Waterous TC10 User manual

All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.
TC10 Power Take
-
of f Overhaul Instructions
TC10 Power Take-of f Overhaul Instructions
Overhaul Instructions
Form No.
T-360
Issue Date Rev. Date
01/19/06 1/9/18
TC10 Power Take-Off
Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
Instructions subject to change without notice.
Table of Contents
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Disconnect and Accessory Removal 1. . . . . . . . . . . . . . . . .
Eclipse ES CAFSystem Removal from PTO 1. . . . . . . . . . . . . . . . . . . . . . . . .
Pump Removal from Transmission 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly of PTO 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal End Yokes 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling Shaft Housing Removal 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Bottom Section 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of the Chain 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of the Drive Shaft and Housing 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Shift Components (Pneumatic, Electric Shift) 6. . . . . . . . . . . . .
Removal of Mid-Section from Cap 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly of Driven Shaft Assembly 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Facing End Yoke 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Facing End Yoke 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Facing Hydraulic Pump Provision 8. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Facing Hydraulic Pump Provision 9. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Facing End Yoke/Rear Facing Hydr. Pump Prov. 9. . . . . . . . . . . .
Rear Facing End Yoke/Front Facing Hydr. Pump Prov. 10. . . . . . . . . . .
Eclipse Mounted CAFS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly of Coupling Shaft Assembly 11. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly of Drive Shaft Assembly 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Bearings, Oil Seals and Gaskets 13. . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly of the Driven Shaft 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Facing End Yoke 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Facing End Yoke 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Facing Hydraulic Pump Provision 15. . . . . . . . . . . . . . . . . . . . . . . .
Rear Facing Hydraulic Pump Provision 16. . . . . . . . . . . . . . . . . . . . . . . . .
Front Facing End Yoke/Rear Facing Hydr. Pump Prov. 17. . . . . . . . . . .
Rear Facing End Yoke/Front Facing Hydr. Pump Prov. 18. . . . . . . . . . .
Eclipse Mounted CAFS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dowel Pins and Spacer Installation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly of the Shift Assembly (Pneumatic or Electric) 21. . . . . . . . . . .
Reassembly of the Cap and Mid-Section 23. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly of the Drive Shaft and Drive Shaft Housing 24. . . . . . . . . . . . .
Installing the Chain 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly of the Bottom Section 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Position Adjustments 29, 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling Shaft and Housing Assembly 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling Shaft Housing to Case Assembly 32. . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly of Miscellaneous Items and Accessories 33. . . . . . . . . . . . . . .
Eclipse ES CAFSystem Installation onto PTO 34. . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Connection and Accessory Installation 35. . . . . . . . . . . . . . .
Lubrication and Final Checks 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Illustrations
1. Eclipse ES CAFSystem Removal 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Eclipse ES CAFSystem Air Clutch Assembly (Side View) 2. . . . . . . . . . . . .
3. PTO Support 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Removal of End Yokes 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Removal of Coupling Shaft Housing 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Removal of the Bottom Section 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Removable Connecting Pin Set 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Chain Removal 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Removal of Drive Shaft and Housing 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. Removal of Shift Components 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11. Removal of Mid-Section from Cap 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12. Disassembly of Driven Shaft Assemblies (Figures 12-18) 7. . . . . . . . . . . .
19. Coupling Shaft Disassembly 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20. Drive Shaft Disassembly -
Shift Collar and Oil Seal Removal 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21. Drive Shaft Disassembly 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22. Needle Bearing Removal from Sprocket 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
23. Reassembly of the Driven Shaft (Figures 23-29) 13. . . . . . . . . . . . . . . . . . .
30. Dowel Pins and Spacer Installation for Extended Drop Cases 20. . . . . . . .
31. Pivot Pin, Shaft Bushing and Sleeve Bearing Installation 21. . . . . . . . . . . .
32. Shift Arm Assembly 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33. Shift Assembly (Pneumatic or Electric) 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
34. Mid-Section Assembly 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35. Cap and Mid-Section Assembly 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36. Needle Bearing Installation into Drive Sprocket 24. . . . . . . . . . . . . . . . . . . .
37. Drive Shaft Installation into Drive Sprocket 24. . . . . . . . . . . . . . . . . . . . . . . .
38. Drive Assembly into Drive Housing 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39. Drive Shaft/Housing Assembly Installation 25. . . . . . . . . . . . . . . . . . . . . . . . .
40. Optional Electronic Tachometer 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41. Installing the Chain 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42. Connecting Pin Set 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43. Connecting Pin Orientation 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44. Assembling Items on the Bottom Section 28. . . . . . . . . . . . . . . . . . . . . . . . . .
45. Assembling Bottom Section to the Cap and Mid-Section 28. . . . . . . . . . . .
46. Retainer Installation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47. Locking Arm Rotation Restrictions 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48. Coupling Shaft Assembly 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49. Coupling Shaft Housing Assembly 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50. Assembling Coupling Shaft Housing to Case 32. . . . . . . . . . . . . . . . . . . . . .
51. End Yoke Assembly 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52. Shift Assembly 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-360 Page 1 of 35
Introduction
This instruction provides the necessary steps required to overhaul the TC10 power take-off. These instructions are divided into Disassembly and
Reassembly sections. Also, refer to the Service Parts List (SPL documents) furnished with your TC10 to aid in further part identification and repair parts
ordering.
General Descri
p
tion
The Waterous TC10 is a chain driven power take-off with a housing
constructed of high-strength aluminum. Drive and driven sprockets are
made of hardened steel and have ground bores. Shafts are made of alloy
steel forgings, hardened and ground to size. A passive lubrication system
eliminates the need for a separate oil pump. The shift mechanism is a
constant-mesh, two-position sliding collar that engages all teeth simulta
neously. Note that the majority of C10 fasteners are metric.
Disassembl
y
Before beginning the disassembly process, drain the fluid from the power take-off by removing the drain plug. Note that these instructions apply for out of
chassis overhaul of the unit.
Propeller Shaft Disconnect and Accessory Removal
Propeller Shaft Disconnect
Disconnect the propeller shafts.
Electrical Connections
Disconnect the tachometer cable, shift wiring and electric shift override
linkage.
Shift Unit
Remove the pneumatic or electric shift unit from the power take-off by
removing the two hex nuts and washers. Note that the adjusting screw
retaining springs are exposed when the shift unit is removed.
Eclipse ES CAFSystemtRemoval from Power Take-Off (See Figure 1)
To remove the Eclipse ES CAFSystem from the PTO, perform the follow
ing steps:
1. Support the Eclipse ES unit with a lifting strap placed under the air
compressor. Two other eyeloops are also provided for lifting (see
Figure 1).
2. Remove all electrical and air connections.
3. Remove the Polychain cover assembly by unscrewing the ten (10) hex
hd screws.
4. Remove the nylon tube from the air clutch assembly.
5. Loosen the 1-29/32" hex screw on the idler sprocket assembly. This
releases the idler sprocket assembly for adjustment.
6. Loosen tension on the Polychain by turning the Polychain tension
screw, counter clockwise.
7. Remove the Polychain from the air clutch assembly, driven sprocket
and idler sprocket.
8. Loosen the set screw that holds the air clutch assembly to the PTO
driven shaft. (See Figure 2).
9. Remove the hex head screw that attaches the air clutch assembly to
the anti-rotation bracket (leave grommet attached to anti-rotation
bracket).
10. Remove the air clutch assembly from the PTO.
11. Remove the five (5) hex hd screws that attach the Eclipse ES unit to
transmission.
12. Remove the compressor bracket that supports the Eclipse ES unit to
the PTO.
13. Lift the unit off the PTO.

T-360 Page 2 of 35
Figure 1. Eclipse ES CAFSystemtRemoval
Figure 2. Eclipse ES - Air Clutch Assembly (Side View)

T-360 Page 3 of 35
Disassembly of the TC10
The TC10 consists of three sections; the cap, the mid-section and the bottom
section. The order of disassembly is bottom section, mid-section and then cap.
NOTE: Out of chassis overhaul will require supporting the PTO initially in
an upside down position, possibly attaching it direct to an engine over
haul stand at the face of the cap (fabrication of an adapter would be
required). Another consideration would be to support it on suitable
supports on the underside of the flange of the mid-section, first remov
ing the flange bolts at the support areas (see Figure 3).
Figure 3. Transmission Supports
IL2153
Removal of End Yokes
1. Remove the end yokes from the driven, drive and coupling shafts. Do
not reuse self-locking nuts. Apply lubricating oil to the threads before
moving. Apply anti-seize to the threads before installing a new self-
locking nut.
2. Remove the lube system hose.
3. Remove the pneumatic shift.
Figure 4. Removal of Companion Flange and End Yokes
Yoke
Washer Nut
Coupling Shaft
Housing
Lube System
Hose Assembly
Cap
Mid
Section
Bottom Section
Yoke
Nut
Pneumatic Shift

T-360 Page 4 of 35
Coupling Shaft Housing Removal
1. Remove the hex head screws and lock washers attaching the coupling
shaft housing to the mid-section.
2. Remove the coupling shaft housing, O-ring and shims. Note that jack
ing screw holes are provided.
NOTE: The coupling shaft and its associated parts may come with the
housing. If not, pull on the coupling shaft to remove.
Figure 5. Removal of Coupling Shaft Housing
Shims
Lock
Washer
Hex Hd
Screw
Jacking Screw Holes (2)
Coupling Shaft
Housing
Removing the Bottom Section
1. Invert the case as shown in Figure 3.
2. Remove lower cap screws connecting the driveshaft housing to the
bottom section. Loosen cap screws connecting housing to case mid-
section.
3. Remove the cap screws, nuts and lock washers attaching the bottom
section to the mid-section.
4. Drive the four dowel pins out of the bottom section flange.
5. Remove the bottom section from the mid-section.
Figure 6. Removal of the Bottom Section
Dowel Pins
Hex Nut
Lock Washer
Hex Hd Screw
Driveshaft
Housing
Driveshaft
Housing
Cap Screw

T-360 Page 5 of 35
Removal of Chain
1. Rotate the drive shaft until removeable connecting pin set of the chain
is visible at the drive sprocket. The removable connecting pin set has a
spirol pins on both ends holding it in place (see Figure 7).
Figure 7. Removable Connecting Pin Set
IL2436
Connecting Pin Assy
and Connecting Rocker
Spirol Pin
Connecting Pin Set
Drive Sprocket
Driven Sprocket
Chain
2. Remove the tapped in spirol pin on one end, tap both the connecting
pin assembly and connecting rocker out of the chain links. Disengage
the chain from the drive and driven sprocket and remove from the
case.
Figure 8. Chain Removal
Driven Sprocket
Drive Sprocket
Chain
Removal of Drive Shaft and Housing
1. Remove the remaining hex head screws and lock washers attaching
the drive shaft housing to the mid-section. The housing, drive shaft,
drive sprocket, shift collar and associated parts can now be removed
as a unit from the mid-section. The shift fork will slip off the shift shaft
when the drive shaft assembly is lifted out.
Figure 9. Removal of Drive Shaft and Housing
Shift Shaft
Drive Shaft Assembly
Drive Shaft Housing
Shift Fork Lock Washer
Hex Hd Screw

T-360 Page 6 of 35
Removal of Shift Components
1. Remove the shift shoe from the locking arm.
2. Slip locking arm off pivot pin.
NOTE: The pivot pin and shift shaft bushing (typically pressed into the
bottom section) need only be removed if bent or otherwise damaged.
3. Remove the shoulder screw that attaches the sector gear and shift
lever to the shift shaft and remove the sector gear, shift lever and
spacer.
4. Reposition mid and cap section assembly on the supports so that the
cap portion is on top or set the assembly on a bench.
5. Remove spirol pin attaching the shift arm to the shift shaft (Figure 10b)
if necessary.
6. Remove the shift arm, shift lock spring and shift shaft.
Figure 10a. Removal of Shift Component - (Internal)
Figure 10b. Removal of Shift Components (External)
IL2232
Sector Spacer
Shift Lever
Sector Gear
Pivot Pin
Locking Arm
Shift Shoe
Shoulder Screw
Shift Shaft
Locking Nut
Spirol Pin
V-ring
(Used
Starting
7/14/2008)
Shift Shaft
Shift Arm
Spirol Pin
Shift Lock Spring
Spring HousingSpirol Pin IL2546

T-360 Page 7 of 35
Removal of Mid-Section from Cap
The cap does not need to be removed from the mid-section unless either is
being replaced. NOTE: Removal will make it easier to handle the assembly
during driven shaft removal and reassembly.
1. Remove cap screws and nuts that attach the cap to the mid-section.
2. Remove cap with driven shaft from the mid-section. Rapping the cap
with a soft hammer will break adhesion with the shims, spacers and
mid-section.
NOTE: Do not drive the dowels through the flange of the cap deeper into
the mid-section or spacer plates.
Figure 11. Removal of Mid-Section from Cap
3. Remove any shims and spacers from the top of the mid-section.
a. The quantity and thickness of shims and spacers depends on PTO
model and ratio.
Disassembly of Driven Shaft Assembly
Front Facing End Yoke
1. Remove the four cap screws that fasten the bearing cover and oil seal
housing to the cap. Remove cover and housing. Discard the oil seal.
2. Straighten tab of the bearing lock washer from slot in bearing lock nut
and then remove the lock nut, lock washer and wave spring.
3. Under a press, support the assembly on the front face side of the cap
and apply a press load to the end of the driven shaft to press the shaft
out of the bearing, spacers and sprockets.
4. Remove the bearing, spacer and sprocket from cap.
Figure 12. Front Facing End Yoke Driven Shaft Disassembly
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Bearing Lock Nut
Bearing Lock Washer
Wave Spring
Oil Seal
IL2539
Cap Screw
Bearing Cover
O-ring
Lock Washer
Lock Washer
Cap Screw
Rear
Front
O-ring
Oil Seal Housing

T-360 Page 8 of 35
Rear Facing End Yoke
1. Remove the four cap screws that fasten the bearing cover and oil seal
housing to the cap. Remove cover and housing. Discard oil seal.
2. Straighten tab of the bearing lock washer from slot in bearing lock nut
and then remove the lock nut, lock washer and wave spring.
3. Under a press, support the assembly on the rear face of the cap and
apply a press load to the end of the driven shaft to press the shaft out
of the bearing, spacers and sprockets.
4. Remove the bearing, spacer and sprocket from sprocket.
Figure 13. Rear Facing End Yoke Driven Shaft Disassembly
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Bearing Lock Nut
Bearing Lock Washer
Wave Spring
Oil Seal
IL2540
Cap Screw
Cap Screw
Lock Washer
Lock Washer
Bearing Cover
O-ring
O-ring
Oil Seal Housing
Front
Rear
Front Facing Hydraulic Pump Provision
1. Remove the four cap screws that fasten the hydraulic pump adapter
and bearing cover to the cap. Remove adapter and cover. Discard oil
seal.
2. Straighten tab of the bearing lock washer from slot in bearing lock nut
and then remove the lock nut, lock washer and wave spring.
3. Under a press, support the assembly on the front face of the cap and
apply a press load to the end of the driven shaft to press the shaft out
of the bearing, spacer and sprocket.
4. Remove the bearing, spacer and sprocket from sprocket.
Figure 14. Front Facing Hydraulic Pump Provision
Driven Shaft Disassembly
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Bearing Lock Nut
Bearing Lock Washer
Wave Spring
Oil Seal
IL2539
Bearing Cover
Cap Screw
Cap Screw
Lock Washer
Lock Washer
Oil Seal
Oil Seal
Rear
Front
Hydraulic Pump Adapter

T-360 Page 9 of 35
Rear Facing Hydraulic Pump Provision
1. Remove the four cap screws that fasten the hydraulic pump adapter
and bearing cover to the cap. Remove adapter and cover. Discard oil
seal.
2. Straighten tab of the bearing lock washer from slot in bearing lock nut
and then remove the lock nut, lock washer and wave spring.
3. Under a press, support the assembly on the rear face of the cap and
apply a press load to the end of the driven shaft to press the shaft out
of the bearing, spacer and sprocket.
4. Remove the bearing, spacer and sprocket from cap.
Figure 15. Rear Facing Hydraulic Pump Provision
Driven Shaft Disassembly
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Bearing Lock Nut
Bearing Lock Washer
Wave Spring
Oil Seal
IL2540
Cap Screw
Cap Screw
Lock Washer
Lock Washer
O-ring
O-ring
Front
Rear
Hydraulic Pump Adapter
Bearing Cover
Front Facing End Yoke /
Rear Facing Hydraulic Pump Provision
1. Remove the four cap screws that fasten the hydraulic pump adapter
and oil seal housing to the cap. Remove adapter and housing. Discard
oil seal.
2. Remove the retaining ring and wave spring.
3. Under a press, support the assembly on front face of the cap and
apply a press load to the end of the driven shaft to press the shaft out
of the bearing, spacer and sprocket.
4. Remove the bearing, spacer and sprocket.
Figure 16. Front Facing End Yoke Rear Facing Hydraulic Pump
Provision Driven Shaft Disassembly
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Retaining Ring
Wave Spring
Oil Seal
IL2539
Cap Screw
Cap Screw
Lock Washer
Lock Washer
Oil Seal
Hydraulic Pump Adapter
O-ring
O-ring
Oil Seal Housing
Rear
Front

T-360 Page 10 of 35
Rear Facing End Yoke /
Front Facing Hydraulic Pump Provision
1. Remove the four cap screws that fasten the hydraulic pump adapter
and oil seal housing to the cap. Remove adapter and housing. Discard
oil seal.
2. Remove the retaining ring and wave spring.
3. Under a press, support the assembly on the rear face of the cap and
apply a press load to the end of the driven shaft to press the shaft out
of the bearing, spacer and sprocket.
4. Remove the bearing, spacer and sprocket from cap.
Figure 17. Rear Facing End Yoke Front Facing Hydraulic Pump
Provision Driven Shaft Disassembly
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Retaining Ring
Wave Spring
Oil Seal
IL2540
Cap ScrewCap Screw
Cap Screw
Lock Washer
Lock Washer
Oil Seal
O-ring
O-ring
Hydraulic Pump Adapter
Front
Rear
Oil Seal Housing
Eclipse Mounted CAFS
1. Remove the four cap screws that fasten the bearing cover and oil seal
housing to the cap. Remove cover, housing and yoke spacer.
2. Straighten tab of the bearing lock washer from slot in bearing lock nut
and then remove the lock nut, lock washer and wave spring.
3. Under a press, support the assembly on the rear side of the case and
apply a press load to the end of the driven shaft and press the shaft
out of the bearing, spacer and sprocket. Rear bearing and retaining
ring will come out with the driven shaft. Remove from shaft.
4. Remove the bearing, spacer and sprocket from cap.
Figure 18. Eclipse Mounted CAFS Driven Shaft Disassembly
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Wave Spring
Oil Seal
IL2616
Bearing Lock Nut
Bearing Lock Washer
Yoke Spacer
O-ring
Cap Screw
Cap Screw
Lock Washer
Lock Washer
Front
Rear
Bearing Cover
Oil Seal Housing
Shim,
.010 in.
Retaining Ring

T-360 Page 11 of 35
Disassembly of Coupling Shaft Assembly
1. Press coupling shaft housing off of bearings if not previously removed.
2. Pull outer bearing from the shaft.
3. Remove the spacer and pull inner bearing from the shaft. Note that
due to the closeness of the bearing to the hub end of the shaft, a split-
plate type puller may be necessary.
4. Tap out pilot bearing if still in coupling shaft by using a punch through
the two access holes in the coupling shaft.
Figure 19. Coupling Shaft Disassembly
Coupling Shaft
Ball Bearing
Shaft Spacer
Ball Bearing
Access Hole (2)
Pilot Bearing
Disassembly of Drive Shaft Assembly
1. Slide shift collar from teeth on the drive shaft.
NOTE: If the transmission is equipped with an electronic tachometer,
remove the pick-up from the housing prior to removal of the drive
shaft housing to avoid damage.
2. Press drive shaft housing from drive shaft assembly and press the oil
seal from housing. Discard the oil seal.
3. Remove the tachometer pulse generator (if equipped) with a suitable
puller (see Figure 21).
Figure 20. Drive Shaft Disassembly - Shift Collar Removal and Oil Seal
Oil Seal
Drive Housing
O-ring
Drive Shaft Assembly
Shift Collar

T-360 Page 12 of 35
Disassembly of Drive Shaft Assembly Cont'd
4. Remove spacer if applicable.
5. Place shaft and sprocket assembly in an arbor press in a vertical posi
tion with the threaded end up and supported on the bottom face of the
sprocket. Press shaft out of drive sprocket assembly. Catch shaft to
avoid damage.
6. Remove needle bearings from the sprocket.
Figure 21. Drive Shaft Disassembly
Pilot Bearing
Drive Shaft
Drive Sprocket
Assembly
Thrust Washer
Ball Bearing
Spacer
Spacer
Tach Pulse Generator
Figure 22. Needle Bearing Removal from Sprocket
Needle Bearing
Needle Bearing
Drive Sprocket
IL2526
Inspection and Repair
Check the following:
•Bent shift forks
•Bent shift shaft
•Worn shifter shoes
•Loose shifter shoe studs
•Damaged locking arm assembly, sector gear or bent pivot pin
•Condition of oil hose
•Worn sprocket teeth
•Worn flanks on inner chain links
•Outside guide links of chain not retained by riveted over" pins
•Wear on inner faces of outside guide links of chain
•Badly worn pointing on teeth of drive sprocket, coupling shaft and shift
collar
•Damaged splines on drive and coupling shafts
Before reassembly, make sure all reusable parts have been cleaned and are
kept free of dirt during reassembly.

T-360 Page 13 of 35
Reassembl
y
Guidelines for Installing Bearings, Oil Seals, O-Rings and Hardware
Installing Bearings
Keep new bearings wrapped until they are to be installed. When pressing the
bearing on a shaft or into a bore, coat appropriate surfaces with grease.
Shaft - grease shaft and bearing bore.
Bore - grease bore and outside of diameter of bearing.
Always apply force to the inner race of a bearing when pressing it on a shaft
and to the outer race if pressing into a bore. Press evenly with a piece of pipe
or tube which just clears the shaft.
NOTE: Wherever silicone or sealant is referenced, use Loctite Ultra Blue
RTV Silicone Sealant or equivalent, unless otherwise specified.
Installing Oil Seals
Before installing an oil seal in its housing, apply a thin coat of sealant to hous
ing oil seal seat. Be sure that the seal, shaft and housing are clean. Always
install a seal with the seal lip facing in. Lubricate seal lip with light oil before
installing shaft. Apply force to the outer edge of the seal and press in evenly.
Installing O-Rings
Grease O-rings prior to installation. This will aid in the installation as well as
preventing damage to the O-ring.
Installing Hardware
Torque spcifications for screws: M10 36-40 lb-ft.
M12 64-69 lb-ft.
Reassembly of the Driven Shaft
Front Facing End Yoke
1. Use high pressure grease to coat the driven shaft.
2. Press the bearing to the shoulder on the yoke end of the driven shaft.
3. Tap the key into place.
4. Place high pressure grease in the rear bore of the cap.
5. Tap the bearing into place.
6. Set the bearing cover on rear face of cap and secure with the hex head
screw and lock washers. Hand tighten only at this stage of reassembly.
7. With the cap resting on the rear face, position the spacer and driven
sprocket inside the cap.
8. Take the driven shaft, bearing and key assembled previously and from
the front face of the cap, slide the shaft through the bore in the cap into
the bore of the driven sprocket, spacer and ball bearing lining up the key
in the shaft with the keyway in the sprocket.
9. Tap into place until the shaft seats.
10. Install O-ring and oil seal in the oil seal housing.
11. Install oil seal housing.
12. Tap lock nut end of driven shaft towards oil seal housing to seat assem
bly.
13. Remove the bearing cover and install the O-ring, bearing lock washer
and lock nut. Make sure the tang of the washer aligns with the keyway
in the shaft.
14. Tighten nut 1/4 turn from finger tight and bend one of the locking tangs
on the washer into one of the slots in the locknut.
15. Install wave spring and bearing cover.
Figure 23. Front Facing End Yoke Reassembly of the Driven Shaft
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Bearing Lock Nut
Bearing Lock Washer
Wave Spring
Oil Seal
IL2541
Cap Screw
Cap Screw
Lock Washer
Lock Washer
O-ring
O-ring
Front
Rear
Oil Seal Housing
Bearing Cover

T-360 Page 14 of 35
Rear Facing End Yoke
1. Use high pressure grease to coat the driven shaft.
2. Press the bearing to the shoulder on the yoke end of the driven shaft.
3. Tap the key into place.
4. Place high pressure grease in the front bore of the cap.
5. Tap the bearing into place.
6. Set the bearing cover in cap and secure with the hex head screws and
lock washers. Hand tighten only at this stage of reassembly.
7. With the cap resting on the front face, position the spacer and driven
sprocket inside the cap.
8. Take the driven shaft, bearing and key assembled previously and from
the rear face of the cap, slide the shaft through the bore in the cap into
the bore of the driven sprocket, spacer and ball bearing lining up the
key in the shaft with the keyway in the sprocket.
9. Tap into place until the shaft seats.
10. Install O-ring and oil seal in the oil seal housing.
11. Install the oil seal housing.
12. Tap lock nut end of driven shaft towards oil seal housing to seat
assembly.
13. Remove the bearing cover and install the O-ring, bearing lock washer
and lock nut. Make sure the tang of the washer aligns with the keyway
in the shaft.
14. Tighten nut 1/4 turn from finger tight and bend one of the locking tangs
on the washer into one of the slots in the locknut.
15. Install wave spring and bearing cover.
Figure 24. Rear Facing End Yoke Reassembly of the Driven Shaft
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Bearing Lock Nut
Bearing Lock Washer
Wave Spring
Oil Seal
IL2542
Cap Screw
Cap Screw
Lock Washer
Lock Washer
Rear
Front
Oil Seal Housing
O-ring
O-ring
Bearing Cover

T-360 Page 15 of 35
Front Facing Hydraulic Pump Provision
1. Use high pressure grease to coat the driven shaft.
2. Press the bearing to the shoulder on the internal spline end of driven
shaft.
3. Tap the key into place.
4. Place high pressure grease in the rear bore of the cap.
5. Tap the bearing into place.
6. Set the bearing cover in the cap and secure with hex head screws and
lock washers. Hand tighten only at this stage of reassembly.
7. With the cap resting on its rear face, position the spacer and driven
sprocket inside the cap.
8. Take the driven shaft, bearing and key assembled previously and from
the front side of the cap, slide the shaft through the bore in the cap into
the bore of the driven sprocket, spacer and ball bearing lining up the
key in the shaft with the keyway in the sprocket.
9. Tap into place until the shaft seats.
10. Install O-ring and oil seal in the hydraulic pump adapter.
11. Install the hydraulic pump adapter.
12. Tap lock nut end of driven shaft towards oil seal housing to seat
assembly.
13. Remove the bearing cover and install the bearing lock washer and lock
nut. Make sure the tang of the washer aligns with the keyway in the
shaft.
14. Tighten nut 1/4 turn from finger tight and bend one of the locking tangs
on the washer into one of the slots in the locknut.
15. Install wave spring and bearing cover.
Figure 25. Front Facing Hydraulic Pump Provision
Reassembly of the Driven Shaft
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Bearing Lock Nut
Bearing Lock Washer
Wave Spring
Oil Seal
IL2541
Cap Screw
Cap Screw
Lock Washer
Lock Washer
O-ring
O-ring
Hydraulic Pump Adapter
Front
Rear
Bearing Cover

T-360 Page 16 of 35
Rear Facing Hydraulic Pump Provision
1. Use high pressure grease to coat the driven shaft.
2. Press the bearing to the should on the internal spline end of the drive
shaft.
3. Tap the key into place.
4. Place high pressure grease in the front bore of the cap.
5. Tap the bearing into place.
6. Set the bearing cover on cap and secure with hex head screws and
lock washers. Hand tighten only at this stage of reassembly.
7. With the cap resting on its front face, position the spacer and driven
sprocket inside the cap.
8. Take the driven shaft, bearing and key assembled previously and from
the rear face of the cap, slide the shaft through the bore in the cap into
the bore of the driven sprocket, spacer and ball bearing lining up the
key in the shaft with the keyway in the sprocket.
9. Tap into place until the shaft seats.
10. Install O-ring and oil seal in the hydraulic pump adapter.
11. Install the hydraulic pump adapter.
12. Tap lock nut end of driven shaft towards oil seal housing to seat
assembly.
13. Remove the bearing cover and install the bearing lock washer and lock
nut. Make sure the tang of the washer aligns with the keyway in the
shaft.
14. Tighten nut 1/4 turn from finger tight and bend one of the locking tangs
on the washer into one of the slots in the locknut.
15. Install wave spring and bearing cover.
Figure 26. Rear Facing Hydraulic Pump Provision
Reassembly of the Driven Shaft
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Bearing Lock Nut
Bearing Lock Washer
Wave Spring
Oil Seal
IL2542
Cap Screw
Cap Screw
Lock Washer
Lock Washer
Hydraulic Pump Adapter
O-ring
O-ring
Bearing Cover
Rear
Front

T-360 Page 17 of 35
Front Facing End Yoke
Rear Facing Hydraulic Pump Provision
1. Use high pressure grease to coat the driven shaft.
2. Press the bearing to the shoulder on splined end of driven shaft.
3. Tap the key into place.
4. Place high pressure grease in the rear bore of the cap.
5. Tap the bearing into place.
6. Set the hydraulic pump adapter on cap and secure with hex head
screws and lock washers. Hand tighten only at this stage of reassemb
ly.
7. With the cap resting on its rear face, position the spacer and driven
sprocket inside the cap.
8. Take the driven shaft, bearing and key assembled previously and from
the front face of the cap, slide the shaft through the bore in the cap into
the bore of the driven sprocket, spacer and ball bearing lining up the
key in the shaft with the keyway in the sprocket.
9. Tap into place until the shaft seats.
10. Install O-ring and oil seal in the oil seal housing.
11. Install the oil seal housing.
12. Remove the hydraulic pump adapter and install retaining ring.
13. Tap internal splined end of driven shaft towards front face to seat
assembly.
14. Install O-ring and oil seal in hydraulic pump adapter.
15. Install wave spring and hydraulic pump adapter.
Figure 27. Front Facing End Yoke
Rear Facing Hydraulic Pump Provision Reassembly of the Driven Shaft
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Retaining Ring
Wave Spring
Oil Seal
IL2541
Cap Screw
Cap Screw
Lock Washer
Lock Washer
Oil Seal Housing
O-ring
O-ring
Front
Rear
Hydraulic Pump Adapter
Oil Seal

T-360 Page 18 of 35
Rear Facing End Yoke
Front Facing Hydraulic Pump Provision
1. Use high pressure grease to coat the driven shaft.
2. Press the bearing to the shoulder on the external splined end of the
driven shaft.
3. Tap the key into place.
4. Place high pressure grease in the front bore of the cap.
5. Tap the bearing into place.
6. Set the hydraulic pump adapter on the front face of the cap and secure
with hex head screws and lock washers. Hand tighten only at this
stage of reassembly.
7. With the cap resting on the front face, position spacer and the driven
sprocket inside the cap.
8. Take the driven shaft, bearing and key assembled previously and from
the rear face of the cap, slide the shaft through the bore in the cap into
the bore of the driven sprocket, spacer and ball bearing lining up the
key in the shaft with the keyway in the sprocket.
9. Tap into place until the shaft seats.
10. Install O-ring and oil seal in the oil seal housing.
11. Install the oil seal housing.
12. Remove the hydraulic pump adapter and install the retaining ring.
13. Tap internal spline end of driven shaft towards rear face to seat
assembly.
14. Install O-ring and oil seal in hydraulic adapter.
15. Install wave spring and hydraulic pump adapter.
Figure 28. Rear Facing End Yoke
Front Facing Hydraulic Pump Provision Reassembly of the Driven Shaft
Sprocket
Key
Ball Bearing
Ball Bearing
Driven Shaft
Cap
Spacer
Retaining Ring
Wave Spring
Oil Seal
IL2542
Cap Screw
Cap Screw
Lock Washer
Lock Washer
Oil Seal
O-ring
O-ring
Oil Seal Housing
Front
Rear
Hydraulic Pump Adapter

T-360 Page 19 of 35
Eclipse ES Mounted CAFS
1. Use high pressure grease to coat the driven shaft.
2. Press the bearing (1) onto the shaft and secure in place with retaining
ring.
3. Tap the key for the driven sprocket into place.
4. Place high pressure grease in the front bore of the cap.
5. Tap the bearing (2) into place.
6. Set the bearing cover on cap and secure with hex head screws and
lock washers. Hand tighten only at this stage of reassembly.
7. With the cap resting on the front face, position the spacer and driven
sprocket inside the cap.
8. Take the driven shaft, bearing and key assembled previously and from
the rear face of the cap, slide the shaft through the bore in the cap into
the bore of the driven sprocket, spacer and ball bearing lining up the
key in the shaft with the keyway in the sprocket.
9. Tap into place until the shaft seats.
10. Install the oil seal in the oil seal housing.
11. Install the shim and oil seal housing.
12. Tap lock nut end of driven shaft towards oil seal housing to seat
assembly.
13. Remove the bearing cover and install the O-ring, bearing lock washer
and lock nut. Make sure the tang of the washer aligns with the keyway
in the shaft.
14. Tighten nut 1/4 turn from finger tight and bend one of the locking tangs
on the washer into one of the slots in the locknut.
15. Install wave spring and bearing cover.
Figure 29. Eclipse ES Mounted CAFS
Reassembly of the Driven Shaft
Sprocket
Key
Ball Bearing (1)
Ball Bearing (2)
Driven Shaft
Cap
Spacer
Wave Spring
Oil Seal
IL2617
Retaining Ring
Bearing Lock Nut
Bearing Lock Washer
Spacer
Cap Screw
Cap Screw
Lock Washer
Lock Washer
Front
Rear
Oil Seal Housing
Shim,
.010 in.
O-ring
Bearing Cover