Eaton FS-4005A Service Manual Download

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Service Manual

Fuller Mid-Range Transmissions

TRSM0130

October 2007

FS-4005A

FS-4005B

FS-4005C

FS-4205A

FS-4205B

FS-4205C

FS-5005A

FS-5005B

FS-5005C

Summary of Contents for FS-4005A

Page 1: ...Service Manual Fuller Mid Range Transmissions TRSM0130 October 2007 FS 4005A FS 4005B FS 4005C FS 4205A FS 4205B FS 4205C FS 5005A FS 5005B FS 5005C ...

Page 2: ...ing brakes and disengage the clutch Before working on a vehicle place the transmission in neutral set the park ing brakes and block the wheels Before towing the vehicle place the transmission in neutral and lift the rear wheels off the ground or discon nect the driveline to avoid damage to the transmission during towing ...

Page 3: ...MAINTENANCE 10 PRECAUTIONS DISASSEMBLY 12 INSPECTION 12 REASSEMBLY 14 DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS GEARSHIFT LEVER HOUSING ASSEMBLY 15 SHIFT BAR HOUSING ASSEMBLY 18 REMOVAL YOKE AND CLUTCH HOUSING 27 DISASSEMBLY TRANSMISSION 29 REASSEMBLY TRANSMISSION 43 INSTALLATION CLUTCH HOUSING 57 INSTALLATION SHIFTING CONTROLS 58 OPTIONS 59 ...

Page 4: ...reassembly on page 15 Instructions for installation are on page 58 Service Manuals Illustrated Parts Lists Drivers Instructions and other forms of product service information for these and other Eaton Fuller Transmissions are available upon re quest A Product Literature Order Form Service Bulletins detailing information on product improve ments repair procedures and other service related subjects ...

Page 5: ...ANSMIS SION IDENTIFICATION TAG Reial ve Soeed No c 2 Note S PTO 3ear _e g111 l eo Q I Caoaci y lnpc ir Los Pi ts Rf ver e Rigrt Li t 1 1 Kg 1Uersi 6 27 460 435 21 9 280 10 5 556 0 127 0 5 0 5 30 543 515 21 9 280 10 5 556 0 127 0 5 0 5 30 543 515 21 9 280 10 5 556 0 127 0 5 0 1 Lengths measured from clutch housing face to speedo gear rear 2 Weights include shift bar housing clutch housing less towe...

Page 6: ...cants Grade Fahrenheit Celsius Type Ambient SAE Temperature Eaton Roadranger CDSO Transmission 50 All Fluid Heavy Duly E 0 gine Oi MIL L 21048 Cor Dor 50 Above 10 F t2 C APl SF 0 AP CD 40 Above 10 F 12 C Pr9ViOJS API 30 Below 10 F 12 C acceotab e1 Mneral Gear OI w h rust 90 Abo e 1JF i 2 C and i hibitor sew Below O F i 2 C ft Pl GL The use of mild EP gear oil or multi purpose gear oil is not recom...

Page 7: ...ing temperatures are above 230 F 110 C In addition transmission oil coolers are not recommended with these gear oils since the oil cooler materials can be attacked by these gear oils The lower temperature limit and oil cooler restriction with these gear oils generally limit their success to milder applications 5 Proper Lubrication Levels as Related to Transmission Operating Angles If the transmiss...

Page 8: ...with short fourth and 2 speed axle FS 5005 transmissions have five forward speeds and one reverse and are shifted as you would shift any synchro nized manual transmission following the simple 5 speed shift pattern Driving Tips Always use the clutch when making upshifts or downshifts Premature synchronizer failure can result from not using the clutch Always select a starting gear that provides suff...

Page 9: ...ngine is transferred to the input shaft and drive gear 2 Torque is transferred to the countershaft drive gear 3 Torque is delivered along the countershaft to all countershaft gears 4 Torque is transferred to engaged mainshaft gear The cross section illustrates 1st speed gear position 5 Engaged mainshaft gear internal clutching teeth transfers torque to mainshaft through synchronizer assembly 6 Mai...

Page 10: ...gs Do not torque capscrews dry 4 FRONT BEARING COVER CAPSCREWS 15 20 LBS FT 5 16 18 THREAD 2 HAND HOLE COVER CAPSCREWS 5 LBS FT 1 4 12 THREAD Adobe 0002 2 88 4 SHIFT LEVER HOUSING CAPSCREWS 20 25 LBS FT 3 8 16 THREAD 9 SHIFT RAIL RETAINER CAPSCREWS 20 25 LBS FT 3 8 16 THREAD 17 SHIFT BAR HOUSING CAPSCREWS 20 25 LBS FT 3 8 16 THREAD 4 CLUTCH HOUSING CAPSCREWS 145 155 LBS FT 5 8 16 THREAD 8 OUTPUT S...

Page 11: ...16 THREADS Adobe 0003 2 88 4 COUTNERSHAFT REAR BEARING COVER CAPSCREWS 20 30 LBS FT 3 8 16 THREAD USE PLAIN FLAT WASHERS 9 OIL FILL PLUG 20 25 LBS FT 3 4 PIPE THREAD 2 COUNTERSHAFT REAR BEARING CAP SET SCREWS 5 10 LBS FT 1 4 THREAD OIL DRAIN PLUG 20 25 LBS FT 3 4 PIPE THREAD NOTE APPLY LOCTITE 262 TO THREADS OF ALL CAPSCREWS BEFORE INSTALLING ...

Page 12: ...PREVENTIVE MAINTENANCE 10 ...

Page 13: ...which can cause oil leakage See TORQUE RECOMMENDATIONS b Check PTO opening and rear bearing covers for oil leakage 7 Gear Shift Lever a Check for looseness and free play in hous ing If lever is loose in housing proceed with Check No 8 11 8 Gear Shift Lever Housing Assembly a Remove the gear shift lever housing assem bly from transmission b Check tension spring and washer for set and wear c Check g...

Page 14: ...t hammers bar and mauls for all disassembly work is recommended Before reassembling the transmission check each part carefully for abnormal or excessive wear and damage to determine reuse or replacement When replacement is necessary use only genuine Eaton Fuller Transmission parts to assure continued performance and extended lite from your unit Since the cost of a new part is generally a small fra...

Page 15: ...ing carrier worn at contact pads 2 Check pedal shafts Replace those worn at bushing surfaces H SHIFT BAR HOUSING ASSEMBLY 1 Check tor wear on shift yokes and finger as sembly at pads and lever slot Replace exces sively worn parts 2 Check yokes for correct alignment Replace sprung yokes 3 Check lockscrews in yoke assembly retainer plates Tighten those loose 13 I GEAR SHIFT LEVER HOUSING ASSEMBLY 1 ...

Page 16: ...on to prevent leakage 4 ASSEMBLY See the illustrations provided in the detailed disassembly instructions as a guide to reassembly 5 INITIAL LUBRICATION Coat all thrust washers synchronizers and bearings with transmission lubricant during reassembly to prevent damage during initial start up 6 AXIAL CLEARANCES Maintain original axial clearances for mainshaft gears 7 BEARINGS Using a sleeve type driv...

Page 17: ...assembly of Gearshift Lever Housing 1 Twnou1 tCMJrcapsctews arld remove the towera5Sem bly and gasket from the shllt bar hous ing 15 2 Removethe shifllevergripandboo1 from theshiftlever sorureassmblyInavisewiththehousingbottom up Use a large scrc wdriver to twisi between spnrig and houSJng forongthe Spl ing fromunder tnellovsinglugs Dooneooi a1 a lime ...

Page 18: ... CONTROLS Gearshift Lever Housing Assembly cont 3 Removo tho ten 1on spring trom the haualng 4 Remove tne wasf le and gearshtl ver trom ttle houM lg Remove the boot from die gear1htflIGVlf 5 Remove the spadO pins lrom housingbo1e 16 I a ...

Page 19: ...ihon gearshlh leverInhousing with the spade pins in1ho levorball slot and ins1all the lension spnng washer over tho ball dlslled side up 17 3 Use a spMg driving tool to Install tho tension sp ing under the housing lugs seating one ooll ata ume 4 Remove ass9 mbtylrom lhevise and tnstaJI lherubbe boot ovEK the gearshlJt klver and against tt1 I housing lnsl all1he shrf1 lev9I gn p ...

Page 20: ...DISASSEMBLYAND REASSEMBLY SHIFTING CONTROLS hift Bar Housing Assembly ...

Page 21: ...using I t 1 Sh 11100 transmissionintoneutralpo81hon remove the capscrewa andI It the shift bar housing and OdSklll honl 11 c oate 1rigtHI 2 Uy h 111 11 _ MOcapecr9W a sshowoandshh Ok o 1 111n itf into th speed position W trl a 19 3 Rcmo11e tile r8 1 of1hecapsorewS and tne two retain ors ...

Page 22: ...mbly and lnteflock pin Inset 6 Rernove 1SJ toverso bar assembly II neoessary remove the front spaoer from 1st reverse shift bar ln el 20 7 Ifneoossary remove tho frontspacerfrom 1st 1evetse shdt baf 8 lhe 1st reverse lock p10 from Iha 1st reverse shift yoke tISsembly Remove the 1st0reverso shift yoke 1nsel ...

Page 23: ...r 9 Remove lhe actua1or 1O Removetile fourinterlockballs 1halhf eedeten1balls 100 ltlrceback upliQht swnch bafls and the 1 hree springs trom the shltc bar hou sing 11 Remove1herevetseplu noerreta intngplug andga Ske t from 1he shift bar housing 12 Remove the reverse plunger spring ...

Page 24: ...ont 13 Remove 1he reverse s1op 22 15 II the nre tObe repl ieed removeworn pnd trom sh1t1 yOke 1n s1 illnowp dandbend tabG overtopand bottom 01 yOke 164 I necess ary itllft bll Cll S and shift yokes ca be removed bydr1vi1 1Q IOCkp n from sh f1 barwitha punch aod hammer as shown ...

Page 25: ...unger 2 1ns1o1 r i ll d 23 3 InstaD he1 ptungorgaske1 ancfplug Tighteo lhO reverse plunger plug 1 0 1 1101ecommended tCKq1 1e 4 If shdt block or st 1flyok were removed ahgn sh 11 yokeor b6ock with 01 gnment holo1 nthe shrl tbarend inaer1 klck P NOTE II p11MOUsly IQl l IOVOdinstall two spacers on 1 l teverse sh1h 1 a1before nstotllngboth shift blocks inse 11 ...

Page 26: ...spnngandball OStbOn 2 balls Inadjacent cross bore and install 2nd 6 Seal the 1st rQVQrse actuatOfIn the sh1 h barhousing over 1he actuatorpll 01 ptn as shown 3rd detent spring and ball Position 2 balls ui adjacent cross bore and install deten1 spnr g and ball NOTE Salls and SJ llngs can be used lnterohangeabl 7 POStbon tst reverse yoke assembly in dle shift bar housing inset Install the 1st revers...

Page 27: ... the 2nd 3rct yoke assembly interlockpin POSlbonthe 2nd 3rd yokeassemblyln thehousing ass em bly as shown 1O Position 1he 4th 5th yoke assembly in lhe hovslng assembly as shown 11 Place lhe still yokes an oou11at and Install the 1 wo retainers atld lhe tout capscrews as sllO llfl Tigh1on the e apsaews10100 recommencedtOtQUB Shih4th Sth yoke as mbfyinto 4tll speed pos111on ...

Page 28: ...DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS Shift Bar Housing Assembly cont 12 lns1au lhe remaln1ng rwo capscrews nnd tighten capsc1 w1 1 0 1 ooommcnded 1 orque ...

Page 29: ... Yoke and Clutch Housing _ A Removal of Yoke Of COVE A 0 1 Lock1he11ansrn r s1onby oogaglnglwomi lnMnl1geat as Shown 111 00 Use a latge b oakCf bar 10 tutn 1he rc1a n ngnul from lheoutput shaft z Removo he yoko from 1heoutput shalt v ...

Page 30: ...REMOVAL YOKE AND CLUTCH HOUSING B Removal of the Clutch Housing 1 Remove lhe four retaining bOlts as sh wn 2 kirclutch houslng Itha rubbermal 6landpul1 lrom the transmission case 28 ...

Page 31: ...isassembly of Input Shaft Assembly 1 Remove ltle four capscrews trom lhe front bearing oovera nd remove 1hecoverand shims The trontbeanng oovershlms can come oft Vlth 1he front bean ng cover If necessary remove the oi1 seal from the cover inset 29 2 Remove I he input shaft assembly from the transmls ...

Page 32: ...atY remDVe me ratan Joo snap r ng Mel the beaung rtltntion ring 4 It neoeuary temove the 1 a roller bearings tron1 tna ma n drive gearbearing poc f et 30 5 use a c hisef lO remove the beamg cage and rollers Ins tall beanng pusteranctremoyethe bearing race lromN shalt ...

Page 33: ...oval and Disassembly of Mainshaft 1 Rffmovt the toor rcta1ntng nuts and and removethe 9at beardlQ rove It R808INI t8 T10Y91he Oii i 1181 lrom covet 5e J 31 2 Remove speedon lelerdrNe gear inset Tap on 1ne tron1 ol Ille main 10 _ U 8 _d abou 1 4 UM pry bwa to t8 nCri9 lh rear beanng a a d locoong mg ...

Page 34: ...nlzer Use a hotst to remove the mainsllaft assembly from the transmtSslon case 4 Install the malnshaft assembly in a vise equipped mlh soh aws or wood shah lronl facing up Remove ht 4th 51h speed synchronizer and wps S Remove the throst bearing and bearing race 6 RemO l e 41h 51 h speed clutch hub 32 ...

Page 35: ...MBLY TRANSMISSION Mainshatt Disassembly cont 7 Remove the 4th spaoo geaf a Remove 4ltlgerubearing 9 Remove 3rd speed gear retaining snap ring 10 Aen1ove 31 d speed gea11 hrusl wasllor Remove the locating ball ...

Page 36: ...RANSMISSION Mainshaft Disassembly cont 11 Remove 1he lid speQd g ear 12 Remove the 3rd gearbeanng 13 Remove lhe 3rd gear synchronizer cup and synehrO lizerassembly 14 Reposition ma inshaltInLhevlsesoreat beatingisup ...

Page 37: ...DISASSEMBLY TRANSMISSION Malnshafl Disassembly cont 15 U8 llg g90r ouller remove lhl bW ll 17 RemoYethelll ip14washer 18 Remov thO 1S I gea1 Use cavtjon so n01 10 IDM beanng rOllors lho gear ...

Page 38: ...DISASSEMBLY TRANSMISSION Malnshaft Disassembly cont 19 Remove 1 hebeanng rollers and spacers 21 Remove the 1si 1eversesliding clu1ch 20 Remove 1s1 reverse sluf1 hvbsnap ring 22 Remove dte shih hub 36 ...

Page 39: ...BLY TRANSMISSION Mainshaft Disassembly cont 23 Remove the reverse gear 24 Remove the rBWrSe gearbeanng 37 25 Remove 2nd gear split washer retainer ring 26 Remove lh 2nd gear spl I washer and locaung bail jmse1 ...

Page 40: ...DISASSEMBLY TRANSMISSION Mainshaft Disassembly cont 27 2l ld speed gear 311 ...

Page 41: ...11 C Removal and Disassembly of Countershaft and Reverse Idler 1 Romovt the lour cac iwewsand Lhe counlerthah rear i aring oover and gaskel 2 Remove the 1 wo ROI screws 1fls 1 Remove 1he beanng reta nor oult r race and shims NOTE Countllrsl llftmay i hde to the rear aoo ou1 oi mo beanng bolt ...

Page 42: ...coun1ershatt assembly to the rear 1 111ti from the transmission case 4 Remove 1ho averse retaining capscrew and the retainer o 5 Using a wedge bar remove the roverse idlershaft 6 Remove the tevers Idiot bearings spacer and thrust washers ...

Page 43: ...ce to the reartoWard the case s insrde 8 Position gearpulAerand c1a1opb h1nd tho earcoun1er shah bearing and remove the beanng 9 U 9 ascrewdriver and snapringpilerstomovethesnap ring out ot snap rlnggroove and against Ihabeanng back 10 Use the countershaft dove gear rear face as a base then f fess thedrive gear snapring andbearing from 1he countershaft ...

Page 44: ...DISASSEMBLY TRANSMISSION Countershaft and Reverse Idler Disassembly cont 13 Remove 4th gear key ltom lhe c ouotlfl Shah 12 Remove eoun1l rshatt ttli gear ...

Page 45: ...1ns t1 Align 41h speed oountorshalt gearkey waytoshal1 key 4th gear on lheex OOl9f h_ n long hub to stlaJt lront 2 Prvs sS1h speed coomor8 lattgearon longhubtostiaft 3 lnstaJI 11nap ring 1 11 the oountersha ft 1ron1 snap nng groove 4 H 11t And 1nstal11he front coun1orshafi beanno CAUTION Do notheat1ne bu tong above 275 F1136 It PM l l usea aathe source ...

Page 46: ...sa bore plug Coat 1he outer diame1er of bore plug with loctita 510 before installing 7 Use grease on the two reverse ldJer thrust washers to holdInplace Installreverse idlergearwtfh tangsof wasti ersInhousinggroove w th the smallreverse idlergear to ttle rear 8 tnsen1herevtuseIdlershaft through 1hecaseandIdler gQarneectiebearings lnsi all the reverse tdlerretrunOfand capscrew Inset Make su1eIlleId...

Page 47: ...11 31 1 mission 10 Pos1t100 100 1raM m1sa1on case oo end RI shown PMtllon ttle coun1 eraliolt assembly ln1 0 the front l M ating 11 klstal h rear beanng race n10 the asshcM t I t 2 Teimporanly inS tall new Shim M ltOthe beanng rat 1 no1 inset lns1at11hereta11 101and Ioghtenthe set sorewttothe recomn1ended lol QU j ...

Page 48: ... End playmust be set aJ 002 008 0 05 0 20 mm Add shims tor more end play and 1emove stllms lorloss end play NOTE Once end playIscotrecl remove the retainet and apply alight coat ot LoctilB 510 to each side of tho shims and the tataln9f lace Coat w1thLoc111 e 262and tighten to the recommended torque 14 InstallIlleoountersha ft1earbaa11ngcovocand gas1 e1 Coatcapscrewthreadswtlh Loeltle 262and bghten...

Page 49: ... Mainshaft 1 1ns1all 1ht maJO ha I in a v Se eq1J ppeid w1hwooa Of t wat1 1W l Lubnc a11tandlnstal 2nd pOed 9 r bOanng 3 tnsian loc allflgball lnsut1and2nc fgearsplr1 washer 50 1he spin nngs JO Ille1ocallng bal 4 f lS lall 2nd gear aplll was hQr riilaine nng ...

Page 50: ...SEMBLY TRANSMISSION Reassembly of Mainshaft cont Install m unshalt nwef Se gearbearing 7 Install mwnshaft 1st reversespeed clutch hub 6 lnsiau malnshaftreverse gear 8 lnstatl 1s1 everse gear slidlng Clutch ...

Page 51: ... ol 44 noecflebeanngs around the ma1os haf I on top o1 tNi spacer ring lnstatr a spacOf ring ovtK 11 e lop ol the second row of needle beat ll IQS 49 11 tt11talltnainlhafl 1 1gaar ovetthetworowsol nee le beat nQt wlli ICl CJ Be ca llflJI 10 calCh d l8 beantlQ 12 ln t u O loc0 1g ball 0 1 tie mainshofl Install Ist spoed ge 11 llJl I washef so 1he SQI nngs Jon at lhe 10Cf 11 ng bad ...

Page 52: ...washerretainer 1lngDveflhe spl 1rings 14 Using a bearing dmrer inslaU mainshaf1 rear bearing as r hcr vn 50 15 Reposition mainshal1in vise so rronl Isup Install he malnshaft 3rd speed gear synch tonizer assel nbly 16 InstallUl mrunshaft3rd speed gearsyndlron12ercup assho Nn ...

Page 53: ...t t7 lnstaD mrunshott 3rd gpeedgear boar no 18 lnsiallmaJnshaft31d pOOd gear ciutcl wng100thtac lng OOvm SI 19 lns1olllocatingball and 3ttl epeedgear ttuus1wo 110 1 r l ll ll IC 20 tn 1 11mainshah3rd speed oearreuun1ng Stl8 1nng1n tt 13 IMP ring groove ...

Page 54: ...REASSEMBLY TRANSMISSION Reassembly of Malnshaft cont 22 Installmalnthaf I 41 1 clutching teetn facing up 24 Install lhru tbearing and boar1ng race on the main shilti c1h 51t1 clu1ch hub ...

Page 55: ...chron1zor UseahOtSItoiflsta the n1runshnft assembly in tranam11slon case 53 27 II previousty removlil d ln talt 1 1 rollerbeafing in 11 11 maindrivegeai beanng poc kal lnslall ttie retenUOtl lf l8 mg and retenlOl nng tntotf 11 bncaJesne beanngs w tr I l ghquality 28 Hl at tf le mputsriaflbeanng ancfinSlal the beanrig on lh W1put stiatL CAUTION Oonol nombconngobove 275 F 136 C II ponlble use a heat...

Page 56: ...all the oil seal on the frontbe anng coveJ wilh a bearing driver as shown lns1ell the input bearing race in the front bearing cover with the proper beruing dflver 54 31 Install Input shafl bearing oover gaske1 and ap sctows The frontbearing coverlubrication oilgroovemust beatthe top ApplyLoctiteD262 tothreads ol capscsrews and lighten 1 0 rooommended torque NOTE Bearing marked lorptopec installa1f...

Page 57: ...lcattonon groove w lh case hole NOTE Roarbflaring covertS marked IOI proper inslalla uon 36 Tigh1 enthe lroo1 beatingcovercapsctewsto 30If lbs ol totque Using 1wo reeler gages at the capsaew toca oons record the gap bB wQeo thefron1 bearing cover and the transmlSSiOn case Average the two recorded moos urementsa11d add 0 016 This you ashim pack 1 hickn ss10starttheend pt aymeasurement Combine1ho hi...

Page 58: ...ge and read 1l1ec aJ _ to get mainst olrt end p ay Endplaymusebebet ktlen ooe 012 0 20 0 30mm Addsllims1olhefrontboarlngoaver lormoreIndplayorremoveshims forless endplay After 1he00t1ec1ond p ay is set remove lhe front boanng cover and tlhlms Coo I bolh s dos of the lilms wl11l a hghl ooal al LOCl le 610 lnstotl tOe shims and 1 ho hont boar1ng oove1 on 1he transmission case Coal the front bearing ...

Page 59: ...ALLATION CLUTCH HOUSING A Installation of Clutch Housing 1 Position the 11ansmlS On as shown Place I hedutch housingonu e1ransmissioncase Instatl1herourretaining bol1s and tighten 10the 1eoommended1orqoe 57 ...

Page 60: ...bothousing innO ltral and ln11au on case make sure 1hG shift yak Gs allg n wilh correspoodlng yn chrOfllt rs and shchog dutch 2 Atll Yloc 0l2 21t ol_ lnolallwO capeo Into Ill nbat hous ng 9 and ngn1en 10 1M recomm f lded 3 Install lhe rem I nlng ca pscrews and lighten to 1 tie recommended torqvo 4 Coat there capecrewsthreads andWlSla TIQIMnlhocapeo IO IO que ...

Page 61: ...OPTIONS REMOTE SHIFT ARM SHIFT FINGER Cut 727 8 87 REMOTE CONTROL HOUSING ASSEMBLY BREATHER CAPSCREW Cut 728 6 87 59 ...

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Page 64: ...ducts with all options installed Although every attempt has been made to ensure the accuracy of information contained within Eaton makes no representation about the completeness correctness or accuracy and assumes no responsibility for any errors or omissions Features and functionality may vary depending on selected options F or spec ing or service assistance call 1 800 826 HELP 4357 or visit www ...

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