TRSM0660 1007 PDF

Service Manual
Fuller Heavy Duty Transmissions

TRSM0660
October 2007
RTLO-14613B
RTLOF-14613B
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . ...* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODEL DESIGNATIONS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOL REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION ............................................................
REASSEMBLY .. mm. m.. . m . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR SYSTEM
RANGE SHIFT AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPLITTER SHIFT AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY SHIFTING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY GEAR SHIFT LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REASSEMBLY GEAR SHIFT LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY AND REASSEMBLY SHIFT BAR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL OUTPUT YOKE, AUXILIARY SECTION AND CLUTCH HOUSING . . . . . . . . . . . .

DISASSEMBLY AUXILIARY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REASSEMBLY -AUXILIARY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY FRONT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REASSEMBLY FRONT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION CLUTCH HOUSING, AUXILIARY SECTION AND OUTPUT YOKE . . . . . . . .
INSTALLATION SHIFTING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIMMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
FOREWORD
This manual is designed to provide detailed information page 116. Service Manuals, Illustrated Parts Lists, Drivers
necessary to service and repair the Fuller Transmissions Instructions, and other forms of product service information
listed on the cover. for these and other Fuller Transmissions are available upon
As outlined in the Table of Contents, the manual is request. A Technical Literature Order Form maybe found in
divided into 3 main sections: the back of this manual. You may also obtain Service
a. Technical information and reference Bulletins, detailing information on product improvements,
b. Removal, disassembly, reassembly and repair procedures and other service-related subjects by
installation writing to the following address:
c. Options
The format of the manual is designed to be followed in its EATON CORPORATION
entirety if complete disassembly and reassembly of the TRANSMISSION DIVISION
transmission is necessary. But if only one component of the Technical Service Department
transmission needs to be repaired, refer to the Table of P.O. Box 4013
Contents for the page numbers showing that component. Kalamazoo, Michigan 49003
For example, if you need to work on the Shifting Controls, (61 6) 342-3344
you will find instructions for removal, disassembly and
reassembly on page 32. Instructions for installation are on
Every effort has been made to ensure the accuracy of all information in this brochure. However, Eaton Transmission Division
makes no expressed or implied warranty or representation based on the enclosed information. Any errors or omissions may
be reported to Training and Publications, Eaton Transmission Division, PO. Box 4013, Kalamazoo, Ml 49003.
2
MODEL DESIGNATIONS
AND SPECIFICATIONS
Nomenclature:
RTLO-14613
IMPORTANT: All Fuller Transmissions are identified by

model and serial number. This information is stamped on
the transmission identification tag and affixed to the case.
DO NOT REMOVE OR DESTROY THE TRANSMISSION
IDENTIFICATION TAG.
13-Speed Transmissions (On/Off Highway):

Relative Speed 1 2 3
Gear Ratios: PTO Gear Length Weight Oil Cap.
Model No To Input R.P.M. In. Lbs. Pints
Spds.
LO 1 St 2nd 3rd 4th 5th 6th 7th 8th Reverse Right Bottom (mm) (Kgs.) (Liters)
324 748 28
RTLO-14613 13 DIR 14.71 10.20 7.34 5.26 3.78 2.70 1.94 1.39 1.00 3.89/14.71 .696 .696 (823.5) (339.3) (13.25)
OD 2.28 1.64 1.18 .85 3.29/12.45
CHART NOTES:
1. Lengths measured from face of clutch housing to front bottoming surface of companion flange or yoke.
2. Weight - Listed weights are with clutch housing* and include standard controls, which consist of gear shift lever housing
and gear shift lever. Weight of standard controls is approximately 10 lbs. (4.5 kg.). All weights are approximate.
3. Oil Capacities are approximate, depending on inclination of engine and transmission. Always fill transmission with proper
grade and type of lubricant to level of filler opening. See LUBRICATION.
*For information on available clutch housings refer to Publication FUL-140 Clutch Housing Chart.
3
LUBRICATION
Proper Recommended Lubricants
Fahrenheit
Lubrication . . . Type
Grade
(SAE)
(Celsius)
Ambient
Temperature
the Key to long

Eaton Roadranger
CD50 Transmission

transmission life Fluid

Heavy Duty Engine 011
50 All
o o
MI L-L-2104B C or D or 50 Above 10 F(-12 C.)
Proper lubrication procedures are the key to a API-SF or API-CD 40 o o
Above 10 F(-12 C.)
good all-around maintenance program. If the (Previous API designations 30 o o
Below 10 F(-12 C.)
oil is not doing its job, or if the oil level is acceptable)
ignored, all the maintenance procedures in the Mineral Gear 011 with rust 90
o o
Above 10 F(-12 C.)
world are not going to keep the transmission and oxidation Inhibitor 80W
o o
Below 10 F(-12 C.)
running or assure long transmission life. API-GL-1
Eaton Fuller Transmissions are designed
so that the internal parts operate in a bath of The use of mild EP gear oil or multi-pur-
oil circulated by the motion of gears and shafts. pose gear oil is not recommended, but if
Thus, ail parts will be amply lubricated if these gear oils are used, be sure to adhere to
these procedures are closely followed: the following limitations:
1. Maintain oil level. Inspect regularly. Do not use mild EP gear oil or multi-pur-
2. Change oil regularly. pose gear oil when operating temperatures are
3. Use the correct grade and type of oil. above 230F (110oC). Many of these gear oils,
4. Buy from a reputable dealer. particularly 85W140, break down above 230F
and coat seals, bearings and gears with de-
Lubrication Change and Inspection
posits that may cause premature failures. If
Eaton Roadranger CD50 Transmission Fluid these deposits are observed (especially a coat-
HIGHWAY USEHeavy Duty and Mid-Range
ing on seal areas causing oil leakage), change
to Eaton Roadranger CD50 transmission fluid,
First 3,000 to 5,000 miles Factory fill heavy duty engine oil or mineral gear oil to
(4827 to 8045 Km) Inltlal drain
assure maximum component life and to main-
Every 10,000 miles Check fluid level tain your warranty with Eaton. (Also see
(16090 Km) Check for leaks
Operating Temperatures.)
Heavy Duty Highway Change Interval
Additives and friction modifiers are not recom-
Every 250,000 miles Change transmission
(402336 Km) fluid, mended for use in Eaton Fuller transmissions.
Mid-Range Highway Change Interval
Every 100,000 miles (160,000 Km) Change transmission
or every 3 years whichever occurs first fluid.
I OFF-HIGHWAY USE
First 30 hours Factory fill Initial drain,
Every 40 hours Inspect fluid level Check for leaks Proper Oil Level
Make sure oil is level with filler opening. Be-
I Every 500 hours Change transmission fluid where
severe dirt conditions exist. cause you can reach oil with your finger does
not mean oil is at proper level. One inch of oil
I Every 1,000 hours Change transmission fluid
(Normal off-highway use), level is about one gallon of oil.
Heavy Duty Engine Lubricant or Draining Oil
Mineral Gear Lubricant
Drain transmission while oil is warm. To drain
I HIGHWAY USE oil remove the drain plug at bottom of case.
Clean the drain plug before re-installing.
I First 3,000 to 5,000 miles
(4827 to 8045 Km)
Factory fill
Initial drain.
Refilling
I Every 10,000 miles
(16090 Km)
Inspect Iubricant level,
Check for leaks, Clean case around filler plug and remove plug
from side of case. Fill transmission to the
I Every 50,000 miles
(80450 Km)
Change transmission
lubricant, level of the filler opening. If transmission has
two filler openings, fill to level of both open-
I OFF-HIGHWAY USE
ings.
First 30 hours Change transmission lubricant on new units
The exact amount of oil will depend on the
Every 40 hours Inspect Iubricant level Check for leaks transmission inclination and model. Do not
Every 500 hours Change transmission Iubricant where over fillthis will cause oil to be forced out
severe dirt conditions exist. of the transmission.
Every 1,000 hours Change transmission Iubricant When adding oil, types and brands of oil
(Normal off-highway use), should not be mixed because of possible in-
Change the oil filter when fluid or lubricant is changed. 4 compatibility.
, .. .. . .
LUBRICATION
Operating Temperatures Proper Lubrication Levels

With Eaton Roadranger

as Related to Transmission
CD50 Transmission Fluid Installation Angles
Heavy Duty Engine Oil If the transmission operating angle is more
and Mineral Oil than 12 degrees, improper lubrication can oc-
cur. The operating angle is the transmission
The transmission should not be operated con- mounting angle in the chassis plus the per-
sistently at temperatures above 250oF (120oC). cent of upgrade (expressed in degrees).
However, intermittent operating temperatures The chart below illustrates the safe percent
to 300oF (149oC) will not harm the transmis- of upgrade on which the transmission can be
used with various chassis mounting angles.
sion. Operating temperatures above 250oF
For example: if you have a 4 degree transmis-
increase the lubricants rate of oxidation and sion mounting angle, then 8 degrees (or 14
shorten its effective life. When the average percent of grade) is equal to the limit of 12
operating temperature is above 250oF, the degrees. If you have a O degree mounting
transmission may require more frequent oil angle, the transmission can be operated on a
changes or external cooling. 12 degree (21 percent) grade.
Anytime the transmission operating angle of
The following conditions in any combina- 12 degrees is exceeded for an extended
tion can cause operating temperatures of over period of time the transmission should be
250oF: (1) operating consistently at slow equipped with an oil pump or cooler kit to
speeds, (2) high ambient temperatures, (3) re- insure proper lubrication.
stricted air flow around transmission, (4) ex- Note on the chart the effect low oil levels
can have on safe operating angles. Allowing
haust system too close to transmission, (5)
the oil level to fall 1/2 below the filler plug
high horsepower, overdrive operation. hole reduces the degree of grade by approxi-
External oil coolers are available to reduce mately 3 degrees (5.5 percent).
operating temperatures when the above condi-
tions are encountered.
Proper Lubrication Levels are Essential!
Transmission Oil Coolers are:
Recommended
With engines of 350 H.P. and above
with overdrive transmissions
Required
With engines 399 H.P. and above with
overdrive transmissions and GCWS
over 90,000 lbs.
With engines 399 H.P. and above and
1400 Lbs.-Ft. or greater torque
With engines 450 H.P. and above
With EP or Multipurpose Gear Oil

Mild EP gear oil and multipurpose gear oil are
not recommended when lubricant operating
temperatures are above 230F (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- Transmission Mounting Angle
ally limit their success to milder applications. Dotted line showing 2 Quarts Low is for
reference only. Not recommended.
5
OPERATION
13-Speed Overdrive Models
Shift Lever Patterns and Shifting Controls
RTO (Overdrive) Models
RTOX (Double-Overdrive) Models
With Splitter Control But

ton in DIR./REARWARD
position . . .
Shift LO-1-2-3-4 in LOW
RANGE.
Range shift . . .
And shift 5.6-7-8 in HIGH
RANGE (Direct).
WHILE IN HIGH RANGE

ONLY . . .
Ratios can be split by
moving Splitter Control
Button to the "O.D./
FORWARD position to
gain OVERDRIVE 5-6-7-8.
Roadranger Valve
(A-4900)
SPLITTER CONTROL BUTTON
6
. ..
POWER FLOW
The transmission must efficiently transfer the engines power, in terms of torque, to the vehicles rear wheels.
Knowledge of what takes place in the transmission during torque transfer is essential when troubleshooting
and making repairs.
Front Section Power Flow

(LO Range Direct)
1. Power (torque) from the vehicles engine is trans- 7. The rear auxiliary drive gear splits torque be-
ferred to the transmissions input shaft. tween the two auxiliary countershaft drive gears.
2. Splines of input shaft engage internal splines in 8. Torque is delivered along both auxiliary counter-
hub of main drive gear. shaft to the engaged reduction gear on output
3. Torque is split between the two countershaft shaft.
drive gears. 9. Torque is transferred to output shaft through slid-
4. Torque is delivered along both countershaft to ing clutch.
mating countershaft gears of engaged main- 10. Output shaft delivers torque to driveline.
shaft gear. The following cross section views il-
lustrate a 1st/5th speed gear engagement.
5. Internal clutching teeth in hub of engaged main-
shaft gear transfers torque to mainshaft through
sliding clutch.
6. Mainshaft transfers torque directly to rear aux-
iliary drive gear.
LO RANGE DIRECT
Cut 8006C-11 /87
7
POWER FLOW
Auxiliary Section Power Flow:
HI RANGE DIRECT
7. The rear auxiliary drive gear transfers torque 8. Torque is delivered through theoutput shaft to
directly to the output shaft through engaged driveline as HI RANGE 5th gear.
sliding clutch.
8
POWER FLOW
Auxiliary Section Power Flow:
HI RANGE OVERDRIVE
7. The front auxiliary drive gear splits torque be- 9. Torque is transferred to output shaft through the
tween the two auxiliary countershaft drive gears. sliding clutch.
8. Torque is delivered along both auxiliary counter- 10. Output shaft delivers torque to driveline as HI
shafts to mating countershaft gears of Range 5th gear OVERDRIVE.
engaged rear auxiliary drive gear.
9
TIMING
Timing Procedures: All ModeIs
It is essential that both countershaft assemblies of C. Meshing marked countershaft drive gear teeth
the front and auxiliary sections are timed. This as- with marked main drive gear teeth.
sures proper tooth contact is made between main- (After placing the mainshaft assembly into case,
shaft gears seeking to center on the mainshaft the countershaft bearings are installed to com-
during torque transfer and mating countershaft gears plete installation of the countershaft assemblies.)
that distribute the load evenly. If not properly timed, 1. When installing the bearings on left counter-
serious damage to the transmission is likely to result shaft, mesh the marked tooth of countershaft
from unequal tooth contact causing the mainshaft drive gear with either set or two marked teeth
gears to climb out of equilibrium. on the main drive gear.
Timing is a simple procedure of marking the appro- 2. Repeat the procedure when installing the
priate teeth of a gear set prior to installation and bearings on right countershaft, making use of
placing them in proper mesh while in the transmis- the remaining set of two marked teeth on the
sion. In the front section, it is necessary to time only main drive gear to time assembly.
the drive gear set. And depending on the model, only
the LO range, deep reduction, or splitter gear set is
timed in the auxiliary section.
Front Section
A. Marking countershaft drive gear teeth.
1. Prior to placing each countershaft assembly
into case, clearly mark the tooth located Countershaft gear teeth
meshed with drive gear teeth
directly over the keyway of drive gear as
for correct timing.
shown. This tooth is stamped with an O to
Cut 7300 F-1 1/86
aid identification.
Tooth on Countershaft
Auxiliary Section
directly over Keyway A. Timing the auxiliary countershaft and LO range
marked for timing gear.
1. Mark any two adjacent teeth on the LO range
gear of set to be timed. Then mark the two ad-
jacent teeth located directly opposite the first
Cut 7300 H-11/86 set marked as shown in Illustration B.
2. Prior to placing each auxiliary countershaft as-
sembly into housing, mark the tooth stamped
B. Marking main drive gear teeth. with an O on gear to mate with timed main-
1. Mark any two adjacent teeth on the main drive shaft gear as shown in Illustration A.
gear. 3. Install the LO range gear on the out put shaft
2. Mark the two adjacent teeth located directly and into the auxiliary case.
opposite the first-set marked on the main drive 4. Seat the auxiliary countershaft bearings.
gear. As shown below, there should be an 5. Install the rear bearing cover and tighten to
equal number of unmarked gear teeth on each recommended torque.
side between the marked sets. 6. Place the auxiliary countershaft assemblies
into position and mesh the marked teeth of the
mating countershaft gears with the marked
teeth of the LO range gear as shown in illustra-
Drive gear teeth correct/y tion C.
marked for timing.
Cut 7300 G-11/86

TORQUE RECOMMENDATIONS
Correct torque application is extremely important to assure long transmission life and dependable performance.
Over-tightening or under-tightening can result in a loose installation and, in many instances, eventually cause
damage to transmission gears, shafts, and/or bearings. Use a torque wrench whenever possible to attain recom-
mended lbs./ft. ratings. Do not torque capscrews dry.
FRONT SECTION: ALL MODELS
Cut 7190 K-11/87
11
TORQUE RECOMMENDATIONS
AUXILIARY SECTIONS
Cut 7191 Q-11/87
12
TOOL REFERENCE
Some repair procedures pictured in this manual show The specialized tools listed below can be obtained from
the use of specialized tools. Their actual use is recom- a tool supplier or made from dimensions as required by the
mended as they make transmission repair easier, faster, individual user. Detailed Fuller Transmission Tool Prints are
and prevent costly damage to critical parts. available upon request by writing.
But for the most part, ordinary mechanics tools such as Eaton Corporation
socket wrenches, screwdrivers, etc., and other standard Transmission Dept.
shop items such as a press, mauls and soft bars are all that Technical Service Dept.
is needed to successfully disassemble and reassemble any P.O. Box 4013
Fuller Transmission. Kalamazoo, Michigan 49003
PAGE TOOL HOW OBTAINED
Made from Fuller Transmission

38 Tension Spring Driver
Print T-11938
46 Countershaft Retaining Strap
Print T-64553
47 Auxiliary Section Hanger Bracket
Print T-22823
Made from Stop Nut or Round
47 Output Shaft Hanger Bracket
Bar Stock Flat Steel Stock
52 Jaw Puller and Bearing Separator Tool Supplier
69 Snap Ring Pliers Tool Supplier
72 Impact Puller (1/2-13 Threaded End) Tool Supplier

97 Countershaft Support Tool
Print T-22247
99 Input Shaft Bearing Driver Tool Supplier
113 Torque Wrench, 1000 Lbs./Ft. Capacity Tool Supplier
13
PREVENTIVE MAINTENANCE
14
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE CHECK CHART
CHECKS WITHOUT PARTIAL 9. Gear Shift Lever Housing Assembly
DISASSEMBLY OF CHASSIS OR CAB a. Remove air lines at slave valve and remove
the gear shift lever housing assembly from
1. Air System and Connections transmission.
a. Check for leaks, worn air lines, loose con- b. Check tension spring and washer for set
nections and capscrews. See AIR SYSTEM. and wear.
c. Check the gear shift lever spade pin and
2. Clutch Housing Mounting slot for wear.
a. Check all capscrews of clutch housing for d. Check bottom end of gear shift lever for
looseness. wear and check slot of yokes and blocks in
shift bar housing for wear at contact points
3. Clutch Release Bearing (Not Shown) with shift lever.
a. Remove hand hole cover and check radial
and axial clearance in release bearing. CHECKS WITH DRIVE LINE DROPPED
b. Check relative position of thrust surface of
release bearing with thrust sleeve on push- 10. Universal Joint Companion Flange
type clutches. or Yoke Nut
a. Check for tightness. Tighten to recom-
4. Clutch Pedal Shaft and Bores mended torque.
a. Pry upward on shafts to check wear.
b. If excessive movement is found, remove 11. Output Shaft (Not Shown)
clutch release mechanism and check bush- a. Pry upward against output shaft to check
ings in bores and wear on shafts. radial clearance in mainshaft rear bearing.
5. Lubricant CHECKS WITH UNIVERSAL JOINT

a. Change at specified service intervals. COMPANION FLANGE OR YOKE
b. Use only the types and grades as recom- REMOVED
mended. See LUBRICATION.
NOTE: If necessary, use solvent and shop rag to
6. Filler and Drain Plugs clean sealing surface of companion flange or
yoke. DO NOT USE CROCUS CLOTH, EMERY
a. Remove filler plugs and check level of lubri-
cant at specified intervals. Tighten filler and PAPER OR OTHER ABRASIVE MATERIALS
drain plugs securely. THAT WILL MAR SURFACE FINISH.
7. 12. Splines on Output Shaft

Capscrews and Gaskets
(Not Shown)
a. Check all capscrews, especially those on
PTO covers and rear bearing covers for a. Check for wear from movement and chuck-
looseness which would cause oil leakage. ing action of the universal joint companion
See TORQUE RECOMMENDATIONS. flange or yoke.
b. Check PTO opening and rear bearing covers 13. Mainshaft Rear Bearing Cover
for oil leakage due to faulty gasket.
a. Check oil seal for wear.
8. Gear Shift Lever
a. Check for looseness and free play in hous-
ing. If lever is loose in housing, proceed
with Check No. 9.
15
PRECAUTIONS
Disassembly
It is assumed in the detailed disassembly instructions that the lubricant has been drained from transmission,
the necessary linkage and air lines disconnected and the transmission has been removed from vehicle chassis.
Removal of the gear shift lever housing assembly (or remote control assembly) is included in the detailed in-
structions (Disassembly and ReassemblyShifting Controls); however, this assembly MUST be detached from
shift bar housing before transmission can be removed.
FOLLOW CLOSELY EACH PROCEDURE IN THE DETAILED INSTRUCTIONS. MAKING USE OF THE TEXT. ILLUS-
TRATIONS AND PHOTOGRAPHS PROVIDED.
1 BEARINGS Carefully wash and relubricate all tershafts, mainshaft, or main drive gear. Special
reusable bearings as removed and protectively procedures are required and provided in this man-
wrap until ready for use. Remove bearings planned ual.
to be reused with pullers designed for this pur- 5. CLEANLINESS Provide a clean place to work. It
pose. is important that no dirt or foreign material enters
2. ASSEMBLIES When disassembling the various the unit during repairs, Dirt is an abrasive and can
assemblies, such as the mainshaft, countershaft, damage bearings. It is always good practice to
and shift bar housing, lay all parts on a clean clean the outside of the unit before starting the
bench in the same sequence as removed. This pro- planned disassembly.
cedure will simplify reassembly and reduce the 6. WHEN USING TOOLS TO MOVE PARTS Always
possibility of losing parts. apply force to shafts, housings, etc, with restraint.
3. SNAP RINGS Remove snap rings with Pliers de- Movement of some parts is restricted. Never apply
signed for this purpose. Snap rings removed in this force to the part being driven after it stops solidly.
manner can be reused, if they are not sprung or The use of soft hammers, bars and mauls for all
loose. disassembly work is recommended.
4 INPUT SHAFT The input shaft can be removed
from transmission without removing the coun-
Inspection
Before reassembling the transmission, check each part carefully for abnormal or excessive wear and damage to
determine reuse or replacement. When replacement is necessary, use only genuine Fuller Transmission parts to
assure continued performance and extended life from your unit.
Since the cost of a new part is generally a small fraction of the total cost of downtime and labor, avoid reus-
ing a questionable part which could lead to additional repairs and expense soon after initial reassembly. To aid
in determining the reuse or replacement of any transmission part, consideration should also be given to the
units history, mileage, application, etc.
Recommended inspection procedures are provided in the following checklist.
A. BEARINGS B. GEARS
1. Wash all bearings in clean solvent. Check 1. Check gear teeth for frosting and pitting.
balls, rollers and raceways for pitting, discol- Frosting of gear tooth faces present no threat
oration, and spalled areas. Replace bearings of transmission failure. Often in continued
that are pitted, discolored, or spalled. operation of the unit, frosted gears will heal
2 . Lubricate bearings that are not pitted, discol- and not progress to the pitting stage. And in
ored, or spalled and check for axial and radial most cases, gears with light to moderate pit-
ted teeth have considerable gear life remain-
clearances.
ing and can be reused. But gears with
3 . Replace bearings with excessive clearances. advanced stage pitting should be replaced.
4 . Check bearing fits. Bearing inner races 2. Check for gears with clutching teeth abnor-
should be tight to shaft; outer races slightly mally worn, tapered, or reduced in length
tight to slightly loose in case bore. If bearing from clashing in shifting. Replace gears
spins freely in bore, however, case should be found in any of these conditions.
replaced.
16
PRECAUTIONS
Inspection (contd.) 1. GEAR SHIFT LEVER HOUSING
3. Check axial clearance of gears. Where exces- ASSEMBLY
sive clearance is found, check gear snap ring, 1. Check spring tension on shift lever. Replace
washer, spacer, and gear hub for excessive tension spring and washer if lever moves too
wear. Maintain .005 to .012 axial clearance f reel y.
between mainshaft gears. 2. If housing is disassembled, check spade pin
and corresponding slot in lever for wear. Re-
C. SPLINES place both parts if excessively worn.
1. Check splines on all shafts for abnormal wear.
If sliding clutch gears, companion flange, or J. BEARING COVERS
clutch hub have worn into the sides of the 1. Check covers for wear from thrust of adjacent
splines, replace the specific shaft affected. bearing. Replace covers damaged from thrust
D. TOLERANCE WASHERS of bearing outer race.
1. Check surfaces of all tolerance washers. 2. Check bores of covers for wear. Replace
Washers scored or reduced in thickness those worn oversize.
should be replaced. K. OIL RETURN THREADS
E. REVERSE IDLER GEAR ASSEMBLIES AND SEALS
1. Check for excessive wear from action of roller 1. Check oil return threads in front bearing
bearings. cover. If sealing action of threads has been
destroyed by contact with input shaft, replace
F. GRAY IRON PARTS bearing cover.
1. Check all gray iron parts for cracks and breaks. 2. Check oil seal in rear bearing cover If sealing
Replace parts found to be damaged. action of lip has been destroyed, replace seal.
G. CLUTCH RELEASE PARTS L. SLIDING CLUTCHES
1. Check clutch release parts. Replace yokes 1. Check all shift yokes and yoke slots in sliding
worn at cam surfaces and bearing carrier clutches for extreme wear or discoloration
worn at contact pads. from heat.
2. Check pedal shafts. Replace those worn at 2. Check engaging teeth of sliding clutches for
bushing surfaces. partial engagement pattern.
H. SHIFT BAR HOUSING ASSEMBLY M. SYNCHRONIZER ASSEMBLY
1. Check for wear on shift yokes and blocks at 1. Check synchronizer for burrs, uneven and ex-
pads and lever slot. Replace excessively worn cessive wear at contact surface, and metal
parts. particles.
2. Check yokes for correct alignment. Replace 2. Check blocker pins for excessive wear or
sprung yokes. looseness.
3. Check Iockscrews in yokes and blocks. 3. Check synchronizer contact surfaces on the
Tighten and rewire those found loose. auxiliary drive and low range gears for exces-
4. If housing has been disassembled, check sive wear.
neutral notches of shift bars for wear from in- N. O-RINGS
terlock balls.
1. Check all O-rings for cracks or distortion. Re-
place if worn.
17
PRECAUTIONS
Reassembly
Make sure that interiors of case and housings are clean. It is important that dirt and other foreign materials be
kept out of the transmission during reassembly. Dirt is an abrasive and can damage polished surfaces of
bearings and washers. Use certain precautions, as listed below, during reassembly.
1. GASKETS Use new gaskets throughout the 6. AXIAL CLEARANCES Maintain original axial
transmission as it is being rebuilt. Make sure all clearances of .005 to .012 for mainshaft gears.
gaskets are installed. An omission of any gasket 7. BEARINGS Use of flanged-end bearing drivers is
can result in oil leakage or misalignment of recommended for the installation of bearings.
bearing covers. These special drivers apply equal force to both
2. CAPSCREWS To prevent oil leakage, use Loctite bearing races, preventing damage to balls/rollers
242 thread sealant on all capscrews. For torque and races while maintaining correct bearing align-
ratings, see TORQUE RECOMMENDATIONS. ment with bore and shaft. Avoid using a tubular or
3. O-RINGS Lubricate all O-rings with silicone lu- sleeve-type driver, whenever possible, as force is
bricant. applied to only one of the bearing races. See
TOOL REFERENCE.
4. ASSEMBLY Refer to the illustrations provided in
the detailed disassembly instructions as a guide 8. UNIVERSAL JOINT COMPANION FLANGE OR
to reassembly. YOKE Pull the companion flange or yoke tightly
into place with the output shaft nut, using 450-500
5. INITIAL LUBRICATION Coat all limit washers foot-pounds of torque. Make sure the speedome-
and splines of shafts with Lubriplate during reas- ter drive gear or a replacement spacer of the same
sembly to prevent scoring and galling of such width has been installed. Failure to pull the com-
parts. panion flange or yoke tightly into place will permit
the output shaft to move axially with resultant
damage to the rear bearing.
IMPORTANT: REFER TO THE APPROPRIATE ILLUSTRATED PARTS LIST (SPECl-

FIE D BY MODEL SERIES) TO ENSURE THAT PROPER PARTS ARE
USED DURING REASSEMBLY OF THE TRANSMISSION.
18
CHANGING INPUT SHAFT
Special Procedure
In some cases, it may become necessary to replace the input shaft due to excessive clutch wear on the splines.
Except for removal of the shift bar housing assembly, the input shaft can be removed without further disas-
sembly of the transmission. Removal of the clutch housing is optional.
NOTE: The following illustration and instructions pertain to changing the input shaft ONLY. To change the main
drive gear, complete disassembly of the front section is required.
Disassembly Reassembly
1. Remove the gear shift lever housing assembly (or 1. If necessary, install bushing in pocket of input
remote control assembly) from shift bar housing, shaft.
and the shift bar housing assembly from transmis-
2. Install new input shaft into splines of main drive
sion case.
gear, just far enough to expose snap ring groove
2. Remove the front bearing cover and gasket. If nec- in I.D. of drive gear.
essary, remove the O-ring from cover of models so
3. Install snap ring in snap ring groove inside drive
equipped.
gear.
3. Remove the bearing retaining snap ring from
4. Install drive gear spacer on input shaft.
groove in shaft.
5. Install drive gear bearing on input shaft and into
4. Push down on input shaft to cock bearing in bore.
case bore.
Drive input shaft toward rear of transmission,
through bearing as far as possible. Pull input shaft 6. Install bearing retainer snap ring.
forward to expose snap ring of bearing.
7. Install front bearing cover and gasket. Make sure
5. Use pry bars to complete removal of bearing. to align oil return hole in the case with hole in
cover.
6. Remove drive gear spacer and snap ring.
7. Pull input shaft forward and out of drive gear and 8. To facilitate proper reinstallation of the shift bar
housing assembly on case, make sure mainshaft
case.
sliding clutches are placed in the neutral posi-
tion.
9. Reinstall the shift bar housing assembly, the
front bearing cover and all other parts and as-
semblies previously removed, making sure to re-
place the gaskets used.
19
AIR SYSTEM
21
AIR SYSTEM
RANGE SHIFT AIR SYSTEM
Operation B. If the air lines are crossed between the slave
The Range Shift Air System consists of the air filter/ valve and range cylinder, the transmission
regulator, slave valve, a Range Control Valve or Mas- gearing will not correspond with the range se-
ter Control Valve, range cylinder, fittings and lection. A LO RANGE selection will result in a
connecting air lines. See Air System Schematics. HI RANGE engagement and vice versa.
CONSTANT AIR from the air filter/regulator is sup-
plied to the S or Supply Port of slave valve and 2. AIR LEAKS
passed through to the INLET or S Port of control With the gear shift lever in neutral, coat all air
valve. lines and fittings with soapy water and check for
WHILE IN LO RANGE, the control valve is OPEN leaks, moving the control that provides range se-
and AIR is returned to slave valve at the P or End lection UP and DOWN.
Port. This signals the valve to supply AIR in line be- A. If there is a steady leak from the exhaust port
tween the LO Range or L Port of slave valve and of control valve, O-rings and/or related parts
the LO Range Port of range cylinder housing. AIR re- of the control valve are defective.
ceived at this port moves the range piston to the rear
and causes the auxiliary LO RANGE gear to become B. If there is a steady leak from breather of slave
engaged. valve: an O-ring in valve is defective, or there
WHILE IN HI RANGE, the control valve is CLOSED is a leak past O-rings of range cylinder piston.
and NO AIR is returned to the slave valve. This C. If transmission fails to shift into LO RANGE
signals the slave valve to supply AIR in line between or is slow to make the range shift and the
the HI Range or H Port of valve and the HI Range case is pressurized, see Check No. 7 of this
Port of range cylinder cover. AIR received at this port section.
moves the range piston forward to engage the aux-
iliary drive gear with sliding clutch and bypass the D. Tighten all loose connections and replace de-
LO RANGE gear set. fective O-rings and parts.
Range shifts can be made ONLY when the gear
shift lever is in, or passing through, neutral. Thus, the 3. AIR FILTER/REGULATOR
range desired can be PRESELECTED while the shift (See illustration, Page 23.)
lever is in a gear position. As the lever is moved With the gear shift lever in neutral, check the
through neutral, the actuating plunger in the shift bar breather of air fiiter/regulator assembly. There
housing releases the slave valve, allowing it to move should be NO AIR leaking from this port. The
to the selected range position. complete assembly should be replaced if a
steady leak is found.
Trouble Shooting Cut off the vehicle air supply to the air filter/
regulator assembly, disconnect the air line at fit-
If the transmission fails to make a range shift or ting in Supply OUTLET and install an air gage in
shifts too slowly, the fault may be in the Range Shift opened port. Bring the vehicle air pressure to nor-
Air System or actuating components of the shift bar mal. Regulated air pressure should be 57.5 to 62.5
housing assembly. Psi.
To locate the trouble, the following checks should
be made with normal vehicle air pressure applied to DO NOT ADJUST SCREW AT BOTTOM OF REGU-
the system, but with the engine off. LATOR TO OBTAIN CORRECT READINGS. The
air regulator has been PREADJUSTED within the
NEVER WORK UNDER A VEHICLE correct operating limits. Any deviation from these
WHILE ENGINE IS RUNNING as limits, especially with regulators that have been
personal injury may result from the sudden and unin- in operation for some time, is likely to be caused
tended movement of vehicle under power. Always by dirt or worn parts. If replacement or cleaning
place transmission in the neutral position. of the filter element does nothing to correct the
air pressure readings, replace the complete as-
1. INCORRECT AIR LINE HOOK-UPS sembly, as the air regulator is nonserviceable.
(See Air System Schematics)
With the gear shift lever in neutral, move the con- 4. RANGE VALVE (See Page 24.)
trol that provides range selection UP and DOWN. With the gear shift lever in neutral, select HI
A. If the air lines are crossed between control RANGE and disconnect the air line at the OUT-
valve and slave valve, there will be CON- LET or P Port of control valve.
STANT AIR flowing from the exhaust port of
control valve WHILE IN HI RANGE.
21
AIR SYSTEM
A. When LO RANGE is selected, a steady blast 6. LO RANGE OPERATION
of air will flow from opened port. Select HI With the gear shift lever in neutral, select HI
RANGE to shut off air flow. This indicates the RANGE and disconnect the 1/4 I.D. air line at the
control valve is operating properly. Reconnect fitting on range cylinder housing. Make sure this
air line. line leads from the LO Range or L Port of slave
valve.
B. If control valve does not operate properly,
check for restrictions and air leaks. Leaks in- A. When LO RANGE is selected, a steady blast
dicate defective or worn O-rings. of air should flow from disconnected line. Se-
lect HI RANGE to shut off air flow.
5. HI RANGE OPERATION
With the gear shift lever in neutral, select LO B. Move the shift lever to a gear position and se-
RANGE and disconnect the 1/4 I.D. air line at the lect LO RANGE. There should be NO AIR flo-
port of range cylinder cover. Make sure this line wing from disconnected line. Return the gear
leads from the HI Range or H Port of slave shift lever to the neutral position. There
valve. should now be a steady flow of air from dis-
connected line. Select HI RANGE to shut off
A. When HI RANGE is selected, a steady blast of air flow and reconnect air line.
air should flow from disconnected line. Select
LO RANGE to shut off air flow. C. If the air system does not operate accord-
ingly, the slave valve or actuating components
B. Move the shift lever to a gear position and se-
of the shift bar housing assembly are defec-
lect HI RANGE. There should be NO AIR flow-
tive.
ing from disconnected line. Return the gear
shift lever to the neutral position. There 7. RANGE CYLINDER (Refer to the following
should now be a steady flow of air from dis- illustration.)
connected line. Select LO RANGE to shut off If any of the seals in the range cylinder assembly
air flow and reconnect air line. are defective, the range shift will be affected.
C. If the air system does not operate accord- A. Leak at either O-ring A results in complete
ingly, the slave valve or actuating components failure to make a range shift; steady flow of
of the shift bar housing assembly are defec- air from breather of slave valve in both
tive. ranges.
B. Leak at gasket B results in a steady flow of air
IMPORTANT: RANGE PRESELECTION
to atmosphere while in HI RANGE.
The plunger pin, located in case bore between
the slave valve and actuating plunger of shift bar C. Leak at O-ring C results in a slow shift to LO
housing, prevents the slave valve from operating RANGE; pressurizing of transmission case.
while the shift lever is in a gear position. When
the lever is moved to or through the neutral po-
sition, the pin is released and the slave valve be-
comes operational.
Cut 7420-5/87
Range Cylinder AssemblyAll Models
22
AIR SYSTEM
AIR FILTER/REGULATOR ASSEMBLY
.
The air filter contains a replaceable filter element which can be removed by turning out the end cap. This ele-
ment should be cleaned at each oil change, or more often under high humidity conditions. Replace if necessary.
SLAVE VALVES
POPPET-TYPE
Refer to the drawing for disassembly and reassembly of the piston-type slave valve assemblies. Should the pop-
pet-type slave valve assembly prove to be defective, replace the complete assembly, as it is non-serviceable.
The actuating components used with these valve assemblies are non-interchangeable. Failure to use the correct
plunger pin, spring, and alignment sleeve during installation on the transmission will cause hard shifting in LO
Range gears.
23
AIR SYSTEM
ROADRANGER VALVE A-4900
Removal and Disassembly 7. If necessary, remove the spring and O-ring from
1. Remove two screws holding bottom cover to valve bores in left housing.
and slide cover down gearshift lever to expose air 8. If necessary, remove the springs, O-ring and
line fittings. Disconnect air lines. sleeve from bores in right housing.
2. Loosen jam nut and turn control valve from gear
shift lever.
Reassembly and Installation
3. Pry medallion from recess in top cover.
1. Refer to the drawing for proper reassembly. Use a
4. Turn out the two screws to remove the top cover VERY SMALL amount of silicone lubricant on the
from valve housing. O-rings to avoid clogging ports. A small amount of
grease on the position springs and balls will help
5. Turn out the two screws in side of valve housing to
to hold them in place during reassembly
separate the housing.
2. Install control valve on gear shift lever and tighten
6. Remove the Range Preelection Lever from left jam nut.
housing and the position balls and guide from
lever. 3. Attach air lines and install bottom cover.
24
AIR SYSTEM
SPLITTER SHIFT AIR SYSTEM:
Operation Trouble Shooting
In addition to the various components of the Range Shift Air If the transmission fails to shift or shifts too slowly to or from
System, the Splitter Shift Air System utilizes a splitter cylin- the (split position, the fault may be in the Splitter Shift Air
der and the Roadranger Valve A-4900. See Air System System or related components of the Range Shift Air Sys-
Schematics. tem.
CONSTANT AIR from the air filter/regulator assembly is To locate the trouble, the following checks should be
supplied to the splitter cylinder at the port on right side of made with normal vehicle air pressure supplied to the sys-
cylinder cover. The Insert valve installed in cover (see tem, but with the engine off.
page 27) provides the proper air flow needed to move the
NEVER WORK UNDER A VEHICLE
splitter piston in the cylinder (rearward to engage rear auxil-
WHILE ENGINE IS RUNNING as
iary drive gear for operation in direct; forward to engage the
personal injury may result from the sudden and unin-
front auxiliary drive gear for operation in overdrive).
tended movement of vehicle under power. Always
WHILE IN HI OR LO RANGE, AIR needed to make the
place transmission in the neutral position.
splitter selection and complete the shift is supplied to the
Roadranger valve from the tee fitting at the HI RANGE or NOTE: It is assumed that correct PSI readings were
H port of the slave valve. When the overdrive selection is obtained from the air filter/regulator and all air
made, the AIR passes through the Roadranger valve and is lines have been checked for leaks.
supplied to the Left Port of cylinder cover.
1. Air Supply (See Air System Schematics.)
With Splitter Control Button in the DIRECT/REAR-
With the gear shift lever in neutral, select HI or LO
WARD position, the SP Port of the Roadranger valve is
RANGE and loosen the connection at the "S Port of
CLOSED and NO AIR is supplied to the Left Port of the
the Roadranger Valve until it can be determined that
Splitter cylinder cover.
AIR is supplied to valve. Reconnect air line.
If there is NO AIR, check for a restriction in the air line
between the Roadranger valve and slave valve. Make
sure this line is connected to fitting at the supply Port of
slave valve.
2. Roadranger Valve (See Page 24 and Air System
Schematics.)
With the gear shift lever in neutral, disconnect the air
Button REARWARD
line at the Left Port of splitter cylinder cover, making
(SP Port Closed)
sure this line leads from the "SP Port of the
Roadranger Valve.
A. WHILE IN HI OR LO RANGE, move the Splitter
While in HI RANGE the button can be moved FOR-
Control Button FORWARD. There should be AIR
WARD to operate in OVERDRIVE. The "SP Port of valve is
flowing from disconnected line. Move the button
OPENED when overdrive is selected, supplying AIR to the
REARWARD to shut off air flow and reconnect air
Left Port of the Splitter cylinder cover.
line.
B. If the preceding conditions do not exist, the
Roadranger valve is defective, or there is a restric-
tion in the air lines.
3. Splitter Cylinder. (Refer to the following illustra-
tion.)
If any of the seals in the splitter cylinder assembly are
defective, the splitter shift will be affected. The degree
Button FORWARD of air lost will govern the degree of failure, from slow
(SP Port Opened) shifting to complete shift failure.
A. Leak at O-ring A results in a slow shift to engage
rear auxiliary drive gear; pressurizing of transmis-
sion case; auxiliary gearing can be disengaged.
25
AIR SYSTEM
B. Leak at O-ring B results in slow shifting or 4. Insert Valve (See Page 27).
complete failure to engage and disengage Any constant flow of air from exhaust port of cyl-
front or rear auxiliary drive gearing; steady inder cover usually indicates a faulty insert valve.
flow of air from exhaust port of Roadranger Exhaust should occur ONLY BRIEFLY when Split-
valve and/or cylinder cover when Splitter Con- ter Control Button is moved REARWARD WHILE
trol Button is in the REARWARD position. IN LO and HI RANGE.
C. Leak at gasket C results in a slow shift to dis- A faulty insert valve, leaking at the O-rings of
engage rear auxiliary drive gear; steady flow valve O.D. or from inner seals results in constant
of air to atmosphere. air leak and shift failure. Two indications of defec-
tive O-rings or seals are:
A. CONSTANT AIR flowing from exhaust port of
cylinder cover.
B. CONSTANT AIR flowing from Exhaust Port
E of control valve WHILE SPLITTER CON-
TROL BUTTON IS REARWARD OR FORWARD
(providing the control valve is operating pro-
perly).
The three O-rings in position on valve O.D. can be
replaced. However, if an inner seal is damaged,
the complete assembly MUST be replaced.
26
AIR SYSTEM
INSERT VALVE:
(EQUIPPED WITH ROADRANGER VALVE A-4900
The insert valve is a self-contained 1 - 3/16 valve as- NOT be disassembled except for the three O-rings on
sembly located in the splitter cylinder cover. It CAN- outer diameter. The O-rings provide a stationary seal
and do not move in cylinder.
When installing the insert valve in bottom edge of
cover, apply Fuller #71206 silicone lubricant or its
equivalent to O-rings and cylinder walls. Install valve
in bore with flat surface to the outside. When install-
ing the special valve retaining nut, apply Fuller
#71204 adhesive/sealant or its equivalent to threads
and tighten. See TORQUE RECOMMENDATIONS.
Travel of the small insert valve piston is only 3/16.
As shown in the illustrations below, when NO AIR is
applied to the top side of valve piston, CONSTANT
AIR supplied from the regulator passes to the
FRONTSIDE of cylinder piston, moving the yoke bar
backward to engage the REAR AUXILIARY DRIVE
GEAR (LO RANGE DIRECT AND HI RANGE DIRECT).
The piston moves up to cut off air to the back side of
the cylinder piston. This air is exhausted out the cyl-
inder cover as the piston moves rearward.
When AIR is applied to top side of valve piston,
through signal line, the piston moves down passing
air through the bottom of insert valve to the front and
backside of the cylinder piston, moving the yoke bar
FORWARD engaging the FRONT AUXILIARY DRIVE
GEAR (LO RANGE OVERDRIVE AND HI RANGE
OVERDRIVE).
LOW RANGE AND HIGH RANGE DIRECT OVERDRIVE
AIR APPLIED THROUGH SIGNAL LINE

PUSHES INSERT VALVE PISTON DOWN
27
RTLO-XX613 Models
LO Range
A-4900 Roadranger
Valve Slave Valve
Identification
Down
A-5000 Valve
Rearward
Fulerl
Transmissions
19470 Valve
H/L P S SP
19470 or A-5000
Slave Valve
H/L
HI
S P
LO Schematic
For all questions

concerning
removal and
Air Filter/Regulator Splitter Cylinder Range Cylinder Assembly replacement,
Assembly Assembly refer to Eaton
SP Service and Parts
No Air Air to Literature.
LO Housing
Port
Air from
Vehicle
Source
Constant Air No Air

HI
System Operation and SchematicsOperation Guide 3A-21

RTLO-XX613 Models
HI Range L
A-4900 Roadranger
Valve Slave Valve
Identification
Up
A-5000 Valve
Rearward
Fulerl
Transmissions
19470 Valve
H/L P S SP
19470 or A-5000
Slave Valve
H/L
HI
S P
Schematic LO
For all questions

concerning
removal and
replacement, Air Filter/Regulator Splitter Cylinder Range Cylinder Assembly
refer to Eaton Assembly Assembly
Service and Parts SP
No Air
Literature. No Air
LO
Air from
Vehicle
Source
Constant Air Air to Cover

Port HI
3A-22 Operation GuideSystem Operation and Schematics

RTLO-XX613 Models
HI Range H
A-4900 Roadranger
Valve Slave Valve
Identification
Up
A-5000 Valve
Forward
Fulerl
Transmissions
19470 Valve
H/L P S SP
19470 or A-5000
Slave Valve
H/L
HI
S P
LO Schematic
For all questions

concerning
removal and
Air Filter/Regulator Splitter Cylinder Range Cylinder Assembly replacement,
Assembly Assembly refer to Eaton
SP Service and Parts
No Air Literature.
LO
Air from
Vehicle
Source
Constant Air Air to Cover

Port
HI
System Operation and SchematicsOperation Guide 3A-23

DISASSEMBLY SHIFTING CONTROLS
Air System
A. Removal of Air Control
1. Disconnect the two air lines at the "S" or Supply Port 2. Remove the air line at the splitter cylinder cover.
and "P" or End Port of the slave valve on the transmis-
NOTE: If desired, the gear shift lever housing assem-
sion case.
bly can now be removed from shift bar housing by
removing the four capscrews from the tower.
32
3. Turn out the two mounting screws in the Roadranger

valve cover.
5. Loosen the jam nut and turn the valve and nut from
gear shift lever. Remove the valve cover, air lines
sheathing and O-rings from lever.
4. Slide the cover down to expose the valve ports and

disconnect the three air lines.
6. Disconnect and remove the 1/4" I.D. air line between

Splitter Cylinder and air filter/regulator.
33
7. Disconnect and remove the 1/4" I.D. air hoses be- 2. Turn out the four retaining capscrews and remove slave
tween the slave valve (inset) and air filter/regulator valve from transmission case.
assembly and range cylinder assembly.
B. Removal of Air
Filter/Regulator Assembly
3. Remove the hat-type alignment sleeve from bore in

slave valve.
1. Turn out the two capscrews and remove the air filter/
regulator assembly.
NOTE: For disassembly and reassembly of Air Filter/
Regulator Assembly, see Page 23.
34
4. Remove the spring and plunger pin from bore in trans- 5. If necessary, remove the air line fittings from slave
mission case. Remove slave valve gasket. valve.
NOTE: For disassembly and reassembly of piston-type
Slave Valve Assembly, see Page 23.
35
DISASSEMBLY GEAR SHIFT LEVER
ASSEMBLY
A. Removal and Disassembly
1. Turn out the four retaining capscrews, jar lightly to

break gasket seal and remove the gear shift lever
housing and gasket from shift bar housing.
NOTE: Remote control housings are removed from

shift bar housing in the same manner. For disas-
sembly and reassembly of LRC Assemblies, see 11-
Iustrated Parts List No. P-541. For disassembly
and reassembly of SRC Assemblies, see illus-
trated Parts List No. P-515.
2. Remove the boot from gear shift lever and secure

assembly in vise with bottom of housing up. Use a large
screwdriver to twist between the spring and housing,
forcing the spring from under the lugs in housing.
Do one coil at a time.
Cut 7288D2/86
36
REASSEMBLY GEAR SHIFT LEVER
ASSEMBLY
B. Reassembly of Gear Shift Lever
Housing Assembly
3. Remove the tension spring, washer and gear shift 1. With the gear shift lever housing secured in vise
lever from housing. as suring disassembly, install the spade pin in
bore of housing tower. If previously removed, in-
stall the O-ring in tower groove.
4. Remove the spade pin from bore in housing 2. Position the gear shift lever in housing with
tower. If necessary, remove the O-ring from spade pin in leaver ball slot and install the tension
groove inside tower. spring washer over ball, dished-side up.
37
REASSEMBLY GEAR SHIFT LEVER
ASSEMBLY
3. Install the tension spring under lugs in housing, seating 4. Remove the assembly from vise and install the
one coil at a time. Use of a spring driving tool is rubber boot over gear shift lever and against
recommended. housing.
38
DISASSEMBLY AND REASSEMBLY
SHIFT BAR HOUSING
SHIFT BAR HOUSING ASSEMBLY
A. Removal and Disassembly of the Shift

Bar Housing Assembly
For models equipped with an Oil Pump
and/or Cooler Assemblies, make sure to
disconnect the lube line at the fitting on the shift
bar housing before doing the following
instructions.
1. Turn out the retaining capscrews. Jar the top to 2. Tilt the assembly and remove the three sets of ten-
break the gasket seal and lift the shift bar housing sion springs and balls from the housing bores.
from the transmission case. Remove the gasket.
NOTE: During disassembly, lay all parts on a

clean bench in order of removal from the housing
to make reassembly easier. Shift bars not being re-
moved must be kept in the neutral position or the
interlocking parts will lock the bars.
39
SHIFT BAR HOUSING
3. Secure the assembly in a vise with the plunger- 5. Move the 1st-2nd speed shift bar to the housing
side up. (The front of the housing will be to the rear, removing the yoke and block from the bar. As
left.) For models so equipped, cut the lockwire the neutral notch in the bar clears the rear boss,
and turn out the retaining capscrews to remove remove the small interlock pin from the bore.
the oil trough from the housing.
NOTE: Start with the upper shift bar, move all bars
to the right and out the rear boss bore. Cut the
lockwire and remove the Iockscrews from each bar
just before their removal.
4. Move the 3rd-4th speed shift bar to the housing 6. Remove the actuating plunger from the center
rear, removing the yoke and block from the bar. boss bore.
40
SHIFT BAR HOUSING
B. Reassembly of the Shift Bar Housing
Assembly.
7. Move the short LO-Reverse speed shift bar to the 1. If previously removed, install the reverse-stop
housing rear, remove the yoke from the bar. As the plunger in the LO-Reverse shift yoke, making sure
shift bar is removed from the housing, two 3/4 in- the plunger is fully seated in the yoke slot bore.
terlock balls will drop from the rear boss bottom
bore.
8. If necessary, remove the plug, spring, and reverse- 2. Install the spring in the yoke bore and on the
stop plunger from the LO-Reverse speed shift plunger shank.
yoke bore.
41
SHIFT BAR HOUSING
3. Install the plug and tighten to compress th e

spring (left). Back the plug out 1 - 1 1/2 turns and
stake the plug through the small hole in the yoke
(right.)
5. While holding the plunger shank, install the ac-

tuating plunger in the center boss bore.
4. Secure the shift bar housing in a vise. Hold the 6. Install one 3/4" interlock ball in the rear boss top
notched-end of the short LO-Reverse speed shift bore. This ball rides between LO-Reverse and 1st-
bar, install the bar in the lower bore of the shift bar 2nd speed shift bars.
housing bosses. Install the yoke Iockscrew ,
tighten and wire securely.
NOTE: Start with the lower shift bore of the rear

boss and move to the left (front of the housing).
Keep bars in the neutral position during installa-
tion. DO NOT EXCEED the recommended torque
ratings for the yoke Iockscrews as over-tightening
may distort the shift bars.
42
SHIFT BAR HOUSING
7. While holding the notched-end of the bar, install 9. While holding notched-end of the bar, install the
the 1st-2nd speed shift bar in the housing boss 3rd-4th speed shift bar in the housing boss upper
middle bore. Position the shift block on the bar be- bore, position the shift block on the bar between
tween the center and rear bosses, and the yoke on the front and center bosses, long hub to the
the bar between the front and center bosses, long housing rear. Install the block and yoke lock-
hub to the housing front. Just before inserting the screws, tighten, and lockwire securely.
notched-end of the rear boss bar, install the small
interlock pin VERTICALLY in the neutral notch 10. For models so equipped, install the oil trough on
bore. Install the block and yoke Iockscrews, the housing. Tighten the capscrews and lockwire
tighten, and lockwire securely. securely.
NOTE: It is necessary that the interlock pin re-
main in a vertical position during reassembly as
rotation of the bar causes the pin to jam in the ten-
sion spring bores.
8. Install the other 3/4" interlock ball in the rear boss

top bore. This ball rides between the 1st-2nd and
the 3rd-4th speed shift bars.
43
SHIFT BAR HOUSING
11. Remove the assembly from the vise. Install the 12. Install the three tension springs, one over each
three tension balls, one in each bore on the hous- ball in the housing bores.
ing top.
44
REMOVAL - OUTPUT YOKE, AUXILIARY
SECTION, AND CLUTCH HOUSING
A. Removal Output Yoke
1. Lock transmission by engaging two mainshaft gears 2. Pull yoke straight to the rear and off the output shaft.
with the mainshaft sliding clutches (inset.) Use a large
breaker bar to turn the output shaft nut from the output
shaft.
45
B. Removal of the Auxiliary Section
Bar Stock - 3/8" x 1"

Tool Print T-65853 Auxiliary Countershaft Retaining Straps
may be installed to hold countershaft in
1. Place the transmission in the vertical position. Put place. Auxiliary can be removed without straps use
blocks under the clutch housing to prevent damage to caution.
the input shaft. Removal can also be completed in the
horizontal position. 3. Install an Auxiliary Countershaft Retaining Strap with
3-3/8" x 1" dean capscrews. Place a flat washer under
the strap to prevent damage to the rear auxiliary coun-
tershaft bearing.
Do not use an air gun. Tighten by
hand until the capscrews are snug.
4. Repeat Steps 2 and 3 for the remaining auxiliary coun-
tershaft.
2. Remove the four capscrews and the auxiliary counter-

shaft rear bearing cover, gasket, and rear bearing shim.
5. Remove the nineteen capscrews that hold the auxiliary

section to the transmission case.
NOTE: There are three lengths of capscrews, note their
location.
46
1. Insert three capscrews in the tapped holes of housing

flange. Tighten evenly to move auxiliary section to the
rear and just far enough from front section to break
gasket seal.
3. The auxiliary section can also be removed with the

transmission set in the vertical position. Block under the
clutch housing to prevent damage to the imput shaft.
Remove the retaining capscrews from the housing flange.
Lift the assembly form the front section. Re-
move the gasket
2. Remove capscrews and attach a chain hoist to auxiliary

section. Move the assmbley to the rear until free of front
section and remove gasket.
47
D. Removal Clutch Housing
NOTE: For models so equipped remove the

clutch release mechanism and/or clutch brake
assembly.
1. Remove the six capscrews, six nuts, and six lock-

washers form studs that secure the clutch hous-
ing to trasmission case.
2. .Jar the clutch housing with a rubber mallet to

break gasket seal and pull from transmission
case. Remove gasket.
48
DISASSEMBLY - AUXILIARY SECTION
A. Removal and Disassembly Rear

Auxiliary Drive Gear and Yoke
1. Cut the lockwire on the splitter yoke retaining bolt and 2. Remove the retaining bolt, splitter yoke and sliding
loosen the bolt. clutch assembly from the auxiliary section.
49
AUXILIARY MAINSHAFT
ASSEMBLY
NUT
WASHER
SPACER
WASHER
b
GEAR
SLIDING REAR AUXILIARY

CLUTCH DRIVE GEAR
Cut 6593 L-4/87
3. Temporarily install an output yoke on the output shaft 4. Break loose the 15/16" retaining capscrew on the front
and secure it by placing a bar through the yoke. of the output shaft.
50
AUXILIARY COUNTERSHAFT
ASSEMBLY
Cut 6503M-11/91
B. Removal of the Auxiliary

Countershaft Assemblies
1. Secure the auxiliary housing in a vise. Remove the

auxiliary countershaft retaining straps or rear bearing
covers, shim and rear bearing race.
The countershaft will fall loose in the

auxiliary section.
2. Use a soft bar and maul to partially drive the output
shaft forward.
51
C. Removal Rear Auxiliary Drive Gear
Assembly
3. Remove the auxiliary countershaft from the auxiliary

section case.
1. Remove the 15/16" retaining capscrew, retainer and

auxiliary drive gear from the auxiliary section.
4. If necessary, secure the countershaft assemblies in a

vise and remove both the front and rear bearings with a
bearing separator and jaw pullers.
52
DISASSEMBLY AUXILIARY SECTION
RANGE CYLINDER
ASSEMBLY
*Note: Use lockwire at

Cut 6427-5/83 this position
D. Removal and Disassembly of Range

Cylinder Assembly.
1. Remove the capscrews, range cylinder cover, and 2. Remove nut from yoke bar.
gasket.
53
DISASSEMBLY-AUXILIARY SECTION
3. Cut the lockwire. Remove the two 3/4" yoke lock- 5. Remove the shift yoke and synchronizer assembly
screws (inset). from output shaft.
4. Pull the yoke bar from the cylinder housing bore. 6. Remove the range piston from the cylinder bore. If
necessary, remove the O-rings from the position
I.D. and O.D. (inset).
54
7. Remove capscrews and range cylinder housing.
8. If necessary, remove the small O-ring from the

range cylinder housing bore.
55
E. Disassembly Synchronizer Assembly
1. Place the larger LO range synchronizer ring on the 2. Remove the sliding clutch from the synchronizer
bench. Cover the assembly with a shop rag to pre- ring LO range pins.
vent losing the three springs released from the
high range synchronizer at the pin locations. Pull
the HI range synchronizer from the blocker pins.
56
F. Removal and Disassembly Output Shaft
and Rear Bearing Assemblies.
1. Use a soft bar and maul to drive the output shaft

forward and through the rear bearing assembly.
3. Use the front face of the reduction gear as a base,

press the output shaft through the bearing and
gear. This frees the bearing, LO range gear, and
the splined washer.
2. Remove the bearing inner spacer from the output

shaft.
4. Remove the stepped washer, LO range gear, and

splined washer from the shaft.
57
G. Removal Splitter Cover
5. Remove the rear bearing retaining capscrews, rear

bearing cover, and gasket from the auxiliary housing.
The rear bearing cone drops from the housing bore 1. Remove the capscrews from the splitter cylinder cover
when the cover is removed. If necessary, remove the and remove the splitter cylinder cover and gasket from
oil seal from the cover (inset). the auxiliary section case.
6. Remove the two bearing cups and spacer from the 2. If necessary, turn out the insert valve retaining nut and
bearing bore. remove insert valve from bore.
58
3. Pull the yoke bar from cylinder housing. If necessary,

4. If necessary, remove the small O-ring from the cylinder
remove the O-ring from piston O.D. (inset).
housing bore.
59
REASSEMBLY-AUXILIARY SECTION
A. Reassembly and Installation of
NOTE: Make sure magnetic plugs preinstalled in

auxiliary housing.
1. IMPORTANT: Mark timing teeth on the LO Range

gear. A highly visible color of toolmaker's dye is
recommended.
a. Mark any two adjacent gear teeth on LO Range
gear, front side.
b. Then mark the two adjacent teeth which are
directly opposite the first set marked. There 2. Placed splined washer on output shaft shoulder
should be the same number of teeth between facing up as shown.
the markings on each side of the gear.
60
REASSEMBLY-AUXILIARY SECTION
3. Install the LO Range gear on the output shaft, 5. Using a heat lamp or hot plate and oil heat the out-
clutching teeth engaged with the splines down to put shaft rear bearing and install on output shaft.
engage the washer splines. Seat the bearing securely on shaft. Bearing can
also be installed using the appropriate driver.
NOTE: DO NOT HEAT BEARING ABOVE 275oF
(136oC).
4. Install the LO Range gear rear washer on output

shaft and against gear, with chamfer side facing 6. Install the bearing inner spacer on the output
up. shaft.
61
REASSEMBLY - AUXILIARY SECTION
2. Install the three springs in bores in HI range synchro-

7. Place the auxiliary housing on a flat bench and install nizer ring.
the 2 bearing cups and spacer in the rear bearing bore,
the cup with a lip seats next to the rear of the auxiliary
case.
B. Reassembly Synchronizer Assembly
3. Place the HI range synchronizer ring over pins of LO

speed synchronizer ring, seating springs against pins.
1. Place the larger LO range synchronizer ring face down

on bench with pins up. Place the sliding clutch, re-
cessed side up, on pins of LO range synchronizer.
NOTE: Pins on LO range synchronizer must line up
with chamfered holes on bottom of sliding clutch.
62
C. Installation of Auxiliary Driver Gear.
4. Apply downward pressure to the HI range synchronizer

ring WHILE TWISTING COUNTER-CLOCKWISE to
compress the springs and fully seat ring on blocker pins 1. Place auxiliary drive gear, retainer and k capscrew o
of LO range synchronizer. It is suggested that a shop output shaft assembly. Secure capscrew on shaft till
towel be placed over the synchronizer to prevent injury tight, recommended torque will be applied during final
to your hands. assembly (pg. 67)
D. Reassembly of Auxiliary
Countershaft Assemblies and
Timing.
5. Install synchronizer assembly to front of output shaft To make reassembly of the auxiliary section easier, you can
assembly. make this auxiliary section fixture out of a section of 2 x 12.
63
NOTE: Auxiliary countershaft bearings will be installed 3. Install the range yoke into the synchronizer sliding
at this time if replacement was required. clutch slot, offset side facing down.
1. Mark each countershaft for correct timing. Locate the
"O" stamped on the countershaft and mark the tooth
with highly visible toolmakers dye or paint.
4. Place the auxiliary housing over countershaft assem-

blies and output shaft assemblies.
2. Place the countershaft in fixture or on a flat surface for

reassembly. Locate output shaft assembly between
countershaft, timing of the auxiliary will be checked at
this time. The single marked tooth of each countershaft
must align with the two teeth marked on each side of
the LO range gear,
64
E. Reassembly Range Cylinder
5. Heat the rear output shaft bearing cone and install the
bearing on the shaft taper side down.
NOTE: Do not heat the bearing above 275oF (136oC). 1. Install O-ring in slot of small bore in cylinder. Apply
silicone to all O-rings (inset).
6. Install the rear bearing cover on the auxiliary housing.

The nylon collar and brass washer are installed in the 2. If previously removed, install the O-rings in the I.D. and
chamfered hole on the lower right side of the cover. O.D. of the range position.
NOTE: Because the collar becomes distorted when
compressed, DO NOT REUSE OLD NYLON COLLAR.
65
F. Reassembly and Installation
of Splitter Cylinder Assembly
3. Position new gasket on housing. Install range cylinder,

piston yoke, piston and retaining nut into housing.
Tighten retaining nut to recommended torque. Install 4
capscrews into range cylinder housing and tighten to
recommended torque.
1. If previously removed, install the small O-ring in the

cylinder housing bore.
4. Place range cylinder cover and new gasket on range 2. If removed, install the O-ring on the piston O.D. (left).
cylinder, install 4 capscrews and tighten to recom- Insert the yoke bar in the cylinder housing bore (right).
mended torque.
66
G. Reassembly of Auxiliary Rear
Bearing Assembly
1. Place the rear bearing cone over the bearing and into
the rear bore. Align the .100 shim over the cone and
install the rear bearing cover with 4 capscrews tighten
only till snug (right). Retaining straps may also be used
at this time they are required for horizontal installation.
3. If previously removed, install the insert valve, flat end to Complete assembly by installing remaining rear bear-
ing cover (left).
the outside, and the valve retaining nut in the bottom
bore of the cylinder cover. Tighten to recommended
torque ratings.
H. Installation of Range Yoke
NOTE: Prior to installation of the insert valve, make
sure the three O-rings on the valve O.D. are not defec- Capscrews and Recommended
tive. Replace, if necessary. Torque of Auxiliary Drive Gear Nut
1. Install the 2 capscrews into the range yoke and tighten

to recommended torque (right). Tighten auxiliary drive
gear retaining nut to recommended torque (left).
4. Place the new splitter cylinder gasket, splitter cylinder

assembly, new splitter cylinder cover gasket and split-
ter cylinder cover onto the auxiliary housing. Install 4
capscrews into the assembly and tighten to recom-
mended torque.
67
I. Installation of Splitter Sliding Clutch
and Yoke
1. Place splitter shift yoke into splitter sliding clutch slot.

Install assembly onto auxiliary section engaging the
sliding clutch teeth into the suxiliary drive gear clutching
teeth and splitter yoke onto yoke bar align lockscrew
tighten to recommended torque and lockwire.
68
DISASSEMBLY - FRONT SECTION
AUXILIARY DRIVE GEAR
ASSEMBLY
*Note: Use lock wire at

Cut 6417 L-3/87 this position
A. Removal Front Auxiliary Drive Gear
1. Cut lockwire from auxiliary bearing retainer ring 2. Remove snap ring from mainshaft rear groove.
capscrews.
69
3. Remove the splined washer from inside front auxiliary 5. Remove front auxiliary drive gear from mainshaft.
drive gear assembly.
4. Remove six capscrews from the auxiliary bearing re- 6. Remove the spline d washer from the mainshaft also
tainer ring. Insert three puller screws in the specially remove the front auxiliary drive gear retaining snap ring
tapped holes of retainer ring. Tighten screws evenly to from the mainshaft.
pull the front auxiliary drive gear assembly from case
bore.
70
?
DISASSEMBLY-FRONT SECTION
Cut 6382-9/80
B. Removal and Disassembly of Left

Reverse Idler Gear Assembly
1. Move the mainshaft reverse gear as far to the rear 2. Move the reverse gear forward and against the LO
as possible and remove the snap ring from I.D. of speed gear, engaging the splines of mainshaft
gear. sliding clutch.
71
3. Using inside jaw pullers or impact puller, remove the 5. Remove the pipe plug from rear of idler shaft and use
auxiliary countershaft front bearing race from left an impact puller, 1/2"-13 threaded end, to remove shaft
reverse idler gear bore. If necessary, repeat the from case bore (inset).
procedure for removing the auxiliary countershaft front
bearing race from right reverse idler gear bore.
6. As the idler shaft and idler plate are moved to the rear,
4. Loosen the nut on the idler shaft, (inset). Remove the
remove the thrust washer, and gear from case. If nec-
stop nut and washer from front of idler shaft.
essary, remove the inner race from bearing and
remove needle bearing from idler gear.
72
c. Removal of Countershaft Bearings
NOTE: In the following instructions, the front

and rear bearings from BOTH countershaft are
removed. For removal of the mainshaft assembly
from case, it is necessary to remove the bearings
from right countershaft ONLY.
1. Temporarily reinstall front auxiliary drive gear on 3. Remove front bearing cover.
mainshaft, remove snap ring from each counter-
shaft rear groove.
2. Remove six capscrews from front bearing cover. 4. From inside the case, use a soft bar and maul to
drive the countershaft rear bearings to the rear
and from case bores.
NOTE: This procedure will damage the bearings

and should not be attempted unless replacement
of the bearings is planned.
73
5. Turn out the capscrew and remove the front 7. From the case rear, use a soft bar and maul to
bearing retainer plate from each countershaft. drive each countershaft forward to unseat the
front bearings from case bores and expose the
bearing snap rings.
8. Use a bearing puller or pry bars to remove the

countershaft front bearings.
NOTE: The bearing inner race of models equipped

with roller-type front bearings will remain pressed
on countershaft.
6. Use a soft bar and maul to drive each countershaft

to the rear as far as possible. This will partially un-
seat the front bearings.
NOTE: The soft bar used should have a flattened

end that is large enough so as not to damage
holes for roll pin and capscrew.
74
D. Removal and Disassembly of Mainshaft

Assembly
1. Block the right countershaft assembly against 2. Remove the 3rd-4th speed sliding clutch from
case wall and pull the mainshaft assembly to the mainshaft front.
rear to free pilot from input shaft pocket. Tilt front
of mainshaft up and lift the assembly from case
(inset). Use caution as the reverse gear is free and
can fall from shaft.
75
3. Remove the reverse gear and spacer from main-

shaft rear.
5. Turn the reverse gear limit washer to align its

splines with those of the mainshaft and remove
washer.
4. From mainshaft rear, pull the key from mainshaft

key way.
NOTE: When removing limit washers, spacers and

gears, note their location on mainshaft to facili-
tate reassembly. Keep the internal-splined
washers and external-splined spacers with the
gear from which they were removed. There is
ONLY one limit washer and one spacer belonging
to each gear. 6. Remove the LO-Reverse speed sliding clutch from
mainshaft.
76
7. Using a small screwdriver, turn the limit washer in 8. Remove each remaining gear, limit washer, spacer,
hub of LO speed gear to align its splines with and sliding clutch from mainshaft in the same
those of the mainshaft. Pull the LO speed gear manner previously detailed. And, if necessary, re-
from rear of mainshaft to remove limit washer, move the snap ring from I.D. of each gear.
spacer, and gear. If necessary, remove the snap
ring from I.D. of gear (inset).
77
DRIVE GEAR
ASSEMBLY
E. Input Shaft Removal
2. Use a rubber maul on the input shaft to cock the

bearing in bore.
1. Remove the bearing retaining snap ring from

groove in shaft.
78
5. Remove drive gear spacer, and snap ring (inset).
3. Drive input shaft toward rear of transmission,

through bearing as far as possible. Pull input
shaft.
6. Pull input shaft forward and out of drive gear and

case.
4. Use pry bars or screwdriver to complete removal

of bearing.
79
8. Remove main drive gear from case.
7. Check the bushing in pocket of input shaft, re-

place if worn.
80
F. Removal and Disassembly of

Countershaft Assemblies
NOTE: Except for the PTO gears, the left and right
countershaft assemblies are identical and disas-
sembled in the same manner.
..
1. Move the right countershaft assembly to the rear as far
as possible so front of shaft can be removed from case 2. Remove the drive gear retaining snap ring from front of
bore and moved to the center of the case. Lift the
each countershaft.
assembly from case and repeat the procedure for left
countershaft assembly.
NOTE: The left and right reverse idler gear assemblies
are identical and disassembled in the same manner. If
removal and disassembly of this assembly is neces-
sary, refer to Part B of this section.
81
3. Use the rear face of 3rd speed gear as a base, press 4. Disassembly is complete at this point due to the welded
the drive gear, PTO gear, and 3rd speed gear from countershaft design. Replacement of reverse, low first
each countershaft. This removes the front bearing inner and 2nd speed gears will be completed as an assembly
race from the countershaft. gears are not available separately.
IMPORTANT: NEVER USE THE PTO GEAR AS A
PRESSING BASE. The narrow face width of this gear
makes it very susceptible to breakage. G. Removal and Disassembly of Right
NOTE: To remove the right reverse idler gear assembly
see section B. The right and left reverse idler gear
assemblies are disassembled in the same manner.
82
H. Removed and Disassembly of Integral

Oil Pump
2. Remove three Allen head capscrews and washers

that retain the integral oil pump to front of case.
1. Straighten Iocktang on suction tube (inset), re-

move suction tube from oil pump. If necessary re-
move O-ring from suction tube.
83
3. Remove the integral oil pump from case. 5. Remove outer oil pump element from pump.
4. Remove integral oil pump retainer plate from case. 6. Remove drive gear retaining snap ring from drive
shaft.
84
7. Remove drive gear from pump drive shaft 9. Remove element retaining snap ring from drive
shaft.
8. Remove key from drive shaft keyway. 10. Remove internal oil pump element from drive
shaft.
85
11. Remove two keys from drive shaft keyways.

14. Remove relief valve from housing bore.
12. Remove the drive shaft from integral oil pump

housing. If necessary, remove rear drive gear re-
tention snap ring from drive shaft.
15. If necessary front case plug can be removed from
case by driving the plug through front of case.
Remove O-ring from O.D. of plug if necessary.
13. Remove relief valve roll pin from pump housing,

relief valve spring can now be removed from re-
Iief valve housing bore (inset).
86
1. Disassembly Auxiliary Drive Gear
Assembly
1. Remove the snap ring from hub of front auxiliary 3. If necessary, remove the O-rings from hub O.D. of
drive gear. front auxiliary drive gear.
2. Using the rear face of retainer ring as a base,

press the drive through bearing.
87
REASSEMBLY-FRONT SECTION
1. If previously removed, install the O-rings on 3. Start the front auxiliary drive gear bearing on front
extended front hub of front auxiliary drive gear. hub, bearing snap ring facing groove in retainer
ring. Using both hands, press the bearing on gear
with snap ring in groove of retainer ring (inset).
2. Install the retainer ring on front auxiliary drive 4. Install the snap ring in groove of front gear hub to
gear, snap ring groove facing front hub and away retain bearing.
from gear teeth.
88
,
B. Reassembly and Installation of Integral
Oil Pump
1. Replace O-ring on front case plug. Seat plug in 3. Install relief valve spring in oil pump housing.
front case bore with a maul.
2. Install relief valve in intergral oil pump housing as 4. Secure oil pump housing in a vice. Depress spring
shown. in housing bore and drive relief valve retention roll
pin into roll pin bore.
89
5. If removed replace drive shaft snap ring on pump 7. Install inner element retention snap ring in drive
drive shaft and insert drive shaft through pump shaft snap ring groove.
housing bore as shown.
6. Install two keys on drive shaft (inset), and install 8. Install drive gear key in keyway of drive shaft (in-
integral oil pump inner element on drive shaft, set), install drive gear on drive shaft aligning key-
aligning keys on drive shaft with keyways on inner way on drive gear with key on drive shaft.
element.
NOTE: Place round key in the round keyway;

square key in the square keyway.
90
9. Install outer drive gear retention snap ring in

groove of drive shaft.
11. Install integral oil pump retainer over alignment

pin inside of case, bore in retainer facing rear of
case.
10. Install outer integral oil pump element over inner

element.
12. Install integral oil pump assembly in case align-

ing front face of oil pump with retainer and align-
ment pin.
91
REASSEMBLY-FRONT SECTION ...
13. Install three capscrews and washers through

front of case and into pump housing, tighten
capscrews to recommended torque.
14. Replace O-ring on suction tube and install tube

under case rib and into integral oil pump. Bend
Iocktang of suction tube over case rib.
92
REASSEMBLY - FRONT SECTION
CASE ASSEMBLIES
NOTE: Before starting reassembly, make sure the three
magnetic discs are solidly in place at bottom of case. These
can be secured to disc mounting surfaces with Scotch Grip
Rubber Adhesive or equivalent adhesive.
C. Reassembly and Installation of Right

2. Install the bearing inner race on idler shaft and insert

shaft into case bore, threaded-end of shaft to the front.
As the idler shaft is moved forward, install the reverse
idler gear on shaft, long hub to the front and seating on
bearing inner race. Position the thrust washer on shaft
between the gear and support boss in case and con-
tinue with movement of idler shaft forward into bore of
Support boss.
1. If previously removed, thread pipe plug in rear of re-

verse idler shaft and tighten. Install the thrust washer to
the end of the idler shaft.
NOTE: If previously removed, replace the needle bear-
ing into bore of reverse idler gear.
3. Making sure that the reverse idler shaft is seated in

bore of support boss and forward as far as possible,
install the washer and stop nut on front of shaft. Tighten
nut to recommended torque rating.
93
D. Reassembly of Countershaft
Assemblies
NOTE: Except for the PTO gears, the left and right
countershaft assemblies are identical and reassembled
in the same manner.
NOTE: Reverse low, 1st and 2nd speed gears are part
of the shaft and are note serviceable.
4. Install the OUTER RACE of auxiliary countershaft front

bearing into case bore.
NOTE: The bearing INNER RACE is installed on front
of auxiliary countershaft and never with outer race.
1. Press the 3rd speed gear on the countershaft, long hub

of gear to countershaft front.
94
4. Install the drive gear retaining snap ring in groove on

front of each countershaft.
2. Start the PTO gear onto countershaft, bullet-nose side

of teeth facing up and toward rear of shaft. Align key-
way of drive gear with key in countershaft and press
BOTH gears onto shaft, long hub of drive gear against
PTO gear.
NOTE: The left countershaft assembly has a 47-tooth
PTO gear; the right countershaft assembly has a 45-
tooth PTO gear.
5. Use a flanged-end driver to install bearing inner race on

countershaft, shoulder of race against shoulder of coun-
tershaft.
3. To avoid confusion during installation, mark the end of

left countershaft with an "L", the end of right counter-
shaft with an "R".
95
,
E. Partial Installation of Countershaft
Assemblies
IMPORTANT: Mark the countershaft drive gear for timing

purposes. On the drive gear of each countershaft assem-
bly, mark the tooth aligned with keyway of gear and
stamped with an "O" for easy identification. A highly visible
1. Place the left countershaft assembly into position in
color of toolmakers' dye is recommended for making timing
case, making sure that the "L"-marked assembly has
marks.
the larger 47-tooth PTO gear. Place the right counter-
shaft assembly into position in case, making sure that
the "R"-marked assembly has the smaller 45-tooth PTO
gear.
96
F. Bearing Installation of Left Countershaft
Assembly
1. Move the left countershaft assembly to the rear 3. Center the front of left countershaft in bearing and
and insert countershaft support tool or blocking move the assembly forward.
to center shaft in rear case bore.
2. Use a flanged-end bearing driver to start the 4. Use a flanged-end bearing driver to completely
bearing in case bore. seat front bearing or bearing outer race in case
bore.
NOTE: The inner race of roller-type front bearing
is pressed on front of countershaft.
97
, . . .
G. Reassembly, Installation and Timing of
Main Drive Gear Assembly
5. Position the retainer plate on front of left countershaft, 1. Install the snap ring in I.D. of main drive gear.
roll pin in hole at end of shaft, and secure with capscrew
tightening to recommended torque.
6. Remove countershaft support tool or blocking 2. Mark the main drive gear for timing purposes.
from rear case bore and install the left counter- Mark any two adjacent teeth on drive gear and re-
shaft rear bearing with larger I.D. lead chamfer to peat the procedure for the two adjacent teeth
the front of shaft and install the snap ring in directly opposite the first set marked. A highly vis-
groove at rear of left countershaft. ible color of toolmakers' dye is recommended for
making timing marks.
98
5. Install drive gear bearing on input shaft, seat

bearing into case bore with proper bearing driver.
3. Mesh the marked tooth of left countershaft drive

gear with either set of two marked teeth on main
drive gear. Slide the input shaft through the main
drive gear (inset).
6. Temporarily install the front bearing cover.
4. Install drive gear spacer. Install the bearing on the

input shaft with external snap ring to the outside
(inset).
99
...
7. Use a soft bar and maul to drive the input shaft 9. Install front bearing cover and gasket, making
through bearing. Remove front bearing cover. sure to align the oil return hole in the case with
hole in cover. Secure the front bearing cover on
case with six capscrews, tighten to recommended
torque (inset).
8. Install bearing retainer snap ring.
100
H. Reassembly and Partial Installation of
Mainshaft Assembly
1. If previously removed, install the corresponding
snap rings in I.D. of mainshaft gears.
2. Secure the mainshaft in a vise equipped with

brass jaws or wood blocks, pilot-end of shaft 4. Install the spacer on shaft against washer.
down. If previously removed, install the roll pin in
keyway.
5. Install the 3rd speed gear on mainshaft, clutching

teeth down and engaged with external splines of
spacer.
3. Install the 3rd speed gear limit washer on main- NOTE: Gear limit washers are internally splined
shaft, flat side of washer up. Rotate washer in the and locked to mainshaft by the key. Gear spacers
1st or bottom groove of mainshaft to align the are externally splined to engage with clutching
splines of washer with those of the mainshaft. in- teeth in gear hubs. There is one limit washer and
stall the key in mainshaft keyway to lock washer one spacer for each gear in the mainshaft as-
in place. sembly.
101
REASSEMBLYFRONT SECTION
Setting Correct Axial
Clearances For Mainshaft
Gears
Axial Clearance (End-Play) Limits Are:
.005 -.012 for all mainshaft gears
Washers are used to obtain the correct limits; six

thicknesses are available as follows:
LIMITS (INCH) COLOR CODE

.248 -.250 WHITE
.253 -.255 GREEN
.258 -.260 ORANGE
.263 -.265 PURPLE
.268 -,270 YELLOW
.273 -.275 BLACK
* PLUS RED
*NOTE: New style tolerance washers come in a full

range of tolerances as corresponding colors listed
above plus red. (Example: Orange plus red limit
washer has an inch limit thickness of .258-.260.)
Refer to Illustrated Parts Lists for washer part num-

bers.
Always use the .248 -.250 tolerance washer (White

or white plus red) in the reverse, LO and 2nd speed
gear positions as shown at right.
IMPORTANT: REFER TO THE APPROPRIATE

ILLUSTRATED PARTS LIST
(SPECIFIED BY MODEL SE-
RIES) TO ENSURE THAT
PROPER PARTS ARE USED
DURING REASSEMBLY OF THE
TRANSMISSION.
102
8. Remove the key from keyway and install the 2nd

speed gear limit washer on mainshaft, flat side of
washer down and against spacer. Rotate washer in
6. Install the 2nd speed gear on shaft against 3rd the 2nd groove of mainshaft to align the splines of
speed gear, clutching teeth up. washer with those of the mainshaft and reinsert
key in keyway to lock washer in place (inset).
9. Insert two large screwdrivers between the 2nd and

3rd speed gears to check axial clearances. Apply
slight downward pressure on screwdriver handles
to spread gears evenly. Making sure the gear hubs
are parallel, insert a feeler gage between hubs.
Correct axial clearance is less than the minimum
.005" to .012" If the clearance is less than the
minimum .005" tolerance, the limit washer in the
2nd speed gear should be replaced by a thinner
limit washer. This will increase the axial clearance
between the gears. If the clearance checked is
greater than the maximum .012" tolerance, a
7. Install the spacer in 2nd speed gear, engaging the thicker limit washer should be installed in the 2nd
external splines of spacer with clutching teeth of speed gear. This would decrease the axial clear-
gear. ance between the gears.
103
10. Install the 1st-2nd speed sliding clutch, aligning 12. Install spacer and 1st speed gear on the main-
the missing internal spline of sliding clutch with shaft, clutching teeth down and engaged with en-
key in mainshaft. ternal splines of spacer.
11. Remove the key from keyway and install the 1st 13. Install the LO speed gear on shaft against 1st
speed gear limit washer on mainshaft, flat side of speed gear, clutching teeth up.
washer up. Rotate washer in the 2nd groove of
mainshaft to align the splines of washer with
those of the mainshaft and reinsert key in key-
way to lock washer in place.
104
16. Check axial clearances and make adjustments, if

necessary, between the LO and 1st speed gears
as described in No. 9 of this section.
14. Install the spacer in LO speed gear, engaging the

external splines of spacer with clutching teeth of
17. Install the LO-Reverse speed sliding clutch,

aligning the missing internal spline of sliding
clutch with key in mainshaft.
15. Remove the key from keyway and install the LO

speed gear limit washer on mainshaft, flat side of
washer down and against spacer. Rotate washer
in the 4th groove of mainshaft to align the
splines of washer with those of the mainshaft
and reinsert key in keyway to lock washer in
place.
105
18. Remove the key from keyway and install the re- 20. Install reverse gear on mainshaft. Engage the
verse gear limit washer on mainshaft, flat side of clutching teeth of gear with splines of spacer
washer up. Rotate washer in the 5th groove of and sliding clutch and move the reverse gear
mainshaft to align the splines of washer with against the LO speed gear.
those of the mainshaft and reinsert key in key- NOTE: DO NOT REPLACE REVERSE GEAR lN-
way to lock washer in place. TERNAL SNAP RING AT THIS STEP
21. Remove the mainshaft assembly from vise. Align

the missing internal spline of 3rd-4th speed slid-
ing clutch with key in mainshaft and install on
front of shaft, engaging the external splines of
sliding clutch with clutching teeth of 3rd speed
19. Install the spacer on shaft against washer. gear.
106
.
22. Block the right countershaft assembly against 24. With the reverse gear remaining against LO
case wall and lower the mainshaft assembly into speed gear, mesh the corresponding forward
position with the reverse gear held against LO speed gears of left countershaft assembly.
speed gear and rear of shaft moved into case Check to make sure that marked tooth on left
bore. countershaft drive gear has remained in mesh
with marked set of teeth on main drive gear.
23. Move the pilot-end of mainshaft into pocket 25. Center rear of mainshaft in case bore and install
bushing of input shaft. the auxiliary drive gear assembly on shaft, par-
tially seating the bearing in bore. DO NOT COM-
PLETE INSTALLATION AT THIS TIME.
107
REASSEMBLY-FRONT SECTION . -
1. Remove blocking from right countershaft a s - 3. Position the front countershaft bearing in front
sembly and place it parallel to mainshaft as- bearing bore. Use the proper bearing driver to set
sembly. Mesh the marked tooth of right the bearing (inset).
countershaft drive gear with remaining set of two
marked teeth on main drive gear.
2. Insert countershaft support tool or blocking in 4. Install retainer washer and capscrew. Make sure
rear bearing bore. to match roll pin in retainer with inner bearing,
hole.
108
5. Tighten capscrew to the recommended torque. 7. With bearing installation complete, install the snap ring
in right countershaft rear groove.
8. Move the reverse gear to the rear on mainshaft and use

a screwdriver to engage sliding clutches with all for-
ward speed gears. A sliding clutch that will not engage
with a gear indicates the gear set is not in proper mesh.
The bearings of the right countershaft would then need
to be removed and the drive gear set retimed.
NOTE: Do not engage sliding clutches with more than
one gear at the same time. This will lock the gearing
and prevent the mainshaft and countershaft assem-
blies from rotating.
6. Position the countershaft rear bearing in rear bearing

bore. Use the proper bearing driver to seat bearing in
bore.
109
J. Reassembly and Installation of Left
NOTE: Since the left and right reverse idler gear
assemblies are identical, reassembly and installation of
the left reverse idler gear assembly should be
performed at this time as described in Part C of this
section.
K. Completed Installation of Mainshaft

and Auxiliary Drive Gear Assemblies
3. Install the snap ring in hub of reverse gear and move

the reverse gear forward on mainshaft and into proper
position in case.
1. Move the reverse gear to the rear as far as possible,

meshing teeth of gear with those of the reverse idler
gears.
4. Install snap ring on mainshaft snap ring groove.
2. Align the external splines of spacer with clutching teeth

of reverse gear and move spacer forward on the 5. Install splined washer on mainshaft splines behind re-
mainshaft and into reverse gear. verse gear.
110
6. Reinstall the front auxiliary drive gear assembly on rear 8. Install splines washer on mainshaft splines behind aux-
of mainshaft. Use a flanged-end driver and maul to set iliary drive gear.
bearing in case bore.
7. Align the six capscrew holes in retainer with the tapped 9. Install the snap ring in groove at end of mainshaft.
holes in case and install capscrews. Tighten to recom-
mended torque ratings and lockwire the capscrews in
groups of three.
111
INSTALLATION - CLUTCH HOUSING, OUTPUT YOKE,
AUXILIARY SECTION AND SHIMMING PROCEDURE
A. Installation of Clutch Housing
3. Install the six nuts with washers or lockwashers

on studs and tighten. SEE TORQUE RECOMMEN-
DATIONS.
4. For models so equipped, install the clutch release

mechanism and/or clutch brake assembly.
1. Position the corresponding new gasket on hous-

ing mounting surface and install the clutch hous-
ing on front case, piloting on the six studs an
drive gear bearing cover.
2. Install the six capscrews with lockwashers and

tighten. See TORQUE RECOMMENDATIONS.
112
B. Installation of Output Yoke
NOTE: Replacement of seal and slinger must be com-
pleted prior to yoke or flange installation
3. Install washer and output nut onto the output shaft.

NOTE: It will be necessary to temporarily lock the trans-
mission in two gears by moving sliding into gear for final
torque procedure.
1. Install speedometer gear or spacer on output shaft.
4. Complete installation process by torquing the output

2. Place output yoke or flange onto the output shaft. shaft nut to recommended torque.
113
Installation of the Auxiliary Section
and Shimming Procedure
Tighten the middle bolt on each countershaft strap until
the countershaft are snug. Shift the reduction sliding
clutch into reduction. Attach a chain hoist to the output
shaft.
NOTE: The front box sliding clutches must be in the
neutral position.
4. Remove the countershaft straps. Make sure a 0.125

countershaft rear bearing shim is installed. Be sure the
countershaft rear bearing races are seated in the bear-
ing bores.
2. With the transmission set in the vertical position, block

under the clutch housing to prevent damage to the
input shaft, position the new gasket on the transmission
case. Lower the auxiliary assembly on the front case
rear.
IMPORTANT: Shift the reduction sliding clutch into
deep reduction before installing the auxiliary.
15. Install two clean 3/8" x 1" capscrews without washers

directly across from each other in easy bearing cover.
Tapped holes in auxiliary case must be free of thread
adhesive.
3. Install the retaining capscrews in the housing flange

and tighten to the recommended torque.
114

6. Tighten the capscrews to 7 in./lbs. of torque. DO NOT 8. Remove the countershaft rear bearing covers and
INSTALL THE COUNTERSHAFT REAR BEARING gauging shims.
COVER GASKET.
9. After the correct shim has been selected, place the

7. Rotate the output shaft six times in the clockwise direc- shim on the rear countershaft bearing race, install the
countershaft rear bearing cover and gasket. Check for
tion, then six times counterclockwise to seat the coun-
tershaft rear bearings. Use a feeler gauge, as close to proper shim alignment if misaligned rear bearing cover
may be damaged when proper torque is applied. Posi-
one capscrew location as possible, and measure the
tion a new gasket on each countershaft rear bearing
gap between the countershaft rear bearing cover and
cover mounting surface and install both rear bearing
the auxiliary case. Record the measurement. Using the
covers. Install and tighten the capscrews to the recom-
average measurement, refer to page 122 in this Ser-
mended torque.
vice Manual. Select the numbers in the left column that
compare to the average measurement recorded from
the countershaft rear bearing cover. Follow the column
to the right to identify the proper shim to be used in the
countershaft shim bores. Duplicate this procedure for
the other countershaft rear bearing cover.
115
,
INSTALLATION-SHIFTING CONTROLS
A. Installation Shift Bar Housing
3. Install the thirteen capscrews in shift bar housing and

tighten to recommended torque rating.
1. Place all three mainshaft sliding clutches in the neutral
position. Install shift bar housing gasket in position NOTE: There are two sizes of capscrews. The 1/2"
clutches. capscrews are used with lifting eyes.
2. With all three shift yokes in the neutral position, install

the shift bar housing assembly on case, fitting the shift
yokes into the slots of the corresponding sliding
clutches.
116
GEAR SHIFT LEVER HOUSING ASSEMBLY
B. Installation Gear Shift Lever Housing
Assembly
1. Check the shift bar housing assembly to make sure

2. Install the retaining capscrews in housing flange and
shift block and yoke notches are aligned in the neutral tighten to secure the assembly to shift bar housing.
position.
117
C. Installation of Slave Valve
1. If previously removed, install the air line fittings 3. Install the hat-type alignment sleeve in bore of
on slave valve. slave valve.
2. Install the spring on shank of actuating pin and in- 4. Position gasket on valve mounting surface (inset)
sert in bore of transmission case. and install the slave valve on case, inserting the
end of actuating pin into alignment sleeve. Secure
the valve to case with four capscrews tighten
evenly to recommended torque rating.
118
D. Installation of Air Lines and Air Filter
Regulator
NOTE: Recommended sealant for fittings is

Fuller Sealant part number 71205.
3. Position the air filter/regulator on the auxiliary

1. Connect the 1/4" I.D. air hose between the slave housing rear and install the two retaining cap-
valve (inset) and the HI Range Port of the range screws. Tighten to recommended torque.
cylinder. Tighten fittings securely.
2. Connect the 1/4" I.D. air hose between the slave 4. Connect the 1/4" I.D. air hose between the slave
valve (inset) and the LO Range Port of the range valve (inset) and the air filter/regulator. Tighten fit-
cylinder. Tighten fittings securely. tings securely.
119
5. Connect the 1/4" I.D. air hose between the air filter/
regulator (inset) and the splitter cylinder cover.
Tighten fittings securely.
7. Install the jam nut on the shift lever. Thread the

Roadranger valve on shift lever and secure by
tightening jam nut against valve.
6. Install the Roadranger valve cover and the three 8. Connect the red air line to the "S" or Supply Port, and
air lines. the black air line to the "P" or End Port of the slave
valve. Tighten fittings securely.
120
9. Connect the red air line to the "S" or Supply Port and
the black air line to the "P" Port on the Roadranger
valve. Tighten fittings securely.
11. Position valve cover on Roadranger valve and se-
cure by tightening the two mounting screws in
cover,
10. Connect the blue air line to the "SP" or Splitter Port on
the Roadranger valve (inset). Connect the blue air line
to the splitter cylinder cover. Tighten fittings securely.
121
SHIMMING CHART
Average the feeler gauge measurement and match the measurement to the Feeler Gauge Average Gap in the left column.
Follow the column to the right to identify the Shim Thickness, Part Number, and Color Code to be used.
FEELER GAUGE SHIM STANDARD SHIM OIL PUMP SHIM COLOR CODE
AVERAGE GAP THICKNESS PART NUMBER PART NUMBER
.088-.089 .042-.043 21454 21474 BROWN
.085-.0875 .045-.046 21455 21475 TAN
.082-.0845 .048-.049 21456 21476 ORANGE
.079-.0815 .051-.052 21457 21477 YELLOW
.076.-0785 .054-.055 21458 21478 GREEN
.073.-0755 .057-.058 21459 21479 LIGHT BLUE
.070-.0725 .060-.061 21460 21480 LAVENDER
.067-.0695 .063-.064 21461 21481 WHITE
.064-.0665 .066-.067 21684 21686 BLACK
.061-.0635 .069-.070 21685 21687 SILVER
.058-.0605 .072-.074 21452+21452 21472+21472 RED+RED
.055-.0575 .075-.077 21452+21453 21472+21473 RED+PINK
.052-.-0545 .078+.080 21452+21454 21472+21474 RED+BROWN
.049-.0515 .081-.083 21452+21455 21474+21475 RED+TAN
.046-.0485 .084-.086 21452+21456 21472+21476 RED+ORANGE
.043-.0455 .087-.089 21452+21457 21472+21477 RED+YELLOW
.040-.0425 .090-.092 21452+21458 21472+21478 RED+GREEN
.038-.0395 .093-.095 21452+21459 21472+21479 RED+LT.BLUE
If the transmission is equipped with an auxiliary countershaft oil pump use the fourth column to identify the oil pump shim.
122
Copyright Eaton Corporation, 2012.
Eaton hereby grant their customers,
vendors, or distributors permission
to freely copy, reproduce and/or
distribute this document in printed
format. It may be copied only in
its entirety without any changes or
modifications. THIS INFORMATION
IS NOT INTENDED FOR SALE OR
RESALE, AND THIS NOTICE MUST
REMAIN ON ALL COPIES.
Note: Features and specifications
listed in this document are subject to
change without notice and represent
the maximum capabilities of the
software and products with all options
installed. Although every attempt has
been made to ensure the accuracy of
information contained within, Eaton
makes no representation about the
completeness, correctness or accuracy
and assumes no responsibility for
any errors or omissions. Features and
functionality may vary depending on
selected options.
For specing or service assistance,
call 1-800-826-HELP (4357) or visit
www.eaton.com/roadranger.
In Mexico, call 001-800-826-4357.
Roadranger: Eaton and trusted partners

providing the best products and services in the
industry, ensuring more time on the road.
Eaton Corporation
Vehicle Group
P.O. Box 4013
Kalamazoo, MI 49003 USA
800-826-HELP (4357)
www.eaton.com/roadranger
Printed in USA

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Service Manual

Fuller Heavy Duty Transmissions

REMOVAL OUTPUT YOKE, AUXILIARY SECTION AND CLUTCH HOUSING . . . . . . . . . . . .

IMPORTANT: All Fuller Transmissions are identified by

13-Speed Transmissions (On/Off Highway):

OD 2.28 1.64 1.18 .85 3.29/12.45

the Key to long

transmission life Fluid

With EP or Multipurpose Gear Oil

With Splitter Control But

WHILE IN HIGH RANGE

SPLITTER CONTROL BUTTON

Front Section Power Flow

Cut 8006C-11 /87

Cut 7300 G-11/86

FRONT SECTION: ALL MODELS

Cut 7190 K-11/87

Cut 7191 Q-11/87

PAGE TOOL HOW OBTAINED

Made from Fuller Transmission

52 Jaw Puller and Bearing Separator Tool Supplier

69 Snap Ring Pliers Tool Supplier

72 Impact Puller (1/2-13 Threaded End) Tool Supplier

Made from Fuller Transmission

99 Input Shaft Bearing Driver Tool Supplier

113 Torque Wrench, 1000 Lbs./Ft. Capacity Tool Supplier

5. Lubricant CHECKS WITH UNIVERSAL JOINT

7. 12. Splines on Output Shaft

IMPORTANT: REFER TO THE APPROPRIATE ILLUSTRATED PARTS LIST (SPECl-

Range Cylinder AssemblyAll Models

LOW RANGE AND HIGH RANGE DIRECT OVERDRIVE

AIR APPLIED THROUGH SIGNAL LINE

For all questions

Constant Air No Air

System Operation and SchematicsOperation Guide 3A-21

For all questions

Constant Air Air to Cover

3A-22 Operation GuideSystem Operation and Schematics

For all questions

Constant Air Air to Cover

System Operation and SchematicsOperation Guide 3A-23

A. Removal of Air Control

3. Turn out the two mounting screws in the Roadranger

4. Slide the cover down to expose the valve ports and

6. Disconnect and remove the 1/4" I.D. air line between

3. Remove the hat-type alignment sleeve from bore in

1. Turn out the four retaining capscrews, jar lightly to

NOTE: Remote control housings are removed from

2. Remove the boot from gear shift lever and secure

A. Removal and Disassembly of the Shift

NOTE: During disassembly, lay all parts on a

3. Install the plug and tighten to compress th e

5. While holding the plunger shank, install the ac-

NOTE: Start with the lower shift bore of the rear

8. Install the other 3/4" interlock ball in the rear boss

A. Removal Output Yoke

Bar Stock - 3/8" x 1"

2. Remove the four capscrews and the auxiliary counter-

5. Remove the nineteen capscrews that hold the auxiliary

1. Insert three capscrews in the tapped holes of housing

3. The auxiliary section can also be removed with the

2. Remove capscrews and attach a chain hoist to auxiliary

NOTE: For models so equipped remove the