Eaton RTX-12510 Service Manual
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Eaton RTX-12510 Service Manual

Fuller heavy duty transmissions
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Service Manual
Fuller Heavy Duty Transmissions
TRSM0503
October 2007
RTX-12510
RTX-12515
RTXF-12510
RTXF-12515

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Summary of Contents for Eaton RTX-12510

  • Page 1 Service Manual Fuller Heavy Duty Transmissions TRSM0503 October 2007 RTX-12510 RTX-12515 RTXF-12510 RTXF-12515...

  • Page 2: Table Of Contents

    Table of Contents Inspection ........64 Model Designations .

  • Page 3: Model Designations

    RTF-12510, etc. denotes for- “F” – ward position of the gear shift lever. N O T E Illustrated parts lists with part numbers are available upon request. Write Service Depart- ment, Eaton Corporation, Transmission Division, 222 Mosel Avenue, Kalamazoo, Michigan 49007.

  • Page 4: Description

    Description through the low speed gear of the range section. Sixth The RT-111 O and RT-12510 transmissions are designed for heavy-duty on-highway equipment. The twin countershaft through tenth speeds are obtained by using the five gear ratios in the front section through the high speed (direct design, which splits torque equally between the two shafts, provides a high torque capacity to weight ratio .

  • Page 6: Specifications

    Specifications - RT-1 110 Series 10 progressive forward speeds, 2 reverse Speeds GEAR RATIOS lb.-ft. Nominal Torque Capacity RT-111O and RTF-111O RTO-1 110 and RTOF-1 110 RATIO % STEP SPEED RATIO % STEP 2“ diameter Input Drive Shaft 10th 1.00 10th Power Take-Off 1.27 ‘...
  • Page 7 Specifications - RT-1 2515 Series Speeds RTO-12515 and RTOF-12515 15 forward speeds, 3 reverse. Five deep reduction ratios, Right Side: 45-tooth 6/8 pitch gear turning .888 engine speed. plus evenly spaced ratios for a selective 11 or 12 progressive Bottom: 47-tooth 6/8 pitch gear turning .888 engine speed. ratios.

  • Page 8: Lubrication

    (4827 to 8045 Km) Inltlal drain assure maximum component life and to main- Every 10,000 miles Check fluid level tain your warranty with Eaton. (Also see (16090 Km) Check for leaks “Operating Temperatures”.) Heavy Duty Highway Change Interval Additives and friction modifiers are not recom-...
  • Page 9 LUBRICATION Proper Lubrication Levels Operating Temperatures as Related to Transmission ® ® —With Eaton Roadranger Installation Angles CD50 Transmission Fluid Heavy Duty Engine Oil If the transmission operating angle is more than 12 degrees, improper lubrication can oc- and Mineral Oil cur.

  • Page 10: Operation

    Operation In the following instructions, it is assumed that the driver is familiar with motor trucks and tractors, and that he can coordinate the necessary movements of the shift lever and clutch pedal to make progressive and selective gear engagements in either direction, up or down.
  • Page 11 Downshifting Upshifting get to low range get to high range push button DOWN pull button while in 5th speed, 6th speed, then move lever then move lever to 5th speed. to 6th speed. speed. RANGE Downshifting Upshifting 1. When shifting down, move the lever from 10th through 1.
  • Page 12 Service t, Transmission Division, Eaton Corporation, Kalamazoo, Michigan. Shifts will be fast and short as the gear shift lever stroke is 2% inches between positions. Conical engagement teeth are...
  • Page 13 RT-12515 and RTO-12515 Operation The RT-125 15 transmission, like the RT-125 10, has a five- operating under adverse conditions and only when the speed front section and a two-speed auxiliary or range sec- transmission is in LOW RANGE with the control valve but- ton down.
  • Page 14 SUGGESTED SHIFT PATTERN FOR THE RT-12515 THROUGH REDUCTION AND LOW AND HIGH RANGE (Ratios shown next to each gear shift lever position) Shift 1 through 5 with range control button down and deep reduction valve to “IN” while in 5th reduction . . . and shift through 4th & 5th of low range Move deep reduction valve to “OUT”...
  • Page 15 Important Procedures out of the reduction ratios to low range ratios. Torque will keep the reduction gear engaged until the shift out of fifth position is made. Remember, although shift 1. When making the shift from a reduction ratio to a low range ratio, move the Deep Reduction Valve from “IN”...

  • Page 16: Air Systems

    Air Systems Range Shift Air System – All Models This system consists of an air filter, regulator, air valve, from the constant supply to flow through the high range control valve, shift cylinder, fittings and connecting lines. port in rear, side cap of air valve and to the shift cylinder See Illustration A.
  • Page 17 cylinder and cover to the front of the shift piston moves Hole-Gear Air System – RT-12515 Series the piston and shift bar to the rear to engage the hole-gear. As the hole-gear is engaged the range mainshaft is dis- This system uses the air filter and regulator of the range engaged from the output shaft, removing the low and high shift air system, plus a Deep Reduction Valve, mounted in range sections from the power flow.
  • Page 18 Air Valve Operation With the range control button up the control valve shuts off With the control button down the control valve opens and supplies air to the end cap. Since the piston area is larger on the air supply to the end cap. Thus, the constant air this end of the piston, it is forced in the opposite direction.
  • Page 19 Air Valve Pre-Selection An actuating pin protruding from the shifting bar housing piston when the lever is moved to or through neutral. See prevents the actuating piston in the air valve from moving detailed installation of air valve for installation precaution while the gearshift lever is in a gear position and releases the concerning the actuating pin.
  • Page 20 E. Exploded of control value. The supply. The “OUTLET” port connected by O. L). “IN’’port constant cap of air ualoe. Remove the slide and the two position balls and springs. If the O-rings or parts in the control valve are defective there will be a constant air leak out the exhaust located on Remove the flat metal seal from outlet side and remove bottom of control valve.
  • Page 21 Trouble Shooting Range Shift Air System All Models The following checks are to be made with normal vehicle air pressure but with the engine off. Refer to Illustration A for check points. Incorrect Hook-Up If there is a steady leak from exhaust port, this indicates With normal vehicle air pressure and gearshift lever in a defective air regulator and should be replaced.
  • Page 22 6. Low Range, Check Point D 7. Range Shift Cylinder – Check Point E With the gearshift lever in neutral, pull the control but- If any of the seals in the range shift cylinder are de- ton up and disconnect the low range air line at shift fective the range shift will be affected.
  • Page 23 Hole-Gear Air System RT-12515 and RTO-12515 Transmissions The following checks are to be made with normal vehicle air pressure but with the engine off. It is assumed air lines have been on B for check checked for leaks and the air regulator has been checked and the correct reading obtained. Refer to Illustrat points.

  • Page 24: Preventive Maintenance

    Preventive Maintenance Check Chart CHECKS WITHOUT PARTIAL 8. Gearshift Lever Housing Assembly DISASSEMBLY OF Remove air lines at air valve and remove the gearshift CHASSIS OR CAB lever housing assembly from transmission. Check tension spring and washer for set and wear. Air System and Connections Check the gearshift lever pivot pin and pivot pin slot a.
  • Page 26 Special Procedure For Clutch (Input) Shaft In some cases in field repair it may benecessary to replace Install snap ring in ID of drive gear. only the input shaft due to clutch wear on the splines. Install washer on shaft. In these instances the input shaft can be removed without disassembling the transmission other than removing the Move the fourth-fifth speed sliding clutch gear forward...
  • Page 27 General Precautions for Disassembly IMPORTANT: Read this section before starting the detailed disassembly procedures. assumed in the detailed disassembly instructions that the lubricant has been drained from the transmission, the necessary linkage and air lines removed and the trans- mission has been removed from the chassis. Removal of the gearshift lever housing assembly is included in the detailed instructions;...
  • Page 28 1. Shifting Controls.
  • Page 29 Removal of the Deep Reduction Shift Air System D RT-12515 Series 1. Remove the 1/4" ID air line between the deep reduction shift cylinder and the tee fitting forward of the filter / regulator assembly. Removal of Range Shift Air System 1.
  • Page 30 Disassembly - Air System Removal of the Range Shift Air System - continued 5. Remove the hose clamp and disconnect the two 1/4" ID air lines between air valve and the range shift cylinder. Loosen the clamp holding the range control valve to the lever.
  • Page 31 10. Remove the spring and plunger from the bore in the 8. Turn out the four capscrews and remove the air valve adaptor plate. from the side of the front case. For further disassembly of the air valve, refer to page 18. 11.

  • Page 32: Shift Bar Housing

    Removal and Disassembly of the Gear Shift Lever Housing 1. Turn out the four capscrews, jar lightly to break the gasket seal and lift the gear shift lever assembly from the shift bar housing. 4. Turn out the nut and remove the pivot pin from the housing.
  • Page 33 Removal and Disassembly of the Shift Bar Housing Assembly Turn out the retaining capscrews, jar to break the gasket Mount the housing on its side in a vise with the exposed seal and lift the shift bar housing from the case. end of the actuating plunger facing up.
  • Page 34 Disassembly of the Shift Bar Housing - continued CRemove the actuating plunger from the bore in the 5. Cut the lockwires, turn out the lockscrews and remove housing. the 4th-5th speed shift bar, block and yoke from the housing. Cut the lockwires, turn out the lockscrews and remove 8.
  • Page 35 Shift Bar Housing 9. Remove the two interlock balls from the bore in the housing boss.

  • Page 36: Companion Flange, Auxiliary Housing And Clutch Housing

    Companion Flange, auxiliary housing and Clutch Housing II. Companion Flange, Auxiliary Housing and Clutch Housing Removal of the Companion Flange or Yoke 1. Use a large breaker bar to remove the stop nut from the 2. Remove the stop nut washer and companion flange or output shaft.
  • Page 37 Companion Flange, auxiliary housing and Clutch Housing 3. The transmission can also beset vertically to remove the auxiliary housing. Block under the clutch housing to pre- vent damage to the input shaft and lift the auxiliary housing upwards and from the front case. Removal of the Clutch Housing 2.

  • Page 38: Front Section

    III Front Section Removal and Disassembly of the Auxiliary Drive Gear Assembly 1. Remove the mainshaft rear snap ring from the shaft. Insert three puller screws in the tapped holes of the retainer ring and tighten evenly to remove the drive gear assembly from the case bore.
  • Page 39 Front Section Removal and Disassembly of the Left Reverse Idler Gear Assembly 1. Move the mainshaft reverse gear as far to the rear as 3. Use inside jaw pullers to remove the left auxiliary coun- possible and remove the snap ring from the ID of the tershaft front bearing from the reverse idler bore.
  • Page 40 Disassembly of the Left Reverse Idler Gear Assembly - continued 5. Remove the plug from the bore in the rear of the idler 7. If necessary, remove the bearing inner race and rear shaft, insert an impact puller in the bore and remove the washer from the idler shaft.
  • Page 41 Removal of the Countershaft Bearings 1. Remove the snap ring from the rear of each counter- shaft. 4. Use a soft bar and mall to drive each countershaft as far to the rear as possible. This will partially unseat the front bearings.
  • Page 42 Removal and Disassembly of the Mainshaft Assembly 1. Block the right countershaft against the side of the case 4. Remove the reverse gear spacer and pull the key to the and move the mainshaft as far to the rear as possible. Tip rear and from the mainshaft.
  • Page 43 Removal and Disassembly of the Drive Gear Assembly 3. Move the drive gear assembly to the rear and into the 1. Turn out the f rent bearing cover retaining capscrews and case, working past the countershaft gears. Remove the from inside the case, use a soft bar and mall to move the drive gear assembly from the case.
  • Page 44 Disassembly of the Drive Gear Assembly - continued 5. Turn the bearing nut from the shaft. (LH thread) 6. Using the rear face of the drive gear as abase, press the shaft through the gear to unseat the bearing from the shaft.
  • Page 45 Removal and Disassembly of the Countershaft Assemblies NOTE: Except for the number of teeth on the PTO IMPORTANT: Never use the PTO gear as a pressing gear, the countershaft assemblies are identical and are base. The narrow thickness of this gear makes it suscepti- disassembled in the same manner.
  • Page 46 RT-1110 Series IV. Auxiliary Section - Removal and Disassembly of the Range Shift Cylinder Assembly 1. For ease of disassemble y, mount the auxiliary section 4. Pull the yoke bar to the rear and out of the cylinder. upright in a vise. Turn out the capscrews and remove the Remove the piston from the housing.
  • Page 47 Removal of the Auxiliary Countershaft Assemblies 3. Use a soft bar and mall to drive the countershaft for- ward and from the rear bearings. 1. Turn out the capscrews and remove the two rear bearing covers. 4. Remove the bearings from the bores by tapping lightly and evenly to the rear with a soft bar.
  • Page 48 Removal and Disassembly of the Synchronizer Assembly - continued 3. Remove the sliding clutch gear from the pins of the low speed synchronizer. Disassembly of the Low Speed Gear and Tailshaft Assembly 1. Use a soft bar and mall to drive the output shaft forward 3.
  • Page 49 7. Turn out the capscrews and remove the rear bearing cover. If necessary, remove the oil seal from the cover. 5. Remove the splined spacer from the shaft. 8. Remove the bearing rear cone from the housing. 9. Remove the two bearing cups and outer spacer from the 6.

  • Page 50: Auxiliary Section -Rt-12510 Series

    V Auxiliary Section - RT-12510 Series Removal and Disassembly of the Range Shift Cylinder Assembly 1. For ease of disassembly, mount the auxiliary section up- 3. Cut the lockwire and turn out the two yoke lockscrews. right in a vise. Turn out the capscrews and remove the range shift cylinder cover.
  • Page 51 6. Turn out the capscrews and remove the shift cylinder 5. Remove the O-rings from the OD and ID of the piston housing. Remove the shift yoke from the sliding clutch and from the bore in the shift cylinder. gear of the synchronizer. If necessary, remove O-ring from bore in cylinder housing.
  • Page 52 Removal of the Auxiliary Countershaft Assemblies 1. Turn out the capscrews and remove the two rear bearing Use a soft bar and mall to drive the countershaft for- covers. ward and from the rear bearings. 2. Remove the snap ring from the rear of each counter- Remove the bearings from bores by tapping lightly and shaft.

  • Page 53: Synchronizer

    Removal and Disassembly of the Synchronizer Assembly -- continued 1. Pull the synchronizer assembly from the splines of the 3. Remove the sliding clutch gear from the pins of the low output shaft. speed synchronizer. 2. Pull the direct (high range) cone synchronizer from the pins of the low speed synchronizer ring.
  • Page 54 Removal and Disassembly of the Output Shaft Assembly 1. Use a soft bar and mall to drive the output shaft forward 3. Using the front face of the low speed gear as a base, and from the rear bearing assembly. press the shaft through the gear and bearing.
  • Page 55 5. Remove the two bearing cups and outer spacer from the auxiliary plate bore.

  • Page 56: Auxiliary Section -Rt-12515 Series

    VI Auxiliary Section - RT-12515 Series Removal and Disassembly of the Range Shift Cylinder Assembly 3. Cut the lockwire and turn out the two yoke lockscrews. 1. For ease of disassembly, mount the auxiliary section in a vise in the upright position. Turn out the capscrews and remove the range shift cylinder cover.
  • Page 57 6. Turn out the capscrews and remove the shift cylinder 5. Remove the O-rings from the piston. housing. If necessary, remove the O-ring from the ID of the housing.
  • Page 58 Removal of the Auxiliary Countershaft Assemblies. 1. Turn out the capscrews and remove the two rear bearing covers. 4. Remove the bearings from the bores by tapping lightly and evenly to the rear with a soft bar. 2. Remove the snap ring from the rear of each auxiliary countershaft.

  • Page 59: Synchronizer

    Removal and Disassembly of the Synchronizer Assembly 3. Remove the sliding clutch from the pins of the low 1. Pull the synchronizer assembly from the splines of the speed synchronizer. output shaft. 2. Pull the direct (high range) cone synchronizer from the pins of the low speed synchronizer ring.
  • Page 60 Removal of the Low Range Gear and Range Mainshaft Assembly 1. Remove the key from the keyway between the splines of 3. Pull the gear and washer forward and off the splines of the range mainshaft. the range mainshaft. 2. Turn the washer located in the hub of the gear so that 4.
  • Page 61 7. Remove the bearing from the shaft. If necessary, use an 5. Remove the snap ring from the output shaft quill. inside jaw impact puller. 8. If necessary, remove the snap ring from the OD of the 6. Use a puller or pry bars to pull the range mainshaft shaft.
  • Page 62 Removal and Disassembly of the Deep Reduction Shift Cylinder 1. Cut the lockwire and turn out the lockscrew from the shift yoke. 4. Remove the yoke bar from the housing. Remove the O-ring from the bar. 2. Pull the shift yoke and clutch forward and from the auxiliary housing.
  • Page 63 Removal and Disassembly of the Output Shaft Assembly 1. Turn out the capscrews and remove the rear bearing 4. Use a soft bar and mall to drive the output shaft forward housing. If necessary, remove the oil seal from the hous- and from the auxiliary housing.

  • Page 64: Inspection

    Inspection Before reassembling the transmission, the individual parts should be carefully checked to eliminate those damaged from previous service. This inspection procedure should be carefully followed to insure the maimum of wear life from the rebuilt unit. The cost of a new part is generally a small fraction of the total cost of downtime and labor, should the use of a questionable part make additional repairs necessary before the next regularly scheduled overhaul.
  • Page 65 G. Clutch Release Parts 2. If housing is dismantled, check pivot pin and cor- 1. Check clutch release parts. Replace yokes worn at responding slot in lever for wear. Replace both parts cam surfaces and gearing if worn. carrier worn at contact pads.

  • Page 66: Torque Ratings

    Torque Ratings Recommended torque ratings, location and thread sizes of capscrews and nuts are listed below.Capscrew lengths are given for reference purposes as a guide for installation at proper locations. Correct torque application is extremely important to assure long transmission life and dependable performance. Over-tighten- ing and under-tightening can result in a loose installation and.
  • Page 67 N U T S Torque Rating Location Qty . Thread Size Foot-Pounds Reverse Idler Shafts 75-80 5/18-18 Range Shift Piston 5/8-18 70-85 Clutch Housing to Case 180-190 5/8-18 250-300 Drive Gear 2-1/8-16 Companion Flange or Yoke 2-16 450-500 Location of Gaskets 10.
  • Page 68 General Precautions for Reassembly IMPORTANT: Read this section before starting the detailed reassembly procedures. Make sure that interiors of case and housings are clean. It is BEARINGS - Use o f flanged-end bearing drivers is important that dirt be kept out of transmission during re- recommended for the installation of bearings.

  • Page 69: Reassembly Instructions

    REASSEMBLY INSTRUCTIONS 1. Auxiliary Section - RT-1110 Series Reassembly of the Output Shaft and Rear Bearing Assembly 2. Install the splined spacer on the shaft, large diameter 1. Set the output shaft on bench with threaded end up and install the stepped washer, large diameter down. down.
  • Page 70 Reassembly of the Output Shaft Assembly - continued 3. If previously removed, install the snap ring in the ID of 6. Install the bearing inner spacer on the shaft. the low speed gear and install the gear on-the shaft, flat side up.
  • Page 71 Reassembly and Installation of the Synchronizer Assembly 1. Place the larger low speed ring on the bench with the pins upward and install the sliding clutch on the ring, protruding clutching teeth down. Apply pressure to the direct ring while twisting counter- clockwise to fully seat the direct ring on the low speed ring pins.

  • Page 72: Output Shaft

    Timing and Installation of the Auxiliary Countershafts and Output Shaft 1. On the small diameter low range gear of each counter- 3. Install the output shaft assembly on the synchronizer, shaft, mark the tooth which is stamped with an "O". meshing the splines of the shaft with the synchronizer.
  • Page 73 5. Place the auxiliary housing down over the assembly, cen- tering the countershafts in the rear bearing bores. 8. Install the countershaft rear bearings on the shafts and in the bores. 6. Heat the rear bearing cone and install it on the output shaft, taper facing down.
  • Page 74 Installation of the Range Shift Cylinder Assembly 1. Install the housing in a vise in the upright position. 3. Install the O-rings in the OD and ID of the piston. Install O-ring in the cylinder bore and secure the housing to the rear housing with four capscrews.
  • Page 75 5. Install the shift cylinder cover with the air line fitting to the top left.
  • Page 76 11. Auxiliary Section - RT-12510 Series Reassembly of the Output Shaft and Rear Bearing Assembly 2. Mark any two adjacent teeth on the low speed gear and 1. Place the output shaft on a bench with the threaded end then mark the two teeth directly opposite. up and install the splined spacer on the shaft, large diameter down.
  • Page 77 3. Install the low speed gear on the shaft with the clutching 5. Heat and install the front bearing cone on the shaft and teeth down and engaging the splines of the spacer. against the washer, taper facing up. NOTE: Heating of the bearing will facilitate installation. Do not heat the bearing over 275 4.
  • Page 78 Reassembly of the Output Shaft and Rear Bearing Assembly - continued Place the bearing rear cup on the outer spacer and evenly Place the front cup of the bearing assembly in the plate tap the cup into the plate bore until the lip of the cup bore with the taper to the inside.

  • Page 79: Output Shaft

    Heat and install the rear bearing cone, taper to the Install the rear bearing housing over the output shaft reside. and against the rear plate. If the transmission is equipped with a speedometer drive gear, the gear must NOTE: Heating of the bearing will facilitate installa- be installed on the output shaft prior to installation of tion.
  • Page 80 Reassembly and installation of the Synchronizer Assembly 1. Place the larger (low speed) brass synchronizer ring on a bench with the pins facing up and install the sliding clutch gear over the ring, protruding clutching teeth down. Apply pressure to the direct ring while twisting counter- clockwise to fully seat the direct ring on the low speed ring pins.
  • Page 81 Timing and Installation of the Auxiliary Countershaft Assemblies On the small diameter low range gear of each counter- shaft, mark the tooth which is stamped with an "O". 3. Install the snap ring on the rear of each countershaft. Place one of the countershaft into position in the rear plate, meshing the marked tooth on the countershaft between two of the marked teeth on the low speed gear.
  • Page 82 Installation of the Range Shift Cylinder Assembly 1. If previously removed, install the O-ring in the bore of 3. Insert the two yoke lockscrews; tighten and wire the cylinder housing and install the housing in the rear securely. plate bore, air fitting to the top right. Secure with the four capscrews.
  • Page 83 5. Install the piston on the bar, flat side out and secure 6. Install the shift cylinder cover on the housing with the with the elastic stop nut. air fitting to the top left.
  • Page 84 IIl. Auxiliary Section - RT-12515 Series Reassembly of the Output Shaft and Rear Bearing Assembly 2. Install the splined spacer on the shaft. 1. Place the output shaft on blocking with the threaded end up. Use caution to avoid damage to the quill.
  • Page 85 5. Install the washer on the shaft and against the gear with 3. Mark any two adjacent teeth on the reduction gear and the side with the large groove facing up. then mark the two teeth directly opposite. 6. Install the oil deflector in the rear housing bore with the cupped surface facing up.
  • Page 86 Reassembly of the Output Shaft Assembly - continued 9. Install the bearing inner spacer on the shaft and against 7. Install the rear housing over the output shaft, allowing the front bearing cone. the housing to rest on the reduction gear. 10.
  • Page 87 13. Install the speedometer drive gear or replacement 11. Tap the two cups and outer spacer lightly and evenly spacer on the shaft and against the rear bearing cone. into the case bore until the lip of the rear cup seats against the machined surface.
  • Page 88 Reassembly of the Output Shaft Assembly - continued 15. If previously removed, install the oil seal in the rear 16. Install the rear bearing housing on the auxiliary hous- bearing housing with the side of the seal with the seam ing, making sure that the oil port in the auxiliary facing into the housing.
  • Page 89 Installation of the Range Mainshaft Assembly 3. Install the range mainshaft on the output shaft quill. Install the clutch gear on the shaft, internal clutching teeth to the rear. 4. Install the bearing on the quill and in the range main- shaft.

  • Page 90: Deep Reduction Shift Cylinder

    Reassembly and Installation of the Deep Reduction Shift Cylinder 1. Install an O-ring in the bore of the shift cylinder and 3. Install the O-ring in the yoke bar groove and push the install the cylinder in the auxiliary housing with the air yoke bar forward and through the cylinder housing and channel to the right.
  • Page 91 Installation of the Low Range Gear 3. Install the splined washer on the shaft and in the hub of 1. Install the coupler on the shaft, large diameter to the the gear. Turn the washer to lock the gear on the shaft. rear.
  • Page 92 Reassembly and Installation of the Synchronizer Assembly 1. Place the larger low speed ring on the bench with the pins upward and install the sliding clutch on the ring, protruding clutching teeth down. 4. Apply pressure to the direct ring while twisting counter- clockwise to fully seat the direct ring on the low speed ring pins.
  • Page 93 Timing and Installation of the Auxiliary Countershaft Assemblies 3. Install the snap ring in the groove on the rear of each 1. Mark the tooth which is stamped with an "O" on each of the three sets of gears on the auxiliary countershaft. countershaft.
  • Page 94 Reassembly and Installation of the Range Shift Cylinder 1. Install the O-ring in the bore of the shift cylinder and 2. Hold the shift yoke in position on the sliding clutch with install the cylinder housing in the rear housing with the the long hub of the yoke to the rear and insert the yoke air line fitting to the top.
  • Page 95 5. Install the elastic stop nut on the bar and tighten se- 3. Install the O-rings in the O D and ID of the piston. curely. 6. Install the cover on the shift cylinder with the air fitting 4. Install the piston on the bar with the flat face out. to the top left.

  • Page 96: Front Section

    IV. Front Section Reassembly and Installation of the Right Reverse Idler Gear Assembly NOTE: Check to make sure that the three magnetic discs are solidly in place in the bottom of the case. These can be installed with "3M Brand" adhesive, No. EC 1300.
  • Page 97 4. Install the auxiliary countershaft front bearing in the 3. Seat the shaft securely in the bore, maliing sure that the bore with a bearing driver. needle bearings are positioned properly on the inner race before moving the shaft forward. Secure the shaft with the washer and elastic stop nut.
  • Page 98 Reassembly of the Countershaft Assemblies NOTE: Except for the number of teeth on the PTO gears, the countershaft are identical and assembled in the same manner.

  • Page 99: Drive Gear

    1. If previously removed, install the key in the keyway with the beveled end of the key away from the gears. 4. Press the 4th speed or O/D gear onto the haft with the long hub of the gear facing down. 2.
  • Page 100 Timing and Installation of the Countershaft Assemblies 1. On the drive gear of each countershaft, mark the gear 3. Place the right countershaft into position in the case, but tooth which aligns with the keyway in the shaft. This do not install bearings. Make sure that the right counter- tooth will be-stamped with an "O".
  • Page 101 Reassembly of the Drive Gear Assembly 1. Install the snap ring in the groove in the ID of the drive gear. NOTE: Make sure that the busing is installed in the pocket of the input shaft. 2. Install the drive gear on the shaft, engaging the internal with the shield 4.
  • Page 102 Reassembly of the Drive Gear Assembly - continued 6. Install the bearing nut on the shaft with 250-300 ft. lbs. 7. Peen the nut into the two milled slots of the shaft. of torque. NOTE: To hasten hardening of the Loctite, place the assembly under heat lamps 10 to 15 minutes.
  • Page 103 E. Timing and Installation of the Drive Gear Assembly 1. Mark any two adjacent teeth on the drive gear and then 3, Install the snap ring in the groove in the drive gear bear- mark the two teeth directly opposite. ing.
  • Page 104 Timing of the Left Countershaft Assembly Remove the blocking and install the front bearing on the 1. Use blocking to center the f rent of the left countershaft t countershaft and in-the case bore. Make sure that the in the case bore. timing teeth are still meshed Mesh the marked tooth of the left countershaft drive gear with two of the marked teeth of the main drive...
  • Page 105 Setting Correct Axial Clearances For Mainshaft Gears Axial Clearance (End Play) Limits Are: Reverse speed gear - Minimum of .005" Forward speed gears - .005" to .012" Washers are used to obtain the correct limits; six thick- nesses are available as follows: LIMITS COLOR CODE .248 -.250...
  • Page 106 Reassembly of the Mainshaft Assembly If previously removed, install the snap ring in the groove Install the spacer on the washer, stepped side up. in ID of all mainshaft gears except the reverse gear and mount the mainshaft in a vise with the pilot (front) end down, making sure that the roll pin is in place in the keyway.
  • Page 107 7. Remove the key and install the 3rd speed gear washer on 5. Install the 3rd speed gear on the 4th speed gear, clutch- the shaft and in the gear. Turn the washer to align the ing teeth up. large slot with the keyway. Lock the washer in place with the key.
  • Page 108 Reassembly of the Mainshaft Assembly - continued Install the 2nd speed gear washer on the shaft, flat side Install the 2nd speed gear on the shaft against the up, turn to align the large slot with the keyway and lock stepped spacer, clutching teeth down.
  • Page 109 13. Install the 1st speed gear spacer on the shaft and in the 15. Align the large slot with the keyway and install the lst-reverse speed sliding clutch. gear, flat side up. 16. Remove the key and install the reverse gear washer on 14.
  • Page 110 Reassembly of the Mainshaft Assembly - continued 18. Install the sliding clutch gear on the front of the main- 17. Install the reverse gear on shaft and against the 1st shaft. speed gear, engaging spIines of the sliding clutch gear. Remove the assembly from the vise and install the reverse gear spacer on the shaft, flat side forward.
  • Page 111 Installation of the Mainshaft Assembly and Right Countershaft 1. Block the right countershaft assembly against the side of the case, move the reverse gear on the mainshaft forward and against the mainshaft 1st speed gear and lower the mainshaft assembly, rear end first, into the case. Slide the mainshaft forward, installing the f rent of the shaft in the bushing in the input shaft.
  • Page 112 Reassembly and installation of the Left Reverse Idler Gear 1. Install plug in everse idler shaft. 3. Hold the gear and thtust washer in place in the case with the thrust washer between the gear and housing boss and the idler gear meshed with the teeth of the countershaft reverse gear.
  • Page 113 Final Installation of the Mainshaft Assembly Move the reverse gear as far as possible to the rear, 3. Move the reverse gear forward on the shaft and into against the wall of the case and mesh teeth with those of correct position.
  • Page 114 Reassembly and installation of the Auxiliary Drive Gear Assembly 1. Install the retainer ring on the gear with the groove in Install the bearing on the gear with the snap ring facing the ring facing away from the gear. the groove in the retainer. Tap lightly on the inner race of the bearing with a soft bar and mall.
  • Page 115 5. Install the snap ring on the end of the mainshaft. 3. Install the snap ring in the drive gear groove to secure the bearing to the gear. Install the auxiliary drive gear on the end of the main- shaft and use a driver and mall to seat the bearing in the bore.

  • Page 116: Companion Flange, Auxiliary Housing And

    V. Companion Flange, Auxiliary Housing and Clutch Housing Installation of the Clutch Housing 1. Install the clutch housing on the six studs on the front 2. Install the lockwashers and nuts on the studs and install of the case. Move the housing evenly against the case the four bolts in the housing.
  • Page 117 Installation of the Companion Flange or Yoke Secure the flange or yoke with the elastic stop nut, and 1. Lock the mainshaft in two speeds and install the speed- washer tightening with a torque wrench to 450-500 ometer drive gear on the replacement spacer on the ft./lbs.
  • Page 118 VI. Shifting Controls Reassembly of the Shift Bar Housing Assembly...
  • Page 119 3. Insert an interlock ball in the case boss. 1. Mount the shift bar housing in a vise and hold the 1st-reverse speed yoke in the indicated position. Insert the 1st-reverse shift bar throught the housing boss and the yoke with the end of the bar with the three notched entering the boss last.
  • Page 120 Reassembly of the Shift Bar Housing Assembly - continued Insert an interlock ball in the case boss and install the 7. Remove the housing from the vise and install the three 4th-5th speed shift yoke and block on the bar as it is tension balls in the bores.
  • Page 121 Reassembly of the Gear Shift Lever Housing Assembly Install the tension spring washer in the housing. 1. Install the O-ring in the top of the housing. 2. Install the pivot pin in the housing, threaded end out, and secure with the nut and lockwashers. 5.

  • Page 122: Air System

    Reassembly-Air System Reassembly of the Air System 1. Install the adapter plat on the front case. Use the align- Install the air valve on the adapter plate, tightening the ment sleeve to make sure that the bore in the adapter four capscrews evenly.
  • Page 123 Reassembly-Air System 9. Connect the black and white 1/8" OD air lines to the control valve as indicated. 7. Connect the two 1/4" ID air lines between the air valve and the range shift cylinder. The front fitting on the shift cylinder is connected to the bottom fitting on the air valve side cap (arrow), and the rear fitting on the shift cylinder is connected to the rear bore on the air...

  • Page 124: Tool Reference

    Write: Print Number T-18088-36 (RT-1110) Used to install the oil seal in the rear bearing housing. Service Department / Eaton Corporation / Transmission Division / 222 Mosel Avenue/ Kalamazoo, Michigan 49007 AUXILIARY PLATE HANGER BRACKET...
  • Page 126 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.

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Rtx-12515Rtxf-12510Rtxf-12515

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