Service Manual
Eaton Transmissions TRSM0080 March 2015
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 Disassemble Precautions This manual is designed to provide detailed information It is assumed in the detailed disassembly instructions necessary to service and repair the Eaton® transmis- that the lubricant has been drained and the necessary sions listed on the front. linkage and air lines (if fitted) have been removed from the chassis.
How to use this Manual Removal of the gear shift remote control housing assembly is included in the detailed instructions; how- The procedure sections are laid out with a general ever, this assembly may also be removed from the heading at the top outside edge of each page followed transmission before removing unit from vehicle. by more specific headings and the procedures. To find the information you need in these sections, first go to
Follow each procedure closely in each section, making Introduction the section that contains the procedure you need. Then use of both the text and the pictures. look at the heading at the top and outside edge of each page until you find the one that contains the procedure Assemblies you need. When disassembling the various assemblies, such as the mainshaft, layshaft and remote control housing, lay Transmission Overhaul Procedures follow the general all parts on a clean bench in the same sequence as steps for complete disassembly and then assembly of removed. This procedure will simplify reassembly and the transmission. reduce the possibility of losing parts. When pulling off synchroniser hubs follow the procedures detailed in Note: In some instances the transmission appearance ‘Disassembly’ using a suitable puller of adequate may be different from the illustrations, but the pro- capacity. Failure to adhere to the recommended proce- cedure is the same. 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.
2 Introduction
Inspection Precautions Synchroniser Assemblies • Check to ensure all splines are free from Before reassembling the transmission, the individual excessive wear. parts should be carefully checked to eliminate those • Check that the engagement dog teeth on the damaged. They should be renewed. This inspection sliding sleeves, synchroniser rings are free procedure should be carefully followed to ensure the from chipping and burring. maximum wear life from the rebuilt unit. • Check that the synchroniser ring cones are not excessively worn or showing the effects of The cost of a new part is generally a small fraction of overheating. Check the clearance between the the total cost of downtime and labour, should the use of synchroniser ring and the synchroniser flange a questionable part make additional repairs necessary is between 1.9 mm maximum and 0.5 mm before the next regularly scheduled overhaul. minimum. Recommended inspection procedures are set forth in the following check list. • Renew the springs, plungers and rollers. Bearings Splines • Wash all bearings in clean solvent. Check roll- • Check splines on all shafts for wear. If synchro- ers and races for pits and spalled areas. niser hubs, output drive flange or clutch hub Renew damaged bearings. have worn into the sides of the splines, the shafts in this condition must be renewed. • Lubricate undamaged bearings and check for axial and radial clearances. Renew bearings Thrust Washers with excessive clearances. • Check surfaces of all thrust washers. Washers • Check fits of bearings in housing bores. If outer scored or reduced in thickness should be races turn too freely in the bores, the housing renewed. should be renewed. Check housing bores for signs of wear prior to taking this action. Only Reverse Idler Gear replace housing if wear is seen as a result of bearing spin. • Check bearings and shaft for wear from action of roller bearings. Gears Clutch Release Parts • Check gear teeth for pitting of the tooth faces. Gears with pitted teeth should be renewed. • Check clutch release parts, yokes and bearing Check the reverse gear dog engagement teeth carrier. Check pedal shafts. Renew worn shafts for freedom from damage. and bearings. • Check the internal bearing surfaces for wear of Gear Selector Shaft Assembly the effects of overheating. • Check forks and keys for wear at contact • Check axial clearances of gears. Where points. Renew worn parts. excessive clearance is found, check gear and • Check forks for excessive and uneven wear, hub for excessive wear. renew worn forks. • Maintain the specified axial clearance on main- • Check lockscrew in selector block. A lockscrew shaft forward gears. with worn taper must be renewed.
Bearing Sleeve — Mainshaft • Check condition and fit of selector key and interlock key in shift shaft. Worn or damaged • Sleeves with groove formation, pits or which keys must be renewed. have either been overheated or worn out must be renewed.
3 Introduction
Gear Shift Remove Control Assembly Precautions • Check spring tension on cross shaft. Renew Make sure that interiors of all housings are clean. It is tension springs if shaft moves too freely. important that dirt be kept out of transmission during • If housing is dismantled, check cross shaft and reassembly. Dirt is abrasive and can damage polished inner lever and the bearing bushes for wear. surfaces of bearings and washers. Use certain Renew worn parts. precautions, as listed below, during reassembly. • Check all seals and locating journals. Renew Gaskets worn parts. Use new gaskets where detailed only (neutral detent cover and remote control housing covers). All other Bearing Covers locations ensure mating faces are clean and undam- • Check covers for wear from thrust. Renew cov- aged and apply a continuous bead of Loctite 518
ers worn or grooved from thrust of bearing Flange Sealant to one face only. Do not apply exces- Introduction outer race. sive sealant or allow it to penetrate into the bearings. • Check bores of covers for wear. Renew those Capscrews worn oversize. Use thread sealant (Loctite 641) on all capscrews. Refer section ’Specification’ for torque ratings. Oil Return Threads and Seals ‘O’ Rings • Check oil seal in front bearing cover for dam- Lubricate all ‘O’ rings lightly with silicone lubricant. age and wear, renew if necessary. Initial Lubrication • Check oil seal in speedometer housing for Lubricate bearings with gearbox oil during reassembly. damage or wear, renew if necessary. Renew grit shield if worn or loose on flange. Axial Clearances Refer section ’Specification’ to maintain the end float • Check oil seal journals for wear and renew if of mainshaft gears. worn or grooved. Bearings O-Rings Use of flange-end bearing drivers is recommended for the installation of bearings. These drivers apply equal • Renew all O-rings. 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.
4 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 6 4 0 N m 1 1 7 K g N A FS 4206B 7 0 0 N m 1 1 7 K g N A FSO 4206B 7 5 0 N m 117 Kg N A FS 5206A 7 0 0 N m 11 7 K g N A FS 5206B 7 5 0 N m 117 Kg N A FSO 5206B 8 2 5 N m 117 Kg NA Oil Capacity Vertical 7 . 5 l i t Horizontal 6 . 5 l i t 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 E n g i n e s p e e d x 0 . 2 2 6 Engine speed x 0.434 Specifications FS 4206B E n g i n e s p e e d x 0 . 2 7 1 Engine speed x 0.519 FSO 4206B Engine speed x0.336 E n g i n e s p e e d x 0 . 6 4 4 FS 5206A E n g i n e s p e e d x 0 . 2 2 6 Engine speed x 0.434 FS 5206B E n g i n e s p e e d x 0 . 2 7 1 E n g i n e s p e e d x 0 . 5 1 9 FSO 5206B Engine speed x0.336 E n g i n e s p e e d x 0 . 6 4 4 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 Limit0.670.450.530.550.64 Tolerance0.360.200.180.200.31
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 ON HIGHWAY USE Every 20,000 Km or 2 months Inspect oil level. Check for leaks. Every 100,000 Km or 12 months Change the transmission oil.
OFF HIGHWAY USE Every 40 hours or 4 months Inspect oil level. Check for leaks. Every 500 hours Change the transmission oil where severe dirt conditions exist. Every 1000 hours or 12 months Change the transmission oil.
Recommended Lubricants epyT edarG )EAS( tneibmA erutarepmeT 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 modi ers 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 ON HIGHWAY USE All brands - Every 20,000 Km Inspect oil level. Check for leaks. Every 300,000 Km or three years Change the transmission oil. OFF HIGHWAY USE All brands - Every 40 hours Inspect oil level. Check for leaks. Every 500 hours Change transmission oil where severe dirt conditions exist. Every three years 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 But for the most part, ordinary mechanic's tools such the use of specialized tools. Their actual use is recom- as socket wrenches, screwdrivers, etc., and other stan- mended as they make transmission repair easier, dard shop items such as a press, mauls and soft bars faster, and prevent costly damage to critical parts. 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 Tool Information Special Tools Manufacturers SPX (UK) Ltd. 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 En gla n d Pho n e: + 44 ( 01 3 27 ) 30 34 0 0 SPX 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 Clutch Pedal Shaft and Bores the highways with transmissions in such a neglected • Pry upward on shafts to check wear. mechanical condition, they can be referred to as fail- ures looking for a place to break down. They lack a • If excessive movement is found, remove clutch proper and organized preventive maintenance pro- release mechanism and check bushings on gram. bores and wear on shafts. See OEM literature.
Preventive maintenance is a general term which Lubricant applies to all procedures necessary to have maximum • Change at specified service intervals. Preventive Maintenance life and satisfactory service at the lowest possible cost, short of removing and repairing the unit. • Use only the types and grades as recom- mended. Refer section ’Lubrication Informa- tion’. Checks Before Transmission Removal 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. A number of conditions contrary to good preventive Gear Shift Lever maintenance can generally be pointed to when inspect- ing a failed transmission. Taking a few minutes every • Check for looseness and free play in housing. so many hours or miles to do a few simple checks If lever is loose in housing, check Direct Con- could help avoid eventual breakdown or reduce the trol Assembly. repair cost. If the transmission is not cared for, it will Direct Control Assembly breakdown. • Remove the direct control assembly from the Note: Transmission appearance may differ, the proce- transmission. dure is the same. • Check the tension spring for set and wear. Clutch Housing Mounting • Check gear shift lever bottom end for wear in • Check all capscrews of clutch housing flange the slots and check for wear of finger assembly for looseness. and housing. 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 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. Remote Control 17. Invert the housing, align the grooved pin in the 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 10. Fit a new ‘O’ ring or gasket (if fitted) and secure the install the new grooved pin. end cover to the housing by screws and washers (if fitted). Note: Inner striking lever should be supported whilst driving grooved pin, to prevent damage 11. Install the reaction bracket (if fitted). to bushes. 12. Tighten the screws to 20 -24 Nm.
Note: The word “TOP” has been cast into the cover to identify correct positioning.
6. Fit the inner circlip onto the shift rod. Install the booster spring retainer. 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
7. Insert the booster spring (if fitted) and bias spring.
8. Install bias spring retainer.
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.
9. Fit the outer circlip onto the shift rod.
28 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 Transmission Case CAUTION: Drain gear oil from the transmission. Clean electronic sender unit (if fitted). 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 13. Remove the half case flange bolts and nuts. on the stand or wooden cradle. Remove the screws and washers (if fitted). Remove the neutral Note: Mark the position of the shorter bolts detent cover, gasket, spring and plunger or detent threaded into the case. assembly (if fitted).
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 Layshaft Assembly sure bearing is fully home.
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 Mainshaft Assembly
1. Mainshaft 25. Needle Roller Brg. 2. Needle Roller Brg. 26. Needle Roller Brg. 3. Gear Mainshaft 3rd 27. Gear Mainshaft 2nd 4a. Synchro Flange 3rd/4th 28. Synchro Flange 1st/2nd 4. Ring Synchro 29. Ring Synchro 5. Roller 30. Spring 6. Plunger 31. Plunger 7. Spring 32. Roller 8. Fixed Hub 3rd/4th 33. Fixed Hub 1st/2nd 9. Sliding Sleeve 3rd/4th 34. Sliding Sleeve 1st/2nd 10. Ring Synchro 35. Ring Synchro 10a. Synchro Flange 3rd/4th 36. Synchro Flange 1st/2nd 11. Gear Mainshaft 4th 38. Graded Circlip Pack 12. Needle Roller Brg. 39. Gear Mainshaft 1st 13. Sleeve Mainshaft Brg. 40. Needle Roller Brg. 14. Circlip Assy. 41. Fixed Hub Reverse 15. Needle Roller Brg. 42. Graded Circlip Pack 16. Gear Mainshaft 5th 43. Needle Roller Brg. 17a. Synchro Flange 5th/6th 44. Gear Mainshaft Reverse 17. Ring Synchro 45. Mainshaft Output Brg. 18. Roller 46. Speedo Drive Gear OR 19. Plunger 46. Tachograph Rotor 20. Spring 47. Dirt Shield 21. Fixed Hub 5th/6th 48. Flange Coupling 22. Sliding Sleeve 5th/6th 49. Mainshaft Locknut 23. Ring Synchro 50. Spacer Tachograph Rotor 24. Graded Circlip Pack
42 Mainshaft Assembly - W/o 1st-2nd Double Cone Synch.
End Float Check Note: The end float of the gears on the mainshaft is Where the end float is found to be excessive it is nec- established in manufacture by machining the cessary to check the gears, mainshaft, synchroniser components to fine tolerances. Before disassembly of hubs and bearing sleeve for wear. See section ‘Inspection Precautions’ and renew where necces- the mainshaft the end floats should be checked to as sary. certain whether they are within the recommended limits.
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 ram) over 5th/6th gear synchroniser hub and the 1. Mount the mainshaft assembly, plain end upper- 5th gear synchroniser ring. most, in soft jawed vice. Remove the synchroniser ring. Carefully slide the 5th/6th synchroniser sleeve Note: Take care not to damage teeth of the later. upwards until the three rollers are clear off the groove in the synchroniser sleeve. Remove the Pull of the synchroniser hub, cone and ring.
three rollers, synchroniser sleeve, three plungers Mainshaft Assembly and theree springs from the synchoniser hub. IMPORTANT: On an overdrive transmission, it 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 10. Slide the 1st/2nd gear synchroniser sleeve, care- three legged puller (Series 1500 with hydraulic fully rearwards until the three rollers are clear off ram) under the reverse gear, remove the gear, the groove in the sleeve. Remove the roller, sleeve, thrust washer, bearing track. Remove the reverse theree plungers and three springs from the syn- gear needle roller bearing. 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. Check clearance between synchro- Note: It is imperative that 3rd gear is supported niser ring and flange and that the flange on the shaft does not foul Before assembling the synchroniser assemblies onto the supporting blocks or press bed when the the mainshaft, check the fit of each synchroniser ring to shaft is being pressed through. the relevant synchroniser flange. Press or pull the shaft through 3rd gear, 3rd/4th gear synchroniser hub and 4th gear bearing sleeve.
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 14. Slide the 3rd/4th gear synchroniser sleeve, care- feeler gauges at several points around the circumfer- fully rearwards until the three rollers are clear off ence as shown. The clearance should be between 0.5 the groove in the sleeve. Remove the roller, sleeve, and 1.9 mm. Renew both parts if the measurement is theree plungers and three springs from the syn- not within the specified limits. Retain the synchroniser chroniser hub. 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.
46 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 8. Assemble the three springs and plungers into the place it over the splines of the mainshaft ensuring synchroniser hub. Place the synchroniser sleeve that the large slots in the hub align with the large over the synchroniser hub and support it with the shoulders on the synchroniser ring. Use a soft drift internal grooves just above the synchroniser hub. or driver E 108 to ensure the hub is fully home after Position the three rollers as shown, retsing on the cooling for 4-5 minutes. 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.
5. From the range of the graded snap rings select the thickest one which fits into the groove with the min- imum free play. 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
6. Install the snap ring in the groove.
Note: Taking care not to damage mainshaft bear- ing surface. 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.
7. Check that the 2nd gear end float is within speci- fied tolerance.
48 Mainshaft Assembly - W/o 1st-2nd Double Cone Synch.
11. Take the heated reverse gear fixed hub and fit it 15. Lubricate the reverse gear bearing. Install the over the splines, boss uppermost, onto the main- bearing and reverse gear onto the mainshaft. shaft.
16. Fit the spacer on the standard cylindrical roller or 12. Use a soft drift or driver E 108 if neccessary, to 4 point roller bearing. If intergral spacer bearing is ensure the hub is fully home against the shoulder. fitted, the spacer is parts of the bearing inner race.
13. From the range of the graded snap rings select the 17. Take the heated inner tarck of the mainshaft rear thickest one which fits into the groove with the min- bearing and fit it over the shaft, flange inner most imum free play. Install the snap ring in the groove. against the spacer. Use a soft drift or driver E 108 if neccessary to ensure that the bearing is fully home Note: Taking care not to damage mainshaft bear- against the shoulder. ing surface. Note: When cooled, the bearing track should be sufficiently tight on the shaft to retain the reverse gear on the shaft.
14. Check that the 1st gear end float is within specified tolerance.
49 Mainshaft Assembly - W/o 1st-2nd Double Cone Synch.
18. Invert the mainshaft in the vice. Lubricate and 22. Assemble the three springs and plungers into the install the 3rd gear bearing and 3rd gear assembly. 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. Mainshaft Assembly 20. 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. 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 29. Position 5th gear synchroniser ring onto the syn- locate it inside the bearing and over the shaft. Use chroniser flange. soft drift or flange driver if neccessary, to ensure the sleeve is firmly home against the synchroniser CAUTION: Ensure that when fitting the synchro- hub. 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.
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 30. Take the heated 5th/6th synchroniser hub and place it over the splines of the mainshaft, boss side Note: Take care not to damage the mainshaft downwards. Ensure that the large slots in the hub bearing surface. 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.
27. Check that the 4th gear end float is within the spec- ified tolerance.
31. From the range of graded circlips select the one which fits into the mainshaft groove with the least amount if free play.
28. Lubricate the 5th gear bearing. Install the bearing and 5th gear assembly onto the mainshaft.
51 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 Mainshaft Assembly
1. Mainshaft 20. Spring 2. Needle Roller Brg. 21. Fixed Hub 5th/6th 3. Gear Mainshaft 3rd 22. Sliding Sleeve 5th/6th 4a. Synchro Flange 3rd/4th 23. Ring Synchro 4. Ring Synchro 24. Graded Circlip Pack 5. Roller 25. Needle Roller Brg. 6. Plunger 26. Needle Roller Brg. 7. Spring 27. Gear Mainshaft 2nd 8. Fixed Hub 3rd/4th 28. Synchro Pack D.C. 1st/2nd 9. Sliding Sleeve 3rd/4th 29. Gear Mainshaft 1st 10. Synchro Flange 3rd/4th 30. Needle Roller Brg. 10a. Ring Synchro 31. Fixed Hub Reverse 11. Gear Mainshaft 4th 32. Graded Circlip Pack 12. Needle Roller Brg. 33. Needle Roller Brg. 13. Sleeve Mainshaft Brg. 34. Gear Mainshaft Reverse 14. Circlip Assy. 35. Mainshaft Output Brg. 15. Needle Roller Brg. 36. Speedo Drive Gear OR 16. Gear Mainshaft 5th 36. Tachograph Rotor 17a. Synchro Flange 5th/6th 37. Spacer Tachograph Rotor 17. Ring Synchro 38. Dirt Shield 18. Roller 39. Flange Coupling 19. Plunger 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 suitable puller remove the mainshaft bearing inner, 1. Mount the mainshaft assembly, plain end upper- reverse gear and reverse gear needle roller bear- most, in soft jawed vice. Remove the synchroniser ing. ring. Care fully slide the 5th/6th synchroniser
sleeve upwards until the three rollers are clear off 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 8. To prevent the synchroniser assembly from sepa- gear fixed hub and 1st speed gear. 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.
6. Remove the 1st speed gear needle roller bearing.
9. Using a press or suitable tool remove the 1st/2nd synchroniser assembly and 2nd speed gear. Remove the needle roller bearing. 7. Remove the 1st/2nd synchroniser assembly retain- ing circlip.
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.
56 Mainshaft Assembly - With 1st-2nd Double Cone Synch.
11. Invert the mainshaft . As the 5th/6th synchroniser 14. Using a suitable press or puller support the main- hub is not symmetrical identify its orientation. Using shaft assembly underneath 3rd speed gear. a press or Puller kit (Series 1500 with hydraulic ram), remove the 5th/6th gear synchroniser hub, Note: It is imperactive that the flange, which is part synchroniser ring and 5th speed gear assembly. of the mainshaft, does not foul the press or puller legs as this may result in damage to Note: Care must be taken to ensure that the dam- the mainshaft. Press or pull the 4th speed age to the teeth on the synchroniser flange gear bearing sleeve, 4th speed needle roller does not occur. On an overdrive tranmission bearing , 4th speed gear assembly, 3rd/4th it may be neccessary to engage the press/ synchroniser assembly and 3rd speed gear puller also over the gear. assembly off. Remove the 3rd speed gear needle roller bearing from the mainshaft.
12. Remove the 5th speed gear needle roller bearing. 15. Place the assembly onto a suitable work surface,
On overdrive transmissions this will be 6th gear. 4th speed gear, uppermost. Remove the bearing Mainshaft Assembly sleeve, needle roller bearing and 4th gear assem- bly.
13. Care fully remove the 4th speed gear bearing sleeve retaining snap ring.
16. Dismantle the 3rd/4th speed synchroniser assem- bly.
57 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- Mainshaft Assembly niser flange ensuring that the tabs on the synchro- 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 12. Place the synchroniser ring onto the synchronsier uppermost, and fit it to the synchroniser hub ensur- hub so that the three bosses enagge with the three ing that the three internal bosses of the synchro- narrow slots on the synchroniser hub. niser sleeve locate in the slots of the synchroniser hub.
13. Lubricate all surfaces of the synchroniser friction 9. Place the detent poppets and springs into the holes ring. Fit the synchroniser friction ring ensuring that of the synchroniser hub. the tabs locate in to the slots of the synchroniser flange.
10. Place the detent balls onto the springs and then using suitable tool push against the detent ball to 14. Place the synchroniser inner ring into position compress spring. ensuring that the three tabs align with the legs of the blocks.
11. Whilst the spring is compressed push the detent poppet downwards into the synchroniser hub until 15. Place the synchroniser flange into position ensur- the ball engages with the annular groove of the ing that the slots of the synchroniser flange align sleeve. Fit the remaining detent springs, balls and with the tabs of the synchroniser friction ring. plungers into the position.
64 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 Mainshaft Assembly the synchroniser hub over the splines on the main- 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 and then fit it, with the shoulder down, onto the mainshaft. Use a press, if neccessary, to ensure 27. From the range of graded circlips select the one that the bearing is fully against the shoulder. 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.
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 Transmission Case Feeler gauge 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. 13. Lower the hoist to allow the mainshaft, layshaft and Support the mainshaft using lifting fixture E 116A selector shaft to seat into their respective bearing with adaptor E 116-2 and hoist. Lower the main- or bushes. Remove the lifting fixture and adaptor. shaft and selector assembly into the case, making sure the selector shaft enters the rear bush. Sup- IMPORTANT: Ensure the selector block is posi- port the mainshaft and selectors approximately 20 tioned so it does not foul front case. mm above the fully installed position.
14. On overdrive transmissions, install the fork pads 11. Lubricate and install the spigot bearing on the into the 5th/6th overdrive selector fork. Engage the mainshaft. Fit the synchroniser ring and install the fork and pads into the synchroniser sleeve. input shaft assembly. Transmission Case
15. Apply Loctite 5900 sealant to the mating flange on 12. Locate the layshaft into mesh with the mainshaft. 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.
77 Transmission Case Assembly
17. When aligning right hand pin, use a screw driver 19. Fit the bearing thrust washer. Place the origional and lift the selector through the remote control spacer against the bearing and check thet the snap aperture. Install screw and washers. Tighten the ring will fit into its groove without free play. Check screws to 20 -40 Nm. 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.
18. Fit the input shaft bearing ensuring oil feed hole is 20. If removed, install a new oil seal into the input shaft kept clear. 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.
78 Transmission Case Assembly
22. Select a shim pack and place it against the layshaft 24. Back off the four screws. Press the cover by hand bearing cup. Place the spacer on the top of the (approx. 200N) in the middle, just sufficiently to nip shim. the bearing cover plate. Using feeler gauges, mea- sure the clearance between the cover plate and Note: The shim pack must be proud of the front the case at several points. From the range of the face of the case when the bearing cup is fully graded spacers select the thickness which give the seated against the bearing cone and roller required preload to the layshaft bearing of 0.01 to assembly. 0.15 mm with new bearings or 0.03 to 0.08 with used bearings. Note: Refer IPL for, shims thickness and part num- bers.
25. Lubricate the layshaft bearing, install the graded spacer of the selected thickness, apply Loctite 23. Install the layshaft front bearing cover (without 5900 sealer and install the cover plate. Apply lock- sealer). Fit the screws without the locking coating. ing coating and tighten the capscrews to 69 - 78 Nm. Note: Carefully and evenlly tighten the screws Transmission Case 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.
26. Turn the transmission to the horizontal position and remove the speedo housing and the mainshaft rear bearing pilot E 114.
79 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 Reverse Idler - Old Design speedo drive pinion using a new sealing washer. Tighten it to 24 - 30 Nm. 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 44. Install the neutral detent punger and spring. Install gasket and cover plate with screws and washers (if 40. Ensure the thrust washer and gear correctly posi- fitted). Tighten screws to 19 -24 Nm. Or install neu- tioned. Drive the shaft into the position ensuring tral detent assembly and tighten to 32 -37 Nm. that the end of the shaft is just below the surface of the case.
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 any changes or modi cations. THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.
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