Service Manual

Eaton Transmissions
TRSM0080
October 2009
FS-4106A
FS-4206B
FSO-4206B
FS-5206A
FS-5206B
FS-5206F
FSO-5206B
Table of Contents

Introduction

Warnings and Precautions ...........................................................................................................................1

Purpose and Scope of Manual .....................................................................................................................2
How to use this Manual .................................................................................................................................2
Disassemble Precautions ..............................................................................................................................2
Inspection Precautions ..................................................................................................................................3
Assembly Precautions ...................................................................................................................................4

Model Information
Serial Tag Information and Model Nomenclature .........................................................................................5
Model Number ..............................................................................................................................................5
Serial Number................................................................................................................................................5

Specifications
Technical Data...............................................................................................................................................6
Torque Rating ...............................................................................................................................................7
Gear End Floats ............................................................................................................................................8
Synchroniser Ring to Synchroniser Flange Clearance .................................................................................8

Lubrication Information
Lubrication ....................................................................................................................................................9
Recommended Lubricants.............................................................................................................................10

Tool Information
Recommended Tools ...................................................................................................................................13
Special Tools Manufacturers .........................................................................................................................14
Locally Made Tools........................................................................................................................................15

Preventive Maintenance
Preventive Maintenance ...............................................................................................................................16
Checks Before Transmission Removal .........................................................................................................16
Checks With Drive Line Dropped ..................................................................................................................17
Checks With Universal Joint Companion Flange or Yoke Removed.............................................................17
Rear Seal Maintenance .................................................................................................................................17
Table of Contents

Power Flow
Power Flow ...................................................................................................................................................18

Direct Control Assembly

Exploded View ..............................................................................................................................................19
How to Disassemble Direct Control Assembly .............................................................................................20
How to Assemble Direct Control Assembly ...................................................................................................22

Remote Control Assembly

Exploded View ..............................................................................................................................................24
How to Disassemble Remote Control Assembly ..........................................................................................25
How to Assemble Remote Control Assembly................................................................................................27

Pneumatic Power Assist (PPA) Assembly

Exploded View ..............................................................................................................................................30
How to Disassemble PPA Assembly ............................................................................................................31
How to Assemble PPA Assembly..................................................................................................................31

Transmission Case Disassembly

Exploded View ..............................................................................................................................................32
How to Disassemble Transmission Case .....................................................................................................33

Layshaft Assembly
Exploded View ..............................................................................................................................................39
How to Disassemble Layshaft ......................................................................................................................40
How to Assemble Layshaft ............................................................................................................................41

Mainshaft Assembly - W/O 1st-2nd Double Cone Synch.

Exploded View ..............................................................................................................................................42
End Float Check ...........................................................................................................................................43
How to Disassemble Mainshaft .....................................................................................................................44
Check Clearance between Synchroniser Ring and Flange ...........................................................................46
How to Assemble Mainshaft ..........................................................................................................................47
Table of Contents

Mainshaft Assembly - With 1st-2nd Double Cone Synch.

Exploded View ..............................................................................................................................................53
End Float Check ...........................................................................................................................................54
How to Disassemble Mainshaft .....................................................................................................................55
Check Clearance between Synchroniser Ring and Flange ..........................................................................58
Check Clearance between Synchroniser Ring and Flange ..........................................................................59
How to Disassemble 1st and 2nd Double Cone Synchroniser Assembly .....................................................61
How to Assemble 1st and 2nd Double Cone Synchroniser Assembly ..........................................................63
How to Assemble Mainshaft ..........................................................................................................................66

Selector Assembly
Exploded View ..............................................................................................................................................72
How to Disassemble Selector Assembly ......................................................................................................73
How to Assemble Selector Assembly............................................................................................................74

Transmission Case Assembly

How to Assemble Transmission Case ..........................................................................................................75
 Introduction

Warnings and Precautions

Before starting a ve hicle always be s eated in the driver’s seat, place the transmission in ne utral, set the
parking brakes and disengage the clutch.

Before working on a vehicle place the transmission in neutral, set the parking brakes and block the wheels.

Before towing the vehicle place the transmission in neutral, and lift the rear wheels off the ground, remove
the axle shafts, or disconnect the driveline to avoid damage to the transmission during towing.

The description and specifications contained in this service publication are current at the time of printing.

Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifi-
cations at any time without notice.

Any reference to brand name in this publication is made as an example of the types of tools and materials recom-
mended for use and should not be considered an endorsement. Equivalents may be used.

This symbol is used throughout this manual to call attention to procedures where carelessness or failure
to follow specific instructions may result in personal injury and/or component damage.

Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may
jeopardize the personal safety of the service technician or vehicle operator.

Warning: Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician.

Caution: Failure to follow indicated procedures may cause component damage or malfunction.
Note: Additional service information not covered in the service procedures.

Tip: Helpful removal and installation procedures to aid in the service of this unit.

Always use genuine Eaton replacement parts.

1
 Introduction
Purpose and Scope of Manual
This manual is designed to provide detailed information
necessary to service and repair the Eaton® transmis-
sions listed on the front.
How to use this Manual
The procedure sections are laid out with a general
heading at the top outside edge of each page followed
by more specific headings and the procedures. To find
the information you need in these sections, first go to
the section that contains the procedure you need. Then
look at the heading at the top and outside edge of each
page until you find the one that contains the procedure
you need.
Transmission Overhaul Procedures follow the general
steps for complete disassembly and then assembly of
the transmission.
Note: In some instances the transmission appearance
may be different from the illustrations, but the pro-
cedure is the same.
2
Disassemble Precautions
It is assumed in the detailed disassembly instructions
that the lubricant has been drained and the necessary
linkage and air lines (if fitted) have been removed from
the chassis.
Removal of the gear shift remote control housing
assembly is included in the detailed instructions; how-
ever, this assembly may also be removed from the
transmission before removing unit from vehicle.
Follow each procedure closely in each section, making
use of both the text and the pictures.
Introduction
Assemblies
When disassembling the various assemblies, such as
the mainshaft, layshaft and remote control housing, lay
all parts on a clean bench in the same sequence as
removed. This procedure will simplify reassembly and
reduce the possibility of losing parts. When pulling off
synchroniser hubs follow the procedures detailed in
‘Disassembly’ using a suitable puller of adequate
capacity. Failure to adhere to the recommended proce-
dures may cause irreparable damage.
Bearings
Carefully wash and relubricate all bearings as removed
and protectively wrap until ready for use. Remove
bearings with pullers designed for this purpose.
Cleanliness
Provide a clean place to work. It is important that no dirt
or foreign material enters the unit during repairs. The
outside of the unit should be carefully cleaned before
starting the disassembly. Dirt is abrasive and can dam-
age bearings.
Snap rings
Remove snap rings with pliers designed for this pur-
pose. New selective fit snap rings must be fitted as
specified in ‘Reassembly’.
When Pressing
Apply force to shafts, housings etc. with restraint.
Movement of some parts is restricted. Do not apply
force after the part being driven stops solidly. Use soft
hammers for all disassembly work.
Do not use pry bars or chisels to separate casing
halves and housings or irreparable damage may be
caused.
 Introduction
Inspection Precautions
Before reassembling the transmission, the individual
parts should be carefully checked to eliminate those
damaged. They should be renewed. This inspection
procedure should be carefully followed to ensure the
maximum wear life from the rebuilt unit.
The cost of a new part is generally a small fraction of
the total cost of downtime and labour, should the use of
a questionable part make additional repairs necessary
before the next regularly scheduled overhaul.
Recommended inspection procedures are set forth in
the following check list.
Bearings
• Wash all bearings in clean solvent. Check roll-
ers and races for pits and spalled areas.
Renew damaged bearings.
• Lubricate undamaged bearings and check for
axial and radial clearances. Renew bearings
with excessive clearances.
• Check fits of bearings in housing bores. If outer
races turn too freely in the bores, the housing
should be renewed. Check housing bores for
signs of wear prior to taking this action. Only
replace housing if wear is seen as a result of
bearing spin.
Gears
• Check gear teeth for pitting of the tooth faces.
Gears with pitted teeth should be renewed.
Check the reverse gear dog engagement teeth
for freedom from damage.
• Check the internal bearing surfaces for wear of
the effects of overheating.
• Check axial clearances of gears. Where
excessive clearance is found, check gear and
hub for excessive wear.
• Maintain the specified axial clearance on main-
shaft forward gears.
Bearing Sleeve — Mainshaft
• Sleeves with groove formation, pits or which
have either been overheated or worn out must
be renewed.
3
Synchroniser Assemblies
• Check to ensure all splines are free from
excessive wear.
• Check that the engagement dog teeth on the
sliding sleeves, synchroniser rings are free
from chipping and burring.
• Check that the synchroniser ring cones are not
excessively worn or showing the effects of
overheating. Check the clearance between the
synchroniser ring and the synchroniser flange
is between 1.9 mm maximum and 0.5 mm
minimum.
• Renew the springs, plungers and rollers.
Splines
• Check splines on all shafts for wear. If synchro-
niser hubs, output drive flange or clutch hub
have worn into the sides of the splines, the
shafts in this condition must be renewed.
Thrust Washers
• Check surfaces of all thrust washers. Washers
scored or reduced in thickness should be
renewed.
Reverse Idler Gear
• Check bearings and shaft for wear from action
of roller bearings.
Clutch Release Parts
• Check clutch release parts, yokes and bearing
carrier. Check pedal shafts. Renew worn shafts
and bearings.
Gear Selector Shaft Assembly
• Check forks and keys for wear at contact
points. Renew worn parts.
• Check forks for excessive and uneven wear,
renew worn forks.
• Check lockscrew in selector block. A lockscrew
with worn taper must be renewed.
• Check condition and fit of selector key and
interlock key in shift shaft. Worn or damaged
keys must be renewed.
 Introduction
Gear Shift Remove Control
• Check spring tension on cross shaft. Renew
tension springs if shaft moves too freely.
• If housing is dismantled, check cross shaft and
inner lever and the bearing bushes for wear.
Renew worn parts.
• Check all seals and locating journals. Renew
worn parts.
Bearing Covers
• Check covers for wear from thrust. Renew cov-
ers worn or grooved from thrust of bearing
outer race.
• Check bores of covers for wear. Renew those
worn oversize.
Oil Return Threads and Seals
• Check oil seal in front bearing cover for dam-
age and wear, renew if necessary.
• Check oil seal in speedometer housing for
damage or wear, renew if necessary. Renew
grit shield if worn or loose on flange.
• Check oil seal journals for wear and renew if
worn or grooved.
O-Rings
• Renew all O-rings.
4
Assembly Precautions
Make sure that interiors of all housings are clean. It is
important that dirt be kept out of transmission during
reassembly. Dirt is abrasive and can damage polished
surfaces of bearings and washers. Use certain
precautions, as listed below, during reassembly.
Gaskets
Use new gaskets where detailed only (neutral detent
cover and remote control housing covers). All other
locations ensure mating faces are clean and undam-
aged and apply a continuous bead of Loctite 518
Flange Sealant to one face only. Do not apply exces-
sive sealant or allow it to penetrate into the bearings.
Introduction
Capscrews
Use thread sealant (Loctite 641) on all capscrews.
Refer section ’Specification’ for torque ratings.
‘O’ Rings
Lubricate all ‘O’ rings lightly with silicone lubricant.
Initial Lubrication
Lubricate bearings with gearbox oil during reassembly.
Axial Clearances
Refer section ’Specification’ to maintain the end float
of mainshaft gears.
Bearings
Use of flange-end bearing drivers is recommended for
the installation of bearings. These drivers apply equal
force to both races of the bearing, preventing damage
to balls and races and maintaining correct bearing
alignment with shaft and bore. A tubular type driver, if
used, will apply force only to the inner race. Heating the
bearing inner tracks will aid installation.
Output Shaft Drive Flange
Tighten the nut to the correct torque.
Synchroniser Hubs
All synchroniser hubs are an interference fit on the
mainshaft splines and must be heated to approximately
85°C (180°F) before installation.
Layshaft
The layshaft gears are a shrink and press fit on the lay-
shaft body. The gears must be heated to 150°C (300°F)
before assembly.
Prior to fitting a flange (or yoke) ensure that the seal
track is not grooved, scored or pitted. If in doubt, it
must be replaced.
 Model Information

Serial Tag Information and Model Nomenclature

All transmissions are fitted with an identification plate on left hand side of the front case on horizontal transmission
and right hand side of the front case on vertical transmission.

Model Information
Identification plate on front case is showing;
1. Transmission serial number
2. Transmission model
3. Manufacturing date code
4. Trasmission specification number

The transmission specification number is unique to each customer and gives precise details of the transmission
design level. This number must be quoted when ordering replacement parts.

Model Number

The model number gives basic information about the transmission and is explained above. Use this number when
calling for service assistance or replacement parts.

Serial Number
The serial number is the sequential indentification number of the transmission. Before calling for service assis-
tance, write number down. It may be needed.

5
 Specifications

Technical Data

Models FS 4106A, FS 4206B, FSO 4206B, FS 5106A, FS 5206B, FSO 5206B, FS 5206 F
Nominal Input Torque Weight (a) Length (b)
FS 4106A 640 Nm 117 Kg NA
FS 4206B 700 Nm 117 Kg NA
FSO 4206B 750 Nm 117 Kg NA
FS 5206A 700 Nm 117 Kg NA
FS 5206B 750 Nm 117 Kg NA
FSO 5206B 825 Nm 117 Kg NA
Oil Capacity Vertical 7.5 lit
Horizontal 6.5 lit
Vertical (Special) 8.5 lit
Clutch Housing SAE Standard
Power Take-off Vertical Installtion - Left side
Openings Horizontal Installation - Bottom right
PTO Drive Gears (c) Rotation to Engine
Driven from the reverse idler Driven from the layshaft front gear
gear
FS 4106A Engine speed x 0.226 Engine speed x 0.434
FS 4206B Engine speed x 0.271 Engine speed x 0.519

Specifications
FSO 4206B Engine speed x0.336 Engine speed x 0.644
FS 5206A Engine speed x 0.226 Engine speed x 0.434
FS 5206B Engine speed x 0.271 Engine speed x 0.519
FSO 5206B Engine speed x0.336 Engine speed x 0.644
Gear FS 4106A % step FS 4106B % step FSO 4106B % step FS 5206F % step
FS 5206A FS 5206B FSO 5206B
6 1.00 38 1.00 30 0.79 27 1.00 21
5 1.38 45 1.30 44 1.00 35 1.21 24
4 2.00 55 1.87 50 1.35 55 1.50 50
3 3.10 69 2.80 57 2.09 69 2.26 57
2 5.25 72 4.38 72 3.53 72 3.53 72
1 9.03 7.54 6.08 6.08
Reverse 8.07 6.74 5.43

a. including output coupling, low remote control; less clutch housing

b. front face of transmission case to rear face of output flange
c. recommended backlash is from 0.15 to 0.25mm.

6
 Specifications

Torque Rating
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 capscrews. Do not torque capscrews dry.

Description Quantity Torque Thread Size Additional Comments

Clutch Housing Studs 12 32 - 37 Nm M12 Studs with scotchgrip
Clutch Housing Nuts 12 140 - 150 Nm M12 For aluminium bolted material
Clutch Housing Nuts 12 120 - 130 Nm M12 For steel bolted material
Clutch Housing Nuts 12 110 - 120 Nm M12 For cast iron bolted material
Front PTO Cover Screw 6 35 - 39 Nm M10
Selector Block Tapered Lockscrew 6 35 - 39 Nm M10 Patchlock or Thread coated
with Loctite 270
Main Casing Halves Screws & Nuts 15 45 - 55 Nm M10
Main Casing Halves Screws 3 32 - 37 Nm M10
LRC End Cover Screws 4 19 - 24 Nm M8

PTO / Reverse Idler Gear Cover Screws 6 35 - 39 Nm M10

Output Shaft Locknut 1 600 -700 Nm M33 With Nylonlocking insert
Remote Control Housing Screws 4/6 35 - 39 Nm M10
Overdrive Selector Fork Pivots Capscrews 2 19 - 24 Nm M8 With spring washers
Remote Control Shaft Lever Capscrew & 1 35 - 39 Nm M10
Nut
Neutral Detent Cover Capscrews 2 19 - 24 Nm M8 With spring washers
Oil Filler Plug 1 32 - 37 Nm M24
Layshaft Front Bearing Cover Screws 4 69 - 78 Nm M12 Flange headed screw with seal-
ing patch
Inputshaft Bearing Cover Screws 5 35 - 39 Nm M10 Flange headed screw with lock-
ing coat
Remote Control Housing Detent Cover 2 19 - 24 Nm M8
Screws
Oil Drain Plug (Magnetic) 1 32 - 37 Nm M24
Speedo Pinion Adaptor 1 24 - 30 Nm M22 With copper washer
Speedo Meter Housing Capscrew 1 35 - 39 Nm M10 With plain and spring washer
Speedo Meter Housing Screws 3 35 - 39 Nm M10
Layshaft Rear Bearing Cover Screws 4 69 - 78 Nm M12
Reverse Lamp Switch 1 24 - 30 Nm M16

7
 Specifications

Gear End Floats

IMPORTANT: All Dimensions are in mm.

Gear 5th (OD, 6th) 4th 3rd 2nd 1st Reverse

Low Limit 0.31 0.25 0.35 0.35 0.33 Sliding Gear
High Limit 0.67 0.45 0.53 0.55 0.64
Tolerance 0.36 0.20 0.18 0.20 0.31

Synchroniser Ring to Sunchroniser Flange Clearance

IMPORTANT: All Dimensions are in mm.

Mainshaft Gear
Minimum 0.5
Maximum 1.9

Specifications

8
 Lubrication Information

Lubrication
Proper Oil Level
Before checking the oil level or refilling, vehicle should be on level ground. Make sure that the oil is level with the
filler opening.

Draining Oil
Drain transmission while oil is warm. To drain oil remove the drain plug at the bottom if case. Clean the drain plug
before re-installing.

Lubrication Information
Refilling
Clean area around filler plug. Fill transmission to the level of the filler opening. The exact amount of oil depends on
the transmission inclination. In every instance, fill to the level of the filler opening. Do not overfill — this causes oil
to be forced out of the case past the mainshaft and input shaft seals.

Adding Oil
It is recommended that different types and brands of oil are not intermixed because of possible incompatibility.

Operating Temprature

It is important that the transmission operating temperature does not exceed 120°C (250°F) for an extended period
of time. Operating temperatures above 120°C (250°F) cause breakdown of the oil and shorten transmission life.
The following conditions in any combination can cause operating temperatures of over 120°C (250°F):
1. Operating consistently at road speeds under 32 km/h (20m.p.h.).
2. High engine RPM.
3. High ambient temperature.
4. Restricted air flow around transmission.
5. Exhaust system too close to transmission.
6. High horsepower, over-drive operation.
7. High power PTO operation for extensive periods while stationary.

High operating temperatures may require more frequent oil changes.

Towing
When towing the vehicle, the propeller shaft between the axle and transmission must be disconnected.

9
 Lubrication Information

Recommended Lubricants

Mineral Oils

Lubrication Change and Inspection

First 5000 to 10,000 Km
Every 20,000 Km or 2 months
Every 100,000 Km or 12 months
First 30 hours
Every 40 hours or 2 months
Every 500 hours
Every 1000 hours or 12 months
ON HIGHWAY USE
Change transmission oil on new units.
Inspect oil level. Check for leaks.
Change the transmission oil.
OFF HIGHWAY USE
Change transmission oil on new units.
Inspect oil level. Check for leaks.
Change transmission oil where severe dirt conditions exist.
Change the transmission oil. (Normal off-highway use)

Recommended Lubricants
Type Grade (SAE) Ambient Temperature
Heavy Duty Engine Oil API-CD 50 Above - 12°C
40 Above - 12°C
30 Below - 12°C
Mild EP Gear Oil 90 -12°C to 38°C
API-GL-4 80W -26°C to 21°C

• Multi-viscosity engine oils (such as 15W40) are not recommended without consultation with with Eaton.
• Do not mix engine oil and gear oils in the same transmission.
• Eaton does not approve mineral lubricants by brand name.
• Additives or friction modifiers which are not part of the original lubricants are not recommended.

IMPORTANT: Refer ’Lubrication Manual’ on following web address for more details:

http://www.roadranger.com/Roadranger/servicesalesliterature/LiteratureCenterResults

10
 Lubrication Information

Semi and Full Synthetic Oils

Semi Synthetic Oils

The following brands of semi-synthetic oils are now approved for use in Eaton transmissions;
1. TEXACO MULTIGEAR MTF 75W80W
2. ELF TRANSELF 75W80W, (also known as RVI Longevia)
3. MOBIL MOBILUBE XHP
4. BP ENERGEAR XHP 75W80

Lubrication Information
5. KUWAIT Q8 T 60
6. FUCHS DEA DEAGEAR LD & TITAN CYTRAC LD
7. FIAT LUBRICANTI TUTELA TRUCK GEAR FE
8. DE OLIEBRON TOR MT/LD GEAR OIL
9. OMV AKTIENGESELLCHAFT OMVLDL 75W80
10. PAKELO MOTOR OIL PAKELO GOLDENGEAR LD
11. YACCO BVX Z-500 SAE 75W80
12. REPSOL CARTAGO CAJAS FE LD

Lubrication Change and Inspection

All brands - Every 20,000 Km
Every 300,000 Km or three years
All brands - Every 40 hours
Every 500 hours
Every three years
ON HIGHWAY USE
Inspect oil level. Check for leaks.
Change the transmission oil.
OFF HIGHWAY USE
Inspect oil level. Check for leaks.
Change transmission oil where severe dirt conditions exist.
Change the transmission oil. (Normal off-highway use)

11
 Lubrication Information

Synthetic Oils

The following brands of semi-synthetic oils are now approved for use in Eaton transmissions:
1. COGNIS ROADRANGER SAE 50

2. COGNIS (HENKEL/EMERY) MTF 4200

3. CASTROL SYNTRANS
4. BP ENERGEAR SHX 30
5. SHELL SPIRAX GSX 75W80
6. CHEVRON TEXACO MULTIGEAR MTF HD 75W80
7. MOBILUBE 1 SHC
8. BP ENERGEAR SHX-M 75W-90
9. CASTROL SAF XM75W-90
10. ANGLAMOL 2005

Lubrication Change and Inspection

ON HIGHWAY USE
All brands - Every 20,000 Km Inspect oil level. Check for leaks.
COGNIS ROADRANGER SAE 50 Change the transmission oil.
Every 800,000 Km or five years
COGNIS (HENKEL/EMERY) MTF 4200 Change the transmission oil.
Every 500,000 Km or three years
CASTROL SYNTRANS Change the transmission oil.
Every 500,000 Km or three years
BP ENERGEAR SHX 30 Change the transmission oil.
Every 500,000 Km or three years
SHELL SPIRAX GSX 75W80 Change the transmission oil.
Every 500,000 Km or three years
CHEVRON TEXACO MULTIGEAR MTF HD 75W80 Change the transmission oil.
Every 500,000 Km or three years
MOBILUBE 1 SHC Change the transmission oil.
Every 300,000 Km or three years
BP ENERGEAR SHX-M 75W-90 Change the transmission oil.
Every 300,000 Km or three years
CASTROL SAF XM 75W-90 Change the transmission oil.
Every 300,000 Km or three years
ANGLAMOL 2005 Change the transmission oil.
Every 300,000 Km or three years
OFF HIGHWAY USE
All brands - Every 40 hours Inspect oil level. Check for leaks.
All brands - Every 500 hours Change transmission oil where severe dirt conditions
exist.
All brands - Every three years Change the transmission oil. (Normal off-highway use)

12
 Tools Information

Recommended Tools
Some repair procedures pictured in this manual show
the use of specialized tools. Their actual use is recom-
mended as they make transmission repair easier,
faster, and prevent costly damage to critical parts.
But for the most part, ordinary mechanic's tools such
as socket wrenches, screwdrivers, etc., and other stan-
dard shop items such as a press, mauls and soft bars
are all that is needed to successfully disassemble and
reassemble any Eaton Transmission.

Illustration T ools No. Description Illustration T ools No. Description

LC 105A Layshaft bearing E 109-5 LRC cross shaft seal
remover and bush installer.
Use with E 109.

E 105-4 Halves layshaft- E 109-6 Layshaft bearing

bearing remover cup installer adaptor.
Use with E 109.

E 108 Driver E 109-7 Input shaft seal

installer

E 108-5 Replacer adaptor E 109-8 Main selector shaft

for mainshaft bear- bush installer adap-
ing and input shaft tor. Use with E 109.
bearing. Use with E
108.
E 108-6 Mainshaft rear seal E 109-9 Main selector shaft
replacer adaptor plug installer adap-
tor. Use with E 109.

E 109 Driver E 109-11 Layshaft bearing

cone installer. Use
with E 109.

E 109-10 Driver extension. E 114 Mainshaft rear bear-

Use with E 109. ing pilot

E 115 Flange holding E 116A Mainshaft assembly

adaptor plate lifting fixture. Use
with E116-2.

E 116-2 Mainshaft assem- LC 113A Flange holding

bly lifting adaptor. wrench
Use with E 116A.

13
 Tools Information

Illustration T ools No. Description Illustration T ools No. Description

MS 284 Slide hammer E 117 Reverse idler shaft
retaining pin installer

MS 284-1 Extractor set

Special Tools Manufacturers SPX (UK) Ltd.

Tool Information
Genoa House
Below are the addresses and phone numbers of the Everdon Park
companies that make tools specifically for Eaton trans- Heartlands Business Park
missions. Daventry
Northamptonshire NN11 8YH
SPX England Phone: + 44 (01327) 303400
Global Headquarters Web site:
3515 Ballantyne Corporate Place http://www.spxuk.co.uk/
Charlotte, North Carolina 28277
United States The following general purpose pullers are available
Phone: +1 (704) 752-4400 from Sykes-Pickavant Ltd., or through their Dealers.
Web site: http://www.spx.com/en/products-and-ser-
vices/diagnostics.aspx

Illustration Des cription

Three Legged Puller - Series 1500 with
Hydraulic Ram

Puller Kit - Series 1500 with Hydraulic

Ram

14
 Tools Information

Locally Made Tools

The following illustration shows a suitable cradle which
can be used to stand the transmission 'on end' during
'Disassembly' and 'Reassembly'. The thickness of the
block has been calculated to lift the mainshaft the
required distance during removal and installation of the
layshaft. If the height of the cradle is increasing, the
thickness of the block should be increased by the same
amount.

Mounting plates - 2 off

IMPORTANT: All dimensions are in mm.

Tool for 4 point ball bearing revomal

1. 1 off hole 1.5 inches diameter 16 threads per
inch whitworth form to suit Sykes Picavant
hydraulic ram No 150 000.
2. 8 holes 11 mm diameter.

15
 Preventive Maintenance
Preventive Maintenance
Everyday there are countless vehicles operating over
the highways with transmissions in such a neglected
mechanical condition, they can be referred to as fail-
ures looking for a place to break down. They lack a
proper and organized preventive maintenance pro-
gram.
Preventive maintenance is a general term which
applies to all procedures necessary to have maximum
life and satisfactory service at the lowest possible cost,
short of removing and repairing the unit.
Checks Before Transmission Removal
A number of conditions contrary to good preventive
maintenance can generally be pointed to when inspect-
ing a failed transmission. Taking a few minutes every
so many hours or miles to do a few simple checks
could help avoid eventual breakdown or reduce the
repair cost. If the transmission is not cared for, it will
breakdown.
Note: Transmission appearance may differ, the proce-
dure is the same.
Clutch Housing Mounting
• Check all capscrews of clutch housing flange
for looseness.
Clutch Release Bearing
• Remove hand hole cover and check radial and
axial clearance in release bearing.
• Check relative position of thrust surface of
release bearing with thrust sleeve on push-
type clutches.
16
Clutch Pedal Shaft and Bores
• Pry upward on shafts to check wear.
• If excessive movement is found, remove clutch
release mechanism and check bushings on
bores and wear on shafts. See OEM literature.
Lubricant
• Change at specified service intervals.
Preventive Maintenance
• Use only the types and grades as recom-
mended. Refer section ’Lubrication Informa-
tion’.
Filler and Drain Plugs
• Remove filler plugs and check level of lubricant
at specified intervals. Tighten fill and drain
plugs securely.
Capscrews and Gaskets
• Check all capscrews, especially those on PTO
covers and rear bearing covers for looseness
which would cause oil leakage.
• Check PTO opening and rear bearing covers
for oil leakage due to faulty gasket.
Gear Shift Lever
• Check for looseness and free play in housing.
If lever is loose in housing, check Direct Con-
trol Assembly.
Direct Control Assembly
• Remove the direct control assembly from the
transmission.
• Check the tension spring for set and wear.
• Check gear shift lever bottom end for wear in
the slots and check for wear of finger assembly
and housing.
 Preventive Maintenance

Checks with drive line dropped

Universal Joint Companion Flange or Yoke Nut
• Check for tightness. Tighten to recommended
torque.
Output Shaft (Yoke Nut Tightened)
• Pry upward against output shaft to check radial
clearance in mainshaft rear bearing.

Checks with Universal Joint Companion

Flange or Yoke removed
Note: If necessary, use solvent and shop rag to clean
sealing surface of companion flange or yoke. Do
not use crocus cloth, emery paper, or other abra-
sive materials that will mar surface finish.
Splines on Output Shaft
• Check for wear from movement and chucking
action of the universal joint companion flange
or yoke.
Mainshaft Rear Bearing Cover
• Check oil seal for wear.

Rear Seal Maintenance

Leakage in transmission rear seals is perhaps the most
common problem in truck transmissions. The problem
is more than a nuisance because if not repaired, a
leaking seal can lead to catastrophic transmission fail-
ure. There have been strides in reducing leakage
through improved designs and the use of new seal
materials. However, the most important way to reduce
this problem continues to be through proper service
and installation procedures.

It can be very time consuming and expensive to

replace a rear seal system, then find the oil seal sys-
tem was not causing the oil leakage. Using the follow-
ing checklist, inspect the transmission to insure proper
identification of the leak path.

Before disassembling the rear seal system, clean the

rear bearing cover, the rear seal, and the output yoke.
DO NOT USE A HIGH PRESSURE SPRAY WASHER
TO CLEAN THE REAR SEAL SYSTEM. USE A
CLEAN DRY CLOTH. Run the vehicle, then inspect
these areas for oil leaks.

17
 Power Flow

Power Flow
The transmission must efficiently transfer the engine's 3. Torque is delivered along layshaft to all lay-
power, in terms of torque, to the vehicle's rear wheels. shaft gears.
Knowledge of what takes place in the transmission dur-
4. Torque is transferred to "engaged" mainshaft
ing torque transfer is essential when trouble-shooting
gear.
and when making repairs become necessary.
5. The engaged mainshaft gear external clutching
teeth transfer torque to the mainshaft through
1. Power (torque) from the engine is transferred
the synchronizer assembly or sliding gear.
to the transmission input shaft.
6. The mainshaft transfers torque directly to
2. Torque is transferred to layshaft drive gear.
driveshaft through the output yoke.

First Gear Second Gear

Third Gear Fourth Gear

Fifth Gear Sixth Gear

Reverse Gear Shift Pattern

18
 Direct Control Assembly

Exploded View
DIRECT CONTROL ASSEMBLY

Direct Control Assembly

1. Direct Control Housing 14. Cover
2. Bush 15. Screw
3. End Cap 16. Gaiter
4. Spring Washer 17. Pivot Pin
5. Screw 18. Washer
6. ‘O’ Ring 19. Plug
7. Neutral Switch 20. End Cap
8. Breather 21. Spring
9. Plunger 22. Seating
10. Spring 23. Selector Shaft
11. Cover 24. Conical Spring
12. Plunger 25. Spring Retainer
13. Spring 26. Yoke

19
 Direct Control Assembly

How to disassemble Direct Control Assembly

Special Instructions

WARNING: Wear safety glasses when removing springs.

Special Tools
Snap ring plier

Procedure - 8. Remove the screws , washers and end covers from

the both side of the housing.
1. Ensure the control assembly is in neutral.

2. Remove bolts, washers and lifting eye (if fitted).

3. Remove the control assembly and dowels.

4. Remove the gaiter and breather.

9. If neccessary the bushes in the end covers can be

replaced.

5. Remove screws and washers.

6. Remove detent cover, spring and plunger.

10. Invert the housing and withdraw the yoke.

7. Remove plug and washer.

20
 Direct Control Assembly

11. Remove the spring retainer and conical spring.

12. Remove the seating and selector shaft.

13. Remove the pivot pin and seating.

Direct Control Assembly

21
 Direct Control Assembly

How to assemble Direct Control Assembly

Special Instructions
Check spring tension before installing.

WARNING: Wear safety glasses when installing springs.

Special Tools
Snap ring plier

Procedure - 3. Apply a coating of grease to the selector shaft. Fit

the selector shaft.
IMPORTANT: Clean all mating faces.
IMPORTANT: Ensure that the slot in the selector
1. Fit the seating ensuring that the slot aligns with the shaft align with the pivot pin in the housing.
hole in the housing for the pivot pin.

4. Fit plug and washer. Tighten plug to 16 - 22 Nm.

2. Apply grease to the seating and then fit the pivot
pin.

5. Fit the another seating.

IMPORTANT: Ensure that the slot in the seating

locates onto the pivot pin and into the bore of the
housing.

22
 Direct Control Assembly

6. Install conical spring and spring retainer. 10. Apply Loctite 5900 to the mating faces. Fit the
plunger, spring and detent cover. Install screws
IMPORTANT: Ensure that the smaller diameter of and washers. Tighten the screws to 20 -24 Nm.
the spring sits against the seating.

11. Fit the gaiter and breather.

7. Install the yoke into the housing.
12. Install dowels and control assembly.

13. Install bolts, washer and lifting eye (if fitted).

14. Tighten screws to 35 - 39 Nm.

Direct Control Assembly

8. Apply a light coating of grease to the bushes in the
end caps. Fit the end caps, screws and washers.
Tighten the screws to 20 -24 Nm.

9. Apply Loctite 5900 to the mating faces. Fit the

plunger, spring (s) and end covers. Install screws
and washers. Tighten the screws to 20 -24 Nm.

23
 Remote Control Assembly

Exploded View
REMOTE CONTROL ASSEMBLY

Remote Control
Assembly
1. Bolt 21. Screw
2. Outer Lever 22. Spring Washer (if fitted)
3. Nut 23. End Cover
4. Boot 24. Gasket (if fitted)
5. Oil Seal 25. ‘O’ Ring
6. Bush 26. ‘O’ Ring (If fitted)
7. LRC Housing 27. Plug (if fitted)
8. Seal 28. Switch Activator Pin
9. Plunger 29. Neutral Switch
10. Spring 30. Breather
11. Gasket 31. Expansion Plug
12. Cover 32. Plug (if fitted)
13. Spring Washer (if fitted) 33. Elbow (if fitted)
14. Screw 34. Shift Rod
15. Circlip 35. Inner Striking Lever
16. Spring Retainer - Booster 36. Grooved Pin
17. Spring - Booster (If fitted) 37. Plain Washer (if fitted)
18. Spring - Bias 38. Spring Washer (if fitted)
19. Spring Retainer - Bias 39. Bolt (if fitted)
20. Reaction Rod Mounting Bracket (If fitted)

24
 Remote Control Assembly

How to disassemble Remote Control Assembly

Special Instructions

WARNING: Wear safety glasses when removing snap rings.

Special Tools

Snap ring pliers

Procedure - 7. Remove screws and washers (if fitted).

1. Ensure the control assembly is in neutral. 8. Remove reverse detent cover and pull out the
spring and plunger (if fitted).
2. Remove bolts, washers and lifting eye (if fitted).
9. Remove gasket.
3. Remove the control assembly, dowels and seal.

10. Remove screws and washers (if fitted).

4. Remove breather or elbow assembly (if fitted) from
the control assembly. 11. Remove reaction bracket (if fitted).

Note: The position of the outer lever is marked on 12. Remove end cover and ‘O’ ring or gasket (if fitted).
the shaft. Check before removal.

5. Remove bolt and nut.

6. Remove the outer lever and rubber boot. Remove

neutral switch or plug, 'O' ring and pin (if fitted).

13. Remove the circlip from the shift rod and remove
the bias spring retainer.

25
 Remote Control Assembly

14. Remove booster spring (if fitted) and bias spring.

15. Remove booster spring retainer and circlip.

16. Invert the housing and carefully drift out the expan-
sion plug.

17. Invert the housing, align the grooved pin in the

Remote Control
inner striking lever with the expansion plug hole.

Assembly
18. Drift out the grooved pin. Remove the shift rod and
inner stricking lever.

26
 Remote Control Assembly

How to assemble Remote Control Assembly

Special Instructions

WARNING: Wear safety glasses when installing snap rings.

Special Tools

Snap ring pliers

E 109-5 Oil Seal and Bush installer

Procedure - 3. Install the inner striking lever, long plain groove

toward the front of the housing.
1. If neccessary renew the bearing bushes in the
housing using the special tool E 109-5. The new
bushes are prefinished to the correct size.

IMPORTANT: Clean the control assembly mating

face properly.

4. Install the shift rod from the right hand side of the
housing.

2. If neccessary renew the oil seal using special tool

E 109-5.

27
 Remote Control Assembly
5. Align the inner striking lever on the shift rod and
install the new grooved pin.
Note: Inner striking lever should be supported
whilst driving grooved pin, to prevent damage
to bushes.
6. Fit the inner circlip onto the shift rod. Install the
booster spring retainer.
7. Insert the booster spring (if fitted) and bias spring.
8. Install bias spring retainer.
9. Fit the outer circlip onto the shift rod.
28
10. Fit a new ‘O’ ring or gasket (if fitted) and secure the
end cover to the housing by screws and washers (if
fitted).
11. Install the reaction bracket (if fitted).
12. Tighten the screws to 20 -24 Nm.
Note: The word “TOP” has been cast into the
cover to identify correct positioning.
13. Install the spring and reverse detent plunger (if fit-
ted).Install gasket and detent cover.
14. Install screws and washers (if fitted). Tighten
screws to 20 -24 Nm.
Remote Control
Assembly
15. Fit the rubber boot onto the housing. Align the
outer lever with the timing mark on the shift rod.
Tighten the capscrew and nut to 35 -39 Nm.
 Remote Control Assembly

16. Fit the breather or elbow assembly (if fitted). Install

the switch activator pin, ‘O’ ring and neutral switch
or plug (if fitted). Tighten the neutral switch to 15 -
22 Nm. Apply sealant and install expansion plug.

17. Install seal and dowel. Apply Loctite 5900 sealant

to mating faces. Fit control assembly to the trans-
mission housing. Tighten capscrews to 35 - 39 Nm.

29
 Pneumatic Power Assist
Assembly

Exploded View
PPA ASSEMBLY

Pneumatic Power Assist

Assembly
1. PPA Assembly
2. Breather
3. ‘O’ Ring
4. Neutral Switch
5. Seal

30
 Pneumatic Power Assist
Assembly

How to remove Pneumatic Power Assist How to install Pneumatic Power Assist
(PPA) Assembly (PPA) Assembly

Procedure - Procedure -
1. Remove screws and lifting eye. 1. Install breather, new 'O' ring (if fitted) and neutral
switch (if fitted). Tighten neutral switch to 24 - 30
2. Remove PPA from housing and seal (if fitted). Nm.

3. Remove breather, 'O' ring (if fitted) and neutral 2. Install seal (if fitted) and PPA on housing.
switch (if fitted).
3. Install screws and lifting eye.

4. Tighten screws to 35 - 39 Nm.

31
 Transmission Case Disassembly

Exploded View

TRANSMISSION CASE

1. Screw 25. Plunger

2. PTO Cover 26. Nut
3. Screw 27. Screw
4. Layshaft Front Bearing Cover 28. Oil Through
5. Cup Plug 29. Oil Through
6. Front Case 30. Screw
7. ‘O’ Ring 31. Screw
8. Overdrive Rotating Pin 32. PTO Cover
9. Spring Washer 33. Dowel
10. Screw 34. Screw
11. Lifting Eye 35. Plate Oil Retention
12. Screw 36. Bushing
13. Dowel 37. Dowel
14. Bushing - Selector Shaft 38. Lifting Eye
15. Bolt 39. Rear Case
16. Washer 40. Layshaft Rear Bearing Cover
17. Drain Plug - Magnetic 41. Screw
18. Washer 42. Spring Washer
19. Filler Plug 43. Bushing
20. Screw 44. ‘O’ Ring
21. Spring Washer 45. Reverse Switch
22. Detent Cover 46. Expansion Plug
23. Gasket 47. Circlip - New Design Reverse Idler
24. Spring

32
 Transmission Case Disassembly

How to disassemble Transmission Case

Special Instructions

WARNING: Wear safety glasses and hand gloves.

Special Tools

Transmission Overhauling Stand

Hoist
Flange Holding Wrench - LC 113A
Special puller for flange/yoke
8 mm Punch
Soft Face Mallet
Lifting Fixture - E 116A & E116-2
Mainshaft Rear Oil Seal Replacer - E 108-6
Replacer adaptor for mainshaft bearing and input shaft bearing - E 108-5
Driver - E 108
Snap Ring pliers
Refer section ‘Tools Information’

Procedure - 2. Remove the speedometer pinion and adaptor or

CAUTION: Drain gear oil from the transmission. Clean electronic sender unit (if fitted).

Transmission Case
and refit the drain and filler plugs.
Note: The transmission illustrated in this section is a
standard ratio horizontally installed unit. The pro-
cedure is the same for all transmissions but the
physical size and number of teeth on some of the
gears will vary from those illustrated on overdrive
and alternative ratio models. Vertically installed
units have the remote control on the side of the
transmission and alternative filler and drain plug
positions. 3. Remove the reverse switch and ‘O’ ring (if fitted).
1. IMPORTANT: Secure the adaptor plates to the
transmission case rear mounting flanges.

Note: This may be a 4 hole square plate on early

models.

Raise the transmission on a hoist and install the

unit onto the stand.

33
 Transmission Case Disassembly

4. Remove flange/yoke retaining nut. Reverse Idler - Old Design

IMPORTANT: Use special wrench LC 113A to hold 7. If the diameter of expansion plug is 32 mm then the
flange/yoke. retaining pin must be removed as per following pro-
cedure.

5. Remove the flange/yoke, using a suitable puller if

neccessary. 8. Remove the PTO cover. Using the special tool or
an 8 mm punch, drive the reverse idler shaft
IMPORTANT: Do not use a hammer or the flange/ grooved pin INWARDS until the end is approxi-
yoke may be damaged. mately 12 mm below the face of the hole.

Note: Do not allow the pin to ‘bottom’ against the

shaft bore.

6. Remove the remote control housing or direct con-

trol housing or PPA unit bolts. Use a soft faced
malet to separate the housing from the transmis-
sion.
Reverse Idler - New Design
Note: Ensure neutral is engaged. 9. If the diameter of expansion plug is 37 mm then
remove the expansion plug and circlip from the
case.

34
 Transmission Case Disassembly

10. Position the transmission forward end upper most
on the stand or wooden cradle. Remove the
screws and washers (if fitted). Remove the neutral
detent cover, gasket, spring and plunger or detent
assembly (if fitted).
13. Remove the half case flange bolts and nuts.
Note: Mark the position of the shorter bolts
threaded into the case.

14. Remove the screws and washers (if fitted) securing

front cover and remove the cover.

IMPORTANT: If fitted, remove ‘O’ ring and housing

from front cover.

11. Rotate the gear selector shaft to the left (vertically

Transmission Case
mounted) or right (horizontally mounted) so that
the case will not foul the selector block on removal.

15. Remove the outer circlip from the input shaft bear-
ing.

12. On Overdrive model, remove the screws and

washers retaining the two overdrive fork rotating
pins. Remove the pins and ‘O’ rings.

16. Remove the spacer and bearing thrust washer.

35
 Transmission Case Disassembly

17. Using a soft face mallet break the seal and sepa- 21. Assemble lifting fixtures to the mainshaft under
rate the front case from the rear case. Lift off the 5th / 6th synchronizer. Raise the shaft by approx.
front case, leaving the input shaft and bearing 20 mm. This allows the layshaft to lift clear.
inplace.

Note: DO NOT USE PRY BARS OR CHISELS.

22. Lift out the layshaft.

18. On Overdrive model, disengage and remove the

overdrive fork and pads.

23. Lift off the input shaft with 6th gear flange. Remove
the 6th gear synchroniser ring.

19. Using a suitable long drift drive out the reverse idler
shaft from the case. Remove the ‘O’ ring from the
reverse idler shaft (old design).

24. Raise the hoist and lift out the mainshaft and selec-
tor assembly. Carefully lower on to a clean bench
and remove the lifting fixture. Separate selector
assembly from the mainshaft.
20. Remove the reverse idler gear and the thrust
washers. Remove the bearing and spacer from the
gear.

36
 Transmission Case Disassembly

25. Invert the rear case on the stand. Remove the cap- 28. Invert the casing on the stand and remove the lay-
screws securing the speedo housing. shaft rear bearing cover and spacer.

Note: Note the positions of the different length

capscrews.

Remove the speedo housing. If neccessary, drift

out the oil seal using seal replacer.

29. Drift out layshaft rear bearing outer cup using the
special tool.

26. Remove the speedometer drive gear or tachograph

rotor and the bearing spacer from the rear case
half.

30. Remove the layshaft front bearing retaining plate

Transmission Case
and graded spacer from the front case.

27. Invert the casing on the stand and using replacer

adaptor with driver drift out the mainshaft rear
bearing.

Note: Do not allow the bearing to fall to the floor.

31. Lift out layshaft front bearing cup using the special
tool.

37
 Transmission Case Disassembly

32. Remove the input shaft bearing using replacer

adaptor with driver.

33. If neccessary, to renew the selector shaft bushes,

drive the selector shaft expansion plug outwards
from the case halves.

34. Invert the case halves and using the special tool or
a suitable (25 mm dia.) mandrel drive the selector
shaft bushes out of the cases.

38
 Layshaft Assembly

Exploded View
LAYSHAFT ASSEMBLY

Layshaft Assembly
1. Layshaft 4. Graded Circlip Pack
2. Bearing 5. Shim Pack
3. Distance Piece 6. Spacer

39
 Layshaft Assembly

How to disassemble Layshaft

Special Instructions

WARNING: Wear safety glasses and hand gloves.

Special Tools

Snap ring pliers

Bearing remover - LC 105A
Halves- Bearing remover - E 105-4
Refer section ‘Tools Information’

Procedure -
1. Support the shaft assembly and remove the
graded circlip retaining the front taper roller bear-
ing.

2. Using the bearing remover LC 105 A and halves E

105-4, remove the bearing cone and roller assem-
bly.

3. Invert the shaft and remove the rear taper roller

bearing

40
 Layshaft Assembly

How to assemble Layshaft

Special Instructions

WARNING: Wear safety glasses and hand gloves.

Special Tools

Bearing heater
Hot plate OR Temperature controlled oven
Bearing installer - E 109-11
Snap ring pliers
Refer section ‘Tools Information’

Procedure - Note: Refer IPL for circlip size and part numbers.

1. Heat the layshaft taper rooler bearing inner races 3. Fit the circlip.
to 85° C (180° F), using bearing heater or hot plate
or temprature controlled oven. Support the shaft
assembly forward end uppermost and place the
heated inner cone and roller assembly onto the
shaft. Use a bearing installer E 109-11 to make
sure bearing is fully home.

Layshaft Assembly
4. Invert the layshaft assembly and fit the heated rear
taper roller bearing inner race onto the shaft. Make
sure the bearing is fully home using a bearing
installer E 109-11.

2. From the range of the graded fit circlips, select the

circlip which fits into the groove with the minimum
free play.

41
 Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
Exploded View
MAINSHAFT ASSEMBLY
1. Mainshaft
2. Needle Roller Brg.
3. Gear Mainshaft 3rd
4a. Synchro Flange 3rd/4th
4. Ring Synchro
5. Roller
6. Plunger
7. Spring
8. Fixed Hub 3rd/4th
9. Sliding Sleeve 3rd/4th
10. Ring Synchro
10a. Synchro Flange 3rd/4th
11. Gear Mainshaft 4th
12. Needle Roller Brg.
13. Sleeve Mainshaft Brg.
14. Circlip Assy.
15. Needle Roller Brg.
16. Gear Mainshaft 5th
17a. Synchro Flange 5th/6th
17. Ring Synchro
18. Roller
19. Plunger
20. Spring
21. Fixed Hub 5th/6th
22. Sliding Sleeve 5th/6th
23. Ring Synchro
24. Graded Circlip Pack
42
Mainshaft Assembly
25. Needle Roller Brg.
26. Needle Roller Brg.
27. Gear Mainshaft 2nd
28. Synchro Flange 1st/2nd
29. Ring Synchro
30. Spring
31. Plunger
32. Roller
33. Fixed Hub 1st/2nd
34. Sliding Sleeve 1st/2nd
35. Ring Synchro
36. Synchro Flange 1st/2nd
38. Graded Circlip Pack
39. Gear Mainshaft 1st
40. Needle Roller Brg.
41. Fixed Hub Reverse
42. Graded Circlip Pack
43. Needle Roller Brg.
44. Gear Mainshaft Reverse
45. Mainshaft Output Brg.
46. Speedo Drive Gear OR
46. Tachograph Rotor
47. Dirt Shield
48. Flange Coupling
49. Mainshaft Locknut
50. Spacer Tachograph Rotor
 Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.

End Float Check

Note: The end float of the gears on the mainshaft is
established in manufacture by machining the
components to fine tolerances. Before disassembly of
the mainshaft the end floats should be checked to as
certain whether they are within the recommended
limits.
Where the end float is found to be excessive it is nec-
cessary to check the gears, mainshaft, synchroniser
hubs and bearing sleeve for wear. See section
‘Inspection Precautions’ and renew where necces-
sary.

End float may be checked with the mainshaft assem-

bled by using a dial gauge as shown or feeler gauges.
Mount the mainshaft assembly on a suitable stand.
Locate the dial gauge on the gear and zero the gauge.
Raise the gear and record the reading.

Gear FS-5th / FSO-6th 4th 3rd 2nd 1st

Minimum 0.31 0.25 0.35 0.35 0.33
Maximum 0.67 0.45 0.53 0.55 0.64
Tolerance 0.36 0.20 0.18 0.20 0.31

All dimensions are in mm.

Note: Reverse gear is a sliding gear.

43
 Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.

How to disassemble Mainshaft

Special Instructions

WARNING: Wear safety glasses and hand gloves.

Special Tools

Vice
Snap ring plier
Puller kit - Series 1500 with hydraulic ram
Three legged puller - Series 1500 with hydraulic ram
Refer section ‘Tools Information’

Procedure - 3. Assemble the puller kit (Series 1500 with hydraulic

1. Mount the mainshaft assembly, plain end upper-
most, in soft jawed vice. Remove the synchroniser
ring. Carefully slide the 5th/6th synchroniser sleeve
upwards until the three rollers are clear off the
groove in the synchroniser sleeve. Remove the
three rollers, synchroniser sleeve, three plungers
ram) over 5th/6th gear synchroniser hub and the
5th gear synchroniser ring.
Note: Take care not to damage teeth of the later.
Pull of the synchroniser hub, cone and ring.
IMPORTANT: On an overdrive transmission, it

Mainshaft Assembly
and theree springs from the synchoniser hub.
may be neccessary to engage the puller over the
6th gear also.

2. Remove the 5th/6th gear synchroniser hub retain-

ing circlip.
4. Lift off the 5th gear and needle roller bearing.

IMPORTANT: On an overdrive transmission, this

will be 6th gear.

44
 Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.

5. Carefully remove 4th gear bearing sleeve reatining 9. Lift off steel cage bearing and 1st gear synchro-
snap ring. niser ring.

6. Invert the shaft assembly and using a suitable
three legged puller (Series 1500 with hydraulic
ram) under the reverse gear, remove the gear,
thrust washer, bearing track. Remove the reverse
gear needle roller bearing.
10. Slide the 1st/2nd gear synchroniser sleeve, care-
fully rearwards until the three rollers are clear off
the groove in the sleeve. Remove the roller, sleeve,
theree plungers and three springs from the syn-
chroniser hub.

7. Remove the reverse gear fixed hub retaining snap 11. Remove the 1st/2nd synchroniser hub retaining
ring. snap ring.

8. Using a press or three legged puller (Series 1500 12. Assmeble the puller kit (Series 1500 with hydraulic
with hydraulic ram), pull off the 1st gear assembly ram) over the 2nd gear and pull off 2nd gear, syn-
and the reverse gear fixed hub. chroniser ring , flange, hub and bearing.

45
 Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
13. Support the shaft on the press under the 3rd gear.
Note: It is imperative that 3rd gear is supported
and that the flange on the shaft does not foul
the supporting blocks or press bed when the
shaft is being pressed through.
Press or pull the shaft through 3rd gear, 3rd/4th
gear synchroniser hub and 4th gear bearing
sleeve.
14. Slide the 3rd/4th gear synchroniser sleeve, care-
fully rearwards until the three rollers are clear off
the groove in the sleeve. Remove the roller, sleeve,
theree plungers and three springs from the syn-
chroniser hub.
46
Check clearance between synchro-
niser ring and flange
Before assembling the synchroniser assemblies onto
the mainshaft, check the fit of each synchroniser ring to
the relevant synchroniser flange.
Place the synchroniser ring to the relevant flange and
while holding the two parts firmly together, measure the
clearance between the two component parts using
feeler gauges at several points around the circumfer-
ence as shown. The clearance should be between 0.5
and 1.9 mm. Renew both parts if the measurement is
not within the specified limits. Retain the synchroniser
rings and flanges in their respective pairs for assembly
Mainshaft Assembly
in the same relative position.
The gears and flanges are then treated as one assem-
bly.
 Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.

How to assemble Mainshaft

Special Instructions

WARNING: Wear safety glasses and hand gloves.

Special Tools

Vice
Snap ring plier
Hot plate or Temperature controlled oven
Driver E 108
Dial gauge
Feeler gauge
Refer section ‘Tools Information’

IMPORTANT: The following parts must be heated to 2. Lubricate the bearing with clean gear oil and fit the
the 85°C prior to assembly. Place the parts on a hot 2nd gear assembly over the bearing.
plate or in temperature controlled oven for not less than
30 minute to make sure that parts are thoroughly
heated placing them in position. Once fitted and cooled
the parts will shrink to an interference fit.
• 4th gear bearing sleeve
• Reverse fixed hub
• Mainshaft rear bearing inner track
• Synchroniser hubs
3. Then fit the synchroniser ring.
Procedure -

1. Support the mainshaft rear end uppermost. Fit the

2nd gear bearing.

47
 Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
4. Take the heated 1st/2nd synchroniser hub and
place it over the splines of the mainshaft ensuring
that the large slots in the hub align with the large
shoulders on the synchroniser ring. Use a soft drift
or driver E 108 to ensure the hub is fully home after
cooling for 4-5 minutes.
5. From the range of the graded snap rings select the
thickest one which fits into the groove with the min-
imum free play.
6. Install the snap ring in the groove.
Note: Taking care not to damage mainshaft bear-
ing surface.
7. Check that the 2nd gear end float is within speci-
fied tolerance.
48
8. Assemble the three springs and plungers into the
synchroniser hub. Place the synchroniser sleeve
over the synchroniser hub and support it with the
internal grooves just above the synchroniser hub.
Position the three rollers as shown, retsing on the
heads of the plungers and press downward on the
synchroniser sleeve. This compress the springs
allowing the synchroniser sleeve to centralise in
the neutral position.
9. Place the 1st gear synchroniser ring onto the syn-
chroniser assembly ensuring that the shoulders on
the synchroniser rings locate into the slots of the
synchroniser hub. Lubricate synchroniser ring.
Mainshaft Assembly
10. Lubricate 1st gear bearing and install the steel
cage bearing into the gear. Place the 1st gear
assembly and bearing onto the shaft and into the
synchroniser ring.
 Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
11. Take the heated reverse gear fixed hub and fit it
over the splines, boss uppermost, onto the main-
shaft.
12. Use a soft drift or driver E 108 if neccessary, to
ensure the hub is fully home against the shoulder.
13. From the range of the graded snap rings select the
thickest one which fits into the groove with the min-
imum free play. Install the snap ring in the groove.
Note: Taking care not to damage mainshaft bear-
ing surface.
14. Check that the 1st gear end float is within specified
tolerance.
49
15. Lubricate the reverse gear bearing. Install the
bearing and reverse gear onto the mainshaft.
16. Fit the spacer on the standard cylindrical roller or
4 point roller bearing. If intergral spacer bearing is
fitted, the spacer is parts of the bearing inner race.
17. Take the heated inner tarck of the mainshaft rear
bearing and fit it over the shaft, flange inner most
against the spacer. Use a soft drift or driver E 108 if
neccessary to ensure that the bearing is fully home
against the shoulder.
Note: When cooled, the bearing track should be
sufficiently tight on the shaft to retain the
reverse gear on the shaft.
 Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.

18. Invert the mainshaft in the vice. Lubricate and
install the 3rd gear bearing and 3rd gear assembly.
22. Assemble the three springs and plungers into the
synchroniser hub. Place the synchroniser sleeve
over the synchroniser hub and support it with the
internal grooves just above the synchroniser hub.
Position the three rollers as shown, retsing on the
heads of the plungers, and press downward on the
synchroniser sleeve. This compress the springs
allowing the synchroniser sleeve to centralise in
the neutral position.

19. Install the 3rd gear synchroniser ring over the

flange.

23. Place the 4th gear synchroniser ring into the syn-
chroniser hub assembly.

20. Take the heated 1st/2nd synchroniser hub and

Mainshaft Assembly
place it over the splines of the mainshaft ensuring
that the large slots in the hub align with the large
shoulders on the synchroniser ring. Use a soft drift
or driver E 108 to ensure the hub is fully home after
cooling for 4-5 minutes. Recheck that the shoul-
ders are in the correct slots.
24. Lubricate the 4th gear and bearing. Position the
gear into the synchroniser ring and the bearing into
the gear.

Note: If a smear of petroleum jelly if applied to the

outer edge of bearing, this will support the
bearing to stand proud of the gear and ease
the procedure of aligning the bearing sleeve
in the next operation.

21. Check that the 3rd gear end float is within specified
tolerance.

50
 Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
25. Take the heated 4th gear bearing sleeve and
locate it inside the bearing and over the shaft. Use
soft drift or flange driver if neccessary, to ensure
the sleeve is firmly home against the synchroniser
hub.
26. From the range of graded circlips select the one
which fits into the mainshaft groove with the least
amount if free play. Fit the ciclip into the groove
Note: Take care not to damage the mainshaft
bearing surface.
27. Check that the 4th gear end float is within the spec-
ified tolerance.
28. Lubricate the 5th gear bearing. Install the bearing
and 5th gear assembly onto the mainshaft.
51
29. Position 5th gear synchroniser ring onto the syn-
chroniser flange.
CAUTION: Ensure that when fitting the synchro-
niser flange on the 5th gear, the correct flange is
used. on overdrive transmission it is possible to fit
the overdrive flange to the 5th gear.
30. Take the heated 5th/6th synchroniser hub and
place it over the splines of the mainshaft, boss side
downwards. Ensure that the large slots in the hub
align with the large shoulders on the synchroniser
ring. Use a soft drift or driver E 108 if neccessary,
to ensure the hub is fully home against the shoul-
ders. Recheck that the shoulders are in the correct
slots.
31. From the range of graded circlips select the one
which fits into the mainshaft groove with the least
amount if free play.
 Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.

32. Fit the ciclip into the groove.

Note: Take care not to damage the mainshaft

bearing surface.

33. Check that the 5th gear end float is within the spec-
ified tolerance.

Mainshaft Assembly
34. Assemble the three springs and plungers into the
synchroniser hub. Place the synchroniser sleeve
over the synchroniser hub and support it with the
internal grooves just above the synchroniser hub.
Position the three rollers as shown, retsing on the
heads of the plungers, and press downward on the
synchroniser sleeve. This compress the springs
allowing the synchroniser sleeve to centralise in
the neutral position.

52
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

Exploded View
MAINSHAFT ASSEMBLY

1. Mainshaft
2. Needle Roller Brg.
3. Gear Mainshaft 3rd
4a. Synchro Flange 3rd/4th
4. Ring Synchro
5. Roller
6. Plunger
7. Spring
8. Fixed Hub 3rd/4th
9. Sliding Sleeve 3rd/4th
10. Synchro Flange 3rd/4th
10a. Ring Synchro
11. Gear Mainshaft 4th
12. Needle Roller Brg.
13. Sleeve Mainshaft Brg.
14. Circlip Assy.
15. Needle Roller Brg.
16. Gear Mainshaft 5th
17a. Synchro Flange 5th/6th
17. Ring Synchro
18. Roller
19. Plunger
Mainshaft Assembly
20. Spring
21. Fixed Hub 5th/6th
22. Sliding Sleeve 5th/6th
23. Ring Synchro
24. Graded Circlip Pack
25. Needle Roller Brg.
26. Needle Roller Brg.
27. Gear Mainshaft 2nd
28. Synchro Pack D.C. 1st/2nd
29. Gear Mainshaft 1st
30. Needle Roller Brg.
31. Fixed Hub Reverse
32. Graded Circlip Pack
33. Needle Roller Brg.
34. Gear Mainshaft Reverse
35. Mainshaft Output Brg.
36. Speedo Drive Gear OR
36. Tachograph Rotor
37. Spacer Tachograph Rotor
38. Dirt Shield
39. Flange Coupling
40. Mainshaft Locknut

53
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

End Float Check

Note: The end float of the gears on the mainshaft is See ‘Inspection Precautions’ and renew where nec-
established in manufacture by machining the cessary.
components to fine tolerances. Before disassembly of
the mainshaft the end floats should be checked to
ascertain whether they are within the recommended
limits.
Where the end float is found to be excessive it is nec-
cessary to check the gears, mainshaft, synchroniser
hubs and bearing sleeve for wear.

End float may be checked with the mainshaft assem-

bled by using a dial gauge as shown or feeler gauges.
Mount the mainshaft aseembly on a suitable stand.
Locate the dial gauge on the gear and zero the gauge.
Raise the gear and record the reading.

Gear FS-5th / FSO-6th 4th 3rd 2nd 1st

Minimum 0.31 0.25 0.35 0.35 0.33
Maximum 0.67 0.45 0.53 0.55 0.64
Tolerance 0.36 0.20 0.18 0.20 0.31

All dimensions are in mm.

Note: Reverse gear is a sliding gear.

54
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

How to disassemble Mainshaft

Special Instructions

WARNING: Wear safety glasses and hand gloves.

Special Tools

Vice
Snap ring plier
Press
1st / 2nd synchroniser assembly retaining tool
Puller kit - Series 1500 with hydraulic ram
Three legged puller - Series 1500 with hydraulic ram
Refer section ‘Tools Information’

Procedure - 3. Invert the mainshaft assembly. Using a press or

1. Mount the mainshaft assembly, plain end upper-
most, in soft jawed vice. Remove the synchroniser
ring. Care fully slide the 5th/6th synchroniser
sleeve upwards until the three rollers are clear off
suitable puller remove the mainshaft bearing inner,
reverse gear and reverse gear needle roller bear-
ing.

Mainshaft Assembly
the groove in the synchroniser sleeve. Remove the
three rollers, synchroniser sleeve, three plungers
and theree springs from the synchoniser hub.

4. Remove the reverse gear fixed hub retaining snap

ring.

2. Remove the 5th/6th gear synchroniser hub retain-

ing circlip.

55
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
5. Using a press or suitable puller remove the reverse
gear fixed hub and 1st speed gear.
6. Remove the 1st speed gear needle roller bearing.
7. Remove the 1st/2nd synchroniser assembly retain-
ing circlip.
56
8. To prevent the synchroniser assembly from sepa-
rating during removal, fit the retaining tool. The tool
fits onto the mainshaft , boss down, with the three
retainers located underneath 2nd speed gear.
Adjust the retainers so that there is no free play
between 2nd speed gear and synchroniser assem-
bly.
Note: Should the synchroniser separate then refer
to the relevant section for assembly instruc-
tions.
9. Using a press or suitable tool remove the 1st/2nd
synchroniser assembly and 2nd speed gear.
Remove the needle roller bearing.
10. Carefully remove the retaining tool and then place
the synchroniser assembly and 2nd speed gear
onto a suitable work surface. Remove 2nd speed
gear.
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
11. Invert the mainshaft . As the 5th/6th synchroniser
hub is not symmetrical identify its orientation. Using
a press or Puller kit (Series 1500 with hydraulic
ram), remove the 5th/6th gear synchroniser hub,
synchroniser ring and 5th speed gear assembly.
Note: Care must be taken to ensure that the dam-
age to the teeth on the synchroniser flange
does not occur. On an overdrive tranmission
it may be neccessary to engage the press/
puller also over the gear.
12. Remove the 5th speed gear needle roller bearing.
On overdrive transmissions this will be 6th gear.
13. Care fully remove the 4th speed gear bearing
sleeve retaining snap ring.
57
14. Using a suitable press or puller support the main-
shaft assembly underneath 3rd speed gear.
Note: It is imperactive that the flange, which is part
of the mainshaft, does not foul the press or
puller legs as this may result in damage to
the mainshaft. Press or pull the 4th speed
gear bearing sleeve, 4th speed needle roller
bearing , 4th speed gear assembly, 3rd/4th
synchroniser assembly and 3rd speed gear
assembly off. Remove the 3rd speed gear
needle roller bearing from the mainshaft.
15. Place the assembly onto a suitable work surface,
4th speed gear, uppermost. Remove the bearing
Mainshaft Assembly
sleeve, needle roller bearing and 4th gear assem-
bly.
16. Dismantle the 3rd/4th speed synchroniser assem-
bly.
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

17. Lift off synchroniser hub and synchroniser ring.
Check clearance between synchroniser
ring and flange (Only for 3rd & 4th, 5th &
6th speed synchroniser assemblies)
Before assembling the synchroniser assemblies onto
the mainshaft, check the fit of each synchroniser ring to
the relevant synchroniser flange.

Place the synchroniser ring to the relevant flange and

while holding the two parts firmly together, measure the
clearance between the two component parts using
feeler gauges at several points around the circumfer-
ence as shown. The clearance should be between 0.5
and 1.9 mm. Renew both parts if the measurement is
not within the specified limits. Retain the synchroniser
rings and flanges in their respective pairs for assembly
in the same relative position.

58
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

Check clearance between synchroniser 5. Fit the synchroniser inner ring, tangs uppermost,
onto the synchroniser flange.
ring and flange (Only for 1st & 2nd Double
Cone Synchroniser Assembly)

Procedure -

1. Stand the synchroniser assembly onto a flat sur-

face (either way up).

6. Remove the synchroniser friction ring.

2. Remove the synchroniser flange.

7. Fit the synchroniser friction ring onto the synchro-

niser flange ensuring that the tabs on the synchro-

Mainshaft Assembly
niser friction ring locate into the slots on the
synchroniser flange.

3. Place the synchroniser flange, spigot uppermost

onto the bench.

8. Remove the synchroniser ring.

4. Remove the synchroniser inner ring.

59
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

9. Fit the synchroniser ring onto the assembly.

10. While holding the parts firmly together, measure

the clearance between the synchroniser ring and
synchroniser flange using feeler gauges at several
points around the circumference as shown. The
clearance should be between 0.5 to 1.9 mm. If the
measured dimension is outside these tolerances
then the synchroniser assembly must be changed.

11. Invert the synchroniser assembly and repeat the

process.

12. Refer section ‘1st and 2nd Double Cone Syn-

chroniser Assembly’ for assembly procedure.

60
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

1st and 2nd Double Cone Synchroniser Assembly

How to disassemble 1st and 2nd Double 4. Remove the synchroniser inner ring.
Cone Synchroniser Assembly
Note: The synchroniser is supplied as an assembly.
Parts that are used to make the complete assem-
bly are not available separately.

Procedure -

1. Stand the synchroniser assembly on a flat surface

with the spigot of the synchroniser sleeve upper-
5. Remove the synchroniser friction ring.
most.

Mainshaft Assembly
6. Remove the synchroniser ring.
2. Push the synchroniser sleeve downwards.

7. Remove the three retainers.

3. Remove the synchroniser flange.

61
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

8. Taking care not to loose the balls or springs, lift the 12. Remove the synchroniser ring.
detent poppets to release the balls. Once the balls
have been removed it is possible to remove the
detent poppets and springs.

13. Remove the synchroniser friction ring.

9. Remove the synchroniser sleeve.

14. Remove the synchroniser inner ring.

10. If not already removed, remove detent poppets and

springs.

11. Remove the synchroniser hub.

62
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

How to assemble 1st and 2nd Double Cone 4. Fit the synchroniser ring ensuring that the under-
Synchroniser Assembly cuts (1) line up with the tabs (2) of the sybchroniser
inner ring and that bosses (3) of the synchroniser
ring are to the left hand side of tabs (2) of the syn-
Procedure - chroniser inner ring as shown.

1. Place the synchroniser flange, spigot uppermost

onto the bench.

5. With holes in the synchroniser hub uppermost.

2. Fit the synchroniser inner ring, tangs uppermost,

on to the synchroniser flange.

Mainshaft Assembly
6. Fit the synchroniser hub ensuring that the narrow
slots are in line with the bosses of the synchroniser
ring.

3. Lubricate all surfaces of the synchroniser friction

ring. Fit the synchroniser friction ring ensuring that
the tabs locate in to the slots of the synchroniser
flange.

7. Place the three retainer in the large recesses of

synchroniser hub so that the leg of the blocks
engage with the tabs of the synchroniser inner ring
and the undercuts of the synchroniser ring.

63
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
8. Take the synchroniser sliding sleeve, stepped side
uppermost, and fit it to the synchroniser hub ensur-
ing that the three internal bosses of the synchro-
niser sleeve locate in the slots of the synchroniser
hub.
9. Place the detent poppets and springs into the holes
of the synchroniser hub.
10. Place the detent balls onto the springs and then
using suitable tool push against the detent ball to
compress spring.
11. Whilst the spring is compressed push the detent
poppet downwards into the synchroniser hub until
the ball engages with the annular groove of the
sleeve. Fit the remaining detent springs, balls and
plungers into the position.
64
12. Place the synchroniser ring onto the synchronsier
hub so that the three bosses enagge with the three
narrow slots on the synchroniser hub.
13. Lubricate all surfaces of the synchroniser friction
ring. Fit the synchroniser friction ring ensuring that
the tabs locate in to the slots of the synchroniser
flange.
14. Place the synchroniser inner ring into position
ensuring that the three tabs align with the legs of
the blocks.
15. Place the synchroniser flange into position ensur-
ing that the slots of the synchroniser flange align
with the tabs of the synchroniser friction ring.
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

16. Hold the synchronsier assembly down against the

bench and at the same time lift the synchroniser
sleeve upwards to engage the neutral position.

Mainshaft Assembly

65
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

How to assemble Mainshaft

Special Instructions

WARNING: Wear safety glasses and hand gloves.

Special Tools

Vice
Snap ring plier
Press
1st / 2nd synchroniser assembly retaining tool
Hot plate or Temperature controlled oven
Dial gauge
Feeler Gauge
Refer section ‘Tools Information’

IMPORTANT: The following parts must be heated to 2. Place 1st/2nd speed synchroniser assembly onto
the 85°C prior to assembly. Place the parts on a hot the retaining tool ensuring that the chamfer on the
plate or in temperature controlled oven for not less than synchroniser sleeve is uppermost.
30 minute to make sure that parts are thoroughly
heated placing them in position. Once fitted and cooled
the parts will shrink to an interference fit.
• 4th gear bearing sleeve
• Reverse fixed hub
• Mainshaft rear bearing inner track
• Synchroniser hubs

3. Heat the assembly to 85°C and then place the

Procedure -
retaining tool and synchroniser assembly onto the
press table.
1. Place the retaining tool, boss uppermost, on to a
suitable surface.

66
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

4. Fit the 2nd speed gear to the synchroniser assem- 7. Lubricate and install the 3rd gear needle roller
bly ensuring that the splines on the gear engage bearing and 3rd gear assembly.
into the splines on the synchroniser assembly. Fit
and lubricate the needle roller bearing.

8. Lubricate the 3rd gear synchroniser flange and

then fit the synchroniser ring.
5. Fit the mainshaft, plain end uppermost, into the
2nd speed gear and synchroniser assembly ensur-
ing that the splines on the mainshaft engages into
the the splines of the synchroniser assembly.
Press the mainshaft into the synchroniser assem-
bly.

9. Heat the 3rd/4th gear synchroniser hub to 85°C. Fit

the synchroniser hub over the splines on the main-

Mainshaft Assembly
shaft ensuring that the large slots in the synchro-
niser hub align with the large shoulders on the
synchroniser ring. Press the synchroniser fully
home.

6. To prevent the synchroniser assembly separating

the retainers should be used. Adjust the retainers
so that there is no free play between 2nd speed
gear and the synchroniser assembly.
10. Check that the 3rd gear end float is within the spec-
ified tolerance.

67
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

11. Assemble the three srpings and plungers into the 14. Heat the 4th speed gear bearing sleeve to 85°C.
synchroniser hub. Place the synchroniser sleeve Locate it onto the mainshaft and inside the needle
over the synchroniser hub and support it with the roller bearing. Press the bearing sleeve into posi-
internal grooves just above the synchroniser hub. tion.
Position the three rollers as shown, retsing on the
heads of the plungers, and press downward on the
synchroniser sleeve. This compress the springs
allowing the synchroniser sleeve to centralise in
the neutral position.

15. Fit a new snap ring into the mainshaft groove tak-
ing care not to damage the mainshaft bearing sur-
face.

12. Place the 4th gear synchroniser ring onto the syn-
chroniser assembly ensuring that the shoulders on
the synchroniser rings locate into the slots of the
synchroniser hub. Lubricate synchroniser ring.

16. Check that the 4th gear end float is within the spec-
ified tolerance.

13. Fit the 4th speed gear assembly. Lubricate the

needle roller bearing and then install it into the
gear.

17. Fit the 5th speed gear assembly. Lubricate the

needle roller bearing and then install it into the
gear.

68
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

18. Lubricate the 5th gear synchroniser flange and 22. Invert the mainshaft and then remove the retaining
synchroniser ring. tool.

19. Heat the 5th/6th gear synchroniser hub to 85°C

and then install it. Ensure that the large slots in the
synchroniser hub align with the large shoulders on
the synchroniser ring. Press the synchroniser hub
fully home.

23. Install the circlip into the groove of the mainshaft.

Note: Take care not to damage the mainshaft

bearing surface.

Mainshaft Assembly
20. From the range of graded circlips select the one
which fits into the mainshaft groove with the least
amount if free play. Fit the ciclip into the groove.

24. Check that the 2nd gear end float is within the
specified tolerance.

21. Using feeler gauges check that the 5th gear end
float is within the specified tolerance.

69
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

25. Fit and lubricate needle roller bearing. Fit the 1st 28. Check that the 1st gear end float is within the spec-
speed gear ensuring that the splines on the 1st ified tolerance.
speed gear engage into the the splines of the syn-
chroniser flange.

29. Fit the reverse gear needle roller bearing. Lubri-

cate the bearing and then fit the reverse gear, boss
26. Heat the reverse gear hub to 85°C and then, with down, onto the mainshaft.
the boss uppermost, fit it onto the splines of the
mainshaft. Press the reverse gear hub until it is
fully seated.

30. Heat the mainshaft bearing inner track to 85°C

27. From the range of graded circlips select the one
which fits into the mainshaft groove with the least
amount if free play. Fit the ciclip into the groove.
and then fit it, with the shoulder down, onto the
mainshaft. Use a press, if neccessary, to ensure
that the bearing is fully against the shoulder.

Note: Take care not to damage the mainshaft

bearing surface.

70
 Mainshaft Assembly - With 1st-2nd
Double Cone Synch.

31. Invert the mainshaft. Assemble the three springs

and plungers into the synchroniser hub. Place the
synchroniser sleeve over the synchroniser hub and
support it with the internal grooves just above the
synchroniser hub. Position the three rollers as
shown, retsing on the heads of the plungers, and
press downward on the synchroniser sleeve. This
compress the springs allowing the synchroniser
sleeve to centralise in the neutral position.

32. Place the 6th gear synchroniser ring onto the syn-
chroniser assembly ensuring that the shoulders on
the synchroniser rings locate into the slots of the
synchroniser hub. Lubricate synchroniser ring.

Mainshaft Assembly

71
 Selector Assembly

Exploded View
SELECTOR ASSEMBLY - DIRECT DRIVE SELECTOR ASSEMBLY - OVERDRIVE

1. Selector Shaft 1. Selector Shaft

2. Selector Key 2. Selector Key
3. Interlock Key 3. Interlock Key
4. Fork Reverse 4. Fork Reverse
5. Fork 1st/2nd 5. Fork 1st/2nd

Selector Assembly
6. Fork 3rd/4th 6. Fork 3rd/4th
7. Dowel 7. Dowel
8. Screw 8. Screw
9. Selector Block 9. Selector Block
10. Fork 5th/6th 10. Selector Overdrive
11. Fork Overdrive
12. Overdrive Shift Pad

72
 Selector Assembly

How to disassemble Selector Assembly

Procedure -
Note: Tapered screw fitted on opposite side on hori-
zontal transmission.
1. Place selector assembly on bench with the selector
block to the left. Mark the front of the shaft and key
to aid reassembly.

2. Hold the assembly by the selector block and with-

draw the interlock key from the rear.

3. Remove the selector forks from the shaft.

4. Remove the screw from the selector block. Slide

the selector block and selector key off the shaft.

73
 Selector Assembly

How to assemble Selector Assembly

Procedure - key from the rear.

1. Place selector key into slot on the selector shaft

with the three small lugs to the front.

5. On overdrive transmissions, the 5th/6th fork is

replaced by a selector overdrive. Check the fit of
selector before assembling the transmission.
2. Put the selector block onto the shaft. Install screw
and tighten it to 35 - 39 Nm.

Note: If reusing the screw, apply Loctite 270 to the

threads before fitting.

Selector Assembly
3. Place the forks in their respective positions on the
selector shaft.

4. Support the selector shaft and slide in the interlock

74
 Transmission Case Assembly

How to assemble Transmission Case

Special Instructions

WARNING: Wear safety glasses and hand gloves.

Apply appropriate Loctite or Sealant to mating faces.

Special Tools

Transmission Overhauling Stand

Hoist
Snap ring plier
Main selector shaft bush installer E 109-8
Main selector shaft plug installer E 109-9
Driver E 109
Layshaft bearing cup installer E 109-6
Mainshaft and Inputshaft bearing replacer E 108-5
Driver E 108
Mainshaft rear bearing pilot E 114
Mainshaft assembly lifting fixture E 116A
Mainshaft assembly lifting adaptor E 116-2
Inputshaft seal installer E 109-7
Feeler gauge

Transmission Case
Mainshaft rear seal replacer E 108-6
Flange holding wrench LC 113A
Reverse idler shaft retaining pin installer E 117
Refer section ‘Tools Information’

Procedure - 1. If removed apply Loctite 518 sealant and install

new selector shaft expansion plugs, dished side
IMPORTANT: Before reassembling the transmission facing inwards into the case from the inside.
case ensure that each half case and covers are clean
and that all gaskets and joining/sealing materials are
cleaned from the mating faces. When reusing patch
lock bolts or fitting capscrews to through holes apply
the recommended threadlock or sealant to the threads
(Loctite 641).

75
 Transmission Case Assembly

2. Using special tool E 109-8 with E 109 to install the 6. Apply Loctite 5900 to the housing, install the lay-
selector shaft bushes into the cases. Drive it until shaft rear bearing cover to the case. Install the cap-
fully home. screws and washers (if fitted). Tighten the
capscrews evenly to 69 -78 Nm.

Note: Making sure that the bearing cup is pressed

into the case.

3. Install the layshaft front bearing outer cup into the

front case until approximately 5mm below the face
of the case. Use special tool E 109-6 with E 109.

7. Install the mainshaft rear bearing outer track and

roller assembly, snap ring groove outermost, into
the case. Use special tool E 108-5 with E 108.

4. Install the layshaft rear bearing cup into the rear

case, drive in until just below the rear face of the
case. Use special tool E 109-6 with E 109.

8. Temporarily install the speedo housing with two or

three capscrews.

5. Using the spacer on the bearing cup, making sure

it is protuding above the case.

9. Fit mainshaft rear bearing pilot E 114 over the

mainshaft.

76
 Transmission Case Assembly
10. Locate the selector assembly to the mainshaft.
Support the mainshaft using lifting fixture E 116A
with adaptor E 116-2 and hoist. Lower the main-
shaft and selector assembly into the case, making
sure the selector shaft enters the rear bush. Sup-
port the mainshaft and selectors approximately 20
mm above the fully installed position.
11. Lubricate and install the spigot bearing on the
mainshaft. Fit the synchroniser ring and install the
input shaft assembly.
12. Locate the layshaft into mesh with the mainshaft.
77
13. Lower the hoist to allow the mainshaft, layshaft and
selector shaft to seat into their respective bearing
or bushes. Remove the lifting fixture and adaptor.
IMPORTANT: Ensure the selector block is posi-
tioned so it does not foul front case.
14. On overdrive transmissions, install the fork pads
into the 5th/6th overdrive selector fork. Engage the
fork and pads into the synchroniser sleeve.
Transmission Case
15. Apply Loctite 5900 sealant to the mating flange on
the rear case and install the front case. Install the
capscrews and nuts.
16. On overdrive transmissions, using a suitable probe
as shown in illustration, align the pivot pins with the
holes in the case. Apply sealer (Loctite 518) to the
pivot pin flange and install the pins.
 Transmission Case Assembly
17. When aligning right hand pin, use a screw driver
and lift the selector through the remote control
aperture. Install screw and washers. Tighten the
screws to 20 -40 Nm.
18. Fit the input shaft bearing ensuring oil feed hole is
kept clear.
78
19. Fit the bearing thrust washer. Place the origional
spacer against the bearing and check thet the snap
ring will fit into its groove without free play. Check
at several places around the diameter of ths shaft.
If there is a free play, or the snap ring will not fit into
the groove, a new thicker or thinner spacer respec-
tively will be required in place of the origional.
Note: Refer IPL for, graded spacers thickness and
part numbers.
When the correct thickness spacer has been
selected and fitted, fit the new snap ring.
20. If removed, install a new oil seal into the input shaft
bearing front cover using the special tool E 109-7.
Press the seal firmly down to the shoulder ensuring
the seal is not damaged.
21. Lubricate the shaft seal surface and apply Loctite
5900 sealant to the mating face of the front cover.
Install the front cover and tighten the screws to 35 -
39 Nm.
 Transmission Case Assembly
22. Select a shim pack and place it against the layshaft
bearing cup. Place the spacer on the top of the
shim.
Note: The shim pack must be proud of the front
face of the case when the bearing cup is fully
seated against the bearing cone and roller
assembly.
Note: Refer IPL for, shims thickness and part num-
bers.
23. Install the layshaft front bearing cover (without
sealer). Fit the screws without the locking coating.
Note: Carefully and evenlly tighten the screws
while rotating the input shaft backwards and
forwards to settle the bearings. Continue to
tighten the screws until some resistance can
be felt on the input shaft.
79
24. Back off the four screws. Press the cover by hand
(approx. 200N) in the middle, just sufficiently to nip
the bearing cover plate. Using feeler gauges, mea-
sure the clearance between the cover plate and
the case at several points. From the range of the
graded spacers select the thickness which give the
required preload to the layshaft bearing of 0.01 to
0.15 mm with new bearings or 0.03 to 0.08 with
used bearings.
25. Lubricate the layshaft bearing, install the graded
spacer of the selected thickness, apply Loctite
5900 sealer and install the cover plate. Apply lock-
ing coating and tighten the capscrews to 69 - 78
Nm.
Transmission Case
26. Turn the transmission to the horizontal position and
remove the speedo housing and the mainshaft rear
bearing pilot E 114.
 Transmission Case Assembly

27. Install the bearing thrust spacer onto the mainshaft, 30. Apply flange sealer Loctite 5900 and install the
over the shoulder against the rear bearing. Ensure speedo hosuing.
the oil groove is against the rollers.
Note: Install the longer screws at right position on
speedo housing.
Tighten screws to 35 - 39 Nm.

CAUTION: It may be neccessary to install the

speedo pinion into the housing prior to this stage.

28. Install the speedo drive gear or tachograph rotor

onto the mainshaft against the spacer.

31. Apply a light grease to the oil seal lips and install
the drive flange.

CAUTION: Do not hammer the flange/yoke onto

the shaft or the bearing spacer may be dislodged
from its location on the shaft. This could be cause
damage to the spacer, bearing or shaft and /or seri-
ously affect mainshaft end float.
29. If removed, install a new oil seal to correct depth
into the speedo housing using the special tool E
108-6. Press the seal firmly to the shoulder ensur-
ing the seal is not damaged.

32. Fit and tighten the flange/yoke retaining locknut to

600 - 700 Nm.

IMPORTANT: Use a flange/yoke holding wrench

LC 113A.

80
 Transmission Case Assembly

33. If not already installed, install the sender unit or
speedo drive pinion using a new sealing washer.
Tighten it to 24 - 30 Nm.
Reverse Idler - Old Design
36. Ensure the thrust washer and gear correctly posi-
tioned and that the parallel groove pin holes are in
alignment and install the reverse idler gear shaft,
with new ‘O’ ring into the case. Take care to ensure
that the components are not dislodged as shaft is
driven home with a soft mallet.

34. Apply petroleum jelly to the reverse idler gear

thrust washer and locate it into the case.

IMPORTANT: Ensure the tab of thrust washer

locates into recess of case.
37. Align the pin holes and install new parallel groove
pin using special tool E 117. Drive in until flush.

Transmission Case
35. Install the bearing and spacer into the reverse idler
gear. Locate the assembled gear between the
thrust washers and into mesh with the layshaft and 38. Install the reverse idler gear/PTO cover plate.
the mainshaft reverse gear. Install screws and washers (if fitted). Tighten
screws to 35 - 39 Nm.
IMPORTANT: Ensure the tab of thrust washer
locates into recess of case.

39. Apply sealant to the expansion plug. Fit expansion

plug into the reverse idler bore.

81
 Transmission Case Assembly

Reverse Idler - New Design
40. Ensure the thrust washer and gear correctly posi-
tioned. Drive the shaft into the position ensuring
that the end of the shaft is just below the surface of
the case.
44. Install the neutral detent punger and spring. Install
gasket and cover plate with screws and washers (if
fitted). Tighten screws to 19 -24 Nm. Or install neu-
tral detent assembly and tighten to 32 -37 Nm.

41. Install circlip into the reverse idler bore. Apply seal-
ant to the expansion plug and fit into the reverse
idler bore.

45. Apply flange sealer and install the remote control

assembly making sure that the inner lever locates
over the selector block.

42. Install the reverse idler gear/PTO cover plate.

Install screws and washers (if fitted). Tighten cap-
screws to 35 - 39 Nm. Apply sealant to the expan-
sion plug.

43. Turn the transmission to the horizontal position.

Rotate the selector block to position the pin upper-
most.

82
 Transmission Case Assembly

46. Install screws and washers (if fitted). Tighten

screws to 35 - 39 Nm.

47. Apply sealant and intall reverse switch, tighten to

24 - 30 Nm.

48. Check manually using the shift lever that all gears

Transmission Case
can be engaged. It may be neccessary to rotate
input shaft to obtain full gear engagement.

83
Copyright Eaton Corporation, 2009.
Eaton hereby grants 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
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INFORMATION IS NOT INTENDED FOR
SALE OR RESALE, AND THIS NOTICE
MUST REMAIN ON ALL COPIES.

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