Professional Documents
Culture Documents
Service Manual
TRSM0930
August 2011
F-5405B-DM3 RTO-12910B-AS3 FO-14E308LL-VCS
F-6405B-DM3 RTO-12910B-DM3 FO-16E308LL-VCS
FM-14D310B-LST RTO-14910B-AS3 FO-14E309ALL-VMS
FM-15D310B-LST RTO-14910B-DM3 FO-16E309ALL-VMS
FO-16D313E-LEP RTO-14910C-AS3 FO-14E313B-MHP
FO-5406B-DM3 RTO-16910B-AS3 FO-16E313B-MHP
FO-6406A-AW3 RTO-16910B-DM3 FO-18E313B-MHP
FO-6406B-DW3 RTO-16910C-AS3 FO-20E313B-MHP
FO-8406A-AW3 RTO-18910B-AS3 FO-14E318B-MXP
FOM-16D313E-LEP RTOM-16910B-DM3 FO-16E318B-MXP
RTLO-14918A-AS3 FO-14E310C-LAS FO-18E318B-MXP
RTLO-16913L-DM3 FO-16E310C-LAS FO-20E318B-MXP
RTLO-16918A-AS3 FO-18E310C-LAS FO-22E318B-MXP
RTLO-18918A-AS3 FOM-14E310C-LAS FO-14E318B-VXP
RTLO-20918A-AS3 FOM-15E310C-LAS FO-16E318B-VXP
RTLO-22918A-AS3 FOM-16E310C-LAS FO-18E318B-VXP
RTLOM-16913L-DM3 FM-14E310B-LAS FO-20E318B-VXP
RTO-10910B-AS3 FM-15E310B-LAS FO-22E318B-VXP
RTO-10910B-DM3 EO-11E406B-PV
Warnings & Cautions
WARNING
Follow the specified procedures in the indicated order to avoid personal injury
Note: Additional relevant information not covered in the service procedure.
CAUTION
Follow the specified procedures in the indicated order to avoid equipment malfunction or damage.
Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level.
Do not operate the vehicle if alternator lamp is lit or if gauges indicate low voltage.
i
Table of Contents
Table of Contents
Input Shaft Speed Sensor Removal . . . . 30
General Information Heavy Duty Procedure . . . . . . . . . . . 31
Transmission Overview . . . . . . . . . . . . . 1 Medium Duty Procedure. . . . . . . . . . 31
Heavy Duty 8LL / VCS & 9ALL / VMS 1 Input Shaft Speed Sensor Installation . . 32
Heavy Duty 8LL / VCS & 9ALL / VMS 2 Heavy Duty Procedure . . . . . . . . . . . 33
Heavy Duty 10-Speed LAS . . . . . . . 3 Medium Duty Procedure. . . . . . . . . . 33
Heavy Duty 10-Speed LAS . . . . . . . 4 Main Shaft Speed Sensor Removal . . . . 35
Heavy Duty 13-Speed MHP & Main Shaft Speed Sensor Installation . . 37
18-Speed VXP/MXP . . . . . . . . . . . . 5
Output Shaft Speed Sensor Removal . . 39
Heavy Duty 13-Speed MHP &
Heavy Duty . . . . . . . . . . . . . . . . . . . . 40
18-Speed VXP/MXP . . . . . . . . . . . . 6
Medium Duty . . . . . . . . . . . . . . . . . . 40
Heavy Duty 13-Speed DM3 &
18-Speed AS3 . . . . . . . . . . . . . . . . . 7 Output Shaft Speed Sensor Installation . 41
Heavy Duty 10-Speed AS3 & DM3 . 8 Heavy Duty Procedure . . . . . . . . . . . 42
Medium Duty 6 & 5-Speed DM3 . . . 9 Medium Duty Procedure. . . . . . . . . . 42
Medium Duty 6-Speed AW3 . . . . . . 10 Directional Output Shaft Speed
Sensor Removal . . . . . . . . . . . . . . . . . . . 43
Medium Duty 6-Speed PV . . . . . . . . 11
Directional Output Shaft Speed
How to use this Manual . . . . . . . . . . . . . 12
Sensor Installation . . . . . . . . . . . . . . . . . 45
General Information . . . . . . . . . . . . . 12
Splitter Valve Removal . . . . . . . . . . . . . . 47
Service Repair Procedures . . . . . . . 12
Splitter Valve Installation . . . . . . . . . . . . 49
Appendix . . . . . . . . . . . . . . . . . . . . . 12
Range Valve Removal . . . . . . . . . . . . . . 51
Serial Tag Information and Model
Range Valve Installation. . . . . . . . . . . . . 53
Nomenclature. . . . . . . . . . . . . . . . . . . . . 13
Combination Valves Removal
Model Number . . . . . . . . . . . . . . . . . 13
(Range and Deep Reduction). . . . . . . . . 55
Transmission Tag . . . . . . . . . . . . . . 14
Combination Valves Installation
Serial Number . . . . . . . . . . . . . . . . . 16 (Range and Deep Reduction). . . . . . . . . 57
Bill of material or Customer number 16 Air Filter/Regulator Removal . . . . . . . . . 59
Air Filter/Regulator Installation . . . . . . . . 61
Service Procedure
Inertia Brake Removal . . . . . . . . . . . . . . 63
Clutch Greasing Guidelines . . . . . . . . . . 17
Heavy Duty Procedure . . . . . . . . . . . 64
Lubricant Filter Removal
Medium Duty Procedure. . . . . . . . . . 65
(AW3 Models Only) . . . . . . . . . . . . . . . . 18
Inertia Brake Installation . . . . . . . . . . . . . 66
Lubricant Filter Installation
(AW3 Models Only) . . . . . . . . . . . . . . . . 20 Heavy Duty Procedure . . . . . . . . . . . 67
Gear Select Sensor Removal . . . . . . . . 22 Medium Duty Procedure. . . . . . . . . . 68
Gear Select Sensor Installation . . . . . . . 24 Electric Shifter Removal . . . . . . . . . . . . . 69
Rail Select Sensor Removal . . . . . . . . . 26 Electric Shifter Installation . . . . . . . . . . . 71
Table of Contents
General Information
Transmission Overview
Heavy Duty 8LL / VCS & 9ALL / VMS
General Information
Input Shaft Speed Sensor
Electric Shifter
Mainshaft
Speed Sensor Air Filter
Regulator
Output Shaft
Speed Sensor Range Deep Reduction
(Combination Valve)
1
General Information
Electronic Clutch
Actuator (ECA)
Low Capacity
Inertia Brake (LCIB)
2
General Information
General Information
Electric Shifter
Transmission ECU
Transmission Harness
3
General Information
Electronic Clutch
Actuator (ECA)
Low Capacity
Inertia Brake (LCIB)
4
General Information
Electric Shifter
General Information
Gear Select Sensor
Output Shaft
Speed Sensor
5
General Information
Electronic Clutch
Actuator (ECA)
Low Capacity
Inertia Brake (LCIB)
6
General Information
Input Shaft
Speed Sensor
Electric Shifter
General Information
Gear Select Sensor
Transmission Harness
Transmission ECU
Inertia Brake
(13-Speed DM3 Only)
7
General Information
Input Shaft
Speed Sensor
Electric Shifter
Main Shaft
Speed Sensor Rail Select Sensor
Output Shaft
Speed Sensor Range Valve Solenoid
Transmission ECU
Transmission Harness
Inertia Brake
(10-Speed DM3 Only)
8
General Information
Electric Shifter
General Information
Gear Select Sensor
Output Shaft
Speed Sensor
Input Shaft
Speed Sensor Location
Transmission Harness
Transmission ECU
Inertia Brake
9
General Information
Electric Shifter
Output Shaft
Speed Sensor
Input Shaft
Speed Sensor Location
Transmission Harness
Transmission ECU
Wetclutch Solenoid
Connector
10
General Information
Output Shaft
Speed Sensor
General Information
Transmission ECU
Inertia
Brake
Transmission
Harness
Input Shaft
Speed Sensor
11
General Information
ECA
Release Yoke
& Cross-Shaft
Assembly
Electronic Clutch
Actuator (ECA)
The service procedures in this manual are for transmission automation components only. To find the information you need, simply
locate the procedure in the Table of Contents, turn to the page specified, and follow the procedure. If you are unsure of a compo-
nents name, you can reference the Transmission Overview pages.
To service the mechanical portion of the transmission system, refer to the specific transmission service manual.
12
General Information
When calling for service assistance or parts, have the model and serial numbers handy.
General Information
Model RTLO-16913L-DM3
Serial Made In
Eaton Fuller
R R
Eaton Corporation
Transmissions Transmission Div.
Kalamazoo, MI. 49003
Model Number
The model number gives basic information about the transmission and is explained below. Use this number when calling for ser-
vice assistance or replacement parts.
13
General Information
Transmission Tag
5-Speed F X - X 4 0 5 X - D M 3
Fuller Generation 3 Electronics
Overdrive Automatic
Torque x 100 w/DM Autoclutch
Design Level Gear Ratio
Forward Speeds
6-Speed F X - X 4 0 6 X - AW3
Fuller Generation 3 Electronics
Overdrive Automatic with WetClutch
Torque x 100 Gear Ratio
Design Level Forward Speeds
6-Speed F X - X 4 0 6 X - D M 3
Fuller Generation 3 Electronics
Overdrive Automatic
Torque x 100 w/DM Autoclutch
Design Level Gear Ratio
Forward Speeds
10-Speed
R T O - 1 X 9 1 0 X -AS3
Roadranger
Twin Countershaft
Overdrive Generation 3 Electronics
Torque x 100 AutoShift
Design Level Gear Ratio
Forward Speeds
10-Speed
R T O - 1 X 9 1 0 X - D M 3
Roadranger Generation 3 Electronics
Twin Countershaft Automatic
Overdrive
w/DM Autoclutch
Torque x 100
Gear Ratio
Design Level
Forward Speeds
13-Speed R T L O M- 1 X 9 13 X-DM3
Roadranger
Twin Countershaft Gen 3 Electronics
Low-Inertia Automatic w/DM Autoclutch
Overdrive Gear Ratio
1750 lb.ft. Torque in Forward Speeds
Top Two Gears Only Design Level
Torque x 100
18-Speed R T L O- 1 X 9 18 X-AS 3
Roadranger
Twin Countershaft Gen 3 Electronics
Low-Inertia AutoShift
Overdrive Gear Ratio
Forward Speeds
Design Level
Torque x 100
14
General Information
6-Speed E O - 1 X E 4 0 6 B P V
Passenger
Brand - Eaton Vehicle
Overdrive
Ratio Set
X 100 + 50
Nominal Torque Lb. Ft. Number of Speeds
Configuration
Design Level
Mechicanical & Electronic
10-Speed F O - 1 X E 3 0 8 L L - V C S
Construction
Brand - Fuller Series
Overdrive UltraShift
X 100 + 50
General Information
Vocational
Nominal Torque Lb. Ft.
Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic
10-Speed F O M 1 X E 3 1 0 C - L A S
Brand - Fuller Active
Shifting
Overdrive
Line Haul
Multi-Torque
Ratio Set
X 100 + 50
Nominal Torque Lb. Ft. Number of Speeds
Starting Device
(Clutch Type)
Design Level
Mechicanical & Electronic
11-Speed F O - 1 X E 3 0 9 A L L - V M S
Mixer
Brand - Fuller Series
Overdrive UltraShift
X 100 + 50 Vocational
Nominal Torque Lb. Ft.
Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic
13-Speed F O - 1 X E 3 1 3 A - M H P
Brand - Fuller High Performance
Overdrive UltraShift
X 100 + 50 Multipurpose
Nominal Torque Lb. Ft. Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic
18-Speed F O - 1 X E 3 1 8 B - M X P
15
General Information
Serial Number
The serial number is the sequential identification number of the transmission. Before calling for service assistance, write the num-
ber down as it may be needed.
Bill of material or Customer number
This number may be located below the model and serial numbers. It is a reference number used by Eaton.
16
Service Procedure
Service Procedure
IMPORTANT
It is highly important to follow proper clutch lube intervals as specified in Lubrication Manual, TCMT0021. Failure to do so may
result in clutch failure and unnecessary repairs.
The heavy-duty ECA clutch housing has two grease fittings on the lower right side. The upper port is marked CS for the upper
cross-shaft assembly, while the lower port is marked RB for the release bearing.
Service Procedure
For more detailed cross-shaft greasing information refer to the Release Yoke and Cross-shaft(s) Installation section of this
manual. Refer to Clutch Service Manual, CLSM0200, for release bearing greasing information.
17
Service Procedure
Transmission filters should be changed during regular lube intervals. Inspection of the transmission filter should be con-
ducted during preventative maintenance checks for damage or corrosion. Replace as necessary.
Special Instructions
None
Special Tools
Basic Hand Tools
1
2
7
1. High Pressure Oil Filter (Large opening)
2. Low Pressure Oil Filter (Small opening)
3. Gasket
4. Oil Pan
5. Short Cap Screw
6. Long Cap Screw
7. Drain Plug
18
Service Procedure
4. Using a 1/2 drive at the filter base, remove the two (2)
WARNING
WetClutch filters. Make sure filter seals are removed.
Fluid may be hot. Note: The filters will contain fluid when they are removed.
1. Remove the drain plug and drain the fluid from the Wet-
Clutch portion of the transmission.
Service Procedure
3. Remove the WetClutch oil pan and gasket.
19
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
1
2
20
Service Procedure
1. Lubricate each filter seal ring with synthetic Dexron III 4. Install a new gasket and the WetClutch oil pan.
prior to installation.
Note: The High and Low pressure filters are non-interchange-
able.
Note: Clean filter seal mating surfaces on the transmission.
Note: Clean and remove all old gasket material from the mat-
ing surfaces of the clutch housing and the oil pan.
CAUTION
Make sure to put the long and short bolts back in their
proper location to avoid damaging the transmission. The
short bolts are used in the back of the oil pan.
Service Procedure
6. Install the oil pan drain plug and tighten to 34-48 lb-ft.
3. Install the Low-pressure filter by hand and turn until the (46-64 Nm).
seal touches. Then, tighten with a 1/2 drive 3/4 to 1 full Note: Fill the WetClutch portion with the proper fluid page 115
turn.
21
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
3
2
1. Cap Screw
2. Sensor
3. Gasket
22
Service Procedure
CAUTION
2. Using a 5/32 hex key wrench, remove the two (2) sensor
hex key mounting screws.
Service Procedure
3. Remove the Gear Select Sensor and gasket from the
housing.
23
Service Procedure
Special Instructions
Special Tools
Basic Hand Tools
3
2
1. Cap Screw
2. Sensor
3. Gasket
24
Service Procedure
CAUTION
2. Using a 5/32" hex key wrench, install the hex key mount-
Service Procedure
ing screws and tighten to 21-27 lb-in. (2.3-3.0 Nm).
25
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
3
2
1. Cap Screw
2. Sensor
3. Gasket
26
Service Procedure
CAUTION
2. Using a 5/32 hex key wrench, remove the two (2) sensor
hex key mounting screws.
Service Procedure
3. Remove the Rail Select Sensor and gasket from the
housing.
27
Service Procedure
Special Instructions
Special Tools
Basic Hand Tools
3
2
1. Cap Screw
2. Sensor
3. Gasket
28
Service Procedure
1. Align the sensors tabs with the slot in the Electric Shifter 3. Reconnect the Transmission Harness to the Rail Select
rail. Then, insert the Rail Select Sensor, with gasket, into Sensor.
its mounting location.
Note: Install the sensor, so the connector opening faces the
right side of the transmission. (As viewed from the rear
of the transmission)
CAUTION
Service Procedure
2. Using a 5/32" hex key wrench, install the two (2) hex key
mounting screws and tighten to 21-27 lb-in. (2.3-3.0
Nm).
29
Service Procedure
Special Instructions
Special Tools
Basic Hand Tools
1
1
3
3
1. Cap Screw
2. Sensor
3. O-ring
30
Service Procedure
Service Procedure
3. Remove the Input Shaft Speed Sensor, with o-ring, from
the transmission housing.
3. Remove the Input Shaft Speed Sensor, with o-ring, from
the transmission housing.
31
Service Procedure
Special Instructions
Special Tools
Basic Hand Tools
1
1
3
3
1. Cap Screw
2. Sensor
3. O-ring
32
Service Procedure
Clean the mounting surface on the housing and remove any Clean the mounting surface on the housing and remove any
burrs or sharp edges. burrs or sharp edges.
Lubricate the o-ring with Eaton Fuller silicone #71214 or Lubricate the o-ring with Eaton Fuller silicone #71214 or
equivalent. equivalent.
1. Using a smooth, twisting motion, fully insert the Input 1. Using a smooth, twisting motion, fully insert the Input
Shaft Speed Sensor in the transmission housing opening. Shaft Speed Sensor in the Inertia Brake opening.
Service Procedure
2. Using a 3/8" socket, install the retaining bolt and tighten 2. Using a 3/8" wrench, install the sensor retaining bolt and
to 8-10 lb-ft. (11-13 Nm). tighten to 8-10 lb-ft. (11-13 Nm).
3. Reconnect the Transmission Harness to the Input Shaft 3. Reconnect the Transmission Harness to the Input Shaft
Speed Sensor or Pigtail Connector if equipped. Speed Sensor.
33
Service Procedure
34
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
1
1
Service Procedure
3
3
1. Cap Screw
2. Sensor
3. O-ring
35
Service Procedure
36
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
1
1
Service Procedure
3
3
1. Cap Screw
2. Sensor
3. O-ring
37
Service Procedure
IMPORTANT
38
Service Procedure
Special Instructions
The Output Shaft Speed Sensor location may vary depending on OEM design specifications. The sensor will be located at the 10
oclock position for Heavy Duty and the 12 oclock for Medium Duty on the Output Shaft Housing.
Special Tools
Basic Hand Tools
1
1
Service Procedure
3
3
1. Cap Screw
2. Sensor
3. O-ring
39
Service Procedure
2. Using a 13 mm socket, remove the sensor retaining bolt. 2. Using a 3/8 socket, remove the sensor retaining bolt.
3. Remove the Output Shaft Speed Sensor, with o-ring, 3. Remove the Output Shaft Speed Sensor, with o-ring,
from the transmission housing. from the transmission housing.
40
Service Procedure
Special Instructions
None.
Special Tools
Basic Hand Tools
1
1
Service Procedure
3
3
1. Cap Screw
2. Sensor
3. O-ring
41
Service Procedure
Clean the mounting surface on the housing and remove any Clean the mounting surface on the housing and remove any
burrs or sharp edges. burrs or sharp edges.
Lubricate the o-ring with Eaton Fuller silicone #71214 or Lubricate the o-ring with Eaton Fuller silicone #71214 or
equivalent. equivalent.
1. Using a smooth, twisting motion, fully insert the Output 1. Using a smooth, twisting motion, fully insert the Output
Shaft Speed Sensor in the transmission housing opening. Shaft Speed Sensor in the transmission housing opening.
2. Using a 13mm socket, install the retaining bolt and 2. Using a 3/8 socket, install the retaining bolt and tighten
tighten to 15-19 lb-ft. (20-25 Nm). to 8-10 lb-ft. (11-13 Nm).
3. Reconnect the Transmission Harness to the Output Shaft 3. Reconnect the Transmission Harness to the Output Shaft
Speed Sensor or Pigtail Connector if equipped. Speed Sensor or Pigtail Connector if equipped.
42
Service Procedure
Special Instructions
The Directional Output Shaft Speed Sensor is used on the Fuller UltraShift PLUS model transmissions. The Output Shaft
Speed Sensor location may vary depending on OEM design specifications. The sensor will be located at the 10 oclock position
for Heavy Duty and the 12 oclock for Medium Duty on the Output Shaft Housing.
Special Tools
Basic Hand Tools
Service Procedure
1
1. Cap Screw
2. Sensor with Harness
43
Service Procedure
44
Service Procedure
Special Instructions
None.
Special Tools
Basic Hand Tools
Service Procedure
1
1. Cap Screw
2. Sensor with Harness
45
Service Procedure
46
Service Procedure
Special Instructions
The Splitter Valve may be difficult to remove from the housing because of the o-rings.
Special Tools
Basic Hand Tools
Service Procedure
3
47
Service Procedure
1. If equipped, remove Protective Cover by pulling up on the 4. Lift and remove the Splitter Valve from the housing.
Release Tab.
CAUTION
48
Service Procedure
Special Instructions
Special Tools
Basic Hand Tools
Service Procedure
3
49
Service Procedure
1. Install and push the Splitter Valve down into the housing.
50
Service Procedure
Special Instructions
The Range Valve may be difficult to remove from the transmission housing because of the o-rings.
Special Tools
Basic Hand Tools
Service Procedure
3
51
Service Procedure
1. If equipped, remove the Protective Cover by pulling up on 4. Lift and remove the Range Valve from the housing.
the Release Tab.
CAUTION
52
Service Procedure
Special Instructions
Special Tools
Basic Hand Tools
Service Procedure
3
53
Service Procedure
1. Install and push the Range Valve down into the housing.
54
Service Procedure
Special Instructions
The Valves may be difficult to remove from the transmission housing because of the o-rings.
Special Tools
Basic Hand Tools
Service Procedure
3
55
Service Procedure
56
Service Procedure
Special Instructions
Special Tools
Basic Hand Tools
Service Procedure
3
57
Service Procedure
Note: Follow same procedure for the installation of the Deep 3. Reconnect the Transmission Harness to the Valve and
Reduction Valve or Range Valve. close all air tanks drains.
Note: Install the Range harness back into the tie-down on the
IMPORTANT Valve.
58
Service Procedure
Special Instructions
The Air Filter/Regulator has two (2) o-rings located between the Air Filter/Regulator and the Range or Combination Cylinder
Cover.
Special Tools
Basic Hand Tools
Service Procedure
1
59
Service Procedure
60
Service Procedure
Special Instructions
The Air Filter/Regulator has (2) o-rings located between the Air Filter/Regulator and the Range or Combination Cylinder Cover.
Special Tools
Basic Hand Tools
Service Procedure
1
61
Service Procedure
3. Reinstall the vehicle air supply line to the Air Filter Regu-
IMPORTANT lator and close all air tank drains.
Lubricate o-rings with Eaton Fuller silicone #71214 or
Equivalent.
62
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
3 5
Service Procedure
2
1. Capscrew 1. Capscrew
2. Inertia Brake 2. Inertia Brake
3. Gasket 3. Gasket
4. Spacer (Used on all Medium Duty ratios except the N)
5. Gasket (Used on all Medium Duty ratios except the N)
63
Service Procedure
Heavy Duty Procedure 4. Remove the Inertia Brake and gasket from the transmis-
1. Drain the lubricant from the transmission and disconnect sion.
the Transmission Harness from the Inertia Brake Coil.
WARNING
The Inertia Brake is heavy. Be prepared to handle the
weight of the Inertia Brake when the mounting bolts are
removed.
64
Service Procedure
Medium Duty Procedure 4. Using a 9/16 wrench, remove the (6) mounting bolts
1. Drain the lubrication from the transmission and discon- from the Inertia Brake.
nect the Transmission Harness from the Input Shaft
Speed Sensor and the Inertia Brake Coil.
2. Using a 3/8 wrench, remove the Input Shaft Speed Sen- Note: The Inertia Brake will contain some lubricant.
sor. Note: The spacer and extra gasket are used on all transmis-
sion ratios except the N.
Service Procedure
3. Using a 7/8 wrench, remove the lubricant supply line
from the transmission.
CAUTION
65
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
3 5
1. Capscrew 1. Capscrew
2. Inertia Brake 2. Inertia Brake
3. Gasket 3. Gasket
4. Spacer (Used on all Medium Duty ratios except the N)
5. Gasket (Used on all Medium Duty ratios except the N)
66
Service Procedure
Heavy Duty Procedure 3. Using a 7/8 wrench, reconnect the Inertia Brake lubri-
cant supply line to the transmission and tighten to 20-22
lb-ft. (27-29 Nm).
WARNING
The Inertia Brake is heavy. Be prepared to handle the
weight of the Inertia Brake until the mounting bolts are
installed.
1. Clean and remove all old gasket material. Then, install the
Inertia Brake and new gasket, being careful to align the
Inertia Brake gear with the drive gear.
Service Procedure
Tighten mounting bolts to 35-45 lb-ft. (47-60 Nm) using
a cross pattern.
67
Service Procedure
Medium Duty Procedure 3. Using a 7/8 wrench, reconnect the Inertia Brake lubri-
cant supply line to the transmission and tighten to 20-22
lb-ft. (27-29 Nm).
WARNING
The Inertia Brake is heavy. Be prepared to handle the
weight of the Inertia Brake until the mounting bolts are
installed.
68
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
Service Procedure
3
1. Cap Screw
2. Electric Shifter
3. Gasket
69
Service Procedure
70
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
Service Procedure
3
1. Cap Screw
2. Electric Shifter
3. Gasket
71
Service Procedure
1. Check to ensure the shift blocks are in the neutral posi- 4. Position the Electric Shifter on the Shift Bar Housing.
tion, then move the shift finger to the center (neutral) Then using a 9/16 socket, install the mounting cap
location. screws and tighten in a cross pattern as follows:
Note: If the shift finger is not properly aligned, the Electric 5, and 6-Speed (Aluminum Housing)- Tighten to 20-
Shifter will not fit properly at its mounting location. 25 lb-ft. (27-34 Nm).
2. Clean and remove old gasket material from the Shift Bar
Housing. Then, install the new gasket on the Shift Bar
Housing.
Note: Apply Eaton sealant #71205 or equivalent to the mount-
ing cap screws before installing. 5. Reconnect the Rail Select Sensor and Gear Select Sensor.
3. The Dowel pin on the Electric Shifter must be aligned 6. Reconnect the Transmission Harness to the Rail Select
with the hole in the Shift Bar Housing (used on 10 and 13 and Gear Select motors. Using nylon ties, secure the
& 18-Speed models only). motor wires to the transmission in their previous posi-
tion.
72
Service Procedure
IMPORTANT
The Electric Shifter must be calibrated before the vehicle is
placed into operation.
Service Procedure
73
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
1 1
2 3 2
3
4
74
Service Procedure
CAUTION
Service Procedure
3. Using a 7/16 socket, remove the three (3) mounting
nuts.
75
Service Procedure
Medium Duty Procedure 4. Remove the Transmission Controller assembly from the
locating studs.
CAUTION
76
Service Procedure
Special Instructions
IMPORTANT
Fault Code 68 will be active after a new ECU is installed on the Fuller UltraShift PLUS until a Grade Sensor Calibration is per-
formed. Refer to Grade Sensor Calibration section in the Appendix of this manual for detailed information.
Fault Code 27 will be active after a new ECU is installed on the Fuller UltraShift PLUS until the clutch finishes calibrating. This
occurs automatically when the engine is started and takes approximately 50 seconds to complete. Refer to Clutch Calibration
section in the Service Manual CLSM0200 for detailed information.
The Fuller UltraShift PLUS Transmission Controller can be programmed to count clutch actuations in order to provide a clutch
grease notification to the driver. To ensure an accurate count, it is important to grease the clutch release bearing when replacing
a Transmission Controller. Refer to the Clutch Service Manual CLSM0200 for greasing instructions.
Special Tools
Basic Hand Tools
Service Procedure
1 1
2 3
2
4 3
77
Service Procedure
1. Position the Transmission Controller on the locating Using a 5/32 wrench, reconnect the Vehicle Inter-
studs. face 38-way connector and tighten to 25 +/- 3 lb-in.
(2.82 +/- .33 Nm).
Reconnect the negative battery cable.
IMPORTANT
The Electric Shifter must be calibrated before the vehicle is
placed in operation.
3. Using a 7/16 socket, install the three (3) Transmission
Controller mounting nuts and tighten to 7 - 9 lb-ft. (9.5 -
6. To operate properly, the system must be calibrated as fol-
12.2 Nm).
lows:
Turn the ignition switch on and allow the transmis-
sion to power up.
Turn the ignition off and wait two minutes.
78
Service Procedure
Medium Duty Procedure Using a 5/32 wrench, reconnect the Vehicle Inter-
face 38-way connector and tighten to 25 +/- 3 lb-in.
(2.82 +/- .33 Nm).
CAUTION
Reconnect the negative battery cable.
Battery negative must remain disconnected until the Trans-
mission ECU 38-Way connectors are installed.
CAUTION
The Electric Shifter must be calibrated before the vehicle is
placed in operation.
Service Procedure
2. Using a 7/16 socket, install the three (3) Transmission
sion to power up.
Controller mounting bolts and tighten to 7 - 9 lb-ft. (9.5 -
12.2 Nm). Turn the ignition off and wait two minutes.
Note: UltraShift AW3- Perform clutch calibration: page 115.
IMPORTANT
Do not exceed the torque on the Transmission Harness or
Vehicle Harness connector or bolt failure will occur.
79
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
2 9
10 3
4
3
7
2
5 11 4
1 8 8
1
7
9
5
6 6
80
Service Procedure
9
7
7
5 10 8
10 8 5
2 2 3
3
11 11
12
12
11 9
11
4 1 4
1
13
6
6
13
Service Procedure
1. ECU 38-Way Connector 1. ECU 38-Way Connector
2. Gear Sensor Connector 2. Gear Sensor Connector
3. Rail Sensor Connector 3. Rail Sensor Connector
4. 4-Way Diagnostic Connector 4. 4-Way Diagnostic Connector
5. Input Shaft Speed Sensor Connector 5. Input Shaft Speed Sensor Connector
6. ECA 8-Way Connector 6. ECA 8-Way Connector
7. Range Solenoid Connector 7. Range Solenoid Connector
8. Output Shaft Speed Sensor Connector 8. Output Shaft Speed Sensor Connector
9. Reduction Solenoid Connector 9. Splitter Solenoid Connector
10. Mainshaft Speed Sensor 10. Mainshaft Speed Sensor
11. Electric Shifter Connector 11. Electric Shifter Connector
12. Engine Speed Sensor Connector 12. Engine Speed Sensor Connector
13. Terminating Resistor Connector 13. Terminating Resistor Connector
81
Service Procedure
LAS Models
5
10
8
3
2
11
11
9 4
1
12
82
Service Procedure
CAUTION CAUTION
The battery negative must be disconnected prior to unhook- The battery negative must be disconnected prior to unhook-
ing the Transmission ECU 38-Way connectors. ing the Transmission ECU 38-Way connectors.
Do not allow contamination into the Transmission ECU or Do not allow contamination into the Transmission ECU or
connectors. connectors.
1. Disconnect the following connectors: 1. Using a 5/32 allen wrench, disconnect the Transmission
Harness 38-way connector.
Using a 5/32 allen wrench, unscrew and disconnect
the Transmission Harness 38-way connector and
Vehicle Interface 38-way connector.
Service Procedure
2. Disconnect the following harness connectors:
Inertia Brake Coil (if equipped)
2. Disconnect the following harness connectors:
Input Shaft Speed Sensor
Inertia Brake Coil (if equipped)
Gear Select Sensor and Rail Select Sensor
Input Shaft Speed Sensor
WetClutch solenoid (AW3 only)
Main Shaft Speed Sensor
Output Shaft Speed sensor (location may vary)
Gear Select Sensor and Rail Select Sensor
4-way Transmission Diagnostic connector
Output Shaft Speed Sensor
Electric Shifter
Range and Splitter Valve Solenoids
page 1
4-Way Transmission Diagnostic connector
Electric Shifter
page 1
83
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
10 2 9
3
4
3
7
2
5 11 4
1 8 8
1
7
9
5
6
6
84
Service Procedure
9
7
7
5 10 8
10 8 5
2 2 3
3
11 11
12
12
11 9
11
4 1 4
1
13
6
6
13
Service Procedure
1. ECU 38-Way Connector 1. ECU 38-Way Connector
2. Gear Sensor Connector 2. Gear Sensor Connector
3. Rail Sensor Connector 3. Rail Sensor Connector
4. 4-Way Diagnostic Connector 4. 4-Way Diagnostic Connector
5. Input Shaft Speed Sensor Connector 5. Input Shaft Speed Sensor Connector
6. ECA 8-Way Connector 6. ECA 8-Way Connector
7. Range Solenoid Connector 7. Range Solenoid Connector
8. Output Shaft Speed Sensor Connector 8. Output Shaft Speed Sensor Connector
9. Reduction Solenoid Connector 9. Splitter Solenoid Connector
10. Mainshaft Speed Sensor 10. Mainshaft Speed Sensor
11. Electric Shifter Connector 11. Electric Shifter Connector
12. Engine Speed Sensor Connector 12. Engine Speed Sensor Connector
13. Terminating Resistor Connector 13. Terminating Resistor Connector
85
Service Procedure
7 4
3
11 9
2
10
5
10 6 7
8
2 3 9
1
11
11 8
9 4
1
12 5
86
Service Procedure
CAUTION CAUTION
Do not allow contamination into the Transmission ECU con- Do not allow contamination into the Transmission ECU con-
nectors. nectors.
You need to leave a service loop in the Transmission Har- You need to leave a service loop in the Transmission Har-
ness. ness.
Do not put sharp bends in the Transmission Harness. Do not put sharp bends in the Transmission Harness.
The battery negative must be disconnected, while installing The battery negative must be disconnected, while installing
the Transmission ECU connectors. the Transmission ECU connectors.
1. Reconnect the following harness connectors: 1. Reconnect the following harness connectors:
Gear Select and Rail Select Sensor Gear Select and Rail Select Sensor
Main Shaft Speed Sensor Input Shaft Speed Sensor
Input Shaft Speed Sensor Inertia Brake Coil
Inertia Brake Coil (if equipped) Output Shaft Speed Sensor
Output Shaft Speed Sensor 4-way Transmission Diagnostic connector
Service Procedure
4-way Transmission Diagnostic connector Electric Shifter
Electric Shifter WetClutch solenoid (AW3 only) page 1
Range and Splitter Valve Solenoids page 1
CAUTION
CAUTION Do not exceed the torque on the Transmission Harness or
Do not exceed the torque on the Transmission Harness or Vehicle harness connector or bolt failure will occur.
Vehicle harness connector or bolt failure will occur.
2. Using a 5/32 allen wrench, reconnect the Transmission
Using a 5/32 allen wrench, reconnect the Transmission Har- Harness 38-way connector and tighten to 25 +/- 3 lb-in.
ness 38-way connector and tighten to 25 +/- 3 lb-in. (2.82 +/- (2.82 +/- .33 Nm).
.33 Nm).
87
Service Procedure
Special Instructions
Special Tools
Basic Hand Tools
2
1
1. Nut
2. Washer
3. Push Button Shift Control 30-Way Connector
4. Backing Plate
5. Push Button Shift Control
88
Service Procedure
2. Using a 11/32 wrench, remove the two (2) nuts and lock
washers from the back of the Shift Control and remove
the Shift Control.
Note: Shift Control location and use varies with each truck.
Service Procedure
89
Service Procedure
Special Instructions
Special Tools
Basic Hand Tools
2
1
1. Nut
2. Washer
3. Push Button Shift Control 30-Way Connector
4. Backing Plate
5. Push Button Shift Control
90
Service Procedure
Service Procedure
91
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
1. Tower
2. Screw
3. 8-Way Cobra Lever Harness Connector
92
Service Procedure
Service Procedure
93
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
1. Tower
2. Screw
3. 8-Way Cobra Lever Harness Connector
94
Service Procedure
Service Procedure
95
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
9
1. Plug
2. O-ring
3. Upper Cross-shaft
4. Bushing
5. Seal
6. Lock Washer
7. Mounting Screw
8. Release Yoke
9. Lower Cross-shaft
96
Service Procedure
Note: The Transmission and ECA must be removed prior to 4. If necessary, remove the cross-shaft plug with o-ring.
removing the Release Yoke and Cross-shaft(s).
Service Procedure
6. If necessary, remove the two (2) upper cross-shaft bush-
ings.
97
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
1. Plug
2. O-ring
3. Upper Cross-shaft
4. Bushing
5. Seal
6. Lock Washer
7. Mounting Screw
8. Release Yoke
9. Lower Cross-shaft
98
Service Procedure
1. If previously removed, install the two (2) upper cross- 4. Install the upper cross-shaft into the bore.
shaft bushings.
Note: Make sure to apply grease to the bushings.
Service Procedure
6. Install lower cross-shaft assembly and install one (1) cap
3. If previously removed, install the o-ring onto the cross-
screw and lock washer by hand.
shaft plug and then install the cross-shaft plug into the
transmission housing and torque to 34-48 lb-ft. (46-65
Nm).
99
Service Procedure
7. Tighten the two (2) yoke cap screws to 35-45 lb-ft. (47-
61 Nm).
100
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
Service Procedure
2
1. Mounting Nut
2. Low Capacity Inertia Brake (LCIB)
101
Service Procedure
102
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
Service Procedure
1
1. Mounting Nut
2. Low Capacity Inertia Brake (LCIB)
103
Service Procedure
1. Slide the LCIB onto the splined input shaft while center-
ing the holes onto the retaining studs.
2. Install the two (2) retaining nuts and torque nuts to 140-
150 lb-ft. (190-203 Nm).
Note: The LCIB can only be installed one way. The label is
toward the right side of the vehicle and facing the fly-
wheel.
104
Service Procedure
Special Instructions
Note: If vehicle is equipped with an 8-bolt PTO, removal may be required prior to ECA removal. Follow PTO manufacturers
guidelines for removal.
Special Tools
Basic Hand Tools
Service Procedure
4
5
105
Service Procedure
4. Remove the four (4) cap screws from the ECA mounting
flange.
CAUTION
Ensure the hand hole cover is closed when removing the ECA.
3. Remove the four (4) cap screws from the ECA shield and
remove shield.
Note: Medium Duty models are mounted with (3) cap screws
and (1) lock nut.
Note: The ECA has an alignment pin that requires the unit to
be rotated to exit the clutch housing bore.
Note: If ECA will not slide from the clutch housing after all the
fasteners are removed use the available pusher holes
found on both sides of the ECA casting. Place the
included jackscrews into the holes and turn each jack-
screw until they touch. Next, turn the upper jackscrew
one (1) turn then rotate to the lower jackscrew and
rotate it one (1) turn. Continue until the ECA is fully dis-
placed from the bore.
106
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
Service Procedure
4
5
107
Service Procedure
1. Install the ECA into the clutch housing bore. Align it with 3. If applicable, install the four (4) cap screws for the ECA
the lower cross-shaft. shield. Tighten them to 35-45 lb-ft. (47-61 Nm).
Note: The ECA will have to be rotated to align with the slot in 4. Apply Nyogel to terminals and reconnect the 8-way and
the clutch housing. 3-way connectors to the ECA.
Note: Ensure you rotate the release yoke as close to the case
dowel in the clutch housing prior to mating with the
cross-shaft. This allows the release yoke to clear the
release bearing during installation.
2. Install the four (4) cap screws from the ECA mounting
flange. Tighten them to 35-45 lb-ft. (47-61 Nm).
Note: Medium duty models are mounted with three (3) cap
screws and one (1) lock nut. Tighten to 35-45 lb-ft. (47-
61 Nm).
Note: Apply just enough material to cover the end of the ter-
minal.
Note: Use only Eaton lubricant part number 5564527 (Nye
Lubricants NYOGEL 760G. For MSDS safety or other
information see www.nyelubricants.com.)
108
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
Service Procedure
2
1. Sensor
2. Jam Nut
109
Service Procedure
110
Service Procedure
Special Instructions
None
Special Tools
Basic Hand Tools
Service Procedure
2
1. Sensor
2. Jam Nut
111
Service Procedure
1. Thread speed sensor into the engine bell housing until it 5. Connect engine speed sensor connector to the mating
touches the flywheel. connector on the transmission and fasten harness if
needed.
3. Hold the sensor in place and tighten the 3/4 - 16 jam nut
to 15 lb-ft. (20.3 Nm).
112
Appendix
Appendix
Operation
For more detailed information on transmission operation and shifting go to the Roadranger.com Literature Center (www.road-
ranger.com) and look for the drivers manual on your model transmission.
Generation 3 UltraShift Driver Instructions - TRDR0940
Generation 3 AutoShift Driver Instructions - TRDR0930
Lubrication Specifications
CAUTION
Never mix engine oils and synthetic transmission oils in the same transmission. When switching between types of lubri-
cants, all areas of each affected component must be thoroughly drained.
IMPORTANT
Transmission filters should be changed during regular lube intervals. Inspection of the transmission filter should be con-
ducted during preventative maintenance checks for damage or corrosion. Replace as necessary.
113
Appendix
External oil coolers are available to reduce operating temperatures when the above conditions are encountered. Eaton Oil cooler
systems must meet a minimum requirement of 3/4 I.D. cooler lines and 8 GPM. system flow @ 1500 RPM. The end user is ulti-
mately responsible for maintaining transmission lube temperatures below 250F [121C].
Transmission Oil Coolers are recommended Transmission Oil Coolers are required
With engines of 350 H.P. and above With engines 400 H.P. and above and GCWs of
90,000 lbs [40,823 kg] or greater
With engines 400 H.P. and above and 1400 lb-ft.
[1898 Nm] or Greater torque
With engines 450 H.P. and above
With engines 1500 lb-ft. [2033 Nm] and above
114
Appendix
CAUTION
Never mix engine oils and synthetic transmission oils in the same transmission. When switching between types of lubri-
cants, all areas of each affected component must be thoroughly drained.
CD-50
CD-50 must be used in the gearbox portion of the transmission.
Interval Description
Appendix
First 1,000 to 1,500 miles Inspect oil levels. Check for leaks.
Every 5 years or 500,000 miles, whichever oc- Change WetClutch oil and filters.
curs first
115
Appendix
Cooler
A transmission clutch cooler must be used with the Eaton UltraShift AW3 transmission. The cooler sizing must meet the require-
ments specified in this TRIG-0930
116
Appendix
IMPORTANT
Transmission filters should be changed during regular lube intervals. Inspection of the transmission filter should be con-
ducted during preventative maintenance checks for damage or corrosion. Replace as necessary.
Appendix
8. Install the dipstick and tighten securely.
117
Appendix
Clutch Calibration
The ASW system automatically provides for clutch wear. The system will initiate a clutch calibration once per vehicle power up,
when certain vehicle conditions are right. Of these conditions, the most important ones include: when the engine is running at
idle speed, during normal operating temperature, when the vehicle is stopped, and when neutral is selected on the Shift Control.
During the calibration, the clutch is partially engaged until the engine begins to slightly lug down. It will then disengage the clutch
and repeat this process several times. The calibration process usually takes as little as thirty seconds but can take as long as
two(2) minutes. The calibration will be aborted when any position other than neutral is selected on the Shift Control.
If it appears that the vehicle is not engaging smoothly from a stop, it is possible that the clutch needs to be re-calibrated. If it has
not been previously calibrated during the current power up, stop the vehicle with the engine idling at its normal operating tem-
perature and place the Shift Control in neutral and wait two(2) minutes. If the calibration is being performed you should hear the
engine slightly lug down and then return to its no load condition several times.
118
Appendix
Inspection Procedures
For all inspection procedures on assembly and disassembly refer to the service manual covering the base box procedures. These
manuals can be found on roadranger.com under the Literature Center.
Weep: Stained, damp, no drips, light oil film, Leak: Extremely wet or dripping of oil in the
dirt adhered to the contaminated area. contaminated area.
Step 1
1. Clean suspected oil weep 1. Do not repair: Rear seal is 1. Determine the origin of the leak path.
area with a clean dry cloth designed to allow minimal 2. If origin of leak is obvious skip to Step 3.
or mild soluble degreaser. seepage (refer to Roadranger 3. If the origin of the oil leak is not obvious then
TCSM-0912 Seal Maintance use either of the two following steps to determine
2. Ensure lube is to proper Guide). the oil leak:
level.
2. Ensure lube is to proper Note: Do not use a high pressure spray washer to
3. Notify the customer that it level. clean the area. Use of a high pressure spray may
is only a weep and it is not force contamination into the area of concern and
considered to be detrimental temporarily disrupt the leak path.
to the life of the transmission.
i. Clean area with a clean dry cloth or mild
4. Repair is complete. soluble degreaser and fill the transmission to
the proper lube level.
OR
ii. Clean the area as noted above and insert tracer
dye into the transmission lube and fill
transmission to proper lube level.
Step 2
Operate vehicle to normal transmission operating
temperature and inspect the area for oil leak(s)
visually or if tracer dye was introduced use an UVL
(Ultraviolet Light) to detect the tracer dyes point
of origin.
Note: When inspecting for the origin of the leak(s)
Appendix
make sure the assumed leak area is not being
contaminated by a source either forward or above
the identified area such as the engine, shift tower,
shift bar housing, top mounted oil cooler, etc...
Step 3
Once the origin of the leak is identified, repair the
oil leak using proper repair procedures from the
designated model service manual.
Step 4
After the repair is completed, verify the leak is
repaired and operate the vehicle to normal
transmission operating temperature.
Inspect repaired area to ensure oil leak has been
eliminated. If the leak(s) still occurs, repeat steps
or contact the Roadranger Call Center at
1-800-826-4357.
119
Appendix
Basic Troubleshooting
For all Basic Troubleshooting questions refer to the appropriate service manual covering the base box procedures. These manu-
als can be found on roadranger.com under the Literature Center.
120
Appendix
An active FC68 FMI13 indicates a calibration is needed, and it will go inactive upon successful calibration. (See TRTS0930 Trou-
bleshooting Guide for detailed information on FC68)
The Grade Sensor can be calibrated via ServiceRanger or an Operator Triggered Special Function.
ServiceRanger Procedure
2 Plug 9-pin connector
into dash port.
OFF
1 Turn ignition
ON
switch to on.
START
121
Appendix
4 Open and expand the Advanced 5 Click on transmission. 6 Click on Grade Sensor
Product Functions tree. NOTE: Advanced Product Calibration.
Functions appear.
122
Appendix
5
2
Appendix
Gear Display will show a 0.
0
R el eas e
6 Select Neutral and turn
ignition to Off in order to
save the calibration.
OFF
ON
R
N
START
D
MANUAL
SHIFT
LOW
123
Appendix
Tool Specifications
General Tools
The following General Tools are available from several tool manufacturers such as Snap-On, OTC, and many others.
Table 5 General Tools
TOOL PURPOSE
0 - 100 lb-ft. (0-135 Nm) 1/2" (12.7mm) drive Torque General torquing of fasteners (Typically 15-80 lb-ft. (20-108
Wrench Nm))
0 - 600 lb-ft. (0-810 Nm) 3/4" or 1" (19mm or 25.4mm) Torquing of Output Nut
drive Torque Wrench
0 - 50 lb. in. (0-5.62 Nm) 3/8" (9.52mm) drive Torque General torquing of fasteners
Wrench
2 3/4" (70mm) or Socket - Standard Depth To remove the Output Yoke/Flange Nut
Large Brass Drift 3/4" x 12" (19mm x 304.8mm) Used to protect shafts and bearings during removal
Large Dead Blow Hammer or Maul 32 ounces To provide force for shaft and bearing removal
(2) Air Pressure Gauges (0-150 PSI) 0-10.34 BAR To troubleshoot and verify correct operation of air system
3/8" Drive Deepwell socket set 3/8"- 1" (9.5mm - 25.4mm) To remove/install capscrews and nuts
3/8" Drive Shallow socket set 3/8" - 1" (9.5mm - 25.4mm) To remove/install capscrews and nuts
Snap Ring Pliers - Large Standard External To remove the snap rings at the auxiliary drive gear, input shaft
bearing, and countershaft bearings
Feeler Gauges To set mainshaft washer endplay and auxiliary tapered bearing
endplay
Open-end wrench set 3/8" - 1" (9.52mm -25.4mm) To remove certain airline connections
124
Appendix
Torque Specifications
Correct torque application is extremely important to assure long transmission life and dependable performance. Overtightening
or under-tightening can result in a loose installation and, in many instances, eventually cause damage to transmission gears,
shafts or bearings. Use of a thread sealer/locking compound is recommended for all cap screws. Do not torque cap screws dry.
Appendix
3 ECU Nuts (Heavy Duty) 7 - 9 lb-ft. .250 - 20 UNC
[9.5 - 12.2 Nm]
2 Transmission ECU 38-Way Connectors 25 +/- 3 lb-in. M5 x 0.8
Cap screws [2.82 +/- .33 Nm]
3 ECU Bracket Nuts (Heavy Duty) 20 - 25 lb-ft. .3125 - 18 UNC
[27 - 34 Nm]
3 ECU Bracket Studs (Heavy Duty) 35 - 45 lb-ft. .375 - 16 UNC
[48 - 61 Nm]
2 Harness Bracket Cap screws 20-25 lbs. ft. .3125 - 18 UNC
[27-34 Nm]
125
Appendix
126
Appendix
Appendix
127
Appendix
Torque Overview
Heavy Duty
Electric Shifter
Capscrews
Gear Select
Sensor Capscrews
Main Shaft
Rail Select
Speed Sensor Capscrew
Sensor Capscrews
Splitter Valve
Solenoid Capscrew Range Valve Solenoid
Output Shaft
Speed Sensor Capscrew
128
Appendix
Cross-shaft Plug
Low Capacity
Inertia Brake (LCIB)
Release Yoke Capscrew
Mounting Nut
Appendix
129
Appendix
Medium Duty
Gear Select
Sensor Capscrews
Rail Select
Sensor Capscrews
Output Shaft
Speed Sensor Capscrew
Input Shaft
Speed Sensor Capscrew
130
Change Control Log
08/30/2011 Changed Transmission Tag info pages 14 and 15 to add 5 speed transmission on page 14, and orient
the transmission speeds from lowest to highest on page 15.
Updated Table of Contents for correct Page Numbering and Sub Title Changes as listed below.
Changed image on page 15 by moving 5-Speed transmission tag info to top of page and added USP
Passenger transmission tag info into group.
Changed Page 105 to reflect the following: Subtitle change -, Electronic Clutch Actuator (ECA) Remov-
al instead of Electronic Clutch Actuator (ECA) Removal on a Heavy-Duty Transmission. & Item #6
to ECA Bracket to ECA Shield (Optional).
Changed Page 107 to reflect the following: Subtitle change -, Electronic Clutch Actuator (ECA) Instal-
lation instead of Electronic Clutch Actuator (ECA) Installation on a Heavy-Duty Transmission. &
Item #6 to ECA Bracket to ECA Shield (Optional).
Modified page 108 for the following: Removed Apply one (1) inch band of anti-seize to barrel of ECU
and from beginning of item #1. Added Note to item 2. Fixed second note on item #2 by removing four
(4). Added If applicable to beginning of item #3. Changed ECA Bracket to ECA Shield on item #3.
Changed Sub Title on page 109 to read Thread-In ECA Speed Sensor Removal instead of ECA Speed
Sensor Removal.
Changed Sub Title on page 111 to read Thread-In ECA Speed Sensor Installation instead of ECA
Speed Sensor Installation.
08/10/2011 Added Item #1 to Service Procedure, Transmission Controller Removal, Heavy Duty section.
Added Item #1 to Service Procedure, Transmission Controller Removal, Heavy Duty section.
Added Item #5 to Service Procedure, Transmission Controller Installation, Heavy Duty section.
Added Item #5 to Service Procedure, Transmission Controller Installation, Heavy Duty section.
Performed Spell Check, updated Lbs. ft to lb-ft and Lbs. in to lb-in, reduced book to having 5 chapters
and a Table of Contents by incorporating the sections into the chapters and corrected pagination and
page numbering.
131
Copyright Eaton Corporation and
Dana Limited, 2011. Eaton and Dana
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.
For specing or service assistance, call 1-800-826-HELP (4357) or visit our web site at
www.roadranger.com. In Mexico, call 1-80-826-4357.
Roadranger: Eaton, Dana and other trusted partners providing the best
products and services in the industry, ensuring more time on the road.
2011 Eaton Corporation All rights reserved. Eaton Corporation Truck Components Operations P.O. Box 4013 Kalamazoo, MI 49003 U.S.A. www.roadranger.com
Printed in USA