Eaton UltraShift PLUS FM-14E310B-LAS Service Manual Download Page 82

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2018.12.12

VCS/VMS Combination Cylinder Disassembly and Assembly

Service Procedures

TRSM0940

Remove the Range and Reduction Pistons from the
cylinder bores

Inspect the Range and Reduction Piston O-Rings for
damage. Remove and replace if damage is present.

Inspect the O-ring inside the Range Cylinder Housing,
remove and replace if damaged.

Summary of Contents for UltraShift PLUS FM-14E310B-LAS

Page 1: ...y 2019 Linehaul Active Shifting LAS Vocational Active Shifting VAS Multipurpose Extreme Performance MXP Multipurpose High Performance MHP Vocational Construction Series VCS Vocational High Performance VHP Vocational Multipurpose Series VMS Vocational Extreme Performance VXP ...

Page 3: ...0C VAS FO 10E308LL VCS FO 11E308LL VCS FO 12E308LL VCS FO 14E308LL VCS FO 16E308LL VCS FO 17E308LL VCS FO 16E313A VHP FO 18E313A VHP FO 20E313A VHP FO 10E309ALL VMS FO 11E309ALL VMS FO 12E309ALL VMS FO 14E309ALL VMS FO 16E309ALL VMS FO 17E309ALL VMS FO 14E313B MHP FO 16E313B MHP FO 18E313B MHP FO 20E313B MHP FO 14E318B MXP FO 16E318B MXP FO 18E318B MXP FO 20E318B MXP FO 22E318B MXP FO 18E318A VXP ...

Page 4: ......

Page 11: ...tion 130 Shift Bar Housing Removal and Installation 132 Shift Bar Housing Disassembly and Assembly 134 Main Case Disassembly and Lubrication Tube Removal 140 Oil Pump and Lube Tube Installation 149 Main Case Main Shaft Disassembly with Low Force Gearing 164 Main Case Main Shaft Assembly with Low Force Gearing 170 Main Case Main Shaft without Low Force Gearing Disassembly 176 Main Case Main Shaft A...

Page 12: ...heels Warning When parking vehicle or leaving cab Place shift lever in Neutral Set parking brake Caution Follow specified procedures in indicated order to avoid equipment malfunction or damage Caution Do not release parking brake or attempt to select a gear until air pressure is at correct level Caution To avoid damaging the transmission during tow ing Place shift lever in Neutral Lift drive wheel...

Page 13: ...n Below the Component Identifica tion diagram is a numerical listing for each part with the part name Appendix This section contains information such as Operation Lubri cation Specifications Inspection in base box manuals Power Flow in base box manuals Air System Operation and Troubleshooting in base box manuals General Trou bleshooting in base box manuals Tool Specifications Torque Specifications...

Page 14: ...ral Information TRSM0940 Transmission Overview Transmission Top View 1 Input Shaft Speed Sensor 2 X Y Shifter 3 Gear Position Sensor 4 Rail Position Sensor 5 Range Solenoid Valve 6 Air Filter Regulator 7 Output Shaft Speed Sensor 8 Main Shaft Speed Sensor 1 2 3 4 5 6 7 8 ...

Page 15: ...aton All rights reserved 4 TRSM0940 General Information Transmission Overview Transmission Side View 1 Electronic Clutch Actuator ECA Speed Sensor 2 Transmission Electronic Control Unit TECU 3 Transmission Harness 1 2 3 ...

Page 16: ...al Information TRSM0940 Driver Instruction Manual Complete operation instructions can be found in the Driver Instruction Manual TRDR1110 Transmission Front View 1 Release Yoke and Cross Shaft Assembly 2 Electronic Clutch Actuator ECA 3 Low Capacity Inertia Brake LCIB 1 2 3 ...

Page 17: ...on tag Model Number The model number gives basic information about the trans mission and is explained below Use this number when call ing for service assistance or replacement parts Serial Number The serial number is the sequential identification number of the transmission Before calling for service assistance write the number down as it may be needed Bill of Material or Customer Number This numbe...

Page 18: ...ar of the transmission Upper Countershaft Internal lubrication pump driven off the PTO gear and can be plumbed to an external oil cooler Power Take Off PTO Usage PTOs can be mounted in two ways 6 or 8 Bolt The 6 or 8 bolt openings are standard with the transmis sion The PTO is mounted to the opening and driven from the PTO gear on the front Counter Shaft Thru Shaft The Thru Shaft PTO mounts on the...

Page 19: ...r gear set is timed in the auxiliary section Front Section 1 Clearly mark the tooth located directly over the drive gear keyway as shown prior to placing each Counter Shaft assembly into the case This tooth is stamped with an O to aid identification 2 Mark any two adjacent teeth on the Main Drive Gear 3 Mark the two adjacent teeth located directly oppo site the first set marked on the Main Drive G...

Page 20: ...bly low range gear stamped with O prior to placing each Auxiliary Counter Shaft assembly into the housing 3 Repeat the procedure on each Auxiliary Counter Shaft Reduction Gear 4 To time the Auxiliary Counter Shafts find the O at the rear bearing and place a straight edge from the O up to the front and mark the gear tooth See Service Bulletin TMIB0150 for further timing instructions Note Timing mar...

Page 21: ... Bearing Check relative position of thrust surface of Release Bearing with thrust sleeve on push type clutches 4 Lubricant Change at specified service intervals Use only the types and grades as recommended See Manual TCMT0021 Roadranger Lubricant Prod ucts 5 Filler and Drain Plugs Remove filler plugs and check level of lubricant at specified intervals Tighten fill and drain plugs securely 6 Cap Sc...

Page 22: ...ng Important See the appropriate Illustrated Parts List speci fied by model series to ensure that proper parts are used during assembly of the transmission Disassembly Precautions General Information It is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission the nec essary linkage and vehicle air lines disconnected and the transmission has been re...

Page 23: ...Auxiliary Section Removal and Disassembly In Chassis Special Instructions The following procedure covers the removal and disassem bly of the Auxiliary section with the transmission remaining in the chassis If the transmission is removed from the truck refer to the LAS VAS Auxiliary Section Removal and Disassembly on page 15 Special Tools None ...

Page 24: ...erved 2018 12 12 LAS VAS Auxiliary Section Removal and Disassembly In Chassis Service Procedures TRSM0940 Component Identification 1 Wiring Harness 2 Auxiliary Case Bolts x19 3 Auxiliary Main Shaft Retaining Flange and Yoke 2 3 1 ...

Page 25: ...the way 4 Disconnect the Wiring Harness from the Range Sole noid Valve and speed sensor 5 If any OEM equipment needs to be removed refer to the OEM for guidelines 6 Remove the 19 bolts securing the Auxiliary Section to the Transmission 7 Put the removal jack in place and secure to the Auxil iary Section 8 Slowly remove the Auxiliary Section from the Main Case and the dowel pins 9 Once the Auxiliar...

Page 26: ...2TR Counter Shaft Support Tools Component Identification 1 Auxiliary Drive Gear 2 Synchronizer Assembly 3 Reduction Gear 4 Washer 5 Spacer 6 Auxiliary Main Shaft 7 Auxiliary Counter Shaft 8 Spacer 9 Bearing 10 Race 11 Auxiliary Case 12 Auxiliary Counter Shaft Cover 13 Auxiliary Main Shaft Bearing Set 14 Gasket 15 Bearing Cover 16 Seal 17 Dust Shield 18 Speed Rotor Assembly 19 Output Yoke Retainer ...

Page 27: ...hat fasten the Output Yoke to the Output Shaft 2 Remove the Output Yoke from the Output Shaft a maul or hammer may be required to apply force to the yoke for removal LAS VAS Auxiliary Section Removal 1 Remove both Auxiliary Counter Shaft Bearing Covers Note Mark the covers to indicate which position they are in as they will need to be reinstalled in the same location ...

Page 28: ...bolts 3 out of the 4 bolts for the Auxiliary Counter Shaft Bearing Covers Use the longer bolts to secure the cen ter of each strap as this will ensure the Auxiliary Counter Shafts will remain in time 3 Remove the 19 bolts that fasten the Auxiliary Section to the Transmission Main Case Note Remove the Range Cylinder Assembly if needed in order to remove all Auxiliary Case bolts ...

Page 29: ...ry Section Removal and Disassembly 4 Using prying points separate the Auxiliary Section from the Transmission Main Case enough to fit the Auxiliary Section Lifting Bracket into place 5 Using an overhead crane or hoist remove the Auxiliary Section with the Auxiliary Section Lifting Bracket ...

Page 30: ...that fasten the Output Shaft Bearing Cover to the Auxiliary Section remove the Out put Shaft Bearing Cover 2 Remove the cap screws that fasten the Range Cover to the Range Cylinder Remove the Range Cover 3 Remove the single cap screw that fasten the Range Piston to the Range Shift Yoke Bar 4 Remove the Range Cylinder assembly Caution Auxiliary Counter Shafts will fall out part way through this pro...

Page 31: ...utput Shaft out of the case 6 As the Auxiliary Main Shaft is driven out remove the Synchronizer assembly and the Range Yoke 7 Remove the bearing cup and outer spacer from the Auxiliary Case bore 8 Using the front face of the low range gear as a base press the Output Shaft through the gear and bearing Remove the bearing and washer from the hub of the Auxiliary Reduction Gear Note If reusing the bea...

Page 32: ...2 LAS VAS Auxiliary Section Removal and Disassembly Service Procedures TRSM0940 9 Remove the splined spacer and stepped washer from the Auxiliary Reduction Gear Range Synchronizer Disassembly 1 Remove the Range Synchronizer from the Output Shaft ...

Page 33: ...tion Removal and Disassembly 2 Place the Low Range Synchronizer on a bench with the larger ring facing down place a shop towel over the assembly to avoid losing any springs pull the High Range Synchronizer from the Blocker Ring 3 Remove the Sliding Clutch from the pins of the Syn chronizer Ring ...

Page 34: ...SM0940 Range Synchronizer Assembly 1 Install the Sliding Clutch on the Blocker Pins with the recessed side up 2 Install the three springs into the bores of the High Range Synchronizer Ring 3 Place the High Range Synchronizer Ring over the Blocker Pins of the Low Range Synchronizer seating the springs against the pins ...

Page 35: ...ly downward pressure to the High Range Synchro nizer Ring while twisting counterclockwise to com press the springs and fully seat the ring on the Blocker Pins of the Low Range Synchronizer 5 Install the Synchronizer assembly on the splines of the Auxiliary Main Shaft with the Synchronizer seated against the Range Reduction Gear ...

Page 36: ...l x 4 diameter Component Identification 1 Auxiliary Drive Gear 2 Synchronizer Assembly 3 Reduction Gear 4 Washer 5 Spacer 6 Auxiliary Main Shaft 7 Auxiliary Counter Shaft 8 Spacer 9 Bearing 10 Race 11 Auxiliary Case 12 Auxiliary Counter Shaft Cover 13 Auxiliary Main Shaft Bearing Set 14 Gasket 15 Bearing Cover 16 Seal 17 Dust Shield 18 Speed Rotor Assembly 19 Output Yoke Retainer Flange 4 1 2 3 5 ...

Page 37: ...liary Section Assembly 1 Place Output Shaft on bench with yoke end facing up 2 Install the stepped washer onto the backside of the Auxiliary Reduction Gear 3 Install the splined spacer into the clutching teeth of the Auxiliary Reduction Gear 4 Install the Auxiliary Reduction Gear onto the Output Shaft with the clutching teeth facing down ...

Page 38: ...k any two teeth 180 degrees apart on the Range Reduction Gear using a highly visible dye 6 Place the inner bearing longer rollers tapered side up over the Auxiliary Main Shaft 7 Drive the bearing down to the Auxiliary Reduction Gear using the Output Shaft Bearing Driver 8 Slide the bearing spacer down on top of the inner bear ing ...

Page 39: ... Installation and Timing 1 If previously removed install the bearings onto the rear of each Counter Shaft 2 On each Auxiliary Counter Shaft assembly use a highly visible color of dye to mark the valley between the two gear teeth of each auxiliary Counter Shaft assembly low range gear stamped with O for timing purposes Note The O may be behind the washer and bearing on the rear of the Counter Shaft...

Page 40: ... with a 4 inner diameter PVC pipe is recommended 4 Move the upper and lower Counter Shafts into place on the Range Reduction Gear lining up the timing marks previously made 5 Position the Range Shift Yoke on the Range Synchro nizer Sliding Clutch with the shaft aligned above the lower Counter Shaft 6 Install the double bearing race into the Auxiliary Case with the race flange out 7 Before installi...

Page 41: ...to the Auxiliary Case 10 Install the Auxiliary Counter Shaft Support Straps to hold the Counter Shafts in place Note Hold the Counter Shafts from spinning while tightening Auxiliary Counter Shaft Support Straps fail ure to do this could allow Counter Shafts to come out of time with the Range Reduction Gear 11 Place the outer Auxiliary Shaft Bearing over the shaft with the tapered side down short r...

Page 42: ...Apply lube to the o ring on the Range Shift Fork Shaft and Range Cylinder O ring install the Range Cylinder 14 Apply lube to the Range Piston O ring install piston into the Range Cylinder Install the Range Piston cap screw and torque to 20 25 lb ft 15 If the Main Case gearing does not need to be serviced attach the Auxiliary Section Lifting Bracket to the top of the Auxiliary Case ...

Page 43: ... the Auxiliary Case forward until it is as far for ward as possible Remove the Auxiliary Section Lifting Bracket 18 Push Auxiliary Section flush with the Transmission Main Case and install cap screws Torque cap screws to 40 45 lb ft Note If Auxiliary Case does not come flush with the Transmission Main Case with minimal force this could indicate an issue with Auxiliary gearing timing Note If Auxili...

Page 44: ...nug 2 Install new gasket between the Main Case and Auxiliary Case 3 Using a transmission jack and support bracket lift the Auxiliary Case assembly and line up the two holes in the Auxiliary Case with the Transmission Main Case alignment pins Push the case forward toward the Transmission Main Case Note Verify the Auxiliary Counter Shafts are still timed to the Auxiliary Reduction Gear before instal...

Page 45: ...e flush with the Transmission Main Case a timing issue with the Auxiliary Section gearing may be the cause 5 Install the 16 cap screws that fasten the Auxiliary Sec tion to the Transmission Main Case Torque bolts to 35 45 lb ft LAS VAS Auxiliary Counter Shaft Shimming 1 Remove the Auxiliary Counter Shaft Support Straps and install a 0 100 shim between the cover and Auxil iary Counter Shaft Use two...

Page 46: ...r to pick a shim that will allow for end play of within 0 001 0 005 Note Example 0 042 of feeler gauges fit in between Auxiliary Case and the Auxiliary Counter Shaft Bearing Cover Subtract 0 042 from 0 100 which equals 0 058 A shim of 0 052 0 055 would be required for the 0 003 0 005 end play If the required thickness shim does not exist use the closest undersized shim 4 Install required shim into...

Page 47: ... None Special Tools None Component Identification 1 Air Filter Regulator Bolts x2 2 Air Filter Regulator 3 Range Cylinder Cover Bolts x4 4 Range Cylinder Cover and Range Solenoid Valve 5 Range Solenoid Valve Cover 6 Range Cylinder Piston Bolt 7 Range Cylinder Piston 8 Range Cylinder Piston O ring 9 Range Cylinder O ring 10 Range Cylinder Bolts x4 11 Range Cylinder 2 3 1 4 5 6 7 8 9 10 11 ...

Page 48: ...efore disconnecting the air sup ply line to the Air Filter Regulator 2 Disconnect the air lines and mark lines that go to the Range Cylinder low and high side fitting 3 Remove the Air Filter Regulator 4 Disconnect the Transmission Harness from the Range Cylinder Actuator 5 Remove the 4 bolts that hold the range cover and range cylinder to the auxiliary case Remove the cover ...

Page 49: ...LAS VAS Model Rebuild In Chassis 6 Remove the retaining bolt for the Range Cylinder Pis ton 7 Remove the Range Cylinder and piston from the Auxil iary Case 8 Remove the piston from the Range Cylinder 9 Inspect for cut O rings rust or debris in the cylinder scoring and blocked air passages ...

Page 50: ...1 Install a new gasket on the Range Cylinder to seal against the Auxiliary Case Clean off any remaining debris from the old gasket 2 Install the Range Cylinder in the bore Make sure the cylinder is positioned so that the concave corner is in the top right This allows for proper access to the bolt that secures the Auxiliary Case to the Main Case ...

Page 51: ...e Yoke Bar Lube with silicone 4 Install the Range Piston into the cylinder and onto the yoke bar 5 Torque the bolt 35 45 lb ft 6 Install a new gasket between the Range Cylinder and the Range Cylinder Cover Note Verify that the small air passage is located at the bottom to align properly with the cover 7 Install the Range Cylinder Cover and 4 bolts Torque bolts 30 35 lb ft ...

Page 52: ...ansmission Harness to the Range Cyl inder Actuator 9 Install the Air Filter Regulator and torque bolts 8 12 lb ft 10 Install the air lines to the Range Cover as marked and connect the air supply lines to the Air Filter Regulator 11 Verify all the work is done correctly Air up the truck and verify operation of the Transmission Range Sys tem ...

Page 53: ...sembly In Chassis Special Instructions The following procedure covers the removal and disassem bly of the Auxiliary Section with the transmission remaining in the chassis If the transmission is removed from the truck refer to the VCS VMS Auxiliary Section Removal and Disassembly on page 44 Special Tools RR1002TR Counter Shaft Support Tools Support jack Component Identification ...

Page 54: ...ul to mark the covers to indicate which position they are in as they will need to be reinstalled in the same location 7 Install Auxiliary Counter Shaft Support straps with 2 3 8 NC x 1 and 1 3 8 NCx1 1 2 clean capscrews Use the longer bolts to secure the center of each strap as this will ensure the Auxiliary Countershafts will remain in time Note Do not use an air gun Tighten by hand until the scr...

Page 55: ...VMS Auxiliary Section Removal and Disassembly VCS VMS Auxiliary Section Removal and Disassembly Special Instructions None Special Tools RR1006TR Auxiliary Section Hanger RR1002TR Counter Shaft Support Tools Soft bar Maul Press Hoist with lifting chain ACM Alignment Pins P N XXXX ...

Page 56: ...mbly 3 Sliding Clutch 4 Synchronizer Assembly 5 Nut 6 Dowel Pin 7 Washer 8 Washer 9 Reduction Gear 10 Bushing 11 Mainshaft Assembly 12 Pin 13 Sliding Clutch 14 Mainshaft 15 Washer 16 Deep Reduction Gear 17 Washer 18 Output Yoke Retainer Flange 19 Hex Flange Head Screw 20 Tapered Roller Bearing 21 Universal Joint Yoke 1 2 3 18 4 5 6 7 8 9 10 11 12 13 14 15 10 12 19 16 17 20 21 ...

Page 57: ...e for removal Auxiliary Section Removal 1 Remove both Auxiliary Counter Shaft Bearing Covers Note It is helpful to mark the covers to indicate which position they are in as they will need to be reinstalled in the same location 2 Install Auxiliary Counter Shaft Support straps with 2 3 8 NC x 1 and 1 3 8 NCx1 1 2 clean capscrews Use the longer bolts to secure the center of each strap as this will en...

Page 58: ...ary section hanger RR1006TR into place Note If unable to free Auxiliary section use the two 2 longest bolts from the Auxiliary Case housing and insert them into the housing flange tapped holes Tighten bolts evenly to move the Auxiliary Section away from the front box Tighten until the gasket seal is broken 5 Using an overhead crane or hoist remove the Auxiliary Section with the auxiliary section h...

Page 59: ...linder Cover to the Auxiliary Main case Remove the Range Cover 2 Remove the 15 16 3 4 nuts that fasten the Range and Reduction Pistons to the Range and Reduction shift Yoke bars 3 Remove the Combination Cylinder assembly Note For Combination Disassembly and Assembly see 4 Prepare the Auxiliary Section to remove the Auxiliary Counter Shafts For ease of disassembly mount the Auxiliary Section uprigh...

Page 60: ...g or equivalent between the splitter gear and one counter shaft 6 Using a soft bar and maul drive the Output Shaft for ward far enough to partially unseat the bearing 7 Support the Auxiliary Countershaft and remove the strap from the rear of the Auxiliary Case Housing 8 As the counter shaft straps are removed the Counter Shaft can fall 9 Repeat process to remove 2nd Auxiliary Counter Shaft 10 Remo...

Page 61: ...n Removal and Disassembly 11 If necessary secure the Countershafts in a vise and remove both the front and rear bearings from the shafts with a bearing separator and jaw pullers 12 Remove the 1 nut retainer that was loosened in step 6 13 Remove the washer and dowel pin from the Auxiliary Mainshaft ...

Page 62: ...bly and assembly of the Synchro nizer please refer to the How to disassemble the Synchronizer Assembly section 15 Remove the Low Range Gear and Coupler Assembly 16 Using a punch and hammer drive the two coupler pins from the front of the coupler Align the coupler splines with the washer splines and remove the range coupler from the Low Ranger Gear Reduction Gear 17 Remove the bushings from inside ...

Page 63: ...gn the Splined Washer along the Coupler Shaft Remove the Coupler from the Range Gear and Washer 19 Remove the splined washer from inside the Low Range Gear Reduction Gear 20 Remove the sliding clutch and Deep Reduction Yoke Assembly 21 Using a soft bar and maul drive the Output Shaft for ward and through the Rear Bearing Assembly ...

Page 64: ... screws that fasten the Output Shaft bearing cover tot eh Auxiliary Section 23 Remove the Output Shaft bearing cover 24 Inspect the Rear Bearing Cover oil seal for damage Remove if damage is found 25 Remove the rear portion of the tapered bearing which should be free sitting in the race in the case Also remove the one piece race from it s bore ...

Page 65: ... Assembly Disassembly 1 Remove the bearing inner spacer from the Output Shaft 2 Using the Deep Reduction Gear front as a base press the Output Shaft through the bearing and gear Note If reusing the bearing set the tapered roller bear ings are specific to each side of the race 3 Remove the spacer and stepped washer from the Deep Reduction Gear ...

Page 66: ...sing To assist in the assembly of the Auxiliary Section you can make an Auxiliary section fixture out of a 2 by 12 piece of wood This fixture is designed to ease the assembly of the auxil iary gearing Set the Auxiliary Countershaft front bearings in the 3 holes Set the assembled Auxiliary Mainshaft between the countershafts with the timing marks aligned Special Tools Bearing Drivers Maul PVC Pipe ...

Page 67: ... Regulator Bolts x2 2 Air Filter Regulator 3 Range Cylinder Cover Bolts x4 4 Range Cylinder Cover and Range Solenoid Valve 5 Range Solenoid Valve Cover 6 Range Cylinder Piston Bolt 7 Range Cylinder Piston 8 Range Cylinder Piston O ring 9 Range Cylinder O ring 10 Range Cylinder Bolts x4 11 Range Cylinder 1 2 3 18 4 5 6 7 8 9 10 11 12 13 14 15 10 12 19 16 17 20 21 ...

Page 68: ...l the clutch from the front of the shaft 2 Prepare the Low Range Gear for timing Mark any tooth on the gear and repeat on the tooth directly opposite of the first marked 3 On the Low Range Gear Coupler install the bushings if removed 4 Install the Low Range Gear Reduction Gear over the Coupler 5 With the splined washer facing up place the washer in ID of the Low Range Gear Rotate the washer so tha...

Page 69: ...ote Make sure pins are installed below coupler thrust surface 7 Position the Low Range Gear Reduction Gear on the Output Shaft with the coupler facing forward on the shaft 8 Install the dowel pin on the shaft 9 Position retainer washer on the front of the shaft 10 Install retainer nut on the front of the shaft If reusing nut apply locking compound to the threads New nuts should have a pre applied ...

Page 70: ...xiliary Section Assembly and Installation Service Procedures TRSM0940 11 Flip the Mainshaft so that it is sitting with the forward section down 12 Install the stepped washer over the Auxiliary Mainshaft with the stepped side up facing the rear of the shaft ...

Page 71: ... timing Mark any tooth on the gear and repeat on the tooth directly opposite of the first marked 14 Install the Deep Reduction Gear over the Auxiliary Mainshaft with the clutching splines facing towards the front of the shaft Line up the marked teeth on both the Low Range Gear and the Deep Reduction Gear 15 Apply grease to Deep Reduction Gear rear thrust sur face ...

Page 72: ...her 17 Select the front tapered Output Bearing bearing with longer rollers With the tapered side up use heat or a small punch to install the Output Shaft Rear Bearing Note A Bearing Driver can also be used to seat the bearing however if using a bearing driver install the Bearing inner spacer prior to driving to avoid getting the driver stuck on the shaft ...

Page 73: ...Assembly and Installation 18 Install the Bearing Inner Spacer on the Output Shaft 19 Lay the Auxiliary Mainshaft Assembly on its side 20 Apply light coating of transmission lubricant to the sur face of the synchronizer assembly 21 Install the Synchronizer Assembly on the Auxiliary Mainshaft Assembly ...

Page 74: ...Use a straight edge to line up the marked teeth with the teeth on the remaining two 2 countershaft gears Paint these teeth 2 Position the two Auxiliary Countershaft assemblies on a clean flat surface Position the shafts so that the painted timing teeth are facing inward towards each other Note To ease in the assembly and timing procedure Use a fixture similar to the one outlined at the begin ning ...

Page 75: ... on a clean flat surface Install the Bearing Race in the Bearing Bore 7 Position the Auxiliary Case Housing over the Counter shaft and Auxiliary Mainshaft Assemblies Note Ensure the inner spacer is installed on the Auxil iary Mainshaft 8 Install the rear Auxiliary Mainshaft bearing with the tampered side forward Use heat or a bearing driver to fully seat the bearing 9 Position a new Output Bearing...

Page 76: ...tall the Auxiliary Countershaft support straps RR1002TR with 2 3 8 NC x 1 and 1 3 8 NC x 2 clean capsrews Note Do not torque with an air gun Tighten only to hand tight 14 Apply lube to the o rings on the Combination Cylinder and the yoke bars for the Range and Reduction 15 Position a new gasket on the Combination Cylinder mounting surface Install the Combination Cylinder 16 Apply lube to the Range...

Page 77: ...nting surface Install the Combination Cylinder Cover Apply Eaton Sealant 71205 or equivalent to the five 5 retaining cap screws and torque to 35 45 lb ft 20 Attach the Auxiliary Section lifting bracket to the top of the Auxiliary Case 21 Position a new Auxiliary Case Gasket on the mounting surface of the Main Case 22 Install the Auxiliary Case Assembly onto the transmis sion Main Case dowel pins U...

Page 78: ...d 2018 12 12 VCS VMS Auxiliary Section Assembly and Installation Service Procedures TRSM0940 23 Apply Eaton Sealant 71205 or equivalent to the 19 retaining cap screws Secure the Auxiliary Section to the main case Torque to 35 45 lb ft ...

Page 79: ...n Lubricant or equivalent to Shift Cylinder Assembly and insert valve O Rings so a film covers the entire surface of each O Ring The same Installation and Removal procedures can be fol lowed for both the range and reduction valves of the Combi nation Cylinder Assembly The Range and Reduction Valves may be difficult to remove from the Transmission Housing because of the O rings Special Tools Typica...

Page 80: ...n 1 Yoke Assembly 2 Yoke Assembly 3 Cylinder 4 Gasket 5 O Ring 6 Piston 7 O Ring 8 O Ring 9 Nut 10 O Ring 11 Piston 12 O Ring 13 Nut 14 Combination Cylinder Cover 15 O Ring 16 Hex Screw 17 Hex Screw 18 Cylinder Cover Gasket 19 Pipe Plug 20 Range Splitter Valve 21 Hex Flange Head Screw 22 O Ring 1 2 3 4 5 6 7 9 8 14 16 10 15 11 12 13 21 20 22 17 18 19 ...

Page 81: ...n Cylinder Disassembly and Assembly VCS VMS Combination Cylinder Disassembly 1 On the Combination Cover remove the five 5 cap screws cover and gasket 2 Remove the 15 16 nut that secures the range yoke bar 3 Remove the 3 4 nut on the reduction yoke bar 4 Remove the cylinder housing and gasket ...

Page 82: ...nd Assembly Service Procedures TRSM0940 5 Remove the Range and Reduction Pistons from the cylinder bores 6 Inspect the Range and Reduction Piston O Rings for damage Remove and replace if damage is present 7 Inspect the O ring inside the Range Cylinder Housing remove and replace if damaged ...

Page 83: ...mbination Cylinder Assembly VCS VMS 1 Install the small O Ring in the Range and Reduction cylinder housing bores Lightly lubricate O rings with Eaton silicone lubricant 71206 or equivalent 2 Install the Range and Reduction Piston O rings on the pistons I D and O D Lightly lubricate O rings with Eaton silicone lubricant 71206 or equivalent ...

Page 84: ...ion back with the Range Cylinder upward Insert the Range piston with flat side to rear Push it as far back as far as it will go 5 Secure the Range piston with the 15 16 retaining nut torque to 70 85 lb ft 94 91 115 24 N m 6 Insert the Reduction piston with flat side to rear Push it as far back as far as it will go 7 Secure the Range piston with the 3 4 retaining nut torque to 50 65 lb ft Note If r...

Page 85: ...res VCS VMS Combination Cylinder Disassembly and Assembly 8 Install a new gasket on the Cylinder Housing Cover mounting surface and install the Combination cylinder cover Apply Eaton Sealant 71205 or equivalent to the five 5 retaining cap screws and torque to 35 45 lb ft ...

Page 86: ... reserved 2018 12 12 VCS VMS Combination Valve Removal and Installation Service Procedures TRSM0940 VCS VMS Combination Valve Removal and Installation Special Instructions None Special Tools None Component Identification None ...

Page 87: ... hous ing 5 Do not use a hammer to loosen the Combination Valve or it could be damaged Combination Valve Installation 1 If equipped remove the protective cover by pulling up on the release tab Important Follow each procedure closely in the detailed instructions Be sure to make use of the text illustrations and photographs provided 2 Relieve system air pressure by draining air tanks on the vehicle ...

Page 88: ...ction Removal and Disassembly Service Procedures TRSM0940 MHP MXP VHP VXP Auxiliary Section Removal and Disassembly Special Instructions None Special Tools RR1006TR Auxiliary Section Hanger RR1002TR Counter Shaft Support Tools Soft bar Maul Press ACM Alignment Pins P N XXXX ...

Page 89: ... Identification 1 Rotor Assembly 2 O Ring 3 Oil Seal 4 Capscrew 5 Rear Bearing Cover Assembly 6 Gasket 7 Capscrew 8 Capscrew 9 Cover 10 Gasket 11 Shim 12 Gasket 13 Rear Housing 14 Yoke 1710 Half Round 15 Lifting Eye 16 Capscrew 17 Capscrew 18 Directional Speed Sensor 19 Plug 20 Shield 4 6 3 7 5 2 1 9 8 10 11 12 13 14 15 16 17 18 19 20 4 19 ...

Page 90: ...0 Output Yoke Removal 1 Remove the two bolts that fasten the output Yoke to the output shaft 2 Remove the Output Yoke from the Output Shaft A maul or hammer may be required to apply force to the yoke for removal Auxiliary Section Removal 1 Remove the 4 9 16 cap screws on the Range Cylinder Cover 2 Remove the Range Cover Assembly ...

Page 91: ...oval and Disassembly 3 Remove the 4 1 2 cap screws retaining the Splitter Cylinder Cover 4 Remove the Splitter cylinder cover 5 Remove both Auxiliary Counter Shaft Bearing Covers Note It is helpful to mark the covers to indicate which position they are in as they will need to be reinstalled in the same location ...

Page 92: ...he longer bolts to secure the center of each strap as this will ensure the Auxiliary Counter shafts will remain in time 7 Remove the 19 bolts that fasten the Auxiliary Section to the Transmission Main Case 8 Using a pry bar to assist separate the Auxiliary Section from the transmission main case enough to fit the aux iliary section hanger RR1006TR into place Note It may be necessary to drive the d...

Page 93: ...oval and Disassembly 9 Using an overhead crane or hoist remove the Auxiliary Section with the auxiliary section hanger Auxiliary Section Disassembly 1 Too ease in the disassembly of the Auxiliary Section Place in a vise 2 Remove the 15 16 nut that fastens the Range Cylinder Assembly to the range shift Yoke bar ...

Page 94: ...ion Removal and Disassembly Service Procedures TRSM0940 3 Remove the two 3 4 cap screws that secure the Range Yoke Bar to the Range Yoke Fork 4 Using a soft maul drive the Range Yoke Bar towards the rear of the auxiliary case Remove the piston once relieved from cylinder bore ...

Page 95: ...Remove the 3 4 Lock Nut on the Splitter Yoke Bar 7 Remove the Splitter Sliding Clutch and Splitter Yoke bar and fork 8 Remove the Splitter Cylinder Assembly 9 Prepare the Auxiliary Section to remove the Auxiliary Counter Shafts For ease of disassembly mount the Auxiliary Section upright in a vise Caution As the counter shaft straps are remove the Counter Shaft can fall ...

Page 96: ...ove the cap screw Note To prevent the counter shafts from turning place a shop rag or equivalent between the splitter gear and one counter shaft 11 Using a soft bar and maul drive the Output Shaft for ward far enough to partially unseat the bearing 12 Support the Auxiliary Countershaft and remove the strap from the rear of the Auxiliary Case Housing 13 Repeat process to remove 2nd Auxiliary Counte...

Page 97: ...secure the Countershafts in a vise and remove both the front and rear bearings from the shafts with a bearing separator and jaw pullers 16 Remove the 15 16 cap screw and retainer bolt that was loosened in step 9 17 Remove the splitter gear from the Output Shaft Note For disassembly and assembly of the Splitter Gear assembly please refer to the Splitter Gear Bear ing Disassembly and Assembly MHP MX...

Page 98: ...d assembly of the Syn crhonizer please refer to the How to disassemble the Sychronizer Assembly section 19 Using a soft bar and maul drive the Output Shaft for ward and through the Rear Bearing Assembly 20 Remove the six cap screws that fasten the Output Shaft bearing cover to the Auxiliary Section 21 Remove the Output Shaft bearing cover 22 Inspect the Rear Bearing Cover oil seal for damage Remov...

Page 99: ...ould be free sitting in the race in the case Also remove the one piece race from it s bore Auxiliary Mainshaft Disassembly 1 Remove the bearing inner spacer from the Output Shaft 2 Using the Auxiliary Mainshaft Assembly Gear front as a base press the Output Shaft through the bearing and gear Note If reusing the bearing set the tapered roller bear ings are specific to each side of the race ...

Page 100: ...17 Eaton All rights reserved 2018 12 12 MHP MXP VHP VXP Auxiliary Section Removal and Disassembly Service Procedures TRSM0940 3 Remove the splined spacer and stepped washer from the Auxiliary Reduction Gear ...

Page 101: ...sions the Auxiliary section requires R R prior to Range Cylinder removal Damage to internal components will result if Auxiliary Sec tion is not properly removed prior to Cylinder removal During installation apply Eaton Lubricant or equivalent to Shift Cylinder Assembly and insert valve O Rings so a film covers the entire surface of each O Ring Special Tools Typical Service Tools Component Identifi...

Page 102: ...ervice Procedures TRSM0940 Range Cylinder Disassembly 1 On the Range Cylinder Cover remove cap screws cover and gasket 2 Remove the 15 16 nut that secures the range yoke 3 Remove the Range Piston from the cylinder bore 4 Inspect the Range Piston O Rings for damage Remove and replace if damage is present ...

Page 103: ...P MXP VHP VXP Range Cylinder Disassembly and Assembly 5 Remove the 2 cap screws that secure the Range Yoke Bar to the Range Yoke 6 Remove the Range Yoke Bar 7 Remove the Range cylinder housing 8 Inspect the O ring inside the Range Cylinder Housing remove and replace if damaged ...

Page 104: ...the small O Ring in the cylinder housing bore 2 Install the piston O rings on the piston I D and O D 3 Install a new gasket on the Range Cylinder Housing Mounting Surface 4 Install the Cylinder housing into the Auxiliary Case Housing 5 Install Range Yoke Bar from the rear of the Auxiliary case Note Ensure that the Yoke Bar passes through the eye of the Yoke fork ...

Page 105: ...roves on the Yoke Bar and install the 2 retaining bolts through the bores on the Range Yoke Fork 7 Insert the piston pushing it as far back as far as it will go 8 Secure the piston with the retaining nut torque to 70 85 lb ft 94 91 115 24 N m 9 Install a new gasket on the Cylinder Housing Cover mounting surface Install the Range cylinder cover ...

Page 106: ...ghts reserved 2018 12 12 MHP MXP VHP VXP Range Cylinder Disassembly and Assembly Service Procedures TRSM0940 10 Apply Eaton Sealant 71205 or equivalent to the retain ing cap screws and torque to 20 25 lb ft 27 12 33 90 N m ...

Page 107: ...ction is not properly removed prior to Cylinder removal During removal if replacing only the O Rings in the Splitter Cylinder Auxiliary Section removal is not necessary During installation apply Eaton Lubricant or equivalent to Shift Cylinder Assembly and insert valve O Rings so a film covers the entire surface of each O Ring During installation apply Eaton rust preventative 71213 or equivalent to...

Page 108: ...bly Service Procedures TRSM0940 Component Identification 1 Splitter Yoke Assembly 2 Gasket 3 Splitter Cylinder 4 O Ring 5 Piston 6 O Ring 7 Nut 8 O Ring 9 Gasket 10 Splitter Cylinder Cover 11 Pipe Plug 12 Capscrew 13 O Ring 14 Hex Flange Head Screw 15 Solenoid Valve 1 11 12 2 3 4 5 6 7 8 9 10 13 14 15 ...

Page 109: ...r Disassembly and Assembly Splitter Cylinder Removal 1 Ensure transmission is drained of oil 2 Remove retaining cap screws from the Splitter Cylinder Cover 3 Remove cover and gasket 4 Remove 3 4 nut on the Splitter Yoke Bar 5 Remove the Splitter Cylinder Housing from the rear of the Auxiliary Case Housing ...

Page 110: ...te If spool valve needs to be replaced it must be done as an entire unit which is part of splitter cover Splitter Cylinder Assembly 1 Install the Splitter Sliding Clutch on the Splitter Yoke Fork and engage into the Splitter Gear to maintain posi tion 2 Install small O ring in the Cylinder Housing Bore if pre viously removed 3 On the Piston O D install the Piston O ring if previ ously removed ...

Page 111: ...nstall O Ring on the end of the yoke bar inside of the Cylinder Housing 6 Install the O ring on the ID and OD of the piston 7 Install Piston into the bore of the Range Cylinder Install with the flat side of the piston facing rearward 8 Position new gasket on the Cylinder Housing Cover mounting surface and install the Splitter Cylinder Cover Note Ensure that the gasket air passage aligns with the h...

Page 112: ...s reserved 2019 07 11 MHP MXP VHP VXP Splitter Cylinder Disassembly and Assembly Service Procedures TRSM0940 9 Apply Eaton Sealant 71205 or equivalent to the retain ing cap screws and install on the cover Torque to 20 25 lb ft ...

Page 113: ...HP MXP VHP VXP Splitter Gear Bearing Disassembly and Assembly MHP MXP VHP VXP Splitter Gear Bearing Disassembly and Assembly Special Instructions Make sure to use proper drivers for the bearing and sleeve Special Tools 3 30 Diameter Bearing Driver Component Identification None ...

Page 114: ...P Splitter Gear Bearing Disassembly and Assembly Service Procedures TRSM0940 Splitter Gear Bearing Disassembly 1 Remove the internal coiled snap ring 2 Remove the Tapered Bearing Pack Assembly using bearing driver RR1012TR 4 3 Separate the Bearing Pack Assembly ...

Page 115: ...04 TRSM0940 Service Procedures MHP MXP VHP VXP Splitter Gear Bearing Disassembly and Assembly Splitter Gear Bearing Assembly 1 Install the Front Bearing Race 2 Install the bearing spacer 3 Install Bearing assembly 4 Install the Rear Bearing Race ...

Page 116: ...l rights reserved 2018 12 12 MHP MXP VHP VXP Splitter Gear Bearing Disassembly and Assembly Service Procedures TRSM0940 5 Drive the bearing into place using the bearing driver RR1012TR 4 6 Install the internal snap ring ...

Page 117: ...Maul PVC Pipe RR1002TR Auxiliary Countershaft Support Straps Component Identification 1 Sliding Clutch 2 Screw 3 Retainer 4 Splitter Gear 5 Tapered Roller Bearing 6 Bearing Sleeve 7 Snap Ring 8 Spring 9 Synchronizer Assembly 10 Sliding Clutch 11 Synchronizer Assembly 12 Mainshaft 13 Washer 14 Reduction Gear 15 Spacer 16 Tapered Roller Bearing 17 Output Yoke 18 Hex Flange Screw 19 Universal Joint Y...

Page 118: ...tooth on the gear and repeat on the tooth directly opposite of the first marked 2 With the splined washer facing up place the washer on the Output Shaft shoulder 3 Position the Reduction Gear on the Output Shaft with the clutching teeth facing down Engage the washer splines to fully position the gear 4 Position the Reduction Gear Rear Washer on the Out put Shaft with the chamfer side up against th...

Page 119: ... on the shaft 6 Install the Bearing Inner Spacer on the Output Shaft Set aside once installed Synchronizer Assembly and Splitter Gear Installation 1 Lay the Auxiliary Mainshaft Assembly on its side 2 Install the Synchronizer Assembly on the Auxiliary Mainshaft Assembly Note Apply light coating of transmission lubricant to the surface of the synchronizer assembly Note For Synchronizer Assembly Disa...

Page 120: ...0940 4 Install the Splitter Gear on the Output Shaft Note For Splitter Gear Disassembly and Assembly see the section Splitter Gear Bearing Disassembly Assembly in this manual 5 Install the Splitter Gear retainer and 15 16 cap screw Torque to 190 210 lb ft 257 61 284 72 N m Note Ensure proper torque is applied to the retainer bolt ...

Page 121: ...a 2 x 12 piece of wood This fixture is designed to ease the assembly of the Auxil iary gearing Set the Auxiliary Countershaft Front bearings in the 3 holes to maintain the gearing positions when com bining with the Auxiliary Mainshaft Assembly Set the Assembled Auxiliary Mainshaft between the Countershafts with the timing marks on all 3 sets of gearing aligned Special Tools RR1002TR Auxiliary Coun...

Page 122: ...sembly vertical on a clean flat surface If the countershaft bearings were removed use the proper bearing driver and maul to reinstall the Countershaft Bearings 2 Mark each Countershaft for correct timing On each countershaft there is a 0 stamped on the counter shaft Mark the corresponding tooth with a highly visi ble paint pen Also mark the Splitter Gear mating gears on each countershaft ...

Page 123: ...are towards the middle 4 Align the Auxiliary Mainshaft Assembly so the timing marks on the Reduction Gear match up with the timing marks on the 2 Auxiliary Countershafts Also align the timing marks on the splitter gear to match time 5 Install Range Yoke into the Synchronizer Sliding Slot Note Ensure the Range Yoke offset side is facing down 6 Lay the Auxiliary Case Housing front on a clean flat su...

Page 124: ...xiliary Housing over the Countershaft Assemblies and the Auxiliary Mainshaft Assembly 8 Ensure the rear Auxiliary Mainshaft bearing spacer is installed on the shaft 9 Heat the Rear Auxiliary Mainshaft Bearing cone and install the bearing tapered side down on the shaft 10 Position a new gasket on the Rear Bearing Cover and install the cover ...

Page 125: ... the retain ing cap screws and install the six 6 cap screws in the non chamfered holes Torque to 35 45 lb ft 47 45 61 01N m 12 Install the Auxiliary Countershaft Bearing Races 13 Install each Auxiliary Countershaft Retaining Strap with 2 3 8 NC x 1 NC and 1 3 8 NC x 2 1 2 clean cap screws Note Do not use an air gun on strap bolts Tighten by hand until cap screws are snug ...

Page 126: ...inder Mounting Surface of the Auxiliary Case 3 Install the Range Cylinder through the Range Cylinder Bore on the Auxiliary Case housing Position the Range Yoke Fork inside the open section of the cylinder 4 Install Range Yoke Bar from the rear of the Auxiliary case Note Ensure that the Yoke Bar passes through the eye of the Yoke fork 5 Align the 2 groves on the Yoke Bar and install the 2 retaining...

Page 127: ...lat side of the piston facing rearward 8 Secure the piston with the retaining nut torque to 70 85 lb ft 94 91 115 24 N m Splitter Cylinder Installation 1 With the Auxiliary Section still in the vice Position the Splitter Sliding Clutch on the Splitter Yoke fork and bar Engage into the Splitter Gear to maintain its position 2 Install small O ring in the Cylinder Housing Bore if pre viously removed ...

Page 128: ...Auxiliary Case Housing bore Install the Splitter Cylinder 4 Install new O rings on the ID and OD of the piston Lubricate with silicone 5 Install new O ring on the end of the yoke bar inside of the cylinder housing 6 Install the piston into the Splitter Cylinder with the recessed side facing the rear of the transmission 7 Secure piston with the 3 4 lock nut Torque to 30 36 lb ft 41 49N m ...

Page 129: ... Auxiliary Section lifting bracket to the top of the Auxiliary Case 2 Position a new Auxiliary Case Gasket on the mounting surface of the Main Case 3 Install the Auxiliary Case Assembly onto the transmis sion Main Case dowel pins Using the Output Shaft wiggle the auxiliary case forward until it is as far for ward as possible Remove the auxiliary section lifting bracket ...

Page 130: ...mming and Installation 1 Remove the Auxiliary Countershaft support straps and install a 0 100 shim between the cover and Auxiliary Countershaft Use two of the counter shaft bearing cover bolts and torque bolts to 7 lb in Spin the Output Shaft multiple times to assist in seating the bearing races Ensure cap screws are still torqued at 7 lb in 2 Using feeler gages measure the gap between the Aux ili...

Page 131: ...ing cover Subtract 0 042 from 0 100 which equals 0 058 A shim of 0 052 0 055 would be required for the 0 003 0 005 end play If the required thickness shim does not exist use the closest undersized shim 4 Install required shim into bearing bore Install new Auxiliary Countershaft gaskets and install Auxiliary Countershaft Covers Range and Splitter Cylinder Cover Installation 1 Position new gasket on...

Page 132: ...P VXP Auxiliary Countershaft Installation Service Procedures TRSM0940 Output Yoke Installation 1 Install the Output Yoke Ensure yoke is properly seated against Output Shaft 2 Secure the Output Yoke with the 2 retaining bolts Torque to 84 92 lb ft 113 124 N m ...

Page 133: ...prings under pressure from the HI Range Syn chronizer Pin locations Perform assembly on a clean flat surface slightly lower than your waist Pins on the LO range synchronizer must line up with the chamfered holes on the sliding clutch bottom When compressing the HI range synchronizer springs cover with a shop rag This will prevent the springs from leaving the area if compression is not achieved Spe...

Page 134: ...bly and Assembly Service Procedures TRSM0940 Range Synchronizer Disassembly 1 Place the low range synchronizer on a bench with the larger ring facing down place a shop towel over the assembly to avoid losing any springs 2 Grab both sides of the HI Range Synchronizer and pull ...

Page 135: ...24 TRSM0940 Service Procedures Range Synchronizer Disassembly and Assembly 3 Remove the sliding clutch from the pins of the syn chronizer ring Range Synchronizer Assembly 1 Install the Sliding Clutch on the blocker pins with the recessed side up ...

Page 136: ...springs against the pins 4 Cover with shop rag and apply downward pressure to the HI range synchronizer ring while twisting counter clockwise to copress the springs and fully seat the ring on the blocker pins of the LO range Synchronizer Note To prevent losing springs it is helpful to cover the synchronizer with a shop rag as downward pres sure is applied 5 Install the synchronizer assembly on the...

Page 137: ...emoval and Installation Input Shaft Removal and Installation Special Instructions None Special Tools RR1023TR Input Shaft Bearing Puller RR1019TR Hand Maul RR1005TR Input Shaft Bearing Driver Component Identification 1 Input Shaft 2 Bearing Cover 3 Input Bearing 4 Input Snap Ring 1 2 3 4 ...

Page 138: ... If present remove and discard the rubber seal on the Input Shaft This rubber seal is only used to seal the Transmission during shipment 3 Remove the snap ring from the Input Shaft 4 Using a soft maul drive the Input Shaft towards the rear of the Transmission Case as far as possible Pull the Input Shaft forward 5 Install the Input Shaft Bearing Remover and remove the bearing from the Transmission ...

Page 139: ...Main Drive Gear 8 Inspect the Input Shaft Bushing replace if damaged Input Shaft Installation 1 If necessary complete installation of the Input Shaft Bushing 2 Install the Input Shaft into the Main Drive Gear splines 3 Install the snap ring that retains the Input Shaft to the Main Drive Gear 4 Install the Input Shaft Bearing onto the Input Shaft Note The external snap ring on the Input Shaft Beari...

Page 140: ...ll the Input Shaft Bearing into the Transmission Main Case until the snap ring groove is fully visible 6 Install the Input Shaft snap ring 7 Install the Front Bearing Cover and gasket Make sure the oil return and gasket line up with the oil return hole in the Main Case 8 Install the Front Bearing Cover and gasket torque the six cap screws to 35 45 lb ft ...

Page 141: ...ce Procedures Clutch Housing Removal and Installation Clutch Housing Removal and Installation Special Instructions None Special Tools None Component Identification 1 Main Case 2 Stud 3 Gasket 4 Clutch Housing 5 Cap Screws x6 6 Washers x6 7 Nuts x6 3 5 6 7 2 1 4 ...

Page 142: ...ase 3 Remove the Clutch Housing from the Transmission Main Case Clutch Housing Installation 1 Make sure the Clutch Housing and Main Case surfaces are clean Install a new Clutch Housing gasket on the Main Case side 2 Install the Halo Tube assembly into the case 3 Install the Clutch Housing 4 Put the 6 nuts and washers on the mounting studs and install the bolts into place 5 In a cross pattern seque...

Page 143: ...reserved 132 TRSM0940 Service Procedures Shift Bar Housing Removal and Installation Shift Bar Housing Removal and Installation Special Instructions None Special Tools None Component Identification 1 X Y Shifter 2 Shift Bar Housing 1 2 ...

Page 144: ...r Housing Installation 1 Ensure all Transmission Main Case Main Shaft Sliding Clutches are in their Neutral position 2 Ensure that the Main Case and Shift Bar Housing gas ket surfaces are clean and free of debris 3 Position a new Shift Bar Housing gasket on the surface of the main case 4 Install the Shift Bar Housing onto the Transmission Main Case 5 Install the 16 cap screws that fasten the Shift...

Page 145: ...omponent to ensure proper part replacement 1 Detent Cap Assembly 2 Ball and Spring 3 Reverse Plunger 4 Shift Bar Housing 5 Cap Screws x16 6 Actuator Assembly 7 Neutral Switch Interlock 8 Air Valve Shaft 9 Reverse LO Shift Yoke 10 Lock Screws 11 Reverse LO Shift Rail 12 Direct Overdrive Shift Yoke 13 1st 2nd Shift Yoke 14 1st 2nd Shift Rail 15 Steel Balls x2 16 1st 2nd Shift Block 17 Direct Overdri...

Page 146: ...on a flat workspace The front of the housing facing to the left 4 Cut and remove the lock wire from the Shift Bar retain ing cap screws Note Start with the upper Shift Bar move all bars to the right and out the rear boss bore 5 Remove Shift Bar retaining cap screws 6 Move the 4th 5th Gear Shift Bar to the housing rear removing the yoke and block from the bar 7 Move the 2nd 3rd Gear Shift Bar to th...

Page 147: ...ousing Disassembly and Assembly 9 Move the short 1st Reverse Gear Shift Bar to the hous ing rear removing the yoke from the bar 10 Remove the actuating plunger from the center boss bore 11 Tilt the Shift Bar Housing on its side to remove the two 3 4 interlock balls from the housing bore ...

Page 148: ... used on vise teeth if used to avoid damaging the Shift Bar Housing gasket surface 4 Install the actuating plunger in the center boss bore 5 Install one 3 4 interlock ball in the rear boss top bore This ball rides between the 1st Reverse and 2nd 3rd Gear Shift Bars Note Coating the 3 4 interlock balls with grease will help keep them in place in the bores 6 While holding the notched end of the bar ...

Page 149: ...he rear boss bar install the small interlock pin vertically in the Neu tral notch bore 9 Install the block and yoke Sock screws tighten and lock wire securely 10 Install the second 3 4 interlock ball in the rear boss top bore This ball rides between the 2nd 3rd and the 4th 5th Shift Bars 11 Install the 4th 5th Gear Shift Bar in the housing boss upper bore 12 Position the shift block on the bar bet...

Page 150: ...and yoke lock screws tighten and lock wire securely 14 After all lock screws and safety wire have been installed flip the Shift Bar Housing over 15 Install the three tension balls and springs into the bores on the top of the Shift Bar Housing 16 Install the Detent Spring Caps over the springs in each bore thread in and torque 12 15 lb ft ...

Page 151: ...rication Tube Removal Main Case Disassembly and Lubrication Tube Removal Special Instructions None Special Tools None Component Identification 1 Upper Idler Lubricant Tube 2 Auxiliary Lubricant Tube 3 Idler Feed Lubricant Tube 4 Halo Lubricant Tube 5 Upper Counter Shaft 6 Main Shaft 7 Lower Counter Shaft ...

Page 152: ... screws fastening the Input Shaft Bearing Cover to the Transmission Main Case 2 Remove the Input Shaft snap ring from the Input Shaft 3 Remove Holo Lubrication Tube 4 Remove the snap ring holding the Auxiliary Drive Gear to the Main Shaft remove the Auxiliary Drive Gear 5 Remove the six cap screws fastening the bearing retainer ring to the Main Case intermediate wall ...

Page 153: ...n Main Case 7 Use a rolling head pry bar Crow s foot to work the Main Shaft Bearing from the Main Case intermediate wall 8 Remove the spiral lock from the front of the upper Reverse Idler using a small screwdriver to pry it from the groove 9 Using a soft bar drive the Reverse Idler Shaft out from its bore in the case Note When driving the shaft out of position the washers that are on either side o...

Page 154: ...ounter Shaft Rear Bearing 11 Using a soft bar drive the rear Counter Shaft Bearing out from the intermediate wall and off of the upper Counter Shaft 12 Remove the front Counter Shaft Bearing bolt and retainer using a 15 16 socket 13 Using the K Line soft maul with hand guard strike the case to the left of the front Counter Shaft Bearing to drive it out of the bore ...

Page 155: ... wire to pull it away from the Main Shaft 15 Slide the Reverse Gear as far to the rear of the case as possible Using a flat head screw driver remove the snap ring by working it out of the I D of the gear Note When removing the snap ring the tension of the snap ring can cause the ring to spring out 16 Remove the Keyed Washer from back of the Reverse Gear 17 Move the Reverse Gear forward against 1st...

Page 156: ...ove the Main Shaft as far towards the back of the case as possible Lift the front of the Main Shaft out and swivel the Main Shaft out of the Main Case Note Use caution when lifting the Main Shaft from the Main Case as the Reverse Gear can move freely If low force gearing is present the 1st Rev hub as well as the Reverse gear will move freely 21 Remove the snap ring from the rear lower Counter Shaf...

Page 157: ...nd guard strike the case to the right of the front lower Counter Shaft Bearing to remove it from the bore Main Drive Gear and Input Shaft Removal 1 Using the K Line tools Input Bearing Puller remove the Input Shaft Bearing Note Input Shaft may also be driven through the bear ing using a soft hand maul 2 With the upper Counter Shaft still pushed as far toward the case as possible remove the Input S...

Page 158: ...tion Tube Removal Service Procedures TRSM0940 3 Using the K Line J hook RR1004TR remove the upper and lower Counter Shafts from the Transmission Main Case Main Drive Gear and Input Shaft Removal 1 Remove the two bolts fastening the Main Feed Tube assembly to the Transmission Case ...

Page 159: ...assembly from the Oil Pump and swivel the assembly out of the case while guiding it through the intermediate wall 3 Straighten the lock on the Suction Strainer Unseat from the pump and remove the Suction Strainer from the Main Case 4 Remove the three bolts fastening the Oil Pump to the Transmission Main Case and remove the Oil Pump 5 Remove the Oil Pump Cover from the front of the Transmission Mai...

Page 160: ...ll rights reserved 2018 12 12 Oil Pump and Lube Tube Installation Service Procedures TRSM0940 Oil Pump and Lube Tube Installation Special Instructions None Special Tools None Component Identification 1 Suction Strainer ...

Page 161: ...he Transmission Main Case torque bolts to 8 12 lb ft Lubrication Tubes Installation 1 Install the Suction Strainer into the Transmission Main Case push the tube into the Oil Pump until the tab is flush against the Oil Pump After the Suction Strainer has been installed secure the strainer by pushing down the tube lock 2 Install the Main Feed Tube into the Transmission Main Case Note The tube needs ...

Page 162: ...es TRSM0940 3 Install the two cap screws securing the Main Feed Tube to the Transmission Main Case Main Case Gear Timing and Assembly 1 Using the O stamped onto the rear of the Main Case Counter Shafts mark the corresponding tooth on the Main Drive Gear set front gear with highly visible ink or dye ...

Page 163: ...ing both directions around the gear Main Case Counter Shaft Installation 1 Using a J hook install the lower Counter Shaft into the Transmission Main Case Note Place the back of the lower Counter Shaft into the rear Counter Shaft Bearing bore and carefully swing the Counter Shaft into place 2 Using a J hook install the upper Counter Shaft into the Transmission Main Case Note Place the back of the u...

Page 164: ...ing that retains the Input Shaft to the Main Drive Gear Place one corner of he snap ring in the Main Drive Gear groove With a small screwdriver slowly work around the Input Shaft until the snap ring is fully seated 5 Install the Input Shaft and Main Drive Gear as an assembly into the Transmission Main Case Note Counter Shaft Bearings must not be installed to complete the installation 6 Install the...

Page 165: ...ut Shaft assembly back out Continue driving the bearing onto the Input Shaft Repeat this process until there is enough room to install the Input Shaft snap ring 8 Install the Input Shaft snap ring 9 Line up the marked tooth on the lower Counter Shaft with the two marked teeth on the Main Drive Gear 10 Using the rear Counter Shaft Bearing Driver RR1012TR 4 drive the rear bearing onto the lower Coun...

Page 166: ...12 Using the bearing driver RR1012TR 2 install the front lower Counter Shaft Bearing onto the Counter Shaft and into the bore of the Transmission Main Case Note Using an old race for the front Counter Shaft Bearings helps keep the rollers in place during installation 13 Install the front lower Counter Shaft Bearing retaining washer and bolt and torque to 90 120 lb ft ...

Page 167: ... by placing the rear of the Main Shaft through the opening in the intermediate wall and lowering the front of the Main Shaft into place Pull the Main Shaft forward and pilot the tip into the Input Shaft Bushing Note Reverse Gear needs to be tucked into 1st Gear over the 1st Reverse Sliding Clutch during installa tion to ensure adequate room to position the Main Shaft Caution The front sliding clut...

Page 168: ...re the lower Counter Shaft is still in time with the Main Drive Gear before moving the upper Counter Shaft into place 18 Using the rear Counter Shaft Bearing Driver RR1012TR 4 drive the rear bearing onto the upper Counter Shaft and into the intermediate wall of the Transmission Main Case until there is enough room to install the rear Counter Shaft Bearing snap ring 19 Install the rear upper Counte...

Page 169: ...ring installation 21 Install the front lower Counter Shaft Bearing retaining washer and bolt and torque to 90 120 lb ft 22 Install the upper Reverse Idler Shaft into the bore in the intermediate wall Pilot the shaft through the first thrust washer and into the idler gear Once the shaft has cleared the bore of the gear pilot the shaft through the second thrust washer 23 Using a soft bar and soft ma...

Page 170: ...se as possible Note Placing a hand maul in between the 1st and Reverse Gear will assist in keeping the Reverse Gear in position 26 Install the keyed washer into the Reverse Gear The washer should rest on the upper edge of the snap ring groove of the Reverse Gear Note When installing the washer can drop in front of the gear and rest on the Main Shaft 27 Install the Reverse Gear snap ring place one ...

Page 171: ...crews torque the six cap screws to 35 45 lb ft Note Ensure the Retainer Ring is installed in the proper direction The inner grove should fit over the bearing 30 Install the Auxiliary Drive Gear onto the Transmission Main Case Main Shaft 31 Install the Auxiliary Drive Gear snap ring Note If the snap ring will not fit into the groove verify that the Main Shaft is pulled to the rear of the Trans miss...

Page 172: ... in the front of the Transmission Main Case until all O rings are fully seated 34 Install the Front Bearing Cover and gasket Important Confirm the oil return path from the Front Bearing Cover and the gasket return port are aligned 35 Install the six cap screws that fasten the Front Bearing Cover to the Transmission Main Case Torque the cap screws to 35 45 lb ft ...

Page 173: ...are snug 2 Install new Gasket on the Main Case 3 Using an overhead crane lift the Auxiliary Case assem bly and line up the two holes in the Auxiliary Case with the Transmission Main Case alignment pins Push the case forward toward the Transmission Main Case Note Verify the Auxiliary Counter Shafts are still timed to the Auxiliary Reduction Gear before installing This will allow for easier installa...

Page 174: ...ully seating the Auxiliary Section to the Trans mission Main Case should take light force do not draw it in with bolts If the Auxiliary Section will not come flush with the Transmission Main Case a timing issue with the Auxiliary Section gearing may be the cause 5 Install the 19 cap screws that fasten the Auxiliary Sec tion to the Transmission Main Case Torque bolts to 35 45 lb ft 6 Install requir...

Page 175: ...mbly with Low Force Gearing Special Instructions None Special Tools None Component Identification 1 Main Shaft 2 Roll Pin 3 Main Shaft Key 4 Snap Ring 5 Reverse Gear 6 Spacer 7 Main Shaft Sleeve 8 1st Gear 9 Washer 10 2nd Gear 11 3rd Gear 12 OD Gear 13 Sliding Clutch 14 Washer 15 Sliding Clutch 16 Sliding Clutch 15 14 12 9 11 16 10 8 9 13 1 3 2 4 5 6 7 9 9 9 ...

Page 176: ...Service Procedures TRSM0940 Main Case Main Shaft Disassembly with Low Force Gearing 1 Remove the front 4th and 5th Gear Sliding Clutch from the Main Shaft 2 From the rear of the Main Shaft remove the Reverse Gear 3 Remove the 1st and Reverse Sliding Clutch and hub 4 Remove Snap Ring that retains the key ...

Page 177: ... spacers note their location on the Main Shaft to facilitate reas sembly Keep each washer with the corresponding gear it was mated against 6 Remove the 1st stepped no burn washer from the Main Shaft Note There are two types of washers used on the Main Shaft The stepped washers left fit between gears and sliding clutches with the stepped edge facing the slid ing clutch The flat no burn washers fit ...

Page 178: ... Shaft Disassembly with Low Force Gearing Service Procedures TRSM0940 7 Remove the 1st Gear from the Main Shaft 8 Remove the 2nd stepped no burn washer from the Main Shaft 9 Remove 2nd Gear from the Main Shaft 10 Remove the 3rd stepped washer from the Main Shaft ...

Page 179: ...edures Main Case Main Shaft Disassembly with Low Force Gearing 11 Remove the 2nd 3rd Gear Sliding Clutch 12 Remove the 4th no burn washer and 3rd Gear 13 Remove the 5th flat no burn washer from the Main Shaft 14 Remove 4th Gear 5th for direct drive from the Main Shaft ...

Page 180: ...ce Procedures TRSM0940 15 Remove the last stepped no burn washer from the Main Shaft Note The last or furthest forward no burn washer is smaller than the rest This is specific for the front of the Main Shaft as the 4th 5th Gear Sliding Clutch is smaller than the 1st Reverse and 2nd 3rd Gear Slid ing Clutches ...

Page 181: ...y with Low Force Gearing Special Instructions None Special Tools None Component Identification 1 Main Shaft 2 Roll Pin 3 Main Shaft Key 4 Snap Ring 5 Reverse Gear 6 Spacer 7 Main Shaft Sleeve 8 1st Gear 9 Washer 10 2nd Gear 11 3rd Gear 12 OD Gear 13 Sliding Clutch 14 Washer 15 Sliding Clutch 16 Sliding Clutch 15 14 12 9 11 16 10 8 9 13 1 3 2 4 5 6 7 9 9 9 ...

Page 182: ... TRSM0940 Main Case Main Shaft Assembly with Low Force Gearing 1 Place the Main Shaft vertical and hold the noise in a vise or a pilot hole in a piece of wood 2 Install the first stepped washer The stepped edge should be facing down so that it contacts the 4th 5th sliding clutch Rotate the washer to lock it into place ...

Page 183: ...ve to lock the no burn washers in place as the Main Shaft is built 4 Install the Overdrive Gear or Direct Drive Gear depending on the model of the transmission and the no burn washer Rotate the washer and push the air line through 5 Install the 3rd Gear and stepped washer Rotate the no burn washer and push the air line through 6 Install the 2nd 3rd Sliding Clutch Make sure the wide slot on the sli...

Page 184: ...nd push the air line through 8 Install 2nd Gear and the no burn washer Rotate the no burn washer and push the air line through 9 Install 1st gear and stepped washer Rotate the no burn washer and push the air line through 10 Install the Main Shaft Key through the slot were the 5 32 air line sits by pushing the air line out with the key until it is seated against the role pin ...

Page 185: ...aton All rights reserved 174 TRSM0940 Service Procedures Main Case Main Shaft Assembly with Low Force Gearing 11 Install the snap ring that retains the main shaft key 12 Install the sliding clutch hub and sliding clutch ...

Page 186: ...RSM0940 13 Install the Reverse Gear on the Main Shaft and slide it over the sliding clutch with the snap ring groove facing rearward for installation 14 Remove the Main Shaft assembly from the holding device Flip the Main Shaft up and install the Direct Overdrive Sliding Clutch with the wide slot aligned with the keyway ...

Page 187: ... Disassembly Special Instructions None Special Tools None Component Identification 1 Input Bearing 2 4 5 Sliding Clutch 3 Main Shaft Washers x6 4 5th Gear 5 3rd Gear 6 2 3 Sliding Clutch 7 2nd Gear 8 Main Shaft Key 9 Main Shaft 10 1st Gear 11 1 R Sliding Clutch 12 Reverse Gear 13 Washer 14 Spacer 15 Snap Ring 16 Auxiliary Bearing 16 15 14 13 12 10 9 8 3 7 5 3 4 3 2 1 3 3 6 11 3 ...

Page 188: ...and 5th Gear Sliding Clutch from the Main Shaft 2 From the rear of the Main Shaft remove the key from the Main Shaft keyway Note When removing no burn washers or spacers note their location on the Main Shaft to facilitate reas sembly Keep each washer with the corresponding gear it was mated against 3 Remove the rear spacer from the Main Shaft 4 Remove the Reverse Gear from the Main Shaft ...

Page 189: ...ain Case Main Shaft without Low Force Gearing Disassembly 5 Remove the 1st Reverse Gear Sliding Clutch from the Main Shaft 6 Remove the 1st stepped washer and 1st Gear from the Main Shaft 7 Remove the 2nd no burn washer from the Main Shaft 8 Remove 2nd Gear from the Main Shaft ...

Page 190: ...haft without Low Force Gearing Disassembly Service Procedures TRSM0940 9 Remove the 3rd stepped washer from the Main Shaft 10 Remove the 2nd 3rd Gear Sliding Clutch 11 Remove the 4th stepped washer and 3rd Gear 12 Remove the 5th no burn washer from the Main Shaft ...

Page 191: ...e Main Shaft 14 Remove the last stepped washer from the Main Shaft Note There are 2 types of washers on the Main Shaft stepped and no burn The no burn washers are flat on both sides while the stepped washers on one side and have a raised edge or step on the other The stepped washers should have the stepped side contacting the sliding clutches and the flat side contacting the gear ...

Page 192: ...ions None Special Tools None Component Identification 1 Input Bearing 2 4 5 Sliding Clutch 3 Main Shaft Washers x6 4 5th Gear 5 3rd Gear 6 2 3 Sliding Clutch 7 2nd Gear 8 Main Shaft Key 9 Main Shaft 10 1st Gear 11 1 R Sliding Clutch 12 Reverse Gear 13 Washer 14 Spacer 15 Snap Ring 16 Auxiliary Bearing 16 15 14 13 12 10 9 8 3 7 5 3 4 3 2 1 3 3 6 11 3 ...

Page 193: ...tepped side facing down so it will contact the 4th 5th sliding clutch 3 Use a piece of 5 32 air line to push up through the key way groove to lock the stepped and no burn washers in place as the Main Shaft is built 4 Install the Overdrive Gear or Direct Drive Gear depending on the model of the transmission and the no burn washer Rotate the washer and push the air line through 5 Install the 3rd Gea...

Page 194: ...with the keyway 7 Install the stepped washer Rotate the stepped washer and push the air line through 8 Install 2nd Gear and the no burn washer Rotate the no burn washer and push the air line through 9 Install 1st Gear and the stepped washer Rotate the stepped washer and push the air line through 10 Install the 1st Reverse Sliding Clutch Align the wide slot on the sliding clutch with the keyway ...

Page 195: ... the larger reverse washer Rotate the washer and push the air line through 12 Install the key and push the air line down through the Main Shaft until it contacts the roll pin 13 Install the Reverse Gear on the Main Shaft and slide it over the sliding clutch with the snap ring groove facing rearward for installation ...

Page 196: ...18 12 12 Main Case Main Shaft Assembly Service Procedures TRSM0940 14 Remove the Main Shaft assembly from the holding device Flip the Main Shaft up and install the Direct Overdrive Sliding Clutch with the wide slot aligned with the keyway ...

Page 197: ...finity If it is not remove the switch and recheck it for continuity Replace as necessary 4 Place the Transmission Shift Lever in the Reverse posi tion If the switch is working properly the ohm meter should register continuity or a small reading If it does not remove the switch and recheck it for continuity Replace as necessary Also check for the presence of the Reverse Pin Reverse Switch Removal 1...

Page 198: ...gnet and check it for excessive wear If it is worn replace it Reverse Switch Installation 1 Insert the Reverse Pin in the Reverse Switch bore The Reverse Pin is longer than the Neutral Pin 2 Install the gasket on the switch 3 Install the Reverse Switch Torque to 15 20 lb ft 20 27 N m 4 Connect the OEM wiring connector making sure the locking tab engages properly ...

Page 199: ...nd Installation Electronic Clutch Actuator ECA Removal and Installation Special Instructions If vehicle is equipped with an 8 bolt PTO removal may be required prior to removing the ECA Follow PTO manufac turer s guidelines for removal Special Tools Basic hand tools Component Identification 1 ECA 2 ECA Cap Screw 2 1 ...

Page 200: ...ECA Removal Warning Ensure the Hand Hole Cover is closed when removing the ECA 1 Disconnect the negative battery cable 2 Disconnect the 8 way and 3 way connectors from the ECA Note Some models do not use a shield 3 Remove the 4 cap screws from the ECA Shield and remove shield 4 Remove the 4 cap screws from the ECA mounting flange ...

Page 201: ...ing Place the included jackscrews into the holes Turn each jackscrew until it touches Next turn the upper jack screw 1 turn then rotate the lower jackscrew 1 turn Continue until the ECA is fully displaced from the bore ECA Installation 1 Install the ECA into the Clutch Housing bore Align it with the lower Cross Shaft Note The ECA will have to be rotated to align with the slot in the Clutch Housing...

Page 202: ...to the specified torque 3 If applicable install the 4 cap screws for the ECA Shield Tighten them to 35 45 lb ft 47 61 N m 4 Apply NyoGel to terminals and reconnect the 8 way and 3 way connectors to the ECA Note Apply just enough material to cover the end of the terminal Note Use only Eaton lubricant part number 5564527 Nye Lubricants NYOGEL 760G For MSDS safety or other information see www nyelubr...

Page 203: ... Procedures Low Capacity Inertia Brake LCIB Removal and Installation Low Capacity Inertia Brake LCIB Removal and Installation Special Instructions None Special Tools Basic hand tools Component Identification 1 Mounting Nuts x2 2 Low Capacity Inertia Brake LCIB 1 2 ...

Page 204: ...IB 1 Remove the 2 mounting nuts with a breaker bar and socket 2 Remove the LCIB by hand by sliding off of the splined Input Shaft LCIB Installation 1 Slide the LCIB onto the splined Input Shaft while cen tering the holes onto the retaining studs 2 Install the 2 retaining nuts and torque nuts to 140 150 lb ft 190 203 N m Note The LCIB can only be installed one way The label is toward the right side...

Page 205: ...t s Removal and Installation Release Yoke and Cross Shaft s Removal and Installation Special Instructions None Special Tools Basic hand tools Component Identification 1 Plug 2 O ring 3 Upper Cross shaft 4 Bushing 5 Seal 6 Lock Washer 7 Mounting Screw 8 Release Yoke 9 Lower Cross shaft 1 2 3 4 5 6 7 8 9 ...

Page 206: ...al Note The Transmission and ECA must be removed prior to removing the Release Yoke and Cross Shaft s 1 Remove the upper and lower Cross Shaft mounting cap screws and lock washers from the Release Yoke 2 Remove the Cross Shaft Plug with O ring 3 Push the upper Cross Shaft up out of the Release Yoke and remove the Yoke 4 Remove the lower Cross Shaft and Release Yoke ...

Page 207: ...tion 5 Remove the upper Cross Shaft Seal assembly 6 If necessary remove the 2 upper Cross Shaft Bush ings Release Yoke and Cross Shaft s Installation 1 If previously removed install the 2 upper Cross Shaft Bushings Note Make sure to apply grease to the bushings 2 If previously removed install the upper Cross Shaft Grease Seal ...

Page 208: ...into the bore 4 Slide yoke onto upper Cross Shaft assembly and install 1 cap screw and lock washer by hand 5 Install lower Cross Shaft assembly and install 1 cap screw and lock washer by hand 6 If previously removed install the O ring onto the Cross Shaft Plug and then install the Cross Shaft Plug into the Transmission Housing and torque to 34 48 lb ft 46 65 N m ...

Page 209: ...RSM0940 Service Procedures Release Yoke and Cross Shaft s Removal and Installation 7 Tighten the 2 Yoke cap screws to 35 45 lb ft 47 61 N m 8 Grease upper Cross Shaft assembly refer to the Clutch Service Manual CLSM0200 for proper purging proce dure ...

Page 210: ... Cobra Lever Removal and Installation Service Procedures TRSM0940 Cobra Lever Removal and Installation Special Instructions None Special Tools Basic hand tools Component Identification 1 Tower 2 Screw 3 8 Way Cobra Lever Harness Connector 1 2 3 4 ...

Page 211: ...crewdriver remove the 4 screws from the Cobra Lever Housing 2 Disconnect the 8 way Cobra Lever Harness connector and remove the Cobra Lever from the housing Cobra Lever Installation 1 Connect the 8 way Cobra Lever Harness connector and place the Cobra Lever into the tower 2 Using a Phillips screwdriver install the 4 screws into the Cobra Lever Housing ...

Page 212: ...on Push Button Shift Control Device PBSC Removal and Installation Special Instructions The exact location varies depending on vehicle manufac turer Special Tools Basic hand tools Component Identification 1 Nut 2 Washer 3 30 Way Push Button Shift Control Device PBSC Connector 4 Backing Plate 5 Eaton Push Button Shift Control Device PBSC 1 2 3 4 5 ...

Page 213: ...l 2 Using a 11 32 wrench remove the 2 nuts and lock washers from the back of the Shift Control and remove the Shift Control Note Shift Control location and use varies with each truck Eaton PBSC Installation 1 Install the Shift Control in the mounting location Then using a 11 32 wrench install the 2 lock washers and nuts and tighten to 14 16 lb in 18 21 N m 2 Using a 1 4 wrench reconnect the 30 way...

Page 214: ...cation 1 38 way Transmission Electronic Control Unit TECU Connector 2 Gear Sensor Connector 3 Rail Sensor Connector 4 4 way Diagnostic Connector 5 Input Shaft Speed Sensor Connector 6 8 way Electronic Clutch Actuator ECA Connector 7 Range Solenoid Connector 8 Output Shaft Speed Sensor Connector 9 Engine Speed Sensor Connector 10 Main Shaft Speed Sensor 11 X Y Shifter Connector 12 Terminating Resis...

Page 215: ...ECA Speed Sensor 8 way ECA Connector X Y Shifter Transmission Harness Installation Caution Do not allow contamination into the TECU connec tors Caution Do not over tighten cable ties Caution You need to leave a service loop in the Transmis sion Harness Caution Do not put sharp bends in the Transmission Har ness Caution The battery negative must be disconnected while installing the 38 way Transmiss...

Page 216: ...on Service Procedures TRSM0940 Transmission Electronic Control Unit TECU Removal and Installation Special Instructions None Special Tools Basic hand tools Component Identification 1 Nut 2 Bracket 3 Transmission Electronic Control Unit TECU 4 38 Way Connectors 5 Cap Screw Located inside 38 way connectors 1 2 3 4 ...

Page 217: ... TCMT0072 for more information Caution The battery negative must be disconnected prior to unhooking the Transmission ECU TECU 38 way connectors Caution Do not allow contamination into the TECU or connectors 2 Disconnect the following connectors Using a 5 32 hex wrench unscrew and disconnect the Transmission Harness 38 way Connector and Vehicle Interface 38 way Connector 3 Using a 7 16 socket remov...

Page 218: ...ce the Transmission Controller Retaining Bracket over the TECU 3 Using a 7 16 socket install the 3 Transmission Con troller mounting nuts and tighten to 7 9 lb ft 9 5 12 2 N m 4 Reconnect the following connectors Caution Do not exceed the torque on the Transmission Harness or Vehicle Harness Connector or bolt failure will occur Using a 5 32 wrench reconnect the Transmission Harness 38 way Connecto...

Page 219: ...e informa tion 6 To operate properly the system must be calibrated as follows Important The Grade Sensor and ECA must be cali brated before the vehicle is placed in operation a Turn ignition switch on Allow Transmission to power up b Turn ignition off Wait 2 minutes ECA Calibration 1 Start the truck and let the system air up 2 With ServiceRanger connected perform Clutch ECA Calibration in Service ...

Page 220: ... 2018 12 12 X Y Shifter Removal and Installation Service Procedures TRSM0940 X Y Shifter Removal and Installation Special Instructions None Special Tools Basic hand tools Component Identification 1 Cap Screw 2 X Y Shifter 3 Gasket 1 2 3 ...

Page 221: ...tor wires Disconnect Transmission Harness from the Rail Position Sensor and the Gear Position Sensor 2 Disconnect the Rail Select and Gear Select Motors from the Transmission ECU TECU 3 Using a 9 16 socket remove the 4 mounting cap screws 4 Remove X Y Shifter and gasket Warning Possible Pinch Point Ensure battery is dis connected before removing X Y Shifter ...

Page 222: ...utral location Note If the Shift Finger is not properly aligned the X Y Shifter will not fit properly at its mounting location 2 Clean and remove old gasket material from Shift Bar Housing Then install new gasket on the Shift Bar Housing Note Apply Eaton sealant part number 71205 or equiv alent to the mounting cap screws before installing 3 The dowel pin on the X Y Shifter must be aligned with hol...

Page 223: ...60 N m 5 Reconnect the Rail Position Sensor and Gear Position Sensor 6 Reconnect the Transmission Harness to the Rail Select and Gear Select Motors Using cable ties secure motor wires to the Transmission in their previous position 7 To operate properly the system must be calibrated as follows Important X Y Shifter must be calibrated before the vehicle is placed into operation Turn ignition switch ...

Page 224: ...e Procedures TRSM0940 Range Valve Removal and Installation Special Instructions The Range Valve may be difficult to remove from the Trans mission Housing because of the O rings Special Tools Basic hand tools Component Identification 1 Protective Cover Optional 2 Cap Screw 3 Valve 4 O rings ...

Page 225: ...aining air tanks on the vehicle When air pressure has been relieved dis connect the Transmission Harness from the Range Valve Note The harness should be removed from the Range Valve cable tie prior to removing the cap screws 3 Using a 5 16 socket remove the 4 mounting cap screws from the Range Valve 4 Lift and remove the Range Valve from the housing Caution Do not use a hammer to loosen the Range ...

Page 226: ...gn the key with the notch in the housing 1 Install and push the Range Valve down into the hous ing 2 Using a 5 16 socket install the 4 Range Valve mount ing cap screws and tighten to 21 27 lb in 2 3 3 0 N m using a cross pattern 3 Reconnect the Transmission Harness to the Range Valve and close all air tanks drains Note Install the Range Harness back into the cable tie on the Range Valve 4 If equip...

Page 227: ...ions The Directional Output Shaft Speed Sensor is used on the Fuller Advantage model Transmissions The Output Shaft Speed Sensor location may vary depending on OEM design specifications The sensor will be located at 10 o clock on the Output Shaft Housing in heavy duty models Special Tools Basic hand tools Component Identification 1 Cap Screw 2 2 Way Directional Output Shaft Speed Sensor 1 2 ...

Page 228: ...oval and Installation Service Procedures TRSM0940 Output Shaft Speed Sensor Removal 1 Disconnect the Transmission Harness from the Output Shaft Speed Sensor pigtail connector 2 Remove the sensor retaining bolt 3 Remove the speed sensor from the Transmission Rear Bearing Cover ...

Page 229: ...aft Speed Sensor in the Transmission Rear Bear ing Cover opening 2 Install the Retaining Bolt and tighten to 8 10 lb ft 11 13 N m 3 Apply included material to the Sensor Connector termi nals Note Apply just enough material to cover the end of the terminal Note Use only Eaton lubricant 5564527 Nye Lubri cants NYOGEL 760G For MSDS safety or other infor mation see www nyelubricants com 4 Reconnect th...

Page 230: ...12 Input Shaft Speed Sensor Removal and Installation Service Procedures TRSM0940 Input Shaft Speed Sensor Removal and Installation Special Instructions None Special Tools Basic hand tools Component Identification 1 2 Way Input Shaft Speed Sensor ...

Page 231: ...oval and Installation Input Shaft Speed Sensor Removal 1 Disconnect the Transmission Harness from the Input Shaft Speed Sensor or pigtail connector if equipped 2 Using a 3 8 socket remove the sensor retaining bolt 3 Remove the Input Shaft Speed Sensor with O ring from the Transmission Shift Bar Housing ...

Page 232: ...d remove any burrs or sharp edges Important Lubricate the O ring with Eaton Fuller silicone 71214 or equivalent 1 Using a smooth twisting motion fully insert the Input Shaft Speed Sensor in the Transmission Shift Bar Housing opening 2 Using a 3 8 socket install the retaining bolt and tighten to 8 10 lb ft 11 13 N m 3 Reconnect the Transmission Harness to the Input Shaft Speed Sensor or pigtail con...

Page 233: ...222 TRSM0940 Service Procedures Main Shaft Speed Sensor Removal and Installation Main Shaft Speed Sensor Removal and Installation Special Instructions None Special Tools Basic hand tools Component Identification 1 2 Way Main Shaft Speed Sensor ...

Page 234: ...TRSM0940 Main Shaft Speed Sensor Removal 1 Disconnect the Transmission Harness from the Main Shaft Speed Sensor pigtail 2 Using a 3 8 socket remove the bolt from the retaining clip 3 The clip will not remove from the speed sensor Remove the Main Shaft Speed Sensor with O ring from the rear of the Shift Bar Housing ...

Page 235: ... the housing and remove any burrs or sharp edges Important Lubricate the O ring with Eaton Fuller silicone 71214 or equivalent 1 Use a smooth twisting motion fully insert the Main Shaft Speed Sensor in the rear Transmission Shift Bar Housing bore 2 Using a 3 8 socket install the retaining bolt and tighten 7 9 lb ft 9 12 N m 3 Reconnect the Main Shaft Speed Sensor pigtail to the Transmission Harnes...

Page 236: ... ECA Speed Sensor Removal and Installation Service Procedures TRSM0940 Electronic Clutch Actuator ECA Speed Sensor Removal and Installation Special Instructions None Special Tools Basic hand tools Component Identification 1 2 Way Electronic Clutch Actuator ECA Speed Sensor ...

Page 237: ...will not remove from the speed sensor Remove the ECA Speed Sensor with O ring from the Clutch Housing ECA Speed Sensor Installation Important Clean the mounting surface on the housing and remove any burrs or sharp edges Important Lubricate the O ring with Eaton Fuller silicone 71214 or equivalent 1 Using a smooth twisting motion fully insert the Elec tronic Clutch Actuator ECA Speed Sensor in the ...

Page 238: ...017 Eaton All rights reserved 2018 12 12 Electronic Clutch Actuator ECA Speed Sensor Removal and Installation Service Procedures TRSM0940 3 Reconnect the ECA Speed Sensor pigtail to the Trans mission Harness ...

Page 239: ...940 Service Procedures Rail Position Sensor Removal and Installation Rail Position Sensor Removal and Installation Special Instructions None Special Tools Basic hand tools Component Identification 1 Cap Screw 2 3 Way Rail Position Sensor 3 Gasket 1 2 3 ...

Page 240: ...moval 1 Disconnect the Transmission Harness from the Rail Position Sensor 2 Using a 5 32 hex key wrench remove the 2 sensor hex key mounting screws Caution Carefully allow the sensor to rotate to a relaxed position or the sensor can snap when the hex key mounting screws are removed 3 Remove the Rail Position Sensor and gasket from the housing ...

Page 241: ...or with gasket into its mounting location Note Install the sensor so connector opening faces right side of the Transmission As viewed from the rear of the transmission 2 Using a 5 32 hex key wrench install the 2 hex key mounting screws and tighten to 21 27 lb in 2 3 3 0 N m Caution Carefully hold sensor in position while install ing the hex key mounting screws or sensor can snap 3 Reconnect the Tr...

Page 242: ...Position Sensor Removal and Installation Service Procedures TRSM0940 Gear Position Sensor Removal and Installation Special Instructions None Special Tools Basic hand tools Component Identification 1 Cap Screw 2 3 Way Gear Position Sensor 3 Gasket 1 2 3 ...

Page 243: ...emoval 1 Disconnect the Transmission Harness from the Gear Position Sensor 2 Using a 5 32 hex key wrench remove the two 2 sen sor hex key mounting screws Caution Carefully allow sensor to rotate to a relaxed position or sensor can snap when the hex key mount ing screws are removed 3 Remove the Gear Position Sensor and gasket from the housing ...

Page 244: ... insert Gear Position Sensor with gasket into its mounting location Note Install sensor so the connector opening faces the front of the Transmission 2 Using a 5 32 hex key wrench install the hex key mounting screws and tighten to 21 27 lb in 2 3 3 0 N m Caution Carefully hold sensor in position while install ing hex key mounting screws or sensor can snap 3 Reconnect the Transmission Harness to the...

Page 245: ... such as Snap On Mac OTC and many oth ers Tool Purpose 0 100 lb ft 0 135 N m 1 2 12 7 mm drive Torque Wrench General torquing of fasteners typically 15 80 lb ft 20 108 N m 0 50 lb in 0 5 62 N m 3 8 9 52 mm drive Torque Wrench General torquing of fasteners 0 30 lb in 1 4 drive Torque Wrench Torquing of cap screws to 7 lb in during Auxiliary Counter Shaft Bearing endplay setting procedure Large Bras...

Page 246: ...osition RR1007TR Auxiliary Counter Shaft Support and Shim Tool Hold the Auxiliary Counter Shafts in position while installing the Auxiliary Section in the horizontal position also to simplify the checking and setting of the Auxiliary Counter Shaft Bearing endplay RR1012TR 3 Bearing Puller Remove front section Counter Shaft Bear ings RR1012TR 2 Bearing Driver Install front section Counter Shaft Bea...

Page 247: ...dix Tool Specifications Eaton Tool Number Tool Purpose 4301157 included in kit K 2394 5 32 Air Line Release Tool Remove 5 32 air lines from push to connect fittings 4301158 included in kit K 2394 Air Line Cutting Tool Cut plastic air lines smoothly and squarely ...

Page 248: ...e address and phone number of the company that makes tools specifically for Eaton Fuller Transmis sions K Line Tools 315 Garden Ave Holland MI 49424 800 824 5546 www klineind com Shop Equipment The following tool will be needed to complete the removal and installation of the Eaton Fuller Transmission 20 ton capacity press ...

Page 249: ...emporarily disrupt the leak path i Clean area with a clean dry cloth or mild soluble degreaser and fill the transmission to the proper lube level OR ii Clean the area as noted above and insert tracer dye into the transmission lube and fill transmission to proper lube level Operate vehicle to normal transmission operating temperature and inspect the area for oil leak s visually or if tracer dye was...

Page 250: ...er race Check cover bores for wear Replace those worn or oversized Clutch Release Parts Replace yokes worn at cam surfaces and bearing carrier worn at contact pads Check pedal shafts Replace those worn at bushing surfaces Gears Check gear teeth for frosting and pitting Frosting of gear teeth faces presents no threat of transmis sion failure Often in continued operation of the unit frosted gears he...

Page 251: ... sliding clutches for partial engagement pattern Splines Check splines on all shafts for abnormal wear If sliding clutch gears companion flange or clutch hub has wear marks in the spline sides replace the specific shaft affected Synchronizer Assembly Check Synchronizer for burrs uneven and exces sive wear at contact surface and metal particles Check blocker pins for excessive wear or loose ness Ch...

Page 252: ...ternal clutching teeth on the selected Main Shaft gear Torque will now be provided from both opposing Counter Shaft gears into the engaged Main Shaft gear and through the sliding clutch to the front section Main Shaft 5 The rear of the front section Main Shaft is splined into the Auxiliary Drive Gear and torque is now delivered to the Auxiliary Section Front Section Power Flow Direct Gear In direc...

Page 253: ... Auxiliary Section is in low range the Range Sliding Clutch is rearward and engaged into the Auxiliary Main Shaft Reduction Gear through the Range Sliding Clutch and then into the Output Shaft Auxiliary Main Shaft Auxiliary Section Power Flow High Range If the Auxiliary Section is in high range the Range Sliding Clutch is forward and engaged into the back of the Auxiliary Drive Gear Torque will fl...

Page 254: ...ved 2018 12 12 Power Flow Appendix TRSM0940 3rd Gear 4th Gear FM Direct Drive Transmission 5th Gear FO FOM Overdrive Transmission 5th Gear FM Direct Drive Transmission 4th Gear FO FOM Overdrive Transmission 6th Gear 7th Gear 8th Gear ...

Page 255: ...7 Eaton All rights reserved 244 TRSM0940 Appendix Power Flow 9th Gear FM Direct Drive Transmission 10th Gear FO FOM Overdrive Transmission 10th Gear FM Direct Drive Transmission 9th Gear FO FOM Overdrive Transmission ...

Page 256: ...ications Important Torque specifications not defined in the follow ing diagrams will be referenced in the service procedures Description Qty Size TPI Torque 1 XY Shifter Cap Screws 4 0 375 16 30 40 lb ft 41 54 N m 2 Auxiliary Drive Gear Bearing Retainer Cap Screws 6 0 375 16 35 45 lb ft 48 61 N m 2 1 ...

Page 257: ... TPI Torque 1 Grease Hose Compression Nuts 2 3 5 lb ft 0 34 0 56 N m 2 Grease Hose Elbow Fittings 2 0 25 18 NPTF 84 120 lb ft 9 5 13 6 N m 3 LCIB Nuts 2 0 625 18 140 150 lb ft 190 203 N m 4 LCIB Studs 2 0 625 18 UNC 60 lb ft 81 N m Drive studs until bottomed 5 Release Yoke Pinch Bolts 2 0 4375 14 35 45 lb ft 47 61 N m 3 4 5 1 2 ...

Page 258: ... 1 0 3125 18 10 12 lb ft 4 16 N m 5 Support Studs 2 0 625 11 80 lb ft 81 N m 6 Support Stud Nuts 2 0 625 18 140 150 lb ft 190 203 N m 7 Double Ended Stud 0 375 16 35 45 lb ft 48 61 N m 8 Clutch Housing to OEM Flywheel Housing Interface See OEM for torque specifica tion 9 Range Filter Regulator Plugs 3 0 125 27 PTF 84 120 lb in 9 5 13 6 N m 10 6 Bolt PTO Cover Cap Screws 6 0 375 16 40 45 lb ft 54 6...

Page 259: ...n for PTO Bracket 2 0 375 16 30 35 lb ft 41 47 N m 17 8 Bolt PTO Cover Cap Screws 8 0 4375 14 50 65 lb ft 68 88 N m 18 Oil Fill Plug 1 1 0625 12 35 50 lb ft 47 67 N m 19 Oil Level Sight Glass Plug 1 0 625 12 60 70 lb ft 82 95 N m 20 Output Yoke Retainer Bolts 2 M12 1 25 84 92 lb ft 113 124 N m 21 Auxiliary Housing Cap Screws 19 0 375 16 35 45 lb ft 48 61 N m 22 Auxiliary Counter Shaft Rear Bearing...

Page 260: ...e percent of upgrade expressed in degrees For operating angles over 12 degrees the transmission must be equipped with an oil pump or cooler kit to ensure proper lubrication Transmission filters should be changed during regular lubrication intervals Inspection of the transmission filter should be conducted during preventative maintenance checks for damage or corrosion Replace as necessary Operating...

Page 261: ...B The LCIB does not require lubrication for proper functionality 4 Cross Shaft Bushings Lubricate both the left and the right Cross Shaft Bushings per OEM recom mendations 5 Clutch Control Linkage Lubricate the clutch linkage bell cranks and pivot pins per OEM recommenda tions 6 Pilot Bearing The pilot bearing inside the flywheel is a sealed for life bearing and requires no lubrica tion Use a prem...

Page 262: ...ound surface must be within 0 5 grade 0 28 degrees from level 5 Maximum allowable grade is 0 5 degrees 0 87 grade from level ServiceRanger Procedure 1 Set vehicle parking brake and chock wheels Note Verify vehicle is parked on level ground and the suspension is fully aired if equipped and set to proper ride height 2 Key on with engine off 3 Connect ServiceRanger 4 Go To Service Routines 5 Select S...

Page 263: ... the software and products with all options installed Although every attempt has been made to ensure the accuracy of information contained within Eaton makes no repre sentation about the completeness cor rectness or accuracy and assumes no responsibility for any errors or omis sions Features and functionality may vary depending on selected options For spec ing or service assistance call 1 800 826 ...

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