95 - eaton-RTLO-18918B-transmission-service-manual 65

In-Vehicle Service Procedures
Procedure -
1. Refer to the drawing for proper reassembly. Use a very small amount of Silicone Lubricant on the O-Rings to avoid clogging
the ports. A small amount of grease on the Position Springs and Balls will help to hold them in place during reassembly.
2. Reinstall Roadranger Valve on Gear Shift Lever and tighten the Jam Nut.
3. Attach the Air Lines and reinstall the Bottom Cover.
66
How to Disassemble Roadranger Valve A-4900

Special Instructions
None
Special Tools

• Typical Service Tools
Component Nomenclature and Roadranger Valve Sectional View

1. Medallion 11. Screw
2. Spring 12. O-Ring
3. Retainer 13. Spring
4. Housing 14. 5/32" Ball
5. Spring 15. Spring
6. Washer 16. Ball
7. O-Ring 17. Seal
8. Range Selector 18. Detent
9. Pin 19. Splitter Button
10. Cover 20. Old Style Shift Knob
67
Procedure -
1. Remove the two screws holding the Bottom Cover to the Valve and slide the Cover down the Gear Shift Lever to expose the
Air Line Fittings. Disconnect the Air Lines.
2. Loosen the Jam Nut and turn the Control Valve from the Gear Shift Lever.
3. Pry the Medallion from the recess in the Top Cover.
4. Turn out the two screws to remove the Top Cover from the Valve Housing.
5. Turn out the two screws in the side of the Valve Housing to separate the Housing.
6. Remove the Range Selection Lever from the Left Housing along with the Position Balls and Guide.
7. If necessary, remove the Springs and O-Ring from the Bores in the Left Housing.
8. If necessary, remove the Springs, O-Ring and Sleeve from the Bores in the Right Housing.
68
How to Assemble Roadranger Valve A-4900

None
Special Tools

Component Nomenclature and Roadranger Valve Sectional View

1. Medallion 6. Washer 11. Screw 16. Ball
2. Spring 7. O-Ring 12. O-Ring 17. Seal
3. Retainer 8. Range Selector 13. Spring 18. Detent
4. Housing 9. Pin 14. 5/32" Ball 19. Splitter Button
5. Spring 10. Cover 15. Spring 20. Old Style Shift Knob
69
Procedure -
1. Refer to the drawing for proper reassembly. Use a very small amount of Silicone Lubricant on the O-Rings to avoid clogging
the ports. A small amount of grease on the Position Springs and Balls will help to hold them in place during reassembly
2. Install the Control Valve on the Gear Shift Lever and tighten the Jam Nut.
3. Attach the Air Lines and install the Bottom Cover.
70
How to Remove the Air Lines and Hoses

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

Special Tools
• For “Push-to-Connect” Fittings, the Eaton Service Tool Kit K-2394 is recommended. The Kit contains the Release Tool
and the Tubing Cutter.
Procedure -
1. Disconnect all Air Lines and Hoses.
2. Inspect the Air Lines and Hoses.
71
3. Inspect Air Fittings and remove if damaged.
72
How to Install the Air Lines and Hoses

Make sure Air Lines and Hoses are not damaged.
Install the Air Lines and Hoses at their proper location.

All externally threaded 1/8" or 5/32" Air Lines and Pipe Fittings that are not coated with pre-applied thread sealant must be coated
with Eaton® Sealing Material #71209 or equivalent for at least 5 complete and consecutive threads.
All externally threaded 1/4" Air Fittings that are not coated with pre-applied thread sealant must be coated with Eaton Sealing
Material #71209 or equivalent for at least 3 complete and consecutive threads.
For the 1/4" I.D. Air Hoses, install the fixed nut end first.
To install the Air Lines and Hoses, the Air Filter/Regulator must be in position.
If you are unsure of the Air Line and Hose locations, see the Air System Troubleshooting Guide TRTS0920.
Special Tools
• For 'Push-to-Connect' Fittings, the Eaton Service Tool Kit K-2394 is recommended. The Kit contains the Release Tool
and a Tubing Cutter.
Procedure -
1. Replace damaged Air Fittings.
73
2. Connect the Air Lines from the Slave Valve to the

Range Cylinder.
3. Connect all removed Air Lines and Hoses.
4. Make sure the Fittings are tight and the Lines are not kinked.
74
How to Remove Compression Type Fittings

WARNING

A sudden release of air pressure can cause personal injury or damage to equipment. To prevent injury or equipment damage,
exhaust the Vehicle Air Tanks
CAUTION
Small Air Lines are available in 1/8" or 5/32" sizes. Make sure 1/8" Air Lines are used with 1/8" Fittings and 5/32" Lines are
used with 5/32"Fittings. Mixing sizes can cause air leaks or damage to Fittings.
Before removing the Air Lines and Hoses, label or record their location.
Special Tools
Procedure -
1. Exhaust the Vehicle Air Tanks before continuing.
2. Loosen the nut on the fitting, and slide it back out of the way.
3. Pull the Air Line and attached Collet from the fitting.
4. Inspect the fitting, Air Line, Collet, and Nut for damage or
wear. Replace as necessary.
75
How to Install Compression Type Fittings

WARNING
CAUTION
Small Air Lines are available in 1/8" or 5/32" sizes. Make sure 1/8" Air Lines are used with 1/8" Fittings and 5/32" Air Lines
are used with 5/32" Fittings. Mixing sizes can cause air leaks or damage to Fittings.
Special Tools
Procedure -
1. Check the threads of the fitting for thread sealant. If no
sealant is present, apply Eaton Thread Sealant #71205
or equivalent.
2. Install the fitting.
Note: Do not overtighten the nut. Overtightening can

compress the Collet too much and cause an
air line restriction.
3. Install the Air Line, Collet, and Nut. If installing a new fitting,
place the Collet in the fitting and loosely install the Nut. (Do
not tighten the Nut yet.) Insert the Air Line through the Nut
and into the Collet. Tighten the Nut as usual.
4. Enable the Vehicle Air System. Allow the Air Tanks to

pressurize, and check for leaks. Repair as necessary.
76
How to Remove Push-to-Connect Type Fittings

WARNING

exhaust the vehicle air tank.
CAUTION
Make sure only 5/32" Air Lines are used with Push-to-Connect Fittings. Using sizes other than 5/32" can cause air leaks or
damage to Fittings.
Before removing the Air Lines and Hose, label or record their location.
Special Tools
• See Tool Information (see Table 8)
• For “Push-to-Connect" Fittings, the Eaton Service Tool Kit K-2394 is recommended. The Kit contains the Release Tool
and the Tubing Cutter.
Procedure -
1. Exhaust the Vehicle Air Tanks before continuing.
2. Use the Air Line Release Tool from Kit K-2394 to press
the Release Sleeve down while pulling the Air Line from
the fitting.
3. Inspect the fitting for damage or wear. Remove and

replace as necessary.
77
How to Install Push-to-Connect Type Fittings

WARNING
CAUTION
Make sure only 5/32" Air Lines are used with Push-to-Connect Fittings. Using sizes other than 5/32" can cause air leaks or
damage to Fittings
Special Tools
• See Tool Information (see Table 5)
• For 'Push-to-Connect' Fittings, we recommend Eaton Service Tool Kit K-2394. The Kit contains the Release Tool and the
Tubing Cutter.
Procedure -
1. Check the threads of the fitting for thread sealant. If no
sealant is present, apply Eaton Thread Sealant #71205
or equivalent.
2. Install the fitting.
3. Inspect the Air Line for burrs or deformed areas. Trim the
air line if necessary using a sharp razor blade or the Air Line
Cutting Tool from Kit K-2394. The cut must be smooth and
square. If the tubing end is deformed or burred, the
internal O-Ring in the fitting will be damaged when the Air
Line is inserted.
4. Push the Air Line into the fitting. It should insert

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

pressurize, and check for leaks.
78
How to Remove Rubber 1/4" Air Hoses

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

Procedure -
1. Remove all Air Line Brackets and Ties.
2. Remove swivel end.
3. Remove fixed end.
79
How to Install Rubber 1/4" Air Hoses

For the 1/4" I.D. air Hoses, install the fixed nut end first.
Special Tools
Procedure -
1. If necessary, apply Eaton Thread Sealant #71205 or
equivalent to threads.
2. Install and tighten fixed end first, then install and tighten
swivel end.
3. Replace all Air Line Brackets and Ties.
80
How to Remove the Air Filter/Regulator

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

Procedure -
1. Remove the Air Lines from the air Filter/Regulator.
2. From the Air Filter/Regulator, remove the two (2)

Cap Screws.
81
How to Install the Air Filter/Regulator

The Air Filter/Regulator has two (2) O-Rings located between the Filter/Regulator and the Range Cylinder Cover.
Special Tools
Procedure -
1. Position the Air Filter/Regulator.
2. Apply Eaton Sealant #71205 or equivalent to the two (2)

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

8–12 lb-ft (10.85–16.30 N•m).
82
How to Remove a Roadranger Valve

WARNING

A sudden release of air pressure can injure you or damage equipment. To prevent injury or equipment damage, the Vehicle
Air Tanks must be exhausted.
Special Tools
Procedure -
1. From the Roadranger Valve Cover, remove the two (2)
Mounting Screws.
2. Slide the Roadranger Valve Cover down.
3. From the Air Fittings, disconnect the Air Lines.
4. From the Roadranger base, loosen the Jam Nut. Rotate the
Roadranger Valve until the Valve is removed.
5. Inspect the parts: nut, Valve Cover, Air Lines, sheathing, and
O-Rings from the Lever Shaft.
6. In the Roadranger Valve, inspect the Air Fittings, and remove

if damaged.
83
How to Install a Roadranger Valve

To position the Roadranger Valve, the Range Lever must be to the front or the Splitter Button to the left when facing forward.
Special Tools
Procedure -
1. Make sure the Nut, Valve Cover, Air Lines, sheathing, and
O-Rings are in position on the Lever Shaft.
2. If previously removed, replace the Air Fittings and torque to

84–120 lb-in (9.49–13.56 N•m).
3. Place the Roadranger Valve on the Lever Shaft and rotate so

the Range Selector faces the vehicle front.
4. From the Roadranger Valve bottom, torque the Jam Nut to

35–45 lb-ft (47.45–61.01 N•m).
5. Connect the Air Lines to the Air Fittings.
6. Slide the cover into position on the Roadranger Valve.
7. Install the Roadranger Valve Cover mounting screws.
Note: Make sure the Air Lines are seated fully.
84
How to Remove a Slave Valve

WARNING

A sudden release of air pressure can injure you or damage equipment. To prevent injury or equipment damage, the Vehicle
Air Tanks must be exhausted.
Special Tools
Procedure -
1. Record or mark Air Line locations. Retaining
Capscrews
2. Remove all Air Lines.
Note: Remove three 1/4" ID air Hoses at swivel fitting at

Range Cylinder location. Remove Air Line Bracket at
rear of Transmission. Remove Slave Valve with air
Hoses still attached.
3. Remove the Retaining Cap Screws around Valve perimeter.
4. Remove Slave Valve and Gasket.
5. From the Transmission Case, remove the Sleeve, Spring,

and Plunger Pin. Plunger
Pin
Spring
Sleeve
6. Inspect the Air Fittings, replace if damaged.

Air Line
Fittings
85
How to Install a Slave Valve

None
Special Tools
Procedure -
1. Clean gasket surface and install Air Fittings.
Air Line
Fittings
2. Lightly lubricate and install plunger Pin, Spring, and Sleeve

into Case.
Plunger
Pin
Spring
Sleeve
3. Install any necessary air Hoses at this time.
4. Install new Gasket.
5. Apply Eaton Sealant #71205 or equivalent to the Retaining

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

torqued.
86
How to Remove the Top-2 Valve Assembly (Transmissions with Top-2 Option Only)
The Air Lines must be depressurized.
Special Tools

Procedure -
1. From the 3-Way Connector, disconnect the Wire Harness.
2. From the Air Fittings, disconnect the Air Lines.
3. From the Top-2 Valve Assembly, remove the two (2)

Cap Screws.
Note: If necessary remove the Exhaust Breather from the

Top-2 Valve (arrow indicates location on the Valve).
87
How to Install the Top-2 Valve Assembly (Transmissions with Top-2 Option Only)
The Air Lines must be depressurized.
Special Tools
Procedure -
1. Install the two (2) Retaining Cap Screws, torque to
35–45 lb-ft (47.45–61.01 N•m).
Note: Install the Exhaust Breather on the Top-2 Valve if

previously removed (arrow shows location on the
Top-2 Valve.
2. Connect the Air Lines to the Air Fittings.
Note: Replace any damaged Air Fittings or Lines.
3. Connect the 3-Way Connector to the Harness.
Note: Be sure Connector is free from dirt and debris.
88
How to Remove the Gear Shift Lever/Remote Shift Control

The Air Lines must be disconnected from the Transmission or from the Roadranger Valve.
Different Detent Springs are available to increase or decrease shifting effort. Note and record specific locations for specific springs.

In some cases, a stiffer spring is installed in the top rail position.
Remote Control Housings are removed the same way as Gear Shift Levers.
Special Tools
Procedure -
1. From the Gear Shift Lever Base/Shift Control Housing,
remove the four (4) Retaining Cap Screws.
2. To break the Gasket seal, lightly jar the Gear Shift/Shift

Control Housing.
3. Remove the Gear Shift Lever Housing.
CAUTION
Make sure the Detent Springs do not fall into the

Transmission.
4. Remove Detent Springs as needed.
5. Remove the Gasket and clean the area the Replacement

Gasket will contact.
89
How to Install the Gear Shift Lever/Remote Shift Control

Remote Control Housings are installed the same way as Gear Shift Levers.
For Standard and Forward Shift Bar Housings, make sure the Detent Springs and Balls are in the Shift Bar Housing top Bores.
Make sure the Shift Block and Yoke Notches are aligned in the Neutral position.
Special Tools
Procedure -
1. Thoroughly clean mounting surface.
2. Position a new Gear Shift Lever/Shift Control Housing

Gasket on the Gear Shift Lever mounting surface.
3. Install the Detent Springs.
4. Install the Shift Lever/Shift Control Housing. Make sure the

tip (finger) of the Gear Shift Lever fits into the slots in the
Shift Block.
5. Apply Eaton Sealant #71205 or equivalent to the Retaining

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

(47.45–61.01 N•m).
Note: Make sure the Cap Screws are properly torqued.
Note: Make sure you can shift the Transmission.
90
How to Adjust the Remote Shift Control (LRC Type)

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

Special Tools
Procedure -
1. Move the Gear Shift Lever forward or backward to the
Neutral position.
2. Move the Gear Shift Lever sideways, toward Reverse,

until you feel resistance from the Reverse Plunger Spring.
DO NOT shift to Reverse. The Shift Finger must remain in
this position while you are making all the adjustments.
3. Remove the Cotter Pin, Castle Nut and Ball Joint A (see
figure A) from the Selection Lever. Do not remove the Ball
Joint from the Pivot Link.
4. Loosen the Cap Screw B (see figure A) and remove the

Shift Arm from the inner Shift Shaft. Do not disconnect the
Selection Lever from the Shift Arm.
5. Turn the Shift Arm until it is at a right angle (90°) to the

Selection Lever as viewed from the side (see figure B).
Note: Ideally, the Shift Arm should be adjusted 90° to the
Selection Lever as described, but in some Chassis
configurations it may be necessary to index the
Shift Arm in the vertical position. Indexing the
Shift Lever is done to prevent Shift Lever jump out.
This type of adjustment will cause an unequal amount
of Gear Shift Lever travel between Neutral and a
forward lever position as compared to Neutral and a
rearward lever position.
6. Install the Shift Arm on the Splines of the inner Shift Shaft.
You may have to move the Shift Arm 4 or 5 to align the
Splines of the two parts. Disregard any movement of the
Gear Shift Lever at this point. The Gear Shift Lever will be
adjusted later.
91
7. Tighten the Cap Screw B (see figure A) on the Shift Arm.
8. Connect the Pivot Link assembly Ball Joint to the Selection

Lever. Secure it with the Castle Nut and Cotter Pin.
9. Loosen the Jam Nuts C (see figure C) on the Pivot Link.
10. Check to be sure the inner Shift Finger is still in place.
11. Rotate the Pivot Link until the curved end of the Selection
Lever is parallel with the Shift Arm as viewed from the rear
(see figure C).
12. Tighten the Pivot Link Jam Nuts C (see figure C).
13. Loosen both Cap Screws on the Turnbuckle D (see figure A).
14. Check to be sure inner Shift Finger is still in place.
15. Rotate the Turnbuckle to obtain the proper forward-

backward Neutral position of the Gear Shift Lever in the cab.
16. Tighten one Turnbuckle D Cap Screw (see figure A).
17. Move the Gear Shift Lever to the desired position.
18. Turn the second Turnbuckle D Cap Screw.
19. Check for linkage obstructions in all gear positions.
92
Neutral Switch Operation and Testing

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

Special Tools
• Volt/Ohm Meter
Procedure -
1. Disconnect the wiring from the Switch.
2. Connect an Ohm Meter to check for continuity or a

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

The Ohm Meter should register continuity or a small
reading. If it does, go to the next step. If it does not, remove
the Switch and replace it.
4. Shift the Transmission into all gear positions. The Ohm

Meter should read Open or Infinity. If it does not, remove the
Switch. Then, depress the Switch ball and check for
continuity. The Ohm Meter should read Open or Infinity
when the Ball is depressed.
5. Look into the Neutral Switch hole and verify that the Air
Valve Shaft moves as the Transmission is shifted from
Neutral into gear.
a. If it does, replace the Switch.
b. If not, remove the Shift Bar Housing and check the
Air Valve and Shift Rails for excessive wear. Also, check
the Slave Valve Plunger and Spring for free movement.
93
How to Remove the Neutral Switch

None
Special Tools
Procedure -
1. Remove 2 screws retaining Wire Terminals.
2. Remove the Switch using a 7/8" Deep Well Socket or

Box End Wrench.
94
How to Install the Neutral Switch

None
Special Tools

Procedure -
1. Install a new Gasket.
2. Install the Neutral Switch, torque to 15–20 lb-ft

(20.34–27.12 N•m).
3. Connect the wiring to the Switch.
95
Reverse Switch Operation and Testing

The Reverse Switch is a normally open Ball Switch. When the Transmission is shifted into Reverse, a Ramp on the Reverse Yoke
Bar contacts and raises a Pin. The Pin depresses the Ball on the Switch, which closes the Switch Contact, allowing current to flow
through the Switch and light up the vehicle's backup lights.
Special Tools
• Volt/Ohm Meter
Procedure -
1. Disconnect the wiring from the Switch.
2. Connect an Ohm Meter to check for continuity.
3. Place the Transmission Shift Lever in any position except

Reverse. If the Switch is working properly, the Ohm Meter
should read Open or Infinity. If it is not, remove the Switch
and recheck it for continuity. Replace as necessary.
4. Place the Transmission Shift Lever in the Reverse position.

If the Switch is working properly, the Ohm Meter should
register continuity, or a small reading. If it does not, remove
the Switch and recheck it for continuity. Replace it as
necessary. Also, check for sticking or excessive wear of the
Reverse Pin.
96
How to Remove the Reverse Switch

None
Special Tools

Procedure -
1. Remove 2 screws retaining wire terminals.
2. Remove the switch using a 7/8" Deep Well Socket or Box

End Wrench.
97
How to Install the Reverse Switch

None
Special Tools
Procedure -
1. Insert the Reverse Pin in the Reverse Switch Bore.
2. Install new Gasket on Switch.
3. Install the Reverse Switch, torque to 15–20 lb-ft

(20.34–27.12 N•m).
4. Connect the wiring to the Switch.
98
How to Remove the Shift Bar Housing

Before removing the Shift Bar Housing, the Air Lines must be disconnected.
For models equipped with an Oil Pump and/or Cooler Assemblies, make sure to disconnect the Oil Line connected to the

Shift Bar Housing.
There are three (3) sizes of Cap Screws. The 1 1/2" Cap Screws are used with the Lifting Eyes. The 1 1/4" are used on all
other locations except the left front corner at the Roll Pin location. This Cap Screw is 1 3/4".
Be careful when removing the Shift Bar Housing to prevent damaging the Oil Tube with the Shift Yokes.
Special Tools
Procedure -
1. From the Shift Bar Housing, remove the two Retaining
Cap Screws securing the Oil Cooler. Remove Oil Cooler
and set aside.
2. Remove Slave Valve.
99
3. Remove Interlock parts (Pin, Spring, and Sleeve).
4. From the Shift Bar Housing rim, remove the Retaining

Cap Screws.
5. To break the Gasket seal, jar the Shift Bar Housing.
6. Remove the Shift Bar Housing.
7. Inspect the Roll Pin, replace if damaged.
8. Remove the Gasket and clean all mounting surfaces of

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

the Housing top Bores are loose, tilt the Assembly and
remove them.
100
How to Install the Shift Bar Housing

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

The Slave Valve and Interlock parts must be removed prior to installing the Shift Bar Housing.
Special Tools
Procedure -
1. Place the Shift Bar Housing and Shift Blocks in the
Neutral position.
2. Place the Mainshaft Sliding Clutches in the Neutral position.
3. Position a new Shift Bar Housing gasket on the Shift Bar

Housing mounting surface.
Note: The Slave Valve and Interlock Assembly must remain

off, until the Shift Bar Housing is installed, to avoid
damaging the Interlock Pin.
4. As you install the Shift Bar Housing, make sure the Yokes fit
into the corresponding Sliding Clutch slots and the Housing
aligns with the Roll Pin.
5. Apply Eaton® Sealant #71205 or equivalent to the

Retaining Cap Screws. Torque the Cap Screws to
35–45 lb-ft (47.45–61.01 N•m).
101
6. Install Interlock parts (Pin, Spring and Sleeve).
7. Install Slave Valve. Apply Loctite 242 to Cap Screw threads

and torque to 8–12 lb-ft (10.85–16.30 N•m).
102
How to Remove the Oil Seal - Mechanical Speedometer

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

For additional information on Rear Seal service, refer to the Seal Maintenance Service Brochure TRSM0912.
Special Tools
• Output Yoke Puller
• RR1010TR Slide Hammer
• RR1011TR-1 Slide Hammer Attachment
1. Bushing 5. Oil Seal with Slinger

2. Rear Bearing Cover Assembly 6. O-Ring
3. Cap Screw 7. Speedometer Spacer Assembly
4. Speedometer Drive Gear
103
Procedure -
1. Disconnect the Driveshaft and U-joint from the Output

Yoke according to the OEM or Driveshaft Manufacturer's
instructions.
2. Shift the Transmission into 1st Gear or Low Gear (Low

Range) to prevent the Output Yoke from turning when you
loosen the Output Shaft Nut.
3. Remove the Output Shaft Nut using a 70 mm or 2 3/4"

socket. See “How to Remove Output Yoke/Companion
Flange”.
4. Remove the Output Yoke. If necessary, use an Output

Yoke Puller.
5. Remove the Seal sleeve.
6. Use RR1010TR Slide Hammer and RR1011-1 Attachment to

remove the Seal. Or remove Output Bearing Cover and drive
Seal out from front side.
Note: The Seal will be damaged during removal and must

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

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

burrs, or other damage.
Note: Replace the Seal surface if it is worn or damaged.

Do not attempt to salvage the Seal mating surface
with Crocus Cloth, filing, etc.
104
How to Install the Oil Seal - Mechanical Speedometer

CAUTION

To prevent oil leaks, do not touch the seal lip, and make sure the Seal Driver is clean.
Special Tools
• RR1001TR-2 Output Seal Driver
• RR1001TR-4 Output Seal Slinger Driver
Procedure -
1. The Seal will be damaged during removal and must
be replaced.
2. Place a Seal on the RR1001TR-2 Output Seal Driver, and

drive the new Seal into the Rear Bearing Cover.
3. Install the new Slinger on the Output Yoke using the

RR1001TR-4 Output Seal Slinger Driver.
4. Install the Output Yoke over the Output Shaft. The Yoke
should slide on when the Splines are lined up. If it does not,
clean the Splines with solvent, and oil them lightly.
5. Install the Output Nut and torque to 650–700 lb-ft

(881.28–949.07 N•m).
6. Connect the Driveshaft and U-joint according to the OEM

or Driveshaft Manufacturer's instructions.
105
How to Remove the Oil Seal - Magnetic Speedometer

Prior to replacing the Seal, carefully inspect the Transmission to make sure the oil leakage is coming from the Seal. Pay
particular attention to the Speedometer parts, the Rear Bearing Cover gasket surfaces, Rear Countershaft Bearing Covers,
and Shift Bar Housing.
Special Tools
1. Rear Bearing Cover 6. Oil Seal

2. Sensor Retaining Cap Screw 7. Slinger
3. O-Ring 8. O-Ring
4. Speedometer Sensor 9. Speedometer Spacer Assembly
5. Cap Screw
106
Procedure -
1. Disconnect the Driveshaft and U-joint from the Output
Yoke according to the OEM or Driveshaft Manufacturer's
Instructions.
2. Shift the Transmission into 1st Gear or Low Gear (Low

Range) to prevent the Output Yoke from turning when
you loosen the Output Shaft Nut.
3. Remove the Output Shaft Nut using a 70 mm or

2 3/4" socket.
4. Remove the Output Yoke. If necessary, use an Output

Yoke Puller. See “How to Remove the Output Yoke/
Companion Flange.”
5. Remove the Speedometer Sensors from the Rear

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

threads expose so the Sensor can be reinstalled to the
same depth. If the Sensor is a push in type, remove
the hold down Cap Screw and pull the Sensor out of
the Bore.
6. Remove the Speedometer Rotor/Seal Sleeve and the O-Ring.
7. Pry the Seal out using a large Screwdriver or Pry Bar in the
metal groove of the Seal.
Note: The Seal will be damaged during removal and must

be replaced.
8. Remove Seal Slinger from the Speedometer Rotor/Seal

Sleeve using a Brass Drift and Hammer.
9. Inspect all parts of the Seal surface for wear, scratches,

burrs, or other damage.
Note: Replace the Seal surface if it is worn or damaged.

Do not attempt to salvage the Seal mating surface
with Crocus Cloth, filing, etc.
107
How to Install the Oil Seal - Magnetic Speedometer
Special Tools
• RR1001TR-2 Output Seal Driver
• RR1001TR-8 Seal Driver Insert
• RR1001TR-1 Seal Slinger Driver
Procedure -
1. Using the RR1001TR-2 Seal Driver and RR1001TR-8 Seal
Driver Insert, drive the new Seal into the Rear Bearing Cover.
The Seal is fully installed when the Flange on the Seal is flush
with the shoulder in the Bore.
2. Install the new Slinger on Speedometer Rotor/Seal Sleeve

using the RR1001TR-1 Slinger Driver.
3. If previously removed, install the O-Ring over the

Output Shaft.
Note: To avoid creating oil leaks, make sure the

Speedometer Rotor/Seal Sleeve is free from
contaminants.
108
4. Install the Speedometer Rotor/Seal Sleeve over the Output

Shaft, and install the Speedometer Sensors.
should slide on an stop before contacting the Speedometer
Rotor. As the Output Shaft Nut is installed, the Output Yoke
will contact the Speedometer Rotor.

6. Install the Output Nut and torque to 650–700 lb-ft
(881.28–949.07 N•m).
7. Connect the Driveshaft and U-joint according to the OEM or

Driveshaft Manufacturer's instructions.
109
How to Remove the Output Yoke/Companion Flange and Nut

After removal of the Output Yoke/Companion Flange, temporarily replace the Output Shaft Nut to protect the Output Shaft threads
during Auxiliary Section disassembly.
Special Tools
• A large Breaker Bar or Air Impact Wrench
Procedure -
1. Engage two (2) Mainshaft Sliding Clutches into two (2)
Mainshaft Gears to lock the Transmission or use a Yoke
Holding Tool if available.
2. Use a large Breaker Bar or Air Impact Wrench to remove

the Output Shaft Nut.
3. Remove the Output Yoke.
110
How to Install the Output Yoke/Companion Flange and Nut

Special Tools
• Torque Wrench with 0–700 lb-ft capacity

Procedure -
1. Engage two (2) Mainshaft Sliding Clutches into two (2)
Mainshaft Gears to lock the Transmission, or use a Yoke
Holding Tool if available.
2. Install the Speedometer Drive Gear Rotor or Replacement

Spacer on the Output Shaft inside the Rear Bearing Cover.
3. If the Slinger on the Yoke is damaged, replace using a

Slinger/Seal Kit.
should slide on and stop before contacting the Speedometer
Rotor. As the Output Shaft Nut is installed, the Output Yoke
will contact the Speedometer Rotor.
5. Install the Output Shaft Nut, tighten to 650–700 lb-ft

(881.28–949.07 N•m) of torque.
6. Make sure the Output Shaft Nut is properly torqued and

unlock the Transmission, or remove the Yoke Holding Tool.
111
How to Remove the Output Yoke / Flange and Retaining Cap Screws
None
Special Tools
Procedure -
1. Remove Drive Shaft from the Transmission.
Reference OEM removal guidelines.
2. Remove the End Yoke Retaining Cap Screws and

Washer from Auxiliary Mainshaft.
3. Remove the End Yoke/Flange.
112
How to Install the Output Yoke / Flange and Retaining Cap Screws
Special Tools

Procedure -
1. Install End Yoke, Retaining Washer, and Cap Screws. Apply
Eaton/Fuller #71205 Liquid Thread Sealant to Cap Screws
and then snug each Cap Screw to 35 lbs. ft. [47 N·m.]
2. Fully tighten both Retaining Cap Screws to specified torque

rating 74–81 lbs. ft. [100–110 N·m.]
Note: This fastening design employs Spiralock™ threads.

A conventional metric thread Pitch Tap cannot be
used for thread restoration on this product.
WARNING
Use only Eaton/Fuller #71205 Liquid Thread Sealant

or liquid equivalent on the Yoke Retaining Cap Screws.
Do not use any type of thread locking tape on the
End Yoke Retaining Cap Screws. This may cause the
Cap Screws threads to strip and cause the End Yoke
to loosen.
3. Reinstall Driveshaft per OEM guidelines.
113
How to Remove the Auxiliary Section in Chassis

None
Special Tools
• RR1002TR Auxiliary Countershaft Support Straps
• RR1006TR Auxiliary Section Lifting Bracket
Procedure -
1. Drain the Transmission Oil.
2. Disconnect the Driveshaft and U-joint from the Output Yoke.
3. If the Auxiliary Section is to be disassembled, remove the

Output Nut. To prevent the Output Shaft from rotating while
removing the Nut, shift the Transmission into 1st Gear.
4. Disconnect the vehicle air supply line from the Filter

Regulator Assembly.
5. Mark the locations and disconnect the large rubber Air

Lines. Move the lines aside.
6. Label and remove the small Air Lines.
7. Remove the four (4) Cap Screws and the Auxiliary

Countershaft Rear Bearing Cover, Gasket, and Rear
Bearing Shim.
8. Install RR1002TR Auxiliary Countershaft Support Straps.
Note: Do not use and Air Gun. Tighten by hand until the
Cap Screws are snug.
9. Drive the two Dowel Pins forward, and remove them.
114
10. Remove all but one Cap Screw that secure the Auxiliary
Section to the Main Section. Leave one Cap Screw to secure
the Housing until it is ready to be removed.
Note: Cap Screws are different lengths. Note their locations

for reassembly purposes.

WARNING
Use the proper equipment with safety chains attached to

remove the Auxiliary Section. The Auxiliary Section can
slide rearward and could fall, causing you serious injury
and/or damage to the Auxiliary Section.
11. Attach a Chain and Lifting Device to the Auxiliary Section

Hanger (figure A), or attach the Support Jack to the Auxiliary
Section (figure B).
12. With the Support Device in position, remove the remaining

Cap Screw. If necessary, 3 Cap Screws can be installed into
the three threaded holes in the Auxiliary Section Flange.
When threaded in they will push the Auxiliary Section
rearward. Clean the holes of rust, paint, and other debris by
threading a 3/8-16 Tap into each hole. Thread each Cap
Screw in evenly to prevent damage to the Auxiliary Housing.
CAUTION
The weight of the Auxiliary Section must be supported

during removal to avoid damage to internal
Transmission parts.
13. Support the weight of the Auxiliary Section with a

Lifting Device or Support Jack and move the Auxiliary
Section rearward until it is free from the Front Section
of the Transmission.
115
How to Install the Auxiliary Section in Chassis

None
Special Tools
Procedure -
1. Install the RR1002TR Auxiliary Countershaft Support Straps
to center and hold the Countershafts in position. Install a
3/8"-16 X 2 1/2" long Cap Screw into Countershaft center.
2. Install the Output Yoke and Nut, torque the Nut to

650–700 lb-ft (881.28–949.07 N•m).
Note: To prevent the Output Shaft from rotating while

installing the Nut, place a clean shop rag in the
gear mesh.
Note: Due to Chassis interference, it may not be possible to

install the Yoke at this step. However, the Output
Shaft must be drawn fully into position to prevent it
from sagging when the Auxiliary Section is installed in
the Chassis. If the Chassis causes interference, the
Yoke can be temporarily installed to draw up the
Output Shaft and then removed before the Auxiliary
Section is installed.
3. Use Crocus Cloth or a Wire Wheel to clean rust and paint

from the Dowel Pins before installing them.
CAUTION
If the Dowel Pins are not installed in the Main Case to the
proper depth, the Auxiliary Section will not properly align
with the Main Case and Bearing or Synchronizer failure
may occur.
116
4. Install the Dowel Pins into the Main Case so that 3/8"-1/2" of
the shoulder is exposed or Pin is flush with front of
Case rear.
5. Clean all rust and paint from the Dowel Pin holes in the
Auxiliary Section Housing, and lightly grease the Dowel Pins
on the Main Case and the Dowel Pin holes on the Auxiliary

Section Housing.
6. Make sure the Auxiliary Section is in Low Range. If not, blow

shop air (max 100 PSI) into the Low Range Supply Port to
shift the Range Synchronizer to Low. If necessary, make
sure the Deep Reduction Clutch is engaged into gear.
7. Position the Gasket onto the Main Case mounting surface.
8. Mount the Auxiliary Section on the Lifting Device or Jack.
9. Tighten the center Cap Screw on the Countershaft Support

Tools to draw the Countershafts into a level position. Do not
overtighten the Cap Screws. The Output Yoke and Shaft
must be able to rotate.
10. Position the Auxiliary Section in line with the Main Case, and
slide the Housing onto the Dowel Pins. Mesh the
Countershafts with the Auxiliary Drive Gear. Rotate the
Output Yoke and Shaft slightly to help the gears mesh and
slide the Auxiliary Section forward until it is flush with the
Main Section.
CAUTION
The Auxiliary Section should slide into place fairly easily.

DO NOT force it on or pull it into place with the Cap
Screws. Excessive force may damage the Transmission.
If excessive force is necessary, the gearing is likely out
of time.
11. If the Auxiliary Section does not install fully, slide it back and
check the following:
a. The Output Yoke and Nut should be installed to pull
back and center the Auxiliary Mainshaft Assembly.
b. The Countershaft Support Tool center Cap Screw
should be snug to level the Countershafts.
c. The Dowel Pins and Auxiliary Housing mating holes
should be clean and well oiled.
d. The internal gearing on the Auxiliary Section must have
been properly timed during reassembly.
117
12. Apply Eaton® Thread Sealant #71205 or equivalent to all the

Retaining Cap Screw threads. Install the Cap Screws to
secure the Auxiliary Section to the Main Case, torque to
40–45 lb-ft (54.23–61.01 N•m).
13. If the Countershaft, Countershaft Bearings, or Auxiliary

Housing have been replaced, or if the Countershafts,
Bearings, or Shims were not marked and reassembled in the
same location, the Bearing endplay must be checked and set
by shimming. Shim the Countershaft Bearings using “Shim
Procedure without a Shim Tool”.
14. If shimming is not required, remove the Support Tools, and

install the proper Shim, Gasket, and Countershaft Bearing
Cover. Secure the Bearing Covers with the Cap Screws.
Install sealer. Apply Loctite 242 to Cap Screw threads and
torque to 40–45 lb-ft (54.23–61.01 N•m).
15. Connect all removed air Hoses and lines. Use Eaton®
Fuller® Thread Sealant #71205 or equivalent as necessary.
16. Connect the Driveshaft and U-joint, and refill the

Transmission with the recommended lubricant. For
lubrication instructions refer to the “Lubrication and
Maintenance” section.
118
How to Remove the Splitter Cylinder Assembly
Note: On 9-Series and Super 10 Transmissions, it is necessary to R&R the Auxiliary Section prior to Range Cylinder removal.
Damage to internal components will result if Auxiliary Section is not properly removed prior to Cylinder removal.

Note: When replacing just the O-Rings in the Splitter Cylinder, removal of the Auxiliary Section is not necessary.
When removing the Splitter Cylinder Cover Insert Valve, note the direction the Insert Valve was positioned (nipple in or out).
Special Tools
7
5
2 3
1
8
6
4
18
14
13
13/18-Speed
15
12
9-Speed
1. Splitter Yoke Assembly 8. O-Ring

2. Gasket 12. O-Ring
3. Splitter Cylinder 13. O-Ring
4. O-Ring 14. Breather
5. Piston 15. Splitter Valve Replacement Kit
6. O-Ring 18. Cap Screw
7. Nut
119
Procedure -
1. Drain lube.
2. From the Splitter Cylinder Cover, remove the Retaining

Cap Screws.
3. Remove the Cover and Gasket or O-Ring (new design,

aluminum cover).
4. Remove the 3/4" Nut on the Splitter Yoke Bar.
5. From the Auxiliary rear, remove the Splitter Cylinder

Housing.
6. If necessary, turn out the Insert Valve Retaining Nut and

remove Insert Valve from Bore (only present on old style
13–18 Speed).
7. If Spool Valve needs to be replaced it must be done as an

entire unit which is part of the Splitter Cover.
Note: New 13/18 Speeds Splitter Covers contain a Spool

Valve that is replaced as a unit.
120
How to Install Splitter Cylinder Assembly

Apply Eaton® Lubricant #71214 or equivalent to all Shift Cylinder Assembly and Spool Valve O-Rings so a film covers the entire
surface of each O-Ring.

Apply Eaton® rust preventative #71213 or equivalent to all Shift Cylinder walls and Yoke Bars and cover the entire Yoke Bar
surface that comes in contact with the Shift Cylinder O-Ring.
Special Tools
• Vise with brass jaws or wood blocks
7
5
2 3
1
8
6
4
18
14
13
13/18-Speed
15
12
9-Speed

7. Nut
121
Procedure -
1. If previously removed, in the Cylinder Housing Bore,
install the small O-Ring.
2. If previously removed, on the Piston O.D., install the

Piston O-Ring.
3. Position a new gasket on the Cylinder Housing

mounting surface.
4. With the air passage towards the Rear Bearing Cover,

install the Cylinder Housing.
5. Inside the Cylinder Housing, over the Yoke Bar end,

install the O-Ring.
6. With the recessed side up, install the Splitter

Cylinder Piston.
7. Install the 3/4" Lock Nut. Tighten the Lock Nut to

30–36 lb-ft (41–49 N•m) of torque.
122
8. Position a new Gasket or O-Ring (new design, aluminum

cover) on the Cylinder Housing Cover mounting surface. The
Gasket air passage must align with the Housing air passage.
9. Position the Splitter Cylinder Cover over the Gasket or

O-Ring (new design, aluminum cover).

10. New style Splitter Covers contain a Spool Valve, which must
be replaced as a unit with the entire Cover. Old style Splitter
Covers contain a separate Insert Valve that can be removed
from the bottom of the Splitter Cover.
11. Apply Eaton® Fuller® Sealant #71205 or equivalent to the

12. Install and torque the Retaining Cap Screws to 20–25 lb-ft
(27.12–33.90 N•m).
13. Refill Transmission with lube to the proper level.
Note: Make sure the Retaining Nut and Cap Screws are
tightened to the proper torque.
Note: Make sure Gaskets are used at appropriate positions.
123
How to Disassemble the Range Cylinder Assembly - 7 Series

None
Special Tools
10 11
9
7
11 5 8
6
4
3
2
1. Shift Yoke Assembly 7. O-Ring

2. Gasket 8. Nut
3. Range Cylinder 9. Gasket
4. O-Ring 10. Cover
5. Piston 11. Cap Screw
6. O-Ring
124
How to Disassemble the Range Cylinder Assembly - 9 Series

For RTLO-XX9XX (9 Series), remove the Auxiliary Section before disassembling the Range Cylinder. See instructions for
Removing Auxiliary Section on page 114.

Special Tools
9 13
10 12 11
8
7
6
1 3
2
1. Gasket 8. Piston
2. Shift Yoke 9. O-Ring
3. Bolt 10. O-Ring
4. Range Cylinder Assembly 11. Nut
5. Cap Screw 12. Gasket
6. O-Ring 13. Cover
7. Yoke Bar
125
Procedure -
1. From the Range Cylinder Cover, remove the Cap Screws,
Cover, and Gasket.
2. Clean the Gasket mounting surfaces of all gasket material.
3. From the Range Cylinder Housing Bore, remove the

15/16" nut.
4. From the Cylinder Housing Bore, remove the Range Piston.
5. Inspect the Range Piston O-Rings, remove if damaged.
6. Remove the Cap Screws and Range Cylinder Housing.
7. Clean the Gasket mounting surfaces of all gasket material.
8. Inspect the O-Ring inside the Range Cylinder Housing Bore,

remove if damaged.
126
How to Assemble the Range Cylinder Assembly

Apply Eaton® Lubricant #71214 or equivalent to Shift Cylinder Assembly and Insert Valve O-Rings so a film covers the entire

Special Tools
9 13
10 12 11
8
7
6
1 3
2
1. Gasket 8. Piston
3. Bolt 10. O-Ring
6. O-Ring 13. Cover
7. Yoke Bar
127
Procedure -
1. If previously removed, in the Cylinder Housing Bore, install
the small O-Ring.
2. If previously removed, on the Piston I.D. and O.D., install the

Piston O-Rings.
3. Position a new Gasket on the Range Cylinder Housing

mounting surface.
4. Install the Cylinder Housing.

Retaining Cap Screw threads.
6. Install the Cap Screws, torque to 20–25 lb-ft

(27.12–33.90 N•m).
7. Lean Auxiliary Section back with Range Cylinder upward.
8. Insert the Piston. Push it in as far as it will go.
9. Secure the Piston with the Retaining Nut, torque to

70–85 lb-ft (94.91–115.24 N•m).
128
10. Position a new Gasket on the Cylinder Housing Cover

mounting surface.
11. Over the gasket, position the Range Cylinder Cover.


(27.12–33.90 N•m).
129
Transmission Overhaul Procedures - Bench Service
How to Disassemble the Gear Shift Lever

If total disassembly is needed, the Roadranger® Valve, must be removed first.
Release the Spring one coil at a time.
Special Tools
1. Pin 8. Cap Screw

2. Bushing 9. Gasket
3. Upper Lever 10. O-Ring
4. Snap Ring 11. Washer
5. Rubber Boot 12. Lower Lever
6. Spade Pin 13. Stepped Washer
7. Housing 14. Tension Spring
130
Procedure -
1. On a Non-Isolated Shift Lever, remove the Roadranger®
Valve using the “How to Remove the Roadranger® Valve”
instructions in In-Vehicle Service Procedures. If the Shift
Lever is equipped with a Lever Isolator, remove the Snap
Ring, Bushing, and Cross Pin to disconnect and remove the
upper Lever.
2. Slide the rubber Boot up and off the Shift Lever Shaft.
3. With Housing bottom facing up, secure the Assembly in

a Vise.
4. Use large Screwdriver to twist between the Spring and
Procedures - Bench Service

Transmission Overhaul
Housing, forcing the Spring from under the Housing Lugs
one coil at a time.
5. From inside the Housing Tower, remove the Tension Spring,

washer, and Gear Shift Lever.
6. In models so equipped, from the Housing Bore, remove the

Nut and Washer.
7. From the Housing Tower Spade Pin Bore, remove and

inspect the Spade Pin, discard if damaged.
8. From the Housing Tower inside groove, inspect the O-Ring,

discard if damaged.
131
How to Assemble the Gear Shift Lever

Inspect Tension Spring and Washer for wear.
Apply Eaton® rust preventative Lubricant #71212 or equivalent to the Shift Lever Pivot Ball. A rust preventative lubricant film
should cover all surfaces between and including the Pivot Ball.
Seat the Tension Spring one coil at a time.
Special Tools
1. Pin 8. Cap Screw

2. Bushing 9. Gasket
3. Upper Lever 10. O-Ring
4. Snap Ring 11. Washer
5. Rubber Boot 12. Lower Lever
6. Spade Pin 13. Stepped Washer
7. Housing 14. Tension Spring
132
Procedure -
1. With Housing bottom facing up, secure the Assembly in
a Vise.
2. If the Spade Pin is damaged, replace and install the Spade

Pin, in Housing Tower Bore.
3. In models so equipped, install the Nut and Washer in the

Housing Bore.

4. If the O-Ring is damaged, replace; lubricate the O-Ring with
Eaton® Fuller® Lubricant #71206 or equivalent. Install the
O-Ring in the Housing Tower inside groove.
5. Align the Lever Ball slot with the Spade Pin and position the
Gear Shift Lever in the Housing Tower.
6. With dished-side up, install the Washer over the Ball.
7. Using a large Screwdriver or Pry Bar, install the Tension

Spring under the Housing Lugs.
8. Remove the Assembly from the Vise.
9. Install a rubber Boot over the Gear Shift Lever and against
the Housing.
Note: Make sure the Gear Shift Lever can move.
133
How to Remove the Shift Bar Housing

Before removing the Shift Bar Housing, the Air Lines must be disconnected.
For models equipped with an Oil Pump and/or Cooler Assemblies, make sure to disconnect the oil line connected to the
Shift Bar Housing.
There are three (3) sizes of Cap Screws. The 1 1/2" Cap Screws are used with the Lifting Eyes. The 1 1/4" are used on all
other locations except the left front corner at the Roll Pin location. This Cap Screw is 1 3/4".
Special Tools
Procedure -
1. From the Shift Bar Housing, remove the two Shift Bar
Retaining Cap Screws securing the Oil Cooler. Remove
Oil Cooler and set aside.
134
4. From the Shift Bar Housing rim, remove the Retaining

Cap Screws.
5. To break the Gasket seal, jar the Shift Bar Housing.
6. Remove the Shift Bar Housing.
7. Inspect the Roll Pin, replace if damaged.

gasket material.

the Housing top Bores are loose, tilt the Assembly and
remove them.
135
How to Install the Shift Bar Housing

There are three (3) sizes of Cap Screws. The 1 1/2" Cap Screws are used with the Lifting Eyes. The 1 1/4" are used on all other
locations except the left front corner at the Roll Pin location. This Cap Screw is 1 3/4".
The Slave Valve and Interlock parts must be removed prior to installing the Shift Bar Housing.
Special Tools
Procedure -
1. Place the Shift Bar Housing and Shift Blocks in the
Neutral position.
2. Place the Mainshaft Sliding Clutches in the Neutral position.
3. Position a new Shift Bar Housing Gasket on the Shift Bar

Housing mounting surface.
Note: The Slave Valve and Interlock Assembly must remain

off, until the Shift Bar Housing is installed, to avoid
damaging the Interlock Pin.
4. As you install the Shift Bar Housing, make sure the Yokes fit
into the corresponding Sliding Clutch slots and the Housing
aligns with the Roll Pin.

136
7. Install Slave Valve and tighten to specifications.

137
How to Disassemble the Standard Shift Bar Housing

The Shift Bar Housing must be removed from the Transmission.
During disassembly, lay all parts on a clean bench in order of removal to facilitate assembly.
Shift Bars not being removed must be kept in the Neutral position or the interlocking parts lock the Bars.
Start with the bottom Shift Bar.
Cut the Lockwire and remove the Lock Screws from each Bar just before their removal.
Special Tools
Procedure -
Housing Bores have not been removed, place the Shift Bar
Housing on its side to remove them.
2. Remove the Oil Trough Retaining Cap Screws and Oil

Trough. (Some models do not have an Oil Trough.)
3. With the Housing rear to the right, lay the Assembly on a

flat surface.
138
4. While removing the top Yoke Bar to the right, remove the
two (2) Shift Blocks.

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

Boss Bore.
7. From the bottom Yoke Bar, remove the two (2) Shift Yokes.
139
8. As the Shift Bar clears the last Boss, two (2) 3/4" Interlock
Balls drop from the bottom rear Boss Bore.
9. If damaged, from the 1st and Reverse Shift Yoke, remove

the Plug, Spring, and Plunger.
10. Inspect the Yoke or Block parts; replace the worn parts.
140
How to Assemble the Standard Shift Bar Housing

Inspect Shift Blocks and Shift Yokes for wear.
Apply Eaton® Sealant #71208 or equivalent to the Shift Bar Housing Plugs which are used to plug Oil Cooler provision holes.
The sealant should be applied so at least 5 complete threads are covered.
Apply Eaton® Lockwire #1819 or equivalent to all Shift Bar Housing Assembly Set Screws in both Blocks and Yokes. The wire
should anchor the Cap Screw at least 2 complete 360 turns. The Lockwire ends should be trimmed and bent out of the way of
any part interference.
Keep Yoke Bars in Neutral while assembling.

Special Tools
Procedure -
1. Assemble the Yoke Actuator Assembly:
2. From the Shift Bar Housing bottom, install the Actuator Pin
and Yoke Actuator.
3. On the Shift Bar Housing top, install the Washer and Nut.
141
4. Assemble the 1st and Reverse Shift Yoke Assembly:

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

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

passes the Bosses, install the two (2) bottom Shift
Yoke Assemblies.
7. Install the Shift Yoke Lock Screw, torque to 35–45 lb-ft

(47.45–61.01 N•m). Lockwire securely.
8. Place the Actuating Plunger in the top center Bore.
9. Place one 3/4" Interlock Ball in the Interlock Bore, against the
bottom Bar.
10. Holding the middle Bar notched end, start installation.

As the Bar passes the Rear Boss, position the Shift Block.
11. As the Bar passes the center Boss, position the Shift Yoke
on Bar, long hub to the Housing front.
12. Just prior to inserting notched end of Bar in Rear Boss,

install the small Interlock Pin vertically in the Neutral
Notch Bore.
13. Install the Shift Block and Shift Yoke Lock Screws, torque
to 35–45 lb-ft (47.45–61.01 N•m). Lockwire securely.
14. Place one 3/4" Interlock Ball in the Interlock Bore, against
the middle Bar.
142
15. Holding the top Bar notched end, start installation. As the
Bar passes the Rear Boss, position the Shift Block.
on the Bar, long hub to the Housing rear.

17. Install the Shift Block and Shift Yoke Lock Screws, torque to
35–45 lb-ft (47.45–61.01 N•m). Lockwire securely.
18. Install the Oil Trough. Torque the Retaining Cap Screws to
8–12 lb-ft (10.85–16.30 N•m). (Some models do not have
an Oil Trough.)
19. Install the three (3) Tension Balls, one in each Housing top
Bore. Install the three (3) Detent Springs, one over each
Tension Ball.
Note: Make sure Interlocking System is working - should

not shift into 2 gears at the same time.
Note: Make sure all Lock Screws are lockwired.
143
How to Assemble the Forward Shift Bar Housing

Inspect Shift Blocks and Shift Yokes for wear.
Apply Eaton® Sealant #71208 or equivalent to the Shift Bar Housing Plugs which are used to plug Oil Cooler provision holes.
The sealant should be applied so at least 5 complete threads are covered.
Apply Eaton® Lockwire #1819 or equivalent to all Shift Bar Housing Assembly Set Screws in both Blocks and Yokes. The wire
should anchor the Cap Screw at least 2 complete 360 turns. The Lockwire ends should be trimmed and bent out of the way of
any part.
Keep Yoke Bars in Neutral while assembling.
Special Tools
Procedure -
1. Assemble the Yoke Actuator Assembly:
2. From the Shift Bar Housing bottom, install the Actuator Pin
and Yoke Actuator.
3. On the Shift Bar Housing top, install the Washer and Nut.
144
4. Assemble the 1st and Reverse Shift Yoke Assembly:

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

5. With the Housing rear to the right, lay the Assembly on
a flat surface.
6. Start installation of the bottom Shift Bar, as the Bar

passes the Bosses, install the two (2) bottom Shift
Yoke Assemblies.
7. Install the Shift Yoke Lock Screw, torque to 35–45 lb-ft

(47.45–61.01 N•m). Lockwire securely.
8. Place the Actuating Plunger in the top center Bore.

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

the Bar passes the Rear Boss, position the Shift Block.
on Bar, long hub to the Housing front.
12. Just prior to inserting notched end of Bar in Rear Boss,

install the small Interlock Pin vertically in the Neutral
Notch Bore.
13. Install the Shift Block and Shift Yoke Lock Screws, torque
to 35–45 lb-ft (47.45–61.01 N•m). Lockwire securely.
the middle Bar.
145
15. Holding the top Bar notched end, start installation. As the
Bar passes the Rear Boss, position the Shift Block.
on Bar, long hub to the Housing rear.
17. Install the Shift Block and Shift Yoke Lock Screws, torque to
35–45 lb-ft (47.45–61.01 N•m). Lockwire securely.
18. Install the Oil Trough, torque the Retaining Cap Screws to 8–
12 lb-ft (10.85–16.30 N•m). (Some models do not have an
Oil Trough.)
19. Install the three (3) Tension Balls, one in each Housing top
Bore. Install the three (3) Detent Springs, one over each
Tension Ball.
Note: Make sure Interlocking System is working - should

not shift into 2 gears at the same time.
Note: Make sure all Lock Screws are lockwired.
146
How to Disassemble the Forward Shift Bar Housing

The Shift Bar Housing must be removed from the Transmission.
During disassembly, lay all parts on a clean bench in order of removal to facilitate assembly.
Shift Bars not being removed must be kept in the Neutral position or the interlocking parts lock the Bars.
Start with the bottom Shift Bar.
Cut the Lockwire and remove the Lock Screws from each Bar just before their removal.
Special Tools

Procedure -
Housing Bores have not been removed, place the Shift Bar
Housing on its side to remove them.
2. Remove the Oil Trough Retaining Cap Screws and

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

flat surface.
147
4. While removing the top Yoke Bar to the right, remove the
two (2) Shift Blocks.
5. From the middle Yoke Bar, remove the Shift Yoke and Shift
Block. As the Neutral Notch in the Bar clears the Rear Boss,
remove the small Interlock Pin from the Notch Bore.
6. Remove the Actuating Plunger from the center top

Boss Bore.
7. From the Bottom Yoke Bar, remove the two (2) Shift Yokes.
148
8. As the Shift Bar clears the last Boss, two (2) 3/4" Interlock
Balls drop from the bottom Rear Boss Bore.

9. If damaged, from the 1st and Reverse Shift Yoke, remove
the Plug, Spring, and Plunger.
10. Inspect the Yoke or Block parts, replace the worn parts.
149
How to Remove the Input Shaft Assembly (without Main Case disassembly)
None
Special Tools
• RR1023TR Input Bearing Puller
• RR1019TR Hand Maul
Procedure -
1. From the Front Bearing Cover, remove the six (6)
Retaining Cap Screws and cover. Remove any remaining
gasket material from the Case and Cover.
2. If present, remove and discard the rubber Seal Ring on the

Input Shaft. The Ring is used only to seal the Transmission
during shipment.
3. From the Input Shaft groove, remove the Bearing Retaining

Snap Ring.
150
4. Use a Soft Bar and Maul to drive the Input Shaft toward the
Case rear as far as possible. Pull the Input Shaft forward.
5. Install the RR1023TR Input Bearing Puller and remove the

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

6. From the Drive Gear front, remove Drive Gear Spacer.
7. Remove the Drive Gear Internal Snap Ring.
8. Pull the Input Shaft forward and out of the Drive Gear.
9. Inspect the bushing in the Input Shaft pocket, replace

if damaged.
151
How to Install the Input Shaft Assembly (without Main Case disassembly)
None
Special Tools
Procedure -
1. If necessary, install the bushing in the back of the
Input Shaft.
2. From the front, engage the Input Shaft Spline Teeth into
the Main Drive Gear.
Note: The current design Input Shaft Spline Teeth have

noticeable clearance to the Main Drive Gear internal
Spline Teeth. This is normal.
3. Install the Snap Ring in the Main Drive Gear inside groove.
4. Install the Spacer Washer over the Input Shaft. With the
Bearing External Snap Ring to the outside, position the
bearing on the Input Shaft.
152
5. Install the RR1005TR Input Bearing Driver over the Input

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

6. Install the Input Shaft Retaining Snap Ring.
Note: Do not replace the small rubber Lip Seal. It is used
only to prevent leakage during shipping.
7. Install the Front Bearing Cover. Apply Loctite 242 to

Cap Screw threads and torque to 35–45 lb-ft
(47.45–61.01 N•m).
153
How to Remove the Auxiliary Section with Tapered Bearings

There can be different Cap Screw lengths, note their location.
Auxiliary Sections can be removed either with the Transmission in the horizontal position or the vertical position.
Auxiliary Countershaft Retaining Straps may be installed to hold the Countershafts in place. You can make retaining straps from
3" x 1" bar stock. Auxiliary can be removed without straps, use caution.
Special Tools
Procedure -
1. To remove the Auxiliary Section in the horizontal position.
Remove the four (4) Cap Screws and the Auxiliary
Countershaft Rear Bearing Cover, gasket, and Rear
Bearing shim.
2. Install the RR1002TR Auxiliary Countershaft Support

Straps with 2-3/8" NC x 1" and 1 - 3/8" NC x 1 - 1/2" clean Cap
Screws.
Note: Do not use an Air Gun. Tighten by hand until the

154
3. From the Auxiliary Section Housing, remove the

Retaining Cap Screws that attach the Front Section to
the Auxiliary Section.
4. Insert the two (2) longest Cap Screws in the Housing

flange tapped holes. Tighten evenly to move the Auxiliary
Section away from the Front Box. Go far enough to break
the gasket seal.
5. Remove the Cap Screws from the tapped holes.
6. Attach the RR1006TR Auxiliary Section Lifting Bracket to the

Auxiliary Section top.
7. Attach a Lifting Chain to the Auxiliary Section Hanger
Bracket.
8. Move Assembly to the rear until Auxiliary Section is free.

gasket material.
Procedure -
1. To remove the Auxiliary Section in the vertical position.
With blocks under the Clutch Housing to prevent Input Shaft
damage, place Transmission in the vertical position, Clutch
Housing down.
2. Remove the four (4) Cap Screws and the Auxiliary

Countershaft Rear Bearing Cover, Gasket, and Rear
Bearing Shim. Clean the gasket surface area.
3. Install the RR1002TR Auxiliary Countershaft Support Straps

with 2-3/8" NC x 1" and 1-3/8" NC x 2-1/2" clean Cap Screws.
Note: Do not use an Air Gun. Tighten by hand until the Cap
Screws are snug.
4. From the Auxiliary Section Housing, remove the

Retaining Cap Screws that attach the Front Box to the
Auxiliary Section.
5. Install a Steel Bar through the Yoke.
6. Attach a Lifting Chain to the Steel Bar.
7. Lift assembly from the Front Section.
155
How to Remove the Splitter Cylinder Assembly

Note: On 9-Series and Super 10 Transmissions, it is necessary to R&R the Auxiliary Section Prior to Range Cylinder Removal.
Damage to internal components will result if Auxiliary Section is not properly removed prior to Cylinder Removal.
Note: When replacing just the O-Rings in the Splitter Cylinder, removal of the Auxiliary Section is not necessary.
When removing the Splitter Cylinder Cover Insert Valve, note the direction the Insert Valve was positioned (nipple in or out).
Special Tools
7
5
2 3
1
8
6
4
18
14
13
13/18-Speed
15
12
9-Speed

7. Nut
156
Procedure -
1. Drain lube.
2. From the Splitter Cylinder Cover, remove the Retaining

Cap Screws.
3. Remove the Cover and Gasket or O-Ring (new design,

aluminum cover).

4. Remove the 3/4" nut on the Splitter Yoke Bar.
5. From the Auxiliary rear, remove the Splitter Cylinder
Housing.
6. If necessary, turn out the Insert Valve Retaining Nut and

remove Insert Valve from Bore (only present on old
style
13/18 Speed).
7. If Spool Valve needs to be replaced it must be done as

an entire unit which is part of the Splitter Cover.
Note: New 13/18 Speeds Splitter Covers contain a

Spool Valve that is replaced as a unit.
157
How to Remove the Auxiliary Countershaft Assembly

For ease of disassembly, mount the Auxiliary Section upright in a Vise.
Both Countershafts are removed the same.
As the Countershaft Strap is removed, the Countershaft can fall.
Special Tools
• RR1020TR Soft Bar
158
Procedure -
1. To hold the Auxiliary Countershafts from turning, place a
shop rag or equivalent between the Splitter Gear and one
Countershaft.
2. From the Output Shaft, loosen the 15/16" Cap Screw and
Retainer. Do not remove the Cap Screw.
3. Use a Soft Bar and Maul to drive the Output Shaft forward far

enough to partially unseat the Bearing.
4. Support the Auxiliary Countershaft while removing the
Auxiliary Countershaft Retaining Strap.
5. Remove the Auxiliary Countershaft.
6. Remove the Auxiliary Countershaft Bearing Race from Bore.
159
7. If necessary, secure the Countershaft Assemblies in a Vise

and remove both the Front and Rear Bearings with a Bearing
Separator and Jaw Pullers.
160
How to Remove the Splitter Gear

None
Special Tools
Procedure -
1. From the Output Shaft, remove the 15/16" Cap Screw
and Retainer Bolt.

2. From the Output Shaft, remove the Splitter Gear.
161
How to Disassemble the Range Cylinder Assembly

For RTLO-XX9XX (9 Series), remove the Auxiliary Section before disassembling the Range Cylinder. See page 114 for removing
Auxiliary Section instructions.
Special Tools
9 13
10 12 11
8
7
6
1 3
2
1. Gasket 8. Piston
3. Bolt 10. O-Ring
6. O-Ring 13. Cover
7. Yoke Bar
162
Procedure -
1. From the Range Cylinder Cover, remove the Cap Screws,
Cover, and Gasket.
2. Clean the gasket mounting surfaces of all gasket material.

3. From the Range Cylinder Housing Bore, remove the
15/16" nut.
4. From the Cylinder Housing Bore, remove the Range Piston.
5. Inspect the Range Piston O-Rings, remove if damaged.
6. Remove the Cap Screws and Range Cylinder Housing.
7. Clean the gasket mounting surfaces of all gasket material.
8. Inspect the O-Ring inside the Range Cylinder Housing Bore,

remove if damaged.
163
How to Disassemble the Output Shaft Assembly

When using the Soft Bar and Maul on the Output Shaft, be careful not to damage the threads.
When removing the Rear Bearing Cover, the Rear Bearing Cone drops from the Housing Bore.
Special Tools
• Press
• Soft Bar and Maul
14
1
OEM supplied 23 2
OEM supplied
adjustable non-adjustable
speedometer speedometer
sensor sensor 25
(Threaded) (Non-Threaded)
4
5
tic
gne 20
3 Ma
7 2
26
24 21 l
a
nic
6 19 cha
22 Me
16
15
9
10
11
13
12
1. Speedo Rotor Assembly 13. Rear Housing

2. O-Ring 15. Lifting Eye
3. Oil Seal Kit 16. Cap Screw
4. Cap Screw 19. Speedo Drive Gear
5. Rear Bearing Cover Assembly 20. Speedo Spacer Assembly
6. Gasket 21. Oil Seal w/Slinger
7. Cap Screw 22. Cap Screw
8. Cap Screw 23. Speed Sensor Kit
9. Cover 24. Bushing
11. Shim Kit 26. Rear Bearing Cover Assembly
12. Gasket
164
Procedure -
1. Use a Soft Bar and Maul to drive the Output Shaft forward
and through the Rear Bearing Assembly.

2. From the Auxiliary Housing rear, remove the Rear Bearing
Retaining Cap Screws, Cover, and Gasket.
3. Clean the gasket mounting surface of gasket material.
4. Inspect the Rear Bearing Cover Oil Seal for damage, remove
if damaged.
5. From the Auxiliary Housing rear, remove the Bearing Cup

and Spacer.
165
6. From the Auxiliary Housing front, remove the remaining

Bearing Cup.
7. Some models have a one piece Bearing Race. Remove it

from the Bearing Bore.
8. From the Output Shaft, remove the Bearing Inner Spacer.
9. Use the Output Shaft Assemble Gear front face as a base,

press the Output Shaft through the Bearing and Gear.
166
How to Disassemble the Synchronizer Assembly

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

Synchronizer
HI
Sliding Clutch
Spring
Spring
Procedure -
1. Place the larger LO Range Synchronizer Ring on the bench.
2. Cover the Synchronizer with a shop rag to contain the

springs.
3. Grab both sides of the HI Range Synchronizer and pull.
4. From the Synchronizer Ring LO Range pins, remove the

Sliding Clutch.
167
How to Assemble the Synchronizer Assembly

Assembly should be done on a clean, flat surface slightly lower than your waist.
Pins on the LO Range Synchronizer must line up with the chamfered holes on the Sliding Clutch bottom.
When compressing the HI Range Synchronizer springs cover with a shop rag. In the event compression is not achieved the first
time, this prevents the springs from leaving the bench area.
Special Tools
Synchronizer
LO
Spring
Synchronizer
HI
Sliding Clutch
Spring
Spring
168
Procedure -
1. On the bench, place the larger LO Range Synchronizer Ring
face down with pins up.
2. With the Sliding Clutch recessed side up, place the Sliding
Clutch on the LO Range Synchronizer Pins.

3. In the HI Range Synchronizer Bores, install the three (3)
springs.
4. Place the HI Range Synchronizer Ring over the LO Range

Synchronizer Ring. Rotate the HI Range Synchronizer until
the springs are seated against the pins.
5. Cover the Assembly with a shop rag.
6. Apply downward pressure to the HI Range Synchronizer

Ring while twisting counterclockwise. This compresses the
springs to fully seat HI Range on the LO Range
Synchronizer. This should be done with a rapid twist and
push motion.
Note: Make sure there are three springs and they are fully
compressed.
Note: Make sure you can move the Sliding Clutch from HI to
LO Range and back.
169
How to Assemble the Output Shaft Assembly

Make sure the Magnetic Plugs are installed in the Auxiliary Housing.
Output shaft stack up should be done on a clean, flat surface.
When heating the bearings, do not heat above 275F (136C).
When installing the rear Bearing Race, the proper depth is when the Race shoulder is seated on Bearing Bore top.
Because the collar becomes distorted when compressed, do not use an old nylon collar in the Rear Bearing Cover.
Special Tools
Procedure -
1. Use Toolmaker's Dye and mark the LO Range Gear for
timing purposes.
2. Mark any two (2) adjacent teeth on the LO Range Gear.

Repeat the procedure for the two (2) adjacent teeth directly
opposite the first set marked.
3. With Splined Washer facing up, place the washer on the

Output Shaft shoulder.
170
4. With LO Range Gear Clutching teeth down, position LO

Range Gear on the Output Shaft, engage the Washer Splines.
5. With chamfer side up, position the LO Range Gear rear

washer on the Output Shaft against the LO Range Gear.
6. With tapered side up, use heat or appropriate driver and

install the Output Shaft Rear Bearing.
7. On the Output Shaft, position the Bearing Inner Spacer.

Set aside.
8. Lay the Auxiliary Housing front face down on a clean flat

surface. Install the Bearing Race in the Bearing Bore.

171
How to Install the Splitter Gear

Make sure to use a Splitter Gear Retaining Bolt with thread-locking compound Loctite 242.
The Output Shaft Assembly will need to be placed in a Vise in order to tighten the Retaining Bolt to proper torque.
Applying oil to Synchronizer material will ease the installation of the Auxiliary Section to the Main Case.
Special Tools
Procedure -
1. Lay the Output Shaft Assembly on its side.
2. Submerge Synchronizer in Motor Oil.
3. Install the Synchronizer Assembly.
4. Install the Splitter Gear.
5. Install the Splitter Gear Retainer and 15/16" Cap Screw.
6. Torque the Splitter Gear Retainer Bolt to 190–210 lb-ft

(257.61–284.72 N•m).
Note: Make sure the Splitter Gear Retainer Bolt is properly

torqued.
172
How to Assemble the Range Cylinder Assembly

Apply Eaton® Lubricant #71214 or equivalent to Shift Cylinder Assembly and Insert Valve O-Rings so a film covers the entire
Special Tools

9 13
10 12 11
8
7
6
1 3
2
1. Gasket 8. Piston
3. Bolt 10. O-Ring
6. O-Ring 13. Cover
7. Yoke Bar
173
Procedure -
the small O-Ring.
2. If previously removed, on the piston I.D. and O.D., install the

Piston O-Rings.
3. Position a new gasket on the Range Cylinder Housing

mounting surface.
4. Install the Cylinder Housing.


(27.12–33.90 N•m).
7. Lean Auxiliary Section back with Range Cylinder upward.
8. Insert the Piston. Push it in as far as it will go.
9. Secure the Piston with the Retaining Nut, torque to

70–85 lb-ft (94.91–115.24 N•m).
174
10. Position a new gasket on the Cylinder Housing Cover

mounting surface.
11. Over the gasket, position the Range Cylinder Cover.


(27.12–33.90 N•m).

175
How to Install Splitter Cylinder Assembly

Apply Eaton® Lubricant #71214 or equivalent to all Shift Cylinder Assembly and Spool Valve O-Rings so a film covers the entire
Apply Eaton® rust preventative #71213 or equivalent to all Shift Cylinder walls and Yoke Bars, cover the entire Yoke Bar surface
that comes in contact with the Shift Cylinder O-Ring.
Special Tools
• Typical Service Tools are needed
7
5
2 3
1
8
6
4
18
14
13
13/18-Speed
15
12
9-Speed

7. Nut
176
Procedure -
the small O-Ring.
2. If previously removed, on the piston O.D., install the Piston

O-Ring.
3. Position a new gasket on the Cylinder Housing mounting

surface.
4. With the air passage towards the Rear Bearing Cover, install
the Cylinder Housing.
5. Inside the Cylinder Housing, over the Yoke Bar end, install
the O-Ring.
6. With the recessed side up, install the Splitter Cylinder

Piston.
7. Install the 3/4" lock nut, torque to 30–36 lb-ft (41–49 N•m).
177
8. Position a new gasket or O-Ring (new design, aluminum

cover) on the Cylinder Housing Cover mounting surface. The
gasket air passage must align with the Housing air passage.
9. Position the Splitter Cylinder Cover over the gasket or

O-Ring (new design, aluminum cover).
10. New style Splitter Covers contain a Spool Valve, which must
be replaced as a unit with the entire Cover. Old style Splitter
Covers contain a separate Insert Valve that can be removed
from the bottom of the Splitter Cover.

12. Install and torque the Retaining Cap Screws to 20–25 lb-ft
(27.12–33.90 N•m).
13. Refill Transmission with lube to the proper level.
Note: Make sure the Retaining Nut and Cap Screws are
tightened to proper torque.
Note: Make sure gaskets were used at appropriate

positions.
178
How to Install the Auxiliary Countershaft Assembly

To make Auxiliary Section Assembly easier, you can make an Auxiliary Section fixture out of a 2" x 12" piece of wood.
3'
4.56"
1'
3"

10.74" 2"
This fixture is designed to ease the assembly of the Auxiliary gearing. Set the Auxiliary Countershaft Rear Bearings in the 3" holes.
Set the assembled Auxiliary Mainshaft between the Countershafts with the timing marks aligned.
Special Tools
179
Procedure -
1. Place the Countershaft Assembly vertical on a clean, flat
surface. If previously removed, use the proper Driver and
Maul to install the Countershaft Bearings.
2. Mark each Countershaft for correct timing. Locate the “O’s”

stamped on the Countershaft and mark the teeth with highly
visible Toolmaker’s Dye or paint.
3. Place the Countershafts in the fixture or on a flat surface for

reassembly. Turn the Countershafts so that the two teeth
marked on each LO Range Gear are towards the middle.
Refer to Timing Procedure on page 57.
4. Align the Output Shaft between the Countershafts, match the

timing marks.
5. With Range Yoke offset side facing down, install into the
Synchronizer Sliding Slot.
6. Place the Auxiliary Housing over the Countershaft

Assemblies and the Output Shaft Assembly.
180
7. Make sure the Output Shaft Bearing Spacer is on the

Output Shaft.
8. Heat the rear Output Bearing Cone and install the Bearing,
tapered side down, on the Shaft.
9. Position a new gasket on the Rear Bearing Cover

mounting surface.

10. Position the Rear Bearing Cover.

12. Install the six (6) Retaining Cap Screws in the non-
chamfered hole, torque to 35–45 lb-ft (47.45–61.01 N•m).
13. Install the Bearing Races.
14. Install each Auxiliary Countershaft Retaining Strap with

2-3/8" NC x 1" and 1-3/8" NC x 2-1/2" clean Cap Screws.
Note: Do not use an Air Gun. Tighten by hand until the

181
How to Disassemble the Splitter Gear Bearing Assembly

Make sure to use the proper Drivers for the Bearing and Sleeve.
Special Tools
• 3.30" diameter Bearing Driver
Procedure -
1. Remove the Internal Snap Ring.
2. Remove the Splined Washer.
3. Remove the Rear Bearing Race using he proper

Bearing Driver.
4. Remove the Bearing Spacer.
5. Remove the Bearing.
6. Remove the Front Bearing Race using the proper Driver.
7. If damaged, remove the Bearing Sleeve.
182
How to Assemble the Splitter Gear Bearing Assembly

Make sure to use the proper Drivers for the Bearing and Sleeve.
When installing the Inner Bearing Sleeve, it must be flush with the Bearing.
The Splitter Gear Cups and Cones are matched — do not mix.
Special Tools
• 3.30" Diameter Bearing Driver
Procedure -

1. If removed, install the Bearing Sleeve.
2. Install the Front Bearing Race.
3. Turn the Splitter Gear over and position the Bearing

against the Front Bearing Race.
4. Install the Bearing Spacer.
5. Install the Rear Bearing Race using the proper

Bearing Driver.
6. Install the Splined Washer.
7. Install the Internal Snap Ring.
183
How to Remove the Auxiliary Drive Gear Assembly

Before removing the Auxiliary Drive Gear, the Auxiliary Section must be removed.
Special Tools
• Large pair of Snap Ring Pliers
• Brass Maul
• Crow's Foot
Procedure -
1. Remove the Mainshaft rear groove Snap Ring.
2. Remove the Auxiliary Drive Gear and Washer from the

Mainshaft.
3. Remove the Auxiliary Bearing Retainer Ring Cap Screws and

Bearing Retainer Ring.
4. From the Mainshaft, remove the Splined Washer.
5. From inside the Case, carefully tap the Auxiliary Bearing

rearward.
184
6. Use a Crow's Foot and work the Bearing out of the Bore.
7. Inspect the Bearing and Spacer. If the parts have been

damaged, press the Spacer out of the Bearing and replace
the parts.

185
How to Remove the Clutch Housing (with Internal Oil Tube)

Removal of the Clutch Housing is performed in the horizontal position.
The Clutch Release Mechanism must be removed.
Some early production models do not have an Oil Tube behind the Clutch Housing. For these models, skip step 5.
Special Tools
Procedure -
1. From inside the Clutch Housing, remove the Nuts and
Washers.
2. From inside the Clutch Housing, remove the Cap Screws.
3. Jar Clutch Housing to break Gasket seal.
4. Pull the Clutch Housing from the studs and

Transmission Case.
5. If Oil Tube is not being removed skip to step 10.
6. Remove Oil Tube.
186

9. Remove Shift Bar Housing.
187
10. Remove the gasket and clean all mounting surfaces of

gasket material.
a. Without Oil Tube channel (Old style)
b. With Oil Tube channel (New style)
Note: Clutch Housing with Oil Channel can be used on
Transmissions without the Oil Tube.
188
How to Disassemble the Upper Reverse Idler Gear Assembly

Before the upper Reverse Idler Gear Assembly can be removed, Mainshaft Reverse Gear must be positioned forward against
the next Gear.
While removing the Reverse Idler Shaft, the Thrust Washer can drop to the Transmission case bottom.
The Mainshaft Reverse Gear must be moved in order to remove the upper Reverse Idler Gear.
Special Tools
• RR1010TR Slide Hammer
Procedure -

1. Remove Retaining Bolt from the Idler Shaft.
Note: If Idler Shaft spins in Case Bore, slightly heat bolt with
torch to release loctite adhesive.
2. The Mainshaft Reverse Gear must be moved in order to

remove the Upper Reverse Idler Gear. Remove Reverse Gear
Snap Ring and slide Reverse Gear forward over Clutch.
3. Remove the loosened bolt and remove washer. Reinstall bolt

3–4 threads.
4. Install an Impact Puller, 1/2"-13 threaded end, and remove

the Shaft from Case Bore.
189
5. As the Idler Shaft and Idler Plate are removed, remove the
Thrust Washers and Gear.
6. Inspect the Reverse Gear Assembly, remove the Inner Race

and Needle Bearing, if damaged.
190
How to Disassemble the Lower Reverse Idler Gear Assembly

Before the Lower Reverse Idler Gear Assembly can be removed the Mainshaft and Countershaft Assemblies must be removed.
While removing the Reverse Idler Shaft, the Thrust Washer can drop to the Transmission Case bottom.
Special Tools
• Jaw Pullers or Impact Puller
• Soft Bar and Maul

Procedure -
1. Remove Retaining Bolt from the Idler Shaft.
Note: If Idler Shaft spins in Case Bore, slightly heat bolt with
torch to release loctite adhesive.
2. Remove the loosened bolt and remove washer. Reinstall bolt

3–4 threads.
3. Install an Impact Puller, 1/2"-13 threaded end, and remove

the Shaft from Case Bore.
4. As the Idler Shaft and Idler Plate are removed, remove the
Thrust Washers and Gear.
5. Inspect the Reverse Gear Assembly, remove the Inner Race

and Needle Bearing, if damaged.
191
How to Remove the Upper and Lower Countershaft Bearings

The following instructions are used to remove the Upper and Lower Countershaft Bearings. To remove the Mainshaft Assembly,
only the Upper Countershaft Bearings need to be removed.
Performing the following instructions will damage the bearings and should be not be done unless bearing replacement is planned.
The Bearing Inner Race remains pressed on the Countershaft after removal of the Front Bearings.
Special Tools
• RR1012TR Bearing Puller
Procedure -
1. To keep the Mainshaft Pilot from falling out of the Input
Shaft pocket, temporarily install the Auxiliary Drive Gear on
the Mainshaft.
2. From each Countershaft Rear Groove, remove the

Snap Ring.
3. Remove six Cap Screws from Front Bearing Cover and

remove Front Bearing Cover.
CAUTION
Damage will likely occur to this bearing during removal. It is

strongly recommended that this bearing is discarded.
4. From inside the case, use a Soft Bar and Maul to drive the
Countershaft Rear Bearings rearward off the shaft.
192
5. From the front of each Countershaft, remove the Cap Screw

and front Retainer Plate.
6. Use the Soft Bar and Maul to drive each Countershaft to

the rear as far as possible. This partially unseats the
Front Bearings.
7. Return to the case rear, and drive each Countershaft forward

as far as possible. This exposes the External Snap Ring.

8. Use theRR1012TR Bearing Puller to remove the
Countershaft Front Bearings.
193
How to Remove the Mainshaft Assembly

None
Special Tools
• RR1004TR Mainshaft Lifting Hook
• RR1022TR Countershaft Support Tool
Procedure -
1. With the Upper Countershaft Bearings removed, support the
Countershaft Assembly with a RR1022TR Support Tool.
2. Insert the RR1004TR Mainshaft Hook around the Mainshaft

Assembly.
Note: Keep the Upper Countershaft forward against the

Case front wall.
WARNING
Be careful when removing the Mainshaft Assembly. The

Sliding Clutch on the front and the Reverse Gear on the back
can slip off the shaft.
3. Pull the Mainshaft to the rear to free the pilot from the Input
Shaft pocket.
4. Tilt the Mainshaft front up and lift the Assembly from

the Case.
194
How to Remove the Countershaft Assemblies

Except for the PTO gears, the Upper and Lower Countershaft Assemblies are the same. Mark the Countershafts as UPPER or
LOWER as you remove them.
The Mainshaft and Main Drive Gear must be removed before removing the Countershaft Assemblies.
Special Tools
• RR1012TR Countershaft Bearing Puller

Procedure -
1. Remove the Rear Snap Ring from the Rear Upper
Countershaft Bearing.
2. From inside the case, use a long Soft Bar to drive the Upper
Countershaft Rear Bearing rearward off the Shaft.
Note: Damage will likely occur to this bearing during
removal. It is strongly recommended that this bearing
is discarded.
3. Remove the Cap Screw and the Retainer from the Upper
Countershaft front.
4. Slide the Lower Countershaft forward. This will move the

Front Bearing forward to expose the External Snap Ring.
195
5. Use the RR1012TR Countershaft Bearing Puller to remove

the Lower Front Bearing from its Bore.
6. Move the Upper Countershaft to the rear until the Front

Bearing Journal clears the Front Case Bore.
7. Swing the front of the Countershaft to the center of the Case,

and lift out the Countershaft Assembly.
Note: Follow the same procedure for Lower Countershaft
removal.
196
How to Disassemble the Countershaft Assemblies

As you disassemble the Countershafts, mark each part as belonging to the Upper or Lower Countershaft and mark the gears for
front or back orientation.
Except for the PTO Gears, the Upper and Lower Countershaft Assemblies are identical and disassembled in the same manner.
Special Tools
10
11

13 12
15 2 1
4 3
5
14 6
7
8
9
10364-11-96 CS/RT
1. Snap Ring 8. Gear

2. Bearing 9. Gear
3. Countershaft with Reverse and LO 10. PTO Gear
4. Key 11. Drive Gear
5. Roll Pin 12. Snap Ring
6. Key 13. Bearing
7.Gear 14. Retainer Kit
15. Cap Screw
197
Procedure -
CAUTION
NEVER USE THE PTO GEAR AS A PRESSING BASE. The narrow

face width of this gear makes it very susceptible to breakage
1. Remove the front Countershaft Snap Ring.
2. Place the Countershaft in the Press as shown. Using the rear

face of 3rd/Overdrive Speed Gear as a base, press the Drive
Gear, PTO Gear, and 3rd/Overdrive Speed Gear from each
Countershaft. This removes the Front Bearing Inner Race
from the Countershaft.
3. Position the Countershaft in the Press as shown. Press

the next two gears from the Shaft.
4. Inspect the Keys and Roll Pin. Remove and replace

if damaged.
198
How to Remove the Input Shaft and Main Drive Gear

None
• Special Tools
Procedure -
1. From the Front Bearing Cover, remove the six (6) Retaining

Cap Screws and Cover. Remove any remaining gasket
material from the Case and Cover.
2. If present, remove and discard the Rubber Seal Ring on the

Input Shaft. The Ring is used only to seal the Transmission
during shipment.
3. From the Input Shaft groove, remove the Bearing Retaining

Snap Ring.
199
4. Use a Maul to drive the Input Shaft toward the case rear as
far as possible. Pull the Input Shaft forward.
5. Install the RR1023TR Input Bearing Puller and remove the

Input Bearing from the Case and Input Shaft or use Pry Bars
or Screwdrivers to complete removal of the Bearing.
6. From the Drive Gear front, remove Drive Gear Spacer.
7. Remove the Drive Gear Internal Snap Ring.
200
8. Pull the Input Shaft forward and out of the Drive Gear.
9. From inside the Case, remove the Drive Gear.
10. Inspect the bushing in the Input Shaft pocket, replace

if damaged.
201
How to Disassemble the Mainshaft Assembly

Lay all parts on a clean bench in order of removal to facilitate assembly.
Special Tools
Procedure -
1. Lay the Mainshaft on its side, and from the front, remove
the 4th (or Overdrive) and 5th Sliding Clutch.
2. Place the Mainshaft in a vertical position, pilot end down.
3. Remove Snap Ring (if applicable).
4. Remove Key, Washer, and Reverse Gear. Mark Keyway

location.
Note: When removing washer and Reverse Gear, note their
orientation. Keep the Washer with the Reverse Gear.
5. Remove the 1st and Reverse Sliding Clutch.
202
6. Remove the Offset Washer and 1st Gear.
7. Remove the Flat Washer and 2nd Gear.

8. Remove the Offset Washer and Sliding Clutch.
9. Remove the Offset Washer and 3rd Gear.
10. Remove the Flat Washer.
11. Remove the 4th or Overdrive Gear.
12. Remove the Offset Washer.
203
How to Disassemble the Mainshaft Assembly with Low Force Gearing

The design of the Mainshaft with Low Force Gearing is slightly different from the standard Mainshaft. It still utilizes Non-Selective
(non-adjustable) Tolerance Washers, but the 1st and Reverse Gears and Sliding Clutch have been redesigned. In this
configuration, the 1st/Reverse Sliding Clutch rides on a Clutch Hub, and the 1st and Reverse Gears have been redesigned to
accommodate this change.
Lay all parts on a clean bench in order of removal to facilitate assembly.
Special Tools
Procedure -
1. Lay the Mainshaft on its side, and from the front, remove the
4th (or Overdrive) and 5th Sliding Clutch.
2. Place the Mainshaft in a vertical position, pilot end down.

Remove the Reverse Gear, Clutch Hub, and Sliding Clutch.
3. Remove the Snap Ring and Key. Mark Keyway location.
204
4. Remove the Offset Washer and 1st Gear.
5. Remove the Flat Washer and 2nd Gear.

6. Remove the Offset Washer and Sliding Clutch, and then
remove the Offset Washer and 3rd Gear.
7. Remove the Flat Washer, remove the 4th or Overdrive Gear,

and remove the Offset Washer.
205
How to Assemble the Mainshaft Assembly with Selective (Adjustable) Thickness

Tolerance Washers
There are three distinct Mainshaft Washer and Mainshaft Key designs. They are (listed from oldest design to newest design):
a. Six (6) sided Mainshaft Key with Selective (adjustable) Thickness Tolerance Washers.
b. Three (3) sided Mainshaft Key with Selective (adjustable) Thickness Tolerance Washers.
c. Three (3) sided Mainshaft Key with Non-Selective (non-adjustable) Tolerance Washers.
Note: Between 1993 and 1996, some models were produced with a mixture of Selective Thickness Washers and Non-Selective
Tolerance Washers on the same Mainshaft.
Note: The proper Mainshaft Key must always be used with the proper design Mainshaft Washers. If necessary, refer to the Parts
Manual for your specific model to confirm the proper parts.
Note: Previous design levels can be updated to the current design.
Each Mainshaft Gear must have its inside Snap Ring installed before placement on the Mainshaft. Do not install Reverse Gear
Inside Snap Ring at this time.
Gear Tolerance Washers are internally splined and locked to the Mainshaft by the Key. Gear Spacers are externally splined to
engage with Gear Hub Clutching teeth. There is one Tolerance Washer and one Spacer for each Mainshaft Gear.
Axial Clearance (end-play) limits are 0.006–0.015" for all Mainshaft Gears.
If the Axial Clearance is less than the minimum 0.006" tolerance, the Tolerance Washer should be replaced with a thinner Tolerance
Washer. This will increase the Axial Clearance between the gears. If the Axial Clearance is greater than the maximum 0.015"
tolerance, a thicker Tolerance Washer should be installed. This will decrease the Axial Clearance between the gears.
If necessary, refer to the Parts Manual for your specific Transmission model to determine the correct position of each
Mainshaft Gear.
The Mainshaft you are using may have 3 grooves in certain gear positions. The middle groove is not used with the Selective
Washer design.
Special Tools
• A piece of 5/32" Air Line, 1' long
• Vise with brass jaws
206
Procedure -
1. With Mainshaft pilot-end down, secure the Mainshaft in a
Vise equipped with brass jaws or wood blocks.
2. If previously removed, install the Roll Pin in Keyway.
3. With the washer flat side up, position a gear Tolerance

Washer (white) in the Mainshaft 1st or bottom groove.
Rotate the washer until the Washer Splines and Mainshaft
SpIines align.

4. Start at the Mainshaft bottom and install a 1/8" or 5/32"
diameter plastic line in the Keyway to lock the washer in
place. As Limit Washers and Gears are installed, continue to
push the plastic line up.
5. Against the 4th Speed Gear Washer, position a Spacer

Washer against the Tolerance Washer.
6. With Clutching teeth down and engaged with the Spacer

external Splines, position the proper Gear on the Mainshaft.
If necessary, refer to the illustrated parts list to determine
Gear order.
7. With Clutching teeth up and against this gear, install the next
Gear and Spacer Washer.
207
8. With the washer flat side down, position a Tolerance Washer

against the Spacer. Rotate the washer until the Washer
Splines and Mainshaft Splines align.
9. Push the Air Line up to lock the washer on the Mainshaft.
10. Insert two large Screwdrivers between the two gears. Apply
slight downward pressure to spread the gears evenly.
Between the Gear Hub and Mainshaft Spacer, insert 0.006"
Feeler Gauge and 0.015" Feeler Gauge. If out of tolerance,
change the washer against the Mainshaft Spacer.
11. With the missing Internal Splines aligned with the plastic
line, install a Sliding Clutch.
12. With the washer flat side up, position Tolerance Washer
(white) in the next available groove. Rotate the washer until
the Washer Splines and Mainshaft Splines align.
14. Install a Gear Spacer.
208
15. With Clutching teeth down, position the next Gear on the
Mainshaft engaging with Spacer external Splines.

16. With Clutching teeth up, install the next Gear on Shaft
against the previously positioned gear.
17. Position another Spacer against the previously positioned

gear, engaging the Spacer External Splines with Gear
Clutching teeth.
18. With washer flat side down, position the Tolerance Washer
against the Spacer. Rotate the washer until the Washer
20. Insert two large Screwdrivers between the two gears. Apply
slight downward pressure to spread the gears evenly.
Between the Gear Hub and Mainshaft Spacer, insert 0.006"
Feeler Gauge and 0.015" Feeler Gauge. If out of tolerance,
change the washer against the Mainshaft Spacer. Refer to
information before stepped procedures for further
information.
209
21. Align the Sliding Clutch missing internal Spline with the
Mainshaft Key and install the Reverse Speed Sliding Clutch.
22. With the flat side up, place a washer (blue or white) in the
next available groove. Rotate the washer until the Washer
SpIines and Mainshaft Splines align.
24. Against the Tolerance Washer, position Reverse Speed

Gear Spacer.
25. Install Reverse Gear on the Mainshaft. Engage the Gear

Clutching teeth with Spacer External Splines and Sliding
Clutch. Move the Reverse Gear down against the 1st
Speed Gear.
26. At this time remove the Air Line and insert the Mainshaft
Key. Be careful not to move the gears while doing this
procedure, the Tolerance Washers are unlocked and can
rotate which would cause the gears to drop.
27. Remove the Mainshaft from the Vise.
28. On the shaft front, align the Sliding Clutch missing internal
Spline with the Mainshaft Key and install the front Sliding
Clutch. Engage the Sliding Clutch external Splines with the
gear Clutching teeth.
210
29. Washers for 6-Sided Key
Part Size Color
14711 0.248–0.250 White
14712 0.253–0.255 Green
14713 0.258–0.260 Orange
14714 0.263–0.265 Purple
14715 0.268–0.270 Yellow

14716 0.273–0.275 Black
30. Washers for 3-Sided Key
Part Size Color
4300830 0.244 Blue-Light Blue
4300382 0.249 White-Light
4300383 0.254 Green-Light
4300384 0.259 Orange-Light
4300385 0.264 Purple-Light
4300386 0.269 Yellow-Light
4300387 0.274 Black-Light Blue
211
How to Assemble the Mainshaft Assembly with Non-Selective (Non-Adjustable)

Tolerance Washers
The proper Mainshaft Key must always be used with the proper design Mainshaft Washers. If necessary, refer to the Parts Manual
for your specific model to confirm the proper parts.
Previous design levels can be updated to the current design.
Special Tools
• A piece of 5/32" Air Line, 1" long
Procedure -
3. With Mainshaft pilot-end down, install Offset Washer (flat

surface up). Rotate the washer until the Washer Splines and
Mainshaft SpIines align.
4. Start at the Mainshaft bottom and install a plastic line in the

marked Keyway to lock the washer in place.
5. With Clutching teeth down, position the proper gear on the

Mainshaft. Refer to the illustrated parts list for correct gear.
6. Install the Flat Washer. Rotate the washer until the Washer
212
7. With Clutching teeth up and against the spacer, install the

next Gear.
8. Position the Offset Washer (flat surface down) against the

gear. Rotate the washer until the Washer Splines and
Mainshaft Splines align.
9. Push the Air Line up to lock the washers on the Mainshaft.

10. With the missing internal Splines aligned with the plastic
line, install the proper Sliding Clutch.
11. Position the next Offset Washer in the next available groove.
Splines align.
13. With Clutching teeth down, position the next proper gear on
the Mainshaft.
14. Position the Flat Washer against the gear. Rotate the washer
until the Washer Splines and Mainshaft Splines align.
213
15. With Clutching teeth up, install next Gear on the Shaft
against previously installed Gear.
Gear. Rotate the Washer until the Washer Splines and
17. Push the Air Line up to lock the Washer on the Mainshaft.
line, install the Reverse Sliding Clutch.
19. Install the Reverse Gear Offset Washer in the last groove.
20. From the Mainshaft rear, install the Mainshaft Key into the
Spline with the Air Line. Pull the Air Line from the Spline
while installing the Key.
21. Install the Reverse Gear Spacer Washer (with external

Spline teeth) over the Mainshaft rear and against the
Offset Washer.
Note: Some models, the Reverse Gear Offset Washer has a

large chamfer machined in the backside. This special
Offset Washer must be used in this position. The large
chamfer faces rearward.
22. From the rear, install the Reverse Gear over the Sliding
Clutch teeth.
23. Install the Snap Ring in the Mainshaft groove.
Note: Some models do not use a Snap Ring at this position.
24. Remove the Mainshaft from the Vise and lay on its side.
25. Install the front Sliding Clutch into position.
214
How to Assemble the Mainshaft Assembly with Low Force Gearing

The design of the Mainshaft with Low Force Gearing is slightly different from the standard Mainshaft. It still utilizes Non-Selective
(non-adjustable) Tolerance Washers, but the 1st and Reverse Gears and Sliding Clutch have been redesigned. In this
configuration, the 1st/Reverse Sliding Clutch rides on a Clutch Hub and the 1st and Reverse Gears have been redesigned to
accommodate this change.
The proper Mainshaft Key must always be used with the proper design Mainshaft Washers. If necessary, refer to the Parts Manual
for your specific model to confirm the proper parts.
Special Tools
• A piece of 5/32" Air Line, 1" long

Procedure -
3. With Mainshaft pilot-end down, install Offset Washer (flat

surface up). Rotate the washer until the Washer Splines and
Mainshaft SpIines align.
4. Start at the Mainshaft bottom and install a plastic line in the

marked Keyway to lock the washer in place.
5. With Clutching teeth down, position the 4th gear on the

Mainshaft.
6. Install the Flat Washer. Rotate the washer until the Washer
215
7. With Clutching teeth up and against the Spacer, install the

3rd Gear.

Gear. Rotate the washer until the Washer Splines and
9. Push the Air Line up to lock the washers on the Mainshaft.
line, install the proper Sliding Clutch.
11. Position the next Offset Washer in the next available groove.
Splines align.
13. With Clutching teeth down, position the 2nd Gear on the
Mainshaft.
14. Position the Flat Washer against the Gear. Rotate the washer
until the Washer Splines and Mainshaft Splines align.
216
15. With Clutching teeth up, install the 1st Gear on the Shaft
against previously installed Gear.

Gear. Rotate the Washer until the Washer Splines and
17. From the Mainshaft rear, install the Mainshaft Key into the
Spline with the Air Line. Pull the Air Line from the Spline
while installing the Key.
18. Install the Snap Ring in the Mainshaft groove.
19. Install the 1st/Reverse Sliding Clutch.
20. Install the Clutch Hub with the bezel facing up.
21. Install the Reverse Gear.
22. Remove the Mainshaft from the Vise and lay on its side.
Install the front Sliding Clutch into position.
217
How to Prepare the Main Case for Assembly

Thoroughly clean Main Case of metal particles. Remove the gasket material from flange surfaces. Inspect flange surfaces for
damage. Inspect Bearing Bores for damage or excessive wear. Replace as necessary.
If necessary, replace any damaged or worn Clutch Housing or rear support studs. Apply Eaton® Fuller® Thread Sealant #71205
or equivalent to any replacement studs before installing them.
Verify the three Magnetic Discs are firmly attached to the bottom of the Main Case. If they are not firmly attached, apply 3M Scotch
Grip or equivalent adhesive to the bottom of the Discs and attach them to the Main Case.
218
How to Assemble the Countershaft Assemblies

Except for the PTO Gears, the Upper and Lower Countershaft Assemblies are the same. To avoid confusion during installation,
mark the Upper Countershaft (45-Tooth PTO Gear) with an "U". The Lower Countershaft has a 47-Tooth PTO Gear.
Special Tools
• Snap Ring Pliers
• Press
Procedure -
1. If previously removed, install the Keys in each Countershaft

Keyway.
2. Align smallest diameter gear Keyway with the Countershaft
Key, long hub to Countershaft front, and press the gear on
the Countershaft.
3. Align 2nd smallest diameter gear Keyway with the

Countershaft Key, long hub against 1st Speed Gear, and
press the Gear on the Countershaft.
219
4. Align 3rd smallest diameter gear Keyway with the

Countershaft Key, long hub to Countershaft front, and
press the Gear on the Countershaft.
5. Align PTO Gear Keyway with the Countershaft Key,

bullet-nose of teeth facing up (shaft rear). Align Drive Gear
Keyway with the Countershaft Key, long hub against PTO
Gear, and press both Gears on the Countershaft.
6. On each Countershaft front, install the Drive Gear

Retaining Snap Ring in groove.
7. Use a Flanged-Driver or the Press to install the Bearing

Inner Race on the Countershaft Front against the Drive Gear.
Note: Make sure all Gears are pressed into place.
Note: Make sure the Bearing Inner Race is installed.
220
How to Assemble the Lower Reverse Idler Gear Assembly

In 1996 Eaton® changed the Reverse Idler System design. In the Nut design, the Reverse Idler Bearing was lubricated through a
hole in the Main Case Reverse Idler Support Boss and a oil passage through the Idler Shaft middle.
Special Tools
Previous Design

1. Idler Plate 5. Bearing
2. Inner Race 6. Reverse Idler Gear
3. Washer 7. Reverse Idler Shaft
4. Nut and Washer 8. Plug
221
The Cap Screw design eliminates the Case hole and Idler Shaft hole. The Reverse Idler Bearing is supplied oil through the use of
star design Thrust Washers. If the Nut design parts are used with the Cap Screw design, where Main Case does not have the oil
feed hole, the Reverse Idler Bearing will fail.
Current Design
1. Star Washer 6. Idler Plate

2. Inner Race 7. Bearing
3. Star Washer 8. Reverse Idler Gear
4. Retaining Ring 9. Reverse Idler Shaft
5. Cap Screw
222
Procedure -
1. Position the Reverse Idler Bearing and Inner Race into the
Reverse Idler Gear.

2. Position the gear in the Case. The Gear's long hub is
positioned forward.
3. Place the Rear Thrust Washer on the Idler Shaft.
4. From the Case rear, insert the Idler Shaft through the Main
Case Bearing Bore and into the Reverse Idler Gear Bearing.
5. As the Idler Shaft slides into the gear, insert the Front Thrust
Washer into position. Continue sliding the Idler Shaft into
the Case Support Boss.
6. From the rear, gently tap the Idler Shaft forward until
resistance is felt.
223
7. Install the Flat Washer over the Shaft’s threaded portion.
8. Apply Eaton® Fuller® Sealant #71205 or equivalent. Install

Cap Screw and torque to 67–75 lb-ft (90.84–101.69 N•m).
9. Using a Bearing Race Driver, install the Auxiliary

Countershaft Bearing Race into the Lower Reverse
Idler Bore.
Note: The Bearing Races have a slip fit in their Bores.

They should slide or rotate easily into the Case Bore
if they are not cocked.
224
How to Install Countershaft Assemblies

Make sure the Countershaft Assemblies have been marked for proper position, 47- tooth PTO gear in the lower position.
Prior to installing the Countershafts, the Lower Reverse Idler Gear Assembly should be installed. In addition, if the Transmission
is equipped with an Internal Oil Pump, this should also be installed.
Special Tools
• Toolmaker’s Dye
Procedure -

1. On the Drive Gear of each Countershaft Assembly, mark the
tooth aligned with the gear Keyway and stamped with an “O”
for easy identification. A highly visible color of Toolmaker’s
Dye is recommended for making timing marks.
Note: Prior to installing the Countershafts, the Lower

Reverse Idler Gear Assembly should be installed. In
addition, if the Transmission is equipped with an
Internal Oil Pump, this should also be installed.
2. Place the lower, 47-tooth PTO gear Countershaft, into the

Main Case with the Shaft seated in the Lower Countershaft
Case Bores.
Note: Use a large hook or piece of rope to support the

Countershaft if necessary.
3. Place the Upper Countershaft (with the 45 tooth PTO gear)

into the Main Case with the Shaft seated in the Upper
Countershaft Case Bores.
225
How to Remove the Integral Oil Pump

None
Special Tools
Procedure -
1. Remove the Cap Screws holding the Suction and Auxiliary

Oil Tubes in position.
2. Straighten Tube Lock on Suction Tube.
3. Remove Suction Tube from Oil Pump. If necessary, remove

O-Ring from Suction Tube.
226
4. Remove three (3) Allen Head Cap Screws and Washers that
retain the Integral Oil Pump to the Case.

5. Remove the Integral Oil Pump Assembly from inside
the Case.
6. Remove the Integral Oil Pump Retainer Plate from inside

the Case.
7. If necessary, the Front Case Plug can be removed from

the case. To remove, insert a Bar from inside the Case and
tap the Plug out.
8. Inspect the plug O-Ring for cracks and pitting. Replace

if damaged.
227
How to Install the Lower Countershaft Bearings

The Lower Reverse Idler Assembly should be installed before the Lower Countershaft.
The Front Bearing Inner Race must be pressed on the Countershaft front.
The Flanged-End Driver must cover the Bearing Outer Race for proper installation.
Special Tools
• RR1012TR-2 Bearing Driver (front)
• RR1012TR-4 Bearing Driver (rear)
• RR1013TR Timing Block
Procedure -
1. Move the Countershaft to the rear and insert the
RR1013TR Timing Block to center Shaft in rear Case Bore.
2. Obtain a spare Inner Countershaft Race.
3. Temporarily install the spare Countershaft Inner Race inside

the Front Roller Bearing for installation.
228
4. Use the RR1012TR-2 Bearing Driver to start the Front

Bearing in Case Bore.
5. Use a Screwdriver inserted in the Countershaft Cap Screw

Bore to help center the Countershaft.
6. Move the Countershaft forward into the bearing.
7. Use the RR1012TR-2 Bearing Driver and Maul to completely

seat the Front Bearing in the Case Bore.
Note: Make sure to contact only the Bearing and not the
Temporary Race with the Driver. The Temporary Race
should fall out when installation is complete.

8. On the Countershaft front, position the Retainer Plate with
Roll Pin in hole at Shaft end.
9. Install the Front Bearing Retainer Plate and Cap Screw. If the
Cap Screw is being reused, apply Eaton® Fuller® Thread
Sealant #71205 or equivalent. Torque the Cap Screw to
90–120 lb-ft (122.02–162.70 N•m).
Note: Earlier models may have a Roll Pin in the Retainer.

This Roll Pin is not required and was removed on
units built after 1994.
10. From the rear, remove the Countershaft Support Tool.
11. Install the Rear Countershaft Bearing. Position the Bearing

so that the larger chamfer on the Bearing inside diameter is
installed towards the Shaft. Use the RR1012TR-4 Bearing
Driver and a Hand Maul to completely seat the Bearing.
12. In the Countershaft Rear Groove, install the Rear Snap Ring.
229
How to Install the Input Shaft and Main Drive Gear

None
Special Tools
• RR1005TR Input Bearing Driver
Procedure -
1. Use a highly visible Toolmaker's Dye and mark the Main
Drive Gear for timing purposes. To mark the Gear, paint
Toolmaker's Dye on any two adjacent teeth, and then paint
the two adjacent teeth directly opposite the first two teeth.
2. If necessary, install the bushing in the back of the

Input Shaft.
3. Temporarily position the Upper Countershaft up and away

from the Transmission center.
4. From inside the case, mesh the Lower Countershaft Drive

Gear marked tooth with either set of Main Drive Gear
marked teeth.
5. From the front, engage the Input Shaft Spline Teeth into the
Main Drive Gear.
Note: The current design Input Shaft Spline Teeth have

noticeable clearance to the Main Drive Gear internal
Spline Teeth. This is normal.
6. Install the Snap Ring in the Main Drive Gear inside groove.
230
7. Install the Spacer Washer over the Input Shaft. With the
Bearing External Snap Ring to the outside, position the
bearing on the Input Shaft.

8. Install the Input Shaft Bearing over the Input Shaft. Use the
RR1005TR Input Bearing Driver and a Hand Maul to drive
the Bearing until it contacts the front wall of the Main Case.
9. Temporarily install the Front Bearing Cover with two

Cap Screws.
10. From inside the Main Case, drive the Input Shaft forward
until it is fully seated.
11. Install the Input Shaft Retaining Snap Ring.
Note: Do not replace the small rubber Lip Seal. It is used

only to prevent leakage during shipping.
12. Do not reinstall the Input Bearing Cover at this time. Instead,
pull the Input Shaft and Bearing forward to allow for
Mainshaft installation.
231
How to Install the Mainshaft Assembly

The Lower Countershaft Bearings and the Input Shaft must be installed, but for higher torque ratings do not install the Front
Bearing Cover.
Check to make sure the Lower Countershaft Drive Gear marked tooth is in time with Main Drive Gear set of marked teeth.
Special Tools
• RR1004TR Mainshaft Lifting Hook
Procedure -
1. Block the Upper Countershaft forward and as close to the
case wall as possible.
2. With Reverse Gear forward against the next speed Gear and
Mainshaft pilot end over the Integral Oil Pump gear, lower
the Mainshaft Assembly while pulling the shaft rear through
the Case Bore.
3. Pull the Input Shaft forward until the Drive Gear is against
the case.
4. After the Mainshaft drops into the case, slide the

Countershaft back and the Mainshaft should fall down
between the Countershafts.
5. Move the Mainshaft pilot-end into the Input Shaft Pilot

bushing. Mesh the Mainshaft Gears with the corresponding
Countershaft Assembly gears.
6. Position the upper Reverse Idler Gear in case.
Note: At this time other components of the Front Section

must be installed before the Mainshaft installation can
be completed, see the procedure “How to Install the
Upper Countershaft Bearings”.
232
7. Mesh the Reverse Gear teeth with the Reverse Idler Gear
teeth and move the Reverse Gear to the rear as far as
possible.
8. Align the Reverse Gear Spacer external Splines with the

Reverse Gear and move the Spacer into the Reverse Gear.
9. Install the Reverse Gear I.D. Snap Ring and move the
Reverse Gear forward on the Mainshaft and against the
Reverse Gear Limit Washer.
10. Push the Input Shaft Bearing back into the Case Bore.

11. Position a new gasket on the Bearing Cover mounting
surface, make sure to align the gasket oil return hole with
Case oil return hole.
12. Position the Front Bearing Cover, make sure to align the
Cover oil return hole with Case oil return hole.
13. Secure the Front Bearing Cover with six (6) Cap Screws,
torque to 35–45 lb-ft (47.45–61.01 N•m).
Note: Make sure the Drive Gear is timed with the both
Countershafts.
Note: Make sure the Front Bearing Cover Cap Screws are
tightened properly.
233
How to Install the Upper Countershaft Bearings

The Front Bearing Inner Race must be pressed on the Countershaft front.
The Flanged-End Driver must cover the Bearing Outer Race for proper installation.
Temporarily use the assembled Auxiliary Drive Gear to hold the Mainshaft in the Input Shaft Pilot.
CAUTION: The Upper Countershaft Bearings must be installed after the installation of the Mainshaft.
Special Tools
• RR1012TR-2 Bearing Driver (front)
• RR1012TR-4 Bearing Driver (rear)
• RR1013TR Timing Block
Procedure -
Figure 3
1. Make sure the Lower Countershaft and Main Drive Gear
timing marks are aligned.
2. Mesh the Upper Countershaft marked tooth with the two

remaining Main Drive Gear marked teeth.
3. Move the Countershaft to the rear and insert the

RR1013TR Timing Block to center Shaft in rear Case Bore.
234
4. Obtain a spare Inner Countershaft Race.
5. Temporarily install a spare Countershaft Inner Race inside

the Front Roller Bearing for installation.

6. Use the RR1012TR-2 Bearing Driver to start the Front
Bearing in Case Bore.
7. Use a Screwdriver inserted in the Countershaft Cap Screw

Bore to help center the Countershaft.
8. Move the Countershaft forward into the Bearing.
9. Use the RR1012TR-2 Bearing Driver and Maul to completely

seat the Front Bearing in the Case Bore.
Note: Make sure to contact only the bearing and not the
Temporary Race with the driver. The Temporary Race
should fall out when installation is complete.
10. On the Countershaft front, position the Retainer Plate with

Roll Pin in hole at shaft end.
11. Install the Front Bearing Retainer Plate and Cap Screw.
If the Cap Screw is being reused, apply Eaton® Fuller®
Thread Sealant #71205 or equivalent. Torque the Cap Screw
to 90–120 lb-ft (122.02–162.70 N•m).
Note: Earlier models may have a Roll Pin in the Retainer.

This Roll Pin is not required and was removed on
units built after 1994.
235
12. From the rear, remove the Countershaft Support Tool.
13. Install the Rear Countershaft Bearing. Position the Bearing

so that the larger chamfer on the Bearing inside diameter is
installed towards the Shaft. Use the RR1012TR-4 Bearing
Driver and a Hand Maul to completely seat the Bearing.
14. In the Countershaft Rear Groove, install the Rear Snap Ring.
236
How to Assemble the Upper Reverse Idler Gear Assembly

In 1996 Eaton® changed the Reverse Idler System design. In the Nut design, the Reverse Idler Bearing was lubricated through a
hole in the Main Case Reverse Idler Support Boss and a oil passage through the Idler Shaft middle.
Special Tools
Previous Design

1. Idler Plate 5. Bearing
2. Inner Race 6. Reverse Idler Gear
3. Washer 7. Reverse Idler Shaft
4. Nut and Washer 8. Plug
237
The Cap Screw design eliminates the Case hole and Idler Shaft hole. The Reverse Idler Bearing is supplied oil through the use of
star design Thrust Washers. If the Nut design parts are used with the Cap Screw design Main Case which does not have the oil
feed hole, the Reverse Idler Bearing will fail.
Current Design
1. Star Washer 6. Idler Plate

2. Inner Race 7. Bearing
3. Star Washer 8. Reverse Idler Gear
4. Retaining Ring 9. Reverse Idler Shaft
5. Cap Screw
238
Procedure -
1. Place the rear Thrust Washer on the Idler Shaft.
2. From the rear, insert the Idler Shaft through the Main Case
Bearing Bore and into the Reverse Idler Gear Bearing.

3. As the Idler Shaft slides into the Gear, insert the Front Thrust
Washer into position. Continue sliding the Idler Shaft into
the Case Support Boss.
4. From the rear, gently tap the Idler Shaft forward until
resistance is felt.
5. Install the Flat Washer over the Shaft’s threaded portion.
6. Inspect the Reverse Idler Nut nylon locking material.

Replace the Cap Screw, if necessary. Install the Cap Screw
and torque to 67–75 lb-ft (90.84–101.69 N•m).
7. Using a Bearing Race Driver, install the Auxiliary

Countershaft Bearing Race into the Lower Reverse
Idler Bore.
Note: The Bearing Races have a slip fit in their Bores. They
should slide or rotate easily into the Case Bore if they
are not cocked.
239
How to Install the Auxiliary Drive Gear Assembly

Before installing the Auxiliary Drive Gear, the Mainshaft must be completely installed.
Special Tools
Procedure -
1. If removed, press the Spacer into the Bearing.
2. Slide the Auxiliary Bearing on the Mainshaft up to the

Case Bore.
3. Use a Brass Maul and carefully seat the bearing in Case

Bore.
4. Install the Splined Washer on the Mainshaft.
5. Align the Retainer Ring Cap Screw holes with the tapped
holes.


(47.45–61.01 N•m).
8. Install the Auxiliary Drive Gear and Retaining Washer on

the Mainshaft.
9. Install the Auxiliary Drive Gear Retaining Snap Ring in the

Mainshaft Snap Ring groove.
240
How to Install the Clutch Housing (with Internal Oil Tube)

Installation of the Clutch Housing is performed in the horizontal position.
IMPORTANT: Some early production models do not have an Oil Tube behind the Clutch Housing. For these models skip steps
3, 4, and 5.
The Oil Tube comes in two different lengths. The older units extend 2/3 of the way through the Front Box. The new units go into
the intermediate wall that separates the Main Case from the Auxiliary Case (see step 5).
Special Tools
• Typical Service Tools, Torque wrench

Procedure -
1. Position a new gasket on the Housing mounting surface.
Note: If the Front Bearing Cover was removed, it needs to be

installed before the Clutch Housing to ensure correct
alignment of the Clutch Housing.
2. If Oil Tube is not being replaced follow steps 6–8.
Note: For additional information on the removal of the

Shift Bar Housing and Slave Valve refer to the
proper section.
3. Inspect O-Rings on Oil Tube and replace if damaged.
4. Apply Eaton® Fuller® silicone Lubricant #71203 to O-Rings

and install Oil Tube in Case.
241
5. Press Oil Tube firmly into place.
Note: The Oil Tube has two different lengths. Older units
extend 2/3 of the way into the Main Case and newer
units go into the intermediate wall (Figures in the
next column).
Old Style
New Style
6. Install the Clutch Housing on the Front Box, pilot it on the six
studs and Front Bearing Cover.
7. Install the nuts with washers on the studs, torque to

35 lb-ft (47 N•m) + 90° CW rotation (or 175 lb-ft (237 N•m))
in cross pattern.
8. Install the Cap Screws, torque to 115 lb-ft (156 N•m) in

cross pattern.
Note: Make sure all fasteners are properly torqued.
242
9. Install the Shift Bar Housing and Gasket.
Note: Ensure Roll Pin and proper Cap Screw are installed in
the front left corner. Cap Screw length is 1 3/4".

11. Install Slave Valve.
243
How to Disassemble the Integral Oil Pump without Auxiliary Oil Tube
None
Special Tools
• A Vise with brass jaws or wood blocks
Procedure -
1. From the Assembly, remove the Outer Oil Pump Element.
2. From the Drive Shaft, remove the Drive Gear Retaining

Snap Ring.
3. From the Pump Drive Shaft, remove the Drive Gear.
4. From the Drive Shaft Keyway, remove the Key.
244
5. From the Drive Shaft, remove the Element Snap Ring.

6. From the Drive Shaft, remove the Internal Oil Pump Element.
7. From the Drive Shaft Keyways, remove the two (2) Keys.
8. From the Integral Oil Pump Housing, remove the Drive Shaft.
9. If damaged, from the Drive Shaft, remove the rear Drive Gear
Retention Snap Ring.
245
10. From the Pump Housing, remove the Relief Valve Roll Pin.
11. From the Relief Valve Housing Bore, remove the Relief
Valve Spring.
12. From the Housing Bore, remove the Relief Valve.
13. Inspect all parts for damage, replace damaged parts.
246
How to Assemble the Integral Oil Pump without Auxiliary Oil Tube
When installing the Drive Shaft Keys, the round Key goes in the round Keyway and the square Key in the square Keyway.
Special Tools
Procedure -
1. Install the Relief Valve in the Integral Oil Pump Housing.

2. Install the Relief Valve Spring in Oil Pump Housing.
3. Secure the Oil Pump Housing in a Vice.
4. Depress the Relief Valve Spring and drive the Relief Valve
Retention Roll Pin into the Roll Pin Bore.
247
5. If removed, replace the Drive Shaft Snap Ring on the

Pump Drive Shaft.
6. Insert the Drive Shaft through the Pump Housing Bore.
7. Install the two (2) Keys on the Drive Shaft.
8. Align the Inner Element Keyways with the Drive Shaft Keys
and install the Integral Oil Pump Inner Element.
9. Install the Inner Element Retention Snap Ring in Drive Shaft

Snap Ring groove.
248
10. Install Drive Gear Key in Drive Shaft Keyway.

11. Align Drive Gear Keyway with Drive Shaft Key and install
the Drive Gear on the Drive Shaft.
12. Install the Outer Drive Gear Retention Snap Ring in Drive
Shaft groove.
13. Install the Outer Integral Oil Pump Element over the
Inner Element.
249
How to Install the Integral Oil Pump

Lubricate the Case Front Plug O-Ring with Eaton® Fuller® Lubricant #71206 or equivalent.
Special Tools
Procedure -
1. If removed, replace the Front Case Pump Plug O-Ring.
lubricate the grove of the plug, install the O-Ring onto the
plug, and then lubricate the outer diameter of the O-Ring.
2. Seat the Front Case Pump Plug in the Case Bore by hand.
Do not install the Pump Plug using any type of Impact Tool
(i.e. Hammer, Maul, etc.).
Note: P/N 4303107 Retainer Plate, which has a smaller

outside diameter, must be used with Main Cases
machined after April 1995. If an older Oil Pump
Assembly is installed into a new case, P/N 20510
Retainer Plate will not seat properly in the Spot Face
machined in the case wall
3. With the Retainer Bore facing the case rear, install the
Integral Oil Pump over the Alignment Pin inside the case.
4. Align Oil Pump with Retainer and Alignment Pin and install
the Integral Oil Pump Assembly.
250
5. Install three (3) Allen Head Cap Screws and washers through
the Case Front and into the Pump Housing. Torque the Cap
Screws to 8–12 lb-ft (10.85–16.30 N•m).
6. Replace the O-Ring on the Suction Tube.
7. Install the Tube under the Case Rib and into the Integral
Oil Pump.

8. Bend the Suction Tube Lock over the Case Rib.
9. Position the Oil Tube in the case bottom through the

intermediate wall.
10. Apply Loctite 242 to Cap Screw threads. Torque Cap Screws
to 35–45 lb-ft (47.45–61.01 N•m).
Note: Make sure the Integral Oil Pump Drive Gear can turn.
251
How to Disassemble the Integral Oil Pump with Auxiliary Oil Tube
None
Special Tools
Procedure -
1. From the assembly, remove the Outer Oil Pump Element.
2. From the Drive Shaft, remove the Drive Gear Retaining

Snap Ring.
3. From the Pump Drive Shaft, remove the Drive Gear.
4. From the Drive Shaft Keyway, remove the Key.
252
5. From the Drive Shaft, remove the Element Snap Ring.

6. From the Drive Shaft, remove the Internal Oil Pump Element.
7. From the Drive Shaft Keyways, remove the two (2) Keys.
8. Remove the Transfer Tube.
9. From the Integral Oil Pump Housing, remove the Drive Shaft.
10. If damaged, from the Drive Shaft, remove the Rear Drive
Gear Retention Snap Ring.
253
11. Loosen the Retaining Nut.
12. Remove the Retaining Nut, Spring and Ball.
13. From the Pump Housing, remove the Relief Valve Roll Pin.
14. From the Relief Valve Housing Bore, remove the Relief
Spring and Relief Valve.
254
15. Remove the Valve Cover.
16. Inspect all parts for damage, replace damaged parts.

255
How to Assemble the Integral Oil Pump with Auxiliary Oil Tube
When installing the Drive Shaft Keys, the round Key goes in the round Keyway and the square Key in the square Keyway.
Special Tools
Procedure -
1. Install the Valve Cover.
2. Install the Relief Valve and Relief Valve Spring in the Integral
Oil Pump Housing.
3. Secure the Oil Pump Housing in a Vice.
4. Depress the Relief Valve Spring and drive the Relief Valve
Retention Roll Pin into the Roll Pin Bore.
256
5. Install the Ball, Spring and Retaining Nut.
6. Torque the Retaining Nut to 40–45 lb-ft (54.23–61.01 N•m).

7. If removed, replace the Drive Shaft Snap Ring on the Pump
Drive Shaft.
8. Insert the Drive Shaft through the Pump Housing Bore.
9. Install the two (2) Keys on the Drive Shaft.
257
10. Install the Transfer Tube.
11. Align the Inner Element Keyways with the Drive Shaft Keys
and install the Integral Oil Pump Inner Element.
12. Install the Inner Element Retention Snap Ring in Drive Shaft
Snap Ring groove.
13. Install Drive Gear Key in Drive Shaft Keyway.
14. Align Drive Gear Keyway with Drive Shaft Key and install the
Drive Gear on the Drive Shaft.
15. Install the Outer Drive Gear Retention Snap Ring in Drive
Shaft groove.
258
16. Install the Outer Integral Oil Pump Element over the
Inner Element.

259
How to Install the Auxiliary Section

There are different Cap Screw lengths, install in the correct location.
Auxiliary Sections can be installed either with the Transmission in the horizontal position or the vertical position.
To install in the vertical position, the Clutch Housing must be installed.
Special Tools
Procedure -
1. To install the Auxiliary Section in the horizontal position:
Position a new gasket on the Transmission mounting
surface.
2. Attach the RR1006TR Auxiliary Section Lifting Bracket to

the Auxiliary Section top.
3. Attach a Lifting Chain to the Auxiliary Section Hanger

Bracket.
4. Position the Auxiliary Section on the two (2) Dowel Pins.
5. Slide the Auxiliary Section on until the hanger bracket

contacts the Transmission Main Case.
6. Remove the Auxiliary Section Hanger Bracket.
7. Slide the Auxiliary Section the rest of the way into position.


(47.45–61.01 N•m).
10. To finish installation, see “The Shimming Procedure for

Tapered Bearings”.
260
Procedure -
1. To install the Auxiliary Section in the vertical position:
With blocks under the Clutch Housing to prevent Input Shaft
damage, place the Transmission in the vertical position,
Clutch Housing down.
2. Position a new gasket on the Transmission mounting

surface.
3. Install a Steel Bar through the Yoke.
4. Attach a Lifting Chain to the Steel Bar.
5. Position the Auxiliary Section over the two (2) Dowel Pins.

6. Slide the Auxiliary Section down the Dowels.


(47.45–61.01 N•m).
9. Remove the Steel Bar and chain.
10. To finish installation, see “The Shimming Procedure for

Tapered Bearings”.
Note: Make sure the Input Shaft rotates.
261
Shim Procedure without a Shim Tool for Tapered Bearings

The shim procedure can be done in the horizontal or vertical position. The procedure is done the same.
CAUTION
Use genuine Eaton® replacement gaskets for the Auxiliary Housing and Countershaft Bearing Cover. Do not omit the gaskets.
Bearing endplay is influenced by the compressed thickness of the gasket (0.011–0.012" or 0.28–0.30 mm).
The bearing endplay must be checked and adjusted any time a Countershaft, Bearing, or Housing is replaced. If, during
reassembly, the same Countershaft, Bearings, Housing, and Shims are reused and kept in the same location, it is not necessary
to reset Bearing endplay.
The following procedure is used to adjust the endplay for the Auxiliary Countershaft Tapered Bearings. By correctly following this
procedure, each Countershaft will have 0.001–0.005" (0.03–0.12 mm) endplay.
Shims must be aligned properly or else the Rear Bearing Cover may be damaged when final torque is applied.
Special Tools
• Shims and Feeler Gauge
Procedure -
1. The Auxiliary Countershaft Bearing Covers or Countershaft
straps and shims should be removed. Make sure all old
gasket material is cleaned from the gasket mounting
surfaces on the Countershaft Bearing Covers and the
Auxiliary Housing.
2. Verify that the Auxiliary Section is in gear. When the

Output Shaft is rotated, the Countershafts must also rotate.
If not shift the Auxiliary into gear by applying shop air to the
high range air port on Range Cylinder to shift into gear.
3. Make sure a 0.100 Countershaft Rear Bearing Shim is

installed. Be sure the Countershaft Rear Bearing Races
are seated in the bearing Bores.
4. Install two (2) clean 3/8“ x 1“ Cap Screws without

washers directly across from each other in each Bearing
Cover. Tapped holes in Auxiliary Case must be free of
thread adhesive.
262
5. Evenly torque the Cap Screws to 7 lb-in (0.79 N•m). Do not

install the Countershaft Rear Bearing Cover gasket. The gap
between the Bearing Cover and the Housing surface should
be even from side to side.
Note: 7 lb-in (0.79 N•m) is slightly more than finger tight.

Do not overtighten the Cap Screws. If the Cap Screws
are too tight, the Bearing Cover will become distorted.
6. Rotate the Output Shaft 4 times clockwise and 4 times

counterclockwise. The rotation will seat and align the
rollers in each tapered bearing. Re-torque the Cap Screws
to 7 lb-in (0.79 N•m). If the Countershafts do not rotate, the
Range Sliding Clutch or Deep Reduction Sliding Clutch is in

Neutral. Apply shop compressed air to Shift Cylinders to
shift the Sliding Clutches into gear.
7. Use a Feeler Gauge, as close to each Cap Screw location

as possible, and measure the gap between the
Countershaft Rear Bearing Cover and the Auxiliary
Housing Gasket surface. Measure and record the gap at
both Cap Screw locations.
8. Average the two Feeler Gauge measurements by adding the

measurements together and dividing by 2 as shown in the
following Example:
Example Shim Selection
Gap 1 = 0.060; Gap 2 = 0.050
Total Gap = 0.060 + 0.050 = 0.110
Average = 110/2 = 0.055
Select yellow shim as indicated in the
Shim Table at the end of this selection.
9. Locate the Feeler Gauge average measurement in the

Shim Table to determine the required Shim and Color Code.
Note: The Oil Pump Shim is used when an Auxiliary Oil

Pump or PTO is mounted on the Countershaft. The Oil
Pump Shims have a smaller outside diameter.
263
10. Remove the Countershaft Rear Bearing Cover and

Gauging Shim.
11. Place the selected Shim on the Rear Countershaft

Bearing Race.
12. Position a new gasket on Countershaft Rear Bearing Cover

mounting surface.
13. Position the Countershaft Rear Bearing Cover over the

new gasket.
14. Apply Eaton® Fuller® Thread Sealant #71205 or equivalent

to the Auxiliary Countershaft Rear Bearing Cover Cap
Screws and Auxiliary Countershaft Rear Bearing Cover.
15. Install the Auxiliary Countershaft Rear Bearing Cover and

secure it with the Cap Screws. Make sure the Shim is in the
proper location and is not pinched between the Cover and
the Housing. Torque the Cap Screws to 40–45 lb-ft
(54.23–61.01 N•m).
Note: Use a thick grease to hold the Shim in position when

installing the Cover.
16. Repeat this procedure for the remaining Countershaft.
Note: Make sure the Input Shaft rotates.
264
Shim Table
Feeler Gauge Shim Standard Shim Oil Pump Shim Color
Average Gap Thickness Part Number Part Number Code
0.072–0.075 0.033–0.034 4302345 4302346 Gold
0.69–0.0715 0.036–0.037 21452 21472 Red
0.066–0.0685 0.039–0.040 21453 21473 Pink
0.063–0.0655 0.042–0.043 21454 21474 Brown
0.060–0.0625 0.045–0.046 21455 21475 Tan
0.057–0.0595 0.048–0.049 21456 21476 Orange

0.054–0.0565 0.051–0.052 21457 21477 Yellow
0.051–0.0535 0.054–0.055 21458 21478 Green
0.048–0.0505 0.057–0.058 21459 21479 Light Blue
0.045–0.0475 0.060–0.061 21460 21480 Lavender
0.042–0.0445 0.063–0.064 21461 21481 White
0.039–0.0415 0.066–0.067 21684 21686 Black
0.036–0.0385 0.069–0.070 21685 21687 Silver
265
How to Remove the Boosted or Hydraulic Actuator and Adapter Housing

The Air Line must be disconnected if removing an air over Hydraulic Boosted Actuator.
The hydraulic line does not need to be disconnected for the removal and installation of the Actuator and Actuator Housing.
WARNING
The Air System must be bled prior to removing any Air Lines to prevent possible injury.
CAUTION
Do not press or disengage Clutch Pedal when removing Slave Cylinder or Clutch Servo.
Special Tools
Procedure -
1. If system is an air over hydraulic, the Air Line must be
disconnected from the Boosted Actuator prior to removing
the assembly.
Note: It is not necessary to remove the hydraulic line.

Removing the hydraulic line will allow air to enter the
system, requiring the system to be bleed.
2. Remove the four Cap Screws from the Boosted or

Hydraulic Actuator.
3. Apply force to remove the Actuator Rod from the Clutch

Slave Fork.
266
4. Pull the Boosted or Hydraulic Actuator back and remove it Boosted (Air over Hydraulic Actuator)
from the Actuator Housing.
Hydraulic Actuator

5. Remove the four Cap Screws holding the Actuator Housing
to the Clutch Housing.
6. Lower the Actuator Housing and remove it from the Clutch

Housing.
267
How to Install the Boosted or Hydraulic Actuator and Adapter Housing

The Air Line should remain disconnected until the Boosted Actuator and Boosted Actuator Housing are assembled.
CAUTION
Do not press or disengage Clutch Pedal when Slave Cylinder or Clutch Servo is removed.
Special Tools
Procedure -
1. Lift Boosted or Hydraulic Actuator Housing up through the
Clutch Housing opening.
2. Torque the four Cap Screws for the Actuator Housing to

72–80 lb-ft (97.62–108.47 N•m).
268
3. Slide Boosted or Hydraulic Actuator into the back of the

Boosted (Air over Hydraulic Actuator)
Actuator Housing and snap the Push Rod into the Clutch
Release Fork.
Hydraulic Actuator

4. Install the four Cap Screws holding the Boosted or Hydraulic
Actuator to the Actuator Housing and torque to 14 lb-ft
(18.98 N•m).
5. Install the Air Line if it is a Boosted Actuator.
269
Copyright Eaton, 2013.
Eaton hereby grant their customers,
vendors, or distributors permission
to freely copy, reproduce and/or
distribute this document in printed
format. It may be copied only in
its entirety without any changes or
modifications. THIS INFORMATION
IS NOT INTENDED FOR SALE OR
RESALE, AND THIS NOTICE MUST
REMAIN ON ALL COPIES.
Note: Features and specifications
listed in this document are subject to
change without notice and represent
the maximum capabilities of the
software and products with all options
installed. Although every attempt has
been made to ensure the accuracy of
information contained within, Eaton
makes no representation about the
completeness, correctness or accuracy
and assumes no responsibility for
any errors or omissions. Features and
functionality may vary depending on
selected options.
For spec’ing or service assistance,
call 1-800-826-HELP (4357) or visit
www.eaton.com/roadranger.
In Mexico, call 001-800-826-4357.
Roadranger: Eaton and trusted partners

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

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In-Vehicle Service Procedures

3. Attach the Air Lines and reinstall the Bottom Cover.

How to Disassemble Roadranger Valve A-4900

In-Vehicle Service Procedures

Component Nomenclature and Roadranger Valve Sectional View

3. Pry the Medallion from the recess in the Top Cover.

How to Assemble Roadranger Valve A-4900

In-Vehicle Service Procedures

Component Nomenclature and Roadranger Valve Sectional View

3. Attach the Air Lines and install the Bottom Cover.

How to Remove the Air Lines and Hoses

In-Vehicle Service Procedures

2. Inspect the Air Lines and Hoses.

3. Inspect Air Fittings and remove if damaged.

How to Install the Air Lines and Hoses

Install the Air Lines and Hoses at their proper location.

In-Vehicle Service Procedures

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

3. Connect all removed Air Lines and Hoses.

How to Remove Compression Type Fittings

In-Vehicle Service Procedures

How to Install Compression Type Fittings

2. Install the fitting.

Note: Do not overtighten the nut. Overtightening can

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

How to Remove Push-to-Connect Type Fittings

In-Vehicle Service Procedures

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

How to Install Push-to-Connect Type Fittings

2. Install the fitting.

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

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

How to Remove Rubber 1/4" Air Hoses

In-Vehicle Service Procedures

2. Remove swivel end.

3. Remove fixed end.

How to Install Rubber 1/4" Air Hoses

3. Replace all Air Line Brackets and Ties.

How to Remove the Air Filter/Regulator

In-Vehicle Service Procedures

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

How to Install the Air Filter/Regulator

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

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

How to Remove a Roadranger Valve

In-Vehicle Service Procedures

2. Slide the Roadranger Valve Cover down.

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

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

How to Install a Roadranger Valve

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

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

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

5. Connect the Air Lines to the Air Fittings.

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

7. Install the Roadranger Valve Cover mounting screws.

Note: Make sure the Air Lines are seated fully.

How to Remove a Slave Valve

In-Vehicle Service Procedures