Fuller Mid-Range Transmissions TRSM0110

1 Service ManualFuller Mid-Range TransmissionsTRSM0110 July 2011FS-5205 AFS-5205 BFS-5205 CFS-5306 AFS-5406 AFS-5406 NFS-6205 AFS-6205 BFS-6305 AFS-6305 BFS-6306 AFS-6406 AFS-6406 NFSB-5406 BFSO-4305 FSO-6406 AFSO-8406 AWarnings and PrecautionsBefore starting a vehicle always be seated in the driver s seat, place the transmission in neutral, set the parking brakes anddisengage the working on a vehicle place the transmission in neutral, set the parking brakes and block the towing the vehicle place the transmission in neutral, and lift the rear wheels off the ground, remove the axle shafts,or disconnect the driveline to avoid damage to the transmission during description and specifications contained in this service publication are current at the time of Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at anytime without reference to brand name in this publication is made as an example of the types of tools and materials recommended for useand should not be considered an endorsement.

2 Equivalents may be symbol is used throughout this manual to call attention to procedures where carelessness or failure to followspecific instructions may result in personal injury and/or component from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardizethe personal safety of the service technician or vehicle : Failure to follow indicated procedures creates a high risk of personal injury to the servicing : Failure to follow indicated procedures may cause component damage or : Additional service information not covered in the service : Helpful removal and installation procedures to aid in the service of this use genuine Eaton replacement of ContentsIntroductionPurpose and Scope of Manual .. 1 How to use this 1 Disassemble Precautions.

3 1 Inspection 2 Assembly 3 Model InformationSerial Tag Information and Model Nomenclature .. 5 Model Number .. 6 Serial Number .. 6 Bill of Material or Customer 6 SpecificationsTorque Ratings .. 7 Lubrication InformationLubrication .. 9 Maintain Proper Oil Level .. 9 Maintenance Interval Chart .. 10 Required Lubricant Chart .. 11 Transmission Operating 11 Tool InformationRecommended Tools .. 13 Special Tools Manufacturers .. 13 Preventive MaintenancePreventive Maintenance .. 15 Checks Before Transmission Removal .. 15 Checks With Drive Line 16 Checks With Universal Joint Companion Flange or Yoke Removed .. 16 Inspection .. 17 Rear Seal 17 Power FlowPower Flow .. 19In-Vehicle Service ProceduresShift Bar HousingHow to Remove the Gear Shift Lever .. 23 How to Install the Gear Shift Lever.

4 24 How to Remove the Shift Bar Housing .. 25 How to Install the Shift Bar Housing .. 26 Output YokeHow to Remove the Output Yoke/Companion Flange ..27 How to Install the Output Yoke/Companion Flange ..28 Clutch HousingHow to Remove the Clutch Housing ..29 How to Install the Clutch Housing ..30 Transmission Overhaul Procedures-Bench ServiceShift Bar HousingFunctions of a Shift Bar Housing ..31 How to Disassemble the Gear Shift Lever ..32 How to Assemble the Gear Shift Lever ..33 How to Disassemble the FS-4205 Shift Bar Housing ..34 How to Assemble the FS-4205 Shift Bar Housing ..35 How to Disassemble the FS-5205 Shift Bar Housing ..37 How to Assemble the FS-5205 Shift Bar Housing ..39 How to Disassemble the FS-6205/6305 Shift Bar Housing ..41 How to Assemble the FS-6205/6305 Shift Bar Housing.

5 42 How to Disassemble the FS-5306/6306/5406/6406 Shift Bar Housing ..44 How to Assemble the FS-5306/6306/5406/6406 Shift Bar Housing ..46 How to Disassemble the FSO-6406/8406 Shift Bar Housing ..48 How to Assemble the FSO-6406/8406 Shift Bar Housing ..50 How to Disassemble the Reverse Plunger on FS-4X05/5X05 ..52 How to Assemble the Reverse Plunger on FS-4X05/5X05 ..53 How to Disassemble the Reverse Plunger For All Models Except FS-4205/5205 ..54 How to Assemble the Reverse Plunger For All Models Except FS-4205/5205 ..55 Table of ContentsDisassemble Main SectionHow to Remove the Input Shaft Assembly .. 57 How to Remove the Mainshaft Assembly .. 58 How to Remove the Countershaft Assembly .. 59 How to Remove the Reverse Idler Gear Assembly For All Models Except FS-5306/6306 .. 60 How to Remove the FS-5306/6306 Reverse Idler Gear Assembly.

6 61 Mainshaft AssemblyHow to Disassemble the FS-4205 Mainshaft Assembly .. 63 How to Assemble the FS-4205 Mainshaft Assembly .. 65 How to Disassemble the FS-5205 Mainshaft Assembly .. 67 How to Assemble the FS-5205 Mainshaft Assembly .. 69 How to Disassemble the FS-6205 Mainshaft Assembly .. 71 How to Assemble the FS-6205 Mainshaft Assembly .. 73 How to Disassemble the FS-6305 Mainshaft Assembly .. 75 How to Assemble the FS-6305 Mainshaft Assembly .. 77 How to Disassemble the FS-5306/6306 Mainshaft Assembly .. 79 How to Assemble the FS-5306/6306 Mainshaft Assembly .. 81 How to Disassemble the FS-5406/6406 and FSO-6406 Mainshaft Assembly .. 84 How to Assemble the FS-5406/6406 and FSO-6406 Mainshaft Assembly .. 86 How to Disassemble the FSO-8406 Mainshaft Assembly .. 89 How to Assemble the FSO-8406 Mainshaft Assembly.

7 91 Countershaft AssemblyHow to Disassemble the FS-4X05 Countershaft Assembly .. 95 How to Assemble the FS-4X05 Countershaft Assembly .. 97 How to Disassemble the FS-5X05 Countershaft Assembly .. 99 How to Assemble the FS-5X05 Countershaft Assembly .. 100 How to Disassemble the FS-6X05 Countershaft Assembly .. 101 How to Assemble the FS-6X05 Countershaft Assembly .. 103 How to Disassemble the FS-5306/6306/5406/6406 and FSO-6406/8406 Countershaft Assembly ..105 How to Assemble the FS-5306/6306/5406/6406 and FSO-6406/8406 Countershaft Assembly ..107 Disassemble Main SectionHow to Install the Reverse Idler Gear Assembly For All Models Except FS-5306/6306 ..109 How to Install the FS-5306/6306 Reverse Idler Gear Assembly ..110 How to Install the Countershaft Assembly ..111 How to Install the Mainshaft Assembly.

8 113 How to Install the Input Shaft Assembly ..115 Setting End Play Procedure For All Models Except FS-5205 ..117 Setting End Play Procedure For FS-5205 ..1191 IntroductionIntroductionPurpose and Scope of ManualThis manual is designed to provide detailed information nec-essary to service and repair the Eaton Fuller transmis-sions listed on the to use this ManualThe service procedures have been divided into two sections: In-Vehicle Service Procedures and Transmission Overhaul Procedures Bench Service. In-Vehicle Service Procedures contain procedures that can be performed while the transmis-sion is still installed in the vehicle. Transmission Overhaul Procedures contain procedures that are performed after the transmission has been removed from the procedure sections are laid out with a general heading at the top outside edge of each page followed by more specific headings and the procedures.

9 To find the information you need in these sections, first go to the section that contains the procedure you need. Then look at the heading at the top and outside edge of each page until you find the one that contains the procedure you Overhaul Procedures follow the general steps for complete disassembly and then assembly of the : In some instances the transmission appearance may be different from the illustrations, but the procedure is the PrecautionsIt is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission, the neces-sary linkage and vehicle air lines disconnected and the trans-mission has been removed from vehicle chassis. Removal of the gear shift lever housing assembly (or remote control assembly) is included in the detailed instructions (How to Remove the Gear Shift Lever).

10 This assembly MUST be detached from the shift bar housing before the transmission can be closely each procedure in the detailed instructions, make use of the text, illustrations, and photographs disassembling the various assemblies, such as the mainshaft, countershafts, and shift bar housing, lay all parts on a clean bench in the same sequence as removed. This pro-cedure will simplify assembly and reduce the possibility of losing wash and lubricate all usable bearings as removed and protectively wrap until ready for use. Remove bearings planned to be reused with pullers designed for this a clean place to work. It is important that no dirt or foreign material enters the unit during repairs. Dirt is an abra-sive and can damage bearings. It is always a good practice to clean the outside of the unit before starting the planned ShaftThe input shaft can be removed from the transmission with-out removing the countershafts, or mainshaft.