Fuller Mid Range Transmissions TRSM4106

1 Service ManualFuller Mid Range TransmissionsTRSM4106 October 2007 Service Manual(4106 / 5206)Eaton 6-Speed Synchromesh TransmissionTruck Components Operations EuropePO Box 11 WorsleyManchester M28 5 GJEngland5/01 Section 1 General1/1 Letter and Model Designation1/2 Technical Data1/3 Lubrication1/4 Recommended Lubricants1/5 Torque Tightening Recommendations1/7 Disassembly Precautions and Inspection of Expendable Parts1/9 Reassembly Precautions1/10 Gear End Floats1/11 Special Tools1/14 Locally Made ToolsSection 2 General Discription2/1 Features2/2 Gear Change Pattern2/2 Power Flow DiagramsSection 3 Shifting Controls3/2 Remote Control - Exploded View3/3 Remote Control Disassembly3/4 Remote Control Reassembly3/7 Direct Control - Exploded View3/8 Direct Control Disassembly3/9 Direct Control ReassemblySection 4 Transmission

2 Overhaul4/2 Transmission Case - Exploded View4/3 Transmission Case Disassembly4/9 Layshaft Disassembly4/10 Layshaft Reassembly4/11 Synchroniser Flange Removal / Fitment4/12 Maninshaft Disassembly (New Type)4/13 Maninshaft Reassembly (New Type)4/17 Mainshaft Assembly - Exploded View (NewType)4/31 Mainshaft Disassembly (Old Type)4/32 Mainshaft Assembly - Exploded View (Old Type)4/35 Mainshaft Reassembly (Old Type)4/41 Selector Shaft Disassembly4/42 Selector Shaft Reassembly4/44 Transmission Case Reassembly5/01 Section 2 General5/011/1 GeneralModel DesignationExample: FSO-4106 AFSS tandard prefixOOverdrive4 Nominal torque in 00 lbs ft1 Series 106 number of forward gearsAStandard ratio setB, CAlternative ratio setsTransmission IdentificationAll Transmissions are fitted with an identification plate on the left hand side of the front case serial data specification transmission specification number is unique to each customer and gives precise details of the trans-mission design level.

3 This number must be quoted when ordering replacement are currently two design levels of the 4106 transmission. Each level is identified by the specifica-tion 0400Y 04100 The middle digit denotes the design DataModelsFS-4106A, FS-4106B, FS-5206A, FS(O)-5206B640 Nm650 Nm700 Nm700 Nm115 kg520 mm7,5 lit6,5 litSAE StandardLeft side (vertical installation), bottom right(horizontal installation): 2 SAE 6 bolt facingsplus extended layshaft for Eaton PTOR otation to Engineengine speed x0,226 Same0,2710,336engine speed x0,434 Opposite0,5190,6441) including output coupling, low remote control; less clutch housing2) front face of transmission case to rear face of output flange3) recommended backlash is from to (O)-4106 BFS(O) Input TorqueFS-4106 AFS-4106 BFS-5206 AFS(O)-5206 BWeight 1)Length 2)Oil capacityVerticalHorizontalClutch HousingPower Take-off OpeningsPTO Drive Gears 3)driven from the reverse idler gear at:FS-4106A, FS-5206 AFS-4106B, FS-5206 BFS-4106B, FS(O)-5206 Bdriven from layshaft front gear at:FS-4106A, FS-5206 AFS-4106B, FS-5206 BFS-4106B, FS(O)-5206B5/011/3 GeneralLubricationProper Oil LevelBefore checking the oil level or refilling, vehicle shouldbe on level sure that the oil is level with the filler OilDrain transmission while oil is warn.

4 To drain oil removethe drain plug at the bottom if case. Clean the drain plugbefore area round filler transmission to the level of the filler exact amount of oil depends on thetransmission inclination. In every instance, fill to thelevel of the filler opening. Do not overfill this causesoil to be forced out of the case past the mainshaft andinput shaft OilIt is recommended that different types and brands of oilare not intermixed because of possible TempratureIt is important that the transmission operating tempera-ture does not exceed 120 C (250 F) for an extendedperiod of time. Operating temperatures above 120 C(250 F) cause breakdown of the oil and shorten trans-mission following conditions in any combination can causeoperating temperatures of over 120 C (250 F) consistently at road speedsunder 32 km/h ( ) engine ambient air flow around system too close to horsepower, over-drive power PTO operation forextensive periods while stationaryHigh operating temperatures may require more frequentoil towing the vehicle, the propeller shaft between theaxle and transmission must be use recommended lubricants to ensure smooth UseFirst 5000 to 8000 km (3000 to5000 miles)Every 16000 km (10000 miles)*Every 80000 km (50000 miles)

5 +Off HighwayFirst 30 hoursEvery 40 hours *Every 500 hoursEvery 1000 hours +Change transmission oil on new unitsInspect oil level. Check for leaksChange transmission oilChange transmission oil on new unitsInspect oil level. Check for leaksChange transmission oil when severe dirt condi-tions existChange transmission oil (normal off- highway use)GeneralRecommended LubricantsModelsTemprature RangeGradeMild EP Gear Oilto SpecificationMIL-L-2105 orAPI-GL-4 Heavy Duty Engine Oilto SpecificationMIL-L-2104C orMIL-L-46152 orAPI-CD-26 C to 21 C-12 C to 37 C-26 C to 38 Cabove -12 Cabove -12 Cbelow -12 CSAE 80 WSAE 90 WSAE 80 W/90 SAE 50 SAE 40 SAE 30 Lubrication Change and InspectionRemove and clean oil strainer at each oil fitted with an oil cooler may additionally be fitted with a filter in the cooler line,Renew the filter at every oil change.

6 * Or 2 months, whichever occurs first.+ Or 12 months, whichever occurs NOT use oil additives, friction modifiers or synthetic Intervals5/011 Casing Halves15 Capscrews with Plain Nuts M10 Thread 51 to 58 Nm (38 to 43 lbs ft). With Plain Washers under Capscrews and Flange headed screws and Nuts M10 Thread 45 to 55 Casing Halves3 Capscrews M10 Thread 51 to 58 Nm (38 to 43 lbs ft). Plain Flange headed screws M10 Thread 30 to 40 Control Housing End Cover4 Capscrews M8 Thread 20 to 24 Nm (15 to 18 lbs ft). Spring Idler Gear Cover6 Capscrews M10 Thread - 35 to 39 Nm (25 to 29 lbs ft). ShaftLocknut M33 Thread 490 to 588 Nm (362 to 434 lbs ft). With Nylon Locking Control Housing4/6/8 Capscrews M10 Thread 35 to 39 Nm (25 to 29 lbs ft).

7 Plain Washers and Spring Selector fork Pivots2 Capscrews M8 Thread (with lockwashers) 20 to 24 Nm (15 to 18 lbs ft).GeneralTorque Tightening RecommedationsScrews and Housing12 Studs M12 Thread 59 Nm (43 lbs ft) minimum. Installed with Loctite Housing12 Nuts M12 Thread 69 to 78 Nm (51 to 58 lbs ft). With Plain Washers and Spring Housing12 Capscrews M12 Thread 69 to 78 Nm (51 to 58 lbs ft). With Plain Washers and Cover6 Capscrews M10 Thread 35 to 39 Nm (25 to 29 lbs ft). Block Tapered Lockscrew1 Lockscrew M10 Thread 35 to 39 Nm (25 to 29 lbs ft). Patchlock or Thread coated with Loctite Control Housing Detent Cover2 Capscrews M8 Thread 20 to 24 Nm (15 to 18 lbs ft). Drain Plug (Magnetic)M24 Thread 32 to 37 Nm (24 to 27 lbs ft).

8 Pinion AdaptorM22 Thread 20 to 27 Nm (15 to 20 lbs ft). Copper Housing4 Capscrews M10 Thread 35 to 39 Nm (25 to 29 lbs ft). Plain Washers and Spring Layshaft Rear Bearing Cover (Rear )4 Capscrews M12 Thread 69 to 78 Nm (51 to 58 lbs ft). Spring Reverse Lamp SwitchM16 Thread 16 to 22 Nm (12 to 17 lbs ft).GeneralTorque Tightening Recommedations (continued)Screws and Control Shaft Lever1 Capscrew and Nut M10 Thread 35 to 39 Nm (25 to 29 lbs ft). With Spring shaft Detent Cover2 Capscrews M8 Thread 20 to 24 Nm (15 to 18 lbs ft). Spring Filler PlugM24 Thread 32 to 37 Nm (24 to 27 lbs ft). Front Bearing Cover4 Capscrews M12 Thread 69 to 78 Nm (51 to 58 lbs ft). Spring Shaft Front Bearing Cover5 Capscrews M10 Thread 35 to 39 Nm (25 to 29 lbs ft).

9 Spring is assumed in the detailed disassembly instructionsthat the lubricant has been drained and the necessarylinkage and air lines (if fitted) have been removed fromthe of the gear shift remote control housingassembly is included in the detailed instructions; howev-er, this assembly may also be removed from the trans-mission before removing unit from each procedure closely in each section, makinguse of both the text and the Carefully wash and relubricate allbearings as removed and protectively wrap until readyfor use. Remove bearings with pullers designed for When disassembling the variousassemblies, such as the mainshaft, layshaft and remotecontrol housing, lay all parts on a clean bench in thesame sequence as removed.

10 This procedure will simpli-fy reassembly and reduce the possibility of losing pulling off synchroniser hubs follow the proce-dures detailed in Disassembly using a suitable puller ofadequate capacity. Failure to adhere to the recom-mended procedures may cause irreparable rings Remove snap rings with pliersdesigned for this purpose. New selective fit snap ringsmust be fitted as specified in Reassembly . Provide a clean place to is important that no dirt or foreign material enters theunit during repairs. The outside of the unit should becarefully cleaned before starting the disassembly. Dirt isabrasive and can damage Pressing Apply force to shafts, hous-ings etc. with restraint. Movement of some parts isrestricted. Do not apply force after the part being drivenstops solidly.