Fuller Mid-Range Transmissions TRSM0190

1 Service ManualFuller Mid-Range TransmissionsTRSM0190 October 2007FS-8206A WARNINGB efore starting a vehicle always beseated in the drivers seat, place thetransmission in neutral, set the park-ing brakes and disengage the working on a vehicle place thetransmission in neutral, set the park-ing brakes and block the towing the vehicle place thetransmission in neutral, and lift therear wheels off the ground or discon-nect the drive line to avoid damage tothe transmission during OF CONTENTSFOREWORDMODEL DESIGNATIONS AND FLOWTORQUE RECOMMENDATIONSPREVENTIVE MAINTENANCEPRECAUTIONSDISASSEMBLYINSPECT IONREASSEMBLYDISASSEMBLY AND REASSEMBLY SHIFTING CONTROLSGEARSHIFT LEVER HOUSING ASSEMBLYSHIFT BAR HOUSING ASSEMBLYREMOVAL OUTPUT YOKE AND clutch HOUSINGDISASSEMBLY TRANSMISSION REASSEMBLY TRANSMISSIONINSTALLATION clutch HOUSING AND OUTPUT YOKEINSTALLATION SHIFTING CONTROLSSHIFT BAR HOUSING ASSEMBLYGEARSHIFT LEVER HOUSING ASSEMBLYFOREWORDThis manual is designed to provide detailed informa-tion necessary to service and repair the Eaton Fuller Transmission listed on the outlined in the Table of

2 Contents, the manual isdivided into 3 main sections:a. Technical information and referenceb. Removal, disassembly, reassembly andinstallationc. OptionsThe format of the manual is designed to befollowed in its entirety if complete disassembly andreassembly of the transmission is necessary. But ifonly one component of the transmission needs to berepaired, refer to the Table of Contents for the pagenumbers showing that component. For example, ifyou need to work on the Shift Bar Housing, you willfind instructions for removal, disassembly and reas-sembly on page 18. Instructions for installation are onpage 62. Service Manuals, Illustrated Parts Lists,Drivers Instructions, and other forms of productservice information for these and other Fuller Trans-missions are available upon request.

3 A TechnicalLiterature Order Form may be found in the back of thismanual*.You may also obtain Service Bulletins,detailing information on product improvements, repairprocedures and other service-related subjects bywriting to the following address:EATON CORPORATIONTRANSMISSION DIVISIONT echnical Service Box 4013 Kalamazoo, Michigan 49003(61 6) 342-3344 MODEL DESIGNATIONSAND SPECIFICATIONSS pecifications:IMPORTANT:All Eaton Fuller Transmissions areidentified by model and serial number. This infor-mation is stamped on the transmission identifica-tion tag and affixed to the NOT REMOVE OR DESTROY THE TRANS-MISSION IDENTIFICATION SpeedNote 2 Note 3 Gear RatiosPTO Gear toWeightOil R PMLbsPintsModelSpeeds1 St2nd3rd4th5th6thReverseLeftRight(Kg.)

4 (Liters) ( )( )( )Note 1 LengthIn.(mm)See Chart measured from face of clutch housing to rear of speedo include shift bar housing and end yoke, clutch housing, less tower assembly and clutch releaseparts. For more information on available clutch housings, refer to the transmission s Illustrated Parts List orthe Super Parts Book. All weights are capacities are approximate, depending on inclination of engine and transmission. Always fill transmis-sion with proper grade and type of lubricant to level of filler opening. See LubricantsProperLubrication ..the Key to longtransmission lifeProper lubrication procedures are the key to a good all-around maintenance program, If the 011 ISnot doing itsjob, or if the oil levelISignored, all the maintenance pro-cedures in the world are not going to keep the transmis-sion running or assure long transmission Fuller Transmlsslons are designed so that theInternal parts operate in a bath of 011 circulated by themotion of gears and , all parts wIII be amply lubricated if these proce-dures are closely followed:1.

5 Maintain oil level. Inspect Change oil Use the correct grade and type of Buy from a reputable Change and Inspection Eaton Roadranger CD50 Transmission FluidHIGHWAY USE Heavy Duty and Mid-RangeFirst 3,000 to 5000 milesFactory fill(4827 to 8045 Km)Initial drain -Every 10,000 rnilesCheck fluid-level(16090 Km)Check for leaksHeavy Duty Highway Change IntervalEvery 250,000 milesChange transmission(402336 Km)fluidMid-Range Highway Change IntervalEvery 100,000 miles (160,000 Km)Change transmissionor every 3 years whichever occurs firstfluidOFF. HIGHWAY USEF irst30 hoursFactory fill initial drainEvery 40 hoursInspect fluid-level Checkfor leaksEvery 500 hoursChange transmission fluid wheresevere dirt conditions existEvery 1,000 hoursChange transmission fluid(Normal off-highway use)Heavy Duty Engine Lubricant orMineral Gear LubricantHIGHWAY USEF irst 3000 to 5000 milesFactory fill(4827 to 8045 Km)Initlal drainEvery 10000 milesInspect Iubricant level(16090 Km)Check for leaksEvery 50,000 milesChange transmission(80450 Km)

6 LubricantOFF-HIGHWAY USEF irst 30 hoursChangetransmission Iubricant on new unitsEvery 40 hoursInspect lubricant level Check for leaksEvery 500 hoursChange transmisslon Iubricant wheresevere dirt conditions existEvery 1000 hoursChange transmission Iubricant(Normal off-highway use)Fahrenheit(Celsius)GradeAmbientType( SAE)TemperatureThe use of mild EP gear oil ormulti-purpose gearoil is not recommended, but if these gear oils areused, be sure to adhere to the following limitations:Do not use mild EP gear oil or multi-purpose gearoil when operating temperatures are above 230 F(110 C). Many of these gear oils, particularly 85W140,break down above 230 F and coat seals, bearings andgears with deposits that may cause premature these deposits are observed (especially a coating onseal areas causing oil leakage), change to Eaton Roa-dranger CD50 transmission fluid, heavy duty engine oilor mineral gear oil to assure maximum component lifeand to maintain your warranty with Eaton.

7 (Also see Operating Temperatures . )Additives and friction modifiers are not recom-mended for use in Eaton Fuller Oil LevelMake sure oil is level with filler opening. Because youcan reach oil with your finger does not mean oil is atproper level,One inch of oil level is about one gallonof OilDrain transmission while oil is warm. To drain oil re-move the drain plug at bottom ofplug before case around filler plug andside of case, Fill transmission toopening. If transmission has twolevel of both Clean the drainremove plug fromthe level of the fillerfiller openings, fill toThe exact amount of oil will depend on the trans-mission inclination and model. Do not over fill thiswill cause oil to be forced out of the adding oil, types and brands of oil should notbe mixed because of possible the oil filter when fluid or lubricant is Temperatures With Eaton Roadranger CD50 Transmission FluidHeavy Duty Engine Oiland Mineral OilThe transmission should not be operated con-sistently at temperatures above 250 F (120 C).

8 However, intermittent operating temperaturesto 300 F (149 C) will not harm the transmis-sion. Operating temperatures above 250 Fincrease the lubricant s rate of oxidation andshorten its effective life. When the averageoperating temperature is above 250 F, thetransmission may require more frequent oilchanges or external following conditions in any combina-tion can cause operating temperatures of over250 F: (1) operating consistently at slowspeeds, (2) high ambient temperatures, (3) re-stricted air flow around transmission,(4)ex-haust system too close to transmission, (5)high horsepower, overdrive oil coolers are available to reduceoperating temperatures when the above condi-tions are Oil Coolers are:Recommended With engines of 350 and abovewith overdrive transmissionsRequired With engines 399 and above withoverdrive Transmissions and GCW Sover 90,000 lbs.

9 With engines 399 and above and1400 or greater torque With engines 450 and above With EP or Multipurpose Gear OilMild EP gear oil and multipurpose gear oil arenot recommended when lubricant operatingtemperatures are above 230 F (110 C). In addi-tion, transmission oil coolers are not recom-mended with these gear oils since the oilcooler materials may be attacked by thesegear oils. The lower temperature limit and oilcooler restriction with these gear oils gener-ally limit their success to milder Lubrication Levelsas Related to TransmissionInstallation AnglesIf the transmission operating angle is morethan 12 degrees, improper lubrication can oc-cur. The operating angle is the transmissionmounting angle in the chassis plus the per-cent of upgrade (expressed in degrees).

10 The chart below illustrates the safe percentof upgrade on which the transmission can beused with various chassis mounting example: if you have a 4 degree transmis-sion mounting angle, then 8 degrees (or 14percent of grade) is equal to the limit of 12degrees. If you have a 0 degree mountingangle, the transmission can be operated on a12 degree (21 percent) the transmission operating angle of12 degrees is exceeded for an extendedperiod of time the transmission should beequipped with an oil pump or cooler kit toinsure proper on the chart the effect low oil levelscan have on safe operating angles. Allowingthe oil level to fall 1/2 below the filler plughole reduces the degree of grade by approxi-mately 3 degrees ( percent).