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Eaton Fuller
Automated Transmissions
Service Manual
AutoShift 16
T20891
January 2001
Table of Contents
1
General Information
2
General Information
General Information
Eaton
Date Code
Serial
Model Serial
Eaton
Model
Eaton Corporation
Transmission Div
Europe
RTO-17316A-AS
Eaton Corporation Date Code
Transmission Div
Europe
3
General Information
Model Number
The model number gives basic information about the transmission and is explained below. Use this number
when calling for service assistance or replacement parts.
R T (O) - 17 3 16 A - AS
Serial Number
The serial number is the sequential identification number of the transmission. Have the serial number
available when calling for service assistance.
4
General Information
General Information
1. Recommended Lubricants
Where transmissions are concerned, lubrication is possibly the most important part of keeping a vehicle
operating.
Lubricants
Lubricant must be approved by Eaton Corporation to qualify for use in the AutoShift 16 transmission.
Recommended Lubricants
40 Above -12° C
Heavy duty engine oil API - CD
30 Below -12° C
90 -12° C to 38° C
Mid EP gear oil API-GL-4
80W -26° C to 21° C
5
Preventive Maintenance
Every 500 hours Change transmission oil when severe dirt conditions exist.
Every 1,000 hours Change transmission oil (normal off highway use).
Synthetic Oil
6
Preventive Maintenance
3. Transmission Inspections
When performing preventive maintenance (PM) inspections, several items must be checked. It is important
to perform every step to ensure the transmission will meet its life expectancy. Proper PM consists of the
following steps:
• Check Lubricant Level
Preventive Maintenance
• Inspect for Loose/Missing Capscrews
• Check for Air Leaks
• Check for Lubricant Leaks.
Improper Proper
Lubricant Level Lubricant Level
7
Preventive Maintenance
8
Preventive Maintenance
Preventive Maintenance
Drain the Transmission
1. Locate the drain plug on the bottom of the transmission case.
2. Place a drain pan under the drain plug.
3. Remove the drain plug and allow the lubricant to drain completely.
4. Once drained, reinstall the drain plug and tighten to 61.0-74.6 Nm (45-55 lb-ft). Sealant is not required
on the drain plug threads.
9
Preventive Maintenance
Air System
If the air system is not given recommended preventive maintenance, it can cause problems for the
transmission system. Although the transmission has an Air Filter/Regulator, it can only protect the
transmission from contaminants for so long. This is why it is important to follow OEM recommendations
for air system preventive maintenance. It is important to regularly drain the air tanks and ensure that
lubricant is not being pumped by the air compressor into the vehicle air system. If moisture is allowed to
enter the transmission system, it can cause corrosion or, in cold climates, it could freeze and prevent the
shift mechanisms from operating. If lubricant is allowed into the system, it could fill the air system
components and cause them to lose valuable air volume, slowing or preventing movement.
10
Preventive Maintenance
6. Vehicle Components
The following components, although required for AutoShift operation, are OEM purchased and installed
items. Refer to your OEM service information for removal and replacement procedures.
• Clutch Actuator
• Clutch Solenoid
Preventive Maintenance
• Clutch Switch
• Gear Display
• Gear Selector
• Kick Down Switch
• Power Connect Relay
• System Manager ECU
• Transmission Interface Harness.
11
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Removal
1. Using a flat blade screwdriver, remove the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
12
Service Procedures
1
Turn Attachment Screws
180 Degrees
Service Procedures
13
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Installation
1. Using a flat blade screwdriver, install the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
Final Check
Make sure the mounting screws are locked in place.
14
Service Procedures
1
Turn Attachment Screws
180 Degrees
Service Procedures
15
Service Procedures
Transmission ECU
16
Service Procedures
1
Remove Protective
Covers (see p. 12 - 13)
2
Disconnect Five
Transmission ECU
Connectors
Service Procedures
3
Remove The Two
Mounting Capsrews
4
Lift And Remove
Transmission ECU
17
Service Procedures
Final Check
Make sure the mounting capscrews are properly
torqued.
Make sure all the connectors are properly
connected and locked.
Transmission ECU
18
Service Procedures
1
Install Transmission
ECU
Service Procedures
Install The Two
Mounting Capscrews
3
Re-connect Five
Transmission ECU
Connectors
4
Install Protective Covers
(see p. 14 - 15)
19
Service Procedures
2. Disconnect the negative battery cable and the h. Speed Sensors (T, U, V)
Transmission Interface Harness located on the i. Low Air Switch (G)
right rear side of the Shift Bar Housing.
j. Upshift Brake Solenoid (K).
3. Disconnect the following connectors:
5. Using a Philips screwdriver, remove the four
a. Power connector Transmission Interface Harness connector
mounting screws and any cable ties securing
b. 24-way connector the harness to the transmission. Remove the
c. 32-way connector. harness from the transmission.
Transmission Harness
20
Service Procedures
Transmission
Interface
1 2 Harness
Service Procedures
4 3
Disconnect Harness Disconnect
From Components Transmission ECU
Range Valve
Neutral Assembly
Switch
Cross Gate
Sensor
Splitter
Reverse
Switch Range
Switch
Switch
Low Air
Switch
Splitter Valve
Assembly
Upshift Brake
Solenoid
(see p. 60-63)
Gear Select Front
Sensor Countershaft
Speed Sensor
5
(see 68-71)
Remove Interface
Main Shaft
Speed Sensor
Output Shaft Connector Mounting
Speed Sensor Screws
(see p. 68-71)
21
Service Procedures
f. Reverse Switch (P) Make sure all the connectors are properly
connected and locked.
Transmission Harness
22
Service Procedures
11 2
Install Interface Connector Re-connect Harness
Mounting Screws To Components
Range Valve
Assembly
Neutral
Switch Cross Gate
Sensor Reverse
Splitter
Switch Range
Switch Switch
Low Air
Switch
Splitter Valve
Assembly
Upshift Brake
Service Procedures
Solenoid
(see p. 60-63)
Gear Select
Front
Sensor
Countershaft
Speed Sensor
3 (see 68-71)
Main Shaft
Re-connect Speed Sensor Output Shaft
Transmission ECU Speed Sensor
(see p. 68-71)
4
Re-connect Transmission
Interface Harness
Transmission
Interface Harness
5
Install Protective Covers
(see p. 14 - 15)
23
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Removal
1. Using a flat blade screwdriver, remove the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
2. Remove the cable ties from the motor wires.
Disconnect the Transmission Harness from
the Gear Select Sensor (J) and Cross Gate
Sensor (E).
3. Disconnect the Gear Motor and Cross Gate
Motor connector from the Transmission ECU.
4. Using a 15 mm wrench, remove the four
mounting capscrews from the Electric Shifter.
5. Remove the Electric Shifter and gasket.
Electric Shifter
24
Service Procedures
1 2 Cross Gate
Sensor
Remove Protective Disconnect Transmission
Covers (see p. 12 - 13) Harness From Gear And
Cross Gate Sensors
Cross Gate
Motor Gear Select
Gear Select Sensor
Motor
Service Procedures
Disconnect Gear And
Cross Gate Motors
From ECU
5
Slowly Lift Up And
Remove The Electric
Shifter
4
Remove Mounting
Capscrews
25
Service Procedures
NOTE: If the Electric Shifter is not properly 2. Turn the ignition switch OFF and wait two
aligned, it will not fit properly. minutes.
2. Position the Electric Shifter on the Shift Bar CAUTION: The system must be calibrated
Housing, then using 15mm wrench, install the
! before the vehicle is placed into operation.
four mounting capscrews.Torque to 60-70 Nm
(40-50 lb-ft). Final Check
3. Re-connect the Gear Motor and Cross Gate Make sure all the connectors are properly
Motor connectors to the Transmission ECU. connected and locked.
Using cable ties, secure the motor wires to the
Make sure that the mounting capscrews are
transmission in their previous position.
properly torqued.
Be sure to perform the calibration procedure before
operating the transmission.
Electric Shifter
26
Service Procedures
1 2
Install New Gasket Install Electric Shifter
And Mounting Capscrews
Service Procedures
3
4 Re-connect Gear And
Re-connect Gear And Cross Gate Motors
Cross Gate Sensors
Cross Gate
Motor
Cross Gate Gear Select
Sensor Motor
Gear Select
Sensor
5
Install Protective Covers
(see p. 14 - 15)
27
Service Procedures
Removal
1. Using a flat blade screwdriver, remove the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
2. Disconnect the Transmission Harness from the
Cross Gate Sensor (E).
28
Service Procedures
1
Remove Protective
Covers (see p. 12 - 13)
2
Disconnect Transmission
Harness From Sensor
Service Procedures
3
Remove The Sensor
Mounting Capscrews
4
Remove Sensor
29
Service Procedures
30
Service Procedures
1
Install Sensor
Service Procedures
Install Sensor
Mounting Capscrews
3
Re-connect The
Transmission Harness
To Sensor
4
Install Protective Covers
(see p. 14 - 15)
31
Service Procedures
1. Using a flat blade screwdriver, remove the 7. Remove the Gear Select Sensor, steel sleeves,
Transmission Protective Covers by turning and O-rings from the Electric Shifter.
the attaching screws 180 degrees.
2. Remove the cable ties from the motor wires.
Disconnect the Transmission Harness from
the Gear Select Sensor (J) and Cross Gate
Sensor (E).
3. Disconnect the Gear Motor and Cross Gate
Motor connectors from the Transmission ECU.
32
Service Procedures
1 Cross Gate
Cross Gate
Motor Gear
Sensor
Remove Protective Select
Motor
Covers (see p. 12 - 13)
Gear Select
Sensor
2
Disconnect Transmission 3
Harness From Gear
And Cross Gate Sensors Disconnect Gear And
Cross Gate Motors
From ECU
Service Procedures
5
Remove Electric Shifter
And Gasket
4
Remove Mounting
Capscrews
6
Remove Sensor
Mounting Capscrews
7
Remove Sensor
33
Service Procedures
3. Position a new gasket at the Electric Shifter 2. Turn the ignition switch OFF and wait two
mounting location. Check to ensure the minutes.
transmission is in the neutral position, then
CAUTION: The system must be calibrated
move the Electric Shifter to the neutral position. ! before the vehicle is placed into operation.
NOTE: If the Electric Shifter is not properly
aligned, it will not fit properly. Final Check
Make sure all the connectors are properly
connected and locked.
Make sure that the mounting capscrews are
properly torqued.
Be sure to perform the calibration procedure before
operating the transmission.
34
Service Procedures
1 2
Install Sensor Install Sensor
Mounting Capscres
Service Procedures
Install Electric Shifter
And Gasket
4
Install Mounting
Capscrews
Cross Gate
Sensor
Cross Gate
6
Motor Re-connect Transmission
Gear Select
Motor Harness To Gear
And Cross Gate Sensors
Gear Select
Sensor
5 7
Re-connect Gear And Install Protective Covers
Cross Gate Motors (see p. 14 - 15)
To ECU
35
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Removal
1. Using a flat blade screwdriver, remove the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
2. Disconnect the Transmission Harness from the
Range Switch (R).
3. Using a 27 mm wrench, remove the Range
Switch.
Range Switch
36
Service Procedures
1
Remove Protective
Covers (see p. 12 - 13)
2
Disconnect
Transmission Harness
Service Procedures
3
Remove Range Switch
37
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Installation
1. Using a 27 mm wrench, install the Range
Switch. Torque to 20-25 Nm (15-20 lb-ft).
2. Re-connect the Transmission Harness to the
Range Switch (R).
3. Using a flat blade screwdriver, install the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
Final Check
Make sure the Range Switch is properly torqued.
Make sure all of the connectors are properly
connected and locked.
Range Switch
38
Service Procedures
1
Install Range Switch
Service Procedures
2
Re-connect
Transmission Harness
3
Install Protective Covers
(see p. 14 - 15)
39
Service Procedures
40
Service Procedures
1
Remove Protective
Coves (see p. 12 - 13) 3
Remove The Air
Supply Hose
2
Disconnect
Transmission Harnesses
Service Procedures
Disconnect
Transmission Harness
5
Remove The Air Pipe
7
O-rings
Remove Range
6 Solenoid Assembly
Remove Mounting
Capsrews
41
Service Procedures
42
Service Procedures
O-rings
1
Install Range
Solenoid Assembly
2
Install Mounting
Capscrews
3
Install The Air Pipe
Service Procedures
4
Install The Upshift Brake
Air Supply Line
6
Re-connect
Transmission Harness
5
Install The Air
Supply Hose
7
Install Protective Covers
(see p. 14 - 15)
43
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Removal
1. Using a flat blade screwdriver, remove the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
2. Disconnect the Transmission Harness from the
Neutral Switch (N).
3. Using a 27 mm wrench, remove the Neutral
Switch.
Neutral Switch
44
Service Procedures
1
Remove Protective
Covers (see p. 12 - 13)
Service Procedures
Disconnect
Transmission Harness
3
Remove Neutral Switch
45
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Installation
1. Using a 27 mm wrench, install the Neutral
Switch. Torque to 20-25 Nm (15-20 lb-ft).
2. Re-connect the Transmission Harness to the
Neutral Switch (N).
3. Using a flat blade screwdriver, install the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
Final Check
Make sure the Neutral Switch is properly torqued.
Make sure that all of the connectors are properly
connected and locked.
Neutral Switch
46
Service Procedures
1
Install Neutral Switch
Service Procedures
2
Re-connect
Transmission Harness
3
Install Protective Covers
(see p. 14 - 15)
47
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Removal
1. Using a flat blade screwdriver, remove the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
2. Disconnect the Transmission Harness from the
Reverse Switch (P).
3. Using a 27 mm wrench, remove the Reverse
Switch.
Reverse Switch
48
Service Procedures
1
Remove Protective
Covers (see p. 12 - 13)
Service Procedures
Disconnect
Transmission Harness
3
Remove Reverse Switch
49
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Installation
1. Using a 27 mm wrench, install the Reverse
Switch. Torque to 20-25 Nm (15-20 lb-ft).
2. Re-connect the Transmission Harness to the
Reverse Switch (P).
3. Using a flat blade screwdriver, install the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
Final Check
Make sure that all of the connectors are properly
connected and locked.
Make sure that the Reverse Switch is properly
torqued.
Reverse Switch
50
Service Procedures
1
Install Reverse Switch
Service Procedures
2
Re-connect
Transmission Harness
3
Install Protective Covers
(see p. 14 - 15)
51
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Removal
1. Using a flat blade screwdriver, remove the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
2. Disconnect the Transmission Harness from the
Splitter Switch (M).
3. Using a 27 mm wrench, remove the Splitter
Switch.
Splitter Switch
52
Service Procedures
1
Remove Protective Covers
(see p. 12 - 13)
Service Procedures
2
Disconnect
Transmission Harness
3
Remove Splitter Switchs
53
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Installation
1. Using a 27 mm wrench, install the Splitter
Switch. Torque to 20-25 Nm (15-20 lb-ft).
2. Re-connect the Transmission Harness to the
Splitter Switch (M).
3. Using a flat blade screwdriver, install the
Transmission Protective Covers by turning the
attaching screws 180 degrees.
Final Check
Make sure that all of the connectors are properly
connected and locked.
Make sure that the Splitter Switch is properly
torqued.
Splitter Switch
54
Service Procedures
1
Install Splitter Switch
Service Procedures
2
Re-connect
Transmission Harness
3
Install Protective Covers
(see p. 14 - 15)
55
Service Procedures
Splitter Solenoid
Assembly
56
Service Procedures
1 2
Drain Air System, Disconnect
Remove Protective Covers Transmissioin Harness
(see p. 12 - 13)
Service Procedures
3
Remove The Air Pipe
5
Remove Splitter Solenoid
4
Remove Mounting
Capscrews O-rings
57
Service Procedures
NOTE: Make sure that the O-rings are in place Make sure the mounting capscrews are properly
on the Shift Bar Housing. torqued.
1. Install the Splitter Solenoid Assembly on the Make sure there are no air leaks.
Shift Bar Housing.
Make sure that all of the connectors are properly
2. Using a 13 mm wrench, install the two connected and locked.
mounting capscrews. Torque to 40-45 Nm
(30-33 lb-ft).
Splitter Solenoid
Assembly
58
Service Procedures
1 2
Install Splitter Install Mounting
Solenoid Assembly Capscrews
O-rings
Service Procedures
3 4
Install The Air Pipe Re-connect
Transmission Harnesses
5
Install Protective Covers
(see p. 14 - 15)
59
Service Procedures
Upshift Brake
Solenoid
60
Service Procedures
1 2
Drain Air System, Disconnect The Air Line
Disconnect
Transmission Harness
Service Procedures
3 4
Remove Air Pipe Remove Upshift
Brake Solenoid
61
Service Procedures
Upshift Brake
Solenoid
62
Service Procedures
1 2
Install Upshift Re-Connect The Air Line
Brake Solenois
Service Procedures
3 4
Install The Air Pipe Re-connect The
Tarnsmission Harness
63
Service Procedures
Upshift Brake
64
Service Procedures
1 2
Disconnect Remove Air Pipe
Transmission Harness
Service Procedures
3
Remove Upshift Brake
Solenoid And Bracket
4 5
Remove Mounting Remove Upshift Brake
Capscrews And Gasket
65
Service Procedures
Upshift Brake
66
Service Procedures
1 2
Install Upshift Brake Install Mounting
And Gasket Capscrews With New
Sealing Washers
Service Procedures
3
Install Upshift Brake
Solenoid And Bracket
4 5
Install The Air Pipe Re-connect
And Brass Washers Transmission Harness
67
Service Procedures
Front Counter Shaft / Main Shaft / Output Shaft Speed Sensor – Removal
Removal
1. Disconnect the Transmission Harness from the
Speed Sensor.
NOTE: Before removing Front Counter Shaft
Speed Sensor, drain the lubricant from
transmission.
Output
Shaft
Main Shaft
Figure 57. Front Counter Shaft / Main Shaft / Output Shaft Speed Sensor Location
68
Service Procedures
1
Disconnect
Transmission Harness
Service Procedures
2
Remove Mounting
Capscrews And Plate
3
Remove Sensor
Figure 58. Front Counter Shaft / Main Shaft / Output Shaft Speed Sensor – Removal
69
Service Procedures
Front Counter Shaft / Main Shaft / Output Shaft Speed Sensor – Installation
Output
Shaft
Main Shaft
Figure 59. Front Counter Shaft / Main Shaft / Output Shaft Speed Sensor Location
70
Service Procedures
1
Install Sensor
Service Procedures
2
Install Mounting
Capscrews And Plate
3
Re-connect
Transmission Harness
Figure 60. Front Counter Shaft / Main Shaft / Output Shaft Speed Sensor – Installation
71
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Removal
1. Drain air system. Disconnect the Transmission
Harness from the Low Air Switch (G).
2. Using a 19 mm wrench, remove the Low Air
Switch from the Air Filter Regulator.
3. Using a 16 mm wrench, remove the air lines
from the Air Filter Regulator.
4. Using a 10 mm wrench, remove the two
mounting capscrews and remove the Air Filter
Regulator.
Air Filter
Regulator
72
Service Procedures
1
Drain Air System,
Disconnect
Transmission Harness
2
Remove Low Air Switch
Service Procedures
3
Remove Air Lines
4
Remove Mounting
Capscrews And Air
Filter Regulator
73
Service Procedures
Air Filter
Regulator
74
Service Procedures
1
Install Air Filter Regulator
2
Install Air Lines
Service Procedures
3
Install Low Air Switch
4
Re-connect
Transmission Harness
75
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Removal
1. Drain air system. Disconnect the Transmission
Harness from the Low Air Switch (G).
2. Using a 19 mm wrench, remove the Low Air
Switch from the Air Filter Regulator.
76
Service Procedures
1
Drain Air System,
Disconnect
Transmission Harness
Service Procedures
2
Remove Low Air Switch
77
Service Procedures
Special Instructions
None
Required Tools
Basic Hand Tools
Installation
1. Using a 19 mm wrench, install the Low Air
Switch on the Air Filter Regulator.
Torque to 10-15 Nm (8-12 lb-ft).
2. Re-connect the Transmission Harness to the
Low Air Switch (G).
Final Check
Make sure there are no air leaks.
Make sure that all of the connectors are properly
connected and locked.
Make sure that the Low Air Switch is properly
torqued.
78
Service Procedures
1
Install Air Filter Switch
Service Procedures
2
Re-connect
Transmission Harness
79
Copyrighted by Eaton B.V 2000
All rights reserved
Specifications liable to change in accordance
with technical developments