Automated Transmissions ® ® Eaton Fuller

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CEMT 18-Speed

Eaton Fuller® ® Automated Transmissions

Service Manual TRSM-0011 August 1992

TABLE OF CONTENTSFOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MODEL DESIGNATIONS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .POWER FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TORQUE RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TOOL REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LUBRICATION CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HYDRAULIC SYSTEM FLUSH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HOW TO CHANGE OIL SUMP PAN/STRAINER OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSMISSION OIL FILTER CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PREVENTIVE MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PRECAUTIONS

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AIR SYSTEM

RANGE SHIFT AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPLITTER SHIFT AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AIR SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DISASSEMBLY SHIFTING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND REASSEMBLY SHIFT BAR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . .REMOVAL - OUTPUT YOKE, AUXILIARY SECTION AND TORQUE CONVERTER HOUSINGDISASSEMBLY - AUXILIARY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REASSEMBLY - AUXILIARY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DISASSEMBLY - FRONT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REASSEMBLY - FRONT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INSTALLATION - TORQUE CONVERTER HOUSING,

AUXILIARY SECTION AND OUTPUT YOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INSTALLATION - SHIFTING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..SHIMMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOREWORDThis manual is designed to provide detailed information

necessary to service and repair the Fuller¬ Transmissionslisted on the cover.

As outlined in the Table of Contents, the manual isdivided into 3 main sections:

a. Technical information and referenceb. Removal, disassembly, reassembly and

installationThe format of the manual is designed to be followed in itsentirety if complete disassembly and reassembly of thetransmission is necessary. But if only one component of thetransmission needs to be repaired, refer to the Table ofContents for the page numbers showing that component.For example, if you need to work on the Shifting Controls,you will find instructions for removal, disassembly and

reassembly on page 35. Instructions for installation are onpage 111. Service Manuals, Illustrated Parts Lists, DriversInstructions, and other forms of product service informationfor these and other Fuller Transmissions are available uponrequest. You may also obtain Service Bulletins, detailinginformation on product improvements, repair proceduresand other service-related subjects by writing to the followi ngaddress:

EATON CORPORATIONTRANSMISSION DIVISIONTechnical Service DepartmentP.O. Box 4013Kalamazoo, Michigan 49003(61 6) 342-3344

Every effort has been made to ensure the accuracy of all inf ormation in this brochure. However, Eaton Transmission Divisionmakes no expressed or implied warranty or representation based on the enclosed information. Any errors or omissions maybe reported to Training and Publications, Eaton Transmission Division, PO. Box 4013, Kalamazoo, Ml 49003.

MODEL DESIGNATIONSAND SPECIFICATIONSNomenclature:

IMPORTANT: All Fuller Transmissions are identified bymodel and serial number. This information is stamped onthe transmission identification tag and affixed to the case.DO NOT REMOVE OR DESTROY THE TRANSMISSIONIDENTIFICATION TAG.

18-Speed Transmission (On/Off Highway):

CHART NOTES:

1. Lengths measured from face of converter housing to front bottoming surface of companion flange or yoke.

2. Weight - Listed weights are with torque converter and include standard controls. Weight of standard controls isapproximately 10 lbs. (4.5 kg.). All weights are approximate.

3. Oil Capacities are approximate, depending on inclination of engine and transmission. Always fill transmission with propergrade and type of lubricant to level of filler opening. See LUBRICATION.

Proper Lubrication. . .the Key to long transmission lifeProper lubrication procedures are the key to a good all-around maintenance program. If the oil is not doing itsjob, or if the oil level is ignored, all the maintenance procedures in the world are not going to keep thetransmission running or assure long transmission life.

Eaton® Fuller® Transmissions are designed so that the internal parts operate in an oil bath circulated by themotion of the gears and shafts.Thus, all parts are amply lubricated if these procedures are closely followed:

1. Maintain oil level. Inspect regularly.

2. Change oil and filters regularly.● Use the correct grade and type of oil.• Buy oil from a reputable dealer.

Additives and friction modifiers are not recommended for use in Eaton Fuller Transmissions.

Operating Temperatures

An external oil cooler is required on the converter enhanced transmission in order to maintain proper operatingtemperatures. Transmission oil temperature is sensed from the torque converter outlet port before the oilenters the cooler.Normal operating temperature, when sensed from the torque converter outlet port, should be below 250oF;however, intermittent operating temperatures to 300oF do not harm the transmission. A dash light will signalhigh oil temperatures, 250oF or higher.

On vehicles equipped with two transmission oil temperature gauges, one gauge (required) senses torqueconverter oil as mentioned above, while the other gauge (optional) reads oil temperature from the transmissionsump. The sump temperature represents oil that has circulated through the cooler. This temperature isnormally below 225oF; however, intermittent sump temperatures to 250oF do not harm the transmission.

When the average temperature of the transmission oil exceeds the temperature limits as stated above, morefrequent oil changes may be needed.

The following conditions in any combination can cause the recommended transmission oil temperatures to beexceeded: (1) operating the transmission in a “stall” condition while in the converter ratios; i.e., extendedoperation while in gear with the vehicle stopped or slowly moving, (2) high density of starts and stops at slowoperating speed, (3) minimal cooler capacity and/or restricted air flow to the transmission oil cooler, (4)exhaust system too close to the transmission, (5) improper oil level/incorrect oil.

Proper Lubrication Levels asRelated to Transmission Operating Angles

If the transmission operating angle is more than 12°, improper lubrication can occur. A special kit may berequired for sustained operation on grades greater than 12°.

Oil Dipstick

Maintaining Oil Level

Different Views of the Oil Dipstick

Make sure oil is within dipstick marks for the corresponding oil temperature. Oil should be checked at idlespeed in the neutral position using the corresponding temperature band. Cold checks can be performed whenthe oil temperature is 60–120oF. The oil level should be within the dipstick “cold” band. Additional checks canbe made with the transmission at operating temperature by using the “hot” band on the opposite side of thedipstick. The “hot” band temperature range is 180-220oF.

OPERATION18-Speed TransmissionShift Lever Patterns and Shifting Controls

SHIFT LO-1-2-3-4 INLO RANGE.

RANGE SHIFT . . .AND SHIFT 5-6-7-8 IN

HI RANGE.

OVERDRIVE

WHILE IN LO AND HI RANGE . . .Ratios can be split bymoving the splitterControl Button to theforward position.

ROAD RANGER VALVE(A-5013)

SPLITTER CONTROL BUTTON

FORWARD REARWARD ForFor OVERDRIVE DIRECT

6

POWER FLOWThe transmission must efficiently transfer the engines power. In terms of torque, to the vehicle’s rear wheels.Knowledge of what takes place in the transmission during torque transfer is essential if troubleshooting or repairbecomes necessary.

Parts Identification

POWER FLOWTorque Converter ModePower Flow: LO Range (see figure A)

1.

2.

3.

4.

5.

6.

7.

Power (torque) from the vehicle’s engine is transferredto the torque converter’s drive spline.

The impeller spins directing oil to the torque converterturbine.

The oil flow hits the turbine causing the turbine torotate. The power is related to the speed differencebetween the impeller and the turbine.

The turbine is connected to the interrupt clutch housing.The interrupt clutch inner hub is splined directly to thetransmission input shaft.

When the interrupt clutch is activated the housing andthe inner hub are connected to complete themechanical link and transfers power to the input shaft.

Input shaft splines engage the internal splines in themain drive gear hub.

Torque is split between the two countershaft drivegears.

Lockup Mode (see figure B)

1. Power (torque) from the vehicle’s engine is transferredto the torque converter’s drive spline.

2. The drive spline is connected to the lockup clutch.

3. The lockup clutch is splined directly to the interruptclutch outer hub. When the lockup clutch is activated,the interrupt clutch is driven directly from the engine.

8.

9.

10.

1.

2.

3.

4.

Torque is delivered along both countershaft to matingcountershaft gear of the “engaged” mainshaft gear (1stgear in this example.)

The internal clutching teeth in the engaged mainshaftgear hub, transfers torque to the mainshaft through thesliding clutch.

The mainshaft transfers torque directly to the auxiliarydrive gear.

The auxiliary drive gear splits torque between the twoauxiliary countershaft drive gears.

Torque is delivered along both countershaft to the"(engaged” LO range gear on the range mainshaft oroutput shaft.

Torque is transferred to the output shaft through asliding clutch.

Torque is delivered to the driveline as LO RANGE 1st.

4. The interrupt clutch inner hub is splined directly to thetransmission input shaft.

5. When the interrupt clutch is activated, the torque istransmitted directly from the engine to the input shaftfrom the lockup clutch. The losses from the slippage inthe torque converter are eliminated in this manner.

Auxiliary Section Power Flow: HI Range (see figure C)

6. Input shaft splines engage the internal splines in the 10. The mainshaft transfers torque directly to the auxiliarymain drive gear hub. drive gear.

7. Torque is split between the two countershaft drive 11. The auxiliary drive gear transfers torque directly to thegears. range mainshaft or output shaft through the “engaged”

8. Torque is delivered along both countershaft to matingsliding clutch.

countershaft gear of the “engaged” mainshaft gear. 12. Torque is delivered through the output shaft to the

9. The internal clutching teeth in the engaged mainshaftdriveline as HI RANGE 5th.

gear hub transfers torque to the mainshaft through thesliding clutch.

POWER FLOW

9

POWER FLOWThe transmission must efficiently transfer the engine’s power, in terms of torque, to the vehicle’s rear wheels. Knowledge ofwhat takes place in the transmission during torque transfer is essential when troubleshooting and making repairs.

Front Section Power Flow(LO Range Direct)

1.

2.

3.

4.

5.

Power (torque) from the vehicle’s engine is transferredto the transmission’s torque converter.

Splines of input shaft engage internal splines in hub ofmain drive gear.

Torque is split between the two countershaft drivegears.

Torque is delivered along both countershaft to matingcountershaft gears of “engaged” mainshaft gear. Thefollowing cross section views illustrate a 1st/5th speedgear engagement.

Internal clutching teeth in hub of engaged mainshaft

6. Mainshaft transfers torque directly to rear auxiliary drivegear.

7. The rear auxiliary drive gear splits torque between thetwo auxiliary countershaft drive gears.

8. Torque is delivered along both auxiliary countershaftto the “engaged” reduction gear on output shaft.

9. Torque is transferred to output shaft through slidingclutch.

10. Output shaft delivers torque to driveline.

gear transfers torque to mainshaft through slidingclutch.

LO RANGE DIRECT

\ I

POWER FLOWAuxiliary Section Power Flow:LO RANGE OVERDRIVE

7.

8.

The front auxiliary drive gear splits torque between the 9.two auxiliary countershaft drive gears.

Torque is delivered along both countershaft to 10.“engaged” LO RANGE gear on range mainshaft oroutput shaft.

Torque is transferred to the output shaft through slidingclutch.

Torque is delivered to driveline as LO RANGE 1st gearOVERDRIVE.

LO RANGE OVERDRIVE

Auxiliary Section Power Flow:HI RANGE DIRECT

7. The rear auxiliary drive gear transfers torque directly to 8.the output shaft through ‘(engaged” sliding clutch.

Torque is delivered through the output shaft to drivelineas HI RANGE 5th gear.

POWER FLOWAuxiliary Section Power Flow:HI RANGE OVERDRIVE

7. The front auxiliary drive gear splits torque between the 9.two auxiliary countershaft drive gears.

8. Torque is delivered along both auxiliary countershaft 10.to mating countershaft gears of “engaged” rear auxiliarydrive gear.

Torque is transferred to output shaft through the slidingclutch.

Output shaft delivers torque to driveline as HI Range5th gear OVERDRIVE.

HI RANGE OVERDRIVE

TIMINGTiming Procedures: All ModelsIt is essential that both countershaft assemblies ofthe front and auxiliary sections are “timed. ” This as-sures proper tooth contact is made between main-shaft gears seeking to center on the mainshaftduring torque transfer and mating countershaft gearsthat distribute the load evenly. If not properly timed,serious damage to the transmission is likely to resultfrom unequal tooth contact causing the mainshaftgears to climb out of equilibrium.

Timing is a simple procedure of marking the appro-priate teeth of a gear set prior to installation andplacing them in proper mesh while in the transmis-sion. In the front section, it is necessary to time onlythe drive gear set. And depending on the model, onlythe LO range, deep reduction, or splitter gear set istimed in the auxiliary section.

Front Section

A. Marking countershaft drive gear teeth.1. Prior to placing each countershaft assembly

into case, clearly mark the tooth locateddirectly over the keyway of drive gear asshown. This tooth is stamped with an “O” toaid identification.

Tooth on Countershaftdirectly over Keywaymarked for timing

C. Meshing marked countershaft drive gear teethwith marked main drive gear teeth.(After placing the mainshaft assembly into case,the countershaft bearings are installed to com-plete installation of the countershaft assemblies.)1.

2.

When installing the bearings on left counter-shaft, mesh the marked tooth of countershaftdrive gear with either set or two marked teethon the main drive gear.Repeat the procedure when installing thebearings on right countershaft, making use ofthe remaining set of two marked teeth on themain drive gear to time assembly.

Cut 7300 F-1 1/86

Auxiliary Section

B. Marking main drive gear teeth.1. Mark any two adjacent teeth on the main drive

gear.2. Mark the two adjacent teeth located directly

opposite the first set marked on the main drivegear. As shown below, there should be anequal number of unmarked gear teeth on eachside between the marked sets.

A. Timing the auxiliarygear.1.

Cut 7300 H11/86

2.

Dive gear teeth correct/ymarked for timing.

3.

4.5.

6.

Countershaft gear teethmeshed with drive gear teethfor correct timing.

countershaft and LO range

Mark any two adjacent teeth on the LO rangegear of set to be timed. Then mark the two ad-jacent teeth located directly opposite the firstset marked as shown in Illustration B.Prior to placing each auxiliary countershaft as-sembly into housing, mark the tooth stampedwith an “O” on gear to mate with timed main-shaft gear as shown in Illustration A.Install the LO range gear on the out put shaftand into the auxiliary case.Seat the auxiliary countershaft bearings.Install the rear bearing cover and tighten torecommended torque.Place the auxiliary countershaft assembliesinto position and mesh the marked teeth of themating countershaft gears with the markedteeth of the LO range gear as shown in illustra-tion C.

Cut 7300G.11/86

13

TORQUE RECOMMENDATIONSCorrect torque application is extremely important to assure long transmission life and dependable performance.Over-tightening or under-tightening can result in a loose installation and, in many instances, eventually causedamage to transmission gears, shafts, and/or bearings. Use a torque wrench whenever possible to attainrecommended lbs./ft. ratings. Do not torque capscrews dry.

TORQUE RECOMMENDATIONS

TOOL REFERENCESome repair procedures pictured in this manual show The specialized tools listed below can be obtained from

the use of specialized tools. Their actual use is a tool supplier or made from dimensions as required by therecommended as they make transmission repair easier, individual user. Detailed Fuller Transmission Tool Prints arefaster, and prevent costly damage to critical parts. available upon request by writing.

But for the most part, ordinary mechanic’s tools such as Eaton Corporationsocket wrenches, screwdrivers, etc., and other standard Transmission Dept.shop items such as a press, mauls and soft bars are all that Technical Service Dept.is needed to successfully disassemble and reassemble any P.O. Box 4013Fuller Transmission. Kalamazoo, Michigan 49003

PAGE T O O L HOW OBTAINED

4 5 Countershaft Retaining Strap Made from Fuller TransmissionPrint T-64553

4 5 Auxiliary Section Hanger Bracket Made from Fuller TransmissionPrint T-22823

55 Jaw Puller and Bearing Separator Tool Supplier

72 Snap Ring Pliers Tool Supplier

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

91 Countershaft Support ToolMade from Fuller Transmission

Print T-22247

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

16

Lubrication Change Procedure

Draining Oil

Drain transmission while oil is warm. To drain oil, remove the two (2) drain plugs at the case bottom and oilpan. Clean the drain plugs and flush cooler circuit before re-installing.

Refilling

The operational level should always be within the appropriate temperature bands on the dipstick. The exactamount of oil depends on the transmission inclination and model. Insufficient oil damages the pump and othercomponents, and can affect the function and reduce the life of the transmission.

DO NOT OVERFILL! This causes overheating and loss of fuel economy.When adding oil, types and brands of oil should not be mixed because of possible incompatibility.

Use clean oil and clean containers when filling transmission. Containers that have been used for anti-freeze orwater should not be used for transmission oil.

1. Remove the dipstick and slowly add seven (7) gallons of the prescribed oil through the fill tube.

2. Place the transmission in neutral position and apply the parking brakes. Start the engine and let it idle forfive (5) minutes, (this allows oil to fill the converter, main case, and cooling system), add oil as needed toobtain a level at the proper temperature range. Total oil quantity needed at this time should beapproximately 10 gallons; this varies depending on the cooling system.

3. Increase the engine idle slowly to 1500 RPM for five (5) minutes. Now recheck the oil level at normal idlespeed in neutral, again adding oil to obtain a level at the proper temperature range.

4. Replace the dipstick and tighten securely,

Hydraulic System Flush ProcedureA complete hydraulic circuit flush should be completed when:

● first 1,000 to 1,500 miles for highway use or

30 hours for off-highway use

• a catastrophic failure has occurred.

Assumption: The transmission is at ambient (65°F+/-20) temperature.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Begin draining the transmission from the two drain locations;

1 ) At the transmission main case drain plug (rear@ bottom).

2) At the converter housing oil pan drain plug.

Disconnect the transmission cooler supply line between the transmission outlet and the oil cooler (not betweenthe cooler and the transmission oil pan).

With 80 PSI clean, dry air from a hose and nozzle, use a rubber stopper or clean rag to seal the air hose to theconverter outlet hose.

Apply air to the converter outlet for approximately two minutes to backfush oil into the transmission oil pan.

Disconnect oil lines and dipstick tube from the sump pan.

Remove and clean the sump pan.

Remove the oil strainer/tube from the torque converter housing.

Remove the oil strainer from the tube and clean.

Assemble the oil strainer on the tube.

Position a new gasket and install the oil strainer/tube.

Use the proper tool to tighten the retaining capscrews on the sumppan, damage can occur.

11.

12.

13.

14.

15.

16.

17.

18.

Install the sump pan. Tighten the retaining capscrews to 14 to 20 Lbf.ft of torque.

Connect oil lines and dipstick tube.

Connect the hose between the transmission and cooler. Tighten to vehicle manufacturer’s specifications.

Install the transmission converter housing oil pan drain plug and tighten to 14 to 20 Lbf.ft of torque.

Install the transmission main case drain plug (rear @ bottom) and tighten to 45 to 50 Lbf.ft of torque.

Remove the transmission dipstick and slowly pour 7 gallons of Dexron® II fluid into the transmission.

Apply the vehicle parking brakes and place the transmission lever in neutral. Start the engine and let is idle forfive minutes. Check the dipstick periodically while the engine is idling, adding oil at needed, to obtain a levelthat is in the cold band on the dipstick. Total quantity added at this time should be approximately 10 gallons.

With the transmission still in neutral, increase the engine idle speed to 1500 RPM and retain at this speed forfive minutes. Now check the oil level at normal engine idle speed in neutral, again adding oil as required for alevel 1 1/2” below the “add-hot” mark on the dipstick. Total oil quantity added at this time should be approximately11 gallons.

Transmission temperature (oF)180 to 220—Oil level between the “add-hot” and “full-hot” marks.Below 100—Oil level at the cold fill mark.

18

How to Change Oil Sump Pan/Strainer Oil Filter

NOTE: To prevent oil leakage and loosening, useFuller thread sealant/adhesive #71205 on allcapscrews.

1. Install a new gasket.

2. Using the 2 screws, install the oil filtertransfer tube. Tighten the screws to 14-20Lbf.ft of torque.

3. Check the strainer for contaminants. Ifneeded, wash the strainer in clean solvent.

4. Position the oil sump pan. Install theretaining capscrews in oil sump pan. Tightenthe capscrews to 14-20 L bf.ft of torque.

5. Install the return hose/tube.

19

Transmission Oil Filter Change ProcedureTransmission oil must be drained before proceeding.

1. Remove the retaining capscrews.

2. Remove the filter housing.

3. Replace the oil filter and housing O-ring gasket.

4. Position the filter housing on the transmission.

5. Install the capscrews and tighten to 26 to 32 Lbf.ft of torque.

NOTE: To prevent oil leakage andloosening, use Fuller threadsealant/adhesive #71 205 on allcapscrews.

Note: Item numbers refer to the illustration

Preventive Maintenance Checks1 —

2 —

3 —

4 —

5 —

Lubricant and Filter

● Change at specified service intervals.

● Use only the types and grades recommended.

● Check lubrication lines and cooling circuit for leaks.

● Use only genuine Eaton® Fuller® filter elements, when servicing filter.

Air System

● Annually replace the filter regulator element. If excessive contamination is present, service vehicleair/dryer system. The “MT” 18-Speed requires clean, dry air for proper operation. Check vehicle airdryer system regularly for proper operation.

Dipstick

● Monitor oil level.

● Add oil if necessary.

● Tighten dipstick securely.

Drain Plugs

• Tighten the drain plugs securely. Tighten the main case drain plug to 45-50 Lbf.ft of torque.Tighten oil pan plugs to 14-20 Lbf.ft of torque.

Capscrews and Gaskets

● Check all capscrews, especially those on the PTO covers and rear bearing covers for loosenesswhich can cause oil leakage. Tighten capscrews to 35-45 Lbf.ft of torque,

• Check PTO opening, oil sump pan/strainer, and rear bearing covers for oil leakage due to faultygaskets.

PRECAUTIONSDisassembly

It is assumed in the detailed disassembly instructions that the lubricant has been drained from transmission,the necessary linkage and air lines disconnected and the transmission has been removed from vehicle chassis.Removal of the gear shift lever housing assembly (or remote control assembly) is included in the detailed in-structions (Disassembly and Reassembly—Shifting Controls); however, this assembly MUST be detached fromshift bar housing before transmission can be removed.

FOLLOW CLOSELY EACH PROCEDURE IN THE DETAILED INSTRUCTIONS. MAKING USE OF THE TEXT. iLLUS-TRATIONS AND PHOTOGRAPHS PROVIDED.

1.

2.

3.

4.

BEARINGS - Carefully wash and relubricate allreusable bearings as removed and protectivelywrap until ready for use. Remove bearings plannedto be reused with pullers designed for this pur-pose.

ASSEMBLIES - When disassembling the variousassemblies, such as the mainshaft, countershaft,and shift bar housing, lay all parts on a cleanbench in the same sequence as removed. This pro-cedure will simplify reassembly and reduce thepossibility of losing parts.

SNAP RINGS - Remove snap rings with pliers de-signed for this purpose. Snap rings removed in thismanner can be reused, if they are not sprung orloose.

INPUT SHAFT - The input shaft can be removed

5.

6.

tershafts, mainshaft, or main drive gear. Specialprocedures are required and provided in this man-ual.

CLEANLINESS - Provide a clean place to work. Itis important that no dirt or foreign material entersthe unit during repairs. Dirt is an abrasive and candamage bearings. It is always good practice toclean the outside of the unit before starting theplanned disassembly.

WHEN USING TOOLS TO MOVE PARTS - Alwaysapply force to shafts, housings, etc, with restraint.Movement of some parts is restricted. Never applyforce to the part being driven after it stops solidly.The use of soft hammers, bars and mauls for alldisassembly work is recommended.

from transmission without removing the coun-

lnspectionBefore reassembling the transmission, check each part carefully for abnormal or excessive wear and damage todetermine reuse or replacement. When replacement is necessary, use only genuine Fuller Transmission parts toassure continued performance and extended life from your unit.

Since the cost of a new part is generally a small fraction of the total cost of downtime and labor, avoid reus-ing a questionable part which could lead to additional repairs and expense soon after initial reassembly. To aidin determining the reuse or replacement of any transmission part, consideration should also be given to theunit’s history, mileage, application, etc.

Recommended inspection procedures are provided in the following checklist.

A. BEARINGS B. GEARS1.

2.

3.

4.

Wash all bearings in clean solvent. Checkballs, rollers and raceways for pitting, discol-oration, and spalled areas. Replace bearingsthat are pitted, discolored, or spalled.

Lubricate bearings that are not pitted, discol-ored, or spalled and check for axial and radialclearances.Replace bearings with excessive clearances.

Check bearing f i ts. Bearing inner racesshould be tight to shaft; outer races slightlytight to slightly loose in case bore. If bearingspins freely in bore, however, case should bereplaced.

1. Check gear teeth for frosting and pitting.Frosting of gear tooth faces present no threatof transmission failure. Often in continuedoperation of the unit, frosted gears will “heal”and not progress to the pitting stage. And inmost cases, gears with light to moderate pit-ted teeth have considerable gear life remain-ing and can be reused. But gears withadvanced stage pitting should be replaced.

2. Check for gears with clutching teeth abnor-mally worn, tapered, or reduced in lengthfrom clashing in shifting. Replace gearsfound in any of these conditions.

PRECAUTIONSInspection (cont’d.)

3. Check axial clearance of gears. Where excessiveclearance is found, check gear snap ring, washer,spacer, and gear hub for excessive wear.Maintain .005” to .012“ axial clearance betweenmainshaft gears.

C. SPLINES

1. Check splines on all shafts for abnormal wear. Ifsliding clutch gears, companion flange, have worninto the sides of the splines, replace the specificshaft affected.

D. TOLERANCE WASHERS

1. Check surfaces of all tolerance washers. Washersscored or reduced in thickness should bereplaced.

E. REVERSE IDLER GEAR ASSEMBLIES

1. Check for excessive wear from action of rollerbearings.

F. GRAY IRON PARTS

1. Check all gray iron parts for cracks and breaks.Replace or repair parts found to be damaged.

G. SHIFT BAR HOUSING ASSEMBLY

1. Check for wear on shift yokes and blocks at padsand lever slot. Replace excessively worn parts.

2. Check yokes for correct alignment. Replacesprung yokes.

3. Check Iockscrews in yokes and blocks. Tightenand rewire those found loose.

4. If housing has been disassembled, check neutralnotches of shift bars for wear from interlock balls.

H. GEAR SHIFT LEVER HOUSINGASSEMBLY

1. Check spring tension on shift lever. Replacetension spring and washer if lever moves toofreely.

2. If housing is disassembled, check spade pin andcorresponding slot in lever for wear. Replace bothparts if excessively worn.

I. BEARING COVERS

1. Check covers for wear from thrust of adjacentbearing. Replace covers damaged from thrust ofbearing outer race.

2. Check bores of covers for wear. Replace thoseworn oversize.

J. SLIDING CLUTCHES

1. Check all shift yokes and yoke slots in slidingclutches for extreme wear or discoloration fromheat.

2. Check engaging teeth of sliding clutches forpartial engagement pattern.

K. SYNCHRONIZER ASSEMBLY

1. Check synchronizer for burrs, uneven andexcessive wear at contact surface, and metalparticles.

2. Check blocker pins for excessive wear orlooseness.

3. Check synchronizer contact surfaces on theauxiliary drive and low range gears for excessivewear.

L. O-RINGS

1. Check all O-rings for cracks or distortion. Replaceif worn.

PRECAUTIONSReassembly

Make sure that interiors of case and housings are clean. It is important that dirt and other foreign materials bekept out of the transmission during reassembly. Dirt is an abrasive and can damage polished surfaces ofbearings and washers. Use certain precautions, as listed below, during reassembly.

1.

2.

3.

4.

5.

GASKETS - Use new gaskets throughout thetransmission as it is being rebuilt. Make sure allgaskets are installed. An omission of any gasketcan result in oil leakage or misalignment ofbearing covers.

CAPSCREWS - To prevent oil leakage, use Loctite242 thread sealant on all capscrews. For torqueratings, see TORQUE RECOMMENDATIONS.

O-RINGS - Lubricate all O-rings with silicone lu-bricant.ASSEMBLY - Refer to the illustrations provided inthe detailed disassembly instructions as a guideto reassembly.

INITIAL LUBRICATION - Coat all limit washersand splines of shafts with Lubriplate during reas-sembly to prevent scoring and galling of suchparts.

6.

7.

8.

AXIAL CLEARANCES - Maintain original axialclearances of .005” to .012” for mainshaft gears.

BEARINGS - Use of flanged-end bearing drivers isrecommended for the installation of bearings.These special drivers apply equal force to bothbearing races, preventing damage to balls/rollersand races while maintaining correct bearing align-ment with bore and shaft. Avoid using a tubular orsleeve-type driver, whenever possible, as force isapplied to only one of the bearing races. SeeTOOL REFERENCE.

UNIVERSAL JOINT COMPANION FLANGE ORYOKE - Pull the companion flange or yoke tightlyinto place with the output shaft nut, using 450-500foot-pounds of torque. Make sure the speedome-ter drive gear or a replacement spacer of the samewidth has been installed. Failure to pull the com-panion flange or yoke tightly into place will permitthe output shaft to move axially with resultantdamage to the rear bearing.

IMPORTANT: REFER TO THE APPROPRIATE ILLUSTRATED PARTS LIST (SPECI-FIED BY MODEL SERIES) TO ENSURE THAT PROPER PARTS AREUSED DURING REASSEMBLY OF THE TRANSMISSION.

CHANGING INPUT SHAFTSpecial Procedure

In some cases, it may become necessary to replace the input shaft due to excessive wear on the splines. Except for removalof the shift bar housing assembly, the input shaft can be removed without further disassembly of the transmission. Removal ofthe torque converter housing is required.

NOTE: The following illustration and instructions pertain to changing the input shaft ONLY. To change the main drive gear,complete disassembly of the front section is required.

Disassembly

1. Remove the gear shift lever housing assembly (or re-mote control assembly) from shift bar housing, and theshift bar housing assembly from transmission case.

2. Remove the bearing retaining snap ring from groove inshaft.

3. Push down on input shaft to cock bearing in bore. Driveinput shaft toward rear of transmission, through bearingas far as possible. Pull input shaft forward to exposesnap ring of bearing.

4. Use pry bars to complete removal of bearing.

5. Remove drive gear spacer and snap ring.

Reassembly

1.

2.

3.

4.

5.

6.

7.

6. Pull input shaft forward and out of drive gear and case.

8.

If necessary, install bushing in pocket of input shaft.

Install new input shaft into splines of main drive gear,just far enough to expose snap ring groove in I.D. ofdrive gear.

Install snap ring in snap ring groove inside drive gear.

Install drive gear spacer on input shaft.

Install drive gear bearing on input shaft and into casebore.

Install bearing retainer snap ring.

To facilitate proper reinstallation of the shift bar housingassembly on case, make sure mainshaft slidingclutches are placed in the neutral position.

Reinstall the shift bar housing assembly, the frontbearing cover and all other parts and assembliespreviously removed, making sure to replace thegaskets used.

25

AIR SYSTEM

AIR SYSTEMRANGE SHIFT AIR SYSTEMOperationThe Range Shift Air System consists of the air filter/regulator, slave valve, a Range Control Valve or Mas-ter Control Valve, range cylinder, f i t t ings andconnecting air lines. See Air System Schematics.

CONSTANT AIR from the air filter/regulator is sup-plied to the “S” or Supply Port of slave valve andpassed through to the INLET or “S” Port of controlvalve.

WHILE IN LO RANGE, the control valve is OPENand AIR is returned to slave valve at the “P” or EndPort. This signals the valve to supply AIR in line be-tween the LO Range or “L” Port of slave valve andthe LO Range Port of range cylinder housing. AIR re-ceived at this port moves the range piston to the rearand causes the auxiliary LO RANGE gear to becomeengaged.

WHILE IN HI RANGE, the control valve is CLOSEDand NO AIR is returned to the slave valve. Thissignals the slave valve to supply AIR in line betweenthe HI Range or “H” Port of valve and the HI RangePort of range cylinder cover. AIR received at this portmoves the range piston forward to engage the aux-iliary drive gear with sliding clutch and bypass theLO RANGE gear set.

Range shifts can be made ONLY when the gearshift lever is in, or passing through, neutral. Thus, therange desired can be PRESELECTED while the shiftlever is in a gear position. As the lever is movedthrough neutral, the actuating plunger in the shift barhousing releases the slave valve, allowing it to moveto the selected range position.

Trouble ShootingIf the transmission fails to make a range shift orshifts too slowly, the fault may be in the Range ShiftAir System or actuating components of the shift barhousing assembly.

To locate the trouble, the following checks shouldbe made with normal vehicle air pressure applied tothe system, but with the engine off.

NEVER WORK UNDER A VEHICLEWHILE ENGINE IS RUNNING as

personal injury may result from the sudden and unin-tended movement of vehicle under power. Alwaysplace transmission in the neutral position.

1. INCORRECT AIR LINE HOOK-UPS(See Air System Schematics)With the gear shift lever in neutral, move the con-trol that provides range selection UP and DOWN.A. If the air lines are crossed between control

valve and slave valve, there will be CON-STANT AIR flowing from the exhaust port ofcontrol valve WHILE IN HI RANGE.

B. If the air lines are crossed between the slavevalve and range cylinder, the transmissiongearing will not correspond with the range se-lection. A LO RANGE selection will result in aHI RANGE engagement and vice versa.

2. AIR LEAKSWith the gear shift lever in neutral, coat all airlines and fittings with soapy water and check forleaks, moving the control that provides range se-lection UP and DOWN.

A.

B.

C.

D.

If there is a steady leak from the exhaust portof control valve, O-rings and/or related partsof the control valve are defective.

If there is a steady leak from breather of slavevalve: an O-ring in valve is defective, or thereis a leak past O-rings of range cylinder piston.

If transmission fails to shift into LO RANGEor is slow to make the range shift and thecase is pressurized, see Check No. 7 of thissection.

Tighten all loose connections and replace de-fective O-rings and parts.

3. AIR FILTER/REGULATOR(See illustration, Page 26.)With the gear shift lever in neutral, check thebreather of air filter/regulator assembly. Thereshould be NO AIR leaking from this port. Thecomplete assembly should be replaced if asteady leak is found.

Cut off the vehicle air supply to the air fiIter/regulator assembly, disconnect the air line at fit-ting in Supply OUTLET and install an air gage inopened port. Bring the vehicle air pressure to nor-mal. Regulated air pressure should be 57.5 to 62.5Psi.

DO NOT ADJUST SCREW AT BOTTOM OF REGU-LATOR TO OBTAIN CORRECT READINGS. Theair regulator has been PREADJUSTED within thecorrect operating limits. Any deviation from theselimits, especially with regulators that have beenin operation for some time, is likely to be causedby dirt or worn parts. If replacement or cleaningof the filter element does nothing to correct theair pressure readings, replace the complete as-sembly, as the air regulator is nonserviceable.

4. RANGE VALVE (See Page 27.)With the gear shift lever in neutral, select HIRANGE and disconnect the air line at the OUT-LET or “P” Port of control valve.

AIR SYSTEM

5.

A.

B.

HI

When LO RANGE is selected, a steady blastof air will flow from opened port. Select HIRANGE to shut off air flow. This indicates thecontrol valve is operating properly. Reconnectair line.

If control valve does not operate properly,check for restrictions and air leaks. Leaks in-dicate defective or worn O-rings.

RANGE OPERATIONWith the gear shift lever in neutral, select LORANGE and disconnect the 1/4” I.D. air line at theport of range cylinder cover. Make sure this lineleads from the HI Range or “H” Port of slavevalve.

A.

B.

C.

When HI RANGE is selected, a steady blast ofair should flow from disconnected line. SelectLO RANGE to shut off air flow.

Move the shift lever to a gear position and se-lect HI RANGE. There should be NO AIR flow-ing from disconnected line. Return the gearshift lever to the neutral position. Thereshould now be a steady flow of air from dis-connected line. Select LO RANGE to shut offair flow and reconnect air line.

If the air system does not operate accord-ingly, the slave valve or actuating componentsof the shift bar housing assembly are defec-tive.

IMPORTANT: RANGE PRESELECTIONThe plunger pin, located in case bore betweenthe slave valve and actuating plunger of shift barhousing, prevents the slave valve from operatingwhile the shift lever is in a gear position. Whenthe lever is moved to or through the neutral po-sition, the pin is released and the slave valve be-comes operational.

6.

7.

LO RANGE OPERATIONWith the gear shift lever in neutral, select HIRANGE and disconnect the 1/4” I.D. air line at thefitting on range cylinder housing. Make sure thisline leads from the LO Range or “L” Port of slavevalve.

A.

B.

C.

When LO RANGE is selected, a steady blastof air should flow from disconnected line. Se-lect HI RANGE to shut off air flow.

Move the shift lever to a gear position and se-lect LO RANGE. There should be NO AIR flo-wing from disconnected line. Return the gearshift lever to the neutral position. Thereshould now be a steady flow of air from dis-connected line. Select HI RANGE to shut offair flow and reconnect air line.

If the air system does not operate accord-ingly, the slave valve or actuating componentsof the shift bar housing assembly are defec-tive.

RANGE CYLINDER (Refer to the followingillustration.)If any of the seals in the range cylinder assemblyare defective, the range shift will be affected.

A.

B.

C.

Leak at either O-ring A results in completefailure to make a range shift; steady flow ofair from breather of slave valve in bothranges.

Leak at gasket B results in a steady flow of airto atmosphere while in HI RANGE.

Leak at O-ring C results in a slow shift to LORANGE; pressurizing of transmission case.

Cut 7420-5/87

Range Cylinder Assembly—All Models

28

AIR SYSTEMAIR FILTER/REGULATOR ASSEMBLY

— . . .The air filter contains a replaceable filter element which can be removed by turning out the end cap. This ele-ment should be cleaned at each oil change, or more often under high humidity conditions. Replace if necessary.

SLAVE VALVESPOPPET-TYPE

. . —.. . . .Refer to the drawing for disassembly and reassembly of the piston-type slave valve assemblies. Should the pop-pet-type slave valve assembly prove to be defective, replace the complete assembly, as it is non-serviceable.The actuating components used with these valve assemblies are non-interchangeable. Failure to use the correctplunger pin, spring, and alignment sleeve during installation on the transmission will cause hard shifting in LORange gears.

AIR SYSTEM

ROADRANGER VALVE A-5013

Removal and Disassembly1.

2.

3.

4.

5.

6.

Remove two screws holding bottom cover to valveand slide cover down gearshift lever to expose airline fittings. Disconnect air lines.

Loosen jam nut and turn control valve from gearshift lever.

Pry medallion from recess in top cover.

Turn out the two screws to remove the top coverfrom valve housing.

Turn out the two screws in side of valve housing toseparate the housing.

Remove the Range Preelection Lever from lefthousing and the position balls and guide fromlever.

7. If necessary, remove the spring and O-ring frombores in left housing.

8. If necessary, remove the springs, O-ring andsleeve from bores in right housing.

Reassembly and Installation1.

2.

3.

Refer to the drawing for proper reassembly. Use aVERY SMALL amount of silicone lubricant on theO-rings to avoid clogging ports. A small amount ofgrease on the position springs and balls will helpto hold them in place during reassembly

Install control valve on gear shift lever and tightenjam nut.

Attach air lines and install bottom cover.

AIR SYSTEMSPLITTER SHIFT AIR SYSTEM:Operation

In addition to the various components of the Range ShiftAir System, the Splitter Shift Air System utilizes a splittercylinder and the Roadranger Valve A-5013. See Air SystemSchematics.

CONSTANT AIR from the air filter/regulator assembly issupplied to the splitter cylinder at the port on right side ofcylinder cover. The Insert valve installed in cover (see Page30) provides the proper air flow needed to move the splitterpiston in the cylinder (rearward to engage rear auxiliarydrive gear for operation in direct; forward to engage thefront auxiliary drive gear for operation in overdrive).

WHILE IN HI OR LO RANGE, AIR needed to make thesplitter selection and complete the shift is supplied to theRoadranger valve from the fitting at the “S” Port of slavevalve. When the overdrive selection is made, the AIRpasses through the Roadranger valve and is supplied to theLeft Port of cylinder cover.

With Splitter Control Button in the “DIRECT”/REARWARD position, the “SP” Port of the Roadrangervalve is CLOSED and NO AIR is supplied to the Left Port of

NEVER WORK UNDER A VEHICLEWHILE ENGINE IS RUNNING as

the Splitter cylinder cover.

Button REARWARD(“SP” Port CLOSED)

While in HI or LO Range the button can be movedFORWARD to operate in ‘OVERDRIVE. The "SP" Portof valve is OPENED when overdrive is selected, sup-plying AIR to the Left Port of the Splitter cylindercover.

Button FORWARD(“SP” Port OPENED)

Trouble ShootingIf the transmission fails to shift or shifts too slowlyto or from the “split” position, the fault may be in theSplitter Shift Air System or related components ofthe Range Shift Air System.

To locate the trouble, the following checks shouldbe made with normal vehicle air pressure supplied tothe system, but with the engine off.

personal injury may result from the sudden and unin-tended movement of vehicle under power. Alwaysplace transmission in the neutral position

NOTE: It is assumed that correct PSI readings were

1.

2.

3.

obtained from the air filter/regulator and allair lines have been checked for leaks.

Air Supply (See Air System Schematics.)With the gear shift lever in neutral, select HI orLO RANGE and loosen the connection at the “S”Port of the Roadranger Valve until it can be deter-mined that AIR is supplied to valve. Reconnect airline.

If there is NO AIR, check for a restriction in theair line between the Roadranger valve and slavevalve. Make sure this line is connected to fittingat the supply Port of slave valve.

Roadranger Valve (See Page 27 and Air SystemSchematics.)With the gear shift lever in neutral, disconnectthe air line at the Left Port of splitter cylindercover, making sure this line leads from the “SP”Port of the Roadranger Valve.A.

B.

WHILE IN HI or LO RANGE, move the SplitterControl Button FORWARD. There should beAIR flowing from disconnected line. Move thebutton REARWARD to shut off air flow and re-connect air line.If the preceding conditions do not exist, theRoadranger valve is defective, or there is a re-striction in the air lines.

Splitter Cylinder. (Refer to the following illustra-tion.)If any of the seals in the splitter cylinder as-sembly are defective, the splitter shift will be af-fected. The degree of air lost will govern thedegree of failure, from slow shifting to completeshift failure.A. Leak at O-ring A results in a slow shift to

engage rear auxiliary drive gear pressurizing oftransmission case; auxiliary gearing can be dis-engaged.

AIR SYSTEMB. Leak at O-ring B results in slow shifting or

complete failure to engage and disengagefront or rear auxiliary drive gearing; steadyflow of air from exhaust port of Roadrangervalve and/or cylinder cover when Splitter Con-trol Button is in the REARWARD position.

C. Leak at gasket C results in a slow shift to dis-engage rear auxiliary drive gear; steady flowof air to atmosphere.

4. Insert Valve (See Page 30.)Any constant flow of air from exhaust port of cyl-inder cover usually indicates a faulty insert valve.Exhaust should occur ONLY BRIEFLY when Split-ter Control Button is moved REARWARD WHILEIN LO and HI RANGE.A faulty insert valve, leaking at the O-rings ofvalve O.D. or from inner seals results in constantair leak and shift failure. Two indications of defec-tive O-rings or seals are:A. CONSTANT AIR flowing from exhaust port of

cylinder cover.B. CONSTANT AIR flowing from Exhaust Port

“E” of control valve WHILE SPLITTER CON-TROL BUTTON IS REARWARD OR FORWARD(providing the control valve is operating pro-perly).

The three O-rings in position on valve O.D. can bereplaced. However, if an inner seal is damaged,the complete assembly MUST be replaced.

AIR SYSTEMINSERT VALVE:(EQUIPPED WITH ROADRANGER VALVE A-5013)The insert valve is a self-contained 1-3/16" valve as-sembly located in the splitter cylinder cover. It CAN-

PORTSIGNAL LINE FROM

CONTROL VALVE“SP” PORT

RETAINING NUT

-INSERT VALVE

Cut 7441A-11/87 SUPPLY PORT

LOW RANGE AND HIGH RANGE DIRECT

NO AIR ON SIGNAL LINE

CONSTANT AIR

NOT be disassembled except for the three O-rings onouter diameter. The O-rings provide a stationary sealand do not move in cylinder.

When installing the insert valve in bottom edge ofcover, apply Fuller #71206 silicone lubricant or itsequivalent to O-rings and cylinder walls. Install valvein bore with flat surface to the outside. When install-ing the special valve retaining nut, apply Fuller#71204 adhesive/sealant or its equivalent to threadsand tighten. See TORQUE RECOMMENDATIONS.

Travel of the small insert valve piston is only 3/16”.

As shown in the illustrations below, when NO AIR isapplied to the top side of valve piston, CONSTANTAIR supplied from the regulator passes to theFRONTSIDE of cylinder piston, moving the yoke barbackward to engage the REAR AUXILIARY DRIVEGEAR (LO RANGE DIRECT AND HI RANGE DIRECT).The piston moves up to cut off air to the back side ofthe cylinder piston. This air is exhausted out the cyl-inder cover as the piston moves rearward.

When AIR is applied to top side of valve piston,through signal line, the piston moves down passingair through the bottom of insert valve to the front andbackside of the cylinder piston, moving the yoke barFORWARD engaging the FRONT AUXILIARY DRIVEGEAR (LO RANGE OVERDRIVE AND HI RANGEOVERDRIVE).

OVERDRIVE

For all questionsconcerningremoval andreplacement,refer to EatonService and PartsLiterature.

Schematic

19470 or A-5000 Slave Valve

A-5000 Valve

19470 Valve

Slave ValveIdentification

LO

HI

PS

Air Filter/RegulatorAssembly

Range Cylinder Assembly

LO

HI

Constant Air

Air fromVehicleSource

Splitter CylinderAssembly

A-5013 RoadrangerValve

LO Range L

RTO-15618 and RTLO-XX618 Models

TransmissionsFulerl ®

Rearward

S SPP

Down

No Air

Air toHousingPort

No AirSP


Schematic


A-5000 Valve

19470 Valve


LO

HI

PS



LO

HI

Constant Air


Splitter CylinderAssembly SP


LO Range H



Forward

S SPP

Down

No Air

Air toHousingPort


Schematic


LO

HI

PS



LO

HI

Constant Air



No Air

Air to CoverPort


HI Range L



Rearward

S SPP

A-5000 Valve

19470 Valve


Up

No Air


Schematic


A-5000 Valve

19470 Valve


LO

HI

PS



LO

HI

Constant Air



No Air

Air to CoverPort

HI Range H




Forward

S SPP

Up

DISASSEMBLY SHIFTING CONTROLSAIR SYSTEM

A. Removal of Air Controls1. Disconnect the two air lines at the "S" or Supply Port

and "P" or End Port of the slave valve on thetransmission case. Disconnect the three 1/4" rubberlines from the slave valve.

2. Remove the air line at the splitter cylinder cover (A).Then remove the three (3) 1/4 rubber lines at the rangecylinder (B).

NOTE: If equipped with a shift lever the gear shift leverhousing assembly can now be removed from shift barhousing by removing the four capscrews from thetower.

NOTE: The Roadranger valve mounted in the cab canbe removed as shown.

3. Turn out the two mounting screws in the Roadrangervalve cover.

4. Slide the cover down to expose the valve ports anddisconnect the three air lines.

5. Loosen the jam nut and turn the valve and nut fromgear shift Iever. Remove the valve cover, air lines,sheathing and O-rings from lever.

DISASSEMBLY SHIFTING CONTROLS

6. Remove retaining capscrews on the shift bar housingwhich hold wiring harness clamps (left). Disconnectinput speed sensor and engine speed sensor at wiringharness connectors (right).

7. Disconnect the 1/4" air hose at the inertia brake solenoidalso disconnect the remaining air hose to the splittercylinder (left). Remove the air hose at the inertia brakehousing also disconnect the hydraulic valve wiringharness connector (right).

8. Remove the wiring harness and inertia brake air hosefrom the transmission.

B. Removal of AirFilter/Regulator Assembly

1.Turn out the two capscrews and remove the air filter/regulator assembly.

NOTE: For disassembly and reassembly of Air Filter/Regulator Assembly, see Page 26.

2.Turn out the four retaining capscrews and remove slavevalve from transmission case.

3. If necessary, remove the air line fittings from slavevalve.

NOTE: For disassembly and reassembly of piston-typeSlave Valve Assembly, see Page 26.

DISASSEMBLY SHIFTING CONTROLS

DISASSEMBLY AND REASSEMBLYSHIFT BAR HOUSINGSHIFT BAR HOUSING ASSEMBLY

A. Removal and Disassembly of the ShiftBar Housing Assembly

For models equipped with an Oil Pumpand/or Cooler Assembl ies, make sure t odisconnect the lube line at the fitting on the shiftba r hous ing be fo re do ing the fo l l ow in ginstructions.

1. Turn out the retaining capscrews. Jar the top to 2. Tilt the assembly and remove the three sets of ten-break the gasket seal and lift the shift bar housingfrom the transmission case. Remove the gasket.

sion springs and balls from the housing bores.

NOTE: During disassembly, lay all parts on aclean bench in order of removal from the housingto make reassembly easier. Shift bars not being re-moved must be kept in the neutral position or theinterlocking parts will lock the bars.

DISASSEMBLY AND REASSEMBLYSHIFT BAR HOUSING

3. Secure the assembly in a vise with the plunger-side up. (The front of the housing will be to theleft.) For models so equipped, cut the lockwireand turn out the retaining capscrews to removethe oil trough from the housing.

NOTE: Start with the upper shift bar, move all barsto the right and out the rear boss bore. Cut thelockwire and remove the Iockscrews from each barjust before their removal.

4. Move the 3rd-4th speed shift bar to the housingrear, removing the yoke and block from the bar.

5. Move the 1st-2nd speed shift bar to the housingrear, removing the yoke and block from the bar. Asthe neutral notch in the bar clears the rear boss,remove the small interlock pin from the bore.

6. Remove the actuating plunger from the centerboss bore.


B. Reassembly of the Shift Bar HousingA s s e m b l y .

7. Move the short LO-Reverse speed shift bar to thehousing rear, remove the yoke from the bar. As theshift bar is removed from the housing, two 3/4 in-terlock balls will drop from the rear boss bottombore.

1. If previously removed, install the reverse-stopplunger in the LO-Reverse shift yoke, making surethe plunger is fully seated in the yoke slot bore.

8. If necessary, remove the plug, spring, and reverse-stop plunger from the LO-Reverse speed shiftyoke bore.

2. Install the spring in the yoke bore and on theplunger shank.


3. Install the plug and tighten to compress thespring (left). Back the plug out 1 - 1 1/2 turns andstake the plug through the small hole in the yoke(right.)

4. Secure the shift bar housing in a vise. Hold thenotched-end of the short LO-Reverse speed shiftbar, install the bar in the lower bore of the shift barhousing bosses. Install the yoke Iockscrew,tighten and wire securely.

NOTE: Start with the lower shift bore of the rearboss and move to the left (front of the housing).Keep bars in the neutral position during installa-tion. DO NOT EXCEED the recommended torqueratings for the yoke Iockscrews as over-tighteningmay distort the shift bars.

5. While holding the plunger shank, install the ac-tuating plunger in the center boss bore.

6. Install one 3/4" interlock ball in the rear boss topbore. This ball rides between LO-Reverse and 1st-2nd speed shift bars.


7. While holding the notched-end of the bar, installthe 1st-2nd speed shift bar in the housing bossmiddle bore. Position the shift block on the bar be-tween the center and rear bosses, and the yoke onthe bar between the front and center bosses, longhub to the housing front. Just before inserting thenotched-end of the rear boss bar, install the smallinterlock pin VERTICALLY in the neutral notchbore. Install the block and yoke Iockscrews,tighten, and lockwire securely.

NOTE: It is necessary that the interlock pin re-main in a vertical position during reassembly asrotation of the bar causes the pin to jam in the ten-sion spring bores.

9.

10.

While holding notched-end of the bar, install the3rd-4th speed shift bar in the housing boss upperbore, position the shift block on the bar betweenthe front and center bosses, long hub to thehousing rear. Install the block and yoke lock-screws, tighten, and lockwire securely.

For models so equipped, install the oil trough onthe housing. Tighten the capscrews and lockwiresecurely.

8. Install the other 3/4Ó interlock ball in the rear bosstop bore. This ball rides between the 1st-2nd andthe 3rd-4th speed shift bars.


11. Remove the assembly from the vise. Install thethree tension balls, one in each bore on the hous-ing top.

12. Install the three tension springs, one over eachball in the housing bores.

REMOVAL - OUTPUT YOKE, AUXILIARYSECTION, AND TORQUE CONVERTER HOUSINGA. Removal of the Output Yoke

1. Lock transmission by engaging two mainshaft gearswith the mainshaft sliding clutches (inset.) Use a largebreaker bar to turn the output shaft nut from the outputshaft.

2. Pull yoke straight to the rear and off the output shaft.

B. Removal of the Auxiliary Section

4 2.56254

2.5625

43.0

43.0 b

46.0

.40625 (3-Drilled Holes)

Bar Stock - 3/8" x 1"Tool Print T-65853

1. Place the transmission in the vertical position. Putblocks under the torque converter housing to preventdamage to the torque converter. Removal can also becompleted in the horizontal position.

2. Remove the four capscrews and the auxiliarycountershaft rear bearing cover, gasket, and rearbearing shim.

REMOVAL - OUTPUT YOKE, AUXILIARYSECTION, AND TORQUE CONVERTER HOUSING

Auxiliary Countershaft Retaining Strapsmay be installed to hold countershaft in

place. Auxiliary can be removed without straps, usecaution.

3. Install an Auxiliary Countershaft Retaining Strap with3- 3/8" x 1" clean capscrews. Place a flat washer underthe strap to prevent damage to the rear auxiliarycountershaft bearing.

6. Insert three capscrews in the tapped holes of housingflange. Tighten evenly to move auxiliary section to therear and just far enough from front section to breakgasket seal.

Do not use an air gun. Tighten byhand until the capscrews are snug.

4. Repeat Steps 2 and 3 for the remaining auxiliarycountershaft.

7. Remove capscrews and attach a chain hoist to auxiliarysection. Move the assembly to the rear until free of frontsection and remove gasket.

5. Remove the nineteen capscrews that hold the auxiliarysection to the transmission case.

NOTE: There are three lengths of capscrews, note theirlocation.


C. Removal Torque Converter

NOTE: The transmission rear must be blocked so thetwo aligning pins on the transmission rear case are notdamaged. If the auxiliary section is not being removedthe transmission can be placed vertically on a standusing an output flange or half round yoke affixed to alarge plate.

Care must be taken when placing thetransmission in the vertical position.

Always use safety chains on transmission. Assure thattransmission is stable in vertical position beforeremoving the safety chains.

8. The auxiliary section can also be removed with thetransmission set in the vertical position. Remove theretaining capscrews from the housing flange and lift theassembly from the front section. Remove the gasket.

1.Remove the retaining capscrews from the convertorpilot.

2.Use the two (2) threaded capscrew holes to separatethe converter pilot form the torque converter (Left).Remove the converter pilot from the torque converter(Right).


3. If required the pilot o-ring or hydraulic seals can byserviced at this time.

4. Remove the torque converter snap ring from the inputshaft.

5.

D.

Install 2 lifting eyes into the converter pilot capscrewholes, attach lifting chain and remove converter straightup form the converter housing.

NOTE: Torque converter assembly is Non-Servicable.Do not attempt to disassemble. It will be returned forservice and replaced as a complete assembly.

Removal of the Hydraulic Valve

NOTE: If not previously removed the transmission dipstick and tube can be removed from the oil pan at thistime.

1.Loosen and remove the ten (10) retaining capscrewsfrom the hydraulic valve assembly. Note the location ofthe two (2) allen head capscrews for reassembly.


2. Remove the hydraulic valve assembly form the torqueconverter housing. (Left) Separate the 2 gaskets andmounting plate from the hydraulic valve. (Right)

3. If necessary the electronic solenoids can be removedfrom the hydraulic valve at this time.

NOTE: The hydraulic valve is a NON-SERVICABLEassembly. DO NOT DISASSEMBLE, it will be returnedfor service.

E. Removal of oil pan, oil pick-upand screen and oil filter assembly.

1. Disconnect and remove the oil sump return line fromthe oil pan.

2. Loosen and remove the retaining cap screws from theoil pan (Left). Remove the oil pan from the bottom of thetorque converter housing (Right).

3. Remove the two (2) retaining capscrews from the oilpick-up. Remove the pick-up and screen and oil pangasket from the torque converter housing.


4. Loosen and remove the three retaining capscrews fromthe oil filter housing. Change the oil filter asrecommended. Service the sealing ring if required.

2. Remove the stator support and gasket

F. Removal of the torque converterhousing

3. Remove the four (4) retaining capscrews and six (6)retaining nuts from the torque converter housings.

1. Loosen and remove the six (6) retaining capscrewsfrom the stator support.

NOTE: The staor support bay be set in place a softface mallet or pry bay may be required to loosen thestaor support. The staor support is a NON-SERVICABLE assembly.


7. Loosen and remove the two (2) retaining capscrewsfrom the oil pump assembly (Left). Remove the oilpump from the torque converter housing (Right).

NOTE: The oil pump is a NON-SERVICABLEassembly and should be returned for service. The two(2) oil pump o-rings can be serviced at this time ifnecessary.

G. Removal of the Inertia Brake

4. Jar the torque converter housing to break the sealremove the torqueconverter housing and gasket fromthe transmission case.

1. Loosen the six (6) retaining capscrews form the InertiaBrake Housing.

5. Block the oil pump drive gear to loosen retaining nutfrom oil pump shaft.

6. Remove the oil pump drive gear and retaining nut fromthe torque converter housing.

2. Remove the retaining capscrews from the assemblyand remove from the transmission case.


H. Removal of Hydraulic Pressure Valves

1. The pressure relief valve is located in the torque

2. To service the pressure relief valve, reach into the oilfilter mounting adapter and remove the valve. The valveis NON-SERVICEABLE. Replacement is required.

converter housing oil pan sump area.

3. The filter by-pass valve is located inside the hydraulicvalve main lube passage. Service of the valve is thruthe main lube passage, the valve is N O N -SERVICABLE and replacement is required.

DISASSEMBLY - AUXILIARY SECTION

A. Removal and Disassembly RearAuxiliary Drive Gear and Yoke

1. Cut the lockwire on the splitter yoke retaining bolt and 2. Remove the retaining bolt, splitter yoke and slidingloosen the bolt. clutch assembly from the auxiliary section.


AUXILIARY MAINSHAFTASSEMBLY

WASHER

SPACER

b

GEAR

c

SLIDING REAR AUXILIARYCLUTCH DRIVE GEAR

Cut 6593 L-4/87

NUT

WASHER

3. Temporarily install an output yoke on the output shaftand secure it by placing a bar through the yoke.

4. Break loose the 15/16ñ retaining capscrew on the frontof the output shaft.


BEARING

COUNTERSHAFT ASSEMBLY

BEARING

SPACER

AUXILIARY COUNTERSHAFTASSEMBLY

Cut 6503M - 11/91

B. Removal of the AuxiliaryCountershaft Assemblies

1. Secure the auxiliary housing in a vise.auxiliary countershaft retaining straps orcovers, shim and rear bearing race.

Remove therear bearing

The countershaft will fall loose in theauxiliary section, but will not fall outof auxiliary section.

2. Use a soft bar and maul to partially drive the outputshaft forward.

DISASSEMBLY - AUXILIARY SECTIONC. Removal Rear Auxiliary Drive Gear

Assembly

3. Remove the auxiliary countershaft from the auxiliarysection case.

1. Remove the 15/16" retaining capscrew, retainer andauxiliary drive gear from the auxiliary section.

4. If necessary, secure the countershaft assemblies in avise and remove both the front and rear bearings with abearing separator and jaw pullers.


RANGE CYLINDERASSEMBLY

*Note: Use lockwire atCut 6427-5/83 this position

D. Removal and Disassembly of RangeCylinder Assembly.

1. Remove the capscrews, range cylinder cover, andgasket.

2. Remove nut from yoke bar.

DISASSEMBLY-AUXILIARY SECTION

3. Cut the lockwire. Remove the two 3/4" yoke lock-screws (inset).

4. Pull the yoke bar from the cylinder housing bore.

5. Remove the shift yoke and synchronizer assemblyfrom output shaft.

6. Remove the range piston from the cylinder bore. Ifnecessary, remove the O-rings from the positionI.D. and O.D. (inset).


7. Remove capscrews and range cylinder housing.

8. If necessary, remove the small O-ring from therange cylinder housing bore.


E. Disassembly Synchronizer Assembly

1. Place the larger LO range synchronizer ring on thebench. Cover the assembly with a shop rag to pre-vent losing the three springs released from thehigh range synchronizer at the pin locations. Pullthe HI range synchronizer from the blocker pins.

2. Remove the sliding clutch from the synchronizerring LO range pins.

DISASSEMBLY-AUXILIARY SECTIONF. Removal and Disassembly Output Shaft

and Rear Bearing Assemblies.

1. Use a soft bar and maul to drive the output shaftforward and through the rear bearing assembly.

2. Remove the bearing inner spacer from the outputshaft.

3. Use the front face of the reduction gear as a base,press the output shaft through the bearing andgear. This frees the bearing, LO range gear, andthe splined washer.

4. Remove the stepped washer, LO range gear, andsplined washer from the shaft.

DISASSEMBLY - AUXILIARY SECTIONG. Removal Splitter Cover

5. Remove the rear bearing retaining capscrews, rearbearing cover, and gasket from the auxiliary housing.The rear bearing cone drops from the housing borewhen the cover is removed. If necessary, remove theoil seal from the cover (inset).

1. Remove the capscrews from the splitter cylinder coverand remove the splitter cylinder cover and gasket fromthe auxiliary section case.

6. Remove the two bearing cups and spacer from thebearing bore.

2. If necessary, turn out the insert valve retaining nut andremove insert valve from bore.


3. Pull the yoke bar from cylinder housing. If necessary,remove the O-ring from piston O.D. (inset).

4. If necessary, remove the small O-ring from the cylinderhousing bore.

REASSEMBLY-AUXILIARY SECTION

A. Reassembly and Installation of

NOTE: Make sure magnetic plugs preinstalled inauxiliary housing.

1. IMPORTANT: Mark timing teeth on the LO Rangegear. A highly visible color of toolmaker's dye is

a.

b.

recommended.Mark any two adjacent gear teeth on LO Rangegear, front side.Then mark the two adjacent teeth which aredirectly opposite the first set marked. Thereshould be the same number of teeth betweenthe markings on each side of the gear.

2. Placed splined washer on output shaft shoulderfacing up as shown.

REASSEMBLY-AUXILIARY SECTION

3. Install the LO Range gear on the output shaft,clutching teeth engaged with the splines down toengage the washer splines.

4. Install the LO Range gear rear washer on outputshaft and against gear, with chamfer side facingup.

5. Using a heat lamp or hot plate and oil heat the out-put shaft rear bearing and install on output shaft.Seat the bearing securely on shaft. Bearing canalso be installed using the appropriate driver.

NOTE: DO NOT HEAT BEARING ABOVE 275oF(136oC).

6. Install the bearing inner spacer on the outputshaft.

REASSEMBLY - AUXILIARY SECTION

7.

B.

Place the auxiliary housing on a flat bench and installthe 2 bearing cups and spacer in the rear bearing bore,the cup with a lip seats next to the rear of the auxiliarycase.

Reassembly Synchronizer Assembly

2. Install the three springs in bores in HI range synchro-nizer ring.

3. Place the HI range synchronizer ring over pins of LOspeed synchronizer ring, seating springs against pins.

1. Place the larger LO range synchronizer ring face downon bench with pins up. Place the sliding clutch, re-cessed side up, on pins of LO range synchronizer.

NOTE: Pins on LO range synchronizer must line upwith chamfered holes on bottom of sliding clutch.


4. Apply downward pressure to the HI range synchronizerring WHILE TWISTING COUNTER-CLOCKWISE tocompress the springs and fully seat ring on blocker pinsof LO range synchronizer. It is suggested that a shoptowel be placed over the synchronizer to prevent injuryto your hands.

5. Install synchronizer assembly to front of output shaftassembly.

C. Installation of Auxiliary Driver Gear.

1. Place auxiliary drive gear, retainer and 15/16" capscrew onoutput shaft assembly. Secure capscrew on shaft tilltight, recommended torque will be applied during finalassembly (pg. 67)

D. Reassembly of AuxiliaryCountershaft Assemblies andTiming.

To make reassembly of the auxiliary section easier, you canmake this auxiliary section fixture out of a section of 2 x 12.

63


NOTE: Auxiliary countershaft bearings will be installedat this time if replacement was required.

3. Install the range yoke into the synchronizer slidingclutch slot, offset side facing down.

1. Mark each countershaft for correct timing. Locate the"O" stamped on the countershaft and mark the toothwith highly visible toolmakers dye or paint.

4. Place the auxiliary housing over countershaft assem-blies and output shaft assemblies.

2. Place the countershaft in fixture or on a flat surface forreassembly. Locate output shaft assembly betweencountershaft, timing of the auxiliary will be checked atthis time. The single marked tooth of each countershaftmust align with the two teeth marked on each side ofthe LO range gear.


5. Heat the rear output shaft bearing cone and install thebearing on the shaft taper side down.

NOTE: Do not heat the bearing above 275oF (136oC).

6. Install the rear bearing cover on the auxiliary housing.The nylon collar and brass washer are installed in thechamfered hole on the lower right side of the cover.

E. Reassembly Range Cylinder

1. Install O-ring in slot of small bore in cylinder. Applysilicone to all O-rings (inset).

2. If previously removed, install the O-rings in the I.D. andO.D. of the range position.

NOTE: Because the collar becomes distorted whencompressed, DO NOT REUSE OLD NYLON COLLAR.


3. Position new gasket on housing. Install rangepiston yoke, piston and retaining nut intoTighten retaining nut to recommended torque.

cylinder,housing.Install 4

capscrews into range cylinder housing and tighten torecommended torque.

4. Place range cylinder cover and new gasket on rangecylinder, install 4 capscrews and tighten to recom-mended torque.

F. Reassembly and Installationof Splitter Cylinder Assembly

1. If previously removed, install the small O-ring in thecylinder housing bore.

2. If removed, install the O-ring on the piston O.D. (left).Insert the yoke bar in the cylinder housing bore (right).


3. If previously removed, install the insert valve, flat end tothe outside, and the valve retaining nut in the bottombore of the cylinder cover. Tighten to recommendedtorque ratings.

NOTE: Prior to installation of the insert valve, makesure the three O-rings on the valve O.D. are not defec-tive. Replace, if necessary.

G. Reassembly of Auxiliary RearBearing Assembly

1.

H.

Place the rear bearing cone over the bearing and intothe rear bore. Align the .125 shim over the cone andinstall the rear bearing cover with four (4) capscrewstighten only till snug (right). Retaining straps may alsobe used at this time they are required for horizontalinstallation. Complete assembly by installing remainingrear bearing cover (left).

Installation of Range YokeCapscrews and RecommendedTorque of Auxiliary Drive Gear Nut

1. Install the 2 capscrews into the range yoke and tightento recommended torque (right). Tighten auxiliary drivegear retaining nut to recommended torque (left).

4. Place the new splitter cylinder gasket, splitter cylinderassembly, new splitter cylinder cover gasket and split-ter cylinder cover onto the auxiliary housing. Install 4capscrews into the assembly and tighten to recom-mended torque.

REASSEMBLY - AUXILIARY SECTION1. Installation of Splitter Sliding Clutch

and Yoke

1. Place splitter shift yoke into splitter sliding clutch slot.Install assembly onto auxiliary section engaging thesliding clutch teeth into the auxiliary drive gear clutchingteeth and splitter yoke onto yoke bar align Iockscrewtighten to recommended torque and lockwire.

DISASSEMBLY - FRONT SECTION

RETAINER GEAR - AUXILIARY DRIVE

RING

SNAP RING

Cut 6416- 8/92

A. Removal Front Auxiliary Drive Gear

1. Remove snap ring from mainshaft rear groove. 2. Remove the splined washer from inside front auxiliarydrive gear assembly.


4. Remove front auxiliary drive gear from mainshaft.

3. Remove six capscrews from the auxiliary bearing re-tainer ring. Insert three puller screws in the speciallytapped holes of retainer ring. Tighten screws evenly topull the front auxiliary drive gear assembly from casebore.

5. Remove the spline d washer from the mainshaft alsoremove the front auxiliary drive gear retaining snap ringfrom the mainshaft.

DISASSEMBLY-FRONT SECTION

Cut 6382-9 /80

B. Removal and Disassembly of LeftReverse Idler Gear Assembly

1. Move the mainshaft reverse gear as far to the rearas possible and remove the snap ring from I.D. ofgear.

2. Move the reverse gear forward and against the LOspeed gear, engaging the splines of mainshaftsliding clutch.


3. Using inside jaw pullers or impact puller, remove theauxiliary countershaft front bearing race from leftreverse idler gear bore. If necessary, repeat theprocedure for removing the auxiliary countershaft frontbearing race from right reverse idler gear bore.

5. Remove the pipe plug from rear of idler shaft and usean impact puller, 1/2"-13 threaded end, to remove shaftfrom case bore (inset).

4. Loosen the nut on the idler shaft, (inset). Remove thestop nut and washer from front of idler shaft.

6. As the idler shaft and idler plate are moved to the rear,remove the thrust washer, and gear from case. If nec-essary, remove the inner race from bearing andremove needle bearing from idler gear.

DISASSEMBLY-FRONT SECTIONc. Removal of Countershaft Bearings

NOTE: In the following instructions, the frontand rear bearings from BOTH countershafts areremoved. For removal of the mainshaft assemblyfrom case, it is necessary to remove the bearingsfrom right countershaft ONLY.

1. Remove snap ring from each countershaft rear groove.

3. Loosen and remove capscrew from retainingplate on upper countershaft front.

2. From inside the case, use a soft bar and maul todrive the countershaft rear bearings to the rearand from case bores.

NOTE: This procedure will damage the bearingsand should not be attempted unless replacementof the bearings is planned.

4. Use a soft bar and maul to drive each countershaftto the rear as far as possible. This partially unseats the front bearings.

NOTE: The soft bar should have a flattened end that islarge enough so damage to the countershaft end doesnot occur.


5. From the rear of the countershaft drive the shaftforward to unseat the front bearing from the front casebore to expose the bearing snap ring.

6. Use a bearing puller or pry bars to remove thecountershaft front bearings.

NOTE: The front roller bearing inner race will remainpressed on the front countershaft.


D. Removal and Disassembly of MainshaftAssembly

1. Block the right countershaft assembly againstcase wall and pull the mainshaft assembly to therear to free pilot from input shaft pocket. Tilt frontof mainshaft up and lift the assembly from case(inset). Use caution as the reverse gear is free andcan fall from shaft.

2. Remove the 3rd-4th speed sliding clutch frommainshaft front.


3. Remove the reverse gear and spacer from main-shaft rear.

5. Turn the reverse gear limit washer to align itssplines with those of the mainshaft and removewasher.

4. From mainshaft rear, pull the key from mainshaftkey way.

NOTE: When removing limit washers, spacers andgears, note their location on mainshaft to facili-tate reassembly. Keep the internal-spl inedwashers and external-splined spacers with thegear from which they were removed. There isONLY one limit washer and one spacer belongingto each gear. 6. Remove the LO-Reverse speed sliding clutch from

mainshaft.


7. Using a small screwdriver, turn the limit washer inhub of LO speed gear to align its splines withthose of the mainshaft. Pull the LO speed gearfrom rear of mainshaft to remove limit washer,spacer, and gear. If necessary, remove the snapring from I.D. of gear (inset).

8. Remove each remaining gear, limit washer, spacer,and sliding clutch from mainshaft in the samemanner previously detailed. And, if necessary, re-move the snap ring from I.D. of each gear.


E. Input Shaft Removal

1. Remove the input bearing snap ring from shaft. 2. Use a soft mallet to drive the input shaft toward the rearof the transmission. Pull the shaft forward and repeatas necessary.


3. Use pry bars to complete the input shaft bearingremoval (left). Remove spacer from input shaft (right).

5. Inspect the input shaft bushing for wear and replace ifnecessary.

6. The main drive gear can be removed from the case thistime.

4. Push input shaft through the drive gear and remove theinput shaft from case.

NOTE: The input shaft is a NON-SERVICABLEassembly excluding the sealing rings and should bereplaced if damaged.

NOTE: Input shaft can be serviced without removingthe main shaft. Remove the snap ring and input shaftbearing remove the internal snap ring from the drivegear and remove the input shaft.


F. Removal and Disassembly ofCountershaft Assemblies

NOTE: Except for the PTO gears, the left and rightcountershaft assemblies are identical and disas-sembled in the same manner.

1. Move the right countershaft assembly to the rear as far. .

as possible so front of shaft can be removed from casebore and moved to the center of the case. Lift the

2. Remove the drive gear retaining snap ring from front ofeach countershaft.

assembly from case and repeat the procedure for leftcountershaft assembly.

NOTE: The left and right reverse idler gear assembliesare identical and disassembled in the same manner. Ifremoval and disassembly of this assembly is neces-sary, refer to Part B of this section.


3. Use the rear face of 3rd speed gear as a base, pressthe drive gear, PTO gear, and 3rd speed gear fromeach countershaft. This removes the front bearing innerrace from the countershaft.

IMPORTANT: NEVER USE THE PTO GEAR AS APRESSING BASE. The narrow face width of this gearmakes it very susceptible to breakage.

4.

G.

Disassembly is complete at this point due to the weldedcountershaft design. Replacement of reverse, low firstand 2nd speed gears will be completed as an assemblygears are not available separately.

Removal and Disassembly of RightReverse Idler Gear Assembly

NOTE: To remove the right reverse idler gear assemblysee section B. The right and left reverse idler gearassemblies are disassembled in the same manner.

DISASSEMBLY - FRONT SECTIONH. Disassembly Auxiliary Drive Gear

Assembly

1. Remove the retaining ring from the front of the auxiliarydrive gear (left) remove the snap ring from the auxiliarydrive gear hub (right).

3. If necessary, remove the O-rings from hub O.D. offront auxiliary drive gear.

2. Using the rear face of retainer ring as a base,Dress the drive aear throuah bearina.

Ò

REASSEMBLY - FRONT SECTIONA. Reassembly of Auxiliary Drive Gear

Assembly

NOTE: If previously removed, install the O-rings onextended front hub of front auxiliary drive gear.

1. Install the retainer ring on front auxiliary drive gear,snap ring groove facing front hub and away from gearteeth.

2. Start the front auxiliary drive gear bearing on front hub,bearing snap ring facing groove in retainer ring. Useboth hands, press the bearing on gear with snap ring ingroove of retainer ring (inset).

3. Install the snap ring into its groove (left) place the outerretainer ring and seat with the proper driver (right).

REASSEMBLY - FRONT SECTIONCASE ASSEMBLIESNOTE: Before starting reassembly, make sure the threemagnetic discs are solidly in place at bottom of case. Thesecan be secured to disc mounting surfaces with Scotch GripRubber Adhesive or equivalent adhesive.

C. Reassembly and Installation of RightReverse Idler Gear Assembly

2. Install the bearing inner race on idler shaft and insertshaft into case bore, threaded-end of shaft to the front.As the idler shaft is moved forward, install the reverseidler gear on shaft, long hub to the front and seating onbearing inner race. Position the thrust washer on shaftbetween the gear and support boss in case and con-tinue with movement of idler shaft forward into bore ofSupport boss.

1. If previously removed, thread pipe plug in rear of re-verse idler shaft and tighten. Install the thrust washer tothe end of the idler shaft.

NOTE: If previously removed, replace the needle bear-ing into bore of reverse idler gear.

3. Making sure that the reverse idler shaft is seated inbore of support boss and forward as far as possible,install the washer and stop nut on front of shaft. Tightennut to recommended torque rating.

REASSEMBLY - FRONT SECTION

4. Install the OUTER RACE of auxiliary countershaft frontbearing into case bore.

NOTE: The bearing INNER RACE is installed on frontof auxiliary countershaft and never with outer race.

C. Reassembly of CountershaftAssemblies

NOTE: Except for the PTO gears, the left and rightcountershaft assemblies are identical and reassembledin the same manner.

NOTE: Reverse low, 1st and 2nd speed gears are partof the shaft and are note serviceable.

1. Press the 3rd speed gear on the countershaft, long hubof gear to countershaft front.


2. Start the PTO gear onto countershaft, bullet-nose sideof teeth facing up and toward rear of shaft. Align key-way of drive gear with key in countershaft and pressBOTH gears onto shaft, long hub of drive gear againstPTO gear.

NOTE: The left countershaft assembly has a 47-toothPTO gear; the right countershaft assembly has a 45-tooth PTO gear.

3. To avoid confusion during installation, mark the end ofleft countershaft with an "L", the end of right counter-

4. Install the drive gear retaining snap ring in groove onfront of each countershaft.

5. Use a flanged-end driver to install bearing inner race oncountershaft, shoulder of race against shoulder of coun-tershaft.

shaft with an "R".

REASSEMBLY - FRONT SECTIONE. Partial Installation of Countershaft

Assemblies

IMPORTANT: Mark the countershaft drive gear for timingpurposes. On the drive gear of each countershaft assem-bly, mark the tooth aligned with keyway of gear andstamped with an "O" for easy identification. A highly visiblecolor of toolmakers' dye is recommended for making timingmarks.

1. Place the left countershaft assembly into position incase, making sure that the "L"-marked assembly hasthe larger 47-tooth PTO gear. Place the right counter-shaft assembly into position in case, making sure thatthe "R"-marked assembly has the smaller 45-tooth PTOgear.

REASSEMBLY-FRONT SECTIONF. Bearing Installation of Left Countershaft

Assembly

1. Move the left countershaft assembly to the rearand insert countershaft support tool or blockingto center shaft in rear case bore.

3. Center the front of left countershaft in bearing andmove the assembly forward.

2. Use a flanged-end bearing driver to start thebearing in case bore.

NOTE: The inner race of roller-type front bearingis pressed on front of countershaft.

4. Use a flanged-end bearing driver to completelyseat front bearing or bearing outer race in casebore.

REASSEMBLY - FRONT SECTIONF. Reassembly, Installation and Timing of

Main Drive Gear Assembly

5. Position the retainer plate on front of left countershaft,roll pin in hole at end of shaft, and secure with capscrewtightening to recommended torque.

1. Install the snap ring in I.D. of main drive gear.

6. Remove countershaft support tool or blockingfrom rear case bore and install the left counter-shaft rear bearing with larger I.D. lead chamfer tothe front of shaft and install the snap ring ingroove at rear of left countershaft.

2. Mark the main drive gear for timing purposes.Mark any two adjacent teeth on drive gear and re-peat the procedure for the two adjacent teethdirectly opposite the first set marked. A highly vis-ible color of toolmakers' dye is recommended formaking timing marks.


3. Mesh the marked tooth of left countershaft drivegear with either set of two marked teeth on maindrive gear. Slide the input shaft through the maindrive gear (inset).

4. Install drive gear spacer. Install the bearing on the inputshaft with external snap ring to the outside (inset). Setinput shaft bearing into the bore of the case front.

5. Place two lifting eyes with capscrews over bearingsnap ring to temporary secure bearing in transmissionbore.

6. Use a soft bar and maul to drive the input shaft throughbearing. Remove front bearing cover.

7. Install bearing retainer snap ring to secure input shaft incase bore. Remove the two capscrew and lifting eyes.

REASSEMBLY - FRONT SECTIONH. Reassembly and Partial Installation of

1.

2.

3.

Mainshaft AssemblyIf previously removed, install the correspondingsnap rings in I.D. of mainshaft gears.

Secure the mainshaft in a vise equipped withbrass jaws or wood blocks, pilot-end of shaftdown. If previously removed, install the roll pin inkeyway.

Install the 3rd speed gear limit washer on main-shaft, flat side of washer up. Rotate washer in the1st or bottom groove of mainshaft to align thesplines of washer with those of the mainshaft. in-stall the key in mainshaft keyway to lock washerin place.

4.

5.

Install the spacer on shaft against washer.

Install the 3rd speed gear on mainshaft, clutchingteeth down and engaged with external splines ofspacer.NOTE: Gear limit washers are internally splinedand locked to mainshaft by the key. Gear spacersare externally splined to engage with clutchingteeth in gear hubs. There is one limit washer andone spacer for each gear in the mainshaft as-sembly.

REASSEMBLY—FRONT SECTION

Setting Correct AxialClearances For MainshaftGears

Axial Clearance (End-Play) Limits Are:.005’’ -.012” for all mainshaft gears

Washers are used to obtain the correct limits; sixthicknesses are available as follows:

LIMITS (INCH) COLOR CODE

.248 -.250 WHITE

.253 -.255 GREEN

.258 -.260 ORANGE

.263 -.265 PURPLE

.268 -,270 YELLOW

.273 -.275 BLACK* “PLUS RED”

*NOTE: New style tolerance washers come in a fullrange of tolerances as corresponding colors listedabove “plus red.” (Example: “Orange plus red” limitwasher has an inch limit thickness of .258-.260.)

Refer to Illustrated Parts Lists for washer part num-bers.

Always use the .248 -.250 tolerance washer (“White”or “white plus red”) in the reverse, LO and 2nd speedgear positions as shown at right.

IMPORTANT: REFER TO THE APPROPRIATEILLUSTRATED PARTS LIST(SPECIFIED BY MODEL SE-RIES) TO ENSURE THATPROPER PARTS ARE USEDDURING REASSEMBLY OF THETRANSMISSION.

REASSEMBLY-FRONT SECTION

6. Install the 2nd speed gear on shaft against 3rdspeed gear, clutching teeth up.

7. Install the spacer in 2nd speed gear, engaging theexternal splines of spacer with clutching teeth ofgear.

8. Remove the key from keyway and install the 2ndspeed gear limit washer on mainshaft, flat side ofwasher down and against spacer. Rotate washer inthe 2nd groove of mainshaft to align the splines ofwasher with those of the mainshaft and reinsertkey in keyway to lock washer in place (inset).

9. Insert two large screwdrivers between the 2nd and3rd speed gears to check axial clearances. Applyslight downward pressure on screwdriver handlesto spread gears evenly. Making sure the gear hubsare parallel, insert a feeler gage between hubs.Correct axial clearance is less than the minimum.005" to .012" If the clearance is less than theminimum .005" tolerance, the limit washer in the2nd speed gear should be replaced by a thinnerlimit washer. This will increase the axial clearancebetween the gears. If the clearance checked isgreater than the maximum .012" tolerance, athicker limit washer should be installed in the 2ndspeed gear. This would decrease the axial clear-ance between the gears.


10. Install the 1st-2nd speed sliding clutch, aligningthe missing internal spline of sliding clutch withkey in mainshaft.

11. Remove the key from keyway and install the 1stspeed gear limit washer on mainshaft, flat side ofwasher up. Rotate washer in the 2nd groove ofmainshaft to align the splines of washer withthose of the mainshaft and reinsert key in key-way to lock washer in place.

12. Install spacer and 1st speed gear on the main-shaft, clutching teeth down and engaged with en-ternal splines of spacer.

13. Install the LO speed gear on shaft against 1stspeed gear, clutching teeth up.


14. Install the spacer in LO speed gear, engaging theexternal splines of spacer with clutching teeth of

16. Check axial clearances and make adjustments, ifnecessary, between the LO and 1st speed gearsas described in No. 9 of this section.

17. Install the LO-Reverse speed sliding clutch,aligning the missing internal spline of slidingclutch with key in mainshaft.

15. Remove the key from keyway and install the LOspeed gear limit washer on mainshaft, flat side ofwasher down and against spacer. Rotate washerin the 4th groove of mainshaft to align thesplines of washer with those of the mainshaftand reinsert key in keyway to lock washer inplace.


18.

19.

Remove the key from keyway and install the re-verse gear limit washer on mainshaft, flat side ofwasher up. Rotate washer in the 5th groove ofmainshaft to align the splines of washer withthose of the mainshaft and reinsert key in key-way to lock washer in place.

Install the spacer on shaft against washer.

20. Install reverse gear on mainshaft. Engage theclutching teeth of gear with splines of spacerand sliding clutch and move the reverse gearagainst the LO speed gear.

NOTE: DO NOT REPLACE REVERSE GEAR lN-TERNAL SNAP RING AT THIS STEP

21. Remove the mainshaft assembly from vise. Alignthe missing internal spline of 3rd-4th speed slid-ing clutch with key in mainshaft and install onfront of shaft, engaging the external splines ofsliding clutch with clutching teeth of 3rd speedgear.


22. Block the right countershaft assembly againstcase wall and lower the mainshaft assembly intoposition with the reverse gear held against LOspeed gear and rear of shaft moved into casebore.

23. Move the pilot-end of mainshaft into pocketbushing of input shaft.

.24. With the reverse gear remaining against LO

speed gear, mesh the corresponding forwardspeed gears of left countershaft assembly.Check to make sure that marked tooth on leftcountershaft drive gear has remained in meshwith marked set of teeth on main drive gear.

25. Center rear of mainshaft in case bore and installthe auxiliary drive gear assembly on shaft, par-tially seating the bearing in bore. DO NOT COM-PLETE INSTALLATION AT THIS TIME.

REASSEMBLY - FRONT SECTION. ñ -

1. Remove blocking from right countershaft a s -sembly and place it parallel to mainshaft as-sembly. Mesh the marked tooth of r ightcountershaft drive gear with remaining set of twomarked teeth on main drive gear.

2. Insert countershaft support tool or blocking inrear bearing bore.

3. Position the front countershaft bearing in frontbearing bore. Use the proper bearing driver to set the bearing in bore (left). Install retainer washer and capscrew. Make sure to match roll pin in retainer with inner bearing hole (right).

4. Tighten capscrew to the recommended torque.

H. Bearing Installation and Timing of Right Countershaft AssemblyIMPORTANT: The left countershaft assemblyMUST remain in time with main drive gear whentiming right countershaft assembly.


5. Position the countershaft rear bearing in rear bearingbore. Use the proper bearing driver to seat bearing inbore.

6. With bearing installation complete, install the snap ringin right countershaft rear groove.

7. Move the reverse gear to the rear on mainshaft and usea screwdriver to engage sliding clutches with all forwardspeed gears. A sliding clutch that will not engage with agear indicates the gear set is not in proper mesh. Thebearings of the right countershaft would then need tobe removed and the drive gear set retimed.

NOTE: Do not engage sliding clutches with more thanone gear at the same time. This will lock the gearingand prevent the mainshaft and countershaft assembliesfrom rotating.

REASSEMBLY - FRONT SECTION1. Reassembly and Installation of Left

Reverse Idler Gear AssemblyNOTE: Since the left and right reverse idler gearassemblies are identical, reassembly and installation ofthe left reverse idler gear assembly should beperformed at this time as described in Part C of thissection.

J. Completed Installation of Mainshaftand Auxiliary Drive Gear Assemblies

3. Install the snap ring in hub of reverse gear and movethe reverse gear forward on mainshaft and into properposition in case.

1. Move the reverse gear to the rear as far as possible,meshing teeth of gear with those of the reverse idlergears.

4. Install snap ring on mainshaft snap ring groove.

2. Align the external splines of spacer with clutching teethof reverse gear and move spacer forward on themainshaft and into reverse gear.

5. Install splined washer on mainshaft splines behind re-verse gear.


6. Reinstall the front auxiliary drive gear assembly on rearof mainshaft. Use a flanged-end driver and maul to setbearing in case bore.

7. Align the six capscrew holes in retainer with the tappedholes in case and install capscrews. Tighten to recom-mended torque ratings and lockwire the capscrews ingroups of three.

9. Install the snap ring in groove at end of mainshaft.

8. Install splined washer on mainshaft splines behindauxiliary drive gear.

INSTALLATION - TORQUE CONVERTER HOUSING OUTPUTYOKE, AUXILIARY SECTION AND SHIMMING PROCEDUREA.

B.

Installation of Torque ConverterHousingNote: The transmission rear must be blocked so thetwo aligning pins on the transmission rear case are notdamaged. If the auxiliary section has been installed thetransmission can be placed vertically on a stand usingan output flange or half round yoke affixed to a largeplate.

Care must be taken when placing thetransmission in the vertical position.

Always use safety chains on the transmission. Assurethat the transmission is stable in the vertical positionbefore removing the safety chains.

Installation of the Inertia Brake

1.

c.

2. Place the oil pump on the torque converter housingopening (left). Install the two retaining capscrews andproperly torque the capscrews (right).

3. Install the oil pump drive gear on the pump shaft andthread retaining locknut in place (left). Block the oilpump drive gear and tighten lock nut to proper torque.

Place the inertia brake, gasket and six (6) retainingcapscrews on the transmission case (left). Tighten thesix (6) retaining capscrews to required torquespecifications.

Installation of the Torque ConverterHousing 4. Place the torque converter housing gasket and torque

converter housing onto the front of the main case (left).Install the four (4) retaining capscrews and six (6)retaining nuts and properly torque each retainer (right).

1. If the pressure relief valve was replaced check forproper seating and secure the valve (left). Afterreplacing the filter by-pass valve the valve should beproperly seated and secured (right). 5. Install the sta \tor support and gasket over the input shaft

down into the torque converter housing (left). Install thesix (6) retaining capscrews and properly torquecapscrews.

108

INSTALLATION - TORQUE CONVERTER HOUSING OUTPUTYOKE, AUXILIARY SECTION AND SHIMMING PROCEDURED. Installation of Oil Pan, Pick Up and

Screen and Oil Filter Assembly

3. Place the oil pan over pick-up and screen onto thetorque converter housing (left). Secure the oil pan tothe torque converter housing with the retainingcapscrews (right).

1. Install the oil filter o-ring seal, oil filter and oil filterhousing onto the torque converter housing and tightenthree (3) retaining capscrews to required torque.

4. Install the oil sump return tube to the oil pan. Check thefittings at the oil pan and transmission for proper torque.

E. Installation of the Hydraulic Valve

2. Place the oil pan gasket on the mounting surface andinstall the pick-up screen assembly in place with thethree (3) retaining capscrews.

1. If the electronic solenoids were removed place themback on the hydraulic valve and secure them with theirretaining nuts (left). Place the two (2) gaskets andmounting plate on hydraulic valve (right).

NOTE: Gaskets to hydraulic valve are marked forproper installation. The mounting plate should bechecked for proper alignment.

INSTALLATION - TORQUE CONVERTER HOUSING OUTPUTYOKE, AUXILIARY SECTION AND SHIMMING PROCEDURE

2. Install the hydraulic valve on the torque converterhousing and align mounting holes (left). Install the ten(10) retaining capscrews into the hydraulic valve. Notetwo (2) of the retaining capscrews are allen headcapscrews check their location (right).

NOTE: The transmission dipstick tube can bereinstalled on the transmission at this time.

F. Installation of the Torque Converter2. After the torque converter is properly seated exposing

the snap ring groove install the snap ring.

1. Install two (2) lifting eyes into the converter pilotcapscrew holes. Attach a lifting chain to lifting eyeslower torque onto the input shaft into the torqueconverter housing.

NOTE: The torque converter may not seat itselfcompletely on the shaft. Care must be taken duringinstallation. Do not force the torque converter onto theinput shaft as damage to internal splines will occur.

3. Install the torque converter pilot into the torqueconverter and properly seat the converter pilot (left).Install the eight (8) retaining capscrews into theconverter pilot and properly torque the capscrews(right).

The splines on the input shaft must match those internalto the torque converter interrupt clutch splines. Notmatching these splines will not allow the torqueconverter to properly slide onto the input shaft.

INSTALLATION - CLUTCH HOUSING, OUTPUT YOKE,AUXILIARY SECTION AND SHIMMING PROCEDUREG. Installation of Output Yoke

NOTE: Replacement of seal and slinger must becompleted prior to yoke or flange installation.

1. Install speedometer gear or spacer on output shaft.

2. Place output yoke or flange onto the output shaft.

3. Install washer and output nut onto the output shaft.

NOTE: It will be necessary to temporarily lock the trans-mission in two gears by moving sliding into gear for finaltorque procedure.

4. Complete installation process by torquing the outputshaft nut to recommended torque.

INSTALLATION - CLUTCH HOUSING, OUTPUT YOKE,AUXILIARY SECTION AND SHIMMING PROCEDUREH.

1.

2.

Installation of the Auxiliary Sectionand Shimming Procedure

Tighten the middle bolt on each countershaft strap untilthe countershaft are snug. Shift the reduction slidingclutch into reduction. Attach a chain hois to the outputshaft.

NOTE: The front box sliding clutches must be in theneutral position.

With the transmission set in the vertical position, block

4. Remove the countershaft straps. Make sure a 0.125countershaft rear bearing shim is installed. Be sure thecountershaft rear bearing races are seated in the bear-ing bores.

under the torque converter housing to prevent damageto the torque converter, position the new gasket on thetransmission case. Lower the auxiliary assembly on thefront case rear.

IMPORTANT: Shift the reduction sliding clutch intodeep reduction before installing the auxiliary.

5. Install two clean 3/8" x 1" capscrews without washersdirectly across from each other in each bearing cover.Tapped holes in auxiliary case must be free of threadadhesive.

3. Install the retaining capscrews in the housing flangeand tighten to the recommended torque.

INSTALLATION - CLUTCH HOUSING, OUTPUT YOKE,AUXILIARY SECTION AND SHIMMING PROCEDURE

6. Tighten the capscrews to 7 in./lbs. of torque DO NOTINSTALL THE COUNTERSHAFT REAR BEARINGCOVER GASKET.

8. Remove the countershaft rear bearing covers andgauging shims.

7. Rotate the output shaft six times in the clockswise direc-tion, then six times counterclockwise to seat the coun-tershaft rear bearings. Use a feeler gauge, as close toone capscrew location as possible, and measure thegap between the countershaft rear bearing cover andthe auxiliary case. Record the measurement. Using theaverage measurement, refer to page 115 in this Ser-vice Manual. Select the numbers in the left column thatcompare to the avereage measurement recorded fromthe countershaft rear bearing cover. Follow the columnto the right to identify the proper shim to be used in thecountershaft shim bores. Duplicate this procedure forthe other countershaft rear bearing cover.

9. After the correct shim has been selected, place theshim on the rear countershaft bearing race, install thecountershaft rear bearing cover and gasket. Check forproper shim alignment if misaligned rear bearing covermay be damaged when proper torque is applied. Posi-tion a new gasket on each countershaft rear bearingcover mounting surface and install both rear bearingcovers. Install and tighten the capscrews to the recom-mended torque.

INSTALLATION - SHIFTING CONTROLSA. Installation Shift Bar Housing

1. Place all three mainshaft sliding clutches in the neutralposition. Install shift bar housing gasket in position.

3. Install the thirteen capscrews in shift bar housing andtighten to recommended torque rating.

NOTE: There are two sizes of capscrews. The 11/2"capscrews are used with lifting eyes.

2. With all three shift yokes in the neutral position, installthe shift bar housing assembly on case, fitting the shiftyokes into the slots of the corresponding slidingclutches.

INSTALLATION - SHIFTING CONTROLSC. Installation of Slave Valve

1. If previously removed, install the air line fittingson slave valve.

3. Install the hat-type alignment sleeve in bore ofslave valve.

2. Install the spring on shank of actuating pin and in-sert in bore of transmission case.

4. Position gasket on valve mounting surface (inset)and install the slave valve on case, inserting theend of actuating pin into alignment sleeve. Securethe valve to case with four capscrews tightenevenly to recommended torque rating.

INSTALLATION - SHIFTING CONTROLS

3. Connect the 1/4 air line from the inertia brake to the airfilter regulator at solenoid. Also connect the two (2) airlines from the slave valve to the range cylinder, LOrange connects to the front of the cylinder and HI rangeconnects to the rear (left). Connect the 1/4 air line to theTCB-6 air fitting also connect the hydraulic valve wiringharness at connector (right).

1. Place the inertial brake air hose and wiring harness onthe transmission.

4. Connect the wiring harness clamps to the shift barhousing capscrews (left). Connect the input speedsensor and engine speed sensor at each connector asshown.

2. Install the two capscrews into the air filter regulator andtighten to proper torque.

5. Install the Roadranger valve cover and slide threeairlines through cover. Install the jam nut on the shiftlever. Thread the Roadranger valve on shift lever andsecure by tightening jam nut against valve.

INSTALLATION - SHIFTING CONTROLS

6. Connect the red air line to the "S" or Supply Port andthe black air line to the "P" or End Port of the slavevalve. Tighten fittings securely.

7. Connect the red air line to the "S" or Supply Port andthe black air line to the "P" Port and the blue line to the"SP" on the roadranger valve.

8. Connect the blue air line to the splitter cylinder cover.Tighten fittings securely.

9. Position valve cover on Roadranger valve and secureby tightening the two mounting screws in cover.

SHIMMING CHARTAverage the feeler gauge measurement and match the measurement to the “Feeler Gauge Average Gap” in the left column.Follow the column to the right to identify the “Shim Thickness”, “Part Number”, and “Color Code” to be used.

FEELER GAUGE SHIM STANDARD SHIM OIL PUMP SHIMAVERAGE GAP

COLOR CODETHICKNESS PART NUMBER PART NUMBER

.088-.089 .042-.043 21454 21474 BROWN

.085-.0875 .045-.046 21455 21475 TAN

.082-.0845 .048-.049 21456 21476 ORANGE

.079-.0815 .051 -.052 21457 21477 YELLOW

.076. -0785 .054-.055 21458 21478 GREEN

.073. -0755 .057-.058 21459 21479 LIGHT BLUE

.070-.0725 .060-.061 21460 21480 LAVENDER

.067-.0695 .063-.064 21461 21481 WHITE

.064-.0665 .066-.067 21684 21686 BLACK

.061-.0635 .069-.070 21685 21687 SILVER

.058-.0605 .072-.074 21452+21452 21472+21472 RED + RED

.055-.0575 .075-.077 21452+21453 21472+21473 RED + PINK

.052-.-0545 .078+.080 21452+21454 21472+21474 RED + BROWN

.049-.0515 .081 -.083 21452+21455 21474+21475 RED + TAN

.046-.0485 .084-.086 21452+21456 21472+21476 RED + ORANGE

.043-.0455 .087-.089 21452+21457 21472+21477 RED + YELLOW

.040-.0425 .090-.092 21452+21458 21472+21478 RED + GREEN

.038-.0395 .093-.095 21452+21459 21472+21479 RED + LT. BLUE

If the transmission is equipped with an auxiliary countershaft oil pump use the fourth column to identify the oil pump shim.

TRSM-001108/92 PDFPrinted in USA

The Roadranger® System is an unbeatable combination of the best products from Eaton and Dana – partnering to provide you the most advanced, most trouble-free drivetrain in the industry. And it’s backed by the Roadrangers – the most experienced, most expert, most accessible drivetrain consultants in the business.

For spec’ing or service assistance, call 1-800-826-HELP (4357) 24 hours a day, 7 days a week, (Mexico: 001-800-826-HELP (4357)) for more time on the road. Or visit our web site at www.roadranger.com.

Copyright Eaton and Dana Corporation, 2002. EATON AND DANA CORPORATION hereby grants its customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. THIS INFORMATION IS NOT INTENDED FOR SALE OR RE-SALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.

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