Eaton Fuller HD FR FRO Transmission TRSM2400 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Eaton Fuller HD FR FRO Transmission TRSM2400 Service Manual – PDF DOWNLOAD
FR-11210B
FR-12210B
FR-13210B
FR-14210B
FR-15210B
FR-9210B
FRF-11210B
FRF-12210B
FRF-13210B
FRF-14210B
FRF-15210B
FRF-9210B
FRO-11210B
FRO-11210C
FRO-12210B
FRO-12210C
FRO-13210B
FRO-13210C
FRO-14210B
FRO-14210C
FRO-15210B
FRO-15210C
FRO-16210B
FRO-16210C
FRO-17210C
FRO-18210C
FROF-11210B
FROF-11210C
FROF-12210B
FROF-12210C
FROF-13210B
FROF-13210C
FROF-14210B
FROF-14210C
FROF-15210B
FROF-15210C
FROF-16210B
FROF-16210C
Purpose and Scope of Manual:
This Manual is designed to provide information necessary to service and repair the Eaton Fuller Transmissions listed on the front.
How to use this Manual :
- The 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 Transmission is still installed in the vehicle. Transmission Overhaul Procedures contain procedures that are performed after the Transmission has been removed from the vehicle.
- 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. 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 need. Transmission Overhaul Procedures follow the general steps for complete disassembly and then assembly of the Transmission. Note: In some instances the Transmission appearance may be different from the illustrations, but the procedure is the same.
TABLE OF CONTENTS:
Eaton Fuller HD FR FRO Transmission TRSM2400 Service Manual – PDF DOWNLOAD
Introduction
Purpose and Scope of Manual 1
How to use this Manual 1
Disassemble Precautions 1
Inspection Precautions 2
Assembly Precautions 4
Model Designations
Serial Tag Information and Model Nomenclature 5
Model Options 6
Lubrication
Transmission Lubrication 8
Oil Leak Inspection Process 9
Tools
Tool Specifications 10
General Tools 10
Special Tools Manufacturers 12
Eaton Aftermarket Parts 12
General Information
Torque Specifications 13
Power Flow Diagrams 15
Front Section Power Flow 16
Front Section Power Flow – Direct Gear 17
Front Section Power Flow – Reverse Gear 18
Auxiliary Section Power Flow – Low Range 19
Auxiliary Section Power Flow – High Range 20
FR/FRO-1X210 21
Air System Troubleshooting 25
Air System Symptom – Air leak from Module
Base (Exhaust) 26
Air System Symptom – No or Slow Range Shift
into High (Shift into Low Range is Good) 27
Air System Symptom – No or Slow Range Shift
into Low (Shift into High is Good) 30
Air System Symptom – Constant Air Leak from
Shift Knob 33
Air System Symptom – Range Shift While
Transmission is in Gear 34
Air System Symptom – Air Leak From Breather or
Case is Pressurized 35
General Troubleshooting Chart 36
Air System Overview 39
Air Module Part Nomenclature 41
Air Module Interlock 42
Air System Air Flow 45
Air Module Operation 48
Air System Nomenclature 51
Timing Procedures
Timing Procedures 53
In-Vehicle Service Procedures
How to Disassemble the Roadranger Valve 55
How to Assemble the Roadranger Valve 57
How to Remove Compression Type Fittings 58
How to Install Compression Type Fittings 59
How to Remove Push-To-Connect Type Fittings 60
How to Install Push-To-Connect Type Fittings 61
How to Remove a Roadranger Valve 62
How to Install a Roadranger Valve 63
How to Remove the Gear Shift Lever/
Remote Shift Control 64
How to Install the Gear Shift Lever/
Remote Shift Control 65
In-Vehicle Service ProceduresHow to Adjust
the Remote Shift Control (LRC Type) 66
How to Remove the Detent Spring 68
How to Install the Detent Spring 69
Neutral Switch Operation and Testing 70
How to Remove the Neutral Switch 71
How to Install the Neutral Switch 72
Reverse Switch Operation and Testing 73
How to Remove the Reverse Switch 74
How to Install the Reverse Switch 75
How to Install the Shift Bar Housing 76
How to Remove the Shift Bar Housing 77
How to Remove the Oil Seal Mechanical/
Magnetic Speedometer 78
How to Install the Oil Seal Mechanical/
Magnetic Speedometer 80
How to Remove the Auxiliary Section in Chassis 82
How to Install the Auxiliary Section in Chassis 84
How to Disassemble the Integral Oil Cooler 88
How to Assemble the Integral Oil Cooler 89
How to Remove the Air Module 90
How to Install the Air Module 92
Table of Contents
iii
Transmission Overhaul Procedures – Bench Service
How to Disassemble the Gear Shift Lever 93
How to Assemble the Gear Shift Lever 95
How to Remove the Shift Bar Housing 97
How to Install the Shift Bar Housing 98
How to Disassemble the Shift Bar Housing 99
How to Disassemble the Range Cylinder 102
How Assemble the Range Cylinder 103
How to Assemble the Shift Bar Housing 105
How to Remove the Input Shaft Assembly
(without Main Case disassembly) 109
How to Install the Input Shaft Assembly
(without Main Case disassembly) 111
How to Remove the Auxiliary Section 113
How to Disassemble the Auxiliary Section 115
How to Disassemble the Range Yoke 118
How to Disassemble the Output Shaft 119
How to Disassemble the Synchronizer Assembly 120
How to Assemble the Synchronizer Assembly 121
How to Remove the Clutch Housing 123
How to Assemble the Output Shaft 124
How to Assemble the Range Yoke 125
How to Disassemble the Auxiliary Countershaft 126
How to Remove the Auxiliary Countershaft
Bearing Races 127
How to Install the Auxiliary Countershaft
Bearing Races 128
How to Assemble the Auxiliary Countershaft 129
How to Remove the Auxiliary Drive Gear Assembly 130
How to Disassemble the Upper and Lower
Reverse Idler Gear Assembly 132
How to Remove the Countershaft Bearings and
Countershaft Assemblies 134
How to Remove the Mainshaft Assembly 136
How to Disassemble the Countershaft Assemblies 138
How to Remove the Input Shaft and Main
Drive Gear 140
How to Prepare the Main Case for Reassembly 142
How to Disassemble the Mainshaft Assembly 143
How to Assemble the Mainshaft Assembly 145
How to Install the Mainshaft Assembly 148
How to Assemble the Countershaft Assemblies 150
How to Assemble the Lower Reverse Idler
Gear Assembly 152
How to Install Countershaft Assemblies 154
How to Install the Lower Countershaft Bearings 155
How to Install the Input Shaft and Main Drive Gear 157
How to Install the Input Bearing Cover 159
How to Install the Upper Countershaft Bearings 160
How to Install the Upper Reverse Idler
Gear Assembly 162
How to Install the Auxiliary Drive Gear Assembly 164
How to Install the Clutch Housing 165
How to Remove the Oil Pump 166
How to Install the Oil Pump 167
How to Install the Oil Seal 168
How to Assemble the Auxiliary Section 169
How to Install the Auxiliary Section 173
Shim Procedure without a Shim Tool for
Tapered Bearings 175
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