Eaton FS-4005A User manual

Service Manual
Fuller Mid-Range Transmissions
TRSM0130
October 2007
FS-4005A
FS-4005B
FS-4005C
FS-4205A
FS-4205B
FS-4205C
FS-5005A
FS-5005B
FS-5005C

A WARNING
Before starting a vehicle always be
seated
in the drivers seat, place the
transmission
in neutral, set the park-
ing brakes and disengage the clutch.
Before working on a vehicle place the
transmission
in neutral, set the park-
ing brakes and block the wheels.
Before towing the vehicle place the
transmission
in neutral, and lift the
rear wheels off the ground or discon-
nect the driveline to avoid damage to
the transmission during towing.

TABLE OF CONTENTS
FOREWORD ................................................................ 2
MODEL DESIGNATIONS AND SPECIFICATIONS .................................. 3
LUBRICATION ............................................................... 4
OPERATION ................................................................ 6
POWER FLOW ............................................................... 7
TORQUE RECOMMENDATIONS ................................................ 8
PREVENTIVE MAINTENANCE ................................................. 10
PRECAUTIONS
DISASSEMBLY ............................................................ 12
INSPECTION .............................................................. 12
REASSEMBLY ............................................................. 14
DISASSEMBLY AND REASSEMBLY -SHIFTING CONTROLS
GEARSHIFT LEVER HOUSING ASSEMBLY ....................................... 15
SHIFT BAR HOUSING ASSEMBLY .............................................. 18
REMOVAL -YOKE AND CLUTCH HOUSING ..................................... 27
DISASSEMBLY -TRANSMISSION .............................................. 29
REASSEMBLY -TRANSMISSION .............................................. 43
INSTALLATION- CLUTCH HOUSING ........................................... 57
INSTALLATION -SHIFTING CONTROLS ........................................ 58
OPTIONS .................................................................. 59

FOREWORD
This manual is designed to provide detailed information
necessary to service and repair the Eaton@ Fuller@
Transmission listed on the cover.
As outlined in the Table of Contents, the manual is
divided into 3 main sections:
a. Technical information and reference
b. Removal, disassembly, reassembly, and
installation
c. Options
The format of the manual is designed to be followed in
its entirety if complete disassembly and reassembly of
the transmission is necessary. But if only one compo-
nent of the transmission needs to be repaired, see the
Table of Contents for the page numbers showing that
component. For example, if you need to work
on the
Shifting Controls, you will find instructions for removal,
disassembly, and reassembly on page 15. Instructions
for installation are on page 58. Service Manuals,
Illustrated Parts Lists, Drivers Instructions, and other
forms of product service information for these and other
Eaton Fuller Transmissions are available upon re-
quest. A Product Literature Order Form, Service
Bulletins (detailing information on product improve-
ments), repair procedures, and other service-related
subjects can be obtained by writing to the following
address:
EATON CORPORATION
TRANSMISSION DIVISION
Technical Service Department
P.O. Box 4013
Kalamazoo, Michigan 49003
[phone]
Every effort has been made to ensure the accuracy of all information
in this brochure. However, Eaton Transmis-
sion Division makes no expressed or implied warranty or representation based on the enclosed information.
Any errors or omissions may be reported to Training and Publications, Eaton Transmission Division, P.O. Box 4013,
Kalamazoo, Ml 49003.
2

MODEL DESIGNATIONS
AND SPECIFICATIONS
Nomenclature:
F S-
Fuller"' I
Letter Designations
Synchronized----------""""'
Specifications:
GearRat'os
Ne.
Model
Speecs 1 st 2 nc
3 ·a
4th
FS-5005A 5 7.52 2.54 2.54 1.52
FS-50058
5 6.82 2.15 2.15 1.28
FS-5005C 5 6.82 1.99 1.99 1.17
5005A
I
Number Designations
Ratio Group
5 '.1
1.00
1.00
1.00
Forward Speeds
Design Level
x 100 =Nominal Torque
Capacity
IMPORTANT: All Eaton Fuller Transmissions are
identified by the model and serial number. This
information
is stamped on the transmission identifi-
cation tag and affixed to the case.
DO NOT REMOVE OR DESTROY THE TRANSMIS-
SION IDENTIFICATION TAG.
Reial ve Soeed
No:c · 2
Note S
PTO 3ear:::
_e-g111
l//eo':
Q,I Caoaci:y
lnpc:
ir. Los.
Pi-ts
Rf:'ver:;e
Rig rt Li:/t
'"1:'1)
:Kg)
1Uersi
6.27 .460 .435 21.9 280 10.5
(556.0) (127.0) (5.0}
5.30 .543 .515 21.9 280 10.5
(556.0) (127.0} (5.0)
5.30 .543 .515 21.9 280 10.5
(556.0) (127.0) (5.0}
1. Lengths measured from clutch housing face to speedo gear rear.
2. Weights include shift bar housing, clutch housing, less tower assembly, and clutch release parts. For more
information on available clutch housings, see the transmission's Illustrated Parts List or the Super Parts Book.
All weights are approximate.
3. Oil capacities are approximate, depending on inclination of engine and transmission. Always fill transmission,
with proper grade and type of lubricant, to level of filler opening. See LUBRICATION.
3

LUBRICATION
Proper
Lubrication.
..
the Key to long
transmission life
Proper lubrication procedures are the key to a good all-
around maintenance program. If the oil is not doing its
job, or if the oil level
is ignored, all the maintenance
procedures
in the world are not going to keep the
transmission running or assure long transmission life.
Eaton Fuller Transmissions are designed so that the
internal parts operate in an oil circulating bath by the
motion of the gears and shafts.
Thus, all parts are amply lubricated if these procedures
are closely followed:
1. Maintain oil level. Inspect regularly.
2. Change oil regularly.
3. Use the correct grade and type of oil.
4. Buy from a reputable dealer.
Lubrication Change and Inspection
Eaton® Roadranger® CDSO Transmission Fluid
HIGHWAY USE
Firs' 3,000 tc 5,000 miles
Factory fill
{4827 to 8045 Km! 1rn:ia o·ai:-:.
Every t 0,000 miles
Check flukl level.
(;6090 Ker)
Check ::::r iea;.;s.
Every 250,000 m•les
Craoge t•ans'.'1•sso1
(402336 Krr)
llu·d.
OFF-HIGHWAY USE
30 hour_;
Factory f I
initial d·ain.
Every 40 hours
lnspec: fluic eve!. Creek fa• leaks.
Every 500 hours
Criange tra."sriission 71uic where
severe dirt :::onditions exist.
Every t .:O·J oours
Cra1ge trans11·ss.0° lluid
(Norrra: off-h ahway cse."
Heavy Duty Engine Lubricant or
Mineral Gear Lubricant
HIGHWAY USE
First 3.000 to 5,COO riiles
Fac:oryiill
I 4827 to 8045 Krr I
imtial.
Every 10,000 -;iles
l'isoec: lubrica'lt level.
(t6090 C1eck :or ·eal{s.
Every 50.000 11 les
Cha1ge tra:isr:i1ss1on
(80450) lubr•car:.
OFF-HIGHWAY USE
First 3·J oours
Cnange transrr:issio-;
lubricant en new :.inits.
Every 40 1purs lr.soect lubricaPt Chee!\ br 1eaks.
Every 500 rours
transmissior. lubr:cant where
sevee condit:ons exist.
Every 1,00C hoers
Change 'ransmission lubricant
(Norma: off-h:ghway t.se.]
4
Recommended Lubricants
Grade
Fahrenheit (Celsius)
Type
Ambient
(SAE)
Temperature
Eaton@Roadranger(<,
CDSO Transmission
50
All
Fluid
Heavy Duly E.
0
.gine Oi
MIL-L-21048, C or Dor
50
Above 10' F(-t2'C)
APl-SF 0' AP:-CD
40
Above 10"F (·12"C;
(Pr9ViOJS API
30 Below 10'F :-12''C)
acceotab e1
M neral Gear OI' w '.h rust
90
Abo'e 1 JF i- '.2'·C)
and i'":hibitor
sew
Below 'O'F i-"2'C)
ft.Pl-GL-'.
The use of mild EP gear oil or multi-purpose gear oil
is not recommended, but ifthesegearoilsare used,
be sure to adhere to the following limitations.
Do not use mild EP gear oil or multi-purpose gear oil
when operating temperatures are above 230° F (110"
C). Many of these gear oils, particularly 85W140,
break down above 230° F and coat seals, bearings, and
gears with deposits that can cause premature failures.
If these deposits are observed (especially a coating on
seal areas causing oil leakage), change to Eaton
Roadranger CD50 transmission fluid, heavy duty en-
gine oil, or mineral gear oil to assure maximum compo-
nent life and to maintain your warranty with Eaton.
(Also see "Operating Temperatures".)
Additives and friction modifiers are not recommended
for use
in Eaton Fuller Transmissions.
Proper Oil Level
Proper Oil Level
Make sure oil is level with the filler opening. Because you
can reach oil with your finger does not mean oil is at
proper
level. (One inch of oil level is about one gallon
of oil.)
Draining Oil
Drain transmission while oil is warm. To drain oil remove
the drain plug at case bottom. Clean the drain plug
before re-installing.
Refilling
Clean case around filler plug and remove plug from case
side. Fill the transmission to the level of the filler opening.
If the transmission has two filler openings, fill to the level
of both openings.
The exact amount of oil depends on the transmission
inclination and model. Do not over fill-this causes oil to
be forced out of the case through the front bearing cover.
When adding oil, types and brands of oil should not
be mixed because of possible incompatibility.
-

LUBRICATION
Operating Temperatures
-With Eaton Roadranger
CDSO Transmission Fluid
Heavy Duty Engine Oil
and Mineral Oil
The transmission should not be operated consistently
at temperatures above 250° F (120° C}. However,
intermittent operating temperatures to 300° F (149°
C}
do not harm the transmission. Operating temperatures
above 250° F increase the lubricant's oxidation rate
and shorten its effective life. When the average oper-
ating temperature
is above 250° F, the transmission
can require more frequent oil changes or external
cooling.
The following conditions in any combination can cause
operating temperatures of over 250°
F: (1 )operating
consistently at slow speeds,
(2) high ambient tempera-
tures,
(3) restricted air flow around transmission, (4)
exhaust system too close to transmission, (5) high
horsepower, overdrive operation.
External oil coolers are available to reduce operating
temperatures when the above conditions are encoun-
tered.
Transmission Oil Coolers are:
Recommended
-With engines of 350 H.P. and above with
overdrive transmissions
Required
-With engines 399 H.P. and above with over
drive transmissions and GCW's over
90,000 lbs.
-With engines 399 H.P. and above and 1400
lbs-ft or greater torque
-With engines 450 H.P. and above
With EP or Multipurpose Gear Oil
Mild EP gear oil and multipurpose gear oil are not
recommended when lubricant operating temperatures
are above 230° F (110°
C). In addition, transmission oil
coolers are not recommended with these gear oils
since the oil cooler materials can be attacked by these
gear oils. The
lower temperature limit and oil cooler
restriction with these gear oils generally limit their
success to milder applications.
5
Proper Lubrication Levels
as Related to Transmission
Operating Angles
If the transmission operating angle is more than 12
degrees, improper lubrication can occur. The operat-
ing angle
is the transmission mounting angle in the
chassis plus the percent of upgrade (expressed
in
degrees).
The chart below illustrates the safe percent of upgrade
on which the transmission can be used with various
chassis mounting angles. For example: if you have a
4 degree transmission mounting angle, then 8 degrees
(or 14 percent of grade)
is equal to the limit of 12
degrees. If you have a 0 degree mounting angle, the
transmission can be operated on a 12 degree
(21
percent} grade.
Anytime the transmission operating angle or 12 de-
grees
is exceeded for an extended period of time the
transmission should
be equpped with an oil pump or
cooler kit to insure proper lubrication.
Note
on the chart the effect low oil levels can have on
safe operating angles. Allowing the oil level to fall 1/2"
below the filler plug hole reduces the degree of grade
by approximately 3 degrees (5.5 percent}.
Proper Lubrication Levels are Essential!
2 t---+--l--+--+--l---1---1 1 8'
0 0
0 2 3 4 5 67
Transmission Mounting Angle
Dotted line showing "2 Quarts Low" is for
reference only. Not recommended

OPERATION
Gear Shift Lever Pattern and
Shifting Instructions
Follow the simple 5-speed shift pattern. ..
Simple progressive
shift pattern
-,\
(--
-,
i
R 2 4
"-·-1
\, __ .. __ ) I
I \ j
/ ,
____ _/
I Neutral ]
___ '
-,
I
.,
I ( \
1 3 5
J j \
.. ____ ./
J
··--"
/
Adobe 0001-2/88
General Information
R 2H• 4H
2L i 4L ,
<__; \... I ./ . ,;
- --j
1
1
-1H
.,, 1(- 3H -,i ,-- s -,I
1L , 3L ·
\ __ __ ) "·- : <_ _;
FS-SOOSB with "soft"
fourth and 2-speed axle.
(--\ I .\
R I
2H. I 4H'
I 2L : 4L
\,__) \.._.) ""- _)
Neutral -1
(-- : -..\ (,,.- ·-,,
, 1H , 3H , , SH j
1L 3L SL !
\,_ __/ \ ___ _ .) ,__ -
FS-5005C with "short"
fourth and 2-speed axle.
FS-5005 transmissions have five forward speeds and one reverse, and are shifted as you would shift any synchro-
nized manual transmission, following the simple 5-speed shift pattern.
Driving Tips
• Always use the clutch when making upshifts or downshifts. Premature synchronizer failure can result from not
using the clutch.
• Always select a starting gear that provides sufficient reduction for the load and terrian.
• Never downshift at road speed too high.
• Never slam or jerk the shift lever to complete gear engagement.
• Never coast with the transmission in neutral and the clutch dis-engaged.
6

POWER FLOW
The transmission must efficiently transfer the engine's power, in terms of torque, to the vehicle's rear wheels. Knowl-
edge of whattakes place
in the transmission during torque transfer is essential when troubleshooting and making repairs.
1. Power (torque) from the engine is transferred to the input shaft and drive gear.
2. Torque is transferred to the countershaft drive gear.
3. Torque is delivered along the countershaft to all countershaft gears.
4. Torque is transferred to "engaged" mainshaft gear. The cross section illustrates 1st speed gear position.
5. Engaged mainshaft gear internal clutching teeth transfers torque to mainshaft through synchronizer assembly.
6. Mainshaft transfers torque directly to driveshaft through rear yoke.
1.
5.
3.
4.
7

TORQUE RECOMMENDATIONS
Correct torque application is important to assure long transmission life. Over or under tightening of fasteners can resul1
in a loose installation and, in many instances, can eventually cause damage to the transmission. Use a torque wrench to
obtain recommended torque ratings. Do not torque capscrews dry.
4 FRONT BEARING
COVER CAPSCREWS
15-20 LBS.-FT.
5/16-18 THREAD
2 HAND HOLE
COVER CAPSCREWS
5 LBS.-FT.
1/4-12 THREAD
Adobe 0002-2/88
4 SHIFT LEVER HOUSING
CAPSCREWS
20-25 LBS.-FT.
3/8-16 THREAD
9 SHIFT RAIL RETAINER
CAPSCREWS
20-25 LBS.-FT.
3/8-16 THREAD
17 SHIFT
BAR HOUSING
CAPSCREWS
20-25 LBS.-FT.
3/8-16 THREAD
@
4 CLUTCH HOUSING
CAPSCREWS
145-155 LBS.-FT.
5/8-16 THREAD
8
OUTPUT SHAFT NUT
300-350 LBS.-FT.
11/4-18 THREAD WITH
NYLON LOCKING INSERT
(OILED
AT VEHICLE
INSTALLATION)

-
TORQUE RECOMMENDATIONS
4 MAINSHAFT REAR BEARING
COVER NUTS
60-70 LBS.-FT.
1/2-32 THREAD
USE LOCKWASHERS
14 PTO COVER
CAPSCREWS
10-15 LBS.-FT.
3/8-16 THREADS
Adobe 0003-2/88
4 COUTNERSHAFT REAR BEARING
COVER CAPSCREWS
20-30 LBS.-FT.
3/8-16 THREAD
USE PLAIN FLAT WASHERS
9
OIL FILL PLUG
20-25 LBS.-FT.
3/4 PIPE THREAD
2 COUNTERSHAFT REAR
BEARING CAP SET SCREWS
5-10 LBS.-FT.
1/4 THREAD
OIL DRAIN PLUG
20-25 LBS.-FT.
3/4 PIPE THREAD
NOTE: APPLY LOCTITE #262 TO THREADS OF
ALL CAPSCREWS BEFORE INSTALLING.

PREVENTIVE MAINTENANCE
10

-
PREVENTIVE MAINTENANCE
Preventive Maintenance Check Chart
CHECKS WITHOUT PARTIAL
DISASSEMBLY OF CHASSIS OR CAB
1. Clutch Housing Mounting
a. Check all capscrews of clutch housing flange
for looseness.
2. Clutch Release Bearing (Not Shown)
a. Remove hand hole cover and check radial
and axial clearance in release bearing.
b. Check relative position of thrust surface of
release bearing with thrust sleeve on push-
type clutches.
3. Clutch Pedal Shaft and Bores
a. Pry upward on shafts to check wear.
b. If excessive movement is found, remove
clutch release mechanism and check bush-
ings in bores and wear on shafts.
4. Lubricant
a. Change at specified service intervals.
b. Use only the types and grades as recom-
mended. See LUBRICATION.
5. Filler and Drain Plugs
a. Remove filler plug and check level of lubricant
at specified intervals. Tighten filler and drain
plugs securely.
6. Capscrews and Gaskets
a. Check all capscrews, especially those on
PTO covers, front and rear bearing covers for
looseness which can cause oil leakage.
See TORQUE RECOMMENDATIONS.
b. Check PTO opening and rear bearing covers
for oil leakage.
7. Gear Shift Lever
a. Check for looseness and free play in hous-
ing. If lever is loose in housing, proceed with
Check No. 8.
11
8. Gear Shift Lever Housing Assembly
a. Remove the gear shift lever housing assem-
bly from transmission.
b. Check tension spring and washer for set
and wear.
c. Check gear shift lever bottom end for wear of
slots. Also check finger assembly for wear.
CHECKS WITH DRIVE LINE DROPPED
9. Universal Joint Companion Flange or
Yoke Nut
a. Check for tightness. Tighten to recom-
mended torque rating.
10. Output Shaft (Not Shown)
a. Pry upward against output shaft to check
radial clearance in mainshaft rear bearing.
CHECKS WITH UNIVERSAL JOINT COM-
PANION 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 ABRASIVE
MATERIALS THAT WILL MAR SURFACE
FINISH.
11. Splines on Output Shaft (Not Shown)
a. Check for wear from movement and chucking
action of the universal joint companion flange
or yoke.
12. Mainshaft Rear Bearing Cover
a. Check oil seal for wear.

PRECAUTIONS
Disassembly
It is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission, the
necessary linkage disconnected and the transmission has been removed from vehicle chassis. Removal of the gear shift
lever housing assembly is included in the detailed instructions (Disassembly and Reassembly-Shifting Controls);
however, this assembly must be detached from shift bar housing before transmission can be removed.
FOLLOW CLOSELY EACH PROCEDURE IN THE DETAILED INSTRUCTIONS, MAKING USE OF THE TEXT,
ILLUSTRATIONS, AND PHOTOGRAPHS PROVIDED.
1. BEARINGS-Carefully wash and relubricate all
reuseable bearings as removed and protectively
wrapped until ready for use. Remove bearings
planned to be reused with pullers designed for
this purpose.
2. ASSEMBLIES-When disassembling the various
assemblies, such as the mainshaft, counter-
shafts, and shift bar housing, lay all parts
on a
clean bench in the same order as removed. This
procedure simplifies reassembly and reduces the
possibility of losing parts.
3. SNAP RINGS-Remove snap rings with pliers
designed for this purpose. Snap rings removed
in this manner can be reused, if they are not
sprung or loose.
Inspection
4. CLEANLINESS-Provide a clean place to work.
It is important that no dirt or foreign material
enters the unit during repairs. Dirt
is an abrasive
and can damage bearings. It
is always good
practice to clean the outside of the unit before
starting the planned disassembly.
5. WHEN USING TOOLS TO MOVE PARTS-
Always apply force to shafts, housings, etc, with
restraint. Movement of some parts
is restricted.
Never apply force to the part being driven after it
stops solidly. The use of soft hammers, bar, and
mauls for all disassembly work
is recommended.
Before reassembling the transmission, check each part carefully for abnormal or excessive wear and damage to
determine reuse or replacement. When replacement
is necessary, use only genuine Eaton Fuller Transmission parts
to assure continued performance and extended lite from your unit.
Since the cost of a new part is generally a small fraction of the total cost of downtime and labor, avoid reusing a
questionable part which could lead to additional repairs and expense soon after reassembly. To aid
in determining the
reuse or replacement
of any transmission part, consideration should also be given to the unit's history, mileage,
application, etc.
Recommended inspection procedures are provided
in the following checklist.
A. BEARINGS
1. Wash all bearings in clean solvent. Check balls,
rollers, and raceways for pitting, discoloration,
and spalled areas. Replace bearings that are
pitted, discolored, spalled, or damaged during
disassembly.
2. Lubricate bearings that are not pitted, discol-
ored, or spalled and check for axial and radial
clearances.
Replace bearings with excessive clearances.
3. Check bearing fit. Bearing inner races should
be tight to shaft; outer races slightly tight to
slightly loose in case bore. If bearing spins
freely in bore, case should be replaced.
12
B. GEARS
1. Check gear teeth for frosting and pitting. Frost-
ing of gear teeth faces present no threat of
transmission failure. Often
in continued opera-
tion of the unit, frosted gears "heal" and do not
progress to the pitting stage.
In most cases,
gears with light to moderate pitted teeth have
considerable gear life remaining and can be
reused, but gears with advanced stage pitting
should be replaced.
2. Check for gears with clutching teeth abnormally
worn, tapered, or reduced in length from clash-
ing in shifting. Replace gears found in any of
these conditions.
-

-
PRECAUTIONS
Inspection (cont.)
3. Check axial clearance of gears. Where exces-
sive clearance is found, check gear snap ring,
split washer, clutch hub, and gear hub for ex-
cessive wear.
C. SPLINES
1. Check splines on all shafts for abnormal wear.
If sliding clutch gears, companion flange, or
clutch hub have worn into the sides of the
splines, replace the specific shaft affected.
D. WASHERS
1. Check surfaces of all washers. Washers
scored or reduced in thickness should be
replaced.
E. REVERSE IDLER GEAR ASSEMBLIES
1. Check for excessive wear from action of roller
bearings.
F. GRAY IRON PARTS
1. Check all gray iron parts tor cracks and breaks.
Replace or repair parts found to be damaged.
Heavy castings may be welded or brazed pro-
vided the cracks do not extend into the bearing
bores or bolting surfaces. When welding, never
place the ground so current passes through the
transmission.
G. CLUTCH RELEASE PARTS
1. Check clutch release parts. Replace yokes
worn at cam surfaces and bearing carrier worn
at contact pads.
2. Check pedal shafts. Replace those worn at
bushing surfaces.
H. SHIFT BAR HOUSING ASSEMBLY
1. Check tor wear on shift yokes and finger as
sembly at pads and lever slot. Replace exces-
sively worn parts.
2. Check yokes for correct alignment. Replace
sprung yokes.
3. Check lockscrews in yoke assembly retainer
plates. Tighten those loose.
13
I. GEAR SHIFT LEVER HOUSING ASSEMBLY
1. Check spring tension on shift lever. Replace
tension spring if lever moves too freely.
2. If housing is disassembled, check gear shift
lever bottom end and shift finger assembly for
wear. Replace both gears if excessively worn.
J. BEARING COVERS
1. Check covers for wear from thrust of adjacent
bearing. Replace covers damaged from thrust
of bearing outer race.
2. Check cover bores for wear. Replace those
worn oversized.
K. OIL SEALS
1. Check oil seal in input shaft and rear bearing
cover.
It sealing action of lip has been de-
stroyed, replace seal.
L.
1. Check synchronizer for burrs, uneven and
excessive wear at contact surface, and metal
particles.
2. Check blocker pins for excessive wear or loose-
ness.
3. Check synchronizer contact surfaces on the
synchronizer cups for wear.

PRECAUTIONS
Reassembly
Make sure that case interiors and housings are clean. It is important that dirt and other foreign materials are kept out
of the transmission during reassembly. Dirt is an abrasive and can damage polished surfaces of bearings and washers.
Use certain precautions, as listed below, during reassembly.
1. GASKETS-Use new gaskets throughout the
transmission as it is being rebuilt. Make sure all
gaskets are installed. An omission of any gasket
can result in oil leakage or misalignment of
bearing covers.
2. CAPSCREWS-To prevent oil leakage and
loosening, use Loctite #262 thread sealant on all
capscrews. For recommended torque ratings,
see TORQUE RECOMMENDATIONS.
3. SHIMS-Apply a light coat of Loctite 51 Oto both
sides of shims before final installation to prevent
leakage.
4. ASSEMBLY-See the illustrations provided in the
detailed disassembly instructions as a guide to
reassembly.
5. INITIAL LUBRICATION-Coat all thrust washers,
synchronizers, and bearings with transmission
lubricant during reassembly to prevent damage
during initial start up.
6. AXIAL CLEARANCES-Maintain original axial
clearances for mainshaft gears.
7. BEARINGS-Using a sleeve type driver that
contacts the bearing inner race prevents damage
to the rollers and cage.
8. UNIVERSAL JOINT COMPANION FLANGE OR
YOKE-Pull the companion flange or yoke into
place with the output shaft nut, using 300-350
lbs.-ft. (407-475 Nm) of torque. Make sure the
speed ometer drive gear or a replacement spacer
has been installed. Failure to properly torque the
nut can result in damage to the mainshaft rear
bearing.
IMPORTANT: SEE THE APPROPRIATE ILLUSTRATED PARTS LIST (SPECIFIED BY MODEL SERIES) TO
ENSURE THAT PROPER PARTS ARE USED DURING REASSEMBLY OF THE TRANSMISSION.
14
-

DISASSEMBLY AND REASSEMBLY
SHIFTING CONTROLS
Gearshift Lever Housing Assembly
LCV(RGAl=P,--- ·
9--- ousrcovrR
,,...,,,,
PIN ):t- _PIN
HOUSING
y "SHJFT LEVE.A
A. Removal and Disassembly of Gearshift Lever Housing
1. T wn ou1 tCMJr capsctews arld remove the towe r a5Sem-
bly and gaske t from the shllt bar hous.ing
15
...
2. Remove the shifl levergripand boo1 from the shift lever,
sorure assmbly In avise with the housing bottom up. Use
a large scrc· wdriver to twisi between spnrig and houSJng ,
forongthe Spl'ing
from under tne llovsing lugs- . Dooneooi
a1 a lime .

DISASSEMBLY AND REASSEMBLY
SHIFTING CONTROLS
Gearshift Lever Housing Assembly (cont.)
3. Re m ovo tho ten&1on spring t rom the haua l ng
-
4, Remove tne wasf'le( and gearshtl\ .. ver trom ttle
houM'lg
Remove the boot from die gear 1htflIGVlf
(
5. Remov e the spadO pins lrom ho usi ng bo1e .
16
I a

DISASSEMBLY AND REASSEMBLY
SHIFTING CONTROLS
B. Reassembly of Gearshift Lever Housing Assembly
1. Secure 1he gearshift leverhousing In a vise, Install the
spade pins in housing bore.
-
2. POSihon gearshlh lever In housing with the spade pins
in
1ho levor ball slot and ins1all the lension spnng washer
over tho ball .dlslled side up
17
3. Use a spMg driving tool to Install tho tension sp<ing
under the housing lugs, seating one ooll at a ume
4. Remove ass9'mbty lrom lhe vise and tnstaJI lhe rubbe<
boot ovEK the gearshlJt klver -and against tt1<I housing ,
l nsl.all 1he shrf1 lev9I gn.p .

DISASSEMBLY AND REASSEMBLY
SHIFTING CONTROLS
hift Bar Housing Assembly
..