fuller medium heavy transmissions trsm0200 -...

Service Manual

Fuller Medium Heavy TransmissionsTRSM0200October 2007

TABLE OF CONTENTS

Model DesignationsDescriptionSpecificationsLubricationPreventive Maintenance Torque RecommendationsTimingPrecautionsShifting Controls Removal and Disassembly Changing input Shaft Reassembly and installationTool Reference

MODEL DESIGNATIONS

“T” = Twin Countershaft

“O” = Used as a letter, denotes Overdrive model

“11” x 100 = 1100 Ibs.-ft. torque capacity rating

“6” = Denotes “multi-mesh” gearing

“05” = Five forward speeds

“A”, “B”, etc. = Following numbers indicates a specific setof ratios

Since the models in the T-11605 series are identical in construction,references in this manual apply to all models unless stated otherwise. This in-cludes models not listed above which may have other ratio combinations,designated by letters following the numerals.

ADDITIONAL LITERATUREThe following additional literature is available for the transmissions coveredin this manual. Write: Marketing Communications, Eaton Corporation,Transmission Division, North American Headquarters, P.O. Box 4013,Kalamazoo, Michigan 49003. Phone: (616) 342-3344.

P-533 Illustrated Parts List 16848 Shift Label T-1 1605102 Trouble Shooting Guide 16849 Shift Label TO-1 1605121 Lubrication Recommendations

THE T-11605 SERIES TRANSMISSIONSThe New Generation T-11605 series transmissions,like the proven T-905 series they supersede, aredesigned with five forward speeds and one reversefor medium to heavy duty on-highway vehicles. Thesignificant difference, however, is that most of thecoarse pitch conventional gearing of the T-905series has been replaced by the fine pitch "multi-mesh" gearing of the New Generation Series.

Multi-mesh gearing means there are two or threeteeth per gear always in contact during torquetransfer, instead of just one or two as with conven-tional gearing. With reduced stress on individualgear teeth, this multiple contact insures betterdistribution of engine torque through a smoother,less-nosier power flow that ultimately extends

The twin countershaft design, which splitstorque equally between the two shafts to provide ahigh torque capacity to weight ratio, remains un-changed. Because of torque splitting, each gearset carries only half the load, greatly reducing theface width of each gear. Only the countershaftgears which mate with multi-mesh mainshaftgears have been changed to the new gearing con-cept.

Another unique design feature, also unchangedfrom the T-905 series, is the floating gear principle.The mainshaft gears, when not engaged, "float"between the countershaft gears, eliminating theneed for gear sleeves and bushings. Only the 1st-speed and reverse gears are of the conventionalgearing type. The remaining forward speed gearsof the mainshaft have been changed to the newmulti-mesh gearing concept.

gear and bearing life.

2865

2857

GEAR RATIOSMODELS

Speed TO-11605C

.85

1.00

1.80

3.32

6.12

6.03

T-11605A TO-11605A

1.00 .66

T-11605B TO-11605B T-11605C

1.00

1.18

T-11605D TO-11605Dl T-11605M T-11605F

5th 1.00 .86 1.00

4th 1.16 1.00

1.75

3.23

1.31

2.05

3.23

5.46

3rd 2.04 2.12

3.90

7.20

7.09

2nd 3.75 2.46 3.75 2.46 2.66 3.90

6.35 4.161 St

Reverse

6.35 5.46

5.57

4.16 5.46 7.20

4.25 5.57 7.096.48 4.25 6.48 5.57

GEAR CHART

DRIVEGEAR40-T

1964652-T

1916840-T

1964644-T

1916640-T

1919144-T

1963644-T

1916652-T

1916844-T

1916640-T

19191

M.S.3RD56-T

1961256-T

1961250-T

1962050-T

1962050-T

1962050-T

1962056-T

1961256-T

1961250-T

1962050-T

19620

C.S.2ND33-T

1917833-T

1917833-T

1917833-T

1917833-T

1917833-T

1917833-T

1917833-T

1917834-T

1962533-T

19178

C.S.DRIVEGEAR75-T

19647

C.S.WITH1ST

C.S.WITHREV.

M.S.2ND66-T

1917766-T

1917766-T

1917766-T

1917766-T

1917766-T

1917766-T

1917766-T

1917756-T

1962466-T

19177

MODEL

T-11605A

TO-11605A

M.S.4TH52-T

1917140-T

1964844-T

19182

C.S.4TH64-T

1917575-T

1964971-T

1918175-T

1964973-T

1963578-T

1918664-T

1917571-T

1918164-T

1917567-T

19985

C.S.3RD

M.S.1ST

44-T1961344-T

1961346-T

1962146-T

1962146-T

1962146-T

19621

44-T1908244-T

19082

13-T1472013-T

1472013-T

1472013-T

14720

11-T1472011-T

1472064-T

1916775-T

1964744-T

1908244-T

19082

11-T1472011-T

1472011-T

1547511-T

15475

TO-11605B

TO-11605B

T-11605C

TO-11605C

71-T1916478-T

19190

40-T1964844-T

1963448-T

1547048-T

15470

13-T1547513-T

1547513-T

1472013-T

1472013-T

1472013-T

15475

73-T1963771-T

19164

40-T1919452-T

1917144-T

1918252-T

1917150-T

19984

44-T1961344-T

1961346-T

1962146-T

19621

44-T1908244-T

1908244-T

19082

11-T1472011-T

14720

T-11605D

TO-11605D64-T

1916771-T

1916478-T

19190

11-T14720T-11605M

T-11605F48-T

1547011-T

15475

M.S. = MAINSHAFTC.S. = COUNTERSHAFT

GEAR SHIFT PATTERN

2858 2859

Shifting Diagram for Shifting Diagram forT-1 1605 Model Transmissions TO-1 1605 Model Transmissions

Clutch Release Mechanism—Push-type clutches-single and2-Plate – Clutch release bearing car-rier, release bearing, extended frontbearing cover, release yoke, pedalshafts and pedal adjusting arm fur-nished.

Pull-Type 2-Plate Clutches — Flat bear-ing cover machined for clutch brakefurnished. Secure release yoke, pedalshafts, and pedal adjusting arm fromclutch manufacturer.

Power Take-Off–Openings—SAE Standard.

Right Side—Regular duty type, 6-bolt,short length.

Bottom—Heavy duty type, 8-bolt.

PTO Gears—Right Side—45-tooth, 6/8 pitch gear.

Bottom—47-tooth, 6/8 pitch gear.

PTO Drive Gear Speeds—Both openings, turning at enginespeed:

T-11605A, T-11605 B . . . . . . . . . . ...533TO-11605A, TO-11605D . . . . . . . ...813TO-11605B, T-11605D,

T-11605 M . . . . . . . . . . . . . . . . ...619T-11605C, T-11605 F . . . . . . . . . . . ..513TO-11605C . . . . . . . . . . . . . . . . . . ..603

Constant mesh type PTO required onall overdrive models, both openings;on T-11605C models, both openings;and on T-11605B right side. (PTO gearsare conventional mesh, not multi-mesh.)

Torque Capacity—Diesel engines up to 370 hp, 1150

Ibs.-ft. torque (1559 N.m).

Torque rating is to be used as a guideand not as an approval. For an ap-proval, submit complete vehicle speci-fications as outlined on SpecificationForm No. 62-14.

Speedometer Drive—Provision is made in the rear bearingcover for the installation of speed-ometer gears and attachment of cable.

Reverse Light Switch—Provision is made in the shift bar hous-ing for the installation of a reverse lightswitch.

Weight—With Standard Controls, SAE No. 1aluminum clutch housing, less clutchrelease parts—429 lbs. (195 Kg).

Oil Capacity–Approximately 22 pints (10 Liters),depending upon inclination of engineand transmission.

Note: Fill to level of case filler opening.

Magnetic Oil Cleaners—Two magnetic discs are installed inbottom of case to catch and holdmetallic particles deposited in the oil.

PROPER LUBRICATION . . .THE KEY TO LONGTRANSMISSION LIFE

Proper lubrication procedures are the key to a goodall-round maintenance program. If the oil is not do-ing its job, or if the oil level is ignored, all themaintenance procedures in the world are not goingto keep the transmission running or assure longtransmission life.

Oil is important, because here are some of thethings it must do:

■ Provide a protective film —Toprotect surface of heavily loadedparts such as gear teeth andbearings, thus preventing metalto metal contact which causesscoring, scuffing and seizure.

Act as a coolant—To dissipateheat.

Have suff icient f luidity—Tofollow, coat and cushion allloaded surfaces.

Be chemically stable—To with-stand heat and agitation with- 2823out separation, gumming-up,oxidizing or corroding.

Be non-foaming—To prevent excessive foamand increased volume under severe conditions.

Be free of sediment and water—To preventsludge and rust.

Fuller Transmissions are designed so that the inter-nal parts operate in a bath of oil circulated by themotion of gears and shafts. Grey iron parts havebuilt-in channels where needed, to help lubricatebearings and shafts.

Thus, all parts will be amply lubricated if theseprocedures are closely followed:

1.2.3.4.

Maintain oil level. Inspect regularly.Change oil regularly.Use the correct grade and type of oil.Buy from a reputable dealer.

First 3,000 to Change transmission oil on new units.5,000 miles (4827 to 8045 Km) IEvery 10,000 miles (16090 Km) Inspect Oil Level. Check for leaks.

I

Every 50,000 miles (80450 Km)

First 30 hours Change transmission oil on new units. IEvery 40 hours Inspect oil level. Check for leaks. IEvery 500 hours Change transmission oil where severe dirt

conditions exist.

Every 1,000 hoursChange transmission oil

(Normal of off-highwav use). IChange oil filter element, if so equipped, at each oil change, I

I Type Grade Ambient(SAE) Temperature I

Heavy Duty Engine Oil 50 Above 10°F.MIL-L-2104C or MIL-L-46152 40 Above 10°F.

or API-SF or API-CD 30 Below 10°F.

Mineral Gear Oil with rustand oxidation inhibitor 90

API-GL-1 80WAbove 10°F.Below 10°F.

I Mild EP Gear Oil* 90 10” F. to 100°F.MI L-L-2105 or API-G L-4 80W -15” F. to 70°F. I

85W140 Above 10°F.

Multipurpose Gear Oil* 80W140 Above — 15°F.

MIL-L-2105B or MIL-L-2105C 90 10°F. to 100°F.

or API-G L-5 80W90 — 15° F. to 100°F.80W — 15°F. to 70°F.75W — 40°F.to —150°F.

I

2824

*Mild EP gear oil or multi-purpose gear oil are not recommended whenlubricant operating temperatures are above 230°F (110°C).

Do not use oil additives, friction modifiers or synthetic lubricants.

Fahrenheit to Celsius: — 40°F = — 40°C— 15°F = — 26°C

10°F = 12°C70°F = 21°C100°F = 38°C

Proper Oil Level Proper Lubrication LevelsMake sure oil is level with filler opening. Becauseyou can reach oil with your finger does not meanoil is at proper level.

2825

Draining OilDrain transmission while oil is warm. To drain oilremove the drain plug at bottom of case. Clean thedrain plug before re-installing.

RefillingClean area around filler plug and remove plug fromside of case. Fill transmission to the level of thefiller opening. If transmission has two filler open-ings, fill to level of rear opening on single counter-shaft models; fill to level of both openings on twincountershaft models.

The exact amount of oil will depend on thetransmission inclination and model. In every in-stance, fill to the level of the filler opening.

Do not over fill—this will cause oil to be forcedout of the case through mainshaft openings. Transmission Mounting Angle

2826

Adding OilIt is recommended that types and brands of oil notbe intermixed because of possible incompatibility.

Operating TemperaturesThe Transmission should not be operated con-sistently at temperatures above 250° F (120°C).However, intermittent operating temperatures to300” F (149°C) will not harm the transmission.Operating temperatures above 250°F increase thelubricant’s rate of oxidation and shortens its effec-tive life. When the transmission is operated inter-mittently above 250” F, heavy duty engine oil pro-vides the best oxidation resistance. When theaverage operating temperature is above 250°F, thetransmission may require more frequent oilchanges or external cooling.

The following conditions in any combinationcan cause operating temperatures of over 250°F:(1) operating consistently at slow speeds, (2) highambient temperatures, (3) restricted air flowaround transmission, (4) exhaust system too closeto transmission, (5) high horsepower, overdriveoperation.

External oil coolers are available to reduceoperating temperatures when the above condi-tions are encountered.

If the transmission operating angle is more than12 degrees, improper lubrication can occur. Theoperating angle is the transmission mountingangle in the chassis plus the percent of upgrade(expressed in degrees).

The above chart illustrates the safe percent ofupgrade on which the transmission can be usedwith various chassis mounting angles. For exam-ple: If you have a 4 degree transmission mountingangle, then 8 degrees (or 14 percent of grade) isequal to the limit of 12 degrees. If you have a Odegree mounting angle, the transmission can beoperated on a 12 degree (21 percent) grade.

Anytime the transmission operating angle of 12degrees is exceeded for an extended period of timethe transmission should be equipped with an oilpump or cooler kit to insure proper lubrication.

Note on the chart the effect low oil levels canhave on safe operating angles. Allowing the oillevel to fall 1/2“ below the filler plug hole reducesthe degree of grade by approximately 3 degrees(5.5 percent).

Proper Lubrication Levels are Important!

PREVENTIVE MAINTENANCE CHECK CHART

CHECKS WITHOUT PARTIALDISASSEMBLY OF CHASSIS OR CAB1. Clutch Housing Mounting

a. Check all capscrews in bolt circle of clutchhousing for looseness.

2. Clutch Pedal Shaft and Boresa. Pry upward on shafts to check wear.

b. If excessive movement is found, removeclutch release mechanism and check bush-ings in bores and wear on shafts.

3. Clutch Release Bearinga. Remove hand hole cover and check radial and

axial clearance in release bearing.

b. Check relative position of thrust surface ofrelease bearing with thrust sleeve on pushtype clutches.

4. Capscrews and Gasketsa. Check all capscrews, especially those on

PTO covers and rear bearing covers forlooseness which would cause oil leakage.See Torque Recommendations Section.

b. Check PTO opening and rear bearing coversfor oil leakage due to faulty gasket.

5. Gear Lubricanta. Change at specified service intervals.

b. Use only gear oils as recommended. SeeLubrication Section.

6. Filler and Drain Plugsa. Remove filler plug and check level of lubri-

cant at specified intervals. Tighten filler anddrain plugs securely.

7. Gear Shift Levera. Check for looseness and free play in housing.

If lever is loose in housing, proceed withCheck No. 8.

8. Gear Shift Lever HousingA s s e m b l ya.

b.

c.

d.

Remove the gear shift lever housingassembly from transmission.

Check tension spring and washer for set andwear.

Check the gear shift lever pivot or spade pinand pin slot for wear.

Check bottom end of gear shift Iever for wearand check slot of yokes and blocks in shiftbar housing for wear at contact points withshift lever.

CHECKS WITH DRIVE LINE DROPPED

9. Universal Joint Companion Flange orYoke Nuta. Check for tightness. Tighten to recom-

mended torque.

CHECKS WITH UNIVERSAL JOINTCOMPANION FLANGE OR YOKE REMOVED

10. Splines on Output Shafta. Check for wear from movement and chuck-

ing action of the universal joint companionflange or yoke.

11. Mainshaft Rear Bearing Covera. Check oil seal for wear.

12. Output Shafta. Pry upward against output shaft to check

radial clearance in mainshaft rear bearing.

Correct torque application is extremely important to assure long transmission life and dependable perfor-mance. Over-tightening or under-tightening can result in a loose installation and, in many instances, even-tually cause damage to transmission gears, shafts, and/or bearings. Use a torque wrench whenever possibleto ensure proper ft.-lbs. ratings. Do not torque capscrews dry.

Recommended torque ratings, location, and thread sizes of capscrews and nuts incorporated into thesetransmissions are provided on the following illustrations.

*With Aluminum Clutch Housing. 2861

PROPER TIMING PROCEDURES

Like other Fuller twin countershaft models, theT-11605 series transmissions are “timed” atassembly. Consequently, when the rebuilding ofthese units is called for, it is essential that propertiming procedures are carried out during reassem-bly and installation. Proper timing assures that thecountershaft gear teeth will come into contact withthe mating mainshaft gear teeth at the same time,allowing the mainshaft gears to center on the main-shaft and split the load between the countershaftgear assemblies. If improperly timed, however, themainshaft gears would climb out of equilibrium,result ing in unequal tooth contact betweenmeshing gears that would lead to more seriousdamage occurring to the transmission later.

By design, the timing of only one set of gears isnecessary—the drive gear set. It is a rather simpleprocedure, consisting of marking the proper teethof the main and countershaft drive gears prior to in-stallation of the complete assemblies in the caseand meshing those marked gear teeth duringassembly.

Carefully following the step-by-step proceduresgiven here should enable even the most inex-perienced persons in transmission rebuilding tosuccessfully and properly time these units.

A. Marking countershaft drive gear teeth.1. Prior to placing each countershaft assembly

into case, clearly mark on each drive gear thegear tooth which is directly over the keywayin gear. (See illustration A.) This tooth isstamped with an “O” to aid identification.

A. TOOTH ONCOUNTERSHAFT DRIVE GEAR

DIRECTLY OVERKEYWAY MARKED

FOR TIMING

B.

c.

Marking main drive gear teeth.1.

2.

Mark any two adjacent teeth on the maindrive gear.Mark the two adjacent teeth on the maindrive gear which are directly opposite thefirst set marked. There should be an equalnumber of teeth between the markings oneach side of gear. (See Illustration B.)

B. MAIN DRIVE GEAR TEETHCORRECTLY MARKED

FOR TIMING

Meshing marked countershaft drivegear teeth with marked main drivegear teeth. (After installing main drivegear and mainshaft assemblies, thecountershaft bearings are installed tocomplete countershaft installation.)1. When installing bearings on the left counter-

shaft, mesh the marked countershaft drivegear tooth between two marked teeth on themain drive gear. Repeat the procedure wheninstalling the right countershaft bearings.(See Illustration C.)

C. COUNTERSHAFT DRIVE GEAR TEETHMESHED WITH MAIN DRIVE GEAR TEETH

FOR PROPER TIMING

REMOVAL AND DISASSEMBLY

It is assumed in the detailed Removal and Dis-assembly instructions that the lubricant has beendrained from the transmission and the unit hasbeen removed from the chassis. Although theremoval of the gear shift lever housing assembly isincluded in the Shifting Controls Section, thisassembly must first be removed from the transmis-sion before removing unit from the vehicle.

FOLLOW EACH PROCEDURE CLOSELY IN EACHSECTION, MAKING USE OF BOTH THE TEXT ANDPICTURES.

1. BEARINGS — Carefully wash and relubricate allreusable bearings as removed and protectivelywrap until ready for use. Remove bearings plannedto be reused with pullers designed for this purpose.

2. ASSEMBLIES — When disassembling the variousassemblies, such as the mainshaft, countershafts,and shift bar housing, lay all parts on a clean benchin the same sequence as removed. This procedurewill simplify reassembly and reduce the possibilityof losing parts.

3. SNAP RINGS — Remove snap rings with pliersdesigned for this purpose. Snap rings removed inthis manner can be reused.

4. INPUT SHAFT — The input shaft can be removedfrom transmission without removing the counter-shafts, mainshaft, or drive gear. Special proceduresare required and provided in the Changing InputShaft Section of this manual.

5. CLEANLINESS — Provide yourself with a cleanplace to work. It is important that no dirt or foreignmaterial enters the unit during repairs. Dirt is anabrasive and can damage bearings. It is alwaysgood practice to clean the outside of the unit beforestarting the planned disassembly.

6. WHEN DRIVING — Always apply force to shafts,housings, etc., with restraint. Movement of someparts is restricted. Never apply force to the part be-ing driven after it stops solidly. The use of soft ham-mers, bars and mauls for all disassembly work isrecommended.

INSPECTIONBefore reassembling the transmission, the individ-ual parts should be carefully checked to eliminatethose which should not be reused due to abnormalor excessive wear or damage. This inspection pro-cedure should be carefully followed to insure thecontinued performance and renewed life of therebuilt unit with the genuine Fuller parts used.

Since the cost of a new part is generally a smallfraction of the total cost of downtime and labor, thereuse of a questionable part which could lead to ad-ditional repairs at a later date is not advisable. Withconsideration also given to the unit’s history,mileage, application, etc., good judgment stem-ming from product knowledge and experience canbe used in determining the reuse or replacement ofany transmission part.

The recommended inspection procedures areprovided in the following check list:

A. BEARINGS1. Wash all bearings in clean solvent. Check balls,rollers and raceways for pitting, discoloration, andspalled areas. Replace bearings that are pitted,discolored, or spalIed.2. Lubricate bearings that are not pitted, discolored,or spalled and check for axial and radial clearances.

Replace bearings with excessive clearances.3. Check bearing fits for damaged case bores. Ifbearing outer races spin freely in the bores, the caseshould be replaced.

B. GEARS1. Check gear teeth for frosting and pitting. Frostingof gear tooth faces present little or no threat oftransmission failure. Often in continued operationof the unit, frosted gears will “heal” themselves andnot progress to the pitting stage. And in most cases,gears with light to moderate pitted teeth have con-siderable gear life remaining and can be reused. Butgears with advanced stage pitting are destructiveand should be replaced.2. Check for gears with clutching teeth abnormallyworn, tapered, or reduced in length from clashing inshifting. Replace gears found in any of these condi-tions.3. Check axial clearance of gears. Where excessiveclearance is found, check gear snap ring, washer,spacer, and gear hub for excessive wear. Maintain.005” to .012” axial clearance on mainshaft forwardspeed gears, .005” minimum on reverse gear.

INSPECTION (Cent’d.)

C. SPLINES1. Check splines on all shafts for wear. If slidingclutch gears, companion flange, or clutch hub haveworn into the sides of the splines, replace thespecific shaft affected.

D. TOLERANCE/LIMIT WASHERS1. Check surfaces of all limit washers. Washersscored or reduced in thickness should be replaced.

E. REVERSE IDLER GEAR ASSEMBLIES1. Check bearing sleeves for wear from action ofroller bearings.

F. GRAY IRON PARTS1. Check all gray iron parts for cracks and breaks.Replace or repair parts found to be damaged. Heavycastings may be welded or brazed provided thecracks do not extend into bearing bores or boltingsurfaces. When doing either A.C. or D.C. welding,however, never place the ground so as to allow cur-rent to pass through the transmission.

G. CLUTCH RELEASE PARTS1. Check clutch release parts. Replace yokes wornat cam surfaces and bearing carrier worn at contactpads.2. Check pedal shafts. Replace those worn at bear-ing surfaces.

H. SHIFT BAR HOUSING ASSEMBLY1. Check for wear on shift yokes and blocks at padsand lever slot. Replace excessively worn parts.2. Check yokes for correct alignment. Replacesprung yokes.3. Check Iockscrews in yokes and blocks. Tightenand re-wire those found loose.4. If housing has been disassembled, check neutralnotches of shift bars for wear from interlock balls.Bars indented at points adjacent to the neutralnotch should be replaced.

L GEAR SHIFT LEVER HOUSINGASSEMBLY1. Check spring tension on shift lever. Replace ten-sion spring and washer if lever moves too freely.2. If housing is disassembled, check pivot or spadepin and corresponding slot in lever for wear.Replace both parts if excessively worn.

J. BEARING COVERS1. Check covers for wear from thrust of adjacentbearing. Replace covers damaged from thrust ofbearing outer race.2. Check bores of covers for wear. Replace thoseworn oversize.

K. OIL RETURN THREADS AND SEALS1. Check oil return threads in front bearing cover. Ifsealing action of threads has been destroyed bycontact with input shaft, replace bearing cover.2. Check oil seal in mainshaft rear bearing cover. Ifsealing action of lip has been destroyed, replaceseal.

L. SLIDING CLUTCHES1. Check all shift yokes and yoke slots in slidingclutches for extreme wear or discoloration fromheat.2. Check engaging teeth of sliding clutches for par-tial engagement pattern.

M. FRONT BEARING COVER1. Check inside hub of front bearing cover for wearcaused by backing off of drive gear bearing nut.

N. O= RINGS1. Check all O-rings for cracks or distortion.Replace if worn.

REASSEMBLY AND INSTALLATION

Since it is important that dirt and other foreignmaterials be kept out of the unit during reassembly,make sure the interiors of the case and housing arethoroughly cleaned before rebuilding begins. Dirt isan abrasive and can damage polished surfaces ofbearings and washers.

Use the following precautions during reassemblyand installation:

1. GASKETS — Use new gaskets throughout thetransmission as it is being rebuilt. Make sure allgaskets are installed, as omission of any gasketcan result in oil Ieakage or misalignment of bearingcovers.2. CAPSCREWS — TO prevent oil leakage, usethread sealant on all capscrews. For recommendedtorque ratings, see Torque RecommendationsSection.3. O-RINGS — Lubricate all O-rings with siliconelubricant.4. ASSEMBLY — Refer to the illustrations providedin the Removal and Disassembly Section as a guideto reassembly.5. INITIAL LUBRICATION — Coat all limit washersand splines of shafts with Lubriplate duringreassembly to prevent scoring and galling of suchparts.

6. AXIAL CLEARANCES — Maintain original axialclearances of .005” to .012” for mainshaft forwardspeed gears; .005” minimum for mainshaft reversegear.7. BEARINGS — Use of flange-end bearing driversare recommended for the installation of bearings.See Tool Reference Section for specific tool recom-mendations. These special drivers apply equalforce to both bearing races, preventing damage toballs and races while maintaining correct bearingalignment with bore and shaft.8. UNIVERSAL JOINT COMPANION FLANGE ORYOKE — Pull the companion flange or yoke tightlyinto place with the mainshaft nut, using 450-500foot-pounds of torque. Make sure the speedometergear has been installed on yoke. If a speedometergear is not used, a replacement spacer of the samewidth must be installed. Failure to pull the compan-ion flange or yoke tightly into place will permit theoutput shaft to move axially with resultant damageto the rear bearing.

I. GEAR SHlFT LEVER HOUSING ASSEMBLY

OLD STYLE NEW STYLE

1. Install the spade pin or pivot pin, nut and washerin the bore in the housing. If previously removed,install the O-ring in the groove.

2. Secure the housing in a vise and use a largescrewdriver to twist between the spring and sideof the housing, forcing the spring from under thethree lugs. Do one coil at a time. Remove the

3. Remove the washer and gear shift lever fromhousing once the rubber boot and ball grip havebeen removed from lever.

4. Remove the spade pin or pivot pin, nut andwasher from the bore in the housing. Ifnecessary, remove the O-ring from the housing.

spring.

B. Reassembly

1.

2.

3.

Install the spade pin or pivot pin, nut andin the bore in the housing. If previously reinstall the O-ring in the groove.

washermoved,

With the gear shift lever positioned in housingby spade or pivot pin in lever ball slot. installthe tension spring washer overwith dished-side up.

the lever ball

Seat the tension spring under the lugs in thehousing, seating one coil at a time. Use of aspring driving tool is recommended.

4. Remove assembly from viserubber boot over the gearagainst neck of housing.

and install theshift lever and

5. Install ball grip on shift lever.

NOTE: For detailed installation instructions of gearshift lever housing assembly on shift bar housingassembly, see Reassembly and Installation Sec-tion, Part III-B, of this manual.

Il. SHIFT BAR HOUSING ASSEMBLY

A. Removal and Disassembly

1. Turn out the attaching capscrews.

2. Jar to break the gasket seal and lift the shiftbar housing from transmission.

NOTE: During disassembly, lay all parts on a cleanbench in the order in which they are removed tofacilitate reassembly. Keep bars not being removedin the neutral position or interlock parts will lockbars.

3. Turn out the two capscrews and remove thetension spring cover from top of housing.

4. Remove the three tension springs from bores inhousing and the gasket for tension springcover.

5. Tilt housing and remove the tension balls in-stalled under springs.

6. Place the housing in a vise with the left sideup; the long 1st-reverse speed shift bar will beat the bottom.

7. Cut lockwire and remove Iockscrews fromeach bar just prior to its removal.

8. Move the top, 4th-5th speed shift bar to thefront and out of housing, removing shift yokefrom bar.

9. Move the 2nd-3rd speed shift bar to the frontand out of housing, removing the shift yokefrom bar. As tile neutral notch in bar clearshousing boss, remove the small interlock pinfrom bore in neutral notch.

10. Move the bottom, 1st-reverse speed shift bar tothe front and out of housing, removing the shiftyoke and block from bar.

11. Two interlock balls will fall from interlock bailopening in front boss as the last bar is removed.

SHIFTING CONTROLS

B. Reassembly

1. Install the housing in a vise with the left sideup.

NOTE: Shift bars should be installed from thefront with neutral and shift notches to the front.Keep bars in the neutral position when installed.

4. Install 3/4" interlock ball in bore in front boss.

2. Install the 1st-reverse shift bar in bottom borein housing, installing the shift yoke and blockon bar, long hub of each to the front.

5.

3. Install Iockscrew in yoke and block, tightenand lockwire securely.

6.

Install the 2nd-3rd speed shift bar in centerbore in housing and install shift yoke, longhub to the rear. At the same time install inter-lock pin in bore in neutral notch of bar asnotch enters front boss.

Install yoke Iockscrew, tighten and lockwiresecurely.

SHIFTING CONTROLS

7. Install 3/4" interlock ball in bore in front boss.

10. Remove housing from vise and install thethree shift bar tension balls in bores in top ofhousing.

8. Install the 4th-5th speed shift bar in upperbore in housing installing shift yoke on bar,fork to the front.

9. Install yoke Iockscrew, tighten and lockwiresecurely.

11. Install three tension springs in bores.

12. Place a new tension spring cover gasket intoposition on shift bar housing and installcover. Tighten capscrews to secure.

NOTE: For detailed installation instructions ofshift bar housing assembly on case, see Re-assembly and Installation Section, Part III-A, ofthis manual.

SHIFTING CONTROLS

Ill. COMPANION FLANGE OR YOKE, REAR BEARING COVERASSEMBLY, AND CLUTCH HOUSING

1.

A. Removal of Companion Flange or Yoke

Lock the mainshaft by engaging two mainshaft 2. Pull flange or yoke from splines of the outputsliding clutches and turn the elastic stop nutfrom the output shaft.


B. Removal and Disassembly of RearBearing Cover Assembly

1. Turn out the attaching caps crews from the rearbearing cover.

2. Pry the bearing cover evenly to the rear to unseatfrom output shaft bearing.

3. Remove the bearing cover and gasket from out-put shaft.

4. Remove oil seal from cover if necessary.


C. Removal of Clutch Housing

NOTE: For models otherwise equipped with Amid-ship Assembly, refer to illustration provided in Op-tions Section of this manual.

1. Remove the clutch release mechanism if thetransmission is so equipped.

2. Turn out the four capscrews and remove the sixnuts and lockwashers from studs at front ofcase.

3. Break gasket seal and pull clutch housing fromcase.


IV. CASE-INNER ASSEMBLIES

A. Removal and Disassembly ofOutput Shaft Assembly

1. Remove the speedometer gear, or replacementspacer, and the bearing washer from output 3. Cut lockwire and turn out the two 5/16-24 x 1"shaft or from cover. capscrews from the two flat retainers or keys.

2. Pull the outer bearing from output shaft. (This 4. Remove the two flat retainers from bores in out-wearing may remain in cover. In this case, move put shaft. These retainers maintain the positionthe bearing evenly forward and from cover.) of the mainshaft in relation to output shaft.


5. Remove output shaft from case bore. Startassembly to the rear with screwdriver, pryingevenly against bearing snap ring.

6. Remove the spl ined coupler from mains haft, orfrom pocket in output shaft.

8. Place output shaft in vise and remove the bear-ing nut, left-hand thread.

9. Press bearing from output shaft.

7. Turn out the two 5/16-24 x 5/8" capscrews andremove the key spacer ring from output shaft.


2213

B. Removal and Disassembly of LeftReverse Idler Gear Assembly

NOTE: The left reverse idler gear must be removedin order to remove the mainshaft assembly.

1. Move the mainshaft assembly forward as far aspossible and the mainshaft reverse gear to therear against case.

2. Remove the snap ring from ID of the mainshaftreverse gear.

3. Engage reverse gear with the 1st-reverse slidingclutch and move the reverse gear forwardagainst the 1st speed gear.

4. Turn out capscrew at rear of transmission andremove the lock plate from slot in the idler shaft.


5. Use impact puller to withdraw the idler shaftfrom case.

.

6. Remove the reverse idler gear and the two thrustwashers from case.

.

7.

c.

If necessary, remove the inner race from idlergear needle bearing, the needle bearing fromidler gear, and the pipe plug from idler shaft.

Removal of CountershaftB e a r i n g s

NOTE: Although the bearings of both countershaftsare removed in the same manner, it is necessary toremove the bearings from only the right counter-shaft to remove the mainshaft assembly from case.

1. Turn out capscrews and remove the rear bearingcover and gasket from each countershaft.


2. Use a soft punch and maul from inside case todrive the rear countershaft bearings to the rearand from case bores. (NOTE: This removal pro-cedure will damage the bearings and should notbe attempted unless replacement of the bear-ings is planned.)

3. Cut lockwire and remove the two capscrewsand retainer plate from the front of eachcountershaft. For models so equipped withbearing retaining snap rings in groove ofcountershafts, remove snap ring from groovein both countershafts.

5. With the same soft bar and maul on the rear ofeach countershaft, drive the countershafts for-ward to expose the front bearing snap rings.

6. Use a bearing puller to remove the front bearingfrom each countershaft.

4. Use a soft bar and maul to drive each counter-shaft to the rear approximately 1/2"., . .


D. Removal and Disassembly ofMainshaft Assembly

2. Holding 3rd and 4th speed gears, tilt the front ofthe mainshaft up and lift assembly from case.Use caution as the reverse gear is free and canfall off the shaft.

NOTE: When removing limit washers, spacers andgears, note their location to facilitate reassembly.

1.Keep limit washers and spacers with the gear from

With the right countershaft moved toward wall of which they were removed. There should be only onecase, pull the mainshaft to the rear to free pilot spacer and one limit washer for each gear in thefrom pocket of input shaft. mainshaft assembly.


3. Remove the reverse gear from rear of mainshaft.

4.

5.

6. With a small screwdriver, rotate the 4th speedgear limit washer, recessed within the gear hub,to align its splines with those of the mainshaft.

Remove the 4th-5thfront of mainshaft.

speed sliding clutch from 7. Pull the 4th speed gear from front of mainshaft toremove limit washer, spacer, and gear.

8.Remove the short key from keyway near front ofmainshaft. This key locks the 4th speed gearlimit washer in position.

Remove the 3rd speed gear and spacer fromfront of mainshaft. The 3rd speed gear limitwasher cannot be removed at this time as it iskeyed in groove of mainshaft.


9. Remove the long key retaining snap ring fromslot near rear of mainshaft.

12. Rotate reverse gear limit washer to align itssplines with those of the mainshaft and removewasher.

10. Remove the reverse gear spacer.

11. From rear of mainshaft, pull the long key frommainshaft keyway.

13. Remove 1st-reverse sliding clutch from main-shaft.

14. With a small screwdriver, rotate the 1st speedgear limit washer, recessed within the gear hub,to align its splines with those of the mainshaft.


15. Pull the 1st speed gear from rear of mainshaft toremove limit washer, spacer, and gear.

18. Remove the 2nd-3rd speed sliding clutch frommainshaft.

16. Remove 2nd speed gear and spacer from main- 19. Rotate 3rd speed gear limit washer to align itsshaft. splines with those of mainshaft and remove

washer.

17. Rotate 2nd speed gear limit washer to align itssplines with those of the mainshaft and removewasher.


E. Removal and Disassemble of MainDrive Gear Assembly

NOTE: For models equipped with an AmidshipAssembly in place of a Drive Gear Assembly, referto Options Section of this manual.

2. Use a soft bar and maul from inside case to move1. Remove front bearing cover and gasket by turn- drive gear assembly forward as far as possible to

ing out capscrews. expose front bearing snap ring from case bore.


3. Remove snap ring from front bearing.

4. Use a soft maul, rubber or rawhide mallet tomove input shaft into case, being careful asnot to damage pilot-end.

5. Remove drive gear assembly from transmissionby lifting it out through top of case.

6. Secure assembly in a vise, pilot end up, on drivegear O. D. The vise used should be equipped witheither brass jaws or wood blocks to preventdamage to the teeth of drive gear.


7. Use a punch and maul to relieve bearing nut fromshaft, left hand thread.

9. Remove assembly from vise to press input shaftthrough bearing and gear. If necessary, removesnap ring from drive gear I.D. Check the bushingin pocket of input shaft and replace if damagedor worn.

8. Use a drive gear bearing nut remover to turn thebearing nut from shaft, left hand thread.


F. Removal and Disassembly of 3. For models so equipped with a countershaftCountershaft Assemblies

1. If not previously done so, remove front and rearbearings of left countershaft as described in PartC of this section.

2. Move either countershaft assembly to the rear,lift front of shaft to the center of case by the driveand PTO gears and remove through top of case.Repeat same process for other countershaftassembly.

NOTE: Except for the PTO gears, the left and rightcountershaft assemblies are identical, Disassem-bly of each should be performed in the same man-ner.

gear retaining snap ring in groove nearest todrive gear, remove snap ring from counter-shaft.

4. Press the drive gear, PTO gear, 4th speed gear,and 3rd speed gear from countershaft. Use cau-tion when pressing ears as it is necessary to

?press these gears of in a cluster of four.


5. Press the 2nd speed gear from countershaft. 6.

G.

If necessary, remove the key and roll pin fromcountershaft.

Removal and Disassembly ofRight Reverse Idler Gear Assembly

NOTE: Since the left and right reverse idler gearassemblies are identical, removal and disassemblyof the Right Reverse Idler Gear Assembly should beperformed in the same manner as described in PartB of this section.


SPECIAL PROCEDUREIn some cases, it may be necessary to replace onlythe input shaft due to clutch wear on the splines.

In these instances, the input shaft can be remov-ed without disassembling the transmission forother than removing the shifting bar housingassembly. Removal of the clutch housing is op-tional. Following is the special procedure.

REMOVAL AND DISASSEMBLY1. Remove gear shift lever housing and shift barhousing assemblies from transmission.

2. Remove the front bearing cover.

3. Engage the mainshaft sliding clutches in twogears and remove the drive gear bearing nut.

4. Move the drive gear assembly as far forward aspossible and remove the drive gear bearing.

5. Remove the spacer from input shaft.

REASSEMBLY AND INSTALLATION1. Install new input shaft into splines of drive gearjust far enough to expose snap ring groove in ID ofdrive gear.

2. Install snap ring in ID of drive gear.

3. Install spacer on shaft against drive gear.

4. Install drive gear bearing on shaft and into casebore.

5. Install a new drive gear bearing nut, left-handthread. Clean threads of nut and input shaft beforeapplying Loctite sealant to threads of both parts.Use 250-300 ft.-lbs. of torque to tighten nut.

6. Peen nut into milled slots of input shaft.

7. Re-install front bearing cover, shift bar housingand gear shift lever housing assemblies.

6. From the front, remove the snap ring from ID of NOTE: The above instructions are for changing the

drive gear. input shaft only. To change the drive gear, removalof the mainshaft assembly and the countershaft

7. Pull the input shaft forward and from splines of bearings is necessary.drive gear.

CHANGING INPUT SHAFT

1. CASE-INNER ASSEMBLIES

A. Reassembly and Installation ofRight Reverse Idler Gear Assembly

1. If previouslv removed, install pipe plug in thread-ed end of idler shaft.

2. Press needgear.

e bearing into bore of reverse idler

4. With the two thrust washers in position on eachside of reverse idler gear, slide the idler shaftthrough bore in rear of case, gear, washers, andbore of idler shaft support boss inside case. Tomake certain the slot in rear of idler shaft is prop-erly located to secure lock plate with capscrewin case, align oil channel hole of idler shaft withthat in top of idler shaft support boss.

5. Insert lock plate into slot of idler shaft andsecure with capscrew.

3. Insert inner race of needle bearing of gear.


B. Reassembly of CountershaftAssemblies

NOTE: Since the left and right countershaftassemblies are identical, except for the PTO gears,reassembly of each should be performed in thesame manner.

1. If previously removed, install roll pin and longkey in keyway of countershaft.

3. Press the 3rd speed gear on countershaft, longhub of gear against 2nd speed gear hub.

4. Press the 4th speed gear on countershaftagainst 3rd speed gear.

2. Align keyway in gear with key in countershaftand press the 2nd speed gear into position onshaft, long hub of gear toward front of counter-shaft.


5. Press the power take-off gear on countershaft,bullet nose teeth against 4th speed gear. (Theleft counteshaft assembly has a 47-tooth PTOgear the right countershaft assembly has a45-tooth PTO gear. To eliminate confusion dur-ing installation, mark the appropriate assemblyas "right" and "left".)

7.

8.

For models so equipped with two snap ringgrooves in front of each countershaft, installcountershaft gear retaining snap ring ingroove nearest to drive gear. Do not installsnap ring in other groove of countershaft atthis time, as it is intended for the front bearingretaining snap ring.

IMPORTANT: Mark countershaft drive gears fortiming. On the drive gear of each countershaftassembly, mark the gear tooth stamped with an"O" that is aligned with the keyway of gear. Useof toolmakers dye of a highly visible color isrecommended.

6. Press the drive gear on countershaft againstPTO gear.


8.

9.

IMPORTANT: Remove assembly from vise andmark the drive gear for timing. Mark any two adja-cent teeth on the drive gear and repeat the sameprocess for the two adjacent teeth directly op-posite the first set marked. Use of toolmakersdye of a highly visible color is recommended.

Remove the snap ring from drive gear bearing.

10. Spread the partially installed countershaftassemblies and insert the drive gear assemblythrough front bore from inside case. Seat thedrive gear bearing in case bore and moveassembly forward until snap ring groove inbearing is exposed.

11. Install snap ring in drive gear bearing groove.

12. Seat bearing in case bore and install the drivegear bearing cover with new gasket, aligningthe oil return slot in cover with oil return hole incase. Secure with capscrews.


E. Completed Installation of Left

1. Insert countershaft support tool in rear bearingbore.

4. Install retainer plate, secure with capscrews,. . .and lockwire. For models so equipped withgroove in countershaft for front bearing re-taining snap ring, install snap ring in groove.

2. Mesh the marked tooth of left countershaft drivegear with either set of two marked timing teeth ofmain drive gear.

3. With timing teeth still in mesh, install counter-shaft front bearing. Center countershaft in casebore using a small screwdriver inserted throughbearing I.D. and in bell center or either threaded

5. Remove countershaft support tool from rearcase bore and install countershaft rear bearingwith the larger I.D. lead chamfer toward front oftransmission. (Note: If damage to original bear-ing resulted from punch andreplace with new rear bearing.)

maul removal,

hole in-end of shaft.


C. Partial Installation of CountershaftAssemblies

D. Reassembly and Installation ofMain Drive Gear Assembly

1. Place the left countershaft assembly with the47-tooth PTO gear into position in case, smallend through the left rear countershaft bore. Donot install bearings at this time,

2. Place the right countershaft assembly with the45-tooth PTO gear into position in case, smallend through right rear countershaft bore. Do notinstall bearings at this time.

1. If previously removed, install the snap ring in I.D.of main drive gear.

2. Install the main drive gear on input shaft, engag-ing internal splines of gear with teeth on shaft,snap ring of gear toward the front.

3. Install the drive gear spacer on input shaftagainst gear.

4.

5.

6. Secure assembly in vise, pilot end up, on drivegear O.D. The vise used should be equipped witheither brass jaws or wood blocks to preventdamage to the teeth of drive gear. Using a drivegear bearing nut installer, install the nut on inputshaft, left hand threads, with 250-300 ft. lbs. oftorque.

Press the drive gear bearing on input shaft, bear-ing shield to the front.

Clean threads of input shaft and apply Ioctite 7. With a punch and maul, peen the nut into the twograde 277 sealant to threads of new drive gear milled slots of input shaft.bearing nut. Do not reuse old nut.

F. Partial Reassembly ofOutput Shaft Assembly

1. Press the front bearing on output shaft, snap ringto the rear.

2. Clean threads of output shaft and bearing nut.Apply Ioctite grade 277 sealant to threads of nut.

3. Install the bearing nut on threads of output shaftand torque to 250-300 ft. lbs.

4. Position the key spacer ring on output shaftusing the two 5/16-24 x 5/8" capscrews, but do nottighten.


G. Reassembly of Mainshaft Assembly

1.

2.

Place mainshaft in vise equipped with brassjaws or wood blocks, pilot end down. (Note: Ifpreviously removed, install all correspondingsnap rings in mainshaft gears with the exceptionof reverse gear.)

Install 3rd speed gear limit washer with flat sidedown in 4th groove of mainshaft. Rotate washerto align splines of washer with those of the main-shaft and install the long key in mainshaftkeyway.

3. Install 2nd-3rd speed sliding clutch, aligningmissing internal spline of sliding clutch with key.

4. Remove key and install 2nd speed gear limitwasher, flat side up, in next groove of mainshaft.Rotate washer to align splines of washer withthose of mainshaft and reinsert key.

NOTE: The long key is moved downward to engageeach limit washer as they are positioned on main-shaft.


5. Install spacer against 2nd speed limit washer.

NOTE: Gear limit washers are internally splined andlocked to mainshaft by key. Gear spacers are exter-nally splined to engage with splines in gear hubs.There is one limit washer and one spacer for eachgear in mainshaft assembly.

7. Install it speed gear, clutching teeth up.

8. Install spacer in 1st speed gear, engaging exter-nal splines of spacer with clutching teeth ofgear.

6. Install 2nd speed gear, clutching teeth down.Engage clutching teeth of gear with externalsplines of spacer..


9. Remove key and install 1st speed limit washer,flat side against spacer.

10. Rotate washer to align splines of wasthose of mainshaft and reinsert key.

her with

11. Insert two large screwdrivers between 1st and2nd speed gea rs . App l y s l i gh t downwardpressure on screwdriver handles to spreadgears evenly. Making certain gear hubs areparallel, insert feeler gage between hubs. Cor-rect axial clearance should be from .005" to.012". If the clearance is less than the minimum.005" tolerance, the l imit washer in the 1stspeed gear should be replaced by a lower limitwasher. This will increase the axial clearancebetween the gears. If the clearance checked isgreater than the maximum .012" tolerance, ahigher limit washer should be installed in the1st speed gear. This would decrease the axialclearance between the gears.


SETTING CORRECT AXIALCLEARANCES FORMAINSHAFT GEARSAxial 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; sixthicknesses are available as follows:

LIMITS (INCH) COLOR CODE.248-.250 WHITE.253-.255 GREEN.258-.260 ORANGE.263-.265 PURPLE.268-.270 YELLOW.273-.275 BLACK

* PLUS RED

* Note: New style limit washers come in full rangeof tolerances and corresponding colors listedabove “plus red”. (Example: “Orange plus red”limit washer has an inch limit thickness of.258-.260.)

Refer to Illustrated Parts Lists for washer partnumbers.

Always use the .248-.250” low limit washer (“white”or “white plus red”) in the 1st and 3rd speed gearpositions as shown at right.

** On overdrive models, the (4th) speed gearbecomes (5th) speed gear.

12.

13.

Install 1st-reverse speed sliding clutch, align-ing missing internal spline of sliding clutchwith key in mainshaft.

Remove key and install reverse gear limitwasher, flat side up, in last groove of mainshaft.Rotate washer to align splines of washer withthose of mainshaft and reinsert key.

14. Install spacer against reverse gear limit washer.

15. Install snap ring in snap ringmainshaft.

groove at rear of


16. Reposition mainshaft assembly in vise, pilotend up.

17. Install spacer against flat side of 3rd speed gearlimit washer.

18. Install 3rd speed gear, clutching teeth down.Engage clutching teeth of gear with externalsplines of spacer.

19. Install 4th speed gear, clutching teeth up,against 3rd speed gear.


20.

21.

Install spacer in 4th speed gear, engaging exter-nal splines of spacer with clutching teeth ofgear.

Install 4th speed gear limit washer, flat sideagainst spacer, in 4th speed gear. Rotatewasher to align splines of washer with those ofmainshaft and install short key in mainshaftkeyway.

22.

23.

Check axial clearances and make adjustments,if necessary, between the 3rd and 4th speedgears in the same manner as performed be-tween the 1st and 2nd speed gears (step #n).

Install 4th-5th speed sliding clutch, aligningmissing internal spline of sliding clutch withkey in mainshaft.


24. Remove mainshaft assembly from vise. Installreverse gear on mainshaft over snap ring in rear,clutching teeth toward front, and move itagainst 1st speed gear, engaging clutchingteeth of gear with external splines of spacer.

2. With the reverse gear as far forward as possible,install the mainshaft assembly into position incase, meshing corresponding gears on leftcountershaft with those on mainshaft.

H. Partial Installation of Mainshaft

1. Move the right countershaft assembly as far aspossible toward case wall.

3. Temporarily install the coupler, counterboretoward front of transmission, and partiallyreassembled output shaft assembly, engagingsplines of output shaft with those of coupler, tocenter the rear of mainshaft assembly.


I. Completed Installation of RightCountershaft Assembly

NOTE: Left countershaft assembly must remain intime with main drive gear when timing right counter-shaft assembly.

3.

1. With the right counteshaft parallel with main-shaft, mesh the marked tooth of right counter-shaft drive gear with the remaining two markedtiming teeth of main drive gear.

4.

With timing teeth still in mesh. install counter-shaft front-bearing. Center countershaft in casebore using a small screwdriver inserted throughbearing I.D. and in bell center or either threadedhole in end of shaft.

Install retainer plate, secure with capscrews,and lockwire. For models otherwise equippedwith front bearing retaining snap ring in grooveof countershaft, install snap ring.

2. Insert countershaft support tool in rear bearingbore.


5. Remove countershaft support tool from rearcase bore and install countershaft rear bearingwith the larger I.D. lead chamfer toward front oftransmission. (NOTE: If damage to original bear-ing resulted from punch and maul removal, re-place with new rear bearing.)

6. Shift the mainshaft sliding clutches into all gearpositions with a screwdriver. A sliding clutchthat cannot be shifted into gear indicates thatthe drive gear set is out of time. The rightcountershaft bearings would then need to beremoved and the countershaft retimed with themainshaft. The transmission is properly timed ifthe sliding clutches can be shifted into all main-shaft gears. (NOTE: Do not shift the transmis-sion into two gears at the same time. This willprevent the mainshaft and countershaft assem-blies from rotating.)

7. If properly timed, install both countershaft rear

J.

bearing covers with new gaskets and secure-tocase with capscrews.

Reassembly and Installation of LeftReverse Idler Gear Assembly

NOTE: Since the left and right reverse idler gearassemblies are identical, reassembly and installa-tion of the Left Reverse Idler Gear Assembly shouldbe performed in the same manner as described inPart I-A of this section.

K. Completed Installation of MainshaftAssembly

1. Remove temporarily installed output shaftassembly from case bore and coupler from rearof mainshaft.


2. Move the reverse gear to the rear on mainshaft asfar as possible, meshing teeth of gear with teethof the two reverse idler gears.

3. With mainshaft forward and reverse gear to therear, seat the reverse gear spacer previously in-stalled on shaft in hub of gear, and install thesnap ring in ID of reverse gear.

L. Completed Reassembly and Installationof Output Shaft Assembly

2. Reinstall output shaft assembly over mainshaft,seating bearing in case bore. Make sure splinesin output shaft engage splines of coupler.

3. Install two flat retainers in bores of output shaftto key in slot of m ainshaft.

1. Reinstall coupler on splines of mainshaft withthe counterbore toward the front of transmis-sion.


4. Secure retainers with 5/16-24 x 1" capscrews andtighten all capscrews in spacer ring evenly. in-stall lockwire to include all four tightenedcapscrews in spacer ring.

5. Install outer bearing on output shaft seating it

6. Install bearing washer on output shaft againstouter bearing, chambered I.D. toward bearing.

7.against shoulder of shaft.

Install the speedometer drive gear or replace-ment spacer on output shaft against bearing washer.


Il. CLUTCH HOUSING, REAR BEARING COVER ASSEMBLY,AND COMPANION FLANGE OR YOKE

A. Installation of Clutch HousingNOTE: For models otherwise equipped with Amid-ship Assembly, refer to illustration provided inOptions Section of this manual.

3. Install the six nuts with washers or lockwasherson studs and tighten. See Torque Recommenda-tions Section.

1. A p p l y wh i te g rease to new c lu tch hous ingg a s k e t a n d i n s t a l l i n p o s i t i o n o n c a s e . -

4.

5.

Install the four capscrews with lockwashers andtighten. See Torque Recommendations Section.

Install the clutch release mechanism if transmis-sion is so equipped.

2. Place clutch housing in position on the six studsin front of case, piloting on drive gear cover.


B. Reassembly and Installation of RearBearing Cover Assembly

1. Install new oil seal in rear bearing cover iforiginal seal was previously removed. A spring isvisible on one side of seal. Install this side withspring toward front of transmission.

C. Installation of Companion Flangeor Yoke

1. Lockshaft

2. Install rear bearing cover with new gasket evenlyon output shaft to seat outer bearing in cover,aligning oil slot in cover and gasket with hole incase.

2.

the mainshaft by engaging any two main-gears with the sliding clutches.

Install companion flange or yoke on output shaftsplines and secure with output shaft nut, using400-450 ft. lbs. of torque.

3. Install attaching capscrews and tighten t osecure rear bearing cover to case.


Ill. SHIFTING CONTROLS

A. Installation of Shift Bar HousingA s s e m b l y

NOTE: For detailed reassembly instructions of shiftbar housing assembly, see Shifting Controls Sec-tion, Part II-B, of this manual.

3. Make certain that all three shift bars of assemblyare in the neutral position.

1. Place all three mainshaft sliding clutches in theneutral position.

2. Apply white grease to new shift bar housinggasket and install in position on case.

4. Install the shift bar housing assembly ontransmission, fitting shift yokes into correspond-ing yoke grooves of mainshaft sliding clutches.

5. Install the thirteen capscrews in flange holes ofhousing and tighten, remembering to include thetwo lifting eyes in position on housing cornersopposite each other.


B. Installation of Gear Shift Lever HousingAssembly.

NOTE: For detailed reassembly instructions ofgear shift lever housing assembly, see ShiftingControls Section, Part l-B, of this manual.

1. Make certain that the shift block notches inthe shift bar housing assembly are aligned inthe neutral position.

3. Install gear shift lever housing assembly, fittingtang of-gear lever into notches of shift bar hous-ing assembly blocks and yokes.

4. Install the four capscrews in flange holes ofhousing and tighten.

2. Apply white grease to new gear shift leverhousing gasket and install in position onshift bar housing assembly.


Some repair procedures pictured in this manual obtained from a regular tool supplier or madeshow the use of specialized tools. Their actual from dimensions as required by the individualuse is recommended as they make transmission user. Detailed Fuller prints and a booklet whichrepair easier, faster, and prevent costly damage gives the use and description of these tools areto critical parts. available upon request by writing:

But for the most part, ordinary mechanic'stools such as socket wrenches, screwdrivers, Eaton Corporationetc., and other standard shop items such as a Transmission Divisionpress, mauls and soft bars are all that is needed Technical Service Dept.to successfully disassemble and reassemble any P.O. Box 4013Fuller Transmission. Kalamazoo, Michigan 49003

The specialized tools listed below can be

PAGE TOOL HOW OBTAINED

Made from Fuller20 Tension Spring Driver Print T-1 1938

Bearing Puller, Large29 (Jaw Type) Tool Supplier

32 Impact Puller (%-13 Threaded End) Tool Supplier

Made from Fuller33 Countershaft Bearing Puller Print T-9824

36, 39, 49, 56 Snap Ring Pliers, Large Tool Supplier

Made from Fuller Print40, 48 Drive Gear Bearing Nut Remover/lnstaller T-22553-D or T-22553-C

Made from Fuller50,60 Countershaft Support Tool Print T-22247

Made from Fuller Print50,60,61,63,65 Bearing Drivers (Flange-End Type) Print Series T-18042*

Made from Fuller Print65 Oil Seal Driver T-1 8088-20 or T-18088-34

65 Torque Wrench, 1000 Ft.-Lb. Capacity Tool Supplier

*Dimensions necessary to determine specific tool number required.

TOOL REFERENCE

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.

Note: Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed. Although every attempt has been made to ensure the accuracy of information contained within, Eaton makes no representation about the completeness, correctness or accuracy and assumes no responsibility for any errors or omissions. Features and functionality may vary depending on selected options.

For spec’ing or service assistance, call 1-800-826-HELP (4357) or visit www.eaton.com/roadranger.In Mexico, call 001-800-826-4357.

Eaton CorporationVehicle GroupP.O. Box 4013Kalamazoo, MI 49003 USA800-826-HELP (4357)www.eaton.com/roadranger

Printed in USA

Roadranger: Eaton and trusted partners providing the best products and services in the industry, ensuring more time on the road.

fuller medium heavy transmissions trsm0200 -...

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