Service Manual - FS 6306A (TA-Y00-400000, TA-Y00-400003) 10 October 2008 1 WARNING 2 Introduction Purpose and Scope of Manual This manual is designed to provide detailed information necessary to service and repair the Eaton ® Fuller ® transmission FS 6306. 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 differ from the illustrations. The procedure is the same. 3 Model Designation Transmission model designation and other transmission identification information are stamped on the transmission tag. To identify the transmission model designation and serial number, locate the tag on the transmission and then locate the numbers as shown below Do not remove or destroy the transmission identification tag. Transmission Tag and Location Model Number The model number gives basic information about the transmission and is explained below. Use this number when calling for service assistance or replacement parts. Serial Number The serial number is the sequential identification number of the transmission. Before calling for service assistance, write the number down. It may be needed. Bill of Material or Customer Number This number is also referred to as the “TA#” and is located below the model and serial numbers. It is a reference number used by Eaton ® and is helpful if calling for technical support. When calling for service assistance or parts, have the model, serial number and handy TA #. 4 Torque Ratings Correct torque application is extremely important to assure long transmission life and dependable performance. Over-tightening or under-tightening can result in a loose installation and, in many instances, eventually cause damage to transmission gears, shafts or bearings. Use of a thread sealer/locking compound is recommended for all cap screws. Do not torque cap screws dry. Torque Chart Description 6 Front Bearing Cover cap screws 4 Remote Control Assy cap screws 9 Shift Rail Retainer cap screws 17 Shift Bar Housing cap screws 1 Output Shaft nut 4 Clutch Housing nuts 2 Hand Hole Cover cap screws 4 Mainshaft Rear Bearing Cover cap screws 1 Oil Fill Plug 1 Oil Drain Plug 4 Countershaft Rear Bearing Cover cap screws 12 PTO Cover cap screws Torque 21-27 Nm 28-33 Nm 28-33 Nm 48-54 Nm 645-711 Nm 149-181 Nm 7-10 Nm 82-88 Nm 34-47 Nm 62-67 Nm 48-54 Nm 14-27 Nm Thread Size 5/16-18 3/8-16 3/8-16 3/8-16 1 ¼ -18 5/8-16 1 ¼ -12 1 ¼ -32 ¾” Pipe ¾” Pipe 3/8”-16 3/8”-16 Comments Apply Loctite 262 to threads Apply Loctite 262 to threads Apply Loctite 262 to threads Apply Loctite 262 to threads With nylon locking insert. Oiled at vehicle installation. Apply Loctite 262 to threads Apply Loctite 262 to threads Apply Loctite 262 to threads Use plain flat washers. Apply Loctite 262 to threads Apply Loctite 262 to threads 5 soft bars. illustrations. and mauls for all disassembly work is recommended. with restraint. Bearings Carefully wash and lubricate all usable bearings as removed and protectively wrap until ready for use. This assembly MUST be detached from the shift bar housing before transmission can be removed. Follow closely each procedure in the detailed instructions. This procedure will simplify assembly and reduce the possibility of losing parts. Assemblies When disassembling the various assemblies. Movement of some parts is restricted. make use of the text. Dirt is an abrasive and can damage bearings. Cleanliness Provide a clean place to work. Never apply force to driven parts after they stop solidly. Snap Rings Remove snap rings with pliers designed for this purpose. 6 . Input Shaft The input shaft can be removed from the transmission without removing the countershaft or mainshaft. housings. and photographs provided. The use of soft hammers. Remove bearings planned to be reused with pullers designed for this purpose. Snap rings removed in this manner can be reused.Disassemble Precautions It is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission. if they are not sprung or loose. such as the mainshaft. countershafts. It is always good practice to clean the outside of the unit before starting the planned disassembly. and shift bar housing. the necessary linkage disconnected and the transmission has been removed from vehicle chassis.. When Using Tools to Move Parts Always apply force to shafts. etc. lay all parts on a clean bench in the same sequence as removed. It is important that no dirt or foreign material enters the unit during repairs. Removal of the remote control assembly is included in the detailed instructions (How to remove the Remote Control Housing). rollers. Gears A. Bearing Covers A. Frosting of gear teeth faces presents no threat of transmission failure. Replace yokes worn at cam surfaces and bearing carrier worn at contact pads. Check bearing fit. or damaged during disassembly. Clutch Release Parts A. frosted gears “heal” and do not progress to the pitting stage. Check gear teeth for pitting. check gear snap ring. mileage. check each part carefully for abnormal or excessive wear and damage to determine reuse or replacement. Bearing inner races should be tight to shaft. Bearings A. B. C. Check balls. gears with light to moderate pitted teeth have considerable gear life remaining and can be reused. Wash all bearings in clean solvent. B. 7 . Replace gears found in any of these conditions. B. or reduced in length from clashing during shifting. discoloured. B. split washer. To aid in determining the reuse or replacement of any transmission part. Check for gears with clutching teeth abnormally worn. Replace covers damaged from thrust of bearing outer race. case should be replaced.Inspection Precautions Before assembling the transmission. but gears in the advanced stage of pitting should be replaced. and spalled areas. Replace those worn or oversized. Replace bearings that are pitted. or spalled and check for axial and radial clearances (per manufacturer’s specifications). etc. Check covers for wear from thrust of adjacent bearing. consideration should also be given to the unit’s history. When replacement is necessary. Replace bearings with excessive clearances. Recommended inspection procedures are provided in the following checklist. In most cases. Lubricate bearings that are not pitted. Check pedal shafts. and gear hub for excessive wear. discoloration. application. Avoid reusing a questionable part which could lead to additional repairs and expense soon after assembly. Often in continued operation of the unit. clutch hub. Where excessive clearance is found. Check clutch release parts. discoloured. and raceways for pitting. If bearing spins freely in bore. C. Check cover bores for wear. tapered. Check axial clearance of gears. Replace those worn at bushing surfaces. use only genuine Eaton ® Fuller ® Transmission parts to assure continued performance and extended life from your unit. outer races slightly tight to slightly loose in case bore. D. spalled. Replace parts found to be damaged. Check blocker pins and pre-energiser springs for excessive wear or looseness. Replace if worn. Check oil return threads on the input shaft. companion flange. Replace shift bar housing if lock screw holes are damaged. Replace sprung yokes. Check engaging teeth of sliding clutches for partial engagement pattern. Check yokes for correct alignment. Check all shift yokes and yoke slots in sliding clutches for extreme wear or discoloration from heat. B. replace the input shaft. If sealing action of lip has been destroyed. Check lock screws in yoke assembly retainer plates. O-Rings A. Check synchroniser for burrs. If return action of threads has been destroyed. or clutch hub have worn marks in the spline sides. Reverse Idler Gear Assemblies A. Check oil seals in input shaft and rear bearing cover. Check detent ball holes for wear. replace oil seal. replace the specific shaft affected. covers) for cracks and breaks. gears.Grey Iron Parts A. Tighten those found loose. Splines A. C. C. B. B. Sliding Clutches A. If sliding clutches. uneven and excessive wear at contact surface. Check splines on all shafts for abnormal wear. Check for wear on shift yokes and finger assembly at pads and lever slot. Check for excessive wear from action of roller bearings. Check all O-rings for cracks or distortion. and metal particles. B. 8 . Shift Bar Housing Assembly A. Synchroniser Assembly A. Replace excessively worn parts. D. Check synchroniser contact surfaces on the synchroniser cups for wear. Check all grey iron parts (case. Oil Return Threads and Seals A. Replace if bores are oblong. using (645 . Washers scored or reduced in thickness should be replaced. during assembly. Dirt is an abrasive and can damage polished surfaces of bearings and washers. IMPORTANT: See the appropriate Illustrated Parts Lists (specified by model series) to ensure that proper parts are used during assembly of the transmission. as listed below. use Eaton/Fuller sealant Loctite 262 on all cap screws. and bearings with transmission lubricant during assembly to prevent damage during initial start-up. preventing damage to balls/rollers while maintaining correct bearing alignment with shaft.Washers A. 9 . Capscrews To prevent oil leakage and loosening. Make sure all gaskets are installed. Assembly Precautions Make sure that case interiors and housings are clean. Use certain precautions.711 Nm) of torque. Initial Lubrication Coat all thrust washers. if not precoated. synchronisers. Gaskets Use new gaskets throughout the transmission as it is being rebuilt. Shims Apply a light coat of Eaton/Fuller sealant Loctite 518 or 515 to both sides of shims. It is important that dirt and other foreign materials are kept out of the transmission during assembly. Failure to properly torque the nut can result in damage to the mainshaft rear bearing. Make sure the speedometer drive gear or a replacement spacer of the same width has been installed. Check surfaces of all washers. Universal Joint Companion Flange Pull the companion flange or yoke tightly into place with the output shaft nut. An omission of any gasket can result in oil leakage or misalignment of bearing covers. Bearings Use a sleeve type bearing driver for bearing installation. O-Rings Lubricate all O-rings with silicone lubricant. These special drivers contact the inner bearing race. Power Flow 10 . The exact amount of oil depends on the transmission inclination. 11 . Make sure that the oil is level with the filler opening. the propeller shaft between the axle and transmission must be disconnected.Lubrication Information Proper Oil Level Before checking the oil level or refilling. To drain oil remove the drain plug at the bottom if case. Fill transmission to the level of the filler opening. Towing When towing the vehicle. Refilling Clean area round filler plug. 1. Correct Draining Oil Drain transmission while oil is warn. Clean the drain plug before re-installing. fill to the level of the filler opening. Being able to reach oil with your finger does not mean oil is at proper level. Incorrect 2. vehicle should be on level ground. Do not overfill — this causes oil to be forced out of the case past the mainshaft and input shaft seals. In every instance. Adding Oil It is recommended that different types and brands of oil are not intermixed because of possible incompatibility. p. 12 . Exhaust system too close to transmission 6.) 2. High engine RPM 3. Operating consistently at road speeds under 32 km/h (20m. over-drive operation 7. High power PTO operation for extensive periods while stationary High operating temperatures may require more frequent oil change. Operating temperatures above 120° (250° cause breakdown of the oil and C F) shorten transmission life. The following conditions in any combination can cause operating temperatures of over 120° (250° C F): 1. Restricted air flow around transmission 5.h. High horsepower. High ambient temperature 4.Operating Temperature It is important that the transmission operating temperature does not exceed 120° (250° for an C F) extended period of time. Transmission Operating Angles If the transmission operating angle is more than 12 degrees. Required Lubricant Type Grade (SAE) Mineral Oil 80W 90 GL-4 Additives and friction modifiers must not be introduced.Maintenance Interval Chart HIGHWAY USE First 3. Check for leaks.2 lit 13 .000 Kms Every 20000 Kms 60. Buy from a reputable dealer. The operating angle is the transmission mounting angle in the chassis plus the percent of upgrade (expressed in degrees). LUBE LEVELS Model FS-6306 Fill Limit 9. improper lubrication will occur. The use of lubricants not meeting these requirements will affect warranty coverage. Change transmission lubricant. Never mix engine oils & gear oils in the same transmission.000 Kms or Once a year Initial oil drain and Fill Inspect lubricant level. No.use with 08 20 ST 6306 20 Universal Dolley 10 ST 6306 06 Mainshaft front bearing cup installer 21 ST 6306 13 Countershaft front & rear bearing cup extractor 11 ST 6306 09 Mainshaft rear bearing cup installer 14 .use with 09 19 ST 6306 17 Mainshaft rear cover seal installer 9 ST 6306 15 Extractor Reverse Idler Shaft . No. Description 1 ST 6306 18 Universal Extractor 12 ST 6306 01 FBC seal installer (only for FBC with tube) 2 ST 6306 08 Mainshaft rear bearing cone installer 13 ST 6306 10 Countershaft front bearing cone extractor 3 ST 6306 21 Extractor bridge & threaded spindle 14 ST 6306 02 FBC seal installer (only for FBC without tube) AND Maninshaft front bearing cone installer 4 ST 6306 04 Inputshaft bearing cone installer 15 ST 6306 07 Mainshaft rear bearing cone extractor 5 ST 6306 03 Inputshaft bearing cone extractor 16 ST 6306 05 Mainshaft front bearing cone extractor 6 ST 6306 11 Countershaft rear bearing cone extractor 17 ST 6306 16 Mainshaft rear cover extractor 7 ST 6306 12 Countershaft rear bearing cone installer 18 ST 6306 19 Support FBC bearing cup extractor .Recommended Tools Sr. Illustration Application Tool No. Illustration Application Tool No.use with 01 8 ST 6306 14 Extractor Reverse Idler Shaft . Description Sr. Taking a few minutes every so many hours or miles to do a few simple checks could help avoid eventual breakdown or reduce the repair cost. They lack a proper and organised preventive maintenance program. Preventive maintenance is a general term which applies to all procedures necessary to have maximum life and satisfactory service at the lowest possible cost. A number of conditions contrary to good preventive maintenance can generally be pointed to when inspecting a failed transmission. Clutch Housing Mounting (1) • Check all cap screws of clutch housing flange for looseness. short of removing and repairing the unit. Transmission appearance may differ. 15 .Preventive Maintenance Everyday there are countless vehicles operating over the highways with transmissions in such a neglected mechanical condition. it will breakdown. they can be referred to as failures looking for a place to break down. If the transmission is not cared for. however the procedure is the same. Checks before Transmission Removal NOTE: Transmission appearance may differ. the procedure is the same. See Original Truck Builder literature.Clutch Pedal Shaft and Bores (3) • • Pry upward on shafts to check wear. • Filler and Drain Plugs (5) • Remove filler plugs and check level of lubricant at specified intervals. Cap screws and Gaskets (6) • • Check all cap screws. remove clutch release mechanism and check bushings on bores and wear on shafts. See “Recommended Lubrication Chart”. Tighten fill and drain plugs securely. 16 . If excessive movement is found. • Use only the types and grades as recommended. especially those on PTO covers and rear bearing covers for looseness which would cause oil leakage. Check PTO opening and rear bearing covers for oil leakage due to faulty gasket. Lubricant (4) • Change at specified service intervals. Checks with Drive Line Dropped Universal Joint Companion Flange or Yoke Nut (9) • Check for tightness. use solvent and shop rag to clean sealing surface of companion flange or yoke. Checks with Universal Joint Companion Flange or Yoke Removed NOTE: If necessary. Tighten to recommended torque. 17 . or other abrasive materials that will mar surface finish. Mainshaft Rear Bearing Cover (12) • Check oil seal for wear. Do not use crocus cloth. emery paper. Output Shaft (Yoke Nut Tightened) • Pry upward against output shaft to check radial clearance in mainshaft rear bearing. Splines on Output Shaft (11) • Check for wear from movement and chucking action of the universal joint companion flange or yoke. Tighten PTO cap screws to 14 – 27 Nm Front Bearing Cover Check front bearing cover. 62 –74 Nm Torque the oil fill plug to 34 – 47 Nm Rear Seal Maintenance Leakage in transmission rear seals is perhaps the most common problem in truck transmissions. USE A CLEAN DRY CLOTH. then find the oil seal system was not causing the oil leakage. the rear seal. and the output yoke. to the cap screw threads. front Replace parts found to be damaged.67 Nm Should be an O-ring or gasket Replace the O-ring/gasket if between the mating speedometer damaged or missing. case. The problem is more than a nuisance because if not repaired. Using the following checklist. PTO Covers and Openings Check the cap screws for Apply Eaton Sealant Loctite 262 tightness. shift bar housing. Do not over nut for tightness. the most important way to reduce this problem continues to be through proper service and installation procedures. if not precoated. Torque speedometer sleeve to 47 .Inspection Part to Inspect What to Check For Speedometer Connections Speedometer cables should not be loose Action to be Done Applied hydraulic thread sealant 71208 to threads. Oil Fill Plug Check the oil drain plug and the oil fill plug for leakage. clean the rear bearing cover. There have been strides in reducing leakage through improved designs and the use of new seal materials. torque the output nut. Torque cap screws to 82 – 94 Nm Output Yoke Retaining Nut Check the output yoke retaining Torque the output yoke retaining nut to 645 . It can be very time consuming and expensive to replace a rear seal system. Check the cap screws for Tighten the cap screws to tightness. sleeve and the rear bearing cover.711 Nm. 21 . However. rear bearing cover. Before disassembling the rear seal system. Run the vehicle.33 Nm Torque the oil drain plug to Oil Drain Plug. Rear Bearing Cover Nuts Check retaining nuts for tightness. a leaking seal can lead to catastrophic transmission failure. Apply Eaton Sealant Loctite 262 to the cap screw threads. DO NOT USE A HIGH PRESSURE SPRAY WASHER TO CLEAN THE REAR SEAL SYSTEM. and clutch housing for cracks or breaks. inspect the transmission to insure proper identification of the leak path. 18 . then inspect these areas for oil leaks. Remove the gasket and clean all mounting surfaces of gasket material. Remove the gear shift lever housing. 4. lightly lever the gear shift lever housing. remove the four (4) retaining cap screws. From the remote control base. 19 . 2.Transmission Overhaul Procedures Remote Control Housing Disassembly Special Instructions 1. To break the gasket seal. 3. Install the retaining cap screws. 20 . 4. Fit the remote control finger into the shift block. 1. if not precoated. Apply Loctite 262 or equivalent to the retaining cap screws. tighten to 28 –33 Nm of torque. Final Check Make sure the cap screws are properly torqued. 3.Assembly Special Instructions Make sure the shift block and yoke notches are aligned in the neutral position. Make sure you can shift the transmission. 2. Position a new remote control gasket on the remote control mounting surface. The 1 ½” cap screws are used with the lifting eyes. Place the synchronisers in the neutral position (refer to picture). 1. From the shift bar housing rim. 1. Assembly Special Instructions There are two (2) lengths of cap screws. 21 . To break the gasket seal. 2. remove the retaining cap screws. Apply Loctite 518 or equivalent to shift bar housing gasket before assembly. 4. Remove the shift bar housing.Shift Bar Housing Disassembly Special Instructions There are two (2) lengths of cap screws. Shift transmission into neutral position. Note their location. jar the shift bar housing. Remove the gasket and clean all mounting surfaces of gasket material. Place the shift bars in the neutral position. 3. 2. The 1 ½” cap screws are used with the lifting eyes. 4. Position a new shift bar housing gasket on the shift bar housing mounting surface. As you install the shift bar housing. Apply Loctite 262 or equivalent to the cap screws. tighten to 48 .3. Final Check Make sure the cap screws are properly torqued. if not precoated. 6.54 Nm torque 7. Install the remaining cap screws. Install the centre rear retaining cap screw first and the centre front retaining cap screw second. 22 . tighten to 48 – 54 Nm of torque. 5. make sure the yokes fit onto the corresponding synchronisers. Special Tools A large breaker bar or air impact wrench 1. 3. Pull the output yoke or flange straight to the rear and off the output shaft. 2. Engage two (2) mainshaft synchronisers into two (2) mainshaft gears to lock the transmission. Use a breaker bar to hold the flange and remove the nut from the output shaft.Output Flange Disassembly Special Instructions You must remove the shift bar housing in order to lock the transmission. 23 . 711 Nm.Assembly Special Instructions You must remove the shift bar housing in order to lock the transmission. Final Check Make sure the output shaft nut is properly torqued. Slide the companion flange or yoke onto the output shaft. 24 . tighten to 645 . 4. Engage two (2) mainshaft synchronisers into two (2) mainshaft gears to lock the transmission. 1. Special Tools Torque wrench with 680 Nm capacity. 3. 2. Install the output shaft nut. Unlock the transmission. Install the speedometer drive gear rotor or replacement spacer on the output shaft inside the rear bearing cover. Assembly 1. Remove the four clutch housing retaining bolts from the case and clutch housing.Clutch Housing Disassembly Special Instructions Removal of the clutch housing is done in the horizontal position. 1. 25 . Install four retaining bolts and torque to the recommended torque. Position clutch housing on front of transmission. Jar clutch housing with a rubber mallet and pull the clutch housing from transmission case. 2. 2. they all provide the same functions: • • • • • Engage the transmission gearing. Actuates the back up lights. Prevents shifting into reverse without force. No matter what kind of shift bar housing your transmission has. How to disassemble the Gear Remote Control How to assemble the Gear Remote Control 26 . Actuates the neutral switches. Prevents the driver from shifting into 2 gears at the same time.Shift Bar Housing Functions of a Shift Bar Housing Shift bar housings are a very important part of the transmission. 2. lay the assembly on a flat surface. Remove cap screws and retainers. lay all parts on a clean bench in order of removal to facilitate assembly. With the housing rear to the right. 27 . 7. and springs. 5.Disassembly Special Instructions The shift bar housing must be removed from the transmission. Remove reverse yoke assembly and interlock pin. Remove 1st–2nd yoke assembly and interlock pin. In order to remove the front retaining cap screws. Remove 5th–6th yoke assembly. Remove 3rd–4th yoke assembly and interlock pin. Shift bars not being removed must be kept in the neutral position or the interlocking parts lock the bars. Start with reverse yoke assembly. 3. 6. When removing the interlock balls. 1. 4. detent balls. remove the interlock balls before removing detent balls and the springs. During disassembly. shift 5th–6th yoke assembly into 5th gear position (rearward). 3rd-4th position. remove worn pad from shift yoke. detent balls and springs in the following sequence. 10. 28 . Inspect the yoke pad bushings. C.8. The shift yoke retainer holes are not tapped on new shift bar housings. 1. If the pads are worn. Install (reverse) detent spring and ball. If the yokes are damaged. It may be necessary to support the yoke bars in position while installing the retainers. Position (3) balls in the reverse light switch bore. Install interlock balls. The cap screws that are used are “thread forming” and can be reused if the shift bar housing is replaced. and springs. Keep yoke bars in neutral while assembling. remove by driving the roll pin through the yoke and rail. Remove the interlock balls. Assembly Special Instructions Interlock balls. B. and springs can be used interchangeably. detent balls. Position (2) balls in adjacent cross bore. NOTE: Balls and springs can be used interchangeably. 9. Lubricate yoke bar grooves with grease before assembly. Lubricate yoke pads and inserts with oil before assembly. Repeat steps B and C for 1st-2nd position. Inspect the yokes. and only step B for 5th-6th position. detent balls. install new pad and bend tabs over yoke top and bottom. A. 9. 8. Position 1st-2nd yoke in housing assembly. 3. Install the cap screws in the middle and rear retainers. front retainer in rear set of holes. 4. 6. 7. Tighten all rail support cap screws to 27-34 Nm. Position 5th-6th shift block in housing assembly. 29 . Position retainers. Install the interlock pin in 1st-2nd yoke assembly. Position 3rd-4th yoke in housing assembly. Install the interlock pin in 3rd-4th yoke assembly. 5. Position reverse yoke in housing assembly as shown.2. 5. Replace worn or damaged parts. 3. 2. Tighten all rail support cap screws to 27-34 Nm.NOTE: It may be necessary to support rails in proper position while installing rail supports. 10. 4. 11. Install the cap screws in front retainer. Remove the reverse plunger springs. Remove snap ring and spring retainer. Reverse Plunger Disassembly Special Instructions Snap ring and retainer are under spring pressure. Remove washer and plunger. Depress reverse plunger springs and retainer. Final Check Make sure interlocking system is working — cannot shift into 2 gears at the same time. 30 . Carefully shift the 5th-6th yoke into 5thgear position (rearward). Inspect reverse plunger parts. ensuring particularly detent spring under 5/6 bar does not bend. 1. Final Check Make sure snap ring is securely in shift block groove. Special Tools Vice with brass jaws or wood blocks 1. 4. Install reverse plunger springs. 3. 2. Install plunger and washer.Assembly Special Instructions Place the reverse yoke bar in a vice. Depress the reverse plunger retainer and springs. Install the snap ring in the shift block groove. 31 . If necessary remove bearing cup from front bearing cover. Remove input shaft assembly from transmission. 2. Turn out six cap screws. 32 . 3.Input Shaft Disassembly 1. 4. If necessary remove bearing cone from Inputshaft. If necessary remove oil seal from cover. Use special tool ST 6306 18 with ST 6306 19. jar front bearing cover with a rubber mallet and remove. Using special tool ST 6306 03 with ST 6306 21. Turn out four retaining nuts and lock washers. 33 . 3. Use a hoist to remove the mainshaft assembly from the case. Remove the speedometer sleeve and driven gear. 2. NOTE: Shims may come off with rear bearing cover. remove rear bearing cover. 4.Main Shaft Disassembly Special Tools Slings and Hoist Rear cover extractor 1. If necessary remove oil seal from cover. Using special tool ST 6306 16. Wrap a sling around the 3rd-4th synchronizer assembly. Remove shims and speedometer drive gear or rotor. NOTE: Countershaft may slide to the rear and out of bearing bore. 34 . Use special tool ST 6306 13. remove countershaft rear bearing cover and shims. Remove the countershaft rear & front bearing cup. 2. 3.Countershaft Disassembly 1. Turn out cap screws. Move countershaft assembly to the rear and lift it from the case. bearings. 3. 35 . Remove the reverse idler assembly. Using the special tool ST 6306 14 and ST 6306 15. 2. remove reverse idler shaft. Remove the locating ball. and spacer.Reverse Idler Gear Disassembly Special Tools Reverse idler shaft extractor 1. 4. Remove the reverse idler gear. Mainshaft Assembly Disassembly Special Instructions During disassembly. lay all parts on a clean bench in order of removal to facilitate reassemble. Special Tools Vice with brass jaws or wood blocks Snap ring pliers Bearing extractor 36 . 7. Remove 5th-6th speed synchronizer and cups. 12. Remove 3rd-4th speed synchronizer and cups. 5. and locating ball. Remove 4th gear and bearings. install the mainshaft assembly vertically in a vice. 6. 2. Remove 5th gear and bearings.1. 4th Gear 9. 3. 1st–2nd Speed Synchroniser 14. 2nd Gear 13. 5th-6th Clutch Hub 4. and locating ball. thrust washer. Remove 5th-6th clutch hub 4. remove front bearing. With mainshaft front facing up. Remove 1st-2nd speed synchroniser. 5th-6th Speed Synchroniser and Cups 3. 3rd-4th Speed Synchroniser 10. Snap Ring 7. 5th Gear 5. Mainshaft 1. 3rd Gear 12. 9. 3rd-4th Clutch Hub 11. thrust washer. 10. Thrust Washer and Locating Ball 8. Remove 2nd gear and bearings. 8. Remove snap ring and 3rd-4th clutch hub. Front Bearing and Cups 2. Gear Bearing 6. Remove snap ring. 11. Remove 3rd gear and bearings. Remove snap ring. Using a special tool ST 6306 05 and ST 6306 21. 37 . 38 . 1st Gear 9. 17. Rear Bearing 2. remove rear bearing cone. Reverse Gear Clutch Hub 8. Sliding Clutch 6.3 1. 16. Remove 1st gear and bearings. Remove reverse gear bearing and sliding clutch. washer. Washer 3. install the mainshaft assembly vertically in a vice. With mainshaft rear facing up. 14. Using special tool ST 6306 07 and ST 6306 21. Snap Ring 7. 14. Gear Bearing 5. Reverse Gear 4. Using a puller mounted behind reverse gear. Remove snap ring and clutch hub. Main shaft 8 13. and rear bearing. 15. remove reverse gear. synchronizer friction surfaces.Assembly Special Instructions CAUTION: Do not heat the bearing above 275° (136° If possible. source. gear hub faces. Lubricate the gear bearing bores. synchronizer cups and the mainshaft with transmission lube as the mainshaft is assembled. WARNING: Wear safety glasses when installing snap rings. use a heat lamp as the F C). Special Tools Vice with brass jaws or wood blocks Bearing installer Snap ring pliers 39 . 1st Gear 9. Install 1st gear bearings. install sliding clutch. Main shaft 1. 9. 6. Reverse Gear 4. Sliding Clutch 6. Washer 3. 7. 40 . Install reverse gear bearing. install the mainshaft assembly vertically in a vice. With 1st gear clutching teeth down. Gear Bearing 5. install 1st gear. Rear Bearing 2. Install snap ring. Reverse Gear Clutch Hub 8. Use a special tool ST 6306 08 or heat lamp and install the rear mainshaft bearing. With reverse gear clutch hub notched teeth facing down. 4. With reverse gear sliding tapered clutching teeth facing up. With mainshaft rear facing up. install clutch hub. 5. 3.1. 8. Snap Ring 7. Install reverse gear washer. With reverse gear clutching teeth facing down. install reverse gear. 10. 2. Washer can be installed either way. Install the 1st-2nd synchronizer and cups. 16. 4th Gear 9. install 5th-6th clutch hub. Install 3rd-4th speed synchronizer and cups. 24. With 4th gear clutching teeth down. Washer can be installed either way. Front Bearing 2. Snap Ring 7. install 3rd gear. install 5th gear. install the mainshaft assembly vertically in a vice. Install 4th gear bearings. Install snap ring in mainshaft groove. Gear Bearing 2 6. install 3rd gear. 5th Gear 5.1. Install 5th gear bearings. Final Check Make sure the mainshaft gears rotate freely. 18. Install 2nd gear bearings. With mainshaft front facing up. With 2nd gear clutching teeth down. 3rd Gear 12. Install 5th-6th speed synchroniser and cups. 26. 41 . Install snap ring in mainshaft groove. 25. Mainshaft 11. 22. 14. 27. 12. 5th 6th Clutch Hub 4. 19. 15. 13. install 3rd-4th clutch hub. Install 3rd gear bearings. 5th-6th Speed Synchroniser and Cups 3. With 5th gear clutching teeth up. 3rd 4th Clutch Hub 11. Thrust Washer and Locking Ball 8. 29. Use a special tool ST 6306 02 and install the front mainshaft bearing on press. 17. 30. install 2nd gear. Install locating ball and washer in mainshaft groove. Install snap ring in mainshaft groove. 2nd Gear 13. With 3rd-4th clutch hub stepped face up. 3rd-4th Speed Synchroniser and Cups 10. 20. With 3rd gear clutching teeth up. 23. Install locating ball and washer. With 5th-6th clutch hub flat surface facing up. Washer can be installed either way. 21. 28. 1st-2nd Speed Synchroniser 14. Remove the drive gear retaining snap ring. remove the drive gear locating key and spacer. 5. remove the front bearing cone.Countershaft Assembly Disassembly Special Instructions As the individual countershaft gears are pressed from the shaft. Using special tool ST 6306 10 with ST6306 21. Use drive gear rear face as a base and press drive gear from the countershaft assembly. 4. 3. Special Tools Bearing extractor Snap ring pliers Press Vice with brass jaws or wood blocks 1. From the shaft. 42 . 2. Position countershaft in a vice with the front bearing up. make sure to remove the corresponding gear key. 6. Use 4th gear rear face as a base and press 4th gear from the countershaft assembly. 9. If damaged. From the shaft. remove the countershaft bearing. 7. 43 . Use 5th gear rear face as a base and press 5th gear from the countershaft assembly. 8. remove 5th gear locating key. Using special tool ST 6306 11 with ST 6306 21. 10. Use 3rd gear rear face as a base and press 3rd gear from the countershaft assembly. With 4th gear splined end hub to shaft rear. Press 5th gear into place. 44 . Special Tools Snap ring pliers Press Bearing cone installer 1. 2. With 5th gear long hub to shaft front. align 5th gear key-way with shaft key. position the gear and shaft in the press.Assembly Special Instructions CAUTION: Do not heat the bearing above 275° (136° If possible. position the gear and shaft in the press. 3. Press 3rd gear into place. 4. With 3rd gear splined end hub to shaft front. Install 5th and drive gear keys on the countershaft. use a heat lamp as the F C). WARNING: Wear safety glasses when installing snap rings. source. position the gear and shaft in the press. Press 4th gear into place. position the gear and shaft in the press. Using a special tool ST 6306 12 or heat lamp and install the rear countershaft bearing. Final Check Make sure all gears are pressed into place. With drive gear long hub to shaft rear.5. Using a sleeve type driver or heat lamp and install the front countershaft bearing. Press the drive gear into place. 6. 7. 45 . Make sure the countershaft bearings are installed. Install drive gear retaining snap ring in countershaft front groove. align drive gear key-way with shaft key. 8. 2. Insert the idler shaft into the case bore. 6. 1.How to Install the Reverse Idler Gear Assembly Special Instructions The reverse idler can be assembled in either the vertical or horizontal case position. install the bearings. 46 . Insert the spacer in the reverse idler gear. Lubricate the bearings and idler shaft with oil before assembly. Install the reverse idler assembly in housing. On either side of the reverse idler spacer. 8. Install the locating ball. Do not install the shaft all the way. 3. Use grease on the reverse idler thrust washers to hold in place. 4. Drive the shaft into position. 7. line up shaft notch with case notch. Final Check Make sure the idler gear rotates freely. Carefully lower countershaft into case. Position countershaft assembly into front bearing race. 5. Tighten cap screws to recommended torque. Install countershaft rear bearing cover and four cap screws. 2. 4. Install countershaft rear bearing race into case. Temporarily install new shims over countershaft rear bearing cup. 3. Turn transmission case on end. 6. 47 . Position dial indicator as shown. lift countershaft to measure end play. Rotate countershaft to seat bearings and races.How to Install the Countershaft Assembly 1. Add shims for less end play and remove shims for more end play. 48 .25 mm 7. NOTE: Once end plays is correct remove bearing cover and apply a light coat of Loctite 510 to face of bearing cover and both sides of shims. 8.End Play Model FS .6306 Countershaft End Play 0. Coat threads of cap screws with Loctite 262 and re-torque to 35 – 40 lb-ft.15-0. If fill plug and drain plugs were removed. coat threads of plugs with Loctite 262 and install to proper recommended torque setting. Special Tools Sling and hoist Flanged driver Dial indicator 1. 2. removed. 4. Carefully lower the mainshaft assembly into the case while guiding the output shaft through the rear case bore. 49 . apply a light coat of Eaton/ Fuller sealant Loctite # 71233 or equivalent to both sides of the shims. yoke and output shaft nut will be installed. Remove the sling and place synchroniser in neutral. and installed again. and cover before assembly. After end play is correct. Using a sling around the mainshaft. 3. When setting end play the rear bearing cover. Top of the rear bearing cover is marked for proper installation. Coat output shaft bearing cover oil seal outer diameter with Eaton / Fuller Sealant # 71217 or equivalent.How to Install the Mainshaft Assembly Special Instructions The countershaft must be installed first. Setting end play is done in the vertical position. Make sure the synchroniser cups on the mainshaft front end stay in position as the mainshaft is lowered into the case. Position the rear bearing cover over the housing. 10. 8. 6. If removed. Make sure the mainshaft rotates freely. 7. Final Check Make sure nuts are properly torqued. Install the retaining nuts and tighten to 82-88 Nm of torque. Using special tool ST 6306 09 with ST 6306 20. Make sure to set end play. 9. Make sure the output shaft rotates. If removed. refer to setting end play procedure. install the oil seal with flanged driver. Using special tool ST 6306 17 with ST 6306 20. install output shaft bearing race.5. Temporarily position shims on the rear bearing cover surface. 50 . Using the special tool ST 6306 4. 51 . 2. Using special tool ST 6306 06 with ST 63906 20. Coat the outer diameter of the front bearing cover oil seal with a light coat of Loctite 510. 4. 3. Using special tool ST 6306 01 with ST 63906 20.How to Install the Input Shaft Assembly Special Tools Bearing cone installer Flanged driver 1. Install the oil seal with a flanged driver. Install the input shaft by aligning the clutching teeth on the 5th-6th speed synchroniser and input shaft clutching teeth. Install a new input shaft bearing race in the front bearing cover. install the front tapered bearing on the input shaft. Install the front bearing cover and gasket. NOTE: The top of the front bearing cover is marked “TOP” for proper installation.5. Install the six cap screws and tighten to the recommended torque. align the cover and gasket with the six cap screws holes in the case. 6. Install the speedometer drive or rotor on the output shaft. 52 . Setting Mainshaft End Play Procedure Special Instructions Setting end play is done in vertical position. Place transmission in vertical position with front end down. apply a light coat of Eaton / Fuller # 71233 or equivalent to both sides of the shims. Special Tools: Dial indicator 1. Position the dial indicator on the output shaft end. and installed again. and cover before assembly. 5. After end play is correct. Temporarily install the flange and output shaft nut. Pry up on the output yoke / companion flange to measure the end play. yoke and output shaft nut will be installed. case. When setting end play the rear bearing cover. Tighten nut to 678 Nm 3. Rotate the output shaft six (6) times clockwise and six (6) times counter-clockwise to seat bearings and races. 3. removed. 4. End play must be set per chart. 53 . Remove output shaft nut. Final Check Make sure nuts are properly torqued. yoke and rear bearing cover. 8. Make sure the output shaft rotates. 54 . End play must be set per table 7. tighten to 82 – 88 Nm of torque.End Play Model FS-6306 A Mainshaft End Play 0. Position shims and rear bearing cover on case. add shims for more end play.15-0. Install the retaining nuts. Remove shims for less end play. Make sure end play is within specification. 9.25 mm 6. rear bearing cover top is marked for proper positioning. coat the shims.