Eaton TRSM0201 Service Manual
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Eaton TRSM0201 Service Manual

Eaton TRSM0201 Service Manual

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Service Manual
Fuller Medium Heavy Transmissions
TRSM0201
October 2007

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  • Page 1 Service Manual Fuller Medium Heavy Transmissions TRSM0201 October 2007...

  • Page 3: Table Of Contents

    Model Designations...........................2 Description............................3 Specifications............................4 Lubrication............................5 Conversion to Overdrive........................6 Clutch Shaft Replacement........................6 General Precautions for Disassembly....................6 Detailed Disassembly Instructions......................7 Exploded Views Drive Gear............................8 Countershafts.............................11 Reverse Idler Shaft..........................11 Reverse Idler Gear and Shaft......................14 Mainshaft............................14 Tailshaft.............................14 Tailshaft and Rear Bearing Cover.......................17 Shifting Bar Housing.........................17 Inspection............................17 Torque Ratings...........................21 Gasket Location..........................21...
  • Page 4 DESCRIPTION CUTAWAY OF FIVE SPEED TWIN-COUNTERSHAFT TRANSMISSION...

  • Page 5: Model Designations

    MODEL DESIGNATIONS MODEL DESIGNATIONS Twin Countershaft Type Used as a letter, denotes overdrive model 900 lbs. ft. capacity rating Five speeds “A”, “B”. etc. Following numbers indicates a specific set of ratios Since the models in the T-905 series are identical in construction, references in this manual apply to all models unless stated otherwise.

  • Page 6: Description

    DESCRIPTION The T-905 model transmissions have five forward speeds and one reverse speed, and are designed for heavy duty vehicles. These models are of twin countershaft design which divides the torque equally between shafts and gears, providing a high capacity to weight ratio.
  • Page 7 DESCRIPTION...

  • Page 8: Specifications

    SPECIFICATIONS SPECIFICATIONS SPEEDOMETER DRIVE Provision is made in the rear bearing cover for the instal- GEAR RATIOS lation of speedometer gears and the attachment of cable. T-905A T-905B TO-905A TO-905B Fifth 1.00 1.00 0.65 0.86 MAGNETIC OIL CLEANERS Fourth 1.54 1.16 1.00 1.00...
  • Page 9 SPECIFICATIONS (SHIFTING DIAGRAMS) Shifting Diagram for T-905 Model Transmissions Shifting Diagram for TO-905 Model Transmissions...

  • Page 10: Lubrication

    LUBRICATION Proper lubrication procedures are the key to a good all- round maintenance program. If the oil is not doing its job, or if the oil level is ignored, all the maintenance pro- LUBRICATION CHANGE AND INSPECTION cedures in the world are not going to keep the transmis- HIGHWAY USE sion running or assure long transmission life.
  • Page 11 Lubrication Proper Oil Level Make sure oil is level with filler opening. Because you can reach oil with your finger does not mean oil is at proper level. Draining Oil Drain transmission while oil is warm. To drain oil, remove the drain plug at bottom of case.

  • Page 12: Conversion To Overdrive

    CONVERSION TO OVERDRIVE TO CONVERT FROM T-905A To TO-905A, or T-905B to TO-905B The transmission must be completely disassembled as To convert from a T-905A or T-905B to an overdrive the countershaft gears must be removed and inter- model TO-905A or TO-905B the 4th speed gear on the changed.
  • Page 13 SPECIAL PROCEDURE FOR CHANGING THE CLUTCH (INPUT) SHAFT Peen nut into milled slot in shaft. In some case it may be necessary to remove only the input shaft due to clutch wear on the splines. In these Re-install front bearing cover, shifting bar housing cases, the input shaft can be removed without disassem- and gear shift lever housing.

  • Page 14: General Precautions For Disassembly

    DISASSEMBLY PRECAUTIONS GENERAL PRECAUTIONS FOR DISASSEMBLY Important: Read this section before starting the detailed disassembly procedures. It is assumed in the detailed disassembly instructions that the transmission lubricant has been drained and the transmission has been removed from the chassis. Removal of the gear shift lever housing assembly is included in the detailed instructions;...

  • Page 15: Detailed Disassembly Instructions

    DETAILED DISASSEMBLY INSTRUCTIONS DETAILED DISASSEMBLY INSTRUCTIONS A. To Remove and Disassemble the Gear Shift Lever Housing Assembly Turn out the four capscrews and lift the gear shift lever housing, or remote control housing, from the shifting bar housing (See Illustration Remove the ball grip and rubber dust cover from the gear shift lever.’...
  • Page 16 DISASSEMBLY #7 - Removing interlock pin from neutral notch in the 2nd #4 - Lifting the shifting bar housing from transmission. & 3rd speed shifting bar. #5 - Removing shifting bar tension springs. #8 - Two interlock balls are located in front boss, one between each bar.
  • Page 17 DISASSEMBLY B. To Remove the Shifting Bar Housing Assembly D. To Remove the Companion Flange or Yoke Turn out the attaching capscrews. Lock the mainshaft by engaging two speeds with the mainshaft sliding clutch gears. Jar to break the gasket seal and lift the shifting bar housing from transmission (See Illustration Turn the elastic stop nut from the output shaft #4).
  • Page 18 DISASSEMBLY #11 - Removing rear bearing cover from tailshaft. #15 - Removing tailshaft from case bore. Start assembly to the rear by prying evenly against bearing snap ring. #12 - Pulling the tailshaft outer bearing. #16 - Removing key spacer ring from tailshaft. #13 - Removing capscrews from flat keys.
  • Page 19 DISASSEMBLY To Remove and Disassemble the Tailshaft Assem- G. To Remove the Clutch Housing NOTE: The clutch housing can be removed at any Cut lockwire and turn out the two 5/16” cap- time during transmission disassembly. How- screws from the two flat keys (See Illustration ever, it must be removed BEFORE the two #13).

  • Page 20: Countershafts

    DISASSEMBLY #20 - Removing snap ring from ID of the mainshaft #23 - Removing left reverse idler gear and the two thrust reverse gear. washers from case. #24 - Removing rear bearing cover from right counter- #21 - Removing lockplate from left reverse idler shaft. shaft.
  • Page 21 DISASSEMBLY H. To Remove the Left Reverse Idler Gear NOTE: The left reverse idler gear must be removed in order to remove the mainshaft assembly. Move the mainshaft assembly forward as far as Use puller to remove rear bearing from shaft. A possible and the mainshaft reverse gear to the snap ring can be installed in rear bearing groove rear against case.
  • Page 22 DISASSEMBLY #28 - Moving right countershaft forward to expose front bearing. #31 - Removing short key from keyway in mainshaft. #29 - Pulling from bearing from right countershaft. #32 - Turning the 4th-speed gear washer to align with mainshaft splines. #30 - Removing mainshaft assembly from case.
  • Page 23 DISASSEMBLY 11. Remove the 1st and 2nd speed gears with washers and spacers from mainshaft (See Illus- J. To Remove the Mainshaft Assembly tration #37). With right countershaft moved toward wall of 12. Remove the quill bearing snap ring. case, pull the mainshaft to the rear, life front of shaft and remove assembly from case (See 13.
  • Page 24 DISASSEMBLY #36 - Removing spacer, washer and sliding clutch from mainshaft. #39 - Lifting the right countershaft from case. #37 - Removing remaining gears, spacers, and washers #40 - Removing the right reverse idler shaft with impact from mainshaft. puller. #38 - Pulling the quill bearing.
  • Page 25 DISASSEMBLY L. To Remove the Right Countershaft Assembly Move the countershaft to the rear, move front of shaft toward center of case and lift the assembly from case (See Illustration #39) M. To Remove the Right Reverse Idler Gear Turn out capscrews at rear of transmission and remove the lock plate from slot in the idler shaft.
  • Page 26 DISASSEMBLY #44 - Pulling rear bearing from left countershaft. #47 - Pressing drive gear, PTO gear, 4th speed gear and 3rd speed gear from countershaft. #45 - Moving left countershaft forward to unseat from bearing. #48 - Pressing 2nd speed gear from countershaft. #49 - Turning capscrews from front bearing cover.
  • Page 27 DISASSEMBLY O. To Disassemble the Countershaft Assemblies NOTE: Both countershafts are disassembled in the same manner. Press the drive gear, PTO gear, 4th speed gear and 3rd speed gear from countershaft. Use cau- tion when pressing gears as it is necessary to press these gears off in a cluster of four (See Illustration #47).
  • Page 28 DISASSEMBLY Q. To Disassemble the Drive Gear Assembly Place the assembly in a vise, pilot end up. Relieve the bearing nut where peened into shaft (See Illustration #52). Turn the bearing nut from shaft, left-hand thread (See Illustration #53). Using the rear face of the drive gear as a base, mount the assembly in a press, and press the shaft through the gear to unseat bearing from shaft.

  • Page 29: Drive Gear Assembly

    DRIVE GEAR ASSEMBLY...

  • Page 30: Countershaft Assembly

    COUNTERSHAFT ASSEMBLY...
  • Page 31 REVERSE IDLER SHAFT AND GEAR ASSEMBLY GRAPH-...
  • Page 32 REVERSE IDLER GEAR AS ASSEMBLED IN CASE...

  • Page 33: Mainshaft Assembly

    MAINSHAFT ASSEMBLY...

  • Page 34: Tailshaft

    TAILSHAFT ASSEMBLY...

  • Page 35: Tailshaft And Rear Bearing Cover

    TAILSHAFT AND REAR BEARING COVER ASSEMBLY...
  • Page 36 SHIFTING BAR HOUSING ASSEMBLY...
  • Page 37 Inspection D. Thrust Washers Before reassembling the transmission, the individual Check surfaces of all parts should be carefully checked to eliminate those thrust washers. Washers damaged from previous service. This inspection proce- scored or reduced in dure should be carefully followed to insure the maximum thickness should be of wear life from the rebuilt unit.

  • Page 38: Shifting Bar Housing

    TORQUE RATINGS Correct torque application is extremely important to Recommended torque ratings, location and thread sizes assure long transmission life and dependable perfor- of capscrews and nuts are listed below. Capscrew length mance. Over-tightening or under-tightening can result in are given for reference purposes as a guide to installation a loose installation and, in many instances, eventually at proper locations.

  • Page 39: Preventative Maintenance Check Chart

    PREVENTATIVE MAINTENANCE CHECK CHART...
  • Page 40 PREVENTATIVE MAINTENANCE CHECK CHART CHECKS WITHOUT PARTIAL DISASSEMBLY OF CHASSIS OR CAB Clutch Housing Mounting Gear Shift Lever Housing Assembly a. Check all capscrews in bolt circle of clutch hous- a. Remove the gear shift lever housing assembly ing for looseness. from transmission.

  • Page 41: General Precautions For Reassembly

    GENERAL PRECAUTIONS FOR REASSEMBLY IMPORTANT: Read this section before starting the 6.BEARINGS - Use of flanged- detailed reassembly procedures. end bearing drivers is recom- mended for the installation of Make sure that interiors of case and housings are clean. bearings. These drivers apply It is important that dirt be kept out of transmission during equal force to both races of reassembly.

  • Page 42: Detailed Reassembly Instructions

    DETAILED REASSEMBLY INSTRUCTIONS A. To Reassemble the Drive Gear Assembly Clean threads of drive gear and nut and apply grade Install snap ring in ID of drive gear (See Illustra- AVV Loctite (See Illustration #59). tion #55). Install the bearing nut on shaft, left-hand thread, Install the drive gear on shaft, engaging internal with 250-300 ft.
  • Page 43 REASSEMBLY #62 - Drive gear teeth marked for timing, two adjacent #59 - Applying Loctite sealant to threads of drive gear teeth plus two adjacent teeth directly opposite. nut. #63 - Installing the drive gear assembly through top of #60 - Installing drive gear bearing nut, left-hand thread. case.
  • Page 44 Clean threads of drive gear and nut and apply grade B. To Reassemble the Countershaft Assemblies AVV Loctite (See Illustration #59). NOTE: Except for the power take-off gears, the coun- Install the bearing nut on shaft, left-hand thread, tershafts are identical. with 250-300 ft.
  • Page 45 REASSEMBLY #67 - Installing keys in countershaft. #70 - Pressing the power take-off gear on countershaft. #68 - Pressing the 2nd speed gear on countershaft. #71 - Pressing the drive gear on countershaft. #72 - Marking timing tooth on countershaft drive gear. #69 - Pressing the 3rd speed gear on countershaft Tooth is aligned with keyway and is stamped with an “O”.
  • Page 46 REASSEMBLY Install the short key in countershaft, tapered end against roll pin. Install the long key in keyway in countershaft (See Illustration #67). Align keyway in gear with keys in shaft and press the 2nd speed gear on shaft, long hub towards front of shaft (See Illustration #68).
  • Page 47 REASSEMBLY #78 - Installing bearing retainer plate on front of left countershaft. #75 - Timing tooth on countershaft meshed with timing teeth on drive gear. #79 - Installing rear bearing cover. #76 - Installing rear bearing on left countershaft. #77 - Installing front bearing on left countershaft. #80 - Installing plug in reverse idler shaft.
  • Page 48 REASSEMBLY Mesh the marked tooth on countershaft drive E. To Place Right Countershaft in Position gear with two teeth marked on the main drive gear (See Illustration #75). Lower the countershaft assembly through top of case, small end through the rear countershaft Center countershaft in rear bore and install the bore in case (See Illustration #82).
  • Page 49 REASSEMBLY #83 - Drawing showing correct dimensions for mainshaft quills. #86 - Installing reverse gear washer on shaft and insert- ing key through keyway and washer. #84 - Installing quill bearing snap ring. #87 - Installing the 1st-Reverse sliding clutch gear on shaft.
  • Page 50 REASSEMBLE To Reassemble the Mainshaft Assembly NOTE: Mainshaft should have quills assembled, one in each end. In case it is necessary to install quills, exact dimensions must be held between end of shaft and end of quill (See Illustration #83) Place the mainshaft in a vise, pilot end up, so that keyway in shaft is exposed for insertion of key.
  • Page 51 REASSEMBLY #89 - Installing the 1st speed gear spacer, flat side to #91 - Installing the 2nd speed gear. washer. #92 - Installing the 2nd speed gear spacer into hub of #90 - Installing the 1st speed gear on shaft and splines of gear, flat side up.
  • Page 52 REASSEMBLY 10. Install the 1st speed gear spacer on shaft, flat side to washer (See Illustration #89). 11. Install the 1st speed gear, snap ring up, on shaft, engaging splines of gear with splines of spacer (See Illustration #90) 12. Install the 2nd speed gear, snap ring down, on shaft and against the 1st speed gear (See Illus- tration #91).
  • Page 53 REASSEMBLY #95 - Installing the 3rd speed gear washer, flat side up, #97 - Installing the 3rd speed gear on shaft and splines of engaging keyway with key. spacer. #96 - Installing the 3rd speed gear spacer, flat side next Illustration #98 - Installing the 4th speed gear on shaft.
  • Page 54 REASSEMBLY 17. Install the 3rd speed gear washer, flat side up, on mainshaft, aligning keyway in washer in shaft (See Illustration #95). 18. Move the key upwards to engage the 3rd speed gear washer. Align snap ring slot at rear of key with snap ring groove in mainshaft.
  • Page 55 REASSEMBLY #103 - Installing the reverse gear on mainshaft. #101 - Installing the short key in keyway in mainshaft to lock the 4th speed gear washer. #104 - Installing the reverse gear spacer on shaft. #105 - Installing key retaining snap ring on mainshaft. #106 - The right countershaft moved towards case wall.
  • Page 56 REASSEMBLY 25. Install the short key in keyway in mainshaft to lock the 4th speed gear washer in position (See Illustration #101). 26. Install the 4th-5th speed sliding clutch gear on shaft, aligning large keyway in gear with key in shaft (See Illustration #102).
  • Page 57 REASSEMBLY #109 right countershaft moved into position to mesh #113 Installing rear bearing cover on right countershaft. with gears of mainshaft. Timing tooth on drive gear must mesh with tining teeth on main drive gear. #110 Installing rear bearing on right countershaft. #114 Installing plug in left rererse idler gear shaft.
  • Page 58 REASSEMBLY H. To Time Right Countershaft and Complete Installa- tion Center front of right countershaft in front bore with wood block and move the right counter- shaft into mesh with the mainshaft gears. At the same time engage timing tooth on countershaft drive gear with timing teeth on main drive gear.
  • Page 59 REASSEMBLY #121 - Installing nuts on case studs with 180-190 ft.lbs of torque. #118 - The mainshaft reverse gear moved to the rear to mesh with the two reverse idler gears. #122 - Installing bolts in clutch housing with 90-100 ft.lbs.
  • Page 60 REASSEMBLY J. To Complete Installation of Mainshaft Assembly Move the reverse gear to the rear on mainshaft as far as possible, meshing teeth of gear with teeth of the two reverse idler gears (See Illustra- tion #118). With mainshaft forward and reverse gear to the rear, seat the reverse gear spacer previously installed on shaft in hub of gear, and install the snap ring in ID of reverse gear (See Illustration...
  • Page 61 REASSEMBLY #130 - Flat keys secured to spacer ring and properly #127 - Installing coupling gear on mainshaft, counter- wired. bore towards the front. #131 - Installing outer bearing on tailshaft. #128 - Installing tailshaft assembly over mainshaft and in case bore.
  • Page 62 REASSEMBLY M. To Install the Tailshaft Assembly Install the coupling gear on splines of mainshaft with the counterbore towards the front and key- way aligned with key in shaft (See Illustration #127). Install the tailshaft assembly over mainshaft, seating bearing in case bore. MAKE SURE SPLINES IN TAILSHAFT ENGAGE SPLINES OF COUPLING GEAR (See Illustration #128).
  • Page 63 REASSEMBLY #139 - Installing interlock ball in front boss. #136 - Securing rear bearing cover to transmission case. #137 - Installing companion flange nut with 400-500 ft.lbs. of torque. #140 - Installing interlock pin in bore in neutral notch of 2nd-3rd speed shifting bar #138 - Installing the 1st-Reverse speed shift bar and shifting yoke and block.
  • Page 64 REASSEMBLY Install attaching capscrews, tighten evenly and securely (See Illustration #136). O. To Install the Companion Flange or Yoke Lock the mainshaft by engaging two speeds with the sliding clutch gears. Install Flange or yoke on tailshaft splines and secure with tailshaft nut, using 400-450 ft. lbs. of torque (See Illustration #137).
  • Page 65 REASSEMBLY #144 - Installing tension balls in bores on top of housing. #147 - Installing the shifting bar housing on transmis- sion, fitting yokes in yoke slots of sliding gears. #145 - Installing the three tension springs in bores. #148 - Installing nut on gear shift lever pivot pin. #146 - Shifting bars in the neutral position.
  • Page 66 REASSEMBLY 11. Install the three shift bar tension balls in bores in top of housing (See Illustration #144). 12. Install three tension springs in bores (See Illus- tration #145). 13. Install tension spring cover, tighten capscrews securely. Q. To Install the Shifting Bar Housing Assembly Place the sliding clutch gears in transmission in the neutral position.
  • Page 67 REASSEMBLY Install the tension spring in housing, seating Make sure the shifting notches in the shifting spring under lugs cast inside the housing (See bar housing are aligned in the neutral position. Illustration #151). 10. Install the gear shift lever housing, fitting lever Remove assembly from vise and install the rub- into notches in block and yokes;...

  • Page 68: Tool Reference

    Service Department, Fuller Transmission Division, prevent costly damage to critical parts. EATON YALE & TOWNE, Inc., Kalamazoo, Michigan. Some of these tools can be obtained from a regular tool Also available upon request is a tool booklet which gives...
  • Page 69 GEAR CHART FOR T-905 SERIES TRANSMISSIONS C.S. Drive Drive M.S. C.S. M.S. C.S. M.S. M.S. M.S. C.S. with Rev, MODEL Gear Gear 1st & Rev. M.S. T-905A 24-T 45-T 32-T 39-T 38-T 30-T 40-T 20-T 44-T 38-T 14745 14747 14725 14746 14737 14741...
  • Page 70 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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