Eaton TRSM0020 Service Manual
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Eaton TRSM0020 Service Manual

Fuller automated transmissions
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Service Manual
Fuller Automated Transmissions
TRSM0020
October 2007
RT-11109A-AT
RT-11109A-ATR
RT-11109A-ATS
RT-12109A-AT
RT-14109A-ATS
RTO-11109A-AT
RTO-11109A-ATS
RTO-11109B-AT
RTO-11109B-ATE
RTO-11109B-ATR
RTO-11109B-ATS
RTO-12109A-AT
RTO-12109B-AT
RTO-13109A-ATE
RTO-13109B-AT
RTO-13109B-ATE
RTO-14109A-ATE
RTO-14109A-ATS
RTO-14109B-AT
RTO-14109B-ATE
RTO-14109B-ATS
RTO-16109A-AT
RTO-16109A-ATE
RTO-16109B-AT
RTO-16109B-ATE
RTO-9109A-AT
RTO-9109B-AT

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  • Page 1 Service Manual Fuller Automated Transmissions TRSM0020 October 2007 RT-11109A-AT RTO-13109B-AT RT-11109A-ATR RTO-13109B-ATE RT-11109A-ATS RTO-14109A-ATE RT-12109A-AT RTO-14109A-ATS RT-14109A-ATS RTO-14109B-AT RTO-11109A-AT RTO-14109B-ATE RTO-11109A-ATS RTO-14109B-ATS RTO-11109B-AT RTO-16109A-AT RTO-11109B-ATE RTO-16109A-ATE RTO-11109B-ATR RTO-16109B-AT RTO-11109B-ATS RTO-16109B-ATE RTO-12109A-AT RTO-9109A-AT RTO-12109B-AT RTO-9109B-AT RTO-13109A-ATE...
  • 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 Warnings & Precautions General Information Model/Assembly Reference External Parts Shift Bar Housing Front Section Auxiliary Section Options...

  • Page 6: Table Of Contents

    Section 1: Warnings and Precautions Warning WARNING ..........11 Precautions Disassemble Assemblies .

  • Page 8: Warning

    WARNING Before starting a vehicle always be seated in the drivers seat, place the transmission in neutral, set the parking brakes. Before working on a vehicle place the transmission in neutral, set the parking brakes and block the wheels. Before towing the vehicle place the transmission in neutral and lift the drive wheels off the ground or disconnect the driveline to avoid...

  • Page 9: Precautions

    Precautions Disassemble It is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission, the necessary linkage, cooler lines, and air lines disconnected, and the transmission has been removed from vehicle chassis. Removal of the gear shift cable and electrical harness is included in the detailed instructions;...

  • Page 10: When Using Tools To Move Parts

    Inspection Before assembling the transmission, check each part carefully for abnormal or excessive wear and damage to determine reuse or ® replacement. When replacement is necessary, use only genuine Eaton ® Fuller Transmission parts to assure continued performance and extended life from your unit.

  • Page 11: Gears

    Precautions Inspection Gears 1. Check gear teeth for frosting and pitting. Frosting of gear teeth faces presents no threat of transmission failure. Often in continued operation of the unit, frosted gears “heal” and do not progress to the pitting stage. In most cases, gears with light to moderate pitted teeth have considerable gear life remaining and can be reused, but gears in the advanced stage of pitting should be replaced.

  • Page 12: Shift Bar Housing Assembly

    Precautions Inspection Shift Bar Housing Assembly 1. Check for wear on shift yokes and blocks at pads and lever slot. Replace excessively worn parts. 2. Check yokes for correct alignment. Replace sprung yokes. 3. Check lockscrews in yoke and blocks. Tighten and rewire those found loose.

  • Page 13: Assemble

    Capscrews To prevent oil leakage and loosening, use Eaton/Fuller sealant #71211 or equivalant on all capscrews. For torque ratings, use the torque recommendations through out the service manual.
  • Page 14 Section 2: General Information How to Use This Manual Model Designation Lubrication Maintain Proper Oil Level Draining Oil Refilling Flush Procedure Maintenance Interval Chart Recommended Lubricant Chart Transmission Operating Angles Operating Temperatures with Oil Coolers Power Flow Torque Converter Mode: LO Range Torque Converter Mode: Lockup Mode Auxiliary Section: HI Range Timing...
  • Page 16 " air fittings that are not coated with pre-applied thread sealant must be coated with Procedures that need to be done before performing the Eaton sealing material #71209 or equivalent for at least 3 complete and consecutive threads. topic covered. Hints that will make the procedure ⁄...
  • Page 17 How to Use This Manual As mentioned on the previous page, the flow charts Auxiliary represent the order in which the transmission should Section be disassembled or assembled. The following is an example of how to disassemble the Range auxiliary section, specifically the synchronizer Cylinder Assembly assembly.
  • Page 18 Model Designation Transmission model designation and other transmission identification information are stamped on the transmission tag. To identify the transmission model designation and serial number, locate the tag on the transmission and then locate the numbers as shown. Do not remove or destroy the transmission identification tag.
  • Page 19 2. Change oil and filters regularly. • Use the correct grade and type of oil. • Buy oil from a reputable dealer. Additives and friction modifiers are not recommended for use in Eaton Fuller Transmissions. 1. Maintain Proper Oil Level...
  • Page 20 Lubrication 2. Draining Oil Drain transmission while oil is at ambient temperature (65°F ± 20). To drain oil, remove the main case drain plug and the converter housing oil pan drain plug. Clean the drain plugs and flush the cooler circuit before re-installing.
  • Page 21 Lubrication 4. Flush Procedure 1. Disconnect the transmission cooler supply line between the transmission outlet and the oil cooler, (not between the cooler and the transmission oil pan). 2. With clean dry air from a hose and nozzle (20 psi), use a rubber stopper or clean rag to seal the air hose to the converter outlet hose.
  • Page 22 Lubrication 5. Maintenance Interval Chart Lubrication Change and Inspection HIGHWAY USE First 1,000 to 1,500 miles Change transmission oil, filter, and strainer on new units. Every 2,500 miles Inspect lubrication level. Check for leaks. Every 50,000 miles or 1 year Change transmission lubricant and filter.
  • Page 23 Lubrication 7. Buy from a reputable dealer For a complete list of approved and reputable dealers, write to: Eaton Corporation Truck Component Marketing Headquarters P.O. Box 4013 Kalamazoo, MI 49003 Transmission Operating Angles If the transmission operating angle is more than 12 degrees, improper lubrication can occur.
  • Page 24 Lubrication Operating Temperatures with Oil Coolers An external oil cooler is required on the automatic transmission in order to maintain proper operating temperatures*. Transmission oil temperature is sensed from the torque converter outlet port before the oil enters the cooler. Normal operating temperature, when sensed from the torque converter outlet port, should be below 250°F;...
  • Page 25 Power Flow The transmission must efficiently transfer the engine's power to the vehicle's driveline. Knowledge of what takes place in the transmission is helpful when troublshooting and making repairs. Torque Converter Mode: LO Range Power (torque) from the vehicle's engine is transferred to the torque converter's splined cover.
  • Page 26 Power Flow Input shaft splines engage the internal splines in the main drive gear hub. Torque is split between the two countershaft drive gears. Torque is delivered along both countershafts to mating countershaft gear of the "engaged" mainshaft gear (1st gear in this example). The internal clutching teeth in the engaged mainshaft gear hub transfers torque to the mainshaft through the sliding clutch.
  • Page 27 Power Flow Torque Converter Mode: Lockup Mode Power (torque) from the vehicle's engine is transferred to the torque converter's splined cover. The splined cover is connected to the lockup clutch. The lockup clutch is splined directly to the interrupt clutch outer hub. When the lockup clutch is activated, the interrupt clutch is driven directly from the engine.
  • Page 28 Power Flow Auxiliary Section: HI Range Input shaft splines engage the internal splines in the main drive gear hub. Torque is split between the two countershaft drive gears. Torque is delivered along both countershafts to mating countershaft gear of the "engaged" mainshaft gear.
  • Page 29 Timing Timing Procedures It is essential that both countershaft assemblies of the front and auxiliary sections are "timed." This assures proper tooth contact is made between mainshaft gears seeking to center on the mainshaft during torque transfer and mating countershaft gears that distribute the load evenly.
  • Page 30 Timing Timing Procedures (cont) C. Meshing marked countershaft drive gear teeth with marked main drive gear teeth. (After placing the mainshaft assembly into the case, the countershaft bearings are installed to complete installation of the countershaft assemblies.) 1. When installing the bearings on the left countershaft, mesh the countershaft drive gear marked tooth with either set of main drive gear two marked teeth.
  • Page 31 Eaton Fuller Transmission. The specialized tools can be obtained from a tool supplier or made from tool prints as required by the individual user.
  • Page 32 Preventive Maintenance Everyday there are countless vehicles operating over the highways with transmissions in such a neglected mechanical condition, they can be referred to as failures looking for a place to break down. They lack a proper and organized preventive maintenance program. Preventive maintenance is a general term which applies to all procedures necessary to have maximum life and satisfactory service at the lowest possible cost, short of...
  • Page 33 Preventive Maintenance Checks Before Transmission Removal 1 Air System and Connections (not shown) 4 Drain Plugs Annually replace the filter/regulator element. If Tighten the drain plugs securely. Tighten the excessive contamination is present, service main case drain plug to 45-50 Lb ·ft of torque.
  • Page 34 Preventive Maintenance Checks with Drive Line Dropped 6 Universal Joint Companion Flange or Yoke Nut 7 Output Shaft Check for tightness. Tighten to recommended Pry upward against output shaft to check radial torque. clearance in mainshaft rear bearing. Checks With Universal Joint Companion Flange or Yoke Removed NOTE: If necessary, use solvent and shop rag to clean sealing surface of companion flange or yoke.
  • Page 36 Section 3: Model/Assembly Reference CEEMAT-AT CEEMAT-ATR CEEMAT-ATS CEEMAT-ATE...
  • Page 37 CEEMAT-AT Remove/ Install/ Disassemble Assemble (page numbers) External Parts Air System Air Supply Hoses for the Power Synchronizer Air Supply Hose for LO and HI Range Air Filter/Regulator Slave Valve Lube System Lube Supply Hose for the Power Synchronizer 14 Oil Pan/Strainer Oil Filter Synchronizer System...
  • Page 38 CEEMAT-AT Remove/ Install/ Disassemble Assemble (page numbers) Shift Bar Housing Shift Bar Housing Front Section Auxiliary Drive Gear Assembly 4, 6 5, 7 Reverse Idler Gear Assembly Countershaft Assembly Countershaft Bearings Countershaft Assembly 12, 14 13, 15 Mainshaft Assembly (may have 3 grooves) 16, 18 17, 19 Input Shaft Assembly...
  • Page 39 CEEMAT-ATE Remove/ Install/ Disassemble Assemble (page numbers) External Parts Air System Air Supply Hoses for theInertia Brake Air Supply Hose for LO and HI Range Air Filter/Regulator Slave Valve Lube System Lube Supply Hose for the Inertia Brake Oil Pan/Strainer Oil Filter Synchronizer System Inertia Brake...
  • Page 40 CEEMAT-ATE Remove/ Install/ Disassemble Assemble (page numbers) Shift Bar Housing Shift Bar Housing Front Section Auxiliary Drive Gear Assembly 4, 6 5, 7 Reverse Idler Gear Assembly Countershaft Assembly Countershaft Bearings Countershaft Assembly 12, 14 13, 15 Mainshaft Assembly (may have 3 grooves) 16, 18 17, 19 Input Shaft Assembly...
  • Page 42 Section 4: External Parts Air System How to Remove the Air Supply Hoses for the Power Synchronizer How to Install the Air Supply Hoses for the Power Synchronizer How to Remove the Air Supply Hose for the Inertia Brake How to Install the Air Supply Hoses for the Inertia Brake How to Remove the Air Supply Hoses for LO and HI Range How to Install the Air Supply Hoses for LO and HI Range How to Remove the Air Filter/Regulator...
  • Page 43 Shift Bar Housing How to Remove the Shift Bar Housing Cover How to Install the Shift Bar Housing Cover How to Remove the Autoshift Harness How to Install the Autoshift Harness How to Remove the Autoshift Assembly How to Install the Autoshift Assembly How to Remove the Shift Bar Housing How to Install the Shift Bar Housing Torque Converter...
  • Page 45 Air System How to Remove the Air Supply Hoses for the Power Synchronizer Special Instructions Before removing the air hoses, label or record their location. Special Tools Typical service mechanic tools To Remove Remove the capscrew holding the air hose clamp to the auxiliary housing.
  • Page 46 All externally threaded ⁄ " air fittings that are not coated with pre-applied thread sealant must be coated with Eaton sealing material #71209 or equivalent for at least 3 complete and consecutive threads. For the ⁄ " I.D. air hoses, install the fixed nut end first.
  • Page 47 Air System How to Remove the Air Supply Hose for the Inertia Brake Special Instructions Before removing the air hose, label or record its location. Special Tools Typical service mechanic tools To Remove If necessary, remove the capscrew holding the air hose to the auxiliary housing.
  • Page 48 All externally threaded ⁄ " air fittings that are not coated with pre-applied thread sealant must be coated with Eaton sealing material #71209 or equivalent for at least 3 complete and consecutive threads. For the ⁄ " I.D. air hoses, install the fixed nut end first.
  • Page 49 Air System How to Remove the Air Supply Hoses for LO and HI Range Special Instructions Before removing the air hoses, label or record their location. Special Tools Typical service mechanic tools To Remove Disconnect the slave valve LO range supply port air hose.
  • Page 50 All externally threaded ⁄ " air fittings that are not coated with pre-applied thread sealant must be coated with Eaton sealing material #71209 or equivalent for at least 3 complete and consecutive threads. For the ⁄ " I.D. air hoses, install the fixed nut end first.
  • Page 51 Air System How to Remove the Air Filter/Regulator Special Instructions The air filter/regulator has two (2) O-rings located between the filter/regulator and the shift bar housing cover. Special Tools Typical service mechanic tools needed To Remove From the air filter/regulator, remove the two (2) H/49-3 capscrews.
  • Page 52 ·ft of torque. On the shift bar cover, position the two (2) O- rings. Over the O-rings, position the air filter/regulator. Apply Eaton/Fuller Sealant #71205 or equivalent to the two (2) retaining capscrews. Install the two (2) retaining capscrews, tighten to H/49-3 8-12 Lb ·ft of torque.
  • Page 53 Air System How to Remove a Slave Valve Special Instructions The air lines should be removed. Special Tools Typical service mechanic tools needed To Remove Remove the retaining capscrews. From the shift bar cover, remove the slave valve and gasket. You may need to use a plastic H/49-4 hammer to remove.
  • Page 54 Range Valve Position the corresponding new gasket on the slave valve mounting surface. Position the slave valve over the gasket. Apply Eaton/Fuller Sealant #71205 or equivalent to the retaining capscrews. Install the retaining capscrews. Tighten to 8-12 ·ft of torque.
  • Page 55 Lube System How to Remove the Lube Supply Hose for the Power Synchronizer Special Instructions Before removing the lube hose, label or record its location. Special Tools Typical service mechanic tools To Remove Disconnect the lube hose from the power synchronizer.
  • Page 56 Lube System How to Install the Lube Supply Hose for the Power Synchronizer Special Instructions Make sure lube hose is not damaged. 2, 3 Install the lube hose at its proper location. Special Tools Typical service mechanic tools To Install If previously removed, install a new oil restrictor.
  • Page 57 Lube System How to Remove the Lube Supply Hose for the Inertia Brake Special Instructions Before removing the lube hose, label or record its location. Special Tools Typical service mechanic tools To Remove Disconnect the lube supply hose connected to the inertia brake.
  • Page 58 Lube System How to Install the Lube Supply Hoses for the Inertia Brake Special Instructions Make sure lube hose is not damaged. 1, 2 Install the lube hose at its proper location. Special Tools Typical service mechanic tools To Install If previously removed, install a new oil retrictor.
  • Page 59 Lube System How to Remove the Oil Tube and Oil Pan/Strainer Special Instructions Special Tools Typical service mechanic tools ⁄ " - 12 Point socket To Remove Disconnect the return tube from the oil pan and H/49-8 H/49-9 transmission. From the oil pan, remove the retaining capscrews. Remove the oil pan.
  • Page 60 Lube System How to Install the Oil Tube and Oil Pan/Strainer Special Instructions If the magnet needs to be replaced, use adhesive #71210 or equivalent and cover the entire mating surface. Special Tools Typical service mechanic tools To Install If previously removed, install the strainer H/50-2 capscrews.
  • Page 61 Lube System How to Remove the Oil Filter Special Instructions Special Tools Typical service mechanic tools To Remove Remove the three (3) retaining capscrews. Remove the oil filter housing and O-ring seal. H/50-5 Remove the oil filter by pulling it straight off. Inspect the oil filter nipple, remove if damaged.
  • Page 62 Lube System How to Install the Oil Filter Special Instructions Depending on the orientation (vertical or horizontal), grease may be needed to hold the seal ring on the filter housing. Special Tools Typical service mechanic tools To Install If removed, apply hydraulic sealant and replace H/50-8 the oil filter nipple.
  • Page 63 Synchronizer Systems How to Remove the Power Synchronizer Special Instructions There are different capscrew lengths, note their location. The hoses need to be disconnected. Special Tools Typical service mechanic tools To Remove From the power synchronizer, remove the H/28-2 mounting capscrews. Remove the power synchronizer and gasket.
  • Page 64 Synchronizer Systems How to Install the Power Synchronizer Special Instructions There are different capscrew lengths, make sure they are in their proper location. Special Tools Typical service mechanic tools To Install If previously removed, install a new roll pin in the middle mounting position.
  • Page 65 Shift Bar Housing How to Remove the Shift Bar Housing Cover Special Instructions Before removing the shift bar housing cover, the air hoses must be disconnected. Removal of the air filter/regulator and the slave valve can be done before removing the shift bar cover. There are different capscrew lengths, note their location.
  • Page 66 5, 6 connector. Use the alignment pins and set the shift bar housing cover in place. Apply Eaton/Fuller Sealant #71205 or equivalent H/46-7 to the retaining capscrews or use dyna seals Install the retaining capscrews with washers. Tighten to 23-30 Lb ·ft of torque.
  • Page 67 Shift Bar Housing How to Remove the Autoshift Harness Special Instructions Make sure all labels are in the right place. Note locations and positions of terminals and connectors. Use the removal tool included on the harness to disconnect the in-line connectors. Special Tools Typical service mechanic tools needed H/46-9...
  • Page 68 Shift Bar Housing How to Install the Autoshift Harness Special Instructions Make sure all labels are in the right place. Note locations and positions of terminals and connectors. When connecting the in-line connectors, make sure the wire locks into position. To check, pull gently on the wires;...
  • Page 69 Shift Bar Housing How to Remove the Autoshift Assembly Special Instructions Make sure all labels are in the right place. KEEP WIRES Note locations and positions of terminals and THIS AREA connectors. Use the removal tool included on the harness to disconnect the in-line connectors.
  • Page 70 Shift Bar Housing How to Install the Autoshift Assembly Special Instructions Make sure all labels are in the right place. KEEP WIRES Note locations and positions of terminals and THIS AREA connectors. When connecting the in-line connectors, make sure the wire locks into position.
  • Page 71 Shift Bar Housing How to Remove the Shift Bar Housing Special Instructions Before removing the shift bar housing, the shift bar housing cover and autoshifter must be removed. Special Tools Typical service mechanic tools needed To Remove Inspect the input and output shaft magnetic speed sensors, remove if damaged or defective.
  • Page 72 Shift Bar Housing How to Install the Shift Bar Housing Special Instructions When installing the shift bar housing, make sure the auxiliary section is in LO range. Make sure the shift bar housing yokes are in the neutral position. Special Tools Typical service mechanic tools needed To Install H/11-9...
  • Page 73 Torque Converter How to Remove the Torque Converter Special Instructions Removal of the torque converter is done with the transmission in the vertical position. Special Tools Typical service mechanic tools are needed A hoist with a lifting chain To Remove Remove the pilot retaining capscrews.
  • Page 74 Torque Converter How to Install the Torque Converter Special Instructions Installation of the torque converter is done with the transmission in the horizontal position. When installing the torque converter pilot, do not damage the seal rings, O-ring, or input shaft seal rings. Special Tools Typical service mechanic tools are needed.
  • Page 75 Torque Converter How to Remove the Hydraulic Valve Special Instructions Removal of the hydraulic valve can be vertically or horizontally. Special Tools Typical service mechanic tools are needed To Remove Loosen the dip stick tube nut and remove the dip stick tube.
  • Page 76 How to Install the Hydraulic Valve Special Instructions Installation of the hydraulic valve can be vertically or horizontally. Liberally apply Eaton Lubricant #71230 or equivalent to the hydraulic valve stems where the magnetic coils sit. Special Tools Typical service mechanic tools are needed.
  • Page 77 Torque Converter How to Remove the Dip Stick Special Instructions Removal of the dip stick can be done in the vertical or horizontal position. Special Tools Typical service mechanic tools are needed To Remove Loosen the dip stick tube nut and remove the dip stick tube.
  • Page 78 Torque Converter How to Install the Dip Stick Special Instructions Installation of the dip stick can be done in the vertical or horizontal position. Special Tools Typical service mechanic tools are needed. To Install If previously removed, install the dip stick connector O-ring and connector.
  • Page 79 Torque Converter How to Remove the Torque Converter Housing Special Instructions Removal of the torque converter housing is done in the vertical position. Disconnect the torque converter and harness from ECU. Disconnect the hydraulic valve. Remove the synchronizer system lube line, the sump return tube, and the dipstick.
  • Page 80 How to Install the Torque Converter Housing Special Instructions Installation of the torque converter housing is done in the vertical position. Apply Eaton Lubricant #71214 to stator support O-ring. Cover entire surface. The O-ring is not used on 9109 Models. Special Tools Typical service mechanic tools are needed.
  • Page 81 Torque Converter How to Remove the Oil Pump Special Instructions The oil pump gear can be removed while removing the torque converter housing. The oil pump is a non-serviceable assembly and should be returned for service. The converter and converter housing must be removed before removing the oil pump gear.
  • Page 82 Torque Converter How to Install the Oil Pump Special Instructions The oil pump gear can be installed during the torque converter housing installation. When installing the oil pump, do not damage the O- rings and use grease. Special Tools Typical service mechanic tools are needed. To Install H/27-3 H/27-2...
  • Page 83 Torque Converter How to Remove the Filter Bypass Valve Special Instructions The hydralic valve must be removed. Special Tools Typical service mechanic tools are needed To Remove Use a hex socket to remove the filter bypass valve. H/52-5 Inspect the valve for damage, replace if damaged. H/52-6 How to Remove the HI Pressure Relief Valve Special Instructions...
  • Page 84 Torque Converter How to Install the Filter Bypass Valve Special Instructions The hydralic valve must be removed. Special Tools Typical service mechanic tools are needed To Install Use a hex socket to install the filter bypass valve. Tighten the valve to 26-32 Lb ·ft of torque.
  • Page 85 Output Yoke/Companion Flange How to Remove the Output Yoke/Companion Flange Special Instructions If no impact or special tools are available, the shift bar housing must be removed in order to lock the transmission. For proper cleaning and maintenance, see Form 193 “Rear Seal Maintenance Guide”.
  • Page 86 Output Yoke/Companion Flange How to Install the Output Yoke/Companion Flange Special Instructions If no impact or special tools are available, the shift bar housing must be removed in order to lock the transmission. For proper cleaning and maintenance, see Form 193 “Rear Seal Maintenance Guide”.
  • Page 87 Auxiliary Section How to Remove the Auxiliary Section Special Instructions There are different capscrew lengths, note their location. The auxiliary section should be removed with the transmission in the horizontal position. The range cylinder housing must be loosened to remove the auxiliary section.
  • Page 88 Remove the auxiliary section hanger bracket. Install the two (2) allen setscrews. Tighten to 35- 45 Lb ·ft of torque. Apply Eaton/Fuller Sealant #71205 or equivalent to the retaining capscrews. Install the retaining capscrews, tighten to 35-45 H/27-7 H/28-2 ·ft of torque.
  • Page 89 Auxiliary Section How to Remove the Rear Bearing Cover Assembly Special Instructions The rear bearing cover can be removed without disassembling the auxiliary section. Special Tools Typical service mechanic tools are needed To Remove Remove the retaining capscrews and the rear bearing cover and gasket.
  • Page 90 Because the collar becomes distorted when compressed, do not re-use an old nylon collar in the rear bearing cover. Apply Eaton Lubricant #71214 or equivalent to speedometer plug O-rings, cover the entire surface. If the electronic sensor hole has a seal, apply lubricant #71214 or equivalent, covering the top surface.
  • Page 92 Section 5: Shift Bar Housing Functions of a Shift Bar Housing Shift Bar Housing How to Disassemble the Shift Bar Housing How to Assemble the Shift Bar Housing Transmission appearance may differ, procedure is the same.
  • Page 94 Functions of a Shift Bar Housing Shift bar housings are a very important part of the transmission. No matter what kind of shift bar housing your transmission has, they all provide the same functions: √ Engage the transmission gearing, √ Prevents the driver from shifting into 2 gears at the same time.
  • Page 95 Shift Bar Housing How to Disassemble the Shift Bar Housing Special Instructions The shift bar housing must be removed from the transmission. During disassembly, lay all parts on a clean bench in order of removal to facilitate assembly. Shift bars not being removed must be kept in the neutral position or the interlocking parts lock the bars.
  • Page 97 How to Assemble the Shift Bar Housing Special Instructions Inspect shift blocks and shift yokes for wear. Apply Eaton lockwire #1819 or equivalent to all shift bar housing assembly set screws in both blocks and yokes. The wire should anchor the capscrew at least 2 complete 360°...
  • Page 98 Shift Bar Housing continued How to Assemble the Shift Bar Housing Holding the third bar notched-end, start installation. As the bar passes the rear boss, position the shift block. As the bar passes the center boss, position the shift yoke on bar, long hub to the housing front. Install the shift block and shift yoke lockscrews.
  • Page 100 Section 6: Front Section How to Disassemble the Front Section How to Assemble the Front Section Auxiliary Drive Gear Assembly How to Remove the Auxiliary Drive Gear Assembly How to Install the Auxiliary Drive Gear Assembly How To Disassemble the Auxiliary Drive Gear Assembly How To Assemble the Auxiliary Drive Gear Assembly Reverse Idler Gear Assembly How to Remove the Reverse Idler Gear Assembly...
  • Page 101 How to Disassemble the Front Section Remove Follow the solid line, then the dash/dot line, External then the dashed line Parts Auxiliary Disassemble Drive Gear Auxiliary Assembly Drive Gear Move Reverse Gear Reverse upper reverse idler gear Idler Gear Assembly upper countershaft Remove Disassemble...
  • Page 102 How to Assemble the Front Section Follow the solid line, Front then the dash/dot line, then the dashed line lower reverse idler gear Reverse upper reverse idler gear Idler Gear Assembly Assemble Countershafts lower countershaft bearings Countershaft Assemblies Install Countershaft Bearings Input Shaft Assemble...
  • Page 103 Auxiliary Drive Gear Assembly How to Remove the Auxiliary Drive Gear Assembly Special Instructions Before removing the auxiliary drive gear, the auxiliary section must be removed. Special Tools Typical service tools are needed Large pair of snap ring pliers To Remove Remove the mainshaft rear groove snap ring.
  • Page 104 Use a flanged-end driver and maul to seat the auxiliary drive gear bearing. Align the retainer ring capscrew holes with the tapped holes. Apply Eaton/Fuller sealant #71205 or equivalent to the retaining capscrews. Install the retaining capscrews, tighten to 23-30 H/32-3 ·ft of torque.
  • Page 105 Auxiliary Drive Gear Assembly How To Disassemble the Auxiliary Drive Gear Assembly Special Instructions To disassemble, the auxiliary drive gear must be removed. Special Tools Typical service tools are needed A large pair of snap ring pliers To Disassemble B/20-4 Lay the front auxiliary drive gear on a clean, flat surface.
  • Page 106 Auxiliary Drive Gear Assembly How To Assemble the Auxiliary Drive Gear Assembly Special Instructions Apply Eaton Lubricant #71214 or equivalent to the auxiliary drive gear O-rings. Special Tools Typical service tools are needed To Assemble If the O-rings were removed, apply lube and install on the drive gear.
  • Page 107 Reverse Idler Gear Assembly How to Remove the Reverse Idler Gear Assembly Special Instructions The following instructions are used to remove upper and lower reverse idler gears. Before the upper reverse idler gear assembly can be removed, mainshaft reverse gear must be positioned forward against the next gear.
  • Page 108 How to Install the Reverse Idler Gear Assembly Special Instructions If you are installing the bottom reverse idler gear assembly, make sure the three (3) magnetic discs are securely in place at case bottom. Use Eaton Adhesive #71210 or equivalent. Special Tools Typical service tools are needed...
  • Page 109 Countershaft Assembly How to Remove the Countershaft Bearings Special Instructions The following instructions are used to remove the upper and lower countershaft bearings. To remove the mainshaft assembly, only the upper countershaft bearings need to be removed. Performing the following instructions will damage the bearings and should be not be done unless bearing replacement is planned.
  • Page 110 Countershaft Assembly How to Install the Countershaft Bearings Special Instructions The front bearing inner race must be pressed on the countershaft front. The flanged-end driver must cover the bearing outer race for proper installation. Special Tools Typical service tools are needed Countershaft support tool B/21-7 Flanged-end driver and maul...
  • Page 111 Countershaft Assembly How to Remove the Countershaft Assemblies Special Instructions Except for the PTO gears the upper and lower countershaft assemblies are the same. Make sure and mark each as they are removed. Special Tools Typical service tools are needed To Remove Move the upper countershaft assembly to the B/19-1...
  • Page 112 Countershaft Assembly How to Install the Countershaft Assemblies Special Instructions Make sure the countershaft assemblies have been marked for proper position, 47-tooth PTO gear in the lower position. On the drive gear of each countershaft assembly, mark the tooth aligned with the gear keyway and stamped with an “O”...
  • Page 113 Countershaft Assembly How to Disassemble the Countershaft Assembly Special Instructions Never use the PTO gear as a pressing base. The narrow width of this gear can cause breakage. Special Tools Snap ring pliers Press To Disassemble From each countershaft front remove the drive B/19-2 gear retaining snap ring.
  • Page 114 Countershaft Assembly How to Assemble the Countershaft Assembly Special Instructions Except for the PTO gears, the upper and lower countershaft assemblies are the same. To avoid confusion during installation, mark the upper countershaft (45-tooth PTO gear) with an “U”. The lower countershaft has a 47-tooth PTO gear.
  • Page 115 Mainshaft Assembly How to Remove the Mainshaft Assembly Special Instructions Be careful when removing the mainshaft assembly, the sliding clutch on the end can slip off the mainshaft. Reverse gear is also free and can fall off the shaft. Special Tools Typical service tools are needed Large hook or 3 foot piece of rope B/14-6...
  • Page 116 Check to make sure the lower countershaft drive gear marked tooth is in time with main drive gear set of marked teeth. Apply Eaton Lubricant #71215 or equivalent to the mainshaft pilot bushing, cover the entire surface. Special Tools B/16-7...
  • Page 117 Mainshaft Assembly How to Disassemble the Mainshaft Assembly Special Instructions During disassembly, lay all parts on a clean bench in order of removal to facilitate reassembly. When removing limit washers, spacers and gears, note their location. Keep the internal-splined washers and external-splined spacers with the gear from which they were removed.
  • Page 118 Mainshaft Assembly How to Assemble the Mainshaft Assembly Special Instructions Each mainshaft gear must have its I.D. snap ring installed before placement on the mainshaft. Do not replace reverse gear I.D. snap ring. Gear limit washers are internally splined and locked to the mainshaft by the key.
  • Page 119 Mainshaft Assembly continued How to Assemble the Mainshaft Assembly Against the 4th speed gear washer, position the 4th speed gear spacer. With clutching teeth down and engaged with the spacer external splines, position the 4th speed gear on the mainshaft. With clutching teeth up and against 4th speed gear, install the 3rd speed gear and spacer.
  • Page 120 Mainshaft Assembly continued How to Assemble the Mainshaft Assembly Position 1st speed gear spacer against 1st speed gear, engaging the spacer external splines with gear clutching teeth. With washer flat side down, position the limit washer against the spacer. Rotate the washer until the washer splines and mainshaft splines align.
  • Page 121 Mainshaft Assembly continued How to Assemble the Mainshaft Assembly Remove the reverse gear snap ring from reverse gear hub. Position reverse gear on the mainshaft against 1st speed gear, align reverse gear splines with sliding clutch. At this time remove the air line and insert the mainshaft key.
  • Page 123 Input Shaft Assembly How to Remove the Input Shaft Assembly Special Instructions The input shaft assembly is a non-serviceable assembly, one exception is the seal rings which can be purchased and replaced. Use fingers to install the new seal rings. Special Tools Typical service tools are needed Soft hammer...
  • Page 124 As part of assembling the input shaft assembly, the mainshaft drive gear must be installed and timed. Apply Eaton lubricant #71215 or equivalent to the pilot bushing so that a film of lubricant covers the entire internal surface of the bushing.
  • Page 125 Input Shaft Assembly continued How to Install the Input Shaft Assembly With the bearing external snap ring to the outside, position the bearing on the input shaft. Temporarily install two lifting eyes to hold the bearing in the case bore. Use a soft bar and maul to drive the input shaft through the bearing.
  • Page 126 Section 7: Auxiliary Section How to Disassemble the Auxiliary Section How to Assemble the Auxiliary Section Range Cylinder Assembly How to Disassemble the Range Cylinder Assembly How to Assemble the Range Cylinder Assembly How to Disassemble the Synchronizer Assembly How to Assemble the Synchronizer Assembly Countershaft Assembly How to Remove the Countershaft Assembly How to Install the Countershaft Assembly...
  • Page 127 How to Disassemble the Auxiliary Section Auxiliary Section Range Cylinder Assembly Synchronizer Assembly Countershaft Assemblies Output Shaft Assembly Rear Bearing Cover DS/AS-3 Transmission appearance may differ, procedure is the same.
  • Page 128 How to Assemble the Auxiliary Section Output Shaft Assembly Assemble Synchronizer Assembly Countershaft Assemblies Range Cylinder Assembly Rear Bearing Cover Auxiliary Section AS/AS-4 Transmission appearance may differ, procedure is the same.
  • Page 129 Range Cylinder Assembly How to Disassemble the Range Cylinder Assembly Special Instructions Apply Eaton Lubricant #71214 or equivalent to the O- rings. Special Tools Typical service tools needed Vise with brass jaws or wood blocks To Disassemble For ease of disassembly, mount the auxiliary...
  • Page 130 Apply Eaton Rust Preventative #71213 to the cylinder walls, cylinder bottom, and the yoke bar. A film should completely cover the surfaces. Apply Eaton Lubricant #71214 or equivalent to the O- rings. Apply Eaton lockwire #1819 or equivalent to the actuator capscrews.
  • Page 131 Range Cylinder Assembly How to Disassemble the Synchronizer Assembly Special Instructions Place the synchronizer assembly on a clean, flat surface. Cover the synchronizer assembly with a shop rag to prevent losing the three (3) springs under pressure from the HI range synchronizer pin locations. Special Tools Shop rag To Disassemble...
  • Page 132 Range Cylinder Assembly How to Assemble the Synchronizer Assembly Special Instructions Assembly should be done on a clean, flat surface slightly lower than your waist. Pins on the LO range synchronizer must line up with the chamfered holes on the sliding clutch bottom. When compressing the HI range synchronizer springs cover with a shop rag.
  • Page 133 Countershaft Assembly How to Remove the Countershaft Assembly Special Instructions Both countershafts are removed the same. When driving the countershaft to the rear, be careful not to damage the bearing inner race. Special Tools Typical service tools are needed Vise with brass jaws or wood blocks Gear Puller H/29-8 Soft bar and Maul...
  • Page 134 Countershaft Assembly How to Install the Countershaft Assembly Special Instructions When installing the countershaft assemblies into the countershaft bearings, keep the countershaft assemblies straight. Do not cock the countershafts. If, when the countershaft bearing cover is removed and you can not see the snap ring groove, install the cover and drive the countershaft further until you can see the groove.
  • Page 135 Countershaft Assembly continued How to Install the Countershaft Assembly To Assemble Remove the rear bearing cover and install the retaining snap ring in the countershaft rear snap ring groove. Position a new gasket on the rear bearing cover mounting surface and install the rear bearing cover.
  • Page 137 Output Shaft Assembly How to Disassemble the Output Shaft Assembly Special Instructions When using the soft bar and maul on the output shaft, be careful not to damage the threads. When removing the rear bearing cover, the rear bearing cone drops from the housing bore. Special Tools Typical service tools are needed Vise with brass jaws or wood blocks...
  • Page 138 Because the collar becomes distorted when compressed, do not re-use an old nylon collar in the rear bearing cover. Apply Eaton Lubricant #71214 or equivalent to speedometer plug O-rings, cover the entire surface. If the electronic sensor hole has a seal, apply lubricant #71214 or equivalent, covering the top surface.
  • Page 139 Output Shaft Assembly continued How to Assemble the Output Shaft Assembly With chamfer side up, position the LO range gear rear washer on the output shaft against the LO range gear. With tapered side up, use heat or appropriate driver and install the output shaft front rear bearing.
  • Page 140 S/35-8 cover. Position the rear bearing cover over the new gasket. Apply Eaton/Fuller Sealant #71205 or equivalent to the retaining capscrews. On AT/ATR/ATS models, use a new nylon collar and brass washer at the chamfered hole, the hole that intersects the speedometer bore.
  • Page 141 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 142 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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