TC10 Power Take-of f Overhaul Instructions

C10 Chain Drive Transmission Overhaul Instructions

Overhaul Instructions
C10 Chain Drive Transmission Form No. Section Issue Date Rev. Date
F-1031 4314 04/20/06 07/25/08

Table of Contents Illustrations

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1. Eclipse ES CAFSystem Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. Eclipse ES CAFSystem Air Clutch Assembly (Side View) . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3. Supporting Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Propeller Shaft Disconnect and Accessory Removal . . . . . . . . . . . . . . . . . . 1 4. Removal of End Yokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Eclipse CAFSystem Removal from Transmission . . . . . . . . . . . . . . . . . . . . . 1 5. Removal of Coupling Shaft Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Eclipse ES CAFSystem Removal from Transmission . . . . . . . . . . . . . . . . . . 1 6. Removal of the Bottom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump Removal from Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7. Removable Connecting Pin Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8. Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of End Yokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9. Removal of Drive Shaft and Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Coupling Shaft Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10. Removal of Shift Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removing the Bottom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
11. Removal of Mid-Section from Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal of Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
12. Disassembly of Driven Shaft Assemblies (Figures 12-18) . . . . . . . . . . . . . 7
Removal of the Drive Shaft and Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
19. Coupling Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal of Shift Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of Mid-Section from Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 20. Drive Shaft Disassembly -
Shift Collar and Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly of Driven Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
21. Drive Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Separable Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
22. Needle Bearing Removal from Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Separable Shaft - Eclipse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Separable Shaft - Hydraulic Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 23. Reassembly of the Driven Shaft (Figures 23-29) . . . . . . . . . . . . . . . . . . . 13
Separable Shaft - Combination Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 30. Dowel Pins and Spacer Installation for Extended Drop Cases . . . . . . . . 20
Separable Shaft - Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 31. Pivot Pin, Shaft Bushing and Sleeve Bearing Installation . . . . . . . . . . . . 21
IL 2742 One-Piece Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 32. Shift Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Eclipse ES Mounted CAFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 33. Shift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly of Coupling Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 34. Mid-Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassembly of Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 35. Cap and Mid-Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 36. Needle Bearing Installation into Drive Sprocket . . . . . . . . . . . . . . . . . . . . 24
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 37. Drive Shaft Installation into Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . 24
Installing Bearings, Oil Seals and O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . 13 38. Drive Assembly into Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Reassembly of the Driven Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 39. Drive Shaft/Housing Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . 25
Separable Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 40. Optional Electronic Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Separable Shaft - Eclipse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 41. Installing the Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Separable Shaft - Hydraulic Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 42. Connecting Pin Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Separable Shaft - Combination Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 16 43. Connecting Pin Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Separable Shaft - Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 44. Assembling Items on the Bottom Section . . . . . . . . . . . . . . . . . . . . . . . . . 28
One-Piece Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 45. Assembling Bottom Section to the Cap and Mid-Section . . . . . . . . . . . . 28
Eclipse ES Mounted CAFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
46. Retainer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dowel Pins and Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
47. Coupling Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Reassembly of the Shift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
48. Coupling Shaft Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Reassembly of the Cap and Mid-Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
49. Assembling Coupling Shaft Housing to Case . . . . . . . . . . . . . . . . . . . . . . 31
Reassembly of the Drive Shaft and Drive Shaft Housing . . . . . . . . . . . . . . 24
Installing the Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 50. End Yoke Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Reassembly of the Bottom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 51. Shift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Shift Position Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Coupling Shaft and Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Coupling Shaft Housing to Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 31
Reassembly of Miscellaneous Items and Accessories . . . . . . . . . . . . . . . . 32
Eclipse CAFSystem Installation onto Transmission . . . . . . . . . . . . . . . . . . 33
Eclipse ES CAFSystem Installation onto Transmission . . . . . . . . . . . . . . . 33
Propeller Shaft Connection and Accessory Installation . . . . . . . . . . . . . . . 34
Lubrication and Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450-5000
Instructions subject to change without notice.
All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.
 Introduction
This instruction provides the necessary steps required to overhaul the C10 transmission. These instructions are divided into Disassembly and Reassembly
sections. Also, refer to the Service Parts List (SPL documents) furnished with your C10 transmission to aid in further part identification and repair parts
ordering.
General Description
The Waterous C10 is a chain driven transmission with a housing eliminates the need for a separate oil pump. The shift mechanism is a
constructed of high-strength aluminum. Drive and driven sprockets are constant-mesh, two-position sliding collar that engages all teeth simulta‐
made of hardened steel and have ground bores. Shafts are made of alloy neously. Note that the majority of C10 fasteners are metric.
steel forgings, hardened and ground to size. A passive lubrication system
Disassembly
Before beginning the disassembly process, drain the fluid from the transmission by removing the drain plug. Note that these instructions apply for out of
chassis overhaul of the unit.
Propeller Shaft Disconnect and Accessory Removal
Propeller Shaft Disconnect Shift Unit
Disconnect the propeller shafts. Remove the pneumatic shift unit from the transmission by removing the
Electrical Connections two hex nuts and washers. Note that the adjusting screw retainers are
exposed when the shift unit is removed. Special care should be taken to
Disconnect the tachometer cable, shift wiring and electric shift override prevent the retainers from falling out of the transmission.
linkage.
Eclipse CAFSystemt Removal from Transmission
To remove the Eclipse CAFSystem from the transmission, perform the 4. Loosen tension on the Polychain by turning the Polychain tension
following steps: screw, counter clockwise.
1. Remove air connections from the air clutch assembly. 5. Remove the Polychain from the air clutch assembly, driven sprocket
2. Remove the Polychain cover assembly by unscrewing the four (4) hex and idler sprocket.
nuts. 6. Remove the four (4) cap screws that attach the transmission to the
3. Loosen the 1- 29/32” hex screw on the idler sprocket assembly. This re‐ pump.
leases the idler sprocket assembly for adjustment. 7. Remove the transmission from the pump. Note that the air clutch
assembly will remain on the transmission.
Eclipse ES CAFSystemt Removal from Transmission (See Figure 1)
To remove the Eclipse ES CAFSystem from the transmission, perform the 5. Loosen the 1- 29/32” hex screw on the idler sprocket assembly. This re‐
following steps: leases the idler sprocket assembly for adjustment.
1. Support the Eclipse ES unit with a lifting strap placed under the air 6. Loosen tension on the Polychain by turning the Polychain tension
compressor. Two other eyeloops are also provided for lifting (see screw, counter clockwise.
Figure 1). 7. Remove the Polychain from the air clutch assembly, driven sprocket
2. Remove all electrical and air connections. and idler sprocket.
3. Remove the Polychain cover assembly by unscrewing the ten (10) hex 8. Loosen the set screw that holds the air clutch assembly to the trans‐
hd screws. mission driven shaft. (See Figure 2).
4. Remove the nylon tube from the air clutch assembly.
F-1031, Section 4314 Rev: 07/25/08 Page 1 of 34
9. Remove the hex head screw that attaches the air clutch assembly to 10. Remove the air clutch assembly from the transmission.
the anti-rotation bracket (leave grommet attached to anti-rotation 11. Remove the five (5) hex hd screws that attach the Eclipse ES unit to
bracket). transmission.
12. Remove the compressor bracket that supports the Eclipse ES unit to
the transmission.
13. Lift the unit off the transmission.
Figure 1. Eclipse ES CAFSystemt Removal Figure 2. Eclipse ES - Air Clutch Assembly (Side View)

F-1031, Section 4314 Rev: 07/25/08 Page 2 of 34

 Pump Removal from Transmission for Separable Impeller Shafts
Refer to the pump overhaul instructions for information on how to remove the pump from the transmission.

Disassembly of the C10 Transmission

The C10 consists of three sections; the cap, the mid-section and the Removal of End Yokes
bottom section. The order of disassembly is bottom section, mid-section
and then cap. 1. Remove the end yokes from the drive and coupling shafts. Do not
reuse self-locking nuts. Apply lubricating oil to the threads before
NOTE: Out of chassis overhaul will require supporting the transmission moving. Apply anti-seize to the threads before installing a new self-
initially in an upside down position, possibly attaching it direct to an locking nut.
engine overhaul stand at the face of the cap (fabrication of an adapter
would be required) or using the side mounting pads (see Figure 3). 2. Remove the lube system hose.
Figure 3. Supporting Transmission (CXC10 Shown) Figure 4. Removal of End Yokes
Cap

Lube System
Hose Assembly

Mid Section

Coupling Shaft
Housing

Yoke
Washer
Bottom Section Nut

F-1031, Section 4314 Rev: 07/25/08 Page 3 of 34

Coupling Shaft Housing Removal Removing the Bottom Section
1. Remove the hex head screws and lock washers attaching the coupling 1. Invert the case.
shaft housing to the mid-section. 2. Remove lower cap screws connecting the driveshaft housing to the
2. Remove the coupling shaft housing, O-ring and shims. Note that jack‐ bottom section. Loosen cap screws connecting housing to case mid-‐
ing screw holes are provided. section.
NOTE: The coupling shaft and its associated parts may come with the 3. Remove the cap screws, nuts and lock washers attaching the bottom
housing. If not, pull on the coupling shaft to remove. section to the mid-section.
Figure 5. Removal of Coupling Shaft Housing 4. Drive the four dowel pins out of the bottom section flange.
5. Remove the bottom section from the mid-section.
Figure 6. Removal of the Bottom Section

Shims
Cap Screw

Coupling Shaft
Housing

Driveshaft
Housing
Lock Washer
Driveshaft
Hex Hd
Screw

Lock Washer
Hex Nut Flange
Sealed
by
RTV.
Jacking Screw Holes (2)

Dowel Pins

F-1031, Section 4314 Rev: 07/25/08 Page 4 of 34

Removal of Chain Removal of Drive Shaft and Housing
1. Rotate the drive shaft until removeable connecting pin set of the chain 1. Remove the remaining hex head screws and lock washers attaching
is visible at the drive sprocket. The removable connecting pin set has a the drive shaft housing to the mid-section. The housing, drive shaft,
spirol pins on both ends holding it in place (see Figure 7). drive sprocket, shift collar and associated parts can now be removed
Figure 7. Removable Connecting Pin Set as a unit from the mid-section. The shift fork will slip off the shift shaft
Chain when the drive shaft assembly is lifted out.
Figure 9. Removal of Drive Shaft and Housing
Spirol Pin

Drive Shaft Assembly

Shift Fork
Driven Sprocket
Connecting Pin Set
Connecting Pin Assy
and Connecting Rocker Hex Hd Screw
Drive Sprocket
Lock Washer

Drive Shaft Housing

IL2436

2. Remove the tapped in spirol pin on one end, tap both the connecting
pin assembly and connecting rocker out of the chain links. Disengage
the chain from the drive and driven sprocket and remove from the
case.
Figure 8. Chain Removal

Shift Shaft

Drive Sprocket

IL2790
Chain

Driven Sprocket

F-1031, Section 4314 Rev: 07/25/08 Page 5 of 34

Removal of Shift Components Figure 10a. Removal of Shift Component - (Internal)
1. Remove the shift shoe from the locking arm.
2. Slip locking arm off pivot pin.
Shift Shoe
NOTE: The pivot pin and shift shaft bushing (typically pressed into
the bottom section) need only be removed if bent or otherwise dam‐ Locking Arm
aged.
3. Remove the shoulder screw that attaches the sector gear and shift Shift Shaft
lever to the shift shaft and remove the sector gear, shift lever and
spacer.
Pivot Pin
4. Reposition mid and cap section assembly on the supports so that the
cap portion is on top or set the assembly on a bench.
5. Remove spirol pin attaching the shift arm to the shift shaft (Figure 10b) if
necessary. Shift Lever
Shoulder Screw (Pneumatic
6. Remove the shift arm, shift lock spring and shift shaft. Only)

Locking Nut
Sector Gear

Sector Spacer

IL2232

Figure 10b. Removal of Shift Components (External)

Spirol Pin

Shift Arm
V-ring
(Used
Starting
7/14/2008)

Shift Shaft Spirol Pin

Shift Lock Spring

Spirol Pin Spring Housing

IL2546

F-1031, Section 4314 Rev: 07/25/08 Page 6 of 34

Removal of Mid-Section from Cap Disassembly of Driven Shaft Assembly
The cap does not need to be removed from the mid-section unless either Separable Shaft
is being replaced. NOTE: Removal will make it easier to handle the
assembly during driven shaft removal and reassembly. 1. Remove the four cap screws from the bearing cover and the four
1. Remove cap screws and nuts that attach the cap to the mid-section. socket hd screws from oil seal housing. Remove cover and housing
from cap.
2. Remove cap with driven shaft from the mid-section. Rapping the cap
with a soft hammer will break adhesion with the shims, spacers and 2. Straighten tab of the bearing lock washer from slot in bearing lock nut
mid-section. and then remove the lock nut, lock washer and wave spring.
NOTE: Do not drive the dowels through the flange of the cap deeper 3. Under a press, support the assembly on the front (pump flange) face
into the mid-section or spacer plates. side of the cap and apply a press load to the end of the driven shaft to
press the shaft out of the ball bearing, spacers and sprockets.
Figure 11. Removal of Mid-Section from Cap
4. Remove the ball bearing, spacers and sprocket from cap.
Figure 12. Driven Shaft Disassembly - Separable Shaft

Cap Screw
Lock Washer
Bearing Cover

O-ring
Bearing Lock Nut

Bearing Lock Washer

Wave Spring

Ball Bearing
Spacer
Rear
Sprocket

Cap

Front (Pump Flange)

Spacer

Driven Shaft Ball Bearing

3. Remove any shims and spacers from the top of the mid-section. Key
a. The quantity and thickness of shims and spacers depends on trans‐
mission model and ratio. Gasket
IL2744 Oil Seal Housing
Oil Seal Lock Washer
Sealing Boot Socket Hd Screw

F-1031, Section 4314 Rev: 07/25/08 Page 7 of 34

Separable Shaft - Eclipse Separable Shaft - Hydraulic Adapter
1. Remove the four cap screws and four socket hd screws that fasten the 1. Remove the four cap screws from the hydraulic pump adapter and the
oil seal housings to the cap. Remove housings. four socket hd screws from the oil seal housing. Remove adapter and
2. Remove the retaining ring and wave spring. housing from cap.
3. Under a press, support the assembly on the front (pump flange) face 2. Remove the retaining ring and wave spring.
of the cap and apply a press load to the end of the driven shaft to 3. Under a press, support the assembly on the front (pump flange) face
press the shaft out of the ball bearing, spacers and sprockets. of the cap and apply a press load to the end of the driven shaft to
4. Remove the ball bearing, spacer and sprocket from cap. press the shaft out of the ball bearing, spacers and sprocket.
Figure 13. Driven Shaft Disassembly - Eclipse 4. Remove the ball bearing, spacers and sprocket from cap.
Cap Screw Figure 14. Driven Shaft Disassembly - Hydraulic Adapter
Oil Seal Oil Seal
Cap Screw
Lock Washer Lock Washer Hydraulic Pump Adapter
Oil Seal Housing

O-ring
O-ring
Wave Spring
Wave Spring
Retaining Ring Retaining Ring
Ball Bearing
Ball Bearing

Spacer Spacer
Rear
Rear
Cap
Cap
Sprocket
Front (Pump Flange)
Spacer Sprocket Front (Pump Flange)

Spacer Ball Bearing

Ball Bearing

Driven Shaft Driven Shaft

Key

Key Key Gasket

Gasket
Lock Washer
Oil Seal Housing Oil Seal Housing Socket Hd Screw
Oil Seal Lock Washer
IL2745 Oil Seal
Socket Hd Screw
Sealing Boot IL2746
Sealing Boot

F-1031, Section 4314 Rev: 07/25/08 Page 8 of 34

Separable Shaft - Combination Pump Separable Shaft - Oil Cooler
1. Remove the four cap screws and four socket hd screws that fasten the 1. Remove the four hex hd screws from the oil pump and the four socket
oil seal housings to the cap. Remove housings. hd screws from the oil seal housing. Remove oil pump and housing
from cap.
2. Straighten tab of the bearing lock washer from slot in bearing lock nut
and then remove the lock nut, lock washer and wave spring. 2. Straighten tab of the bearing lock washer from slot in bearing lock nut
and then remove the lock nut, lock washer and wave spring.
3. Under a press, support the assembly on the front (pump flange) face
of the cap and apply a press load to the end of the driven shaft to 3. Under a press, support the assembly on front (pump flange) face of
press the shaft out of the ball bearing, spacers and sprocket. the cap and apply a press load to the end of the driven shaft to press
the shaft out of the ball bearing, spacers and sprocket.
4. Remove the ball bearing, spacers and sprocket from cap.
4. Remove the ball bearing, spacers and sprocket from cap.
Figure 15. Driven Shaft Disassembly - Combination Pump
Figure 16. Driven Shaft Disassembly - Oil Cooler
Cap Screw
Oil Seal Hex Hd Screw
Lock Washer
Oil Pump
Oil Seal Housing Lock Washer
O-ring
Cap Screw

Bearing Lock Nut Gasket

Bearing Lock Washer Lock Washer
Oil Pump Support Housing
Oil Seal Sleeve
O-ring
Bearing Lock Nut
Wave Spring Ball Bearing

Bearing Lock Washer

Spacer Rear Wave Spring Ball Bearing

Cap

Spacer Rear
Sprocket
Front (Pump Flange)
Cap
Spacer Ball Bearing
Sprocket Front (Pump Flange)
Driven Shaft Spacer
Ball Bearing

Key
Driven Shaft
Gasket

Key
Gasket
Oil Seal Housing Lock Washer
Socket Hd Screw
Oil Seal IL2748
IL2747 Oil Seal Housing Lock Washer
Sealing Boot
Oil Seal
Socket Hd Screw
Sealing Boot
F-1031, Section 4314 Rev: 07/25/08 Page 9 of 34
One- Piece Shaft (CG, CX Models) Eclipse ES Mounted CAFS (CX Models)
1. Remove the four cap screws from the bearing cover and the four 1. Remove the four cap screws and four socket hd screws that fasten the
socket hd screws from the oil seal housing. Remove cover and hous‐ oil seal housings to the cap. Remove housings.
ing from cap. 2. Remove the retaining ring and wave spring.
2. Straighten tab of the bearing lock washer from slot in bearing lock nut 3. Under a press, support the assembly on the front (pump flange) side of
and then remove the lock nut, lock washer and wave spring. the case and apply a press load to the end of the driven shaft and
3. Under a press, support the assembly on the front (pump flange) face press the shaft out of the ball bearing, spacers and sprocket. Rear ball
of the cap and apply a press load to the end of the driven shaft to bearing and retaining ring will come out with the driven shaft. Remove
press the shaft out of the ball bearing, spacers and sprocket. from shaft.
4. Remove the ball bearing, spacers and sprocket from cap. 4. Remove the ball bearing, spacers and sprocket from cap.
Figure 17. Driven Shaft Disassembly - One-Piece Shaft (CG, CX) Figure 18. Driven Shaft Disassembly - Eclipse ES (CX Models)
Cap Screw Cap Screw
Bearing Cover
Lock Washer Oil Seal Lock Washer
O-ring Oil Seal Housing O-ring
Bearing Lock Nut
Wave Spring
Bearing Lock Washer
Wave Spring Retaining Ring
Ball Bearing
Ball Bearing

Spacer
Spacer
Rear
Rear
Cap Cap

Sprocket Front (Pump Flange) Sprocket Front (Pump Flange)

Spacer Double-Row Ball Bearing Spacer Double-Row Ball Bearing

Driven Shaft Driven Shaft

(Pump Impeller Shaft) (Pump Impeller Shaft)

Gasket
Gasket
Oil Seal Housing

IL2749 Oil Seal Housing

Oil Seal Lock Washer
Socket Hd Screw Lock Washer IL2750
Oil Seal
Socket Hd Screw

F-1031, Section 4314 Rev: 07/25/08 Page 10 of 34

Disassembly of Coupling Shaft Assembly Disassembly of Drive Shaft Assembly
1. Press coupling shaft housing off of ball bearings if not previously re‐ 1. Slide shift collar from teeth on the drive shaft.
moved.
NOTE: If the transmission is equipped with an electronic tachom‐
2. Pull outer ball bearing from the shaft. eter, remove the pick-up from the housing prior to removal of the
3. Remove the spacer and pull inner ball bearing from the shaft. Note that driveshaft housing to avoid damage.
due to the closeness of the ball bearing to the hub end of the shaft, a 2. Press drive shaft housing from drive shaft assembly and press the oil
split-plate type puller may be necessary. seal from housing. Discard the oil seal.
4. Tap out pilot bearing if still in coupling shaft by using a punch through 3. Remove the tachometer pulse generator (if equipped) with a suitable
the two access holes in the coupling shaft. puller (see Figure 21).
Figure 19. Coupling Shaft Disassembly Figure 20. Drive Shaft Disassembly - Shift Collar Removal and Oil Seal

Shift Collar
Ball Bearing

Shaft Spacer
Drive Shaft Assembly

Ball Bearing

Coupling Shaft
O-ring

Access Hole (2)

Drive Housing
Pilot Bearing

Oil Seal

F-1031, Section 4314 Rev: 07/25/08 Page 11 of 34

Disassembly of Drive Shaft Assembly Cont'd Figure 22. Needle Bearing Removal from Sprocket
4. Remove spacer if applicable.
5. Place shaft and sprocket assembly in an arbor press in a vertical posi‐
tion with the threaded end up and supported on the bottom face of the
sprocket. Press shaft out of drive sprocket assembly. Catch shaft to
avoid damage.
6. Remove needle bearings from the sprocket. Needle Bearing
Figure 21. Drive Shaft Disassembly
Pilot Bearing

Drive Shaft

Drive Sprocket

Drive Sprocket
Assembly
Needle Bearing IL2526

Thrust Washer
Inspection and Repair
Spacer Check the following:
• Bent shift forks
• Bent shift shaft
Ball Bearing
• Worn shifter shoes
• Loose shifter shoe studs
• Damaged locking arm assembly, sector gear or bent pivot pin
Spacer • Condition of oil hose
Tach Pulse Generator • Worn sprocket teeth
• Worn flanks on inner chain links
• Outside guide links of chain not retained by “riveted over” pins
• Wear on inner faces of outside guide links of chain
• Badly worn pointing on teeth of drive sprocket, coupling shaft and shift
collar
• Damaged splines on drive and coupling shafts
Before reassembly, make sure all reusable parts have been cleaned and
are kept free of dirt during reassembly.

F-1031, Section 4314 Rev: 07/25/08 Page 12 of 34

 Reassembly
Guidelines for Installing Ball Bearings, Oil Seals, O-Rings and Hardware
Installing Ball Bearings Installing Oil Seals
Keep new ball bearings wrapped until they are to be installed. When pressing the Before installing a new oil seal in its housing, apply a thin coat of sealant to
ball bearing on a shaft or into a bore, coat appropriate surfaces with grease. housing oil seal seat. Be sure that the seal, shaft and housing are clean. Always
Shaft - grease shaft and ball bearing bore. install a seal with the seal lip facing in. Lubricate seal lip with light oil before
installing shaft. Apply force to the outer edge of the seal and press in evenly.
Bore - grease bore and outside of diameter of ball bearing.
Installing O-Rings
Always apply force to the inner race of a ball bearing when pressing it on a
shaft and to the outer race if pressing into a bore. Press evenly with a piece of Grease new O-rings prior to installation. This will aid in the installation as well
pipe or tube which just clears the shaft. as preventing damage to the O-ring.
NOTE: Wherever silicone or sealant is referenced, use Loctite Ultra Blue Installing Hardware
RTV Silicone Sealant or equivalent, unless otherwise specified. Torque spcifications for screws: M10 36-40 lb-ft.
M12 64-69 lb-ft.
Reassembly of the Driven Shaft
Separable Shaft Figure 23. Reassembly of the Driven Shaft - Separable Shaft
1. Use high pressure grease to coat the driven shaft. Cap Screw
2. Press the ball bearing to the shoulder of the driven shaft. Lock Washer
Bearing Cover
3. Tap the key into place.
4. Place high pressure grease in the rear bore of the cap.
O-ring
5. Tap the ball bearing into place. Bearing Lock Nut
6. Set the bearing cover on rear face of cap and secure with the cap screws
and lock washers. Hand tighten only at this stage of reassembly. Bearing Lock Washer
Wave Spring
7. With the cap resting on the rear face, position the spacer and driven sprocket
inside the cap.
Spacer Ball Bearing
8. Take the driven shaft, ball bearing and key assembled previously and from
the front (pump flange) face of the cap, slide the shaft through the bore in
the cap into the bore of the driven sprocket, spacers and ball bearing Sprocket Rear
lining up the key in the shaft with the keyway in the sprocket. Cap
9. Tap into place until the shaft seats.
10. Install gasket and oil seal in the oil seal housing.
Spacer Front (Pump Flange)
11. Install oil seal housing.
12. Tap lock nut end of driven shaft towards oil seal housing to seat assembly.
Ball Bearing
13. Remove the bearing cover and install the O-ring, bearing lock washer and Driven Shaft
lock nut. Make sure the tang of the washer aligns with the keyway in the
shaft. Key Gasket
14. Tighten nut 1/4 turn from finger tight and bend one of the locking tangs on
the washer into one of the slots in the locknut. Oil Seal Housing
Oil Seal
15. Install wave spring and bearing cover. Lock Washer
16. Install sealing boot. IL2744 Sealing Boot
Socket Hd Screw

F-1031, Section 4314 Rev: 07/25/08 Page 13 of 34

 Separable Shaft - Eclipse Figure 24. Reassembly of the Driven Shaft - Eclipse
1. Use high pressure grease to coat the driven shaft.
Cap Screw
2. Press the ball bearing to the shoulder of the driven shaft. Oil Seal
Lock Washer
3. Tap the key into place.
Oil Seal Housing (A)
4. Place high pressure grease in the rear bore of the cap.
5. Tap the ball bearing into place. O-ring
6. Set the oil seal housing (A) in cap and secure with the cap screws and Wave Spring
lock washers. Hand tighten only at this stage of reassembly.
Retaining Ring
7. With the cap resting on the rear face, position the spacers and driven
sprocket inside the cap. Ball Bearing
8. Take the driven shaft, ball bearing and key assembled previously and Spacer
from the front (pump flange) face of the cap, slide the shaft through the Rear
bore in the cap into the bore of the driven sprocket, spacers and ball
bearing lining up the key in the shaft with the keyway in the sprocket. Cap
9. Tap into place until the shaft seats. Sprocket
Front (Pump Flange)
10. Install gasket and oil seal in the oil seal housing (B).
11. Install the oil seal housing (B) using four socket hd screws. Spacer

12. Tap end of driven shaft towards oil seal housing (B) to seat assembly.
Ball Bearing
13. Remove the oil seal housing (A) and install retaining ring
14. Install wave spring , O-ring and oil seal and install oil seal housing (A) Driven Shaft
onto cap.
15. Install sealing boot. Key

Key

Gasket

Oil Seal Housing (B)

Oil Seal Lock Washer

IL2745
Socket Hd Screw
Sealing Boot

F-1031, Section 4314 Rev: 07/25/08 Page 14 of 34

 Separable Shaft - Hydraulic Adapter Figure 25. Reassembly of the Driven Shaft - Hydraulic Adapter
1. Use high pressure grease to coat the driven shaft. Oil Seal
Cap Screw
2. Press the ball bearing to the shoulder of driven shaft. Lock Washer Hydraulic Pump Adapter
3. Tap the key into place.
4. Place high pressure grease in the rear bore of the cap. O-ring
5. Tap the ball bearing into place. Wave Spring
6. Set the hydraulic pump adapter on cap and secure with cap screws and Retaining Ring
lock washers. Hand tighten only at this stage of reassembly.
Ball Bearing
7. With the cap resting on its rear face, position the spacers and driven
sprocket inside the cap.
Spacer
8. Take the driven shaft, ball bearing and key assembled previously and
from the front (pump flange) face of the cap, slide the shaft through the Rear
bore in the cap into the bore of the driven sprocket, spacers and ball
bearing lining up the key in the shaft with the keyway in the sprocket. Cap

9. Tap into place until the shaft seats.

10. Install O-ring and oil seal in the oil seal housing. Sprocket Front (Pump Flange)
11. Install the oil seal housing.
Spacer Ball Bearing
12. Remove the hydraulic pump adapter and install retaining ring.
13. Tap internal splined end of driven shaft towards front face to seat
assembly. Driven Shaft
14. Install O-ring and oil seal in hydraulic pump adapter.
15. Install wave spring and hydraulic pump adapter.
Key Gasket
16. Install sealing boot.

Lock Washer
Oil Seal Housing Socket Hd Screw
Oil Seal
IL2746
Sealing Boot

F-1031, Section 4314 Rev: 07/25/08 Page 15 of 34

 Separable Shaft - Combination Pump Figure 26. Reassembly of the Driven Shaft - Combination Pump
1. Use high pressure grease to coat the driven shaft.
Cap Screw
2. Press the ball bearing to the shoulder on the internal spline end of the Oil Seal
Lock Washer
drive shaft.
Oil Seal Housing
3. Tap the key into place. O-ring
4. Place high pressure grease in the rear bore of the cap.
5. Tap the ball bearing into place. Bearing Lock Nut Bearing Lock Washer
6. Set the oil seal housing (A) on cap and secure with cap screws and
lock washers. Hand tighten only at this stage of reassembly. Oil Seal Sleeve
7. With the cap resting on its rear face, position the spacers and driven Ball Bearing
sprocket inside the cap. Wave Spring

8. Take the driven shaft, ball bearing and key assembled previously and
from the front (pump flange) face of the cap, slide the shaft through the Spacer
bore in the cap into the bore of the driven sprocket, spacers and ball Rear
bearing lining up the key in the shaft with the keyway in the sprocket. Cap
9. Tap into place until the shaft seats.
Sprocket
10. Install gasket and oil seal in the oil seal housing (B). Front (Pump Flange)
11. Install the oil seal housing (B) using four socket hd screws. Spacer Ball Bearing
12. Tap end of driven shaft towards oil seal housing (B) to seat assembly.
13. Remove the oil seal housing (A) and install oil seal.
Driven Shaft
14. Install wave spring, O-ring and and install oil seal housing (A) onto
cap.
Key
15. Reapply high pressure grease to coat the driven shaft and apply light
Gasket
oil on the oil seal lip and oil seal sleeve O.D.
16. Install oil seal sleeve onto shaft.
Oil Seal Housing Lock Washer
17. Install bearing lock washer and lock nut. Make sure the tang of the
Socket Hd Screw
washer aligns with the keyway in the shaft. Oil Seal
IL2747
18. Tighten nut 1/4 turn from finger tight and bend one of the locking tangs Sealing Boot
on the washer into one of the slots in the locknut.
19. Install sealing boot.

F-1031, Section 4314 Rev: 07/25/08 Page 16 of 34

 Separable Shaft - Oil Cooler Figure 27. Reassembly of the Driven Shaft - Oil Cooler
1. Use high pressure grease to coat the driven shaft. Hex Hd Screw
2. Press the ball bearing to the shoulder of driven shaft. Oil Pump
Lock Washer
3. Tap the key into place.
4. Place high pressure grease in the rear bore of the cap. Cap Screw

5. Tap the ball bearing into place. Gasket

Lock Washer
6. Set the oil pump support housing on cap and secure with hex head Oil Pump Support Housing
screws and lock washers. Hand tighten only at this stage of reassembly.
O-ring
7. With the cap resting on its rear face, position the spacers and driven Bearing Lock Nut
sprocket inside the cap.
8. Take the driven shaft, ball bearing and key assembled previously and Bearing Lock Washer
from the front (pump flange) face of the cap, slide the shaft through the Ball Bearing
Wave Spring
bore in the cap into the bore of the driven sprocket, spacers and ball
bearing lining up the key in the shaft with the keyway in the sprocket.
9. Tap into place until the shaft seats. Spacer Rear
10. Install gasket and oil seal in the oil seal housing.
Cap
11. Install the oil seal housing.
12. Remove the oil pump adapter and install the bearing lock washer and Sprocket Front (Pump Flange)
lock nut. Make sure the tang of the washer aligns with the keyway in
the shaft. Spacer
Ball Bearing
13. Tap internal splined end of driven shaft towards front face to seat
assembly.
Driven Shaft
14. Tighten nut 1/4 turn from finger tight and bend one of the locking tangs
on the washer into one of the slots in the locknut.
Key
15. Install O-ring in oil pump adapter. Gasket
16. Install wave spring, oil pump support housing.
IL2748
17. Install oil pump and gasket, aligning the tang on the driven shaft with Oil Seal Housing Lock Washer
the slot in the oil pump shaft.
Oil Seal
18. Install sealing boot. Socket Hd Screw
Sealing Boot

F-1031, Section 4314 Rev: 07/25/08 Page 17 of 34

One-Piece Shaft (CG, CX Models) Figure 28. Reassembly of the Driven Shaft - One-Piece Shaft
(CG, CX Models)
1. Use high pressure grease to coat the driven shaft.
2. Press the double-row ball bearing to the shoulder of the driven shaft. Cap Screw
3. Tap the key into place. Bearing Cover
Lock Washer
4. Place high pressure grease in the rear bore of the cap.
O-ring
5. Tap the ball bearing into place.
6. Set the bearing cover on rear face of cap and secure with the cap Bearing Lock Nut
screws and lock washers. Hand tighten only at this stage of reassembly. Bearing Lock Washer
7. With the cap resting on the rear face, position the spacers and driven Wave Spring
sprocket inside the cap. Ball Bearing
8. Take the driven shaft, double-row ball bearing and key assembled
previously and from the front (pump flange) face of the cap, slide the Spacer
shaft through the bore in the cap into the bore of the driven sprocket,
spacers and ball bearing lining up the key in the shaft with the keyway in Rear
the sprocket.
Cap
9. Tap into place until the shaft seats.
10. Install gasket and oil seal in the oil seal housing.
Sprocket Front (Pump Flange)
11. Install oil seal housing.
12. Tap lock nut end of driven shaft towards oil seal housing to seat assem‐ Spacer Double-Row Ball Bearing
bly.
13. Remove the bearing cover and install the O-ring, bearing lock washer
and lock nut. Make sure the tang of the washer aligns with the keyway Driven Shaft
in the shaft. (Pump Impeller Shaft)
14. Tighten nut 1/4 turn from finger tight and bend one of the locking tangs
on the washer into one of the slots in the locknut.
15. Install wave spring and bearing cover.
Gasket

Oil Seal Housing

IL2749 Oil Seal Lock Washer

Socket Hd Screw

F-1031, Section 4314 Rev: 07/25/08 Page 18 of 34

 Eclipse ES Mounted CAFS (CX Models) Figure 29. Reassembly of the Driven Shaft - Eclipse ES (CX Models)
1. Use high pressure grease to coat the driven shaft.
Cap Screw
2. Press the double-row ball bearing to the shoulder of driven shaft. Oil Seal Lock Washer
3. Tap the key for the driven sprocket into place.
Oil Seal Housing (A) O-ring
4. Place high pressure grease in the rear bore of the cap.
5. Tap the ball bearing into place. Wave Spring
6. Set the oil seal housing (A) on cap and secure with cap screws and Retaining Ring
lock washers. Hand tighten only at this stage of reassembly. Ball Bearing
7. With the cap resting on the rear face, position the spacers and driven
sprocket inside the cap. Spacer
8. Take the driven shaft, double-row ball bearing and key assembled Rear
previously and from the front (pump flange) face of the cap, slide the
shaft through the bore in the cap into the bore of the driven sprocket, Cap
spacers and ball bearing lining up the key in the shaft with the keyway
in the sprocket.
Sprocket Front (Pump Flange)
9. Tap into place until the shaft seats.
10. Install the oil seal in the oil seal housing (B). Spacer Double-Row Ball Bearing

11. Install the gasket and oil seal housing (B).

12. Tap end of oil seal housing (A) end of driven shaft towards oil seal Driven Shaft
housing (B) to seat assembly. (Pump Impeller Shaft)
13. Remove the oil seal housing (A) and install the O-ring and oil seal.
14. Install wave spring and oil seal housing (A).

Gasket

Oil Seal Housing (B)

Lock Washer IL2750

Oil Seal
Socket Hd Screw

F-1031, Section 4314 Rev: 07/25/08 Page 19 of 34

 Dowel Pins and Spacer Installation (Extended Drop Chain Cases)
1. Place high pressure grease on the dowel pin holes and install into the Figure 30. Dowel Pins and Spacer Installation (for Extended Drop
cap. Chain Cases - C, D & E Drop)
2. Apply a bead of silicone to the inside of the bolt hole pattern of the cap. Cap
Cap Screw
3. If shims are required, apply bead of silicone inside bolt pattern on
spacer, then lay shims on the spacer or mid-section on B drop (see
Service Parts List SPL82890 for shims).
4. Position cap on spacer and tap dowel pins into place. Cap Screw
5. Secure with appropriated hardware (see Service Parts List SPL82890
- C10 Transmission or SPL82821 - Eclipse ES).

Silicone

Dowel Pin
If shims are
required, install
Lock between cap and
Washer spacer.

Dowel
Pin

Hex
Nut

Cap
Screw
Spacer
(Not used with
B drops)

F-1031, Section 4314 Rev: 07/25/08 Page 20 of 34

 Reassembly of the Shift Assembly
1. File and clean sealing surfaces of the mid-section and clean out any Shift Assembly
metal chips or shavings.
1. Invert mid-section.
2. Apply a small amount of grease to the O-ring and install on the groove
of the pivot pin. Apply Loctite #242 to the pivot pin and install the pivot 2. Attach shift arm to shift shaft with spirol pin (see Figure 32).
pin per Figure 31 into the mid-section. 3. Install shift lock spirol pin in shift arm.
NOTE: Avoid getting Loctite #242 on O-ring surface. 4. Grease the shift shaft.
3. Install the sleeve bushing 1/2” down into the shift shaft bore. Apply Figure 32. Shift Arm Assembly
silicone sealant to the outside diameter of the flange bearing and then
install it into the shift shaft bore. Make sure there is a 1/8” gap between
the bushing and bearing.
4. Apply a small amount of grease on the O-ring and install between the Mid-Section
bushing and bearing.
5. Install spirol pin in mid-section.
6. Install the spring housing into the spirol pin.
Figure 31. Pivot Pin, Shaft Bushing and Sleeve Bearing Installation Spirol Pin
Spring Housing
Pivot Pin Mid-Section Shift Lock Spring
O-Ring
Spriol Pin
Flange Bearing

O-Ring
Shift Arm
Shift Shaft
Sleeve Bushing V-Ring
Spirol Pin

IL2521

F-1031, Section 4314 Rev: 07/25/08 Page 21 of 34

Figure 33. Shift Assembly 5. Slide the shift lever into the sector gear aligning the holes (see Figure 33).
6. Set shift lever/sector gear over the shift shaft opening in the mid-sec‐
tion.
Pneumatic Shift 7. Slide shift shaft up through the shift shaft opening, engaging spacer
and shift lever or shift lever/sector gear.
8. Install the shift lock spring into the spring housing (see Figure 32).
9. Engage shift arm spirol pin with the shift lock spring (see Figure 32).
Shift 10. Rotate the shift arm to compress the shift lock spring into the housing.
Shoe Line up the holes in the shift lever/sector gear and install shoulder
screw and locking nut.
Locking
11. Install the locking arm onto the pivot pin (see Figure 33) and mesh the
Arm
teeth with the sector gear. Proper alignment is important. The center
IL2195 tooth space in the sector gear should be centered with the locking arm.
12. Install the shift shoe assembly on the pin of the locking arm.
Pivot
Pin Screw Retainer NOTE: Shift shoe can be installed with the counter bore either up or
Shift Shaft down.
Adjusting Screw
NOTE: Shift mechanism may not shift smoothly until bottom cover is
Shoulder installed.
Screw 13. Install adjusting screws in the mid-section and adjust so the locking
arm is rotatable slightly less than 90_ each direction (see Figure 33).
Locking Nut
Sector 14. Install screw retainers. Place a dab of grease on the retainers to hold
Gear them in place until the shift unit or cover can be installed.
15. Check assembly for proper shifting.
Sector Spacer
IL2233
IL2249

F-1031, Section 4314 Rev: 07/25/08 Page 22 of 34

 Reassembly of the Cap and Mid-Section
1. Make sure the face of the mid-section is clean and free of nicks and 5. Install cap or cap and spacer to mid-section.
burrs.
a. Cap only: Position cap on mid-section and tap dowel pins into mid-‐
2. Clean shims or spacer. If assembly includes a spacer, grease dowel section.
pin holes in mid-section and install dowel pins. If no spacer is
required, grease dowel pin holes in cap and install dowel pins. b. Cap with spacer: Position cap assembly on the dowels previously
installed in the mid-section and tap down into place.
3. Apply a bead of silicone inside the bolt hole pattern of the mid-section.
6. Install appropriate hardware.
4. If no spacer is being used and shims are required, install shims on the
mid-section. Apply a bead of silicone inside the bolt hole pattern on 7. Support the mid-section and cap assembly in an upside down posi‐
top of shims. tion.
Figure 34. Mid-Section Assembly Figure 35. Cap and Mid-Section Assembly

Hex
Nut
Lock Cap Screw
Washer

Lock Washer

Dowel Spacer
Pin (D&E Drop Only)

Dowel Pin

Cap
Screw

Mid-Section

IL2790

F-1031, Section 4314 Rev: 07/25/08 Page 23 of 34

 Reassembly of the Drive Shaft and Drive Shaft Housing
Drive Shaft Assembly 7. Install the thrust washer onto the drive shaft.
1. File and clean the sprocket faces and check teeth for burrs. 8. Apply grease and install the ball bearing.
2. Use high pressure grease in the bore of the drive sprocket. 9. If the tachometer option is used, add the tach pulse generator and
spacer required. If no tach is required, install appropriate spacer.
3. Press the needle needle bearings into each end of the bore of the
drive sprocket. Press rounded end of needle bearing into sprocket NOTE: Drive sprocket assembly should turn freely.
bore. Needle bearings should set just below the slots in the sprocket. Figure 37. Drive Shaft Installation into Drive Sprocket
Figure 36. Needle Bearing Installation into Drive Sprocket
Pilot Bearing

Drive Shaft

Drive Sprocket
Assembly

Needle Bearing Thrust Washer

Spacer

Ball bearing

Drive Sprocket

Spacer
Needle Bearing
Tach Pulse Generator
IL2526

4. Install pilot bearing on end of drive shaft.

5. Use high pressure grease on the drive shaft and press into the drive
sprocket assembly.
6. Check the shift collar (not shown) for proper fit. Do not install at this
time.

F-1031, Section 4314 Rev: 07/25/08 Page 24 of 34

Drive Shaft Housing Assembly Drive Shaft/Housing Assembly Installation
1. Apply a light coat of silicone to the housing bore and install the oil seal. 1. Apply grease to stud on the shift shoes for temporary installation.
2. Apply grease to the O-ring and insert into the housing. Then, install the drive shaft assembly into the mid-section and onto
the shift shaft. Make sure the shift shoe on the locking arm is mated
3. Use high pressure grease in the bore of the housing and press the with the slot in the fork. The drive shaft housing should be seated.
housing onto the drive shaft assembly.
2. Install hex head screws and lock washers to secure the drive housing
4. Add the shift collar onto the drive line. to the mid-section. Do not completely tighten. Leave a small gap
5. Check the shift fork shoes for free movement. between the drive shaft housing and mid-section flange to allow instal‐
lation of the bottom cover.
6. Grease the shift shoe studs and insert into shift fork.
Figure 39. Drive Shaft/Housing Assembly Installation
7. Slide the shift fork onto the shift collar.
Figure 38. Drive Assembly into Drive Housing
Drive Shaft Assembly
Shift Collar Shift Shoe Stud
Shift Fork

Drive Shaft Assembly Hex Hd Screw

Lock Washer

Drive Shaft Housing

Shift Fork
Shift Shoe Stud

O-ring

Drive Shaft Housing

Oil Seal

Shift Shaft

IL2790

F-1031, Section 4314 Rev: 07/25/08 Page 25 of 34

Optional Electronic Tachometer Figure 40. Optional Electronic Tachometer
1. Install the O-ring onto the tachometer pick-up. Pick-Up
2. Rotate drive shaft until tach tooth lines up with the tach opening. Hex Nut
3. Install the tachometer pick-up into the drive shaft housing until it con‐ O-ring
tacts the tach pulse generator. Turn back 1/2 turn.
4. Tighten hex nut.

Drive Shaft Housing IL2530

Installing the Chain

1. Wrap the chain around the drive and driven sprockets making sure Figure 41. Installing the Chain
everything meshes and then lace the joining ends together using the
connecting pin set (see Figure 41).
2. Insert the connecting pin rocker partway through the holes in the join‐
ing end links being careful of orientation (see Figure 43). The connect‐
Chain
ing rocker must be on the side of the guide link opposite the joining
end with the connecting rockers wide curved surface towards the
center of the hole.
Push to
3. Insert the connecting pin assembly along side the connecting rocker.
The two wide curved surfaces of the connecting pin and connecting determine
rocker must face each other. chain
tension
4. After the connecting pin assembly and connecting rocker have been
pushed all the way through the joining ends of the chain, insert the
spirol pin into the open hole at the end of the connecting pin assembly Driven Sprocket
(see Figure 43). Make sure the spirol pin overlaps the connecting
rocker. Connecting Pin Set
Drive Sprocket
5. Check chain for proper tension. Check deflection half-way between
the drive sprocket and driven sprocket (see chart below for maximum
deflection). Replace chain if deflection is greater than those displayed
in the chart below.

Max Deflection (In.)

Drop
(Both Directions)
IL2431
B 1.75
C 1.75
D 1.75
E 2.0
F 2.0

F-1031, Section 4314 Rev: 07/25/08 Page 26 of 34

Figure 42. Connecting Pin Set Figure 43. Connecting Pin Orientation

Connecting Pin Set

(Spirol pin on opposite
side must be tapped in to
complete installation.) Connecting Rocker
Joining End of Chain

Chain

IL2432

Spirol Pin Spirol Pin

Guide Link
IL2433

Connecting Rocker

Connecting Pin Set

(V 2062)

The connecting pin set contains one connecting pin

Connecting Pin Assembly assembly, connecting rocker and two spirol pins.
(Consists of a connecting pin
and tapped-in spirol pins.)

F-1031, Section 4314 Rev: 07/25/08 Page 27 of 34

 Reassembly of the Bottom Section to the Cap and Mid-Section
1. Apply Loctite #242 to the shift shaft bushing and install into the bottom 4. Tap back the drive shaft assembly to allow for the bottom section
of the case. installation.
2. Apply pipe joint compound to the sight plug. 5. Apply silicone around the inside of the bolt hole pattern as shown in
3. Install the sight and magnetic plugs in the case. Figure 45.
6. Install the bottom section onto the mid-section. Be sure to engage the
Figure 44. Assembling Items on the Bottom Section
shift shaft with shift shaft bushing.
Shift Shaft Bushing 7. Install four dowel pins into place.
Apply Loctite #242 to Bottom Case
Bottom Nose of 8. Secure the bottom section to the mid-section with fasteners.
Bushing Figure 45. Assembling Bottom Section to the Cap and Mid-Section

Magnetic
(4) Dowel Pins Oil Fill Plug Dowel Pins

Hex Nut
Sight Plug Lock Washer

Magnetic Drain Plug

IL2796

Cap Screw

F-1031, Section 4314 Rev: 07/25/08 Page 28 of 34

 Shift Position Adjustments
1. Check the distance from shift collar to face of coupling shaft housing 2. Adjust as necessary.
bore. Distances should read as follows: 3. Install retainers. Apply grease into the slots to help secure retainers.
• ROAD mode: 1-3/8 inches (right adjusting screw)
• PUMP mode: 2-11/16 inches (left adjusting screw)
Figure 46. Retainer Installation

Adjusting Screw
Pump

Retainer

Road

F-1031, Section 4314 Rev: 07/25/08 Page 29 of 34

 Coupling Shaft and Housing Assembly
Coupling Shaft Assembly Coupling Shaft Housing Assembly
1. Use high pressure grease and press ball bearing, spacer and ball 1. Coat the seal outer diameter evenly with sealant. Be sure that the seal,
bearing onto shaft. shaft and housing are clean. Always install a seal with the seal lip
facing in. Apply force to the outer edge of the seal and press in evenly.
Figure 47. Coupling Shaft Assembly
2. Use high pressure grease in bore of the coupling housing and press
coupling shaft assembly into place.
Figure 48. Coupling Shaft Housing Assembly
Coupling Shaft

Coupling Shaft Assembly

O-ring
(Install after shimming)

Housing
Ball Bearing

Shaft Spacer

Ball Bearing
IL2527

Oil Seal IL2528

F-1031, Section 4314 Rev: 07/25/08 Page 30 of 34

Coupling Shaft Housing Assembly to Case Assembly Figure 49. Assembling Coupling Shaft Housing to Case
The driveline assembly was factory shimmed to limit the axial float of the
drive line. If any of the drive line parts have been changed, it may be nec‐
essary to change the total thickness of shims between the coupling shaft
housing and the transmission case. Shims are color coded for thickness as
follows:
.005” Blue
.007” Natural
.010” Brown Breather
The correct thickness of shims can be determined as follows:
1. Install coupling shaft and housing assembly with no O-ring or shims
between the housing and case. Lightly tighten the cap screws evenly Hose Assembly
and tap the end of the coupling shaft with a soft mallet to force the
drive line all the way forward. Do not overtighten causing bending or Shims
breakage of the coupling shaft housing. (.005 - .010”)
2. Measure the gap between the housing and case in several places to Axial float
assure a uniform gap and add .005 in. This will be the total thickness
of shims needed to provide the recommended axial float of .005 - .010
in.
3. Remove the coupling shaft assembly from the case after measuring Lock Washer
the gap.
NOTE: Field conditions may make it difficult to determine the correct
amount of shims. If in doubt, add another .005 in. shims. No harm will
result from a small amount of additional axial float but ball bearing
life will be shortened if ball bearings are excessively preloaded.
4. Install the correct amount of shims on the coupling shaft housing or if Hex Hd Screw
all original parts are being used, reinstall original shims on coupling
shaft housing.
5. Coat O-ring with grease and install O-ring on housing.
6. Install the coupling shaft housing assembly.
7. Install fasteners.
Breather and Hose Assembly Installation
1. Apply thread sealer to breather and install.
2. Connect hose assembly from the cap to the mid-section.

F-1031, Section 4314 Rev: 07/25/08 Page 31 of 34

 Reassembly of Miscellaneous Items and Accessories
End Yoke Assembly Shift Accessory Assembly
1. Slide yoke onto the coupling shaft and drive shaft. 1. Attach the switch to the switch bracket using a seal and locking nut.
2. Secure in place using washers and self-locking nuts. Anti-seize Install the cap.
should be applied to the threads before installing a self-locking nut. Do 2. Set the gasket on the mid-section.
not reuse self-locking nuts. Torque to 475-525 lb-ft. 3. Align the shift arm with the piston in the shift unit and install bracket,
Figure 50. End Yoke Assembly gasket and shift unit to the case with lock washers and hex nuts. Note
that the word “TOP” cast into the shift unit.
4. Test the shift operations as required.
Figure 51. Shift Assembly

Studs
Grease Oil Seal
Before Installing Yoke

Yoke

Gasket
Shift Arm Bracket
Washer Cap Gasket
Nut Lock
Locking Nut Washer
Seal
Switch Hex Nut

Shift Unit

F-1031, Section 4314 Rev: 07/25/08 Page 32 of 34

 Eclipse CAFSystemt Installation onto Transmission
To install the Eclipse CAFSystem onto the transmission, perform the fol‐ 4. Install the Polychain onto the air clutch assembly, driven sprocket and
lowing steps: idler sprocket.
NOTE: If air clutch was not removed from the transmission during the 5. Attach air connections to the air clutch assembly.
overhaul procedure, proceed to step 4. 6. Tighten Polychain until taut using the Polychain tensioning screw.
NOTE: Apply anti-seize to shaft before installing air clutch. Polychain tension may be checked by applying a 10 lb. load to the
1. Apply Loctite 609 to keyway, install key and align clutch assembly. Polychain, mid-span between drive and driven sprocket. The Poly‐
Push assembly into place. chain should deflect .250 to .313”.
NOTE: Locate clutch assembly to ensure proper interface 7. Tighten the large hex head screw on the idler sprocket.
between set screw and its seating hole. 8. Attach the Polychain cover using the four hex nuts and lock washers.
2. Lock air clutch assembly into place for final polychain adjustment using 9. See Lubrication and Final Checks section for final polychain adjust‐
set screw (use Loctite 242). ment.
3. Attach the transmission and air clutch assembly to the pump using four
(4) cap screws.
Eclipse ES CAFSystemt Installation onto transmission (See Figure 1)
To install the Eclipse ES CAFSystem onto the C10 transmission, perform 6. Lock air clutch assembly into place for final polychain adjustment using
the following steps: set screw (use Loctite 242).
1. Support the Eclipse ES unit with a lifting strap placed under the air 7. Install the Polychain onto the air clutch assembly, driven sprocket and
compressor. Two other eyeloops are provided for lifting (see Figure 1). idler sprocket.
2. Lift the unit onto the C10. 8. Connect the nylon tube to the air clutch assembly.
3. Install the compressor bracket that supports the Eclipse ES unit to the 9. Tighten Polychain until taut using the Polychain tensioning screw.
C10. Polychain tension may be checked by applying a 10 lb. load to the
4. Install the five (5) hex hd screws that attach the Eclipse ES unit to the Polychain, mid-span between drive and driven sprocket. The Poly‐
C10. chain should deflect .250 to .313”.
NOTE: Apply anti-seize to shaft before installing air clutch. 10. Tighten the large hex head screw on the idler sprocket.
5. Apply Loctite 609 to keyway, install key and align clutch assembly. 11. Reconnect all electrical and air connections.
Push assembly into place. 12. See Lubrication and Final Checks section for final polychain adjust‐
NOTE: Locate clutch assembly to ensure proper interface ment.
between set screw and its seating hole.

F-1031, Section 4314 Rev: 07/25/08 Page 33 of 34

 Propeller Shaft Connection and Accessory Installation
Electrical Connections Drain Valve
Connect the tachometer cable, electric shift wiring and primer motor wiring Connect the manifold drain valve.
as required.
Propeller Shaft
Primer
Connect the propeller shafts to the drive and coupling shafts
Connect the priming pump and hose to the priming pump.
Pneumatic Shift
• Connect power supply and truck transmission interfaces.
• SAE J1402 air brake hose recommended, 1/4” to 3/8”. Connect air lines
from main truck supply.

Lubrication and Final Checks

1. Fill the transmission through the fluid level hole or by removing the 2. Ensure that the green THROTTLE READY light on the operator's
breather and addling fluid through this opening. Any type of automatic panel is off.
transmission fluid (ATF) can be used. Capacity is approximately 12
d. Engage the parking brake and shift truck transmission to NEUTRAL.
quarts (fill to the bottom of threads of the oil level port).
2. Recheck fasteners for tightness. 1. Ensure that the green OK TO PUMP light in the cab is off (auto‐
matic truck transmission only).
3. Check for fluid leaks.
e. Shift to ROAD following the shifting instructions section of this docu‐
4. Recheck for proper operation of shift mechanism and that the shift ment.
indicator light system is functioning properly.
1. Ensure that the green PUMP ENGAGED and OK TO PUMP
Indicating Lights Operation lights in the cab are off.
Check the operation of the pump shift indicating lights at least weekly 2. Ensure that the green THROTTLE READY light on the operator's
as follows: panel is off.
NOTE: Block wheels with wheel chocks before beginning. Eclipse Units Only
a. With the pump in the ROAD position, truck transmission in NEUTRAL 5. Engage water pump and CAFS per appropriate operating instructions.
and the parking brake engaged, ensure that the PUMP ENGAGED Operate system for ten (10) minutes.
and OK TO PUMP lights in the cab are off.
6. Check Polychain tension. Apply a 10 lb. load to the Polychain, mid-‐
b. Shift to PUMP following the shifting instructions section of this docu‐ span between drive and driven sprocket. The Polychain should deflect
ment. .250 to .313. Adjust tension with Polychain tensioning screw. When
1. Ensure that the green PUMP ENGAGED and OK TO PUMP tension is correct, loosen large hex head screw on the idler sprocket
lights in the cab are on. and apply a bead of Loctite 243 Blue to the threads. Tighten hex head
screw.
2. Ensure that the green THROTTLE READY light on the operator's
panel is on. 7. Install the Polychain cover.

c. Apply the service (foot) brake and release the parking brake.
1. Ensure that the green OK TO PUMP light in the cab is off.

F-1031, Section 4314 Rev: 07/25/08 Page 34 of 34