Eaton FSO-2105 Service Manual Download

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Summary of Contents for FSO-2105

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Page 2: ...5 FSO 2505 4x2 and 4x4 Models 9 Countershaft Assembly FSO 2105 FSO 2505 4x2 and 4x4 Models 10 Lubrication Information 11 Operation 13 Gear shift lever pattern 13 Power Flow 14 Adhesive and Sealant Application 16 Torque Recommendation 17 Precautions 19 Troubleshooting 21 Tool Information 26 Universal Tools 26 Essential Special Tools 27 Complementary Tools 29 Installation Reference 31 FSO 2105 Model...

Page 3: ...y 59 Mainshaft Disassembly 61 Assembly 61 Countershaft Disassembly 65 Assembly 65 Input Shaft Disassembly 66 Assembly 66 Shift Yoke Bars Disassembly 67 Assembly 67 Expansion Plugs Removal 69 Installation 70 Permaglide Bushing Removal 70 Installation 71 Reverse Shifting Interlocking System Description 71 Disassembly 72 Assembly 72 Double Gear Shifting Interlocking System Description 73 Disassembly ...

Page 4: ...d Countershaft Rear Bearing Cups Removal 78 Installation 78 Synchronizer Assemblies Description 79 1st 2nd Speed Synchronizer 79 3rd 4th Speed Synchronizer 81 5th Reverse Speed Synchronizer 83 Front Section Assembly 84 End Play Adjustment Mainshaft End Play Measurement 88 Countershaft End Play Measurement 89 Determining Shim Pack Thickness for End Play Adjustment 89 Table of Contents ...

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Page 6: ...rmation and technical references placed all together into one section 2 Disassembly and assembly instructions by its turn divided into sections gathering specific component assemblies For the complete disassembly and assembly of the transmission follow the manual in its natural sequence However if only a component should be serviced locate in the index the section to which the component belongs an...

Page 7: ...y reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement Equivalents may be used This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and or component damage Departure from th...

Page 8: ...s stamped on the identification plate fixed to the transmission case Eaton Synchronized Overdrive FSO 2105A Gear ratio Forward speeds Design level Nominal torque capacity x100 Lb ft WARNING Do not remove or destroy the transmission identification plate Note When ordering replacement parts or calling for service support please inform identification plate numbers ...

Page 9: ...4 14 3 143 1 423 x 3 143 4 472 FSO 2105 FSO 2505 A A B Torque N m 270 440 440 Lb ft 200 325 325 ND Ratio ND Ratio ND Ratio Input shaft 26 26 26 Countershaft 37 37 37 1st CE EP 14 44 4 47 15 43 4 08 15 43 4 08 2nd CE EP 22 38 2 46 23 37 2 29 23 37 2 29 3rd CE EP 29 30 1 47 29 30 1 47 29 30 1 47 4th CE EP 1 00 1 00 1 00 5th CE EP 45 26 0 82 53 27 0 72 51 29 0 81 Reverse CE RV EP 12 29 32 3 79 12 29 ...

Page 10: ...r shift lever housing 2 Threaded pin 3 Locating pin 4 Spring 5 Threaded plug 6 Gear shift lever pivoting support 7 Thrust washer 8 Boot 9 Gear shift lever 10 Pivot pin 11 Gear shift lever bushing 12 Shock absorbing rubber gasket 13 Flat washer 14 Support spacer 15 Shock absorbing bushing 16 Washer 17 Screw M8 x 35 ...

Page 11: ...d yoke bar 40 1st 2nd speed shift yoke assembly 41 Yoke pads 42 Roll pin 43 Shift selector block assembly 44 Bushing 45 Pin 46 Washer 47 Spring 48 Spring support 49 Snap ring 50 Shift selector bar main bar 51 Shift lug 4x4 51a Shift lug 4x2 52 Roll pin 53 5th reverse speed shift block 54 Roll pin 55 5th reverse speed yoke bar 56 5th reverse speed shift block 57 Roll pin 58 5th reverse speed shift ...

Page 12: ...g 83 Filling plug 84 Threaded pin 85 Screw 86 Dowel pin 87 Screw 88 Harness bracket 89 Reverse light switch 90 Ball 91 Lock spring 92 Threaded plug 93 Drain plug 94 Bracket 95 Rear housing 96 Oil seal 97 Actuator s bushing 98 Actuator 99 Actuator s spring 100 Threaded plug 101 Magnetic speed sensor 102 Screw 103 Oil pick up 104 Reverse idle gear shaft 105 Needle bearing 106 Reverse idle gear 107 B...

Page 13: ...k assembly 82 Intermediate housing 83 Filling plug 84 Threaded pin 85 Screw 86 Dowel pin 87 Screw 88 Harness bracket 89 Reverse light switch 90 Ball 91 Lock spring 92 Threaded plug 93 Drain plug 94 Rear housing 95 Oil seal 96 Actuator s bushing 97 Actuator 98 Actuator s spring 99 Threaded plug 100 Oil pick up 101 Reverse idle gear shaft 102 Needle bearing 103 Reverse idle gear 104 Bearing 105 Shif...

Page 14: ...35 Mainshaft 4x2 135a Mainshaft 4x4 136 Needle bearing 137 Mainshaft 2nd speed gear 138 Mainshaft 2nd speed gear cone 139 1st 2nd speed synchronizer inner ring 140 1st 2nd speed synchronizer middle ring 141 1st 2nd speed synchronizer outer ring 142 1st 2nd speed synchronizer assembly 143 Key 144 Mainshaft 1st speed gear 145 Needle bearing 146 Bushing 147 Mainshaft intermediate bearing cone 148 Mai...

Page 15: ...him 0 178 mm 165 Shim 0 254 mm 165 Shim 0 508 mm 165 Shim 0 762 mm 165 Shim 1 016 mm 166 Ball 167 5th speed gear thrust washer 168 Needle bearing 169 Countershaft 5th speed gear 170 5th speed synchronizer ring 171 5th reverse speed synchronizer assembly 172 Spring 173 Key 174 Snap ring 2 215 mm 174 Snap ring 2 365 mm 174 Snap ring 2 290 mm 175 Countershaft reverse speed gear synchronizer ring 176 ...

Page 16: ...rly lubricated if these procedures are closely followed 1 Maintain proper oil level by inspecting it regularly 2 Change oil regularly following the maintenance interval chart 3 Use the recommended grade and type of oil 4 Buy from a reputable dealer Oil change and level inspection Periodic transmission oil change eliminates possible bearing failures ring wear and seizures since the products of norm...

Page 17: ...il varies with the position of vehicle related to the ground and the installation angle of transmission Before refilling place vehicle on a flat and level surface Fill up transmission until lubricant begins to leak through the filler plug Lubricant oil volume 2 7 to 3 3 liters Correct Oil Level Incorrect Oil Level Oil level inspection Before checking oil level clean case area around filler plug an...

Page 18: ...m prevents from accidental transmission shifting from 5th to reverse gear Tips for the driver Always use the clutch to change gears The incorrect use of the clutch may cause premature failures of the synchronizer assembly Always select a starting gear that will provide sufficient power torque for the vehicle s load and working conditions terrain Never slam or jerk the gear shift lever to complete ...

Page 19: ...ransferred to the countershaft drive gear In this way input shaft and countershaft always run together 3 The torque along the countershaft is delivered to all mainshaft gears assembled on bearings These gears rotate free unless one gear is shifted 4 When a gear is shifted the torque is transferred from the corresponding engaged mainshaft gear through the clutching teeth of the synchronizer assembl...

Page 20: ...nd there are no gears under load 5th and Reverse Speed The 5th and reverse speed gears synchronizer unit is assembled on the countershaft unlike the other speed synchronizers that are assembled on the mainshaft By its turn their corresponding gears on mainshaft are assembled fixed to the mainshaft 1 With the 5th speed gear engaged torque is transferred from countershaft to the mainshaft correspond...

Page 21: ...mpounds is important to assure a proper assembly and to avoid leakages FSO 2105 torque3 Apply Eaton 680 or Eaton 679 to plug threads Apply Eaton 680 to mounting surface of rear cover and intermediate housing Apply Eaton 680 to mounting surface of front and intermediate housings Apply Eaton 679 to expansion cup type plugs ...

Page 22: ...nd to avoid oil leakage assuring a long transmission life Additionally apply the recommended adhesive to the threads WARNING Always use a torque wrench to tight to the recommended torque 2 Item Description Thread Torque N m Lb ft Remarks 1 Gear shift control M8 19 25 14 19 housing capscrews Apply Eaton 677 to threads 2 Housing capscrews M8 19 25 14 19 Apply Eaton 677 to threads 2 1 ...

Page 23: ...in face only 6 Gear shift control M16 14 21 10 15 housing threaded plug Apply Eaton 680 to thrust face 7 Shift control actuator M24 10 16 7 12 plug Apply Eaton 680 to thrust face 8 Speedometer sensor 13 16 20 UNEF 10 16 7 12 Apply Eaton 677 to threads 9 Mainshaft nut M37 217 270 160 200 Lock the nut in position using a center punch 10 Oil drain plug 3 4 14 NPTF 40 47 29 34 Apply Eaton 680 or Eaton...

Page 24: ...bling or assembling may cause them to lock Housings Clean interior and exterior of cases covers etc thoroughly Cast parts may be cleaned in weak alkaline solution baths we recommend a 7 soluble degreasing oil solution The parts are to remain in the bath for the time it takes to become completely clean The parts cleaned in alkaline solutions should be rinsed with clean water to remove any alkaline ...

Page 25: ...e the cost of a new part is generally a small fraction of the total cost of downtime and labor do not reuse a questionable part which could lead to additional repairs and expense soon after assembly To aid in determining the reuse or replacement of any transmission part consideration should also be given to the unit s history mileage application etc Oil seals and snap ringselásticos Any oil seal s...

Page 26: ...n manual As to vehicle s instruction manual Recommended lubricant in this manual Recommended lubricant in this manual As to this manual instructions Transmission noise with engaged gear Improper or damaged clutch disc Low lubricant level Worn or damaged flywheel bushing or bearing Vibration from other vehicle components drive shaft yoke mounts Misalignment between engine and transmission Worn or d...

Page 27: ...ting system components shift yokes nylon pads bars shift blocks Mainshaft or countershaft end play improperly Verify and adjust clutch Replace Replace Replace damaged parts Replace rings Replace synchronizer assemblies Replace worn or damaged parts Adjust end play As to vehicle s instruction manual As to vehicle s instruction manual Recommended lubricant in this manual Gear shift lever housing in ...

Page 28: ...end play As to vehicle s instruction manual Gear shift housing in this manual Synchronizer assemblies in this manual As to this manual instructions End play adjustment in this manual Problem Probable cause Possible solution Reference Gear shift rubbing Malfunction of clutch Malfunction of clutch linkage Worn or damaged flywheel bushing or bearing Worn or damaged synchronizer rings Shift yoke nylon...

Page 29: ...instructions Requires specific procedure Transmission slips out of gear Gear shift lever console out of position forcing the lever Worn or damaged synchronizer assemblies 1st 2nd and 3rd 4th synchronizer hub swapped anti escape relief Mainshaft or countershaft end play improperly adjusted Worn or damaged shifting system components gear shift lever shift yokes bars shift blocks etc Adjust console R...

Page 30: ...t Transmission components assembled improperly Mainshaft or countershaft end play improperly adjusted Bearings were not lubricated before assembling Fill with recommended oil to the proper level Drain and replace with recommended lubricant Reassemble Adjust end play Replace damaged parts Reassemble as to proper procedure Recommended lubricant in this manual Recommended lubricant in this manual As ...

Page 31: ...len wrench 12 mm Combination wrench open box end 11 mm Combination wrench open box end 13 mm Combination wrench open box end 19 mm Open end wrench 16 x 17 mm Open end wrench 21 x 23 mm Screw driver 12 Hand scraper Ratchet extension 1 2 square drive x 10 long Ratchet extension 1 2 square drive x 4 long Magnet Sandpaper sheet 240 grit Ball pein hammer 300 g Plastic tip hammer soft mallet Center punc...

Page 32: ...stallers E001015 Input shaft bearing cup installer E001016 Mainshaft front bearing cup installer Note Use with E001013 E001039 Countershaft front bearing cup installer Note Use with E001013 E001086 Front seal installer E003001 Slide hammer impact puler Illustration Tool Ref Description E004002 Slide hammer adapter end E005003 Pocket bearing cone puller E006004 Spline socket for input shaft 23 spli...

Page 33: ...g transmission disassem bly and assembly by one mechanic only The tool allows using transmission gear ratio as a means to help in removing and installing the mainshaft nut Other complementary tools are provided to make transmission service easier to be carried out A complete list of these tools can be seen below in this manual Illustration Tool Ref Description E019001 Socket for locking mainshft n...

Page 34: ...er Note Use with E001037 E001038 Intermediate housing mainshaft bearing cup installer Note Use with E001037 E001044 1st 2nd 3rd 4th and 5th Reverse speed yoke bar roll pin punch E001045 Shift lug roll pin punch Illustration Tool Ref Description E005005 Thread cutter E006002 Special socket 30 mm E006006 Special wrench 54 mm E006007 Mainshaft lock 27 splines Note Use with E014010 E006017 Mainshaft n...

Page 35: ... stand E014019 Transmission overhauling stand Option Without reduction with reduction or electric stand E024001 Intermediate housing bearing cup puller installer support Note Use with E001016 and E001039 tools Illustration Tool Ref Description E027001 Oil seal installer E028011 Ol seal remover ...

Page 36: ...Installation Reference Installation Reference 31 FSO2105_Flex2 4L_SOHC4x2_1 FSO 2105 Model Application Flex 2 4L SOHC 4x2 PAGE 1 2 ...

Page 37: ...Installation Reference 32 FSO2105_Flex2 4L_SOHC4x2_2 FSO 2105 Model Application Flex 2 4L SOHC 4x2 PAGE 2 2 ...

Page 38: ...Installation Reference Installation Reference 33 FSO2105_Flex2 4L_SOHC4x4_1 FSO 2105 Model Application Flex 2 4L SOHC 4x4 PAGE 1 2 ...

Page 39: ...Installation Reference 34 FSO2105_Flex2 4L_SOHC4x4_2 FSO 2105 Model Application Flex 2 4L SOHC 4x4 PAGE 2 2 ...

Page 40: ...Installation Reference Installation Reference 35 FSO2505_Diesel4x2_2 5_2 8_1 FSO 2505 Model Application Diesel 4x2 2 5 2 8 PAGE 1 2 ...

Page 41: ...Installation Reference 36 FSO2505_Diesel4x2_2 5_2 8_2 FSO 2505 Model Application Diesel 4x2 2 5 2 8 PAGE 2 2 ...

Page 42: ...Installation Reference Installation Reference 37 FSO2505_Diesel4x4_2 5_2 8_1 FSO 2505 Model Application Diesel 4x4 2 5 2 8 PAGE 1 2 ...

Page 43: ...Installation Reference 38 FSO2505_Diesel4x4_2 5_2 8_2 FSO 2505 Model Application Diesel 4x4 2 5 2 8 PAGE 2 2 ...

Page 44: ...Installation Reference Installation Reference 39 FSO2505_HFV6_4x2_1 FSO 2505 Model Application HFV6 4x2 PAGE 1 2 ...

Page 45: ...Installation Reference 40 FSO2505_HFV6_4x2_2 FSO 2505 Model Application HFV6 4x2 PAGE 2 2 ...

Page 46: ...Installation Reference Installation Reference 41 FSO2505_HFV6_4x4_1 FSO 2505 Model Application HFV6 4x4 PAGE 1 2 ...

Page 47: ...Installation Reference 42 FSO2505_HFV6_4x4_2 FSO 2505 Model Application HFV6 4x4 PAGE 2 2 ...

Page 48: ...assembly from your dealer 1 Remove the four retaining capscrews from the gear shift lever housing and remove gear shift lever housing assembly from the transmission 2 Remove the boot 3 From the housing remove locating pin spring and threaded plug 4 From the housing remove the two threaded pins 819 827 836 840 5 Remove gear shift lever by hands and remove the pivot pin from the lever 6 Remove gear ...

Page 49: ...assembly 1 Install thrust washers into the gear shift lever housing 2 Install the nylon bushing gear shift lever pivoting support and the thrust washers onto the lever pivoting support Note Use grease to hold thrust washers in position 3 With the hands install gear shift lever in the gear shift lever housing 857 849 843 ...

Page 50: ...ransmission horizontal and install the four washers on rear housing 8 Place the shock absorbing rubber gasket onto the rear housing 9 Install the four shock absorbing bushings with the four support spacers onto gear shift lever housing Note Install support spacer with its chamfered face down 835 827 777 782 796 10 Apply multi purpose grease on the shift lever end and install the nylon bushing push...

Page 51: ...gear shift lever housing capscrews and tighten them to the specified torque Note Apply Eaton 677 on threads Torque 19 25 N m 14 19 Lb ft 822 11 Install the gear shift lever housing assembly on the shock absorbing rubber gasket on the transmission 808 ...

Page 52: ...screws securing the rear case to the intermediate housing 7 Using a rubber or plastic hammer to break the gasket seal carefully hit case to detach the rear case from the intermediate housing Remove rear case by pulling it upwards 8 Remove the speedometer rotor snap ring 046 026 030 EA029B 1 Remove the gear shift lever housing assembly from the transmission Refer to Gear Shift Lever Housing in this...

Page 53: ...t snap ring 049 EA028 12 Shift transmission into 1st gear using the shift yoke bars Note With no gear shift lever housing installed the gear shift lever pattern is inverted 10 Remove the rotor retaining ball from the mainshaft 11 Lock mainshaft using tool E019001 socket for locking mainshaft nut For this purpose install the special socket hexagonal hole on the mainshaft nut as shown in the figure ...

Page 54: ...moved 092 092 18 Using special tools E012001 and E012002 remove the reverse gear and the ball bearing together from the mainshaft by pulling them off 19 Remove the reverse idler gear 112 117 20 Remove the reverse idler gear needle bearing 21 Remove the reverse gear from the countershaft 118 123 22 Remove the reverse gear needle bearing and spacer from the countershaft 23 Remove the reverse speed s...

Page 55: ...remove the yoke by pulling it upwards 138 26 Remove the 5th reverse speed synchronizer hub snap ring from the countershaft 27 Remove the 5th reverse speed synchronizer assembly 138 28 Remove the 5th speed synchronizer ring 29 Remove the 5th speed gear from the countershaft 139 140 30 Remove the 5th speed gear needle bearing from the countershaft 31 Remove the 5th speed gear thrust washer from the ...

Page 56: ...ve the 5th speed gear from the mainshaft 148 145 055 060 34 Remove the reverse light switch 35 Remove the 5th reverse speed linked shift block retaining roll pin Note Use the special pin punch E021002 and the special reverse light switch thread protector bushing E021001 36 Remove the 5th reverse speed linked shift block 663 ...

Page 57: ...ol Note Use the proper device for the transmission refer to Special Tools in this manual EA070 EA071 Rear Section Assembly 1 Place transmission with the rear section facing up 2 Install the 5th reverse linked shift block 3 Install the 5th reverse linked shift block retaining roll pin using the recommended special pin E0021001 punch and the reverse light switch thread protector bushing Note Replace...

Page 58: ... speed gear needle bearing on the countershaft 148 147 143 9 Install the 5th speed gear on the countershaft 139 10 Install the 5th speed ring synchronizer on the countershaft Note The 5th speed synchronizer ring is NOT coated with EFM II and is smaller than the other rings 11 Install the 5th reverse synchronizer assembly on the countershaft Make sure it is installed in the proper position Note Bot...

Page 59: ...ings 689 127 14 If necessary replace the 5th reverse shift yoke nylon pads 15 Install the 5th reverse shift yoke in synchronizer sleeve groove Pull the yoke backwards until engaging with the linked shift block EA099 136 16 Install the two pivot pins of 5th reverse shift yoke Note Apply Eaton 677 sealant to pin threads Torque 10 16 N m 7 12 Lb ft 125 135 134 17 Install the reverse gear needle beari...

Page 60: ... protruding side of the hub facing the housing outside 704 21 Install the reverse gear with the rear ball bearing together on the mainshaft with the most protruding side of the hub facing the housing inside 22 Install the ball bearing thrust washer on the countershaft Note The thrust washer has a retaining ball which should be installed with the washer 114 702 701b 23 Install the countershaft rear...

Page 61: ...ocket to the housing with two housing s capscrews WARNING Be careful do not overtighten capscrews or leave them loose in order to avoid damage to the aluminum housing 049 088b 078 28 Place transmission horizontal and install the special socket E006004 or E006005 depending on the input shaft spline type onto the input shaft Using a torque wrench rotate the shaft clockwise for tightening the mainsha...

Page 62: ...o be applied on the tool using the 1st speed reduction ratio Transmission Gear ratio at 1st speed Torque to be applied FSO 2105A 4 473 49 to 60 N m FSO 2505A B 4 079 54 to 66 N m 29 Remove the tools Note As an option for the above procedure the special tool E014010 may be used for locking the mainshaft and the tool E006006 to tighten the nut In this case the torque is applied directly to the nut a...

Page 63: ...y Eaton 680 or Eaton 679 sealant to sensor threads Torque 10 16 N m 7 12 lb ft 029b 029b 36 Install the plug spring and spherical actuator pin of the cam threaded actuator using the special socket E018001 030 EA029b 766 37 Align the shift lug with the gear shift bar matching the roll pin holes and install the retaining roll pin using tool E001045 38 Install the gear shift lever housing assembly on...

Page 64: ...rews securing the front housing to the intermediate housing 152 154 156 003 6 Remove the intermediate housing Note Use pry bars between the housing special bosses provided to detach the intermediate housing If necessary carefully hit housing s capscrews area with a rubber or plastic hammer to brake the gasket seal and detach the housing WARNING Do not support pry bar on housing s contact surface i...

Page 65: ...pull the yoke bar upwards When the bar lower end rises over the housing surface see detail remove the bar and shift yoke assembly 171 11 Simultaneously remove from the housing the remaining assemblies of mainshaft countershaft 3rd 4th bar and shift yoke and input shaft while grasping them all together and pulling them upwards 173 EA037a EA036b EA037B 12 Take the assemblies apart ...

Page 66: ...mainshaft through and remove the set of components up to the rear bearing cone WARNING Be careful NOT to use mainshaft flange as a pressing base when using the 3rd speed gear 5 Turn the mainshaft over in the press and use the 3rd speed gear as a base 6 Press mainshaft and remove the 3rd 4th synchronizer assembly 3rd speed gear and the needle bearing 180 186 190 EA041 183 Mainshaft Assembly 1 Insta...

Page 67: ...oth the largest chamfer of the synchronizer sleeve and the most protruding side of the hub of the 1st 2nd speed synchronizer must face the 1st speed gear refer to Synchronizer Assemblies 426 429 438 427 430 439 5 Align the center of the recess in the synchronizer sleeve teeth with the center of the key at the three positions and install the synchronizer sleeve 6 Install the 1st speed outer and mid...

Page 68: ...ponents onto the mainshaft Make sure to align the synchronizer ring lugs with hub key slots to properly fit WARNING Apply force to bearing inner race NEVER apply force to the bearing cage Do NOT use the shaft flange as a pressing base 13 Check if the pressing procedure has been successful disengage the synchronizer and put it in an intermediate position between 1st and 2nd speed gears The gears in...

Page 69: ...cedure has been successful disengage the synchronizer and put it in an intermediate position between 3rd and 4th speed gears The gears in this condition should rotate freely 493 EA166 20 Install the 3rd 4th speed synchronizer hub retaining snap ring 502 18 Using special tools E010001 and 010002 press the late installed set of components onto the mainshaft Make sure to align the synchronizer ring l...

Page 70: ...ver and use the rear bearing cone as a pressing base by using the E007008 special device 4 Press the countershaft through the rear bearing and remove the bearing EA043 EA167 EA043 EA167 Assembly 1 Position both the front and the rear bearing cones on the countershaft 2 Use two tubes of the appropriate size and diameter or use the special tool E010010 and place the countershaft in the press using t...

Page 71: ...ugh the bearing and remove the bearing Assembly 1 Position the bearing cone on the input shaft 2 With the synchronizer side down place the input shaft on a base Be careful not to damage the synchronizer cone 3 Using the bearing inner race as a base press the bearing assembly with the appropriate tubular tool until the race shoulder be against the shaft face WARNING Apply force to bearing inner rac...

Page 72: ...shift block is properly positioned regarding the notch at the yoke bar end and install the shift block on the yoke bar EA110 2 Make sure the 3rd 4th speed shift yoke is properly positioned regarding the notch at the yoke bar end and install the shift yoke on the yoke bar EA110 3 Align the shift yoke with the yoke bar matching the roll pin holes and install the retaining roll pin Using tool E001044...

Page 73: ... the roll pin until it is flush with selector block hub Note Replace the roll pins with new ones 576 4 Install the spring supporting washers on both sides of the selector block 580 5 Install springs and supporting bushings 585 6 Install the retaining snap rings of the selector block using the E017021 special device 602 548 5th reverse Yoke Bar Assembly 1 Make sure the shift block is properly posit...

Page 74: ... cup type metal expansion plugs During the transmission life it is possible to happen that some of those plugs should be removed and reinstalled when servicing the unit Removal 1 In the housing locate the expansion plug that should be removed Use the special device E005005 and make a thread in the plug Expansion Plugs 639b 2 Use one retaining capscrew removed from the housing and insert it into th...

Page 75: ...020 hit with a hammer to force the plug into the plug bore until the plug penetrates 2 mm below the plug bore top that is the proper plug depth EA170 Removal 1 Inspect bushing and replace if worn Note Inspect other transmission bushing too The pictures here show only the front housing bushing however the procedure is the same for all other transmission permaglide bushing Note Use special tools E00...

Page 76: ...o deactivate the locking mechanism just gearshift to neutral and then to reverse speed 608 4 Use pliers and pull the bushing out from the bushing bore Installation 1 Place the bushing on the special tool E001010 2 Position the bushing in the bushing bore and install the bushing by hitting the tool until it rest against the housing This condition gives the proper bushing depth 3 Use a center punch ...

Page 77: ...h 3 Pull the interlock pin upward and remove the mechanism assembly Assembly 1 Align the roll pin hole on the interlock pin with the corresponding hole on the housing and then install the interlocking mechanism into the interlock pin bore EA061 EA062 EA062 2 Give the spring as much as the tension you can by winding the spring on the pin and then set its free end in the housing hole 3 Install a new...

Page 78: ...displacing the remaining balls and locking the other yoke bars into the neutral position 260 280 Double Gear Shifting Interlocking System WARNING Be careful when removing the yoke bars Interlock balls may drop into the bar bores Keep a close watch on the interlock balls when disassembling and assembling the transmission 4 Install a new expansion plug in the housing hole Note Refer to Expansion Plu...

Page 79: ...towards the removed expansion plug hole and remove the pin through the housing hole Assembly 1 Apply grease to interlock bores to keep the balls in place 2 Install three interlock balls aligned from the 3rd 4th yoke bar bore and install the smallest ball 8 0 mm diameter located in the 1st 2nd yoke bar bore 280 292 EA084 3 Install the interlock pin through the housing hole whose expansion plug was ...

Page 80: ...t Bearing Cup Installation 1 Support properly the front housing with bearing bore side up 2 Prior installing the bearing cup carefully clean bearing cup and bore 3 Using the driver and special installer 001013 and E001015 drive the bearing cup into the bearing bore until cup seats on the bottom 5 Install a new expansion plug in the housing hole Note Refer to Expansion Plugs in this manual for inst...

Page 81: ...put Shaft Oil Baffle and Oil Seal Installation Note Replace baffle and seal with new ones whenever they are removed 1 Coat the new seal lips with the recommended grease 2 Install the input shaft oil seal in its bore using the special tool E001086 to guide the seal properly 909 211 3 Install the input shaft oil baffle observing its correct mounting position 220 281 ...

Page 82: ... the cup bottom and remove the bearing cup Countershaft Front Bearing Cup Installation 1 Support properly the front housing with bearing bore side up 2 Prior to installing the bearing cup carefully clean both bearing bore and cup 3 Use the E001039 special tool and drive the bearing cup into the bearing bore until cup is completely seated on the bottom Note Use with the special tool E001013 199 296...

Page 83: ... intermediate housing with bearing bore side up 2 Prior to installing the bearing cup carefully clean both bearing bore and cup WARNING Dirt between the bearing cup and the bearing bore can lead to axial clearance end play adjustment error 3 Install the bearing cups without any shim before adjusting the transmission end play WARNING Refer to End Play Adjustment later in this manual 4 Use special d...

Page 84: ...ibed below WARNING Before installing synchronizer assemblies on shafts is very important to be acquainted with their design features and be able to identify them as well 1st 2nd Speed Synchronizer The 1st 2nd speed synchronizer has keys assembled with balls and does not use springs Synchronizer Assemblies Both the 1st and the 2nd speed synchronizer rings are composed of 3 three rings one inner rin...

Page 85: ... hub with its most protruding side facing to the 1st speed gear 2 Install the synchronizer sleeve with its chamfered side facing to the same side of the most protruding side of the synchronizer hub 2 The center of the key must coincide with the center of the recess in the synchronizer sleeve teeth at the three positions With that in mind align the synchronizer sleeve with the synchronizer hub 376 ...

Page 86: ...installed with lugs facing to the synchronizer hub and should fit into hub slots 451 429 454 3rd 4th Speed Synchronizer Both the 3rd and the 4th speed synchronizer rings have the special EFM II coating Spring 3x Key 3x Synchronizer hub Synchronizer sleeve Disassembly 1 With the hands remove the synchronizer sleeve from the hub EA075 388 Synchronizer ring with EFM II coating 2x ...

Page 87: ...he synchronizer sleeve with the synchronizer hub EA076 3 To help when assembling position a synchronizer ring at the sleeve opposite side and insert the ring lugs into the synchronizer hub key slots EA077 4 Place the assembly on the bench with the synchronizer ring facing down 5 With the hands install the synchronizer sleeve on the synchronizer hub by forcing the sleeve downwards EA075 Installatio...

Page 88: ...s the special EFM II coating Disassembly and Assembly The procedure for disassembling and assembling the 5th reverse speed synchronizer is the same as described above for the 3rd and 4th speed synchronizer Installation The teeth ends of the 5th reverse speed synchronizer sleeve have one side rounded and the other side sharp ended Install the 5th reverse synchronizer assembly with the sleeve teeth ...

Page 89: ...chronizer hub key slots 526 493b 4 With the input shaft down position the input shaft and mainshaft assembly on the front housing 516 517 527 5 Position the 3rd 4th speed shift yoke and bar and the countershaft on the mainshaft assembly holding the whole assembly with the hands 6 Align the whole assembly as set before with the input shaft bearing cup with the countershaft bearing cup and with the ...

Page 90: ... aligned with the 3rd 4th shift block groove formerly installed 615 10 Install the shift selector bar in the bar bore positioning the shortest arm of the selector block between the 1st 2nd yoke bar notch and the 3rd 4th shift block groove The longest arm must be ahead the reverse shifting interlocking mechanism To do that rotate the interlocking mechanism by hand while positioning the shift select...

Page 91: ...que Torque 19 25 N m 14 19 Lb ft 652 15 Proceed to mainshaft and countershaft end play adjustment as recommended in End Play Adjustment later in this manual 16 After determining the shim pack thickness necessary for adjusting both mainshaft and countershaft end play remove intermediate housing 17 Use the proper drive tool and remove the rear bearing cups see Mainshaft and Countershaft Rear Bearing...

Page 92: ...ning sealant material from housing threaded holes 22 Apply a Eaton 680 sealant string of approximately 1 5 mm 1 16 inch of thickness to the center of the front housing mounting surface Inner side 1 5 mm 1 16 inch thick FSO 2105 3a 23 Install the intermediate housing on the front housing Note If necessary carefully hit the housing s capscrews area with a plastic hammer to match the housings 24 Appl...

Page 93: ...clearance end play remove ALL existing adjusting shims under both the mainshaft and countershaft rear bearing cups refer to Mainshaft and Countershaft Rear Bearing Cups Removal and Installation in this manual The bearing cups must have been installed in the bearing bores completely clean and perfectly seated on the bearing bore bottom Note Special tools used for measuring the end play see Tool Inf...

Page 94: ...tershaft end center Set the pointer to zero 6 Place the pry bar tool E008001 under the countershaft rigged up support and push the countershaft upwards at once Keep the countershaft in that position while taking the dial indicator reading Record that reading Determining Shim Pack Thickness for End Play Adjustment Specified end play mm Minimum Maxi mum Remarks Counter shaft 0 06 0 11 Positive clear...

Page 95: ...shaft end play adjustment Specified end play 0 06 mm to 0 11 mm Measured end play 0 47 mm As the measured value is greater than 0 11 mm maximum specified calculate 0 47 0 11 0 36 mm R1 0 47 0 06 0 41 mm R2 The shim pack thickness must be within 0 36 mm and 0 41 mm Example 2 countershaft end play adjustment Specified end play 0 06 mm to 0 11 mm Measured end play 0 02 mm In this case it is not possi...

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