Fuller Automated Transmissions TRSM0011: Service Manual

Service Manual
Fuller Automated Transmissions

TRSM0011
October 2007
RTLO-11118A-MT
RTLO-9118A-MT
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 HOUSING
DISASSEMBLY - 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOREWORD
This manual is designed to provide detailed information reassembly on page 35. Instructions for installation are on
necessary to service and repair the Fuller¬ Transmissions page 111. Service Manuals, Illustrated Parts Lists, Drivers
listed on the cover. Instructions, and other forms of product service information
As outlined in the Table of Contents, the manual is for these and other Fuller Transmissions are available upon
divided into 3 main sections: request. You may also obtain Service Bulletins, detailing
a. Technical information and reference information on product improvements, repair procedures
b. Removal, disassembly, reassembly and and other service-related subjects by writing to the followi ng
installation address:
The format of the manual is designed to be followed in its
entirety if complete disassembly and reassembly of the EATON CORPORATION
transmission is necessary. But if only one component of the TRANSMISSION DIVISION
transmission needs to be repaired, refer to the Table of Technical Service Department
Contents for the page numbers showing that component. P.O. Box 4013
For example, if you need to work on the Shifting Controls, Kalamazoo, Michigan 49003
you will find instructions for removal, disassembly and (61 6) 342-3344
Every effort has been made to ensure the accuracy of all inf ormation in this brochure. However, Eaton Transmission Division
makes no expressed or implied warranty or representation based on the enclosed information. Any errors or omissions may
be reported to Training and Publications, Eaton Transmission Division, PO. Box 4013, Kalamazoo, Ml 49003.
MODEL DESIGNATIONS
AND SPECIFICATIONS
Nomenclature:
IMPORTANT: All Fuller Transmissions are identified by

model and serial number. This information is stamped on
the transmission identification tag and affixed to the case.
DO NOT REMOVE OR DESTROY THE TRANSMISSION
IDENTIFICATION 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 is
approximately 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 proper
grade and type of lubricant to level of filler opening. See LUBRICATION.
Proper Lubrication. . .
the Key to long transmission life
Proper lubrication procedures are the key to a good all-around maintenance program. If the oil is not doing its
job, or if the oil level is ignored, all the maintenance procedures in the world are not going to keep the
transmission running or assure long transmission life.
® ®
Eaton Fuller Transmissions are designed so that the internal parts operate in an oil bath circulated by the
motion 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 operating
temperatures. Transmission oil temperature is sensed from the torque converter outlet port before the oil
enters the cooler.
o
Normal operating temperature, when sensed from the torque converter outlet port, should be below 250 F;
o
however, intermittent operating temperatures to 300 F do not harm the transmission. A dash light will signal
o
high oil temperatures, 250 F or higher.
On vehicles equipped with two transmission oil temperature gauges, one gauge (required) senses torque
converter oil as mentioned above, while the other gauge (optional) reads oil temperature from the transmission
sump. The sump temperature represents oil that has circulated through the cooler. This temperature is
o o
normally below 225 F; however, intermittent sump temperatures to 250 F do not harm the transmission.
When the average temperature of the transmission oil exceeds the temperature limits as stated above, more
frequent oil changes may be needed.
The following conditions in any combination can cause the recommended transmission oil temperatures to be
exceeded: (1) operating the transmission in a “stall” condition while in the converter ratios; i.e., extended
operation while in gear with the vehicle stopped or slowly moving, (2) high density of starts and stops at slow
operating 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 as

Related to Transmission Operating Angles
If the transmission operating angle is more than 12°, improper lubrication can occur. A special kit may be
required 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 idle
speed in the neutral position using the corresponding temperature band. Cold checks can be performed when
o
the oil temperature is 60–120 F. The oil level should be within the dipstick “cold” band. Additional checks can
be made with the transmission at operating temperature by using the “hot” band on the opposite side of the
o
dipstick. The “hot” band temperature range is 180-220 F.
OPERATION
18-Speed Transmission
Shift Lever Patterns and Shifting Controls
SHIFT LO-1-2-3-4 IN
LO RANGE.
RANGE SHIFT . . .
AND SHIFT 5-6-7-8 IN
HI RANGE.
OVERDRIVE
WHILE IN LO AND HI RANGE . . .

Ratios can be split by
moving the splitter
Control Button to the
forward position.
ROAD RANGER VALVE

(A-5013)
SPLITTER CONTROL BUTTON

FORWARD REARWARD For
For OVERDRIVE DIRECT
6
POWER FLOW
The 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 repair
becomes necessary.
Parts Identification
POWER FLOW
Torque Converter Mode
Power Flow: LO Range (see figure A)
1. Power (torque) from the vehicle’s engine is transferred 8. Torque is delivered along both countershaft to mating
to the torque converter’s drive spline. countershaft gear of the “engaged” mainshaft gear (1st
gear in this example.)
2. The impeller spins directing oil to the torque converter
turbine. 9. The internal clutching teeth in the engaged mainshaft
gear hub, transfers torque to the mainshaft through the
3. The oil flow hits the turbine causing the turbine to
sliding clutch.
rotate. The power is related to the speed difference
between the impeller and the turbine. 10. The mainshaft transfers torque directly to the auxiliary
drive gear.
4. The turbine is connected to the interrupt clutch housing.
The interrupt clutch inner hub is splined directly to the 1. The auxiliary drive gear splits torque between the two
transmission input shaft. auxiliary countershaft drive gears.
5. When the interrupt clutch is activated the housing and 2. Torque is delivered along both countershaft to the
the inner hub are connected to complete the "(engaged” LO range gear on the range mainshaft or
mechanical link and transfers power to the input shaft. output shaft.
6. Input shaft splines engage the internal splines in the 3. Torque is transferred to the output shaft through a
main drive gear hub. sliding clutch.
7. Torque is split between the two countershaft drive 4. Torque is delivered to the driveline as LO RANGE 1st.
gears.
Lockup Mode (see figure B)

1. Power (torque) from the vehicle’s engine is transferred 4. The interrupt clutch inner hub is splined directly to the
to the torque converter’s drive spline. transmission input shaft.
2. The drive spline is connected to the lockup clutch. 5. When the interrupt clutch is activated, the torque is
transmitted directly from the engine to the input shaft
3. The lockup clutch is splined directly to the interrupt
from the lockup clutch. The losses from the slippage in
clutch outer hub. When the lockup clutch is activated,
the torque converter are eliminated in this manner.
the interrupt clutch is driven directly from the engine.
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 auxiliary
main drive gear hub. drive gear.
7. Torque is split between the two countershaft drive 11. The auxiliary drive gear transfers torque directly to the
gears. range mainshaft or output shaft through the “engaged”
sliding clutch.
8. Torque is delivered along both countershaft to mating
countershaft gear of the “engaged” mainshaft gear. 12. Torque is delivered through the output shaft to the
driveline as HI RANGE 5th.
9. The internal clutching teeth in the engaged mainshaft
gear hub transfers torque to the mainshaft through the
sliding clutch.
POWER FLOW
9
POWER FLOW
The transmission must efficiently transfer the engine’s power, in terms of torque, to the vehicle’s rear wheels. Knowledge of
what takes place in the transmission during torque transfer is essential when troubleshooting and making repairs.
Front Section Power Flow
(LO Range Direct)
1. Power (torque) from the vehicle’s engine is transferred 6. Mainshaft transfers torque directly to rear auxiliary drive
to the transmission’s torque converter. gear.
2. Splines of input shaft engage internal splines in hub of 7. The rear auxiliary drive gear splits torque between the
main drive gear. two auxiliary countershaft drive gears.
3. Torque is split between the two countershaft drive 8. Torque is delivered along both auxiliary countershaft
gears. to the “engaged” reduction gear on output shaft.
4. Torque is delivered along both countershaft to mating 9. Torque is transferred to output shaft through sliding
countershaft gears of “engaged” mainshaft gear. The clutch.
following cross section views illustrate a 1st/5th speed
gear engagement. 10. Output shaft delivers torque to driveline.
5. Internal clutching teeth in hub of engaged mainshaft

gear transfers torque to mainshaft through sliding
clutch.
LO RANGE DIRECT
\ I
POWER FLOW
Auxiliary Section Power Flow:
LO RANGE OVERDRIVE
7. The front auxiliary drive gear splits torque between the 9. Torque is transferred to the output shaft through sliding
two auxiliary countershaft drive gears. clutch.
8. Torque is delivered along both countershaft to 10. Torque is delivered to driveline as LO RANGE 1st gear
“engaged” LO RANGE gear on range mainshaft or OVERDRIVE.
output shaft.
LO RANGE OVERDRIVE

HI RANGE DIRECT
7. The rear auxiliary drive gear transfers torque directly to 8. Torque is delivered through the output shaft to driveline
the output shaft through ‘(engaged” sliding clutch. as HI RANGE 5th gear.
POWER FLOW
HI RANGE OVERDRIVE
7. The front auxiliary drive gear splits torque between the 9. Torque is transferred to output shaft through the sliding
two auxiliary countershaft drive gears. clutch.
8. Torque is delivered along both auxiliary countershaft 10. Output shaft delivers torque to driveline as HI Range
to mating countershaft gears of “engaged” rear auxiliary 5th gear OVERDRIVE.
drive gear.
HI RANGE OVERDRIVE
TIMING
Timing Procedures: All Models
It is essential that both countershaft assemblies of C. Meshing marked countershaft drive gear teeth
the front and auxiliary sections are “timed. ” This as- with marked main drive gear teeth.
sures proper tooth contact is made between main- (After placing the mainshaft assembly into case,
shaft gears seeking to center on the mainshaft the countershaft bearings are installed to com-
during torque transfer and mating countershaft gears plete installation of the countershaft assemblies.)
that distribute the load evenly. If not properly timed, 1. When installing the bearings on left counter-
serious damage to the transmission is likely to result shaft, mesh the marked tooth of countershaft
from unequal tooth contact causing the mainshaft drive gear with either set or two marked teeth
gears to climb out of equilibrium. on the main drive gear.
Timing is a simple procedure of marking the appro- 2. Repeat the procedure when installing the
priate teeth of a gear set prior to installation and bearings on right countershaft, making use of
placing them in proper mesh while in the transmis- the remaining set of two marked teeth on the
sion. In the front section, it is necessary to time only main drive gear to time assembly.
the drive gear set. And depending on the model, only
the LO range, deep reduction, or splitter gear set is
timed in the auxiliary section.
Front Section
A. Marking countershaft drive gear teeth.
1. Prior to placing each countershaft assembly
Countershaft gear teeth
into case, clearly mark the tooth located
meshed with drive gear teeth
directly over the keyway of drive gear as for correct timing.
shown. This tooth is stamped with an “O” to
Cut 7300 F-1 1/86
aid identification.
Tooth on Countershaft
Auxiliary Section
directly over Keyway A. Timing the auxiliary countershaft and LO range
marked for timing gear.
1. Mark any two adjacent teeth on the LO range
gear of set to be timed. Then mark the two ad-
jacent teeth located directly opposite the first
Cut 7300 H11/86 set marked as shown in Illustration B.
2. Prior to placing each auxiliary countershaft as-
sembly into housing, mark the tooth stamped
B. Marking main drive gear teeth. with an “O” on gear to mate with timed main-
1. Mark any two adjacent teeth on the main drive shaft gear as shown in Illustration A.
gear. 3. Install the LO range gear on the out put shaft
2. Mark the two adjacent teeth located directly and into the auxiliary case.
opposite the first set marked on the main drive 4. Seat the auxiliary countershaft bearings.
gear. As shown below, there should be an 5. Install the rear bearing cover and tighten to
equal number of unmarked gear teeth on each recommended torque.
side between the marked sets. 6. Place the auxiliary countershaft assemblies
into position and mesh the marked teeth of the
mating countershaft gears with the marked
teeth of the LO range gear as shown in illustra-
Dive gear teeth correct/y tion C.
marked for timing.
Cut 7300G.11/86
13
TORQUE RECOMMENDATIONS
Correct 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 cause
damage to transmission gears, shafts, and/or bearings. Use a torque wrench whenever possible to attain
recommended lbs./ft. ratings. Do not torque capscrews dry.
TORQUE RECOMMENDATIONS
TOOL REFERENCE
Some 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 the
recommended as they make transmission repair easier, individual user. Detailed Fuller Transmission Tool Prints are
faster, and prevent costly damage to critical parts. available upon request by writing.
But for the most part, ordinary mechanic’s tools such as Eaton Corporation
socket 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 4013
Fuller Transmission. Kalamazoo, Michigan 49003
PAGE TOOL HOW OBTAINED
45 Countershaft Retaining Strap Made from Fuller Transmission

Print T-64553
45 Auxiliary Section Hanger Bracket Made from Fuller Transmission

Print 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
Made from Fuller Transmission

91 Countershaft Support Tool
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 oil
pan. 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 exact
amount of oil depends on the transmission inclination and model. Insufficient oil damages the pump and other
components, 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 or
water 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 for
five (5) minutes, (this allows oil to fill the converter, main case, and cooling system), add oil as needed to
obtain a level at the proper temperature range. Total oil quantity needed at this time should be
approximately 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 idle
speed in neutral, again adding oil to obtain a level at the proper temperature range.
4. Replace the dipstick and tighten securely,
Hydraulic System Flush Procedure
A 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. 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.
2. Disconnect the transmission cooler supply line between the transmission outlet and the oil cooler (not between
the cooler and the transmission oil pan).
3. With 80 PSI clean, dry air from a hose and nozzle, use a rubber stopper or clean rag to seal the air hose to the
converter outlet hose.
4. Apply air to the converter outlet for approximately two minutes to backfush oil into the transmission oil pan.
5. Disconnect oil lines and dipstick tube from the sump pan.
6. Remove and clean the sump pan.
7. Remove the oil strainer/tube from the torque converter housing.
8. Remove the oil strainer from the tube and clean.
9. Assemble the oil strainer on the tube.
10. 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. Install the sump pan. Tighten the retaining capscrews to 14 to 20 Lbf.ft of torque.
12. Connect oil lines and dipstick tube.
13. Connect the hose between the transmission and cooler. Tighten to vehicle manufacturer’s specifications.
14. Install the transmission converter housing oil pan drain plug and tighten to 14 to 20 Lbf.ft of torque.
15. Install the transmission main case drain plug (rear @ bottom) and tighten to 45 to 50 Lbf.ft of torque.
16. Remove the transmission dipstick and slowly pour 7 gallons of Dexron® II fluid into the transmission.
17. Apply the vehicle parking brakes and place the transmission lever in neutral. Start the engine and let is idle for
five minutes. Check the dipstick periodically while the engine is idling, adding oil at needed, to obtain a level
that is in the cold band on the dipstick. Total quantity added at this time should be approximately 10 gallons.
18. With the transmission still in neutral, increase the engine idle speed to 1500 RPM and retain at this speed for
five minutes. Now check the oil level at normal engine idle speed in neutral, again adding oil as required for a
level 1 1/2” below the “add-hot” mark on the dipstick. Total oil quantity added at this time should be approximately
11 gallons.
o
Transmission temperature ( F)
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, use

Fuller thread sealant/adhesive #71205 on all
capscrews.
1. Install a new gasket.
2. Using the 2 screws, install the oil filter

transfer tube. Tighten the screws to 14-20
Lb f.ft of torque.
3. Check the strainer for contaminants. If

needed, wash the strainer in clean solvent.
5. Install the return hose/tube.
4. Position the oil sump pan. Install the

retaining capscrews in oil sump pan. Tighten
the capscrews to 14-20 L bf.ft of torque.
19
Transmission Oil Filter Change Procedure
Transmission 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 and

loosening, use Fuller thread
sealant/adhesive #71 205 on all
capscrews.
Note: Item numbers refer to the illustration
Preventive Maintenance Checks

1 — 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.
2 — Air System
●Annually replace the filter regulator element. If excessive contamination is present, service vehicle
air/dryer system. The “MT” 18-Speed requires clean, dry air for proper operation. Check vehicle air
dryer system regularly for proper operation.
3 — Dipstick
● Monitor oil level.
● Add oil if necessary.
● Tighten dipstick securely.
4 — 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.
5 — Capscrews and Gaskets
●Check all capscrews, especially those on the PTO covers and rear bearing covers for looseness
which 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 faulty
gaskets.
PRECAUTIONS
Disassembly
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 from
shift 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. BEARINGS - Carefully wash and relubricate all tershafts, mainshaft, or main drive gear. Special
reusable bearings as removed and protectively procedures are required and provided in this man-
wrap until ready for use. Remove bearings planned ual.
to be reused with pullers designed for this pur- 5. CLEANLINESS - Provide a clean place to work. It
pose. is important that no dirt or foreign material enters
2. ASSEMBLIES - When disassembling the various the unit during repairs. Dirt is an abrasive and can
assemblies, such as the mainshaft, countershaft, damage bearings. It is always good practice to
and shift bar housing, lay all parts on a clean clean the outside of the unit before starting the
bench in the same sequence as removed. This pro- planned disassembly.
cedure will simplify reassembly and reduce the 6. WHEN USING TOOLS TO MOVE PARTS - Always
possibility of losing parts. apply force to shafts, housings, etc, with restraint.
3. SNAP RINGS - Remove snap rings with pliers de- Movement of some parts is restricted. Never apply
signed for this purpose. Snap rings removed in this force to the part being driven after it stops solidly.
manner can be reused, if they are not sprung or The use of soft hammers, bars and mauls for all
loose. disassembly work is recommended.
4. INPUT SHAFT - The input shaft can be removed
from transmission without removing the coun-
lnspection
Before reassembling the transmission, check each part carefully for abnormal or excessive wear and damage to
determine reuse or replacement. When replacement is necessary, use only genuine Fuller Transmission parts to
assure continued performance and extended life from your unit.
Since the cost of a new part is generally a small fraction of the total cost of downtime and labor, avoid reus-
ing a questionable part which could lead to additional repairs and expense soon after initial reassembly. To aid
in determining the reuse or replacement of any transmission part, consideration should also be given to the
unit’s history, mileage, application, etc.
Recommended inspection procedures are provided in the following checklist.
A. BEARINGS B. GEARS
1. Wash all bearings in clean solvent. Check 1. Check gear teeth for frosting and pitting.
balls, rollers and raceways for pitting, discol- Frosting of gear tooth faces present no threat
oration, and spalled areas. Replace bearings of transmission failure. Often in continued
that are pitted, discolored, or spalled. operation of the unit, frosted gears will “heal”
2. Lubricate bearings that are not pitted, discol- and not progress to the pitting stage. And in
most cases, gears with light to moderate pit-
ored, or spalled and check for axial and radial
ted teeth have considerable gear life remain-
clearances.
ing and can be reused. But gears with
3. Replace bearings with excessive clearances. advanced stage pitting should be replaced.
4. Check bearing fits. Bearing inner races 2. Check for gears with clutching teeth abnor-
should be tight to shaft; outer races slightly mally worn, tapered, or reduced in length
tight to slightly loose in case bore. If bearing from clashing in shifting. Replace gears
spins freely in bore, however, case should be found in any of these conditions.
replaced.
PRECAUTIONS
Inspection (cont’d.) H. GEAR SHIFT LEVER HOUSING
3. Check axial clearance of gears. Where excessive ASSEMBLY
clearance is found, check gear snap ring, washer, 1. Check spring tension on shift lever. Replace
spacer, and gear hub for excessive wear. tension spring and washer if lever moves too
Maintain .005” to .012“ axial clearance between freely.
mainshaft gears.
2. If housing is disassembled, check spade pin and
C. SPLINES corresponding slot in lever for wear. Replace both
parts if excessively worn.
1. Check splines on all shafts for abnormal wear. If
sliding clutch gears, companion flange, have worn I. BEARING COVERS
into the sides of the splines, replace the specific
shaft affected. 1. Check covers for wear from thrust of adjacent
bearing. Replace covers damaged from thrust of
D. TOLERANCE WASHERS bearing outer race.
1. Check surfaces of all tolerance washers. Washers 2. Check bores of covers for wear. Replace those
scored or reduced in thickness should be worn oversize.
replaced.
J. SLIDING CLUTCHES
E. REVERSE IDLER GEAR ASSEMBLIES
1. Check all shift yokes and yoke slots in sliding
1. Check for excessive wear from action of roller clutches for extreme wear or discoloration from
bearings. heat.
F. GRAY IRON PARTS 2. Check engaging teeth of sliding clutches for
partial engagement pattern.
1. Check all gray iron parts for cracks and breaks.
Replace or repair parts found to be damaged. K. SYNCHRONIZER ASSEMBLY
G. SHIFT BAR HOUSING ASSEMBLY 1. Check synchronizer for burrs, uneven and
excessive wear at contact surface, and metal
1. Check for wear on shift yokes and blocks at pads particles.
and lever slot. Replace excessively worn parts.
2. Check blocker pins for excessive wear or
2. Check yokes for correct alignment. Replace looseness.
sprung yokes.
3. Check synchronizer contact surfaces on the
3. Check Iockscrews in yokes and blocks. Tighten auxiliary drive and low range gears for excessive
and rewire those found loose. wear.
4. If housing has been disassembled, check neutral
L. O-RINGS
notches of shift bars for wear from interlock balls.
1. Check all O-rings for cracks or distortion. Replace
if worn.
PRECAUTIONS
Reassembly
Make sure that interiors of case and housings are clean. It is important that dirt and other foreign materials be
kept out of the transmission during reassembly. Dirt is an abrasive and can damage polished surfaces of
bearings and washers. Use certain precautions, as listed below, during reassembly.
1. GASKETS - Use new gaskets throughout the 6. AXIAL CLEARANCES - Maintain original axial
transmission as it is being rebuilt. Make sure all clearances of .005” to .012” for mainshaft gears.
gaskets are installed. An omission of any gasket 7. BEARINGS - Use of flanged-end bearing drivers is
can result in oil leakage or misalignment of recommended for the installation of bearings.
bearing covers. These special drivers apply equal force to both
2. CAPSCREWS - To prevent oil leakage, use Loctite bearing races, preventing damage to balls/rollers
242 thread sealant on all capscrews. For torque and races while maintaining correct bearing align-
ratings, see TORQUE RECOMMENDATIONS. ment with bore and shaft. Avoid using a tubular or
3. O-RINGS - Lubricate all O-rings with silicone lu- sleeve-type driver, whenever possible, as force is
bricant. applied to only one of the bearing races. See
TOOL REFERENCE.
4. ASSEMBLY - Refer to the illustrations provided in
the detailed disassembly instructions as a guide 8. UNIVERSAL JOINT COMPANION FLANGE OR
to reassembly. YOKE - Pull the companion flange or yoke tightly
into place with the output shaft nut, using 450-500
5. INITIAL LUBRICATION - Coat all limit washers foot-pounds of torque. Make sure the speedome-
and splines of shafts with Lubriplate during reas- ter drive gear or a replacement spacer of the same
sembly to prevent scoring and galling of such width has been installed. Failure to pull the com-
parts. panion flange or yoke tightly into place will permit
the output shaft to move axially with resultant
damage to the rear bearing.
IMPORTANT: REFER TO THE APPROPRIATE ILLUSTRATED PARTS LIST (SPECI-

FIED BY MODEL SERIES) TO ENSURE THAT PROPER PARTS ARE
USED DURING REASSEMBLY OF THE TRANSMISSION.
CHANGING INPUT SHAFT
Special Procedure
In some cases, it may become necessary to replace the input shaft due to excessive wear on the splines. Except for removal
of the shift bar housing assembly, the input shaft can be removed without further disassembly of the transmission. Removal of
the 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 Reassembly
1. Remove the gear shift lever housing assembly (or re- 1. If necessary, install bushing in pocket of input shaft.
mote control assembly) from shift bar housing, and the
2. Install new input shaft into splines of main drive gear,
shift bar housing assembly from transmission case.
just far enough to expose snap ring groove in I.D. of
2. Remove the bearing retaining snap ring from groove in drive gear.
shaft.
3. Install snap ring in snap ring groove inside drive gear.
3. Push down on input shaft to cock bearing in bore. Drive
4. Install drive gear spacer on input shaft.
input shaft toward rear of transmission, through bearing
as far as possible. Pull input shaft forward to expose 5. Install drive gear bearing on input shaft and into case
snap ring of bearing. bore.
4. Use pry bars to complete removal of bearing. 6. Install bearing retainer snap ring.
5. Remove drive gear spacer and snap ring. 7. To facilitate proper reinstallation of the shift bar housing
assembly on case, make sure mainshaft sliding
6. Pull input shaft forward and out of drive gear and case.
clutches are placed in the neutral position.
8. Reinstall the shift bar housing assembly, the front
bearing cover and all other parts and assemblies
previously removed, making sure to replace the
gaskets used.
25
AIR SYSTEM
AIR SYSTEM
RANGE SHIFT AIR SYSTEM
Operation B. If the air lines are crossed between the slave
valve and range cylinder, the transmission
The Range Shift Air System consists of the air filter/
gearing will not correspond with the range se-
regulator, slave valve, a Range Control Valve or Mas-
lection. A LO RANGE selection will result in a
ter Control Valve, range cylinder, fittings and
HI RANGE engagement and vice versa.
connecting air lines. See Air System Schematics.
CONSTANT AIR from the air filter/regulator is sup-
2. AIR LEAKS
plied to the “S” or Supply Port of slave valve and
With the gear shift lever in neutral, coat all air
passed through to the INLET or “S” Port of control
lines and fittings with soapy water and check for
valve.
leaks, moving the control that provides range se-
WHILE IN LO RANGE, the control valve is OPEN lection UP and DOWN.
and AIR is returned to slave valve at the “P” or End
Port. This signals the valve to supply AIR in line be- A. If there is a steady leak from the exhaust port
tween the LO Range or “L” Port of slave valve and of control valve, O-rings and/or related parts
the LO Range Port of range cylinder housing. AIR re- of the control valve are defective.
ceived at this port moves the range piston to the rear
B. If there is a steady leak from breather of slave
and causes the auxiliary LO RANGE gear to become
valve: an O-ring in valve is defective, or there
engaged.
is a leak past O-rings of range cylinder piston.
WHILE IN HI RANGE, the control valve is CLOSED
and NO AIR is returned to the slave valve. This C. If transmission fails to shift into LO RANGE
signals the slave valve to supply AIR in line between or is slow to make the range shift and the
the HI Range or “H” Port of valve and the HI Range case is pressurized, see Check No. 7 of this
Port of range cylinder cover. AIR received at this port section.
moves the range piston forward to engage the aux-
iliary drive gear with sliding clutch and bypass the D. Tighten all loose connections and replace de-
LO RANGE gear set. fective O-rings and parts.
Range shifts can be made ONLY when the gear
shift lever is in, or passing through, neutral. Thus, the 3. AIR FILTER/REGULATOR
range desired can be PRESELECTED while the shift (See illustration, Page 26.)
lever is in a gear position. As the lever is moved With the gear shift lever in neutral, check the
through neutral, the actuating plunger in the shift bar breather of air filter/regulator assembly. There
housing releases the slave valve, allowing it to move should be NO AIR leaking from this port. The
to the selected range position. complete assembly should be replaced if a
steady leak is found.
Trouble Shooting Cut off the vehicle air supply to the air fiIter/
regulator assembly, disconnect the air line at fit-
If the transmission fails to make a range shift or ting in Supply OUTLET and install an air gage in
shifts too slowly, the fault may be in the Range Shift opened port. Bring the vehicle air pressure to nor-
Air System or actuating components of the shift bar mal. Regulated air pressure should be 57.5 to 62.5
housing assembly. Psi.
To locate the trouble, the following checks should
DO NOT ADJUST SCREW AT BOTTOM OF REGU-
be made with normal vehicle air pressure applied to
LATOR TO OBTAIN CORRECT READINGS. The
the system, but with the engine off.
air regulator has been PREADJUSTED within the
NEVER WORK UNDER A VEHICLE correct operating limits. Any deviation from these
WHILE ENGINE IS RUNNING as limits, especially with regulators that have been
personal injury may result from the sudden and unin- in operation for some time, is likely to be caused
tended movement of vehicle under power. Always by dirt or worn parts. If replacement or cleaning
place transmission in the neutral position. of the filter element does nothing to correct the
air pressure readings, replace the complete as-
sembly, as the air regulator is nonserviceable.
1. INCORRECT AIR LINE HOOK-UPS
(See Air System Schematics)
4. RANGE VALVE (See Page 27.)
With the gear shift lever in neutral, move the con-
trol that provides range selection UP and DOWN. With the gear shift lever in neutral, select HI
A. If the air lines are crossed between control RANGE and disconnect the air line at the OUT-
valve and slave valve, there will be CON- LET or “P” Port of control valve.
STANT AIR flowing from the exhaust port of
control valve WHILE IN HI RANGE.
AIR SYSTEM
A. When LO RANGE is selected, a steady blast 6. LO RANGE OPERATION
of air will flow from opened port. Select HI With the gear shift lever in neutral, select HI
RANGE to shut off air flow. This indicates the RANGE and disconnect the 1/4” I.D. air line at the
control valve is operating properly. Reconnect fitting on range cylinder housing. Make sure this
air line. line leads from the LO Range or “L” Port of slave
valve.
B. If control valve does not operate properly,
check for restrictions and air leaks. Leaks in- A. When LO RANGE is selected, a steady blast
dicate defective or worn O-rings. of air should flow from disconnected line. Se-
lect HI RANGE to shut off air flow.
5. HI RANGE OPERATION
With the gear shift lever in neutral, select LO B. Move the shift lever to a gear position and se-
RANGE and disconnect the 1/4” I.D. air line at the lect LO RANGE. There should be NO AIR flo-
port of range cylinder cover. Make sure this line wing from disconnected line. Return the gear
leads from the HI Range or “H” Port of slave shift lever to the neutral position. There
valve. should now be a steady flow of air from dis-
connected line. Select HI RANGE to shut off
A. When HI RANGE is selected, a steady blast of air flow and reconnect air line.
air should flow from disconnected line. Select
LO RANGE to shut off air flow. C. If the air system does not operate accord-
ingly, the slave valve or actuating components
B. Move the shift lever to a gear position and se-
of the shift bar housing assembly are defec-
lect HI RANGE. There should be NO AIR flow-
tive.
ing from disconnected line. Return the gear
shift lever to the neutral position. There 7. RANGE CYLINDER (Refer to the following
should now be a steady flow of air from dis- illustration.)
connected line. Select LO RANGE to shut off If any of the seals in the range cylinder assembly
air flow and reconnect air line. are defective, the range shift will be affected.
C. If the air system does not operate accord- A. Leak at either O-ring A results in complete
ingly, the slave valve or actuating components failure to make a range shift; steady flow of
of the shift bar housing assembly are defec- air from breather of slave valve in both
tive. ranges.
B. Leak at gasket B results in a steady flow of air
IMPORTANT: RANGE PRESELECTION
to atmosphere while in HI RANGE.
The plunger pin, located in case bore between
the slave valve and actuating plunger of shift bar C. Leak at O-ring C results in a slow shift to LO
housing, prevents the slave valve from operating RANGE; pressurizing of transmission case.
while the shift lever is in a gear position. When
the lever is moved to or through the neutral po-
sition, the pin is released and the slave valve be-
comes operational.
Cut 7420-5/87
Range Cylinder Assembly—All Models
28
AIR SYSTEM
AIR 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 VALVES
POPPET-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 correct
plunger pin, spring, and alignment sleeve during installation on the transmission will cause hard shifting in LO
Range gears.
AIR SYSTEM
ROADRANGER VALVE A-5013
Removal and Disassembly 7. If necessary, remove the spring and O-ring from
1. Remove two screws holding bottom cover to valve bores in left housing.
and slide cover down gearshift lever to expose air 8. If necessary, remove the springs, O-ring and
line fittings. Disconnect air lines. sleeve from bores in right housing.
2. Loosen jam nut and turn control valve from gear
shift lever. Reassembly and Installation
3. Pry medallion from recess in top cover.
1. Refer to the drawing for proper reassembly. Use a
4. Turn out the two screws to remove the top cover VERY SMALL amount of silicone lubricant on the
from valve housing. O-rings to avoid clogging ports. A small amount of
grease on the position springs and balls will help
5. Turn out the two screws in side of valve housing to to hold them in place during reassembly
separate the housing.
2. Install control valve on gear shift lever and tighten
6. Remove the Range Preelection Lever from left jam nut.
housing and the position balls and guide from
lever. 3. Attach air lines and install bottom cover.
AIR SYSTEM
SPLITTER SHIFT AIR SYSTEM:
Operation Trouble Shooting
In addition to the various components of the Range Shift If the transmission fails to shift or shifts too slowly
Air System, the Splitter Shift Air System utilizes a splitter to or from the “split” position, the fault may be in the
cylinder and the Roadranger Valve A-5013. See Air System Splitter Shift Air System or related components of
Schematics. the Range Shift Air System.
CONSTANT AIR from the air filter/regulator assembly is To locate the trouble, the following checks should
be made with normal vehicle air pressure supplied to
supplied to the splitter cylinder at the port on right side of
the system, but with the engine off.
cylinder cover. The Insert valve installed in cover (see Page
30) provides the proper air flow needed to move the splitter NEVER WORK UNDER A VEHICLE
piston in the cylinder (rearward to engage rear auxiliary WHILE ENGINE IS RUNNING as
drive gear for operation in direct; forward to engage the personal injury may result from the sudden and unin-
front auxiliary drive gear for operation in overdrive). tended movement of vehicle under power. Always
WHILE IN HI OR LO RANGE, AIR needed to make the place transmission in the neutral position
splitter selection and complete the shift is supplied to the
Roadranger valve from the fitting at the “S” Port of slave NOTE: It is assumed that correct PSI readings were
valve. When the overdrive selection is made, the AIR obtained from the air filter/regulator and all
passes through the Roadranger valve and is supplied to the air lines have been checked for leaks.
Left Port of cylinder cover. 1. Air Supply (See Air System Schematics.)
With Splitter Control Button in the “DIRECT”/ With the gear shift lever in neutral, select HI or
REARWARD position, the “SP” Port of the Roadranger LO RANGE and loosen the connection at the “S”
valve is CLOSED and NO AIR is supplied to the Left Port of Port of the Roadranger Valve until it can be deter-
the Splitter cylinder cover. mined that AIR is supplied to valve. Reconnect air
line.
If there is NO AIR, check for a restriction in the
air line between the Roadranger valve and slave
valve. Make sure this line is connected to fitting
at the supply Port of slave valve.
2. Roadranger Valve (See Page 27 and Air System
Schematics.)
Button REARWARD With the gear shift lever in neutral, disconnect
(“SP” Port CLOSED) the air line at the Left Port of splitter cylinder
cover, making sure this line leads from the “SP”
While in HI or LO Range the button can be moved Port of the Roadranger Valve.
FORWARD to operate in ‘OVERDRIVE. The "SP" Port A. WHILE IN HI or LO RANGE, move the Splitter
of valve is OPENED when overdrive is selected, sup- Control Button FORWARD. There should be
plying AIR to the Left Port of the Splitter cylinder AIR flowing from disconnected line. Move the
cover. button REARWARD to shut off air flow and re-
connect air line.
B. If the preceding conditions do not exist, the
Roadranger valve is defective, or there is a re-
striction in the air lines.
3. Splitter Cylinder. (Refer to the following illustra-
tion.)
If any of the seals in the splitter cylinder as-
Button FORWARD
sembly are defective, the splitter shift will be af-
(“SP” Port OPENED) fected. The degree of air lost will govern the
degree of failure, from slow shifting to complete
shift failure.
A. Leak at O-ring A results in a slow shift to
engage rear auxiliary drive gear pressurizing of
transmission case; auxiliary gearing can be dis-
engaged.
AIR SYSTEM
B. Leak at O-ring B results in slow shifting or 4. Insert Valve (See Page 30.)
complete failure to engage and disengage Any constant flow of air from exhaust port of cyl-
front or rear auxiliary drive gearing; steady inder cover usually indicates a faulty insert valve.
flow of air from exhaust port of Roadranger Exhaust should occur ONLY BRIEFLY when Split-
valve and/or cylinder cover when Splitter Con- ter Control Button is moved REARWARD WHILE
trol Button is in the REARWARD position. IN LO and HI RANGE.
C. Leak at gasket C results in a slow shift to dis- A faulty insert valve, leaking at the O-rings of
engage rear auxiliary drive gear; steady flow valve O.D. or from inner seals results in constant
of air to atmosphere. air 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 be
replaced. However, if an inner seal is damaged,
the complete assembly MUST be replaced.
AIR SYSTEM
INSERT VALVE:
(EQUIPPED WITH ROADRANGER VALVE A-5013)
The insert valve is a self-contained 1-3/16" valve as- NOT be disassembled except for the three O-rings on
sembly located in the splitter cylinder cover. It CAN- outer diameter. The O-rings provide a stationary seal
and do not move in cylinder.
PORT
SIGNAL LINE FROM When installing the insert valve in bottom edge of
CONTROL VALVE cover, apply Fuller #71206 silicone lubricant or its
“SP” PORT equivalent to O-rings and cylinder walls. Install valve
in bore with flat surface to the outside. When install-
RETAINING NUT
ing the special valve retaining nut, apply Fuller
#71204 adhesive/sealant or its equivalent to threads
and tighten. See TORQUE RECOMMENDATIONS.
Travel of the small insert valve piston is only 3/16”.
As shown in the illustrations below, when NO AIR is
applied to the top side of valve piston, CONSTANT
-INSERT VALVE
AIR supplied from the regulator passes to the
FRONTSIDE of cylinder piston, moving the yoke bar
backward to engage the REAR AUXILIARY DRIVE
GEAR (LO RANGE DIRECT AND HI RANGE DIRECT).
The piston moves up to cut off air to the back side of
the 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 passing
air through the bottom of insert valve to the front and
backside of the cylinder piston, moving the yoke bar
FORWARD engaging the FRONT AUXILIARY DRIVE
Cut 7441A-11/87 SUPPLY PORT GEAR (LO RANGE OVERDRIVE AND HI RANGE
OVERDRIVE).
OVERDRIVE
LOW RANGE AND HIGH RANGE DIRECT
NO AIR ON SIGNAL LINE
CONSTANT AIR
RTO-15618 and RTLO-XX618 Models
LO Range L
A-5013 Roadranger
Valve
Slave Valve
Rearward Identification
Down
®
Fulerl
Transmissions
A-5000 Valve
19470 Valve
P S SP
19470 or A-5000 Slave Valve
HI
S P
LO
Schematic
For all questions

concerning
removal and
replacement, Air Filter/Regulator Splitter Cylinder Range Cylinder Assembly
refer to Eaton Assembly Assembly
Service and Parts SP
Literature. No Air Air to
LO Housing
Port
Air from
Vehicle
Source
Constant Air No Air

HI
LO Range H
A-5013 Roadranger
Valve
Slave Valve
Forward Identification
Down
®
Fulerl
Transmissions
A-5000 Valve
19470 Valve
P S SP
HI
S P
LO
Schematic
For all questions

concerning
removal and
Air Filter/Regulator Splitter Cylinder Range Cylinder Assembly replacement,
Assembly Assembly refer to Eaton
SP
Service and Parts
Air to Literature.
LO Housing
Port
Air from
Vehicle
Source
Constant Air No Air

HI
HI Range L
A-5013 Roadranger
Valve Slave Valve
Rearward Identification
Up
®
Fulerl
Transmissions
A-5000 Valve
19470 Valve
P S SP
HI
S P
LO
Schematic
For all questions

concerning
removal and
replacement, Air Filter/Regulator Splitter Cylinder Range Cylinder Assembly
refer to Eaton Assembly Assembly
Service and Parts SP
No Air
Literature. No Air
LO
Air from
Vehicle
Source
Constant Air Air to Cover

Port HI
HI Range H
A-5013 Roadranger
Valve Slave Valve
Forward Identification
Up
®
Fulerl
Transmissions
A-5000 Valve
19470 Valve
P S SP
HI
S P
LO
Schematic
For all questions

concerning
removal and
Air Filter/Regulator Splitter Cylinder Range Cylinder Assembly replacement,
Assembly Assembly refer to Eaton
SP
Service and Parts
No Air
Literature.
LO
Air from
Vehicle
Source
Constant Air Air to Cover

Port
HI
DISASSEMBLY SHIFTING CONTROLS
AIR SYSTEM
3. Turn out the two mounting screws in the Roadranger

valve cover.
A. Removal of Air Controls
1. Disconnect the two air lines at the "S" or Supply Port
and "P" or End Port of the slave valve on the
transmission case. Disconnect the three 1/4" rubber
lines from the slave valve.
4. Slide the cover down to expose the valve ports and

disconnect the three air lines.
2. Remove the air line at the splitter cylinder cover (A).

Then remove the three (3) 1/4 rubber lines at the range
cylinder (B).
NOTE: If equipped with a shift lever the gear shift lever
housing assembly can now be removed from shift bar
housing by removing the four capscrews from the
tower.
NOTE: The Roadranger valve mounted in the cab can
be removed as shown.
5. Loosen the jam nut and turn the valve and nut from
gear shift Iever. Remove the valve cover, air lines,
sheathing and O-rings from lever.
B. Removal of Air
Filter/Regulator Assembly
6. Remove retaining capscrews on the shift bar housing

which hold wiring harness clamps (left). Disconnect
input speed sensor and engine speed sensor at wiring
harness connectors (right).
Turn
1. out the two capscrews and remove the air filter/
regulator assembly.
7. Disconnect the 1/4" air hose at the inertia brake solenoid
also disconnect the remaining air hose to the splitter NOTE: For disassembly and reassembly of Air Filter/
cylinder (left). Remove the air hose at the inertia brake Regulator Assembly, see Page 26.
housing also disconnect the hydraulic valve wiring
harness connector (right).
8. Remove the wiring harness and inertia brake air hose Turn
2. out the four retaining capscrews and remove slave
from the transmission. valve from transmission case.
3. If necessary, remove the air line fittings from slave

valve.
NOTE: For disassembly and reassembly of piston-type
Slave Valve Assembly, see Page 26.
DISASSEMBLY AND REASSEMBLY
SHIFT BAR HOUSING
SHIFT BAR HOUSING ASSEMBLY
A. Removal and Disassembly of the Shift

Bar Housing Assembly
For models equipped with an Oil Pump
and/or Cooler Assemblies, make sure t o
disconnect the lube line at the fitting on the shift
bar housing before doing the followin g
instructions.
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 housing sion springs and balls from the housing bores.
from the transmission case. Remove the gasket.
NOTE: During disassembly, lay all parts on a

clean bench in order of removal from the housing
to make reassembly easier. Shift bars not being re-
moved must be kept in the neutral position or the
interlocking parts will lock the bars.
SHIFT BAR HOUSING
3. Secure the assembly in a vise with the plunger- 5. Move the 1st-2nd speed shift bar to the housing
side up. (The front of the housing will be to the rear, removing the yoke and block from the bar. As
left.) For models so equipped, cut the lockwire the neutral notch in the bar clears the rear boss,
and turn out the retaining capscrews to remove remove the small interlock pin from the bore.
the oil trough from the housing.
NOTE: Start with the upper shift bar, move all bars
to the right and out the rear boss bore. Cut the
lockwire and remove the Iockscrews from each bar
just before their removal.
4. Move the 3rd-4th speed shift bar to the housing 6. Remove the actuating plunger from the center
rear, removing the yoke and block from the bar. boss bore.
SHIFT BAR HOUSING
B. Reassembly of the Shift Bar Housing
Assembly.
7. Move the short LO-Reverse speed shift bar to the 1. If previously removed, install the reverse-stop
housing rear, remove the yoke from the bar. As the plunger in the LO-Reverse shift yoke, making sure
shift bar is removed from the housing, two 3/4 in- the plunger is fully seated in the yoke slot bore.
terlock balls will drop from the rear boss bottom
bore.
8. If necessary, remove the plug, spring, and reverse- 2. Install the spring in the yoke bore and on the
stop plunger from the LO-Reverse speed shift plunger shank.
yoke bore.
SHIFT BAR HOUSING
3. Install the plug and tighten to compress the

spring (left). Back the plug out 1 - 1 1/2 turns and
stake the plug through the small hole in the yoke
(right.)
5. While holding the plunger shank, install the ac-

tuating plunger in the center boss bore.
4. Secure the shift bar housing in a vise. Hold the 6. Install one 3/4" interlock ball in the rear boss top
notched-end of the short LO-Reverse speed shift bore. This ball rides between LO-Reverse and 1st-
bar, install the bar in the lower bore of the shift bar 2nd speed shift bars.
housing bosses. Install the yoke Iockscrew,
tighten and wire securely.
NOTE: Start with the lower shift bore of the rear

boss and move to the left (front of the housing).
Keep bars in the neutral position during installa-
tion. DO NOT EXCEED the recommended torque
ratings for the yoke Iockscrews as over-tightening
may distort the shift bars.
SHIFT BAR HOUSING
7. While holding the notched-end of the bar, install 9. While holding notched-end of the bar, install the
the 1st-2nd speed shift bar in the housing boss 3rd-4th speed shift bar in the housing boss upper
middle bore. Position the shift block on the bar be- bore, position the shift block on the bar between
tween the center and rear bosses, and the yoke on the front and center bosses, long hub to the
the bar between the front and center bosses, long housing rear. Install the block and yoke lock-
hub to the housing front. Just before inserting the screws, tighten, and lockwire securely.
notched-end of the rear boss bar, install the small
interlock pin VERTICALLY in the neutral notch 10. For models so equipped, install the oil trough on
bore. Install the block and yoke Iockscrews, the housing. Tighten the capscrews and lockwire
tighten, and lockwire securely. securely.
NOTE: It is necessary that the interlock pin re-
main in a vertical position during reassembly as
rotation of the bar causes the pin to jam in the ten-
sion spring bores.
8. Install the other 3/4Ó interlock ball in the rear boss

top bore. This ball rides between the 1st-2nd and
the 3rd-4th speed shift bars.
SHIFT BAR HOUSING
11. Remove the assembly from the vise. Install the 12. Install the three tension springs, one over each
three tension balls, one in each bore on the hous- ball in the housing bores.
ing top.
REMOVAL - OUTPUT YOKE, AUXILIARY
SECTION, AND TORQUE CONVERTER HOUSING
A. Removal of the Output Yoke B. Removal of the Auxiliary Section
2.5625 2.5625
4 4
3.0 3.0 b
4 4
6.0
4
.40625 (3-Drilled Holes)
Bar Stock - 3/8" x 1"

Tool Print T-65853
1. Place the transmission in the vertical position. Put

1. Lock transmission by engaging two mainshaft gears
blocks under the torque converter housing to prevent
with the mainshaft sliding clutches (inset.) Use a large
damage to the torque converter. Removal can also be
breaker bar to turn the output shaft nut from the output
completed in the horizontal position.
shaft.
2. Pull yoke straight to the rear and off the output shaft. 2. Remove the four capscrews and the auxiliary
countershaft rear bearing cover, gasket, and rear
bearing shim.
Auxiliary Countershaft Retaining Straps 6. Insert three capscrews in the tapped holes of housing
may be installed to hold countershaft in flange. Tighten evenly to move auxiliary section to the
place. Auxiliary can be removed without straps, use rear and just far enough from front section to break
caution. gasket seal.
3. Install an Auxiliary Countershaft Retaining Strap with
3- 3/8" x 1" clean capscrews. Place a flat washer under
the strap to prevent damage to the rear auxiliary
countershaft bearing.
Do not use an air gun. Tighten by
hand until the capscrews are snug.
4. Repeat Steps 2 and 3 for the remaining auxiliary
countershaft.
7. Remove capscrews and attach a chain hoist to auxiliary

section. Move the assembly to the rear until free of front
section and remove gasket.
5. Remove the nineteen capscrews that hold the auxiliary

section to the transmission case.
NOTE: There are three lengths of capscrews, note their
location.
C. Removal Torque Converter
NOTE: The transmission rear must be blocked so the
two aligning pins on the transmission rear case are not
damaged. If the auxiliary section is not being removed
the transmission can be placed vertically on a stand
using an output flange or half round yoke affixed to a
large plate.
Care must be taken when placing the
transmission in the vertical position.
Always use safety chains on transmission. Assure that
transmission is stable in vertical position before
removing the safety chains.
8. The auxiliary section can also be removed with the

transmission set in the vertical position. Remove the
retaining capscrews from the housing flange and lift the
assembly from the front section. Remove the gasket.
Remove
1. the retaining capscrews from the convertor
pilot.
Use2.the two (2) threaded capscrew holes to separate

the 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 by 5.

Install 2 lifting eyes into the converter pilot capscrew
serviced at this time. holes, attach lifting chain and remove converter straight
up form the converter housing.
NOTE: Torque converter assembly is Non-Servicable.
Do not attempt to disassemble. It will be returned for
service and replaced as a complete assembly.
D. Removal of the Hydraulic Valve

NOTE: If not previously removed the transmission dip
stick and tube can be removed from the oil pan at this
time.
4. Remove the torque converter snap ring from the input

shaft.
Loosen
1. and remove the ten (10) retaining capscrews
from the hydraulic valve assembly. Note the location of
the two (2) allen head capscrews for reassembly.
E. Removal of oil pan, oil pick-up
and screen and oil filter assembly.
2. Remove the hydraulic valve assembly form the torque

converter housing. (Left) Separate the 2 gaskets and
mounting plate from the hydraulic valve. (Right)
1. Disconnect and remove the oil sump return line from

the oil pan.
3. If necessary the electronic solenoids can be removed

2. Loosen and remove the retaining cap screws from the
from the hydraulic valve at this time.
oil pan (Left). Remove the oil pan from the bottom of the
NOTE: The hydraulic valve is a NON-SERVICABLE torque converter housing (Right).
assembly. DO NOT DISASSEMBLE, it will be returned
for service.
3. Remove the two (2) retaining capscrews from the oil

pick-up. Remove the pick-up and screen and oil pan
gasket from the torque converter housing.
4. Loosen and remove the three retaining capscrews from 2. Remove the stator support and gasket
the oil filter housing. Change the oil filter as
recommended. Service the sealing ring if required.
F. Removal of the torque converter

housing
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 capscrews

from the stator support.
NOTE: The staor support bay be set in place a soft
face mallet or pry bay may be required to loosen the
staor support. The staor support is a NON-
SERVICABLE assembly.
7. Loosen and remove the two (2) retaining capscrews

from the oil pump assembly (Left). Remove the oil
pump from the torque converter housing (Right).
NOTE: The oil pump is a N O N - S E R V I C A B L E
assembly and should be returned for service. The two
4. Jar the torque converter housing to break the seal
(2) oil pump o-rings can be serviced at this time if
remove the torqueconverter housing and gasket from
necessary.
the transmission case.
G. Removal of the Inertia Brake
1. Loosen the six (6) retaining capscrews form the Inertia

Brake Housing.
5. Block the oil pump drive gear to loosen retaining nut

from oil pump shaft.
2. Remove the retaining capscrews from the assembly

6. Remove the oil pump drive gear and retaining nut from and remove from the transmission case.
the torque converter housing.
H. Removal of Hydraulic Pressure Valves
3. The filter by-pass valve is located inside the hydraulic

valve main lube passage. Service of the valve is thru
1. The pressure relief valve is located in the torque
converter housing oil pan sump area. the main lube passage, the valve is N O N -
SERVICABLE and replacement is required.
2. To service the pressure relief valve, reach into the oil

filter mounting adapter and remove the valve. The valve
is NON-SERVICEABLE. Replacement is required.
DISASSEMBLY - AUXILIARY SECTION
A. Removal and Disassembly Rear

Auxiliary Drive Gear and Yoke
1. Cut the lockwire on the splitter yoke retaining bolt and 2. Remove the retaining bolt, splitter yoke and sliding
loosen the bolt. clutch assembly from the auxiliary section.
AUXILIARY MAINSHAFT
ASSEMBLY
NUT
WASHER
SPACER
WASHER
b
GEAR
SLIDING REAR AUXILIARY

CLUTCH DRIVE GEAR
Cut 6593 L-4/87
3. Temporarily install an output yoke on the output shaft 4. Break loose the 15/16ñ retaining capscrew on the front
and secure it by placing a bar through the yoke. of the output shaft.
AUXILIARY COUNTERSHAFT
ASSEMBLY
BEARING
BEARING
SPACER
COUNTERSHAFT ASSEMBLY
Cut 6503M - 11/91
B. Removal of the Auxiliary

Countershaft Assemblies
1. Secure the auxiliary housing in a vise. Remove the

auxiliary countershaft retaining straps or rear bearing
covers, shim and rear bearing race.
The countershaft will fall loose in the

auxiliary section, but will not fall out
of auxiliary section.
2. Use a soft bar and maul to partially drive the output
shaft forward.
C. Removal Rear Auxiliary Drive Gear
Assembly
3. Remove the auxiliary countershaft from the auxiliary

section case.
1. Remove the 15/16" retaining capscrew, retainer and

auxiliary drive gear from the auxiliary section.
4. If necessary, secure the countershaft assemblies in a

vise and remove both the front and rear bearings with a
bearing separator and jaw pullers.
RANGE CYLINDER
ASSEMBLY
*Note: Use lockwire at

Cut 6427-5/83 this position
D. Removal and Disassembly of Range

Cylinder Assembly.
1. Remove the capscrews, range cylinder cover, and 2. Remove nut from yoke bar.
gasket.
DISASSEMBLY-AUXILIARY SECTION
3. Cut the lockwire. Remove the two 3/4" yoke lock- 5. Remove the shift yoke and synchronizer assembly
screws (inset). from output shaft.
4. Pull the yoke bar from the cylinder housing bore. 6. Remove the range piston from the cylinder bore. If
necessary, remove the O-rings from the position
I.D. and O.D. (inset).
7. Remove capscrews and range cylinder housing.
8. If necessary, remove the small O-ring from the

range cylinder housing bore.
E. Disassembly Synchronizer Assembly
1. Place the larger LO range synchronizer ring on the 2. Remove the sliding clutch from the synchronizer
bench. Cover the assembly with a shop rag to pre- ring LO range pins.
vent losing the three springs released from the
high range synchronizer at the pin locations. Pull
the HI range synchronizer from the blocker pins.
F. Removal and Disassembly Output Shaft
and Rear Bearing Assemblies.
1. Use a soft bar and maul to drive the output shaft

forward and through the rear bearing assembly.
3. Use the front face of the reduction gear as a base,

press the output shaft through the bearing and
gear. This frees the bearing, LO range gear, and
the splined washer.
2. Remove the bearing inner spacer from the output

shaft.
4. Remove the stepped washer, LO range gear, and

splined washer from the shaft.
G. Removal Splitter Cover
5. Remove the rear bearing retaining capscrews, rear

bearing cover, and gasket from the auxiliary housing.
The rear bearing cone drops from the housing bore 1. Remove the capscrews from the splitter cylinder cover
when the cover is removed. If necessary, remove the and remove the splitter cylinder cover and gasket from
oil seal from the cover (inset). the auxiliary section case.
2. If necessary, turn out the insert valve retaining nut and

remove insert valve from bore.
6. Remove the two bearing cups and spacer from the

bearing bore.
3. Pull the yoke bar from cylinder housing. If necessary,

4. If necessary, remove the small O-ring from the cylinder
remove the O-ring from piston O.D. (inset).
housing bore.
REASSEMBLY-AUXILIARY SECTION
A. Reassembly and Installation of
NOTE: Make sure magnetic plugs preinstalled in

auxiliary housing.
1. IMPORTANT: Mark timing teeth on the LO Range

gear. A highly visible color of toolmaker's dye is
recommended.
a. Mark any two adjacent gear teeth on LO Range
gear, front side.
b. Then mark the two adjacent teeth which are
directly opposite the first set marked. There 2. Placed splined washer on output shaft shoulder
should be the same number of teeth between facing up as shown.
the markings on each side of the gear.
REASSEMBLY-AUXILIARY SECTION
3. Install the LO Range gear on the output shaft, 5. Using a heat lamp or hot plate and oil heat the out-
clutching teeth engaged with the splines down to put shaft rear bearing and install on output shaft.
engage the washer splines. Seat the bearing securely on shaft. Bearing can
also be installed using the appropriate driver.
NOTE: DO NOT HEAT BEARING ABOVE 275oF
(136oC).
4. Install the LO Range gear rear washer on output

shaft and against gear, with chamfer side facing 6. Install the bearing inner spacer on the output
up. shaft.
REASSEMBLY - AUXILIARY SECTION
2. Install the three springs in bores in HI range synchro-

7. Place the auxiliary housing on a flat bench and install nizer ring.
the 2 bearing cups and spacer in the rear bearing bore,
the cup with a lip seats next to the rear of the auxiliary
case.
B. Reassembly Synchronizer Assembly
3. Place the HI range synchronizer ring over pins of LO

speed synchronizer ring, seating springs against pins.
1. Place the larger LO range synchronizer ring face down

on 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 up
with chamfered holes on bottom of sliding clutch.
C. Installation of Auxiliary Driver Gear.
4. Apply downward pressure to the HI range synchronizer

ring WHILE TWISTING COUNTER-CLOCKWISE to
compress the springs and fully seat ring on blocker pins 1. Place auxiliary drive gear, retainer and 15/16" capscrew on
of LO range synchronizer. It is suggested that a shop output shaft assembly. Secure capscrew on shaft till
towel be placed over the synchronizer to prevent injury tight, recommended torque will be applied during final
to your hands. assembly (pg. 67)
D. Reassembly of Auxiliary
Countershaft Assemblies and
Timing.
5. Install synchronizer assembly to front of output shaft To make reassembly of the auxiliary section easier, you can
assembly. make this auxiliary section fixture out of a section of 2 x 12.
63
NOTE: Auxiliary countershaft bearings will be installed 3. Install the range yoke into the synchronizer sliding
at this time if replacement was required. clutch slot, offset side facing down.
1. Mark each countershaft for correct timing. Locate the
"O" stamped on the countershaft and mark the tooth
with 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 for

reassembly. Locate output shaft assembly between
countershaft, timing of the auxiliary will be checked at
this time. The single marked tooth of each countershaft
must align with the two teeth marked on each side of
the LO range gear.
E. Reassembly Range Cylinder
5. Heat the rear output shaft bearing cone and install the
bearing on the shaft taper side down.
NOTE: Do not heat the bearing above 275oF (136oC). 1. Install O-ring in slot of small bore in cylinder. Apply
silicone to all O-rings (inset).
6. Install the rear bearing cover on the auxiliary housing.

The nylon collar and brass washer are installed in the 2. If previously removed, install the O-rings in the I.D. and
chamfered hole on the lower right side of the cover. O.D. of the range position.
NOTE: Because the collar becomes distorted when

compressed, DO NOT REUSE OLD NYLON COLLAR.
F. Reassembly and Installation
of Splitter Cylinder Assembly
3. Position new gasket on housing. Install range cylinder,

piston yoke, piston and retaining nut into housing.
Tighten retaining nut to recommended torque. Install 4
capscrews into range cylinder housing and tighten to
recommended torque.
1. If previously removed, install the small O-ring in the

cylinder housing bore.
4. Place range cylinder cover and new gasket on range 2. If removed, install the O-ring on the piston O.D. (left).
cylinder, install 4 capscrews and tighten to recom- Insert the yoke bar in the cylinder housing bore (right).
mended torque.
G. Reassembly of Auxiliary Rear
Bearing Assembly
1. Place the rear bearing cone over the bearing and into
the rear bore. Align the .125 shim over the cone and
install the rear bearing cover with four (4) capscrews
tighten only till snug (right). Retaining straps may also
be used at this time they are required for horizontal
3. If previously removed, install the insert valve, flat end to installation. Complete assembly by installing remaining
the outside, and the valve retaining nut in the bottom rear bearing cover (left).
bore of the cylinder cover. Tighten to recommended
torque ratings.
H. Installation of Range Yoke
NOTE: Prior to installation of the insert valve, make
sure the three O-rings on the valve O.D. are not defec- Capscrews and Recommended
tive. Replace, if necessary. Torque of Auxiliary Drive Gear Nut
1. Install the 2 capscrews into the range yoke and tighten

to recommended torque (right). Tighten auxiliary drive
gear retaining nut to recommended torque (left).
4. Place the new splitter cylinder gasket, splitter cylinder

assembly, new splitter cylinder cover gasket and split-
ter cylinder cover onto the auxiliary housing. Install 4
capscrews into the assembly and tighten to recom-
mended torque.
1. Installation of Splitter Sliding Clutch
and Yoke
1. Place splitter shift yoke into splitter sliding clutch slot.

Install assembly onto auxiliary section engaging the
sliding clutch teeth into the auxiliary drive gear clutching
teeth and splitter yoke onto yoke bar align Iockscrew
tighten 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 auxiliary
drive gear assembly.
3. Remove six capscrews from the auxiliary bearing re- 5. Remove the spline d washer from the mainshaft also
tainer ring. Insert three puller screws in the specially remove the front auxiliary drive gear retaining snap ring
tapped holes of retainer ring. Tighten screws evenly to from the mainshaft.
pull the front auxiliary drive gear assembly from case
bore.
4. Remove front auxiliary drive gear from mainshaft.

DISASSEMBLY-FRONT SECTION
Cut 6382-9/80
B. Removal and Disassembly of Left

Reverse Idler Gear Assembly
1. Move the mainshaft reverse gear as far to the rear 2. Move the reverse gear forward and against the LO
as possible and remove the snap ring from I.D. of speed gear, engaging the splines of mainshaft
gear. sliding clutch.
3. Using inside jaw pullers or impact puller, remove the 5. Remove the pipe plug from rear of idler shaft and use
auxiliary countershaft front bearing race from left an impact puller, 1/2"-13 threaded end, to remove shaft
reverse idler gear bore. If necessary, repeat the from case bore (inset).
procedure for removing the auxiliary countershaft front
bearing race from right reverse idler gear bore.
6. As the idler shaft and idler plate are moved to the rear,
4. Loosen the nut on the idler shaft, (inset). Remove the
remove the thrust washer, and gear from case. If nec-
stop nut and washer from front of idler shaft.
essary, remove the inner race from bearing and
remove needle bearing from idler gear.
c. Removal of Countershaft Bearings
NOTE: In the following instructions, the front

and rear bearings from BOTH countershafts are
removed. For removal of the mainshaft assembly
from case, it is necessary to remove the bearings
from right countershaft ONLY.
3. Loosen and remove capscrew from retaining

plate on upper countershaft front.
1. Remove snap ring from each countershaft rear groove.
4. Use a soft bar and maul to drive each countershaft

to the rear as far as possible. This partially
unseats the front bearings.
NOTE: The soft bar should have a flattened end that is

large enough so damage to the countershaft end does
not occur.
2. From inside the case, use a soft bar and maul to
drive the countershaft rear bearings to the rear
and from case bores.
NOTE: This procedure will damage the bearings

and should not be attempted unless replacement
of the bearings is planned.
5. From the rear of the countershaft drive the shaft 6. Use a bearing puller or pry bars to remove the
forward to unseat the front bearing from the front case countershaft front bearings.
bore to expose the bearing snap ring.
NOTE: The front roller bearing inner race will remain
pressed on the front countershaft.
D. Removal and Disassembly of Mainshaft

Assembly
1. Block the right countershaft assembly against 2. Remove the 3rd-4th speed sliding clutch from
case wall and pull the mainshaft assembly to the mainshaft front.
rear to free pilot from input shaft pocket. Tilt front
of mainshaft up and lift the assembly from case
(inset). Use caution as the reverse gear is free and
can fall from shaft.
3. Remove the reverse gear and spacer from main-

shaft rear.
5. Turn the reverse gear limit washer to align its

splines with those of the mainshaft and remove
washer.
4. From mainshaft rear, pull the key from mainshaft

key way.
NOTE: When removing limit washers, spacers and

gears, note their location on mainshaft to facili-
tate reassembly. Keep the internal-splined
washers and external-splined spacers with the
gear from which they were removed. There is
ONLY one limit washer and one spacer belonging
to each gear. 6. Remove the LO-Reverse speed sliding clutch from
mainshaft.
7. Using a small screwdriver, turn the limit washer in 8. Remove each remaining gear, limit washer, spacer,
hub of LO speed gear to align its splines with and sliding clutch from mainshaft in the same
those of the mainshaft. Pull the LO speed gear manner previously detailed. And, if necessary, re-
from rear of mainshaft to remove limit washer, move the snap ring from I.D. of each gear.
spacer, and gear. If necessary, remove the snap
ring from I.D. of gear (inset).
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 rear
of the transmission. Pull the shaft forward and repeat
as necessary.
3. Use pry bars to complete the input shaft bearing

removal (left). Remove spacer from input shaft (right).
5. Inspect the input shaft bushing for wear and replace if

necessary.
6. The main drive gear can be removed from the case this
time.
4. Push input shaft through the drive gear and remove the
input shaft from case.
NOTE: The input shaft is a NON-SERVICABLE
assembly excluding the sealing rings and should be
replaced if damaged.
NOTE: Input shaft can be serviced without removing
the main shaft. Remove the snap ring and input shaft
bearing remove the internal snap ring from the drive
gear and remove the input shaft.
F. Removal and Disassembly of

Countershaft Assemblies
NOTE: Except for the PTO gears, the left and right
countershaft 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 case 2. Remove the drive gear retaining snap ring from front of
bore and moved to the center of the case. Lift the
each countershaft.
assembly from case and repeat the procedure for left
countershaft assembly.
NOTE: The left and right reverse idler gear assemblies
are identical and disassembled in the same manner. If
removal 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, press 4. Disassembly is complete at this point due to the welded
the drive gear, PTO gear, and 3rd speed gear from countershaft design. Replacement of reverse, low first
each countershaft. This removes the front bearing inner and 2nd speed gears will be completed as an assembly
race from the countershaft. gears are not available separately.
IMPORTANT: NEVER USE THE PTO GEAR AS A
PRESSING BASE. The narrow face width of this gear
makes it very susceptible to breakage. G. Removal and Disassembly of Right
NOTE: To remove the right reverse idler gear assembly
see section B. The right and left reverse idler gear
assemblies are disassembled in the same manner.
H. Disassembly Auxiliary Drive Gear
Assembly
1. Remove the retaining ring from the front of the auxiliary 3. If necessary, remove the O-rings from hub O.D. of
drive gear (left) remove the snap ring from the auxiliary front auxiliary drive gear.
drive gear hub (right).
2. Using the rear face of retainer ring as a base,

Dress the drive aear throuah bearina.
Ò
REASSEMBLY - FRONT SECTION
A. Reassembly of Auxiliary Drive Gear
Assembly
NOTE: If previously removed, install the O-rings on
extended front hub of front auxiliary drive gear.
2. Start the front auxiliary drive gear bearing on front hub,

bearing snap ring facing groove in retainer ring. Use
both hands, press the bearing on gear with snap ring in
groove of retainer ring (inset).
1. Install the retainer ring on front auxiliary drive gear,

snap ring groove facing front hub and away from gear
teeth.
3. Install the snap ring into its groove (left) place the outer
retainer ring and seat with the proper driver (right).
CASE ASSEMBLIES
NOTE: Before starting reassembly, make sure the three
magnetic discs are solidly in place at bottom of case. These
can be secured to disc mounting surfaces with Scotch Grip
Rubber Adhesive or equivalent adhesive.
C. Reassembly and Installation of Right

2. Install the bearing inner race on idler shaft and insert

shaft into case bore, threaded-end of shaft to the front.
As the idler shaft is moved forward, install the reverse
idler gear on shaft, long hub to the front and seating on
bearing inner race. Position the thrust washer on shaft
between the gear and support boss in case and con-
tinue with movement of idler shaft forward into bore of
Support boss.
1. If previously removed, thread pipe plug in rear of re-

verse idler shaft and tighten. Install the thrust washer to
the 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 in

bore of support boss and forward as far as possible,
install the washer and stop nut on front of shaft. Tighten
nut to recommended torque rating.
C. Reassembly of Countershaft
Assemblies
NOTE: Except for the PTO gears, the left and right
countershaft assemblies are identical and reassembled
in the same manner.
NOTE: Reverse low, 1st and 2nd speed gears are part
of the shaft and are note serviceable.
4. Install the OUTER RACE of auxiliary countershaft front

bearing into case bore.
NOTE: The bearing INNER RACE is installed on front
of auxiliary countershaft and never with outer race.
1. Press the 3rd speed gear on the countershaft, long hub

of gear to countershaft front.
4. Install the drive gear retaining snap ring in groove on

front of each countershaft.
2. Start the PTO gear onto countershaft, bullet-nose side

of teeth facing up and toward rear of shaft. Align key-
way of drive gear with key in countershaft and press
BOTH gears onto shaft, long hub of drive gear against
PTO gear.
NOTE: The left countershaft assembly has a 47-tooth
PTO gear; the right countershaft assembly has a 45-
tooth PTO gear.
5. Use a flanged-end driver to install bearing inner race on

countershaft, shoulder of race against shoulder of coun-
tershaft.
3. To avoid confusion during installation, mark the end of

left countershaft with an "L", the end of right counter-
shaft with an "R".
E. Partial Installation of Countershaft
Assemblies
IMPORTANT: Mark the countershaft drive gear for timing

purposes. On the drive gear of each countershaft assem-
bly, mark the tooth aligned with keyway of gear and
stamped with an "O" for easy identification. A highly visible
1. Place the left countershaft assembly into position in
color of toolmakers' dye is recommended for making timing
case, making sure that the "L"-marked assembly has
marks.
the larger 47-tooth PTO gear. Place the right counter-
shaft assembly into position in case, making sure that
the "R"-marked assembly has the smaller 45-tooth PTO
gear.
REASSEMBLY-FRONT SECTION
F. Bearing Installation of Left Countershaft
Assembly
1. Move the left countershaft assembly to the rear 3. Center the front of left countershaft in bearing and
and insert countershaft support tool or blocking move the assembly forward.
to center shaft in rear case bore.
2. Use a flanged-end bearing driver to start the 4. Use a flanged-end bearing driver to completely
bearing in case bore. seat front bearing or bearing outer race in case
bore.
NOTE: The inner race of roller-type front bearing
is pressed on front of countershaft.
F. Reassembly, Installation and Timing of
Main Drive Gear Assembly
5. Position the retainer plate on front of left countershaft, 1. Install the snap ring in I.D. of main drive gear.
roll pin in hole at end of shaft, and secure with capscrew
tightening to recommended torque.
6. Remove countershaft support tool or blocking 2. Mark the main drive gear for timing purposes.
from rear case bore and install the left counter- Mark any two adjacent teeth on drive gear and re-
shaft rear bearing with larger I.D. lead chamfer to peat the procedure for the two adjacent teeth
the front of shaft and install the snap ring in directly opposite the first set marked. A highly vis-
groove at rear of left countershaft. ible color of toolmakers' dye is recommended for
making timing marks.
5. Place two lifting eyes with capscrews over bearing

snap ring to temporary secure bearing in transmission
bore.
3. Mesh the marked tooth of left countershaft drive

gear with either set of two marked teeth on main
drive gear. Slide the input shaft through the main
drive gear (inset).
6. Use a soft bar and maul to drive the input shaft through
bearing. Remove front bearing cover.
4. Install drive gear spacer. Install the bearing on the input

shaft with external snap ring to the outside (inset). Set
input shaft bearing into the bore of the case front.
7. Install bearing retainer snap ring to secure input shaft in

case bore. Remove the two capscrew and lifting eyes.
H. Reassembly and Partial Installation of
Mainshaft Assembly
1. If previously removed, install the corresponding
snap rings in I.D. of mainshaft gears.
2. Secure the mainshaft in a vise equipped with

brass jaws or wood blocks, pilot-end of shaft 4. Install the spacer on shaft against washer.
down. If previously removed, install the roll pin in
keyway.
5. Install the 3rd speed gear on mainshaft, clutching

teeth down and engaged with external splines of
spacer.
3. Install the 3rd speed gear limit washer on main- NOTE: Gear limit washers are internally splined
shaft, flat side of washer up. Rotate washer in the and locked to mainshaft by the key. Gear spacers
1st or bottom groove of mainshaft to align the are externally splined to engage with clutching
splines of washer with those of the mainshaft. in- teeth in gear hubs. There is one limit washer and
stall the key in mainshaft keyway to lock washer one spacer for each gear in the mainshaft as-
in place. sembly.
REASSEMBLY—FRONT SECTION
Setting Correct Axial
Clearances For Mainshaft
Gears
Axial Clearance (End-Play) Limits Are:
.005’’ -.012” for all mainshaft gears
Washers are used to obtain the correct limits; six

thicknesses 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 full

range of tolerances as corresponding colors listed
above “plus red.” (Example: “Orange plus red” limit
washer 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 speed
gear positions as shown at right.
IMPORTANT: REFER TO THE APPROPRIATE

ILLUSTRATED PARTS LIST
(SPECIFIED BY MODEL SE-
RIES) TO ENSURE THAT
PROPER PARTS ARE USED
DURING REASSEMBLY OF THE
TRANSMISSION.
8. Remove the key from keyway and install the 2nd

speed gear limit washer on mainshaft, flat side of
washer down and against spacer. Rotate washer in
6. Install the 2nd speed gear on shaft against 3rd the 2nd groove of mainshaft to align the splines of
speed gear, clutching teeth up. washer with those of the mainshaft and reinsert
key in keyway to lock washer in place (inset).
9. Insert two large screwdrivers between the 2nd and

3rd speed gears to check axial clearances. Apply
slight downward pressure on screwdriver handles
to spread gears evenly. Making sure the gear hubs
are parallel, insert a feeler gage between hubs.
Correct axial clearance is less than the minimum
.005" to .012" If the clearance is less than the
minimum .005" tolerance, the limit washer in the
2nd speed gear should be replaced by a thinner
limit washer. This will increase the axial clearance
between the gears. If the clearance checked is
greater than the maximum .012" tolerance, a
7. Install the spacer in 2nd speed gear, engaging the thicker limit washer should be installed in the 2nd
external splines of spacer with clutching teeth of speed gear. This would decrease the axial clear-
gear. ance between the gears.
10. Install the 1st-2nd speed sliding clutch, aligning 12. Install spacer and 1st speed gear on the main-
the missing internal spline of sliding clutch with shaft, clutching teeth down and engaged with en-
key in mainshaft. ternal splines of spacer.
11. Remove the key from keyway and install the 1st 13. Install the LO speed gear on shaft against 1st
speed gear limit washer on mainshaft, flat side of speed gear, clutching teeth up.
washer up. Rotate washer in the 2nd groove of
mainshaft to align the splines of washer with
those of the mainshaft and reinsert key in key-
way to lock washer in place.
16. Check axial clearances and make adjustments, if

necessary, between the LO and 1st speed gears
as described in No. 9 of this section.
14. Install the spacer in LO speed gear, engaging the

external splines of spacer with clutching teeth of
17. Install the LO-Reverse speed sliding clutch,

aligning the missing internal spline of sliding
clutch with key in mainshaft.
15. Remove the key from keyway and install the LO

speed gear limit washer on mainshaft, flat side of
washer down and against spacer. Rotate washer
in the 4th groove of mainshaft to align the
splines of washer with those of the mainshaft
and reinsert key in keyway to lock washer in
place.
18. Remove the key from keyway and install the re- 20. Install reverse gear on mainshaft. Engage the
verse gear limit washer on mainshaft, flat side of clutching teeth of gear with splines of spacer
washer up. Rotate washer in the 5th groove of and sliding clutch and move the reverse gear
mainshaft to align the splines of washer with against the LO speed gear.
those of the mainshaft and reinsert key in key- NOTE: DO NOT REPLACE REVERSE GEAR lN-
way to lock washer in place. TERNAL SNAP RING AT THIS STEP
21. Remove the mainshaft assembly from vise. Align

the missing internal spline of 3rd-4th speed slid-
ing clutch with key in mainshaft and install on
front of shaft, engaging the external splines of
sliding clutch with clutching teeth of 3rd speed
19. Install the spacer on shaft against washer. gear.
.
22. Block the right countershaft assembly against 24. With the reverse gear remaining against LO
case wall and lower the mainshaft assembly into speed gear, mesh the corresponding forward
position with the reverse gear held against LO speed gears of left countershaft assembly.
speed gear and rear of shaft moved into case Check to make sure that marked tooth on left
bore. countershaft drive gear has remained in mesh
with marked set of teeth on main drive gear.
23. Move the pilot-end of mainshaft into pocket 25. Center rear of mainshaft in case bore and install
bushing of input shaft. the 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 -
H. Bearing Installation and Timing of

Right Countershaft Assembly
IMPORTANT: The left countershaft assembly
MUST remain in time with main drive gear when
timing right countershaft assembly.
3. Position the front countershaft bearing in front

bearing 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).
1. Remove blocking from right countershaft a s -

sembly and place it parallel to mainshaft as-
sembly. Mesh the marked tooth of right
countershaft drive gear with remaining set of two
marked teeth on main drive gear.
4. Tighten capscrew to the recommended torque.
2. Insert countershaft support tool or blocking in

rear bearing bore.
5. Position the countershaft rear bearing in rear bearing 6. With bearing installation complete, install the snap ring
bore. Use the proper bearing driver to seat bearing in in right countershaft rear groove.
bore.
7. Move the reverse gear to the rear on mainshaft and use
a screwdriver to engage sliding clutches with all forward
speed gears. A sliding clutch that will not engage with a
gear indicates the gear set is not in proper mesh. The
bearings of the right countershaft would then need to
be removed and the drive gear set retimed.
NOTE: Do not engage sliding clutches with more than
one gear at the same time. This will lock the gearing
and prevent the mainshaft and countershaft assemblies
from rotating.
1. Reassembly and Installation of Left
NOTE: Since the left and right reverse idler gear
assemblies are identical, reassembly and installation of
the left reverse idler gear assembly should be
performed at this time as described in Part C of this
section.
J. Completed Installation of Mainshaft

and Auxiliary Drive Gear Assemblies
3. Install the snap ring in hub of reverse gear and move

the reverse gear forward on mainshaft and into proper
position in case.
1. Move the reverse gear to the rear as far as possible,

meshing teeth of gear with those of the reverse idler
gears.
4. Install snap ring on mainshaft snap ring groove.
2. Align the external splines of spacer with clutching teeth

of reverse gear and move spacer forward on the 5. Install splined washer on mainshaft splines behind re-
mainshaft and into reverse gear. verse gear.
6. Reinstall the front auxiliary drive gear assembly on rear 8. Install splined washer on mainshaft splines behind
of mainshaft. Use a flanged-end driver and maul to set auxiliary drive gear.
bearing in case bore.
7. Align the six capscrew holes in retainer with the tapped 9. Install the snap ring in groove at end of mainshaft.
holes in case and install capscrews. Tighten to recom-
mended torque ratings and lockwire the capscrews in
groups of three.
INSTALLATION - TORQUE CONVERTER HOUSING OUTPUT
YOKE, AUXILIARY SECTION AND SHIMMING PROCEDURE
A. Installation of Torque Converter
Housing
Note: The transmission rear must be blocked so the
two aligning pins on the transmission rear case are not
damaged. If the auxiliary section has been installed the
transmission can be placed vertically on a stand using
an output flange or half round yoke affixed to a large
plate.
Care must be taken when placing the 2. Place the oil pump on the torque converter housing
transmission in the vertical position. opening (left). Install the two retaining capscrews and
Always use safety chains on the transmission. Assure properly torque the capscrews (right).
that the transmission is stable in the vertical position
before removing the safety chains.
B. Installation of the Inertia Brake
3. Install the oil pump drive gear on the pump shaft and
thread retaining locknut in place (left). Block the oil
pump drive gear and tighten lock nut to proper torque.
1. Place the inertia brake, gasket and six (6) retaining

capscrews on the transmission case (left). Tighten the
six (6) retaining capscrews to required torque
specifications.
c. Installation of the Torque Converter

Housing 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 for

proper seating and secure the valve (left). After
replacing the filter by-pass valve the valve should be
properly seated and secured (right). 5. Install the sta \tor support and gasket over the input shaft
down into the torque converter housing (left). Install the
six (6) retaining capscrews and properly torque
capscrews.
108
D. Installation of Oil Pan, Pick Up and
Screen and Oil Filter Assembly
3. Place the oil pan over pick-up and screen onto the
torque converter housing (left). Secure the oil pan to
the torque converter housing with the retaining
capscrews (right).
1. Install the oil filter o-ring seal, oil filter and oil filter
housing onto the torque converter housing and tighten
three (3) retaining capscrews to required torque.
4. Install the oil sump return tube to the oil pan. Check the
fittings 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 and

install the pick-up screen assembly in place with the
three (3) retaining capscrews.
1. If the electronic solenoids were removed place them

back on the hydraulic valve and secure them with their
retaining nuts (left). Place the two (2) gaskets and
mounting plate on hydraulic valve (right).
NOTE: Gaskets to hydraulic valve are marked for
proper installation. The mounting plate should be
checked for proper alignment.
2. Install the hydraulic valve on the torque converter

housing and align mounting holes (left). Install the ten
(10) retaining capscrews into the hydraulic valve. Note
two (2) of the retaining capscrews are allen head
capscrews check their location (right).
NOTE: The transmission dipstick tube can be
reinstalled on the transmission at this time.
2. After the torque converter is properly seated exposing

F. Installation of the Torque Converter the snap ring groove install the snap ring.
3. Install the torque converter pilot into the torque

converter and properly seat the converter pilot (left).
Install the eight (8) retaining capscrews into the
converter pilot and properly torque the capscrews
(right).
1. Install two (2) lifting eyes into the converter pilot

capscrew holes. Attach a lifting chain to lifting eyes
lower torque onto the input shaft into the torque
converter housing.
NOTE: The torque converter may not seat itself
completely on the shaft. Care must be taken during
installation. Do not force the torque converter onto the
input shaft as damage to internal splines will occur.
The splines on the input shaft must match those internal
to the torque converter interrupt clutch splines. Not
matching these splines will not allow the torque
converter to properly slide onto the input shaft.
INSTALLATION - CLUTCH HOUSING, OUTPUT YOKE,
AUXILIARY SECTION AND SHIMMING PROCEDURE
G. Installation of Output Yoke
NOTE: Replacement of seal and slinger must be
completed prior to yoke or flange installation.
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 final
torque procedure.
1. Install speedometer gear or spacer on output shaft.
4. Complete installation process by torquing the output

2. Place output yoke or flange onto the output shaft.
shaft nut to recommended torque.
H. Installation of the Auxiliary Section
and Shimming Procedure
1. Tighten the middle bolt on each countershaft strap until
the countershaft are snug. Shift the reduction sliding
clutch into reduction. Attach a chain hois to the output
shaft.
NOTE: The front box sliding clutches must be in the
neutral position.
4. Remove the countershaft straps. Make sure a 0.125

countershaft rear bearing shim is installed. Be sure the
countershaft rear bearing races are seated in the bear-
ing bores.
2. With the transmission set in the vertical position, block

under the torque converter housing to prevent damage
to the torque converter, position the new gasket on the
transmission case. Lower the auxiliary assembly on the
front case rear.
IMPORTANT: Shift the reduction sliding clutch into
deep reduction before installing the auxiliary.
5. Install two clean 3/8" x 1" capscrews without washers

directly across from each other in each bearing cover.
Tapped holes in auxiliary case must be free of thread
adhesive.
3. Install the retaining capscrews in the housing flange

and tighten to the recommended torque.
6. Tighten the capscrews to 7 in./lbs. of torque DO NOT 8. Remove the countershaft rear bearing covers and
gauging shims.
INSTALL THE COUNTERSHAFT REAR BEARING
COVER GASKET.
9. After the correct shim has been selected, place the

7. Rotate the output shaft six times in the clockswise direc- shim on the rear countershaft bearing race, install the
tion, then six times counterclockwise to seat the coun- countershaft rear bearing cover and gasket. Check for
tershaft rear bearings. Use a feeler gauge, as close to proper shim alignment if misaligned rear bearing cover
one capscrew location as possible, and measure the may be damaged when proper torque is applied. Posi-
gap between the countershaft rear bearing cover and tion a new gasket on each countershaft rear bearing
the auxiliary case. Record the measurement. Using the cover mounting surface and install both rear bearing
average measurement, refer to page 115 in this Ser-
covers. Install and tighten the capscrews to the recom-
vice Manual. Select the numbers in the left column that
mended torque.
compare to the avereage measurement recorded from
the countershaft rear bearing cover. Follow the column
to the right to identify the proper shim to be used in the
countershaft shim bores. Duplicate this procedure for
the other countershaft rear bearing cover.
INSTALLATION - SHIFTING CONTROLS
A. Installation Shift Bar Housing
3. Install the thirteen capscrews in shift bar housing and

tighten to recommended torque rating.
1. Place all three mainshaft sliding clutches in the neutral
position. Install shift bar housing gasket in position. 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, install

the shift bar housing assembly on case, fitting the shift
yokes into the slots of the corresponding sliding
clutches.
C. Installation of Slave Valve
1. If previously removed, install the air line fittings 3. Install the hat-type alignment sleeve in bore of
on slave valve. slave valve.
2. Install the spring on shank of actuating pin and in- 4. Position gasket on valve mounting surface (inset)
sert in bore of transmission case. and install the slave valve on case, inserting the
end of actuating pin into alignment sleeve. Secure
the valve to case with four capscrews tighten
evenly to recommended torque rating.
3. Connect the 1/4 air line from the inertia brake to the air
filter regulator at solenoid. Also connect the two (2) air
lines from the slave valve to the range cylinder, LO
range connects to the front of the cylinder and HI range
connects to the rear (left). Connect the 1/4 air line to the
TCB-6 air fitting also connect the hydraulic valve wiring
harness at connector (right).
1. Place the inertial brake air hose and wiring harness on

the transmission.
4. Connect the wiring harness clamps to the shift bar

housing capscrews (left). Connect the input speed
sensor and engine speed sensor at each connector as
shown.
2. Install the two capscrews into the air filter regulator and
tighten to proper torque.
5. Install the Roadranger valve cover and slide three

airlines through cover. Install the jam nut on the shift
lever. Thread the Roadranger valve on shift lever and
secure by tightening jam nut against valve.
6. Connect the red air line to the "S" or Supply Port and 8. Connect the blue air line to the splitter cylinder cover.
the black air line to the "P" or End Port of the slave Tighten fittings securely.
valve. Tighten fittings securely.
9. Position valve cover on Roadranger valve and secure

by tightening the two mounting screws in cover.
7. Connect the red air line to the "S" or Supply Port and
the black air line to the "P" Port and the blue line to the
"SP" on the roadranger valve.
SHIMMING CHART
Average 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 SHIM COLOR CODE
AVERAGE GAP THICKNESS 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.
Copyright Eaton Corporation, 2012.
Eaton hereby grant their customers,
vendors, or distributors permission
to freely copy, reproduce and/or
distribute this document in printed
format. It may be copied only in
its entirety without any changes or
modifications. THIS INFORMATION
IS NOT INTENDED FOR SALE OR
RESALE, AND THIS NOTICE MUST
REMAIN ON ALL COPIES.
Note: Features and specifications
listed in this document are subject to
change without notice and represent
the maximum capabilities of the
software and products with all options
installed. Although every attempt has
been made to ensure the accuracy of
information contained within, Eaton
makes no representation about the
completeness, correctness or accuracy
and assumes no responsibility for
any errors or omissions. Features and
functionality may vary depending on
selected options.
For spec’ing or service assistance,
call 1-800-826-HELP (4357) or visit
www.eaton.com/roadranger.
In Mexico, call 001-800-826-4357.
Roadranger: Eaton and trusted partners

providing the best products and services in the
industry, ensuring more time on the road.
Eaton Corporation
Vehicle Group
P.O. Box 4013
Kalamazoo, MI 49003 USA
800-826-HELP (4357)
www.eaton.com/roadranger
Printed in USA

Fuller Automated Transmissions TRSM0011: Service Manual

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Fuller Automated Transmissions TRSM0011: Service Manual

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Service Manual

Fuller Automated Transmissions

IMPORTANT: All Fuller Transmissions are identified by

18-Speed Transmission (On/Off Highway):

• Buy oil from a reputable dealer.

Proper Lubrication Levels as

Maintaining Oil Level

Different Views of the Oil Dipstick

WHILE IN LO AND HI RANGE . . .

ROAD RANGER VALVE

SPLITTER CONTROL BUTTON

Lockup Mode (see figure B)

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

5. Internal clutching teeth in hub of engaged mainshaft

Auxiliary Section Power Flow:

PAGE TOOL HOW OBTAINED

45 Countershaft Retaining Strap Made from Fuller Transmission

45 Auxiliary Section Hanger Bracket Made from Fuller Transmission

55 Jaw Puller and Bearing Separator Tool Supplier

72 Snap Ring Pliers Tool Supplier

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

Made from Fuller Transmission

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

NOTE: To prevent oil leakage and loosening, use

1. Install a new gasket.

2. Using the 2 screws, install the oil filter

3. Check the strainer for contaminants. If

5. Install the return hose/tube.

4. Position the oil sump pan. Install the

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 and

Preventive Maintenance Checks

● Change at specified service intervals.

IMPORTANT: REFER TO THE APPROPRIATE ILLUSTRATED PARTS LIST (SPECI-

Range Cylinder Assembly—All Models

NO AIR ON SIGNAL LINE

19470 or A-5000 Slave Valve

For all questions

Constant Air No Air

19470 or A-5000 Slave Valve

For all questions

Constant Air No Air

19470 or A-5000 Slave Valve

For all questions

Constant Air Air to Cover

19470 or A-5000 Slave Valve

For all questions

Constant Air Air to Cover

3. Turn out the two mounting screws in the Roadranger

4. Slide the cover down to expose the valve ports and

2. Remove the air line at the splitter cylinder cover (A).

6. Remove retaining capscrews on the shift bar housing

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

A. Removal and Disassembly of the Shift

NOTE: During disassembly, lay all parts on a

3. Install the plug and tighten to compress the