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11. Install 1st speed gear on mainshaft, clutching

teeth down, fitting gear splines on those of
washer.

13.

14.

12. Install 2nd speed gear on mainshaft, clutching

teeth up, and against 1st speed gear.

Remove the long key from keyway in main-

shaft.

Install 2nd speed gear splined washer on main-

shaft and into hub of 2nd speed gear.

15. Install long key in keyway in mainshaft to lock

washer to shaft.

FRONT SECTION REASSEMBLY

Summary of Contents for TRSM0515

Page 1: ...Service Manual Fuller Heavy Duty Transmissions TRSM0515 October 2007...

Page 2: ...tenance Torque Recommendations Air System Precautions Disassembly Front Section Disassembly Auxiliary Disassembly Auxiliary Reassembly Front Section Reassembly Reassembly Tool Reference Changing Clutc...

Page 3: ...shing marked countershaft gear teeth with marked drive gear teeth After installing drive gear and main shaft assemblies the countershaft bearings are installed to complete countershaft installation 1...

Page 4: ...DESCRIPTION...

Page 5: ...r is familiar with motor trucks and tractors and that he can coordinate the necessary movements of the shift lever and clutch pedal to make progressive and selective gear engagements in either directi...

Page 6: ...a 6 7 8 9 or 10 speed transmission When you skip shift going up make sure to pull the range control up to high range before the shift which passes 5th Skip shifting down make sure to push the range c...

Page 7: ...f highway use I Recommended Lubricants Fahrenheit Celsius Grade Ambient Type SAE Temperature Eaton Roadranger CD50 Transmission Fluid 50 All Heavy Duty Engine 011 MIL L 2104B C or D or 50 Above 10 E 1...

Page 8: ...lubricant operating temperatures are above 230 F 110 C In addi tion transmission oil coolers are not recom mended with these gear oils since the oil cooler materials may be attacked by these gear oils...

Page 9: ...intervals Tighten filler and drain plugs securely 7 Gear Shift Lever a Check for looseness and free play in hous ing If lever is loose in housing proceed with Check No 8 8 Gear Shift Lever Housing Ass...

Page 10: ...PREVENTATIVE MAINTENANCE CHECK CHART...

Page 11: ...TORQUE RECOMMENDATIONS...

Page 12: ...Cut 7191D 7 84 TORQUE RECOMMENDATIONS...

Page 13: ...AIR SYSTEM...

Page 14: ...o the S port of air valve and to the IN port of range con trol valve With control button down the control valve is open and air passes through control valve and to the P port of slave valve This permi...

Page 15: ...m this port Cut off the vehicle air pressure and install air gauge in line at output port of air regulator Bring vehicle air pressure to normal Regulated pressure should be 57 5 to 62 5 Only as a last...

Page 16: ...ree of failure from slow shift to complete failure a Leak at seal A or B as shown in diagram re sults in failure to shift into either low or high range steady leak out air valve breather in both range...

Page 17: ...and the range shift cylinder B Installation 1 Connect the black and white 1 8 OD supply air line between the forward port on the slave air valve and the rear port on the range shift control valve 2 I...

Page 18: ...roll pin to remove the button from the slide B Reassembly and Installation 1 Refer to the drawing for proper reassembly Use a VERY SMALL amount of silicone lubricant on the O rings to avoid clogging t...

Page 19: ...er contains a replaceable filter element which can be removed by turning out the end cap and removing the spring and tension plate This element should be cleaned at each oil change or more often under...

Page 20: ...his purpose Rings removed in this manner can be reused 4 INPUT SHAFT The input shaft can be removed without removing the countershafts mainshaft or drive gear 5 CLEANLINESS Provide a clean place to wo...

Page 21: ...on of roller bearings F Gray Iron Parts 1 Check all gray iron parts for cracks and breaks Replace or repair parts found to be damaged Heavy castings may be welded or brazed providing the cracks do not...

Page 22: ...ended torque 3 O RINGS Lubricate all O Rings with silicone lubricant 4 ASSEMBLY Refer to the disassembly illustra tions as a guide to reassembly 5 INITIAL LUBRICATON Coat all thrust washers and spline...

Page 23: ...If desired the gear shift lever housing lever and range control valve can now be remov ed from the transmission as a unit by turning out the four capscrews which attach the hous ing to the transmissio...

Page 24: ...ir regulator 2 3 4 Remove street ell and reducer from regulator if necessary Turn the nipple from air regulator Turn out capscrews and remove the air regula tor and filter assembly from transmission 1...

Page 25: ...IX GEAR SHIFT LEVER HOUSING I SHIFTING CONTROLS...

Page 26: ...l at a time Remove the spring 3 Remove the washer and gear shift lever 4 Remove the spade pin or pivot pin nut and washer from the bore in the housing If necessary remove the O ring from the housing 2...

Page 27: ...sing 1 Turn out the attaching capscrews jar to break 2 Turn out the two capscrews and remove the gasket seal and lift the shifting bar housing tension spring cover from top of housing from transmissio...

Page 28: ...ews from each bar just prior to its removal 7 Move top shifting bar to the right and out of 8 housing removing shifting yoke from bar Move center bar to the right and out of hous ing removing shifting...

Page 29: ...9 Remove the actuating plunger from rear web 11 Remove the two interlock balls from front web 10 Move the lower bar to the right and out of hous ing removing shifting yoke from bar DISASSEMBLY...

Page 30: ...ve the Universal Joint Companion Flange or Yoke Lock the transmission by engaging two speeds 2 Pull the flange or yoke straight to the rear and with the mainshaft sliding clutches Use a large breaker...

Page 31: ...evenly to move the aux iliary section straight to the rear and from front section C 1 To Remove the Clutch Housing and Front Bearing Cover Remove the clutch release mechanism if so equipped 2 Remove n...

Page 32: ...g 2 Using soft bar and maul against rear of counter rings on auxiliary drive gear This will allow shaft move the assembly forward as far as movement to the rear of the countershaft and possible until...

Page 33: ...6 Using soft bar and maul against rear of counter shaft again move the countershaft as far for ward as possible to unseat front bearing from case bore 8 Use a maul and punch from inside the case to dr...

Page 34: ...put shaft to cock bearing in bore Drive input shaft toward rear of transmiss ion through bearing as far as possible Pull in put shaft forward to expose snap ring of bear ing Remove the bearing retaini...

Page 35: ...ove in ID of drive gear 8 If necessary remove bushing from pocket in clutch shaft 9 Move the drive gear to the rear and against the 4th speed gear engaging teeth of sliding clutch gear 7 Pull shaft fo...

Page 36: ...rews and remove the two bearing retainer rings from case 2 Remove the snap ring from the rear of main shaft located in bore of auxiliary drive gear 3 Tap against front of mainshaft to move the aux ili...

Page 37: ...he auxiliary drive gear assembly from case bore and from splines of mainshaft 6 Press or use driver to remove bearing from aux iliary drive gear 5 Remove snap ring from groove in auxiliary drive gear...

Page 38: ...Reverse Idler Gear 2 1 Use curved pry bar to walk bearing from idler bore in case Remove the rear idler washer and retainer from bore If necessary bend holder lugs and remove washer from holder FRONT...

Page 39: ...3 Remove reverse idler gear from case 5 Remove the front idler washer from case 4 Remove the idler bearing from reverse idler gear FRONT SECTION DISASSEMBLY...

Page 40: ...the right as far as possible and lift the mainshaft assembly from case 2 Remove the drive gear and the 4th 5th sliding clutch from mainshaft 3 Inside hub of the 4th speed gear remove snap ring from g...

Page 41: ...5 Remove the 3rd speed gear and washer 6 Remove the 2nd 3rd speed sliding clutch 7 Remove the long key from slot in mainshaft 8 Remove the 2nd speed gear and washer FRONT SECTION DISASSEMBLY...

Page 42: ...9 Remove the 1st speed gear and washer 11 Remove the reverse gear and washer 10 Remove the 1st reverse sliding clutch FRONT SECTION DISASSEMBLY...

Page 43: ...Lift the left countershaft from case 1 2 Lift the right countershaft from case Remove bearings from the left countershaft in the same manner in which bearings were removed from right countershaft See...

Page 44: ...shaft 3 Press the 4th speed gear from shaft 4 Using the rear face of the PTO gear as a base in press press the 3rd speed gear and the PTO 2nd speed gear cluster from shaft 5 If necessary remove woodru...

Page 45: ...0 A To Remove the Auxiliary Countershaft Assemblies 1 Use pullers to remove bearing from front of tailshaft 2 Turn out capscrews and remove the rear bear ing cover 3 If necessary remove the rear seal...

Page 46: ...the counters shafts forward and out of housing 6 From inside housing use long punch to move outer races of countershaft rear bearings to the rear move races approximately one half inch 8 If necessary...

Page 47: ...es 1 Turn out capscrews and remove the air cylin der cover 2 3 Use air to remove piston CAUTION DO not stand in front of cylinder opening Remove the nut and Iockwasher from air cylin der piston shaft...

Page 48: ...r ring on bench 10 Pull upward to remove the high range synchro nizer from pins CAUTION There are three springs located in housing of high range synchronizer which will be released as high range synch...

Page 49: ...y 2 Remove cylinder from housing 1 Drive or press against rear of tailshaft to move assembly forward and from rear bearing 3 Remove O ring from small bore in cylinder if necessary 2 Remove the rear wa...

Page 50: ...ve spline washer from hub of low speed gear 4 5 Move the mainshaft rear bearing to the rear and out of housing Use bearing driver to remove the countershaft rear bearings from housing AUXILIARY DISASS...

Page 51: ...ar shoulder toward rear 2 IMPORTANT Mark timing teeth on the reduc tion gear a Mark any two adjacent gear teeth on low speed gear b Then mark the two adjacent teeth which are directly opposite the fir...

Page 52: ...and against gear chamfer to the rear 7 Seat mainshaft rear bearing securely on shaft and in bore 6 Set the tailshaft with the forward end down and place auxiliary housing over rear of shaft so that sh...

Page 53: ...Cylinder 1 Install O ring in slot in small bore in cylinder Lubricate O ring with silicone lubricant 2 Install range cylinder in housing with air port in cylinder aligned with air port in top of auxil...

Page 54: ...hree springs in bores in high range synchronizer ring 1 Place the larger low range synchronizer ring face down on bench with pins up 2 Place the sliding clutch recessed side up on pins of low range sy...

Page 55: ...of the shaft Align slots in shaft with bores in Yoke hub and Place yoke in slot of sliding clutch threaded end of piston shaft is towards the larger low range synchronizer Place the entire assembly in...

Page 56: ...washer and nut on shaf to secure piston 9 E Install gasket and cylinder cover tighten the four capscrews securely To Reassemble the Countershaft Assemblies 1 Install bearing inner race on front and re...

Page 57: ...inner races into the partially installed outer races IMPORTANT Timing countershaft gears with low speed gears As the countershafts are in stalled mesh the marked low speed gear tooth on each counters...

Page 58: ...spacer on shaft and against washer If previously removed install oil seal in rear bearing cover lip of seal to the rear The spring in the seal should be toward the inside of the transmission 6 Install...

Page 59: ...all needle bearing through rear bore and in to hub of reverse gear 4 Place rear washer in holder if previously remov ed and bend lugs to secure washer 5 Place washer and holder into reverse gear case...

Page 60: ...same manner 1 If previously removed install roll pin long key and woodruff key in slots in countershaft 3 Press the 3rd speed gear on shaft 4 Press the 4th speed gear on shaft long hub to the front 2...

Page 61: ...f shaft 3 On the drive gear of each countershaft mark the gear tooth which is aligned with the keyway in shaft This tooth will be stamped with an O Place the left countershaft into position in case in...

Page 62: ...nstall rear bearing on countershaft and in case bore with flanged driver 7 Install snap ring in groove in rear bore of case D To Assemble Auxiliary Drive Gear Assembly 1 Press bearing on auxiliary dri...

Page 63: ...h speed gear splined washer is of smaller diameter 2 Install reverse gear splined washer in groove near rear of mainshaft NOTE Make sure long key is positioned with the word top on key to the outside...

Page 64: ...in the 1st GEAR and 3rd SPEED GEAR positions as shown at right Refer to the service manual covering mainshaft reassembly for method of assembling parts Reverse gear clearance must be set as low as po...

Page 65: ...from keyway in mainshaft Install 1st speed gear splined washer on main shaft at 1st speed gear location and re install the long key to lock splined washer to shaft 8 Check clearance between the two g...

Page 66: ...12 Install 2nd speed gear on mainshaft clutching teeth up and against 1st speed gear Remove the long key from keyway in main shaft Install 2nd speed gear splined washer on main shaft and into hub of 2...

Page 67: ...y upward slightly in order to fit gears to check axial clearance Correct clear splined washer over key cross pin and to fit key ante should be 005 to 012 in keyway Re position key so that cross pin re...

Page 68: ...gear splined washer on mainshaft and in hub of 4th speed gear Install snap ring in groove in mainshaft which will hold the 4th speed gear in position on shaft 23 Install the 4th 5th speed sliding clut...

Page 69: ...gs on each side of F gear Remove the assembly from vise and install the reverse gear on rear of mainshaft engaging splines of gear with those of splined washer on mainshaft To Install Mainshaft Assemb...

Page 70: ...nshaft in rear bore of case and install auxiliary drive gear on splines of mainshaft 4 Install input shaft through bore of case and onto mainshaft This will prevent the mainshaft as sembly from droppi...

Page 71: ...ck ing tangs over capscrews 9 With large screwdriver move mainshaft assem bly to rear to expose snap ring groove on rear of mainshaft Install snap ring on rear of main shaft 10 Install the input shaft...

Page 72: ...drive gear with the two marked timing teeth of the main drive gear 13 Install drive gear spacer on input shaft 12 Install snap ring in groove in I D of drive gear 14 Install drive gear bearing on inp...

Page 73: ...ar enough to cause a possible timing error in the 4th speed gear set 17 Mesh the marked timing tooth of the right countershaft drive gear with the two marked timing teeth of the main drive gear making...

Page 74: ...moved and the countershaft retimed with the main shaft The front box is properly timed if the sliding clutches can be shifted into all the mainshaft gears Note Do not shift the trans mission into two...

Page 75: ...ease on washer and on pin in upper left of case 5 Place washer and holder into reverse gear case bore holder flange to the rear 2 Install needle bearing in hub of reverse idler gear 6 Install the auxi...

Page 76: ...perfect alignment with center of case bores as the front of the auxiliary counter shafts must be inserted in these parts during aux iliary installation A heavy grease or Iubriplate will help hold wash...

Page 77: ...Yoke NOTE The auxiliary can also be installed with front section in a vertical position Place clutch housing on blocks and use chain hoist to lower auxiliary section into position 1 Lock transmission...

Page 78: ...and the speedometer gear or replacement spacer are installed on tailshaft 3 Install the companion flange on splines of tailshaft 4 Install the companion flange nut Tighten securely using the correct...

Page 79: ...utral posi tion 3 Install interlock ball in vertical bore in front web 4 Install plunger in vertical bore in rear web 5 Install the 2nd 3rd speed shift bar in center bore and install yoke on bar Iocks...

Page 80: ...reads in the hole Install first reverse shift bar in upper bore neu tral notches to the front installing yoke on bar fork to the rear Install yoke Iockscrew and safety wire 11 Remove assembly from vis...

Page 81: ...on transmis sion fitting yokes into yoke slots of correspond ing clutch gears 1 Make sure the shift bars are in the neutral posi tion 4 Install the attaching capscrews tighten securely 2 Place the sl...

Page 82: ...rews evenly and securely Actuating plunger in case fits into alignment sleeve in air valve 1 Install the actuating pin and spring in bore in transmission 4 Install the high range air line between the...

Page 83: ...slave valve B To Reassemble and Install the Air Regulator and Filter Assembly 6 Install air line between output port of air regula tor and the tee in supply port of air valve 5 Install the air regula...

Page 84: ...es and 6 Install the black nylon air line from the OUT port of control valve to the airport marked P in hexagonal end cap of air valve 7 Install the white nylon air line from the IN port of control va...

Page 85: ...ial tools which are needed consist mostly of snap ring pliers Listed below are the illustrations which show these tools PAGE TOOL HOW OBTAINED 38 45 74 Snap ring pliers large Tool Supplier 37 69 Snap...

Page 86: ...from splines of drive gear Reassembly Install bushing in new input shaft 1 Install new input shaft into splines of drive gear just far enough to expose snap ring groove in ID of drive gear 2 Install...

Page 87: ......

Page 88: ...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...

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