Eaton Fuller FSO-2405 Service Manual
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Eaton Fuller FSO-2405 Service Manual

Eaton Fuller FSO-2405 Service Manual

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FSO-2405
Service Manual
Transmission
®
®
Eaton
Fuller
Light Duty Transmissions
2nd Ed. 02/07

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Summary of Contents for Eaton Fuller FSO-2405

  • Page 1 FSO-2405 Service Manual Transmission ® ® Eaton Fuller Light Duty Transmissions 2nd Ed. 02/07...
  • Page 3 General Information Input Shaft Bearing Cover Rear Section Front Section Gear Shift Lever Housing FSO-2405 2nd Ed. 02/07...

  • Page 5: Table Of Contents

    General Table of Contents Section 1 General Information........11 Foreword ..........13 How to Use This Manual......14 Identification and Specifications ..... 15 Exploded View ........18 Lubrication ..........23 Operation ..........25 Power Flow ..........26 Sealant Application ......... 30 Torque Recommendation ......
  • Page 6 General Table of Contents Section 3 Rear Section ..........89 Output Sleeve, Yoke and 4x4 Transmission Differences ......91 Rear Section Disassembly...... 92 Oil Seal Replacement ......100 Rear Section Assembly ......101 Section 4 Front Section..........111 Front Section Disassembly ....115 Mainshaft Disassembly ......
  • Page 7 General Table of Contents Reverse Idler Gear Shaft Removal ........126 Installation ......... 126 Expansive Plugs Removal ........127 Installation ......... 128 Permaglide Bushing Removal ........129 Installation ......... 130 Reverse Shifting Interlocking System Description ........ 131 Disassembly ......132 Assembly ........
  • Page 8 General Table of Contents Synchronizer Assemblies Description ........ 140 Disassembly ......140 Assembly ........141 Installation ......... 142 Front Section Assembly......145 End Play Adjustment Mainshaft End Play Measurement ......148 Countershaft End Play Measurement ......149 Determination of End Play Adjusting Shims ......
  • Page 9 General Table of Contents FSO-2405 2nd Ed. 02/07...

  • Page 11: General Information

    Table of Contents General Information Foreword ..........13 How to Use This Manual......14 Identification and Specifications ..... 15 Exploded View ........18 Lubrication ..........23 Operation ..........25 Power Flow ..........26 Sealant Application ......... 30 Torque Recommendation ......31 Precautions..........

  • Page 13: Foreword

    13270 - Valinhos - São Paulo - Brazil Fone: (19) 3881-9962 Fax: (19) 3881-9858 WARNING! Eaton reserves the right to make modifications in its products and to change specifications included in this manual at any time without previous notice. FSO-2405 General Information 2nd Ed.

  • Page 14: How To Use This Manual

    How to Use This Manual To disassemble and reassemble the entire transmission, follow the manual in sequence. However, if the problem involves only one component, refer to the table of contents of its related section, for the page number showing that component. Example •...

  • Page 15: Identification And Specifications

    Forward speeds Design level Nominal torque capacity (x100 Lb.ft) All Eaton transmissions are identified by the model designation and serial number. These information are stamped on the identification tag fixed to the transmission case. WARNING! Do not remove or destroy the transmission identification tag.
  • Page 16 Identification and Specifications Specifications FSO 2405 A FSO 2405 B FSO 2405 C FSO 2405 D Lb.ft Torque Gear Ratio Gear Ratio Gear Ratio Gear Ratio Input Shaft Countershaft 1st Speed (CE) 4.079 4.079 4.473 4.473 (EP) 2nd Speed (CE) 2.289 2.289 2.458...
  • Page 17 Identification and Specifications FSO 2405 K FSO 2405 M FSO 2405 N Lb.ft Torque Gear Ratio Gear Ratio Gear Ratio Input Shaft Countershaft 1st Speed (CE) 4,473 4,994 4,473 (EP) 2nd Speed (CE) 2,289 2,625 2,289 (EP) 3rd Speed (CE) 1,376 1,469 1,376...

  • Page 18: Exploded View

    Exploded View Housings 34 35 17 18 20 18 21 22 44 45 26 27 46 47 48 49 FSO-2405/178 Rear housing 4x2 18 - Ball 34 - Pivot threaded pin Rear housing 4x4 19 - Ball 35 - Capscrew Capscrew 20 - Interlock pin 36 - Actuator...
  • Page 19 Exploded View Gearing Input Shaft and Mainshaft FSO-2405/179 Input shaft bearing cup 12 - Needle bearing Mainshaft bearing shim (0.254) 13 - Mainshaft Input shaft bearing cone Mainshaft bearing shim 14 - Spring Input shaft (0.508) 15 - Key Mainshaft front bearing cone Mainshaft bearing shim 16 - Needle bearing 3rd/4th speed synchronizer...
  • Page 20 Exploded View Gearing Countershaft and Reverse Idler Gear FSO-2405/180 Countershaft front bearing cup Countershaft bearing shim 17 - 5th/reverse speed (1.016) synchronizer snap ring Countershaft front bearing (2.215) cone NOTE: Use shim thickness and 5th/reverse speed quantity as required (see “End Countershaft synchronizer snap ring Play Adjustment”)
  • Page 21 Exploded View Shifting System Shift Yokes and Bars FSO-2405/181 3rd/4th speed shift yoke Roll pin 17 - Shift lug 18 - 5th/reverse speed yoke bar Roll pin 10 - Roll pin 19 - 5th/reverse speed linked shift 3rd/4th speed shift block 11 - Shift selecting block block Roll pin...
  • Page 22 Exploded View Gear Shift Lever Housing Direct FSO-2405/182 Gear shift lever Capscrew 11 - Nut Lower bushing 12 - Boot Thrust washer Gear shift lever end bushing 13 - Capscrew Wave washer Gear shift lever housing 14 - Cover Oil baffle 10 - Pin 15 - Upper bushing General Information...

  • Page 23: Lubrication

    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 amply lubricated if these procedures are closely followed: 1.
  • Page 24 Lubrication Draining Drain the transmission while oil is warm. To drain the oil, remove the magnetic drain plug. Clean the drain plug before re-installing it. Refilling Correct Oil Level Incorrect Oil Level FSO-2405/87 Clean the case around the oil fill plug, remove the plug and refill the transmission to the level of the filler opening.

  • Page 25: Operation

    Operation Gear shift lever pattern FSO-2405 transmissions have 5 forward speeds and one reverse, all of them synchronized. To shift the speeds follow the shift pattern shown by the illustration on the side. A reverse gear shifting interlocking system prevents from accidental transmission shifting from 5th to reverse gear.

  • Page 26: Power Flow

    Power Flow 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 27 Power Flow 2nd Speed FSO-240590 3rd Speed FSO-240591 FSO-2405 General Information 2nd Ed. 02/07...
  • Page 28 Power Flow 4th Speed The 4th speed gear is also named direct speed gear. 1. Torque from the engine is transferred to the transmission’s input shaft that, despite driving the countershaft at the same time, transfers the torque directly to the mainshaft. The input shaft clutching teeth engage the clutching teeth of the 4th speed synchronizer unit which transfers the torque to the mainshaft.
  • Page 29 Power Flow 5th and Reverse Speed The 5th and reverse speed gears synchronizer unit is assembled on the countershaft, unlike the other speed synchronizers that are assembled on the mainshaft. By its turn, their corresponding gears on mainshaft are assembled fixed to the mainshaft. 1.

  • Page 30: Sealant Application

    Eaton E680 Apply Eaton E677 Apply mounting surface of rear cover and intermediate to expansion plugs housing Apply Eaton E680 or Eaton E679 to mounting surface of gear shift lever housing Eaton E680 Apply Apply Eaton E680 to mounting surface of input...

  • Page 31: Torque Recommendation

    WARNING! Allways use a torque wrench to tight to the recommended torque. FSO-2405/97 FSO-2405/96 Item Description Thread Torque N.m (Lb.ft) Remarks Apply Eaton E677 Yoke nut 1” - 20 UNEF 217-270 (160-200) to threads Apply Eaton E677 Gear shift 19-25 (14-19)
  • Page 32 Torque Recommendation FSO-2405/95 Item Description Thread Torque N.m (Lb.ft) Remarks Apply Eaton E680 or Shift control 10-16 (7-12) Eaton E679 actuator plug threads Apply Eaton E680 or Shift positioning 10-16 (7-12) Eaton E679 device plug threads Apply Eaton E680 Reverse light...
  • Page 33 Torque Recommendation NOTE: On clutch housings made of cast iron, apply torque of 165 to 185 N.m (122 to 136 lb.ft) to tightening capscrews. FSO-2405/146 FSO-2405/145 FSO-2405 General Information 2nd Ed. 02/07...

  • Page 34: Precautions

    Precautions Precautions during disassembly and assembly WARNING! In order to prevent damage to transmission parts during initial gears movement, it is important when assembling the transmission, to lubricate gear bearings, needle bearings, non sealed bearings and all other parts under friction conditions, with the same transmission lubricant oil.
  • Page 35 Precautions Housings Clean interior and exterior of cases, covers, etc., thoroughly. Cast parts may be cleaned in hot alkaline solution baths (we recommend a 7% soluble degreasing oil solution). The parts are to remain in the bath for the time it takes to become completely clean. The parts cleaned in alkaline solutions should be rinsed with clean water to remove any alkaline trace after cleaning process.
  • Page 36 Precautions Needle roller bearings Check carefully every needle roller for wear, pitting or spalled areas to determine whether they are suitable for reuse or replacement. After inspection, dip the needle roller bearings in an oil bath and then wrap them in a lint free cloth or paper, so as to protect them until they are ready for assembling.
  • Page 37 Precautions 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 “pirate” or remanufactured parts, besides have not the factory’s warranty, may lead to severe damage of the unit.

  • Page 38: Troubleshooting

    Troubleshooting The following chart presents some transmission malfunctions with their most common causes and possible solutions. Problem Probable cause Possible solution Reference Transmission Incorrect idle Adjust idle speed As to vehicle’s noise when in speed adjustment instruction manual neutral Improper or Replace disc As to vehicle’s damaged clutch...
  • Page 39 Troubleshooting Problem Probable cause Possible solution Reference Hard shifting Malfunction of Verify and adjust clutch As to vehicle’s clutch shop manual Worn or damaged Replace As to vehicle’s flywheel bushing or instruction manual bearing Not recommended Replace Recommended lubricant lubricant - page 23 Worn or damaged Replace damaged Gear shift housing...
  • Page 40 Troubleshooting Problem Probable cause Possible solution Reference Hard gear Excessively worn Replace synchronizer Synchronizer disengaging or damaged assemblies assemblies - (continuation) synchronizer page 140 assemblies (springs, keys, sleeve or hub) Worn or damaged Replace worn or As to this manual shifting system damaged parts instructions...
  • Page 41 Troubleshooting Problem Probable cause Possible solution Reference Transmission 1st/2nd and 3rd/4th Remove and assemble Synchronizer slips out of gear synchronizer hub properly assemblies - (continuation) swapped page 140 (anti-escape relief) Mainshaft or Adjust end play End play countershaft end adjustment - play improperly page 148 adjusted...
  • Page 42 Troubleshooting Problem Probable cause Possible solution Reference Bearing failures Mainshaft or Adjust end play End play (continuation) countershaft end adjustment - play improperly page 148 adjusted Bearings were Replace damaged As to this manual not lubricated parts. Reassemble instructions before assembling as to proper procedure Double shifting Double gear shifting Reassemble...

  • Page 43: Special Tools

    Special Tools To properly service the Eaton FSO-2405 transmission, the following specialized tools are recommended: Eaton Ref. Description E001010 Permaglide bushing installer E001013 Universal handle E001020 Front housing expansion plug installer E001021 Input shaft bearing cover seal installer E001032 Input shaft bearing cover oil baffle installer...
  • Page 44 Special Tools Eaton Ref. Description E006009 Mainshaft lock - 30 splines E006010 Mainshaft lock - 25 splines E007002 Input shaft bearing cone puller E007007 Mainshaft bearing cone puller E007008 Countershaft bearing cone puller E008001 Pry bar for measuring end play...
  • Page 45 Special Tools E001010 Permaglide bushing installer E001010 E001010 E001013 Universal handle E001013 E001020 Front housing expansion plug installer E001020 E001021 Input shaft bearing cover seal installer NOTE: Used with E001013 E001021 E001021 FSO-2405 General Information 2nd Ed. 02/07...
  • Page 46 Special Tools E001032 Input shaft bearing cover oil baffle installer NOTE: Used with E001013 E001032 E001032 E001033 Front housing bearing cup installer NOTE: Used with E001037 E001033 E001034 Rear seal installer Application: All 4x4 vehicles E001034 E001035 Mainshaft bearing cup puller NOTE: Used with E001037 E001035 General Information...
  • Page 47 Special Tools E001036 Countershaft bearing cup puller NOTE: Used with E001037 E001036 E001037 Bearing cup puller/installer support E001037 E001038 Mainshaft bearing cup installer NOTE: Used with E001037 E001038 E001039 Countershaft bearing cup installer NOTE: Used with E001037 E001039 FSO-2405 General Information 2nd Ed.
  • Page 48 Special Tools E001040 Rear seal installer Application: Ranger 4x2 / Troller 4x2 / VM Motori / Agrale Daily NOTE: Used with E001013 E001041 Rear seal installer Application: Frontier 4x2 NOTE: Used with E001013 E001040 E001042 Rear seal installer Application: S10 4x2 NOTE: Used with E001013 E001043 Countershaft bearing cone...
  • Page 49 Special Tools E001045 Shift lug pin punch E001045 E001045 E003001 Slide hammer (impact puller) E003001 E004002 Slide hammer end - for removing the expansion bushing E004002 E005003 Pocket bearing cone puller E005003 E005003 FSO-2405 General Information 2nd Ed. 02/07...
  • Page 50 Special Tools E005005 Thread cutter E005005 E006002 30 mm special socket E006002 E006003 54 mm special socket E006003 E006003 E006004 23-spline input shaft spline socket Application: Ranger 4x2 / Ranger 4x4 / Crosslander E006004 General Information FSO-2405 2nd Ed. 02/07...
  • Page 51 Special Tools E006005 10-spline input shaft spline socket Application: Frontier 4x2 / Frontier 4x4 / VM Motori / S10 4x2 / S10 4x4 / L200 RS 4x4 / Jinbei / Troller 4x4 Jeep / Troller 4x2 Pickup / A g r a l e D a i l y E006005 E006006 54 mm special wrench...
  • Page 52 Special Tools E007002 Input shaft bearing cone puller E007002 E007002 E007007 Mainshaft bearing cone puller E007007 E007007 E007008 Countershaft bearing cone puller E007008 E007008 E008001 Pry bar for measuring end play E008001 E009001 Plate for measuring end play E009001 E008001 / E009001 General Information FSO-2405 2nd Ed.
  • Page 53 Special Tools E010001 Mainshaft front bearing cone installer E010002 Mainshaft rear bearing cone installer E010001 E010002 E010001 / E010002 E010003 Input shaft bearing cone installer E010003 E010003 E012001 2-hook universal puller E012001 E012002 Reverse gear puller NOTE: Used with E012001 E012002 FSO-2405 General Information...
  • Page 54 Special Tools E012003 Input shaft bearing puller NOTE: Used with E012001 E012003 E012004 Front housing bearing cup puller E012004 E014002 Transmission stand adapter plate E014002 E014003 Transmission stand Option: Without reductor, with reductor or electric powered E014003 General Information FSO-2405 2nd Ed.
  • Page 55 Special Tools E014010 Base for locking the mainshaft NOTE: Used with E006007, E006008, E006009 or E006010 E014010 E014011 Support for transmission stand adapter plate E014011 FSO-2405 General Information 2nd Ed. 02/07...
  • Page 56 Special Tools Using the Eaton tool # E006003 This tool is used as an option for locking the transmission mainshaft, allowing transmission disassembly and assembly by one mechanic only. The tool uses the transmission gear ratio as a torque amplifier wrench.
  • Page 57 Special Tools Removing and installing mainshaft nut 1. Lock mainshaft as described before, using tool # E006003. Shift transmission into 1st gear. E006003 2. Install tool # E006004 or # E006005 depending on the application, on the input shaft spline. E006005 E006004 E006004 / E006005...
  • Page 58 Special Tools 4. For tightening the nut, see the following table for the torque to be applied. Use a torquemeter and rotate clockwise to the calculated torque. Transmission 1st gear Torque to be Transmission 1st gear Torque to be ratio applied ratio applied...
  • Page 59 Special Tools Removing and installing countershaft nut 1. Lock mainshaft as described before, using tool # E006003. Shift transmission into 1st gear. 2. Remove the nut using the 30 mm special socket (tool # E006002) directly on the countershaft nut. 3.
  • Page 80 Installation Reference Input shaft splines and lenghts Ford Ranger 4x2 / Ford Ranger 4x4 / Cross Lander CL 224 Mx 23 splines 3348808 3348850 25,50 FSO 2405 F = 28 Teeth (3348808) FSO 2405 B = 26 Teeth (3348850) FSO-2405/157 Nissan Frontier 4x2 / Nissan Frontier 4x4 207,66 176,24...
  • Page 81 Installation Reference GM S10 4x2 / GM S10 4x4 / Mitsubishi L200 RS 4x4 212,66 185,24 10 splines 3348806 28,25 59,5 FSO 2405 A/B/E = 26 Teeth FSO-2405/159 GM Jinbei Pickup Lw9 / VM Motori 238,50 210,40 10 splines 3348870 3348871 28,25 62,50...
  • Page 82 Installation Reference Troller Jeep 4x4 174,55 10 splines 3348902 28,25 56,5 FSO 2405 B = 26 Teeth FSO-2405/159 Agrale Daily 228,64 192,39 10 splines 3362118 28,25 60,0 B = 26 Teeth FSO-2405/160 FSO-2405 General Information 2nd Ed. 02/07...
  • Page 83 Installation Reference Mainshaft splines and lenghts 200,64 235,56 3348572 - 27 splines Ref. S10 4 x 2 70,34 52,8 3348573 - 27 splines Ref. S10 4 x 4 Ref. GM Jinbei Lw9 Ref. Cross Lander CL 224 MX 218,94 102,96 14,6 3348671 - 31 splines Ref.
  • Page 85 Table of Contents Input Shaft Bearing Cover Removal ..........87 Installation ..........88 FSO-2405 2nd Ed. 02/07...
  • Page 87 Input Shaft Bearing Cover Removal 1. Remove the five retaining capscrews from the input shaft bearing cover. FSO-2405/50 2. Place two pry bars under the input shaft bearing cover by using the existing slots. 3. By forcing the pry bars, remove the input shaft bearing cover.
  • Page 88 3. Apply sealant to the mounting surface of input shaft bearing cover. E001021 NOTE: Apply Eaton E680 sealant to the cover. FSO-2405/150 4. Align the lubrication slots of both input shaft cover and front housing and install the cover. If necessary, carefully hit the cover with a plastic hammer to seat it.
  • Page 89 Table of Contents Rear Section Output Sleeve, Yoke and 4x4 Transmission Differences ......91 Rear Section Disassembly...... 92 Oil Seal Replacement ......100 Rear Section Assembly ......101 FSO-2405 2nd Ed. 02/07...

  • Page 91: Rear Section

    Output Sleeve, Yoke and 4x4 Transmission Differences Transmission with Output Sleeve (used in this manual) With the exception of some rear section parts, the remaining transmission configuration is the same for all other models. FSO-2405/142 4x4 Transmission This transmission model has a shorter mainshaft and there is neither the speedmoter sensor nor the rotor, whose functions are not performed by the transmission itself.

  • Page 92: Rear Section Disassembly

    # E006005 may be used for removing the mainshaft rear nut, locking the mainshaft with the tool # E006003. See "Special Tools, Using the Eaton tool # E006003". 9. Place the special tool and lock the mainshaft. Loosen the rear nut.
  • Page 93 NOTE: See “Special Tools”, Ref. E014010. NOTE: As an option, the tool # E006003 may be used for locking the mainshaft. See "Special Tools, Using the Eaton tool # E006003". 12. Remove the countershaft rear nut (or snap ring). NOTE: On 2006, the nut was replaced by a snap ring in some applications.
  • Page 94 Rear Section Disassembly 16. Remove the reverse gear spacer bushing from the mainshaft. FSO-2405/9 17. Remove the reverse idler gear. FSO-2405/10 18. Remove the reverse idler gear needle bearing. FSO-2405/11 19. Remove the reverse gear from the countershaft. FSO-2405/12 Rear Section FSO-2405 2nd Ed.
  • Page 95 (p/n 3342286) and spacer (p/n 3342287) by the new lone bearing (p/n 3348906). FSO-2405/13 Old part 2 (two) bearings - Eaton P/N 3342286 1 (one) spacer - Eaton P/N 3342287 Old needle bearing FSO-2405/154 New part 1 (one) bearing - Eaton P/N 3348906...
  • Page 96 Rear Section Disassembly 22. Push the 5th/reverse shift yoke towards the synchronizer in order to loosen it from the linked shift block. Lift the yoke end and remove by pulling the yoke upwards. FSO-2405/15 23. Remove the reverse speed synchronizer ring. 24.
  • Page 97 Rear Section Disassembly 27. Remove the 5th speed gear from the countershaft. FSO-2405/19 28. Remove the two needle bearings of 5th speed gear from the countershaft. FSO-2405/20 29. Remove the 5th speed gear thrust washer from the countershaft. FSO-2405/21 30. Remove the retaining ball of the 5th speed gear thrust washer from the countershaft.
  • Page 98 Rear Section Disassembly 31. Remove the 5th speed gear from the mainshaft. FSO-2405/23 32. Remove the 5th speed gear thrust washer from the mainshaft. FSO-2405/24 33. Remove the reverse light switch. FSO-2405/25 34. Remove the 5th/reverse linked shift block retaining roll pin. NOTE: Use a 4 mm diameter pin punch.
  • Page 99 Rear Section Disassembly 35. Remove the 5th/reverse linked shift block. FSO-2405/27 FSO-2405 Rear Section 2nd Ed. 02/07...

  • Page 100: Oil Seal Replacement

    Oil Seal Replacement Removal 1. Use pry bars or screwdriver to remove the oil seal. NOTE: The removed oil seal should not be reused. FSO-2405/70 Installation NOTE: If removed, allways replace the oil seal. 1. Coat the new seal lips with the recommended grease.

  • Page 101: Rear Section Assembly

    NOTE: Use a 4 mm diameter pin punch. NOTE: Replace the roll pin by a new one. FSO-2405/26 4. Install the reverse light switch. NOTE: Apply Eaton E680 or Eaton E679 sealant to the switch threads. FSO-2405/25 5. Install the 5th speed gear thrust washer on the mainshaft.
  • Page 102 Rear Section Assembly 6. Install the 5th speed gear on the mainshaft. FSO-2405/23 7. Install the retaining ball of the countershaft 5th speed gear thrust washer on the countershaft. Apply grease to hold the ball in place. FSO-2405/22 8. Install the 5th speed gear thrust washer on the countershaft.
  • Page 103 Rear Section Assembly 10. Install the 5th speed gear on the countershaft. FSO-2405/19 11. Install the 5th speed ring synchronizer on the countershaft. NOTE: The 5th speed synchronizer ring is not coated with EFM II and is smaller than the other rings. FSO-2405/18 12.
  • Page 104 FSO-2405/15 17. Install the two pivot threaded pins of 5th/reverse shift yoke. NOTE: Apply Eaton E677 sealant to the pin threads. Torque = 10-16 N.m (7-12 Lb.ft) NOTE: See “Special Tools”, Ref. E001044. FSO-2405/14 18.
  • Page 105 Rear Section Assembly Old part 2 (two) bearings - Eaton P/N 3342286 1 (one) spacer - Eaton P/N 3342287 Old needle bearing FSO-2405/154 New part 1 (one) bearing - Eaton P/N 3348906 New needle bearing FSO-2405/155 19. Install the reverse gear on the countershaft.
  • Page 106 Rear Section Assembly 21. Install the reverse idler gear on the shaft with the prominent side facing the housing outside. FSO-2405/10 22. Install the reverse gear spacer bushing on the mainshaft. FSO-2405/9 23. Install the reverse gear on the mainshaft with the hub prominent side facing the housing inside.
  • Page 107 NOTE: See “Special Tools”, Ref. E014010. NOTE: As an option, the tool # E006003 may be used for locking the mainshaft. See “Special Tools, Using the Eaton tool # E006003”. Install the rear nut (or snap ring) on counter- shaft and tighten to the proper torque.
  • Page 108 FSO-2405/156 with the tool # E006003. See “Special Tools, Using the Eaton tool # E006003”. 32. Place the special tool and lock the mainshaft. NOTE: See “Special Tools”, Ref. E014010. 33. Tighten the mainshaft rear nut to the proper torque.
  • Page 109 FSO-2405/2 39. Apply sealant compound gasket to the rear cover mounting surface with the intermediate housing. NOTE: Apply Eaton E680 sealant to the mounting surface. 40. Install the rear cover. 41. Install the thirteen retaining capscrews of rear case to the intermediate housing. Tighten the capscrews crosswise to the proper torque.

  • Page 111: Front Section

    Table of Contents Front Section Front Section Disassembly ....115 Mainshaft Disassembly ......118 Assembly ........119 Countershaft Disassembly ......122 Assembly ........122 Input Shaft Disassembly ......123 Assembly ........123 Shift Yoke Bars Disassembly ......124 Assembly ........124 Reverse Idler Gear Shaft Removal ........
  • Page 112 Table of Contents Reverse Shifting Interlocking System Description ........ 131 Disassembly ......132 Assembly ........133 Double Gear Shifting Interlocking System Description ........ 134 Disassembly ......135 Assembly ........136 Input Shaft Bearing Cup Removal ........137 Installation ......... 137 Countershaft Front Bearing Cup Removal ........
  • Page 113 Table of Contents Front Section Assembly ......145 End Play Adjustment Mainshaft End Play Measurement ......148 Countershaft End Play Measurement ......149 Determination of End Play Adjusting Shims ......150 FSO-2405 2nd Ed. 02/07...

  • Page 115: Front Section Disassembly

    Front Section Disassembly 1. Disassemble the rear section (see “Rear Section Disassembly”). 2. Shift the 1st speed gear. WARNING! Remove the shift lug roll pin BEFORE removing the threaded actuator of shifting cam. 3. Remove the shift lug roll pin by pushing it forward into the housing.
  • Page 116 Front Section Disassembly 8. Remove the intermediate housing together with the shift lug. NOTE: Carefully hit the housing’s capscrews area with a rubber or plastic hammer to brake the gasket seal and detach the housing. FSO-2405/32 9. Pull the 5th/reverse yoke bar (the longest) upwards and remove it.
  • Page 117 Front Section Disassembly 12. Hold the 1st/2nd shift yoke in its place on synchronizer groove and pull the yoke bar upwards. When the bar lower end rises over the housing surface (see detail), remove the bar and shift yoke assembly. FSO-2405/36 13.

  • Page 118: Mainshaft

    Front Section Disassembly Mainshaft Disassembly 1. Use the bearing puller and remove the front bearing cone from mainshaft. NOTE: See “Special Tools”, Ref. E005003. FSO-2405/38 2. Remove the 3rd/4th synchronizer hub retaining snap ring. FSO-2405/39 3. Place the mainshaft in the press, using the 2nd speed gear as a base.

  • Page 119: Assembly

    Front Section Disassembly Mainshaft Assembly 1. Install the 2nd speed gear needle bearing. NOTE: The 2nd speed gear needle bearing was modified. When servicing the unit, replace the old needle bearing by the new one. Old part: 239818 / New part: 3348857 They are interchangeable.
  • Page 120 Front Section Disassembly Mainshaft 10. Use two tubular tools and press the late installed set of components of the mainshaft. Make sure to align the synchronizer ring lugs with hub key slots. WARNING! Apply force to bearing inner race. NEVER apply force to the bearing cage.
  • Page 121 Front Section Disassembly Manishaft 16. Use two tubular tools and press the late installed set of components of the mainshaft. Make sure to align the synchronizer ring lugs with hub key slots. WARNING! Apply force to bearing inner race. NEVER apply force to the bearing cage.

  • Page 122: Countershaft Disassembly

    Front Section Disassembly Countershaft 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 proper support. NOTE: See “Special Tools”, Ref.

  • Page 123: Input Shaft Disassembly

    Front Section Disassembly Input Shaft 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. Use the bearing inner race as a base by using the proper support. NOTE: See “Special Tools”, Ref.

  • Page 124: Shift Yoke Bars Disassembly

    Front Section Disassembly Shift Yoke Bars Disassembly 1. Remove the retaining roll pins and remove the parts from the shift bars. NOTE: Use a 4 mm diameter pin punch. 2. If necessary, replace the shift yoke permaglide bushing. After installing the bushing, use a punch to lock the bushing in the bushing bore.
  • Page 125 Front Section Disassembly Shift Yoke Bars Shift Selecting Bar Assembly 1. The shift selecting bar has two holes simmetricaly positioned to the bar center to install retaining roll pins. Thus, the shift selecting block can be assembled on any bar end.

  • Page 126: Reverse Idler Gear Shaft Removal

    Front Section Disassembly Reverse Idler Gear Shaft Removal 1. In the intermediate housing, locate the reverse idler gear shaft retaining capscrew and remove 2. Remove the idler shaft. FSO-2405/69 Installation 1. Align the shaft hole with the housing hole and install the idler shaft into the shaft bore.

  • Page 127: Expansive Plugs Removal

    Front Section Disassembly Expansive Plugs Some through holes in housings are drilled for machining purpose only and must be blocked later by using expansive metallic plugs. During the transmission life, it is possible to happens that those plugs should be removed and reinstalled when servicing the unit.

  • Page 128: Installation

    Do not use sand paper. 2. Apply sealant to the new plug and insert it into the hole using the hands to guide the plug. NOTE: Apply Eaton E677 to plugs. FSO-2405/48 FSO-2405/49 3. Use the proper tool and a hammer to force the plug into the plug bore.

  • Page 129: Permaglide Bushing Removal

    Front Section Disassembly Permaglide Bushing Removal 1. Inspect bushing and replace if worn. NOTE: Inspect other transmission bushing too. The pictures here show only the front housing bushing, however the procedure is the same for all other transmission permaglide bushing. FSO-2405/54 2.

  • Page 130: Installation

    Front Section Disassembly Permaglide Bushing Installation 1. Place the bushing on the proper tool. NOTE: See “Special Tools”, Ref. E001010. 2. Position the bushing in the bushing bore and install the bushing by hitting the tool until it rest against the housing. This condition gives the proper bushing depth.

  • Page 131: Reverse Shifting Interlocking System

    Front Section Disassembly Reverse Shifting Interlocking System Description The reverse shifting interlocking mechanism prevents the driver from shifting accidentally into reverse speed when downshifting from 5th to 4th speed. 1. Reverse shifting interlocking mechanism. FSO-2405/58 The mechanism comprises a lock device working together with the shift selecting bar.

  • Page 132: Disassembly

    Front Section Disassembly Reverse Shifting Interlocking System Disassembly 1. Remove the expansive plug from housing hole where is located the interlocking mechanism retaining roll pin. NOTE: See “Expansive Plugs” for instructions. FSO-2405/60 2. Through the housing hole, remove the roll pin. NOTE: Use a 4 mm diameter pin punch.

  • Page 133: Assembly

    Front Section Disassembly Reverse Shifting Interlocking System Assembly 1. Align the interlok pin hole with the housing hole and install the interlocking mechanism into the pin bore. FSO-2405/62 2. Give the spring as much as the tension you can by winding the spring on the pin and then set its free end in the housing hole.

  • Page 134: Double Gear Shifting Interlocking System

    Front Section Disassembly Double Gear Shifting Interlocking System Description The double gear shifting interlocking mechanism prevents shifting into two gears at the same time. 1. Double gear shifting interlocking mechanism FSO-2405/58 Such mechanism comprises one interlock pin and five interlock balls. NOTE: One interlock ball has a 8,0 mm diameter while the other four interlock balls have a 9,5 mm diameter.

  • Page 135: Disassembly

    Front Section Disassembly Double Gear Shifting Interlocking System Disassembly 1. Remove the expansive plug near to the 5th/ reverse yoke bar. NOTE: See “Expansive Plugs” for instructions. FSO-2405/83 2. Push the interlock pin to the opposite side in order the interlock balls drop from their bores. FSO-2405/65 3.

  • Page 136: Assembly

    Front Section Disassembly Double Gear Shifting Interlocking System Assembly 1. Apply grease to interlock bores to keep the balls in place. 2. Install the three interlock balls aligned from the 3rd/4th yoke bar bore and install the smallest ball (8,0 mm diameter) located on the 1st/2nd yoke bar bore.

  • Page 137: Input Shaft Bearing Cup

    Front Section Disassembly Input Shaft Bearing Cup Removal 1. Place the front housing properly supported with the input shaft bearing cup removing side down. 2. Use the bearing cup puller and remove the bearing cup from the bearing bore. NOTE: See “Special Tools”, Ref. E012004. FSO-2405/171 Installation 1.

  • Page 138: Countershaft Front Bearing Cup

    Front Section Disassembly Countershaft Front Bearing Cup Removal 1. Place the front housing properly supported with the countershaft bearing bore side up. 2. Use the proper tool placed under the bearing cup counterbore at the cup bottom and remove the bearing cup. NOTE: See “Special Tools”, Ref.

  • Page 139: Removal

    Front Section Disassembly Mainshaft and Countershaft Rear Bearing Cups Removal 1. Place the intermediate housing properly supported with the bearing cup removing side down. 2. Use the proper device along with the support and remove the mainshaft and countershaft rear bearing cups from the bearing bore. NOTE: See “Special Tools”, Ref.

  • Page 140: Synchronizer Assemblies

    Front Section Disassembly Synchronizer Assemblies Description Synchronizers and synchronizer rings together are responsible for engaging the transmission gears. There are three synchronizer assemblies in this transmission model: • 1st/2nd speed synchronizer • 3rd/4th speed synchronizer • 5th/reverse speed synchronizer NOTE: When repairing synchronizer FSO-2405/72 assemblies, do not replace a single part only.

  • Page 141: Assembly

    Front Section Disassembly Synchronizer Assemblies 2. Slide the keys and springs out from the synchronizer hub slots and remove them. FSO-2405/74 Assembly 1. Place the spring inside the key hole, depress the spring and slide spring and key together into the synchronizer hub. Repeat this procedure for the three keys.

  • Page 142: Installation

    Front Section Disassembly Synchronizer Assemblies 4. Place the assembly on the bench with the synchronizer ring facing down. 5. With the hands, install the synchronizer sleeve on the synchronizer hub by forcing the sleeve downwards. FSO-2405/75 Installation WARNING! Before installing synchronizer assemblies on shafts is very important to be acquainted with their design features and be able to...
  • Page 143 Front Section Disassembly Synchronizer Assemblies 4. Install the synchronizer assemblies with the hub most prominent side facing the odd speed gear (either 1st or 3rd depending on the assemly). FSO-2405/81 5. Install the synchronizer assemblies with the sleeve largest chamfer side facing the odd speed gear (either 1st or 3rd depending on the assemly).
  • Page 144 Front Section Disassembly Synchronizer Assemblies Synchronizer Rings 8, 10 8. The 1st, 2nd, 3rd and 4th speed synchronizer rings are the same and all coated with EFM II. 9. The 5th and reverse speed synchronizer rings are smaller than the others. 10.

  • Page 145: Front Section Assembly

    Front Section Assembly 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. NOTE: The 1st, 2nd, 3rd and 4th speed synchronizer rings are the same and all coated with EFM II.
  • Page 146 Front Section Assembly 6. Align the whole assembly, as set before, with the input shaft bear ing cup, with the countershaft bearing cup and with the 3rd/4th yoke bar bore, and install the assembly in the front housing. NOTE: Be careful to keep the double shifting interlock balls in place.
  • Page 147 Front Section Assembly 11. Align the 5th/reverse yoke bar with the bar bore, with the selecting block longest arm and with the reverse shifting interlock pin, and install the yoke bar. FSO-2405/119 WARNING! Do not apply sealant to both housing and retaining capscrews by now! Prior to finishing the transmission assembly is necessary to check the end play.

  • Page 148: End Play Adjustment

    Front Section Assembly End Play Adjustment WARNING! Before measuring and adjusting the transmission axial clearance (end play), remove ALL existing adjusting shims under both the mainshaft and countershaft rear bearing cups (see “Mainshaft and Countershaft Rear Bearing Cups - Removal and Installation”).

  • Page 149: Countershaft End Play Measurement

    Front Section Assembly End Play Adjustment Countershaft End Play Measurement 20. Choose one from housing threaded holes and install the special plate (tool # E009001) to support a dial indicator with magnetic base. 21. Install one from those removed transmission capscrews in the hole at countershaft end center.

  • Page 150: Determination Of End Play Adjusting Shims

    Front Section Assembly End Play Adjustment Determination of End Play Adjusting Shims Specified end play (mm) Minimum Maximum Remarks Countershaft 0,010 0,080 Positive clearance Mainshaft 0,010 0,060 Positive clearance 26. Use the following flowchart and determine the shims pack thickness to adjust the transmission end play: Measure the clearance Is the measured...
  • Page 151 Front Section Assembly End Play Adjustment Example #1: countershaft end play adjustment Specified end play: 0,010 mm to 0,080 mm Measured end play: 0,47 mm As the measured value is greater than 0,080 mm (maximum specified), calculate: 0,470 – 0,080 = 0,390 mm (R1) 0,470 –...
  • Page 152 Front Section Assembly End Play Adjustment 30. Use the proper drive tool and remove the rear bearing cups (see “Mainshaft Countershaft Rear Bearing Cups - Removal and Installation”). FSO-2405/173 WARNING! Be careful to not swap the adjustment shim pack between mainshaft and countershaft when installing.
  • Page 153 35. Apply sealant to the front housing mounting surface. Spread the sealant properly to prevent leaks. NOTE: Use Eaton E680 sealant. FSO-2405/125 36. Position the shift lug in the gear shift control tower opening in the intermediate housing, and install the intermediate housing on the front housing.
  • Page 154 NOTE: See “Special Tools”, Ref. E001045. E001045 40. Install the ball, spring and shift positioning plug. NOTE: Apply Eaton E680 or Eaton E679 sealant to plug threads. Torque = 10-16 N.m (7-12 lb.ft) FSO-2405/30 Front Section FSO-2405 2nd Ed.
  • Page 155 Front Section Assembly 41. Install the spherical actuator pin, spring and plug of the cam threaded actuator. NOTE: Apply Eaton E680 or Eaton E679 sealant to plug threads. Torque = 10-16 N.m (7-12 lb.ft) 42. Assemble the rear section (see “Rear Section - Assembly”).
  • Page 157 Table of Contents Gear Shift Lever Housing Disassembly ......... 159 Assembly ..........161 FSO-2405 2nd Ed. 02/07...
  • Page 159 Gear Shift Lever Housing Disassembly Replace all internal parts, but gear shift lever. Inspect the gear shift lever and replace if worn. In case the housing should be replaced, get a complete assembly from your dealer. 1. Remove the four retaining capscrews from the gear shift lever housing and remove the gear shift lever housing assembly from the transmission.
  • Page 160 Gear Shift Lever Housing Disassembly 6. Use a pin punch and remove the two spade pins from the housing tower bores by punching the pins from inside outwards. FSO-2405/131 7. Remove the lower bushing. 8. Remove the wave washer. 9. Remove the thrust washer. FSO-2405/132 10.
  • Page 161 Gear Shift Lever Housing Assembly 1. Position the oil baffle on the housing and install the oil baffle using a proper drive tool. FSO-2405/134 2. Turn the housing over. 2,3,4 3. Install the wave washer and next, the thrust washer. 4.
  • Page 162 12. Apply sealant to the gear shift lever housing mounting surface. Spread the sealant properly to prevent leaks. NOTE: Apply Eaton E680 or Eaton E679 sealant to the mounting surface. FSO-2405/127 13. Install the gear shift lever housing assembly on the transmission.
  • Page 163 ® ® Eaton Fuller Light Duty Transmissions...

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