Eaton UltraShift PLUS Service Manual Download Page 207

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204

2022.10.7

Range Synchronizer

Disassembly and Assembly

TRSM0940

Remove the sliding clutch from the pins of the syn-
chronizer ring.

Range Synchronizer Assembly

Install the Sliding Clutch on the blocker pins with the
recessed side up.

Summary of Contents for UltraShift PLUS

Page 1: ...er 2022 Linehaul Active Shifting LAS Vocational Active Shifting VAS Multipurpose Extreme Performance MXP Multipurpose High Performance MHP Vocational Construction Series VCS Vocational High Performanc...

Page 2: ...15E310C VAS FOM 16E310C 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 V...

Page 3: ...Clutch Actuator ECA 110 Low Capacity Inertia Brake LCIB 114 Release Yoke and Cross Shaft s 116 Cobra Lever 121 Eaton Push Button Shift Control Device PBSC 123 Transmission Harness 125 Transmission Ele...

Page 4: ...parking brake Block wheels 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 malfunct...

Page 5: ...moval and installation 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 Spe...

Page 6: ...940 General Information Transmission Overview 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...

Page 7: ...ion Technologies All rights reserved 2022 10 7 Transmission Overview General Information TRSM0940 Transmission Side View 1 Electronic Clutch Actuator ECA Speed Sensor 2 Transmission Electronic Control...

Page 8: ...0 General Information Transmission Overview Driver Instruction Manual Complete operation instructions can be found in the Driver Instruction Manual TRDR1110 Transmission Front View 1 Release Yoke and...

Page 9: ...mission identification 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 part...

Page 10: ...ocated toward the rear 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 mounte...

Page 11: ...reduction or splitter 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 assembl...

Page 12: ...Counter Shaft assembly 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...

Page 13: ...clearance in Release 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...

Page 14: ...Main Shaft Rear Bearing 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...

Page 16: ...sassembly In Chassis LAS VAS Auxiliary Section Removal and Disassembly In Chassis Special Instructions The following procedure covers the removal and disassem bly of the Auxiliary section with the tra...

Page 17: ...ll rights reserved 2022 10 7 LAS VAS Auxiliary Section Removal and Disassembly In Chassis Auxiliary Section Service Procedures TRSM0940 Component Identification 1 Wiring Harness 2 Auxiliary Case Bolts...

Page 18: ...t the driveline a move out of 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 Remov...

Page 19: ...16 2022 Eaton Cummins Automated Transmission Technologies All rights reserved 2022 10 7 LAS VAS Auxiliary Section Removal and Disassembly In Chassis Auxiliary Section Service Procedures TRSM0940...

Page 20: ...uxiliary Section Hanger RR1002TR 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 Auxilia...

Page 21: ...oval 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 LAS V...

Page 22: ...er Shaft Support Straps using 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 Count...

Page 23: ...al and Disassembly Auxiliary Section Service Procedures TRSM0940 4 Using prying points separate the Auxiliary Section from the Transmission Main Case enough to fit the Auxiliary Section Lifting Bracke...

Page 24: ...1 Remove the six cap screws 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...

Page 25: ...using a hand maul drive the Output 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...

Page 26: ...reserved 23 TRSM0940 Auxiliary Section Service Procedures LAS VAS Auxiliary Section Removal and Disassembly 9 Remove the splined spacer and stepped washer from the Auxiliary Reduction Gear Range Sync...

Page 27: ...Disassembly Auxiliary Section Service Procedures TRSM0940 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 sprin...

Page 28: ...ary Section Removal and Disassembly 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...

Page 29: ...vice Procedures TRSM0940 4 Apply 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...

Page 30: ...cial Tools PVC pipe 4 3 8 tall 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...

Page 31: ...cedures TRSM0940 LAS VAS Auxiliary 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 s...

Page 32: ...ssembly and Installation 5 Mark 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...

Page 33: ...Timing Auxiliary Counter Shaft 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...

Page 34: ...Cone size must be 4 3 8 tall 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 mad...

Page 35: ...er Shaft Rear Bearing Races into 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 tightenin...

Page 36: ...Bearing Cover and gasket 13 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 th...

Page 37: ...Using the Output Shaft wiggle 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...

Page 38: ...and all three cap screws are snug 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 hol...

Page 39: ...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 16 cap screws that fasten the Auxiliary Sec tion...

Page 40: ...ers from 0 100 Use that number 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 Beari...

Page 41: ...ary 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...

Page 42: ...aring 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 7 Install Auxiliary Counter Shaft Support straps with...

Page 43: ...tion Removal and Disassembly Auxiliary Section Service Procedures TRSM0940 VCS VMS Auxiliary Section Removal and Disassembly Special Instructions None Special Tools RR1006TR Auxiliary Section Hanger R...

Page 44: ...1 Spring 2 Synchronizer Assembly 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 1...

Page 45: ...red to apply force to the yoke 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 a...

Page 46: ...ase enough to fit the aux iliary 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 housin...

Page 47: ...hat fasten the Combination Cylinder 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 Yok...

Page 48: ...s from turning place a shop rag 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 S...

Page 49: ...sassembly Auxiliary Section Service Procedures TRSM0940 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...

Page 50: ...Output Shaft Note For disassembly 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...

Page 51: ...ce Procedures TRSM0940 18 Align 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...

Page 52: ...assembly 22 Remove the six cap 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...

Page 53: ...TRSM0940 Auxiliary Mainshaft 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 an...

Page 54: ...installed in the auxiliary housing 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 asse...

Page 55: ...t 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 Pi...

Page 56: ...e Auxiliary Main Shaft Install 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...

Page 57: ...er using a punch and hammer Note 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...

Page 58: ...5 TRSM0940 Auxiliary Section Service Procedures VCS VMS Auxiliary Section Assembly and Installation 11 Flip the Mainshaft so that it is sitting with the forward section down 12 Install the stepped was...

Page 59: ...e the Deep Reduction Gear for 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 c...

Page 60: ...16 Install the large flat washer 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...

Page 61: ...tallation Auxiliary Section Service Procedures TRSM0940 18 Install the Bearing Inner Spacer on the Output Shaft 19 Lay the Auxiliary Mainshaft Assembly on its side 20 Apply light coating of transmissi...

Page 62: ...ntified with a 0 on the shaft 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 assem...

Page 63: ...Auxiliary Case Housing front 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...

Page 64: ...tershaft Bearing Races 13 Install 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...

Page 65: ...the Combination Cylinder mounting 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 Aux...

Page 66: ...All rights reserved 63 TRSM0940 Auxiliary Section Service Procedures VCS VMS Auxiliary Section Assembly and Installation 23 Apply Eaton Sealant 71205 or equivalent to the 19 retaining cap screws Secu...

Page 67: ...64 2022 Eaton Cummins Automated Transmission Technologies All rights reserved 2022 10 7 VCS VMS Auxiliary Section Assembly and Installation Auxiliary Section Service Procedures TRSM0940...

Page 68: ...ry Section Service Procedures MHP MXP VHP VXP Auxiliary Section Removal and Disassembly MHP MXP VHP VXP Auxiliary Section Removal and Disassembly Special Instructions None Special Tools RR1006TR Auxil...

Page 69: ...Procedures TRSM0940 Component 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 H...

Page 70: ...Section Removal and Disassembly 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 requir...

Page 71: ...bly Auxiliary Section Service Procedures TRSM0940 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...

Page 72: ...ter Shaft Bearing covers Use the 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 Se...

Page 73: ...mbly Auxiliary Section Service Procedures TRSM0940 9 Using an overhead crane or hoist remove the Auxiliary Section with the auxiliary section hanger Auxiliary Section Disassembly 1 Too ease in the dis...

Page 74: ...Section Service Procedures MHP MXP VHP VXP Auxiliary Section Removal and Disassembly 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 th...

Page 75: ...the Range Cylinder assembly 6 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...

Page 76: ...the Out put Shaft Do not remove 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 ma...

Page 77: ...m their bores 15 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 16 Remove the 15 16 cap screw and...

Page 78: ...Shaft Note For disassembly and 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 th...

Page 79: ...the tapered bearing which should 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 Outpu...

Page 80: ...ed Transmission Technologies All rights reserved 77 TRSM0940 Auxiliary Section Service Procedures MHP MXP VHP VXP Auxiliary Section Removal and Disassembly 3 Remove the splined spacer and stepped wash...

Page 81: ...pecial Tools Bearing Drivers 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 Bearin...

Page 82: ...Gear for timing Mark any one 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 Positio...

Page 83: ...void getting the driver stuck 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 Main...

Page 84: ...Section Assembly and Installation 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 man...

Page 85: ...n fixture can be made out of 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...

Page 86: ...n 1 Place the Countershaft Assembly 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...

Page 87: ...o teeth marked on each shaft 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 A...

Page 88: ...t Installation 7 Place the Auxiliary 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...

Page 89: ...ealant 71205 or equivalent to 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 R...

Page 90: ...the range Cylinder 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 secti...

Page 91: ...e Cylinder Install with the flat 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 Auxiliar...

Page 92: ...he Splitter Cylinder and the 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 t...

Page 93: ...ion Installation 1 Attach the 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...

Page 94: ...ft Auxiliary Countershaft Shimming 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 shaf...

Page 95: ...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 u...

Page 96: ...TRSM0940 Auxiliary Section Service Procedures MHP MXP VHP VXP Auxiliary Countershaft Installation Output Yoke Installation 1 Install the Output Yoke Ensure yoke is properly seated against Output Shaf...

Page 97: ...94 2022 Eaton Cummins Automated Transmission Technologies All rights reserved 2022 10 7 MHP MXP VHP VXP Auxiliary Countershaft Installation Auxiliary Section Service Procedures TRSM0940...

Page 98: ...mins Automated Transmission Technologies All rights reserved 95 TRSM0940 Removal and Installation VCS VMS Combination Valve VCS VMS Combination Valve Special Instructions None Special Tools None Compo...

Page 99: ...ve from the 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...

Page 101: ...Input Shaft Removal and Installation TRSM0940 Input Shaft Special Instructions None Special Tools RR1023TR Input Shaft Bearing Puller RR1019TR Hand Maul RR1005TR Input Shaft Bearing Driver Component...

Page 102: ...Main Case 2 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...

Page 103: ...the Input Shaft to the Main Drive Gear 8 Remove the Input Shaft from the Main Drive Gear 9 Inspect the Input Shaft Bushing replace if damaged Input Shaft Installation 1 If necessary complete installa...

Page 104: ...t Shaft Bearing should face out 6 Using a Flanged end Bearing Driver install the Input Shaft Bearing into the Transmission Main Case until the snap ring groove is fully visible 7 Install the Input Sha...

Page 105: ...ll rights reserved 2022 10 7 Clutch Housing Removal and Installation TRSM0940 Clutch Housing Special Instructions None Special Tools None Component Identification 1 Main Case 2 Stud 3 Gasket 4 Clutch...

Page 106: ...sion Main Case 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 gask...

Page 107: ...l rights reserved 2022 10 7 Shift Bar Housing Removal and Installation TRSM0940 Shift Bar Housing Special Instructions None Special Tools Gasket Sealant Loctite 5810F RTV or 5188 anaero bic sealant Co...

Page 108: ...ift Bar Housing Installation Cast Iron 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...

Page 109: ...surfaces are clean and free of debris NOTICE Ensure there is nothing in the threaded bolt holes or the Main Case may be damaged when cap screws are tightened 3 Apply gasket sealant with a bead width...

Page 110: ...Switch is a normally open ball switch When the transmission is shifted into Reverse a ramp on the Reverse Shift Yoke contacts and raises a pin The pin depresses the ball on the switch which closes th...

Page 111: ...l 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 Disconnect the OEM wiring Remove t...

Page 112: ...on Reverse Switch 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 Revers...

Page 113: ...ECA Removal and Installation TRSM0940 Electronic Clutch Actuator ECA Special Instructions If vehicle is equipped with an 8 bolt PTO removal may be required prior to removing the ECA Follow PTO manufa...

Page 114: ...tuator ECA 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 mod...

Page 115: ...he ECA casting 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...

Page 116: ...tightening 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 conne...

Page 117: ...rights reserved 2022 10 7 Low Capacity Inertia Brake LCIB Removal and Installation TRSM0940 Low Capacity Inertia Brake LCIB Special Instructions None Special Tools Basic hand tools Component Identific...

Page 118: ...ving the LCIB 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 S...

Page 119: ...and Cross Shaft s Removal and Installation TRSM0940 Release Yoke and Cross Shaft s Special Instructions None Special Tools Basic hand tools Component Identification 1 Plug 2 O ring 3 Upper Cross shaft...

Page 120: ...aft s Removal 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...

Page 121: ...lation TRSM0940 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 u...

Page 122: ...ross Shaft 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 ha...

Page 123: ...ll rights reserved 2022 10 7 Release Yoke and Cross Shaft s Removal and Installation TRSM0940 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...

Page 124: ...ission Technologies All rights reserved 121 TRSM0940 Removal and Installation Cobra Lever Cobra Lever Special Instructions None Special Tools Basic hand tools Component Identification 1 Tower 2 Screw...

Page 125: ...Phillips screwdriver 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 Conne...

Page 126: ...Control Device PBSC Eaton Push Button Shift Control Device PBSC Special Instructions The exact location varies depending on vehicle manufac turer Special Tools Basic hand tools Component Identificati...

Page 127: ...hift Control 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...

Page 128: ...tion 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 C...

Page 129: ...Solenoids 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 Cautio...

Page 130: ...nstallation Transmission Electronic Control Unit TECU Transmission Electronic Control Unit TECU Special Instructions None Special Tools Basic hand tools Component Identification 1 Nut 2 Bracket 3 Tran...

Page 131: ...User Guide 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 T...

Page 132: ...studs 2 Place 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 t...

Page 133: ...072 for more 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 ignitio...

Page 134: ...ted Transmission Technologies All rights reserved 131 TRSM0940 Removal and Installation X Y Shifter X Y Shifter Special Instructions None Special Tools Basic hand tools Component Identification 1 Cap...

Page 135: ...ies from motor 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 Usi...

Page 136: ...e center Neutral 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...

Page 137: ...5 lb ft 45 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 th...

Page 138: ...TRSM0940 Removal and Installation Range Valve Range Valve 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 139: ...ssure by draining 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 t...

Page 140: ...care to align 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...

Page 141: ...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 142: ...TRSM0940 Removal and Installation Output Shaft Speed Sensor Output Shaft Speed Sensor Removal 1 Disconnect the Transmission Harness from the Output Shaft Speed Sensor pigtail connector 2 Remove the s...

Page 143: ...Out put Shaft 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 nal...

Page 144: ...mission Technologies All rights reserved 141 TRSM0940 Removal and Installation Input Shaft Speed Sensor Input Shaft Speed Sensor Special Instructions None Special Tools Basic hand tools Component Iden...

Page 145: ...emoval and Installation TRSM0940 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 t...

Page 146: ...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 Input Shaft Speed Sensor in...

Page 147: ...ion Technologies All rights reserved 2022 10 7 Main Shaft Speed Sensor Removal and Installation TRSM0940 Main Shaft Speed Sensor Special Instructions None Special Tools Basic hand tools Component Iden...

Page 148: ...Shaft Speed Sensor 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 cl...

Page 149: ...surface on 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 Spe...

Page 150: ...hts reserved 147 TRSM0940 Removal and Installation Electronic Clutch Actuator ECA Speed Sensor Electronic Clutch Actuator ECA Speed Sensor Special Instructions None Special Tools Basic hand tools Comp...

Page 151: ...3 The clip 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 r...

Page 152: ...on Cummins Automated Transmission Technologies All rights reserved 149 TRSM0940 Removal and Installation Electronic Clutch Actuator ECA Speed Sensor 3 Reconnect the ECA Speed Sensor pigtail to the Tra...

Page 153: ...ologies All rights reserved 2022 10 7 Rail Position Sensor Removal and Installation TRSM0940 Rail Position Sensor Special Instructions None Special Tools Basic hand tools Component Identification 1 Ca...

Page 154: ...n Sensor Removal 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 rot...

Page 155: ...sition Sensor 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 ke...

Page 156: ...Technologies All rights reserved 153 TRSM0940 Removal and Installation Gear Position Sensor Gear Position Sensor Special Instructions None Special Tools Basic hand tools Component Identification 1 Ca...

Page 157: ...on Sensor Removal 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 r...

Page 158: ...r Rail Then 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 th...

Page 159: ...ion Technologies All rights reserved 2022 10 7 Oil Pump and Lube Tube Installation Removal and Installation TRSM0940 Oil Pump and Lube Tube Installation Special Instructions None Special Tools None Co...

Page 160: ...tall the Oil Pump into the 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 Pu...

Page 161: ...n Removal and Installation 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...

Page 162: ...etween both marks counting 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...

Page 163: ...ear 4 Install the snap ring 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 Sha...

Page 164: ...Case and wiggle the Input 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 I...

Page 165: ...Shaft Bearing snap ring 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 ra...

Page 166: ...Transmission Main Case 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...

Page 167: ...in Drive Gear Note Ensure 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 d...

Page 168: ...the rollers in place during 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...

Page 169: ...ar to the rear of the case 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 Gea...

Page 170: ...etaining plate and cap screws 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 Aux...

Page 171: ...halo through the bores 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...

Page 172: ...nd all three cap screws 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...

Page 173: ...mission Main Case Note Fully 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 Tra...

Page 175: ...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 176: ...entification 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...

Page 177: ...tion Cylinder Disassembly and Assembly TRSM0940 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 th...

Page 178: ...assembly and Assembly VCS VMS Combination Cylinder 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 da...

Page 179: ...Procedure Combination 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...

Page 180: ...iliary section 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...

Page 181: ...10 7 VCS VMS Combination Cylinder Disassembly and Assembly TRSM0940 8 Install a new gasket on the Cylinder Housing Cover mounting surface and install the Combination cylinder cover Apply Eaton Sealan...

Page 183: ...tions 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 So...

Page 184: ...air on truck before 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 Fi...

Page 185: ...LAS VAS Model Disassembly and Assembly TRSM0940 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...

Page 186: ...inder Assembly 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...

Page 187: ...iston and Range 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 R...

Page 188: ...connect the Transmission 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 ai...

Page 189: ...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 190: ...sembly MHP MXP VHP VXP Range Cylinder 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...

Page 191: ...MHP MXP VHP VXP Range Cylinder Disassembly and Assembly TRSM0940 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 hous...

Page 192: ...y 1 Install 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 Cyl...

Page 193: ...lign the 2 groves 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 th...

Page 194: ...ated Transmission Technologies All rights reserved 191 TRSM0940 Disassembly and Assembly MHP MXP VHP VXP Range Cylinder 10 Apply Eaton Sealant 71205 or equivalent to the retain ing cap screws and torq...

Page 195: ...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 196: ...Assembly MHP MXP VHP VXP Splitter Cylinder 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...

Page 197: ...nder Disassembly and Assembly TRSM0940 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 Remo...

Page 198: ...Cylin der Note 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 Yo...

Page 199: ...Cylinder Housing and install the Splitter Cylinder 5 Install O Ring on the end of the yoke bar inside of the Cylinder Housing 6 Install new O rings on the ID and OD of the piston then lubricate with...

Page 200: ...VHP VXP Splitter Cylinder 9 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 housing...

Page 201: ...ed 2022 10 7 MHP MXP VHP VXP Splitter Gear Bearing Disassembly and Assembly TRSM0940 MHP MXP VHP VXP Splitter Gear Bearing Special Instructions Make sure to use proper drivers for the bearing and slee...

Page 202: ...ts reserved 199 TRSM0940 Disassembly and Assembly MHP MXP VHP VXP Splitter Gear Bearing Splitter Gear Bearing Disassembly 1 Remove the internal coiled snap ring 2 Remove the Tapered Bearing Pack Assem...

Page 203: ...es All rights reserved 2022 10 7 MHP MXP VHP VXP Splitter Gear Bearing Disassembly and Assembly TRSM0940 Splitter Gear Bearing Assembly 1 Install the Front Bearing Race 2 Install the bearing spacer 3...

Page 204: ...utomated Transmission Technologies All rights reserved 201 TRSM0940 Disassembly and Assembly MHP MXP VHP VXP Splitter Gear Bearing 5 Drive the bearing into place using the bearing driver RR1012TR 4 6...

Page 205: ...ings 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 chamfe...

Page 206: ...03 TRSM0940 Disassembly and Assembly Range Synchronizer Range Synchronizer Disassembly 1 Place the low range synchronizer on a bench with the larger ring facing down place a shop towel over the assemb...

Page 207: ...es All rights reserved 2022 10 7 Range Synchronizer Disassembly and Assembly TRSM0940 3 Remove the sliding clutch from the pins of the syn chronizer ring Range Synchronizer Assembly 1 Install the Slid...

Page 208: ...eating the 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...

Page 210: ...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 211: ...pside down 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...

Page 212: ...Disassembly and Assembly Shift Bar Housing 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...

Page 213: ...ers must be 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...

Page 214: ...ed end of the 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 inte...

Page 215: ...the block 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 sprin...

Page 216: ...ithout Low Force Gearing 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 Slid...

Page 217: ...1 Remove the front 4th 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 t...

Page 218: ...assembly and Assembly Main 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...

Page 219: ...7 Main Case Main Shaft without Low Force Gearing Disassembly Disassembly and Assembly TRSM0940 9 Remove the 3rd stepped washer from the Main Shaft 10 Remove the 2nd 3rd Gear Sliding Clutch 11 Remove t...

Page 220: ...or direct drive from the 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 s...

Page 221: ...ithout Low Force Gearing Assembly 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...

Page 222: ...l the first stepped washer with the stepped 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...

Page 223: ...e slot on the sliding clutch aligns 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 wa...

Page 224: ...ow Force Gearing Assembly 11 Install 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 th...

Page 225: ...ved 2022 10 7 Main Case Main Shaft without Low Force Gearing Assembly Disassembly and Assembly TRSM0940 14 Remove the Main Shaft assembly from the holding device Flip the Main Shaft up and install the...

Page 226: ...Case Main Shaft with Low Force Gearing Disassembly 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...

Page 227: ...ring Disassembly Disassembly and Assembly 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...

Page 228: ...ving 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 6 Remove the 1st stepped no burn washe...

Page 229: ...7 Main Case Main Shaft with Low Force Gearing Disassembly Disassembly and Assembly TRSM0940 7 Remove the 1st Gear from the Main Shaft 8 Remove the 2nd stepped no burn washer from the Main Shaft 9 Rem...

Page 230: ...M0940 Disassembly and Assembly Main Case Main Shaft with Low Force Gearing Disassembly 11 Remove the 2nd 3rd Gear Sliding Clutch 12 Remove the 4th no burn washer and 3rd Gear 13 Remove the 5th flat no...

Page 231: ...Disassembly Disassembly and Assembly 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 f...

Page 232: ...Case Main Shaft with Low Force Gearing Assembly 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 Mai...

Page 233: ...isassembly and Assembly 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 firs...

Page 234: ...through the key way groove 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...

Page 235: ...sher Rotate the 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 stepped washer Rotate the...

Page 236: ...smission Technologies All rights reserved 233 TRSM0940 Disassembly and Assembly Main Case Main Shaft with Low Force Gearing Assembly 11 Install the snap ring that retains the main shaft key 12 Install...

Page 237: ...assembly and Assembly TRSM0940 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 as...

Page 238: ...ase Disassembly and Lubrication Tube Removal Main Case Disassembly and Lubrication Tube Removal Special Instructions None Special Tools None Component Identification 1 Upper Idler Lubricant Tube 2 Aux...

Page 239: ...ly 1 Remove the six cap 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...

Page 240: ...ing from the Transmission 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 Re...

Page 241: ...ap ring from the upper Counter 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...

Page 242: ...Counter Shaft and use a 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...

Page 243: ...ucked against 1st Gear move 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 lif...

Page 244: ...ing a soft maul with hand 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...

Page 245: ...sembly and Lubrication Tube Removal Disassembly and Assembly 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 I...

Page 246: ...ion Case by pulling the 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...

Page 247: ...l tool manufacturers 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...

Page 248: ...in the horizontal position 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...

Page 249: ...2 10 7 Tool Specifications Appendix TRSM0940 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 includ...

Page 250: ...ufacturer Below is the 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...

Page 251: ...area of concern and temporarily 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 abo...

Page 252: ...rust of bear ing outer 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 shaf...

Page 253: ...eck engaging teeth of 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...

Page 254: ...lutch will engage internal 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 c...

Page 255: ...ounter Shafts If the 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...

Page 256: ...chnologies All rights reserved 253 TRSM0940 Appendix Power Flow 3rd Gear 4th Gear FM Direct Drive Transmission 5th Gear FO FOM Overdrive Transmission 5th Gear FM Direct Drive Transmission 4th Gear FO...

Page 257: ...smission Technologies All rights reserved 2022 10 7 Power Flow Appendix TRSM0940 9th Gear FM Direct Drive Transmission 10th Gear FO FOM Overdrive Transmission 10th Gear FM Direct Drive Transmission 9t...

Page 258: ...ations Torque Specifications 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...

Page 259: ...Description Qty Size 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...

Page 260: ...Shoulder Bolt and Nut 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 6...

Page 261: ...9 24 N m 16 Provision 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...

Page 262: ...the chassis plus the 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 Transmi...

Page 263: ...ty Inertia Brake LCIB 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...

Page 264: ...to proper height 4 Ground 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 an...

Page 265: ......

Page 266: ...ities of 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 representation about the comple...

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Summary of Contents for UltraShift PLUS

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Summary of Contents for UltraShift PLUS

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