MODELS ES52-7B TRANSMISSION ES56-7B ES066 …

1 TRANSMISSIONTECHNOLOGIESC orporationTechnology in Motion MODELSES52-7 BES56-7 BES066-7B7 SPEEDTRANSMISSIONS ervice ManualBulletin No. 2366 Revised August 2002 Tech Support 1-800-401-9866 TABLE OF CONTENTSSECTION I GENERAL 1 TORQUE SPECIFICATIONS .. 2 DRIVER INSTRUCTIONS .. 3 SECTION II MAINTENANCELUBRICATION .. 4 TOOL 5 SECTION III GENERAL 6 SECTION IV SHIFT TOWER 8 SECTION V REAR CASE DISASSEMBLYREAR CASE EXPLODED DRAWING .. 9 REAR CASE GEARS EXPLODED DRAWING .. 10 REAR CASE DISASSEMBLY .. 11 REAR CASE DISASSEMBLY (OPTI-RAIL) .. 16 SECTION VI MAIN CASE DISASSEMBLYMAIN CASE EXPLODED DRAWING .. 21 CLUTCH HOUSING & SHIFT FORKS EXPLODED DRAWING .. 22 MAIN CASE DISASSEMBLY .. 23 MAIN CASE DISASSEMBLY (OPTI-RAIL) .. 26 SECTION VII MAINSHAFT DISASSEMBLYMAINSHAFT EXPLODED DRAWING .. 29 MAINSHAFT 30 SECTION VIII COUNTERSHAFT DISASSEMBLY & 32 SECTION IX CLEANING & INSPECTION 33 SECTION X MAINSHAFT 34 SECTION XI MAIN CASE 36 MAIN CASE REASSEMBLY (OPTI-RAIL).

2 38 SECTION XII REAR CASE 41 REAR CASE REASSEMBLY (OPTI-RAIL) .. 45 SECTION XIII SHIFT TOWER 50 SECTION XIV 51 Tech Support 1-800-401-9866 GENERALINFORMATIONSECTION I1 Gear RatiosES52-7B ES066 -7 BES56-7 BGearRatioRatio% 69 61 45 41 34 35 Capacity .. ES52-7B - 520 lbs. ft. (704 nm) ES56-7B - 560 lbs. ft. (758 nm)ESO66-7B - 660 lbs. ft. (894 nm)Ratio Coverage .. 10 Gears 35 (clutch housing mounting face to washer seat face)Weight .. 454 lbs. (206 kg)Clutch SAE No. 2 Clutch .. 13 or 14 single or 2-plate push or pullInput Shaft .. 1 3/4 - 10-spline or 1 1/2 - 10-splineLube 22 pints ( liters) Provision for mechanical and electronicPower Take-Off .. 6-bolt right & left, countershaft rear34 tooth 18 right-hand pressure anglePTO Speeds: ..% of engine RPM ES52-7B , , , Application GuidelinesOn-Highway UseES56-7 BES52-7 BES066-7 BGVW:50,000 ,000 Range:155 - 210 HP185 - 250 HPRPM Range:1,800 - 3,000 Engine Types:5 - 9 Liter DieselSimple Shift PatternR24613N57 Tech Support 1-800-401-9866 GENERALINFORMATIONSECTION I2 TORQUE SPECIFICATIONS FOR NUTS AND CAP SCREWSNom.

3 Size (Dia.)Wrench Torque (ft. lbs.)Part trough (16 x .750) shift bar support(16 x ) mainshaft bearing cap(16 x ) linkage (16 x ) mainshaft bearing cap(16 x ) countershaft bearing cap(16 x ) housing to main case(16 x ) shift bar support(16 x ) mainshaft brake cap(14 x ) tower PTO aperture output mainshaft (spanner) light switch4040 Tech Support 1-800-401-9866 GENERALINFORMATIONSECTION I3 How to Shift the Spicer Easy-Shift7-Speed TransmissionsSynchronizer InformationThe purpose of a synchronizer is to simplify shifting and helpdeliver clash-free shifts. Only 1st and reverse gears aren shift, the driver depresses the clutch and moves the levertoward the desired gear. When the synchronizer ring makescontact with the desired gear, blockers automatically preventthe shift collar from completing the shift until the gear andmainshaft speeds are matched. When the speeds are matched,the synchronizer allows the shift to be completed pressure on the shift lever helps the synchronizer doits job.

4 When speeds are synchronized, the lever moves intogear smoothly and easily. If the driver jabs or teases thesynchronizer, the synchronizer can t do its job. It is possible tooverride a blocker if the lever is forced into gear. However, thisdefeats the purpose of the synchronizer and can shorten thelife of the InstructionsUpshiftingTo drive a vehicle containing this TRANSMISSION , first depressthe clutch and wait for complete release. Next, move the shiftlever into 1st gear and engage the clutch. Accelerate to anRPM that will allow enough momentum to select the nexthigher gear and still have vehicle acceleration after complet-ing the shift into 2nd gear. This is known as the progressive shifttechnique. Using this shift technique saves fuel. There is usuallyno reason to go all the way to the governor before you shift to1R23N45672nd gear. This method can vary depending on the GVW of thevehicle, road conditions, and type of 2nd gear is desired, declutch and move the shift levertoward that gear.

5 The synchronizer will pick up 2nd gear andsynchronize its speed to the mainshaft speed. When synchro-nized, the lever moves easily into 2nd in the same manner to top road speed. Notice that asyou approach top road speed you must accelerate close tothe governed speed before allowing the engine to drop to thenext gear shift point. This is because air resistance at higherspeeds requires more of the available horsepower to getadequate performance. Maximum performance and horse-power are achieved at governed begin downshifting form top gear, declutch and move theshift lever steadily toward 6th gear and speed it up to the vehiclespeed. This will allow a clash-free shift from 7th to 6th gear. Afterthe shift, reengage the clutch while accelerating the engine tokeep the vehicle moving at the desired speed. If furtherdownshifts are required, continue in a similar that 1st gear isn t synchronized. Therefore, shift-ing into gear will require a double clutch operation to completea clash-free not tow vehicles without first pulling the axlesor disconnecting the driveshaft.

6 If you tow thevehicle without doing this, you can damage drive traincomponents because the system lubrication is inad-equate when the vehicle is Support 1-800-401-98664 MAINTENANCESECTION IILubricationTo insure proper lubrication and operating tem-peratures in this unit, the proper lubricantsmust be used. Correct oil levels must be main-tained. TTC recommends using only lubricants produced byreputable, well-known suppliers. If you want to use a lubricantnot specified below, please contact your local truck dealer todetermine whether the lubricant is suitable for your LubricantsThe lubricants listed below are recommended for use in all Spicermechanical transmissions , auxiliaries, and transfer ChangesFor off highway use, TTC recommends that the oil be changedafter the first 24 hours of service, but before 100 hours of servicehave been factors influence the following oil change periods. There-fore, a definite mileage interval is not specified here.

7 In general,a drain and flush should be scheduled at 50,000 miles,or one-year intervals. If synthetic oil is used, a drain and flushshould be scheduled at 500,000 miles, or 5 year intervals. Off-highway uses usually require an oil change every 1,000 oil level in the TRANSMISSION should be checked every 5,000miles (8045 km) on-highway, or every 40 hours in off-highwayoperation. When it is necessary to add oil, TTC recommendsthat types and brands of oil not be mixed. The correct oil level inthis TRANSMISSION is established by the filler plug , remove all dirt around the filler plug. Then refill thetransmission with now oil. Use the grade recommended for theexisting season and prevailing service. The lubricant should belevel with the oil fill plug located on the right side of thetransmission not overfill the TRANSMISSION . This usually results in oilbreakdown due to excessive heat and aeration formthe churning action of the breakdown of the oil will result in heavy varnishand sludge deposits that plug up oil ports and build up on splinesand bearings.

8 !TEMPERATUREGRADETYPEA bove 0 F (-18 C)SAE 30 or 40 Heavy duty engine oil meeting MIL-L-2104 D orBelow 0 F (-18 C)SAE 30 MIL-L-46152 B, API-SF, or API-CD(MIL-L-2104 B & C, or 46152 are also acceptable)Above 0 F (-18 C)SAE 90 Straight mineral gear oilBelow 0 F (-18 C)SAE 80R & O type API-GL-1 AllCD SAE 50 Synthetic engine oil meetingCD SAE 30 MIL-L-2104 D or MIL-L-46152 B,API-SF or API-CDDo not use extreme pressure additive such as those found in multi-purpose or rear axle type lubricants. Theseadditives are not required for this unit and my, in some cases, create TRANSMISSION problems. Multi-purpose oils, as agroup, have relatively poor oxidation stability, a high rate of sludge formation, and a greater tendency to react on orcorrode the bronze parts in this Support 1-800-401-98665 MAINTENANCESECTION IITool ReferenceThis Spicer TRANSMISSION can be repaired with ordinarymechanic s tools. However, if your TRANSMISSION has a mainshaftintermediate nut rather than a snap ring, vehicle downtime canbe minimized with the use of this special socket.

9 It is availablethrough Sealed Power Corporation, part number OEM6599To order, contact:OTC DivisionSealed Power Sales655 Eisenhower DriveOwatonna, MN 55060 Phone: (800) 533-6127 Fax: (800) 283-8665 Tech Support 1-800-401-9866 GENERALDISASSEMBLYSECTION III6 Important ProcedureTo locate and correct unit power or auxiliary transmissiontroubles, a systematic procedure should be test whenever possible. Mechanics usually get second-or third-hand reports of trouble experienced with the unit. Thesereports do not always accurately describe the actualconditions. Sometimes symptoms seem to indicate trouble inthe TRANSMISSION , while actually the problem is with the axle,driveshaft, universal joints, engine or clutch. This is especiallytrue of noise complaints. Therefore, before removing thetransmission or related components to locate trouble, roadtest to check the possibility of trouble in other closely associ-ated units. Road testing is most effective when the mechanicdrives the vehicle.

10 However, riding with the driver can be FunctioningPrior to DisassemblyIf a remote control is used, a careful check of the remote andconnecting linkages (and their adjustment) must be made. Theremote unit must be in good working order if the transmis-sion is expected to shift times, the answer to the trouble is apparent when the unitis inspected prior to disassembly. But this evidence is often lostwhen the parts are separated. If possible, check theunit prior to disassembly. Bear in mind that a careful inspectionof the unit should be made as each disassembly step ThoroughlyDuring DisassemblyIt is poor practice to disassemble a unit or the completetransmission as quickly as possible without examining theparts. The mechanic may completely dissemble a unit and failto find the cause of the trouble, unless he examines the the TRANSMISSION is disassembled, check the lubricantfor foreign particles, This is a source of trouble often overlookedduring the or Replace Worn PartsMany times the parts or critical adjustments causing the troubleare not replace or corrected because the mechanic onlyinspects and replaced parts that have failed completely.