Eaton Transmission

Service Manual
Eaton Transmissions
TRSM0005
September 2016
FS(O)-10309
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 ...................................................................................................................................5
Model Information
Serial Tag Information and Model Nomenclature .........................................................................................6
Model Number ..............................................................................................................................................7
Serial Number ...............................................................................................................................................7
Specifications
Technical Data...............................................................................................................................................8
Torque Rating ...............................................................................................................................................10
Torque Chart ................................................................................................................................................12
Gear End Floats ............................................................................................................................................13
Synchroniser Ring to Synchroniser Flange Clearance..................................................................................13
Lubrication Information
Lubrication ....................................................................................................................................................14
Recommended Lubricants.............................................................................................................................15
Tool Information
Recommended Tools ...................................................................................................................................17
Special Tools Manufacturers .........................................................................................................................18
Preventive Maintenance
Preventive Maintenance ...............................................................................................................................19
Checks Before Transmission Removal .........................................................................................................19
Checks With Drive Line Dropped ..................................................................................................................19
Checks With Universal Joint Companion Flange or Yoke Removed.............................................................20
Rear Seal Maintenance .................................................................................................................................20
Table of Contents
Power Flow
Power Flow ...................................................................................................................................................21
General
Features .......................................................................................................................................................23
The Epicyclic Reduction Gear .......................................................................................................................23
Transmission Installations .............................................................................................................................25
Air System
System Theory .............................................................................................................................................26
Integrated Air System (IAS) ..........................................................................................................................27
Type of IAS Unit ............................................................................................................................................28
Description of Internal Channels....................................................................................................................29
Range Change Shift Air Lines ......................................................................................................................30
Range Change Shift Air Circuit Diagram - Double H.....................................................................................31
Range Change Shift Air Circuit Diagram - Single H ......................................................................................34
Bi-stable Relay Switch (RL)...........................................................................................................................37
Remote Control Assembly

Exploded View - Single H ..............................................................................................................................38
How to Disassemble Remote Control Assembly (Single H) ..........................................................................39
How to Assemble Remote Control Assembly (Single H)...............................................................................43
Exploded View - Double H.............................................................................................................................47
How to Disassemble Remote Control Assembly (Double H).........................................................................48
How to Assemble Remote Control Assembly (Double H) .............................................................................52
How to Remove Pneumatic Power Assist (PPA) Unit....................................................................................57
How to Install Pneumatic Power Assist (PPA) Unit........................................................................................58
How to Remove Pneumatic Power Assist (PPA) Unit with Hydraulic Gear Shifting (HGS) Unit....................59
How to Install Pneumatic Power Assist (PPA) Unit with Hydraulic Gear Shifting (HGS) Unit........................60
Transmission Case Overhauling

Exploded View ..............................................................................................................................................61
How to Disassemble Transmission Case .....................................................................................................62
Exploded View ..............................................................................................................................................68
How to Disassemble Rear Case....................................................................................................................69
Exploded View ..............................................................................................................................................73
How to Disassemble Planet carrier Assembly...............................................................................................74
How to Assemble Planet Carrier Assembly...................................................................................................75
How to Assemble Rear Case ........................................................................................................................77
Table of Contents
Mainshaft Assembly
Exploded View ..............................................................................................................................................84
End Float Check ...........................................................................................................................................85
How to Disassemble Mainshaft .....................................................................................................................86
Check Clearance between Synchroniser Ring and Flange ...........................................................................90
How to Assemble Mainshaft ..........................................................................................................................91
Layshaft Assembly
Exploded View ..............................................................................................................................................96
How to Disassemble Layshaft ......................................................................................................................97
How to Assemble Layshaft ............................................................................................................................98
Input Shaft Assembly

Exploded View ..............................................................................................................................................99
How to Disassemble Input Shaft Assembly...................................................................................................100
How to Assemble Input Shaft Assembly........................................................................................................101
Selector Assembly
Exploded View ..............................................................................................................................................103
Selector Assembly - Single H ........................................................................................................................104
How to Disassemble Selector Assembly ......................................................................................................104
How to Assemble Selector Assembly............................................................................................................105
Selector Assembly - Double H.......................................................................................................................106
How to Disassemble Selector Assembly ......................................................................................................106
How to Assemble Selector Assembly............................................................................................................106
Transmission Case Assembly

Exploded View...............................................................................................................................................108
How to Assemble Transmission Case...........................................................................................................109
Layshaft Front Bearing Preload Setting.........................................................................................................112
Clutch Housing
Exploded View...............................................................................................................................................117
How to Disassemble Clutch Housing ............................................................................................................118
How to Assemble Clutch Housing .................................................................................................................119
Warnings and Precautions
Before starting a vehicle always be seated in the driver’s seat, place the transmission in neutral, 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, or 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 Disassembly 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
the section that contains the procedure you need. Then
use of both the text and the pictures.
Introduction
look at the heading at the top and outside edge of each
page until you find the one that contains the procedure Cleanliness
you need. Provide a clean place to work. It is important that no dirt
or foreign material enters the unit during repairs. The
Transmission Overhaul Procedures follow the general outside of the unit should be carefully cleaned before
steps for complete disassembly and then assembly of starting the disassembly. Dirt is abrasive and can dam-
the transmission. age bearings.
Note: In some instances the transmission appearance Assemblies
may be different from the illustrations, but the pro- When disassembling the various assemblies, such as
cedure is the same. the mainshaft, range change epicyclic, 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 procedures may cause irreparable dam-
age.
Snap rings
Remove snap rings with pliers designed for this pur-
pose. New selective fit snap rings must be fitted as
specified in ‘Reassembly’.
Input shaft
The input shaft on direct drive transmission can be
removed without removing the front case. Take care
not to misplace or lose the mainshaft spigot bearing.
Bearings
Carefully wash and relubricate all bearings as removed
and protectively wrap until ready for use. Remove
bearings with pullers designed for this purpose.
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.
2
Introduction
Do not use pry bars or chisels to separate casing Inspection Precautions

halves and housings or irreparable damage may be
caused.
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.
• Planet gear bearings consist of two tracks of
18 loose assembled rollers, i.e. 36 rollers per
gear, separated by a spacer. If any rollers in a
gear set are worn or damaged the whole set
must be renewed.
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 all
mainshaft gears.
3
Introduction
Bearing Sleeve — Mainshaft Gear Selector Shaft Assembly

• Sleeves with groove formation, pits or which • Check forks and keys for wear at contact
have either been overheated or worn out must points. Renew worn parts.
be renewed.Synchroniser Assemblies
• Check forks for alignment. Check forks for
• Check to ensure all splines are free from excessive and uneven wear, renew worn forks.
excessive wear.
• Check lockscrew in selector block. A lockscrew
• Check that the engagement dog teeth on the with worn taper must be renewed.
sliding sleeves, synchroniser rings are free
• Check condition and fit of selector key and
from chipping and burring.
interlock key in shift shaft. Worn or damaged
• Check that the synchroniser ring cones are not keys must be renewed.
excessively worn or showing the effects of
overheating. Check the clearance between the Gear Shift Remote Control
Introduction
synchroniser ring and the synchroniser flange • Check spring tension on cross shaft. Renew
is between 2.94 mm maximum and 0.50 mm tension springs if shaft moves too freely.
minimum.
• If housing is dismantled, check cross shaft and
• Renew the springs, plungers and rollers. inner lever and the bearing bushes for wear.
Renew worn parts.
Splines
• Check all seals and locating journals. Renew
• Check splines on all shafts for wear. If synchro-
worn parts.
niser hubs, output drive flange or clutch hub
have worn into the sides of the splines, the Bearing Covers
shafts in this condition must be renewed.
• Check covers for wear from thrust. Renew cov-
ers worn or grooved from thrust of bearing
Thrust Washers
outer race.
• Check surfaces of all thrust washers. Washers
• Check bores of covers for wear. Renew those
scored or reduced in thickness should be
worn oversize.
renewed.
Range Change Planet Gears, Spindles and Needle Oil Return Seals
Roller Bearings • Check oil seal in front bearing cover for dam-
• It is found necessary to dismantle the planet age and wear, renew if necessary.
gears, retain each gear, spindle, rollers, spac- • Check oil seal in speedometer housing for
ers and washers in their respective set for damage or wear, renew if necessary. Renew
reassembly in the same relative position. grit shield if worn or loose on flange.Check oil
• If uneven wear is found in the planet gears, seal tracks for wear and renew if worn or
check lubrication holes for blockage and renew grooved.
all rollers. • Check the oil sealing ring in the muff ring for
• Renew planet spindle grub screws on reas- wear or breakage.
sembly.
O-Rings
Reverse Idler Gear • Renew all O-rings.
• Check bearings and shaft for wear from action
of roller bearings. Oil Pump
• Check the oil pump rotors and covers for scor-
Clutch Release Parts ing and wear. The complete pump assembly
• Check clutch release parts, yokes and bearing must be renewed if scored or excessively
carrier. Check pedal shafts. Renew worn shafts worn, or its serviceability is suspect in any way
and bearings.
4
Introduction
Assembly Precautions Synchroniser Hubs & Flanges

All synchroniser hubs are an interference fit on the
Make sure that interiors of all housings are clean. It is mainshaft splines and must be heated to approximately
important that dirt be kept out of transmission during 85°C (180°F) before installation.
reassembly. Dirt is abrasive and can damage polished
surfaces of bearings and washers. Use certain Press fully home and hold under pressure for a short
precautions, as listed below, during reassembly. period to prevent creep while cooling.
Gaskets
Use new gaskets where detailed only (neutral detent All synchroniser flanges to be lubricated before assem-
cover and remote control housing covers). All other bly.
locations ensure mating faces are clean and undam- Layshaft
aged and apply a continuous bead of Loctite 5900 The shaft is only available as a complete assembly for
Flange Sealant to one face only. Do not apply exces-
service.
sive sealant or allow it to penetrate into the bearings.
Capscrews
Use thread sealant 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 the correct special tools and bearing drivers is
recommended for the installation of bearings. Heating
the bearing inner tracks will aid installation.
Output Shaft Drive Flange
Tighten the nut to the correct torque.
During disassembly and again during reassembly prior

to tightening the new nut, it is important to ensure that
the output shaft does not slide through the bearing, or
the assembled range change synchroniser roller,
plungers and springs may be displaced.
5
Model Information
Serial Tag Information and Model Nomenclature

All transmissions are fitted with an identification plate on the top in vertical transmission and left hand side of the
front case on horizontal transmission.
Model Information
Identification plate on front case shows;
1. Transmission serial number

2. Transmission model
3. Manufacturing date code
4. Transmission 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.
6
Model Information
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 identification number of the transmission. Before calling for service assistance,
write number down. It may be needed.
7
Specifications
Technical Data
FS(O)-10309 Dual Outlet PTO 2830 Series
Speeds
PTO Output speed 1000
9 Forward (1 to 8 synchronised), 1 Reverse
R.P.M.
Power Take-off - Side PTO
Type Output Torque FS 10309 FSO 10309
Mounted on the left side (vertical) and bottom Position Nm
(horizontal) - 8 bolts 2831 1 640 1160 1570
Driven from layshaft 2831 2 640 1160 1570

2832 1 540 1500 2050
Type Gear- Torque Power Output 2832 2 540 1500 2050

box Nm Kw speed 2833 1 400 2000 2720
1000
R.P.M. 2833 2 400 2000 2720
6090 FS 430 33.9 704 2834 1 640 1160 1570

10309 2834 2 720 940 1280
FSO 41.9 932 2835 1 540 1500 2050
10309
2835 2 720 940 1280
Specifications
Power Take-off - Rear PTO 2836 1 400 2000 2720
Single Outlet 2836 2 720 940 1280
PTO Output speed 1000

R.P.M. Speedometer
Type Ratio Torque Nm FS 10309 FSO 10309 Provision in rear bearing cover - standard mag-
netic pick-up or mechanical drive
2250 Direct 1000 756 1029
Reverse Switch
2266 1.93:1 300 1459 1985
Normally open - provision in maincase for
2264 1.38:1 400 1043 1420 installation of switch
82Z2 1.32:1 300 998 1358 Neutral Switch
Normally closed - provision in maincase for
installation of switch
Weight
Including output flange, low remote control
assembly, clutch housing, without oil 240 Kg
Oil Capacity
11.4 liters
8
Specifications
Ratios and Steps
Gear FS 10309A FSO 10309A

8 1 0.74
7 1.36 1
6 1.92 1.41
5 2.71 1.99
4 3.71 2.73
3 5.05 3.71
2 7.11 5.22
1 10.04 7.38
Crawler 14.39 10.58
Reverse 14.41 10.59
Overall ratio 14.34 14.3
Torque 1500 Nm 1750 Nm
9
Specifications
Torque Rating eventually cause damage to transmission gears, shafts

Correct torque application is extremely important to or bearings. Use of a thread sealer/locking compound
assure long transmission life and dependable is recommended for all capscrews. Do not torque
performance. Overtightening or under-tightening can capscrews dry.
result in a loose installation and, in many instances,
Description Quantity Torque Value Thread Size Additional Comments

Clutch Housing Screws 10 200 - 240 Nm M18 Verbus ripp flange bolt for alumi-
num cases
Clutch Housing Screws 10 70 - 80 Nm M10 Verbus ripp flange bolt for verti-
cal cases only
Selector Block Tapered Lockscrew 1 35 - 39 Nm M10 Loctite 235 for used screw only
Front Case to Intermediate Case 21 45 - 55 Nm M10
Rear Case to Intermediate Case 22 45 - 55 Nm M10
Mainshaft Rear Bearing Retainer 4 42 - 48 Nm M10
Layshaft Rear Bearing Retainer 4 35 - 39 Nm M8
Rear PTO Cover 4 69 - 78 Nm M12
Overdrive Selector Fork Pivot Pins 2 19 - 24 Nm M8 If fitted
Oil Strainer 1 40 - 47 Nm M40
Specifications
Sun Gear Retaining Capscrew 2 225 - 255 Nm M16 Use thread adhesive
Reaction Plate 3 24 - 30 Nm M8 Use thread adhesive
Planet Gear Spindle Grubscrew 5 4 - 6 Nm M6 Use Loctite 270 for new scews
only
PTO / Reverse Idler Cover 6 35 - 39 Nm M8
Oil Pump 14 35 - 39 Nm M10
Front Bearing Cover 3 35 - 39 Nm M8
Remote Control Hsg. Detent Cover 2 19 - 24 Nm M8
Remote Control Hsg. End Cover 4 19 - 24 Nm M8
Remote Control Housing 4/6 35 - 39 Nm M10 Flange headed screws
Mainshaft Bearing Retaintion Plate 4 42 - 48 Nm M10
Layshaft Bearing Retaintion Plate 4 35 - 39 Nm M8
Front PTO Cover 8 35 - 39 Nm M12
Speedometer Pinion Adaptor 1 24 - 30 Nm M22
Remote Control Shift Lever 1 35 - 39 Nm M10 1 cap screw and nut, If fitted
Clutch Booster 4 20 - 24 Nm M8 If fitted
Clutch Yoke 2 100 - 110 Nm M14 Flange bolt, if fitted
Clutch Yoke 2 250 - 300 Nm M18 Verbus ripp flange bolt, if fitted
Neutral Detent Cover 2 19 - 24 Nm M8 Verbus ripp flange bolt
10
Specifications
Output Drive Flange Retainer 2 100 - 110 Nm M12

Plate
Integrated Air System Unit 3 35 - 39 Nm M10
Range Change Piston Nut 1 95 - 115 Nm M16 With Loctite 243
Rear Cover - Oil Seal 5 35 - 39 Nm M10
Oil Filler Plug 1 32 - 37 Nm M24
Oil Drain Plug 1 32 - 37 Nm M24 In horizontal transmission
Reverse Switch 1 24 - 30 Nm M16
Range Indicator Switch 1 24 - 30 Nm M16
Neutral Switch 1 24 - 30 Nm M16
Air Connectors NA 8 - 14 Nm 1/8” - 28
BSP
Air Supply NA 8 - 14 Nm 3/8” NPTF
Air Supply NA 9 - 10 Nm 3/8” - 19
BSP
11
Specifications
Torque Chart
Specifications
12
Specifications
Gear End Floats

IMPORTANT: All Dimensions are in mm.
Gear Overdrive / 3rd 2nd 1st Low Reverse

Low Limit 0.30 0.35 0.35 0.35 0.35
High Limit 0.40 0.45 0.48 0.48 0.60
Synchroniser Ring to Synchroniser Flange Clearance

Mainshaft Gear
Minimum 0.50
Maximum 2.94
Range Change
Minimum 0.50
Maximum 3.00
Layshaft Taper Bearing Preload

Layshaft Preload
Minimum 0.075
Maximum 0.125
13
Lubrication
Proper Oil Level
Before checking the oil level, lubricant temperature must be between 15.5°C and 48.8°C (60°F and 120°F).
Before working on the vehicle, place vehicle on level ground, put transmission in neutral, set brakes, and block
wheels.
Check lubricant level by using the fill hole usually located on the right side of the transmission.
Lubricant must be level with the bottom of the filler plug hole opening.
Draining Oil
Drain transmission oil while the oil is warm. To drain oil, remove the drain plug from the bottom of the case. Clean
the drain plug before re-installing.
Refilling
Clean area around filler plug. Fill transmission until lubricant is level with the bottom of the filler plug hole. The
exact amount of oil varies with the transmission and the installation angle.
Do not overfill. This causes oil to be forced out of the case through the mainshaft and input shaft seals.
Operating Temperature
It is important that the transmission operating temperature do 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 (20 m.p.h.).
2. High engine RPM
3. High ambient air temperatures
4. Restricted air flow around transmission
5. Exhaust system too close to transmission
6. High horsepower, over-drive gear operation
7. High power PTO operation for extended periods of time while stationary
High operating temperatures may require more frequent oil changes.
14
Recommended Lubricants
Note: Original Equipment manufacturers (OEMs) may ha lubricant requirements. These recommenda-
tions require Eaton approval. Refer to the OEM
• Multi-viscosity engine oils (such as 15W-40) are not recommended.
• Do not mix engine oil and gear oils in the same transmission.
• Do not mix lubricants with di viscosities (SAE Grades).
• Do not introduce additives and/or friction mo s. Additives of any kind added later to the oil can result
unpredictable consequences.
• Use clean containers when transferring the lubricant from bulk storage to transmission.
• Eaton does not approve mineral lubricants by brand name.
• Visit www.Roadranger.com (select Products, Lubricants) for a copy of the latest Lubricant Recommenda-
tions via Manual #TCMT0021.
Mineral Oils
Type Viscosity Grade (SAE) Ambient Temperature
API GL-4 90 Above -12 °C
(as per Eaton requirements) 80W Above -26 °C
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.
15
Semi-Synthetic Oils
Eaton PS-321 50 Above -40°C
75W-80 Above -40°C
ON HIGHWAY USE
Every 300,000 Km or 3 years Change the transmission oil.
OFF HIGHWAY USE
Every 5000 hours or 2 years Change transmission oil.
Synthetic Oils
Eaton PS-321 50 Above -40°C
75W-80, 75W-90 Above -40°C

ON HIGHWAY USE
Every 500,000 Km or 3 years Change the transmission oil.
OFF HIGHWAY USE
Every 5000 hours or 3 years Change transmission oil.
16
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 Tool No. Description Illustration Tool No. Description

E 601 Oil pump seal E 611 Driver (option for E
installer 109)
E 602 Layshaft front bear- E 612 Bearing remover

ing installer. Use
with E 605.
E 603 Input shaft main

bearing installer.
Use with E 109.
E 604 Mainshaft rear E 109-2 Driver

bearing installer.
Use with E 109.
E 605 Layshaft rear bear- E 109-5 Range selector shaft

ing installer. Use bush installer. Use
with E 109. with E 109.
E 606 Rear case seal E 109-11 Layshaft bearing

installer. Use with cone installer
E 109.
E 607 Outputshaft bear- E 116A Mainshaft assembly

ing installer. Use lifting fixture
with E 109.
E 608 Main selector shaft E119 Adaptor Reverse

bush installer. Use Idler Shaft. use with
with E 109. MS 284.
E 609 Sun gear retainer MS-284 Slide hammer
E 610 Mainshaft rear MS 284-1 Extractor set - bear-

bearing pilot ing / bush
17
Tools Information
Special Tools Manufacturers

Below are the addresses and phone numbers of the
companies that make tools specifically for Eaton trans-
missions.
SPX
Global Headquarters
3515 Ballantyne Corporate Place
Charlotte, North Carolina 28277
United States
Phone: +1 (704) 752-4400
Web site: http://www.spx.com/en/products-and-ser-
Tool Information
vices/diagnostics.aspx
SPX (UK) Ltd.

Genoa House
Everdon Park
Heartlands Business Park
Daventry
Northamptonshire NN11 8YH
England Phone: + 44 (01327) 303400
Web site:
http://www.spxuk.co.uk/
NMR Engineers
19/1, Vitthalwadi,
Sinhagad Road, Pune - 411 051,
Maharashtra, India.
Phone: +91 020 24345544
E-mail: nmrengg@pn2.vsnl.net.in
The following general purpose puller are available from

Sykes-Pickavant Ltd., or through their Dealers.
Illustration Description
Three Legged Puller -
Series 1500 with
Hydraulic Ram
Puller Kit - Series

1500 with Hydraulic
Ram
18
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.
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 • Remove the remote control assembly from the
maintenance can generally be pointed to when inspect- transmission.
ing a failed transmission. Taking a few minutes every
• Check the range and reverse springs for set
so many hours or miles to do a few simple checks
and wear.
could help avoid eventual breakdown or reduce the
repair cost. If the transmission is not cared for, it will • Check inner striking finger bottom end for wear
breakdown. in the slots.
Note: Transmission appearance may differ, the proce-
dure is the same. Checks with drive line dropped
Clutch Housing Mounting Universal Joint Companion Flange or Yoke Nut
• Check all capscrews of clutch housing flange • Check for tightness. Tighten to recommended
for looseness. torque.
Clutch Release Bearing Output Shaft (Yoke Nut Tightened)
• Remove hand hole cover and check radial and • Pry upward against output shaft to check radial
axial clearance in release bearing. clearance in mainshaft rear bearing.
• Check relative position of thrust surface of
release bearing with thrust sleeve on push-
type clutches.
19
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.
20
Power Flow
Power Flow
Direct Drive Transmission
Reverse Gear Crawler Gear
First Gear Second Gear
Third Gear Forth Gear
Fifth Gear Sixth Gear
Seventh Gear Eighth Gear
21
Power Flow
Overdrive Transmission
Power Flow
Reverse Gear Crawler Gear
First Gear Second Gear
Third Gear Forth Gear
Fifth Gear Sixth Gear
Seventh Gear Eighth Gear
22
General
Features
The Eaton 9-speed transmissions have nine forward speed main section of the transmission and the output
speeds and are part of a medium duty range of flange. With the reduction gear engaged, crawler (low)
synchromesh transmissions. They have a simple shift gear and 1st, 2nd, 3rd and 4th gears can be selected
pattern using a unique single rail selector mechanism. and engaged in the normal way. With the reduction
Direct drive or overdrive top gear versions are gear locked out, 5th, 6th, 7th and 8th gears are
available. An epicyclic reduction gear with air operated similarly available. Single H or double H shift systems
synchromesh engagement is located between the 5- may be fitted.
General
The Epicyclic Reduction Gear transmission output shaft.
The epicyclic reduction gear consists of three main
components:
1. Annulus
2. Sun Gear
3. Planet Gear
The annulus, which is the outer, internally toothed ring

gear, is secured to the sliding sleeve of the range
change synchroniser assembly.
The sun gear, which is splined and bolted to the
transmission mainshaft and runs concentrically with,
but independent of the annulus.
The planet gear, which runs in mesh with both the
annulus and the sun gear. In this application it consists
of a series of five planet gears, running independently
on their axes by which they are attached to the planet
gear carrier. The carrier is an integral part of the
23
General
System Theory With the double H shift system, a spring loaded detent
If the annulus is held stationary and the sun gear is is placed in the neutral gate between the 3/4 and 5/6
rotated, the planet gears are driven round the annulus gear positions. As the gear lever is pushed past this
at a speed governed by the size of the sun gear and detent to the 5th gear position, a slave valve
planet gears relative to the annulus. The planet gears automatically supplies air to shift the range change
turn on their axes and force the carrier to rotate in the from low to high. The unique single rail selector
same direction as, but slower than, the sun gear. The mechanism engages 1st, 2nd, 3rd or 4th gears in the
output shaft, being an integral part of the carrier rotates main section, but now with the range change in 'high'
with it. thus giving 5th, 6th, 7th and 8th gears.
Operation When changing from 5th to 4th, past the detent, the
In the Eaton 9-speed transmissions, the 'LOW RANGE' slave valve operates to change from 'high' to 'low'
or reduction mode ratio is achieved by sliding the range range.
change synchroniser sleeve and the annulus into mesh
Note: Low gear must only be used when transmis-
with a flange which is secured by a reaction plate to the
sion in low range.
transmission rear case.
This locks the annulus, and the output shaft therefore

rotates in the same direction as, but slower than, the
mainshaft.
In the 'HIGH RANGE' or direct drive mode the synchro-

niser sleeve is slid out of mesh with the reaction plate
and into mesh with a flange splined to the planet gear
carrier. As the annulus and the planet carrier are now
locked together, the planet gears are no longer able to
rotate, and the whole epicyclic assembly rotates as a
single unit. The output shaft therefore runs at the same
speed as the mainshaft. Range changes are selected automatically as gear
lever is moved over detent.
With the single H shift system, a manually operated air
switch on the gear lever knob engages 'high' or 'low'
range as required.
An interlock pin between the two selector shafts and an

air control valve, fitted to the LRC, prevent the range
change operating unless the gear change selector
shaft is in the neutral position.
24
General
Transmission Installations
General
The transmission will be installed from factory as verti- The oil is drawn through a strainer in the front side of
cally or horizontally mounted. The gear change remote the transmission by the rotor oil pump which is driven
control will also be installed either right or left sided. directly from the front of the layshaft. The pump takes
These installation orientations can not be changed dur- oil to the input shaft bearing, the mainshaft is drilled
ing service. throughout its entire length and cross drillings take the
oil to all the mainshaft bearings, and the range change
The synchroniser assemblies are of the ring cones epicyclic planet gear bearings. The oil pump also takes
manufactured separately from the gears. This allows oil to the spray-bar mounted in the main section of both
the synchroniser rings and flanges to be renewed with- vertical and horizontal transmissions. The spray-bar is
out the need to renew the gears themselves. Reverse used to spray oil directly to the gears. Their is also an
gear is engaged by sliding the reverse/crawler sliding oil feed pipe in the range change section that is used to
sleeve to engage with the flange on reverse gear but lubricate the output bearing and a rear mounted PTO
without the assistance of a synchroniser cone. (when fitted). Transmissions are available with the oil
pump and front case modified to enable an external oil
The transmission is fitted with a pressure fed lubrica- cooler to be fitted.
tion system.
25
Air System
System Theory
Air System
The Eaton nine-speed synchromesh transmissions An air control valve works in conjunction with the inter-
consist of a four-speed plus crawler (low) gear and lock mechanism to prevent the range change operating
reverse gear main section, and an auxiliary, two speed prematurely after pre- selection.
range change section. This provides either a direct
drive 'high' range or 'low' range output through the With the double H shift system the range change is
medium of an epicyclic reduction gear. activated automatically as the gear lever is moved
across a detent in the neutral gate between the 3/4 and
All the forward gears (except crawler) in the main sec- 5/6 gear lever positions. Additional speed limit protec-
tion have synchromesh engagement and are manually tion should be implemented to the system to protect
selected and engaged. The range change also has change low range at the vehicle high speed (above 35
synchromesh engagement and is air operated. A shift km/h)
cylinder, mounted in the rear transmission case, slides
a synchroniser sleeve, which forms an integral part of Air System Maintenance
the epicyclic annulus gear, into or out of mesh with the In order to ensure that the transmission functions with-
planet gear carrier or a reaction plate in the case giving out problems and has a long life, the compressed air
high or low ratio accordingly. reservoirs on the vehicle must be drained regularly*
Air, to operate range section, is supplied to the and the filter on the transmission cleaned every 80,000
Integrated Air System unit (IAS) mounted on the back km (or 6 months).
of transmission. A main valve, inside IAS, is operated *Please consult the Operating Instructions supplied by
by electric pilot valve which is activated directly by the the vehicle manufacturer.
electric signal. This signal comes from switch on LRC
(HH), vehicle Engine Control Unit (ECU) or range
inhibitor unit (RI). There is not electric signal required
to have high range - default position of IAS unit.
With the single H shift system, 'high' or 'low' range

should be pre-selected before the gear lever is moved,
the actual range change taking place only when the
selector shaft is moved through the neutral position.
26
Air System
Integrated Air System (IAS)

RANGE CHANGE SHIFT CYLINDER - IAS
1. IAS Body 10. O-Ring

2. High Range Air Port 11. O-Ring
3. Low Range Air Port 12. O-Ring
4. Piston and Piston Rod 13. Main Air Supply
5. Low Range 14. Outlet
6. High Range 15. Signal Inlet
7. O-Ring 16. Rear Case
8. O-Ring 17. Piston Rod Bush
9. O-Ring
Operation
By switching the switch on the gear lever on single H,
or by moving the gear lever across the detent between
3/4 and 5/6 gear lever positions air is supplied by the
IAS internal main valve to either the high range or low
range air port.
Air pressure on the other side of the piston is

exhausted to atmosphere through the IAS outlet. There
is a constant air pressure acting against either side of
the piston at all times on double H and single H.
27
Air System
Types of IAS
IAS - Electric Version
Air System
Operation
By switching the electrical switch gear lever for
single H or LRC housing for double H.
Main air supply 6 - 10 (Max. 12 bar)
Power supply 24 V DC
Operation pressure is 5.5 bar +/-0.5 bar
Range can be change in neutral only.
28
Air System
Description of internal channels
29
Air System
Range Change Shift Air Lines

The pneumatics used on the Nine speed synchromesh The following diagrams should be used to determine
transmission can be categorised as either single H or the type and design level of the air system used on the
double H control. transmission being serviced in conjunction with the
shift pattern in the vehicle.
IAS Electric - Double H
Air System
IAS Electric - Single H
30
Air System
Range Change Shift Air Circuit Diagram - Double H
31
Air System
Air Circuit Diagram - Double H Shift - Low Range
Air System
32
Air System
Air Circuit Diagram - Double H Shift - High Range
33
Air System
Range Change Shift Air Circuit Diagram - Single H
Air System
34
Air System
Transmission In Neutral - Low Range Engaged
• Vehicle range inhibitor system is necessary specially for single H option to protect synchronisers and
range section when driver chose pre-selection during range change (change range switch on gear knob
when some gear is engaged).
• Additional range inhibitor protect low range section from vehicle overspeed. It mean that low range
engage is possible when vehicle achieve speed below about 35 km/h.
• Range inhibitor module is responsible for collect following signals:
• - Signal from neutral switch (1)
• - Signal from gear knob (2)
• - Signal from speedo sensor (or vehicle speed system) (3)
• When combination of above signals is according to the implemented logic (neutral switch in neutral posi-
tion, gear knob in low position, speed below 35 km/h), the change to low range is possible - signal is ON
to IAS unit.
35
Air System
Transmission in Neutral - High Range Engaged
Air System
• Range inhibitor module is responsible for collect following signals:
• - Signal from neutral switch (1)
• - Signal from gear knob (2)
• - Signal from speedo sensor (or vehicle speed system) (3)
When combination of above signals is according to the implemented logic (neutral switch in neutral position, gear
knob in high position), the change to high range is possible - signal is OFF to IAS unit (default IAS unit position).
36
Air System
Bi-stable Relay Switch (RL)
Note: Instead of ECU or range Inhibitor, bi-stable relay switch (RL) can be used.
When gearbox is in neutral Neutral Switch (NSW) is closed and ready to transmit signal. Driver change position on
gear knob switch (SW) to LOW. Signal from NSW is passed to Bi-stable Relay Switch (RL) which changes its posi-
tion and activates coil on pilot valve. Air passes through and changes position of piston in valve. IAS is switched to
LOW. RL keeps signal on all the time when transmission is in LOW so there is no false movement of cylinder pis-
ton when gears are changed (when in gear NSW is open and cannot keep electric signal to keep IAS in LOW
range). Driver preselects when transmission is in gear, there is no signal (NSW is opened). Driver changes to neu-
tral, signal from NSW is on opposite contact in RL and causes change of its position and opens electric circuit. Sig-
nal on pilot valve coil is now off and IAS switched to HIGH.
37
Exploded View - Single H

REMOTE CONTROL ASSEMBLY - SINGLE H
Remote Control
Assembly
1. Bolt 16. Snap Ring
2. Nut 17. Booster Spring (if fitted)
3. Outer Lever 18. Bias Spring
4. Rubber Boot 19. Reatiner - Bias Spring
5. Oil Seal 20. ‘O’ Ring
6. Bush 21. End Cover
7. Breather 22. Screw
8. Expansion Plug 23. Seal
9. Detent Punger 24. Housing
10. Spring 25. Actuating Pin
11. Gasket 26. Switch
12. Detent Cover 27. Shift Rod
13. Screw 28. Inner Striking Finger
14. Bush 29. Parallel Grooved Pin
15. Retainer - Booster Spring
38
How to disassemble Remote Control Assembly (Single H)
Special Instructions
WARNING: Wear safety glasses when removing snap rings.
Special Tools
Snap ring plier
Procedure - 2. Remove screws, washers (if fitted) and lifting eye.
1. Disconnect the vehicle linkage. Note the position of IMPORTANT: Ensure the control assembly is in
the drop lever. Disconnect harness from the switch neutral.
on the LRC. Disconnect the air lines from the
across gate interlock adaptor (if fitted) or from PPA
unit. Disconnect hydraulic lines from HGS cylinders
on LRC and PPA unit, if fitted.
3. Remove the control assembly, dowels and seal.
4. Remove breather from the control assembly.
39
5. Remove the switch, adaptor (if fitted) and actuating 8. Remove rubber boot.
pin from LRC.
6. Across Gate Interlock Assembly (if fitted):

9. Remove screws and washers (if fitted). Remove
Remove adaptor, piston sealing, piston with slide
detent cover and gasket. Pull out spring and
rings and spring.
plunger.
10. Remove screws, end cover and ‘O’ ring.
Remote Control
7. Remove bolt, washer (if fitted) and nut. Remove Assembly
the outer lever.
Note: The position of the outer lever is marked on

the shaft. Check before removal.
40
Power Pneumatic Assist (PPA) and 14. Remove the circlip from the shift rod and spring
Hydraulic Gear Shifting (HGS)- if fitted retainer. Remove the booster spring (if fitted) and
bias spring.
11. Ensure transmission is in neutral. Remove the two
screws and remove HGS cylinder from HGS adap-
tor.
15. Remove inner spring retainer and circlip.
12. Remove two screws and remove shift cylinder from

PPA unit, if required. Remove six capscrews.
Remove PPA unit with HGS shift cylinder from
LRC.
16. Invert the housing, slide the shift rod and inner
striking finger toward the left-hand end of the hous-
ing and carefully drift out the expansion plug.
13. Remove the drop lever and needle roller bearings.

Remove oil seal, if required. 17. Invert the housing, align the grooved pin in the
inner striking finger with the expansion plug hole.
Drift out the grooved pin. Remove the shift rod and
inner striking finger.
41
18. Remove the shift rod and inner striking finger.
Remote Control
Assembly
42
How to assemble Remote Control Assembly (Single H)
WARNING: Wear safety glasses when installing snap rings.
Special Tools
Snap ring plier

Extractor set MS 284-1
Oil Seal and bush installer E 109-5
Procedure - 3. Locate the inner striking finger into the housing,

long grooved side and retaining pin hole toward the
1. If necessary renew the bearing bushes in the hous- rear. Install the shift rod through the housing and
ing. Remove the old bushes using special tool MS the lever from the oil seal end of the housing.
284-1. Install the new bushes using special tool E
109-5.
IMPORTANT: Clean the control assembly mating

face properly.
4. Align the inner striking finger on the shaft and

install a new grooved pin, using a suitable brass
drift. Ensuring identification mark is in correct posi-
tion.
2. If necessary renew the oil seal using special tool E Note: Inner striking finger should be supported
109-5. whilst driving grooved pin, to prevent damage
to bushes.
43
5. Fit the inner circlip onto the shift rod. Install the Power Pneumatic Assist (PPA) and
booster spring retainer. Hydraulic Gear Shifting (HGS)- if fitted
9. Install the needle roller bearings and install the oil

seal. Install the drop lever and cup plug.
6. Insert the booster spring (if fitted) and bias spring.

Install outer spring retainer and outer circlip onto
the shift rod.
10. Ensure transmission is in neutral. Install PPA unit

with HGS shift cylinder to LRC. Install six screws.
Install shift cylinder to PPA unit and tighten the two
screws, if removed.
7. Replace ‘O’ ring in end cover if necessary.
Remote Control
Assembly
11. Install HGS adaptor and tighten the two screws.
8. Apply suitable thread lock sealant on screws.

Secure the end cover to the housing by screws.
Tighten the screws to 19 -24 Nm.
44
12. Support the housing assembly in the vice and 15. Apply Loctite 7649 and Loctite 326 on adpator (if
install reverse detent plunger and spring. Install fitted). Install the actuating pin, adaptor and switch.
gasket and detent cover. Install screws and wash- Tighten the switch to 24 -30 Nm.
ers (if fitted). Tighten screws to 19 - 24 Nm.
16. Fit the breather. Apply a light coating of Loctite

grade 5900 to the expansion plug and then install.
13. Fit the rubber boot.
17. Replace seal, if necessary. Install dowels on hous-

ing. Apply Loctite 5900 sealant to mating faces, if
seal is not fitted.
14. Across Gate Interlock Assembly (if fitted):
Install the spring, slide rings, piston, piston sealing
and adaptor. Tighten the adaptor to specification.
45
18. Fit the LRC to the transmission ensuring that the

inner striking finger of the LRC locates the selector
shaft shift block correctly. Connect harness to
switch on LRC. Fit the air pipes to the PPA unit (if
fitted) and across gate interlock adaptor (if fitted).
Connect hydraulic lines to HGS shift cylinders (if fit-
ted). Install screws, washers (if fitted) and lifting
eye. Tighten the screws to 35 - 39 Nm.
IMPORTANT: Fit the air pipes as per marking.
Remote Control
Assembly
19. Install the outer lever with the timing mark on the
shift rod. Tighten the bolt, washer (if fitted) and nut
to 35 -39 Nm. Connect vehicle linkage to the outer
lever.
46
Exploded View - Double H

REMOTE CONTROL ASSEMBLY - DOUBLE H
1. Nut 16. Spring

2. Washer (if fitted) 17. ‘O’ Ring
3. Outer Lever 18. Retainer
4. Bolt 19. Circlip
5. Rubber Boot 20. End Cover
6. Oil Seal 21. Screw
7. Bush 22. Seal
8. Breather 23. Housing
9. Expansion Plug 24. Detent Plunger
10. Switch 25. Detent Spring
11. Adaptor (if fitted) 26. Detent Plug
12. Actuating Pin 27. Shift Rod
13. Bush 28. Inner Striking Finger
14. Retainer 29. Parallel Grooved Pin
15. Circlip
47
How to disassemble Remote Control Assembly (Double H)
WARNING: Wear safety glasses when removing snap rings.
Special Tools
Snap ring pliers
Procedure - 2. Remove screws, washers (if fitted) and lifting eye.
1. Disconnect the vehicle linkage. Note the position of IMPORTANT: Ensure the control assembly is in
the drop lever. Note the position and then discon- neutral.
nect the air lines from the PPA unit (if fitted). Dis-
connect harness from the switch on the LRC or on
the reverse gate switch housing (if fitted).
Remote Control
3. Remove the control assembly, dowels and seal.
Assembly
4. Remove breather from the control assembly.
5. Remove the switch, adaptor (if fitted) and actuating

pin.
48
6. Reverse Gate Switch Housing (if fitted): Power Pneumatic Assist (PPA) - if fitted
Remove the switch from the housing.
9. Remove the PPA unit unscrewing four screws.
Clean the LRC and PPA surface from sealant.
7. Remove bolt, washer (if fitted) and nut. Remove

the outer lever.
10. Remove two screws. Remove cross gate assem-

bly.
Note: The position of the outer lever is marked on

the shaft. Check before removal.
8. Remove rubber boot.

11. Remove two detents.
12. Remove dust cover (if fitted) and oil seal from the
LRC using screw driver.
49
13. Remove the circlip. 17. Remove the screws, end cover and ‘O’ ring.
14. Remove the input shaft.
18. Reverse Gate Switch Housing (if fitted):

Remove the four nuts, studs, reverse gate switch
housing and ‘O’ ring.
15. Remove the levers on the shift rod.
Remote Control
Assembly
16. Remove the detent plugs. Lift out springs and
plungers. 19. Remove the circlip from the end of shift rod.
20. Remove the spring retainer. Remove the booster

spring (if fitted) and bias spring.
50
21. Remove inner spring retainer and circlip.
22. Invert the housing, slide the shift rod and inner fin-
ger toward the left-hand end of the housing and
carefully drift out the expansion plug.
23. Invert the housing, align the grooved pin in the

inner striking finger with the expansion plug hole.
Drift out the grooved pin.
24. Remove the shift rod and inner striking finger.
51
How to assemble Remote Control Assembly (Double H)
WARNING: Wear safety glasses when installing snap rings.
Special Tools
Snap ring pliers

Extractor set MS 284-1
Oil Seal and bush installer E 109-5
Procedure - 3. Fit the breather. Apply a light coating of loctite

grade 5900 to the expansion plug and then install.
1. If necessary renew the bearing bushes in the hous-
ing. Remove the old bushes using special tool MS
284-1. Install the new bushes using special tool E
109-5.
IMPORTANT: Clean the control assembly mating

face properly.
Remote Control
4. Install inner circlip on the shift rod.
Assembly
2. If necessary renew the oil seal using special tool E
109-5.
5. Locate the inner striking finger into the housing,

long grooved side and retaining pin hole toward the
rear. Install the shift rod through the housing and
the finger from the oil seal end of the housing.
52
6. Align the inner striking finger on the shift rod and 10. Insert the booster spring (if fitted) and bias spring.
install a new grooved pin, ensuring identification Install outer spring retainer.
mark is in correct position.
Note: Inner striking finger should be supported

whilst driving grooved pin, to prevent damage
to bushes.
11. Fit outer circlip on the shift rod.
7. Support the housing in the vice. Install the reverse

and range detent plunger.
12. Replace ‘O’ ring in end cover if necessary.
8. Install the springs and detent plugs.
13. Apply suitable thread lock sealant to the screws.

Secure the end cover to the housing by the screws.
Tighten the screws to 19 -24 Nm.
9. Install the inner spring retainer.
53
14. Reverse Gate Switch Housing (if fitted): Install Power Pneumatic Assist (PPA) - if fitted
the ‘O’ ring and reverse gate switch housing. Install
the four studs and nuts. Tighten the nuts to 19 - 24 15. Install the levers on the shift rod.
Nm.
16. Install the input shaft.
17. Install the oil seal and dust cover (if fitted).
Remote Control
Assembly
18. Install the circlip.
19. Apply Loctite 243 on the both detents threads.

Install the two detents.
54
20. Install dowel in PPA unit. Apply Loctite 5900 on the 24. Apply Loctite 7649 and Loctite 326 on adpator (if
PPA unit flange. Install PPA unit to LRC placing fitted). Install the actuating pin, adaptor and switch.
levers on the correct slots. Tighten the switch to 24 -30 Nm.
25. Reverse Gate Switch Housing (if fitted): Install

the switch on the housing. Tighten the switch to 24
21. Apply Loctite 243 on the four screws. Tighten the -30 Nm.
screws to 35 - 39 Nm.
26. Replace seal, if necessary. Install dowels on hous-

ing. Apply Loctite 5900 sealant to mating faces, if
seal is not fitted.
22. Install the cross gate assembly. Install the two
bolts.
23. Fit the rubber boot. Ensure that the hole on the
rubber boot is on the bottom side.
55
27. Fit the LRC to the transmission ensuring that the

inner striking finger of the LRC locates the selector
shaft shift block correctly. Fit the air pipes to the
PPA unit (if fitted). Connect harness to the switch
on LRC or reverse gate switch housing (if fitted).
Install the screws, washers (if fitted) and lifting
eye. Tighten the screws to 35 - 39 Nm.
IMPORTANT: Fit the air pipes as per marking.
Remote Control
Assembly
28. Install the outer lever with the timing mark on the
shift rod. Tighten the bolt, washer (if fitted) and nut
to 35 -39 Nm. Connect vehicle linkage to the outer
lever.
56
How to remove Pneumatic Power Assist (PPA) unit
WARNING: Wear safety glasses and hand gloves.
Procedure -
1. Disconnect air lines from PPA unit. Ensure trans-

mission is in neutral. Remove the four screws.
Remove PPA unit with dowels from LRC.
57
How to install Pneumatic Power Assist (PPA) unit
Procedure -
1. Ensure transmission is in neutral. Install dowel in

PPA unit. Apply Loctite 5900 on the PPA unit
flange. Install PPA unit to LRC placing levers on
the correct slots.
2. Apply Loctite 243 on the four screws. Install the

four screws. Tighten the screws to 35 - 39 Nm.
Remote Control
Connect air lines to PPA unit.
Assembly
58
How to remove Pneumatic Power Assist (PPA) unit with Hydraulic Gear
Shifting (HGS) unit
Procedure -
1. Disconnect air lines from PPA unit. Disconnect

hydraulic lines from HGS cylinders on LRC and
PPA unit.
2. Ensure transmission is in neutral. Remove two

screws and remove shift cylinder from LRC.
Remove two screws and remove shift cylinder from
PPA unit, if required.
3. Remove the six screws. Remove PPA Unit with

HGS shift cylinder from LRC.
59
How to install Pneumatic Power Assist (PPA) unit with Hydraulic Gear Shift-
ing (HGS) unit
Procedure - 3. Install HGS cylinder to PPA unit, if removed. Install

the two screws. Tighten the screws to specified
1. Install the two screws and install shift cylinder from torque.
LRC. Tighten the screws to specified torque.
4. Connect air lines to PPA unit. Connect hydraulic
Remote Control
2. Ensure transmission is in neutral. Install PPA unit lines to HGS cylinders.
Assembly
to the LRC. Install the six capscrews.Tighten the
screws to specified torque.
60
Exploded View
TRANSMISSION CASE
1. Screw 29. Dowel

2. Washer 30. ‘O’ Ring
3. Front Bearing Cover 31. Oil Spray Bar Front
4. Screw 32. Washer
5. Oil Seal 33. Filler Plug
6. Oil Pump 34. Bush
7. Shim 35. Bush
8. Spacer 36. Reverse Switch
9. ‘O’ Ring 37. Neutral Switch
10. Cup Plug 38. Detent Ball
11. Screw 39. Pin Interlock
12. Washer 40. Washer
13. Detent Cover 41. Plug (if Itted)
14. Gasket 42. Range Switch
15. Spring 43. Intermediate Case
16. Plunger 44. ‘O’ Ring
17. Dowel 45. Bearing Retention Plate
18. Screw 46. Screw
19. Front Case 47. Screw
20. Bush 48. Bearing Retention Plate
21. ‘O’ Ring (if fitted) 49. Screw
22. Rotation Pin 50. Washer
23. Washer 51. Reverse Gear Aperture Cover
24. Screw 52. Plug
25. Bolt 53. Washer
26. PTO Cover 54. Oil Strainer
27. Screw 55. Oil Suction Pipe
28. Suction Pipe Assy.
61
How to disassemble Transmission Case
Special Tools
Transmission overhauling stand

Hoist
Lifting sling
Soft faced mallet
Snap ring plier
Sun gear retainer E 609
Slide hammer MS 284
Adaptor reverse idler shaft E 119
Mainshaft lifting fixture E 116A
Extractor set bearing / bush MS 284-1
Refer section ‘Tools Information’
Procedure - 1. Using a hoist, mount the transmission onto the

CAUTION: Drain gear oil from the transmission. Clean stand. Mark the air pipes to ensure reassembly to
and refit the drain and filler plug. the correct ports and disconnect the air pipes from
Transmission Case
the transmission.
Overhauling
Note: The transmission illustrated in this section is a
standard ratio vertically installed unit. The proce-
dure 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. Horizontally installed
units have the remote control on the side of the
transmission and alternative filler and drain plug
positions.
It is recommended that the transmission is overhauled, 2. Ensure neutral is engaged and remove the remote
mounted on the stand illustrated. If a stand is not avail- control housing reatining screws. If necessary,
able place transmission on a bench or wood pallet and using a soft faced mallet, separate the housing
remove clutch housing and range case assembly. from the transmission.
Remove sun gear from end of mainshaft. Invert front/
intermediate case and place on blocks across the inter-
mediate case facing, taking care not to damage the
case flange, with the input shaft uppermost. Remove
front case assembly and input shaft. Remove reverse
idler and then remove mainshaft assembly.
62
3. Rotate the transmission on the stand to the vertical 7. Attach a sling and hoist to the output drive flange
position, rear end uppermost. and remove range section. Place on wooded
blocks across the intermediate case joint face, with
the input shaft uppermost.
4. Unscrew and remove the oil strainer, remove and

discard the washer. 8. Use the two screws M10x1.5 on the special thread
hole in the intermediate case for separation.
Note: Attach the sling so as to lift the rear case as
near vertically as possible. Raise the hoist and
separate the rear case from the intermediate case.
Do not use pry bars or levers or the case
flanges may be damaged.
5. Remove the reverse switch (B). Remove the range

indicator switch (C) (if fitted) and neutral switches
(A), collect the ball from each bore as the switches
are removed. Use a magnet or tap the case gently
to release the balls if necessary.
9. Using the sun gear retaining tool E 609 to lock the
sun gear, unscrew and remove the sun gear retain-
ing bolt and the special washer.
6. Remove the screws securing the rear case to the

intermediate case.
10. Lift off the sun gear.
Note: Transmission main section must be in

neutral to allow range section to be removed.
63
11. Lift out the muff ring. 14. Remove the screws and reverse idle cover.
12. Lift out bearing loose ring.

15. Screw the slide hammer MS284 and adaptor E119
into the rear of the reverse idler gear shaft and
withdraw the shaft from the case.
Reverse Idler Assembly

REVERSE IDLER ASSEMBLY 16. Remove the reverse idler gear, bearings and two
Transmission Case
thrust washers from the case.
Overhauling
1. Shaft
2. Thrust Washer 17. Invert the transmission assembly on the stand,
3. Reverse Idler Gear Collect the range change / selector shaft interlock
4. Needle Roller Bearing pin, located in the bore between the selector rods,
5. Spacer as the transmission is inverted using a magnet if
necessary.
13. Remove the circlip from the maincase.
64
18. Remove the screws and washers (if fitted) from the 22. Using a soft faced mallet to break the compound
neutral detent cover. Remove the neutral detent seal, separate the front half case from the interme-
cover, gasket, spring and plunger from the front diate case.
case.
IMPORTANT: Do not use pry bars or levers or the

case flanges may be damaged.
19. On overdrive models, remove the screws and
washer retaining the two overdrive fork rotation- 23. Remove the input shaft and spigot bearing.
pins. Remove the rotation pins and O rings (if fit-
ted).
24. On the overdrive models, to prevent loss or dam-

age, disengage and remove the overdrive fork
20. Remove the oil pump mounting screws. Remove assembly from the 3rd/4th gear synchroniser
the oil pump. Remove graded spacer and shim sleeve and selector. Take care not to lose the
from layshaft. Collect also two O rings from pump. selector pads.
21. Remove the screws securing the front case to the

intermediate case.
65
25. Assemble the special tool E 116A (not shown in 28. Drift out the layshaft rear bearing track from the
illustration) under the 3rd/4th gear synchroniser case using a suitable tool. Do not allow the bearing
hub assembly and using the hoist raise the main- to fall to the floor.
shaft approximately 10 to 20 mm. This allows the
layshaft to tilt clear of the mainshaft. Lift out lay-
shaft.
29. Drift out the mainshaft rear bearing from the case
using a suitable tool. Do not allow the bearing to
fall to the floor.
26. Raise the hoist and lift out the mainshaft and selec-
tor assembly. Carefully lower onto a clean bench
and remove the special tool E 116A (not shown in
illustration). Separate the selector shaft and forks
from the Mainshaft.
Transmission Case
Overhauling
30. Remove and replace the selector shaft bush if nec-
essary. For removing use the special tool MS 284-
1 with MS 284.
27. Invert the intermediate casing and remove the
retaining plates.
31. Replace the range change shaft bush if necessary.

For removing use the special tool MS 284-1 with
MS 284.
66
32. Place front case on the bench. Remove circlip from

the input shaft bearing.
33. Drift out the input shaft bearing from the front case
using suitable tool.
34. Drift out the layshaft front bearing from the front
case using suitable tools.
35. Remove the selector shaft bush in the front case

using special tool if necessary. For removing use
the special tools MS 284-1 with MS 284.
67
Exploded View
REAR CASE
Transmission Case
Overhauling
1. Oil Spray Bar - Rear 31. Tachograph Rotor
2. Selector Fork - Range 32. Spacer
3. Parallel Grooved Pin 33. Adaptor (if fitted)
4. High/Low Range Shift Rod 34. Washer (if fitted)
5. Reaction Plate 35. Speedo Pinion (if fitted)
6. Socket Head Capscrew 36. Bush (if fitted)
7. Dowel 37. Speedo Housing - Mechanical (if fitted)
8. Rear Case 38. Speedometer Drive Gear (if fitted)
9. Lifting Eyez 39. Spacer (if fitted)
10. ‘O’ Ring - Outer - Bush 40. Screw
11. Bush 41. Layshaft Rear Bearing Cover
12. ‘O’ Ring - Inner - Bush 42. Screw
13. ‘O’ Ring - Inner - Piston 43. Dowel
14. ‘O’ Ring - Outer - Piston 44. Disc Magnet
15. Piston Range Cylinder 45. Planet Gear Assy.
16. Nut 46. Synchro Flange
17. IAS Gasket 47. Circlip - M90
18. IAS Unit 48. Bearing - Synchro Hub
19. Screw 49. Circlip - M115
20. Screw 50. Synchro Ring
21. Retainer Plate 51. Circlip
22. Screw 52. Synchro Hub - Range
23. Output Drive Flange 53. Spring
24. Screw 54. Plunger
25. Rear Cover - Oil Seal 55. Roller
26. Dirt Shield 56. Annulus
27. Speedo Sensor 57. Circlip
28. Oil Seal 58. Sliding Sleeve
29. Ouputshaft Bearing 59. Synchro Flange
30. Speedo Housing - Electronic 60. Roll Pin
68
How to disassemble Rear Case
Special Tools
Wooden Block or Spacer

Soft faced mallet
Snap Ring pliers
Procedure - 4. Remove speedo sensor or speedo pinion and

adaptor (as fitted).
1. Support the rear case assembly on a suitable clean
block or spacer under the range change epicyclic.
Remove the output drive flange retaining bolts.
5. Remove the screws securing the IAS unit to the

rear case. Remove the IAS unit.
2. Remove the screw and output flange.
6. Remove the nut retaining the range change piston

to the shaft. Remove the piston.
3. Remove the screws retaining rear PTO cover.
Remove the rear PTO cover.
69
7. Use the locally made tools or support case on the 11. Remove the rear case.
wooden block, carefully push the output shaft using
soft mallet and lift the case allowing the output
shaft to slide out of the bearing and the range
change selector rod to slide out of the bush.
12. Remove the socket headed countersunk screws

retaining the rear 'low'' synchroniser flange and
reaction plate to the rear case.
8. Remove the six screws retaining the rear cover - oil

seal and the output shaft bearing housing. Remove
the rear cover.
13. Lift out the reaction plate, rear (low) synchroniser
Transmission Case
flange. Remove location pin from rear side of low
Overhauling
synchroniser flange, if fitted.
9. Remove the output shaft bearing housing.
14. Remove the positioning plugs.

10. If necessary drive the bearing out of the housing
using a suitable drift.
70
15. Remove the oil pipe. 19. Lift off the electronic tachograph rotor and spacer
or the speedometer drive gear and spacer (as fit-
ted).
16. Remove the selector fork assembly from the syn-

chroniser sliding sleeve.
20. Collect the plungers and the springs.
17. Lift off the synchroniser ring.
21. Remove the snap ring securing the synchroniser

hub bearing to the output shaft.
18. Remove the sliding sleeve and annulus assembly.

Note the position of the spring, plungers and roll-
ers. If possible remove spring plungers and rollers
from the hub. 22. Invert the assembly and while restraining the hub,
drop the end of the shaft onto a stout wood block to
shock the hub, bearing assembly and synchroniser
ring off the shaft.
71
23. Remove the synchronizer hub and ring. 27. To separate the annulus from the sliding sleeve,
insert a rivet or steel pin, approximately 2-2.3 mm
diameter and 10 mm long, into a holes in the annu-
lus ensuring they are abutting the internal snap
ring.
24. Remove the snap ring securing the synchronizer

flange to the planet carrier.
28. Tighten a large (air cleaner) hose clip around the

rivets or pins to compress the internal snap ring
into the sliding sleeve.
25. Remove the synchroniser flange.
Transmission Case
Overhauling
29. Slide the sliding sleeve from the annulus.
26. If necessary, remove the bearing retaining snap

ring from the range change synchroniser hub and
remove bearing.
30. Use suitable brass drift to remove grooved pin from

range change shaft.
72
Exploded View
PLANET CARRIER ASSEMBLY
1. Outputshaft and Planet Carrier

2. Retainer
3. Grub Screw
4. Thrust Washer
5. Spacer
6. Planet Gear
7. Needle Roller
8. Spindle
73
How to disassemble Planet Carrier Assembly
Special Tools
Soft faced mallet

Drift
Procedure - 3. Slide the gear, bearing rollers, spacers and thrust

washers from the carrier. Repeat these operations
1. Remove the bearing spindle retaining grub screws for the other four gears.
from the planet gear carrier. The screws are
peened so that the area around the screw has to
be drilled out before the screw is removed.
Transmission Case
Overhauling
2. Using a soft faced mallet and suitable drift, drive
the bearing spindle out of the carrier in the direc-
tion illustrated.
IMPORTANT: The spindle is shouldered and

MUST NOT be driven the other way.
74
How to assemble Planet Carrier Assembly
Special Tools
Vice
Soft faced mallet
Procedure - 4. Fit the remaining rollers.
1. Place one thrust washer, grooved face uppermost,

and one spacer on a flat plate. Place the gear onto
the thrust washer. Apply a coating of petroleum
jelly to the bore of the gear. Put through the spin-
dle.
5. Fit the spacer.
2. Place half the total quantity of rollers into position.
6. Fit the thrust washer, grooved side downwards.
3. Place the spacer into position.
75
7. Support the output shaft in a soft jawed vice or in 9. Ensure the locating hole in the spindle aligns with
the hole in the bench, planet carrier uppermost and the hole in the carrier and drive the spindle into the
slide the assembled gear into position in the car- carrier using a soft faced mallet.
rier. Note: There is a lubrication hole directly opposite
the locating hole. Do not align the wrong holes.
8. Slide in the gear assembly until the bore of the

planet carrier and gear assembly align, after then 10. Ensure the threads are clean and dry. Install a new
put the planet gear spindle into the hole. Make sure locating grub screw, using thread locking sealer
that it is fitted on the correct position. Loctite 270. Tighten to 4 - 6 Nm. Repeen with a
suitable drift. Repeat sub-operations 1-10 for the
remaining gears.
Transmission Case
Overhauling
76
How to assemble Rear Case
Special Tools
Soft faced mallet

Drift
Range selector shaft bush installer - E 109-5
Driver - E 109
Outputshaft bearing installer - E 607
Rear cover oil seal installer - E 606
Procedure - 3. Install the bush until the O-ring has just entered the
case. Wipe off any surplus grease and apply sealer
1. Drift out the range change selector rod bush from Loctite 641 around the exposed part of the bush.
the rear case. Drive it into the case using bush installer E 109-5
with diver E 109.
2. Install a new O-ring into the groove on the outer

periphery of the bush. Lubricate sparingly with sili- 4. Install a new O-ring into the range change selector
cone grease. rod bush. Lubricate with silicone grease.
77
5. Support the range change selector fork and install 9. Stand the annulus, plain end down, on a clean
the selector rod, threaded end to the plain side of bench. Locate the snap ring in the synchroniser
the fork. sleeve, place the sleeve in the annulus and align
the snap ring so that the ends are positioned mid-
way between any two holes in the annulus. Com-
press the snap ring and push the sleeve into the
annulus until the snap ring expands into the annu-
lus locking the two parts together.
6. Align the retaining pin holes so that with the

threaded end of the selector shaft to the left, the
interlock detents are facing you. Install a new
grooved pin.
10. Stand the output shaft assembly on a firm support

or block approximately 100 mm thick and place the
synchroniser flange over the locating splines.
Transmission Case
Overhauling
7. Install the snap ring into the range change synchro-
niser hub and place the bearing into the hub
against the snap ring.
11. Install the retaining snap ring.
8. Install the second snap ring to retain the bearing in

the hub.
78
12. Place the synchroniser ring over the synchroniser 16. Use a soft mallet and drift or mandrel to ensure the
flange. Press the cone firmly down and using feeler bearing is fully home against the stop.
gauges, measure the clearance between the ring
and the flange. Renew the flange and ring if the
clearance is not within specification.
17. Install the retaining snap ring.

IMPORTANT: Clearance between the ring and the
flange should be 0.50 mm - 3.00 mm. See section
‘Specification’.
13. Lubricate the synchroniser ring and flange.
18. Install the plungers and springs in the slots. Slide

the annulus and sliding sleeve assembly over the
planet gears. Align the marks on the sleeve and
the middle slot of each group of three in the hub.
14. Install the synchroniser ring.
19. Support the sleeve in the slightly raised position

(approximately 15mm). Install the rollers into the
outer slots of each set of grooves on the synchro-
15. Place the synchroniser hub and bearing assembly niser hub.
onto the shaft aligning the slots in the hub with the
shoulders on the synchroniser ring.
79
20. Place the synchronisers ring. 24. Locate the selector fork and shaft assembly into
the synchroniser sleeve, threaded end of shaft
uppermost.
21. Remove the support lower the sleeve.
25. Install the lubrication pipe.
22. Ensure that the rollers are sitting in the groove of

26. Install location pin (if fitted) into rear face of low
the synchroniser sleeve. Fit the rollers into the cen-
range synchroniser flange.
tral slot of each set of grooves of the synchroniser
hub.
Transmission Case
Overhauling
27. Place the synchroniser flange into rear case lining
up pin (if fitted) in rear face of synchroniser flange
with mating hole in rear case.
23. Place the low synchroniser ring into the synchro-
niser hub ensuring that the bosses on the synchro-
niser ring locate in slots of the synchroniser hub.
Lubricate the synchroniser ring with transmission
oil.
28. Place the reaction plate over the synchroniser

flange.
80
29. Check lubrication holes in the synchroniser flange 32. Invert the partly assembled case, ensure that the
are opposite the magnet and near to the rear PTO selector shaft bore O-ring is in position and lubri-
cover. cated with silicone grease. Locate the case over
the output shaft and selector rod.
30. Apply Loctite 243 on screw and screw the reaction

plate. Tighten the screws to 24 - 30 Nm. 33. Place the spacer and speedometer drive gear or
spacer and tachograph rotor over the output shaft
(as fitted).
31. Place the synchroniser ring over the synchroniser

flange. Press the cone firmly down and, using
feeler gauges, measure the clearance between the
ring and the flange. Renew the flange and ring if
the clearance is not within specification. Lubricate
the synchroniser ring and flange.
34. Change the 'O' rings in the piston if necessary.
IMPORTANT: Clearance between the ring and the Apply silicon lubricant to the 'O' rings and fit the
flange should be 0.5 mm - 3.00 mm. Refer section piston, flat face uppermost.
‘Specification’.
35. Apply Loctite 243 and fit the nut. Tighten the nut to
95 - 115 Nm.
81
36. Install the output shaft bearing in the speedo hous- 40. Apply Loctite 243 to the five screws. Tighten the
ing using special tool E 607 with E 109. screws to 35 - 39 Nm.
37. Install a new oil seal into the rear cover using spe- 41. Change the IAS 'O' ring if necessary. Apply silicone
cial tool E 606. The oil seal and flinger must be lubricant to the 'O' ring and to the bore of the IAS
replaced as a pair. unit, then fit the IAS on to the case.
42. Apply Loctite 243 to the three screws. Tighten the
Transmission Case
38. Apply Loctite 5900 to the face of the case. Place
the bearing and housing assembly over the shaft screws to 35 - 39 Nm.
Overhauling
and against the case.
43. Fit the speedo sensor or speedo pinion and adap-

39. Apply Loctite 5900 to the face of the bearing hous- tor assembly (as fitted).
ing and install the oil seal and rear cover assembly.
82
44. Check the dirt shield for damage. Dirt shield and oil
seal must be replaced as pair.
45. Apply a smear of grease to the inner periphery of

the oil seal and install the output drive flange.
46. Apply Loctite 243 on screws threads. Install

retainer plate and screws. Tighten the screws to
100 - 110 Nm.
83
Mainshaft Assembly
Exploded View
MAINSHAFT ASSEMBLY
1. Mainshaft 23. Synchro Ring

2. Sleeve 24. Synchro Flange
3. Gear Mainshaft 1st 25. Circlip
Mainshaft Assembly
4. Needle Brg. Assy. 26. Needle Brg. Assy.
5. Fixed Hub 1st/2nd 27. Gear Mainshaft Crawler
6. Sliding Sleeve 28. Needle Brg. Assy.
7. Spring 29. Fixed Hub Reverse / Crawler
8. Plunger 30. Sliding Sleeve
9. Roller 31. Spring
10. Synchro Ring 32. Plunger
11. Synchro Flange 33. Roller
12. Gear Mainshaft 2nd 34. Synchro Flange
13. Needle Brg. Assy. 35. Circlip
14. Sleeve 36. Gear Mainshaft Reverse
15. Sleeve 37. Needle Brg. Assy.
16. Gear Mainshaft 3rd 38. Thrust Washer
17. Needle Brg. Assy. 39. Output Bearing
18. Fixed Hub 3rd/4th 40. Gear Sun
19. Sliding Sleeve 41. Sun Gear
20. Spring 42. Retainer
21. Plunger 43. Screw
22. Roller
84
Mainshaft Assembly
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.End float may be checked with the mainshaft
components to fine tolerances. Before disassembly of assembled by using a dial gauge as shown or feeler
gauges.
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-
essary to check the gears, mainshaft, synchroniser
hubs and bearing sleeve for wear.
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 End Floats

Gear Overdrive /3rd 2nd 1st Low Reverse

Low Limit 0.30 0.35 0.35 0.35 0.35
High Limit 0.40 0.45 0.48 0.48 0.60
85
Mainshaft Assembly
How to disassemble Mainshaft Assembly
Note: All snap rings and the circlip on the shaft are graded for selective fit. Take care not to score the bearing sur-
faces of the mainshaft when removing the snap rings.
Special Tools
Vice
Snap ring plier
Press
Protective cover
Puller kit - Series 1500 with hydraulic ram
Procedure - 3. Remove the bearing inner race.
1. Put mainshaft assembly on the table or in the press

and using suitable hydraulic puller or puller plates,
Mainshaft Assembly
under the reverse gear, remove the reverse gear
and integrated bearing/thrust washer. The use of a
protective cover is recommended.
4. Remove the thrust washer.
2. Use suitable ball or plate between puller and Main-

shaft to prevent damage of the sun gear retaining
thread. Fit the puller under the reverse gear as
shown.
5. Remove the reverse gear.
86
Mainshaft Assembly
6. Remove the reverse gear needle roller bearing. 10. Remove synchroniser hub.
7. Remove the synchroniser flange. 11. Remove synchroniser flange.
8. Remove the snap ring. 12. Remove the low gear.
9. Assemble hydraulic puller under the low gear or 13. Remove low gear needle roller bearing.
use hydraulic press and puller and support on the
press. Press the shaft through low gear and the
low/reverse synchroniser. The use of a protective
cover is recommended.
14. Invert the shaft, remove the synchroniser flange

and synchroniser ring.
87
Mainshaft Assembly
15. Remove the synchroniser sleeve, rollers, plungers 17. Remove the synchroniser hub 3th/4th gear.
and springs. Remove the circlip.
16. Support the shaft on the press under 1st gear and
press down the shaft. This removing can be done
using hydraulic puller.
18. Place the overdrive or 3rd gear assembly on a

bench. Remove the bearing sleeve and needle
roller bearing.
Mainshaft Assembly
Note: It is imperative that 1st gear is supported and
that the flange on the shaft does not foul the sup- 19. Remove 2nd speed gear bearing sleeve.
porting blocks or press bed when the shaft is being
pressed through. Do not allow the shaft to drop
through and become damaged or scored.
20. Remove 2nd speed gear needle bearing.
88
Mainshaft Assembly
21. Remove 2nd speed gear. 25. Remove the synchroniser flange and synchroniser
ring from the 1st speed gear.
22. Remove synchroniser flange and synchroniser

ring. 26. Remove the 1st gear needle roller bearings (2
pieces).
23. Remove the synchroniser sleeve, synchroniser

rollers, plungers and springs.
27. Disassemble Mainshaft bearing sleeve.
24. Remove the synchroniser hub. Note: Heat area to approx 85°C and split sleeve
with chisel taking care not to damage mainshaft
diameter. once partially split bearing sleeve should
tap off.
89
Mainshaft Assembly
Check clearance between synchroniser

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 2.94 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.
Mainshaft Assembly
Note: The reverse gear is fitted with a synchroniser
flange which engages with the sliding sleeve and which
is similar in appearance to a synchroniser flange. The
conical face however is not machine finished and no
synchroniser ring is fitted to the assembly for reverse
gear.
90
Mainshaft Assembly
How to assemble Mainshaft Assembly
Special Tools
Vice
Snap ring plier
Press
Bearing heater
Hot plate or Temperature controlled oven
Dial gauge
Feeler gauge
IMPORTANT: The following parts must be heated to

the 85°C prior to assembly using bearing heater. OR
place the parts on a hot plate or in temperature con- 2. Support the mainshaft rear end uppermost. Fit the
trolled oven for not less than 30 minute to make sure crawler gear bearing.
that parts are thoroughly heated placing them in posi-
tion. Once fitted and cooled the parts will shrink to an
interference fit.
• 1st/2nd and 3rd/4th fixed hubs
• Reverse/Crawler fixed hub
• 2nd and 3rd gear bearing sleeve
• Mainshaft rear bearing inner track
Procedure - 3. Lubricate the bearing with clean gear oil and fit the
crawler gear over the bearing.
1. Install mainshaft bearing sleeve using LOCTITE
638.
91
Mainshaft Assembly
4. Fit the low gear synchroniser flange to the gear. 7. Place the synchroniser sleeve over the hub,
pointed teeth downwards, and support it with the
internal annular groove just above the hub.
5. Take the heated reverse/crawler synchroniser hub,

with the internal snap ring groove uppermost, and
place it over the splines of the mainshaft. Ensuring 8. Install the reverse gear flange onto the synchro-
that the shoulders on the synchroniser ring align niser hub.
with the slots on the synchroniser hub press it fully
home.
Mainshaft Assembly
9. Lubricate reverse gear bearing and install the bear-
ing.
6. Check graded circlips is correct size, a range of
grade circlips are available. Install graded circlip.
Install springs and balls into the hub, using grease
to aid fitment.
10. Install reverse gear onto the shaft.
Note: Refer Illustrated Part List for part number

and thickness of circlip.
92
Mainshaft Assembly
11. Install thrust washer. 15. Install the 1st gear synchroniser flange to the gear.
12. Take the heated mainshaft bearing roller race and 16. Lubricate and fit the synchroniser ring.
fit it, flange face downwards, on to the Mainshaft.
17. Support the mainshaft on the press or use suitable

13. Invert the shaft in the vice or other suitable fixtures, tool and hammer. Place the heated 1st/2nd syn-
lubricate and install the 1st gear bearings (2 chroniser hub over the splines on the shaft. Align
pieces). the slots with the shoulders on the synchroniser
ring and press the hub fully home. Check that the
gear end float is within the tolerances. See section
‘Specification’ for gear end float.
14. Install the 1st gear.
18. Assemble the three springs and plungers into the

synchroniser hub. Place the synchroniser sleeve
over the hub, pointed teeth downwards, and sup-
port it with the internal annular groove just above
the hub.
93
Mainshaft Assembly
19. Position the three rollers as shown, resting on the 23. Lubricate the 2nd gear and bearing. Position the
heads of the plungers, and press downward on the gear into the synchroniser ring and the bearing into
sleeve. the gear.
20. Lubricate the synchroniser ring with transmission 24. Take the heated 2nd gear bearing sleeve and
oil. Place the 2nd gear synchroniser ring, ensuring locate it inside the bearing and over the shaft. Use
that the shoulders of the synchroniser ring engage the press to ensure the sleeve is firmly home
the slots of the synchroniser hub, onto the assem- against the synchroniser hub.
bly.
Mainshaft Assembly
25. Install the Overdrive gear or 3rd gear (direct drive)
21. Place the synchroniser flange onto the assembly. onto the shaft.
22. Install the 2nd gear. 26. Lubricate the 3rd gear bearing and install the bear-
ing.
94
Mainshaft Assembly
27. Take the heated 3rd gear bearing sleeve and 31. From the range of graded circlips select the thick-
locate it inside the bearing and over the shaft. Use est one which fits into the groove with the minimum
the press to ensure the sleeve is firmly home free play and fit the circlip into the Mainshaft.
against the synchroniser hub. Check the gear end float using feeler gauges.
32. Assemble the three springs and plungers into the

synchroniser hub. Place the synchroniser sleeve
28. Fit the 4th gear synchroniser flange. over the hub, pointed teeth downwards, and sup-
port it with the internal annular groove just above
the hub.
29. Lubricate the synchroniser ring with transmission

oil. Fit the 4th gear synchroniser flange and syn- 33. Install the synchroniser ring.
chroniser ring.
34. Install the synchroniser flange.
30. Take the heated 3rd/4th synchroniser hub and

place it, boss side downwards on the shaft. Ensure
that the slots in the hub align with the shoulders on
the synchroniser ring. Press the hub fully home
and hold under pressure for 3 to 5 minutes.
35. Install the spigot mainshaft bearing.
95
Layshaft Assembly
Exploded View
LAYSHAFT ASSEMBLY
1. Circlip
2. Bearing
3. Layshaft
4. Bearing
Layshaft Assembly
96
Layshaft Assembly
How to disassemble Layshaft
Special Tools
Snap ring plier

Layshaft bearing remover E 612
Procedure -
1. Support the shaft assembly and remove the
graded circlip retaining the front taper roller bear-
ing.
2. Remove the bearing cone and roller assembly

using the special tool E 612.
3. Support the shaft and remove the rear bearing

cone and taper roller bearing assembly using the
special tool E 612.
97
Layshaft Assembly
How to assemble Layshaft
Special Tools
Bearing heater
Snap ring plier
Layshaft bearing cone installer E 109-11
Procedure - 3. Fit the circlip.
1. Heat the layshaft taper roller bearing inner races to

85° C. Support the shaft assembly forward end
uppermost and place the heated inner cone and
roller assembly onto the shaft. Use the special tool
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 the special tool
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.
Note: Refer Illustrated Part List for circlip part num-

bers and size.
98
Exploded View
INPUT SHAFT ASSEMBLY
1. Circlip
2. Thrust Washer
3. Bearing
4. Inner Track
5. Input Shaft

6. Lubrication Pipe
99
How to disassemble Input Shaft Assembly
Special Tools
Snap ring plier
Puller Kit - Series 1500 with Hydraulic Ram 2. Remove the oil pump from the front case. Collect
also two O rings from pump.
Procedure -
In some cases in service it may be necessary to renew
the input shaft either due to wear on the splines caused
by the clutch or for implementing a change in clutch
type or hub diameter.
The input shaft can be renewed on direct drive

transmissions only without disassembling the
transmission other than the removal of the clutch 3. Support the input shaft and remove the snap ring.
housing by carrying out the following detailed Remove the bearing loose thrust ring.
procedure.
Overdrive transmissions require the remote control

and the front case assembly to be removed for access.
IMPORTANT: It is recommended that the layshaft

taper bearing pre-load setting be rechecked when
changing input shaft. This could help to prevent future
damage to the transmission.
IMPORTANT: Size of input shaft gear for Over-
1. Remove the clutch housing assembly. drive and Direct drive transmissions are different.
4. Support the bearing on a press or using a suitable

puller, press the shaft through the bearing track.
100
How to assemble Input Shaft
Special Tools
Bearing heater
Snap ring plier
Soft mallet
Procedure - 3. Fit the bearing loose thrust ring and place the origi-
nal circlip. Check that circlip fits into its groove
Note: Heat the bearing assembly thoroughly to without free play.
approximately 85°C before assembly. This greatly
eases assembly and in most cases the bearing track
will fit over the shaft without the need to drift it in place.
1. Fit the heated bearing track, use suitable tools to

press down into position.

Check at several places around the diameter of the
shaft. If there is too much free play or the circlip
does not fit into the groove, a new thicker or thinner
circlip respectively is required in place of the ori-
gional.
Note: See Illustrated Parts List for circlip part num-
bers and sizes.
2. Fit the heated outer bearing assembly on the input 4. Install the input shaft using a soft mallet.
shaft.
101
5. Refit the original layshaft spacer and shims. 9. Lubricate the shaft seal surface. Install the oil
pump assembly over input shaft, taking care not to
damage oil seal and place on to front case. Install
screws using Loctite 243 nutlock and tighten to 35 -
39 Nm.
IMPORTANT: Rechecked preload as per proce-

dure.
6. Change the oil pump input oil seal, if neccessary.
10. Install the clutch housing.
7. Install new O ring on the front case, if neccessary.
8. Apply light coating of Loctite grade 5203 sealant to

the pump face.
CAUTION: Do not apply excessive sealant and
ensure oil feeds to case circled in black on above
pictures do not become blocked with sealant.
102
Selector Assembly
Exploded View
SELECTOR ASSEMBLY - DIRECT DRIVE SELECTOR ASSEMBLY - OVERDRIVE
1. Selector Key 1. Selector Key

2. Selector Shaft 2. Selector Shaft
Selector Assembly
3. Interlock Key 3. Interlock Key
4. Fork Reverse / Crawler 4. Fork Reverse / Crawler
5. Fork 1st / 2nd 5. Fork 1st / 2nd
6. Screw 6. Screw
7. Selector Block 7. Dowel
8. Dowel 8. Selector Block
9. Fork 3rd / 4th 9. Fork Overdrive
10. Selector Overdrive
11. Overdrive Shift Pad
103
Selector Assembly
Selector Assembly - Single H
How to disassemble Selector Assembly
Procedure - 4. Remove the screw from the selector block. Slide

the interlock key from the rear the selector block.
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 and the selector key off the selector shaft.
3. Remove the selector forks from the shaft.
104
Selector Assembly
How to assemble Selector Assembly 4. Rotate the forks until the slots line up with the
groove on the selector shaft for the interlock key.
Fit the interlock key from the rear.
Procedure -
1. Place selector key into slot on the selector shaft

with the three small lugs to the front.
5. On overdrive transmissions, the 3rd/4th 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.
IMPORTANT: If reusing the screw, apply Loctite

235 to the threads before fitting.
Selector Assembly
3. Place the forks in their respective positions on the
selector shaft.
105
Selector Assembly
Selector Assembly - Double H
How to disassemble Selector How to assemble Selector Assembly

Assembly
Procedure -
Procedure -
1. Hold the selector key, front end to the left. Place 1st/
2nd selector fork, in the third slot from left.
1. Remove the tapered capscrew from the selector
block.
2. Place the selector block, pin uppermost and threaded

2. Hold the selector block and 1st/2nd fork; withdraw the hole facing (vertically mounted unit), into the second
selector shaft towards the right. slot in the key.
IMPORTANT: In horizontal units, place the selec-

tor block, with the groove uppermost and the
thread hole facing, into the second slot in the key.
3. Place the 3rd/4th selector fork, crank to the left,

into the first slot in the key. On overdrive transmis-
sions, place the overdrive selector, ball pin end to
the left, into the first slot in the selector key.
106
Selector Assembly
4. Place the reverse / crawler selector fork, crank to

the right into the last slot in the key.
5. Support the key and forks and pass the interlock key,
forward end to the left, into position through the forks.
6. Still holding the key and forks insert the shaft,
Selector Assembly
smaller segment between the slots facing you, first
over the interlock key, then under the selector key
and through the forks.
7. Pass the shaft through the forks, and align the hole
in the selector block with the hole in the shaft. Fit a
new tapered cap screw and tighten to 35 -39 Nm.
IMPORTANT: If a new screw is not available apply

Loctite 235 to the screw threads before fitting.
107
Exploded View
TRANSMISSION CASE
1. Screw 29. Dowel

2. Washer 30. ‘O’ Ring
3. Front Bearing Cover 31. Oil Spray Bar Front
4. Screw 32. Washer
5. Oil Seal 33. Filler Plug
6. Oil Pump 34. Bush
7. Shim 35. Bush
8. Spacer 36. Reverse Switch
9. ‘O’ Ring 37. Neutral Switch
10. Cup Plug 38. Detent Ball
11. Screw 39. Pin Interlock
12. Washer 40. Washer
13. Detent Cover 41. Plug (if Itted)
14. Gasket 42. Range Switch
15. Spring 43. Intermediate Case
16. Plunger 44. ‘O’ Ring
17. Dowel 45. Bearing Retention Plate
18. Screw 46. Screw
19. Front Case 47. Screw
20. Bush 48. Bearing Retention Plate
21. ‘O’ Ring (if fitted) 49. Screw
22. Rotation Pin 50. Washer
23. Washer 51. Reverse Gear Aperture Cover
24. Screw 52. Plug
25. Bolt 53. Washer
26. PTO Cover 54. Oil Strainer
27. Screw 55. Oil Suction Pipe
28. Suction Pipe Assy.
108
How to assemble Transmission Case
Special Tools

Hoist
Soft faced mallet
Snap ring plier
Mainshaft rear bearing installer - E 604
Layshaft rear bearing installer - E 605
Mainshaft rear bearing pilot E 610
Mainshaft lifting fixture - E 116A
Layshaft front bearing installer - E 602
Input shaft bearing installer E 603
Oil pump seal installer - E 601
Sun gear retainer E 609
Driver - E 109
Transmission Case
Procedure - 2. Using special tool E 604 install the mainshaft rear
Note: Before reassembling the transmission case bearing outer race assembly into the case. Drive in
Assembly
ensure that each section case and covers are clean until almost flush with the rear face of the bearing
and that all gaskets and jointing/sealing materials are bore.
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.
1. Support the intermediate case on the stand, rear

face uppermost. Check the O ring in the intermedi-
ate case, change it if necessary.
3. Using special tool E 605 install the layshaft rear

bearing cup into the case. Drive in until almost
flush with the rear face of the bearing bore.
109
4. Install the retaining plates using the appropriate 8. Support the mainshaft and selector shaft approxi-
screws. Tighten the mainshaft bearing retention mately 20 mm above the normal installed position.
plate screws to 42 - 48 Nm. Tighten the layshaft On overdrive transmissions locate the selector
bearing retention plate screws to 35 - 39 Nm. shaft assembly to the mainshaft without the 3rd/4th
overdrive selector fork. This can be assembled
later and avoids the risk of the fork pads dropping
into the transmission.
5. Invert the intermediate cases and fit the layshaft.
9. Lower the hoist and allow the mainshaft, layshaft

and selector shaft to rest in their respective bear-
ings and bushes. Ensure the selector block is posi-
tioned so that it will not foul the front case and
remove the lifting tool.
6. Fit E 610 special tool mainshaft bearing pilot over

the rear end of the mainshaft. Retain in place with
a large washer and the sun gear retaining bolt or
suitable equivalent.
10. On overdrive transmissions, install the fork pads

into the 3rd/4th overdrive selector fork. Engage the
fork and pads into the synchroniser sleeve.
7. Locate the selector shaft assembly to the main-

shaft. Using special tool E 116A (not shown in illus-
tration) and a hoist, lower the mainshaft assembly
into the case making sure the selector shaft enters
the rear bush.
110
11. Manoeuvre the 3rd/4th overdrive fork into the 15. Using special tool E 602 install the layshaft front
selector ball end and rotate the selector until the bearing cup into the front case assembly.
centre line of the fork pivot pin holes is at approxi-
mately 90° to the centre line through the overdrive
selector.
16. In the overdrive transmissions install the input shaft

outer race bearing assembly into the front case
using special tool E 603.
12. Install the input shaft overdrive.
Note: In the direct drive transmissions input shaft
Transmission Case
Note: In the direct drive transmissions input shaft can be mounted with bearing after closing cases.
can be mounted with bearing after closing cases.
Assembly
17. Apply sealer to the case mating flange ensuring
13. Install o-ring on the spray-bar and install them into that there is a continuous bead around the flange
intermediate case. and the retaining capscrew holes.
14. Install main feed pipe into the socket near the oil
plug the main feed oil pipe. 18. Locate the front case onto the intermediate case
making sure the selector shaft enters the front
bush and that the locating teeth on the input gear
engage with the teeth on the synchroniser flange.
111
19. Ensure also that the spray bar and oil pipe are in Layshaft Front Bearing Preload Set-
the correct positions. For help to fit the pipes on the
positions use lubrication hole in the front case. ting
Rotate the input shaft slightly to ensure engage-
ment. Preload for bearings ~ 0.075 mm to 0.125 mm
Note: The spacer and shim/s combination must be
stand proud of the front face of the case. Measure
the thickness of the combination.
Selected spacers are available.

Spacer 8878261 6.1 mm
The following shims are available.
20. Install the screws. Tighten the capscrews to 45 - 55

Nm. Part No. Thickness (mm)
F88891 0.051
F88892 0.127
F88893 0.254
F88894 0.508
Measure distance from front housing to bearing outer

race. Next calculate the shim using below example.
21. On overdrive transmissions using a suitable
probe align the overdrive selector fork pivots with
the holes in the case and fit the overdrive pads.
Apply a coating of sealant to the inside face of the
pin flanges and install the rotation pins with O rings
(if fitted). Tighten the screws to 19 - 24 Nm.
Example
Measured distance 6.490 mm
Subtract the measured thickness of 6.100 mm
existing spacer and shim/s combi- = 0.390 mm
nation
22. Ensuring that the layshaft bearing is fully seated Add preload setting 0.125
select a shim(s)/spacer and place them against on = 0.515 mm
the layshaft bearing.
Additional shim size required = 0.515 mm
(Use 0.508
mm)
112
26. Lubricate the input oil seal and fit onto the oil pump
using special tool E 601.
IMPORTANT: Check the spacer thickness with correct

shim pack . 27. Apply light coating of Loctite 5203 sealant to the
pump face.
23. Install spacer onto the input shaft.
Transmission Case
24. From the range of graded circlips select the thick-
est one which fits into the grove with minimum free-
Assembly
play and fit the circlip into the input shaft grove.
CAUTION:– Do not apply excessive sealant and

ensure oil feeds to case circled in black on above
picture do not become blocked with sealant.
28. Lubricate the shaft seal surface. Install the oil

pump assembly over input shaft, taking care not to
Note: See Illustrated Parts List for circlip part num- damage oil seal and place on to front case. Install
bers and sizes. bolts using Loctite 243 nutlock and tighten to 35 -
39 Nm.
25. Install new O rings on the front case.
113
29. Install the front bearing cover and screws. Using 33. Using special tool E 609 to restrain the sun gear.
Loctite 243 nutlock and tighten the screws to 35 - Tighten the retaining capscrew to 225 - 255 Nm.
39 Nm.
34. Apply petroleum jelly to the reverse idler gear

thrust washers and locate them into position in the
30. Invert the case and remove the mainshaft bearing
transmission case.
pilot tool. Install the mainshaft bearing thrust
washer.
35. Install the bearings and bearing spacer into the

reverse idler gear.
31. Install the oil muff.
32. Install the sun gear. 36. Locate the assembled gear between the thrust
washers and into mesh with the layshaft and the
mainshaft reverse gear.
114
37. Ensuring that the thrust washers and reverse idler 41. Support the rear case assembly on a suitable sling
gear are aligned fit the reverse idler shaft. When fit- and hoist as illustrate, ensuring that the shaft is as
ted refit the circlip. near vertical as possible.
42. Lower the rear case over the intermediate case,

38. Install the reverse idler cover plate using Loctite
ensuring that the range change selector rod aligns
5900. Apply Loctite 243 nutlock sealant to screws.
with the bush in the intermediate case. Rotate the
Tighten the screws to 35 - 39 Nm.
output drive flange slightly to aid alignment over
the sun gear if neces-
sary.
Transmission Case
39. Lubricate the selector interlock pin and install it,
Assembly
rounded end first, into the range indicator switch
Important: Ensure transmission is in neutral,
bore hole. Push it right through until it is located in
before installing rear case assembly.
the selector shaft detent groove.
43. Ensure through rear PTO bore that oil pipe is in the
IMPORTANT: The interlock pin must be installed
correct position.
now, before the rear case assembly is fitted.
44. Apply Loctite 243 nutlock sealant to the screws.

40. Apply Loctite 5900 to the intermediate case rear
Tighten the screws to 45 - 55 Nm.
flange ensuring there is a continuous bead around
the flange and the retaining capscrew holes.
115
45. Fit the rear PTO cover using Loctite 5900. Install 49. Apply Loctite 243 nutlock sealant to the screws.
screws and washers. Tighten the screws to 69 - 78 Tighten the screws to 35 - 39 Nm.
Nm.
50. Install the reverse switch black (A), tighten to 24 -

46. Apply Loctite 5900 and fit the PTO cover. Apply 30 Nm. Install the neutral switch ball and neutral
Loctite 243 nutlock sealant to the screws. Tighten switch grey (B), tighten to 24 - 30 Nm. If fitted
the screws to 35 - 39 Nm. install the range switch ball and range switch (C),
tighten to 24 - 30 Nm OR install washer and plug.
51. Refit the clutch housing assembly. Reconnect all

47. Turn the transmission to the horizontal position. the air lines.
Rotate the selector block to the position the pin
uppermost. Install the neutral detent plunger and
spring. Fit the cover with a new gasket. Install the
screws and washers. Tighten the screws to 19 - 24
Nm.
Attach the hoist and remove the transmission. Fit

any remaining screws and fasteners and tighten to
the correct torque. Refit the airline connectors and
PTO’s etc if removed. Check manually that all
48. Replace remote control housing seal if necessary. gears can be engaged using the shift lever noting
Refit the remote control housing ensuring that the that it will be necessary to attach a temporary air
inner striking finger engages in the selector block. supply to check the operation of the range change.
Re install the transmission and gear linkage.
116
Clutch Housing
Exploded View
Clutch Housing
117
Clutch Housing
How to disassemble Clutch assembly
Special Tools

Soft face mallet
Procedure - 3. Remove the screws and washers (if fitted).

Remove the inspection cover.
1. Support the transmission on the stand. Remove
the fork assembly retaining screws. Remove the
fork assembly.
4. Remove the clutch housing retaining screws.

Loosen the clutch housing using a soft faced mal-
let. Lift off the clutch housing.
2. Remove the sealing and yoke shaft from the fork.
Remove the bushing from fork, if required.
118
Clutch Housing
How to assemble Clutch assembly
Special Tools
Procedure - 3. Install the fork assembly into the clutch housing.

Apply Loctite 243 on screws. Install the screws and
1. Install the clutch housing. Install the clutch housing tighten to specified torque.
retaining screws. Tighten the screws to the speci-
fied torque.
Clutch Housing
4. Install the inspection cover. Install the washers (if
fitted) and screws. Tighten the screws to specified
2. Install the bushing into the fork, if removed. Install torque.
the sealing and yoke shaft into the fork. Note: Use
the grease on the yoke shaft.
119
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 modifications. THIS
INFORMATION IS NOT INTENDED FOR
SALE OR RESALE, AND THIS NOTICE
MUST REMAIN ON ALL COPIES.
Eaton Corporation • Truc k Components Operations • P. O. Bo x 4013 • Galesburg, MI 490 53 • U.S.A. • www.eaton.com
©20 09 Eaton Corporation · All rights reserved.

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Service Manual

Remote Control Assembly

Transmission Case Overhauling

Input Shaft Assembly

Transmission Case Assembly

Always use genuine Eaton replacement parts.

Purpose and Scope of Manual Disassembly Precautions

Do not use pry bars or chisels to separate casing Inspection Precautions

The cost of a new part is generally a small fraction of

Bearing Sleeve — Mainshaft Gear Selector Shaft Assembly

Assembly Precautions Synchroniser Hubs & Flanges

During disassembly and again during reassembly prior

Serial Tag Information and Model Nomenclature

1. Transmission serial number

FS(O)-10309 Dual Outlet PTO 2830 Series

(horizontal) - 8 bolts 2831 1 640 1160 1570

Driven from layshaft 2831 2 640 1160 1570

Type Gear- Torque Power Output 2832 2 540 1500 2050

6090 FS 430 33.9 704 2834 1 640 1160 1570

PTO Output speed 1000

Ratios and Steps

Gear FS 10309A FSO 10309A

Torque Rating eventually cause damage to transmission gears, shafts

Description Quantity Torque Value Thread Size Additional Comments

Output Drive Flange Retainer 2 100 - 110 Nm M12

Gear End Floats

Gear Overdrive / 3rd 2nd 1st Low Reverse

Synchroniser Ring to Synchroniser Flange Clearance

Layshaft Taper Bearing Preload

High operating temperatures may require more frequent oil changes.

Lubrication Change and Inspection

OFF HIGHWAY USE

Every 40 hours or 4 months Inspect oil level. Check for leaks.

75W-80 Above -40°C

Lubrication Change and Inspection

75W-80, 75W-90 Above -40°C

Lubrication Change and Inspection

Illustration Tool No. Description Illustration Tool No. Description

E 602 Layshaft front bear- E 612 Bearing remover

E 603 Input shaft main

E 604 Mainshaft rear E 109-2 Driver

E 605 Layshaft rear bear- E 109-5 Range selector shaft

E 606 Rear case seal E 109-11 Layshaft bearing

E 607 Outputshaft bear- E 116A Mainshaft assembly

E 608 Main selector shaft E119 Adaptor Reverse

E 609 Sun gear retainer MS-284 Slide hammer

E 610 Mainshaft rear MS 284-1 Extractor set - bear-

Special Tools Manufacturers

SPX (UK) Ltd.

The following general purpose puller are available from

Puller Kit - Series

Preventive maintenance is a general term which Lubricant

Checks with Universal Joint Companion

Rear Seal Maintenance

It can be very time consuming and expensive to

Before disassembling the rear seal system, clean the

First Gear Second Gear

Third Gear Forth Gear

Fifth Gear Sixth Gear

Seventh Gear Eighth Gear