Eaton Fuller FSO-2405 User manual

Eaton®Fuller®
Light Duty Transmissions
2nd Ed. 02/07
FSO-2405
Service Manual
Transmission

FSO-2405 2nd Ed. 02/07
General Information
3
1
2
3
4
5
Input Shaft Bearing Cover
Rear Section
Front Section
Gear Shift Lever Housing

5
General Table of Contents
FSO-2405 2nd Ed. 02/07
Section 1
General Information................................... 11
Foreword ................................................ 13
How to Use This Manual......................... 14
Identification and Specifications ............. 15
Exploded View ........................................ 18
Lubrication .............................................. 23
Operation................................................ 25
Power Flow ............................................. 26
Sealant Application ................................. 30
Torque Recommendation........................ 31
Precautions............................................. 34
Troubleshooting ...................................... 38
Special Tools........................................... 43
Installation Reference ............................. 60
Section 2
Input Shaft Bearing Cover ........................ 85
Removal ................................................. 87
Installation .............................................. 88

6
General Table of Contents
2nd Ed. 02/07 FSO-2405
Section 3
Rear Section ............................................... 89
Output Sleeve, Yoke and 4x4
Transmission Differences........................ 91
Rear Section Disassembly...................... 92
Oil Seal Replacement ........................... 100
Rear Section Assembly ........................ 101
Section 4
Front Section............................................ 111
Front Section Disassembly ................... 115
Mainshaft
Disassembly .............................. 118
Assembly .................................. 119
Countershaft
Disassembly .............................. 122
Assembly .................................. 122
Input Shaft
Disassembly .............................. 123
Assembly .................................. 123
Shift Yoke Bars
Disassembly .............................. 124
Assembly .................................. 124

7
General Table of Contents
FSO-2405 2nd Ed. 02/07
Reverse Idler Gear Shaft
Removal .................................... 126
Installation ................................. 126
Expansive Plugs
Removal .................................... 127
Installation ................................. 128
Permaglide Bushing
Removal .................................... 129
Installation ................................. 130
Reverse Shifting Interlocking System
Description ................................ 131
Disassembly .............................. 132
Assembly .................................. 133
Double Gear Shifting Interlocking System
Description ................................ 134
Disassembly .............................. 135
Assembly .................................. 136
Input Shaft Bearing Cup
Removal .................................... 137
Installation ................................. 137
Countershaft Front Bearing Cup
Removal .................................... 138
Installation ................................. 138
Mainshaft and Countershaft Rear Bearing
Cups
Removal .................................... 139
Installation ................................. 139

8
General Table of Contents
2nd Ed. 02/07 FSO-2405
Synchronizer Assemblies
Description ................................ 140
Disassembly .............................. 140
Assembly .................................. 141
Installation ................................. 142
Front Section Assembly........................ 145
End Play Adjustment
Mainshaft End Play
Measurement ............................ 148
Countershaft End Play
Measurement ............................ 149
Determination of End Play
Adjusting Shims ........................ 150
Section 5
Gear Shift Lever Housing........................ 157
Disassembly ......................................... 159
Assembly .............................................. 161

9
General Table of Contents
FSO-2405 2nd Ed. 02/07

11
Table of Contents
1
FSO-2405 2nd Ed. 02/07
General Information
Foreword ................................................ 13
How to Use This Manual......................... 14
Identification and Specifications ............. 15
Exploded View ........................................ 18
Lubrication .............................................. 23
Operation................................................ 25
Power Flow ............................................. 26
Sealant Application ................................. 30
Torque Recommendation........................ 31
Precautions............................................. 34
Troubleshooting ...................................... 38
Special Tools........................................... 43
Installation Reference ............................. 60

13
Foreword
1
FSO-2405 2nd Ed. 02/07 General Information
Eaton Ltda. - Transmission Division
Aftermarket and Service
Rua Clark, 2061 - P.O.Box 304
13270 - Valinhos - São Paulo - Brazil
Fone: (19) 3881-9962
Fax: [phone]
This manual is designed to provide detailed information necessary to service and repair the
Eaton transmission FSO-2405.
Disassembly and assembly instructions in this manual make use of a typical FSO-2405
transmission.Provided ilustrations and pictures show parts that may differ from one transmission
model to another, according to its application and serial number.
In addition, it is also assumed that the transmission has been removed from the vehicle and
the lubricant has been drained.
The manual has been divided into two main groups as follows:
1. Information and technical references, placed all together into one section.
2. Disassembly and assembly instructions, by its turn, divided into sections gathering specific
component assemblies.
For more detailed information on product improvement, repair procedures and other subjects
related to service, please contact:
WARNING! Eaton reserves the right to make modifications in its products and to
change specifications included in this manual at any time without previous notice.

14
How to Use This Manual
1
General Information 2nd Ed. 02/07 FSO-2405
To disassemble and reassemble the entire transmission, follow the manual in sequence.
However, if the problem involves only one component, refer to the table of contents of its related
section, for the page number showing that component.
Example
• Component: Double gear shifting interlocking system
• Location: Front Section
• From the table of contents: Disassembly instructions, page 115.
Assembly instructions, page 145.
General page layout description
1. Heading of the topic covered in the
section.
2. Subheading with a more specific
description of the topic covered.
3. Number and description of the procedure
in sequence.
4. Illustration or fotograph illustrating the
procedures.
5. WARNING! Information requiring special
attention to avoid personal injury or
product damage.
6. NOTE: Useful information to perform the
procedure.
7. Manual’s section number.
8. Manual’s section description.
9. Page number.
FSO-2405/40
FSO-2405/38
FSO-2405/39
FSO-2405/41
WARNING! Be careful NOT to use mainshaft
flange as a pressing base when using the 3rd
speed gear.
5. Turn the mainshaft over in the press and use the
3rd speed gear as a base.
118
Front Section Disassembly
4
Front Section
Mainshaft
Disassembly
1. Use the bearing puller and remove the front
bearing cone from mainshaft.
NOTE: See “Special Tools”, Ref. E005003.
2. Remove the 3rd/4th synchronizer hub retaining
snap ring.
3. Place the mainshaft in the press, using the 2nd
speed gear as a base.
4. Press the mainshaft through and remove the set
of components up to the rear bearing cone.
1
2
3
5
1
2
3
4
5
6
7
89

15
Identification and Specifications
1
FSO-2405 2nd Ed. 02/07 General Information
Eaton Fuller
Synchronized
Overdrive
FSO - 2405A
Gear ratio
Forward speeds
Design level
Nominal torque
capacity (x100 Lb.ft)
FSO-2405/86
FSO-2405/85
Identification
Model designation
All Eaton transmissions are identified by the model
designation and serial number. These information
are stamped on the identification tag fixed to the
transmission case.
WARNING! Do not remove or destroy the
transmission identification tag.
NOTE: When ordering parts or consulting
service dept., please inform identification tag
numbers.

16
Identification and Specifications
1
General Information 2nd Ed. 02/07 FSO-2405
Specifications
FSO 2405 E FSO 2405 F FSO 2405 G FSO 2405 J
Torque Lb.ft 280 391 369 369
N.m 380 530 500 500
ND Gear Ratio ND Gear Ratio ND Gear Ratio ND Gear Ratio
Input Shaft 26 28 27 27
Countershaft 37 34 35 35
1st Speed (CE) 14 4.473 15 3.481 12 4.213 15 3.716
(EP) 44 43 39 43
2nd Speed (CE) 22 2.458 22 2.097 22 2.239 22 2.239
(EP) 38 38 38 38
3rd Speed (CE) 29 1.472 29 1.382 29 1.475 29 1.475
(EP) 30 33 33 33
4th Speed (CE) -1.000 -1.000 -1.000 -1.000
(EP) --- -
5th Speed (CE) 53 0.725 44 0.745 45 0.749 45 0.749
(EP) 27 27 26 26
Reverse Speed (CE) 12 3.795 12 3.238 12 3.457 12 3.457
Reverse Idler Gear 29 29 29 29
(EP) 32 32 32 32
FSO 2405 A FSO 2405 B FSO 2405 C FSO 2405 D
Torque Lb.ft 310 310 280 280
N.m 420 420 380 380
ND Gear Ratio ND Gear Ratio ND Gear Ratio ND Gear Ratio
Input Shaft 26 26 26 26
Countershaft 37 37 37 37
1st Speed (CE) 15 4.079 15 4.079 14 4.473 14 4.473
(EP) 43 43 44 44
2nd Speed (CE) 23 2.289 23 2.289 22 2.458 22 2.458
(EP) 37 37 38 38
3rd Speed (CE) 29 1.472 29 1.472 29 1.472 29 1.472
(EP) 30 30 30 30
4th Speed (CE) -1.000 -1.000 -1.000 -1.000
(EP) --- -
5th Speed (CE) 53 0.725 51 0.809 53 0.698 51 0.809
(EP) 27 29 26 29
Reverse Speed (CE) 12 3.795 12 3.795 12 3.795 12 3.795
Reverse Idler Gear 29 29 29 29
(EP) 32 32 32 32
ND =Number of teeth CE = Countershaft EP = Mainshaft
ND =Number of teeth CE = Countershaft EP = Mainshaft

17
Identification and Specifications
1
FSO-2405 2nd Ed. 02/07 General Information
NOTE: The transmission specifications may be modified at any time. The data on table
is provided for reference purpose only.
Weight
Transmission 4x2 = 60 kg
Transmission 4x4 = 57,5 kg
NOTE: Weight does not include the gear shift lever housing assembly.
Lubricant volume
3,0 liters (standard)
NOTE: The supplied oil volume may vary according the vehicle model and depends on
both the engine and transmission inclination. Always refill the transmission with proper
grade and type of lubricant to the level of the filler plug opening (see “Lubrication”).
FSO 2405 K FSO 2405 M FSO 2405 N
Torque Lb.ft 280 369 280
N.m 380 500 380
ND Gear Ratio ND Gear Ratio ND Gear Ratio
Input Shaft 26 25 26
Countershaft 37 38 37
1st Speed (CE) 14 4,473 14 4,994 14 4,473
(EP) 44 46 44
2nd Speed (CE) 23 2,289 22 2,625 23 2,289
(EP) 37 38 37
3rd Speed (CE) 30 1,376 30 1,469 30 1,376
(EP) 29 29 29
4th Speed (CE) -1,000 -1,000 -1,000
(EP) ---
5th Speed (CE) 61 0,653 53 0,774 53 0,698
(EP) 28 27 26
Reverse Speed (CE) 12 3,795 12 4,053 12 3,795
Reverse Idler Gear 29 29 29
(EP) 32 32 32
ND =Number of teeth CE = Countershaft EP = Mainshaft

18
Exploded View
1
General Information 2nd Ed. 02/07 FSO-2405
Housings
FSO-2405/178
1 - Rear housing 4x2
2 - Rear housing 4x4
3 - Capscrew
4 - Rear housing 4x2
5 - Oil baffle
6 - Universal joint yoke
7 - Nut
8 - Oil seal
9 - Speedometer sensor
10 - Capscrew
11 - Input shaft bearing cover
12 - Oil seal
13 - Oil baffle
14 - Front housing
15 - Plug
16 - Plug
17 - Plug
18 - Ball
19 - Ball
20 - Interlock pin
21 - Roll pin
22 - Oil fill plug
23 - Dowel pin
24 - Permaglide bushing
25 - Spring
26 - Reverse shifting interlock
assembly
27 - Oil drain plug
28 - Plug
29 - Expansion plug
30 - Dowel pin
31 - Intermediate housing
32 - Permaglide bushing
33 - Capscrew
34 - Pivot threaded pin
35 - Capscrew
36 - Actuator
37 - Spring
38 - Plug
39 - Dowel pin
40 - Reverse light switch
41 - Capscrew
42 - Reverse idler gear shaft
43 - Ball
44 - Needle bearing
45 - Reverse idler gear
46 - Dowel pin
47 - Pivot threaded pin
48 - Spring
49 - Plug
10 11 12 13
14 15 16
17 18 20 1819
23
25
21 22
28
29
24 26 27
34 35
33
9
30
31
32
46 47 48 49
44 45
43
4140
383736
39
8
7
6
1
2
4
5
3
42

19
Exploded View
1
FSO-2405 2nd Ed. 02/07 General Information
Gearing
Input Shaft and Mainshaft
1 - Input shaft bearing cup
2 - Input shaft bearing cone
3 - Input shaft
4 - Mainshaft front bearing cone
5 - 3rd/4th speed synchronizer
snap ring (2.175)
3rd/4th speed synchronizer
snap ring (2.250)
3rd/4th speed synchronizer
snap ring (2.325)
NOTE: Use one snap ring
thickness according to
selective fit
6 - 4th speed synchronizer ring
7 - Spring
8 - Key
9 - 3rd/4th speed synchronizer
assembly
10 - 3rd speed synchronizer ring
11 - 3rd speed gear - mainshaft
12 - Needle bearing
13 - Mainshaft
14 - Spring
15 - Key
16 - Needle bearing
17 - 2nd speed gear - mainshaft
18 - 2nd speed synchronizer ring
19 - 1st/2nd speed synchronizer
assembly
20 - 1st speed synchronizer ring
21 - Needle bearing
22 - 1st speed gear - mainshaft
23 - 1st speed gear bushing
24 - Mainshaft intermediate bearing
cone
25 - Mainshaft intermediate bearing
cup
26 - Mainshaft bearing shim (0.050)
Mainshaft bearing shim (0.102)
Mainshaft bearing shim (0.178)
Mainshaft bearing shim
(0.254)
Mainshaft bearing shim
(0.508)
Mainshaft bearing shim
(0.762)
Mainshaft bearing shim
(1.016)
NOTE: Use shim thickness
and quantity as required (see
“End Play Adjustment”)
27 - Spacer
28 - 5th speed gear - mainshaft
29 - Bushing
30 - Reverse speed gear -
mainshaft
31 - Ball bearing
32 - Nut
33 - Speedometer rotor
34 - Ball
35 - Snap ring
FSO-2405/179
12
16
11
10
9
8
7
6
5
4
3
2
1
13
17
18
19 20 21 22 23 24 25
26
15
14
27 28 29 30 31 32 33
34 35

20
Exploded View
1
General Information 2nd Ed. 02/07 FSO-2405
Gearing
Countershaft and Reverse Idler Gear
1- Countershaft front bearing cup
2 - Countershaft front bearing
cone
3 - Countershaft
4 - Countershaft intermediate
bearing cone
5 - Countershaft intermediate
bearing cup
6 - Countershaft bearing shim
(0.050)
Countershaft bearing shim
(0.102)
Countershaft bearing shim
(0.178)
Countershaft bearing shim
(0.254)
Countershaft bearing shim
(0.508)
Countershaft bearing shim
(0.762)
Countershaft bearing shim
(1.016)
NOTE: Use shim thickness and
quantity as required (see “End
Play Adjustment”)
7 - Ball
8 - Thrust washer
9 - Needle bearing
10 - Needle bearing
11 - Key
12 - Spring
13 - 5th speed gear - countershaft
14 - 5th speed gear synchronizer
ring
15 - 5th/reverse speed synchronizer
assembly
16 - Reverse speed gear
synchronizer ring
FSO-2405/180
13
10
9
8
7
6
5
4
3
2
1
14 15
16 17 18 21 22 23 24
11
12
19
20
17 - 5th/reverse speed
synchronizer snap ring
(2.215)
5th/reverse speed
synchronizer snap ring
(2.290)
5th/reverse speed
synchronizer snap ring
(2.365)
NOTE: Use one snap ring
thickness according to
selective fit
18 - Spacer
19 - Needle bearing
20 - Needle bearing
21 - Reverse speed gear -
countershaft
22 - Thrust washer
23 - Ball bearing
24 - Nut