Service Manual

Eaton Gen III Automated

Transmissions
TRSM0930 EN-US
December 2019

UltraShift®
AutoShift®
UltraShift® PLUS Linehaul Active Shifting (LAS)
UltraShift® PLUS Linehaul Small Step Efficiency (LSE)
UltraShift® PLUS Multipurpose Extreme Performance (MXP)
UltraShift® PLUS Multipurpose High Performance (MHP)
UltraShift® PLUS Vocational Active Shifting (VAS)
UltraShift® PLUS Vocational Construction Series (VCS)
UltraShift® PLUS Vocational High Performance (VHP)
UltraShift® PLUS Vocational Multipurpose Series (VMS)
UltraShift® PLUS Vocational Extreme Performance (VXP)
UltraShift® PLUS Passenger Vehicle (PV)
TRTS0930 General Information |

Model:

F-5405B-DM3 RTO-14910C-AS3 FOM-15E310C-LAS FO-14E313B-MHP

F-6405B-DM3 RTO-16910B-AS3 FOM-16E310C-LAS FO-16E313B-MHP
F-14E316B-LSE RTO-16910B-DM3 FM-14E310B-LAS FO-18E313B-MHP
F-15E316B-LSE RTO-16910C-AS3 FM-15E310B-LAS FO-20E313B-MHP
F-17E316B-LSE RTO-18910B-AS3 EO-11E406B-PV FO-14E318B-MXP
FM-15E316B-LSE FO-10E310C-VAS FOM-15E310C-VAS FO-16E318B-MXP
FM-14D310B-LST FO-12E310C-VAS FOM-16E310C-VAS FO-18E318B-MXP
FM-15D310B-LST FO-14E310C-VAS FO-10E308LL-VCS FO-20E318B-MXP
FO-16D313E-LEP FO-16E310C-VAS FO-11E308LL-VCS FO-22E318B-MXP
FO-5406B-DM3 FOM-14E310C-VAS FO-12E308LL-VCS FO-18E318A-VXP
FO-6406A-AW3 F-5505B-DM3 FO-14E308LL-VCS FO-20E318A-VXP
FO-6406B-AW3 F-6505B-DM3 FO-16E308LL-VCS FO-22E318A-VXP
FO-8406A-AW3 RTLO-18918A-AS3 FO-17E308LL-VCS FO-14E318B-VXP
FOM-16D313E-LEP RTLO-20918A-AS3 FO-16E313A-VHP FO-16E318B-VXP
RTLO-14918A-AS3 RTLO-22918A-AS3 FO-18E313A-VHP FO-18E318B-VXP
RTLO-16913L-DM3 RTLOM-16913L-DM3 FO-20E313A-VHP FO-20E318B-VXP
RTLO-16918A-AS3 RTO-10910B-AS3 FO-10E309ALL-VMS FO-22E318B-VXP
RTO-10910B-DM3 RTOM-16910B-DM3 FO-11E309ALL-VMS FO-22E318B-VXP
RTO-12910B-AS3 FO-14E310C-LAS FO-12E309ALL-VMS EO-11E406B-PVER
RTO-12910B-DM3 FO-16E310C-LAS FO-14E309ALL-VMS EO-11E406B-PVHR
RTO-14910B-AS3 FO-18E310C-LAS FO-16E309ALL-VMS EO-11E406B-PV
RTO-14910B-DM3 FOM-14E310C-LAS FO-17E309ALL-VMS

2019.12.12 © 2013 Eaton. All rights reserved 2

TRSM0930 Table of Contents

Table of Contents

General Information Appendix

Warnings & Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Operation and Basic Troubleshooting . . . . . . . . . . . . 145
How to Use this Manual. . . . . . . . . . . . . . . . . . . . . . . . . 2 Inspection Procedures. . . . . . . . . . . . . . . . . . . . . . . . 146
Transmission Overview . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . 147
Serial Tag Information and Model Nomenclature. . . . . 15 UltraShift DM3 and AutoShift AS3 . . . . . . . . . . . 147
Clutch Greasing Guidelines . . . . . . . . . . . . . . . . . . . . . 19 Buy From a Reputable Dealer. . . . . . . . . . . . . . . 147
Grease Interval Count Reset. . . . . . . . . . . . . . . . . 19 Transmission Operating Angles . . . . . . . . . . . . . 147
Operator Triggered Procedure . . . . . . . . . . . . . . . 20 Operating Temperatures with Oil Coolers. . . . . . 147
UltraShift™ ASW Models . . . . . . . . . . . . . . . . . . 147
Service Procedure Buy From a Reputable Dealer. . . . . . . . . . . . . . . 148
DM Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Synthetic Dextron III ATF . . . . . . . . . . . . . . . . . . 148
DM Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . 24 CD-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Thread-In ECA Speed Sensor. . . . . . . . . . . . . . . . . . . . 31 Maintenance and Lubricant Change Intervals. . . 148
Electronic Clutch Actuator (ECA) . . . . . . . . . . . . . . . . . 35 Checking Wet Clutch Lubricant . . . . . . . . . . . . . 148
Low Capacity Inertia Brake . . . . . . . . . . . . . . . . . . . . . 39 Proper Wet Clutch Lubricant Level. . . . . . . . . . . 148
Release Yoke and Cross-shaft(s) . . . . . . . . . . . . . . . . . 43 Checking Gearbox Lubricant . . . . . . . . . . . . . . . 148
Cobra Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Proper Gearbox Lubricant Level. . . . . . . . . . . . . 148
Medium-Duty Transmission Harness. . . . . . . . . . . . . . 55 Drain the Transmission Gearbox and Wet Clutch
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Heavy-Duty Transmission Harness . . . . . . . . . . . . . . . 59
Change Wet Clutch Filters . . . . . . . . . . . . . . . . . 149
Medium-Duty Transmission Electronic Control Unit (TE-
CU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Fill the Transmission . . . . . . . . . . . . . . . . . . . . . 149
Heavy-Duty Transmission Electronic Control Unit (TECU) Clutch Calibration. . . . . . . . . . . . . . . . . . . . . . . . 149
67 Maintenance and Lubricant Change Intervals . . . . . . 150
Electric Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Checking Wet Clutch Lubricant . . . . . . . . . . . . . 150
Medium-Duty Inertia Brake . . . . . . . . . . . . . . . . . . . . . 75 Proper Wet Clutch Lubricant Level. . . . . . . . . . . 150
Air Filter Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Checking Gearbox Lubricant . . . . . . . . . . . . . . . 150
Heavy-Duty Inertia Brake . . . . . . . . . . . . . . . . . . . . . . . 85 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Combination Valves (Range and Deep Reduction). . . . 89 Proper Gearbox Lubricant Level. . . . . . . . . . . . . 150
Range Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Drain the Transmission Gearbox and Wet Clutch
Splitter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Directional Output Shaft Speed Sensor . . . . . . . . . . . 101 Change Wet Clutch Filters . . . . . . . . . . . . . . . . . 151
Park Actuator Assembly. . . . . . . . . . . . . . . . . . . . . . . 105 Fill the Transmission . . . . . . . . . . . . . . . . . . . . . 151
Park Pawl Position Sensor. . . . . . . . . . . . . . . . . . . . . 109 Clutch Calibration. . . . . . . . . . . . . . . . . . . . . . . . 151
Medium-Duty Output Shaft Speed Sensor . . . . . . . . . 113 Tool Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Heavy-Duty Output Shaft Speed Sensor . . . . . . . . . . 117 General Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Main Shaft Speed Sensor . . . . . . . . . . . . . . . . . . . . . 121 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 153
Medium-Duty Input Shaft Speed Sensor . . . . . . . . . . 125 Torque Overview . . . . . . . . . . . . . . . . . . . . . . . . 157
Heavy-Duty Input Shaft Speed Sensor. . . . . . . . . . . . 129 Grade Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . 160
Rail Select Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 ServiceRanger Procedure . . . . . . . . . . . . . . . . . 160
Gear Select Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Operator-Triggered Procedure . . . . . . . . . . . . . . 162
Lubricant Filter (AW3 Models Only). . . . . . . . . . . . . . 141

2019.12.12 © 2014 Eaton. All rights reserved i

Warnings & Cautions | General Information TRSM0930

Warnings & Cautions

Warning: Follow the specified procedures in the indicated
! order to avoid personal injury.
Note: Additional relevant information not covered in the
service procedure.
Warning: Before starting a vehicle:
!
• Ensure adequate fuel level.
• Sit in the driver's seat.
• Place shift lever in neutral.
• Set the parking brake.
Warning: Before working on a vehicle or leaving the cab
! with engine running:
• Ensure ignition is off while hands are within the
clutch housing area.
• Place shift lever in neutral.
• Set the parking brake.
• Block the wheels.
Warning: When parking the vehicle or leaving the cab:
!
• Place shift lever in neutral.
• Set the parking brake.
Caution: Follow the specified procedures in the indicated
! order to avoid equipment malfunction or damage.
Caution: Do not release the parking brake or attempt to
! select a gear until the air pressure is at the correct
level.
Caution: To avoid damage to the transmission during tow-
! ing:
• Place shift lever in neutral.
• Lift the drive wheels off of the ground or discon-
nect the driveline.
Caution: Do not operate the vehicle if alternator lamp is lit
! or if gauges indicate low voltage.

1 © 2014 Eaton. All rights reserved 2019.12.18

TRSM0930 General Information | How to Use this Manual

How to Use this Manual

This publication is divided into three sections General Infor-
mation, Service Repair Procedures and the Appendix.

General Information
This section contains the basic chapters like “Transmission
Overview,” “How to Use This Manual” and “Serial Tag and
Model Nomenclature.”

Service Repair Procedures

A “Components Identification” diagram is included at the
beginning of each procedure for disassembly, assembly,
removal and installation. Below the “Components Identifi-
cation” diagram is a numerical listing for each part with the
part name.

Appendix
This section contains information like: “Operation,” “Lubri-
cation Specifications,” “Inspection” (in base box manuals),
“Powerflow” (in base box manuals), “Air System Opera-
tion” and “Troubleshooting” (in base box manuals), “Basic
Troubleshooting” (in base box manuals), “Tool Specifica-
tions,” “Torque Specifications,” and the “Torque Overview.”

The service procedures in this manual are for transmission

automation components only. To find the information you
need, simply locate the procedure in the “Table of Con-
tents,” turn to the page specified and follow the procedure.
If you are unsure of a components’ name, you can refer-
ence the “Transmission Overview” pages.

To service the mechanical portion of the transmission sys-

tem, refer to the specific transmission service manual.

2019.12.12 © 2014 Eaton. All rights reserved 2

Transmission Overview | General Information TRSM0930

Transmission Overview
Heavy-Duty 8LL / VCS & 9ALL / VMS

Input Shaft Speed Sensor

Electric Shifter

Gear Selector Sensor

Rail Selector Sensor

Mainshaft
Speed Sensor Air Filter
Regulator

Output Shaft
Speed Sensor Range Deep Reduction
(Combination Valve)

Flywheel Speed Sensor

(Shipping Location)
Transmission Transmission
ECU
Harness

3 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 General Information | Transmission Overview

Heavy-Duty 8LL / VCS & 9ALL / VMS

Release Yoke and

Cross-shaft Assembly

Electronic Clutch
Actuator (ECA)

Low Capacity
Inertia Brake (LCIB)

2019.12.12 © 2014 Eaton. All rights reserved 4

Transmission Overview | General Information TRSM0930

Heavy-Duty 10-Speed LAS/VAS

Input Shaft Speed Sensor

Electric Shifter

Gear Select Sensor

Main Shaft Rail Select Sensor

Speed Sensor
Output Shaft
Speed Sensor Range Valve Solenoid

Air Filter Regulator

Flywheel Speed Sensor

(Shipping Location)

Transmission ECU
Transmission Harness

5 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 General Information | Transmission Overview

Heavy-Duty 10-Speed LAS/VAS

Release Yoke and

Cross-shaft Assembly

Electronic Clutch
Actuator (ECA)

Low Capacity
Inertia Brake (LCIB)

2019.12.12 © 2014 Eaton. All rights reserved 6

Transmission Overview | General Information TRSM0930

Heavy-Duty 13-Speed MHP/VHP, 16-Speed LSE

& 18-Speed VXP/MXP

Input Shaft Speed Sensor

Electric Shifter

Gear Select Sensor

Mainshaft Rail Select Sensor

Speed Sensor

Splitter Valve Range Valve Solenoid

Solenoid Air Filter Regulator

Output Shaft
Speed Sensor

Flywheel Speed Sensor

Transmission Harness
(Shipping Location)
Transmission ECU

7 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 General Information | Transmission Overview

Heavy-Duty 13-Speed MHP/VHP, 16-Speed LSE

& 18-Speed VXP/MXP

Release Yoke and

Cross-shaft Assembly

Electronic Clutch
Actuator (ECA)

Low Capacity
Inertia Brake (LCIB)

2019.12.12 © 2014 Eaton. All rights reserved 8

Transmission Overview | General Information TRSM0930

Heavy-Duty 13-Speed DM3 & 18-Speed AS3

Input Shaft
Speed Sensor

Electric Shifter

Gear Select Sensor

Main Shaft Rail Select Sensor

Speed Sensor

Range Valve Solenoid

Splitter Valve Solenoid
Air Filter Requlator

Output Shaft Speed Sensor

Transmission Harness
Transmission ECU

Inertia Brake
(13-Speed DM3 Only)

9 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 General Information | Transmission Overview

Heavy-Duty 10-Speed AS3 & DM3

Input Shaft
Speed Sensor

Electric Shifter

Gear Select Sensor

Main Shaft
Speed Sensor Rail Select Sensor

Output Shaft
Speed Sensor Range Valve Solenoid

Air Filter Regulator

Transmission ECU
Transmission Harness

Inertia Brake
(10-Speed DM3 Only)

2019.12.12 © 2014 Eaton. All rights reserved 10

Transmission Overview | General Information TRSM0930

Medium-Duty 6 & 5-Speed DM3

Electric Shifter

Gear Select Sensor

Rail Select Sensor

Output Shaft
Speed Sensor

Input Shaft
Speed Sensor Location
Transmission Harness
Transmission ECU

Inertia Brake

11 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 General Information | Transmission Overview

Medium-Duty 6-Speed AW3

Electric Shifter

Gear Select Sensor

Rail Select Sensor

Output Shaft
Speed Sensor

Input Shaft
Speed Sensor Location

Transmission Harness
Transmission ECU

Wetclutch Solenoid
Connector

Oil Pan and Filters

Inertia Brake

2019.12.12 © 2014 Eaton. All rights reserved 12

Transmission Overview | General Information TRSM0930

Medium-Duty 6-Speed PV
Gear Select
Sensor Rail Select
Electric Shifter Sensor

Output Shaft
Speed Sensor

Transmission ECU

Inertia
Brake

Transmission
Harness

Input Shaft
Speed Sensor

13 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 General Information | Transmission Overview

Medium-Duty 6-Speed PV

ECA

Release Yoke
& Cross-Shaft
Assembly
Electronic Clutch
Actuator (ECA)

2019.12.12 © 2014 Eaton. All rights reserved 14

Serial Tag Information and Model Nomenclature | General Information TRSM0930

Serial Tag Information and Model Nomenclature

Transmission model designation and other transmission
identification information are stamped on the serial tag. To
identify the transmission model and serial number, locate
the tag on the transmission and then locate the numbers as
shown. The figure below shows the tag location for these
transmissions.

Model RTLO-16913L-DM3

Serial Made In

Eaton Fuller
R R

Eaton Corporation
Transmissions Transmission Div.
Kalamazoo, MI. 49003

When calling for service assistance or parts, have the

model and serial numbers handy.

Do not remove or destroy the transmission identification

tag!

Serial Number
The serial number is the sequential identification number of
the transmission. Before calling for service assistance,
write the number down as 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®.

Model Number
The model number gives basic information about the trans-
mission and is explained below. Use this number when call-
ing for service assistance or replacement parts.

15 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 General Information | Serial Tag Information and Model Nomenclature

Transmission Tag
5-Speed F X - X 4 0 5 X - D M 3
Fuller Generation 3 Electronics
Overdrive Automatic
Torque x 100 w/DM Autoclutch
Design Level Gear Ratio
Forward Speeds

6-Speed F X - X 4 0 6 X - AW3
Fuller Generation 3 Electronics
Overdrive Automatic with WetClutch
Torque x 100 Gear Ratio
Design Level Forward Speeds

6-Speed F X - X 4 0 6 X - D M 3
Fuller Generation 3 Electronics
Overdrive Automatic
Torque x 100 w/DM Autoclutch
Design Level Gear Ratio
Forward Speeds

10-Speed
R T O - 1 X 9 1 0 X -AS3
Roadranger
Twin Countershaft
Overdrive Generation 3 Electronics
Torque x 100 AutoShift
Design Level Gear Ratio
Forward Speeds

10-Speed
R T O - 1 X 9 1 0 X - D M 3
Roadranger Generation 3 Electronics
Twin Countershaft Automatic
Overdrive
w/DM Autoclutch
Torque x 100
Gear Ratio
Design Level
Forward Speeds

13-Speed R T L O M- 1 X 9 13 X-DM3
Roadranger
Twin Countershaft Gen 3 Electronics
Low-Inertia Automatic w/DM Autoclutch
Overdrive Gear Ratio
1750 lb.ft. Torque in Forward Speeds
Top Two Gears Only Design Level
Torque x 100

18-Speed R T L O- 1 X 9 18 X-AS 3
Roadranger
Twin Countershaft Gen 3 Electronics
Low-Inertia AutoShift
Overdrive Gear Ratio
Forward Speeds
Design Level
Torque x 100

2019.12.12 © 2014 Eaton. All rights reserved 16

Serial Tag Information and Model Nomenclature | General Information TRSM0930

6-Speed E O - 1 X E 4 0 6 B P V
Passenger
Brand - Eaton Vehicle
Overdrive
Ratio Set
X 100 + 50
Nominal Torque Lb. Ft. Number of Speeds
Configuration
Design Level
Mechicanical & Electronic

10-Speed F O - 1 X E 3 0 8 L L - V C S
Construction
Brand - Fuller Series
Overdrive UltraShift
X 100 + 50 Vocational
Nominal Torque Lb. Ft.
Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic

10-Speed F O M 1 X E 3 1 0 C - L A S
Active
Brand - Fuller Shifting
Overdrive UltraShift
Line Haul
Multi-Torque
Ratio Set
X 100 + 50
Nominal Torque Lb. Ft. Number of Speeds
Starting Device
(Clutch Type)
Design Level
Mechicanical & Electronic

10-Speed F O M 1 X E 3 1 0 C - V A S
Active
Brand - Fuller Shifting
Overdrive UltraShift
Vocational
Multi-Torque
Ratio Set
X 100 + 50
Nominal Torque Lb. Ft. Number of Speeds
Starting Device
(Clutch Type)
Design Level
Mechicanical & Electronic

11-Speed F O - 1 X E 3 0 9 A L L - V M S
Mixer
Brand - Fuller Series
Overdrive UltraShift
X 100 + 50 Vocational
Nominal Torque Lb. Ft.
Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic

13-Speed F O - 1 X E 3 1 3 A - M H P
Brand - Fuller High Performance
Overdrive UltraShift
X 100 + 50 Multipurpose
Nominal Torque Lb. Ft. Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic

17 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 General Information | Serial Tag Information and Model Nomenclature

13-Speed F O - 1 X E 3 1 3 A - V H P
Brand - Fuller High Performance
Overdrive UltraShift
X 100 + 50 Vocational
Nominal Torque Lb. Ft. Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic

16-Speed F M - 1 X E 3 1 6 B - L S E
Small Step
Brand - Fuller Efficiency
Overdrive UltraShift
X 100 + 50 Linehaul
Nominal Torque Lb. Ft.
Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic

18-Speed F O - 1 X E 3 1 8 B - M X P

Brand - Fuller Xtreme Performance

Overdrive UltraShift
X 100 + 50 Multipurpose
Nominal Torque Lb. Ft.
Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic

2019.12.12 © 2014 Eaton. All rights reserved 18

Clutch Greasing Guidelines | General Information TRSM0930

Clutch Greasing Guidelines

Caution: It is highly important to follow proper clutch lube
! intervals as specified in Lubrication Manual
TCMT0021. Failure to do so may result in clutch
failure and unnecessary repairs.
The heavy-duty ECA clutch housing has 2 grease fittings on
the lower right side. The upper port is marked “CS” for the
upper cross-shaft assembly, while the lower port is marked
“RB” for the release bearing.

For more detailed cross-shaft greasing information refer to

the Release Yoke and Cross-shaft Installation section of this
manual. Refer to Clutch Service Manual CLSM0200, for
release bearing greasing information.

Grease Interval Count Reset

The Heavy-Duty UltraShift PLUS has an optional prognostic
feature that notifies the operator when the Clutch Release
Bearing needs greasing. This feature can be enabled or dis-
abled via ServiceRanger.

At the appropriate grease interval and shortly after each

engine start, “GI” will momentarily appear in the gear dis-
play, along with an audible tone. This will continue to occur
at each engine start until clutch service has been com-
pleted.

Note: “GI” stands for grease interval and may be misread

as “G1”on gear display.
The operator can choose to follow this automated lube
schedule or the published lube guidelines in the Lubrication
Manual TCMT0021. When enabled, it is highly important to
reset the grease interval count every time the Release Bear-
ing is greased.

The grease interval count can be reset via ServiceRanger or

Operator-Triggered Special Function.

19 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 General Information | Clutch Greasing Guidelines

Operator Triggered Procedure

2019.12.12 © 2014 Eaton. All rights reserved 20

Clutch Greasing Guidelines | General Information TRSM0930

21 © 2014 Eaton. All rights reserved 2019.12.12

DM Clutch Removal | Service Procedure TRSM0930

DM Clutch Removal
Special Instructions Special Tools
None • Clutch Alignment Tool (RR1009CL)
• Jack Screw (5/16" x 18 UNC x 3")
• Mounting Studs (7/16" x 14 UNC x 5")

Component Identification

3
2

1 7

4 5

1.Alignment Tool
2. Clutch Cover
3. Pilot Bearing
4. Front Disc
5. Flywheel

22 © 2018 Eaton. All rights reserved 2019.12.17

DM Clutch Removal | Service Procedure TRSM0930

Clutch Removal 3. Install the jack screw into one of the four holes located
adjacent to the clutch mounting bolts.
! WARNING: Clutch weighs approximately 182 lb (82 kg). Note: This forces the pressure plate forward clamping
Use proper equipment when lifting clutch to avoid damage, the discs and holding them in place.
serious injury or death.
NOTICE: Do not over-tighten jack screw. Tightening
Note: The following procedure should be followed if servic- more than 9 lb-ft can cause permanent clutch damage.
ing the transmission and the clutch is not being removed
from the flywheel. If the clutch is being replaced, go to Step NOTICE: Failure to remove the jack screw after the
4, followed by Step 7. transmission is re-installed will result in severe clutch
damage.
1. Prior to removing the transmission, rotate the engine
until one of the jack screw locations can be viewed 4. Remove the transmission, supporting its weight to pre-
through the clutch housing inspection opening. vent damage to the clutch discs.

5. Insert alignment shaft and clutch jack.

6. Remove the jack screw.

1. Clutch Housing Inspection Opening
7. Unbolt the clutch from the flywheel and slide the clutch
2. Using a piece of 5/16" x 18 UNC x 3" threaded rod (jack away from the flywheel.
screw), install two nuts on one end and lock them
together. This will allow you to turn the jack screw in ! WARNING: Clutch weighs approximately 182 lb (82
and out of the cover assembly. kg). Use proper equipment when lifting clutch to avoid
damage, serious injury or death.
! CAUTION: When removing the clutch, the flywheel
side disc can fall off of the alignment shaft, perma-
nently damaging the driven disc.
8. Remove the old pilot bearing.

23 © 2018 Eaton. All rights reserved 2019.12.17

DM Clutch Installation | Service Procedure TRSM0930

DM Clutch Installation
Special Instructions Special Tools
None • Clutch Alignment Tool (RR1009CL)
• Jack Screw (5/16" x 18 UNC x 3")
• Mounting Studs (7/16" x 14 UNC x 5")

Component Identification

4 6
5
1 3

1. Alignment Tool
2. Hub
3. 5/16" x 18 UNC x 3" Jack Screws
4. Lock Washers and Mounting Bolts
5. Front Disc
6. Flywheel
7. 7/16" x 14 UNC x 5" Mounting Studs

24 © 2018 Eaton. All rights reserved 2019.12.17

DM Clutch Installation | Service Procedure TRSM0930

Engine Flywheel and Housing Inspection 5. Use a dial indicator to check the pilot bearing bore
runout.
Measure Engine Flywheel Housing a. Secure dial indicator base to flywheel housing face.
and Flywheel
b. Position gauge finger so that it contacts pilot bear-
NOTICE: For machining of the flywheel friction surface, ing bore.
contact the OEM engine manufacture for specifications. c. Rotate flywheel one revolution. Maximum runout is
NOTICE: Engine flywheel housing and flywheel must meet 0.005" (0.13 mm).
these specifications or it may result in premature clutch fail-
ure.
1. Remove and replace old pilot bearing per engine man-
ufacturer instructions. b
a
2. All gauge contact surfaces must be clean and dry.
Clean flywheel surfaces of all grease, oil and rust pre-
ventatives. Failure to perform this function can affect
the performance of the clutch.

3. Contact OEM engine manufacture for specific instruc-

tions for dial indication of the flywheel and flywheel
housing.

4. Use a dial indicator to check the flywheel face runout.

a. Secure dial indicator base to flywheel housing face.

c
b. Put gauge finger in contact with flywheel face near
the outer edge.
c. Rotate flywheel one revolution. Maximum runout is 6. Use a dial indicator to check the flywheel housing I.D.
0.008" (0.20 mm). runout.

a. Secure dial indicator base to crankshaft.

b b. Put gauge finger against flywheel housing pilot I.D.
a c. Rotate flywheel one revolution. Maximum runout is
0.012" (0.30 mm).

a
b

25 © 2018 Eaton. All rights reserved 2019.12.17

 TRSM0930 Service Procedure | DM Clutch Installation

7. Use a dial indicator to check the flywheel housing face Clutch Installation
runout.
Note: The required alignment tool, part number RR1009CL,
a. Secure dial indicator base to flywheel near the can be ordered through K-Line at (800)-824-5546.
outer edge.
! b. Put gauge finger in contact with face of flywheel WARNING: Clutch weighs approximately 182 lb (82 kg).
housing. Use proper equipment when lifting clutch to avoid damage,
serious injury or death.
c. Rotate flywheel one revolution. Maximum runout is
0.008" (0.20 mm). 1. Install pilot bearing.

Note: See Appendix for a list of recommended pilot

bearings.
a
2. Measure the flywheel bore to verify that the damper
will fit into the flywheel bore.

10.0" (7-spring & VCT Plus)

b
c

2019.12.17 © 2018 Eaton. All rights reserved 26

DM Clutch Installation | Service Procedure TRSM0930

3. Insert aligning tool through DM Clutch and rear disc. 5. Install two 7/16" x 14 UNC x 5" studs into upper mount-
ing holes. Using clutch jack or other lifting device,
! CAUTION: The intermediate plate is bolted to the cover install assembled clutch.
assembly and the rear driven disc is held in place
between the pressure plate and intermediate plate. Do NOTICE: Using the transmission to install the clutch
not unbolt the intermediate plate from the cover can result in damage to the clutch assembly.
assembly.

1
2

1. 7/16" x 14 UNC x 5" studs

1. Aligning Tool 2. Lock Washers and Mounting Bolts

4. Install front disc onto aligning tool. Follow the orienta- 6. Install lock washers and mounting bolts (7/16" x 14
tion instructions on the disc. UNC x 2–1/4" grade 5) finger tight. Replace studs with
lock washers and bolts.

1. Front Disc 1. Lock Washers and Mounting Bolts

27 © 2018 Eaton. All rights reserved 2019.12.17

TRSM0930 Service Procedure | DM Clutch Installation

7. Progressively tighten mounting bolts in a crisscross Note: Installing the jack screw into one of the four
pattern starting with the lower left bolt (1, 2, 3, 4, 5, 6, holes located adjacent to the clutch mounting bolts
7, 8). Torque to 40–50 lb-ft (54–68 N•m). forces the pressure plate, forward clamping the discs
and holding them in place.
! CAUTION: Failure to do this could result in improper
piloting of the clutch to the flywheel and can result in a
Option 1:
vibration or the clutch coming loose from the flywheel.

6 2
4

8
7

1
5

Option 2:
8. Prior to removing the alignment tool, complete one of
the following options to ensure the driven discs remain
in place.

- Option 1: Rotate the hub in the center of the cover

counterclockwise will lock the disc in place.
- Option 2: Install the jack screw into one of the four
holes located adjacent to the clutch mounting bolts.
Be sure the hole chosen is at the 6 o’clock position
to allow for removal after the transmission is
installed.
9. Remove the aligning tool.
Note: Using a piece of 5/16" x 18 UNC x 3" threaded
rod (jack screw), install two nuts on one end and lock
them together. This will allow you to turn the jack
screw in and out of the cover assembly.

! CAUTION: Do not overtighten the jack screw.

Tightening more than 9 lb-ft will cause permanent
clutch damage.

2019.12.17 © 2018 Eaton. All rights reserved 28

DM Clutch Installation | Service Procedure TRSM0930

Transmission Inspection Transmission Installation

1. Inspect the transmission for wear. Replace any worn 1. Fasten transmission to flywheel housing.
components.
2. Position the transmission so it is square to and aligned
2. Inspect the input shaft splines. Any wear on the splines with the engine.
will prevent the driven discs from sliding freely, caus-
ing poor clutch release (clutch drag). Slide discs full
length of shaft to check for twisted shaft splines.

NOTICE: Do not add lube (anti-seize or grease) to the

input shaft splines. The disc must be free to slide.

1. Input Shaft Splines

3. Inspect the input shaft spigot. Wear will not provide 3. Mesh splines by moving the transmission forward and
proper interface with the inner race of the pilot bearing. rotating the input shaft. Do not use excessive force. Do
This can result in damage to the clutch or the pilot not let the transmission hang unsupported in the discs.
bearing.

1. Input Shaft Spigot

1. Input Shaft

29 © 2018 Eaton. All rights reserved 2019.12.17

TRSM0930 Service Procedure | DM Clutch Installation

4. Install mounting bolts and torque to OEM specs.

1. Mounting Bolt

5. If a jack screw was installed to hold the driven disc in

position, remove the jack screw.

! CAUTION: Failure to remove the jack screw after the

transmission is re-installed will result in severe clutch
damage.
6. Reconnect UltraShift wiring harness.

! CAUTION: Do not let the transmission drop or hang

unsupported in the driven discs. This can cause the
discs to become distorted and the clutch to not release.
NOTICE: Do not use excessive force. If it does not enter
freely, investigate the cause of problem and make any
necessary changes.
7. Refer to the ServiceRanger 4 Guide (TCMT0072) for
clutch recalibration and instructions to clear clutch
data.

2019.12.17 © 2018 Eaton. All rights reserved 30

Thread-In ECA Speed Sensor | Service Procedure TRSM0930

Thread-In ECA Speed Sensor

Special Instructions Special Tools
None Basic hand tools

Component Identification

1. Sensor
2. Jam Nut

31 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Thread-In ECA Speed Sensor

Procedure - Removal
1. Disconnect ECA Speed Sensor Connector.

2. Loosen jam nut on ECA.

3. Rotate sensor counterclockwise to remove it.

2019.12.12 © 2014 Eaton. All rights reserved 32

Thread-In ECA Speed Sensor | Service Procedure TRSM0930

Procedure - Installation
1. Thread Speed Sensor into the Engine Bell Housing until 3. Hold the sensor in place and tighten the 3/4”-16 jam
it touches the flywheel. nut to 15 lb-ft. (20.3 Nm).

2. After the sensor touches the flywheel, rotate it counter- 4. Apply included material to low-voltage 4-way harness
clockwise 1/2 to 1 full turn. connector terminals.

Note: Apply just enough material to cover the end of

the terminal.
Note: Use only Eaton lubricant part number 5564527.
(Nye Lubricants NYOGEL 760G. For MSDS safety
or other information see www.nyelubri-
cants.com).
5. Connect Engine Speed Sensor Connector to the mating
connector on the transmission and fasten harness, if
needed.

33 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Thread-In ECA Speed Sensor

2019.12.12 © 2014 Eaton. All rights reserved 34

Electronic Clutch Actuator (ECA) | Service Procedure TRSM0930

Electronic Clutch Actuator (ECA)

Special Instructions Special Tools
If vehicle is equipped with an 8-bolt PTO, removal may be Basic hand tools
required prior to removing the ECA. Follow PTO manufac-
turer’s guidelines for removal.

Component Identification

1. Bracket Cap Screw

2. ECA Cap Screw
3. ECA
4. 8-Way Connector
5. 3-Way Connector
6. ECA Shield (Optional)

35 © 2014 Eaton. All rights reserved 2019.12.12

 TRSM0930 Service Procedure | Electronic Clutch Actuator (ECA)

Procedure - Removal
Warning: Ensure the Hand Hole Cover is closed when 4. Remove the 4 cap screws from the ECA mounting
! removing the ECA. flange.
1. Disconnect the negative battery cable.

2. Disconnect the 8-way and 3-way connectors from the

ECA.

Note: Some models do not use a shield.

5. Remove the ECA.

Note: The ECA has an alignment pin that requires the

unit to be rotated to exit the clutch housing bore.
Note: If ECA will not slide from the clutch housing after
3. Remove the 4 cap screws from the ECA shield and all the fasteners are removed, use the available
remove shield. pusher holes found on both sides of the ECA
casting. Place the included jackscrews into the
Note: Medium-duty models are mounted with 3 cap holes. Turn each jackscrew until it touches. Next,
screws and 1 lock nut. turn the upper jackscrew 1 turn; then rotate to
the lower jackscrew and rotate it 1 turn. Continue
until the ECA is fully displaced from the bore.

2019.12.12 © 2014 Eaton. All rights reserved 36

Electronic Clutch Actuator (ECA) | Service Procedure TRSM0930

Procedure - Installation
1. Install the ECA into the clutch housing bore. Align it 3. If applicable, install the 4 cap screws for the ECA
with the lower cross-shaft. shield. Tighten them to 35-45 lb-ft. (47-61 Nm).

Note: The ECA will have to be rotated to align with the

slot in the Clutch Housing.
Note: Ensure you rotate the Release Yoke as close to
the Case Dowel in the Clutch Housing prior to
mating with the cross-shaft. This allows the
Release Yoke to clear the Release Bearing during
installation.

4. Apply NyoGel to terminals and reconnect the 8-way

and 3-way connectors to the ECA.

Note: Apply just enough material to cover the end of

the terminal.
Note: Use only Eaton lubricant part number 5564527
(Nye Lubricants NYOGEL 760G. For MSDS safety
or other information see www.nyelubri-
2. Install the 4 cap screws from the ECA Mounting Flange. cants.com.)
Tighten them to 35-45 lb-ft. (47-61 Nm).

Note: Medium-duty models are mounted with 3 cap

screws and 1 lock nut. Tighten to 35-45 lb-ft. (47-61
Nm).
Note: The cap screws for the ECA are longer than the
ECA Bracket cap screws.
Note: Ensure the ECA does not bind on the cross-shaft
by snugging all cap screws before tightening to
the specified torque.

5. Reconnect the negative 12-volt battery cable.

6. If previously removed, install the 8-bolt PTO after ECA

installation. Follow the PTO manufacturer’s guidelines
for installation instructions.

37 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Electronic Clutch Actuator (ECA)

2019.12.12 © 2014 Eaton. All rights reserved 38

Low Capacity Inertia Brake | Service Procedure TRSM0930

Low Capacity Inertia Brake

Special Instructions Special Tools
None Basic hand tools

Component Identification

1. Mounting Nut
2. Low Capacity Inertia Brake (LCIB)

39 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Low Capacity Inertia Brake

Procedure - Removal
Note: The Transmission and ECA must be removed prior to
removing the LCIB.
1. Remove the 2 mounting nuts with a breaker bar and
socket.

2. Remove the LCIB by hand by sliding off of the splined

Input Shaft.

2019.12.12 © 2014 Eaton. All rights reserved 40

Low Capacity Inertia Brake | Service Procedure TRSM0930

Procedure - Installation
1. Slide the LCIB onto the splined Input Shaft while cen-
tering the holes onto the retaining studs.

2. Install the 2 retaining nuts and torque nuts to 140-150

lb-ft. (190-203 Nm).

Note: The LCIB can only be installed one way. The label
is toward the right side of the vehicle and facing
the flywheel.

41 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Low Capacity Inertia Brake

2019.12.12 © 2014 Eaton. All rights reserved 42

Release Yoke and Cross-shaft(s) | Service Procedure TRSM0930

Release Yoke and Cross-shaft(s)

Special Instructions Special Tools
None Basic hand tools

Component Identification

1. Plug
2. O-ring
3. Upper Cross-shaft
4. Bushing
5. Seal
6. Lock Washer
7. Mounting Screw
8. Release Yoke
9. Lower Cross-shaft

43 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Release Yoke and Cross-shaft(s)

Procedure - Removal
Note: The Transmission and ECA must be removed prior to 3. Remove the upper Cross-Shaft.
removing the Release Yoke and Cross-shaft(s).
1. Remove the upper and lower Cross-Shaft Mounting
cap screws and lock washers from the Release Yoke.

4. If necessary, remove the Cross-Shaft Plug with o-ring.

2. Remove the lower Cross-Shaft and Release Yoke.

5. If necessary, remove the upper Cross-Shaft Seal

assembly.

2019.12.12 © 2014 Eaton. All rights reserved 44

Release Yoke and Cross-shaft(s) | Service Procedure TRSM0930

6. If necessary, remove the 2 upper Cross-Shaft bush-

ings.

45 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Release Yoke and Cross-shaft(s)

Procedure - Installation
1. If previously removed, install the 2 upper Cross-shaft 3. If previously removed, install the o-ring onto the
bushings. Cross-shaft plug and then install the Cross-shaft plug
into the transmission housing and torque to 34-48
Note: Make sure to apply grease to the bushings. lb-ft. (46-65 Nm).

2. If previously removed, install the upper Cross-shaft 4. Install the upper Cross-shaft into the bore.
grease seal.

2019.12.12 © 2014 Eaton. All rights reserved 46

Release Yoke and Cross-shaft(s) | Service Procedure TRSM0930

5. Slide yoke onto upper Cross-shaft assembly and install 8. Grease upper Cross-shaft assembly until grease
1 cap screw and lock washer by hand. purges from the bleed hole in the upper Cross-shaft
boss.

6. Install lower Cross-shaft assembly and install 1 cap

screw and lock washer by hand.

7. Tighten the 2 Yoke cap screws to 35-45 lb-ft. (47-61

Nm).

47 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Release Yoke and Cross-shaft(s)

2019.12.12 © 2014 Eaton. All rights reserved 48

Cobra Lever | Service Procedure TRSM0930

Cobra Lever
Special Instructions Special Tools
None Basic hand tools

Component Identification

1. Tower
2. Screw
3. 8-Way Cobra Lever Harness Connector

49 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Cobra Lever

Removal Installation
1. Using a Phillips screwdriver, remove the 4 screws from 1. Connect the 8-way Cobra Lever Harness connector and
the Cobra Lever housing. place the Cobra Lever into the tower.

2. Disconnect the 8-way Cobra Lever Harness connector 2. Using a Phillips screwdriver install the 4 screws into
and remove the Cobra Lever from the housing. the Cobra Lever housing.

2019.12.12 © 2014 Eaton. All rights reserved 50

Shift Control | Service Procedure TRSM0930

Shift Control
Special Instructions Special Tools
The exact location varies depending on vehicle manufac- Basic hand tools
turer.

Component Identification

2
1

1. Nut
2. Washer
3. Push Button Shift Control 30-Way Connector
4. Backing Plate
5. Push Button Shift Control

51 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Shift Control

Procedure - Removal
1. Using a 1/4” socket, loosen the retaining bolt and dis-
connect the 30-way connector from the back of the
Shift Control.

2. Using a 11/32” wrench, remove the 2 nuts and lock

washers from the back of the Shift Control and remove
the Shift Control.

Note: Shift Control location and use varies with each

truck.

2019.12.12 © 2014 Eaton. All rights reserved 52

Shift Control | Service Procedure TRSM0930

Procedure - Installation
1. Install the Shift Control in the mounting location. Then,
using a 11/32” wrench, install the 2 lock washers and
nuts and tighten to 14-16 lb-in. (18–21 Nm).

2. Using a 1/4” wrench, reconnect the 30-way connector

to the back of the Shift Control and tighten to 10 +/- 3
lb-in. [13.5 +/- 4 Nm]

53 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Shift Control

2019.12.12 © 2014 Eaton. All rights reserved 54

Medium-Duty Transmission Harness | Service Procedure TRSM0930

Medium-Duty Transmission Harness

Special Instructions Special Tools
None Basic hand tools

Component Identification

Medium-Duty

2 9
3
4

8
1
7

1. Transmission ECU 38-way Connector

2. Gear Sensor Connector
3. Rail Sensor Connector
4. Future position of 4-way Transmission Diagnostic Connector
5. Input Shaft Speed Sensor Connector
6. Inertia Brake Connector
7. Wet Clutch Solenoid Connector (AW3 only)
8. Output Shaft Speed Sensor Connector
9. Electric Shifter Connector

55 © 2014 Eaton. All rights reserved 2019.12.12

 TRSM0930 Service Procedure | Medium-Duty Transmission Harness

Procedure - Removal
Caution: The battery negative must be disconnected prior
! to unhooking the Transmission ECU (TECU)
38-way Connectors.
Caution: Do not allow contamination into the TECU or con-
! nectors.
1. Using a 5/32” hex wrench, disconnect the Transmis-
sion Harness 38-way Connector.

2. Disconnect the following harness connectors:

• Inertia Brake Coil (if equipped)

• Input Shaft Speed Sensor
• Gear Select Sensor and Rail Select Sensor
• Wet clutch solenoid (AW3 only)
• Output Shaft Speed Sensor (location may vary)
• 4-way Transmission Diagnostic connector
• Electric Shifter

2019.12.12 © 2014 Eaton. All rights reserved 56

Medium-Duty Transmission Harness | Service Procedure TRSM0930

Procedure - Installation
Caution: Do not allow contamination into the TECU Connec-
! tors.
Caution: Do not over tighten tie-downs.
!
Caution: Leave a service loop in the Transmission Harness.
!
Caution: Do not put sharp bends in the Transmission Har-
! ness.
Caution: The battery negative must be disconnected while
! installing the TECU connectors.
1. Reconnect the following harness connectors:

• Gear Select and Rail Select Sensor

• Input Shaft Speed Sensor
• Inertia Brake Coil
• Output Shaft Speed Sensor
• 4-way Transmission Diagnostic connector
• Electric Shifter
• Wet clutch solenoid (AW3 only)
2. Using a 5/32” hex wrench, reconnect the Transmission
Harness 38-way Connector and tighten to 22–28 lb-in.
(29–37 Nm).

Caution: Do not exceed the torque on the Transmission

! Harness or Vehicle Harness Connector or bolt
failure will occur.

57 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Medium-Duty Transmission Harness

2019.12.12 © 2014 Eaton. All rights reserved 58

Heavy-Duty Transmission Harness | Service Procedure TRSM0930

Heavy-Duty Transmission Harness

Special Instructions Special Tools
None Basic hand tools

Component Identification

Heavy-Duty LAS/VAS Models

10
5
3 10
7 8
3
2
2
5 11 4
1 8 11

11

9 9 4
1
12

6 6

1. ECU 38-way Connector

1. Transmission ECU 38-way Connector
2. Gear Sensor Connector
2. Gear Sensor Connector
3. Rail Sensor Connector
3. Rail Sensor Connector
4. 4-way Diagnostic Connector
4. 4-way Transmission Diagnostic Connector
5. Input Shaft Speed Sensor Connector
5. Input Shaft Speed Sensor Connector
6. ECA 8-way Connector
6. Inertia Brake Connector (DM3 models)
7. Range Solenoid Connector
7. Range Solenoid Connector
8. Output Shaft Speed Sensor Connector
8. Output Shaft Speed Sensor Connector
9. Engine Speed Sensor Connector
9. Splitter Solenoid Connector (13-,18-speeds only)
10. Mainshaft Speed Sensor
10. Mainshaft Speed Sensor Connector
11. Electric Shifter Connector
11. Electric Shifter Connector
12. Terminating Resistor Connector

59 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Heavy-Duty Transmission Harness

VMS and VCS Models LSE, MHP/VHP and MXP/VXP Models

9
7
7

5 10 8

10 8 5
2 2 3
3
11 11
12
12 11 9
11
4 1 4

1
13
6
6
13

1. ECU 38-way Connector 1. ECU 38-way Connector

2. Gear Sensor Connector 2. Gear Sensor Connector
3. Rail Sensor Connector 3. Rail Sensor Connector
4. 4-way Diagnostic Connector 4. 4-Way Diagnostic Connector
5. Input Shaft Speed Sensor Connector 5. Input Shaft Speed Sensor Connector
6. ECA 8-way Connector 6. ECA 8-way Connector
7. Range Solenoid Connector 7. Range Solenoid Connector
8. Output Shaft Speed Sensor Connector 8. Output Shaft Speed Sensor Connector
9. Reduction Solenoid Connector 9. Splitter Solenoid Connector
10. Mainshaft Speed Sensor 10. Mainshaft Speed Sensor
11. Electric Shifter Connector 11. Electric Shifter Connector
12. Engine Speed Sensor Connector 12. Engine Speed Sensor Connector
13. Terminating Resistor Connector 13. Terminating Resistor Connector

2019.12.12 © 2014 Eaton. All rights reserved 60

Heavy-Duty Transmission Harness | Service Procedure TRSM0930

Procedure - Removal
Caution: The battery negative must be disconnected prior
! to unhooking the TECU 38-way connectors.
Caution: Do not allow contamination into the TECU or con-
! nectors.
1. Disconnect the following connectors:

• Using a 5/32” hex wrench, unscrew and disconnect

the Transmission Harness 38-way Connector and
Vehicle Interface 38-way Connector.

2. Disconnect the following harness connectors:

• Inertia Brake Coil (if equipped)

• Input Shaft Speed Sensor
• Main Shaft Speed Sensor
• Gear Select Sensor and Rail Select Sensor
• Output Shaft Speed Sensor
• Range and Splitter Valve Solenoids
• 4-way Transmission Diagnostic connector
• Electric Shifter

61 © 2014 Eaton. All rights reserved 2019.12.12

 TRSM0930 Service Procedure | Heavy-Duty Transmission Harness

Procedure - Installation
Caution: Do not allow contamination into the TECU connec-
! tors.
Caution: Do not over tighten tie-raps.
!
Caution: You need to leave a service loop in the Transmis-
! sion Harness.
Caution: Do not put sharp bends in the Transmission Har-
! ness.
Caution: The battery negative must be disconnected, while
! installing the TECU connectors.
1. Reconnect the following harness connectors:

• Gear Select and Rail Select Sensor

• Main Shaft Speed Sensor
• Input Shaft Speed Sensor
• Inertia Brake Coil (if equipped)
• Output Shaft Speed Sensor
• 4-way Transmission Diagnostic Connector
• Electric Shifter
• Range and Splitter Valve Solenoids
2. Using a 5/32” hex wrench, reconnect the Transmission
Harness 38-way Connector and tighten to 25 +/- 3
lb-in. (2.82 +/- 0.33 Nm).

Caution: Do not exceed the torque on the Transmission

! Harness or Vehicle Harness Connector or bolt
failure will occur.

2019.12.12 © 2014 Eaton. All rights reserved 62

Medium-Duty Transmission Electronic Control Unit (TECU) | Service Procedure TRSM0930

Medium-Duty Transmission Electronic Control Unit (TECU)

Special Instructions Special Tools
None Basic hand tools

Component Identification

Medium-Duty

1
2

1. Cap Screw
2. Transmission ECU (TECU)
3. 38-way Connectors
4. Cap Screw (Located inside 38-way connectors)

63 © 2014 Eaton. All rights reserved 2019.12.12

 TRSM0930 Service Procedure | Medium-Duty Transmission Electronic Control Unit (TECU)

Procedure - Removal
Caution: The battery negative must be disconnected prior 4. Remove the Transmission Controller assembly from
! to unhooking the Transmission ECU (TECU) the locating studs.
38-way connectors.
Caution: Do not allow contamination into the TECU or con-
! nectors.
1. Connect ServiceRanger to vehicle and record current
configuration settings before removing the TECU from
the transmission. (Refer to “ServiceRanger User
Guide” TCMT-0071 for more information.)

2. Disconnect the following connectors:

• Using a 5/32” hex wrench, unscrew and disconnect

the Transmission Harness 38-way Connector and
Vehicle Interface 38-way Connector.

3. Using a 7/16” socket, remove the 3 mounting bolts.

2019.12.12 © 2014 Eaton. All rights reserved 64

Medium-Duty Transmission Electronic Control Unit (TECU) | Service Procedure TRSM0930

Procedure - Installation
Caution: Battery negative must remain disconnected until 3. Reconnect the following connectors:
! the TECU 38-way connectors are installed.
Caution: Do not exceed the torque on the Transmission
Caution: Do not allow contamination into the TECU or con- ! Harness or Vehicle Harness Connector or bolt
! nectors. failure will occur.
1. Position the Transmission Controller on the locating • Using a 5/32” wrench, reconnect the Transmission
studs. Harness 38-way Connector and tighten to 25 +/- 3
lb-in. (2.82 +/- 0.33 Nm).
• Using a 5/32” wrench, reconnect the Vehicle Inter-
face 38-way Connector and tighten to 25 +/- 3 lb-in.
(2.82 +/- 0.33 Nm).
• Reconnect the negative battery cable.

2. Using a 7/16” socket, install the 3 Transmission Con-

troller mounting bolts and tighten to 7-9 lb-ft.
(9.5-12.2 Nm).

4. To operate properly, the system must be calibrated as

follows:

Important: The Electric Shifter must be calibrated

! before the vehicle is placed in operation.
• Turn ignition switch on. Allow the transmission to
power up.
• Turn ignition off and wait 2 minutes.
Note: UltraShift AW3- Perform clutch calibration:
“Clutch Calibration” on page 149.
5. Connect ServiceRanger to vehicle and compare
recorded configuration settings (step 1 in removal pro-
cess) to the replacement TECU. Update and save all
configurations that are different. (Refer to “Ser-
viceRanger User Guide” TCMT-0071 for more informa-
tion.)

65 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Medium-Duty Transmission Electronic Control Unit (TECU)

2019.12.12 © 2014 Eaton. All rights reserved 66

Heavy-Duty Transmission Electronic Control Unit (TECU) | Service Procedure TRSM0930

Heavy-Duty Transmission Electronic Control Unit (TECU)

Special Instructions Special Tools
None Basic hand tools

Component Identification

1
2 3

1. Nut
2. Bracket
3. Transmission ECU (TECU)
4. 38-Way Connectors
5. Cap Screw (Located inside 38-way connectors)

67 © 2014 Eaton. All rights reserved 2019.12.12

 TRSM0930 Service Procedure | Heavy-Duty Transmission Electronic Control Unit (TECU)

Procedure - Removal
Caution: The battery negative must be disconnected prior 4. Remove the Transmission Controller Retaining
! to unhooking the Transmission ECU (TECU) Bracket.
38-way connectors.
Caution: Do not allow contamination into the TECU or con-
! nectors.
1. Connect ServiceRanger to vehicle and record current
configuration settings before removing the TECU from
the transmission. (Refer to “ServiceRanger User
Guide” TCMT-0071 for more information.)

2. Disconnect the following connectors:

• Using a 5/32” hex wrench, unscrew and disconnect

the Transmission Harness 38-way Connector and
Vehicle Interface 38-way Connector.

5. Remove the Transmission Controller assembly from

the locating studs.

3. Using a 7/16” socket, remove the 3 mounting nuts.

2019.12.12 © 2014 Eaton. All rights reserved 68

Heavy-Duty Transmission Electronic Control Unit (TECU) | Service Procedure TRSM0930

Procedure - Installation
Caution: Battery negative must remain disconnected until 3. Using a 7/16” socket, install the 3 Transmission Con-
! the TECU 38-Way connectors are installed. troller mounting nuts and tighten to 7-9 lb-ft. (9.5-12.2
Nm).
Caution: Do not allow contamination into the TECU or con-
! nectors.
1. Position the Transmission Controller on the locating
studs.

4. Reconnect the following connectors:

Caution: Do not exceed the torque on the Transmission

! Harness or Vehicle Harness Connector or bolt
failure will occur.
2. Place the Transmission Controller retaining bracket
over the TECU. • Using a 5/32” wrench, reconnect the Transmission
Harness 38-way Connector and tighten to 25 +/- 3
lb-in. (2.82 +/- 0.33 Nm).
• Using a 5/32” wrench, reconnect the Vehicle Inter-
face 38-way Connector and tighten to 25 +/- 3 lb-in.
(2.82 +/- 0.33 Nm).
• Reconnect the negative battery cable.

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 TRSM0930 Service Procedure | Heavy-Duty Transmission Electronic Control Unit (TECU)

5. Connect ServiceRanger to vehicle and compare

recorded configuration settings (step 1 in removal pro-
cess) to the replacement TECU. Update and save all
configurations that are different. (Refer to “Ser-
viceRanger User Guide” TCMT0071 for more informa-
tion.)

6. To operate properly, the system must be calibrated as

follows:

Important: The Electric Shifter must be calibrated

! before the vehicle is placed in operation.
a. Turn ignition switch on. Allow transmission to
power up.
b. Turn ignition off. Wait 2 minutes.

2019.12.12 © 2014 Eaton. All rights reserved 70

Electric Shifter | Service Procedure TRSM0930

Electric Shifter
Special Instructions Special Tools
None Basic hand tools

Component Identification

1. Cap Screw
2. Electric Shifter
3. Gasket

71 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Electric Shifter

Procedure - Removal
1. Remove nylon cable ties from motor wires. Disconnect 3. Using a 9/16” socket, remove the 4 mounting cap
Transmission Harness from the Rail Select Sensor and screws.
the Gear Select Sensor.

4. Remove X-Y Shifter and gasket.

2. Disconnect the Rail Select and Gear Select Motors
from the Transmission ECU (TECU). Warning: Possible Pinch Point - Ensure battery is dis-
! connected before removing X-Y Shifter.

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Electric Shifter | Service Procedure TRSM0930

Procedure - Installation
1. Ensure Shift Blocks are in the neutral position, then 3. The dowel pin on the X-Y Shifter must be aligned with
move Shift Finger to the center (neutral) location. hole in the Shift Bar Housing (used only on 10-, 13-
and 18-Speed models).
Note: If the Shift Finger is not properly aligned, the X-Y
Shifter will not fit properly at its mounting location.

4. Position X-Y Shifter on the Shift Bar Housing. Using a

9/16” socket, install mounting cap screws and tighten
2. Clean and remove old gasket material from Shift Bar
in a cross pattern as follows:
Housing. Then, install new gasket on the Shift Bar
Housing. • 5- and 6-Speed (aluminum housing)- Tighten to
20-25 lb-ft. (27-34 Nm).
Note: Apply Eaton sealant part number 71205 or equiv-
alent to the mounting cap screws before install- • 10- 13- and 18-Speed (cast iron housing) - Tighten
ing. to 34-45 lb-ft. (45-60 Nm).

73 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Electric Shifter

5. Reconnect the Rail Select Sensor and Gear Select Sen- 7. To operate properly, the system must be calibrated as
sor. follows:

Important: X-Y Shifter must be calibrated before the

! vehicle is placed into operation.
• Turn ignition switch on. Allow the transmission to
power up.
• Turn ignition switch off. Wait 2 minutes.

6. Reconnect the Transmission Harness to the Rail Select

and Gear Select motors. Using nylon ties, secure
motor wires to the transmission in their previous posi-
tion.

2019.12.12 © 2014 Eaton. All rights reserved 74

Medium-Duty Inertia Brake | Service Procedure TRSM0930

Medium-Duty Inertia Brake

Special Instructions Special Tools
None Basic hand tools

Component Identification

1. Cap Screw
2. Inertia Brake
3. Gasket
4. Spacer (Used on all Medium-Duty ratios except the “N”)
5. Gasket (Used on all Medium-Duty ratios except the “N”)

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TRSM0930 Service Procedure | Medium-Duty Inertia Brake

Procedure - Removal
1. Drain the lubrication from transmission and disconnect 3. Using a 7/8” wrench, remove the lubricant supply line
the Transmission Harness from the Input Shaft Speed from the transmission.
Sensor and Inertia Brake Coil.

4. Using a 9/16” wrench, remove the 6 mounting bolts

from the Inertia Brake.

Caution: The Inertia Brake is heavy. Be prepared to

2. Using a 3/8” wrench, remove Input Shaft Speed Sen-
! handle the weight of the Inertia Brake when
sor. mounting bolts are removed.

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Medium-Duty Inertia Brake | Service Procedure TRSM0930

5. Remove the Inertia Brake, gaskets and spacer (depend-

ing on model) from the transmission.

Note: The Inertia Brake will contain some lubricant.

Note: The spacer and extra gasket are used on all
transmission ratios except the N.

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 TRSM0930 Service Procedure | Medium-Duty Inertia Brake

Procedure - Installation
Warning: The Inertia Brake is heavy. Be prepared to handle 3. Using a 7/8” wrench, reconnect Inertia Brake lubricant
! weight of the Inertia Brake until mounting bolts supply line to the transmission and tighten to 42-48
are installed. lb-ft. (57-65 Nm).
1. Install Inertia Brake, gaskets and spacer (depending on
model) being careful to align the Inertia Brake gear
with the drive gear.

Note: The spacer and extra gasket are used on all

transmission ratios except N.

4. Using a 3/8” wrench, install Input Shaft Speed Sensor

and tighten to 8-12 lb-ft. (11-16 Nm).

2. Using a 9/16” socket, install the 6 mounting bolts.

Tighten mounting bolts to 35-45 lb-ft. (47-60 Nm)
using a cross pattern.

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Medium-Duty Inertia Brake | Service Procedure TRSM0930

5. Reconnect the Transmission Harness to Input Shaft

Speed Sensor and Inertia Brake Coil.

Note: Fill transmission with lubricant See “Lubrication

Specifications” on page 147.

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TRSM0930 Service Procedure | Medium-Duty Inertia Brake

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Air Filter Regulator | Service Procedure TRSM0930

Air Filter Regulator

Special Instructions Special Tools
The Air Filter Regulator has 2 o-rings located between the Basic hand tools
Air Filter/Regulator and the Range or Combination Cylinder
Cover.

Component Identification

1. Air Filter Regulator

2. Cap Screw

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TRSM0930 Service Procedure | Air Filter Regulator

Procedure - Removal
1. Relieve system air pressure by draining all air tanks on 3. Remove the Air Filter Regulator assembly.
the vehicle. Then, remove the vehicle air supply line
from the Air Filter Regulator. Note: Be careful not to let the o-rings drop out of the
Range or Combination Cylinder Cover when removing
the Air Filter Regulator.

2. Using a 7/16” socket, remove the 2 mounting cap

screws.

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Air Filter Regulator | Service Procedure TRSM0930

Procedure - Installation
Important: Lubricate o-rings with Eaton Fuller silicone 3. Reinstall the vehicle air supply line to the Air Filter Reg-
! 71214 or Equivalent. ulator and close all air tank drains.
1. If removed, press the two o-rings into the recesses in
the Range or Combination Cylinder Cover.

Note: Apply Eaton Fuller sealant 71205 or equivalent to

the two (2) mounting cap screws.

2. Using a 7/16” socket, install the 2 mounting cap

screws and tighten to 8-12 lb-ft. (11-16 Nm).

Note: Hold the Air Filter Regulator flush with the Range
Cylinder Cover until in place to prevent the
o-rings from dropping out.

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TRSM0930 Service Procedure | Air Filter Regulator

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Heavy-Duty Inertia Brake | Service Procedure TRSM0930

Heavy-Duty Inertia Brake

Special Instructions Special Tools
None Basic hand tools

Component Identification

1. Cap Screw
2. Inertia Brake
3. Gasket

85 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Heavy-Duty Inertia Brake

Procedure - Removal
1. Drain the lubricant from the transmission and discon- 3. Using a 9/16” socket, remove the 6 mounting bolts
nect the Transmission Harness from the Inertia Brake from the Inertia Brake.
Coil.
Caution: The Inertia Brake is heavy. Be prepared to
! handle the weight of the Inertia Brake when
the mounting bolts are removed.

2. Using a 7/8” wrench, disconnect the Inertia Brake

lubricant supply line from the transmission.
4. Remove the Inertia Brake and gasket from the trans-
mission.

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Heavy-Duty Inertia Brake | Service Procedure TRSM0930

Procedure - Installation
Warning: The Inertia Brake is heavy. Be prepared to handle 3. Using a 7/8” wrench, reconnect the Inertia Brake lubri-
! the weight of the Inertia Brake until the mounting cant supply line to the transmission and tighten to
bolts are installed. 20-22 lb-ft. (27-29 Nm).
1. Clean and remove all old gasket material. Then, install
the Inertia Brake and new gasket, being careful to align
the Inertia Brake gear with the drive gear.

4. Reconnect the Transmission Harness to the Inertia

Brake Coil.

Note: Fill the transmission with lubricant. See “Lubri-

2. Using a 9/16” socket, install the 6 mounting bolts. cation Specifications” on page 147..
Tighten mounting bolts to 35-45 lb-ft. (47-60 Nm)
using a cross pattern.

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TRSM0930 Service Procedure | Heavy-Duty Inertia Brake

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Combination Valves (Range and Deep Reduction) | Service Procedure TRSM0930

Combination Valves (Range and Deep Reduction)

Special Instructions Special Tools
Torques given below are in lb-in. Basic hand tools

Component Identification

1. Protective Cover (Optional)

2. Cap Screw
3. Valve
4. O-rings

89 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Combination Valves (Range and Deep Reduction)

Procedure - Removal
Note: Follow same procedure for the removal of Deep 3. Using a 5/16” socket, remove the 4 mounting cap
Reduction or Range Valve. screws from the valve.
1. If equipped, remove Protective Cover by pulling up on
the Release Tab.

4. Lift and remove the valve from the housing.

Caution: Do not use a hammer to loosen the valve in

2. Relieve system air pressure by draining air tanks on ! the housing or it could be damaged.
the vehicle. When air pressure has been relieved, dis-
connect the Transmission Harness from the Valve.

Note: The harness should be removed from the Valve

tie-down prior to removing the cap screws.

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Combination Valves (Range and Deep Reduction) | Service Procedure TRSM0930

Procedure - Installation
Important: Lubricate o-rings with Eaton Fuller silicone 3. Reconnect the Transmission Harness to the valve and
! 71214 or equivalent. close all air tanks drains.
Important: The valve is keyed to fit its mounting location. Note: Install the Range Harness back into the tie-down
! Take care to align the key in the valve with the on the valve.
notch in the housing.
Note: Follow same procedure for installing the Deep Reduc-
tion Valve or Range Valve.
1. Install and push the valve down into the housing.

4. If equipped, install the Protective Cover. Push the cover

down by hand until it snaps into place.

2. Using a 5/16” socket, install the valve mounting cap

screws and tighten to 21-27 lb-in. (2.3-3.0 Nm) using a
cross pattern.

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TRSM0930 Service Procedure | Combination Valves (Range and Deep Reduction)

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Range Valve | Service Procedure TRSM0930

Range Valve
Special Instructions Special Tools
The Range Valve may be difficult to remove from the Trans- Basic hand tools
mission Housing because of the o-rings.

Component Identification

1. Protective Cover (Optional)

2. Cap Screw
3. Valve
4. O-rings

93 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Range Valve

Procedure - Removal
1. If equipped, remove the Protective Cover by pulling up 3. Using a 5/16” socket, remove the 4 mounting cap
on the Release Tab. screws from the Range Valve.

2. Relieve system air pressure by draining air tanks on 4. Lift and remove the Range Valve from the housing.
the vehicle. When air pressure has been relieved, dis-
connect the Transmission Harness from the Range Caution: Do not use a hammer to loosen the Range
! Valve in the housing or it could be damaged.
Valve.

Note: The harness should be removed from the Range

Valve tie-down prior to removing the cap screws.

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Range Valve | Service Procedure TRSM0930

Procedure - Installation
Important: Lubricate o-rings with Eaton Fuller silicone 3. Reconnect the Transmission Harness to the Range
! 71214 or equivalent. Valve and close all air tanks drains.
Important: The valve is keyed to fit its mounting location. Note: Install the Range Harness back into the tie-down
! Take care to align the key with the notch in the on the Range Valve.
housing.
1. Install and push the Range Valve down into the hous-
ing.

4. If equipped, install the Protective Cover. Push the cover

down by hand until it snaps into place.

2. Using a 5/16” socket, install the 4 Range Valve mount-

ing cap screws and tighten to 21-27 lb-in. (2.3-3.0 Nm)
using a cross pattern.

95 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Range Valve

2019.12.12 © 2014 Eaton. All rights reserved 96

Splitter Valve | Service Procedure TRSM0930

Splitter Valve
Special Instructions Special Tools
The Splitter Valve may be difficult to remove from the hous- Basic hand tools
ing because of the o-rings.

Component Identification

1. Protective Cover (Optional)

2. Cap Screw
3. Valve
4. O-rings

97 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Splitter Valve

Procedure - Removal
1. If equipped, remove Protective Cover by pulling up on 3. Using a 5/16” wrench, remove the 4 mounting cap
the Release Tab. screws from the Splitter Valve.

2. Relieve system air pressure by draining the air tanks 4. Lift and remove the Splitter Valve from the housing.
on the vehicle. When air pressure is relieved, discon-
nect the Transmission Harness from the Splitter Valve Caution: Do not use a hammer to loosen the Splitter
! Valve in the housing or it could be damaged.
assembly.

Note: The harness should be removed from the Splitter

Valve tie-down, prior to removing the cap
screws.

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Splitter Valve | Service Procedure TRSM0930

Procedure - Installation
Important: Lubricate o-rings with Eaton Fuller silicone 3. Reconnect the Transmission Harness to the Splitter
! 71214 or equivalent. Valve and close all air tank drains.
Important: The valve is keyed to fit its mounting location. Note: Install the Splitter Harness back into the
! Take care to align the key with the notch in the tie-down on the Splitter Valve.
housing.
1. Install and push the Splitter Valve down into the hous-
ing.

4. If equipped, install the Protective Cover. Push the cover

down by hand until it snaps into place.

2. Using a 5/16” wrench, install the 4 mounting cap

screws and tighten to 21-27 lb-in.(2.3-3.0 Nm) using a
cross pattern.

99 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Splitter Valve

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Directional Output Shaft Speed Sensor | Service Procedure TRSM0930

Directional Output Shaft Speed Sensor

Special Instructions
The Directional Output Shaft Speed Sensor is used on the
Fuller® UltraShift® PLUS model transmissions. The Out-
put Shaft Speed Sensor location may vary depending on
OEM design specifications. The sensor will be located at 10
o’clock on the Output Shaft Housing in heavy-duty models
and 12 o’clock on the Output Shaft Housing in
medium-duty models.

Special Tools
Basic hand tools

101 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Directional Output Shaft Speed Sensor

Component Identification

1. Cap Screw
2. Sensor with Harness

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Directional Output Shaft Speed Sensor | Service Procedure TRSM0930

Procedure - Removal
1. Disconnect the Transmission Harness from the Output 3. Remove the Speed Sensor from the Transmission Rear
Shaft Speed Sensor Pigtail Connector. Bearing Cover.

2. Remove the Sensor Retaining Bolt.

103 © 2014 Eaton. All rights reserved 2019.12.12

 TRSM0930 Service Procedure | Directional Output Shaft Speed Sensor

Procedure - Installation
Important: Lubricate Sensor with Eaton lubricant 5564527. 4. Reconnect the Transmission Harness to the Output
! Shaft Speed Sensor and install the tie-down.
1. Using a smooth, twisting motion, fully insert the Out-
put Shaft Speed Sensor in the transmission housing
opening.

2. Install the Retaining Bolt and tighten to 8-10 lb-ft.

(11-13 Nm).

3. Apply included material to the Sensor Connector termi-

nals.

Note: Apply just enough material to cover the end of

the terminal.
Note: Use only Eaton lubricant 5564527. (Nye Lubri-
cants NYOGEL 760G - For MSDS safety or other
information see www.nyelubricants.com)

2019.12.12 © 2014 Eaton. All rights reserved 104

Park Actuator Assembly | Service Procedure TRSM0930

Park Actuator Assembly

Special Instructions Special Tools
None Basic hand tools

Component Identification

6 5 4

1. Shift Lever connection for OEM supplied Shift Cable

2. Park Actuator Assembly
3. Actuator Gasket
4. Sensor Fasteners (2)
5. Park Sensor
6. Actuator Fasteners (6)

105 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Park Actuator Assembly

Procedure - Removal
1. Remove Shift Cable from Actuator lever.

2. Unplug park sensor from vehicle harness.

3. Remove (6) actuator fasteners.

4. Remove actuator.

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Park Actuator Assembly | Service Procedure TRSM0930

Procedure - Installation
1. Clean old gasket from transmission case and actuator
housing.

2. Install new actuator gasket.

3. Install (6) actuator fasteners and torque to 30 - 35

lb-in.

4. Plug sensor into vehicle harness.

5. Re-attach the shift cable per OEM guidelines.

6. Calibrate sensor.

107 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Park Actuator Assembly

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Park Pawl Position Sensor | Service Procedure TRSM0930

Park Pawl Position Sensor

Special Instructions Special Tools
None Basic hand tools

Component Identification

1. Actuator Fasteners (6)

2. Sensor Fasteners (2)
3. Park Sensor
4. Park Actuator Assembly

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TRSM0930 Service Procedure | Park Pawl Position Sensor

Procedure - Removal
1. Unplug Park Pawl Position Sensor from vehicle har-
ness.

2. Remove the 2 sensor fasteners.

3. Remove Park Pawl Position Sensor.

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Park Pawl Position Sensor | Service Procedure TRSM0930

Procedure - Installation
1. Install new sensor, aligning tab with groove in rod and
rotating to mounting hole location.

2. Install 2 sensor fasteners and torque to 11-12 lb-in.

3. Plug Park Pawl Position Sensor into vehicle harness.

4. Calibrate.

Final Check
Park Sensor Calibration

Note: Sensors should be calibrated from the factory. This

procedure should only be used if it is discovered that
the calibrated and actual position sensor values do
not correlate.
Note: Parking Brake must be set for this procedure to be
performed.
1. Turn ignition off and wait for the XY calibration to com-
plete.
2. Turn ignition on, but do not start the engine.
3. Depress accelerator fully and depress the brake pedal.
4. Key ignition off and on 3 times while maintaining the
throttle and brake application.
5. Monitor the display; it should start to scroll CAL.
6. Release the throttle and brake.
7. The display will now guide you through the calibration
procedure.
8. The display will show a (1) in both digits of the display.
The right digit will be flashing.

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TRSM0930 Service Procedure | Park Pawl Position Sensor

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Medium-Duty Output Shaft Speed Sensor | Service Procedure TRSM0930

Medium-Duty Output Shaft Speed Sensor

Special Instructions
The Output Shaft Speed Sensor location may vary depend-
ing on OEM design specifications. The sensor will be
located at 10 o’clock on the Output Shaft Housing on the
heavy-duty model and at 12 o’clock on the Output Shaft
Housing for medium-duty model.

Special Tools
Basic hand tools

113 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Medium-Duty Output Shaft Speed Sensor

Component Identification

1. Cap Screw
2. Sensor
3. O-ring

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Medium-Duty Output Shaft Speed Sensor | Service Procedure TRSM0930

Removal 3. Remove the Output Shaft Speed Sensor, with o-ring,

from the transmission housing.
1. Disconnect the Transmission Harness from the Output
Shaft Speed Sensor or Pigtail Connector, if equipped.

2. Using a 3/8” socket, remove the sensor retaining bolt.

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 TRSM0930 Service Procedure | Medium-Duty Output Shaft Speed Sensor

Installation 3. Reconnect the Transmission Harness to the Output

Shaft Speed Sensor or Pigtail Connector, if equipped.
Important: Clean the mounting surface on the housing and
! remove any burrs or sharp edges.
Important: Lubricate the o-ring with Eaton Fuller silicone
! 71214 or equivalent.
1. Using a smooth, twisting motion, fully insert the Out-
put Shaft Speed Sensor in the transmission housing
opening.

2. Using a 3/8” socket, install the retaining bolt and

tighten to 8-10 lb-ft. (11-13 Nm).

2019.12.12 © 2014 Eaton. All rights reserved 116

Heavy-Duty Output Shaft Speed Sensor | Service Procedure TRSM0930

Heavy-Duty Output Shaft Speed Sensor

Special Instructions Special Tools
The Output Shaft Speed Sensor location may vary depend- Basic hand tools
ing on OEM design specifications. The sensor will be
located at 10 o’clock on the Output Shaft Housing in the
heavy-duty model and 12 o’clock on the Output Shaft Hous-
ing for medium-duty model.

Component Identification

1. Cap Screw
2. Sensor
3. O-ring

117 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Heavy-Duty Output Shaft Speed Sensor

Procedure - Removal
1. Disconnect the Transmission Harness from the Output 3. Remove the Output Shaft Speed Sensor, with o-ring,
Shaft Speed Sensor or Pigtail Connector, if equipped. from the transmission housing.

2. Using a 13 mm socket, remove the sensor retaining

bolt.

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Heavy-Duty Output Shaft Speed Sensor | Service Procedure TRSM0930

Procedure - Installation
Important: Clean the mounting surface on the housing and 3. Reconnect the Transmission Harness to the Output
! remove any burrs or sharp edges. Shaft Speed Sensor or Pigtail Connector, if equipped.
Important: Lubricate the o-ring with Eaton Fuller silicone
! 71214 or equivalent.
1. Using a smooth, twisting motion, fully insert the Out-
put Shaft Speed Sensor in the transmission housing
opening.

2. Using a 13 mm socket, install the retaining bolt and

tighten to 15-19 lb-ft. (20-25 Nm).

119 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Heavy-Duty Output Shaft Speed Sensor

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Main Shaft Speed Sensor | Service Procedure TRSM0930

Main Shaft Speed Sensor

Special Instructions Special Tools
None Basic hand tools

Component Identification

1. Cap Screw
2. Sensor
3. O-ring

121 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Main Shaft Speed Sensor

Procedure - Removal
1. Disconnect the Transmission Harness from the Main 3. Remove the Main Shaft Speed Sensor, with o-ring,
Shaft Speed Sensor or Pigtail Connector, if equipped. from the transmission housing.

2. Using a 3/8” socket, remove the sensor retaining bolt.

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Main Shaft Speed Sensor | Service Procedure TRSM0930

Procedure - Installation
Important: Clean the mounting surface on the housing and 3. Reconnect the Transmission Harness to the Main Shaft
! remove any burrs or sharp edges. Speed Sensor or Pigtail Connector, if equipped.
Important: Lubricate the o-ring with Eaton Fuller silicone
! 71214 or equivalent.
1. Using a smooth, twisting motion, fully insert the Main
Shaft Speed Sensor in the transmission housing open-
ing.

2. Using a 3/8” socket, install the retaining bolt and

tighten to 8-10 lb-ft. (11-13 Nm).

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TRSM0930 Service Procedure | Main Shaft Speed Sensor

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Medium-Duty Input Shaft Speed Sensor | Service Procedure TRSM0930

Medium-Duty Input Shaft Speed Sensor

Special Instructions Special Tools
Input Shaft Speed Sensor location varies as follows: Basic hand tools
• Medium-Duty: Top of Inertia Brake
• Heavy-Duty: Right front of Shift Bar Housing

Component Identification

1. Cap Screw
2. Sensor
3. O-ring

125 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Medium-Duty Input Shaft Speed Sensor

Procedure - Removal
1. Disconnect the Transmission Harness from the Input 3. Remove the Input Shaft Speed Sensor, with o-ring,
Shaft Speed Sensor. from the transmission housing.

Note: Drain the lubricant before removing the sensor.

2. Using a 3/8” wrench, remove the sensor retaining bolt.

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Medium-Duty Input Shaft Speed Sensor | Service Procedure TRSM0930

Procedure - Installation
Important: Clean the mounting surface on the housing and 3. Reconnect the Transmission Harness to the Input Shaft
! remove any burrs or sharp edges. Speed Sensor.
Important: Lubricate the o-ring with Eaton Fuller silicone
! 71214 or equivalent.
1. Using a smooth, twisting motion, fully insert the Input
Shaft Speed Sensor in the Inertia Brake opening.

4. Fill the transmission with lubricant. See “Lubrication

Specifications” on page 147.
2. Using a 3/8” wrench, install the sensor retaining bolt
and tighten to 8-10 lb-ft. (11-13 Nm).

127 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Medium-Duty Input Shaft Speed Sensor

2019.12.12 © 2014 Eaton. All rights reserved 128

Heavy-Duty Input Shaft Speed Sensor | Service Procedure TRSM0930

Heavy-Duty Input Shaft Speed Sensor

Special Instructions Special Tools
Input Shaft Speed Sensor location varies as follows: Basic hand tools
• Medium-Duty: Top of Inertia Brake
• Heavy-Duty: Right front of Shift Bar Housing

Component Identification

1. Cap Screw
2. Sensor
3. O-ring

129 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Heavy-Duty Input Shaft Speed Sensor

Procedure - Removal
1. Disconnect the Transmission Harness from the Input 3. Remove the Input Shaft Speed Sensor, with o-ring,
Shaft Speed Sensor or Pigtail Connector, if equipped. from the transmission housing.

2. Using a 3/8” socket, remove the sensor retaining bolt.

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Heavy-Duty Input Shaft Speed Sensor | Service Procedure TRSM0930

Procedure - Installation
Important: Clean the mounting surface on the housing and 3. Reconnect the Transmission Harness to the Input Shaft
! remove any burrs or sharp edges. Speed Sensor or Pigtail Connector, if equipped.
Important: Lubricate the o-ring with Eaton Fuller silicone
! 71214 or equivalent.
1. Using a smooth, twisting motion, fully insert the Input
Shaft Speed Sensor in the transmission housing open-
ing.

2. Using a 3/8” socket, install the retaining bolt and

tighten to 8-10 lb-ft. (11-13 Nm).

131 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Heavy-Duty Input Shaft Speed Sensor

2019.12.12 © 2014 Eaton. All rights reserved 132

Rail Select Sensor | Service Procedure TRSM0930

Rail Select Sensor

Special Instructions Special Tools
None Basic hand tools

Component Identification

3
2

1. Cap Screw
2. Sensor
3. Gasket

133 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Rail Select Sensor

Procedure - Removal
1. Disconnect the Transmission Harness from the Rail 3. Remove the Rail Select Sensor and gasket from the
Select Sensor. housing.

2. Using a 5/32” hex key wrench, remove the 2 sensor

hex key mounting screws.

Caution: Carefully allow the sensor to rotate to a

! relaxed position, or the sensor can snap when
the hex key mounting screws are removed.

2019.12.12 © 2014 Eaton. All rights reserved 134

Rail Select Sensor | Service Procedure TRSM0930

Procedure - Installation
1. Align sensor tabs with the slot in the Electric Shifter 3. Reconnect the Transmission Harness to the Rail Select
rail. Then, insert the Rail Select Sensor, with gasket, Sensor.
into its mounting location.

Note: Install the sensor, so connector opening faces

right side of the transmission. (As viewed from
the rear of the transmission)

2. Using a 5/32” hex key wrench, install the 2 hex key

mounting screws and tighten to 21-27 lb-in. (2.3-3.0
Nm).

Caution: Carefully hold sensor in position while install-

! ing the hex key mounting screws, or sensor
can snap.

135 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Rail Select Sensor

2019.12.12 © 2014 Eaton. All rights reserved 136

Gear Select Sensor | Service Procedure TRSM0930

Gear Select Sensor

Special Instructions Special Tools
None Basic hand tools

Component Identification

3
2

1. Cap Screw
2. Sensor
3. Gasket

137 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Gear Select Sensor

Procedure - Removal
1. Disconnect the Transmission Harness from the Gear 3. Remove the Gear Select Sensor and gasket from the
Select Sensor. housing.

2. Using a 5/32” hex key wrench, remove the two (2) sen-
sor hex key mounting screws.

Caution: Carefully allow sensor to rotate to a relaxed

! position, or sensor can snap when the hex
key mounting screws are removed.

2019.12.12 © 2014 Eaton. All rights reserved 138

Gear Select Sensor | Service Procedure TRSM0930

Procedure - Installation
1. Align the sensor tabs with the slots in the Electric 3. Reconnect the Transmission Harness to the Gear
Shifter Rail. Then, insert Gear Select Sensor, with gas- Select Sensor.
ket, into its mounting location.

Note: Install sensor so the connector opening faces the

front of the transmission.

2. Using a 5/32” hex key wrench, install the hex key

mounting screws and tighten to 21-27 lb-in. (2.3-3.0
Nm).

Caution: Carefully hold sensor in position while install-

! ing hex key mounting screws, or sensor can
snap.

139 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Gear Select Sensor

2019.12.12 © 2014 Eaton. All rights reserved 140

Lubricant Filter (AW3 Models Only) | Service Procedure TRSM0930

Lubricant Filter (AW3 Models Only)

Special Instructions Special Tools
Transmission filters should be changed during regular Basic hand tools
lubrication intervals.

Inspection of the transmission filter should be conducted

during preventative maintenance checks for damage or cor-
rosion. Replace as necessary.

Component Identification

1
2

1. High Pressure Oil Filter (Large opening)

2. Low Pressure Oil Filter (Small opening)
3. Gasket
4. Oil Pan
5. Short Cap Screw
6. Long Cap Screw
7. Drain Plug

141 © 2014 Eaton. All rights reserved 2019.12.12

 TRSM0930 Service Procedure | Lubricant Filter (AW3 Models Only)

Procedure - Removal
1. Remove Drain Plug and drain fluid from the wet clutch 3. Remove the wet clutch oil pan and gasket.
portion of the transmission.
!
Warning: Fluid may be hot.
Note: Clean filter seal mating surfaces on the transmis-
sion.

4. Using a 1/2” drive at the filter base, remove the 2 wet

clutch filters. Make sure filter seals are removed.

Note: The filters will contain fluid when they are

removed.
2. Using a 15mm socket, remove the Oil Pan Mounting Note: Clean and remove all old gasket material from
bolts. Record location of the long and short bolts. the mating surfaces of the clutch housing and
oil pan.

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Lubricant Filter (AW3 Models Only) | Service Procedure TRSM0930

Procedure - Installation
1. Install the high-pressure filter with a 1/2” drive and 3. Install new gasket and wet clutch oil pan.
tighten to 25-30 lb-ft. (34-41 Nm).

Note: Lubricate each filter seal ring with synthetic Dex-

ron III prior to installation.

4. Using 15mm socket, install the mounting bolts and

2. Install the low-pressure filter by hand and turn until the tighten to 30-35 lb-ft. (41-47 Nm) using a cross pat-
seal touches. Then, tighten with a 1/2” drive 3/4 to 1 tern.
full turn.
Caution: Make sure to put long and short bolts back in
Note: High and low pressure filters are not inter- ! their proper location to avoid damaging the
changeable. transmission. Short bolts are used in the back
of the oil pan.

143 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Service Procedure | Lubricant Filter (AW3 Models Only)

5. Install oil pan drain plug and tighten to 34-48 lb-ft.

(46-64 Nm).

6. Fill the wet clutch portion with proper fluid, see “Lubri-
cation Specifications” on page 147.

2019.12.12 © 2014 Eaton. All rights reserved 144

Operation and Basic Troubleshooting | Appendix TRSM0930

Operation and Basic Troubleshooting

Operation
For more detailed information on transmission operation
and shifting, go to the Roadranger Literature Center
(www.roadranger.com) and look for the “Driver’s Manual”
on your transmission model.

- Generation 3 UltraShift Driver Instructions -

TRDR0940
- Generation 3 AutoShift Driver Instructions -
TRDR0930
- Driver Instructions for Fuller® UltraShift® PLUS
models - TRDR1110

Basic Troubleshooting
For all Basic Troubleshooting questions refer to the appro-
priate service manual covering the base box procedures.
These manuals can be found on Roadranger.com under the
Literature Center.

Air System Operation and Troubleshooting

For all air system operation and troubleshooting questions
refer to the “Eaton Gen III Automated Transmissions Trou-
bleshooting Guide” TRTS0930, which is found on Road-
ranger.com under the Literature Center.

145 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Appendix | Inspection Procedures

Inspection Procedures
For all inspection procedures on assembly and disassembly
refer to the service manual covering the base box proce-
dures. These manuals can be found in the Literature Center
Roadranger.com.

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 2. If origin of leak is obvious skip to Step 3.
or mild soluble degreaser. seepage (refer to Roadranger 3. If the origin of the oil leak is not obvious then
TCSM-0912 Seal Maintance use either of the two following steps to determine
2. Ensure lube is to proper Guide). the oil leak:
level.
2. Ensure lube is to proper Note: Do not use a high pressure spray washer to
3. Notify the customer that it level. clean the area. Use of a high pressure spray may
is only a weep and it is not force contamination into the area of concern and
considered to be detrimental temporarily disrupt the leak path.
to the life of the transmission.
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.

2019.12.12 © 2014 Eaton. All rights reserved 146

Lubrication Specifications | Appendix TRSM0930

Lubrication Specifications

UltraShift DM3 and AutoShift AS3 Operating Temperatures with Oil Coolers
Transmissions must not be operated at temperatures above
Caution: Do not introduce additives and friction modifiers. 250°F (121°C). Operation at temperatures above this limit
!
Caution: Never mix standard oils and synthetic transmis- causes loaded gear tooth temperatures to exceed 350°F
! sion oils in the same transmission. When switch- (177°C) which will ultimately destroy the heat treatment of
ing between types of lubricants, all areas of each the gears. If the elevated temperature is associated with an
affected component must be thoroughly drained. operating condition that will recur, a cooler should be
added, or the capacity of the existing cooling system
Caution: Do not mix lubricants of different grades. increased.
!
Note: For a list of Eaton Approved Synthetic Lubricants, see The following conditions, in any combination, can cause
TCMT0021 or call 1-800-826-HELP (4357). operating temperatures of over 250°F (120°C):
Note: The use of lubricants not meeting these requirements
• Operating consistently at high loads/slow speeds
will affect warranty coverage.
• High ambient temperatures
Note: For lubrication change and inspection intervals see
TCMT0021. • Restricted air flow around the transmission

Note: Please refer to CLSM0200 for clutch lubrication and • Exhaust system too close to the transmission
service guidelines. • High horsepower operation
• Engine retarders
Buy From a Reputable Dealer External oil coolers are available to reduce operating tem-
For a complete list of approved and reputable dealers, write peratures when the above conditions are encountered.
to: Eaton Corporation, Worldwide Marketing Services, P.O. Eaton oil cooler systems must meet a minimum require-
Box 4013, Kalamazoo, MI 49003 ment of 3/4” ID cooler lines and 8 GPM system flow at
1500 RPM. The end user is ultimately responsible for main-
Transmission Operating Angles taining transmission lube temperatures below 250°F
(121°C).
If the transmission operating angle is more than 12°,
improper lubrication will occur. The operating angle is the
transmission mounting angle in the chassis plus the per- UltraShift™ ASW Models
cent of upgrade (expressed in degrees). For operating
angles over 12°, the transmission must be equipped with Caution: Do not introduce additives and friction modifiers.
an oil pump or cooler kit to insure proper lubrication.
!
Caution: Never mix engine oils and synthetic transmission
Transmission filters should be changed during regular
! oils in the same transmission. When switching
lubrication intervals. Inspection of the transmission filter between types of lubricants, all areas of each
should be conducted during preventative maintenance affected component must be thoroughly drained.
checks for damage or corrosion. Replace as necessary.
Caution: Do not mix lubricants of different grades.
!
Note: For a list of Eaton-approved synthetic lubricants, see
TCMT0021 or call 1-800-826-HELP (4357).
Note: The use of lubricants not meeting these requirements
will affect warranty coverage.
Note: For lubrication change and inspection intervals, see
TCMT0021.

147 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Appendix | Lubrication Specifications

Buy From a Reputable Dealer Checking Wet Clutch Lubricant

For a complete list of approved and reputable dealers, write The wet clutch portion is checked using a dipstick located in
to: Eaton Corporation, Worldwide Marketing Services, P.O. the engine compartment.
Box 4013, Kalamazoo, MI 49003

Proper Wet Clutch Lubricant Level

Synthetic Dextron III ATF Wet clutch lubricant level should be checked when idling in
Synthetic Dextron III ATF must be used in the wet clutch neutral for at least 2 minutes, with the transmission tem-
portion of the transmission. perature between 60° F and 120° F (15.5° C and 48.8° C).
Proper level is obtained when the lubricant is between the
cold Add mark and the cold Full marks on the dipstick. Due
CD-50 to thermal expansion of the lubricant, it is not recom-
CD-50 must be used in the gearbox portion of the transmis- mended to check the level when the transmission is above
sion. 120° F (48.8° C).

Maintenance and Lubricant Change

Intervals
Transmission inspections and lubricant changes are out-
lined below.

For a list of Eaton Roadranger-approved lubricants, order

Checking Gearbox Lubricant
publication TCMT0020. The gearbox portion is checked at the lubricant fill plug
located on the right side of the gear case.
Lubricant Inspection and Change Interval
(On-highway)
Cooler
Interval Description A Transmission Clutch Cooler must be used with the Eaton
UltraShift AW3 transmission. The cooler sizing must meet
First 1,000 to Inspect oil levels. Check for leaks. the requirements specified in TRIG0930.
1,500 miles

Every 2,500 Inspect lubricant level. Perform Proper Gearbox Lubricant Level
miles Transmission Inspection.
The gearbox lubricant is at the proper level when it is even
Every 5 years or Change wet clutch oil and filters. with bottom of the fill hole. When you remove the plug to
500,000 miles, check the lubricant level, lubricant should seep out. Do not
whichever use your finger to feel for the lubricant. Even if you can
occurs first touch the lubricant, it may not be at the proper level. In a
transmission, 1 inch of lubricant level equals about 1 gallon
of lubricant.

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Lubrication Specifications | Appendix TRSM0930

Drain the Transmission Gearbox and Wet 7. Increase the engine idle slowly to 1500 RPM for 2
minutes. Now, recheck the oil level at normal idle
Clutch Housing speed in neutral, again adding oil to obtain a level at
1. Locate drain plugs at the bottom of the transmis- the proper temperature range.
sion gear case and clutch housing oil pan. 8. Install the dipstick and tighten securely.
2. Place a drain pan under each drain plug.
3. Remove both drain plugs. Allow the lubricants to Clutch Calibration
drain completely. The ASW system automatically provides for clutch wear.
The system will initiate a clutch calibration once per vehicle
4. Disconnect both cooler lines at the wet clutch
power up, when certain vehicle conditions are right. Of
housing.
these conditions, the most important ones include:
5. Pressurize one line with 20 PSI until all lubricant is
forced out of the cooler. • When the engine is running at idle speed.

6. Reconnect both cooler lines. • During normal operating temperature.

• When the vehicle is stopped.
Change Wet Clutch Filters • When neutral is selected on the Shift Control.
Change the lubricant filters when the transmission lubricant During calibration, the clutch is partially engaged until the
is changed. Detailed information can be found on removal engine begins to slightly lug down. It will then disengage
and replacement of the oil filters in this service manual. the clutch and repeat this process several times. The cali-
Transmission filters should be changed during regular bration process usually takes as little as 30 seconds, but
lubrication intervals. Inspection of the transmission filter can take as long as 2 minutes. The calibration will be
should be conducted during preventative maintenance aborted when any position other than neutral is selected on
checks for damage or corrosion. Replace as necessary. the Shift Control.

If the vehicle is not engaging smoothly from a stop, it is

Fill the Transmission possible the clutch needs to be re-calibrated. If it was not
calibrated during the current power up, stop the vehicle
1. Install the Transmission Gearbox Drain Plug and with the engine idling at normal operating temperature and
tighten to 45-55 lb-ft. (60-73 Nm). Sealant is not place the Shift Control in neutral. Wait 2 minutes. If the cal-
required on the drain plug threads. ibration is being performed, you should hear the engine
slightly lug down and then return to its no-load condition
2. Install the Clutch Housing Oil Pan Drain Plug and several times.
torque to 34-48 lb-ft. (45-64 Nm). Sealant is not
required on the drain plug thread. If calibration does not occur, a power down or power up will
initiate a calibration.
3. Fill the Transmission Gearbox with the recom-
mended lubricant until the it seeps out of the fill
hole.
4. Install the fill plug and torque to 25-35 lb-ft. (33-47
N•m).
5. Slowly fill the clutch through the dipstick tube with
an initial fill of 18 pints (8.5 liters) of the recom-
mended lubricant.
6. Place the transmission in neutral position apply the
parking brakes. Start the engine and let idle for 5
minutes. This allows oil to fill the wet clutch system
and cooling system. Add oil as needed to obtain a
level at the proper temperature range. Total oil
quantity at this time varies depending on the cool-
ing system capacity.

149 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Appendix | Maintenance and Lubricant Change Intervals

Maintenance and Lubricant Change Intervals

Transmission inspections and lubricant changes are out- Proper Wet Clutch Lubricant Level
lined below.
Wet clutch lubricant level should be checked when idling in
For a list of Eaton Roadranger-approved lubricants, order neutral, with the transmission temperature between 60° F
publication TCMT-0020. and 120° F (15.5° C and 48.8° C) and when the vehicle has
been idling in neutral for at least 2 minutes. Proper lubri-
Lubricant Inspection and Change Interval cant level is obtained when the lubricant is between the cold
(On-highway) Add mark and the cold Full marks on the dipstick. Due to
thermal expansion of the lubricant, it is not recommended
Interval Description to check the level when the transmission is above 120° F
First 1,000 to Inspect oil levels. Check for leaks. (48.8° C).
1,500 miles

Every 2,500 Inspect lubricant level. Perform

miles Transmission Inspection.

Every 5 years or Change wet clutch oil and filters.

500,000 miles,
whichever Checking Gearbox Lubricant
occurs first The gearbox portion is checked at the lubricant fill plug
located on the right side of the gear case.

Checking Wet Clutch Lubricant

The wet clutch portion is checked using a dipstick located in Cooler
the engine compartment. A Transmission Clutch Cooler must be used with the Eaton
UltraShift AW3 transmission. The cooler sizing must meet
the requirements specified in this TRIG0930

Proper Gearbox Lubricant Level

The gearbox lubricant is at the proper level when it is even
with bottom of the fill hole. When you remove the plug to
check lubricant level, lubricant should seep out. Do not use
your finger to feel for the lubricant. Even if you can touch
the lubricant, it may not be at the proper level. In a trans-
mission, 1 inch of lubricant level equals about 1 gallon of
lubricant.

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Maintenance and Lubricant Change Intervals | Appendix TRSM0930

Drain the Transmission Gearbox and Wet 7. Increase the engine idle slowly to 1500 RPM for 2
minutes. Now, recheck the oil level at normal idle
Clutch Housing speed in neutral, again adding oil to obtain a level at
1. Locate drain plugs at the bottom of the transmis- the proper temperature range.
sion gear case and the clutch housing oil pan. 8. Install the dipstick and tighten securely.
2. Place a drain pan under each drain plug.
3. Remove both drain plugs and allow the lubricants Clutch Calibration
to drain completely. The ASW system automatically provides for clutch wear.
The system will initiate a clutch calibration once per vehicle
4. Disconnect both cooler lines at the wet clutch
power up, when certain vehicle conditions are right. Of
housing.
these conditions, the most important ones include:
5. Pressurize 1 line with 20 PSI until all lubricant is
forced out of the cooler. • When the engine is running at idle speed.

6. Reconnect both cooler lines. • During normal operating temperature.

• When the vehicle is stopped.
Change Wet Clutch Filters • When neutral is selected on the Shift Control.
Change the lubricant filters when the transmission lubricant During calibration, the clutch is partially engaged until the
is changed. Detailed information can be found on removal engine begins to slightly lug down. It will then disengage
and replacement of the oil filters in this service manual. the clutch and repeat this process several times. The cali-
Transmission filters should be changed during regular lube bration process usually takes as little as 30 seconds, but
intervals. Inspection of the transmission filter should be can take as long as 2 minutes. Calibration will be aborted
conducted during preventative maintenance checks for when any position other than neutral is selected on the Shift
damage or corrosion. Replace as necessary. Control.

If the vehicle is not engaging smoothly from a stop, it is

Fill the Transmission possible that the clutch needs to be recalibrated. If it was
not calibrated during the current power up, stop the vehicle
1. Install the transmission gearbox drain plug and with the engine idling at its normal operating temperature
tighten to 45-55 lb-ft. (60-73 Nm). Sealant is not and place the Shift Control in neutral. Wait 2 minutes. If cal-
required on the drain plug threads. ibration is being performed, you should hear the engine
slightly lug down and then return to its no-load condition
2. Install the Clutch Housing Oil Pan Drain Plug and several times.
torque to 34-48 lb-ft. (45-64 Nm). Sealant is not
required on the drain plug thread. If calibration does not occur a power down and power up
3. Fill the transmission gearbox with the recom- will initiate a calibration.
mended lubricant until the lubricant seeps out of
the fill hole.
4. Install the fill plug and torque to 25-35 lb-ft. (33-47
Nm).
5. Slowly fill the clutch through the dipstick tube with
an initial fill of 18 pints (8.5 liters) of the recom-
mended lubricant.
6. Place the transmission in neutral position apply the
parking brakes. Start the engine and let idle for 5
minutes. This allows oil to fill the wet clutch system
and cooling system. Add oil as needed to obtain a
level at the proper temperature range. Total oil
quantity at this time varies depending on the cool-
ing system capacity.

151 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Appendix | Tool Specifications

Tool Specifications

General Tools
The following general tools are available from several tool
manufacturers such as Snap-On, OTC and many others.

TOOL PURPOSE

0-100 lb-ft. (0-135 Nm) 1/2” (12.7 mm) drive Torque General torquing of fasteners (Typically 15-80 lb-ft. (20-108
Wrench Nm))

0-600 lb-ft. (0-810 Nm) 3/4” or 1" (19 mm or 25.4 mm) Torquing of Output Nut
drive Torque Wrench

0-50 lb. in. (0-5.62 Nm) 3/8" (9.52 mm) drive Torque General torquing of fasteners
Wrench

2 3/4" (70 mm) or Socket - Standard Depth To remove the Output Yoke/Flange Nut

Large Brass Drift 3/4" x 12" (19 mm x 304.8 mm) Used to protect shafts and bearings during removal

Large Dead Blow Hammer or Maul 32 ounces To provide force for shaft and bearing removal

2 Air Pressure Gauges 0-150 PSI (0-10.34 BAR) To troubleshoot and verify correct operation of air system

3/8" Drive Deepwell socket set 3/8"- 1" (9.5 mm - 25.4 To remove/install cap screws and nuts
mm)

3/8" Drive Shallow socket set 3/8" - 1" (9.5 mm- 25.4 To remove/install cap screws and nuts
mm)

Snap Ring Pliers - Large Standard External To remove the snap rings at the auxiliary drive gear, input shaft
bearing and countershaft bearings

Feeler Gauges To set mainshaft washer endplay and auxiliary tapered bearing
endplay

Open-end wrench set 3/8" - 1" (9.52 mm -25.4 mm) To remove certain airline connections

2019.12.12 © 2014 Eaton. All rights reserved 152

Torque Specifications | Appendix TRSM0930

Torque Specifications
Correct torque application is extremely important to ensure
long transmission life and dependable performance.
Over-tightening or under-tightening can result in a loose
installation and, in many instances, eventually cause dam-
age to transmission gears, shafts or bearings. Use of a
thread sealer and locking compound is recommended for
all cap screws. Do not torque cap screws dry.

Description Torque Value lb-ft. [N•m] Thread size Additional Comments

Transmission-to-Engine Refer to OEM for

Cap Screws specification

Clutch-to-Flywheel Cap
Screws

7/16 x 2.25 x 14 40 - 50 lb-ft. 7/16 x 2.25 x 14

[54 - 68 Nm]

3/8 x 2.25 x 16 30 - 35 lb-ft. 3/8 x 2.25 x 16

[41 - 47 N•m]

M10 x 1-3/8 26 - 35 lb-ft. M10 x 1-3/8

[35 - 47 N•m]

M10 x 1-3/4 26 - 35 lb-ft. M10 x 1-3/4

[35 - 47 N•m]

6 (Small PTO Cover Cap 20 - 25 lb-ft. 3/8"-16 Apply Loctite 242 to

Screws) [27 - 34 N•m] threads.

8 (Large PTO Cover Cap 50 - 65 lb-ft. 7/16"-14 Apply Loctite 242 to

Screws) [68 - 88 N•m] threads.

4 Electric Shifter Cap 30 - 45 lb-ft. 3/8" - 16 Apply Loctite 242 to

Screws [48 - 61 N•m] threads.
cast and 20 - 25 lb-ft.
[27 - 34 N•m] aluminum

1 Reverse Switch 20 - 25 lb-ft. 9/16"-18

[27 - 34 N•m]

1 Neutral Switch/Cap 20 - 25 lb-ft. 3/4"-16

[27 - 34 N•m]

3 ECU Cap Screws 7 - 9 lb-ft. 1/4" - 20 Apply Loctite 242 to

(Medium-Duty) (9.5 - 12.2 N•m) threads.

3 ECU Nuts (Heavy-Duty) 7 - 9 lb-ft. .250 - 20 UNC

[9.5 - 12.2 N•m]

2 Transmission ECU 25 +/- 3 lb-in. M5 x 0.8

38-Way Connectors [2.82 +/-.33 N•m]
Cap Screws

153 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Appendix | Torque Specifications

Description Torque Value lb-ft. [N•m] Thread size Additional Comments

3 ECU Bracket Nuts 20 - 25 lb-ft. .3125 - 18 UNC

(Heavy-Duty) [27 - 34 N•m]

3 ECU Bracket Studs 35 - 45 lb-ft. .375 - 16 UNC

(Heavy-Duty) [48 - 61 N•m]

2 Harness Bracket Cap 20-25 lb-ft. .3125 - 18 UNC

Screws [27-34 N•m]

1 Push Button Shift Con- 10 +/- 3 lb-in.

troller 30-Way Connector [1.1 +/- 0.33 N•m]
Cap Screw

2 Push Button Shift Con- 14-16 lb-in.

troller Backing Plate Nuts [1.6-1.8 N•m]
and Lock Washers

6 Inertia Brake Cap 40-45 lb-ft. 3/8"-16 Apply Loctite 242 to

Screws [54- 61.0 N•m] threads.

2 LCIB Mounting Studs 60 lb-ft. [81 N•m] 5/8”- 11

2 LCIB Mounting Nuts 140-150 lb-ft. 5/8”- 18

[190-203 N•m]

4 ECA Cap Screws 35-45 lb-ft. 3/8”-16 Apply Loctite 242 to

[47-61 N•m] threads.

3 ECA Support Bracket 35-45 lb-ft. 3/8”-16 Apply Loctite 242 to

Cap Screws [47-61 N•m] threads.

1 ECA Engine Speed Sen- 15 lb-ft. 3/4” Turn in until touches and
sor Jam Nut [20 N•m] then back off 1/2-turn. The
jam nut is then torqued
down to hold the sensor in
place.

2 Inertia Brake Hose Fit- 30-40 lb-ft. 3/4"-16

tings [41-54 N•m]

4 Splitter Solenoid Cap 21-27 lb-in. #10-24

Screws [2.4-3.1 N•m]

4 Range Solenoid Cap 21-27 lb-in. #10-24

Screws [2.4-3.1 N•m]

1 Output Shaft Speed Sen- 8-10 lb-ft. 1/4"-20

sor Cap Screw (MD) [10.8-13.6 N•m]

1 Main Shaft Speed Sen- 8-10 lb-ft. 1/4"-20

sor Cap Screw [10.8-13.6 N•m]

1 Input Shaft Speed Sen- 8-10 lb-ft. 1/4"-20

sor Cap Screw [10.8-13.6 N•m]

2019.12.12 © 2014 Eaton. All rights reserved 154

Torque Specifications | Appendix TRSM0930

Description Torque Value lb-ft. [N•m] Thread size Additional Comments

2 Rail Sensor Cap Screws 21–27 lb-in.

[2.4–3.1 N•m]

2 Gear Sensor Cap Screws 21–27 lb-in.

[2.4–3.1 N•m]

2 Air Filter Regulator Cap 8–12 lb-ft. 1/4"-20 Apply Loctite 242 to
Screws [10.8–16.02 N•m] threads.

1 Lubricant fill plug 45–55 lb-ft. 3/4-14 NPT

(6-Speed) [61–75 N•m]

1 Lubricant fill plug 60–75 lb-ft. 1¼-NPT

(13,10,18-speed) [81–102 N•m]

1 Cross-shaft Plug 34–48 lb-ft. 1.3125 - 12

[46–65 N•m]

2 Lifting Bracket Cap 35–45 lb-ft. 3/8"-16 Apply Loctite 242 to

Screws [47–61 N•m] threads.

1 Output Yoke Nut 500 ± 25 lb-ft.

(6-Speed) [678 ±34 N•m]

1 Output Yoke Nut 450–500 lb-ft.

(13,10,18-Speed) [610–678 N•m]

2 Output Yoke Cap Screws 70–85 lb-ft. M12 x 1.25 Spiralock ThreadsTM: No
(ECA) [95–115 N•m] thread adhesive neces-
sary.

4 Rear Bearing Cover Cap 60–70 lb-ft. 1/2-20 Apply Loctite 242 to
Screws (6-Speed) [81–95 N•m] threads.

Transmission Nodal Refer to OEM for Apply Loctite 242 to

Mount Cap Screws Specification threads.

4 Rear Bearing Cover Cap 35–45 lb-ft. 3/8-16 Apply Loctite 242 to
Screws (13,10,18-Speed) [47–61 N•m] threads.

Transmission Rear Mount Refer to OEM for

Nuts/Cap Screws Specification

6-Speed AW3 Specific

Oil cooler line fitting 50–60 lb-ft.

[68–81 N•m]

Oil cooler line nut 50–60 lb-ft.

[68–81 N•m]

2 Dipstick tube fitting 60–70 lb-ft. 1 5/8"-12

[81–95 N•m]

1 Wet clutch drain plug 34–48 lb-ft.

[46–65 N•m]

155 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Appendix | Torque Specifications

Description Torque Value lb-ft. [N•m] Thread size Additional Comments

12 Flywheel to Drive Cou- 35–40 lb-ft. 3/8 x 16 x 1-1/4

pler Cap Screws [47–55 N•m]

High Pressure Oil Filter 25–35 lb-ft.

[34–47 N•m]

Low Pressure Oil Filter Turn until seal touches,

then tighten with a 1/2"
drive 3/4 to 1 full turn.

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Torque Specifications | Appendix TRSM0930

Torque Overview

Heavy-Duty

Input Shaft
ECU Bracket
Nuts & Studs Speed Sensor Capscrew

Electric Shifter
Capscrews
Gear Select
Sensor Capscrews

Main Shaft
Rail Select
Speed Sensor Capscrew
Sensor Capscrews

Splitter Valve
Solenoid Capscrew Range Valve Solenoid

Air Filter Requlator

Output Shaft
Speed Sensor Capscrew

Transmission ECU Nuts

Inertia Brake Capscrews

157 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Appendix | Torque Specifications

Cross-shaft Plug

Low Capacity
Inertia Brake (LCIB)
Release Yoke Capscrew
Mounting Nut

ECA Bracket Capscrew ECA Mounting Capscrew

(View Obscured) (View Obscured)

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Torque Specifications | Appendix TRSM0930

Medium-Duty

Electric Shifter Capscrews

Gear Select
Sensor Capscrews

Rail Select
Sensor Capscrews

Output Shaft
Speed Sensor Capscrew

Input Shaft
Speed Sensor Capscrew

Transmission ECU Nuts

Oil Pan Capscrews

Inertia Brake Capscrews

Oil Pan Drain Plug

159 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Appendix | Grade Sensor Calibration

Grade Sensor Calibration

The Grade Sensor is mounted inside the Transmission ECU Here are instructions required before performing grade
(TECU) and is essential for Hill Start Aid. It also provides sensor calibration with ServiceRanger or Operator Trig-
information to the TECU to assist in smooth vehicle launch gered procedure:
and shifting. This sensor must be calibrated initially at the
OEM factory and anytime the TECU is replaced in the field. 1. Vehicle must be on level ground before initiating
the grade sensor calibration.
An active FC68 FMI13 indicates a calibration is needed, and
2. Verify the suspension is fully aired.
it will go inactive upon successful calibration. (See
TRTS0930 Troubleshooting Guide for detailed information 3. Verify the suspension is set to proper height.
on FC68)
4. Ground surface must be within +/- 0.5% grade
The Grade Sensor can be calibrated via ServiceRanger or an (0.28 degrees) from level.
Operator-Triggered Special Function. 5. Maximum allowable grade is +/- 0.5 degrees
(0.87% grade) from level.

ServiceRanger Procedure

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Grade Sensor Calibration | Appendix TRSM0930

161 © 2014 Eaton. All rights reserved 2019.12.12

TRSM0930 Appendix | Grade Sensor Calibration

Operator-Triggered Procedure
O FF D
ON
SHIFT
MANUAL
4 Press Accelerator to the
LOW
floor. Gear Display will show
START a “Down Arrow.”
Hol d

5 Release the Accelerator.

Gear Display will show a “0.”

0
Re l e a se
6 Select Neutral and turn
ignition to “Off” in order to
save the calibration.

OFF

ON
R

2019.12.12 © 2014 Eaton. All rights reserved 162

Copyright Eaton, 2014.
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 INFOR-
MATION 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 maxi-
mum 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 repre-
sentation about the completeness, cor-
rectness or accuracy and assumes no
responsibility for any errors or omis-
sions. 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 ser-
vices 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