Eaton Roadranger TRSM4106 Service Manual
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Eaton Roadranger TRSM4106 Service Manual

Eaton Roadranger TRSM4106 Service Manual

Fuller mid range transmissions
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Service Manual
Fuller Mid Range Transmissions
TRSM4106
October 2007

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Summary of Contents for Eaton Roadranger TRSM4106

  • Page 1 Service Manual Fuller Mid Range Transmissions TRSM4106 October 2007...
  • Page 2 For parts or service call us Pro Gear & Transmission, Inc. 1 (877) 776-4600 (407) 872-1901 parts@eprogear.com 906 W. Gore St. Orlando, FL 32805...
  • Page 4 Eaton 6-Speed Synchromesh Transmission Truck Components Operations Europe PO Box 11 Worsley Manchester M28 5GJ England Service Manual (4106 / 5206)

  • Page 5: General Discription

    Section 1 General Letter and Model Designation Technical Data Lubrication Recommended Lubricants Torque Tightening Recommendations Disassembly Precautions and Inspection of Expendable Parts Reassembly Precautions 1/10 Gear End Floats 1/11 Special Tools 1/14 Locally Made Tools Section 2 General Discription Features Gear Change Pattern Power Flow Diagrams Section 3...
  • Page 6 Section 2 General 5/01...

  • Page 7: Model Designation

    General Model Designation Example: FSO-4106A Standard prefix Overdrive Nominal torque in 00 lbs ft Series 1 Number of forward gears Standard ratio set B, C Alternative ratio sets Transmission Identification All transmissions are fitted with an identification plate on the left hand side of the front case showing Transmission serial number.

  • Page 8: Technical Data

    SAE Standard Power Take-off Openings Left side (vertical installation), bottom right (horizontal installation): 2 SAE 6 bolt facings plus extended layshaft for Eaton PTO PTO Drive Gears 3) Rotation to Engine driven from the reverse idler gear at: engine speed x...
  • Page 9 General Lubrication Proper Oil Level Before checking the oil level or refilling, vehicle should be on level ground. Make sure that the oil is level with the filler opening. Draining Oil Drain transmission while oil is warn. To drain oil remove the drain plug at the bottom if case.

  • Page 10: Recommended Lubricants

    General Recommended Lubricants Only use recommended lubricants to ensure smooth running. Models Grade Temprature Range Mild EP Gear Oil SAE 80 W -26¡C to 21¡C to Specification SAE 90 W -12¡C to 37¡C MIL-L-2105 or SAE 80 W/90 -26¡C to 38¡C API-GL-4 Heavy Duty Engine Oil to Specification...
  • Page 11 General Torque Tightening Recommedations Screws and Nuts Clutch Housing 12 Studs M12 Thread 59 Nm (43 lbs ft) minimum. Installed with Loctite 242. Clutch Housing 12 Nuts M12 Thread 69 to 78 Nm (51 to 58 lbs ft). With Plain Washers and Spring Lockwashers. Clutch Housing 12 Capscrews M12 Thread 69 to 78 Nm (51 to 58 lbs ft).
  • Page 12 General Torque Tightening Recommedations (continued) Screws and Nuts Remote Control Shaft Lever 1 Capscrew and Nut M10 Thread 35 to 39 Nm (25 to 29 lbs ft). With Spring Lockwasher. Selector shaft Detent Cover 2 Capscrews M8 Thread 20 to 24 Nm (15 to 18 lbs ft). Spring Lockwashers. Oil Filler Plug M24 Thread 32 to 37 Nm (24 to 27 lbs ft).

  • Page 13: Disassembly Precautions

    General Inspection of Expendable Disassembly Precautions It is assumed in the detailed disassembly instructions Before reassembling the transmission, the individual that the lubricant has been drained and the necessary parts should be carefully checked to eliminate those linkage and air lines (if fitted) have been removed from damaged.
  • Page 14 General Inspection of Expendable Parts D. Synchroniser Assemblies Check condition and fit of selector key and inter- lock key in shift shaft. Worn or damaged keys must be Check to ensure all splines are free from excessive renewed. Gear Shift Remove Control wear.
  • Page 15 General Reassembly Precautions Make sure that interiors of all housings are clean. It is Layshaft The layshaft gears are a shrink and important that dirt be kept out of transmission during press fit on the layshaft body. The gears must be heat- reassembly.
  • Page 16 General Gear End Floats All dimensions in mm 5th (o,d. 6th) Reverse Gear 0,31 0,35 0,35 0,35 0,40 Sliding Low Limit 0,53 0,48 0,48 0,48 0,57 Gear High Limit 0,22 0,13 0,13 0,13 0,17 Tolerance 1/10 5/01...

  • Page 17: Special Tools

    General Special Tools Some illustrations show the use of specialised tools. These tools are recommended for disassembly and reassembly of the transmission. They make repair easier, faster and prevent damage. The following tools are available from SPX UK (Ltd) Tel : +44 (0)1327 704461 E 109 Driver.
  • Page 18 General Special Tools (continued) E 109-9 Selector shaft plug installer adaptor. E 116-2 Adaptor gear assembly lifting fixture. Use with E 109. Use with E 116A. E 109-10 Driver extension. LC 113A Flange holding wrench. Use with E 109. E 109-11 Countershaft bearing cone installer. MS 284 Slide hammer.
  • Page 19 General Special Tools (continued) The following general purpose pullers are available from Sykes-Pickavant Ltd., or through their Dealers. Three Legged Puller - Series 1500 with Hydraulic Puller Kit - Series 1500 with Hydraulic Ram Locally Made Tools The following illustration shows a suitable cradle which can be used to stand the transmission ’on end’...
  • Page 20 General Special Tools (continued) Locally made tools 1. 1 off hole 1.5 inches diameter 16 threads per Tool for 4 point ball bearing removal. inch Whitworth form to suit Sykes Picavant hydraulic ram No 150 000. 2. 8 holes 11 mm diameter. 1/14 5/01...
  • Page 21 General Special Tools for United States Eaton 4106/5206 SPX # NEW UK # Description J-45895 LC 105A Bearing Remover J-45896 E 105-4 Countershaft bearing remover J-45902 E 108 Driver Replacer adaptor for auxiliary countershaft bearing and input bearing J-45897 E 108-5...
  • Page 22 Section 2 General Description 5/01...

  • Page 23: General Description

    General Description Features The Eaton six-speed transmissions have six forward speeds and are part of a family of synchromesh transmissions. They have a simple shift pattern using a unique single rail selector mechanism. The transmissions may be mounted vertically or horizontally and in both positions the gear change remote control may be to the right or the left.
  • Page 24 General Description Gear Change Pattern Simple shift pattern with the mechanism biased in neutral between 3rd and 4th gears. Power Flow in the Gears - Direct Drive Top Gear Version 5/01...
  • Page 25 Section 3 Shifting Controls 6 Speed MK.4 5/01...
  • Page 26 Shifting Controls Remote Control - Exploded View 1. Grooved pin 18. Boot 2. Inner striking lever 19. Oil Seal 3. Cross shaft 20. Bush 4. Plug or Neutral switch 21. Reverse plunger 5. Pin 22. Reverse detent spring 6. Washer 23.
  • Page 27 Remote Control Disassembly 1. Ensure neutral is selected and remove the con- 4. Remove the four separate capscrews and lift off trol assembly from the transmission. the end cover. 5. Remove the circlip from the shaft and remove 2. Remove the outer shift lever and rubber boot. the spring retainer.
  • Page 28 Remote Control Reassembly 1. If necessary renew the bearing bushes in the 7. Invert the housing and carefully drift out the housing using the special tool. The new bushes expansion plug. are prefinished to the correct size. 8. Invert the housing, align the grooved pin in the 2.
  • Page 29 7. Insert the springs and outer retainer. 4. Install the shaft from the right hand side of the Note: right hand drive units use a large housing. retainer: left hand drive units use one large (outer) and one small (inner). 5.
  • Page 30 10. Install the reverse detent plunger and spring 13. Apply Loctite 5900 sealant. and fit the cover using a new gasket. Tighten the Fit control assembly to the transmission housing. capscrews to the correct torque (20 to 24 Nm). 11. Fit the rubber boot onto the housing. Align the outer lever with the timing mark on the shaft.
  • Page 31 Shifting Controls Direct Control - Exploded View Item Item Housing Spring washer Bush Screw End cap Gaiter Spring washer Screw Washer Plug Breather End cap Plunger Spring washer Spring compression Screw Spring compression Cover Bush Spring washer Seating Screw Gear lever Plunger Seating Spring...
  • Page 32 Disassembly 1. Remove the rubber gaiter and breather. 4. Remove the screws, washers and end covers from both sides of the housing. 2. Remove the screws, washers, detent cover 5. If necessary the bushes in the end covers can plate, spring and plunger. be replaced.
  • Page 33 Assembly 7. Remove the Circlip and spring. 1. Clean all joint faces. Fit the seat ensuring that the slot aligns with the hole in the housing for the pin. 8. Remove the seat and selector shaft. 2. Apply grease to the seat and then fit the pin. 9.
  • Page 34 4. Fit the seat ensuring that the slot in the seat 7. Apply a light coating of grease to the bushes in locates onto the pin and into the bore of the hous- the end covers. Apply Loctite 5900 to the joint ing.
  • Page 35 10. Refit the rubber gaiter and breather. 3/11 5/01...
  • Page 36 Section 4 Transmission Overhaul 5/01...

  • Page 37: Transmission Case

    Transmission Case Exploded View 26. Oil trough 1. Screw M12 27. Hammer drive screw 2. Washer M12 28. Oil trough 3. Cover 29. Hammer drive screw 4. Washer 30. Dowel 5. Screw M8 31. Bushing 6. Rotation pins, overdrive 32. Reverse light switch or plug 7.
  • Page 38 Disassembly of Transmission Case Caution: Drain gear oil from the transmission and clean and refit the drain and filler plugs. Note: The transmission illustrated in this section is a standard ratio horizontally installed unit. The pro- cedure is the same for all transmissions but the physical size and number of teeth on some of the gears will vary from those illustrated on overdrive and alternative ratio models.
  • Page 39 7. Ensure neutral is engaged and remove the 10 Position the transmission forward end upper- remote control housing bolts. Use a soft faced mal- most on the stand or wooden cradle and remove let to separate the housing from the transmission. the detent spring cover plate, spring and plunger as above or detent assembly (see below).
  • Page 40 12. Rotate the gear selector shaft to the left (verti- 15. Remove the capscrews securing the input shaft cally mounted) or right (horizontally mounted) so cover and remove the cover. that the case will not foul the selector block on removal.
  • Page 41 18. Using a soft face mallet break the seal and sepa- 20. Using a suitable long drift drive out the reverse rate the front case from the rear case. DO NOT USE idler shaft and expansion plug from the case. PRY BARS OR CHISELS.
  • Page 42 26. Invert the rear case on the stand and remove 23. Lift out the layshaft the capscrews securing the speedometer housing. Note the positions of the different length cap- screws. Remove the housing. If necessary drift out the oil seal. 24.
  • Page 43 29. Invert the casing on the stand and remove the 32. Drift out the layshaft front bearing cup using the layshaft rear bearing cover and bearing spacer. special tool. Remove the input shaft bearing using the special tool. 30. Drift out the layshaft rear bearing outer cup 33.
  • Page 44 Layshaft Disassembly 1. Support the shaft assembly and remove the 3. Invert the shaft and remove the rear taper roller graded circlip retaining the front taper roller bear- bearing. ing. 2. Using the special tool remove the bearing cone and roller assembly. Countershaft assembly Taper roller bearing Distance piece...
  • Page 45 Layshaft Reassembly 1. Heat the layshaft taper roller bearing inner races 3. Fit the circlip using circlip pliers. to 85¡¡C (180¡F). Support the shaft assembly for- ward end uppermost and place the heated inner cone and roller assembly onto the shaft. Use a suitable mandrel to make sure bearing is fully home.
  • Page 46 Synchroniser Flange Removal / Fitment Disassembly Assembly 1. Heat the gear and flange assembly to 80¡C to 1. Using a suitable solvent ensure that both parts deactiveate the Loctite. Using a suitable press or are clean and free from oil. puller, remove the flange from the gear.
  • Page 47 Mainshaft Disassembly Mainshaft Assembly Note: All snap rings and circlips on the mainshaft Eaton have recently introduced a new design of are graded for selective fit. Take care not to score mainshaft assembly. As both designs are currently the bearing surfaces of the mainshaft when remov- in use strip and rebuid procedures for both are ing or fitting the snap rings or circlips.
  • Page 48 Exploded View Mainshaft. 5th/6th gear synchroniser sleeve 3rd gear needle roller bearing. 5th gear synchroniser ring (FSO) 3rd speed gear. Circlip 3rd gear synchroniser ring. 6th gear needle roller bearing (FS) 3rd gear synchroniser flange 5th gear needle roller bearing (FSO) Roller.
  • Page 49 Disassembly 3. Invert the mainshaft assembly. Using a press or suitable puller remove the mainshaft bearing inner, 1. Mount the mainshaft assembly, plain end upper- reverse gear and reverse gear needle roller bear- most, in a soft jawed vice. Remove the synchronis- ing.
  • Page 50 9. Using a press or suitable tool remove the syn- 6. Remove the 1st speed gear needle roller bear- chroniser assembly and 2nd speed gear. Remove ing. the needle roller bearing. 7. Remove the synchroniser assembly retaining 10. Carefully remove the retaining tool and then Circlip.
  • Page 51 12. Remove the 5th gear needle roller bearing. (On overdrive transmissions this will be 6th gear). 15. Place the assembly on to a suitable work sur- face, 4th speed gear, uppermost. Remove the bearing sleeve, needle roller bearing and 4th gear assembly 13.
  • Page 52 Mainshaft Reassembly Procedure for 1st and 2nd speed Synchronisers Before assembling the synchroniser assem- Note: The synchroniser flanges, apart from those blies on to the mainshaft, check the fit of each fitted to the 1st and 2nd speed gears, must be loc- synchroniser ring to the relevant synchroniser tited to the gears.
  • Page 53 d) Remove the synchroniser inner ring. g) Fit the synchroniser friction ring on to the syn- chroniser flange ensuring that the tabs on the syn- chroniser friction ring locate into the slots on the synchroniser flange. e) Fit the synchroniser inner ring, tangs uppermost, on to the synchroniser flange.
  • Page 54 Reassembly Note: The synchroniser flanges, apart from those fitted to the 1st and 2nd speed gears, must be loc- tited to the gears. j) While holding the parts firmly together, measure the clearance between the synchroniser ring and synchroniser flange using feeler gauges at several 1.
  • Page 55 4. Fit the 2nd speed gear to the synchroniser assembly ensuring that the splines on the gear engage into the splines on the synchroniser assembly. Fit and lubricate the needle roller bear- ing. 6. To prevent the synchroniser assembly separat- ing the retainers should be used.
  • Page 56 11. Assemble the three springs and plungers into 8. Lubricate the 3rd gear synchroniser flange and the synchroniser hub. Place the synchroniser then fit the synchroniser ring. sleeve over the synchroniser hub and support it with the internal groove just above the synchronis- er hub.
  • Page 57 14. Heat the 4th speed gear-bearing sleeve to 85¡ 17. Fit the 5th speed gear assembly. Lubricate the Centigrade and locate it onto the mainshaft and needle roller bearing and then install it into the inside the needle roller bearing. Press the bearing gear.
  • Page 58 20. From the range of graded circlips select the one which fits into the mainshaft groove with the least amount of free play. Fit the Circlip into the groove. 22. Invert the mainshaft and then remove the retaining tool. 21. Using feeler gauges check that the 5th gear end float is within the tolerance stated in the chart.
  • Page 59 24. Check that the 2nd speed gear end float is 27. From the range of graded circlips select the within the tolerances stated in the chart. one which fits into the mainshaft groove with the least amount of free play. Fit the Circlip into the groove taking care not to damage the mainshaft needle roller bearing surface.
  • Page 60 1st /2nd speed Synchroniser assembly. Note: The synchroniser is supplied as an assem- bly. Parts that are used to make the complete assembly are not available separately. 30. Heat the mainshaft bearing inner to 85¡ Centigrade and then fit it, shoulder down, onto the mainshaft.
  • Page 61 4. Remove the synchroniser inner ring. 7. Remove the three retainers. 8. Taking care not to lose the balls or springs lift 5. Remove the synchroniser friction ring. the detent poppets to release the balls. Once the balls have been removed it is possible to remove the detent poppets and springs.
  • Page 62 10. If not already removed at step eight remove the 13. Remove the synchroniser friction ring. detent poppets and springs. 11. Remove the synchroniser hub. 14. Remove the synchroniser inner ring. 12. Remove the synchroniser ring. 4/27 5/01...
  • Page 63 Assembly 4. Fit the synchroniser ring ensuring that the under- cuts (1) line up with the tabs (2) of the synchronis- er inner ring and that bosses (3) of the synchronis- 1. Place the synchroniser flange, spigot uppermost er ring are to the left hand side of tabs (2) of the onto the bench.
  • Page 64 7. Place the three retainers in the large recesses of 10. Place the detent ball onto the spring and then the synchroniser hub so that the legs of the blocks using a suitable tool push against the detent ball to engage with the tabs of the synchroniser inner ring compress the spring.
  • Page 65 13. Lubricate all surfaces of the synchroniser fric- 16. Hold the synchroniser assembly down against tion ring. Place the synchroniser friction ring, tabs the bench and at the same time lift the synchronis- uppermost, on to the synchroniser hub. er sleeve upwards to engage the neutral position. 14.
  • Page 66 Old Design Disassembly Mainshaft Disassembly Note: All snap rings and circlips on the mainshaft are graded for selective fit. Take care not to score the bearing surfaces of the mainshaft when remov- ing or fitting the snap rings or circlips. Note: The end float of the gears on the mainshaft is established in manufacture by machining the components to fine tolerances.
  • Page 67 Exploded View 1. Needle roller bearing 23. Mainshaft 2. Circlip 24. Needle roller bearing 3. Synchro ring 25. Gear 2nd. 4. Sliding sleeve 26. Synchro flange 5. Fixed hub 27. Synchro ring 6. Roller 28. Fixed hub 7. Plunger 29. 4,00 mm graded circlip pack 8.
  • Page 68 6. Invert the shaft assembly and using a suitable 3. Assemble the puller over the 5th/6th gear syn- puller under the reverse gear remove the gear, chroniser hub and the 5th gear synchroniser ring, thrust washer and bearing track. Remove the taking care not to damage the teeth of the latter.
  • Page 69 9. Lift off the steel cage bearing, 1st gear synchro- 12. Assemble the puller over the 2nd gear and pull niser ring. off 2nd gear, 2nd gear synchroniser ring and flange the 1st/2nd gear synchroniser hub and the bearing. 13. Support the shaft on the press under 3rd gear. 10.
  • Page 70 Mainshaft Reassembly Note: The following parts must be heated to the temperatures recommended prior to assembly. Place the parts on a hotplate or in a temperature controlled oven for not less than 30 minutes to make sure they are thoroughly heated before plac- ing them in position.
  • Page 71 5. Take the heated 1st/2nd gear synchroniser hub 8. Check that the gear end float is within the toler- and place it over the spines on the mainshaft ances stated in the chart. ensuring that the large slots in the hub align with the large shoulders on the synchroniser ring.
  • Page 72 11. Lubricate 1st gear bearing and install the steel 14. From the range of graded snap rings, carefully cage bearing into the gear. Place the gear assem- install the thickest one which will fit into the groove bly and bearing onto the shaft and into the syn- with the minimum free play taking care not to dam- chroniser ring.
  • Page 73 17. Fit the spacer on the standard cylindrical roller 20. Install the 3rd gear synchroniser ring over the or 4 point ball bearing. If integral spacer bearing is flange. fitted the spacer is part of the bearing inner race. 18. Take the heated inner track of the mainshaft 21.
  • Page 74 23. Assemble the three springs and plungers into 26. Take the heated 4th gear bearing sleeve and the hub and install the synchroniser sleeve and locate it inside the bearing and over the shaft. Use rollers as described in sub operation 9. a soft drift or flanged driver if necessary, to ensure the sleeve is firmly home against the synchroniser hub.
  • Page 75 29. Lubricate the 5th gear bearing and install the bearing and 5th gear assembly onto the shaft. 32. From the range of graded circlips select the thickest one which fits into the groove with the min- imum free play. 30. Position the 5th gear synchroniser ring onto the synchroniser flange of 5th gear.
  • Page 76 Selector Shaft Disassembly Note: Tapered capscrew fitted on opposite side on horizontal unit. 35. Assemble the three springs and plungers into the hub and install the synchroniser sleeve and rollers as described in sub operation 9. Selector Shaft Disassembly 1. Place selector assembly on bench with the selector block to the left.
  • Page 77 4. Remove the capscrew from the selector block and slide the block off the shaft. Selector Shaft - Reassembly 1. Overdrive shift pad 8. Selector block 2. Overdrive fork 9. Set screw 3. Overdrive selector 10. Pin 4. Selector keys 11.
  • Page 78 1. Place selector key into slot on the selector shaft 4. Support the selector shaft and slide in the inter- with the three small lugs to the front. lock key from the rear. 5. On overdrive units the 5th/6th fork is replaced by 2.
  • Page 79 Transmission Case - Reassembly Note: Before reassembling the transmission case ensure that each half case and covers are clean and that all gaskets and joining/sealing materials are cleaned from the mating faces. When reusing patch lock bolts or fitting capscrews to through holes apply the recommended threadlock or sealant to the threads (Loctite: 641).
  • Page 80 10. Locate the selector shaft assembly to the main- 7. Apply Loctite 5900 to the housing, install the shaft. Support the mainshaft using the special tool layshaft rear bearing cover to the case. Tighten the and hoist and lower the assembly into the case capscrews evenly to the correct torque (69 to making sure the selector shaft enters the rear 78Nm) making sure that the bearing cup is pressed...
  • Page 81 13. Lower the hoist to allow the mainshaft, layshaft 16. On overdrive transmissions, using a suitable and selector shaft to seat into their respective probe as illustrated, align the pivot pins with the bearings or bushes. Remove the special tool. holes in the case.
  • Page 82 19. Fit bearing thrust washer. Place the original spacer against the bearing and check that the snap 21. Lubricate the shaft seal surface and apply ring will fit into its groove without free play. Check Loctite 5900 sealant to the mating face of the front at several places around the diameter of the shaft.
  • Page 83 23. Install the layshaft front bearing cover (without 25. Lubricate the layshaft bearing, install the grad- sealer). Fit the capscrews without spring washers. ed spacer of the selected thickness, apply Loctite Carefully and evenly tighten the capscrews while 5900 sealer and install the cover plate. Apply rotating the input shaft backwards and forwards to sealant and tighten the capscrews to the correct settle the bearings.
  • Page 84 31. Apply a light grease to the oil seal lips and install the drive flange. Do not hammer the 28. Install the speedo drive gear or rotor onto the flange/yoke onto the shaft or the bearing spacer mainshaft against the spacer. may be dislodged from its location on the shaft.
  • Page 85 Reverse Idler Gear Assembly 35. Install the bearings and bearing spacer into the 34. Apply petroleum jelly to the reverse idler gear reverse idler gear and locate the assembled gear thrust washer and locate it into position in the between the thrust washers and into mesh with the transmission case.
  • Page 86 38. Install the reverse idler gear/PTO cover plate. 41. Install the reverse idler gear/PTO cover plate. Tighten the capscrews to the correct torque (35 to Tighten the capscrews to the correct torque (35 to 35 Nm). Apply sealant to the expansion plug in the 39 Nm).
  • Page 87 44. Apply flange sealer and install the remote con- trol making sure that the inner lever locates over the selector block. 45. Tighten the capscrews to the correct torque (35 to 39 Nm). 46. Apply sealant and install the reverse lamp switch, tighten to the correct torque (16 to 22 Nm).
  • Page 89 Copyright Eaton Corporation, 2012. Eaton hereby grant their customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. It may be copied only in its entirety without any changes or modifications. THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.
  • Page 90 For parts or service call us Pro Gear & Transmission, Inc. 1 (877) 776-4600 (407) 872-1901 parts@eprogear.com 906 W. Gore St. Orlando, FL 32805...

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