Eaton TRSM0605 Service Manual Download

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Service Manual

Fuller Heavy Duty Transmissions

TRSM0605

October 2007

Summary of Contents for TRSM0605

Page 1: ...Service Manual Fuller Heavy Duty Transmissions TRSM0605 October 2007 ...

Page 2: ......

Page 3: ...orporation Transmission Div 1972 Service Manual Operation Lubrication Maintenance Repair RT 613 Series Fuller Twin Countershaft Roadranger Transmissions 1 Eaton Corporation Transmission Division Kalamazoo Michigan ...

Page 4: ...g ____________________________________________22 III Auxiliary Rear Housing ____________________________________________66 A Tailshaft and Rear Bearing Assembly ________________66 A Rear Housing ______________________________________________________22 B Auxiliary Shift Cylinder ______________________________________26 B Synchronizer Assembly ______________________________________69 C Auxiliary Shi...

Page 5: ...ission T Twin Countershaft type O Indicates overdrive Unless stated otherwise this manual applies to all models in the RT 613 series which includes RT 613 RT0 613 NOTE Illustrated parts lists with parts numbers are available upon re quest 3 ...

Page 6: ...iminate gear bushings and sleeves as gears float between mating gears on the countershafts FLOATING GEAR PRINCIPLE Malnshaft gear floats between countershaft gears no bushing no shaft sleeve Malnshafl entirely free of gear Twin countershafl gears rotate malnshafl gear SPECIFICATIONS Speeds 13 forward 3 reverse Torque Capacity 600 lb ft Clutch Housing Size SAE No 2 gray iron deep only 6 5 8 for pus...

Page 7: ... 29 Direct Range 11th 1 60 1 29 28 28 10th 2 05 1 65 28 27 9th 2 62 2 11 Range Shift 26 28 8th 3 29 2 65 24 24 7th 4 09 3 29 29 29 Intermediate 6th 5 26 4 24 Range 28 28 5th 6 74 5 43 28 28 4th 8 64 6 96 Range Shift 27 27 3rd 10 96 8 83 28 28 2nd 14 04 11 31 28 28 Low Range 1st 18 00 14 50 Dir Rev 2 77 Inter Rev 9 12 Low Rev 19 00 5 ...

Page 8: ... Shift Lever Pattern and Selector Valve Positions SELECTOR VALVE _____ NEUJRAL t 4 5 6 7 8 1 2 3 NOTE For RT0 613 models the 7 12 and 8 13 speed locations are reversed UPSHIFTING 1 With the transmission in neutral start engine and bring vehicle s air pressure to normal 2 Make sure the selector valve is in the LOW range position 3 Shift into the 1st speed gear position See page relating to transmis...

Page 9: ... soon as there is a relief in torque 9 llDITUI cb 6 Downshift from 3rd to 2nd and to 1st 7 Figure 2 Model RT 613 transmission is equipped with either a Transmission Countershaft Brake or an Upshift Clutch Brake Transmission Countershaft Brake Model TCB 6 or TCB 8 To be used only to assist initial gear engagement in first or reverse when vehicle is standing still Disengage clutch press down control...

Page 10: ...ollowed 1 Maintain oil level Inspect regularly 2 Change oil regularly 3 Use the correct grade and type of oil 4 Buy from a reputable dealer 8 Lubrication Change and Inspection HIGHWAY USE Fi rs 3 000 to 5 000 miles 4827 to 8045 Km Change transmission oil on new units Every 5 000 miles 8045 Km Inspect Oil Level Check for leaks Every 50 000 miles 80450 Km Change transmission oil OFF HIGHWAY First 30...

Page 11: ...3 high ambient temperature 4 restricted air flow around transmission 5 exhaust system too close to transmission 6 high horsepower overdrive operation High operating temperatures may require more frequent oil changes External cooler kits are available to keep the transmission operating temperature under 250 F when the conditions described above are encountered 9 Proper Lubrication 9 16 n g 14 Q c e...

Page 12: ...ck level of lubricant at speci fied intervals Tighten filler and drain plugs securely 7 Gear Shift Lever a Check for looseness and free play in housing If lever is loose in housing proceed with Check No 8 8 Gear Shift Lever Housing Assembly a Remove air lines at air valve and remove the gear shift lever housing assembly from transmission b Check tension spring and washer for set and wear c Check t...

Page 13: ...ith pullers designed for this purpose BEARING REMOVED WITH CHISEL DAMAGED OUTER RACE BEARING REMOVED WITH PUNCH DAMAGED SHIELD 11 2 ASSEMBLIES When disassembling the various assem blies such as the mainshaft countershafts and shifting bar housing lay all parts on a clean bench in the same se quence as removed This procedure will simplify reassem bly and reduce the possibility of losing parts 00 3 ...

Page 14: ...DISASSEMBLY INSTRUCTIONS I SHIFTING CONTROLS AIR FILTER REGULATOR ASSEMBLY 1 4 l D 12 LINE ...

Page 15: ... brake control valve from the shifting lever 3 Disconnect the Vs OD air line at the TCB 6 brake on the right side PTO opening 13 4 Disconnect the Vs OD air line at the tee block fitting be tween the air filter and regulator 5 Disconnect the Ys OD range shift control air line at the rear port of the slave air valve 6 Disconnect the Vs OD range shift air line at the for ward port of the slave air va...

Page 16: ...sconnect the three Ys OD air lines at the control valve 9 Loosen the jam nut and turn the nut and control valve from the shifting lever Remove the air lines sheathing and 0 rings from the lever 14 10 Remove the ID air line between the air valve and the direct range port of the auxiliary shift cylinder 11 Remove the ID air line between the air valve and the low range port of the auxiliary shift cyl...

Page 17: ... filter regulator assembly For further disassembly of the unit refer to page 85 15 Turn out the four retaining capscrews and remove the slave air valve from the transmission For further dis assembly of the valve refer to page 84 15 16 Remove the hat type sleeve from the bore in the valve 17 Remove the spring and plunger from the bore in the transmission ...

Page 18: ...ar lightly to break the gasket seal and lift the assembly from the shift bar housing 16 2 Secure the assembly upside down in a vise and remove the tension spring by prying it up and over the spring retainers one coil at a time 3 Remove the washer and lever from the housing 4 Remove the housing from the vise and if necessary re move the nut washer pivot pin and 0 Ring ...

Page 19: ...C Removal and Disassembly of the Shift Bar Housing SHIFT BAR HOUSING 1st REVERSE SHIFT BAR 2nd 3rd SPEED SHIFT YOKE 17 2nd 3rd SPEED SHIFT BAR 4th 5th SPEED SHIFT BAR ...

Page 20: ...lls located under the springs NOTE For ease of reassembly lay all parts on a clean bench in order of removal Bars not being removed must be kept in the neutral position or interlock parts will lock the bars 5 Place the shift bar housing in a vise cut the lockwire turn out the lockscrew and pull the 1st reverse shift bar from the housing removing the yoke 6 Cut the lockwire turn out the lockscrew a...

Page 21: ... the actuating plunger from the housing 8 Cut the lockwire tum out the lockscrew and pull the 4th 5th speed bar from the housing removing the yoke 19 9 Remove the two interlock balls from the web of the housing ...

Page 22: ... Companion Flange 1 Lock the transmission in two speeds and turn the nut from the tailshaft 2 Pull the companion flange or yoke from the splines of the tailshaft 20 3 Remove the speedometer drive gear or replacement spacer from the companion flange or yoke ...

Page 23: ...ve the clutch release mechanism or upshift clutch brake assembly and turn out the six nuts and two bolts which attach the clutch housing to the case 21 2 Jar the housing to break the gasket seal and pull from the studs and transmission case ...

Page 24: ...G AUXILIARY REAR HOUSING A Removal of the Rear Housing Assembly SPEEDO REPLACEMENT SPACER GASKET 2 AUXILIARY COUNTERSHAFT REAR BEARING COVER 2 I Turn out the four capscrews and remove the cover from the intermediate shift cylinder 2 Remove the locknut from the shaft in the cylinder 22 ...

Page 25: ... If necessary remove the 0 rings from the bore in the cylinder housing and the shaft 23 6 Turn out the capscrews and remove the two rear coun tershaft bearing covers 7 Remove the snap ring from the rear of both counter shafts 8 Turn out the 19 capscrews which attach the rear housing to the intermediate case Re insert one capscrew near both dowel pin locations and turn in just far enough to catch t...

Page 26: ...soft bar and mall against the rear of both coun tershafts to move them as far forward as possible This will move the bearings to the rear on the shafts 24 12 Remove the flat stock and puller screws Move the rear housing to its original position against the intermediate housing by turning in evenly the two remaining cap screws This will expose the two rear bearing snap rings 13 Attach a bearing pul...

Page 27: ...Attach a chain hoist to the rear housing and move the assembly straight to the rear and away from the intermediate housing taking care not to damage the oil trough located at the top rear of the intermediate housing Mount the assem bly in a vise in the upright position 25 ...

Page 28: ... Shift Cylinder CYLINDER COVER YOKE LOCKSCREW 2 ELASTIC STOP NUT SHIFT YOKE SHIFT YOKE BAR HOUSING 0 RING I Turn out the four capscrews and remove the cover from the shift cylinder 26 2 Remove the locknut from the shifting shaft in the cyl inder ...

Page 29: ...ousing At the same time remove shifting yoke from sliding clutch gear 27 5 Remove the piston from the shaft and remove the 0 rings on the inner and outer diameters of the piston 6 Turn out the four capscrews and remove the cylinder housing from the bore in the auxiliary rear housing Re move the 0 ring from the bore in the cylinder housing Remove synchronizer assembly from splines of tailshaft ...

Page 30: ... direct synchronizer from the blocker pins of the low speed synchronizer Place a cloth over rings during removal as the three springs in the direct ring will be re leased at the pin locations 28 LOW SPEED RING 2 Remove the sliding clutch from the low speed synchro nizer ...

Page 31: ...ilshaft and Low Speed Gear Assembly TAILSHAFT STEPPED WASHER I Use a soft bar and mall against the rear of the tailshaft to move the assembly forward and from the rear bearing 29 LOW SPEED GEAR I SNAP RING TAILSHAFT NUT 2 Remove the bearing inner sleeve from the shaft ...

Page 32: ...y Continued 3 Use the low speed gear as a base to press the bearing from the shaft and to free the gear and rear washer 4 Remove the splined washer from the shaft 30 5 Remove the stepped washer from the shaft 6 If necessary remove the snap ring from the inner diam eter of the low speed gear ...

Page 33: ...16 1 1 iii 11 11 i1 iji 7 Turn out the capscrews and remove the rear bearing cov er If necessary remove the oil seal from the cover 8 Remove the bearing rear cone 31 9 Remove the two bearing cups and outer spacer from the housing bore ...

Page 34: ...ET OIL FILLER PLUG OIL RESERVOIR DOWEL PIN 2 A Removal and Disassembly of the Intermediate Housing and Gearing 1 Cut the lockwire turn out the two capscrews and remove the plate from the rear of the mainshaft 32 2 Remove the intermediate drive gear from the shaft and if necessary remove the two snap rings and plate from the inner diameter of the intermediate drive gear ...

Page 35: ... 4 Remove the intermediate shift shaft from the housing 33 5 Remove the left countershaft from the housing using caution to avoid damage to the oil trough 6 Remove the shift yoke and pull the auxiliary drive gear and sliding clutch assembly from the splines of the main shaft Both sections must align with the splines for re moval ...

Page 36: ...i ate case 8 Pull the front bearings from the countershafts if neces sary 34 9 Turn out the three capscrews and remove the oil trough from the intermediate housing 10 Remove the snap ring spacers from the front counter shaft bearing bores 11 Turn out the 13 remaining capscrews and remove the intermediate housing from the transmission ...

Page 37: ...ise 2 Remove the bended end of the pin and drive the pin down and through the hole in the drive gear 35 CLUTCH GEAR 3 Position the snap ring in the clutch gear so that the re taining pin hole is approximately 1h from the open sec tion of the snap ring Insert a small Allen wrench or equivalent into the retaining pin hole and force down so that the snap ring is forced out of the groove Insert a smal...

Page 38: ...embly as far forward as possible exposing the snap ring groove in the front bearing 36 3 Remove the snap ring from the rear countershaft bear ing bore and install in the front bearing snap ring groove 4 Use a soft bar and mall to move the assembly to the rear as far as possible partially unseating the front bearing from the shaft 5 Move the countershaft forward and remove the front bearing with a ...

Page 39: ...the outer race to avoid damaging the bear ing 7 Use a soft bar and a mall to drive the countershaft to the rear exposing the snap ring groove in the rear bearing 37 8 Remove the snap ring from the front bearing and install on the rear bearing Use a puller or pry bars to remove the rear bearing and re tighten the two mainshaft rear bearing retainers ...

Page 40: ...clutch brake plate 2 Move the drive gear and shaft as far forward as pos sible and remove the snap ring from the groove in the clutch shaft 38 3 Hold the shaft in position and then tap the drive gear forward to unseat the front mainshaft bearing 4 Use a puller or pry bars to remove the bearing from the shaft ...

Page 41: ...ft 6 Remove the snap ring from the inner diameter of the drive gear 39 7 Pull the shaft forward and from the splines of the drive gear 8 Move the drive gear to the rear and against the 4th speed gear engaging the splines of the sliding clutch ...

Page 42: ...ER I Remove the elastic stop nut and washer from the reverse idler shaft 2 Push the shaft to the rear and remove from the case 40 IDLER GEAR IDLER SHAFT AND PIN ASSEMBLY 3 Remove the thrust washer and gear from the case 4 Remove the needle bearing from the gear ...

Page 43: ...aft Use caution as this will free the spring loaded centering ring NOTE It may be necessary to relieve pressure on the snap ring by tapping on the front of the mainshaft 2 Remove the splined retainer from the mainshaft SPLINED WASHER I REVERSE GEAR MAINSHAFT SLIDING CLUTCH GEAR 41 3 Center the front of the mainshaft in the case bore and remove the centering ring Remove the six springs from the cen...

Page 44: ...he side of the case and move the mainshaft assembly to the rear Tilt the front of the shaft up and lift the assembly from the case Use caution as the reverse gear is free and can fall from the shaft during removal Remove the reverse gear from the mainshaft 42 8 Secure the mainshaft assembly in a vise with the pilot front end up and remove the drivegear 9 Remove the 4th 5th speed sliding clutch ...

Page 45: ...ove the snap ring from the groove in the hub of the 4th speed gear 11 Remove the 4th speed gear and splined washer 43 12 Remove the 3rd speed gear 13 Lift the key and remove the 3rd speed gear splined washer ...

Page 46: ...nshaft Continued 14 Remove the 2nd 3rd speed sliding clutch 15 Remove the assembly from the vise and pull the key from the mainshaft 44 16 Remove the reverse gear splined spacer and the lst reverse sliding clutch 17 Remove the 1st and 2nd speed gears and splined spac ers ...

Page 47: ...ODRUFF KEY FRONT BEARING I DRIVE GEAR 3rd SPEED GEAR 1 Remove the blocking and lift the right countershaft from the case 2 Remove the left countershaft bearings in the same man ner as those removed from the right and lift the left countershaft from the case 45 COUNTERSHAFT REAR SNAP RING 3 Remove the snap ring from the front of both counter shafts ...

Page 48: ... of the PTO gear as a base press the 3rd speed gear and PTO 2nd speed gear cluster from the shaft If necessary remove the Woodruff key long key and roll pin from the shaft NOTE Countershafts are identical and disassembled in the same manner F Removal of the Right Reverse Idler Gear 1 Remove the right reverse idler gear in the same manner as the left as both are identical ...

Page 49: ...he bores the case should be re placed B Gears 1 Check operating gear teeth for pitting on the tooth faces Gears with pitted teeth should be replaced 1 2 Check all engaging gear teeth Gears with teeth worn ta pered or reduced in length from clashing in shifting should be replaced 3 Check axial clearances of gears Where excessive clear ance is found check gear snap ring washer spacer and gear hub fo...

Page 50: ...d correspond ing slot in lever for wear Replace both parts if worn If so equipped check 0 ring in housing for wear or cracks J Bearing Covers 48 1 Check covers for wear from thrust of adjacent bearing Replace covers worn and grooved from thrust of bearing outer race 2 Check bores of covers for wear Replace those worn over size K Oil Return Threads and Seals 1 Check oil return threads in front bear...

Page 51: ... as a guide to reassembly 5 INITIAL LUBRICATION Coat all thrust washers and splines of shafts with Lubriplate during installation to provide initial lubrication preventing scoring and galling 6 AXIAL CLEARANCES Maintain original axial clear ances of mainshaft forward speed gears of 005 to 011 Mainshaft reverse gear clearance is 011 to 032 49 7 BEARINGS Use of flanged end bearing drivers is recomme...

Page 52: ...he thrust washer into position on the rear of the case boss and hold the gear behind the washer 50 3 Make sure that the roll pin is in place in the large diam eter of the idler shaft and insert the saft through the gear washer and boss aligning the roll pin with the notch in the rear case bore 4 Secure the shaft with the washer and elastic stop nut ...

Page 53: ...tall the roll pin long key and Woodruff key in the countershaft 2 Press the PTO 2nd speed gear cluster onto the shaft NOTE For RT0 613 models the drive gear and 4th speed gear locations are reversed 51 3 Press the 3rd speed gear onto the shaft with the long hub to the rear 4 Press the 4th speed gear onto the shaft with the long hub to the front ...

Page 54: ...he shaft with the long hub to the rear 6 Install the snap ring in the groove in the front of the countershaft 52 7 On the drive gear of each shaft mark the gear tooth which is aligned with the keyway The tooth is also stamped with an O 8 Place the left countershaft into position in the case ...

Page 55: ...aring on the shaft and in the case bore Partially install the rear bearing 10 Use a bearing driver to complete installation of the front and rear bearings 53 11 Install the snap ring in the groove in the rear bearing bore 12 Place the right countershaft into position but DO NOT install the bearings ...

Page 56: ...free for insertion of the key 2 Install the 2nd speed gear washer at the 2nd speed gear location inserting the key from the bottom to lock the washer in position 54 3 Install the 2nd speed gear on the splined washer clutch ing teeth down 4 Install the 1st speed gear against the 2nd speed gear clutching teeth up ...

Page 57: ...Install the 1st reverse sliding clutch aligning the slot in the clutch with the key 55 7 Install the reverse gear splined washer align the keyway and lock in position with the key 8 Reposition the assembly in the vise with the pilot end up and pull the key up approximately Install the 2nd 3rd speed sliding clutch aligning the slot in the clutch with the key ...

Page 58: ...e key down into position with the pin in the ke restin on top of the washer 10 Install the 3rd speed gear on the splined washer clutch ing teeth down 56 11 Install the 4th speed gear against the 3rd speed gear clutching teeth up 12 Install the 4th speed gear splined washer on the shaft and in the hub of the gear ...

Page 59: ...r and the two teeth directly opposite for timing pur poses 57 15 Remove the mainshaft from the vise Install the 4th 5th speed sliding clutch on shaft and install the drive gear against the 4th speed gear clutching teeth towards the 4th speed gear and engaging the sliding clutch 16 Place the reverse gear on the splined washer which is locked to the shaft ...

Page 60: ...haft rear bearing in the case bore 58 4 Install the six springs in the centering ring using a small amount of grease or equivalent in each of the centering ring bores to hold the springs in place Place the center ing ring on the shaft and slide into the rear bearing against the reverse gear washer 5 Install the splined retainer washer on the shaft cone sur face towards the centering ring 6 Place t...

Page 61: ...eats in the groove in the mainshaft 8 Install the rear bearing retainers and secure the cap screws with the locking lugs 59 9 Slide the drive gear forward off the splines of the sliding clutch and align the timing marks with the marked tooth on the left countershaff 10 SHcie the 4th 5th speed sliding clutch forward to en gage the splines of the drive gear ...

Page 62: ... Insert the clutch shaft into the drive gear 3 Install the snap ring in the inner diameter of the drive gear 60 4 Install the spacer on the shaft flat side against the gear 5 Install the drive gear bearing on the shaft and in the case bore 6 Install the snap ring in the groove in the shaft flat side towards the bearing 7 Install the front bearing cover or upshift clutch brake ...

Page 63: ... and partially in stall the front bearing Partially install the rear bearing G Installation of the Left Reverse Idler Gear 1 The left reverse idler gear is installed in the same man ner as the right as both are identical Refer to page 50 61 3 Use a bearing driver to complete the installation of the bearings 4 Install the snap ring in the groove in the rear counter shaft bearing bore Drive both cou...

Page 64: ...tallation of the retaining pin place the snap ring so that the open section is underneath the retaining pin hole 62 3 Use two screwdrivers to pry the snap ring into position inside the clutch gear 4 Align one of the holes in the drive gear with the retain ing pin hole and insert the pin from inside the drive gear into place in the pin hole with the elbow bend facing away from the clutch gear Turn ...

Page 65: ... auxiliary counter shaft bearing bores 63 4 Install the metal oil trough in the intermediate housing with two capscrews in the front wall and one capscrew in the top of the housing The spacer is placed between the oil trough and the top of case 5 IMPORTANT Mark the low speed gear tooth identified with an O on each auxiliary countershaft for timing purposes Then mark the tooth on the intermediate a...

Page 66: ...ear and sliding clutch assembly mark two adjacent teeth on the drive larger width gear and mark the two teeth directly opposite 64 9 Install the auxiliary drive gear and sliding clutch assem bly on the splines of the mainshaft aligning both sections with the splines Mesh the marked tooth on each coun tershaft between the marked teeth of the auxiliary drive gear NOTE Keep the marked teeth on the co...

Page 67: ...drive gear noting that the raised side of the plate faces towards the clutching teeth of the drive gear Mark two adjacent teeth on the gear and the two teeth directly opposite 65 13 Place the drive gear on the rear of the mainshaft mesh ing the marked tooth on each countershaft between the marked teeth on the drive gear 14 Install the retaining plate on the rear of the mainshaft with the two capsc...

Page 68: ... For timing purposes mark two adjacent teeth on the low speed gear and mark the two teeth directly opposite 2 Set the tailshaft on a bench with the threaded end up and install the low speed gear stepped washer large di ameter down 66 3 Install the splined spacer onto the shaft and washer 4 Install the low speed gear on the splined spacer clutch ing teeth down ...

Page 69: ...earing on the shaft and against the washer Heating of the bearing will facili tate installation Use heat lamps but do not heat over 275 F 67 7 Install the bearing inner spacer on the shaft 8 Place the front bearing cup partially into the bore of the housing taper to the inside 9 Place the bearing outer spacer on the front cup and place the rear bearing cup on the spacer ...

Page 70: ...sing 11 Place the auxiliary rear housing over the end of the shaft and seat the front bearing cone in the front cup 12 Install the bearing rear cone on shaft and into the rear cup Heating of the bearing cone will facilitate instal lation but do not heat over 275 F 68 13 Install the oil seal in the rear bearing cover 14 Install the rear bearing cover using a brass washer at the speedometer gear loc...

Page 71: ...synchronizer 3 Place the direct synchronizer over the low speed blocker pins seating the springs against the pins 69 4 Compress the springs to fully seat the direct synchronizer on the pins of the low speed synchronizer 5 Place the direct low shift fork into the yoke slot of the sliding clutch short hub to the rear and install the syn chronizer assembly on the splines of the output shaft ...

Page 72: ...r housing bore and secure with four capscrews noting that the air fitting is on the top right of the housing 70 3 Install the shifting shaft from the front through the yoke hub and cylinder aligning the notches with the lock screw bores in the yoke hub 4 Install the two yoke lockscrews tighten and wire se curely 5 Install 0 rings in the OD and ID of the piston ...

Page 73: ...n the shifting shaft flat side out 7 Install the locknut on the shifting shaft 71 REASSEMBLY AUXILIARY REAR HOUSING 8 Install the shift cylinder cover with four capscrews not ing that the air fitting is on the top left side ...

Page 74: ...eck the synchronizer occasionally to make sure that the direct synchronizer is not sliding off the low speed blocker pins Look through the rear bearing bores and mesh the marked tooth on each countershaft between the two marked teeth on each side of the auxiliary low speed gear Move the rear housing evenly onto the two dowel pins using caution to prevent damage to the oil trough 2 Secure the rear ...

Page 75: ...cylinder bore Cyl inder is installed with the small air channel in the hous ing to the right 73 8 Install the 0 ring on the outer diameter of the piston and install the piston on the shaft in the cylinder 9 Install the elastic stop nut on the shift shaft 10 Install the shift cylinder cover aligning the small air channel on the cover with the channel in the housing The insert valve opening on the c...

Page 76: ... 11 i t ____________________ D Installation of the Auxiliary Rear Housing Continued 11 If previously removed install the insert valve in the cover with the flat end facing up 74 12 Install the insert valve retaining nut in the cover ...

Page 77: ... the speedometer drive gear or replacement spacer on the hub of the yoke or flange lock the transmission in two speeds and install the yoke or flange on the splines of the tailshaft Install the tailshaft nut and torque to 450 500 ft lbs 75 2 Install the washers and nuts on the studs and then install the washers and bolts using the correct torque Nuts 170 185 ft lbs Bolts 70 75 ft lbs ...

Page 78: ...e lockscrew and tighten and wire securely Keep the bar in the neutral position 2 Install an interlock ball in the front web 76 3 Install the actuating plunger in the rear web 4 Install the 2nd 3rd speed shift bar and yoke inserting the interlock pin in the bore of the neutral notch Install the yoke lockscrew and tighten and wire securely ...

Page 79: ...reverse shift bar and yoke Install the yoke lockscrew and tighten and wire securely 77 7 Remove the assembly from the vise and install the three tension balls one in each bore in the top of the housing 8 Install the tension springs on top of the balls in the bores ...

Page 80: ...tension spring cover and retain with the two capscrews 78 10 Check to make sure that the shift yokes and sliding clutches are in the neutral position and install the shift bar housing on the transmission tension spring cover to the front and the yoke forks in the sliding clutches Secure with the 13 capscrews ...

Page 81: ... the gear shift lever in the housing fitting the pivot pin in the slot in the lever 79 4 Install the tension spring washer in the housing 5 Seat the tension spring under the lugs in the housing 6 Check to make sure that the shift bar housing is in the neutral position and install the gear shift lever housing fitting the lever into the shifting slots in the forks Secure with four capscrews ...

Page 82: ...ove the piston all the way forward or to the rear before installing the air valve 80 4 Attach the air filter regulator assembly to the rear hous ing with the two retaining capscrews 5 Connect the air line between the intermediate shift cylinder and the air filter regulator assembly 6 Connect the ID air line between the air filter regu lator assembly and the rear port of the tee fitting on top of t...

Page 83: ...ve and back the jam nut up against the control valve to se cure it in the desired position 81 NOTE To avoid confusion only the air line being installed in each of the following three steps is shown attached to the control valve 10 Connect the Vs OD long black air line between the intermediate shift cylinder and the port in the control valve identified with an F See insert 11 Connect the l s OD whi...

Page 84: ... brake control valve and clamp to the shift lever and secure the valve by tightening the screw on the clamp 14 Attach the black Ys OD brake control air line to the elbow fitting on the front of the valve and attach the white air line to the fitting on the bottom of the valve 82 15 Attach the black Ys OD air line to the TCB 6 coun tershaft brake located on the right PTO opening 16 Attach the white ...

Page 85: ...RANGE SHIFT AIR SYSTEM RANGE CONTROL VALVE 83 ...

Page 86: ...lled in housing for proper pre select operation The four 0 rings are indicated by circled numbers If any of these are defective there will be a constant air leak out of the exhaust on the air valve In normal operation exhaust will occur only for an instant as the range shift is made The follow ing chart is to be used as a guide to determine defective 0 rings Defective 0 Rings CD or To Disassemble ...

Page 87: ... in the air valve from mov ing while the gear shift lever is in a gear position and re leases the piston when the lever is moved to or through neu tral See detailed installation of air valve for installation pre caution concerning the actuating pin 85 AIR FILTER FILTER ELEMENT Clean and re install at each oil change HOUSING GASKET SPRING END CAP PLATE AIR FILTER REGULATOR ASSEMBLY TEE NIPPLE I REG...

Page 88: ...orts 86 TOP PLATE CONTROL VALVE BODY 2 Maintenance and Assembly The range control valve is easily disassembled by removing the top plate screw In dividual parts can be obtained in an A number kit Critical assembly factors are a Make sure that the jam nut locking the control valve to the shifting lever is secure b Make sure that when reassembled the top plate screw is torqued with 90 to 120 inch po...

Page 89: ...GNAL LINE I I I ___ 87 Travel of the small piston in insert valve is only 3 16 The insert valve is a normally open valve Thus when there is no signal or delivery of air to top side of insert piston the constant air from regulator passes through the insert valve and to the backside of the piston and moves the shift bar forward low range When the insert valve piston is activated by a signal or deliv...

Page 90: ...nge shift between low and in termediate plus leak out cover exhaust when in inter mediate or direct 1 1 1n 1 CENTER PORT SIGNAL LINE FROM RANGE CONTROL BOTTOM EXHAUST PORT 88 Trouble Shooting Cover Assembly 1 Exhaust port Any constant flow of air out the cov er exhaust port usually indicates a faulty insert valve Exhaust should occur briefly ONLY when the splitter control is moved from low to inte...

Page 91: ...leak results in failure to shift into low range pressurizing of transmission 0 ring leak results in failure to shift in either low or direct range Will also cause steady leak out breather in air valve Gasket leak results in slow shift to direct range CROSS SECTION OF AUXILIARY SHIFT CYLINDER 89 ...

Page 92: ...NT AIR FROM REGULATOR AIR FLOW DIAGRAMS CONTROL VALVE TOP CONTROL VALVE SIDE Note Control Valve is shown in reversed position position for clarity of air line connections NO AIR SUPPLY AIR LINE Constant Air AUXILIARY SHIFT CYLINDER 90 LOW RANGE ...

Page 93: ...DER J AUXILIARY SHIFT CYLINDER 91 CONTROL VALVE SIDE Note Control Valve is shown in reversed position position for clarity of air line connections NO AIR AIR LINE Constant Air INTERMEDIATE RANGE CONTROL VALVE SIDE Note Control Valve is shown in reversed position position for clarity of air line connections AIR LINE Constant Air DIRECT RANGE ...

Page 94: ...aring Driver 68 13 Oil Seal Driver 72 3 Bearing Driver 75 2 Torque Wrench 185 ft lb cap 75 1 Torque Wrench 500 ft lb cap 92 supplier while others can be made either from prints or di mensions as required by the individual user Listed below are illustrations which show these specialized tools the tool name and how it can be obtained Prints are available for tools which have a Fuller tool number sen...

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Page 96: ...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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