Eaton UltraShift PLUS User manual

Service Manual
UltraShift PLUS
Automated Transmissions
TRSM0940 EN-US
October 2022
Linehaul Active Shifting (LAS)
Vocational Active Shifting (VAS)
Multipurpose Extreme Performance (MXP)
Multipurpose High Performance (MHP)
Vocational Construction Series (VCS)
Vocational High Performance (VHP)
Vocational Multipurpose Series (VMS)
Vocational Extreme Performance (VXP)

2022.10.7 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2
TRSM0940 General Information |
Model:
FM-14E310B-LAS
FM-15E310B-LAS
FO-10E310C-VAS
FO-12E310C-VAS
FO-14E310C-VAS
FO-16E310C-VAS
FO-14E310C-LAS
FO-16E310C-LAS
FO-18E310C-LAS
FOM-14E310C-LAS
FOM-15E310C-LAS
FOM-16E310C-LAS
FOM-14E310C-VAS
FOM-15E310C-VAS
FOM-16E310C-VAS
FO-10E308LL-VCS
FO-11E308LL-VCS
FO-12E308LL-VCS
FO-14E308LL-VCS
FO-16E308LL-VCS
FO-17E308LL-VCS
FO-16E313A-VHP
FO-18E313A-VHP
FO-20E313A-VHP
FO-10E309ALL-VMS
FO-11E309ALL-VMS
FO-12E309ALL-VMS
FO-14E309ALL-VMS
FO-16E309ALL-VMS
FO-17E309ALL-VMS
FO-14E313B-MHP
FO-16E313B-MHP
FO-18E313B-MHP
FO-20E313B-MHP
FO-14E318B-MXP
FO-16E318B-MXP
FO-18E318B-MXP
FO-20E318B-MXP
FO-22E318B-MXP
FO-18E318A-VXP
FO-20E318A-VXP
FO-22E318A-VXP
FO-14E318B-VXP
FO-16E318B-VXP
FO-18E318B-VXP
FO-20E318B-VXP
FO-22E318B-VXP

2022.10.7 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved. i
TRSM0940 Table of Contents |
Table of Contents
General Information
Warnings & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . .1
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . .2
Transmission Overview . . . . . . . . . . . . . . . . . . . . . . . . .3
Serial Tag Information and Model Nomenclature . . . . .6
Timing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . .10
Assembly and Disassembly Precautions . . . . . . . . . . .11
Auxiliary Section Service Procedures
LAS/VAS Auxiliary Section Removal
and Disassembly – In Chassis . . . . . . . . . . . . . . . . . . .13
LAS/VAS Auxiliary Section Removal
and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
LAS/VAS Auxiliary Section Assembly
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
VCS/VMS Auxiliary Section Removal
and Disassembly – In Chassis . . . . . . . . . . . . . . . . . . .38
VCS/VMS Auxiliary Section Removal
and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
VCS/VMS Auxiliary Section Assembly
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
MHP/MXP/VHP/VXP Auxiliary Section
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . .65
MHP/MXP/VHP/VXP Auxiliary Section
Assembly and Installation . . . . . . . . . . . . . . . . . . . . . .78
MHP/MXP/VHP/VXP Auxiliary Countershaft
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Removal and Installation
VCS/VMS Combination Valve . . . . . . . . . . . . . . . . . . .95
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Shift Bar Housing . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Electronic Clutch Actuator (ECA) . . . . . . . . . . . . . . . .110
Low Capacity Inertia Brake (LCIB) . . . . . . . . . . . . . . .114
Release Yoke and Cross-Shaft(s) . . . . . . . . . . . . . . .116
Cobra Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Eaton Push Button Shift Control Device (PBSC) . . . .123
Transmission Harness . . . . . . . . . . . . . . . . . . . . . . . .125
Transmission Electronic Control Unit (TECU) . . . . . .127
X-Y Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Range Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Output Shaft Speed Sensor . . . . . . . . . . . . . . . . . . . .138
Input Shaft Speed Sensor . . . . . . . . . . . . . . . . . . . . .141
Main Shaft Speed Sensor . . . . . . . . . . . . . . . . . . . . .144
Electronic Clutch Actuator (ECA) Speed Sensor . . . .147
Rail Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . .150
Gear Position Sensor . . . . . . . . . . . . . . . . . . . . . . . .153
Oil Pump and Lube Tube Installation . . . . . . . . . . . . .156
Disassembly and Assembly
VCS/VMS Combination Cylinder . . . . . . . . . . . . . . . .172
Range Cylinder LAS/VAS Model . . . . . . . . . . . . . . . .180
MHP/MXP/VHP/VXP Range Cylinder . . . . . . . . . . . . .186
MHP/MXP/VHP/VXP Splitter Cylinder . . . . . . . . . . . .192
MHP/MXP/VHP/VXP Splitter Gear Bearing . . . . . . . .198
Range Synchronizer . . . . . . . . . . . . . . . . . . . . . . . . .202
Shift Bar Housing . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Main Case Main Shaft without Low Force
Gearing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .213
Main Case Main Shaft without Low Force
Gearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .218
Main Case Main Shaft with Low Force
Gearing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .223
Main Case Main Shaft with Low Force
Gearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .229
Main Case Disassembly and Lubrication
Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235
Appendix
Tool Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .244
Oil Leak Inspection Process . . . . . . . . . . . . . . . . . . .248
Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . .249
Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . .255
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . .259
Clutch Greasing Guidelines . . . . . . . . . . . . . . . . . . . .260
Grade Sensor Calibration . . . . . . . . . . . . . . . . . . . . .261

2022.10.7 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 1
TRSM0940 General Information |Warnings & Cautions
Warnings & Cautions
Warning: Follow specified procedures in indicated order to
avoid personal injury.
Note: Additional relevant information not covered in service
procedure.
Warning: Before starting a vehicle:
• Ensure adequate fuel level.
• Sit in driver’s seat.
•Place shift lever in Neutral.
•Set parking brake.
Warning: Before working on a vehicle or leaving cab with
engine running:
• Ensure ignition is Off while hands are within the
clutch housing area.
•Place shift lever in Neutral.
•Set parking brake.
•Block wheels.
Warning: When parking vehicle or leaving cab:
• Place shift lever in Neutral.
•Set parking brake.
Caution: Follow specified procedures in indicated order to
avoid equipment malfunction or damage.
Caution: Do not release parking brake or attempt to select a
gear until air pressure is at correct level.
Caution: To avoid damaging the transmission during tow-
ing:
• Place shift lever in Neutral.
•Lift drive wheels off of the ground or disconnect
the driveline.
Caution: Do not operate vehicle if alternator light is illumi-
nated or if gauge indicates low voltage.
This symbol is used throughout this manual to call attention
to procedures where carelessness or failure to follow spe-
cific instructions may result in personal injury and/or com-
ponent damage.
Always use genuine Eaton replacement parts.
!
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!
!
!
!
!
!
!

2© 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 2022.10.7
How to Use This Manual |General Information TRSM0940
How to Use This Manual
This publication is divided into three sections: General
Information, Service Repair Procedures and Appendix.
General Information
This section contains basic chapters such as Transmission
Overview, How to Use This Manual and Serial Tag and
Model Nomenclature.
Service Repair Procedures
A Component Identification diagram is included at the
beginning of each procedure for disassembly, assembly,
removal and installation. Below the Component Identifica-
tion diagram is a numerical listing for each part with the
part name.
Appendix
This section contains information such as Operation, Lubri-
cation Specifications, Inspection (in base box manuals),
Power Flow (in base box manuals), Air System Operation
and Troubleshooting (in base box manuals), General Trou-
bleshooting (in base box manuals), Tool Specifications,
Torque Specifications and Torque Overview.
The service procedures in this manual are for transmission
mechanical components only. To find the information you
need, simply locate the procedure in the Table of Contents,
turn to the page specified and follow the procedure. If you
are unsure of the name of a component, reference the
Transmission Overview pages.

2022.10.7 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 3
TRSM0940 General Information |Transmission Overview
Transmission Overview
Transmission - Top View
1. Input Shaft Speed Sensor
2. X-Y Shifter
3. Gear Position Sensor
4. Rail Position Sensor
5. Range Solenoid Valve
6. Air Filter/Regulator
7. Output Shaft Speed Sensor
8. Main Shaft Speed Sensor
1
2
3
4
5
6
7
8

4© 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 2022.10.7
Transmission Overview |General Information TRSM0940
Transmission - Side View
1. Electronic Clutch Actuator (ECA) Speed Sensor
2. Transmission Electronic Control Unit (TECU)
3. Transmission Harness
1 2 3

2022.10.7 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 5
TRSM0940 General Information | Transmission Overview
Driver Instruction Manual
Complete operation instructions can be found in the Driver
Instruction Manual TRDR1110.
Transmission - Front View
1. Release Yoke and Cross Shaft Assembly
2. Electronic Clutch Actuator (ECA)
3. Low Capacity Inertia Brake (LCIB)
1
2
3

6© 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 2022.10.7
Serial Tag Information and Model Nomenclature |General Information TRSM0940
Serial Tag Information and Model Nomenclature
Transmission model designation and other transmission
identification information are stamped on the serial tag. To
identify the transmission model and serial number, locate
the tag on the transmission and then locate the numbers as
shown. The figure below shows the tag location for these
transmissions.
When calling for service assistance or parts, have the
model and serial numbers handy.
Important: Do not remove or destroy the transmission
identification tag.
Model Number
The model number gives basic information about the trans-
mission and is explained below. Use this number when call-
ing 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 the number down as it may be needed.
Bill of Material or Customer Number
This number may be located below the model and serial
numbers. It is a reference number used by Eaton.
!
Eaton
®
Transmissions
Fuller
®
Transmissions
Model
Serial Assembled In
Eaton Corporation
Kalamazoo, MI USA
F A O 11 8 1O B
Ratio SetFuller
Advantage
O = Overdrive
X = Direct
Multi torque
Forward Speeds
DesignLevel
Torque x 100
M
Prefix Definition
FM Fuller Multi-Torque
FO Fuller Overdrive
FOM Fuller Overdrive Multi-Torque
F Fuller

2022.10.7 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 7
TRSM0940 General Information | Serial Tag Information and Model Nomenclature
Model Options
Torque Rating
The torque rating of the transmission specified in the model
number is the input torque capacity in lb-ft. Various torque
ratings are available. For more information, call
1-800-826-HELP (4357).
Shift Bar Housing
The Shift Bar Housing has a gear shifter opening located
toward the rear of the transmission.
Upper Countershaft
Internal lubrication pump driven off the PTO gear, and can
be plumbed to an external oil cooler.
Power Take-Off (PTO) Usage
PTOs can be mounted in two ways.
6- or 8-Bolt
The 6- or 8-bolt openings are standard with the transmis-
sion. The PTO is mounted to the opening and driven from
the PTO gear on the front Counter Shaft.
Thru-Shaft
The Thru-Shaft PTO mounts on the rear of the transmis-
sion. It requires a special auxiliary housing and main case
Counter Shaft with internal splines.
Split-Shaft
The split-shaft PTO mounts between the transmission and
the drive axle.
Standard Shift Bar Housing

8© 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 2022.10.7
Timing Procedures |General Information TRSM0940
Timing Procedures
It is essential that both Counter Shaft assemblies of the
front and auxiliary sections are timed. This ensures proper
tooth contact is made between Main Shaft gears seeking to
center on the Main Shaft during torque transfer and mating
Counter Shaft gears that distribute the load evenly. If not
properly timed, serious damage to the transmission is likely
to result from unequal tooth contact, causing the Main
Shaft gears to climb out of equilibrium.
Timing is a simple procedure of marking the appropriate
teeth of a gear set prior to installation and placing them in
proper mesh while in the transmission. In the front section,
it is necessary to time only the drive gear set. Depending on
the model, only the low range, deep reduction or splitter
gear set is timed in the auxiliary section.
Front Section
1. Clearly mark the tooth located directly over the
drive gear keyway as shown prior to placing each
Counter Shaft assembly into the case, This tooth is
stamped with an “O” to aid identification.
2. Mark any two adjacent teeth on the Main Drive
Gear.
3. Mark the two adjacent teeth located directly oppo-
site the first set marked on the Main Drive Gear.
There should be an equal number of unmarked
gear teeth on each side between the marked sets.
4. After placing the Main Shaft assembly into the
case, the Counter Shaft Bearings are installed to
complete installation of the Counter Shaft assem-
blies. This meshes marked Counter Shaft drive gear
teeth with marked Main Drive Gear teeth.
When installing the bearings on the left Counter Shaft,
mesh the Counter Shaft drive gear marked tooth with either
set of Main Drive Gear two marked teeth.
Repeat the procedure when installing the bearings on the
right Counter Shaft; make use of the remaining set of Main
Drive Gear two marked teeth to time the assembly.

2022.10.7 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 9
TRSM0940 General Information | Timing Procedures
Auxiliary Section Timing
1. Mark any tooth on the low-range gear. Then mark
the tooth located 180° from the first marked tooth.
2. Mark the valley between the two gear teeth of each
Auxiliary Counter Shaft assembly low-range gear
stamped with “O” prior to placing each Auxiliary
Counter Shaft assembly into the housing.
3. Repeat the procedure on each Auxiliary Counter
Shaft Reduction Gear.
4. To time the Auxiliary Counter Shafts, find the “O” at
the rear bearing and place a straight edge from the
“O” up to the front and mark the gear tooth. See
Service Bulletin TMIB0150 for further timing
instructions.
Note: Timing mark may be under bearing and washer.
Two Marked Teeth 180 Degrees Apart
Auxiliary Counter Shaft Marked

10 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 2022.10.7
Preventive Maintenance |General Information TRSM0940
Preventive Maintenance
See Drivers Instructions TRDR1110 for daily maintenance
checks.
Inspection Before Transmission Removal
1. Air System and Connections: Check for leaks, worn
air lines, loose connections and cap screws. See
the “Servicing Air System” section.
2. Clutch Housing Mounting: Check all cap screws of
Clutch Housing flange for looseness.
3. Clutch Release Bearing (not shown): Remove hand
hole cover and check radial and axial clearance in
Release Bearing. Check relative position of thrust
surface of Release Bearing with thrust sleeve on
push-type clutches.
4. Lubricant: Change at specified service intervals.Use
only the types and grades as recommended. See
Manual TCMT0021, Roadranger Lubricant Prod-
ucts.
5. Filler and Drain Plugs: Remove filler plugs and
check level of lubricant at specified intervals.
Tighten fill and drain plugs securely.
6. Cap Screws and Gaskets: Check all cap screws,
especially those on PTO covers and Rear Bearing
Covers, for looseness that would cause oil leakage.
Check PTO opening and Rear Bearing Covers for oil
leakage due to faulty gaskets.
1. Oil Fill Plug
47–68 N•m (35–50 lb-ft)
1.0625-12 Straight Thread
2. Oil Drain Plug
47–68 N•m (35–50 lb-ft)
1.0625-12 Straight Thread

2022.10.7 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 11
TRSM0940 General Information |Assembly and Disassembly Precautions
Assembly and Disassembly Precautions
Assembly Precautions
General Information
Ensure that case interiors and housings are clean. It is
important that dirt and other foreign material are kept out of
the transmission during assembly. Dirt is abrasive and can
damage polished surfaces of bearings and washers. Use
certain precautions, as listed below, during assembly.
Bearings
Use a flange-end bearing driver for bearing installation.
These special drivers apply equal force to both bearing
races, preventing damage to balls/rollers and races while
maintaining correct bearing alignment with bore and shaft.
Avoid using a tubular or sleeve-type driver, whenever possi-
ble, as force is applied to only one of the bearing races.
Cap Screws
To prevent oil leakage and loosening, use Eaton Fuller Seal-
ant, Part Number 71205, on all cap screws.
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 bear-
ing covers.
Initial Lubrication
Coat all limit washers and shaft splines with lubricant
during assembly to prevent scoring and galling of such
parts.
O-Rings
Lubricate all O-rings with silicon lubricant.
Universal Joint Companion Flange or Yoke
Pull the companion flange or yoke tightly into place with the
two Output Shaft bolts, using 84–92 lb-ft of torque. Ensure
the speedometer drive gear or a replacement spacer of the
same width has been installed. Failure to pull the compan-
ion flange or yoke tightly into place can result in damage to
the Main Shaft Rear Bearing.
Important: See the appropriate Illustrated Parts List (speci-
fied by model series) to ensure that proper parts are used
during assembly of the transmission.
Disassembly Precautions
General Information
It is assumed in the detailed assembly instructions that the
lubricant has been drained from the transmission, the nec-
essary linkage and vehicle air lines disconnected and the
transmission has been removed from vehicle chassis
Important: Follow each procedure closely in the detailed
instructions. Be sure to make use of the text, illustrations
and photographs provided.
Assemblies
When disassembling the various assemblies, such as the
Main Shaft, Counter Shafts and Shift Bar Housing, lay all
parts on a clean bench in the same sequence as removed.
This procedure will simplify assembly and reduce the possi-
bility of losing parts.
Bearings
Carefully wash and lubricate all usable bearings as removed
and protectively wrap until ready for use. Remove bearings
planned for reuse with pullers designed for this purpose.
Cleanliness
Provide a clean place to work. It is important that no dirt or
foreign material enters the unit during repairs. Dirt is abra-
sive and can damage bearings. It is always good practice to
clean the outside of the unit before starting the planned dis-
assembly.
Input Shaft
The Input Shaft can be removed from the transmission
without removing the Counter Shafts, Main Shaft or Main
Drive Gear. Special procedures are required and provided in
this manual.
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.
When Using Tools to Move Parts
Always use restraint when applying force to shafts, hous-
ings, etc. Movement of some parts is restricted. Never
apply force to driven parts after they stop solidly. The use of
soft hammers, soft bars and mauls for all disassembly work
is recommended.
!
!

12 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved 2022.10.7
Assembly and Disassembly Precautions |General Information TRSM0940

2022.10.7 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved. 13
TRSM0940 Auxiliary Section Service Procedures |LAS/VAS Auxiliary Section Removal and Disassembly – In Chassis
LAS/VAS Auxiliary Section Removal and Disassembly – In Chassis
Special Instructions
The following procedure covers the removal and disassem-
bly of the Auxiliary section with the transmission remaining
in the chassis. If the transmission is removed from the
truck refer to the “LAS/VAS Auxiliary Section Removal and
Disassembly” on page 17.
Special Tools
None

14 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2022.10.7
LAS/VAS Auxiliary Section Removal and Disassembly – In Chassis |Auxiliary Section Service Procedures TRSM0940
Component Identification
1. Wiring Harness
2. Auxiliary Case Bolts (x19)
3. Auxiliary Main Shaft Retaining Flange and Yoke
2
3
1

2022.10.7 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved. 15
TRSM0940 Auxiliary Section Service Procedures | LAS/VAS Auxiliary Section Removal and Disassembly – In Chassis
In Chassis
1. Drain the oil.
2. Disconnect the OEM supplied air line. (Refer to Air Line
disconnection for the procedure.)
3. Disconnect the driveline a move out of the way.
4. Disconnect the Wiring Harness from the Range Sole-
noid Valve and speed sensor.
5. If any OEM equipment needs to be removed refer to the
OEM for guidelines.
6. Remove the 19 bolts securing the Auxiliary Section to
the Transmission.
7. Put the removal jack in place and secure to the Auxil-
iary Section.
8.Slowly remove the Auxiliary Section from the Main
Case and the dowel pins.
9. Once the Auxiliary Section is on the bench, go to
LAS/VAS Auxiliary Section Removal and Disassembly
on page 17.

16 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2022.10.7
LAS/VAS Auxiliary Section Removal and Disassembly – In Chassis |Auxiliary Section Service Procedures TRSM0940

2022.10.7 © 2022 Eaton Cummins Automated Transmission Technologies. All rights reserved. 17
TRSM0940 Auxiliary Section Service Procedures |LAS/VAS Auxiliary Section Removal and Disassembly
LAS/VAS Auxiliary Section Removal and Disassembly
Special Instructions
None
Special Tools
• RR1006TR - Auxiliary Section Hanger
• RR1002TR - Counter Shaft Support Tools
Component Identification
1. Auxiliary Drive Gear
2. Synchronizer Assembly
3. Reduction Gear
4. Washer
5. Spacer
6. Auxiliary Main Shaft
7. Auxiliary Counter Shaft
8. Spacer
9. Bearing
10. Race
11. Auxiliary Case
12. Auxiliary Counter Shaft Cover
13. Auxiliary Main Shaft Bearing Set
14. Gasket
15. Bearing Cover
16. Seal
17. Dust Shield
18. Speed Rotor Assembly
19. Output Yoke Retainer Flange
4
1
2
3
5
6
7
89
10
12
13
14
16
17
18
19
11
15