Service Manual

Fuller Heavy-Duty Transmissions

TRSM1500 EN-US
May 2017

RT-8908LL RTO-14908LL RTX-14715

RTO-11707LL RTO-14909ALL RTXF-11715
RTO-11708LL RTO-14909MLL RTXF-14715
RTOF-11707LL RTO-16908LL RTXF-15715
RTOF-11708LL RTO-16909ALL
RTOF-14708LL RTOF-11709MLL
RTX-11708LL RTOF-11908LL
RTX-14708LL RTOF-11909ALL
RTXF-11708LL RTOF-11909MLL
RTXF-14708LL RTOF-13707DLL
RTO-11707DLL RTOF-13707MLL
RTO-11709MLL RTOF-14709MLL
RTO-11908LL RTOF-14908LL
RTO-11909ALL RTOF-14909ALL
RTO-11909MLL RTOF-14909MLL
RTO-13707DLL RTOF-16908LL
RTO-13707MLL RTOF-16909ALL
RTO-14709MLL RTX-11715
 Warnings and Precautions

Warnings and Precautions

! WARNING
Before starting a vehicle always be seated in the driver’s seat, place the transmission in neutral, set the parking brakes and
disengage the clutch.

Before working on a vehicle place the transmission in neutral, set the parking brakes and block the wheels.

Service Procedure
Before towing the vehicle place the transmission in neutral, and lift the rear wheels off the ground, remove the axle shafts,
or disconnect the driveline to avoid damage to the transmission during towing.

The description and specifications contained in this service publication are current at the time of printing.

Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any
time without notice.

Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use
and should not be considered an endorsement. Equivalents may be used.

This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow
specific instructions may result in personal injury and/or component damage.

Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize
the personal safety of the service technican or vehicle operator.

Warning: Failure to follow indicated procedures creates a high risk of personal injury to the service technician.

Caution: Failure to follow indicated procedures may cause component damage or malfunction.
Note: Additional service information not covered in the service procedures.

Tip: Helpful removal and installation procedures to aid in the service of this unit.

Always use genuine Eaton replacement parts.

i
Introduction

Transmission Overview

Air System:
Roadranger® Valve

Shift Bar Housing:

Levers/Housings
& Isolators

Auxiliary Section:
Combination Cylinder

Air System:
Air Filter/Regulator

Shift Bar Housing:

Shift Bar Housing Assembly
Auxiliary Section:
Auxiliary Countershaft
Front Section:
Reverse Idler
Auxiliary Section:
Auxiliary Case Assy

Auxiliary Section:
Mainshaft & Synchro

Front Section:
Clutch Housing / Case Assembly Auxiliary Section:
Auxiliary Drive Gear
Front Section:
Mainshaft

Front Section:
Input Shaft / Drive Gear Auxiliary Section:
Countershaft

Air System:
Front Section: Slave Valve
Reverse Idler
Front Section:
Countershafts

ii
 Table of Contents

General Information How to Remove the Oil Seal -

Magnetic Speedometer .....................................106
How to Install the Oil Seal - Magnetic Speedometer 108
Purpose and Scope of Manual .................................... 1 How to Remove the Output Yoke/Companion
Serial Tag Information and Model Nomenclature ........ 5 Flange and Nut .................................................110
Lubrication Specifications ........................................... 7 How to Install the Output Yoke/Companion
Transmission Operation .............................................. 9 Flange and Nut .................................................112
Tool Specifications .................................................... 13 How to Remove the Output Yoke / Flange and
Preventive Maintenance Inspection ........................... 16 Retaining Cap Screws .......................................114
Power Flow Diagrams ............................................... 20 How to Install the Output Yoke / Flange and
Air System Overview ................................................. 34 Retaining Cap Screws .......................................115
General Troubleshooting Chart ................................. 46 How to Remove the Auxiliary Section in Chassis .....116
Air System Troubleshooting ...................................... 49 How to Install the Auxiliary Section in Chassis ........118
How to Remove the
Combination Cylinder Assembly .......................121
How to Install the Combination Cylinder Assembly .123
In-Vehicle Service Procedures
Timing Procedures .................................................... 65
How to Disassemble Roadranger Valve A-4900 ........ 69
Transmission Overhaul
How to Assemble Roadranger Valve A-4900 ............. 71
How to Remove the Air Lines and Hoses .................. 73
Procedures-Bench Service
How to Install the Air Lines and Hoses ...................... 75
How to Remove Compression Type Fittings .............. 77 How to Disassemble the Gear Shift Lever ................125
How to Install Compression Type Fittings ................. 78 How to Assemble the Gear Shift Lever ....................127
How to Remove Push-to-Connect Type Fittings ........ 79 How to Remove the Shift Bar Housing ....................129
How to Install Push-to-Connect Type Fittings ........... 80 How to Install the Shift Bar Housing ........................131
How to Remove Rubber 1/4" Air Hoses ..................... 81 How to Disassemble the Standard Shift Bar Housing 133
How to Install Rubber 1/4" Air Hoses ........................ 82 How to Assemble the Standard Shift Bar Housing ...136
How to Remove the Air Filter/Regulator .................... 83 How to Disassemble the Forward Shift Bar Housing 139
How to Install the Air Filter/Regulator ....................... 84 How to Assemble the Forward Shift Bar Housing ....142
How to Remove a Roadranger Valve ......................... 85 How to Remove the Input Shaft Assembly
How to Install a Roadranger Valve ............................ 86 (without Main Case disassembly) .....................145
How to Remove a Slave Valve ................................... 87 How to Install the Input Shaft Assembly
How to Install a Slave Valve ...................................... 88 (without Main Case disassembly) .....................147
How to Remove the How to Remove the Auxiliary Section
Gear Shift Lever/Remote Shift Control ...................... 89 with Tapered Bearings ......................................149
How to Install the How to Remove the
Gear Shift Lever/Remote Shift Control ............... 90 Combination Cylinder Assembly .......................151
How to Adjust the Remote Shift Control (LRC Type) . 91 How to Remove the
Neutral Switch Operation and Testing ....................... 93 Auxiliary Countershaft Assembly ......................153
How to Remove the Neutral Switch ........................... 94 How to Disassemble the Output Shaft Assembly .....156
How to Install the Neutral Switch .............................. 95 How to Disassemble the Synchronizer Assembly ....160
Reverse Switch Operation and Testing ...................... 96 How to Assemble the Synchronizer Assembly .........161
How to Remove the Reverse Switch ......................... 97 How to Assemble the Output Shaft Assembly ..........163
How to Install the Reverse Switch ............................. 98 How to Install the Combination Cylinder Assembly .169
How to Remove the Shift Bar Housing ...................... 99 How to Install the Auxiliary Countershaft Assembly 171
How to Install the Shift Bar Housing ....................... 101 How to Remove the Clutch Housing ........................175
How to Remove the Oil Seal - How to Remove the Auxiliary Drive Gear Assembly .177
Mechanical Speedometer ................................. 103 How to Disassemble the
How to Install the Oil Seal - Upper Reverse Idler Gear Assembly .................180
Mechanical Speedometer ................................. 105 How to Disassemble the
Lower Reverse Idler Gear Assembly .................182

iii
Table of Contents

How to Remove the

Upper and Lower Countershaft Bearings ......... 183
How to Remove the Main Shaft Assembly .............. 185
How to Remove the Countershaft Assemblies ........ 186
How to Disassemble the Countershaft Assemblies . 188
How to Remove the
Input Shaft and Main Drive Gear ...................... 190
How to Disassemble the Main Shaft Assembly ....... 193
How to Disassemble the Main Shaft Assembly
with Low Force Gearing ................................... 195
How to Assemble the Main Shaft Assembly with
Selective (Adjustable) Thickness
Tolerance Washers .......................................... 197
How to Assemble the Main Shaft Assembly with
Non-Selective (Non-Adjustable)
Tolerance Washers .......................................... 203
How to Assemble the Main Shaft Assembly
with Low Force Gearing ................................... 206
How to Prepare the Main Case for Assembly .......... 209
How to Assemble the Countershaft Assemblies ...... 210
How to Assemble the
Lower Reverse Idler Gear Assembly ................ 212
How to Install Countershaft Assemblies .................. 216
How to Install the Lower Countershaft Bearings ..... 217
How to Install he Input Shaft and
Main Drive Gear ............................................... 219
How to Install the Main Shaft Assembly .................. 221
How to Install the Upper Countershaft Bearings ..... 223
How to Assemble the
Upper Reverse Idler Gear Assembly ................. 226
How to Install the Auxiliary Drive Gear Assembly .... 229
How to Install the Clutch Housing ........................... 232
How to Disassemble the Integral Oil Pump
without Auxiliary Oil Tube ................................ 233
How to Assemble the Integral Oil Pump
without Auxiliary Oil Tube ................................ 236
How to Remove the Integral Oil Pump .................... 239
How to Install the Integral Oil Pump ....................... 241
How to Install the Auxiliary Section
with Tapered Bearings ..................................... 243
Shim Procedure without a Shim Tool
for Tapered Bearings ........................................ 245

iv
 Introduction

Purpose and Scope of Manual

General Information
This manual is designed to provide information necessary to service and repair the Fuller® Transmissions listed on the front.

How to use this Manual

The service procedures have been divided into two sections: In-Vehicle Service Procedures and Transmission Overhaul
Procedures—Bench Service. In-Vehicle Service Procedures contain procedures that can be performed while the Transmission is
still installed in the vehicle. Transmission Overhaul Procedures contain procedures that are performed after the Transmission has
been removed from the vehicle.

The procedure sections are laid out with a general heading at the top outside edge of each page followed by more specific headings
and the procedures. To find the information you need in these sections, first go to the section that contains the procedure you
need. Then look at the heading at the top and outside edge of each page until you find the one that contains the procedure you need.

Transmission Overhaul Procedures follow the general steps for complete disassembly and then assembly of the Transmission.
Note: In some instances the Transmission appearance may be different from the illustrations, but the procedure is the same.

Disassemble Precautions
It is assumed in the detailed assembly instructions that the lubricant has been drained from the Transmission, the necessary
linkage and vehicle 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 instructions (How to Remove the Gear
Shift Lever). This Assembly MUST be detached from the Shift Bar Housing before the Transmission can be removed.

Follow closely each procedure in the detailed instructions, make use of the text, illustrations, and photographs provided.
Assemblies
• When disassembling the various Assemblies, such as the Mainshaft, Countershafts, and Shift Bar Housing, lay all parts
on a clean bench in the same sequence as removed. This procedure will simplify assembly and reduce the possibility of
losing parts.

Bearings
• Carefully wash and lubricate all usable bearings as removed and protectively wrap until ready for use. Remove bearings
planned to be reused with pullers designed for this purpose.

Cleanliness
• Provide a clean place to work. It is important that no dirt or foreign material enters the unit during repairs. Dirt is an
abrasive and can damage bearings. It is always a good practice to clean the outside of the unit before starting the
planned disassembly.

Input Shaft
• The Input Shaft can be removed from the Transmission without removing the Countershafts, Mainshaft, or Main Drive
Gear. Special procedures are required and provided in this manual.

1
Introduction

Snap Rings
• Remove Snap Rings with pliers designed for this purpose. Snap rings removed in this manner can be reused, if they
are not sprung or loose.

When Using Tools to Move Parts

• Always apply force to Shafts, Housings, etc., with restraint. Movement of some parts is restricted. Never apply force
to driven parts after they stop solidly. The use of soft Hammers, Soft Bars, and Mauls for all disassembly work is
recommended.

Inspection Precautions
Before assembling 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 reusing a questionable part
which could lead to additional repairs and expense soon after assembly. To aid in determining the reuse or replacement of any
Transmission part, consideration should also be given to the unit's history, mileage, application, etc.
Recommended inspection procedures are provided in the following checklist:
Bearings
• Wash all Bearings in clean solvent. Check Balls, Rollers, and Raceways for pitting, discoloration, and spalled areas.
Replace Bearings that are pitted, discolored, spalled, or damaged during disassembly.
• Lubricate Bearings that are not pitted, discolored, or spalled and check for axial and radial clearances.
• Replace bearings with excessive clearances.
• Check bearing fit. Bearing Inner Races should be tight to Shaft; Outer Races slightly tight to slightly loose in Case Bore.
If the Bearing spins freely in the Bore the Case should be replaced.

Bearing Covers
• Check Covers for wear from thrust of adjacent Bearing. Replace Covers damaged from thrust of Bearing Outer Race.
• Check Cover Bores for wear. Replace those worn or oversized.

Clutch Release Parts

• Check Clutch Release parts. Replace Yokes worn at Cam surfaces and Bearing Carrier worn at Contact Pads.
• Check Pedal Shafts. Replace those worn at Bushing surfaces.

Gears
• Check gear teeth for frosting and pitting. Frosting of gear teeth faces presents no threat of Transmission failure. Often in
continued operation of the unit, frosted gears "heal" and do not progress to the pitting stage. In most cases, gears with
light to moderate pitted teeth have considerable gear life remaining and can be reused, but gears in the advanced stage
of pitting should be replaced.
• Check for gears with Clutching teeth abnormally worn, tapered, or reduced in length from clashing during shifting.
Replace gears found in any of these conditions.
• Check Axial Clearance of gears.

2
 Introduction

Gear Shift Lever Housing Assembly

General Information
• Check spring tension on Shift Lever. Replace Tension Spring if lever moves too freely.
• If Housing is disassembled, check Gear Shift Lever bottom end and Shift Finger Assembly for wear. Replace both gears
if excessively worn.

Gray Iron Parts

• Check all gray iron parts for cracks and breaks. Replace parts found to be damaged.

Oil Return Threads and Seals

• Check oil return threads on the Input Shaft. If return action of threads has been destroyed, replace the Input Shaft.
• Check Oil Seal in Rear Bearing Cover. If sealing action of lip has been destroyed, replace Seal.

O-Rings
• Check all O-Rings for cracks or distortion. Replace if worn.

Reverse Idler Gear Assemblies

• Check for excessive wear from action of Roller Bearings.

Shift Bar Housing Assembly

• Check for wear on Shift Yokes and Block at pads and lever slot. Replace excessively worn parts.
• Check Yokes for correct alignment. Replace sprung Yokes.
• Check lock screw in Yoke and Blocks. Tighten and rewire those found loose.
• If Housing has been disassembled, check Neutral Notches of Shift Bars for wear from Interlock Balls.

Sliding Clutches
• Check all Shift Yokes and Yoke slots in Sliding Clutches for extreme wear or discoloration from heat.
• Check engaging teeth of Sliding Clutches for partial engagement pattern.

Splines
• Check Splines on all shafts for abnormal wear. If Sliding Clutch gears, Companion Flange, or Clutch Hub has wear
marks in the Spline sides, replace the specific shaft effected.

Synchronizer Assembly
• Check Synchronizer for burrs, uneven and excessive wear at contact surface, and metal particles.
• Check Blocker Pins for excessive wear or looseness.
• Check Synchronizer contact surfaces on the Synchronizer cups for wear.

Washers
• Check surfaces of all washers. Washers scored or reduced in thickness should be replaced.

3
Introduction

Assembly Precautions
Make sure that Case interiors and Housings are clean. It is important that dirt and other foreign materials are kept out of the
Transmission during assembly. Dirt is an abrasive and can damage polished surfaces of Bearings and Washers. Use certain
precautions, as listed below, during assembly.

Axial Clearances
• Maintain original Axial Clearances of 0.006–0.015 in. for Mainshaft Gears.

Bearings
• Use a Flange-End Bearing Driver for bearing installation. These special drivers apply equal force to both Bearing Races,
preventing damage to Balls/Rollers and Races while maintaining correct Bearing alignment with Bore and Shaft. Avoid
using a Tubular or Sleeve-Type Driver, whenever possible, as force is applied to only one of the Bearing Races.

Cap Screws
• To prevent oil leakage and loosening, use Fuller® Sealant #71205 on all Cap Screws.

Gaskets
• Use new Gaskets throughout the Transmission as it is being rebuilt. Make sure all Gaskets are installed. An omission of
any Gasket can result in oil leakage or misalignment of Bearing Covers.

Initial Lubrication
• Coat all Limit Washers and Shaft Splines with Lubricant during assembly to prevent scoring and galling of such parts.

O-Rings
• Lubricate all O-Rings with silicon lubricant.

Universal Joint Companion Flange or Yoke

• Pull the Companion Flange or Yoke tightly into place with the Output Shaft Nut, using 650–700 lb-ft (881.28–949.07
N•m) of torque. Make sure the Speedometer Drive Gear or a Replacement Spacer of the same width has been installed.
Failure to pull the Companion Flange or Yoke tightly into place can result in damage to the Mainshaft Rear Bearing.

IMPORTANT

See the appropriate Illustrated Parts Lists (specified by model series) to ensure that proper parts are used during assembly of
the Transmission.

4
 Model Designations and Specifications

Serial Tag Information and Model Nomenclature

Transmission model designation and other transmission identification information are stamped on the transmission tag. To iden-
tify the transmission model designation and serial number, locate the tag on the transmission and then locate the numbers as
shown.

When calling for service assistance or parts, have the model and serial numbers handy.

Do not remove or destroy the transmission identification tag.

R T O - 1 1 9 0 9 M L L
Eaton Fuller Model Designation Prefix
See options below:
Prefix Definition Ratio Set
RT Roadranger¨ Twin Countershaft

General Information
Forward Speeds
RTF w/ Forward Shift Bar Housing
RTO w/ Overdrive 6 = "Multi-Mesh" Gearing
RTOF w/ Overdrive and Forward Shift Bar Housing 7 = Helical Auxilary Gearing and
RTX w/ Overdrive and Direct Shift Pattern "Multi-Mesh" Front Gearing
RTXF w/ Overdrive, Direct Shift Pattern and Forward Shift Bar Housing 9 = Improved Seal System
This (x) 100 = Nominal Torque Capacity

L or LL notation used here indicates one (L)

or two Low (LL) gears in addition to designated speeds

The model number gives basic information about the transmission. Use this number when calling for service assistance or re-
placement parts.
Serial Number
The serial number is the sequential identification number of the transmission. Before calling for service assistance, write the num-
ber down. It may be needed.
Bill of Material or Customer Number
This number may be located below the model and serial numbers. It is a reference number used by Eaton®.

5
Model Designations and Specifications

Model Options
Torque Rating
The torque rating of the transmission specified in the model number is the input torque capacity in Lb·ft. Various torque ratings
are available. For more information, call your Eaton Fuller regional sales and service office at 1-800-826-HELP (4357).
Shift Bar Housings
Two types of shift bar housings are available for this transmission. Both are described and shown below.
Standard
The standard shift bar housing has a gear shift lever opening that is located toward the rear of the transmission.
Forward
The forward shift bar housing has a gear shift lever opening located three inches closer to the transmission front than the standard
opening. This forward design allows greater flexibility in mounting the transmission and is indicated by an "F" in the model number
.

Lubrication Pumps
Internal: An internal lubrication pump is located in the lower front of the transmission and is driven off the upper coun-
tershaft. Transmissions rated 1550 Lb·ft. and above include the internal pump standard.
PTO Driven: A PTO driven pump is externally mounted on the 6 or 8 bolt PTO openings and driven off the PTO gear.
Power Take Off (PTO) Usage
PTOs can be mounted in the following way:
6 or 8 Bolt: The 6 or 8 bolt openings are standard with the transmission. The PTO is mounted to the opening and driven
from the PTO gear on the front countershaft.
Thru-Shaft: The thru-shaft PTO mounts on the rear of the transmission. It requires a special auxiliary housing and main
case countershaft with internal splines.

6
 Lubrication

• Lubrication Specifications

General Information
IMPORTANT

Transmission Filters should be changed during regular lube intervals. Inspection of the Transmission Filter should be
conducted during preventive maintenance checks for damage or corrosion. Replace as necessary.
• For a list of Eaton® Approved Synthetic Lubricants, see TCMT0021 or call 1-800-826-HELP (4357).
• The use of lubricants not meeting these requirements will affect warranty coverage.
• Additives and friction modifiers must not be introduced. Never mix engine oils and gear oils in the same Transmission.

Transmission Operating Angles

If the Transmission operating angle is more than 12 degrees, improper lubrication will occur. The operating angle is the
Transmission mounting angle in the Chassis plus the percent of upgrade (expressed in degrees). For operating angles over
12 degrees, the Transmission must be equipped with an Oil Pump or Cooler kit to insure proper lubrication.

Operating Temperatures with Oil Coolers

The Transmission must not be operated consistently at temperatures above 250 °F. Operation at temperatures above 250 °F
[121 °C] causes loaded gear tooth temperatures to exceed 350 °F [177 °C] which will ultimately destroy the heat treatment of
the gears. If the elevated temperature is associated with an unusual operating condition that will reoccur, a Cooler should be
added, or the capacity of the existing cooling system increased.
The following conditions in any combination can cause operating temperatures of over 250 °F [121 °C]:
• Operating consistently at slow speed.
• High ambient temperatures.
• Restricted air flow around Transmission.
• Use of engine retarder.
• High horsepower operation.
Note: Transmission Coolers must be used to reduce the operating temperatures when the above conditions are encountered.

7
Lubrication

• Oil Cooler Chart

• Table 4
Transmission Oil Coolers are:
• Recommended
• With engines of 350 H.P. and above.
• Required
• With engines 399 H.P. and above and GCW’s over 90,000 lbs.
• With engines 399 H.P. and above and 1400 lb-ft (1898.15 N•m) or greater torque.
• With engines 1500 lb-ft (2033.73 N•m) and above
• 18-speed AutoShift Transmissions require use of an Eaton® supplied Oil-to-Water Cooler or approved
equivalent.
• With engines 450 H.P. and above.

8
 Transmission Operation and Theory

Transmission Operation

Depending on specific model, this Fuller® transmission model contains from 9 to 15 forward gear ratios and three reverse gear
ratios. The gear shift lever mechanically engages and disengages five forward gears and one reverse gear in the transmission
front section. The rear section of the transmission (auxiliary section) contains three additional gear sets which are shifted with
air. The auxiliary section provides deep reduction (low low range), low range, and high range. The driver can shift in or out of
deep reduction by moving the deep reduction button found on the shift knob side. Low and high range are shifted by moving the
range selection lever found on the shift knob front. Therefore, when a front section gear is combined with the proper auxiliary
section condition (deep reduction, low range, or high range) a corresponding forward or reverse gear ratio is obtained. See the
operating instructions and power flow charts found in this section for specific details.

Shift Patterns
A shift pattern decal that explains how to properly shift the transmission should be in your vehicle (Figure 2-1). If it has been lost,

General Information
a replacement may be obtained from any Eaton® parts distributor.

RTO-11707LL Eaton ® Fuller ¨ Roadranger ¨ 7 SPEED +LO & LO-LO (RTO)

RANGE
RTO-11709MLL Eaton ¨ Fuller ¨ Roadranger ¨
9 SPEED +LO & LO-LO
RANGE
Transmissions DEEP REDUCTION SELECTOR Transmissions DEEP REDUCTION

RTO-11707DLL RTO-14709MLL
SELECTOR SELECTOR
SELECTOR
(LO-LO) HI
RR 4 LO RR 15 7 (LO-LO)
IN
HI

R 1 7 PRE-SELECT
R LL2 3
LO

RTO-11909MLL
OUT

RTO-13707MLL
ALL RANGE SHIFTS
(MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER) PRE-SELECT ALL RANGE SHIFTS
UPSHIFTING MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER
START WITH RANGE SELECTOR DOWN UPSHIFTING
Neutral SHIFT LO-1-2-3 RAISE RANGE SELECTOR Neutral START WITH RANGE SELECTOR DOWN
SHIFT 4-5-6 SHIFT LO-1-2-3-4 RAISE RANGE SELECTOR

RTO-13707DLL LO 5 6
DOWNSHIFTING
SHIFT 7-6-5-4 MOVE RANGE SELECTOR DOWN
SHIFT 3-2-1-LO
DO NOT CHANGE RANGE WHILE MOVING IN REVERSE
RTO-14909MLL LO 6 8
SHIFT 5-6-7-8
DOWNSHIFTING
SHIFT 8-7-6-5 MOVE RANGE SELECTOR DOWN
SHIFT 4-3-2-1-LO
LO-LO
2 3 2 4

4302441
LL1 DO NOT CHANGE RANGE WHILE MOVING IN REVERSE
20464

PUT TRANSMISSION IN NEUTRAL

! WARNING BEFORE STARTING ENGINE ! WARNING PUT TRANSMISSION IN NEUTRAL
BEFORE STARTING ENGINE

RTO-11708LL Eaton ¨ Fuller ¨ Roadranger ¨ 8 SPEED +LO & LO-LO (RTO)

RANGE
RT-11715 Eaton ¨ Fuller ¨ Roadranger ¨
15 SPEED
RANGE
(RT & RTX)
Transmissions DEEP REDUCTION SELECTOR Transmissions DEEP REDUCTION SELECTOR

RT-14715
SELECTOR SELECTOR

RTO-14708LL RR 5 8 (LO-LO) HI
LO R
R
HI 7 9 (LO-LO) IN
OUT
HI
LO

R 1 4 PRE-SELECT ALL RANGE SHIFTS

R 2 4 PRE-SELECT ALL RANGE SHIFTS

Neutral
(MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER)
UPSHIFTING
START WITH RANGE SELECTOR DOWN
SHIFT LO-1-2-3-4 RAISE RANGE SELECTOR
SHIFT 5-6-7-8
RT-15715 LO
Neutral
(MOVE RANGE SELECTOR
UPSHIFTING
BEFORE
START WITH RANGE SELECTOR DOWN
SHIFT 1-2-3-4-5 RAISE RANGE SELECTOR
SHIFT 6-7-8-9-10
MOVING SHIFT LEVER)

LO 6 7
DOWNSHIFTING
SHIFT 8-7-6-5- MOVE RANGE SELECTOR DOWN
SHIFT 4-3-2-1-LO
DO NOT CHANGE RANGE WHILE MOVING IN REVERSE
RT-14915 6 8 10
DOWNSHIFTING
SHIFT 10-9-8-7-6 MOVE RANGE SELECTOR DOWN
SHIFT 5-4-3-2-1
DO NOT CHANGE RANGE WHILE MOVING IN REVERSE
LO-LO
2 3 1 3 5
RTX-11715
20465

20468
PUT TRANSMISSION IN NEUTRAL PUT TRANSMISSION IN NEUTRAL
! WARNING BEFORE STARTING ENGINE ! WARNING BEFORE STARTING ENGINE

RTX-14715
RTX-15715
RTO-14915
RTO-16915
RTX-11708LL Eaton ¨ Fuller ¨ Roadranger ¨ 8 SPEED +LO & LO-LO
RANGE
RTO-11715 Eaton ¨ Fuller ¨ Roadranger
Transmissions
¨
15 SPEED
RANGE
(RTO)

Transmissions DEEP REDUCTION SELECTOR DEEP REDUCTION SELECTOR

RTX-14708LL RTO-14715
SELECTOR SELECTOR
(LO-LO) HI (LO-LO)
7 HI 7 10
IN HI
RR 5 LO
R OUT LO

R 1 3 PRE-SELECT ALL RANGE SHIFTS

LO 2 5 PRE-SELECT ALL RANGE SHIFTS

RTO-11908LL Neutral
(MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER)
UPSHIFTING
START WITH RANGE SELECTOR DOWN
SHIFT LO-1-2-3-4 RAISE RANGE SELECTOR
SHIFT 5-6-7-8
RTO-15715 Neutral
(MOVE RANGE SELECTOR
UPSHIFTING
BEFORE
START WITH RANGE SELECTOR DOWN
SHIFT 1-2-3-4-5 RAISE RANGE SELECTOR
SHIFT 6-7-8-9-10
MOVING SHIFT LEVER)

RTO-14908LL LO 6 8
DOWNSHIFTING
SHIFT 8-7-6-5- MOVE RANGE SELECTOR DOWN
SHIFT 4-3-2-1-LO
DO NOT CHANGE RANGE WHILE MOVING IN REVERSE
6 8 9
DOWNSHIFTING
SHIFT 10-9-8-7-6 MOVE RANGE SELECTOR DOWN
SHIFT 5-4-3-2-1
DO NOT CHANGE RANGE WHILE MOVING IN REVERSE
LO-LO
2 4 1 3 4
20467

RTO-16908LL
22466

PUT TRANSMISSION IN NEUTRAL PUT TRANSMISSION IN NEUTRAL

! WARNING BEFORE STARTING ENGINE ! WARNING BEFORE STARTING ENGINE

Figure 2-1. Shift Pattern Decal

9
Transmission Operation and Theory

Initial Start-Up
WARNING

Before starting a vehicle always be seated in the driver’s seat, move the shift lever to neutral, and set the parking brakes.

CAUTION

Before moving a vehicle, make sure you understand the shift pattern configuration.
1. Make sure the shift lever is in neutral and the parking brakes are set.
2. Turn on the key switch, and start the engine.
3. Allow the vehicle air pressure to build to the correct level. Refer to your “Operator and Service Manual” supplied with
the truck.
4. Apply the service brakes.
5. Release the parking brakes on the vehicle.
6. Make sure the Range Selector is down in the low range position (Figure 2-2).

Range Selector MUST be

in the Low Range position
for Low Range.

Figure 2-2.

7. Depress the clutch pedal to the floor.

8. Move the shift lever to the desired initial gear.
9. Slowly release the clutch pedal and apply the accelerator.

Double-Clutching Procedure
1. Depress the pedal to disengage the clutch.
2. Move the shift lever to neutral.
3. Release the pedal to engage the clutch.*
a. Upshifts—decelerate engine until engine RPM and road speed match.
b. Downshifts—accelerate engine until engine RPM and road speed match.
4. Quickly depress the pedal to disengage the clutch and move the shift lever to the next gear speed position.
5. Release the pedal to engage the clutch.
Note: By engaging the clutch with the shift lever in the neutral position, the operator is able to control the
mainshaft gear RPM since it is regulated by engine RPM. This procedure allows the operator to

10
 Transmission Operation and Theory

speed up or slow down the mainshaft gearing to properly match the desired gear speed and the
outputshaft speed.

Lever Shifts
When moving the shift lever, double-clutching is recommended.

Range Shifts
CAUTION

Avoid moving the Range Selector with the shift lever in neutral while the vehicle is moving.

General Information
Low range to high range
When in the last gear position for low range and ready for the next upshift, preselect by moving the
range selector lever up. The move the shift lever, double-clutch, to the next higher speed position
according to your shift pattern. As the shift lever passes through neutral, the transmission will
automatically shift from low to high range.
High range to low range
While still in gear, preselect for low by moving the range selector down. Then move the shift lever,
double-clutching, to the next desired gear position in low range. As the shift lever passes through
neutral, the transmission automatically shifts from high range to low range.

Deep Reduction Shifts

Note: Deep reduction is only available in low range.

Button back - deep reduction not selected.

Ful le r
¨

T ransmissions

Button forward - deep reduction selected

Ful le r
¨

T ransmissions

To obtain deep reduction (low low), first make sure range selection lever is down for low range. Then, move deep reduction but-
ton forward.
Upshifts
An upshift from deep reduction can be performed while the vehicle is moving.

If the driver is not moving the shift lever during the shift (example: RTO-14708LL) depress the clutch pedal once immediately
after moving the deep reduction button rearward. Decrease engine RPM to obtain synchronous for shift completion.

If the driver is moving the shift lever during the shift (example: RTO-14715) move the deep reduction button rearward and imme-
diately double-clutch while moving the shift lever. Decrease engine RPM to obtain synchronous for shift completion.

11
Transmission Operation and Theory

Downshifts
Downshifts into deep reduction while moving are generally not recommended, but are possible if
operating conditions make it necessary. In this situation, complete the shift immediately after moving
the deep reduction button. Single clutch if not moving the shift lever, double-clutch if the shift lever
will be moved.

Special Notes
15 Speed Models
When upshifting from a deep reduction gear into a low range gear, it is recommended that the shift lever is moved back one gear
position during the shift out of deep reduction. For example:

If the driver is in deep reduction 5th gear position, he/she should double-clutch and move the shift lever to the 4th gear position
immediately after moving the deep reduction button. If the shift lever is not moved during this shift, the vehicle must have
enough speed to make a 42% step upshift.

4th Gear Position

R 4 Low Range
1
Neutral

5 5th Gear Position

Deep Reduction

DLL and MLL Models

The three lowest gears (LL1, LO, LL2) are used for road speed control. These shifts are not intended
to be used as progressive shifts.

Additional Operating Information

Preselect
IMPORTANT: Always preselect all range shifts when upshifting or downshifting. Preselection requires that the Range Selector is
moved to the needed position before starting the lever shift. Preselected range shifts are completed automatically as the lever is
moved through neutral and into the next gear. Preselecting all range shifts prevents damage to the transmission and provides for
smoother shifts.
Clutch Brake (Used with pull-type clutches)
The Clutch Brake is applied by fully depressing the clutch pedal to the floor board. When applied, the brake slows down and can
stop the transmission front box gearing. It is a disc-type brake incorporated into the clutch and transmission drive gear assem-
blies. Never use the Clutch Brake when upshifting or downshifting. Use only for initial gear engagement when the vehicle is
standing still.
Countershaft Brake (Used with push-type clutches)
The control button is mounted on the shift lever just below the shift knob. To operate the brake, disengage the clutch, press down
the control button, and shift into 1st or reverse. This is an air operated mechanical brake which slows down the transmission
gearing by forcing a piston against the countershaft PTO gear
Note: Never use the Countershaft Brake when upshifting or downshifting. Use only for initial gear engagement when the vehicle
is standing still.

12
 Recommended Tools

Tool Specifications

General Information
Some repair procedures pictured in this Manual show the use of specialized tools. Their actual use is recommended as they make
Transmission repair easier, faster, and prevent costly damage to critical parts.

For the most part, ordinary Mechanic's Tools such as Socket Wrenches, Screwdrivers, etc., and other standard shop items such
as a Press, Mauls and Soft Bars are the only tools needed to successfully disassemble and reassemble any Fuller® Transmission.

The following tables list and describe the typical tools required to properly service this model Transmission above and beyond the
necessary basic Wrenches, Sockets, Screwdrivers, and Pry Bars.

General Tools
The following tools are available from several Tool Manufacturers such as Snap-On, Mac, Craftsman, OTC, and many others:

Tool Purpose

General torquing of fasteners (Typically 15–80 lb-ft

0–100 lb-ft 1/2" drive Torque Wrench
[20.34–108.47 N•m])

0–700 lb-ft 3/4" or 1" drive Torque Wrench Torquing of Output Nut to 650–700 lb-ft (881.28–949.07 N•m)

0–50 lb-in 3/8" drive Torque Wrench General torquing of fasteners

Torquing of Cap Screws to 7 lb-in (0.79 N•m) during Auxiliary Countershaft

0–30 lb-in 1/4" drive Torque Wrench
Bearing endplay setting procedure

70 MM or 2 2/4" Socket - Standard Depth To remove the Output Shaft Nut

To remove the Snap Rings at the Auxiliary Drive Gear, Input Shaft Bearing,
Snap Ring Pliers - Large Standard External
and Countershaft Bearings

Feeler Gauges To set Mainshaft Washer Endplay and Auxiliary Tapered Bearing Endplay

Rolling Head Pry Bar To remove the Auxiliary Drive Gear Bearing

(2) Air Pressure Gauges 0–100 PSI (0–1034 kPa) To troubleshoot and verify correct operation of Air System

To remove and install Clutch Housing Bushings. Bushing

Universal Bushing Driver
OD = 1.125 in., ID = 1.000 in.

13
Recommended Tools

Special Tools
The following Transmission Tools are available directly from K-Line Industries. To obtain any of these tools listed, contact K-Line
by phone or visiting the online store.
K-Line Industries, Inc.
315 Garden Avenue
Holland, MI 49424
1-800-824-KLINE (5546)
http://www.klineind.com/

K-Line Part # Tool Tool Description

Used to install Output Seal Protective Slinger on FR & RT-Series
RR1001TR-1 Driver - Output Seal Slinger
(Gen 9) Transmission Output Yokes.
Used to install Output Seal in Rear Bearing Cover on RT-Series
RR1001TR-2 Driver - Output Seal
(Gen 6 & 7) Transmissions with 2.75" Output Shaft.
Used to install Output Seal Protective Slinger on RT-Series (Gen 6 &
RR1001TR-4 Driver - Output Seal Slinger
7) Transmission Output Yokes.
Used with Seal Driver RR1001TR-2 to install Output Seal in Rear
RR1001TR-8 Driver - Output Seal
Bearing Cover on FR & RT-Series (Gen 9) Transmissions.
Used to support the aux-Countershaft Assemblies when servicing the
RR1002TR Auxiliary Countershaft Support Straps
aux-section on FR & RT-Series (Gen 7 & 9) Transmissions.
Used to remove/install Mainshaft Assembly into the Transmission
RR1004TR Mainshaft Lifting Hook
Main Case.
Used to install the Input Bearing on Transmissions with 2" & 1.75"
RR1005TR Driver - Input Bearing
Input Shafts.
RR1006TR Auxiliary Section Lifting Bracket Used to lift Transmission Auxiliary Sections.
Shimming Gauge - Auxiliary Used for setting proper Auxiliary Countershaft Bearing clearance on
RR1007TR
Countershaft (0.100") FR-Series and RT-Series (Gen 7 & 9) Transmissions.
RR1010TR Slide Hammer Used to remove Bearing Races, Reverse Idler Shafts, and Seals.
RR1011TR-1 Slide Hammer Attachment Used for removing Output Seals.
RR1011TR-2 Slide Hammer Attachment Used for removing Bearing Races from the Transmission Case.
RR1011TR-3 Slide Hammer attachment Used for removing Bearing Races from the Transmission Case.
Used to install Front Countershaft Bearings on RT-Series
RR1012TR-2 Driver - Countershaft Front Bearings
Transmissions.
Used to remove Front Countershaft Bearings on RT-Series
RR1012TR-3 Puller - Countershaft Front Bearings
Transmissions.
RR1012TR-4 Driver - Countershaft Rear Bearings Used to install Rear Countershaft Bearings, RT-Series Transmissions.
Driver - Auxiliary Countershaft Used to install Auxiliary Countershaft Bearings on FR & RT-Series
RR1012TR-5
Bearings Transmissions with Auxiliary Section helical gearing.
Driver - Auxiliary Countershaft Used to install Auxiliary Countershaft Bearings on RT-Series
RR1012TR-6
Bearings Transmissions with Auxiliary Section spur gearing.
Used to support the Upper Countershaft during Main Box assembly on
RR1013TR Timing Block - RT-Series Countershaft
RT-Series Transmissions.

14
 Recommended Tools

K-Line Part # Tool Tool Description

General Information
Driver - Countershaft Front/Rear Used to install Front and Rear Countershaft Bearings on FR-Series
RR1015TR
bearings Transmissions.
Used to push the Countershaft Assembly rearward to create clearance
RR1017TR Pusher - Countershaft
for Bearing Puller on FR & RT-Series Transmissions.
RR1019TR Hand Maul Used with Bearing and Seal Drivers for part installation/removal.
RR1020TR Soft Bar Used with hand Maul to remove parts from the Transmission.
Used to support the Upper Countershaft during Main Box disassembly
RR1022TR Countershaft Support Tool
on FR & RT-Series Transmissions.
RR1023TR Puller - Input Bearing Used to remove the Input Bearing on FR & RT-Series Transmissions.
RR1024TR Driver - Output Bearing Used to install the Output Bearing on FR & RT-Series Transmissions.

Shop Equipment

Tool Purpose

20 Ton capacity Press To press Countershaft Gears from Countershaft.

Eaton Aftermarket Parts

The following tools are available through Eaton Aftermarket Parts. To obtain any of the tools listed, contact your local Eaton
Parts Distributor.

Tool Purpose Eaton Part Number

To remove 5/32" Air Lines from Push-to-

5/32" Air Line Release Tool P/N 4301157 included in Kit K-2394
Connect Fittings.

To cut plastic Air Lines smoothly and

Air Line Cutting Tool P/N 4301158 included in Kit K-2394.
squarely.

15
Preventive Maintenance

Preventive Maintenance Inspection

Everyday there are countless vehicles operating over the highways with Transmissions in such a neglected mechanical condition,
they can be referred to as failures looking for a place to break down. They lack a proper and organized preventive
maintenance program.

Preventive maintenance is a general term which applies to all procedures necessary to have maximum life and satisfactory service
at the lowest possible cost, short of removing and repairing the unit.

A number of conditions contrary to good preventive maintenance can generally be pointed to when inspecting a failed
Transmission. Taking a few minutes every so many hours or miles to do a few simple checks could help avoid eventual breakdown
or reduce the repair cost. If the Transmission is not cared for, it will breakdown.

Preventative Maintenance Check Points

Note: Transmission appearance may differ, however the procedure is the same.

16
 Preventive Maintenance

1. Air System and Connections

General Information
• Check for leaks, worn Air Lines, loose connections and Cap Screws.
2. Clutch Housing Mounting
• Check all Cap Screws of Clutch Housing flange for looseness.
3. Clutch Release Bearing (Not Shown)
• Remove Hand Hole Cover and check Radial and Axial Clearance in Release Bearing.
• Check relative position of thrust surface of Release Bearing with Thrust Sleeve on Push-type Clutches.
4. Clutch Pedal Shaft and Bores
• Pry upward on Shafts to check wear.
• If excessive movement is found, remove Clutch Release Mechanism and check Bushings on Bores and wear on
Shafts. See OEM literature.
5. Lubricant
• See Lubrication Manual TCMT0021.
6. Oil Filter
• Oil Filter Inspection (during vehicle PM schedule):
- Inspect Oil Filter for damage or rust. Replace as necessary.
- Inspect Oil Filter Adapter for damage or leakage. Replace as necessary.
• Oil Filter Replacement
- Replace every 100,000 miles and top off fluid.
- Every Transmission fluid change.
7. Filler and Drain Plugs
• Remove Filler Plugs and check level of lubricant at specified intervals. Tighten fill and Drain Plugs securely.
8. Cap Screws and Gaskets
• For applicable models, check all Cap Screws, especially those on PTO Covers and Rear Bearing Covers for
looseness which would cause oil leakage.
• Check PTO opening and Rear Bearing Covers for oil leakage due to faulty Gasket.
9. Gear Shift Lever
• Check for looseness and free play in Housing. If Lever is loose in Housing, proceed with Check No. 10.
10. Gear Shift Lever Housing Assembly
• If present, remove Air Lines at Air Valve or Slave Valve. Remove the Gear Shift Lever Housing Assembly from
the Transmission.
• Check the Tension Spring and Washer for set and wear.
• Check the Gear Shift Lever Spade Pin and slot for wear.
• Check bottom end of Gear Shift Lever for wear and check slot of Yokes and Blocks in Shift Bar Housing for wear
at contact points with Shift Lever.

Checks With Drive Line Dropped

11. Universal Joint Companion Flange or Shaft Nut
• Check for tightness. Tighten to recommended torque.
12. Output Shaft (Not Shown)
• Pry upward against Output Shaft to check radial clearance in Mainshaft Rear Bearing.

17
Preventive Maintenance

Checks With Universal Joint Companion Flange or Yoke Removed

Note: If necessary, use solvent and shop rag to clean sealing surface of Companion Flange or Yoke. Do not use Crocus Cloth,
Emery Paper, or other abrasive materials that will mar surface finish.
13. Splines on Output Shaft (Not Shown)
• Check for wear from movement and chucking action of the Universal Joint Companion Flange or Yoke.
14. Mainshaft Rear Bearing Cover (Not Shown)
• Check Oil Seal for wear.

Inspection
Part to Inspect What to Check For Action to be Done
Applied hydraulic Thread Sealant #71208 to threads,
Speedometer Cables should not be
torque Speedometer Sleeve to 35–50 lb-ft
loose.
(47.45–67.79 N•m).
Speedometer Connections
Should be an O-Ring or gasket between
the mating Speedometer Sleeve and the Replace the O-Ring/gasket if damaged or missing.
Rear Bearing Cover.
Check Retaining Cap Screws for Apply Eaton Sealant #71205 to the Cap Screw
tightness. threads, torque to 35–45 lb-ft (47.45–61.01 N•m).
Verify Nylon Collar and Gasket are
Rear Bearing Cover Cap Use new parts if need to replace. Apply Eaton
installed at the chamfered hole, aligned
Screws, Gasket, and Nylon Sealant #71205 to the Cap Screw threads, torque to
near the mechanical Speedometer
Collar 35–45 lb-ft (47.45–61.01 N•m).
opening.
Verify that a Rear Bearing Cover gasket Install a new Gasket if Rear Bearing Cover was
is in place. removed.
Torque the Output Shaft Nut to 650–700 lb-ft
Check the Output Shaft Nut for
Output Shaft Nut (881.28–949.07 N•m). Do not over torque the
tightness.
Output Nut.
Apply Eaton Sealant #71205 to the Cap Screw
threads. Torque 6 bolt PTO Cap Screws to
PTO Covers and Openings Check the Cap Screws for tightness.
35–45 lb-ft (47.45–61.01 N•m), 8 bolt PTO Cap
Screws to 50–65 lb-ft (67.79–88.13 N•m).
Check Front Bearing Cover, Front Case,
Shift Bar Housing, Rear Bearing Cover,
Gray Iron Parts Replace parts found to be damaged.
and Clutch Housing for cracks or
breaks.
Check return threads for damage. If threads damaged, replace the Input Shaft.
Front Bearing Cover Torque the Cap Screws to 35–45 lb-ft
Check the Cap Screws for tightness.
(47.45–61.01 N•m).
Check all connectors, Fittings, Hoses,
Oil Cooler and Oil Filter Tighten any loose Fittings.
and Filter Element for tightness.
Torque the Oil Drain Plug to 45–55 lb-ft
Check the Oil Drain Plug and the Oil Fill
Oil Drain Plug, Oil Fill Plug (61.01–74.57 N•m), Oil Fill Plug to 60–70 lb-ft
Plug for leakage.
(81.35–94.91 N•m).

18
 Preventive Maintenance

Oil Leak Inspection Process

General Information
Inspect for Oil Leak

Determine if it is a Weep or a Leak

Weep: Stained, damp, no drips, light oil film, Leak: Extremely wet or dripping of oil in the
dirt adhered to the contaminated area. contaminated area.

Gasket Rear Seal Leak

Step 1
1. Clean suspected oil weep 1. Do not repair: Rear seal is 1. Determine the origin of the leak path.
area with a clean dry cloth designed to allow minimal
or mild soluble degreaser. seepage. 2. If origin of leak is obvious skip to Step 3.
3. If the origin of the oil leak is not obvious then
2. Ensure lube is to proper 2. Ensure lube is to proper use either of the two following steps to determine
level. level. the oil leak:

3. Notify the customer that it Note: Do not use a high pressure spray washer to
is only a weep and it is not clean the area. Use of a high pressure spray may
considered to be detrimental force contamination into the area of concern and
to the life of the transmission. temporarily disrupt the leak path.
i. Clean area with a clean dry cloth or mild
4. Repair is complete. soluble degreaser and fill the transmission to
the proper lube level.
OR
ii. Clean the area as noted above and insert tracer
dye into the transmission lube and fill
transmission to proper lube level.

Step 2
Operate vehicle to normal transmission operating
temperature and inspect the area for oil leak(s)
visually or if tracer dye was introduced use an UVL
(Ultraviolet Light) to detect the tracer dye’s point of origin.
Note: When inspecting for the origin of the leak(s)
make sure the assumed leak area is not being
contaminated by a source either forward or above
the identified area such as the engine, shift tower,
shift bar housing, top mounted oil cooler, etc...

Step 3
Once the origin of the leak is identified, repair the
oil leak using proper repair procedures from the
designated model service manual.

Step 4
After the repair is completed, verify the leak is repaired
and operate the vehicle to normal transmission
operating temperature. Inspect repaired area to ensure
oil leak has been eliminated. If the leak(s) still occurs,
repeat steps or contact the Roadranger Call Center
at 1-800-826-4357.

19
Power Flow

Power Flow Diagrams

An understanding of the engine’s power flow through a transmission in each particular gear will assist the technician in trouble-
shooting and servicing a transmission.

The Fuller® transmission can be thought of as two separate “transmissions” combined into one unit. The first “transmission” or
front section contains six gear sets which are shifted with the gear shift lever. The second “transmission” called the auxiliary sec-
tion, contains two gear sets and is shifted with air pressure.
Note: This transmission is referred to as a constant mesh type transmission. When in operation, all gears are turning even
though only some of them are transferring power.

The illustration below shows the transmission with the main components called out. Note that the transmission is in the neutral
position because the sliding clutches are all in their center positions and not engaged in any gears.

Mainshaft Gear Auxiliary Countershaft

Auxiliary Drive Gear
Deep-Reduction
Sliding Clutch

Auxiliary Deep-Reduction Gear

Output Shaft

Auxiliary Range Gear

Input Shaft Mainshaft Gear

Sliding Clutch Range Sliding Clutch

Countershaft

20
 Power Flow

Front Section Power Flow

Note: The heavy lines in Figure 2-4 outline the power flow description below. For help in understanding the transmission compo-
nents, refer to Figure 2-3.
1. Power (torque) from the vehicle’s engine is transferred to the transmission’s input shaft.
2. The input shaft rotates the main drive gear through internal splines in the hub of the gear
3. The main drive gear meshes with both countershaft driven gears and the torque is split between both countershafts
4. Because the countershaft gears are in constant mesh with the mainshaft gears, all the front section gearing rotates.
However, only the engaged or selected mainshaft gear will have torque. External clutching teeth on the sliding clutch
will engage internal clutching teeth on the selected mainshaft gear. Torque will now be provided from both opposing
countershaft gears, into the engaged mainshaft gear, and through the sliding clutch to the front section mainshaft
5. The rear of the front section mainshaft is splined into the auxiliary drive gear and torque is now delivered to the auxiliary
section.

General Information
Deep Reduction
Sliding Clutch Rearward

Sliding Clutch For ward Range Sliding Clutch Rearward

Figure 2-4. Front Section Power Flow

21
Power Flow

Front Section Power Flow - Direct Gear

In direct gear, the front sliding clutch is moved forward and engages into the back of the main drive gear. Torque will flow from
the input shaft to the main drive gear, main drive gear to sliding clutch, sliding clutch straight into the front section mainshaft
which delivers the torque to the auxiliary drive gear. See Figure 2- 5.
Note: All countershaft and mainshaft gears will rotate, but the gears will not be loaded.

Deep Reduction
Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Rearward

Figure 2-5. Front Section Power Flow - Direct Gear

22
 Power Flow

Front Section Power Flow - Reverse Gear

Torque will flow from the countershafts to the reverse idler gears. Torque will then flow from the reverse idler gears to the main-
shaft reverse gear. Torque will now travel through the mainshaft reverse gear, the sliding clutch in the reverse position and then
to the mainshaft and auxiliary drive gear. See Figure 2-6, 2-7, 2-8.

Deep Reduction
Sliding Clutch Rearward

General Information
Sliding Clutch Rearward Range Sliding Clutch Rearward

Figure 2-6. Reverse Gear-Deep Reduction

Deep Reduction Deep Reduction

Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Rearward Range Sliding Clutch Rearward Sliding Clutch Rearward Range Sliding Clutch Forward

Figure 2-7. Reverse Gear-Low Range Figure 2-8. Reverse Gear-High Range

23
Power Flow

Auxiliary Section Power Flow- Low Range

The auxiliary drive gear transfers torque to both auxiliary countershafts. If the auxiliary section is in low range, the range sliding
clutch is rearward and engaged into the auxiliary mainshaft reduction gear. Torque will flow from the auxiliary countershafts, into
the auxiliary mainshaft reduction gear, through the range sliding clutch and then into the output shaft (auxiliary mainshaft).
Deep Reduction
Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Rearward

Figure 2-9. Low Range Selected (Range Sliding Clutch Rearward)

24
 Power Flow

Auxiliary Section Power Flow- High Range

If the auxiliary section is in high range, the range sliding clutch is forward and engaged into the back of the auxiliary drive gear.
Torque will flow from the auxiliary drive gear to the range sliding clutch. Because the range sliding clutch has internal splines
which connect to the output shaft, torque will flow straight through the auxiliary section.
Note: The auxiliary gearing will still turn, but the gears will not be loaded.

Deep Reduction
Sliding Clutch Forward

General Information
Sliding Clutch Forward Range Sliding Clutch Forward

Figure 2-10. High Range Selected (Range Sliding Clutch Forward)

25
Power Flow

RTO-1X707LL/DLL/MLL

Deep Reduction Deep Reduction

Sliding Clutch Rearward Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Rearward Sliding Clutch Forward Range Sliding Clutch Rearward

Low Low Low

Deep Reduction Deep Reduction

Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Rearward Range Sliding Clutch Rearward Sliding Clutch Forward Range Sliding Clutch Rearward

1st Gear 2nd Gear

Deep Reduction Deep Reduction

Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Rearward Range Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Rearward

3rd Gear 4th Gear

26
 Power Flow

RTO-1X707LL/DLL/MLL Continued

Deep Reduction
Sliding Clutch Forward Deep Reduction
Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Forward

General Information
5th Gear 6th Gear

Deep Reduction
Sliding Clutch Forward

Sliding Clutch Rearward Range Sliding Clutch Forward

7th Gear

27
Power Flow

RTO/X-1XX08LL
Deep Reduction Deep Reduction
Sliding Clutch Rearward Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Rearward Sliding Clutch Forward Range Sliding Clutch Rearward

Low Low Low

Deep Reduction Deep Reduction

Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Rearward Range Sliding Clutch Rearward Sliding Clutch Forward Range Sliding Clutch Rearward

1st Gear 2nd Gear

Deep Reduction Deep Reduction

Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Rearward Range Sliding Clutch Rearward

Sliding Clutch Forward Range Sliding Clutch Rearward

3rd Gear 4th Gear

28
 Power Flow

RTO/X-1XX08LL Continued

Deep Reduction
Sliding Clutch Forward Deep Reduction
Sliding Clutch Forward

and Theory
Sliding Clutch Forward Range Sliding Clutch Forward
Sliding Clutch Rearward Range Sliding Clutch Forward

General Information
5th Gear 6th Gear

Deep Reduction Deep Reduction

Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Forward Sliding Clutch Rearward Range Sliding Clutch Forward

7th Gear 8th Gear

29
Power Flow

RTO-1XX09MLL

Deep Reduction Deep Reduction

Sliding Clutch Rearward Sliding Clutch Rear ward

Sliding Clutch Forward Range Sliding Clutch Rear ward Sliding Clutch Rear ward Range Sliding Clutch Rear ward

Low Low 1 Low Low 2

Deep Reduction Deep Reduction

Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Rearward Sliding Clutch Rearward Range Sliding Clutch Rearward

Low 1st Gear

Deep Reduction Deep Reduction

Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Rearward Sliding Clutch Forward Range Sliding Clutch Rearward

2nd Gear 3rd Gear

30
 Power Flow

RTO-1XX09MLL Continued

Deep Reduction Deep Reduction

Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Rearward Range Sliding Clutch Rearward

Sliding Clutch Rearward Range Sliding Clutch Forward

General Information
4th Gear 5th Gear

Deep Reduction Deep Reduction

Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Forward

6th Gear
7th Gear

Deep Reduction
Sliding Clutch Forward

Sliding Clutch Rearward Range Sliding Clutch Forward

8th Gear

31
Power Flow

RT/O/X-1XX15
Deep Reduction Deep Reduction
Sliding Clutch Rear ward Sliding Clutch Rearward

Sliding Clutch For ward Range Sliding Clutch Rear ward Sliding Clutch Rearward Range Sliding Clutch Rearward

Deep Reduction-1 Deep Reduction-2

Deep Reduction Deep Reduction
Sliding Clutch Forward Sliding Clutch Rearward

Sliding Clutch Forward Range Sliding Clutch Rearward Sliding Clutch Rearward Range Sliding Clutch Rearward

Deep Reduction-3 (RT) Deep Reduction-4, (RTO) Deep Reduction-5

Deep Reduction Deep Reduction
Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Rearward Sliding Clutch Forward Range Sliding Clutch Rearward

(RT) Deep Reduction-5, (RTO) Deep Reduction-4 1st Gear - Low Range
Deep Reduction Deep Reduction
Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Rearward Range Sliding Clutch Rearward Sliding Clutch Forward Range Sliding Clutch Rearward

2nd Gear - Low Range 3rd Gear - Low Range

32
 Power Flow

RT/O/X-1XX15 Continued
Deep Reduction Deep Reduction
Sliding Clutch Forward Sliding Clutch Forward

and Theory
Sliding Clutch Forward Range Sliding Clutch Rearward
Sliding Clutch Rearward Range Sliding Clutch Rearward

(RT) 4th Gear, (RTO) 5th Gear (RT) 5th Gear, (RTO) 4th Gear
Deep Reduction Deep Reduction
Sliding Clutch Forward Sliding Clutch Forward

General Information
Sliding Clutch Forward Range Sliding Clutch Forward Sliding Clutch Rearward Range Sliding Clutch Forward

6th Gear 7th Gear

Deep Reduction Deep Reduction
Sliding Clutch Forward Sliding Clutch Forward

Sliding Clutch Forward Range Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Forward

8th Gear (RT) 10th Gear, (RTO) 9th Gear

Deep Reduction
Sliding Clutch Forward

Sliding Clutch Rearward Range Sliding Clutch Forward

(RT) 9th Gear, (RTO) 10th Gear

33
Air System

Air System Overview

Pressurized air from the vehicle’s air system is used to shift the transmission low/high range and deep reduction ratios. The low/
high range and deep reduction gearing and shift mechanisms are located in the auxiliary section of the transmission. The vehicle
operator controls these shifts with two separate switches on the shift knob (master control valve). The following components are
part of the air shift systems.

Air System Components

34
 Air System

Shift Knob
The shift knob contains two switches. 1) The range selector lever on the front of the knob is moved down to select low range.
When the range selector lever is moved up, high range is selected. 2) A blue deep reduction button on the side of the shift knob
is moved forward to select the deep reduction ratios and moved rearward for remaining ratios. A mechanical interlock prevents
moving the deep reduction button forward when the range selector lever is up in high range.

General Information
Component Nomenclature and Auxiliary Countershaft Sectional View
1. Medallion 11. Screw
2. Spring 12. O-Ring
3. Retainer 13. Spring
4. Housing 14. 5/32” Ball
5. Spring 15. Spring
6. Washer 16. Ball
7. O-Ring 17. Seal
8. Range Selector 18. Detent
9. Pin 19. Splitter Button
10. Cover 20. Old Style Shift Knob

35
Air System

Air Filter/Regulator
The filter / regulator assembly filters the vehicle supply air and regulates the pressure to 58 - 63 PSI. Two holes in the front face
of the air filter / regulator assembly supply air to the range cylinder cover. The filter element can be removed by turning out the
end cap.

Component Nomenclature and Auxiliary Countershaft Sectional View

1. End Cap 4. Housing
2. O-Rings 5. Capscrews
3. Filter Element 6. Air Regulator

36
 Air System

Slave Valve
The slave valve controls the supply of air to the low and high range sides of the range shift cylinder. A small air line from the shift
knob (master control valve) provides a signal pressure to the slave valve.

6 5 Slave-Valve
4 3 2 1
18
19
7
8
13 14
12 15

General Information
16
11

10
9

Sleeve

Plunger Pin Slave Valve

Assembly
Spring

Gasket

Poppet-Type
Component Nomenclature and Auxiliary Countershaft Sectional View
1. Slave Valve Housing 11. Gasket
2. “U” Seal 12. Seal
3. Washer 13. O-Ring
4. Spring 14. Piston
5. Plug 15. “U” Seal
6. Snap Ring 16. Cap
7. O-Rings 17. O-Ring
8. Plate 18. Seal
9. Capscrew 19. Spring
10. Cap

37
Air System

Slave Valve Preselection System

This interlock mechanism prevents the slave valve from shifting when the transmission is engaged into gear. The air valve shaft
is moved towards the slave valve by the shift rails when the transmission is shifted into gear. A spring pushes the air valve shaft
back when the front section is shifted into a neutral position.

Component Nomenclature and Auxiliary Countershaft Sectional View

1. Actuation Spring 4. Shift Bar Housing
2. Actuating Pin 5. Slave Valve
3. Air Valve Shaft 6. Alignment Sleeve

38
 Air System

Range Cylinder
Within the range cylinder is a piston which is fastened to the range yoke bar. Air pressure on the front side of the piston shifts the
range sliding clutch into low range ratio. Air pressure on the rear side shifts the range sliding clutch into high range ratio.

Deep Reduction Cylinder

The deep reduction cylinder contains a piston and reduction yoke bar. Air pressure on the front side of the piston shifts the trans-
mission into the deep reduction ratio. Air pressure on the rear of the piston shifts the transmission out of deep reduction.

Range Piston Low Range Port

High Range Port

Range Yoke Bar

General Information
Deep Reduction
Signal Line

Insert Valve

Deep Reduction
Yoke Bar Filter/Regulator

Deep Reduction Piston

39
Air System

Insert valve
The insert valve is a small 3/16” diameter self-contained switching valve which is located adjacent to the deep reduction cylinder.
When deep reduction is selected at the shift knob (master control valve), an air pressure signal is applied to the insert valve
which then exhausts the air on the rear side of the deep reduction cylinder piston.

LO Range and HI Range

No air on
Signal Line

Constant
Air

To deep reduction
piston back
side, moves
yoke bar forward

Deep Reduction

Air on
Signal Line

Constant
Air

Constant
air sealed
off at this
point

Air exhausted
through bottom port
from piston back side
Deep reduction piston moves rear-
ward due to constant air on front side.

40
 Air System

Low Range
1. Vehicle supply air 110 - 130 PSI is supplied to inlet port on filter regulator where it is filtered and regulated to 58 - 63
PSI.
2. Thru a 1/4” I.D. rubber air line, a constant 58 - 63 PSI regulated air is supplied to the “S” (supply) port on the slave
valve.
3. Thru a 5/32” or 1/8” air line, a constant 58 - 63 PSI regulated air is also supplied to the “S” (supply) port on the shift
knob.
4. The driver selects low range by moving the range selection lever down. This allows the constant supply air at the shift
knob to exit at the “P” (pilot) port air line. This 1/8” or 5/32” “P” air line connects to the “P” (pilot) 1/8” or 5/32” “P” air
line connects to the “P” (pilot) port on the slave valve. The air pressure on the “P” line causes a valve within the slave
valve to move to the low range position.
5. The constant supply air at the slave valve is now supplied thru a 1/4” hose to the low range port on the range cylinder.
This air pressure moves the range piston, range bar, range yoke, and range sliding clutch rearward to shift the trans-

General Information
mission into low range.
Note: The slave valve preselection system interlock will prevent the slave valve from changing from low to high or vise versa if
the transmission is engaged in a front section gear. This system allows the driver to “preselect” by moving the range selec-
tion lever while still in gear, the range change will then occur as the driver moves the shift lever through neutral.

Roadranger Valve

Rearward
Down
ul le r
FTransmissions ®

H/L P S SP

19470 or A-5000 Slave Valve

HI

S P

H/L LO

41
Air System

Cylinder Assembly
HI
No Air
LO
Air to Cover
Port

SP Air from
Range Vehicle
Source

Deep Reduction
Air Filter/Regulator
Insert Valve Assembly

High Range
1. Vehicle supply air 110 - 130 PSI is supplied to inlet port on the filter regulator where it is filtered and regulated to 58 -
63 PSI.
2. Thru a 1/4” I.D. rubber air line, a constant 58 - 63 PSI regulated air is supplied to the “S” (supply) port on the slave
valve.
3. Thru a 5/32” or 1/8” air line, a constant 58 - 63 PSI regulated air is also supplied to the “S” (supply) port on the shift
knob.
4. The driver selects high range by moving the range selection lever up. This shuts off the supply air to the “P” line. The air
in the “P” line will then exhaust at the shift knob port “E”. With the air pressure off of the “P” port at the slave valve, a
the valve will shift and air will be supplied to the high range “H” port.
5. The constant supply air at the slave valve is now supplied thru a 1/4” hose to the high range port on the range cylinder.
This air pressure moves the range piston, range bar, range yoke, and range sliding clutch forward to shift the transmis-
sion into high range.
6. Note: The slave valve preselection system interlock will prevent the slave valve from changing from low to high or vise
versa if the transmission is engaged in a front section gear. This system allows the driver to “preselect” by moving the
range selection lever while still in gear, the range change will then occur as the driver moves the shift lever through neu-
tral.

42
 Air System

Roadranger Valve

Rearward
Up
ul le r
FTransmissions
®

H/L P S SP

General Information
19470 or A-5000 Slave Valve

HI

S P

H/L LO

Cylinder Assembly
HI
No Air
LO
Air to Cover
Port

SP Air from
Range Vehicle
Source

Deep Reduction
Air Filter/Regulator
Insert Valve Assembly

43
Air System

Deep Reduction

Roadranger Valve

Forward
Down
Ful le r
®

Transmissions

H/L P S SP

1. A tee fitting on the low range port of the slave valve will supply air through a 5/32” or 1/8” air line to the “H/L” port on
the shift knob. Because this line is connected to the low range port, air is only available when low range has been
selected.

19470 or A-5000 Slave Valve

HI

S P

H/L LO

2. When the deep reduction button is moved forward, air from the “H/L” port will pass through the shift knob to the “SP”
port. A 1/8” or 5/32” air line connected to the shift knob transfers this air to the insert valve at the deep reduction cylin-
der cover.
3. When air is applied to the Insert Valve, the valve will shut off the constant air to the rear of the deep reduction piston.
The air on the rear of the deep reduction piston will exhaust through the insert valve and out a hole in the cylinder cover.
Constant air on the front of the deep reduction piston will move the deep reduction piston, bar, yoke and sliding clutch
rearward to engage the deep reduction gear.

44
 Air System

4. To shift out of deep reduction, the button on the shift knob is moved rearward. The air on the “SP” is shut off and
exhausted at the shift knob. This results in the insert valve supplying air to the rear side of the deep reduction piston.
Supply air is present on both sides of the deep reduction piston, however, due to the greater piston surface area on the
rear side, the piston moves forward. This forward movement shifts the deep reduction yoke bar, yoke, and sliding clutch
out of the deep reduction ratio.

Cylinder Assembly
Air to Housing Port HI
LO No Air

SP Air from

General Information
Range Vehicle
Source

Deep Reduction
Air Filter/Regulator
Insert Valve Assembly

45
General Troubleshooting

General Troubleshooting Chart

The chart on the following pages contains some of the most common problems that may occur with this transmission along with
the most common causes and solutions.

Complaint Cause Corrective Action

Noise - Growl / Rumble Torsional Vibration. Check driveline angles for proper u-joint
working angles.
[Noise may be most pronounced when Check driveline for out of balance or
transmission is in a “float” (low torque) damage.
condition. May also be confined to a par- Check u-joints for proper phasing.
ticular vehicle speed.] Check clutch assembly for broken
damper springs.
Check for inadequate clutch disc damp-
ing.
Transmission bearing or gear failure. Check transmission oil for excessive
[Noise may be most pronounced under metal particles.
hard pull or coast (high torque).]
Noise - Growl / Rumble at Idle (Idle Gear Excess engine torsional vibration at idle. Check for low engine RPM.
Rattle) Check for uneven engine cylinder perfor-
mance.
Check for proper clutch damper opera-
tion.
Noise - High Pitched Whine Gear Noise. Check for worn or defective shift lever
Isolate as to axle or transmission noise. isolator.
If transmission, isolate to specific gear Check for direct cab or bracket contact
or gears. with transmission (“grounding”).
Check for proper driveline u-joint work-
ing angles.
Check for damaged or worn gearing.

46
 General Troubleshooting

General Troubleshooting Chart (cont)

Complaint Cause What to do next

Hard Lever Shifting Master clutch dragging. Check master clutch for proper disen-
(Shift lever is hard to gear into or out of gagement.
gear) Check master clutch for proper adjust-
ment (both release bearing travel and
clutch brake height).
Shift linkage problem. (Remote shifter) Check shift linkage or cables for proper
adjustment, binding, lubrication, or
wear.
Shift bar housing problem. Check shift bar housing components for
binding, wear, or damage.

General Information
Transmission mainshaft problem. Check mainshaft for twist.
Check sliding clutches for binding, dam-
age, or excessive wear.
Driver technique. Driver not familiar or skilled with proper
double-clutching technique.
Driver contacting the clutch brake during
shifts.
Shift Lever Jumpout Loose or worn engine mounts. Check engine mounts for damage, wear,
(Shift lever comes out of gear on rough or excessive looseness.
roads)
Shift lever problem. Check shift lever floor boot for binding
or stretching.
Check shift lever isolator for excessive
looseness or wear.
Check for excessive offset or overhang
on the shift lever.
Check for extra equipment or extra
weight added to shift lever or knob.
Worn or broke detent spring or mecha- Check for broken detent spring.
nism. Check for excessive wear on the detent
key of detent plunger.
Replace detent spring with heavier
spring or add additional spring.

47
General Troubleshooting

General Troubleshooting Chart (cont)

Complaint Cause Corrective Action

Shift Lever Slipout Internal transmission problem. Check for excessively worn or damaged
(Transmission comes out of gear under sliding clutches or shift yokes.
torque)
Transmission goes to neutral Low air pressure. Check air regulator pressure.
(Shift lever doesn’t move)
Internal transmission problem. Check for excessively worn or damaged
range sliding clutch or yoke.
No range shift or slow range shift Transmission air system problem. Preform air system troubleshooting pro-
(Also see Air System Troubleshooting) cedure.
Check for proper air signal from master
valve.
Check air module test ports for proper
air delivery.
Range cylinder problem. Check for failed or damaged range pis-
ton, piston bar, or cylinder.
Check for failed or loose range piston
snap ring.
Range yoke assembly problem. Check for failed or damaged range yoke.
Check for failed or loose range yoke
snap rings.
Check for excessively long fastener
installed in rear support hole.
Check for binding between range yoke
bar and range alignment lock cover.
Range synchronizer problem. Check for failed or damaged range syn-
chronizer, sliding clutch, or mating gear.
Check for excessively worn range syn-
chronizer friction material.
Grinding Noise on Range Shift Driver not preselecting range shift. Instruct driver to preselect range shifts.
Range synchronizer worn or defective. Check range synchronizer and mating
parts for excessive wear or damage.

48
 Air System

Air System Troubleshooting

The symptoms listed below are covered on the following pages. Before beginning any of those troubleshooting procedures, place
the transmission in neutral and move the range selection lever from low to high. Listen for any constant air leak from the shift
knob, air module base (exhaust), or transmission breather. If a constant leak is heard, go to that particular leak troubleshooting
procedure first.

If you do not see the symptom you need to correct, refer to the General Troubleshooting chart.
Symptom
• Air Leak from Air Module Base (Exhaust Leak)
• No or Slow Range Shift into High (Shift into low range is good)
• No or Slow Range Shift into Low (Shift into high range is good)
• Constant Air Leak from Shift Knob

General Information
• Range Shifts in Gear
• Air Leak from Transmission Breather or Transmission Case is Pressurized
Note: Use the air system troubleshooting procedures for part replacement only if the symptom can be duplicated. If the problem
is intermittent, parts that are not defective could be replaced.
Note: During all testing, the vehicle air pressure must be greater than 90 PSI (620 kPa). If during testing the pressure falls below
90 PSI (620 kPa), make sure the transmission is in neutral, start the engine and let the pressure build to governor cutoff.
After the pressure reaches the governor cutoff, continue testing. The pressure is critical if the vehicle is equipped with a
vehicle air system Pressure Protection Valve that would shut off the air supply to certain air circuits if the system pressure
dropped below a preset level.
Note: A 0-150 PSI (0-1034 kPa) air gauge with a 1/16” male pipe thread fitting attachment is required for some of the test proce-
dures.

WARNING

Prior to removing the air module, exhaust the air from it. Failure to exhaust the air module may result in personal injury or dam-
age to parts from the sudden release of air.

WARNING

Use care when removing the test port pipe plugs. If air pressure is present on the plug, it can become a projectile during removal.
When removing the “L” plug or “H” plug, pressure can be shut off by selecting the opposite range mode. If removing the “F”
plug, exhaust the air to the module inlet.

49
Air System

Procedure 1: Symptom - Air leak at shift knob

Normal operation:
A burst of air will be exhausted from the shift knob when moving the range selector from low to high. This is the air being
exhausted from the "P" air line.

A burst of air will be exhausted from the shift knob when moving the deep reduction button rearward (shifting out of deep reduc-
tion).This is the air being exhausted from the “SP” air line.
Possible causes:
• Incorrectly attached air lines
• Internal leak in slave valve
• Internal leak at insert valve
• Internal leak at shift knob

Procedure Result What to do next

Step A Remove lower skirt on shift knob. Check Leak found. Repair leaking fitting or air
for leaking fitting at the shift knob. line.
No leak found. Go to step B.
Step B Check air lines to make sure all lines are Air lines are not connected to the Connect lines properly.
connected to the proper ports on the proper ports.
shift knob. Reversal of “S” and “P” lines
will result in a constant leak from the
exhaust when high range is selected.
Reversal of the H/L and “SP” lines will
result in a constant leak when the deep
reduction button is rearward.
Air lines are connected to proper ports. Go to step C.
Step C Move the range selector lever down to Constant air flow from “E” port. Replace knob.
Low range. Check for constant air flow
from the exhaust “E” port.
No air flow from “E” port. Go to Step D.
Step D Move the range selector up to high Constant air is leaking from the “P” Repair or replace the shift
range. Disconnect the small air line con- port or the “E” port. knob.
nected to the “P” port of the shift knob.
Check for air flow from the port and air
line.
Air is coming out of the disconnected 1. Verify that the air line is
air line. connected to the slave valve
“p” port.
2. If properly connected,
replace\ the slave valve.
Air is not leaking from either port or Go to Step D.
disconnected air line.

50
 Air System

Procedure Result What to do next

Step E Reattach the air line to the “P” port. Air is flowing from the SP line. 1. Check to make sure the
Move the range selector down to low “SP” line is connected to the
range and move the deep reduction but- deep reduction cylinder
ton rearward. Disconnect the air line cover.
from the “SP” port. Check for air flowing
from the SP line.
2. If the line is properly
attached, check that the
insert valve is properly
installed (stem facing
inward) and that the insert
valve bore is not defective.

General Information
3. Replace the insert valve.
Air is not flowing from the line. Repair or replace the shift-
knob.

51
Air System

Procedure 2: Symptom - Air leak at slave valve

Normal operation:
A momentary exhaust of air at the slave valve occurs during a range shift. The air from the low side of the range cylinder is
exhausted as air pressure is applied to the high range side. Likewise, air from the high range side of the piston is exhausted as air
pressure is applied to the low range side. The exhaust port is located at the slave valve to transmission mounting interface.
Possible Causes:
• Internal leak in range cylinder
• Internal leak in slave valve.

Procedure Result What to do next

Step A Confirm that air is leaking from the Air is leaking from fitting or air line. Repair or replace fitting or air line.
exhaust port on the slave valve and
not a fitting or air line.
Air is definitely leaking from slave Go to Step B.
valve exhaust port.
Step B Move range selector down to select Air is flowing from high range sup- Remove range cylinder cover and
low range. Remove the 1/4” I.D. ply port on range cylinder. repair leaking range piston or piston
rubber air line at the high range seal. After repair, check for proper
supply port on the range cylinder. range operation.
Feel for air flow from the open port
on the range cylinder. Note: If the
air leak at the slave valve only
occurs when the transmission is in
high range, repeat the above test,
but remove the low range air hose
and check with high range selected.
No air flow from high range port. Repair or replace slave valve.

52
 Air System

Procedure 3: Symptom - Air Leak from Transmission Breather or Transmission Case is

Pressurized
Normal Operation:
There should be no measurable air flow from the transmission breather.
Possible causes:
• Leak at range yoke bar O-ring
• Leak at deep reduction yoke bar O-ring

Procedure Result What to do next

Step A Listen for the air leak with the trans- Leak is only in low range. Remove range cylinder and inspect
mission shifted to both low and high for damaged range yoke bar, yoke bar

General Information
range. O-ring, or range cylinder. Repair as
necessary.
Leak is in both low and high range. Remove deep reduction cylinder.
Inspect for damaged deep reduction
yoke bar, O-ring, or cylinder. Repair
as necessary.

53
Air System

Procedure 4: Symptom: Air leak at deep reduction cylinder cover exhaust port
Normal operation:
A burst of air will exhaust from this port when shifting into deep reduction (the deep reduction button is moved forward while in
low range).
Possible causes:
• Damaged/defective insert valve
• Leak past insert valve external O-rings
• Leak past deep reduction cylinder piston

Procedure Result What to do next

Step A Remove insert valve. Check for con- Contamination or damage found. Repair or replace as necessary.
tamination, damaged seals, or sticky
movement. Check the insert valve
bore in the deep reduction cylinder
cover for contamination or damage
which would result in leakage past
the insert valve O-rings.
No contamination or damage found. Go to step B.
Step B Remove the deep reduction cylinder Contamination or damage found. Repair or replace as necessary.
cover and piston. Check the piston
bore for contamination or damage.
Check the piston seals for damage.
NOTE: Early production transmis-
sions used a paper gasket to seal
the piston to the yoke bar, if neces-
sary, replace this configuration with
the current design which uses an O-
ring.

54
 Air System

Procedure 5: Symptom - No or Slow Range Shift into Low

Normal Operation:
When the range selector on the shift knob is moved down to select low range, air pressure will flow through the shift knob to the
‘P port on the slave valve. The slave valve will direct air pressure through the low range 1/4” rubber hose to the range cylinder to
shift the range. There will be a brief burst of air at the slave valve as the high range side of the range piston exhausts. Likewise,
when high range is selected, the air pressure in the “P” will be exhausted at the shift knob. This will cause the slave valve to direct
air to the rear side of the range cylinder piston. The air pressure on the low range side will be exhausted at the slave valve.
Possible Causes:
• Incorrect air line hook up
• Insufficient air supply to transmission
• Damaged or defective air filter / regulator assembly
• Damaged or defective shift knob master valve

General Information
• Damaged or defective slave valve
• Damaged or defective range cylinder
• Damaged or defective range yoke or yoke bar
• Damaged or defective range synchronizer
• Damaged or defective gearing in auxiliary section of transmission

Procedure Result What to do next

Step A Place the shift lever in neutral. Check Constant air leak is detected. Go to the other corresponding symp-
for constant air leakage at the shift tom first. See beginning of Air System
knob, slave valve, and transmission Troubleshooting section.
case breather when both low and
high range have been selected.
No constant leak is detected. Go to step B.
Step B Place shift lever in neutral. Move Air flows from the low range port. Remove range cylinder cover and
range selector up to high range posi- repair leaking range piston or piston
tion. At the rear of the transmission, seal.
disconnect the 1/4” rubber air line
from the low range supply port on
the range cylinder. Check for air flow
from the low range port.
No air flow from low range port. Go to step C.
Step C Check for air flow from the discon- Air flows from disconnected air line. Go to step F.
nected air line.
No air flow from disconnected line. Go to step D.
Step D Install a 100 PSI air gauge in the dis- The gauge read 0 PSI. Go to step F.
connected air line end. With the shift
lever in neutral, move the range
selector down to select low range
and observe the gauge.

55
Air System

Procedure Result What to do next

The gauge reads pressure but is Replace the filter/regulator and check
lower than 58 PSI or higher than 63 for proper range operation.
PSI.
The gauge reads between 58 - 63 Go to step E.
PSI.
Step E Confirm that shift lever is still in neu- Pressure rapidly changes between Air system appears to be operating
tral. Have an assistant move the 58-63 PSI and 0 at the gauge. satisfactory. Go to step R.
range selector up and down
between low and high range. Does
the pressure measured at the gauge
respond rapidly when going from
high to low.
Pressure does not change rapidly at 1. Check for a plugged or dirty filter in
gauge. the filter/regulator assembly.
2. Check for a pinched or obstructed
1/4” rubber air line between the filter/
regulator and slave valve.
3. Check for a pinched or obstructed
1/4” rubber air line between the slave
valve and the test gauge.
4. If all are satisfactory, Go to step F.
Step F Place shift lever in neutral. At the Air flows from the disconnected line. 1. Confirm that the air lines are con-
shift knob, move the range selection nected to the correct ports at the shift
lever up to select high range. At the knob.
slave valve, remove the air line from
the “P” port (should be black line).
Check for air flow from the discon-
nected line.
2. If the lines are correct, replace the
shift knob.
No air flow from the disconnected Go to step G.
line.
Step G Check for air flow from the “P” por- Air flows from this port. Replace the slave valve.
tion the slave valve.
No air flow from this port. Continue to step H.
Step H Place the shift lever in neutral. Install The gauge responds slowly. 1. Check for a restricted line between
a 100 PSI pressure gauge in line the shift knob and slave valve.
with the “P” line. Move the range
selector back and forth from low to
high range. The gauge should show
rapid pressure change.
2. Check for a restricted exhaust port
on the shift knob.

56
 Air System

Procedure Result What to do next

3. Check for a plugged or dirty filter in
the filter / regulator assembly.
4. Check for a pinched or obstructed
1/4” rubber air line between the filter/
regulator and slave valve.
5. Check for a pinched or obstructed
air line between the slave valve and
the “S” port on the shift knob.
6. If all are good, replace the shift
knob.
The gauge rapidly moves between Go to step I.

General Information
58-63 PSI and 0 PSI.
Step I If possible, leave air lines attached to Actuating plunger pin does not 1. Remove actuating plunger pin and
slave valve. Unbolt the slave valve move freely. check for damage.
from transmission side. Check for
free movement of the plunger pin
protruding from the case under the
slave valve. The pin should extract
when the transmission is shifted into
gear and retract when shifted into
neutral.
2. Check for missing or broken
spring.
Actuating plunger pin moves freely. Repair or replace slave valve and
check for proper range operation.
Step R If air system has been tested and
found to operate satisfactory, the
auxiliary section must be removed to
inspect for mechanical problem.
Remove auxiliary section and
inspect for:
Binding of range yoke bar or piston
Damaged or defective range yoke
Damaged or defective range syn-
chronizer
Cracked c/s weld resulting in gear
turning on shaft
Damaged or defective range sliding
clutch
Auxiliary section gearing out of time.

57
Air System

Procedure 6: Symptom - No or Slow Range Shift into High

Normal Operation:
When the range selector on the shift knob is moved down to select low range, air pressure will flow through the shift knob to the
‘P” port on the slave valve. The slave valve will direct air pressure through the low range 1/4” rubber supply hose to the range
cylinder to shift the range. There will be a brief burst of air at the slave valve as the high range side of the range piston exhausts.
Likewise, when high range is selected, the air pressure in the “P” will be exhausted at the shift knob. This will cause the slave
valve to direct air to the rear side of the range cylinder piston. The air pressure on the low range side will be exhausted at the
slave valve.
Possible Causes:
• Incorrect air line hook up
• Insufficient air supply to transmission
• Plugged filter
• Incorrect regulator pressure
• Damaged or defective shift knob master valve
• Damaged or defective slave valve
• Damaged or defective range cylinder
• Damaged or defective range yoke or yoke bar
• Damaged or defective range synchronizer
• Damaged or defective gearing in auxiliary section of transmission

Procedure Result What to do next

Step A Place the shift lever in neutral. Check Constant air leak is detected. Go to the above corresponding
for constant air leakage at the shift symptom first. See beginning of Air
knob, slave valve, and transmission System Troubleshooting section.
case breather when both low and
high range have been selected.
No constant leak is detected. Go to step B.
Step B Place shift lever in neutral. Move Air flows from the high range port. Remove range cylinder cover and
range selector down to low range repair leaking range piston or piston
position. At the transmission rear, seal. After repair, check for proper
disconnect the 1/4” rubber air line range operation.
from the range cylinder high range
supply port. Check for air flow from
the cylinder high range port.
No air flow from high range port. Go to step C.
Step C Check for air flow from the discon- Air flows from disconnected air line. Go to step F.
nected air line.

No air flow from disconnected line Go to step D.

58
 Air System

Procedure Result What to do next

Step D Install a 100 PSI air gauge in the dis- The gauge reads 0 PSI. Go to step F.
connected air line end. With the shift
lever in neutral, move the range
selector up to select high range.
Observe the gauge.
The gauge reads pressure but is Replace the filter/regulator and check
lower than 58 PSI or higher than 63 for proper range operation.
PSI.
The gauge reads between 58-63 PSI. Go to Step E.
Step E Confirm that a shift lever is still in Pressure rapidly changes between Air system appears to be operating
neutral. Have an assistant move the 58-63 PSI and O at the gauge. satisfactory. Go to Step R.

General Information
range selector up and down between
low and high range. Does the pres-
sure measured at the gauge respond
rapidly when going from low to high
to low.
Pressure does not respond rapidly 1. Check for a plugged or dirty filter
at gauge. in the filter/regulator assembly.
2. Check for a pinched or obstructed
1/4" rubber air line between the filter/
regulator and slave valve.
3. Check for a pinched or obstructed
1/4" rubber air line between the slave
valve and the test gauge.
4. If all are satisfactory, Go to Step F.
Step F Place shift lever in neutral. At the shift Air flows from the disconnected line. 1. Confirm proper air line hook-up at
knob, move the range selector up to the shift knob.
select high range. At the slave valve,
remove the air line from the "P" port
(should be black line). Check for air
flow from the disconnected line.
2. If correct hook-up, replace the
shift knob.
No air flow from the disconnected Go to Step G.
line.
Step G Check for air coming out of the slave Air flows from this port. Replace the slave valve.
valve "P" port.
No air flow from this port. Continue to Step H.
Step H Place the shift lever in neutral. Install The gauge responds slowly. 1. Check for a restricted line between
a 100 PSI pressure gauge in line with the shift knob and slave valve.
the "P" line end. Move the range
selection lever back and forth from
low to high range. The gauge should
show rapid pressure change.

59
Air System

Procedure Result What to do next

2. Check for a restricted exhaust port
on the shift knob.
3. Check for a plugged or dirty filter
in the filter/regulator assembly.
4. Check for a pinched or obstructed
1/4" rubber air line between the filter/
regulator and slave valve.
5. Check for a pinched or obstructed
air line between the slave valve and
the "S" port on the shift knob.
6. If all are good, replace the shift
knob.
The gauge rapidly moves between Go to Step I.
58-63 PSI and 0 PSI.
Step I If possible, leave air lines attached to Actuating plunger pin does not 1. Remove actuating plunger pin and
slave valve. Unbolt the slave valve move freely. check for damage.
from the transmission side. Check for
free movement of the plunger pin
protruding from the case under the
slave valve. The pin should extract
when the transmission is shifted into
gear and retract when shifted into
neutral. NOTE: If desired, the slave
valve can be actuated and tested
while unbolted from the transmission
case. The air lines, of course, must
remain attached.
2. Check for missing or broken
spring.
Actuating plunger pin moves freely. Repair or replace slave valve and
check for proper range operation.
Step R If air system has been tested and
found to operate satisfactory, the
auxiliary section must be removed to
inspect for a mechanical problem.
Remove the auxiliary section and
inspect for:
Binding of range yoke bar or piston
Damaged or defective range yoke
Damaged or defective range synchro-
nizer
Cracked c/s weld resulting in gear
turning on shaft
Damaged or defective range sliding
clutch
Auxiliary section gearing out of time.

60
 Air System

Procedure 7: Symptom - No or slow shift into Deep Reduction

Normal Operation:
When the deep reduction button is moved forward to select deep reduction, air pressure is supplied through the “SP” air line to
the insert valve signal port. This air pressure causes the insert valve to exhaust the air pressure on the rear of the deep reduction
piston and the piston moves rearward. A burst of air occurs at the deep reduction cylinder exhaust port as this air is exhausted
from the piston back side. A burst of air also occurs at the shift knob when the deep reduction button is moved rearward. This is
the signal air being exhausted out of the “SP” line.
Possible causes:
• Incorrect air line hook up, Plugged filter.
• Incorrect regulator pressure. Insufficient air supply to transmission.
• Damaged or defective shift knob master valve.
• Damaged or defective deep reduction insert valve.

General Information
• Damaged or defective deep reduction piston or cylinder.
• Damaged or defective deep reduction yoke bar or yoke.
• Damaged or defective deep reduction sliding clutch or gearing.
Note: Before completing the following troubleshooting procedure, move the deep reduction button both rearward and forward an
check for constant exhaust air at either the shift knob or deep reduction cylinder exhaust port. If a constant leak is noticed,
go to that troubleshooting procedure first. In addition, confirm that the low and high range shifts are occurring properly. If
not, go to the appropriate range shift troubleshooting procedure before completing the following procedure.

Procedure Result What to do next

Step A Move range selector down to select Air flows from the disconnected line. Go to Step K.
low range. Move the deep reduction
button rearward. At the deep reduc-
tion cylinder on the transmission
back, remove the small air line which
provides the signal to the insert valve
(SP line). Make sure this line was
connected to the proper port location
on the cylinder cover. Check for air
flow from the line.
No air flow from disconnected line. Go to Step B.
Step B Connect a 100 PSI pressure gauge to Gauge reads 0 PSI. Go to Step F.
the disconnected signal port line.
Move the deep reduction button for-
ward. Read the pressure on the
gauge.
Gauge reads pressure, but is lower Replace filter / regulator assembly.
than 58 PSI or higher than 63 PSI.
Gauge reads between 58 PSI and 63 Go to Step C.
PSI.

61
Air System

Procedure Result What to do next

Step C Have an assistant move the deep Pressure rapidly changes between 58- Go to Step D.
reduction button forward and rear- 63 PSI and 0 PSI at the gauge.
ward. Observe the pressure gauge.

Pressure does not respond rapidly at Go to Step F.

gauge.

Step D Remove the insert valve. NOTE: After Insert valve is contaminated, sticking, Replace insert valve, reconnect air
the insert valve plug has been or damaged. line, and check if deep reduction
removed, cover the opening with a shifts normally.
shop rag and apply shop air to the
signal line port to blow the insert
valve out of it’s bore. Catch the valve
with the shop rag. If the vehicle air
pressure is still present, constant air
flow should be blowing out of the
insert valve bore. Inspect the insert
valve for contamination or damage.
Make sure the small piston inside the
valve can freely move 1/32”.
Insert valve is clean and small internal Go to step E.
piston moves freely.
Step E Remove the deep reduction cylinder Deep reduction cylinder bore or piston Repair as necessary, replace insert
cover and deep reduction piston. is contaminated or damaged. valve and air line. Check if deep
Inspect piston and bore for contami- reduction shifts normally
nation or damage.
Deep reduction cylinder bore or piston 1. Remove deep reduction cylinder
is in good condition. assembly. Inspect for contamina-
tion or damage causing deep
reduction yoke bar to bind in cylin-
der. Repair as necessary.
2. Remove auxiliary section and
inspect deep reduction yoke, slid-
ing clutch, and gearing for damage
which would prevent deep reduc-
tion shift. Repair as necessary.

62
 Air System

Procedure Result What to do next

Step F At the shift knob, remove the two Air flows from “SP” port. Replace shift knob.
screws attaching the lower cover, and
slide the lower cover down to access
the fittings. Confirm that the air lines
are connected to the proper ports.
Make sure the shift lever is in neutral.
Move the range selector down to
select low range, and move the deep
reduction button rearward. Discon-
nect the air line connected to the “SP”
port. Check for air flow from the “SP”
port.

General Information
No air flow from “SP” port. Go to Step G.
Step G Move deep reduction button forward. Air flows from “SP” port. 1. Check for proper air line connec-
Check for air flow from “SP” port. tion from “SP” port on shift knob
to “SP port on deep reduction cyl-
inder.
2. Check for obstruction in “SP” air
line or fittings.
3. If clear, reconnect the air line at
the shift knob, go to step A.
No air flow from “SP” port. Go to step H.
Step H Disconnect air line H/L port on shift Air flows from disconnected line. Replace shift knob.
knob. Check for air flow from the dis-
connected line.
No air flow from disconnected 1. Check to make sure that the shift
line. lever is in neutral, the range selec-
tor is down in low range and the
“H/L” line is properly connected to
the low range hose at the slave
valve.
2. If no air pressure is available on
low range hose, perform low range
shift troubleshooting procedure to
correct this problem.

63
Air System

Procedure 8: Symptom - Range shifts with shift lever in gear.

Normal Operation:
Range shift should only occur when the shift lever is in neutral. The range selector can be moved up or down while the shift lever
is in a gear position, but the shift will not occur until the shift lever is moved to neutral.
Possible Causes:
• Worn or missing actuating pin or air valve shaft.
• Worn shift rail
Procedure:
If the range has been confirmed to shift with the shift lever in gear, unbolt the slave valve from the side of the transmission. Con-
firm that the actuating pin is present and that it is the proper P/N for the corresponding slave valve. If correct, remove the shift
bar housing assembly and check for a worn or damaged air valve shaft or worn shift rails. Replace necessary parts.

64
 Timing

Timing Procedures

General Information
Special Instructions
It is essential that both Countershaft Assemblies of the Front and Auxiliary Sections are “timed.” This assures proper tooth
contact is made between Mainshaft Gears seeking to center on the Mainshaft during torque transfer and mating Countershaft
Gears that distribute the load evenly. If not properly timed, serious damage to the Transmission is likely to result from unequal
tooth contact causing the Mainshaft Gears to climb out of equilibrium.

Timing is a simple procedure of marking the appropriate teeth of a gear set prior to installation and placing them in proper mesh
while in the Transmission. In the Front Section, it is necessary to time only 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.

Procedure - Front Section

1. Marking Countershaft Drive Gear teeth: Prior to placing
each Countershaft Assembly into the Case, clearly mark the
tooth located directly over the Drive Gear Keyway as shown.
This tooth is stamped with an “O” to aid identification.

2. Marking Main Drive Gear teeth: Mark any two adjacent

Figure 2
teeth on the Main Drive Gear.
Mark the two adjacent teeth located directly opposite the
first set marked on the Main Drive Gear. As shown to the
left, there should be an equal number of unmarked gear
teeth on each side between the marked sets.

3. Meshing marked Countershaft Drive Gear teeth with

marked Main Drive Gear teeth: After placing the Mainshaft
Assembly into the Case, the Countershaft Bearings are Figure 3
installed to complete installation of the Countershaft
Assemblies.
When installing the bearings on the left Countershaft, mesh
the Countershaft Drive Gear marked tooth with either set of
Main Drive Gear two marked teeth.
Repeat the procedure when installing the Bearings on the
Right Countershaft, make use of the remaining set of Main
Drive Gear two marked teeth to time assembly.

65
Timing

Procedure - Time the RT Auxiliary Section

1. Mark a tooth on the Reduction Gear with a highly visible
paint, preferably a yellow or white.

2. Mark a second tooth 180 degrees away from the first.

(Ensure the marks are in the correct position by counting
the teeth between them. You should have exactly the same
number of teeth on the Reduction Gear between the
marked teeth).

FR and RT Stamp Position 3. Locate the two stamped “O’s” on the Countershaft
Reduction Gears and mark both teeth with a highly visible
paint, preferably a yellow or white.

66
 Timing

4. Use a Round File or Bar to properly align from the

marked teeth on the Auxiliary Countershaft to the

General Information
Auxiliary Splitter Gear. When the Bar is lined up with the
root, between the correct teeth, you will notice it’s parallel
with the Auxiliary Countershaft. Mark both the teeth with
a highly visible paint.

Example of correct alignment

Bar in correct position parallel with the Countershaft, and
between the marked Splitter gear and Reduction Gear teeth.

Left
Examples of Left or Right Misalignment

Right

67
Timing

5. Lay the Splitter Gear on a flat surface and mark it similar to

steps 1 and 2 of this procedure. (Make sure the teeth are
painted on both faces of the Splitter Gear front and rear).
Example showing correct view of Reduction Gear timed
to Countershaft Gears on the bench:

6. Install the Reduction Gear and Output Shaft Assembly into

the Auxiliary Case. Then, install the Auxiliary Countershafts
and Splitter Gear. (Countershaft Retaining Straps must be
used to hold the Auxiliary Countershafts in place until the
Auxiliary Section is fully installed. Failure to use the
straps could result in the Auxiliary Section moving out
of time).

Examples of Splitter Gear timed to the Auxiliary

Countershafts:

7. To ensure the timing is correct, check that the marked tooth

on the Splitter Gear is between the two marked teeth on the
Auxiliary Countershaft Gears as shown in the illustrations:

68
 In-Vehicle Service Procedure

How to Disassemble Roadranger Valve A-4900

Special Instructions

None

Special Tools
• Typical service tools

Component Nomenclature and Auxiliary Countershaft Sectional View In-Vehicle Service Procedure
1. Medallion 11. Screw
2. Spring 12. O-Ring
3. Retainer 13. Spring
4. Housing 14. 5/32” Ball
5. Spring 15. Spring
6. Washer 16. Ball
7. O-Ring 17. Seal
8. Range Selector 18. Detent
9. Pin 19. Splitter Button
10. Cover 20. Old Style Shift Knob

69
In-Vehicle Service Procedure

Procedure -

1. Remove the two screws holding the bottom cover to the

valve and slide the cover down the gearshift lever to expose
the air line fittings. Disconnect the air lines.

2. Loosen the jam nut and turn the control valve from the gear
shift lever.

3. Pry the medallion from the recess in the top cover.

4. Turn out the two screws to remove the top cover from the
valve housing.

5. Turn out the two screws in the side of the valve housing to
separate the housing.

6. Remove the range selection lever from the left housing along
with the position balls and guide.

7. If necessary, remove the spring and O-ring from the bores

in the left housing.

8. If necessary, remove the springs, O-ring and sleeve from the

bores in the right housing.

70
 In-Vehicle Service Procedure

How to Assemble Roadranger Valve A-4900

Special Instructions

None

Special Tools
• Typical service tools

Component Nomenclature and Auxiliary Countershaft Sectional View In-Vehicle Service Procedure
1. Medallion 11. Screw
2. Spring 12. O-Ring
3. Retainer 13. Spring
4. Housing 14. 5/32” Ball
5. Spring 15. Spring
6. Washer 16. Ball
7. O-Ring 17. Seal
8. Range Selector 18. Detent
9. Pin 19. Splitter Button
10. Cover 20. Old Style Shift Knob

71
In-Vehicle Service Procedure

Procedure -

1. Refer to the drawing for proper reassembly. Use a very small

amount of silicone lubricant on the O-rings to avoid clogging
the ports. A small amount of grease on the position springs
and balls will help to hold them in place during reassembly

2. Install the control valve on the gear shift lever and tighten the
jam nut.

3. Attach the air lines and install the bottom cover.

72
 In-Vehicle Service Procedures

How to Remove the Air Lines and Hoses

Special Instructions
Before removing the Air Lines and Hoses, label or record their location.
If you are unsure of their location, after you remove the Air Lines and Hoses, see the Air System Troubleshooting Guide TRTS0920.

In-Vehicle Service Procedures

Special Tools
• Typical Service Tools
• For “Push-to-Connect” Fittings, the Eaton Service Tool Kit K-2394 is recommended. The Kit contains the Release Tool
and the Tubing Cutter.

Procedure -
1. Disconnect all Air Lines and Hoses.

2. Inspect the Air Lines and Hoses.

73
In-Vehicle Service Procedures

3. Inspect Air Fittings and remove if damaged.

74
 In-Vehicle Service Procedures

How to Install the Air Lines and Hoses

Special Instructions
Make sure Air Lines and Hoses are not damaged.

Install the Air Lines and Hoses at their proper location.

In-Vehicle Service Procedures

All externally threaded 1/8" or 5/32" Air Lines and Pipe Fittings that are not coated with pre-applied thread sealant must be coated
with Eaton® Sealing Material #71209 or equivalent for at least 5 complete and consecutive threads.

All externally threaded 1/4" Air Fittings that are not coated with pre-applied thread sealant must be coated with Eaton Sealing
Material #71209 or equivalent for at least 3 complete and consecutive threads.

For the 1/4" I.D. Air Hoses, install the fixed nut end first.

To install the Air Lines and Hoses, the Air Filter/Regulator must be in position.

If you are unsure of the Air Line and Hose locations, see the Air System Troubleshooting Guide TRTS0920.

Special Tools
• Typical Service Tools
• For 'Push-to-Connect' Fittings, the Eaton Service Tool Kit K-2394 is recommended. The Kit contains the Release Tool
and a Tubing Cutter.

Procedure -
1. Replace damaged Air Fittings.

75
In-Vehicle Service Procedures

2. Connect the Air Lines from the Slave Valve to the

Range Cylinder.

3. Connect all removed Air Lines and Hoses.

4. Make sure the Fittings are tight and the Lines are not kinked.

76
 In-Vehicle Service Procedures

How to Remove Compression Type Fittings

Special Instructions

WARNING

In-Vehicle Service Procedures

A sudden release of air pressure can cause personal injury or damage to equipment. To prevent injury or equipment damage,
exhaust the Vehicle Air Tanks

CAUTION

Small Air Lines are available in 1/8" or 5/32" sizes. Make sure 1/8" Air Lines are used with 1/8" Fittings and 5/32" Lines are
used with 5/32"Fittings. Mixing sizes can cause air leaks or damage to Fittings.

Before removing the Air Lines and Hoses, label or record their location.

Special Tools
• Typical Service Tools

Procedure -
1. Exhaust the Vehicle Air Tanks before continuing.

2. Loosen the nut on the fitting, and slide it back out of the way.

3. Pull the Air Line and attached Collet from the fitting.

4. Inspect the fitting, Air Line, Collet, and Nut for damage or
wear. Replace as necessary.

77
In-Vehicle Service Procedures

How to Install Compression Type Fittings

Special Instructions

WARNING

A sudden release of air pressure can cause personal injury or damage to equipment. To prevent injury or equipment damage,
exhaust the Vehicle Air Tanks

CAUTION

Small Air Lines are available in 1/8" or 5/32" sizes. Make sure 1/8" Air Lines are used with 1/8" Fittings and 5/32" Air Lines
are used with 5/32" Fittings. Mixing sizes can cause air leaks or damage to Fittings.

Special Tools
• Typical Service Tools

Procedure -
1. Check the threads of the fitting for thread sealant. If no
sealant is present, apply Eaton Thread Sealant #71205
or equivalent.

2. Install the fitting.

Note: Do not overtighten the nut. Overtightening can

compress the Collet too much and cause an
air line restriction.

3. Install the Air Line, Collet, and Nut. If installing a new fitting,
place the Collet in the fitting and loosely install the Nut. (Do
not tighten the Nut yet.) Insert the Air Line through the Nut
and into the Collet. Tighten the Nut as usual.

4. Enable the Vehicle Air System. Allow the Air Tanks to

pressurize, and check for leaks. Repair as necessary.

78
 In-Vehicle Service Procedures

How to Remove Push-to-Connect Type Fittings

Special Instructions

WARNING

In-Vehicle Service Procedures

A sudden release of air pressure can cause personal injury or damage to equipment. To prevent injury or equipment damage,
exhaust the vehicle air tank.

CAUTION

Make sure only 5/32" Air Lines are used with Push-to-Connect Fittings. Using sizes other than 5/32" can cause air leaks or
damage to Fittings.

Before removing the Air Lines and Hose, label or record their location.

Special Tools
• See Tool Information (see Table 8)
• For “Push-to-Connect" Fittings, the Eaton Service Tool Kit K-2394 is recommended. The Kit contains the Release Tool
and the Tubing Cutter.

Procedure -
1. Exhaust the Vehicle Air Tanks before continuing.

2. Use the Air Line Release Tool from Kit K-2394 to press
the Release Sleeve down while pulling the Air Line from
the fitting.

3. Inspect the fitting for damage or wear. Remove and

replace as necessary.

79
In-Vehicle Service Procedures

How to Install Push-to-Connect Type Fittings

Special Instructions

WARNING

A sudden release of air pressure can cause personal injury or damage to equipment. To prevent injury or equipment damage,
exhaust the Vehicle Air Tanks

CAUTION

Make sure only 5/32" Air Lines are used with Push-to-Connect Fittings. Using sizes other than 5/32" can cause air leaks or
damage to Fittings

Special Tools
• See Tool Information (see Table 5)
• For 'Push-to-Connect' Fittings, we recommend Eaton Service Tool Kit K-2394. The Kit contains the Release Tool and
the Tubing Cutter.

Procedure -
1. Check the threads of the fitting for thread sealant. If no
sealant is present, apply Eaton Thread Sealant #71205
or equivalent.

2. Install the fitting.

3. Inspect the Air Line for burrs or deformed areas. Trim the
air line if necessary using a sharp razor blade or the Air Line
Cutting Tool from Kit K-2394. The cut must be smooth and
square. If the tubing end is deformed or burred, the
internal O-Ring in the fitting will be damaged when the Air
Line is inserted.

4. Push the Air Line into the fitting. It should insert

approximately 3/4". If it does not insert far enough or is
difficult to insert, the fitting may be damaged and should be
replaced. After inserting, give the Air Line a slight tug to
make sure the line stays in place. If line does not stay in
place, replace the fitting.

5. Enable the vehicle Air System. Allow the Air Tanks to

pressurize, and check for leaks.

80
 In-Vehicle Service Procedures

How to Remove Rubber 1/4" Air Hoses

Special Instructions
For the 1/4" I.D. air Hoses, install the fixed nut end first.

Special Tools

In-Vehicle Service Procedures

• Typical Service Tools

Procedure -
1. Remove all Air Line Brackets and Ties.

2. Remove swivel end.

3. Remove fixed end.

81
In-Vehicle Service Procedures

How to Install Rubber 1/4" Air Hoses

Special Instructions
For the 1/4" I.D. air Hoses, install the fixed nut end first.

Special Tools
• Typical Service Tools

Procedure -
1. If necessary, apply Eaton Thread Sealant #71205 or
equivalent to threads.

2. Install and tighten fixed end first, then install and tighten
swivel end.

3. Replace all Air Line Brackets and Ties.

82
 In-Vehicle Service Procedures

How to Remove the Air Filter/Regulator

Special Instructions
The Air Filter/Regulator has two (2) O-Rings located between the Filter/Regulator and the Auxiliary Section.

Special Tools

In-Vehicle Service Procedures

• Typical Service Tools

Procedure -
1. Remove the Air Lines from the air Filter/Regulator.

2. From the Air Filter/Regulator, remove the two (2)

Cap Screws.

83
In-Vehicle Service Procedures

How to Install the Air Filter/Regulator

Special Instructions
The Air Filter/Regulator has two (2) O-Rings located between the Filter/Regulator and the Range Cylinder Cover.

Special Tools
• Typical Service Tools

Procedure -
1. Position the Air Filter/Regulator.

2. Apply Eaton Sealant #71205 or equivalent to the two (2)

Retaining Cap Screws.

3. Install the two (2) Retaining Cap Screws, torque to

8–12 lb-ft (10.85–16.30 N•m).

84
 In-Vehicle Service Procedures

How to Remove a Roadranger Valve

Special Instructions

In-Vehicle Service Procedures

WARNING

A sudden release of air pressure can injure you or damage equipment. To prevent injury or equipment damage, the Vehicle
Air Tanks must be exhausted.

Special Tools
• Typical Service Tools

Procedure -
1. From the Roadranger Valve Cover, remove the two (2)
Mounting Screws.

2. Slide the Roadranger Valve Cover down.

3. From the Air Fittings, disconnect the Air Lines.

4. From the Roadranger base, loosen the Jam Nut. Rotate the
Roadranger Valve until the Valve is removed.

5. Inspect the parts: nut, Valve Cover, Air Lines, sheathing, and
O-Rings from the Lever Shaft.

6. In the Roadranger Valve, inspect the Air Fittings, and remove

if damaged.

85
In-Vehicle Service Procedures

How to Install a Roadranger Valve

Special Instructions
To position the Roadranger Valve, the Range Lever must be to the front or the Splitter Button to the left when facing forward.

Special Tools
• Typical Service Tools

Procedure -
1. Make sure the Nut, Valve Cover, Air Lines, sheathing, and
O-Rings are in position on the Lever Shaft.

2. If previously removed, replace the Air Fittings and torque to

84–120 lb-in (9.49–13.56 N•m).

3. Place the Roadranger Valve on the Lever Shaft and rotate so

the Range Selector faces the vehicle front.

4. From the Roadranger Valve bottom, torque the Jam Nut to

35–45 lb-ft (47.45–61.01 N•m).

5. Connect the Air Lines to the Air Fittings.

6. Slide the cover into position on the Roadranger Valve.

7. Install the Roadranger Valve Cover mounting screws.

Note: Make sure the Air Lines are seated fully.

86
 In-Vehicle Service Procedures

How to Remove a Slave Valve

Special Instructions

WARNING

In-Vehicle Service Procedures

A sudden release of air pressure can injure you or damage equipment. To prevent injury or equipment damage, the Vehicle
Air Tanks must be exhausted.

Special Tools
• Typical Service Tools

Procedure -
1. Record or mark Air Line locations. Retaining
Capscrews
2. Remove all Air Lines.

Note: Remove three 1/4" ID air Hoses at swivel fitting at Range Cylinder location. Remove Air Line Bracket at rear of
Transmission. Remove Slave Valve with air Hoses still attached.

3. Remove the Retaining Cap Screws around Valve perimeter.

4. Remove Slave Valve and Gasket.

5. From the Transmission Case, remove the Sleeve, Spring, and Plunger Pin.
P
P

6. Inspect the Air Fittings, replace if damaged.

87
In-Vehicle Service Procedures

How to Install a Slave Valve

Special Instructions
None

Special Tools
• Typical Service Tools

Procedure -
1. Clean gasket surface and install Air Fittings.
Air Line
Fittings

2. Lightly lubricate and install plunger Pin, Spring, and Sleeve

into Case.

Plunger
Pin

Spring

Sleeve

3. Install any necessary air Hoses at this time.

4. Install new Gasket.

5. Apply Eaton Sealant #71205 or equivalent to the Retaining

Cap Screws.
Retaining
Capscrews 6. Install the Retaining Cap Screws, torque to 8–12 lb-ft
(10.85–16.30 N•m).

Note: Make sure the Retaining Cap Screws are properly

torqued.

88
 In-Vehicle Service Procedures

How to Remove the Gear Shift Lever/Remote Shift Control

Special Instructions
The Air Lines must be disconnected from the Transmission or from the Roadranger Valve.

Different Detent Springs are available to increase or decrease shifting effort. Note and record specific locations for specific springs.

In-Vehicle Service Procedures

In some cases, a stiffer spring is installed in the top rail position.

Remote Control Housings are removed the same way as Gear Shift Levers.

Special Tools
• Typical Service Tools

Procedure -
1. From the Gear Shift Lever Base/Shift Control Housing,
remove the four (4) Retaining Cap Screws.

2. To break the Gasket seal, lightly jar the Gear Shift/Shift

Control Housing.

3. Remove the Gear Shift Lever Housing.

CAUTION

Make sure the Detent Springs do not fall into the

Transmission.

4. Remove Detent Springs as needed.

5. Remove the Gasket and clean the area the Replacement

Gasket will contact.

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In-Vehicle Service Procedures

How to Install the Gear Shift Lever/Remote Shift Control

Special Instructions
Remote Control Housings are installed the same way as Gear Shift Levers.

For Standard and Forward Shift Bar Housings, make sure the Detent Springs and Balls are in the Shift Bar Housing top Bores.

Make sure the Shift Block and Yoke Notches are aligned in the Neutral position.

Special Tools
• Typical Service Tools

Procedure -
1. Thoroughly clean mounting surface.

2. Position a new Gear Shift Lever/Shift Control Housing

Gasket on the Gear Shift Lever mounting surface.

3. Install the Detent Springs.

4. Install the Shift Lever/Shift Control Housing. Make sure the

tip (finger) of the Gear Shift Lever fits into the slots in the
Shift Block.

5. Apply Eaton Sealant #71205 or equivalent to the Retaining

Cap Screws.

6. Install the Retaining Cap Screws, torque to 35–45 lb-ft

(47.45–61.01 N•m).

Note: Make sure the Cap Screws are properly torqued.

Note: Make sure you can shift the Transmission.

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 In-Vehicle Service Procedures

How to Adjust the Remote Shift Control (LRC Type)

Special Instructions
The following is a typical adjustment procedure for an LRC type slave control. It is recommended that the OEM Chassis Service
Manual be consulted first.

In-Vehicle Service Procedures

Special Tools
• Typical Service Tools

Procedure -
1. Move the Gear Shift Lever forward or backward to the
Neutral position.

2. Move the Gear Shift Lever sideways, toward Reverse,

until you feel resistance from the Reverse Plunger Spring.
DO NOT shift to Reverse. The Shift Finger must remain in
this position while you are making all the adjustments.

3. Remove the Cotter Pin, Castle Nut and Ball Joint A (see
figure A) from the Selection Lever. Do not remove the Ball
Joint from the Pivot Link.

4. Loosen the Cap Screw B (see figure A) and remove the

Shift Arm from the inner Shift Shaft. Do not disconnect the
Selection Lever from the Shift Arm.

5. Turn the Shift Arm until it is at a right angle (90°) to the

Selection Lever as viewed from the side (see figure B).
Note: Ideally, the Shift Arm should be adjusted 90° to the
Selection Lever as described, but in some Chassis
configurations it may be necessary to index the
Shift Arm in the vertical position. Indexing the
Shift Lever is done to prevent Shift Lever jump out.
This type of adjustment will cause an unequal amount
of Gear Shift Lever travel between Neutral and a
forward lever position as compared to Neutral and a
rearward lever position.

6. Install the Shift Arm on the Splines of the inner Shift Shaft.
You may have to move the Shift Arm 4° or 5° to align the
Splines of the two parts. Disregard any movement of the
Gear Shift Lever at this point. The Gear Shift Lever will be
adjusted later.

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In-Vehicle Service Procedures

7. Tighten the Cap Screw B (see figure A) on the Shift Arm.

8. Connect the Pivot Link assembly Ball Joint to the Selection

Lever. Secure it with the Castle Nut and Cotter Pin.

9. Loosen the Jam Nuts C (see figure C) on the Pivot Link.

10. Check to be sure the inner Shift Finger is still in place.

11. Rotate the Pivot Link until the curved end of the Selection
Lever is parallel with the Shift Arm as viewed from the rear
(see figure C).

12. Tighten the Pivot Link Jam Nuts C (see figure C).

13. Loosen both Cap Screws on the Turnbuckle D (see figure A).

14. Check to be sure inner Shift Finger is still in place.

15. Rotate the Turnbuckle to obtain the proper forward-

backward Neutral position of the Gear Shift Lever in the cab.

16. Tighten one Turnbuckle D Cap Screw (see figure A).

17. Move the Gear Shift Lever to the desired position.

18. Turn the second Turnbuckle D Cap Screw.

19. Check for linkage obstructions in all gear positions.

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 In-Vehicle Service Procedures

Neutral Switch Operation and Testing

Special Instructions
The Neutral Switch is a normally closed switch. An electrical current flows through it when the Transmission Shifter is in the
Neutral position. When the Transmission Shifter is in gear, the Switch is open and no current flows through it. Likewise, the Switch
is open when the Ball is depressed. The Switch is actuated by the Air Valve Shaft.

In-Vehicle Service Procedures

Special Tools
• Typical Service Tools
• Volt/Ohm Meter

Procedure -
1. Disconnect the wiring from the Switch.

2. Connect an Ohm Meter to check for continuity or a

small reading.

3. Place the Transmission Shift Lever in the Neutral position.

The Ohm Meter should register continuity or a small
reading. If it does, go to the next step. If it does not, remove
the Switch and replace it.

4. Shift the Transmission into all gear positions. The Ohm

Meter should read Open or Infinity. If it does not, remove the
Switch. Then, depress the Switch ball and check for
continuity. The Ohm Meter should read Open or Infinity
when the Ball is depressed.

5. Look into the Neutral Switch hole and verify that the Air
Valve Shaft moves as the Transmission is shifted from
Neutral into gear.
a. If it does, replace the Switch.
b. If not, remove the Shift Bar Housing and check the
Air Valve and Shift Rails for excessive wear. Also, check
the Slave Valve Plunger and Spring for free movement.

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In-Vehicle Service Procedures

How to Remove the Neutral Switch

Special Instructions
None

Special Tools
• Typical Service Tools

Procedure -
1. Remove 2 screws retaining Wire Terminals.

2. Remove the Switch using a 7/8" Deep Well Socket or

Box End Wrench.

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 In-Vehicle Service Procedures

How to Install the Neutral Switch

Special Instructions
None

Special Tools

In-Vehicle Service Procedures

• Typical Service Tools

Procedure -
1. Install a new Gasket.

2. Install the Neutral Switch, torque to 15–20 lb-ft

(20.34–27.12 N•m).

3. Connect the wiring to the Switch.

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In-Vehicle Service Procedures

Reverse Switch Operation and Testing

Special Instructions
The Reverse Switch is a normally open Ball Switch. When the Transmission is shifted into Reverse, a Ramp on the Reverse Yoke
Bar contacts and raises a Pin. The Pin depresses the Ball on the Switch, which closes the Switch Contact, allowing current to flow
through the Switch and light up the vehicle's backup lights.

Special Tools
• Typical Service Tools
• Volt/Ohm Meter

Procedure -
1. Disconnect the wiring from the Switch.

2. Connect an Ohm Meter to check for continuity.

3. Place the Transmission Shift Lever in any position except

Reverse. If the Switch is working properly, the Ohm Meter
should read Open or Infinity. If it is not, remove the Switch
and recheck it for continuity. Replace as necessary.

4. Place the Transmission Shift Lever in the Reverse position.

If the Switch is working properly, the Ohm Meter should
register continuity, or a small reading. If it does not, remove
the Switch and recheck it for continuity. Replace it as
necessary. Also, check for sticking or excessive wear of the
Reverse Pin.

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 In-Vehicle Service Procedures

How to Remove the Reverse Switch

Special Instructions
None

Special Tools

In-Vehicle Service Procedures

• Typical Service Tools

Procedure -
1. Remove 2 screws retaining wire terminals.

2. Remove the switch using a 7/8" Deep Well Socket or Box

End Wrench.

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In-Vehicle Service Procedures

How to Install the Reverse Switch

Special Instructions
None

Special Tools
• Typical Service Tools

Procedure -
1. Insert the Reverse Pin in the Reverse Switch Bore.

2. Install new Gasket on Switch.

3. Install the Reverse Switch, torque to 15–20 lb-ft

(20.34–27.12 N•m).

4. Connect the wiring to the Switch.

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 In-Vehicle Service Procedures

How to Remove the Shift Bar Housing

Special Instructions
Before removing the Shift Bar Housing, the Air Lines must be disconnected.

For models equipped with an Oil Pump and/or Cooler Assemblies, make sure to disconnect the Oil Line connected to the

In-Vehicle Service Procedures

Shift Bar Housing.

There are three (3) sizes of Cap Screws. The 1 1/2" Cap Screws are used with the Lifting Eyes. The 1 1/4" are used on all
other locations except the left front corner at the Roll Pin location. This Cap Screw is 1 3/4".

Be careful when removing the Shift Bar Housing to prevent damaging the Oil Tube with the Shift Yokes.

Special Tools
• Typical Service Tools

Procedure -
1. From the Shift Bar Housing, remove the two Retaining
Cap Screws securing the Oil Cooler. Remove Oil Cooler
and set aside.

2. Remove Slave Valve.

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In-Vehicle Service Procedures

3. Remove Interlock parts (Pin, Spring, and Sleeve).

4. From the Shift Bar Housing rim, remove the Retaining

Cap Screws.

5. To break the Gasket seal, jar the Shift Bar Housing.

6. Remove the Shift Bar Housing.

7. Inspect the Roll Pin, replace if damaged.

8. Remove the Gasket and clean all mounting surfaces of

gasket material.

9. If the three (3) sets of Tension Springs and Balls from

the Housing top Bores are loose, tilt the Assembly and
remove them.

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 In-Vehicle Service Procedures

How to Install the Shift Bar Housing

Special Instructions

There are three (3) sizes of Cap Screws. The 1 1/2" Cap Screws are used with the Lifting Eyes. The 1 1/4" are used on all other
locations except the left front corner at the Roll Pin. This Cap Screw is 1 3/4".

In-Vehicle Service Procedures

Be careful when removing the Shift Bar Housing to prevent damaging the Oil Tube with the Shift Yokes.

The Slave Valve and Interlock parts must be removed prior to installing the Shift Bar Housing.

Special Tools
• Typical Service Tools

Procedure -
1. Place the Shift Bar Housing and Shift Blocks in the
Neutral position.

2. Place the Mainshaft Sliding Clutches in the Neutral position.

3. Position a new Shift Bar Housing gasket on the Shift Bar

Housing mounting surface.

Note: The Slave Valve and Interlock Assembly must remain

off, until the Shift Bar Housing is installed, to avoid
damaging the Interlock Pin.

4. As you install the Shift Bar Housing, make sure the Yokes fit
into the corresponding Sliding Clutch slots and the Housing
aligns with the Roll Pin.

5. Apply Eaton® Sealant #71205 or equivalent to the

Retaining Cap Screws. Torque the Cap Screws to
35–45 lb-ft (47.45–61.01 N•m).

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In-Vehicle Service Procedures

6. Install Interlock parts (Pin, Spring and Sleeve).

7. Install Slave Valve. Apply Loctite 242 to Cap Screw threads

and torque to 8–12 lb-ft (10.85–16.30 N•m).

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 In-Vehicle Service Procedures

How to Remove the Oil Seal - Mechanical Speedometer

Special Instructions
Prior to replacing the Seal, carefully inspect the Transmission to make sure the oil leakage is coming from the Seal.
Pay particular attention to the Speedometer parts, the Rear Bearing Cover gasket surfaces, Rear Countershaft Bearing Covers,
and Shift Bar Housing.

In-Vehicle Service Procedures

For additional information on Rear Seal service, refer to the Seal Maintenance Service Brochure TRSM0912.

Special Tools
• Output Yoke Puller
• RR1010TR Slide Hammer
• RR1011TR-1 Slide Hammer Attachment

1. Bushing 5. Oil Seal with Slinger

2. Rear Bearing Cover Assembly 6. O-Ring
3. Cap Screw 7. Speedometer Spacer Assembly
4. Speedometer Drive Gear

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In-Vehicle Service Procedures

Procedure -

1. Disconnect the Driveshaft and U-joint from the Output

Yoke according to the OEM or Driveshaft Manufacturer's
instructions.

2. Shift the Transmission into 1st Gear or Low Gear (Low

Range) to prevent the Output Yoke from turning when you
loosen the Output Shaft Nut.

3. Remove the Output Shaft Nut using a 70 mm or 2 3/4"

socket. See “How to Remove Output Yoke/Companion
Flange”.

4. Remove the Output Yoke. If necessary, use an Output

Yoke Puller.

5. Remove the Seal sleeve.

6. Use RR1010TR Slide Hammer and RR1011-1 Attachment to

remove the Seal. Or remove Output Bearing Cover and drive
Seal out from front side.

Note: The Seal will be damaged during removal and must

be replaced.

7. Remove Seal Slinger from the Output Yoke using a Brass

Drift and Hammer.

8. Inspect all parts of the Seal surface for wear, scratches,

burrs, or other damage.

Note: Replace the Seal surface if it is worn or damaged.

Do not attempt to salvage the Seal mating surface
with Crocus Cloth, filing, etc.

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 In-Vehicle Service Procedures

How to Install the Oil Seal - Mechanical Speedometer

Special Instructions

CAUTION

In-Vehicle Service Procedures

To prevent oil leaks, do not touch the seal lip, and make sure the Seal Driver is clean.

Special Tools
• RR1001TR-2 Output Seal Driver
• RR1001TR-4 Output Seal Slinger Driver

Procedure -
1. The Seal will be damaged during removal and must
be replaced.

2. Place a Seal on the RR1001TR-2 Output Seal Driver, and

drive the new Seal into the Rear Bearing Cover.

3. Install the new Slinger on the Output Yoke using the

RR1001TR-4 Output Seal Slinger Driver.

4. Install the Output Yoke over the Output Shaft. The Yoke
should slide on when the Splines are lined up. If it does not,
clean the Splines with solvent, and oil them lightly.

5. Install the Output Nut and torque to 650–700 lb-ft

(881.28–949.07 N•m).

6. Connect the Driveshaft and U-joint according to the OEM

or Driveshaft Manufacturer's instructions.

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In-Vehicle Service Procedures

How to Remove the Oil Seal - Magnetic Speedometer

Special Instructions
Prior to replacing the Seal, carefully inspect the Transmission to make sure the oil leakage is coming from the Seal. Pay
particular attention to the Speedometer parts, the Rear Bearing Cover gasket surfaces, Rear Countershaft Bearing Covers,
and Shift Bar Housing.

Special Tools

1. Rear Bearing Cover 6. Oil Seal

2. Sensor Retaining Cap Screw 7. Slinger
3. O-Ring 8. O-Ring
4. Speedometer Sensor 9. Speedometer Spacer Assembly
5. Cap Screw

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 In-Vehicle Service Procedures

Procedure -
1. Disconnect the Driveshaft and U-joint from the Output
Yoke according to the OEM or Driveshaft Manufacturer's
Instructions.

2. Shift the Transmission into 1st Gear or Low Gear (Low

In-Vehicle Service Procedures

Range) to prevent the Output Yoke from turning when
you loosen the Output Shaft Nut.

3. Remove the Output Shaft Nut using a 70 mm or

2 3/4" socket.

4. Remove the Output Yoke. If necessary, use an Output

Yoke Puller. See “How to Remove the Output Yoke/
Companion Flange.”

5. Remove the Speedometer Sensors from the Rear

Bearing Cover.

Note: If the Sensor is a thread in type, note the number of

threads expose so the Sensor can be reinstalled to the
same depth. If the Sensor is a push in type, remove
the hold down Cap Screw and pull the Sensor out of
the Bore.

6. Remove the Speedometer Rotor/Seal Sleeve and the O-Ring.

7. Pry the Seal out using a large Screwdriver or Pry Bar in the
metal groove of the Seal.

Note: The Seal will be damaged during removal and must

be replaced.

8. Remove Seal Slinger from the Speedometer Rotor/Seal

Sleeve using a Brass Drift and Hammer.

9. Inspect all parts of the Seal surface for wear, scratches,

burrs, or other damage.

Note: Replace the Seal surface if it is worn or damaged.

Do not attempt to salvage the Seal mating surface
with Crocus Cloth, filing, etc.

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In-Vehicle Service Procedures

How to Install the Oil Seal - Magnetic Speedometer

Special Instructions
Special Tools
• RR1001TR-2 Output Seal Driver
• RR1001TR-8 Seal Driver Insert
• RR1001TR-1 Seal Slinger Driver

Procedure -
1. Using the RR1001TR-2 Seal Driver and RR1001TR-8 Seal
Driver Insert, drive the new Seal into the Rear Bearing Cover.
The Seal is fully installed when the Flange on the Seal is flush
with the shoulder in the Bore.

2. Install the new Slinger on Speedometer Rotor/Seal Sleeve

using the RR1001TR-1 Slinger Driver.

3. If previously removed, install the O-Ring over the

Output Shaft.

Note: To avoid creating oil leaks, make sure the

Speedometer Rotor/Seal Sleeve is free from
contaminants.

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 In-Vehicle Service Procedures

4. Install the Speedometer Rotor/Seal Sleeve over the Output

Shaft, and install the Speedometer Sensors.

5. Install the Output Yoke over the Output Shaft. The Yoke should slide on an stop before contacting the Speedometer Rotor.
As the Output Shaft Nut is installed, the Output Yoke will contact the Speedometer Rotor.

6. Install the Output Nut and torque to 650–700 lb-ft

In-Vehicle Service Procedures

(881.28–949.07 N•m).

7. Connect the Driveshaft and U-joint according to the OEM or Driveshaft Manufacturer's instructions.

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In-Vehicle Service Procedures

How to Remove the Output Yoke/Companion Flange and Nut

Special Instructions

You must remove the shift bar housing in order to lock the transmission.

For proper cleaning and maintenance, see TRSM0912 - Rear Seal Maintenance Guide.

After removal of the output yoke/companion flange, temporarily replace the output shaft nut to protect the output shaft threads
during auxiliary section disassembly.

Special Tools
• See Tool Information
• A large breaker bar or air impact wrench

Procedure -

1. Engage two (2) mainshaft sliding clutches into two (2) main-
shaft gears to lock the transmission, or use a yoke holding
tool if available.

2. Use a large breaker bar or air impact wrench to remove the

output shaft nut.

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 In-Vehicle Service Procedures

3. Remove the output yoke. Use the output yoke puller (Tool
ref. ID T1).

In-Vehicle Service Procedures

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In-Vehicle Service Procedures

How to Install the Output Yoke/Companion Flange and Nut

Special Instructions

You must remove the shift bar housing in order to lock the transmission.

For proper cleaning and maintenance, see TCSM0912 - Seal Maintenance Guide.

Special Tools
• See Tool Information
• Torque wrench with 0-700 Lb•ft capacity

Procedure -

1. Engage two (2) mainshaft sliding clutches into two (2) main-
shaft gears to lock the transmission or use a yoke holding
tool if available.

2. Install the speedometer drive gear rotor or replacement

spacer on the output shaft inside the rear bearing cover.

3. If the slinger on the yoke is damaged, replace using a Sling-

er/Seal kit.

4. Install the output yoke over the output shaft. The yoke
should slide on and stop before contacting the speedometer
rotor. As the output shaft nut is installed, the output yoke will
contact the speedometer rotor.

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 In-Vehicle Service Procedures

5. Install the output shaft nut, tighten to 650-700 Lb·ft of

torque.

6. Make sure the output shaft nut is properly torqued and un-
lock the transmission, or remove the holding tool.

In-Vehicle Service Procedures

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In-Vehicle Service Procedures

How to Remove the Output Yoke / Flange and Retaining Capscrews

Special Instructions

None

Special Tools
• Typical service tools

Procedure -

1. Remove drive shaft from transmission. Reference OEM

removal guidelines.

2. Remove the end yoke retaining capscrews and washer from

auxiliary mainshaft.

3. Remove the end yoke/flange.

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 In-Vehicle Service Procedures

How to Install the Output Yoke / Flange and Retaining Capscrews

Special Instructions

For proper cleaning and maintenance, see TCSM0912 Seal Maintenance Guide.

Special Tools
• Typical service tools

Procedure -

1. Install end yoke, retaining washer, and capscrews. Apply

Eaton/Fuller #71205 liquid thread sealant to capscrews and
then snug each capscrew to 35 lb-ft (47 Nm).

Auxiliary Section
2. Fully tighten both retaining capscrews to specified torque
rating 84-92 lb-ft (114-124 Nm).

Note: This fastening design employs SpiralockTM threads. A

conventional metric thread pitch tap cannot be used
for thread restoration on this product.

WARNING

Use only Eaton/Fuller #71205 liquid thread sealant or liquid

equivalent on the yoke retaining capscrews. Do not use any type
of thread locking tape on the end yoke retaining capscrews. This
may cause the capscrews threads to strip and cause the end yoke
to loosen.

3. Reinstall driveshaft per OEM guidelines.

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In-Vehicle Service Procedures

How to Remove the Auxiliary Section in Chassis

Special Instructions

None

Special Tools
• See Tool Information (see Table 6)
• Item T2: Auxiliary section hanger
• Item T14: Auxiliary section removal adapter plate
• A hoist with lifting chain

Procedure -

1. Drain the transmission oil.

2. Disconnect the driveshaft and U-joint from the output yoke.

3. If the auxiliary section is to be disassembled, remove the

output nut. To prevent the output shaft from rotating while
removing the nut, engage the transmission into two gears or
use a yoke holding tool.

4. Disconnect the vehicle air supply line from the filter regula-
tor assembly.

5. Mark the locations and disconnect the large rubber air lines
placing them aside.

6. Label and remove the small air lines.

7. Remove the four (4) capscrews and the auxiliary counter-

shaft rear bearing cover, gasket, and rear bearing shim.

8. Install the auxiliary countershaft retaining straps with 2-3/8"

NC x 1" and 1-3/8" NC x 1-1/2" clean capscrews.

Note: Do not use an air gun. Tighten by hand until the cap-
screws are snug.

9. Drive the two dowel pins forward, and remove them.

10. Remove all but one capscrew that secure the auxiliary sec-
tion to the main section. Leave one capscrew to secure the
housing until it is ready to be removed.

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 In-Vehicle Service Procedures

Note: Capscrews are different lengths. Note their locations

for reassembly purposes.

WARNING

In-Vehicle Service Procedures

Use the proper equipment with safety chains attached to re-
move the auxiliary section. The auxiliary section can slide
rearward and could fall, causing you serious injury and/or
damage to the auxiliary section.

11. Attach a chain and lifting device to the auxiliary section

hanger, or attach the support jack to the auxiliary section
(as shown in the pictures to the left).

12. With the support device in position, remove the remaining

capscrew. If necessary, 3 capscrews can be installed into the
three threaded holes in the auxiliary section flange. When
threaded in they will push the auxiliary section rearward.
Clean the holes of rust, paint, and other debris by threading
a 3/8-16 tap into each hole. Thread each capscrew in evenly
to prevent damage to the auxiliary housing.

CAUTION

The weight of the auxiliary section must be supported during

removal to avoid damage to internal transmission parts.

13. Support the weight of the auxiliary section with a lifting de-
vice or support jack and move the auxiliary section rearward
until it is free from the front section of the transmission.

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In-Vehicle Service Procedures

How to Install the Auxiliary Section in Chassis

Special Instructions

None

Special Tools
• See Tool Information (see Table 6)
• Item T3: Countershaft support tools
• Item T14: Auxiliary section removal adapter plate
• A hoist with lifting chain

Procedure -

1. Install the countershaft support tools on the auxiliary section

countershafts to center and hold the countershafts in posi-
tion. Install a 3/8"-16 X 2 1/2" long capscrew into counter-
shaft center.

2. Install output yoke and nut, torque to 650-700 lb·ft (881.28-

949.07 Nm).

Note: To prevent the output shaft from rotating while install-

ing the nut, place a clean shop rag in the gear mesh,
or use a yoke holding tool.

Note: Due to chassis interference, it may not be possible to

install the yoke at this step. However, the output shaft
must be drawn fully into position to prevent it from
sagging when the auxiliary section is installed in the
chassis. If the chassis causes interference, the yoke
can be temporarily installed to draw up the output
shaft and then removed before the auxiliary section is
installed.

3. Use crocus cloth or a wire wheel to clean rust and paint from
the dowel pins before installing them.

CAUTION

If the dowel pins are not installed in the main case to the
proper depth, the auxiliary section will not properly align
with the main case and bearing or synchronizer failure may
occur.

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 In-Vehicle Service Procedures

4. Install the dowel pins into the main case so that 3/8"-1/2" of
the shoulder is exposed or pin is flush with front of case ear.

5. Clean all rust and paint from the dowel pin holes in the aux-
iliary section housing, and lightly grease the dowel pins on
the main case and the dowel pin holes on the auxiliary sec-
tion housing.

6. Make sure the auxiliary section is in low range. If not, blow

shop air (max 100 PSI) into the low range supply port to
shift the range synchronizer to low. If necessary, make sure
the deep reduction clutch is engaged into gear.

7. Position the gasket onto the main case mounting surface.

In-Vehicle Service Procedures

8. Mount the auxiliary section on the lifting device or jack.

9. Tighten the center capscrew on the countershaft support

tools to draw the countershafts into a level position. Do not
overtighten the capscrews. The output yoke and shaft must
be able to rotate.

10. Position the auxiliary section in line with the main case, and
slide the housing onto the dowel pins. Mesh the counter-
shafts with the auxiliary drive gear. Rotate the output yoke
and shaft slightly to help the gears mesh and slide the auxil-
iary section forward until it is flush with the main section.

CAUTION

The auxiliary section should slide into place fairly easily. DO

NOT force it on or pull it into place with the capscrews. Ex-
cessive force may damage the transmission. If excessive
force is necessary, the gearing is likely out of time.

11. If the auxiliary section does not install fully, slide it back and
check the following:
a. The output yoke and nut should be installed to pull back
and center the auxiliary mainshaft assembly.
b. The countershaft support tool center capscrew should
be snug to level the countershafts.
c. The dowel pins and auxiliary housing mating holes
should be clean and well oiled.
d. The internal gearing on the auxiliary section must have
been properly timed during reassembly.

12. Apply Eaton® Fuller® thread sealant #71205 or equivalent

to the all the retaining capscrew threads. Install the cap-
screws to secure the auxiliary section to the main case.
Torque the capscrews to 40-45 Lb·ft (54-61 Nm).

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In-Vehicle Service Procedures

13. If the countershaft, countershaft bearings, or auxiliary hous-

ing have been replaced, or if the countershafts, bearings, or
shims were not marked and reassembled in the same loca-
tion, the bearing endplay must be checked and set by shim-
ming. Shim the countershaft bearings using “Shim
Procedure without a Shim Tool”.

14. If shimming is not required, remove the support tools, and

install the proper shim, gasket, and countershaft bearing
cover. Secure the bearing covers with the capscrews. Install
sealer. Tighten the capscrews to 40-45 Lb·ft (54-61 Nm).

15. Connect all removed air hoses and lines. Use Eaton® Full-
er® thread sealant #71205 or equivalent as necessary.

16. Connect the driveshaft and U-joint, and refill the transmis-
sion with the recommended lubricant. For lubrication in-
structions refer to the "Lubrication" section.

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 In-Vehicle Service Procedures

How to Remove the Combination Cylinder Assembly

Special Instructions

None

Special Tools
• Typical service tools

Procedure -

In-Vehicle Service Procedures

1. Drain lube.

2. At the combination cylinder cover, remove the 5 capscrews

with washers.

3. Remove the cylinder cover and gasket.

4. If necessary, remove the insert valve retaining nut from the

cylinder cover. Remove the insert valve from the bore.

5. Remove the 15/16” nut on the range yoke bar.

6. Remove the 3/4” nut on the reduction yoke bar.

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In-Vehicle Service Procedures

7. Remove the cylinder housing and gasket.

8. Remove the range and reduction pistons from the cylinder

bores.

9. If necessary, remove the O-rings from the range cylinder

bore and the reduction cylinder bore.

10. If necessary, remove the O-rings from the range piston I.D.
and O.D. and the reduction piston O.D.

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 In-Vehicle Service Procedures

How to Install the Combination Cylinder Assembly

Special Instructions

Apply Eaton lubricant #71206 or equivalent to all shift cylinder assembly and spool valve O-rings so a film covers the entire sur-
face.

Apply Eaton rust preventative #71213 or equivalent to all shift cylinder walls and yoke bars, cover the entire yoke bar surface that
comes in contact with the shift cylinder O-ring.

Special Tools
• Typical service tools

In-Vehicle Service Procedures

Procedure -

1. Lightly lubricate O-rings with Eaton® Fuller® Silicone lubri-

cant P/N 71206 or equivalent.

2. Install O-rings into range and deep reduction shift cylinders.

3. Install O-rings onto range and reduction pistons.

4. Install gasket and shift cylinder.

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In-Vehicle Service Procedures

5. Install range piston with flat side to rear. Install range piston
nut and torque to 70-85 Lb•ft.

6. Install deep reduction piston with flat side to rear. Install nut
and torque to 50-65 Lb•ft.

Note: If reusing existing nut, make sure nylon locking mate-

rial is in good shape, if not, use new nut.

7. Lightly lubricate insert valve O-rings with Eaton® Fuller®

Silicone lubricant P/N 71206 or equivalent. Install insert
valve with flat side to the inside. Install insert valve retaining
nut and torque to 40-50 Lb•ft.

8. Install gasket and cover. Apply Eaton® Fuller® thread seal-

ant P/N 71205 or equivalent to capscrew threads. Install
capscrews and torque to 35-45 Lb•ft.

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 Transmission Overhaul Procedures-Bench Service

How to Disassemble the Gear Shift Lever

Special Instructions

If total disassembly is needed the Roadranger valve must be removed first.

Release the spring one coil at a time.

Special Tools
• Vise with brass jaws or wood blocks

Procedures-Bench Service
Transmission Overhaul

1. Pin 8. Capscrew
2. Bushing 9. Gasket
3. Upper Lever 10. O-Ring
4. Snap Ring 11. Washer
5. Rubber Boot 12. Lower Lever
6. Spade Pin 13. Stepped Washer
7. Housing 14. Tension Spring

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Transmission Overhaul Procedures-Bench Service

Procedure -

1. On a non-isolated shift lever, remove the Roadranger valve

using the “How to Remove the Roadranger valve” instruc-
tions in In-Vehicle Service Procedures. If the shift lever is
equipped with a lever isolator, remove the snap ring, bush-
ing, and cross pin to disconnect and remove the upper lever.

2. Slide the rubber boot up and off the shift lever shaft.

3. With housing bottom facing up, secure the assembly in a

vise.

4. Use large screwdriver to twist between the spring and hous-

ing, forcing the spring from under the housing lugs one coil
at a time.

5. From inside the housing tower, remove the tension spring,

washer, and gear shift lever.

6. In models so equipped, from the housing bore, remove the

nut and washer.

7. From the housing tower spade pin bore, remove and inspect
the spade pin, discard if damaged.

8. From the housing tower inside groove, inspect the O-ring,

discard if damaged.

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 Transmission Overhaul Procedures-Bench Service

How to Assemble the Gear Shift Lever

Special Instructions

Inspect tension spring and washer for wear.

Apply Eaton rust preventative lubricant #71212 or equivalent to the shift lever pivot ball. A rust preventative lubricant film should
cover all surfaces between and including the pivot ball.

Seat the tension spring one coil at a time.

Special Tools
• Vise with brass jaws or wood blocks

Procedures-Bench Service
Transmission Overhaul
• Item T4: Tension Spring Driver

1. Pin 8. Capscrew
2. Bushing 9. Gasket
3. Upper Lever 10. O-Ring
4. Snap Ring 11. Washer
5. Rubber Boot 12. Lower Lever
6. Spade Pin 13. Stepped Washer
7. Housing 14. Tension Spring

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Transmission Overhaul Procedures-Bench Service

Procedure -

1. With housing bottom facing up, secure the assembly in a

vise.

2. If the spade pin is damaged, replace and install the spade pin
in housing tower bore.

3. In models so equipped, install the nut and washer in the

housing bore.

4. If the O-ring is damaged, replace it and lubricate the O-ring

with Eaton/Fuller lubricant #71206 or equivalent. Install the
O-ring in the housing tower inside groove.

5. Align the lever ball slot with the spade pin and position the
gear shift lever in the housing tower.

6. With dished-side up, install the washer over the ball.

7. Use a tension spring driver to install the tension spring un-

der the housing lugs.

8. Remove the assembly from the vise.

9. Install a rubber boot over the gear shift lever and against the
housing.

Note: Make sure the gear shift lever can move.

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 Transmission Overhaul Procedures - Bench Service

How to Remove the Shift Bar Housing

Special Instructions
Before removing the Shift Bar Housing, the Air Lines must be disconnected.

For models equipped with an Oil Pump and/or Cooler Assemblies, make sure to disconnect the oil line connected to the
Shift Bar Housing.

There are three (3) sizes of Cap Screws. The 1 1/2" Cap Screws are used with the Lifting Eyes. The 1 1/4" are used on all
other locations except the left front corner at the Roll Pin location. This Cap Screw is 1 3/4".

Be careful when removing the Shift Bar Housing to prevent damaging the Oil Tube with the Shift Yokes.

Special Tools

Procedures - Bench Service

Transmission Overhaul
• Typical Service Tools

Procedure -
1. From the Shift Bar Housing, remove the two Shift Bar
Retaining Cap Screws securing the Oil Cooler. Remove
Oil Cooler and set aside.

2. Remove Slave Valve.

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Transmission Overhaul Procedures - Bench Service

3. Remove Interlock parts (Pin, Spring, and Sleeve).

4. From the Shift Bar Housing rim, remove the Retaining

Cap Screws.

5. To break the Gasket seal, jar the Shift Bar Housing.

6. Remove the Shift Bar Housing.

7. Inspect the Roll Pin, replace if damaged.

8. Remove the Gasket and clean all mounting surfaces of

gasket material.

9. If the three (3) sets of Tension Springs and Balls from

the Housing top Bores are loose, tilt the Assembly and
remove them.

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 Transmission Overhaul Procedures - Bench Service

How to Install the Shift Bar Housing

Special Instructions
There are three (3) sizes of Cap Screws. The 1 1/2" Cap Screws are used with the Lifting Eyes. The 1 1/4" are used on all other
locations except the left front corner at the Roll Pin location. This Cap Screw is 1 3/4".

Be careful when removing the Shift Bar Housing to prevent damaging the Oil Tube with the Shift Yokes.

The Slave Valve and Interlock parts must be removed prior to installing the Shift Bar Housing.

Special Tools
• Typical Service Tools

Procedures - Bench Service

Procedure -

Transmission Overhaul
1. Place the Shift Bar Housing and Shift Blocks in the
Neutral position.

2. Place the Mainshaft Sliding Clutches in the Neutral position.

3. Position a new Shift Bar Housing Gasket on the Shift Bar

Housing mounting surface.

Note: The Slave Valve and Interlock Assembly must remain

off, until the Shift Bar Housing is installed, to avoid
damaging the Interlock Pin.

4. As you install the Shift Bar Housing, make sure the Yokes fit
into the corresponding Sliding Clutch slots and the Housing
aligns with the Roll Pin.

5. Apply Eaton® Fuller® Sealant #71205 or equivalent to the

Retaining Cap Screw threads.

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Transmission Overhaul Procedures - Bench Service

6. Install Interlock parts (Pin, Spring and Sleeve).

7. Install Slave Valve and tighten to specifications.

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 Transmission Overhaul Procedures - Bench Service

How to Disassemble the Standard Shift Bar Housing

Special Instructions
The Shift Bar Housing must be removed from the Transmission.

During disassembly, lay all parts on a clean bench in order of removal to facilitate assembly.

Shift Bars not being removed must be kept in the Neutral position or the interlocking parts lock the Bars.

Start with the bottom Shift Bar.

Cut the Lockwire and remove the Lock Screws from each Bar just before their removal.

Special Tools

Procedures - Bench Service

Transmission Overhaul
• Typical Service Tools

Procedure -
1. If the three (3) sets of Tension Springs and Balls from
Housing Bores have not been removed, place the Shift Bar
Housing on its side to remove them.

2. Remove the Oil Trough Retaining Cap Screws and Oil

Trough. (Some models do not have an Oil Trough.)

3. With the Housing rear to the right, lay the Assembly on a

flat surface.

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Transmission Overhaul Procedures - Bench Service

4. While removing the top Yoke Bar to the right, remove the
two (2) Shift Blocks.

5. From the middle Yoke Bar, remove the Shift Yoke and
Shift Block. As the Neutral Notch in the Bar clears the
Rear Boss, remove the small Interlock Pin from the
Notch Bore.

6. Remove the Actuating Plunger from the top center

Boss Bore.

7. From the bottom Yoke Bar, remove the two (2) Shift Yokes.

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Transmission Overhaul Procedures - Bench Service

8. As the Shift Bar clears the last Boss, two (2) 3/4" Interlock
Balls drop from the bottom rear Boss Bore.

Procedures - Bench Service

Transmission Overhaul
9. If damaged, from the 1st and Reverse Shift Yoke, remove
the Plug, Spring, and Plunger.

10. Inspect the Yoke or Block parts; replace the worn parts.

135
Transmission Overhaul Procedures - Bench Service

How to Assemble the Standard Shift Bar Housing

Special Instructions
Inspect Shift Blocks and Shift Yokes for wear.

Apply Eaton® Sealant #71208 or equivalent to the Shift Bar Housing Plugs which are used to plug Oil Cooler provision holes.
The sealant should be applied so at least 5 complete threads are covered.

Apply Eaton® Lockwire #1819 or equivalent to all Shift Bar Housing Assembly Set Screws in both Blocks and Yokes. The wire
should anchor the Cap Screw at least 2 complete 360° turns. The Lockwire ends should be trimmed and bent out of the way of
any part interference.

Keep Yoke Bars in Neutral while assembling.

Special Tools
• Vise with brass jaws or wood blocks

Procedure -
1. Assemble the Yoke Actuator Assembly:

2. From the Shift Bar Housing bottom, install the Actuator Pin
and Yoke Actuator.

3. On the Shift Bar Housing top, install the Washer and Nut.

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Transmission Overhaul Procedures - Bench Service

4. Assemble the 1st and Reverse Shift Yoke Assembly:

• Install the Plunger in the 1st and Reverse Shift Yoke
Bore, Plunger Shank to the outside.
• Install the Spring into the Bore over the Plunger Shank.
• Install the Plug and tighten to compress the Spring.
• After Plug bottoms out, back the plug out 1 to
1-1/2 turns.
• Complete the Block Assembly process by staking
the plug through the small hole in Block.

Procedures - Bench Service

Transmission Overhaul
5. With the Housing rear to the right, lay the Assembly on a
flat surface.

6. Start installation of the bottom Shift Bar, as the Bar

passes the Bosses, install the two (2) bottom Shift
Yoke Assemblies.

7. Install the Shift Yoke Lock Screw, torque to 35–45 lb-ft

(47.45–61.01 N•m). Lockwire securely.

8. Place the Actuating Plunger in the top center Bore.

9. Place one 3/4" Interlock Ball in the Interlock Bore, against the
bottom Bar.

10. Holding the middle Bar notched end, start installation.

As the Bar passes the Rear Boss, position the Shift Block.

11. As the Bar passes the center Boss, position the Shift Yoke
on Bar, long hub to the Housing front.

12. Just prior to inserting notched end of Bar in Rear Boss,

install the small Interlock Pin vertically in the Neutral
Notch Bore.

13. Install the Shift Block and Shift Yoke Lock Screws, torque
to 35–45 lb-ft (47.45–61.01 N•m). Lockwire securely.

14. Place one 3/4" Interlock Ball in the Interlock Bore, against
the middle Bar.

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Transmission Overhaul Procedures - Bench Service

15. Holding the top Bar notched end, start installation. As the
Bar passes the Rear Boss, position the Shift Block.

16. As the Bar passes the center Boss, position the Shift Yoke
on the Bar, long hub to the Housing rear.

17. Install the Shift Block and Shift Yoke Lock Screws, torque to
35–45 lb-ft (47.45–61.01 N•m). Lockwire securely.

18. Install the Oil Trough. Torque the Retaining Cap Screws to
8–12 lb-ft (10.85–16.30 N•m). (Some models do not have
an Oil Trough.)

19. Install the three (3) Tension Balls, one in each Housing top
Bore. Install the three (3) Detent Springs, one over each
Tension Ball.

Note: Make sure Interlocking System is working - should

not shift into 2 gears at the same time.

Note: Make sure all Lock Screws are lockwired.

138
 Transmission Overhaul Procedures - Bench Service

How to Disassemble the Forward Shift Bar Housing

Special Instructions
The Shift Bar Housing must be removed from the Transmission.

During disassembly, lay all parts on a clean bench in order of removal to facilitate assembly.

Shift Bars not being removed must be kept in the Neutral position or the interlocking parts lock the Bars.

Start with the bottom Shift Bar.

Cut the Lockwire and remove the Lock Screws from each Bar just before their removal.

Special Tools

Procedures - Bench Service

Transmission Overhaul
• Typical Service Tools

Procedure -
1. If the three (3) sets of Tension Springs and Balls from
Housing Bores have not been removed, place the Shift Bar
Housing on its side to remove them.

2. Remove the Oil Trough Retaining Cap Screws and

Oil Trough. (Some models do not have an Oil Trough.)

3. With the Housing rear to the right, lay the Assembly on a

flat surface.

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Transmission Overhaul Procedures - Bench Service

4. While removing the top Yoke Bar to the right, remove the
two (2) Shift Blocks.

5. From the middle Yoke Bar, remove the Shift Yoke and Shift
Block. As the Neutral Notch in the Bar clears the Rear Boss,
remove the small Interlock Pin from the Notch Bore.

6. Remove the Actuating Plunger from the center top

Boss Bore.

7. From the Bottom Yoke Bar, remove the two (2) Shift Yokes.

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 Transmission Overhaul Procedures - Bench Service

8. As the Shift Bar clears the last Boss, two (2) 3/4" Interlock
Balls drop from the bottom Rear Boss Bore.

Procedures - Bench Service

9. If damaged, from the 1st and Reverse Shift Yoke, remove

Transmission Overhaul
the Plug, Spring, and Plunger.

10. Inspect the Yoke or Block parts, replace the worn parts.

141
Transmission Overhaul Procedures - Bench Service

How to Assemble the Forward Shift Bar Housing

Special Instructions
Inspect Shift Blocks and Shift Yokes for wear.

Apply Eaton® Sealant #71208 or equivalent to the Shift Bar Housing Plugs which are used to plug Oil Cooler provision holes.
The sealant should be applied so at least 5 complete threads are covered.

Apply Eaton® Lockwire #1819 or equivalent to all Shift Bar Housing Assembly Set Screws in both Blocks and Yokes. The wire
should anchor the Cap Screw at least 2 complete 360° turns. The Lockwire ends should be trimmed and bent out of the way of
any part.

Keep Yoke Bars in Neutral while assembling.

Special Tools
• Vise with brass jaws or wood blocks

Procedure -
1. Assemble the Yoke Actuator Assembly:

2. From the Shift Bar Housing bottom, install the Actuator Pin
and Yoke Actuator.

3. On the Shift Bar Housing top, install the Washer and Nut.

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 Transmission Overhaul Procedures - Bench Service

4. Assemble the 1st and Reverse Shift Yoke Assembly:

• Install the plunger in the 1st and Reverse Shift Yoke
Bore, Plunger Shank to the outside.
• Install the Spring into the Bore over the Plunger Shank.
• Install the Plug and tighten to compress the Spring.
• After Plug bottoms out, back the Plug out 1 to
1-1/2 turns.
• Complete the Block Assembly process by staking the
Plug through the small hole in Block.

Procedures - Bench Service

Transmission Overhaul
5. With the Housing rear to the right, lay the Assembly on
a flat surface.

6. Start installation of the bottom Shift Bar, as the Bar

passes the Bosses, install the two (2) bottom Shift
Yoke Assemblies.

7. Install the Shift Yoke Lock Screw, torque to 35–45 lb-ft

(47.45–61.01 N•m). Lockwire securely.

8. Place the Actuating Plunger in the top center Bore.

9. Place one 3/4" Interlock Ball in the Interlock Bore, against

the bottom Bar.

10. Holding the middle Bar notched end, start installation. As

the Bar passes the Rear Boss, position the Shift Block.

11. As the Bar passes the center Boss, position the Shift Yoke
on Bar, long hub to the Housing front.

12. Just prior to inserting notched end of Bar in Rear Boss,

install the small Interlock Pin vertically in the Neutral
Notch Bore.

13. Install the Shift Block and Shift Yoke Lock Screws, torque
to 35–45 lb-ft (47.45–61.01 N•m). Lockwire securely.

14. Place one 3/4" Interlock Ball in the Interlock Bore, against
the middle Bar.

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Transmission Overhaul Procedures - Bench Service

15. Holding the top Bar notched end, start installation. As the
Bar passes the Rear Boss, position the Shift Block.

16. As the Bar passes the center Boss, position the Shift Yoke
on Bar, long hub to the Housing rear.

17. Install the Shift Block and Shift Yoke Lock Screws, torque to
35–45 lb-ft (47.45–61.01 N•m). Lockwire securely.

18. Install the Oil Trough, torque the Retaining Cap Screws to 8–
12 lb-ft (10.85–16.30 N•m). (Some models do not have an
Oil Trough.)

19. Install the three (3) Tension Balls, one in each Housing top
Bore. Install the three (3) Detent Springs, one over each
Tension Ball.

Note: Make sure Interlocking System is working - should

not shift into 2 gears at the same time.

Note: Make sure all Lock Screws are lockwired.

144
 Transmission Overhaul Procedures - Bench Service

How to Remove the Input Shaft Assembly (without Main Case disassembly)
Special Instructions
None

Special Tools
• RR1023TR Input Bearing Puller
• RR1019TR Hand Maul

Procedure -
1. From the Front Bearing Cover, remove the six (6)
Retaining Cap Screws and cover. Remove any remaining

Procedures - Bench Service

gasket material from the Case and Cover.

Transmission Overhaul
2. If present, remove and discard the rubber Seal Ring on the
Input Shaft. The Ring is used only to seal the Transmission
during shipment.

3. From the Input Shaft groove, remove the Bearing Retaining

Snap Ring.

145
Transmission Overhaul Procedures - Bench Service

4. Use a Soft Bar and Maul to drive the Input Shaft toward the
Case rear as far as possible. Pull the Input Shaft forward.

5. Install the RR1023TR Input Bearing Puller and remove the

Input Bearing from the Case and Input Shaft or use Pry Bars
or Screwdrivers to complete removal of the Bearing.

6. From the Drive Gear front, remove Drive Gear Spacer.

7. Remove the Drive Gear Internal Snap Ring.

8. Pull the Input Shaft forward and out of the Drive Gear.

9. Inspect the bushing in the Input Shaft pocket, replace

if damaged.

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 Transmission Overhaul Procedures - Bench Service

How to Install the Input Shaft Assembly (without Main Case disassembly)
Special Instructions
None

Special Tools
• RR1023TR Input Bearing Puller
• RR1019TR Hand Maul

1. Procedure -
2. If necessary, install the bushing in the back of the
Input Shaft.

Procedures - Bench Service

Transmission Overhaul
3. From the front, engage the Input Shaft Spline Teeth into
the Main Drive Gear.

Note: The current design Input Shaft Spline Teeth have

noticeable clearance to the Main Drive Gear internal
Spline Teeth. This is normal.

4. Install the Snap Ring in the Main Drive Gear inside groove.

5. Install the Spacer Washer over the Input Shaft. With the
Bearing External Snap Ring to the outside, position the
bearing on the Input Shaft.

147
Transmission Overhaul Procedures - Bench Service

6. Install the RR1005TR Input Bearing Driver over the Input

Shaft. Use a Flanged-End Bearing Driver which contacts
both the Bearing Inner Race and Outer Race. Drive the
Bearing until it contacts the Front Case.

7. Install the Input Shaft Retaining Snap Ring.

Note: Do not replace the small rubber Lip Seal. It is used

only to prevent leakage during shipping.

8. Install the Front Bearing Cover. Apply Loctite 242 to

Cap Screw threads and torque to 35–45 lb-ft
(47.45–61.01 N•m).

148
 Transmission Overhaul Procedures-Bench Service

How to Remove the Auxiliary Section with Tapered Bearings

Special Instructions

There can be different capscrew lengths, note their location.

Auxiliary sections can be removed either with the transmission in the horizontal position or the vertical position.

Auxiliary countershaft retaining straps may be installed to hold the countershafts in place. You can make retaining straps from 3"
x 1" bar stock. The auxiliary section can be removed without straps, use caution.

Special Tools
• See Tool Information (see Table 6)

Procedures-Bench Service
Transmission Overhaul
• Item T2: Auxiliary section hanger bracket for horizontal removal
• A steel bar longer than the width of the output yoke for vertical removal
• A hoist with a lifting chain
• Auxiliary countershaft retaining straps

Procedure -

1. To remove the auxiliary section in the horizontal position.

Remove the four (4) capscrews and the auxiliary counter-
shaft rear bearing cover, gasket, and rear bearing shim.

2. Install the auxiliary countershaft retaining straps with 2 - 3/

8" NC x 1" and 1 - 3/8" NC x 1 - 1/2" clean capscrews.

Note: Do not use an air gun. Tighten by hand until the cap-
screws are snug.

149
Transmission Overhaul Procedures-Bench Service

3. From the auxiliary section housing, remove the retaining

capscrews that attach the front section to the auxiliary sec-
tion.

4. Insert the two (2) longest capscrews in the housing flange

tapped holes. Tighten evenly to move the auxiliary section
away from the front box. Go far enough to break the gasket
seal.

5. Remove the capscrews from the tapped holes.

6. Attach an auxiliary section hanger bracket to the auxiliary

section top.

7. Attach a lifting chain to the auxiliary section hanger bracket.

8. Move assembly to the rear until auxiliary section is free.

9. Remove the gasket and clean all mounting surfaces of gas-

ket material.

Procedure -

1. To remove the auxiliary section in the vertical position.

With blocks under the clutch housing to prevent input shaft
damage, place transmission in the vertical position, clutch
housing down.

2. Remove the four (4) capscrews and the auxiliary counter-

shaft rear bearing cover, gasket, and rear bearing shim.
Clean the gasket surface area.

3. Install the auxiliary countershaft retaining straps with 2 - 3/

8" NC x 1" and 1 - 3/8" NC x 2 - 1/2" clean capscrews.

Note: Do not use an air gun. Tighten by hand until the cap-
screws are snug.

4. From the auxiliary section housing, remove the retaining

capscrews that attach the front box to the auxiliary section.

5. Install a steel bar through the yoke.

6. Attach a lifting chain to the steel bar.

7. Lift assembly from the front section.

150
 Transmission Overhaul Procedures-Bench Service

How to Remove the Combination Cylinder Assembly

Special Instructions

None

Special Tools
• Typical service tools

Procedure -

1. Drain lube.

Procedures-Bench Service
Transmission Overhaul
2. At the combination cylinder cover, remove the 5 capscrews
with washers.

3. Remove the cylinder cover and gasket.

4. If necessary, remove the insert valve retaining nut from the

cylinder cover. Remove the insert valve from the bore.

5. Remove the 15/16” nut on the range yoke bar.

6. Remove the 3/4” nut on the reduction yoke bar.

151
Transmission Overhaul Procedures-Bench Service

7. Remove the cylinder housing and gasket.

8. Remove the range and reduction pistons from the cylinder

bores.

9. If necessary, remove the O-rings from the range cylinder

bore and the reduction cylinder bore.

10. If necessary, remove the O-rings from the range piston I.D.
and O.D. and the reduction piston O.D.

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 Transmission Overhaul Procedures-Bench Service

How to Remove the Auxiliary Countershaft Assembly

Special Instructions

For ease of disassembly, mount the auxiliary section upright in a vise.

Both countershafts are removed the same.

As the countershaft strap is removed, the countershaft can fall.

Special Tools
• See Tool Information (see Table 6)

Procedures-Bench Service
• Vise with brass jaws or wood blocks

Transmission Overhaul
• Item T11: Bearing Puller
• Soft bar and maul

153
Transmission Overhaul Procedures-Bench Service

Procedure -

1. To hold the auxiliary countershafts from turning, place a

shop rag or equivalent between the splitter gear and one
countershaft.

2. From the output shaft, loosen 1 1/2" nut. Do not remove yet.

3. Install countershaft retaining strap.

4. Use a soft bar and maul to drive the output shaft forward far
enough to partially unseat the bearing.

5. Support the auxiliary countershaft while removing the auxil-

iary countershaft retaining strap.

6. Remove the auxiliary countershaft.

154
 Transmission Overhaul Procedures-Bench Service

7. Remove the auxiliary countershaft bearing race from bore.

Procedures-Bench Service
Transmission Overhaul
8. If necessary, secure the countershaft assemblies in a vise
and remove both the front and rear bearings with a bearing
separator and jaw pullers.

155
Transmission Overhaul Procedures-Bench Service

How to Disassemble the Output Shaft Assembly

Special Instructions

When using the soft bar and maul on the output shaft, be careful not to damage the threads.

When removing the rear bearing cover, the rear bearing cone drops from the housing bore.

Special Tools
• Vise with brass jaws or wood blocks
• Press
• Soft bar and maul

Procedure -

1. Remove the range yoke assembly and synchronizer. Re-

move the range yoke assembly from the synchronizer slid-
ing clutch.

2. Use a 1 1/2” socket or wrench to remove the auxiliary main-

shaft nut.

3. Remove the washer and dowel pin from the auxiliary main-
shaft.

156
 Transmission Overhaul Procedures-Bench Service

4. Remove the low range gear and coupler assembly.

Procedures-Bench Service
5. From front with a punch and hammer, drive the two coupler

Transmission Overhaul
pins from the coupler. Align the coupler splines with the
washer splines and remove the range coupler from the LO
range gear.

6. If necessary, remove the bushings from inside the coupler.

7. Remove the splined washer from inside the LO range gear.

157
Transmission Overhaul Procedures-Bench Service

8. Remove the sliding clutch and the reduction yoke assembly

from the auxiliary housing.

9. Use a soft bar and maul to completely drive the output shaft
forward and through the rear bearing assembly.

10. Remove the bearing inner spacer from the output shaft.

11. Use the reduction gear front face as a base, press the output
shaft through the bearing and gear. This frees the bearing,
reduction gear, washer, and the splined washer.

158
 Transmission Overhaul Procedures-Bench Service

12. Remove the flat washer, reduction gear, and the stepped
washer from the shaft.

Procedures-Bench Service
Transmission Overhaul
13. Remove the rear bearing cover retaining capscrews, rear
bearing cover, and the gasket from the auxiliary housing.
The rear bearing cone drops from the housing bore when the
cover is removed. If necessary, replace the oil seal on the
rear bearing cover.

14. Remove the complete bearing race from the bearing bore.

159
Transmission Overhaul Procedures - Bench Service

How to Disassemble the Synchronizer Assembly

Special Instructions
Place the Synchronizer Assembly on a clean, flat surface. Cover the Synchronizer Assembly with a shop rag to prevent losing the
three (3) springs under pressure from the HI Range Synchronizer Pin locations.

Special Tools
• Typical Service Tools

Synchronizer
LO
Spring

Synchronizer
HI

Sliding Clutch
Spring
Spring

Procedure -

1. Place the larger LO Range Synchronizer Ring on the bench.

2. Cover the Synchronizer with a shop rag to contain the

springs.

3. Grab both sides of the HI Range Synchronizer and pull.

4. From the Synchronizer Ring LO Range pins, remove the

Sliding Clutch.

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 Transmission Overhaul Procedures - Bench Service

How to Assemble the Synchronizer Assembly

Special Instructions
Assembly should be done on a clean, flat surface slightly lower than your waist.

Pins on the LO Range Synchronizer must line up with the chamfered holes on the Sliding Clutch bottom.

When compressing the HI Range Synchronizer springs cover with a shop rag. In the event compression is not achieved the first
time, this prevents the springs from leaving the bench area.

Special Tools
• Typical Service Tools

Procedures - Bench Service

Transmission Overhaul
Synchronizer
LO
Spring

Synchronizer
HI

Sliding Clutch
Spring
Spring

161
Transmission Overhaul Procedures - Bench Service

Procedure -
1. On the bench, place the larger LO Range Synchronizer Ring
face down with pins up.

2. With the Sliding Clutch recessed side up, place the Sliding
Clutch on the LO Range Synchronizer Pins.

3. In the HI Range Synchronizer Bores, install the three (3)

springs.

4. Place the HI Range Synchronizer Ring over the LO Range

Synchronizer Ring. Rotate the HI Range Synchronizer until
the springs are seated against the pins.

5. Cover the Assembly with a shop rag.

6. Apply downward pressure to the HI Range Synchronizer

Ring while twisting counterclockwise. This compresses the
springs to fully seat HI Range on the LO Range
Synchronizer. This should be done with a rapid twist and
push motion.

Note: Make sure there are three springs and they are fully
compressed.

Note: Make sure you can move the Sliding Clutch from HI to
LO Range and back.

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 Transmission Overhaul Procedures-Bench Service

How to Assemble the Output Shaft Assembly

Special Instructions

Make sure the magnetic plugs are installed in the auxiliary housing.

When heating the bearings, do not heat above 275°F (136°C).

Special Tools
• See Tool Information (see Table 6)
• Toolmakers’s dye
• Heat lamp or hot plate and oil

Procedures-Bench Service
Transmission Overhaul
• Oil seal installation tool

Procedure -

1. From auxiliary mainshaft front, assemble deep reduction

clutch over splines.

2. Mark, with toolmaker’s dye, two opposing teeth on the low

range gear.

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Transmission Overhaul Procedures-Bench Service

3. Assemble low range gear to coupler and install bushings if

removed.

4. Install splined washer in low range gear

5. Assemble gear over coupler.

6. Rotate splined washer to align pins and drive pins through

lock washer.

Note: Make sure pins are installed below coupler thrust surface.

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 Transmission Overhaul Procedures-Bench Service

7. Slide low gear assembly on auxiliary mainshaft front.

8. Install dowel pin.

Procedures-Bench Service
Transmission Overhaul
9. Place retainer washer in position.

10. If reusing nut, apply a thread locking compound to the

threads. New nuts should have a pre-applied locking com-
pound. Torque the nut to 180-210 Lbf·ft.

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Transmission Overhaul Procedures-Bench Service

11. Assemble mainshaft assembly into transmission rear.

Splines on mainshaft end must slide into range synchroniz-
er. Marked teeth on low a range gear must be aligned with
marked teeth on countershafts.

12. Install O-ring or gasket onto deep reduction yoke end. NOTE:
Early versions used P/N 21338 gasket with P/N 21337 pis-
ton. Current designs use a P/N 4301348 O-ring with P/N
43013320 piston. The proper gasket or O-ring must be in-
stalled with the respective piston.

13. Install deep reduction yoke into slot on deep reduction slid-
ing clutch. Make sure positioning is correct.

14. Install stepped washer over auxiliary mainshaft with stepped

side up.

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 Transmission Overhaul Procedures-Bench Service

15. Mark, with toolmaker’s dye, two opposing teeth on the re-
duction gear.

16. Install reduction gear over auxiliary mainshaft. Line up

Procedures-Bench Service
marked teeth.

Transmission Overhaul
17. Apply grease to reduction gear rear thrust surface.

18. Install large flat washer.

19. Select front tapered output bearing (bearing with longer roll-
ers). Heat and install.

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Transmission Overhaul Procedures-Bench Service

20. Install inner bearing spacer.

21. If not previously installed, install dowel pins. Confirm instal-

lation to proper distance.

22. Position gasket and install auxiliary housing.

23. Install bearing cup.

24. Heat rear tapered bearing and install over outputshaft.

25. Position a new gasket on the rear bearing cover mounting

surface.

26. Apply Eaton/Fuller Sealant #71205 or equivalent to the re-

taining capscrews.

27. Install the bearing cover and capscrews. Tighten to 35-45

Lb•ft.

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 Transmission Overhaul Procedures-Bench Service

How to Install the Combination Cylinder Assembly

Special Instructions

Apply Eaton lubricant #71206 or equivalent to all shift cylinder assembly and spool valve O-rings so a film covers the entire sur-
face.

Apply Eaton rust preventative #71213 or equivalent to all shift cylinder walls and yoke bars, cover the entire yoke bar surface that
comes in contact with the shift cylinder O-ring.

Special Tools
• Typical service tools

Procedures-Bench Service
Transmission Overhaul
Procedure -

1. Lightly lubricate O-rings with Eaton® Fuller® Silicone lubri-

cant P/N 71206 or equivalent.

2. Install O-rings into range and reduction shift cylinders.

3. Install O-rings onto range and reduction pistons.

4. Install gasket and shift cylinder.

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Transmission Overhaul Procedures-Bench Service

5. Install range piston with flat side to rear. Install range piston
nut and torque to 70-85 Lb•ft.

6. Install deep reduction piston with flat side to rear. Install nut
and torque to 50-65 Lb•ft.

Note: If reusing existing nut, make sure nylon locking mate-

rial is in good shape, if not, replace nut.

7. Lightly lubricate insert valve O-rings with Eaton® Fuller®

Silicone lubricant P/N 71206 or equivalent. Install insert
valve with flat side to the inside. Install insert valve retaining
nut and torque to 40- 50 Lb•ft.

8. Install gasket and cover. Apply Eaton® Fuller® thread seal-

ant P/N 71205 or equivalent to capscrew threads. Install
capscrews and torque to 35-45 Lb•ft.

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 Transmission Overhaul Procedures-Bench Service

How to Install the Auxiliary Countershaft Assembly

Special Instructions

To make auxiliary section assembly easier, you can make an auxiliary section fixture out of a 2" x 12" piece of wood.

24"

3"
12"

11.67"

Procedures-Bench Service
Transmission Overhaul
2"
This fixture is designed to ease the assembly of the auxiliary gearing. Set the auxiliary countershaft rear bearings in the 3” holes.

Set the assembled auxiliary mainshaft between the countershafts with the timing marks aligned.

Special Tools
• Auxiliary countershaft retaining straps
• Toolmaker’s dye

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Transmission Overhaul Procedures-Bench Service

Procedure -

1. Place the front section in a vertical position.

2. Install the auxiliary countershaft bearing cups into their re-

spective bores in front section.

3. Mark, with toolmaker’s dye, two opposing teeth on the aux-

iliary drive gear.

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 Transmission Overhaul Procedures-Bench Service

4. For timing purposes, identify and mark with toolmaker’s dye

the two teeth on each countershaft that are identified with a
“O”. Use a straight edge to line up the marked teeth with the
teeth on the remaining two countershaft gears, paint these
teeth.

Procedures-Bench Service
Transmission Overhaul
5. Install both countershaft assemblies. Match the timing
marks on the auxiliary drive gear with the timing marks on
the countershafts.

Note: If assembling auxiliary section on a bench using fix-

ture, position the auxiliary countershaft with timing
marks facing inward. Follow the remaining steps.

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Transmission Overhaul Procedures-Bench Service

6. Install the assembled outputshaft (see Outputshaft Assem-

bly) between the countershafts and match the timing marks.

7. Install range and reduction yokes.

8. Place the auxiliary housing over the countershaft assemblies

and the outputshaft assembly.

9. Make sure the outputshaft bearing spacer is on the output-

shaft.

10. Heat the rear output bearing cone and install the bearing, ta-
pered side down, on the shaft.

11. Position a new gasket on the rear bearing cover mounting

surface.

12. Position the rear bearing cover.

13. Apply Eaton/Fuller Sealant #71205 or equivalent to the re-

taining capscrews.

14. Install the six (6) retaining capscrews in the non-chamfered

hole, tighten to 35-45 Lb•ft of torque.

15. Install the bearing races.

16. Install each auxiliary countershaft retaining strap with 2 - 3/

8" NC x 1" and 1 - 3/8" NC x 21/2" clean capscrews.

Note: Do not use an air gun. Tighten by hand until the cap-
screws are snug.

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 Transmission Overhaul Procedures-Bench Service

How to Remove the Clutch Housing

Special Instructions

Removal of the clutch housing is done in the horizontal position.

The clutch release mechanism must be removed.

Special Tools
• Typical service tools

Procedure -

Procedures-Bench Service
Transmission Overhaul
1. From inside the clutch housing, remove the nuts and wash-
ers.

2. From inside the clutch housing, remove the bolts.

3. Jar clutch the housing to break the gasket seal.

4. Pull the clutch housing from the studs and transmission

case.

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Transmission Overhaul Procedures-Bench Service

5. Remove the gasket and clean all mounting surfaces of gas-

ket material.

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 Transmission Overhaul Procedures-Bench Service

How to Remove the Auxiliary Drive Gear Assembly

Procedures-Bench Service
Transmission Overhaul
Special Instructions

Before removing the auxiliary drive gear, the auxiliary section must be removed.

Special Tools
• Large pair of snap ring pliers
• Brass maul
• Crow’s foot

Standard Torque Capacity Models

Procedure -

1. Remove the mainshaft rear groove snap ring.

2. Remove the six (6) auxiliary bearing retainer ring capscrews

and bearing retainer ring.

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Transmission Overhaul Procedures-Bench Service

3. Insert a prybar into the main case gearing and use it to slide
the mainshaft assembly rearward to move the auxiliary drive
gear bearing from its bore.

4. If if does not move easily, it may be necessary to install three

capscrews in the threaded holes on the retainer plate. Tight-
en the three screws evenly to force the auxiliary drive gear
assembly from the case. The three threaded holes are only
found on earlier models.

High Torque Capacity Models

Procedure -

1. Remove the mainshaft rear groove snap ring.

2. Slide the auxiliary drive gear off the mainshaft.

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 Transmission Overhaul Procedures-Bench Service

3. Remove six capscrews from auxiliary drive gear bearing re-

Procedures-Bench Service
Transmission Overhaul
tainer and remove the retainer plate.

4. Insert prybar into main case gearing, use to slide mainshaft

assembly rearward to move mainshaft rear bearing slightly
rearward.

5. Use a rolling head prybar (crow’s foot) to work the main-

shaft rear bearing from its bore.

6. If the bearing must be replaced, press the inner spacer from

the mainshaft rear bearing.

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Transmission Overhaul Procedures - Bench Service

How to Disassemble the Upper Reverse Idler Gear Assembly

Special Instructions
Before the upper Reverse Idler Gear Assembly can be removed, Mainshaft Reverse Gear must be positioned forward against
the next Gear.

While removing the Reverse Idler Shaft, the Thrust Washer can drop to the Transmission case bottom.

The Mainshaft Reverse Gear must be moved in order to remove the upper Reverse Idler Gear.

Special Tools
• RR1010TR Slide Hammer

Procedure -
1. Remove Retaining Bolt from the Idler Shaft.

Note: If Idler Shaft spins in Case Bore, slightly heat bolt with
torch to release loctite adhesive.

2. The Mainshaft Reverse Gear must be moved in order to

remove the Upper Reverse Idler Gear. Remove Reverse Gear
Snap Ring and slide Reverse Gear forward over Clutch.

3. Remove the loosened bolt and remove washer. Reinstall bolt

3–4 threads.

4. Install an Impact Puller, 1/2"-13 threaded end, and remove

the Shaft from Case Bore.

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Transmission Overhaul Procedures - Bench Service

5. As the Idler Shaft and Idler Plate are removed, remove the
Thrust Washers and Gear.

Procedures - Bench Service

6. Inspect the Reverse Gear Assembly, remove the Inner Race

Transmission Overhaul
and Needle Bearing, if damaged.

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Transmission Overhaul Procedures - Bench Service

How to Disassemble the Lower Reverse Idler Gear Assembly

Special Instructions
Before the Lower Reverse Idler Gear Assembly can be removed the Mainshaft and Countershaft Assemblies must be removed.

While removing the Reverse Idler Shaft, the Thrust Washer can drop to the Transmission Case bottom.

Special Tools
• Typical Service Tools
• Jaw Pullers or Impact Puller
• Soft Bar and Maul

Procedure -
1. Remove Retaining Bolt from the Idler Shaft.

Note: If Idler Shaft spins in Case Bore, slightly heat bolt with
torch to release loctite adhesive.

2. Remove the loosened bolt and remove washer. Reinstall bolt

3–4 threads.

3. Install an Impact Puller, 1/2"-13 threaded end, and remove

the Shaft from Case Bore.

4. As the Idler Shaft and Idler Plate are removed, remove the
Thrust Washers and Gear.

5. Inspect the Reverse Gear Assembly, remove the Inner Race

and Needle Bearing, if damaged.

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 Transmission Overhaul Procedures - Bench Service

How to Remove the Upper and Lower Countershaft Bearings

Special Instructions
The following instructions are used to remove the Upper and Lower Countershaft Bearings. To remove the Mainshaft Assembly,
only the Upper Countershaft Bearings need to be removed.

Performing the following instructions will damage the bearings and should be not be done unless bearing replacement is planned.

The Bearing Inner Race remains pressed on the Countershaft after removal of the Front Bearings.

Special Tools
• RR1019TR Hand Maul
• RR1020TR Soft Bar

Procedures - Bench Service

Transmission Overhaul
• RR1012TR Bearing Puller

Procedure -
1. To keep the Mainshaft Pilot from falling out of the Input
Shaft pocket, temporarily install the Auxiliary Drive Gear on
the Mainshaft.

2. From each Countershaft Rear Groove, remove the

Snap Ring.

3. Remove six Cap Screws from Front Bearing Cover and

remove Front Bearing Cover.

CAUTION

Damage will likely occur to this bearing during removal. It is

strongly recommended that this bearing is discarded.

4. From inside the case, use a Soft Bar and Maul to drive the
Countershaft Rear Bearings rearward off the shaft.

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Transmission Overhaul Procedures - Bench Service

5. From the front of each Countershaft, remove the Cap Screw

and front Retainer Plate.

6. Use the Soft Bar and Maul to drive each Countershaft to

the rear as far as possible. This partially unseats the
Front Bearings.

7. Return to the case rear, and drive each Countershaft forward

as far as possible. This exposes the External Snap Ring.

8. Use theRR1012TR Bearing Puller to remove the

Countershaft Front Bearings.

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 Transmission Overhaul Procedures - Bench Service

How to Remove the Mainshaft Assembly

Special Instructions
None

Special Tools
• RR1004TR Mainshaft Lifting Hook
• RR1022TR Countershaft Support Tool

Procedure -
1. With the Upper Countershaft Bearings removed, support the

Procedures - Bench Service

Countershaft Assembly with a RR1022TR Support Tool.

Transmission Overhaul
2. Insert the RR1004TR Mainshaft Hook around the Mainshaft
Assembly.

Note: Keep the Upper Countershaft forward against the

Case front wall.

WARNING

Be careful when removing the Mainshaft Assembly. The

Sliding Clutch on the front and the Reverse Gear on the back
can slip off the shaft.

3. Pull the Mainshaft to the rear to free the pilot from the Input
Shaft pocket.

4. Tilt the Mainshaft front up and lift the Assembly from

the Case.

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Transmission Overhaul Procedures - Bench Service

How to Remove the Countershaft Assemblies

Special Instructions
Except for the PTO gears, the Upper and Lower Countershaft Assemblies are the same. Mark the Countershafts as UPPER or
LOWER as you remove them.

The Mainshaft and Main Drive Gear must be removed before removing the Countershaft Assemblies.

Special Tools
• RR1012TR Countershaft Bearing Puller
• RR1019TR Hand Maul
• RR1020TR Soft Bar

Procedure -
1. Remove the Rear Snap Ring from the Rear Upper
Countershaft Bearing.

2. From inside the case, use a long Soft Bar to drive the Upper
Countershaft Rear Bearing rearward off the Shaft.
Note: Damage will likely occur to this bearing during
removal. It is strongly recommended that this bearing
is discarded.

3. Remove the Cap Screw and the Retainer from the Upper
Countershaft front.

4. Slide the Lower Countershaft forward. This will move the

Front Bearing forward to expose the External Snap Ring.

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Transmission Overhaul Procedures - Bench Service

5. Use the RR1012TR Countershaft Bearing Puller to remove

the Lower Front Bearing from its Bore.

6. Move the Upper Countershaft to the rear until the Front

Bearing Journal clears the Front Case Bore.

Procedures - Bench Service

7. Swing the front of the Countershaft to the center of the Case,

Transmission Overhaul
and lift out the Countershaft Assembly.
Note: Follow the same procedure for Lower Countershaft
removal.

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Transmission Overhaul Procedures - Bench Service

How to Disassemble the Countershaft Assemblies

Special Instructions
As you disassemble the Countershafts, mark each part as belonging to the Upper or Lower Countershaft and mark the gears for
front or back orientation.

Except for the PTO Gears, the Upper and Lower Countershaft Assemblies are identical and disassembled in the same manner.

Special Tools

10
11

13 12

15 2 1
4 3
5
14 6
7
8
9

10364-11-96 CS/RT

1. Snap Ring 8. Gear

2. Bearing 9. Gear
3. Countershaft with Reverse and LO 10. PTO Gear
4. Key 11. Drive Gear
5. Roll Pin 12. Snap Ring
6. Key 13. Bearing
7.Gear 14. Retainer Kit
15. Cap Screw

Procedure -

CAUTION

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Transmission Overhaul Procedures - Bench Service

NEVER USE THE PTO GEAR AS A PRESSING BASE. The narrow

face width of this gear makes it very susceptible to breakage

1. Remove the front Countershaft Snap Ring.

2. Place the Countershaft in the Press as shown. Using the rear

face of 3rd/Overdrive Speed Gear as a base, press the Drive
Gear, PTO Gear, and 3rd/Overdrive Speed Gear from each

Procedures - Bench Service

Countershaft. This removes the Front Bearing Inner Race

Transmission Overhaul
from the Countershaft.

3. Position the Countershaft in the Press as shown. Press

the next two gears from the Shaft.

4. Inspect the Keys and Roll Pin. Remove and replace

if damaged.

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Transmission Overhaul Procedures - Bench Service

How to Remove the Input Shaft and Main Drive Gear

Special Instructions
None
• Special Tools
• RR1023TR Input Bearing Puller
• RR1019TR Hand Maul
• RR1020TR Soft Bar

Procedure -
1. From the Front Bearing Cover, remove the six (6) Retaining
Cap Screws and Cover. Remove any remaining gasket
material from the Case and Cover.

2. If present, remove and discard the Rubber Seal Ring on the

Input Shaft. The Ring is used only to seal the Transmission
during shipment.

3. From the Input Shaft groove, remove the Bearing Retaining

Snap Ring.

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Transmission Overhaul Procedures - Bench Service

4. Use a Maul to drive the Input Shaft toward the case rear as
far as possible. Pull the Input Shaft forward.

Procedures - Bench Service

Transmission Overhaul
5. Install the RR1023TR Input Bearing Puller and remove the
Input Bearing from the Case and Input Shaft or use Pry Bars
or Screwdrivers to complete removal of the Bearing.

6. From the Drive Gear front, remove Drive Gear Spacer.

7. Remove the Drive Gear Internal Snap Ring.

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Transmission Overhaul Procedures - Bench Service

8. Pull the Input Shaft forward and out of the Drive Gear.

9. From inside the Case, remove the Drive Gear.

10. Inspect the bushing in the Input Shaft pocket, replace

if damaged.

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 Transmission Overhaul Procedures - Bench Service

How to Disassemble the Mainshaft Assembly

Special Instructions
Lay all parts on a clean bench in order of removal to facilitate assembly.

Special Tools
• Typical Service Tools

Procedure -
1. Lay the Mainshaft on its side, and from the front, remove
the 4th (or Overdrive) and 5th Sliding Clutch.

Procedures - Bench Service

Transmission Overhaul
2. Place the Mainshaft in a vertical position, pilot end down.

3. Remove Snap Ring (if applicable).

4. Remove Key, Washer, and Reverse Gear. Mark Keyway

location.
Note: When removing washer and Reverse Gear, note their
orientation. Keep the Washer with the Reverse Gear.

5. Remove the 1st and Reverse Sliding Clutch.

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Transmission Overhaul Procedures - Bench Service

6. Remove the Offset Washer and 1st Gear.

7. Remove the Flat Washer and 2nd Gear.

8. Remove the Offset Washer and Sliding Clutch.

9. Remove the Offset Washer and 3rd Gear.

10. Remove the Flat Washer.

11. Remove the 4th or Overdrive Gear.

12. Remove the Offset Washer.

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 Transmission Overhaul Procedures-Bench Service

How to Disassemble the Mainshaft Assembly with Low Force Gearing

Special Instructions

The design of the mainshaft with Low Force Gearing is slightly different from the standard mainshaft. It still utilizes Non-Selective
(Non-Adjustable) Tolerance Washers, but the 1st and reverse gears and sliding clutch have been redesigned. In this configuration,
the 1st/reverse sliding clutch rides on a clutch hub, and the 1st and reverse gears have been redesigned to accommodate this
change.

Lay all parts on a clean bench in order of removal to facilitate assembly.

Special Tools
• Typical service tools

Procedures-Bench Service
Transmission Overhaul
Procedure -

1. Lay the mainshaft on its side, and from the front, remove the
4th (or overdrive) and 5th sliding clutch.

2. Place the mainshaft in a vertical position, pilot end down.

Remove the reverse gear, clutch hub, and sliding clutch.

3. Remove the snap ring and key. Mark keyway location.

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Transmission Overhaul Procedures-Bench Service

4. Remove the offset washer and 1st gear.

5. Remove the flat washer and 2nd gear.

6. Remove the offset washer and sliding clutch, and then re-
move the offset washer and 3rd gear.

7. Remove the flat washer, remove the 4th or overdrive gear,

and remove the offset washer.

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 Transmission Overhaul Procedures - Bench Service

How to Assemble the Mainshaft Assembly with Selective (Adjustable) Thickness

Tolerance Washers
Special Instructions
There are three distinct Mainshaft Washer and Mainshaft Key designs. They are (listed from oldest design to newest design):
a. Six (6) sided Mainshaft Key with Selective (adjustable) Thickness Tolerance Washers.
b. Three (3) sided Mainshaft Key with Selective (adjustable) Thickness Tolerance Washers.
c. Three (3) sided Mainshaft Key with Non-Selective (non-adjustable) Tolerance Washers.
Note: Between 1993 and 1996, some models were produced with a mixture of Selective Thickness Washers and Non-Selective
Tolerance Washers on the same Mainshaft.

Procedures - Bench Service

Note: The proper Mainshaft Key must always be used with the proper design Mainshaft Washers. If necessary, refer to the Parts

Transmission Overhaul
Manual for your specific model to confirm the proper parts.
Note: Previous design levels can be updated to the current design.

Each Mainshaft Gear must have its inside Snap Ring installed before placement on the Mainshaft. Do not install Reverse Gear
Inside Snap Ring at this time.

Gear Tolerance Washers are internally splined and locked to the Mainshaft by the Key. Gear Spacers are externally splined to
engage with Gear Hub Clutching teeth. There is one Tolerance Washer and one Spacer for each Mainshaft Gear.

Axial Clearance (end-play) limits are 0.006–0.015" for all Mainshaft Gears.

If the Axial Clearance is less than the minimum 0.006" tolerance, the Tolerance Washer should be replaced with a thinner Tolerance
Washer. This will increase the Axial Clearance between the gears. If the Axial Clearance is greater than the maximum 0.015"
tolerance, a thicker Tolerance Washer should be installed. This will decrease the Axial Clearance between the gears.

If necessary, refer to the Parts Manual for your specific Transmission model to determine the correct position of each
Mainshaft Gear.

The Mainshaft you are using may have 3 grooves in certain gear positions. The middle groove is not used with the Selective
Washer design.

Special Tools
• A piece of 5/32" Air Line, 1' long
• Vise with brass jaws

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Transmission Overhaul Procedures - Bench Service

Procedure -
1. With Mainshaft pilot-end down, secure the Mainshaft in a
Vise equipped with brass jaws or wood blocks.

2. If previously removed, install the Roll Pin in Keyway.

3. With the washer flat side up, position a gear Tolerance

Washer (white) in the Mainshaft 1st or bottom groove.
Rotate the washer until the Washer Splines and Mainshaft
SpIines align.

4. Start at the Mainshaft bottom and install a 1/8" or 5/32"

diameter plastic line in the Keyway to lock the washer in
place. As Limit Washers and Gears are installed, continue to
push the plastic line up.

5. Against the 4th Speed Gear Washer, position a Spacer

Washer against the Tolerance Washer.

6. With Clutching teeth down and engaged with the Spacer

external Splines, position the proper Gear on the Mainshaft.
If necessary, refer to the illustrated parts list to determine
Gear order.

7. With Clutching teeth up and against this gear, install the next
Gear and Spacer Washer.

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Transmission Overhaul Procedures - Bench Service

8. With the washer flat side down, position a Tolerance Washer

against the Spacer. Rotate the washer until the Washer
Splines and Mainshaft Splines align.

9. Push the Air Line up to lock the washer on the Mainshaft.

Procedures - Bench Service

10. Insert two large Screwdrivers between the two gears. Apply

Transmission Overhaul
slight downward pressure to spread the gears evenly.
Between the Gear Hub and Mainshaft Spacer, insert 0.006"
Feeler Gauge and 0.015" Feeler Gauge. If out of tolerance,
change the washer against the Mainshaft Spacer.

11. With the missing Internal Splines aligned with the plastic
line, install a Sliding Clutch.

12. With the washer flat side up, position Tolerance Washer
(white) in the next available groove. Rotate the washer until
the Washer Splines and Mainshaft Splines align.

13. Push the Air Line up to lock the washer on the Mainshaft.

14. Install a Gear Spacer.

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Transmission Overhaul Procedures - Bench Service

15. With Clutching teeth down, position the next Gear on the
Mainshaft engaging with Spacer external Splines.

16. With Clutching teeth up, install the next Gear on Shaft
against the previously positioned gear.

17. Position another Spacer against the previously positioned

gear, engaging the Spacer External Splines with Gear
Clutching teeth.

18. With washer flat side down, position the Tolerance Washer
against the Spacer. Rotate the washer until the Washer
Splines and Mainshaft Splines align.

19. Push the Air Line up to lock the washer on the Mainshaft.

20. Insert two large Screwdrivers between the two gears. Apply
slight downward pressure to spread the gears evenly.
Between the Gear Hub and Mainshaft Spacer, insert 0.006"
Feeler Gauge and 0.015" Feeler Gauge. If out of tolerance,
change the washer against the Mainshaft Spacer. Refer to
information before stepped procedures for further
information.

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Transmission Overhaul Procedures - Bench Service

21. Align the Sliding Clutch missing internal Spline with the
Mainshaft Key and install the Reverse Speed Sliding Clutch.

22. With the flat side up, place a washer (blue or white) in the
next available groove. Rotate the washer until the Washer
SpIines and Mainshaft Splines align.

23. Push the Air Line up to lock the washer on the Mainshaft.

24. Against the Tolerance Washer, position Reverse Speed

Gear Spacer.

Procedures - Bench Service

25. Install Reverse Gear on the Mainshaft. Engage the Gear

Transmission Overhaul
Clutching teeth with Spacer External Splines and Sliding
Clutch. Move the Reverse Gear down against the 1st
Speed Gear.

26. At this time remove the Air Line and insert the Mainshaft
Key. Be careful not to move the gears while doing this
procedure, the Tolerance Washers are unlocked and can
rotate which would cause the gears to drop.

27. Remove the Mainshaft from the Vise.

28. On the shaft front, align the Sliding Clutch missing internal
Spline with the Mainshaft Key and install the front Sliding
Clutch. Engage the Sliding Clutch external Splines with the
gear Clutching teeth.

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Transmission Overhaul Procedures - Bench Service

29. Washers for 6-Sided Key

Part Size Color

14711 0.248–0.250 White

14712 0.253–0.255 Green

14713 0.258–0.260 Orange

14714 0.263–0.265 Purple

14715 0.268–0.270 Yellow

14716 0.273–0.275 Black

30. Washers for 3-Sided Key

Part Size Color

4300830 0.244 Blue-Light Blue

4300382 0.249 White-Light

4300383 0.254 Green-Light

4300384 0.259 Orange-Light

4300385 0.264 Purple-Light

4300386 0.269 Yellow-Light

4300387 0.274 Black-Light Blue

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 Transmission Overhaul Procedures - Bench Service

How to Assemble the Mainshaft Assembly with Non-Selective (Non-Adjustable)

Tolerance Washers
Special Instructions
The proper Mainshaft Key must always be used with the proper design Mainshaft Washers. If necessary, refer to the Parts Manual
for your specific model to confirm the proper parts.

Previous design levels can be updated to the current design.

Special Tools
• A piece of 5/32" Air Line, 1" long
• Vise with brass jaws

Procedures - Bench Service

Transmission Overhaul
Procedure -
1. With Mainshaft pilot-end down, secure the Mainshaft in a
Vise equipped with brass jaws or wood blocks.

2. If previously removed, install the Roll Pin in Keyway.

3. With Mainshaft pilot-end down, install Offset Washer (flat

surface up). Rotate the washer until the Washer Splines and
Mainshaft SpIines align.

4. Start at the Mainshaft bottom and install a plastic line in the

marked Keyway to lock the washer in place.

5. With Clutching teeth down, position the proper gear on the

Mainshaft. Refer to the illustrated parts list for correct gear.

6. Install the Flat Washer. Rotate the washer until the Washer
Splines and Mainshaft Splines align.

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Transmission Overhaul Procedures - Bench Service

7. With Clutching teeth up and against the spacer, install the

next Gear.

8. Position the Offset Washer (flat surface down) against the

gear. Rotate the washer until the Washer Splines and
Mainshaft Splines align.

9. Push the Air Line up to lock the washers on the Mainshaft.

10. With the missing internal Splines aligned with the plastic
line, install the proper Sliding Clutch.

11. Position the next Offset Washer in the next available groove.
Rotate the washer until the Washer Splines and Mainshaft
Splines align.

12. Push the Air Line up to lock the washer on the Mainshaft.

13. With Clutching teeth down, position the next proper gear on
the Mainshaft.

14. Position the Flat Washer against the gear. Rotate the washer
until the Washer Splines and Mainshaft Splines align.

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Transmission Overhaul Procedures - Bench Service

15. With Clutching teeth up, install next Gear on the Shaft
against previously installed Gear.

16. Position the Offset Washer (flat surface down) against the

Procedures - Bench Service

Transmission Overhaul
Gear. Rotate the Washer until the Washer Splines and
Mainshaft Splines align.

17. Push the Air Line up to lock the Washer on the Mainshaft.

18. With the missing internal Splines aligned with the plastic
line, install the Reverse Sliding Clutch.

19. Install the Reverse Gear Offset Washer in the last groove.

20. From the Mainshaft rear, install the Mainshaft Key into the
Spline with the Air Line. Pull the Air Line from the Spline
while installing the Key.

21. Install the Reverse Gear Spacer Washer (with external

Spline teeth) over the Mainshaft rear and against the
Offset Washer.

Note: Some models, the Reverse Gear Offset Washer has a

large chamfer machined in the backside. This special
Offset Washer must be used in this position. The large
chamfer faces rearward.

22. From the rear, install the Reverse Gear over the Sliding
Clutch teeth.

23. Install the Snap Ring in the Mainshaft groove.

Note: Some models do not use a Snap Ring at this position.

24. Remove the Mainshaft from the Vise and lay on its side.

25. Install the front Sliding Clutch into position.

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How to Assemble the Mainshaft Assembly with Low Force Gearing

Special Instructions

The design of the mainshaft with Low Force Gearing is slightly different from the standard mainshaft. It still utilizes Non-Selective
(Non-Adjustable) Tolerance Washers, but the 1st and reverse gears and sliding clutch have been redesigned. In this configuration,
the 1st/reverse sliding clutch rides on a clutch hub and the 1st and reverse gears have been redesigned to accommodate this
change.

The proper mainshaft key must always be used with the proper design mainshaft washers. If necessary, refer to the parts manual
for your specific model to confirm the proper parts.

Special Tools
• A piece of 5/32" air line, 1" long
• Vise with brass jaws

Procedure -

1. With mainshaft pilot-end down, secure the mainshaft in a

vise equipped with brass jaws or wood blocks.

2. If previously removed, install the roll pin in keyway.

3. With mainshaft pilot-end down, install offset washer (flat

surface up). Rotate the washer until the washer splines and
mainshaft spIines align.

4. Start at the mainshaft bottom and install a plastic line in the

marked keyway to lock the washer in place.

5. With clutching teeth down, position the 4th gear on the

mainshaft.

6. Install the flat washer. Rotate the washer until the washer
splines and mainshaft splines align.

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 Transmission Overhaul Procedures-Bench Service

7. With clutching teeth up and against the spacer, install the

3rd gear.

8. Position the offset washer (flat surface down) against the

gear. Rotate the washer until the washer splines and main-
shaft splines align.

9. Push the air line up to lock the washers on the mainshaft.

Procedures-Bench Service
Transmission Overhaul
10. With the missing internal splines aligned with the plastic
line, install the proper sliding clutch.

11. Position the next offset washer in the next available groove.
Rotate the washer until the washer splines and mainshaft
splines align.

12. Push the air line up to lock the washer on the mainshaft.

13. With clutching teeth down, position the 2nd gear on the
mainshaft.

14. Position the flat washer against the gear. Rotate the washer
until the washer splines and mainshaft splines align.

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Transmission Overhaul Procedures-Bench Service

15. With clutching teeth up, install the 1st gear on the shaft
against previously installed gear.

16. Position the offset washer (flat surface down) against the
gear. Rotate the washer until the washer splines and main-
shaft splines align.

17. From the mainshaft rear, install the mainshaft key into the
spline with the air line. Pull the air line from the spline while
installing the key.

18. Install the snap ring in the mainshaft groove.

19. Install the 1st/reverse sliding clutch.

20. Install the clutch hub with the bezel facing up.

21. Install the reverse gear.

22. Remove the mainshaft from the vise and lay on its side. In-
stall the front sliding clutch into position.

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 Transmission Overhaul Procedures - Bench Service

How to Prepare the Main Case for Assembly

Thoroughly clean Main Case of metal particles. Remove the gasket material from flange surfaces. Inspect flange surfaces for
damage. Inspect Bearing Bores for damage or excessive wear. Replace as necessary.

If necessary, replace any damaged or worn Clutch Housing or rear support studs. Apply Eaton® Fuller® Thread Sealant #71205
or equivalent to any replacement studs before installing them.

Verify the three Magnetic Discs are firmly attached to the bottom of the Main Case. If they are not firmly attached, apply 3M Scotch
Grip or equivalent adhesive to the bottom of the Discs and attach them to the Main Case.

Procedures - Bench Service

Transmission Overhaul

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Transmission Overhaul Procedures - Bench Service

1. How to Assemble the Countershaft Assemblies

Special Instructions
Except for the PTO Gears, the Upper and Lower Countershaft Assemblies are the same. To avoid confusion during installation,
mark the Upper Countershaft (45-Tooth PTO Gear) with an "U". The Lower Countershaft has a 47-Tooth PTO Gear.

Special Tools
• Snap Ring Pliers
• Press

Procedure -
1. If previously removed, install the Keys in each Countershaft
Keyway.

2. Align smallest diameter gear Keyway with the Countershaft

Key, long hub to Countershaft front, and press the gear on
the Countershaft.

3. Align 2nd smallest diameter gear Keyway with the

Countershaft Key, long hub against 1st Speed Gear, and
press the Gear on the Countershaft.

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Transmission Overhaul Procedures - Bench Service

4. Align 3rd smallest diameter gear Keyway with the

Countershaft Key, long hub to Countershaft front, and
press the Gear on the Countershaft.

Procedures - Bench Service

5. Align PTO Gear Keyway with the Countershaft Key,

Transmission Overhaul
bullet-nose of teeth facing up (shaft rear). Align Drive Gear
Keyway with the Countershaft Key, long hub against PTO
Gear, and press both Gears on the Countershaft.

6. On each Countershaft front, install the Drive Gear

Retaining Snap Ring in groove.

7. Use a Flanged-Driver or the Press to install the Bearing

Inner Race on the Countershaft Front against the Drive Gear.

Note: Make sure all Gears are pressed into place.

Note: Make sure the Bearing Inner Race is installed.

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Transmission Overhaul Procedures - Bench Service

How to Assemble the Lower Reverse Idler Gear Assembly

Special Instructions
In 1996 Eaton® changed the Reverse Idler System design. In the Nut design, the Reverse Idler Bearing was lubricated through a
hole in the Main Case Reverse Idler Support Boss and a oil passage through the Idler Shaft middle.

Special Tools

Previous Design

1. Idler Plate 5. Bearing

2. Inner Race 6. Reverse Idler Gear
3. Washer 7. Reverse Idler Shaft
4. Nut and Washer 8. Plug

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 Transmission Overhaul Procedures - Bench Service

The Cap Screw design eliminates the Case hole and Idler Shaft hole. The Reverse Idler Bearing is supplied oil through the use of
star design Thrust Washers. If the Nut design parts are used with the Cap Screw design, where Main Case does not have the oil
feed hole, the Reverse Idler Bearing will fail.

Current Design

Procedures - Bench Service

Transmission Overhaul
1. Star Washer 6. Idler Plate
2. Inner Race 7. Bearing
3. Star Washer 8. Reverse Idler Gear
4. Retaining Ring 9. Reverse Idler Shaft
5. Cap Screw

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Transmission Overhaul Procedures - Bench Service

Procedure -
1. Position the Reverse Idler Bearing and Inner Race into the
Reverse Idler Gear.

2. Position the gear in the Case. The Gear's long hub is

positioned forward.

3. Place the Rear Thrust Washer on the Idler Shaft.

4. From the Case rear, insert the Idler Shaft through the Main
Case Bearing Bore and into the Reverse Idler Gear Bearing.

5. As the Idler Shaft slides into the gear, insert the Front Thrust
Washer into position. Continue sliding the Idler Shaft into
the Case Support Boss.

6. From the rear, gently tap the Idler Shaft forward until
resistance is felt.

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Transmission Overhaul Procedures - Bench Service

7. Install the Flat Washer over the Shaft’s threaded portion.

8. Apply Eaton® Fuller® Sealant #71205 or equivalent. Install

Cap Screw and torque to 67–75 lb-ft (90.84–101.69 N•m).

9. Using a Bearing Race Driver, install the Auxiliary

Countershaft Bearing Race into the Lower Reverse
Idler Bore.

Note: The Bearing Races have a slip fit in their Bores.

They should slide or rotate easily into the Case Bore
if they are not cocked.

Procedures - Bench Service

Transmission Overhaul

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Transmission Overhaul Procedures - Bench Service

How to Install Countershaft Assemblies

Special Instructions
Make sure the Countershaft Assemblies have been marked for proper position, 47- tooth PTO gear in the lower position.

Prior to installing the Countershafts, the Lower Reverse Idler Gear Assembly should be installed. In addition, if the Transmission
is equipped with an Internal Oil Pump, this should also be installed.

Special Tools
• Toolmaker’s Dye

Procedure -
1. On the Drive Gear of each Countershaft Assembly, mark the
tooth aligned with the gear Keyway and stamped with an “O”
for easy identification. A highly visible color of Toolmaker’s
Dye is recommended for making timing marks.

Note: Prior to installing the Countershafts, the Lower

Reverse Idler Gear Assembly should be installed. In
addition, if the Transmission is equipped with an
Internal Oil Pump, this should also be installed.

2. Place the lower, 47-tooth PTO gear Countershaft, into the

Main Case with the Shaft seated in the Lower Countershaft
Case Bores.

Note: Use a large hook or piece of rope to support the

Countershaft if necessary.

3. Place the Upper Countershaft (with the 45 tooth PTO gear)

into the Main Case with the Shaft seated in the Upper
Countershaft Case Bores.

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 Transmission Overhaul Procedures - Bench Service

How to Install the Lower Countershaft Bearings

Special Instructions
The Lower Reverse Idler Assembly should be installed before the Lower Countershaft.

The Front Bearing Inner Race must be pressed on the Countershaft front.

The Flanged-End Driver must cover the Bearing Outer Race for proper installation.

Special Tools
• RR1012TR-2 Bearing Driver (front)
• RR1012TR-4 Bearing Driver (rear)

Procedures - Bench Service

• RR1013TR Timing Block

Transmission Overhaul
• RR1019TR Hand Maul

Procedure -
1. Move the Countershaft to the rear and insert the
RR1013TR Timing Block to center Shaft in rear Case Bore.

2. Obtain a spare Inner Countershaft Race.

3. Temporarily install the spare Countershaft Inner Race inside

the Front Roller Bearing for installation.

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Transmission Overhaul Procedures - Bench Service

4. Use the RR1012TR-2 Bearing Driver to start the Front

Bearing in Case Bore.

5. Use a Screwdriver inserted in the Countershaft Cap Screw

Bore to help center the Countershaft.

6. Move the Countershaft forward into the bearing.

7. Use the RR1012TR-2 Bearing Driver and Maul to completely

seat the Front Bearing in the Case Bore.

Note: Make sure to contact only the Bearing and not the
Temporary Race with the Driver. The Temporary Race
should fall out when installation is complete.

8. On the Countershaft front, position the Retainer Plate with

Roll Pin in hole at Shaft end.

9. Install the Front Bearing Retainer Plate and Cap Screw. If the
Cap Screw is being reused, apply Eaton® Fuller® Thread
Sealant #71205 or equivalent. Torque the Cap Screw to
90–120 lb-ft (122.02–162.70 N•m).

Note: Earlier models may have a Roll Pin in the Retainer.

This Roll Pin is not required and was removed on
units built after 1994.

10. From the rear, remove the Countershaft Support Tool.

11. Install the Rear Countershaft Bearing. Position the Bearing

so that the larger chamfer on the Bearing inside diameter is
installed towards the Shaft. Use the RR1012TR-4 Bearing
Driver and a Hand Maul to completely seat the Bearing.

12. In the Countershaft Rear Groove, install the Rear Snap Ring.

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 Transmission Overhaul Procedures - Bench Service

How to Install the Input Shaft and Main Drive Gear

Special Instructions
None

Special Tools
• RR1005TR Input Bearing Driver
• RR1019TR Hand Maul
• RR1020TR Soft Bar

Procedure -

Procedures - Bench Service

1. Use a highly visible Toolmaker's Dye and mark the Main

Transmission Overhaul
Drive Gear for timing purposes. To mark the Gear, paint
Toolmaker's Dye on any two adjacent teeth, and then paint
the two adjacent teeth directly opposite the first two teeth.

2. If necessary, install the bushing in the back of the

Input Shaft.

3. Temporarily position the Upper Countershaft up and away

from the Transmission center.

4. From inside the case, mesh the Lower Countershaft Drive

Gear marked tooth with either set of Main Drive Gear
marked teeth.

5. From the front, engage the Input Shaft Spline Teeth into the
Main Drive Gear.

Note: The current design Input Shaft Spline Teeth have

noticeable clearance to the Main Drive Gear internal
Spline Teeth. This is normal.

6. Install the Snap Ring in the Main Drive Gear inside groove.

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Transmission Overhaul Procedures - Bench Service

7. Install the Spacer Washer over the Input Shaft. With the
Bearing External Snap Ring to the outside, position the
bearing on the Input Shaft.

8. Install the Input Shaft Bearing over the Input Shaft. Use the
RR1005TR Input Bearing Driver and a Hand Maul to drive
the Bearing until it contacts the front wall of the Main Case.

9. Temporarily install the Front Bearing Cover with two

Cap Screws.

10. From inside the Main Case, drive the Input Shaft forward
until it is fully seated.

11. Install the Input Shaft Retaining Snap Ring.

Note: Do not replace the small rubber Lip Seal. It is used

only to prevent leakage during shipping.

12. Do not reinstall the Input Bearing Cover at this time. Instead,
pull the Input Shaft and Bearing forward to allow for
Mainshaft installation.

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 Transmission Overhaul Procedures - Bench Service

How to Install the Mainshaft Assembly

Special Instructions
The Lower Countershaft Bearings and the Input Shaft must be installed, but for higher torque ratings do not install the Front
Bearing Cover.

Check to make sure the Lower Countershaft Drive Gear marked tooth is in time with Main Drive Gear set of marked teeth.

Special Tools
• RR1004TR Mainshaft Lifting Hook

Procedure -
1. Block the Upper Countershaft forward and as close to the

Procedures - Bench Service

Transmission Overhaul
case wall as possible.

2. With Reverse Gear forward against the next speed Gear and
Mainshaft pilot end over the Integral Oil Pump gear, lower
the Mainshaft Assembly while pulling the shaft rear through
the Case Bore.

3. Pull the Input Shaft forward until the Drive Gear is against
the case.

4. After the Mainshaft drops into the case, slide the

Countershaft back and the Mainshaft should fall down
between the Countershafts.

5. Move the Mainshaft pilot-end into the Input Shaft Pilot

bushing. Mesh the Mainshaft Gears with the corresponding
Countershaft Assembly gears.

6. Position the upper Reverse Idler Gear in case.

Note: At this time other components of the Front Section

must be installed before the Mainshaft installation can
be completed, see the procedure “How to Install the
Upper Countershaft Bearings”.

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Transmission Overhaul Procedures - Bench Service

7. Mesh the Reverse Gear teeth with the Reverse Idler Gear
teeth and move the Reverse Gear to the rear as far as
possible.

8. Align the Reverse Gear Spacer external Splines with the

Reverse Gear and move the Spacer into the Reverse Gear.

9. Install the Reverse Gear I.D. Snap Ring and move the
Reverse Gear forward on the Mainshaft and against the
Reverse Gear Limit Washer.

10. Push the Input Shaft Bearing back into the Case Bore.

11. Position a new gasket on the Bearing Cover mounting

surface, make sure to align the gasket oil return hole with
Case oil return hole.

12. Position the Front Bearing Cover, make sure to align the
Cover oil return hole with Case oil return hole.

13. Secure the Front Bearing Cover with six (6) Cap Screws,
torque to 35–45 lb-ft (47.45–61.01 N•m).

Note: Make sure the Drive Gear is timed with the both
Countershafts.

Note: Make sure the Front Bearing Cover Cap Screws are
tightened properly.

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 Transmission Overhaul Procedures - Bench Service

How to Install the Upper Countershaft Bearings

Special Instructions
The Front Bearing Inner Race must be pressed on the Countershaft front.

The Flanged-End Driver must cover the Bearing Outer Race for proper installation.

Temporarily use the assembled Auxiliary Drive Gear to hold the Mainshaft in the Input Shaft Pilot.

CAUTION: The Upper Countershaft Bearings must be installed after the installation of the Mainshaft.

Special Tools
• RR1012TR-2 Bearing Driver (front)

Procedures - Bench Service

• RR1012TR-4 Bearing Driver (rear)

Transmission Overhaul
• RR1013TR Timing Block
• RR1019TR Hand Maul

Procedure -
Figure 3
1. Make sure the Lower Countershaft and Main Drive Gear
timing marks are aligned.

2. Mesh the Upper Countershaft marked tooth with the two

remaining Main Drive Gear marked teeth.

3. Move the Countershaft to the rear and insert the

RR1013TR Timing Block to center Shaft in rear Case Bore.

223
Transmission Overhaul Procedures - Bench Service

4. Obtain a spare Inner Countershaft Race.

5. Temporarily install a spare Countershaft Inner Race inside

the Front Roller Bearing for installation.

6. Use the RR1012TR-2 Bearing Driver to start the Front

Bearing in Case Bore.

7. Use a Screwdriver inserted in the Countershaft Cap Screw

Bore to help center the Countershaft.

8. Move the Countershaft forward into the Bearing.

9. Use the RR1012TR-2 Bearing Driver and Maul to completely

seat the Front Bearing in the Case Bore.

Note: Make sure to contact only the bearing and not the
Temporary Race with the driver. The Temporary Race
should fall out when installation is complete.

10. On the Countershaft front, position the Retainer Plate with

Roll Pin in hole at shaft end.

11. Install the Front Bearing Retainer Plate and Cap Screw.
If the Cap Screw is being reused, apply Eaton® Fuller®
Thread Sealant #71205 or equivalent. Torque the Cap Screw
to 90–120 lb-ft (122.02–162.70 N•m).

Note: Earlier models may have a Roll Pin in the Retainer.

This Roll Pin is not required and was removed on
units built after 1994.

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Transmission Overhaul Procedures - Bench Service

12. From the rear, remove the Countershaft Support Tool.

13. Install the Rear Countershaft Bearing. Position the Bearing

so that the larger chamfer on the Bearing inside diameter is
installed towards the Shaft. Use the RR1012TR-4 Bearing
Driver and a Hand Maul to completely seat the Bearing.

Procedures - Bench Service

14. In the Countershaft Rear Groove, install the Rear Snap Ring.

Transmission Overhaul

225
Transmission Overhaul Procedures - Bench Service

How to Assemble the Upper Reverse Idler Gear Assembly

Special Instructions
In 1996 Eaton® changed the Reverse Idler System design. In the Nut design, the Reverse Idler Bearing was lubricated through a
hole in the Main Case Reverse Idler Support Boss and a oil passage through the Idler Shaft middle.

Special Tools

1. Previous Design

2. 1. Idler Plate 8. 5. Bearing

3. 2. Inner Race 9. 6. Reverse Idler Gear
4. 3. Washer 10. 7. Reverse Idler Shaft
5. 4. Nut and Washer 11. 8. Plug
6. 12.
7.

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 Transmission Overhaul Procedures - Bench Service

The Cap Screw design eliminates the Case hole and Idler Shaft hole. The Reverse Idler Bearing is supplied oil through the use of
star design Thrust Washers. If the Nut design parts are used with the Cap Screw design Main Case which does not have the oil
feed hole, the Reverse Idler Bearing will fail.

13. Current Design

Procedures - Bench Service

Transmission Overhaul
14. 1. Star Washer 20. 6. Idler Plate
15. 2. Inner Race 21. 7. Bearing
16. 3. Star Washer 22. 8. Reverse Idler Gear
17. 4. Retaining Ring 23. 9. Reverse Idler Shaft
18. 5. Cap Screw
19.

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Transmission Overhaul Procedures - Bench Service

Procedure -
1. Place the rear Thrust Washer on the Idler Shaft.

2. From the rear, insert the Idler Shaft through the Main Case
Bearing Bore and into the Reverse Idler Gear Bearing.

3. As the Idler Shaft slides into the Gear, insert the Front Thrust
Washer into position. Continue sliding the Idler Shaft into
the Case Support Boss.

4. From the rear, gently tap the Idler Shaft forward until
resistance is felt.

5. Install the Flat Washer over the Shaft’s threaded portion.

6. Inspect the Reverse Idler Nut nylon locking material.

Replace the Cap Screw, if necessary. Install the Cap Screw
and torque to 67–75 lb-ft (90.84–101.69 N•m).

7. Using a Bearing Race Driver, install the Auxiliary

Countershaft Bearing Race into the Lower Reverse
Idler Bore.

Note: The Bearing Races have a slip fit in their Bores. They
should slide or rotate easily into the Case Bore if they
are not cocked.

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 Transmission Overhaul Procedures-Bench Service

How to Install the Auxiliary Drive Gear Assembly

Special Instructions

Before installing the auxiliary drive gear, the mainshaft must also be completely installed.

Special Tools
• See Tool Information (see Table 6)
• Large pair of snap ring pliers
• Item T10: Flanged-end driver and maul

Procedures-Bench Service
Transmission Overhaul
Standard Torque High Torque

Procedure - Standard torque capacity models

1. Install the retainer ring on the front auxiliary drive gear, snap
ring groove facing hub and away from gear teeth.

229
Transmission Overhaul Procedures-Bench Service

2. Start the front auxiliary drive gear bearing on the hub, bear-
ing snap ring facing groove in retainer ring. Press the bear-
ing fully into position.

Note: Once the bearing is fully installed, it is normal for

clearance to exist between the auxiliary drive gear hub
and the mainshaft rear bearing inside.

3. Install the snap ring in gear hub groove to retain the bearing.

4. Install the outer retainer ring, grooved side down (inset),

with a flanged driver.

5. Install the auxiliary drive gear assembly on the mainshaft

rear. Use a flanged-end driver to fully seat the assembly in
the case bore.

230
Transmission Overhaul Procedures-Bench Service

6. Apply Eaton®Fuller® thread sealant #71205 or equivalent to

the capscrew threads, and install the six (6) capscrews.
Torque the capscrews to 35- 45 Lb•ft. NOTE: On some pre-
vious designs, lock wire was used on the capscrews, lock
wire as needed.

7. Install the snap ring in the mainshaft groove rear. The main-
shaft may need to slide rearward.

Procedure - High torque capacity models (16908LL

and 16915)

1. Press the inner sleeve into the rear mainshaft bearing.

Procedures-Bench Service
Transmission Overhaul
2. Slide the bearing and sleeve assembly over mainshaft rear.

Note: The missing spline tooth is positioned over the main-

shaft key. Use a flanged driver to fully seat the rear
mainshaft bearing assembly.

3. With the stepped side facing forward, install the rear main-
shaft bearing retainer plate. Apply Eaton®Fuller® thread
sealant #71205 or equivalent to the capscrew threads, and
install the six (6) capscrews. Torque the capscrews to 35-45
Lb•ft.

4. Slide the auxiliary dirver gear over the mainshaft splines. In-
stall the rear snap ring in the mainshaft groove.

Note: For the snap ring to install fully, it may be necessary

to slide the mainshaft assembly rearward. If the snap
ring cannot be installed in the groove, the reverse gear
spacer washer may be improperly positioned-the
chamfer in the washer must face rearward.

231
Transmission Overhaul Procedures-Bench Service

How to Install the Clutch Housing

Special Instructions

Installation of the clutch housing is done in the horizontal position.

Special Tools
• Typical service tools, Torque wrench

Procedure -

1. Make sure maincase and cluch housing gasket surfaces are

clean and free of debris.

2. Position a new gasket on the housing mounting surface.

3. Install the clutch housing on the front box, pilot it on the six
studs and drive gear bearing cover.

4. Install the nuts with washers on the studs, tighten to 35 Lb·ft

( 47 N.m) + 90° CW rotation (or 175 Lb·ft (237 N.m) of
torque) in cross-pattern.

5. Install the capscrews, tighten to 115 Lb·ft (156 N.m) of

torque in cross pattern.

Recommended Clutch Housing Tightening Pattern

Note: Make sure all fasteners are properly torqued.

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 Transmission Overhaul Procedures - Bench Service

How to Disassemble the Integral Oil Pump without Auxiliary Oil Tube
Special Instructions
None

Special Tools
• Typical Service Tools
• A Vise with brass jaws or wood blocks

Procedure -
1. From the Assembly, remove the Outer Oil Pump Element.

Procedures - Bench Service

Transmission Overhaul
2. From the Drive Shaft, remove the Drive Gear Retaining
Snap Ring.

3. From the Pump Drive Shaft, remove the Drive Gear.

4. From the Drive Shaft Keyway, remove the Key.

233
Transmission Overhaul Procedures - Bench Service

5. From the Drive Shaft, remove the Element Snap Ring.

6. From the Drive Shaft, remove the Internal Oil Pump Element.

7. From the Drive Shaft Keyways, remove the two (2) Keys.

8. From the Integral Oil Pump Housing, remove the Drive Shaft.

9. If damaged, from the Drive Shaft, remove the rear Drive Gear
Retention Snap Ring.

234
Transmission Overhaul Procedures - Bench Service

10. From the Pump Housing, remove the Relief Valve Roll Pin.

Procedures - Bench Service

11. From the Relief Valve Housing Bore, remove the Relief

Transmission Overhaul
Valve Spring.

12. From the Housing Bore, remove the Relief Valve.

13. Inspect all parts for damage, replace damaged parts.

235
Transmission Overhaul Procedures - Bench Service

How to Assemble the Integral Oil Pump without Auxiliary Oil Tube
Special Instructions
When installing the Drive Shaft Keys, the round Key goes in the round Keyway and the square Key in the square Keyway.

Special Tools
• A Vise with brass jaws or wood blocks

Procedure -
1. Install the Relief Valve in the Integral Oil Pump Housing.

2. Install the Relief Valve Spring in Oil Pump Housing.

3. Secure the Oil Pump Housing in a Vice.

4. Depress the Relief Valve Spring and drive the Relief Valve
Retention Roll Pin into the Roll Pin Bore.

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Transmission Overhaul Procedures - Bench Service

5. If removed, replace the Drive Shaft Snap Ring on the

Pump Drive Shaft.

6. Insert the Drive Shaft through the Pump Housing Bore.

Procedures - Bench Service

7. Install the two (2) Keys on the Drive Shaft.

Transmission Overhaul
8. Align the Inner Element Keyways with the Drive Shaft Keys
and install the Integral Oil Pump Inner Element.

9. Install the Inner Element Retention Snap Ring in Drive Shaft

Snap Ring groove.

237
Transmission Overhaul Procedures - Bench Service

10. Install Drive Gear Key in Drive Shaft Keyway.

11. Align Drive Gear Keyway with Drive Shaft Key and install
the Drive Gear on the Drive Shaft.

12. Install the Outer Drive Gear Retention Snap Ring in Drive
Shaft groove.

13. Install the Outer Integral Oil Pump Element over the
Inner Element.

238
 Transmission Overhaul Procedures-Bench Service

How to Remove the Integral Oil Pump

Special Instructions

None

Special Tools
• Typical service tools

Procedure -

1. Remove the capscrews holding the suction tube in position.

Procedures-Bench Service
Transmission Overhaul
2. Straighten tube lock on suction tube.

3. Remove suction tube from oil pump. If necessary, remove

O-ring from suction tube.

4. Remove three (3) allen head capscrews and washers that re-
tain the integral oil pump to the case.

239
Transmission Overhaul Procedures-Bench Service

5. Remove the integral oil pump assembly from inside the

case.

6. Remove the integral oil pump retainer plate from inside the
case.

7. If necessary, the front case plug can be removed from the

case. To remove, insert a bar from inside the case and tap
the plug out.

8. Inspect the plug O-ring, replace if damaged.

240
 Transmission Overhaul Procedures-Bench Service

How to Install the Integral Oil Pump

Special Instructions

None

Special Tools
• Typical service tools

Procedure -

1. If removed, replace the front case plug O-ring. Lubricate the

Procedures-Bench Service
Transmission Overhaul
groove of the plug, install the O-ring onto the plug, and then
lubricate the outer diameter of the O-ring.

2. Seat the front case plug in the case bore by hand. Do not in-
stall the pump plug using any type of impact tool (i.e. ham-
mer, maul, etc.).

3. With the retainer bore facing the case rear, install the integral
oil pump over the alignment pin inside the case.

4. Align oil pump with retainer and alignment pin and install the
integral oil pump assembly.

241
Transmission Overhaul Procedures-Bench Service

5. Install three (3) allen head capscrews and washers through

the case front and into the pump housing. Tighten the cap-
screws to 8-12 Lb•ft of torque.

6. Replace the O- ring on the suction tube.

7. Install the suction tube under the case rib and into the inte-
gral oil pump.

8. Bend the suction tube lock over the case rib.

9. Install the capscrews to hold the oil tube in position. Tighten

the capscrews to 35-45 Lb•ft of torque (if applicable).

Note: Make sure the integral oil pump drive gear can turn.

242
 Transmission Overhaul Procedures-Bench Service

How to Install the Auxiliary Section with Tapered Bearings

Special Instructions

There are different capscrew lengths, install in the correct location.

Auxiliary sections can be installed either with the transmission in the horizontal position or the vertical position.

To install in the vertical position, the clutch housing must be installed.

Special Tools
• See Tool Information (see Table 6)

Procedures-Bench Service
• Item T2: Auxiliary section hanger bracket for horizontal removal

Transmission Overhaul
• A steel bar longer than the width of the output yoke for vertical removal
• A hoist with a lifting chain

Procedure -

1. To install the auxiliary section in the horizontal position:

Position a new gasket on the transmission mounting sur-
face.

2. Attach an auxiliary section hanger bracket to the auxiliary

section top.

3. Attach a lifting chain to the auxiliary section hanger bracket.

4. Position the auxiliary section on the two (2) dowel pins.

5. Slide the auxiliary section on until the hanger bracket con-

tacts the front section back.

6. Remove the auxiliary section hanger bracket.

7. Slide the auxiliary section the rest of the way into position.

8. Apply Eaton/Fuller Sealant #71205 or equivalent to the re-

taining capscrews.

9. Install the retaining capscrews, tighten to 35-45 Lb·ft of

torque.

10. To finish installation, see "The Shimming Procedure for Ta-

pered Bearings".

243
Transmission Overhaul Procedures-Bench Service

Procedure -

1. To install the auxiliary section in the vertical position:

With blocks under the clutch housing to prevent input shaft
damage, place the transmission in the vertical position,
clutch housing down.

2. Position a new gasket on the transmission mounting sur-

face.

3. Install a steel bar through the yoke.

4. Attach a lifting chain to the steel bar.

5. Position the auxiliary section over the two (2) dowel pins.

6. Slide the auxiliary section down the dowels.

7. Apply Eaton/Fuller Sealant #71205 or equivalent to the re-

taining capscrews.

8. Install the retaining capscrews, tighten to 35-45 Lb·ft of

torque.

9. Remove the steel bar and chain.

10. To finish installation, see "The Shimming Procedure for Ta-

pered Bearings".

Note: Make sure capscrews are properly torqued.

Note: Make sure the input shaft rotates.

244
 Transmission Overhaul Procedures-Bench Service

Shim Procedure without a Shim Tool for Tapered Bearings

Special Instructions

The shim procedure can be done in the horizontal or vertical position. The procedure is done the same.

CAUTION

Use genuine Eaton® replacement gaskets for the auxiliary housing and countershaft bearing cover. Do not omit the gaskets. Bear-
ing endplay is influenced by the compressed thickness of the gasket (.011-.012" or .28-.30 mm).

The bearing endplay must be checked and adjusted any time a countershaft, bearing, or housing is replaced. If, during reassembly,
the same countershaft, bearings, housing, and shims are reused and kept in the same location, it is not necessary to reset bearing

Procedures-Bench Service
endplay.

Transmission Overhaul
The following procedure is used to adjust the endplay for the auxiliary countershaft tapered bearings. By correctly following this
procedure, each countershaft will have .001"-.005" (.03-.12 mm) endplay.

Shims must be aligned properly or else the rear bearing cover may be damaged when final torque is applied.

Procedure -

1. The auxiliary countershaft bearing covers or countershaft

straps and shims should be removed. Make sure all old gas-
ket material is cleaned from the gasket mounting surfaces
on the countershaft bearing covers and the auxiliary hous-
ing.

2. Verify that the auxiliary section is in gear. When the output

shaft is rotated, the countershafts must also rotate. If not
shift the auxiliary into gear by applying shop air to the high
range air port on range cylinder to shift into gear.

3. Make sure a 0.100 countershaft rear bearing shim is in-

stalled. Be sure the countershaft rear bearing races are seat-
ed in the bearing bores.

4. Install two (2) clean 3/8 " x 1" capscrews without washers di-
rectly across from each other in each bearing cover. Tapped
holes in auxiliary case must be free of thread adhesive.

5. Evenly tighten the capscrews to 7 Lb·in of torque. Do not in-

stall the countershaft rear bearing cover gasket. The gap be-
tween the bearing cover and the housing surface should be
even from side to side.

245
Transmission Overhaul Procedures-Bench Service

Note: 7 Lb·in is slightly more than finger tight. Do not over-

tighten the capscrews. If the capscrews are too tight,
the bearing cover will become distorted.

6. Rotate the output shaft 4 times clockwise and 4 times coun-

terclockwise. The rotation will seat and align the rollers in
each tapered bearing. Re-torque the capscrews to 7 Lb·in.
If the countershafts do not rotate, the range sliding clutch or
deep reduction sliding clutch is in neutral. Apply shop com-
pressed air to shift cylinders to shift the sliding clutches into
gear.

7. Use a feeler gauge, as close to each capscrew location as

possible, and measure the gap between the countershaft
rear bearing cover and the auxiliary housing gasket surface.
Measure and record the gap at two capscrew locations.

8. Average the two feeler gauge measurements by adding the

measurements together and dividing by 2 as shown in Ex-
ample.
Shim Chart
Gap 1 = .060 ; Gap 2 = .050
Total Gap = .060 + .050 = .110
Average = 110/2 = .055
Select yellow shim as indicated in the shim chart at the end of
this selection.

9. Locate the feeler gauge average measurement in the shim

chart to determine the required shim and color code.

Note: The oil pump shim is used when an auxiliary oil pump
or PTO is mounted on the countershaft. The oil pump
shims have a smaller outside diameter.

10. Remove the countershaft rear bearing cover and gauging

shim.

11. Place the selected shim on the rear countershaft bearing

race.

12. Position a new gasket on countershaft rear bearing cover

mounting surface.

13. Position the countershaft rear bearing cover over the new
gasket.

246
 Transmission Overhaul Procedures-Bench Service

14. Apply Eaton® Fuller® thread sealant #71205 or equivalent

to the auxiliary countershaft rear bearing cover capscrews
and auxiliary countershaft rear bearing cover.

15. Install the auxiliary countershaft rear bearing cover and se-
cure it with the capscrews. Make sure the shim is in the
proper location and is not pinched between the cover and
the housing. Tighten the capscrews to 40-45 Lb·ft (54-61
Nm).

Note: Use a thick grease to hold the shim in position when

installing the cover.

16. Repeat this procedure for the remaining countershaft.

Procedures-Bench Service
Transmission Overhaul
Note: Make sure capscrews are properly torqued.

Note: Make sure the input shaft rotates.

Shim Table
Feeler Gauge Average Shim Thickness Standard Shim Part Oil Pump Shim Part Num- Color Code
Gap Number ber
.072-.075 .033-.034 4302345 4302346 Gold
.69-.0715 .036-.037 21452 21472 Red
.066-.0685 .039-.040 21453 21473 Pink
.063-.0655 .042-.043 21454 21474 Brown
.060-.0625 .045-.046 21455 21475 Tan
.057-.0595 .048-.049 21456 21476 Orange
.054-.0565 .051-.052 21457 21477 Yellow
.051-.0535 .054-.055 21458 21478 Green
.048-.0505 .057-.058 21459 21479 Light Blue
.045-.0475 .060-.061 21460 21480 Lavender
.042-.0445 .063-.064 21461 21481 White
.039-.0415 .066-.067 21684 21686 Black
.036-.0385 .069-.070 21685 21687 Silver

247
Copyright Eaton, 2017.
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 spec’ing 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
Vehicle Group
P.O. Box 4013
Kalamazoo, MI 49003 USA
800-826-HELP (4357)
www.eaton.com/roadranger
Printed in USA