109B-ATE

RTO-14109A-ATE

RTO-14109A-ATS

RTO-14109B-AT

RTO-14109B-ATE

RTO-14109B-ATS

RTO-16109A-AT

RTO-16109A-ATE

RTO-16109B-AT

RTO-16109B-ATE

RTO-9109A-AT

RTO-9109B-AT

Summary of Contents for TRSM0020

Page 1: ...4109A ATS RTO 11109A AT RTO 11109A ATS RTO 11109B AT RTO 11109B ATE RTO 11109B ATR RTO 11109B ATS RTO 12109A AT RTO 12109B AT RTO 13109A ATE RTO 13109B AT RTO 13109B ATE RTO 14109A ATE RTO 14109A ATS RTO 14109B AT RTO 14109B ATE RTO 14109B ATS RTO 16109A AT RTO 16109A ATE RTO 16109B AT RTO 16109B ATE RTO 9109A AT RTO 9109B AT ...

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 ...

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Page 4: ...Warnings Precautions General Information Model Assembly Reference External Parts Shift Bar Housing Front Section Auxiliary Section Options ...

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Page 6: ...rings 13 Bearing Covers 14 Gears 14 Gray Iron Parts 14 O Rings 14 Power Synchronizer Assembly 14 Rear Oil Seals 14 Reverse Idler Gear Assemblies 14 Shift Bar Housing Assembly 15 Sliding Clutches 15 Splines 15 Synchronizer Assembly 15 Washers 15 Assemble Axial Clearances 16 Bearings 16 Capscrews 16 Gaskets 16 Initial Lubrication 16 O Rings 16 Universal Joint Companion Flange or Yoke 16 Warning Prec...

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Page 8: ...arking brakes Before working on a vehicle place the transmission in neutral set the parking brakes and block the wheels Before towing the vehicle place the transmission in neutral and lift the drive wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing Warning Precautions ...

Page 9: ...nd protect the unit from damage Assemblies When disassembling the various assemblies such as the reverse idler countershafts and auxiliary section lay all parts on a clean bench in the same sequence as removed This procedure will simplify assembly and reduce the possibility of losing parts Bearings Carefully wash and lubricate all usable bearings as removed and protectively wrap until ready for us...

Page 10: ...checklist Autoshift Assembly 1 Autoshift finger should move side to side fore and aft with frictional resistance only Bearings 1 Wash all bearings in clean solvent Check balls rollers and raceways for pitting discoloration and spalled areas Replace bearings that are pitted discolored spalled or damaged during disassembly 2 Lubricate bearings that are not pitted discolored or spalled and check for ...

Page 11: ...ial clearance of gears Gray Iron Torque Converter Housing Parts 1 Check all gray iron parts for cracks and breaks Replace parts found to be damaged Hydraulic Valve 1 Should be clean and free of contamination O Rings 1 Check all O rings for cracks or distortion Replace if worn Oil Pump 1 Free from damage with no apparent leaks Power Synchronizer Inertia Brake Assembly 1 Check the splined shaft and ...

Page 12: ...of sliding clutches for partial engagement pattern Splines 1 Check splines on all shafts for abnormal wear If sliding clutch gears companion flange or clutch hub has worn marks in the spline sides replace the specific shaft affected Range Synchronizer Assembly 1 Check synchronizer for burrs uneven and excessive wear at contact surface and metal particles 2 Check blocker pins for excessive wear or ...

Page 13: ...t 71211 or equivalant on all capscrews For torque ratings use the torque recommendations through out the service manual Gaskets Use new gaskets throughout the transmission as it is being rebuilt Make sure all gaskets are installed An omission of any gasket can result in oil leakage or misalignment of bearing covers Initial Lubrication Coat all limit washers and shaft splines with Lubriplate during...

Page 14: ...erval Chart 9 Recommended Lubricant Chart 9 Transmission Operating Angles 10 Operating Temperatures with Oil Coolers 11 Power Flow Torque Converter Mode LO Range 12 Torque Converter Mode Lockup Mode 14 Auxiliary Section HI Range 15 Timing Front Section 16 Auxiliary Section 17 Tool Reference 18 Preventive Maintenance 19 Checks Before Transmission Removal 20 Checks with Drive Line Dropped 21 Checks ...

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Page 16: ... necessary to service and repair the Eaton Fuller transmissions listed on the front As outlined on the first page the manual has been divided into its main components external parts shift bar housing front section auxiliary section and options if applicable Each component has its own tabbed section Each tabbed section has its own table of contents and procedural flow charts The table of contents l...

Page 17: ... box 2 Remove the range cylinder assembly 3 Disassemble the synchronizer Once the synchronzier parts have been replaced assemble the auxiliary section according to the How to Assemble the Auxiliary Section 1 Assemble the synchronizer assembly 2 Install the countershaft assemblies if they were removed 3 Install the range cylinder assembly 1 3 Auxiliary Section Assemble Synchronizer Assembly Rear Be...

Page 18: ...serial number locate the tag on the transmission and then locate the numbers as shown Do not remove or destroy the transmission identification tag C E E M A T Transmission Automatic Managed Converter Enhanced Electronically Roadranger Twin Countershaft Overdrive X 100 Nominal Torque Capacity Design Level Forward Speeds R T O 11 1 09 A A T E S Special Duty R Regular Duty E Electronic Governed Engin...

Page 19: ... level Inspect regularly 2 Change oil and filters regularly Use the correct grade and type of oil Buy oil from a reputable dealer Additives and friction modifiers are not recommended for use in Eaton Fuller Transmissions 1 Maintain Proper Oil Level Different Views of the Oil Dipstick Make sure oil is within dipstick marks for the corresponding oil temperature Oil should be checked at idle speed in...

Page 20: ...se of possible incompatibility When changing oil viscosity to Arctic oil or alternate viscosity ranges follow the recommended transmission oil flush procedure Use clean oil and clean containers when filling transmssion Containers that have been used for anti freeze or water should not be used for transmission oil 1 Remove the dipstick and slowly add seven 7 gallons of the prescribed oil through th...

Page 21: ...case drain plug rear bottom tighten to 45 50 Lbf ft of torque 7 Remove the transmission dipstick and slowly pour 7 gallons of the appropriate oil into the transmission 8 Apply the vehicle parking brakes and place the transmission lever in neutral Start the engine and let it idle for 5 minutes Check the dipstick periodically while the engine is idling adding oil as needed to obtain a level that is ...

Page 22: ...art Lubrication Change and Inspection HIGHWAY USE First 1 000 to 1 500 miles Change transmission oil filter and strainer on new units Every 2 500 miles Inspect lubrication level Check for leaks Every 50 000 miles or 1 year Change transmission lubricant and filter Check the strainer for dirt OFF HIGHWAY USE First 30 hours Change transmission oil filter and strainer on new units Every 40 hours Inspe...

Page 23: ...ved and reputable dealers write to Eaton Corporation Truck Component Marketing Headquarters P O Box 4013 Kalamazoo MI 49003 Transmission Operating Angles If the transmission operating angle is more than 12 degrees improper lubrication can occur A special kit may be required for sustained operation on grades greater than 12 degrees ...

Page 24: ...erature from the transmission sump The sump temperature represents oil that has circulated through the cooler This temperature is normally below 225 F however intermittent sump temperatures to 250 F do not harm the transmission When the average temperature of the transmission oil exceeds the temperature limits as stated above more frequent oil changes may be needed The following conditions in any ...

Page 25: ...transferred to the torque converter s splined cover 2 The impeller spins directing oil through the torque converter 3 The oil flow hits the turbine causing the turbine to rotate The power is related to the speed difference between the impeller and the turbine 4 The turbine is connected to the interrupt clutch housing The interrupt clutch inner hub is splined directly to the transmission input shaf...

Page 26: ...example 9 The internal clutching teeth in the engaged mainshaft gear hub transfers torque to the mainshaft through the sliding clutch 10 The mainshaft transfers torque directly to the auxiliary drive gear 11 The auxiliary drive gear splits torque between the two auxiliary countershaft drive gears 12 Torque is delivered along both countershafts to the engaged LO range gear on the range mainshaft or...

Page 27: ...tch is splined directly to the interrupt clutch outer hub When the lockup clutch is activated the interrupt clutch is driven directly from the engine 4 The interrupt clutch inner hub is splined directly to the transmission input shaft 5 When the interrupt clutch is activated the torque is transmitted directly from the engine to the input shaft from the lockup clutch The losses from the slippage in...

Page 28: ...hafts to mating countershaft gear of the engaged mainshaft gear 9 The internal clutching teeth in the engaged mainshaft gear hub transfers torque to the mainshaft through the sliding clutch 10 The mainshaft transfers torque directly to the auxiliary drive gear 11 The auxiliary drive gear transfers torque directly to the range mainshaft or output shaft through the engaged sliding clutch 12 Torque i...

Page 29: ...or to installation and placing them in proper mesh while in the transmission In the front section it is necessary to time only the drive gear set And depending on the model only the LO range deep reduction or splitter gear set is timed in the auxiliary section Front Section A Marking countershaft drive gear teeth 1 Prior to placing each countershaft assembly into the case clearly mark the tooth lo...

Page 30: ...shaft drive gear marked tooth with either set of main drive gear two marked teeth 2 Repeat the procedure when installing the bearings on the right countershaft make use of the remaining set of main drive gear two marked teeth to time assembly Auxiliary Section Standard Auxiliary Section 1 Mark any two teeth on the LO range gear Then mark two teeth located directly opposite the first marked 2 Prior...

Page 31: ... s tools such as socket wrenches screwdrivers etc and other standard shop items such as a press mauls and soft bars are all that is needed to successfully disassemble and reassemble any Eaton Fuller Transmission The specialized tools can be obtained from a tool supplier or made from tool prints as required by the individual user Detailed Eaton Fuller Transmission Tool Prints are available upon req...

Page 32: ...ve maintenance program Preventive maintenance is a general term which applies to all procedures necessary to have maximum life and satisfactory service at the lowest possible cost short of removing and repairing the unit A number of conditions contrary to good preventive maintenance can generally be pointed to when inspecting a failed transmission Taking a few minutes every so many hours or miles ...

Page 33: ...ling circuit for leaks 3 Dipstick not shown Remove dipstick and check level of lubricant at specificed intervals Check oil in neutral at engine idle 4 Drain Plugs Tighten the drain plugs securely Tighten the main case drain plug to 45 50 Lbf ft of torque Tighten oil pan plugs to 14 20 Lbf ft of torque 5 Capscrews and Gaskets Check all capscrews especially those on PTO covers and rear bearing cover...

Page 34: ...heck radial clearance in mainshaft rear bearing Checks With Universal Joint Companion Flange or Yoke Removed NOTE If necessary use solvent and shop rag to clean sealing surface of companion flange or yoke Do not use crocus cloth emery paper or other abrasive materials that will mar sur face finish 8 Splines on Output Shaft Check for wear from movement and chucking action of the universal joint com...

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Page 36: ...1 Model Assembly Reference Section 3 Model Assembly Reference CEEMAT AT 2 CEEMAT ATR 4 CEEMAT ATS 6 CEEMAT ATE 8 ...

Page 37: ... Strainer 18 19 Oil Filter 20 21 Synchronizer System Power Synchronizer 22 23 Shift Bar Housing Shift Bar Housing Cover 24 25 Autoshift Harness 26 27 Autoshift Assembly 28 29 Shift Bar Housing 30 31 Torque Converter Torque Converter 32 33 Hydraulic Valve 34 35 Dip Stick 36 37 Torque Converter Housing 38 39 Oil Pump 40 41 Filter Bypass Valve 42 43 HI Pressure Relief Valve 42 43 Output Yoke Companio...

Page 38: ...bly 4 6 5 7 Reverse Idler Gear Assembly 8 9 Countershaft Assembly Countershaft Bearings 10 11 Countershaft Assembly 12 14 13 15 Mainshaft Assembly may have 3 grooves 16 18 17 19 Input Shaft Assembly 22 23 Auxiliary Section Range Cylinder Assembly Range Cylinder Assembly 4 5 Synchronizer Assembly 6 7 Countershaft Assembly 8 9 Output Shaft Assembly Rear Bearing 12 13 ...

Page 39: ...trainer 18 19 Oil Filter 20 21 Synchronizer System Inertia Brake 22 23 Shift Bar Housing Shift Bar Housing Cover 24 25 Autoshift Harness 26 27 Autoshift Assembly 28 29 Shift Bar Housing 30 31 Torque Converter Torque Converter 32 33 Hydraulic Valve 34 35 Dip Stick 36 37 Torque Converter Housing 38 39 Oil Pump 40 41 Filter Bypass Valve 42 43 HI Pressure Relief Valve 42 43 Output Yoke Companion Flang...

Page 40: ...mbly 4 6 5 7 Reverse Idler Gear Assembly 8 9 Countershaft Assembly Countershaft Bearings 10 11 Countershaft Assembly 12 14 13 15 Mainshaft Assembly may have 3 grooves 16 18 17 19 Input Shaft Assembly 22 23 Auxiliary Section Range Cylinder Assembly Range Cylinder Assembly 4 5 Synchronizer Assembly 6 7 Countershaft Assembly 8 9 Output Shaft Assembly Rear Bearing 12 13 ...

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Page 42: ...0 How to Install the Air Filter Regulator 11 How to Remove a Slave Valve 12 How to Install a Slave Valve 13 Lube System How to Remove the Lube Supply Hose for the Power Synchronizer 14 How to Install the Lube Supply Hose for the Power Synchronizer 15 How to Remove the Lube Supply Hose for the Inertia Brake 16 How to Install the Lube Supply Hoses for the Inertia Brake 17 How to Remove the Oil Tube ...

Page 43: ...nstall the Hydraulic Valve 35 How to Remove the Dip Stick 36 How to Install the Dip Stick 37 How to Remove the Torque Converter Housing 38 How to Install the Torque Converter Housing 39 How to Remove the Oil Pump 40 How to Install the Oil Pump 41 How to Remove the Filter Bypass Valve 42 How to Install the Filter Bypass Valve 43 How to Remove the HI Pressure Relief Valve 42 How to Install the HI Pr...

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Page 45: ...o the auxiliary housing 2 Disconnect the air hose at the shift bar housing power synchronizer disc port labeled Port A 3 Disconnect the air supply hose connected to the power synchronizer disc port 4 Disconnect the air hose at the shift bar housing port air supply hose labeled Port B 5 Disconnect the air supply hose connected to the power synchronizer band port 6 Inspect the air supply fittings on...

Page 46: ...previously removed install new air fittings Tighten to 7 10 Lbf ft of torque 2 Connect one air supply hose end to the power synchronizer band port Tighten to 7 10 Lbf ft of torque 3 Connect the other end to the shift bar housing cover band port labeled Port B Tighten to 7 10 Lbf ft of torque 4 Connect one air supply hose end to the power synchronizer disc port Tighten to 7 10 Lbf ft of torque 5 Co...

Page 47: ... its location Special Tools Typical service mechanic tools To Remove 1 If necessary remove the capscrew holding the air hose to the auxiliary housing 2 Disconnect the air hose at the shift bar housing inertia brake port labeled Port A 3 Disconnect the air supply hose connected to the inertia brake air port 4 Inspect the air supply fittings on the shift bar housing and the inertia brake remove if d...

Page 48: ...he hose the air filter regulator must be in position Special Tools Typical service mechanic tools To Install 1 If previously removed install new air fittings Tighten to 7 10 Lbf ft of torque 2 The pipe plug in Port B is tighten to 7 10 Lbf ft of torque 3 Connect the air supply hose to the inertia brake air port Tighten to 7 10 Lbf ft of torque 4 Connect the other end to the shift bar houisng inert...

Page 49: ...ic tools To Remove 1 Disconnect the slave valve LO range supply port air hose 2 Disconnect the air supply hose connected to the range cylinder LO range supply port 3 Disconnect the slave valve HI range supply port air hose 4 Disconnect the air supply hose connected to the range cylinder HI range supply port 5 Inspect the air supply fittings on the shift bar housing and the range cylinder remove if...

Page 50: ...I D air hoses install the fixed nut end first To install the hoses the air filter regulator must be in position Special Tools Typical service mechanic tools To Install 1 If previously removed install new air supply fittings Tighten to 7 10 Lbf ft of torque 2 Connect one air supply hose end to the range cylinder HI range supply port Tighten to 7 10 Lbf ft of torque 3 Connect the other end to the sl...

Page 51: ...cated between the filter regulator and the shift bar housing cover Special Tools Typical service mechanic tools needed To Remove 1 From the air filter regulator remove the two 2 capscrews 2 From the shift bar cover remove the two 2 O rings 3 Inspect the O rings for cracks or distortion 4 Inspect the air fittings on the air filter regulator remove if damaged H 49 3 H 04 4 2 1 ...

Page 52: ...nsmission Special Tools Typical service mechanic tools needed To Install 1 If previously removed install new air supply fittings Tighten the larger fitting to 14 20 Lbf ft of torque and the smaller to 7 10 Lbf ft of torque 2 On the shift bar cover position the two 2 O rings 3 Over the O rings position the air filter regulator 4 Apply Eaton Fuller Sealant 71205 or equivalent to the two 2 retaining ...

Page 53: ...ic tools needed To Remove 1 Remove the retaining capscrews 2 From the shift bar cover remove the slave valve and gasket You may need to use a plastic hammer to remove 3 Thoroughly clean gasket area Do not get gasket material or dirt in the shift bar housing ports or valve ports 4 If the insert valves have been damaged remove the plugs and insert valves 2 4 H 49 4 H 49 5 Range Valve 1 4 4 ...

Page 54: ...viously removed install new insert valves Tighten to 20 25 Lbf ft of torque 2 Position the corresponding new gasket on the slave valve mounting surface 3 Position the slave valve over the gasket 4 Apply Eaton Fuller Sealant 71205 or equivalent to the retaining capscrews 5 Install the retaining capscrews Tighten to 8 12 Lbf ft of torque Final Check Make sure the retaining capscrews are properly tor...

Page 55: ...ial Tools Typical service mechanic tools To Remove 1 Disconnect the lube hose from the power synchronizer 2 To ease in removal remove the capscrew and clamp holding the hose to the auxiliary section 3 Disconnect the lube supply line connected to the converter housing 4 Inspect the fitting and connector remove if damaged 5 Inspect the oil restrictor behind the connector remove if damaged H 49 7 H 4...

Page 56: ...oil restrictor Tighten to 20 30 Lbf in of torque 2 If previously removed install a new connector and or fitting Tighten to 14 20 Lbf ft of torque 3 Connect one lube supply hose end to the converter housing lube port Tighten to 15 20 Lbf ft of torque 4 Connect the other end to the power synchronizer lube port Tighten to 15 20 Lbf ft of torque 5 Install the capscrew and clamp to hold the hose to the...

Page 57: ...se label or record its location Special Tools Typical service mechanic tools To Remove 1 Disconnect the lube supply hose connected to the inertia brake 2 Disconnect the lube supply hose at the torque converter housing lube port 3 Inspect the fittings remove if damaged 4 Inspect the oil restrictor behind the torque converter fitting remove if damaged H 51 5 H 43 5 2 1 ...

Page 58: ...ocation Special Tools Typical service mechanic tools To Install 1 If previously removed install a new oil retrictor Tighten to 20 30 Lbf in of torque 2 If previously removed install new connectors Tighten to 15 20 Lbf ft of torque 3 Connect one lube supply hose end to the converter housing lube port 4 Connect the other lube supply hose end to the inertia brake Final Check Make sure air hoses are n...

Page 59: ...the retaining capscrews 3 Remove the oil pan 4 Remove the retaining capscrews oil transfer tube and oil pan gasket 5 Inspect the oil return adapter tube remove if damaged 6 Inspect the dip stick adaptor fitting remove if damaged 7 Inspect the cooler back pressure valve if damaged replace 8 Clean the oil pan magnet 9 Clean and inspect the strainer Replace if damaged 10 Inspect the return tube fitti...

Page 60: ...2 retaining capscrews Tighten the screws to 14 20 Lbf ft of torque 4 Position the oil pan 5 Install the retaining capscrews Tighten the screws to 14 20 Lbf ft of torque 6 If previously removed install the dip stick adaptor O ring and fitting Tighten to 34 48 Lbf ft of torque 7 If previously removed install the oil return adaptor O ring and adaptor Tighten to 34 48 Lbf ft of torque 8 If previously ...

Page 61: ...ecial Instructions Special Tools Typical service mechanic tools To Remove 1 Remove the three 3 retaining capscrews 2 Remove the oil filter housing and O ring seal 3 Remove the oil filter by pulling it straight off 4 Inspect the oil filter nipple remove if damaged H 50 5 H 50 6 H 50 7 H 50 8 2 3 1 4 ...

Page 62: ... Typical service mechanic tools To Install 1 If removed apply hydraulic sealant and replace the oil filter nipple Tighten to 34 48 Lbf ft of torque 2 Install the oil filter on the oil filter nipple 3 Position the O ring seal on the oil filter housing 4 Position the oil filter housing over the oil filter 5 Install the three 3 capscrews Tighten to 26 32 Lbf ft of torque Final Check Make sure the cap...

Page 63: ...n the middle mounting position HowtoRemovetheInertia Brake Special Instructions There are different capscrew lengths note their location The hoses need to be disconnected The removal replacement procedure is typical Your inertai brake may be installed in a 6 bolt or rotated 6 bolt PTO configuration The process for the removal replacement is the same Refer to the Illustrated Parts Lists for further...

Page 64: ...s Tighten to 35 45 Lbf ft of torque The middle capscrew uses a washer Final Check Make sure the capscrews are properly torqued How to Install the Inertia Brake Special Instructions There are different capscrew lengths note their location Special Tools Typical service mechanic tools To Remove 1 If previously removed install new fittings Tighten the 1 8 elbow to 7 10 Lbf ft of torque Tighten the 90 ...

Page 65: ... CAUTION Do not touch the electronic components Cover and set aside in a clean area Special Tools Typical service mechanic tools needed To Remove 1 Disconnect the torque converter wire harness 2 Remove the shift bar housing cover capscrews and shift cable bracket 3 Lift the shift bar housing cover up vertically past the alignment pins 4 Carefully tip the cover on its side 5 Disconnect the internal...

Page 66: ...ifter harness connector 4 Use the alignment pins and set the shift bar housing cover in place 5 Apply Eaton Fuller Sealant 71205 or equivalent to the retaining capscrews or use dyna sealsTM 6 Install the retaining capscrews with washers Tighten to 23 30 Lbf ft of torque 7 Install the shift cable bracket with washers Tighten to 23 30 Lbf ft of torque 8 If previously remove install the shift cable l...

Page 67: ...toshifter harness Slide the tool along the wire into the insert cavity until it engages the contact and resistance is felt The contact retaining clip will be in the unlocked position 2 Pull the contact wire assembly out of the connector 3 Repeat steps 1 and 2 to disconnect the output shaft speed pick up 4 On the shift bar housing loosen the four 4 ball switch screws on the range ball switches and ...

Page 68: ...4 Install autoshifter gasket and O ring 5 Install the autoshifter with four 4 hex head bolts with washers Tighten to 20 30 Lbf ft of torque 6 Position the autoshift harness S4 lead ends under the washers in the HI range ball switch 7 Tighten the screws to 15 20 Lbf in of torque 8 Position the autoshift harness S5 lead ends under the washers in the LO range ball switch 9 Tighten the screws to 15 20...

Page 69: ...he tool along the wire into the insert cavity until it engages the conact and resistance is felt The contact retaining clip will be in the unlocked position 2 Pull the contact wire assembly with tool out of the connector 3 Repeat steps 1 and 2 to disconnect the output shaft speed pick up 4 On the shift bar housing loosen the two switch screws on the range switches and remove the autoshift harness ...

Page 70: ...r 4 hex head bolts with washers Tighten to 20 30 Lbf ft of torque 4 Position the autoshift harness S4 lead end under the washers in the HI range ball switch 5 Tighten the screws to 15 20 Lbf in of torque 6 Position the autoshift harness S5 lead end under the washers in the LO range ball switch 7 Tighten the screws to 15 20 Lbf in of torque 8 Connect the 2 pin in line connector for the input shaft ...

Page 71: ...o Remove 1 Inspect the input and output shaft magnetic speed sensors remove if damaged or defective 2 Inspect the ball switches remove if defective or damaged 3 From the shift bar housing remove the three 3 Allen head screws 4 Remove the shift bar housing 5 Remove the gasket and clean all mounting surfaces of gasket material 6 If the three 3 sets of tension springs and balls from the housing top b...

Page 72: ...t bar housing mounting surface 4 As you install the shift bar housing make sure the yokes fit into the corresponding sliding clutch slots 5 Install the three 3 interlock balls in the housing bores 6 Install the three 3 tension springs in the housing bores 7 Install the three 3 allen head screws in the shift bar housing rim Tighten to 35 45 Lbf ft of torque 8 If previously removed install the two 2...

Page 73: ...ighten evenly to work the pilot out 3 Remove and discard the O ring on the pilot 4 Remove the two 2 seal rings on the pilot 5 Remove the two 2 piston rings from the input shaft 6 From the input shaft remove the torque converter retaining snap ring 7 Mark the location of the input shaft lube slots on the input shaft end 8 Install two 2 lifting eyes in the torque converter pilot holes directly acros...

Page 74: ...the snap ring groove is visible You may need to wiggle the converter gently 5 On the input shaft install the torque converter retaining snap ring in the snap ring groove 6 Apply a thin coat of lubriplate to the input shaft piston rings and install on the input shaft Ring ends need to be interlocked Ring ends need to be interlocked 7 Prepare the pilot seal rings for installation Cross seal ends be ...

Page 75: ...mechanic tools are needed To Remove 1 Loosen the dip stick tube nut and remove the dip stick tube 2 Remove the two 2 retaining nuts from the magnetic coils 3 Remove the two 2 magnetic coils from the hydraulic valve Check for distortion or cracks if damaged replace 4 Remove the hydraulic valve mounting capscrews and socket head screws 5 Remove the hydraulic valve mounting plate and gaskets 2 1 3 4 ...

Page 76: ... valve gaskets mounting plate and hydraulic valve Gaskets marked housing and valve must be installed in their respective locations 2 Install the hydraulic valve mounting capscrews and socket headscrews Tighten to 26 32 Lbf ft of torque 3 Install the two 2 magnetic coils on the hydraulic valve stems wires towards the front 4 Install the two 2 retaining nuts on the magnetic coils Tighten to 30 Lbf i...

Page 77: ...Stick Special Instructions Removal of the dip stick can be done in the vertical or horizontal position Special Tools Typical service mechanic tools are needed To Remove 1 Loosen the dip stick tube nut and remove the dip stick tube 2 Inspect the dip stick connector remove if damaged H 21 9 H 50 4 1 2 ...

Page 78: ...in the vertical or horizontal position Special Tools Typical service mechanic tools are needed To Install 1 If previously removed install the dip stick connector O ring and connector Tighten to 34 48 Lbf ft of torque 2 Install the dip stick tube and tighten the dip stick tube nut Tighten to 35 45 Lbf ft of torque Final Check Make sure the parts are properly torqued H 50 4 H 21 9 2 1 ...

Page 79: ...port remove the retaining capscrews 3 Remove the stator support and gasket 4 Remove the torque converter housing retaining capscrews with washers 5 Remove the torque converter housing nuts with washers 6 Remove the torque converter housing and gasket from the transmission case 7 Inspect the synchronizer system lube elbow adaptor remove if damaged 8 Inspect the torque converter housing seal remove ...

Page 80: ...ssion case 5 Install the torque converter housing over the gasket 6 Install the nuts with washers Tighten to 130 170 Lbf ft of torque 7 Install the capscrews with washers Tighten to 70 80 Lbf ft of torque 8 Install the 3 piston rings in the input shaft base Ring ends need to be interlocked 9 If previously removed apply lubrication and install the O ring in the stator support bottom The O ring is n...

Page 81: ...p gear Special Tools Typical service mechanic tools are needed To Remove 1 From the oil pump gear remove the retaining nut Use a screwdriver to keep the gear from moving 2 Remove the oil pump drive gear 3 Remove the two 2 pump mounting capscrews 4 Use the two 2 capscrews previously removed and insert them into the pump to lift the pump 5 Remove the oil pump 6 Remove the oil pump O ring 7 Inspect t...

Page 82: ...ue converter housing oil pump bore 2 If previously removed install a new snap ring 3 Lube and install the oil pump O ring 4 Lube the oil pump bore 5 Install the oil pump tap with soft faced hammer if necessary 6 Install the two 2 pump mounting capscrews Tighten to 35 45 Lbf ft of torque 7 Inside the torque converter housing install the oil pump drive gear 8 On the oil pump gear install a new retai...

Page 83: ... a hex socket to remove the filter bypass valve 2 Inspect the valve for damage replace if damaged How to Remove the HI Pressure Relief Valve Special Instructions The oil filter must be removed Special Tools Typical service mechanic tools are needed To Remove 1 Remove the oil filter adaptor 2 Use a hex socket to remove the HI pressure relief valve 3 Inspect the valve for damage replace if damaged H...

Page 84: ...socket to install the filter bypass valve 2 Tighten the valve to 26 32 Lbf ft of torque Final Check Make sure the valve is properly torqued How to Install the HI Pressure Relief Valve Special Instructions The oil filter must be removed Special Tools Typical service mechanic tools are needed To Install 1 Use a hex socket to install the HI pressure relief valve 2 Tighten the valve to 26 32 Lbf ft of...

Page 85: ...uide After removal of the output yoke companion flange temporarily replace the output shaft nut to protect the output shaft threads during auxiliary section disassembly Special Tools Typical service mechanic tools are needed A large breaker bar or air impact wrench To Remove 1 Engage two 2 mainshaft sliding clutches into two 2 mainshaft gears to lock the transmission 2 Use a large breaker bar or a...

Page 86: ...chanic tools are needed A torque wrench with 1000 Lbf ft capacity To Install 1 Engage two 2 mainshaft sliding clutches into two 2 mainshaft gears to lock the transmission 2 Install the speedometer drive gear rotor or replacement spacer on the output shaft inside the rear bearing cover 3 If the slinger on the yoke is damaged replace using a Slinger Seal kit 4 Slide the companion flange or yoke onto...

Page 87: ...the range cylinder to the side and down 3 From the power synchronizer remove the mounting capscrews 4 Remove the power synchronizer and gasket 5 From the auxiliary section housing remove the retaining capscrews that attach the front section to the auxiliary section 6 From the auxiliary case remove the two 2 allen head setscrews 7 Insert the three 3 capscrews in the housing flange tapped holes Tigh...

Page 88: ...section top 3 Attach a lifting chain to the auxiliary section hanger bracket 4 Position the auxiliary section on the two 2 dowel pins 5 Slide the auxiliary section on until the hanger bracket contacts the front section back 6 Remove the auxiliary section hanger bracket 7 Install the two 2 allen setscrews Tighten to 35 45 Lbf ft of torque 8 Apply Eaton Fuller Sealant 71205 or equivalent to the reta...

Page 89: ...ver Assembly Special Instructions The rear bearing cover can be removed without disassembling the auxiliary section Special Tools Typical service mechanic tools are needed To Remove 1 Remove the retaining capscrews and the rear bearing cover and gasket 2 Inspect the oil seal remove if damaged H 46 6 TA 08 7 1 2 ...

Page 90: ...equivalent covering the top surface Do not use an O ring with the seal Special Tools Typical service mechanic tools are needed Bearing driver and maul Oil seal installation tool K 2091 To Install 1 If previously removed install the oil seal in the rear bearing cover with the proper driver 2 The seal should be installed so the spring is to the transmission front 3 Position a new gasket on the rear ...

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Page 92: ...ance may differ procedure is the same 1 Shift Bar Housing Section 5 Shift Bar Housing Functions of a Shift Bar Housing 3 Shift Bar Housing How to Disassemble the Shift Bar Housing 4 How to Assemble the Shift Bar Housing 6 ...

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Page 94: ...ns of a Shift Bar Housing Shift bar housings are a very important part of the transmission No matter what kind of shift bar housing your transmission has they all provide the same functions Engage the transmission gearing Prevents the driver from shifting into 2 gears at the same time ...

Page 95: ...ice mechanic tools needed Vise with brass jaws or wood blocks To Disassemble 1 If the three 3 sets of tension springs and balls from housing bores have not been removed place the shift bar housing on its side to remove them 2 With the housing rear to the right place the assembly in a vise 3 While removing the top yoke bar to the right remove the shift yoke and shift block 4 From the second yoke ba...

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Page 97: ...ling Start with the bottom yoke bar Special Tools Typical service mechanic tools needed Vise with brass jaws or wood blocks To Reassemble 1 With the housing rear to the right place the assembly in a vise 2 Assemble the spring and range sensor bar Install the range sensor bar 3 Install the longer about 1 range sensor pin Make sure the pin are all the way in against the range sensor bar 4 Install th...

Page 98: ...kwire securely 10 Holding the top bar notched end start installation As the bar passes the rear boss position the shift block 11 As the bar passes the center boss position the shift yoke on bar long hub to the housing rear 12 Install the shift block and shift yoke lockscrews Tighten to 35 45 Lbf ft of torque Lockwire securely 13 Install the three 3 tension balls one in each housing top bore Instal...

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Page 100: ...erse Idler Gear Assembly 8 How to Install the Reverse Idler Gear Assembly 9 Countershaft Assembly How to Remove the Countershaft Bearings 10 How to Install the Countershaft Bearings 11 How to Remove the Countershaft Assemblies 12 How to Install the Countershaft Assemblies 13 How to Disassemble the Countershaft Assembly 14 How to Assemble the Countershaft Assembly 15 Mainshaft Assembly How to Remov...

Page 101: ...emble Mainshaft Move Reverse Gear Disassemble Auxiliary Drive Gear Remove Countershaft Bearings Reverse Idler Gear Assembly Mainshaft Assembly Input Shaft Assembly Auxiliary Drive Gear Assembly Countershaft Assembly Disassemble Countershaft upper reverse idler gear upper countershaft bearings upper countershaft lower reverse idler gear lower countershaft bearings lower countershaft DS FS 1 ...

Page 102: ...e dashed line Front Box Assemble Mainshaft Assemble Auxiliary Drive Gear Install Countershaft Bearings Reverse Idler Gear Assembly Mainshaft Assembly Input Shaft Assembly Auxiliary Drive Gear Assembly Countershaft Assemblies Assemble Countershafts upper reverse idler gear upper countershaft bearings lower reverse idler gear lower countershaft bearings AS FS 1 ...

Page 103: ...cial Tools Typical service tools are needed Large pair of snap ring pliers To Remove 1 Remove the mainshaft rear groove snap ring 2 Remove the auxiliary bearing retainer ring capscrews 3 Insert three 3 of the capscrews in the specially tapped holes of the retainer ring 4 Tighten the capscrews evenly to force the auxiliary drive gear assembly from the case 5 Remove the auxiliary drive gear from the...

Page 104: ...nap ring pliers Flanged end driver and maul To Install 1 Position the auxiliary drive gear assembly on the mainshaft 2 Use a flanged end driver and maul to seat the auxiliary drive gear bearing 3 Align the retainer ring capscrew holes with the tapped holes 4 Apply Eaton Fuller sealant 71205 or equivalent to the retaining capscrews 5 Install the retaining capscrews tighten to 23 30 Lbf ft of torque...

Page 105: ...large pair of snap ring pliers To Disassemble 1 Lay the front auxiliary drive gear on a clean flat surface 2 From the front auxiliary drive gear hub use a screwdriver to pry off the snap ring retainer 3 From the front auxiliary drive gear hub remove the snap ring 4 Use the front hub as a base and press the drive gear through the bearing 5 Remove the retaining ring 6 Inspect the drive gear O rings ...

Page 106: ...tall on the drive gear 2 Lay the front auxiliary drive gear on a clean flat surface 3 With snap ring groove away from gear teeth install the retaining ring on the front auxiliary drive gear 4 With bearing snap ring facing groove in bearing ring start the bearing on hub Press into position until fully seated 5 To retain the bearing install the snap ring in front gear hub groove 6 With grooved side ...

Page 107: ...l service tools are needed Jaw Pullers or Impact Puller To Remove 1 From the idler shaft inside the case loosen the lock nut and washer 2 The mainshaft reverse gear must be moved in order to remove the upper reverse idler gear see How to Remove the Mainshaft Assembly steps 1 3 3 From the reverse idler gear bore use an impact puller to remove the auxiliary countershaft front bearing race 4 Remove t...

Page 108: ... end to the front As the shaft passes through the case bore position the reverse idler gear on the shaft long hub to the front and seated on the bearing inner race Insert the thrust washer between the reverse idler gear and the case support boss Finish inserting the idler shaft 4 Make sure the reverse idler shaft is seated in the support boss bore and as forward as far as possible 5 Install the wa...

Page 109: ...bar and maul Bearing puller or pry bars To Remove 1 To keep the mainshaft pilot from falling out of the input shaft pocket temporarily install the auxiliary drive gear on the mainshaft 2 From each countershaft rear groove remove the snap ring 3 From inside the case use a soft bar and maul to drive the countershaft rear bearings from the case bores 4 From the each countershaft front remove the caps...

Page 110: ... case bore 3 Use a screwdriver inserted in the countershaft capscrew bore to help center the countershaft 4 Move the countershaft forward into the bearing 5 Use a flanged end bearing driver and maul to completely seat the front bearing in case bore 6 On the countershaft front position the retainer plate with roll pin in shaft end hole 7 Secure with capscrew tightening to 90 120 Lbf ft of torque 8 ...

Page 111: ...for the PTO gears the upper and lower countershaft assemblies are the same Make sure and mark each as they are removed Special Tools Typical service tools are needed To Remove 1 Move the upper countershaft assembly to the rear as far as possible 2 Swing the countershaft front to middle of the case 3 Lift the countershaft assembly from the case B 19 1 3 ...

Page 112: ...making timing marks Special Tools No service tools are needed Toolmaker s dye To Install 1 Mark the countershaft drive gear for timing purposes 2 Place the lower 47 tooth PTO gear countershaft assembly in the case the drive gear to the front 3 Position as far to the left as possible the opposite side as the lower reverse idler gear assembly 4 Place the upper 45 tooth PTO gear countershaft assembly...

Page 113: ... pliers Press To Disassemble 1 From each countershaft front remove the drive gear retaining snap ring 2 Using the rear face of 4th speed gear as a base press the drive gear PTO gear and 4th speed gear from each countershaft This removes the front bearing inner race 3 Using the rear face of 2nd speed gear as a base press 3rd speed gear and 2nd speed gear from each countershaft 4 Inspect the keys an...

Page 114: ...haft 3 Align 3rd speed gear keyway with the countershaft key long hub against 2nd speed gear and press the gear on the countershaft 4 Align 4th speed gear keyway with the countershaft key long hub to countershaft front and press the gear on the countershaft 5 Align PTO gear keyway with the countershaft key bullet nose of teeth facing up shaft rear Align drive gear keyway with the countershaft key ...

Page 115: ...inshaft sliding clutch spline If not removing the upper reverse idler gear assembly you must remove the upper reverse idler gear assembly shaft and roll the gear to the outside see How to Remove the Reverse Idler Gear Assembly steps 1 4 4 Use a large screwdriver and block the upper countershaft assembly against the case wall If removing the upper reverse idler gear assembly see How to Remove the R...

Page 116: ...xt speed gear lower the mainshaft assembly while pulling the shaft rear through the case bore 3 After the mainshaft drops into the case slide the countershaft back and the mainshaft should fall down between the countershafts 4 Move the mainshaft pilot end into the input shaft pilot bushing Mesh the mainshaft gears with the corresponding countershaft assembly gears 5 Position the upper reverse idle...

Page 117: ... To Disassemble 1 Remove the mainshaft key snap ring 2 Tilt the mainshaft up and from the opposite end remove the sliding clutch 3 Remove reverse gear 4 Remove reverse gear spIine spacer 5 Place the mainshaft in a vertical position 6 From the mainshaft rear pull the mainshaft key from the mainshaft key way 7 Turn the reverse gear limit washer to align its splines with the mainshaft and remove the ...

Page 118: ... a thinner limit washer This will increase the axial clearance between the gears If the axial clearance is greater than the maximum 015 tolerance a thicker limit washer should be installed This will decrease the axial clearance between the gears Special Tools A vise with brass jaws or wood blocks Feeler gauges A piece of 5 32 air line 2 long To Assemble 1 With mainshaft pilot end down secure the m...

Page 119: ...shaft spacer insert 006 feeler gauge and 015 feeler gauge If out of tolerance change the limit against the mainshaft spacer See Special Instructions for further information 11 With the missing internal splines aligned with the plastic line install the 2nd 3rd speed sliding clutch 12 With the washer flat side up position the 2nd speed gear limit washer white in the next available groove Rotate the ...

Page 120: ...nd apply light pressure Between the gear hub and mainshaft spacer insert 006 feeler gauge and 015 feeler gauge If out of tolerance change the limit against the mainshaft spacer See Special Instructions for further information 21 Align the sliding clutch missing internal spline with the mainshaft key and install the 1st Reverse speed sliding clutch 22 With the flat side up position the Reverse spee...

Page 121: ...the limit washers are unlocked and can rotate which would cause the gears to drop 27 Install the mainshaft key snap ring 28 Remove the mainshaft from the vise 29 On the shaft front align the sliding clutch missing internal spline with the mainshaft key and install the 4th Drive gear sliding clutch Engage the sliding clutch external splines with the 4th speed gear clutching teeth Final Check Make s...

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Page 123: ... ring 2 Use a soft hammer and drive the input shaft toward the case rear as far as possible Pull the input shaft forward 3 Use pry bars or screwdrivers to complete removal of the bearing 4 Push the input shaft through the drive gear and out of the case 5 From inside the case remove the drive gear and spacer 6 Inspect the input shaft bushing replace if damaged 7 Remove the input shaft piston rings ...

Page 124: ...ng Special Tools Typical service tools are needed Toolmaker s dye To Install 1 In I D of main drive gear install the snap ring 2 Use toolmaker s dye and mark the main drive gear for timing purposes Mark any two 2 adjacent teeth on the drive gear Repeat the procedure for the two 2 adjacent teeth directly opposite the first set marked 3 Position the spacer and main drive gear in the transmission cas...

Page 125: ...e bearing on the input shaft 7 Temporarily install two lifting eyes to hold the bearing in the case bore 8 Use a soft bar and maul to drive the input shaft through the bearing 9 Install the bearing retainer snap ring in the input shaft snap ring groove Final Check Make sure the drive gear is timed with the lower countershaft Remove the temporary lifting eyes H 35 1 H 35 2 H 35 3 H 35 4 6 7 8 9 ...

Page 126: ...ly How to Disassemble the Range Cylinder Assembly 4 How to Assemble the Range Cylinder Assembly 5 How to Disassemble the Synchronizer Assembly 6 How to Assemble the Synchronizer Assembly 7 Countershaft Assembly How to Remove the Countershaft Assembly 8 How to Install the Countershaft Assembly 9 Output Shaft Assembly How to Disassemble the Output Shaft Assembly 12 How to Assemble the Output Shaft A...

Page 127: ...arance may differ procedure is the same 2 How to Disassemble the Auxiliary Section Auxiliary Section Synchronizer Assembly Range Cylinder Assembly Countershaft Assemblies Output Shaft Assembly DS AS 3 Rear Bearing Cover ...

Page 128: ...iffer procedure is the same 3 Auxiliary Section How to Assemble the Auxiliary Section Auxiliary Section Assemble Synchronizer Assembly Rear Bearing Cover Range Cylinder Assembly Countershaft Assemblies Output Shaft Assembly AS AS 4 ...

Page 129: ...se 2 Remove the range cylinder capscrews 3 Loosen the range piston nut 4 Cut the lockwire on the yoke lockscrews and remove the two 2 lockscrews and actuating bracket 5 Remove the range yoke and cylinder housing from the synchronizer assembly sliding clutch 6 Remove the range piston nut and piston 7 Inspect the piston O rings replace if damaged or distorted 8 Pull the yoke bar out the range cylind...

Page 130: ...rimmed and bent out of the way of any part interference Special Tools Typical service tools needed To Assemble 1 Inspect the range cylinder O rings replace if damaged 2 From the range cylinder housing front insert the yoke bar 3 Install the range piston and nut Finger tighten 4 Position a new gasket on the range cylinder housing mounting surface 5 Install the range cylinder housing and sliding clu...

Page 131: ...t surface Cover the synchronizer assembly with a shop rag to prevent losing the three 3 springs under pressure from the HI range synchronizer pin locations Special Tools Shop rag To Disassemble 1 Place the larger LO range synchronizer ring on the bench 2 Grab both sides of the HI range synchronizer and pull 3 From the synchronizer ring LO range pins remove the sliding clutch A 07 4 A 07 5 3 2 1 ...

Page 132: ...place the larger LO range synchronizer ring face down with pins up 2 With the sliding clutch recessed side up place the sliding clutch on the LO range synchronizer pins 3 In the HI range synchronizer bores install the three 3 springs 4 Place the HI range synchronizer ring over the LO range synchronizer ring Rotate the HI range synchronizer until the springs are seated against the pins 5 With the s...

Page 133: ... and Maul To Disassemble 1 Remove the auxiliary countershaft rear bearing cover capscrews and remove the auxiliary countershaft rear bearing cover and gasket 2 Remove the snap ring from the countershaft rear groove 3 Use a soft bar and maul to drive the countershaft forward and from the rear bearings 4 Remove the bearing from the auxiliary housing bore by tapping lightly and evenly to the rear wit...

Page 134: ...ls are needed Vise with brass jaws or wood blocks Bearing driver and maul Toolmaker s dye Large snap ring pliers To Assemble 1 Place the countershaft assembly vertical on a clean flat surface If previously removed using the proper driver and maul install the countershaft bearing race 2 In the countershaft rear bearing bore using the proper driver and maul install the countershaft bearing 3 Tempora...

Page 135: ...mble 7 Remove the rear bearing cover and install the retaining snap ring in the countershaft rear snap ring groove 8 Position a new gasket on the rear bearing cover mounting surface and install the rear bearing cover 9 Apply sealant adhesive and install the capscrews tighten to 35 45 Lbf ft of torque continued H 31 7 H 31 5 7 8 9 ...

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Page 137: ...and maul to drive the output shaft forward and through the rear bearing assembly 2 From the auxiliary housing rear remove the rear bearing retaining capscrews cover and gasket 3 Clean the gasket mounting surface of gasket material 4 Inspect the rear bearing cover oil seal for damage remove if damaged 5 From the auxiliary housing rear remove the bearing cup and spacer 6 From the auxiliary housing f...

Page 138: ...14 or equivalent to speedometer plug O rings cover the entire surface If the electronic sensor hole has a seal apply lubricant 71214 or equivalent covering the top surface Do not use an O ring with the seal Special Tools Typical service tools are needed Toolmaker s dye Heat lamp or hot plate and oil Oil seal installation tool To Assemble 1 Use toolmaker s dye and mark the LO range gear for timing ...

Page 139: ...tput shaft front rear bearing 7 On the output shaft position the bearing inner spacer Set aside 8 Lay the auxiliary housing front face down on a clean flat surface Install the front bearing cup 9 Install the rear bearing spacer and rear bearing race in the bearing bore 10 Place the rear bearing cup against the spacer Use a flanged end driver to move all three 3 parts evenly into the bore until the...

Page 140: ...oles 14 If previously removed use an oil seal installation tool and install the oil seal in the rear bearing cover 15 Position the rear bearing cover over the new gasket 16 Apply Eaton Fuller Sealant 71205 or equivalent to the retaining capscrews 17 On AT ATR ATS models use a new nylon collar and brass washer at the chamfered hole the hole that intersects the speedometer bore 18 Install the retain...

Page 141: ...oducts 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 accuracy and assumes no responsibility for any errors or omissions Features and functionality may vary depending on selected options For spec ing or service assistance call 1 800 826 HELP 4357 or visit www ...

Page 142: ...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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