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Eaton TRSM0515 Service Manual

Summary of TRSM0515

  • Page 1

    Service manual fuller heavy duty transmissions trsm0515 october 2007.

  • Page 2: Table of Contents

    Table of contents timing description operations lubrication preventive maintenance torque recommendations air system precautions disassembly front section disassembly auxiliary disassembly auxiliary reassembly front section reassembly reassembly tool reference changing clutch (input shaft) eaton cor...

  • Page 3: Timimg

    It is essential that the two countershafts are timed. This assures that the countershaft gears will con- tact the mating mainshaft gears at the same instant, allowing the mainshaft gears to seek their equilibrium position. This prohibits the mainshaft gears from climbing out of position and prevents...

  • Page 4: Description

    Description.

  • Page 5: Shifting The

    Shifting the 10 s p e e d r o a d r a n g e r t r a n s m i s s i o n r t - 6 6 1 o s e r i e s general instructions the 10-speed roadranger transmissions provide ten selective ratios, evenly and progressively spac- ed and shifted with one lever. But you do not shift the roadranger as you would a co...

  • Page 6: Operation

    Downshifting to get to low range push button down while in 6th speed, then move lever to 5th speed. 1. When shifting down, move the lever from 10th through each succes- sive lower speed to 6th. 2. When in 6th, and ready for the next downward shift, push the range control button down and move the lev...

  • Page 7: Lubrication

    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 transmissi...

  • Page 8: Lubrication

    Lubrication operating temperatures —with eaton ® roadranger ® cd50 transmission fluid heavy duty engine oil and mineral oil the transmission should not be operated con- sistently at temperatures above 250°f (120°c). However, intermittent operating temperatures to 300°f (149°c) will not harm the tran...

  • Page 9: Preventative Maintenance

    Preventive maintenance check chart checks without partial disassembly 1. Air system and connections a. Check for leaks, worn air lines, loose con- nections and capscrews. See air system section. 2. Clutch housing mounting a. Check all capscrews in bolt circle clutch housing for looseness. 3. Clutch ...

  • Page 10: Preventative Maintenance

    Preventative maintenance check chart.

  • Page 11: Torque Recommendations

    Torque recommendations.

  • Page 12: Torque Recommendations

    Cut 7191d-7/84 torque recommendations.

  • Page 13: Air System

    Air system.

  • Page 14: Air System

    Note: basic installation and trouble shooting guide if the transmission is equipped with a a-5010 roadranger valve, see the air systems troubleshooting guide, trsm-0920, for operation and assembly instructions . Operation the range shift air system consists of an air filter, regulator, air valve, co...

  • Page 15: Trouble Shooting

    Trouble shooting range shift air system if transmission fails to make a range shift or shifts too slow, the fault may be in the air system or actuating parts in the shifting bar housing. To check the air system and pin-point the trouble area, the following procedures are recommended, using the check...

  • Page 16: Air System

    6. Check point d with normal vehicle air pressure and gear shift lever in the neutral position, pull the control button up to high range and disconnect the low range air line, either at fitting on range cylinder or at bottom port of air valve. A. Repeat procedures under check point c, reversing the ...

  • Page 17: Air System

    Iv. Range shift air linesãall models cut 7001 d-7/84 a. Removal 1. Disconnect the black and white l/8" od air lines (a and b) from between the slave air valve and the range shift control valve. 2. Disconnect the two 1/4" id air lines from between the slave air valve and the range shift cylinder. B. ...

  • Page 18: VI. Range Control Valve

    Vi. Range control valve a. Removal and disassembly 1. Disconnect the air lines and loosen the clamp securing the valve to the gear shift lever. Remove valve. 2. Remove the four screws to separate the front and rear housings and remove the slide and two sets of position springs and balls. 3. Remove t...

  • Page 19: Air Filter and Regulator

    Air filter and regulator the air filter contains a replaceable filter element which can be removed by turning out the end cap and removing the spring and tension plate. This element should be cleaned at each oil change, or more often under high humidity conditions. Air system.

  • Page 20: Disassembly

    Disassembly it is assumed in the detailed disassembly instruc- tions that the lubricant has been drained from the transmission, the necessary linkage and air lines removed and the transmission has been removed from the chassis. Removal of the gear shift lever housing assembly is included in the deta...

  • Page 21: Precautions

    A. Bearings 1. Wash all bearings in clean solvent. Check balls, rollers and races for pits and spalled areas. Replace bearings which are pitted or spalled. 2. Lubricate bearings which are not spalled or pit- ted and check for axial and radial clearances. Replace bearings with excessive clearances. 3...

  • Page 22: Reassembly

    K. Synchronizers 1. Check high and low range synchronizers for burrs, uneven and excessive wear at contact sur- face, and metal particles. 2. Check blocker pins for excessive wear or loose- ness. 3. Check synchronizer contact surfaces on the high and low range gears for excessive wear. L. Sliding cl...

  • Page 23: I. Range Shift Air System

    I. Range shift air system a. To remove the range shift control valve. 1. Disconnect the two nylon air lines at air valve on transmission. Note: if desired, the gear shift lever housing lever and range control valve can now be remov- ed from the transmission as a unit by turning out the four capscrew...

  • Page 24: Disassembly

    C. To remove the slave valve. 3. Loosen the mounting clamp and remove the range control valve and mounting clamp from lever. 4 . Remove nylon air lines, sheathing and o-ring clamp from the gear shift lever. B. To remove air regulator and filter assembly. 1. Disconnect and remove the air line between...

  • Page 25: Ix. Gear Shift Lever Housing

    Ix. Gear shift lever housing i shifting controls.

  • Page 26: Shift Controls

    A. Removal and disassembly b. Reassembly and installation 1. Turn out the capscrews, jar lightly to break the 1. Install the spade pin or pivot pin, nut and gasket seal and remove the gear shift lever hous- washer in the bore in the housing. If previously ing from the shift bar housing. Removed, ins...

  • Page 27: Ill. Shifting Bar Housing

    Ill. Shifting bar housing a. To remove and disassemble the shifting bar housing. 1. Turn out the attaching capscrews, jar to break 2. Turn out the two capscrews and remove the gasket seal, and lift the shifting bar housing tension spring cover from top of housing. From transmission. 3. Remove the th...

  • Page 28: Disassembly

    4. Tilt housing and remove the three tension balls 5. 6. Installed under springs. Place the housing in a vise with the plunger side up; front of housing will be to the right. Starting with the upper bar, move all bars to the right and out front of housing as detailed in the f o l l o w i n g i n s t...

  • Page 29: Disassembly

    9. Remove the actuating plunger from rear web. 11. Remove the two interlock balls from front web. 10. Move the lower bar to the right and out of hous- ing, removing shifting yoke from bar. Disassembly.

  • Page 30: Housing Removal

    Iv. Companion flange, auxiliary section and clutch housing removal 1. A. To remove the universal joint companion flange or yoke. Lock the transmission by engaging two speeds 2. Pull the flange or yoke straight to the rear and with the mainshaft sliding clutches. Use a large breaker bar to turn the o...

  • Page 31: Disassembly

    B. To remove the auxiliary section from transmission. 1. Turn out the capscrews that attach the two sec- tions. 3. Break gasket seal and remove clutch housing from case. 2. 3. Insert puller screws in auxiliary housing flange. Tighten puller screws evenly to move the aux- iliary section straight to t...

  • Page 32: V. Front Section Disassembly

    V. Front section disassembly a. To remove bearings from right countershaft. 3. Install snap ring in the exposed bearing snap ring groove. (use snap ring which was removed from rear bearing bore.) 1. Remove snap ring in rear bearing bore of case. 4. Loosen the capscrews at the bearing retaining 2. Us...

  • Page 33: Front Section Disassembly

    5. Using soft bar and maul against front of 7. Use puller or pry bars to remove front bearing. Countershaft, move the countershaft assembly to the rear as far as possible. This will move front bearing forward on shaft. 6. Using soft bar and maul against rear of counter- shaft, again move the counter...

  • Page 34: Front Section Disassembly

    B. To remove the input shaft. 1. Move the drive gear and shaft forward as far as possible. 2. 3. Push down on input shaft to cock bearing in bore. Drive input shaft toward rear of transmiss- ion, through bearing as far as possible. Pull in- put shaft forward to expose snap ring of bear- ing. Remove ...

  • Page 35: Front Section Disassembly

    . - Ó 5. Remove the drive gear washer. 6. Remove the snap ring from groove in id of drive gear. 8. If necessary, remove bushing from pocket in clutch shaft. 9. Move the drive gear to the rear and against the 4th speed gear, engaging teeth of sliding clutch gear. 7. Pull shaft forward and from spline...

  • Page 36: Front Section Disassembly

    Cut 6421 -2/80 c. To remove and disassemble the auxiliary drive gear assembly. 1. Turn out capscrews and remove the two bearing retainer rings from case. 2. Remove the snap ring from the rear of main- shaft (located in bore of auxiliary drive gear). 3. Tap against front of mainshaft to move the aux-...

  • Page 37: Front Section Disassembly

    4. Use pry bars to remove the auxiliary drive gear assembly from case bore and from splines of mainshaft. 6. Press or use driver to remove bearing from aux- iliary drive gear. 5. Remove snap ring from groove in auxiliary drive gear. Front section disassembly.

  • Page 38: Front Section Disassembly

    D. To remove the left reverse idler gear. 2. 1. Use curved pry bar to walk bearing from idler bore in case. Remove the rear idler washer and retainer from bore. (if necessary, bend holder lugs and remove washer from holder.) front section disassembly.

  • Page 39: Front Section Disassembly

    3. Remove reverse idler gear from case. 5. Remove the front idler washer from case 4. Remove the idler bearing from reverse idler gear. Front section disassembly.

  • Page 40: Front Section Disassembly

    E. To remove and disassemble the mainshaft assembly. 1. Block the right countershaft to the right as far as possible-and lift the mainshaft assembly from case. 2. Remove the drive gear and the 4th-5th sliding clutch from mainshaft. . 3. Inside hub of the 4th speed gear, remove snap ring from groove ...

  • Page 41: Front Section Disassembly

    5. Remove the 3rd speed gear and washer. 6. Remove the 2nd-3rd speed sliding clutch. 7. Remove the long key from slot in mainshaft. 8. Remove the 2nd speed gear and washer. Front section disassembly.

  • Page 42: Front Section Disassembly

    9. Remove the 1st speed gear and washer. 11. Remove the reverse gear and washer. 10. Remove the 1st-reverse sliding clutch. Front section disassembly.

  • Page 43: Front Section Disassembly

    F. To remove the countershaft assemblies. 3. Lift the left countershaft from case. 1. 2. Lift the right countershaft from case. Remove bearings from the left countershaft in the same manner in which bearings were removed from right countershaft. (see pages 33 and 34.) front section disassembly.

  • Page 44: Front Section Disassembly

    G. To disassemble the countershaft assemblies. Note: both countershafts are disassembled in the same manner as construction is iden- tical. 1. Remove snap ring from front of countershaft. 2. Press the drive gear from shaft. 3. Press the 4th speed gear from shaft. 4. Using the rear face of the pto ge...

  • Page 45: VI. Auxiliary Disassembly

    Vi. Auxiliary disassembly cut 6482 Ð2/80 a. To remove the auxiliary countershaft assemblies. 1. Use pullers to remove bearing from front of tailshaft. 2. Turn out capscrews and remove the rear bear- ing cover. 3. If necessary remove the rear seal from cover. Front section disassembly.

  • Page 46: Auxiliary Disassembly

    4. Remove the speedometer gear or replacement spacer from tailshaft. 5. Remove the speedometer gear washer. 7. Pull the counters shafts forward and out of housing. 6. From inside housing, use long punch to move outer races of countershaft rear bearings to the rear; move races approximately one-half ...

  • Page 47: Auxiliary Disassembly

    I c. To remove the range shift a i r c y l i n d e r a n d - synchronizer assemblies. 1. Turn out capscrews and remove the air cylin- der cover. 2. 3. Use air to remove piston. Caution - do not stand in front of cylinder opening. Remove the nut and iockwasher from air cylin- der piston shaft. 4. If ...

  • Page 48: Auxiliary Disassembly

    5. Remove the copper seal from shaft. . 6. Move the synchronizer assembly, shift yoke, and piston shaft forward and out of housing as a complete assembly. 7. 8. Remove the shaft and yoke from synchronizer assembly. Cut lockwire, turn out the two iock screws and remove yoke from shaft. 9. Place the l...

  • Page 49: Auxiliary Disassembly

    E. To remove and disassemble the low speed gear and tailshaft assembly. 2. Remove cylinder from housing. 1. Drive or press against rear of tailshaft to move assembly forward and from rear bearing. 3. Remove o-ring from small bore in cylinder, if necessary. 2. Remove the rear washer and the low speed...

  • Page 50: Auxiliary Disassembly

    3. Remove spline washer from hub of low speed gear. 4. 5. Move the mainshaft rear bearing to the rear and out of housing. Use bearing driver to remove the countershaft rear bearings from housing. Auxiliary disassembly.

  • Page 51: I. Auxiliary Reassembly

    I. Auxiliary reassembly cut 6549-9/85 a. To reassemble and install the low speed gear and tailshaft assembly. 1. Make sure magnetic cleaner is installed in recess in auxiliary case. 3. Place splined spacer in hub of low speed gear, shoulder toward rear. 2. Important: mark timing teeth on the reduc- ...

  • Page 52: Auxiliary Reassembly

    5. Install the low speed gear rear washer on shaft and against gear, chamfer to the rear. 7. Seat mainshaft rear bearing securely on shaft and in bore. 6. Set the tailshaft with the forward end down and place auxiliary housing over rear of shaft so that shaft extends through rear bore. Auxiliary rea...

  • Page 53: Auxiliary Reassembly

    B. To install the range shift air cylinder. 1. Install o-ring in slot in small bore in cylinder. Lubricate o-ring with silicone lubricant. 2. Install range cylinder in housing with air port in cylinder aligned with air port in top of auxiliary housing. Auxiliary reassembly.

  • Page 54: Auxiliary Reassembly

    3. Install dust cover and airport extension through housing and into bore of air cylinder. C. To reassemble the synchronizer assembly. 3. Install the three springs in bores in high range synchronizer ring. 1. Place the larger low range synchronizer ring face down on bench with pins up. 2. Place the ...

  • Page 55: Auxiliary Reassembly

    5. Seat the direct ring fully on the low speed pins by pushing down and twisting to compress the springs. D. To install the synchronizer and range shift air cylinder assemblies. 3. 4. 1. 2. Place the shifting yoke on piston shaft, long hub towards the rear of the shaft. Align slots in shaft with bor...

  • Page 56: Auxiliary Reassembly

    6. Install o-ring on od of piston. Apply light coat of silicone lubricant to o-ring. - . 7. Install piston on shaft and against copper washer, flat side of piston out. 8. Install iockwasher and nut on shaf to secure piston. 9. E. Install gasket and cylinder cover, tighten the four capscrews securely...

  • Page 57: Auxiliary Reassembly

    F. To install the countershaft assemblies. 1. Seat the outer races of the countershaft rear bearings only partially in bores, just far enough to stay in place. 2. Place countershafts into position in auxiliary housing, inserting inner races into the partially installed outer races. Important: timing...

  • Page 58: Auxiliary Reassembly

    4. 5. Install the speedometer gear rear washer on tailshaft and against bearing, champh ered id towards bearing, and install the speedometer gear or replace merit spacer on shaft and against washer. If previously removed, install oil seal in rear bearing cover, lip of seal to the rear. The spring in...

  • Page 59: Il. Front Section Reassembly

    Il. Front section reassembly a. To install the right reverse idler gear assembly. 1. A p p l y a h e a v y c o a t o f w h i t e g r e a s e o n t h e reverse-idler gear front washer and install it on pin in lower right of case. 2. Set reverse gear in position next to washer, machined surface of gea...

  • Page 60: Front Section Reassembly

    B. To assemble the countershaft assemblies. Note: countershafts are identical and are assem- bled in the same manner. 1. If previously removed, install roll pin, long key and woodruff key in slots in countershaft. 3. Press the 3rd speed gear on shaft. 4. Press the 4th speed gear on shaft, long hub t...

  • Page 61: Front Section Reassembly

    5. Press drive gear on shaft, long hub to the rear. C. To mark timing teeth and position countershaft assemblies. 1. 2. 6. Install snap ring in groove at front of shaft. 3. On the drive gear of each countershaft mark the gear tooth which is aligned with the keyway in shaft. This tooth will be stampe...

  • Page 62: Front Section Reassembly

    4. Center rear of left countershaft in rear bore of case with block. 5. Install front bearing on countershaft and in case bore with flanged driver. 6. Install rear bearing on countershaft and in case bore with flanged driver. 7. Install snap ring in groove in rear bore of case. D. To assemble auxili...

  • Page 63: Front Section Reassembly

    E. To reassemble the mainshaft assembly. 1. Place the mainshaft in a vise with the pilot end down. Keep keyway in mainshaft clear for inser- tion of key. Note: each mainshaft gear is held in position by locking the gear splined washer to the main- shaft with key. There is one splined washer for each...

  • Page 64: Setting Correct Axial

    Setting correct axial clearances for mainshaft gears axial clearance (end play) limits are: reverse speed gear - minimum of .005" forward speed gears - .005" to .012" washers are used to obtain the correct limits; five thicknesses are available as follows: limits color code .259 -.261 orange .264 -....

  • Page 65: Front Section Reassembly

    6. Install snap ring in groove at rear of m/shaft. 7. Insert two large screw drivers between hub of reverse gear and auxiliary drive gear applying light downward pressure on handles of screw- drivers. 9. Install the 1st-reverse clutch over front of main- shaft and against reverse gear splined washer...

  • Page 66: Front Section Reassembly

    11. Install 1st speed gear on mainshaft, clutching teeth down, fitting gear splines on those of washer. 13. 14. 12. Install 2nd speed gear on mainshaft, clutching teeth up, and against 1st speed gear. Remove the long key from keyway in main- shaft. Install 2nd speed gear splined washer on main- shaf...

  • Page 67: Front Section Reassembly

    16. Insert 2 large screwdrivers between the 2 18. Install 3rd gear splined washer on mainshaft at gears. Apply slight downward pressure then 3rd speed gear location. It will be necessary to insert feeler gauge between the hubs of the pull long key upward slightly in order to fit gears to check axial...

  • Page 68: Front Section Reassembly

    20. Install the 4th speed gear on mainshaft 22. (clutching teeth up) and - against 3rd speed gear. 21. Install the 4th speed gear splined washer on mainshaft and in hub of 4th speed gear. Install snap ring in groove in mainshaft which will hold the 4th speed gear in position on shaft. 23. Install th...

  • Page 69: Front Section Reassembly

    24. Important: mark timing teeth on drive gear 26. (5th speed gear). A. Mark two adjacent teeth on drive gear. B. Mark the two adjacent teeth on drive gear which are directly opposite the first set marked. There should be the same number of teeth between markings on each side of f . Gear. Remove the...

  • Page 70: Front Section Reassembly

    3. If previously removed, install bushing in pocket of input shaft, flush with rear of shaft. 5. Center mainshaft in rear bore of case and install auxiliary drive gear on splines of mainshaft. 4. Install input shaft through bore of case and onto mainshaft. This will prevent the mainshaft as- sembly ...

  • Page 71: Front Section Reassembly

    7. Install the two bearing retainer plates and lock- ing tabs on case. 8. Tighten capscrews and secure by bending lock- ing tangs over capscrews. 9. With large screwdriver move mainshaft assem- bly to rear to expose snap ring groove on rear of mainshaft. Install snap ring on rear of main- shaft. 10....

  • Page 72: Front Section Reassembly

    11. Mesh the marked timing tooth of left counter- shaft drive gear with the two marked timing teeth of the main drive gear. 13. Install drive gear spacer on input shaft. 12. Install snap ring in groove in i.D. Of drive gear. 14. Install drive gear bearing on input shaft and in- to case bore. Front s...

  • Page 73: Front Section Reassembly

    15. Install bearing retaining snap ring in groove of input shaft. 16. Engage the 4th-5th sliding clutch into the 4th speed mainshaft gear. This will prevent the 4th speed from dropping far enough to cause a possible timing error in the 4th speed gear set. 17. Mesh the marked timing tooth of the righ...

  • Page 74: Front Section Reassembly

    19. Shift the mainshaft sliding clutches into all the gear positions with a screwdriver. If a clutch cannot be shifted into a gear it indicates that the gear set is out of time. The right counter- shaft bearings would then need to be removed and the countershaft retimed with the main- shaft. The fro...

  • Page 75: Front Section Reassembly

    G. To install the left reverse idler gear assembly. 3. Set reverse-idler gear in position, machined sur- face of gear hub to the rear. 4. Place rear washer in holder if previously remov- ed, and bend lugs to secure washer. 1. Apply heavy coat of white grease on washer and on pin in upper left of cas...

  • Page 76: Flange Installation

    Ill. Clutch housing, auxiliary section and companion flange installation a. To install the clutch housing. B. To install the auxiliary section. 1. Install the drive gear bearing cover. 2. Install the clutch housing, attaching securely with the six nuts and two bolts. 3. If so equipped, install the c...

  • Page 77: Front Section Reassembly

    2. Secure the auxiliary with attaching capscrews. C. To install the companion flange or yoke. Note: the auxiliary can also be installed with front section in a vertical position. Place clutch housing on blocks and use chain hoist to lower auxiliary section into position. 1. Lock transmission by enga...

  • Page 78: Front Section Reassembly

    2. Make sure the speedometer gear washer and the speedometer gear or replacement spacer are installed on tailshaft. 3. Install the companion flange on splines of tailshaft. 4. Install the companion flange nut., tighten securely, using the correct torque rating. Front section reassembly.

  • Page 79: IV. Shifting Bar Housing

    Iv. Shifting bar housing a. To reassemble the shifting bar housing assembly. 1. Place the housing in a vise with the front of housing to the right. 2. Install the 4th-5th speed shift bar in bottom bore with neutral notches to the front, installing yoke on bar, fork towards front. Install yoke lock- ...

  • Page 80: Front Section Reassembly

    8. 9. 10. Install the spring in the bore and on the plunger. Partially install the plug. Use the tip of the gear shift lever to push the plunger back into the bore to compress the spring. Tighten the plug fully and then back off 1/2 -1 1/2 turns. Stake the plug threads in the hole. Install first-rev...

  • Page 81: Front Section Reassembly

    B. To install the shifting bar housing assembly. 3. Install the shifting bar housing on transmis- sion, fitting yokes into yoke slots of correspond- ing clutch gears. 1. Make sure the shift bars are in the neutral posi- tion. 4. Install the attaching capscrews, tighten securely. 2. Place the sliding...

  • Page 82: VI. Range Shift Air System

    Vi. Range shift air system a. To install the air valve note: if previously removed install fittings on slave valve. 3. Install the slave valve on transmission, tighten c a p s c r e w s e v e n l y a n d s e c u r e l y . A c t u a t i n g plunger in case fits into alignment sleeve in air valve. 1. ...

  • Page 83: Reassembly

    5. Install the low range air line from air port in top of cylinder to the street ell in the "l" port of the slave valve. B. To reassemble and install the air regulator and filter assembly. 6. Install air line between output port of air regula- tor and the tee in supply port of air valve. 5. Install ...

  • Page 84: Reassembly

    C. 1. 2. 3. 4. 5. To install the range control valve. Install o-ring clamp on gear shift lever. Install the control valve on gear shift lever with clamp, and replace ball grip on gear shift lever. Position top of control valve button at least six inches below ball grip. If air lines are to be replac...

  • Page 85: Tool Reference

    Tool reference very few special tools are needed to repair the fuller twin countershaft transmis- sions. Ordinary socket wrenches, screwdrivers, etc., which are found in every mechanics tool box can be used. Other standard shop items are necessary, such as a press, bearing pullers, bearing drivers, ...

  • Page 86: (Input) Shaft

    Special procedure for changing clutch (input) shaft in some cases in field repair it may be necessary to replace only the input shaft due to clutch wear on the splines. In these instances the input shaft can be remov- ed without disassembling the transmission other than removing the shifting bar hou...

  • Page 88

    Copyright eaton corporation, 2012. Eaton hereby grant their customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. It may be copied only in its entirety without any changes or modifications. This information is not intended for sal...