Eaton FSO-2105 Service Manual
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Eaton FSO-2105 Service Manual

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Summary of Contents for Eaton FSO-2105

  • Page 2: Table Of Contents

    Model designation ............................3 Gear Ratio ..............................4 Exploded Views ..............................5 Direct Control Assembly FSO-2105 / FSO-2505 (4x2 and 4x4) Models ..................5 Shift Yokes and Bars FSO-2105 / FSO-2505 (4x2 and 4x4) Models ..................6 Transmission Case Assembly FSO-2105 / FSO-2505 (4x2) Models ......................
  • Page 3 Table of Contents Gear Shift Lever Housing Gear Shift Lever Housing Disassembly ......................43 Gear Shift Lever Housing Assembly ........................ 44 Rear Section Rear Section Disassembly ..........................47 Oil Seal Replacement ............................52 Rear Section Assembly ........................... 52 Front Section Front Section Disassembly ..........................
  • Page 4 Table of Contents Input Shaft Bearing Cup Removal ..............................75 Installation ............................. 75 Input Shaft Oil Baffle and Oil Seal Removal ..............................76 Installation ............................. 76 Countershaft Front Bearing Cup Removal ..............................77 Installation ............................. 77 Mainshaft and Countershaft Rear Bearing Cups Removal ..............................

  • Page 6: Purpose And Scope Of The Manual

    FSO-2105 and FSO-2505. How to Use this Manual Disassembly and assembly instructions in this manual make use of a typical FSO-2105 or FSO-2505 transmission. Provided illustrations and pictures show parts that may differ from one transmission model to another, according to its application and serial number.

  • Page 7: Warnings And Precautions

    The description and specifications contained in this service publication are current at the time of printing. Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice.

  • Page 8: Identification

    Identification Model designation All Eaton transmissions are identified by the model designation and serial number. This information is stamped on the identification plate fixed to the transmission case. FSO - 2 105A Eaton Gear ratio Synchronized Overdrive Forward speeds Design level Nominal torque capacity (x100 Lb.ft)

  • Page 9: Gear Ratio

    Example: FSO-2105 Input pair: Input shaft = 26 teeth; = 37 teeth => 37/26 = 1.423 ~ First gear: Countershaft = 14 teeth; Mainshaft = 44 teeth => 44/14= 3.143 ~...

  • Page 10: Exploded Views

    Exploded Views Direct Control Assembly FSO-2105 / FSO-2505 (4x2 and 4x4) Models FSO-2105/explo5 Gear shift lever housing Thrust washer 13. Flat washer Threaded pin Boot 14. Support spacer Locating pin Gear shift lever 15. Shock-absorbing bushing Spring 10. Pivot pin 16.

  • Page 11: Shift Yokes And Bars Fso-2105 / Fso-2505 (4X2 And 4X4) Models

    Exploded Views Shift Yokes and Bars FSO-2105 / FSO-2505 (4x2 and 4x4) Models FSO-2105/explo4 30. 3rd/4th speed shift yoke 41. Yoke pads 52. Roll pin assembly 42. Roll pin 53. 5th/reverse speed shift 31. Yoke pads block 43. Shift selector block assembly 32.

  • Page 12: Transmission Case Assembly Fso-2105 / Fso-2505 (4X2) Models

    Exploded Views Transmission Case Assembly FSO-2105 / FSO-2505 (4x2) Models FSO-2105/explo1 70. Front housing 84. Threaded pin 98. Actuator 71. Oil seal 85. Screw 99. Actuator’s spring 72. Screw 86. Dowel pin 100. Threaded plug 73. Plug 87. Screw 101. Magnetic speed sensor 74.

  • Page 13: Fso-2105 / Fso-2505 (4X4) Models

    Exploded Views Transmission Case Assembly FSO-2105 / FSO-2505 (4x4) Models FSO-2105/explo1a 70. Front housing 83. Filling plug 96. Actuator’s bushing 71. Oil seal 84. Threaded pin 97. Actuator 72. Screw 85. Screw 98. Actuator’s spring 73. Plug 86. Dowel pin 99.

  • Page 14: Input Shaft / Mainshaft Assembly Fso-2105 / Fso-2505 (4X2 And 4X4) Models

    Exploded Views Input Shaft / Mainshaft Assembly FSO-2105 / FSO-2505 (4x2 and 4x4) Models FSO-2105/explo2 120. Input shaft bearing cup 135. Mainshaft (4x2) 148. Mainshaft intermediate bearing cup 121. Input shaft bearing cone 135a. Mainshaft (4x4) 149. Shim 0.050 mm 122.

  • Page 15: Countershaft Assembly Fso-2105 / Fso-2505 (4X2 And 4X4) Models

    Exploded Views Countershaft Assembly FSO-2105 / FSO-2505 (4x2 and 4x4) Models FSO-2105/explo3 160. Countershaft front bearing 165. Shim 0.508 mm 174. Snap ring 2.365 mm 165. Shim 0.762 mm 174. Snap ring 2.290 mm 161. Countershaft front bearing 165. Shim 1.016 mm 175.

  • Page 16: Lubrication Information

    Eaton transmissions are designed so that all the internal parts operate in an oil circulating bath, created by the motion of gears and shafts. Thus, all parts are properly lubricated if these procedures are closely followed: 1.
  • Page 17 Refilling Correct Oil Level Incorrect Oil Level FSO-2105/02 Clean case area around oil filler plug, remove the plug and refill the transmission until lubricant is level with the bottom of the filler plug hole.

  • Page 18: Operation

    Operation Gear shift lever pattern Tips for the driver FSO-2105 and FSO-2505 transmissions have 5 forward speeds and one reverse speed, all of them Always use the clutch to change gears. The incorrect synchronized. use of the clutch may cause premature failures of the To shift speeds, follow the shift pattern shown by the synchronizer assembly.

  • Page 19: Power Flow

    Power Flow Power Flow 1st Speed The transmission must efficiently transfer the engine’s power or torque to the vehicle’s driveline. It is essential to know what takes place in the transmission during torque transfer when troubleshooting or making repairs. 1st, 2nd and 3rd Speeds 1.
  • Page 20 Power Flow 4th Speed 5th and Reverse Speed The 4th speed gear is also named direct speed gear. The 5th and reverse speed gears synchronizer unit is assembled on the countershaft, unlike the other 1. Torque from the engine is transferred to the speed synchronizers that are assembled on the transmission’s input shaft that, despite driving mainshaft.

  • Page 21: Adhesive And Sealant Application

    The correct application of adhesives and sealing compounds is important to assure a proper assembly and to avoid leakages. Apply Eaton 679 to expansion (cup type) plugs Apply Eaton 680 to mounting surface of rear cover and intermediate housing Apply Eaton 680 to mounting surface of front and...

  • Page 22: Torque Recommendation

    WARNING! Always use a torque wrench to tight to the recommended torque. FSO-2105/torque1 FSO-2105/torque2 Item Description Thread Torque N.m (Lb.ft) Remarks Gear shift control 19-25 (14-19) Apply Eaton 677 to housing capscrews threads Housing capscrews 19-25 (14-19) Apply Eaton 677 to threads...
  • Page 23 518 to threads Reverse light switch 14-20 (10-15) Apply Eaton 680 to switch face Gear shift control 10-16 (7-12) Apply Eaton 680 to pin housing threaded pin face only Gear shift control 14-21 (10-15) Apply Eaton 680 to housing threaded plug...

  • Page 24: Precautions

    Precautions Precautions during disassembly Housings and assembly Clean interior and exterior of cases, covers, etc., thoroughly. Cast parts may be cleaned in weak In order to prevent damage to alkaline solution baths (we recommend a 7% soluble transmission parts during initial gear degreasing oil solution).
  • Page 25 Parts replacement When replacement is necessary, use only genuine Eaton transmission parts to assure continued performance and extended life from the transmission. The use of either non-genuine or remanufactured parts, besides have not the factory’s warranty, may lead to severe damage of the unit.

  • Page 26: Troubleshooting

    Troubleshooting The following chart presents some transmission malfunctions with their most common causes and possible solutions. Problem Probable cause Possible solution Reference Transmission noise Incorrect idle speed Adjust idle speed As to vehicle’s when in neutral adjustment instruction manual Improper or damaged Replace disc As to vehicle’s clutch disc...
  • Page 27 Troubleshooting Problem Probable cause Possible solution Reference Hard shifting Malfunction of clutch Verify and adjust clutch As to vehicle’s instruction manual Worn or damaged Replace As to vehicle’s flywheel bushing or instruction manual bearing Replace Non-recommended Recommended lubricant lubricant, in this manual Replace damaged parts Worn or damaged gear Gear shift lever...
  • Page 28 Troubleshooting Problem Probable cause Possible solution Reference Gears hard to Malfunction of clutch Verify and adjust clutch As to vehicle’s disengage instruction manual Worn or damaged gear Replace damaged parts Gear shift housing, in shift lever components this manual Excessively worn or Replace synchronizer Synchronizer damaged synchronizer...
  • Page 29 Troubleshooting Problem Probable cause Possible solution Reference Transmission slips Gear shift lever console Adjust console As to vehicle’s out of gear out of position, forcing instruction manual the lever Replace synchronizer Worn or damaged Synchronizer assemblies synchronizer assemblies, in this assemblies manual Remove and assemble...
  • Page 30 Troubleshooting Problem Probable cause Possible solution Reference Bearing failures Low lubricant level Fill with recommended oil to Recommended the proper level lubricant, in this manual Contaminated or non- Drain and replace with Recommended recommended lubricant recommended lubricant lubricant, in this manual Transmission Reassemble As to this manual...

  • Page 31: Tool Information

    Tool Information Universal Tools To properly servicing the FSO-2105 and FSO-2505 transmissions, it is recommended the use of following univer- sal tools. Tapered section snap ring pliers Constant section snap ring pliers T-handle 1/2” square drive x 12’’ long Ratchet-type wrench 1/2” square drive...

  • Page 32: Essential Special Tools

    Tool Information Essential Special Tools Following tools are essential special tools, required for properly servicing the transmission. The non-use of these essential special tools, the higher are the chances of causing damage to the transmission during disassembly and assembly procedures. Illustration Tool Ref.
  • Page 33 Tool Information Illustration Tool Ref. Description Illustration Tool Ref. Description E010003 Input shaft bearing E019001 Socket for locking cone installer mainshft nut (*) E012001 Universal puller E021001 5th/Reverse speed jaw beam and linked shift block center bolt retaining roll-pin installer E012002 Puller jaws for E021002...

  • Page 34: Complementary Tools

    Tool Information Complementary Tools Illustration Tool Ref. Description Illustration Tool Ref. Description E001020 Front housing E005005 Thread cutter expansion plug installer punch E006002 Special socket 30 E001033 Front bearing cover seal installer Note: Use with E001013 E006006 Special wrench 54 E001034 Rear seal installer Application: All...
  • Page 35 Tool Information Illustration Tool Ref. Description Illustration Tool Ref. Description E014011 Adapter plate for E027001 Oil seal installer transmission stand E014019 Transmission E028011 Ol seal remover overhauling stand Option: Without reduction, with reduction or electric stand E024001 Intermediate housing bearing cup puller/installer support Note: Use with...

  • Page 36: Installation Reference

    Installation Reference FSO-2105 Model Application Flex 2.4L SOHC 4x2 FSO2105_Flex2.4L_SOHC4x2_1...
  • Page 37 Installation Reference FSO-2105 Model Application Flex 2.4L SOHC 4x2 FSO2105_Flex2.4L_SOHC4x2_2...

  • Page 38: Application Flex 2.4L Sohc 4X4

    Installation Reference FSO-2105 Model Application Flex 2.4L SOHC 4x4 FSO2105_Flex2.4L_SOHC4x4_1...
  • Page 39 Installation Reference FSO-2105 Model Application Flex 2.4L SOHC 4x4 FSO2105_Flex2.4L_SOHC4x4_2...

  • Page 40: Fso-2505 Model

    Installation Reference FSO-2505 Model Application Diesel 4x2 2.5 2.8 FSO2505_Diesel4x2_2.5_2.8_1...
  • Page 41 Installation Reference FSO-2505 Model Application Diesel 4x2 2.5 2.8 FSO2505_Diesel4x2_2.5_2.8_2...

  • Page 42: Application Diesel 4X4 2.5 2.8

    Installation Reference FSO-2505 Model Application Diesel 4x4 2.5 2.8 FSO2505_Diesel4x4_2.5_2.8_1...
  • Page 43 Installation Reference FSO-2505 Model Application Diesel 4x4 2.5 2.8 FSO2505_Diesel4x4_2.5_2.8_2...

  • Page 44: Application Hfv6 4X2

    Installation Reference FSO-2505 Model Application HFV6 4x2 FSO2505_HFV6_4x2_1...
  • Page 45 Installation Reference FSO-2505 Model Application HFV6 4x2 FSO2505_HFV6_4x2_2...

  • Page 46: Application Hfv6 4X4

    Installation Reference FSO-2505 Model Application HFV6 4x4 FSO2505_HFV6_4x4_1...
  • Page 47 Installation Reference FSO-2505 Model Application HFV6 4x4 FSO2505_HFV6_4x4_2...

  • Page 48: Gear Shift Lever Housing Disassembly

    Gear Shift Lever Housing Gear shift lever housing disassembly Replace all internal parts, but gear shift lever. Inspect 4. From the housing, remove the two threaded pins. the gear shift lever for wear and replace it if worn. In case the housing should be replaced, get a complete assembly from your dealer.

  • Page 49: Gear Shift Lever Housing Assembly

    Gear Shift Lever Housing Gear shift lever housing assembly 7. Remove the nylon bushing from the gear shift lever lower end. 1. Install thrust washers into the gear shift lever housing. 2. Install the nylon bushing, gear shift lever pivoting support and the thrust washers onto the lever pivoting support.
  • Page 50 Gear Shift Lever Housing 4. Install the two threaded pins on gear shift lever 8. Place the shock-absorbing rubber gasket onto housing. the rear housing. 9. Install the four shock-absorbing bushings with 5. Install the locating pin, spring and threaded plug the four support spacers onto gear shift lever on gear shift lever housing.
  • Page 51 11. Install the gear shift lever housing assembly on the shock-absorbing rubber gasket on the transmission. 12. Install the four gear shift lever housing capscrews and tighten them to the specified torque. Note: Apply Eaton 677 on threads. Torque = 19-25 N.m (14-19 Lb.ft)

  • Page 52: Rear Section

    Rear Section Rear Section Disassembly 1. Remove the gear shift lever housing assembly 6. Remove the thirteen capscrews securing the rear from the transmission. Refer to “Gear Shift Lever case to the intermediate housing. Housing”, in this manual. 7. Using a rubber or plastic hammer to break the gasket seal, carefully hit case to detach the rear case from the intermediate housing.
  • Page 53 Rear Section 10. Remove the rotor retaining ball from the 13. Place transmission horizontal and install the mainshaft. special socket E006004 or E006005, depending on the input shaft spline type, onto the input shaft. Using a suitable wrench, rotate the shaft counterclockwise for loosening the mainshaft nut.
  • Page 54 Rear Section 16. Using special tools E012001 and E012003, 20. Remove the reverse idler gear needle bearing. remove the countershaft ball bearing. 17. Remove the bearing thrust washer. 21. Remove the reverse gear from the countershaft. Note: The thrust washer has a retaining ball (see figure), which should also be removed.
  • Page 55 Rear Section 24. Remove pivot pins of the 5th/reverse speed shift 28. Remove the 5th speed synchronizer ring. yoke. 29. Remove the 5th speed gear from the 25. Push the 5th/reverse speed shift yoke towards countershaft. the synchronizer in order to loosen it from the linked shift block.
  • Page 56 Rear Section 32. Remove the retaining ball of the 5th speed gear 36. Remove the 5th/reverse speed linked shift block. thrust washer from the countershaft. 33. Remove the 5th speed gear from the mainshaft. 34. Remove the reverse light switch. 35.

  • Page 57: Oil Seal Replacement

    Note: Use the proper device for the transmission (refer to “Special Tools”, in this manual). EA071 4. Install the reverse light switch. Note: Apply Eaton 680 or Eaton 679 sealant to the switch threads.
  • Page 58 Rear Section 5. Install the 5th speed gear on the mainshaft. 9. Install the 5th speed gear on the countershaft. 10. Install the 5th speed ring synchronizer on the 6. Install the retaining ball of the countershaft 5th countershaft.. speed gear thrust washer on the countershaft. Apply grease to hold the ball in place.
  • Page 59 12. Install the 5th/reverse synchronizer hub snap ring 16. Install the two pivot pins of 5th/reverse shift yoke. on the countershaft. Note: Apply Eaton 677 sealant to pin threads. Torque = 10-16 N.m (7-12 Lb.ft) 13. Install the reverse speed synchronizer ring.
  • Page 60 Rear Section Note: Use 1 (one) Eaton P/N 3348906 bearing. 21. Install the reverse gear with the rear ball bearing together on the mainshaft with the most protruding side of the hub facing the housing inside. EA155 18. Install the reverse gear on the countershaft.
  • Page 61 Rear Section 24. Install the countershaft snap ring. 27. Shift transmission into 1st gear using the shift yoke bars. Note: Use a new brand snap ring when reassembling the transmission. Note: With no gear shift lever housing installed, the gear shift lever pattern is inverted. EA028 25.
  • Page 62 If not, calculate the torque amount as follows. 32. Apply Eaton 680 gasket compound to the rear • Specified torque for the nut: 217 to 270 N.m cover mounting surface with the intermediate housing.
  • Page 63 E001045. Note: Apply Eaton 677 sealant to capscrew threads. Torque = 19-25 N.m (14-19 lb.ft) 38. Install the gear shift lever housing assembly 029b onto the transmission.

  • Page 64: Front Section

    Front Section Front Section Disassembly 1. Disassemble the rear section (refer to “Rear 6. Remove the intermediate housing. Section Disassembly”). Note: Use pry bars between the housing 2. Shift transmission into Neutral through shift bars. special bosses provided to detach the intermediate housing.
  • Page 65 Front Section 9. Remove the 1st/2nd shift yoke roll pin. 11. Simultaneously, remove from the housing the remaining assemblies of mainshaft, countershaft, Note: Use the 4 mm diameter roll-pin punch 3rd/4th bar and shift yoke and input shaft, while E021002. grasping them all together and pulling them upwards.

  • Page 66: Mainshaft

    Front Section Mainshaft WARNING! Be careful NOT to use mainshaft flange as a pressing base when using the 3rd speed gear. Disassembly 5. Turn the mainshaft over in the press and use the 1. Using the Pocket bearing puller E005003, 3rd speed gear as a base.
  • Page 67 Front Section 3. Install the 2nd speed synchronizer rings, inner, 5. Align the center of the recess in the synchronizer middle and outer, in this order. Make sure they sleeve teeth with the center of the key at the are installed in the proper position. The inner ring three positions and install the synchronizer lugs must be facing to the synchronizer hub while sleeve.
  • Page 68 Front Section 8. Install the 1st speed gear, fitting the holes in the 12. Using the E010002 special tool, press the late gear cone on the middle synchronizer ring lugs. installed set of components onto the mainshaft. Make sure to align the synchronizer ring lugs with hub key slots to properly fit.
  • Page 69 Front Section 16. Install the 3rd speed synchronizer ring. 19. Check if the pressing procedure has been successful: disengage the synchronizer and put it in an intermediate position between 3rd and 4th speed gears. The gears in this condition should rotate freely.

  • Page 70: Countershaft

    Front Section Countershaft 4. Press the countershaft through the rear bearing and remove the bearing. Disassembly WARNING! Do NOT use the bearing roller cage as a pressing base. 1. Place the countershaft in the press with the front bearing facing up. Use the bearing inner race as a base by using the special support E007008.

  • Page 71: Input Shaft

    Front Section Input Shaft 2. With the synchronizer side down, place the input shaft on a base. Be careful not to damage the synchronizer cone. Disassembly WARNING! Do NOT use the bearing roller cage as a pressing base. 1. Place the input shaft in the press with bearing facing up.

  • Page 72: Shift Yoke Bars

    Front Section Shift Yoke Bars 1st/2nd and 3rd/4th Speed Yoke Bar Assembly 1. Make sure the shift block is properly positioned regarding the notch at the yoke bar end and Disassembly install the shift block on the yoke bar. 1. Remove the retaining roll pins and remove the parts from the shift bars.
  • Page 73 Front Section Shift Selector Bar Assembly 5. Install springs and supporting bushings. 1. The shift selector block is assembled on the main bar with two retaining roll pins and therefore can only be installed on one side of this bar. 6.

  • Page 74: Expansion Plugs

    Front Section Expansion Plugs 2. Align the shift block with the shift bar matching the roll-pin holes and install the retaining roll pin. Using tool E001044, push the roll pin until it is Some through holes in housings are drilled for flush with shift block hub.

  • Page 75: Installation

    EA048 2. Apply sealant to the new plug and insert it into the hole using the hands to guide the plug. Note: Apply Eaton 677 to plugs. 2. Place a punch against the bushing outer diameter through the lubrication hole.

  • Page 76: Installation

    Front Section Reverse Shifting Interlocking System 4. Use pliers and pull the bushing out from the bushing bore. Description The reverse shifting interlocking mechanism prevents Installation the driver from shifting accidentally into reverse 1. Place the bushing on the special tool E001010. speed when downshifting from 5th to 4th speed.

  • Page 77: Disassembly

    Front Section Disassembly Assembly 1. Remove the metal expansion plug from housing 1. Align the roll pin hole on the interlock pin with hole where is located the interlocking mechanism the corresponding hole on the housing and retaining roll pin. then install the interlocking mechanism into the interlock pin bore.

  • Page 78: Double Gear Shifting Interlocking System

    Front Section Double Gear Shifting Interlocking System 4. Install a new expansion plug in the housing hole. Note: Refer to “Expansion Plugs” in this manual Description for instructions. The double gear shifting interlocking mechanism prevents shifting into two gears at the same time. Double gear shifting interlocking mechanism EA061...

  • Page 79: Disassembly

    Front Section Disassembly Assembly 1. Remove the metal expansion plug near to the 1. Apply grease to interlock bores to keep the balls 5th/reverse speed yoke bar. in place. Note: Refer to “Expansion Plugs” in this manual 2. Install three interlock balls aligned from the for instructions.

  • Page 80: Input Shaft Bearing Cup

    Front Section Input Shaft Bearing Cup 5. Install a new expansion plug in the housing hole. Note: Refer to “Expansion Plugs” in this manual for instructions. Removal 1. Place the front housing properly supported with the input shaft bearing cup side up. 2.

  • Page 81: Input Shaft Oil Baffle And Oil Seal

    Front Section Input Shaft Oil Baffle and Oil Seal 3. Install the input shaft oil baffle, observing its correct mounting position. Removal 1. Remove the input shaft oil baffle and oil seal using some sort of pry bar or use a pin punch to push them out of their bores by hitting.

  • Page 82: Countershaft Front Bearing Cup

    Front Section Countershaft Front Bearing Cup Removal 1. Place the front housing properly supported with the countershaft bearing cup side up. 2. Use special puller E012009 fitted under the bearing cup counterbore at the cup bottom and remove the bearing cup. Installation 1.

  • Page 83: Mainshaft And Countershaft Rear Bearing Cups

    Front Section Mainshaft and Countershaft Rear Bearing Cups Removal Installation 1. Place the intermediate housing properly support- 1. Support properly the intermediate housing with ed with the bearing cup removing side down. bearing bore side up. 2. Use special devices E001035 and E001036 2.

  • Page 84: Synchronizer Assemblies

    Front Section Synchronizer Assemblies Both the 1st and the 2nd speed synchronizer rings are composed of 3 (three) rings: one inner ring, one middle and one outer ring. The outer ring has the WARNING! When repairing synchronizer assemblies, special EFM II coating. do not replace a single part only.
  • Page 85 Front Section 2. Slide the keys with balls out from the Installation synchronizer hub slots and remove them. 1. Install the synchronizer hub with its most protruding side facing to the 1st speed gear. 2. Install the synchronizer sleeve with its chamfered side facing to the same side of the most protruding side of the synchronizer hub.

  • Page 86: 3Rd/4Th Speed Synchronizer

    Front Section 4. The middle synchronizer ring is installed with lugs 3rd/4th Speed Synchronizer facing to the gear and should fit into gear cone Both the 3rd and the 4th speed synchronizer rings holes. have the special EFM II coating. Spring (3x) Synchronizer hub Key (3x)
  • Page 87 Front Section 2. Slide the keys and springs out from the 3. To help when assembling, position a synchronizer synchronizer hub slots and remove them. ring at the sleeve opposite side and insert the ring lugs into the synchronizer hub key slots. EA074 EA077 Assembly...

  • Page 88: 5Th/Reverse Speed Synchronizer

    Front Section 5th/Reverse Speed Synchronizer Disassembly and Assembly The 5th/reverse speed synchronizer hub has the let- The procedure for disassembling and assembling ter “R” stamped on its body. the 5th/reverse speed synchronizer is the same as described above for the 3rd and 4th speed synchronizer.

  • Page 89: Front Section Assembly

    Front Section Front Section Assembly 4. With the input shaft down, position the input shaft and mainshaft assembly on the front housing. 1. Place the front housing with input shaft and countershaft bearing cups side facing up. 2. Position the 4th speed synchronizer ring on the input shaft.
  • Page 90 Front Section 7. Install the 1st/2nd shift yoke in the respective 10. Install the shift selector bar in the bar bore, synchronizer sleeve groove. positioning the shortest arm of the selector block between the 1st/2nd yoke bar notch and the 3rd/4th shift block groove. The longest arm must be ahead the reverse shifting interlocking mechanism.
  • Page 91 Front Section WARNING! Do not apply sealant to both housing 15. Proceed to mainshaft and countershaft end and retaining capscrews by now! Prior to finishing the play adjustment as recommended in “End Play transmission assembly is necessary to check the end Adjustment”, later in this manual.
  • Page 92 20. Remove any remaining sealant material from match the housings. housing mounting surfaces. 24. Apply Eaton 677 sealant to threads of the 21. Use either a proper tap or screw and remove any thirteen retaining capscrews that secure the remaining sealant material from housing threaded intermediate housing to the front housing and holes.

  • Page 93: End Play Adjustment

    Tighten capscrews to the proper torque. WARNING! Before measuring and adjusting the transmission axial clearance (end play), remove ALL Note: Apply Eaton 677 sealant to capscrew existing adjusting shims under both the mainshaft and threads. countershaft rear bearing cups (refer to “Mainshaft Torque = 19-25 N.m (14-19 Lb.ft)

  • Page 94: Countershaft End Play Measurement

    Front Section 3. Rotate the mainshaft several times in both Countershaft End Play Measurement directions clockwise and counterclockwise to 1. Choose one from housing threaded holes and make sure the mainshaft is completely seated on install the special plate (E009005) to support a the bearing.
  • Page 95 Front Section Use the following flowchart and determine the shim pack thickness to adjust the transmission end play: Measure the clearance Is the measured value greater than the maximum specified? Calculate: Is the measured value Measured value minus Yes/No? greater than the minimum Maximum specified = R1 specified? Measured value minus...

This manual is also suitable for:

Fso-2505

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