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Reassembly and Installation of the Synchronizer Assembly

1. Place the larger low speed ring on the bench with the

pins upward and install the sliding clutch on the ring,
protruding clutching teeth down.

Install the three springs in the direct ring.

Apply pressure to the direct ring while twisting counter-

clockwise to fully seat the direct ring on the low speed
ring pins.

Set the synchronizer assembly on blocking approxi-
mately 2" high on a bench large enough to accommod-
ate the rear housing.

3. Install the direct ring on the low speed ring pins, seating

the springs against the pins.

Содержание RTX-12510

Страница 1: ...Service Manual Fuller Heavy Duty Transmissions TRSM0503 October 2007 RTX 12510 RTX 12515 RTXF 12510 RTXF 12515 ...

Страница 2: ...iary Counterhafts 58 C Synchronizer 59 D Low Range Gear and Range Mainshaft 60 E Deep Reduction Shift Cylinder 62 F Output Shaft 63 Inspection 64 Torque Ratings 66 Reassembly Precautions 68 Reassembly Instructions I Auxiliary Section RT 1110 Series 69 A Output Shaft 69 B Synchronizer 71 C Auxiliary Countershafts 72 D Range Shift Cylinder 74 II Auxiliary Section RT 12510 Series 76 A Output Shaft 76...

Страница 3: ...n twin countershaft 10 speeds 1250 lbs ft torque capacity transmission twin countershaft 10 speeds including an torque capacity transmission twin countershaft 15 speeds 1250 lbs ft transmission twin countershaft 15 speeds including an overdrive ratio torque capacity overdrive ratio letter before numerals such as RTF 12510 etc denotes for ward position of the gear shift lever NOTE Illustrated parts...

Страница 4: ...ed in one case First through fifth speeds are obtained by using the five gear ratios in the front section through the low speed gear of the range section Sixth through tenth speeds are obtained by using the five gear ratios in the front section through the high speed direct drive range gear As in other Roadranger transmissions the ratios are progressively spaced The RT 125 15 transmissions have 15...

Страница 5: ...5 ...

Страница 6: ...5 High High Reverse 2 74 Reverse 2 16 I Low Low I Reverse 9 71 Reverse 7 65 Specifications RT I 2510 Series Speeds 10 progressive forward speeds 2 reverse Nominal Torque Capacity 1250 lb ft Power Take Off Openings Right Side SAE standard 6 bolt regular duty type short length Bottom SAE standard 8 bolt heavy duty type PTO Gear Relative Speed to Input R P M Right Side 45 tooth 6 8 pitch gear turning...

Страница 7: ...NGE RATIO STEP SPEED STEP RATIO STEP SPEED 3 99 5 07 6 56 8 43 10 93 27 29 28 29 79 1 00 1 30 1 66 2 16 29 2 79 1 St 27 30 28 30 27 30 28 30 10th 9th 8th 7th 6th 5th 4th 3rd 2nd 1 St High Reverse 2 16 Low Reverse 7 65 Deep Reduction Reverse 10 93 Clutch Housing Size SAE No 1 deep only 6 5 8 for push or pull type clutches Weight SAE No 1 clutch housing with standard controls less clutch release par...

Страница 8: ... where severe dirt conditions exist Every 1 000 hours Change transmission Iubricant Normal off highway use Change the oil filter when fluid or lubricant is changed Recommended Lubricants Grade Type SAE Eaton Roadranger CD50 Transmission Fluid 50 All Heavy Duty Engine 011 MI L L 2104B C or D or 50 Above 10 o F 12 o C API SF or API CD 40 Above 10 o F 12 o C Previous API designations 30 Below 10 o F ...

Страница 9: ...hen lubricant operating temperatures are above 230 F 110 In addi tion transmission oil coolers are not recom mended with these gear oils since the oil cooler materials may be attacked by these gear oils The lower temperature limit and oil cooler restriction with these gear oils gener ally limit their success to milder applications Proper Lubrication Levels as Related to Transmission Installation A...

Страница 10: ...is and a two speed range section the ten forward speeds are sions as you would a conventional model with an auxiliary obtained by using a five speed shifting pattern twice the or two speed axle because there is no split shifting first time with the transmission in low range and the second time with the transmission in high range All shifts are made with one lever The range control button is used o...

Страница 11: ...ove the lever to 6th speed As the lever passes through the neutral position the transmission will automatically shift from low range to high range 7 With the transmission in high range you may now shift progressively through 7th 8th and 9th to 10th Downshifting To get to low range push button DOWN 6th speed 10 9 then move 8 7 lever to 5th speed 6 speed RANGE Downshifting 1 When shifting down move ...

Страница 12: ...mission the operator may wish to skip some of the gear ratios to offset a particular Operating con dition Skip shifting can be done when upshifting pro viding the range control button is pulled up to the high range position before making any shift which passes fifth speed Skip shifting is also pos sible during downshifting providing the range con trol button is pushed down to the low range Precaut...

Страница 13: ...ar shift lever position One through 10 speeds with Range Control Button and Deep Reduction gear disengaged Five additional ratios with Deep Reduction gear en gaged operating under adverse conditions and only when the transmission is in LOW RANGE with the control valve but ton down Never move the Deep Reduction Valve to IN when in high range When the valve is moved to IN the reduction ratios will b...

Страница 14: ...s of road and load Check gear ratios to determine the best ratio split for your particular condition The fol lowing instructions are recommended for average condi 3 tions 1 With the gearshift lever in neutral the engine started and 4 air system pressure normal PUSH THE RANGE CON TROL BUTTON TO THE DOWN POSITION 6th through 10th 5th of low range Move the Deep Reduction Valve to the IN position to e...

Страница 15: ... from reduction to low range would differ according to the ratios desired Important Procedures 1 When making the shift from a reduction ratio to a low range ratio move the Deep Reduction Valve from IN to OUT IMMEDIATELY BEFORE making the shift This is not a pre select valve and only torque will hold the reduction gear after the lever is moved to OUT the shift cylinder will make the shift by air as...

Страница 16: ...he shift piston and bar to the rear to engage the low range gear from the constant supply to flow through the high range port in rear side cap of air valve and to the shift cylinder cover air port Air on this port moves the shift piston and bar forward to engage the high range gear When the control button is moved from one position to another air from the previously charged line exhausts through t...

Страница 17: ...front of the shift piston moves the piston and shift bar to the rear to engage the hole gear As the hole gear is engaged the range mainshaft is dis engaged from the output shaft removing the low and high range sections from the power flow With the deep reduction valve lever moved to the OUT position air flows out the side port of the valve and to the air port near the center of the hole gearshift ...

Страница 18: ...per operation The four O 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 following chart is to be used as a guide to determine defective O rings Defective O Rings RESULT 1 Constant leak through exhaust in low range only...

Страница 19: ...tailed installation of air valve for installation precaution while the gearshift lever is in a gear position and releases the concerning the actuating pin SLEEVE D Cross section actuating pin and plunger assembly Air Regulator Air Filter Regulator Assembly The air regulator is not serviceable If defective replace the air regulator unit Reading at output of air regulator should be 57 5 to 62 5 psi ...

Страница 20: ...ontrol valve make sure that slot in slide faces the outlet part To Disassemble the Control Valve 1 Remove the four screws to separate front and rear hous ings 2 3 4 5 6 7 supply The OUTLET port connected by O L Remove the slide and the two position balls and springs Remove the flat metal seal from outlet side and remove the O ring from body Remove the valve insert from front housing and re move th...

Страница 21: ...gulator Check Point A With normal line pressure and gearshift lever in neutral check exhaust port on side of air regulator There should be no leak from this port 4 5 If there is a steady leak from exhaust port this indicates a defective air regulator and should be replaced Cut off the vehicle air pressure and install air gauge in line at output port of air regulator Bring vehicle air pressure to n...

Страница 22: ...Shift Cylinder Check Point E If any of the seals in the range shift cylinder are de fective the range shift will be affected The degree of lost air of course will govern the degree of failure from slow shift to complete failure to shift Refer to Illustration F for location of seals Make sure cylinder bore is clean to prevent damage to piston seal Use only a very light amount of shellac or Permatex...

Страница 23: ...his line is connected to constant supply Deep Reduction Valve Check Point G With the deep reduction valve lever to IN remove the line from the deep reduction valve at the port in hole gearshift cylinder there should be no air at this point Move the deep reduction valve lever to OUT There should now be a constant air flow from line Move lever to IN to shut off air If the above conditions do not exi...

Страница 24: ...ler plug and check level of lubricant at specified intervals Tighten filler and drain plugs securely Gear Shift Lever a Check for looseness and free play in housing If lever is loose in housing proceed with Check No 8 8 Gearshift Lever Housing Assembly a b c d Remove air lines at air valve and remove the gearshift lever housing assembly from transmission Check tension spring and washer for set and...

Страница 25: ...25 ...

Страница 26: ...ssembly 1 Install new input shaft into splines of drive gear just far enough to expose snap ring groove in ID of drive gear Make sure that the bushing is installed in the pocket the input shaft 2 3 4 5 6 7 8 Install snap ring in ID of drive gear Install washer on shaft Move the fourth fifth speed sliding clutch gear forward to contact end of input shaft hub of drive gear Block between rear of slid...

Страница 27: ...lly wash and relubricate all bear ings as removed and protectively wrap until ready for use Remove all bearings with pullers designed for this purpose do not remove bearings with hammer and punch 2 3 4 5 SNAP RINGS Remove snap rings with pliers designed for this purpose Rings removed in this manner can be reused INPUT SHAFT The clutch or input shaft can be re moved on most models without removing ...

Страница 28: ...1 Shifting Controls 2 8 ...

Страница 29: ...emoval of the Range Shift Air System 1 Disconnect the black and white 1 8 OD air line at the air valve on the side of the transmission NOTE The gear shift lever housing range control valve and lines may now be removed as a unit by turning out the four capscrews at the base of the gear shift lever housing 2 Disconnect the black and white 1 8 O D air line at the range control valve on the shift leve...

Страница 30: ...fer to page 20 NOTE For ease of reassembly it is advisable to tag the 1 4 I D air lines as to their proper locations during re moval 5 Remove the hose clamp and disconnect the two 1 4 ID air lines between air valve and the range shift cylinder 6 Disconnect the 1 4 ID air line between the air valve and the filter regulator assembly 7 Remove the filter regulator assembly from the auxiliary housing F...

Страница 31: ...assembly of the air valve refer to page 18 Remove the alignment sleeve bore in the adaptor plate from the air valve or the 10 Remove the spring and plunger from the bore in the adaptor plate 11 Turn out the two capscrews and two Allen head screws and remove the adaptor plate from the side of the case 31 ...

Страница 32: ...m the housing 5 Remove the O ring from the groove in the top of the housing 3 Remove the tension spring washer and lever from the housing 32 2 Remove the rubber dust cover from the lever and mount the assembly in a vise by the housing Free the tension spring from the housing by inserting a large heavy bladed scredriver between the spring and the housing and twisting Force the spring from under the...

Страница 33: ...sary remove the reverse light pin and plug from the housing 3 Mount the housing on its side in a vise with the exposed end of the actuating plunger facing up NOTE Lay all parts on a clean bench in the order of removal to facilitate reassembly Bars not being removed must be kept in the neutral position or interlock parts will lock the bars preventing removal 4 Cut the lockwire turn out the lockscre...

Страница 34: ...ing 6 Cut the lockwires turn out the lockscrews and remove the 2nd 3rd speed shift bar block and yoke from the housing As the neutral notch clears the housing boss remove the interlock pin from the notch 8 Cut the lockwire turn out the lockscrew and remove the lst reverse speed shift bar and yoke 3 4 7 CRemove the actuating plunger from the bore in the housing ...

Страница 35: ...9 Remove the two interlock balls from the bore in the housing boss 35 Shift Bar Housing ...

Страница 36: ...he RT 12510 and RT 1110 series transmissions 1 Turn out the capscrews and insert three puller screws in the three tapped holes in the auxiliary housing flange Tighten the puller screws evenly to move the housing approximately 1 2 to the rear 2 Remove the stop nut washer and companion flange or yoke from the splines of the output shaft 2 Attach a chain hoist to the auxiliary housing and move the ho...

Страница 37: ...nt case c Removal of the Clutch Housing 1 If so equipped remove the clutch release mechanism and or upshift clutch brake and turn out nuts and bolts securing the clutch housing to the front case 2 Jar the clutch housing with a rubber mallet to break the gasket seal and pull the housing straight forward and off the studs and front bearing cover 37 Companion Flange auxiliary housing and Clutch Housi...

Страница 38: ...Cut the lockwires and remove the lockscrews from the bearing retainer ring 3 4 Insert three puller screws in the tapped holes of the retainer ring and tighten evenly to remove the drive gear assembly from the case bore Remove the snap ring from the hub of the auxiliary drive gear and press the retainer ring and bearing from the gear 38 ...

Страница 39: ...Move the reverse gear forward and against theist speed gear engaging the splines of the sliding clutch 3 Use inside jaw pullers to remove the left auxiliary coun tershaft front bearing from the reverse idler bore The right auxiliary countershaft front bearing may also be removed at this time 4 Remove the elastic stop nut and washer from the front of the idler shaft 39 Front Section ...

Страница 40: ...e plug from the bore in the rear of the idler shaft insert an impact puller in the bore and remove the shaft 7 If necessary remove the bearing inner race and rear washer from the idler shaft 6 As the shaft is moved to the rear remove the gear and thrust washer from the case 40 ...

Страница 41: ...s replacement of the bearings is planned 3 Cut the lockwires turn out the lockscrews and remove the two front bearing retaining plates 4 Use a soft bar and mall to drive each countershaft as far to the rear as possible This will partially unseat the front bearings 5 Use a soft bar and mall on the rear of each countershaft to drive each shaft as far forward as possible unseating the front bearings ...

Страница 42: ... and from the mainshaft NOTE When removing washers spacers and gears note their location to facilitate reassembly of the mainshaft Keep washers and spacers with the gear from which they were removed there is one spacer and one washer for each gear The spacers have external splines and the washers have internal splines 5 Work the washers spacers and gears from the mainshaft It will be necessary to ...

Страница 43: ...force the front bearing cover away from the case Remove the front bearing cover from the input shaft 2 Remove the snap ring from the drive gear bearing 3 Move the drive gear assembly to the rear and into the case working past the countershaft gears Remove the drive gear assembly from the case 4 Relieve the drive gear bearing nut at the points where it is peened into the milled slots of the shaft 4...

Страница 44: ... bearing nut from the shaft LH thread 6 Using the rear face of the drive gear as abase press the shaft through the gear to unseat the bearing from the shaft This will free the bearing spacer and drive gear If necessary remove the snap ring from the drive gear 44 ...

Страница 45: ...rrow thickness of this gear makes it suscepti ble to breakage 3 Using the 2nd speed gear as a base press the 2nd and 3rd speed gears from the shaft If necessary use a hammer and punch to remove the key from the countershaft keyway 2 Remove the spacer from the front of the countershaft and using the 4th speed gear as a base press the direct PTO and 4th speed gears from the shaft This will re quire ...

Страница 46: ...d of the shift yoke bar 3 Cut the lockwire and turn out the two yoke lockscrews 4 Pull the yoke bar to the rear and out of the cylinder Remove the piston from the housing 5 Remove the O rings from the OD and ID of the piston 6 Turn out the capscrews and remove the shift cylinder housing from the auxiliary plate Remove the shift yoke from the sliding clutch gear of the synchronizer assem bly If nec...

Страница 47: ...ing lightly and evenly to the rear with a soft bar NOTE Check the bearing inner race on the front of each countershaft t If worn or damaged remove with pry bars or appropriate jaw pullers If the auxiliary counter shaft t f rent bearings are to be changed these inner races must be changed also 1 Pull the synchronizer assembly from the splines of the output shaft 2 47 Pull the direct high range cone...

Страница 48: ...ar and Tailshaft Assembly 1 Use a soft bar and mall to drive the output shaft forward and through the rear bearing 2 Remove the bearing inner spacer from the shaft 3 Using the front face of the low speed gear as a base press that shaft through the gear and bearing freeing bearing washer and gear from shaft 4 If necessary remove snap ring from the ID of the low speed gear 48 ...

Страница 49: ...ver If necessary remove the oil seal from the cover 5 Remove the splined spacer from the shaft 8 Remove the bearing rear cone from the housing 6 Remove the stepped washer from the shaft 9 Remove the two bearing cups and outer spacer from the housing bore 49 ...

Страница 50: ...y mount the auxiliary section up right in a vise Turn out the capscrews and remove the range shift cylinder cover 3 Cut the lockwire and turn out the two yoke lockscrews 2 Turn the elastic stop nut from the end of the yoke bar 4 Pull the bar forward and out of the shift cylinder Re move the piston from the cylinder bore 50 ...

Страница 51: ...the piston and from the bore in the shift cylinder 6 Turn out the capscrews and remove the shift cylinder housing Remove the shift yoke from the sliding clutch gear of the synchronizer If necessary remove O ring from bore in cylinder housing 51 ...

Страница 52: ...m the rear of each counter shaft 3 4 Use a soft bar and mall to drive the countershaft for ward and from the rear bearings Remove the bearings from bores by tapping lightly and evenly to the rear with a soft bar NOTE Check bearing inner races on front of each countershaft If worn or damaged remove with pry bars or appropriate jaw pullers 52 ...

Страница 53: ... from the splines of the output shaft 3 Remove the sliding clutch gear from the pins of the low speed synchronizer 2 Pull the direct high range cone synchronizer from the pins of the low speed synchronizer ring Cover with a cloth as the three springs will be released at the blocker pin locations 53 ...

Страница 54: ...move the bearing inner spacer from the shaft 3 Using the front face of the low speed gear as a base press the shaft through the gear and bearing Remove the splined spacer from the hub of the gear 4 Turn out the capscrews and remove the rear bearing housing If necessary remove the oil seal from the hous ing Remove the rear bearing cone from the housing 54 ...

Страница 55: ...5 Remove the two bearing cups and outer spacer from the auxiliary plate bore 55 ...

Страница 56: ...sembly mount the auxiliary section in a vise in the upright position Turn out the capscrews and remove the range shift cylinder cover 3 Cut the lockwire and turn out the two yoke lockscrews 2 Turn the nut from the end of the yoke bar 4 Push the yoke bar to the rear and from the housing Remove the piston from the bar 56 ...

Страница 57: ...5 Remove the O rings from the piston 6 Turn out the capscrews and remove the shift cylinder housing If necessary remove the O ring from the ID of the housing 57 ...

Страница 58: ... from the rear of each auxiliary countershaft 3 Use a soft bar and mall to drive the countershaft for ward and from the rear bearings 4 Remove the bearings from the bores by tapping lightly and evenly to the rear with a soft bar 5 If necessary remove the bearing inner race from the front of each countershaft with a puller or pry bars 58 ...

Страница 59: ... splines of the output shaft 3 Remove the sliding clutch from the pins of the low speed synchronizer 2 Pull the direct high range cone synchronizer from the pins of the low speed synchronizer ring Cover the assembly with a cloth as the three springs will be re leased at the blocker pin locations 59 ...

Страница 60: ...e keyway between the splines of the range mainshaft 2 Turn the washer located in the hub of the gear so that the splines on the washer align with the splines on the 3 Pull the gear and washer forward and off the splines of the range mainshaft 4 Remove the coupler from the shaft shaft 60 ...

Страница 61: ...ry bars to pull the range mainshaft forward and from the output shaft quill 7 Remove the bearing from the shaft If necessary use an inside jaw impact puller 8 If necessary remove the snap ring from the OD of the shaft Check the bushing in the shaft and replace if worn 61 ...

Страница 62: ...shift yoke 2 Pull the shift yoke and clutch forward and from the auxiliary housing 4 Remove the yoke bar from the housing Remove the O ring from the bar 5 Remove the cylinder housing from the auxiliary housing Remove the O ring from the bore in the housing 3 Turn out the capscrews and remove the shift cylinder cover 62 ...

Страница 63: ...utput shaft 3 Remove the speedometer drive gear or replacement spacer from the shaft 4 Use a soft bar and mall to drive the output shaft forward and from the auxiliary housing 5 Use the deep reduction gear as a base to press the rear bearing from the output shaft This will free the gear washer spacer and oil deflector 6 Remove the two bearing cups and outer spacer from the auxiliary housing bore 6...

Страница 64: ...in the bores the case should be replaced B Gears 1 Check operating gear teeth for pitting on the tooth faces Gears with pitted teeth should be replaced 2 Check all engaging gear teeth Gears with teeth worn tapered 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...

Страница 65: ...ves too freely 2 If housing is dismantled check pivot pin and cor responding slot in lever for wear Replace both parts if worn J Bearing Covers 1 Check covers for wear from thrust of adjacent bear ing Replace covers worn and grooved from thrust of bearing outer race 2 Check bores of covers for wear Replace those worn oversize K Oil Return Threads and Seals 1 Check oil return threads in front beari...

Страница 66: ...3 4 12 15 with oil filter PTO Cover small Hole Gear Shift Cylinder 4 5 16 18 xl 7 8 20 25 RT 12515 only Aux Drive Gear Retainer Ring 6 3 8 16 x 1 Range Shift Cylinder 4 3 8 16 x 1 Range Shift Cylinder Cover 4 3 8 16 x 1 Range Shift Cylinder Cover 4 3 8 16 x l 1 4 RT I2515 only 35 45 Shift Bar Housing 16 3 8 16 x 1 1 4 Gear Shift Lever Housing 4 3 8 16 x 1 1 4 Front Bearing Cover 6 3 8 16 x 1 1 4 C...

Страница 67: ...ft rear bearing cover and rear are located between the following parts plate RT 1110 RT 12510 12 Left auxiliary countershaft rear bearing cover and rear 1 Gearshift lever housing and shift bar housing plate 2 Shift bar housing and case 13 Large PTO cover and case 3 Air valve adapter plate and case 14 Small PTO cover and case 4 Air valve and adapter plate 5 Clutch housing and case 6 Front bearing c...

Страница 68: ...or 71203 silicone lubricant INITIAL LUBRICATION Coat all thrust washers and splines of shafts with Lubriplate during installation to provide initial lubrication preventing scoring and galling AXIAL CLEARANCES D Maintain original axial clear ances of mainshaft forward speed gears of 005 to 01 2 Mainshaft reverse gear clearance is 005 to 012 flanged end bearing drivers is installation of bearings Th...

Страница 69: ...n RT 1110 Series A Reassembly of the Output Shaft and Rear Bearing Assembly 1 Set the output shaft on bench with threaded end up and install the stepped washer large diameter down 2 Install the splined spacer on the shaft large diameter down 69 ...

Страница 70: ...ect cone for cup is used as indicated by markings NOTE Heating of bearing cones for installation is rec ommended provided the bearing is not heated over 275 F Heat lamps are recommended as heat source 6 Install the bearing inner spacer on the shaft 7 Place the front cup of the rear bearing into the rear of the housing bore taper to the inside 8 Place the bearing outer spacer on the cup and place r...

Страница 71: ...th down 2 Install the three springs in the direct ring 4 5 Apply pressure to the direct ring while twisting counter clockwise to fully seat the direct ring on the low speed ring pins Set the synchronizer assembly on blocking approxi mately 2 high on a bench large enough to accommod ate the rear housing 3 Install the direct ring on the low speed ring pins seating the springs against the pins 71 ...

Страница 72: ... the front of each auxiliary counter shaft large diameter towards the gear 3 Install the output shaft assembly on the synchronizer meshing the splines of the shaft with the synchronizer 2 Mark any two adjacent teeth on the low speed gear and 4 Place the countershaft into position against the output then mark the two teeth directly opposite shaft meshing the marked tooth on each countershaft betwee...

Страница 73: ... rear housing The capscrew with the brass washer is installed in the hole intersecting the speedometer bore 8 Install the countershaft rear bearings on the shafts and in the bores 9 Install the snap ring in the rear of each countershaft 10 Install the rear bearing covers 73 5 Place the auxiliary housing down over the assembly cen tering the countershafts in the rear bearing bores ...

Страница 74: ...the top 3 Install the O rings in the OD and ID of the piston 2 Hold the shift yoke in position in the sliding clutch slot long hub to the front and insert the yoke bar through the yoke hub and shift cylinder threaded end first Align the slots in the shaft with the lockscrew bores in the yoke hub Insert two yoke lockscrews tighten and wire securely 74 4 Install the piston on the bar flat side out a...

Страница 75: ...5 Install the shift cylinder cover with the air line fitting to the top left 75 ...

Страница 76: ...put Shaft and Rear Bearing Assembly 1 Place the output shaft on a bench with the threaded end up and install the splined spacer on the shaft large diameter down 2 Mark any two adjacent teeth on the low speed gear and then mark the two teeth directly opposite 76 ...

Страница 77: ... the spacer 4 Install the washer on the shaft flat surface down 5 Heat and install the front bearing cone on the shaft and against the washer taper facing up NOTE Heating of the bearing will facilitate installation Do not heat the bearing over 275o F 6 Install the bearing inner spacer on the shaft 77 ...

Страница 78: ...o the plate with a soft bar 8 Place the outer spacer on the front cup and tap the spacer evenly into the plate bore 9 Place the bearing rear cup on the outer spacer and evenly tap the cup into the plate bore until the lip of the cup seats against the plate 10 Place the rear plate over the output shaft assembly Use caution to avoid moving the lip of the rear cup away from the plate 78 ...

Страница 79: ...ed install the oil seal in the rear 13 Install the rear bearing housing over the output shaft and against the rear plate If the transmission is equipped with a speedometer drive gear the gear must be installed on the output shaft prior to installation of the rear bearing housing Use a brass washer on the capscrew intersecting the speedometer drive gear bore bearing housing 79 ...

Страница 80: ... down 2 Install the three springs in the direct ring 4 Apply pressure to the direct ring while twisting counter 5 clockwise to fully seat the direct ring on the low speed ring pins Mount the auxiliary plate in a vise in the upright posi tion and install the synchronizer assembly on the output shaft and into the reduction gear bore 3 Install the direct ring on the low speed ring pins seating the sp...

Страница 81: ...he low speed gear Use a soft bar to start the rear bearing on to the shaft and into the case bore and use a bearing driver to com plete the installation Check the synchronizer assembly during bearing installation to make sure that the springs do not pop out Repeat the procedure for the remaining countershaft NOTE Make sure that the bearing inner race is installed on the front of each auxiliary cou...

Страница 82: ...Secure with the four capscrews 2 Hold the shift yoke in position in the synchronizer slid ing clutch gear with the long hub of the yoke to the rear and insert the yoke bar through the yoke and cylinder housing aligning the notches in the bar with the yoke lockscrew bores 82 3 Insert the two yoke lockscrews tighten and wire securely 4 If previously removed install the O rings in the OD and ID of th...

Страница 83: ...5 Install the piston on the bar flat side out and secure with the elastic stop nut 6 Install the shift cylinder cover on the housing with the air fitting to the top left 83 ...

Страница 84: ... RT 12515 Series A Reassembly of the Output Shaft and Rear Bearing Assembly 1 Place the output shaft on blocking with the threaded end up Use caution to avoid damage to the quill 2 Install the splined spacer on the shaft 84 ...

Страница 85: ...stall the oil deflector in the rear housing bore with the cupped surface facing up Use a large bearing driver to drive the deflector down until the top surface of the deflector is 2 below the machined surface of the output shaft bore NOTE If available use two bearing outer spacers stacked on top of each other to drive the oil deflector into the bore The deflector will be at the proper depth when t...

Страница 86: ...e oil deflector with the cone surface facing up NOTE Heating of the bearings will facilitate installa tion Do not heat the bearings over 275o F 9 Install the bearing inner spacer on the shaft and against the front bearing cone 10 Stack the two bearing cups and outer spacer in the output shaft bore in the proper sequence Make sure that the front bearing cup taper matches the taper direction of the ...

Страница 87: ...ssary to block under the rear housing slightly to permit the output shaft assembly to move far enough 13 Install the speedometer drive gear or replacement spacer on the shaft and against the rear bearing cone 12 Heat and install the rear bearing cone on the shaft and in the rear cup taper facing down 14 Install the snap ring in the output shaft groove 87 ...

Страница 88: ...ing housing with the side of the seal with the seam facing into the housing 16 Install the rear bearing housing on the auxiliary hous ing making sure that the oil port in the auxiliary housing aligns with the notch in the bearing housing Use a brass washer on the capscrew intersecting the speedometer drive bore 88 ...

Страница 89: ...the rear If previously removed install the snap ring on the range mainshaft Check the bushing in the pocket of the main shaft for wear Replace if defective 3 Install the range mainshaft on the output shaft quill 4 Install the bearing on the quill and in the range main shaft 5 Secure the bearing with the snap ring 89 ...

Страница 90: ...r channel to the right 2 Install the yoke in the sliding clutch yoke slot with the lockscrew hole facing up 3 Install the O ring in the yoke bar groove and push the yoke bar forward and through the cylinder housing and the shift yoke Install the yoke Iockscrew tighten and wire securely 4 Install the cylinder cover aligning the air channel with the channel in the cylinder housing 90 ...

Страница 91: ... NOTE Splined washers with varying thicknesses are available Use the washer that provides the tightest fit in the hub of the gear 2 Mark any two adjacent teeth on the low range gear and then mark the two teeth directly opposite Install the gear on the shaft and against the coupler with the dished side facing to the front 4 Install the key in the keyway inserting the thick end between the splines o...

Страница 92: ...ing teeth down 2 Install the three springs in the direct ring 4 Apply pressure to the direct ring while twisting counter clockwise to fully seat the direct ring on the low speed ring pins 5 Install the synchronizer assembly on the splines of the output shaft and in the hub of the low speed gear 3 Install the direct ring on the low speed ring pins seating the springs against the pins 92 ...

Страница 93: ...ld the countershaft in position and use a soft bar to tap the rear bearing on to the shaft and into the case bore Use a bearing driver to complete installation of the bearing Check the synchronizer during bearing installation to make sure that the springs do not pop out Repeat the procedure to install the remaining countershaft IMPORTANT Make sure that the bearing inner race is installed on the fr...

Страница 94: ... in the rear housing with the air line fitting to the top 2 Hold the shift yoke in position on the sliding clutch with the long hub of bar through the in the bar with Install the two curely the yoke to the rear and insert the yoke hub and shift cylinder aligning the slots the lockscrew bores in the yoke hub yoke lockscrews tighten and wire se 94 ...

Страница 95: ...he O D and ID of the piston 4 Install the piston on the bar with the flat face out 5 Install the elastic stop nut on the bar and tighten se curely 6 Install the cover on the shift cylinder with the air fitting to the top left 95 ...

Страница 96: ...idler gear washer on the shaft If previously removed press the needle bearing into the bore of the idler gear 2 If previously removed install the bearing inner race on the shaft and insert the shaft threaded end first into the lower right wall of the case As the shaft is moved for ward install the reverse idler gear and thrust washer on the shaft making sure that the long hub on the idler gear is ...

Страница 97: ...needle bearings are positioned properly on the inner race before moving the shaft forward Secure the shaft with the washer and elastic stop nut Tighten to recommend ed torque 4 Install the auxiliary countershaft front bearing in the bore with a bearing driver 97 ...

Страница 98: ...B Reassembly of the Countershaft Assemblies NOTE Except for the number of teeth on the PTO gears the countershaft are identical and assembled in the same manner 98 ...

Страница 99: ...speed gear on to the shaft with the long hub of the gear facing up 4 Press the 4th speed or O D gear onto the haft with the long hub of the gear facing down 5 Start the PTO gear on to the shaft with the rounded side of the teeth facing up Install the drive gear on the shaft with the long hub facing up and press the PTO and drive gears into position Install the spacer on the shaft next to the drive...

Страница 100: ...PTO gear the right side countershaft takes a 45 tooth PTO gear 2 Place the left countershaft into position in the case but do not install bearings Make sure the left countershaft has the larger 47 tooth PTO gear 3 Place the right countershaft into position in the case but do not install bearings Make sure that the right counter shaft t has the smaller 45 tooth PTO gear 4 Countershafts will now be ...

Страница 101: ...of the input shaft 2 Install the drive gear on the shaft engaging the internal splines of the gear with the teeth on the shaft snap ring of gear towards the front 3 Install the drive gear spacer on the shaft and against the gear 4 Press the drive gear bearing on the shaft to the front with the shield 5 Apply Grade AV Loctite to the threads of the shaft and nut 101 ...

Страница 102: ...embly continued 6 Install the bearing nut on the shaft with 250 300 ft lbs of torque 7 Peen the nut into the two milled slots of the shaft NOTE To hasten hardening of the Loctite place the assembly under heat lamps 10 to 15 minutes 102 ...

Страница 103: ...he drive gear in the forward position as installation is not completed until the countershaft bear ings are installed 2 Make sure that the snap ring is removed from the drive gear bearing and insert the drive shaft from inside the case through the front bore and move as far forward as possible to expose the snap ring groove in the bearing It will be necessary to work the drive gear past the counte...

Страница 104: ...r as possible start the rear bearing on the shaft Center and install the rear bearing on the shaft and in the case bore seating the bearing against the shoulder of the shaft 4 Remove the blocking and install the front bearing on the countershaft and in the case bore Make sure that the timing teeth are still meshed 5 Install the snap ring on the rear of the countershaft 6 Install the bearing retain...

Страница 105: ...e manual covering mainshaft reassembly for method of assembling parts Reverse gear clearance must be set as low as possible to the minimum 005 Clearance can be measured before the mainshaft assembly is installed in the case This is done by securing the reverse gear in position on mainshaft with the reverse gear snap ring and the front snap ring then se cure auxiliary drive gear assembly in positio...

Страница 106: ... mainshaft in a vise with the pilot front end down making sure that the roll pin is in place in the keyway Install the 4th speed gear washer flat side up and lock in place with the key 3 Install the spacer on the washer stepped side up 4 Install the 4th speed gear on the shaft with the clutching teeth down Turn the gear until it engages the splines of the spacer 106 ...

Страница 107: ...ar stepped side down 7 Remove the key and install the 3rd speed gear washer on the shaft and in the gear Turn the washer to align the large slot with the keyway Lock the washer in place with the key 8 Install the 2nd 3rd speed sliding clutch on the shaft aligning the large groove in the clutch with the keyway Remove the key 107 ...

Страница 108: ...eyway and lock in position with the key 10 Install the stepped spacer on the washer flat side down 11 Install the 2nd speed gear on the shaft against the stepped spacer clutching teeth down Turn the gear until its splines engage with the splines of the spacer 12 Install the 1st speed gear on the shaft against the 2nd speed gear clutching teethup 108 ...

Страница 109: ...e speed sliding clutch 14 Remove the key and install the lst speed gear washer 16 Remove the key and install the reverse gear washer on on the shaft flat side down Align the large slot in the the shaft Align the large slot in the washer with the washer with the keyway and lock in position with the keyway and lock in position with the key key 109 ...

Страница 110: ...e gear find install the gear on the shaft in its proper position with the clutching teeth facing down Install the auxiliary drive gear assembly on the shaft in its proper position and secure the assembly to the shaft with the rear mainshaft snap ring Photo A Insert two screwdrivers between the auxiliary drive gear and the reverse gear and pry upwards Insert a feeler gauge between the hubs of the r...

Страница 111: ...ushing in the input shaft 3 Use wood blocks or equivalent to center the rear of the mainshaft and the countershaft and partially install the front countershaft bearing Complete installation of the countershaft bearings in the same manner as used for the left countershaft bearings 2 Remove the blocking from the right countershaft and move the countershaft into position making sure that the marked t...

Страница 112: ...through the bore in the rear case wall the gear and washer and the housing boss Make sure that the long hub of the gear faces to wards the front of the case NOTE Do not force the shaft into the gear as this will result in damage to the bearing Check the needle bear ing to make sure that all the rollers are in place 2 Install the rear washer and bearing inner race on the shaft If previously removed...

Страница 113: ...e to the rear against the wall of the case and mesh teeth with those of the reverse idler gears Slide the reverse gear spacer for ward and into the reverse gear 3 Move the reverse gear forward on the shaft and into correct position 2 Install the snap ring in the hub of the reverse gear 113 ...

Страница 114: ...sembly 1 Install the retainer ring on the gear with the groove in 2 Install the bearing on the gear with the snap ring facing the ring facing away from the gear the groove in the retainer Tap lightly on the inner race of the bearing with a soft bar and mall 114 ...

Страница 115: ...the end of the mainshaft 4 Install the auxiliary drive gear on the end of the main shaft and use a driver and mall to seat the bearing in the bore Align the six lockscrew holes in the retainer with the lockscrew bores in the case boss Install the six lock screws tighten and wire securely in groups of three 115 ...

Страница 116: ...d on the front of each auxiliary counter shaft 2 RT 12515 If the auxiliary housing is to be installed on the front case horizontally it is advisable to time the auxiliary countershaft to the auxiliary drive gear The extreme length and weight of the auxiliary countershaft can cause them to drop a tooth out of time on the auxiliary drive gear 1 Place a chain hoist on the auxiliary section to properl...

Страница 117: ... or yoke Install the flange or yoke on the splines of the output shaft NOTE On RT 12510 and RT 12515 transmissions the speedometer drive gear or replacement spacer should be installed prior to installation of the rear bearing housing 2 Secure the flange or yoke with the elastic stop nut and washer tightening with a torque wrench to 450 500 ft lbs of torque 117 ...

Страница 118: ...VI Shifting Controls A Reassembly of the Shift Bar Housing Assembly 118 ...

Страница 119: ... tighten to 35 45 ft lbs of torque and wire securely CAUTION Installing the yoke lock screws with more than 45 ft lbs of torque can result in distortion of the shift bars 2 Install the actuating plunger in the case boss 3 Insert an interlock ball in the case boss 4 Install the 2nd 3rd speed shift yoke and block on the shift bar as it is inserted into the housing boss Install the pin in the neutral...

Страница 120: ...ighten and wire securely 6 Install the oil trough on the housing Oil trough is op tional Tighten lock screws and wire securely 7 Remove the housing from the vise and install the three tension balls in the bores Install the tension springs over the balls 8 Make sure that the shift bars and the sliding clutches are all in the neutral position and install the shfit bar hous ing on the front case Secu...

Страница 121: ... a soft jawed vise with the bottom facing up and insert the shift lever in the housing fitting the slot in the pivot ball of the lever with the pivot pin 4 Install the tension spring washer in the housing 5 Install the tension spring in the housing seating the spring under the lugs cast in the housing Install the gear shift lever housing on the shift bar housing with the reinforced end over the th...

Страница 122: ...orward or all the way to the rear and install the alignment sleeve in the bore 4 Install the air valve on the adapter plate tightening the four capscrews evenly 5 If previously removed install the brass fittings in the air valve and range shift cylinder Secure the filter regulator assembly and the air valve 6 Connect the 1 4 ID supply air line between the filter regulator assembly and the air valv...

Страница 123: ...ll the range control valve on the gear shift lever so that the control button is approximately 6 below the centerline of the ball Secure the valve by tightening the screw on the clamp 9 Connect the black and white 1 8 OD air lines to the control valve as indicated 10 Connect the 1 8 OD air lines at the air valve as indicated 11 RT 12515 Models Connect the 1 4 ID air line between the T fitting forw...

Страница 124: ... to support the auxiliary plate during removal and in stallation on the front case IMPACT PULLER Make from 18 steel rod threaded 1 2 13 on one end attach end block and sliding block Used to remove reverse idler shafts OIL SEAL DRIVER Print Number T 18088 37 Print Number T 18088 36 RT 1110 Used to install the oil seal in the rear bearing housing SNAP RING INSTALLER Print Number T 16552 1 N Used to ...

Страница 125: ......

Страница 126: ...oducts 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 For spec ing or service assistance call 1 800 826 HELP 4357 or visit www ...

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