Eaton UltraShift PLUS Series Service Manual Download Page 134

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2018.12.12

Range Synchronizer Disassembly and Assembly

Service Procedures

TRSM0940

Range Synchronizer Disassembly

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).

Grab both sides of the HI Range Synchronizer and pull.

Summary of Contents for UltraShift PLUS Series

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

Page 3: ...C 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...

Page 4: ......

Page 11: ...ion 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 Mai...

Page 12: ...eels 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...

Page 13: ...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...

Page 14: ...al 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...

Page 15: ...ton 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 Transmis...

Page 16: ...l 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...

Page 17: ...n 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 s...

Page 18: ...r 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...

Page 19: ...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...

Page 20: ...ly 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 C...

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 recomme...

Page 22: ...g 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 I...

Page 23: ...uxiliary 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 cha...

Page 24: ...rved 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 Ret...

Page 25: ...he 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 Aux...

Page 26: ...TR 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 Be...

Page 27: ...at 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...

Page 28: ...olts 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...

Page 29: ...y 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 overhea...

Page 30: ...hat 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 Cov...

Page 31: ...tput 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 Usin...

Page 32: ...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...

Page 33: ...ion 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 Synchron...

Page 34: ...M0940 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...

Page 35: ...y 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 th...

Page 36: ...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...

Page 37: ...iary 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 clutchi...

Page 38: ...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...

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...

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 Y...

Page 41: ...o 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 Suppo...

Page 42: ...pply 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 R...

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 T...

Page 44: ...ug 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 t...

Page 45: ...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 T...

Page 46: ...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...

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...

Page 48: ...fore 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...

Page 49: ...AS 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...

Page 50: ...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 pos...

Page 51: ...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 C...

Page 52: ...nsmission 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...

Page 53: ...embly 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...

Page 54: ...l 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...

Page 55: ...MS 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...

Page 56: ...bly 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 Gea...

Page 57: ...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 reinsta...

Page 58: ...ry 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...

Page 59: ...inder 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 Combinatio...

Page 60: ...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 Countersha...

Page 61: ...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 ret...

Page 62: ...ly 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 tw...

Page 63: ...n 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 a...

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 R...

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 bea...

Page 66: ...ing 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...

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 Pis...

Page 68: ...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...

Page 69: ...te 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 th...

Page 70: ...iliary 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 Mainshaf...

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 toward...

Page 72: ...er 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...

Page 73: ...ssembly 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...

Page 74: ...se 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 P...

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 ins...

Page 76: ...all 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 t...

Page 77: ...ting 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...

Page 78: ...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 th...

Page 79: ...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 t...

Page 80: ...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...

Page 81: ...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...

Page 82: ...d 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 pres...

Page 83: ...bination 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 th...

Page 84: ...on 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...

Page 85: ...es 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 e...

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 Compo...

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 Importan...

Page 88: ...tion 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 Co...

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...

Page 90: ...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 f...

Page 91: ...val 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...

Page 92: ...e 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...

Page 93: ...val 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 Secti...

Page 94: ...on 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 re...

Page 95: ...emove 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 th...

Page 96: ...ve 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...

Page 97: ...ecure 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...

Page 98: ...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 Assembl...

Page 99: ...uld 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...

Page 100: ...7 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...

Page 101: ...ions 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 install...

Page 102: ...rvice 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...

Page 103: ...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 Inspec...

Page 104: ...he 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...

Page 105: ...oves 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 n...

Page 106: ...hts 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...

Page 107: ...tion 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...

Page 108: ...ly 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...

Page 109: ...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...

Page 110: ...e 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 e...

Page 111: ...stall 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 si...

Page 112: ...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 co...

Page 113: ...P 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 sle...

Page 114: ...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 be...

Page 115: ...4 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 Bear...

Page 116: ...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...

Page 117: ...aul 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...

Page 118: ...ooth 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 Ou...

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 I...

Page 120: ...940 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 Gea...

Page 121: ...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 bi...

Page 122: ...embly 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 timi...

Page 123: ...re 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...

Page 124: ...iliary 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...

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...

Page 126: ...nder 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 cylin...

Page 127: ...at 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 Po...

Page 128: ...uxiliary 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 cyli...

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 transm...

Page 130: ...ming 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 torq...

Page 131: ...ng 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...

Page 132: ...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 wit...

Page 133: ...rings 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 chamf...

Page 134: ...ly 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...

Page 135: ...4 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 o...

Page 136: ...prings 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 block...

Page 137: ...moval 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...

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...

Page 139: ...ain 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 Dri...

Page 140: ...l 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...

Page 141: ...e 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...

Page 142: ...se 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 Ma...

Page 143: ...eserved 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...

Page 144: ...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 fre...

Page 145: ...mponent 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 Shaf...

Page 146: ...n 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 an...

Page 147: ...using 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 Shi...

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 Thi...

Page 149: ...e 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 i...

Page 150: ...nd 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...

Page 151: ...ication 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...

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 A...

Page 153: ...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...

Page 154: ...unter 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 r...

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 ge...

Page 156: ...ve 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...

Page 157: ...d 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 th...

Page 158: ...ion 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 Remo...

Page 159: ...ssembly 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 Sucti...

Page 160: ...l 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...

Page 161: ...e 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...

Page 162: ...s 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...

Page 163: ...ng 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...

Page 164: ...ng 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...

Page 165: ...t 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 Li...

Page 166: ...2 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...

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 Shaf...

Page 168: ...e 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 on...

Page 169: ...ing 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 P...

Page 170: ...e 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...

Page 171: ...rews 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 th...

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 g...

Page 173: ...re 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...

Page 174: ...lly 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 tim...

Page 175: ...bly 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...

Page 176: ...ervice 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 R...

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 No...

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 Ma...

Page 179: ...dures 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 Mai...

Page 180: ...e 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...

Page 181: ...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 Gea...

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 ste...

Page 183: ...e 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...

Page 184: ...d 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 t...

Page 185: ...ton 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...

Page 186: ...SM0940 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...

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 M...

Page 188: ...nd 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...

Page 189: ...in 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...

Page 190: ...aft 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...

Page 191: ...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 w...

Page 192: ...ons 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...

Page 193: ...epped 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 S...

Page 194: ...ith 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...

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 Gea...

Page 196: ...8 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...

Page 197: ...inity 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 sh...

Page 198: ...net 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 th...

Page 199: ...d 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 manuf...

Page 200: ...CA 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 u...

Page 201: ...ng 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 displa...

Page 202: ...o 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...

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 Identifi...

Page 204: ...B 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 c...

Page 205: ...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 shaf...

Page 206: ...l 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...

Page 207: ...ion 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 S...

Page 208: ...nto 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 prev...

Page 209: ...SM0940 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 Servi...

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...

Page 211: ...rewdriver 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...

Page 212: ...n 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 Identificati...

Page 213: ...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 Install...

Page 214: ...ation 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...

Page 215: ...CA 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 t...

Page 216: ...n 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 Tra...

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 conne...

Page 218: ...e 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...

Page 219: ...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...

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...

Page 221: ...or 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 so...

Page 222: ...tral 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...

Page 223: ...0 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 Transmissi...

Page 224: ...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...

Page 225: ...ining 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...

Page 226: ...n 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...

Page 227: ...ons 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...

Page 228: ...val 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 retain...

Page 229: ...ft 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...

Page 230: ...2 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 Ide...

Page 231: ...val 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 re...

Page 232: ...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 Transmi...

Page 233: ...22 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 Iden...

Page 234: ...RSM0940 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...

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...

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 Comp...

Page 237: ...ill 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 bu...

Page 238: ...17 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 H...

Page 239: ...40 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 Ca...

Page 240: ...oval 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 rel...

Page 241: ...r 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 ins...

Page 242: ...osition Sensor Removal and Installation Service Procedures TRSM0940 Gear Position Sensor Removal and Installation Special Instructions None Special Tools Basic hand tools Component Identification 1 Ca...

Page 243: ...moval 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 r...

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 mo...

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 5...

Page 246: ...sition 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 check...

Page 247: ...ix 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 L...

Page 248: ...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 fol...

Page 249: ...mporarily 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 d...

Page 250: ...r 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...

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...

Page 252: ...ernal 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 se...

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 Auxiliar...

Page 254: ...ed 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 Transmi...

Page 255: ...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 Overdri...

Page 256: ...cations 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...

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...

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...

Page 259: ...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...

Page 260: ...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...

Page 261: ...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 Lubr...

Page 262: ...und 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 Ve...

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 c...

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