Servicio g3

Eaton Fuller Automated Transmissions
RTO-1X910X-AS3 RTO-1X910X-DM3 RTLO-1X913X-DM3 RTLO-1X918X-AS3 RTOM-1X910X-DM3 FX-X405X-DM3 FX-X406X-AW3 FX-X406X-DM3
Service Manual TRSM-0930 September 2005
For the most current information, visit the Roadranger web site at www.roadranger.com
Warnings & Cautions
Warnings & Cautions

WARNING
Follow the specified procedures in the indicated order to avoid personal injury Note: Additional relevant information not covered in the service procedure. Before starting a vehicle: Sit in the driver's seat Place shift lever in neutral Set the parking brake
Before working on a vehicle or leaving the cab with engine running: Place shift lever in neutral Set the parking brake Block the wheels
When parking the vehicle or leaving the cab: Place shift lever in neutral Set the parking brake
CAUTION
Follow the specified procedures in the indicated order to avoid equipment malfunction or damage. Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level. To avoid damage to the transmission during towing: Place shift lever in neutral Lift the drive wheels off of the ground or disconnect the driveline
Do not operate the vehicle if alternator lamp is lit or if gauges indicate low voltage.
Table of Contents
General Information
Transmission Overview ............................................... 1 How to use this Manual ............................................... 5 Serial Tag Information and Model Nomenclature ........ 6
Service Procedure
Lubricant Filter Removal (AW3 Models Only) ............. 8 Lubricant Filter Installation (AW3 Models Only) ........ 10 Gear Select Sensor Removal ..................................... 12 Gear Select Sensor Installation ................................. 14 Rail Select Sensor Removal ...................................... 16 Rail Select Sensor Installation ................................... 18 Input Shaft Speed Sensor Removal ........................... 20 Input Shaft Speed Sensor Installation ....................... 22 Main Shaft Speed Sensor Removal ........................... 25 Main Shaft Speed Sensor Installation ....................... 27 Output Shaft Speed Sensor Removal ........................ 29 Output Shaft Speed Sensor Installation ..................... 31 Splitter Valve Removal .............................................. 33 Splitter Valve Installation ........................................... 35 Range Valve Removal ............................................... 37 Range Valve Installation ............................................ 39 Air Filter/Regulator Removal ..................................... 41 Air Filter/Regulator Installation .................................. 43 Inertia Brake Removal ............................................... 45 Inertia Brake Installation ........................................... 48 Electric Shifter Removal ............................................ 51 Electric Shifter Installation ........................................ 53 Transmission Controller Removal ............................. 56 Transmission Controller Installation ......................... 59 Transmission Harness Removal ................................ 62 Transmission Harness Installation ............................ 64 Shift Control Removal ............................................... 66 Shift Control Installation ........................................... 68 Cobra Lever Removal ................................................ 70 Cobra Lever Installation ............................................ 72
Table of Contents
Appendix
Operation .................................................................. 74 Lubrication Specifications ......................................... 75 Inspection Procedures .............................................. 81 Basic Troubleshooting .............................................. 82 Air System Operation and Troubleshooting ............... 83 Tool Specifications .................................................... 84 Torque Specifications ................................................ 85 Torque Overview ....................................................... 88
General Information
Transmission Overview
Heavy Duty 13-Speed DM3 & 18-Speed AS3
Input Shaft Speed Sensor Electric Shifter
Gear Select Sensor
Main Shaft Speed Sensor
Rail Select Sensor
Range Valve Solenoid Splitter Valve Solenoid Air Filter Requlator
Output Shaft Speed Sensor
Transmission ECU
Transmission Harness
Inertia Brake (13-Speed DM3 Only)
General Information
Heavy Duty 10-Speed AS3 & DM3
Input Shaft Speed Sensor Electric Shifter
Gear Select Sensor
Main Shaft Speed Sensor Output Shaft Speed Sensor
Rail Select Sensor
General Information
Range Valve Solenoid Air Filter Regulator
Transmission ECU
Transmission Harness
Inertia Brake (10-Speed DM3 Only)
General Information
Medium Duty 6 & 5-Speed DM3
Electric Shifter
Gear Select Sensor
Rail Select Sensor
Output Shaft Speed Sensor
Input Shaft Speed Sensor Location Transmission Harness Transmission ECU
Inertia Brake
General Information
Medium Duty 6-Speed AW3
Electric Shifter Gear Select Sensor
Rail Select Sensor
General Information
Output Shaft Speed Sensor Input Shaft Speed Sensor Location
Transmission Harness Transmission ECU
Wetclutch Solenoid Connector
Oil Pan and Filters Inertia Brake
General Information
How to use this Manual

This publication is divided into three sections General Information, Service Repair Procedures and the Appendix. General Information This section contains the basic information like Transmission Overview, How to Use This Manual, and Serial Tag and Model Nomenclature. Service Repair Procedures A parts assembly view is included at the beginning of each procedure for disassembly, assembly, removal and installation. Below the parts assembly views is a numerical listing for each part with the component name. Appendix This section contains information like: Operation, Lubrication Specifications, Inspection (in base box manuals), Powerflow (in bas box manuals), Air System Operation and Troubleshooting (in base box manuals), Basic Troubleshooting (in base box manuals), Tool Specifications, Torque Specifications, and the Torque Overview. The service procedures in this manual are for transmission automation components only. To find the information you need, simply locate the procedure in the Table of Contents, turn to the page specified, and follow the procedure. If you are unsure of a components name, you can reference the Transmission Overview pages. To service the mechanical portion of the transmission system, refer to the specific transmission service manual.
General Information
Serial Tag Information and Model Nomenclature

Transmission model designation and other transmission identification information are stamped on the serial tag. To identify the transmission model and serial number, locate the tag on the transmission and then locate the numbers as shown. Figure 1-1 below shows the tag location for these transmissions.
When calling for service assistance or parts, have the model and serial numbers handy.
Do not remove or destroy the transmission identification tag!
Model Serial
RTLO-16913L-DM3
Made In
Eaton Fuller
R
General Information
Transmissions
Eaton Corporation Transmission Div. Kalamazoo, MI. 49003
Fig 1-1
General Information
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. Transmission Tag
6-Speed
Fuller Overdrive Torque x 100 Design Level
- AW3
Generation 3 Electronics AutoShift with WetClutch Gear Ratio Forward Speeds
6-Speed
D M 3
Generation 3 Electronics Automatic w/DM Autoclutch Gear Ratio Forward Speeds
5-Speed
D M 3
10-Speed
Roadranger Twin Countershaft Overdrive Torque x 100 Design Level
- 1 X
1 0
X -AS3
Generation 3 Electronics AutoShift Gear Ratio Forward Speeds
10-Speed
Roadranger Twin Countershaft Overdrive Torque x 100 Design Level
D M 3
13-Speed
Roadranger Twin Countershaft Low-Inertia Overdrive 1750 lb.ft. Torque in Top Two Gears Only
O M- 1 X 9
13 X-DM3
Gen 3 Electronics Automatic w/DM Autoclutch Gear Ratio Forward Speeds Design Level Torque x 100
18-Speed
Roadranger Twin Countershaft Low-Inertia Overdrive
R T L O- 1 X 9
18 X-AS 3
Gen 3 Electronics AutoShift Gear Ratio Forward Speeds Design Level Torque x 100
Serial Number The serial number is the sequential identification number of the transmission. Before calling for service assistance, write the number down as it may be needed. Bill of material or Customer number This number may be located below the model and serial numbers. It is a reference number used by Eaton.
Service Procedure
Lubricant Filter Removal (AW3 Models Only)

Special Instructions
None
Special Tools
Basic Hand Tools
1 2 3
4
Service Procedure
1. High Pressure Oil Filter (Large opening) 2. Low Pressure Oil Filter (Small opening) 3. Gasket 4. Oil Pan 5. Short Capscrew 6. Long Capscrew 7. Drain Plug
Service Procedure
WARNING
Fluid may be hot. 1. Remove the drain plug and drain the fluid from the WetClutch portion of the transmission.
4.
Using a 1/2 drive at the filter base, remove the two (2) WetClutch filters. Make sure filter seals are removed.
Note: The filters will contain fluid when they are removed.
2.
Using a 15mm socket, remove the oil pan mounting bolts. Record location of the long and short bolts.
3.
Remove the WetClutch oil pan and gasket.
Service Procedure
Lubricant Filter Installation (AW3 Models Only)

None
Special Tools
Basic Hand Tools
1 2 3
4
Service Procedure
1. High Pressure Oil Filter (Large opening) 2. Low Pressure Oil Filter (Small opening) 3. Gasket 4. Oil Pan 5. Short Capscrew 6. Long Capscrew 7. Drain Plug
10
Service Procedure
1.
Lubricate each filter seal ring with synthetic Dexron III prior to installation.
4.
Install a new gasket and the WetClutch oil pan.
Note: The High and Low pressure filters are non-interchangeable. Note: Clean filter seal mating surfaces on the transmission. Note: Clean and remove all old gasket material from the mating surfaces of the clutch housing and the oil pan.
CAUTION
Make sure to put the long and short bolts back in their proper location to avoid damaging the transmission. The short bolts are used in the back of the oil pan. 5. 2. Install the High-pressure filter with a 1/2 drive and tighten to 25-30 lbs. ft. (34-41 Nm). Using a 15mm socket, install the mounting bolts and tighten to 30-35 lbs. ft. (41-47 Nm) using a cross pattern.
3.
Install the Low-pressure filter by hand and turn until the seal touches. Then, tighten with a 1/2 drive 3/4 to 1 full turn.
6.
Install the oil pan drain plug and tighten to 34-48 lbs. ft. (46-64 Nm).
Note: Fill the WetClutch portion with the proper fluid (see page 75)
11
Service Procedure
Gear Select Sensor Removal

None
Special Tools
Basic Hand Tools
3 2
Service Procedure
1. Capscrew 2. Sensor 3. Gasket
12
Service Procedure
1.
Disconnect the Transmission Harness from the Gear Select Sensor.
CAUTION
Carefully allow the sensor to rotate (not snap) to a relaxed position, or the sensor can snap when the hex key mounting screws are removed. 2. Using a 5/32 hex key wrench, remove the two (2) sensor hex key mounting screws.
3.
Remove the Gear Select Sensor and gasket from the housing.
13
Service Procedure
Gear Select Sensor Installation

Torques given below are in lbs. in.
Special Tools
Basic Hand Tools
3 2
1
Service Procedure
14
Service Procedure
1.
Align the sensors tabs with the slots in the Electric Shifter rail. Then, insert the Gear Select Sensor, with gasket, into its mounting location.
Note: Install the sensor so the connector opening faces the front of the transmission.
CAUTION
Carefully hold the sensor in position while installing the hex key mounting screws, or the sensor can snap. 2. Using a 5/32" hex key wrench, install the hex key mounting screws and tighten to 21-27 lbs. in. (2.3-3.0 Nm).
3.
Reconnect the Transmission Harness to the Gear Select Sensor.
15
Service Procedure
Rail Select Sensor Removal

None
Special Tools
Basic Hand Tools
3 2
1
Service Procedure
16
Service Procedure
1.
Disconnect the Transmission Harness from the Rail Select Sensor.
CAUTION
Carefully allow the sensor to rotate to a relaxed position, or the sensor can snap when the hex key mounting screws are removed. 2. Using a 5/32 hex key wrench, remove the two (2) sensor hex key mounting screws.
3.
Remove the Rail Select Sensor and gasket from the housing.
17
Service Procedure
Rail Select Sensor Installation

Special Tools
Basic Hand Tools
3 2
1
Service Procedure
18
Service Procedure
1.
Align the sensors tabs with the slot in the Electric Shifter rail. Then, insert the Rail Select Sensor, with gasket, into its mounting location.
3.
Reconnect the Transmission Harness to the Rail Select Sensor.
Note: Install the sensor, so the connector opening faces the right side of the transmission. (As viewed from the rear of the transmission)
CAUTION
Carefully hold the sensor in position while installing the hex key mounting screws, or the sensor can snap. 2. Using a 5/32" hex key wrench, install the two (2) hex key mounting screws and tighten to 21-27 lbs. in. (2.3-3.0 Nm).
19
Service Procedure
Input Shaft Speed Sensor Removal

Input Shaft Speed Sensor location varies as follows: Medium Duty - Top of Inertia Brake Heavy Duty - Right front of Shift Bar Housing
Special Tools
Basic Hand Tools
2
Service Procedure
1. Capscrew 2. Sensor 3. O-ring
20
Service Procedure
Heavy Duty Procedure 1. Disconnect the Transmission Harness from the Input Shaft Speed Sensor.
Medium Duty Procedure 1. Disconnect the Transmission Harness from the Input Shaft Speed Sensor. Note: Drain the lubricant before removing the sensor.
2.
Using a 3/8" socket, remove the sensor retaining bolt. 2. Using a 3/8" wrench, remove the sensor retaining bolt.
3.
Remove the Input Shaft Speed Sensor, with o-ring, from the transmission housing.
3.
Remove the Input Shaft Speed Sensor, with o-ring, from the transmission housing.
21
Service Procedure
Input Shaft Speed Sensor Installation

Input Shaft Speed Sensor location varies as follows: Medium Duty - Top of Inertia Brake Heavy Duty - Right front of Shift Bar Housing.
Special Tools
Basic Hand Tools
2
Service Procedure
22
Service Procedure
Heavy Duty Procedure
Medium Duty Procedure
IMPORTANT
Clean the mounting surface on the housing and remove any burrs or sharp edges. Lubricate the o-ring with Eaton Fuller silicone #71214 or equivalent. 1. Using a smooth, twisting motion, fully insert the Input Shaft Speed Sensor in the transmission housing opening.
IMPORTANT
Clean the mounting surface on the housing and remove any burrs or sharp edges. Lubricate the o-ring with Eaton Fuller silicone #71214 or equivalent. 1. Using a smooth, twisting motion, fully insert the Input Shaft Speed Sensor in the Inertia Brake opening.
2.
Using a 3/8" socket, install the retaining bolt and tighten to 8-10 lbs. ft. (11-13 Nm).
2.
Using a 3/8" wrench, install the sensor retaining bolt and tighten to 8-10 lbs. ft. (11-13 Nm).
3.
Reconnect the Transmission Harness to the Input Shaft Speed Sensor.
23
Service Procedure
3.
Reconnect the Transmission Harness to the Input Shaft Speed Sensor.
Note: Fill the transmission with lubricant (see page 75).
Service Procedure
24
Service Procedure
Main Shaft Speed Sensor Removal

None
Special Tools
Basic Hand Tools
25
Service Procedure
1.
Disconnect the Transmission Harness from the Main Shaft Speed Sensor.
2.
Using a 3/8 socket, remove the sensor retaining bolt.
Service Procedure
3.
Remove the Main Shaft Speed Sensor, with o-ring, from the transmission housing.
26
Service Procedure
Main Shaft Speed Sensor Installation

None
Special Tools
Basic Hand Tools
27
Service Procedure
IMPORTANT
Clean the mounting surface on the housing and remove any burrs or sharp edges. Lubricate the o-ring with Eaton Fuller silicone #71214 or equivalent. 1. Using a smooth, twisting motion, fully insert the Main Shaft Speed Sensor in the transmission housing opening.
2.
Using a 3/8 socket, install the retaining bolt and tighten to 8-10 lbs. ft. (11-13 N m).
Service Procedure
3.
Reconnect the Transmission Harness to the Main Shaft Speed Sensor.
28
Service Procedure
Output Shaft Speed Sensor Removal

The Output Shaft Speed Sensor location may vary depending on OEM design specifications. The sensor will be located at the 10 oclock position for Heavy Duty and the 12 oclock for Medium Duty on the Output Shaft Housing.
Special Tools
Basic Hand Tools
29
Service Procedure
Heavy Duty 1. Disconnect the Transmission Harness from the Output Shaft Speed Sensor.
Medium Duty 1. Disconnect the Transmission Harness from the Output Shaft Speed Sensor.
2.
Using a 13mm socket, remove the sensor retaining bolt.
2.
Using a 3/8 socket, remove the sensor retaining bolt.
Service Procedure
3.
Remove the Output Shaft Speed Sensor, with o-ring, from the transmission housing.
3.
Remove the Output Shaft Speed Sensor, with o-ring, from the transmission housing.
30
Service Procedure
Output Shaft Speed Sensor Installation

None.
Special Tools
Basic Hand Tools
31
Service Procedure
IMPORTANT
Clean the mounting surface on the housing and remove any burrs or sharp edges. Lubricate the o-ring with Eaton Fuller silicone #71214 or equivalent. 1. Using a smooth, twisting motion, fully insert the Output Shaft Speed Sensor in the transmission housing opening.
IMPORTANT
Clean the mounting surface on the housing and remove any burrs or sharp edges. Lubricate the o-ring with Eaton Fuller silicone #71214 or equivalent. 1. Using a smooth, twisting motion, fully insert the Output Shaft Speed Sensor in the transmission housing opening.
Service Procedure
2.
Using a 13mm socket, install the retaining bolt and tighten to 15-19 lbs. ft. (20-25 Nm).
2.
Using a 3/8 socket, install the retaining bolt and tighten to 8-10 lbs. ft. (11-13 Nm).
3.
Reconnect the Transmission Harness to the Output Shaft Speed Sensor.
3.
Reconnect the Transmission Harness to the Output Shaft Speed Sensor.
32
Service Procedure
Splitter Valve Removal

The Splitter Valve may be difficult to remove from the housing because of the o-rings.
Special Tools
Basic Hand Tools
1. Capscrew 2. Valve 3. O-rings
33
Service Procedure
1.
Relieve system air pressure by draining the air tanks on the vehicle. When air pressure is relieved, disconnect the Transmission Harness from the Splitter Valve assembly.
Note: The harness should be removed from the Splitter Valve tie-down, prior to removing the capscrews.
2.
Using a 5/16 wrench, remove the four (4) mounting capscrews from the Splitter valve.
Service Procedure
CAUTION
Do not use a hammer to loosen the Splitter Valve in the housing or it could be damaged. 3. Lift and remove the Splitter Valve from the housing.
34
Service Procedure
Splitter Valve Installation

Torques give below are in lbs. in.
Special Tools
Basic Hand Tools
35
Service Procedure
IMPORTANT
Lubricate o-rings with Eaton Fuller silicone #71214 or equivalent. The valve is keyed to fit its mounting location. Take care to align the key in the valve with the notch in the housing. 1. Install and push the Splitter Valve down into the housing.
3.
Reconnect the Transmission Harness to the Splitter Valve and close all air tank drains.
Note: Install the Splitter harness back into the tie-down on the Splitter Valve.
2.
Using a 5/16 wrench, install the four (4) mounting capscrews and tighten to 21-27 lbs. in.(2.3-3.0 Nm) using a cross pattern.
Service Procedure
36
Service Procedure
Range Valve Removal

The Range Valve may be difficult to remove from the transmission housing because of the o-rings.
Special Tools
Basic Hand Tools
37
Service Procedure
1.
Relieve system air pressure by draining air tanks on the vehicle. When air pressure has been relieved, disconnect the Transmission Harness from the Range Valve.
Note: The harness should be removed from the Range Valve tie-down prior to removing the capscrews.
2.
Using a 5/16 socket, remove the four (4) mounting capscrews from the Range Valve.
Service Procedure
CAUTION
Do not use a hammer to loosen the Range Valve in the housing or it could be damaged. 3. Lift and remove the Range Valve from the housing.
38
Service Procedure
Range Valve Installation

Special Tools
Basic Hand Tools
39
Service Procedure
IMPORTANT
Lubricate o-rings with Eaton Fuller silicone #71214 or equivalent. The valve is keyed to fit its mounting location. Take care to align the key in the valve with the notch in the housing. 1. Install and push the Range Valve down into the housing.
3.
Reconnect the Transmission Harness to the Range Valve and close all air tanks drains.
Note: Install the Range harness back into the tie-down on the Range Valve.
2.
Using a 5/16 socket, install the (4) Range Valve mounting capscrews and tighten to 21-27 lbs. in. (2.3-3.0 N m) using a cross pattern.
Service Procedure
40
Service Procedure
Air Filter/Regulator Removal

The Air Filter/Regulator has two (2) o-rings located between the Air Filter/Regulator and the Range Cylinder Cover.
Special Tools
Basic Hand Tools
1. Air Filter Regulator 2. Capscrew
41
Service Procedure
1.
Relieve system air pressure by draining all air tanks on the vehicle. Then, remove the vehicle air supply line from the Air Filter Regulator.
2.
Using a 7/16 socket, remove the two (2) mounting capscrews.
Service Procedure
3.
Remove the Air Filter/Regulator assembly.
Note: Be careful not to let the o-rings drop out of the Range Cylinder Cover when removing the Air Filter Regulator.
42
Service Procedure
Air Filter/Regulator Installation

The Air Filter/Regulator has (2) o-rings located between the Air Filter/Regulator and the Range Cylinder Cover.
Special Tools
Basic Hand Tools
1. Air Filter Regulator 2. Capscrew
43
Service Procedure
IMPORTANT
Lubricate o-rings with Eaton Fuller silicone #71214 or Equivalent. 1. If removed, press the two o-rings into the recesses in the Range Cylinder Cover.
3.
Reinstall the vehicle air supply line to the Air Filter Regulator and close all air tank drains.
Note: Apply Eaton Fuller sealant #71205 or equivalent to the two (2) mounting capscrews.
2.
Using a 7/16 socket, install the two (2) mounting capscrews and tighten to 8-12 lbs. ft. (11-16 N m).
Service Procedure
Note: Hold the Air Filter Regulator flush with the Range Cylinder Cover until its in place to prevent the o-rings from dropping out.
44
Service Procedure
Inertia Brake Removal

None
Special Tools
Basic Hand Tools
Heavy Duty
Medium Duty
5 4 3 2
1. Capscrew 2. Inertia Brake 3. Gasket
1. Capscrew 2. Inertia Brake 3. Gasket 4. Spacer (Used on all Medium Duty ratios except the N) 5. Gasket (Used on all Medium Duty ratios except the N)
45
Service Procedure
Heavy Duty Procedure 1. Drain the lubricant from the transmission and disconnect the Transmission Harness from the Inertia Brake Coil.
4.
Remove the Inertia Brake and gasket from the transmission.
2.
Using a 7/8 wrench, disconnect the Inertia Brake lubricant supply line from the transmission.
Medium Duty Procedure 1. Drain the lubrication from the transmission and disconnect the Transmission Harness from the Input Shaft Speed Sensor and the Inertia Brake Coil.
Service Procedure
WARNING
The Inertia Brake is heavy. Be prepared to handle the weight of the Inertia Brake when the mounting bolts are removed. 3. Using a 9/16 socket, remove the six (6) mounting bolts from the Inertia Brake. 2. Using a 3/8 wrench, remove the Input Shaft Speed Sensor.
46
Service Procedure
3.
Using a 7/8 wrench, remove the lubricant supply line from the transmission.
5.
Remove the Inertia Brake, gaskets, and spacer (depending on model) from the transmission.
Note: The Inertia Brake will contain some lubricant. Note: The spacer and extra gasket are used on all transmission ratios except the N.
CAUTION
The Inertia Brake is heavy. Be prepared to handle the weight of the Inertia Brake when the mounting bolts are removed. 4. Using a 9/16 wrench, remove the (6) mounting bolts from the Inertia Brake.
47
Service Procedure
Inertia Brake Installation

None
Special Tools
Basic Hand Tools
Heavy Duty
Medium Duty
5 4 3 2
Service Procedure
1. Capscrew 2. Inertia Brake 3. Gasket
1. Capscrew 2. Inertia Brake 3. Gasket 4. Spacer (Used on all Medium Duty ratios except the N) 5. Gasket (Used on all Medium Duty ratios except the N)
48
Service Procedure
3.
WARNING
The Inertia Brake is heavy. Be prepared to handle the weight of the Inertia Brake until the mounting bolts are installed. 1. Clean and remove all old gasket material. Then, install the Inertia Brake and new gasket, being careful to align the Inertia Brake gear with the drive gear.
Using a 7/8 wrench, reconnect the Inertia Brake lubricant supply line to the transmission and tighten to 20-22 lbs. ft. (27-29 N m).
4.
Reconnect the Transmission Harness to the Inertia Brake Coil.
2.
Using a 9/16 socket, install the six (6) mounting bolts. Tighten mounting bolts to 35-45 lbs. ft. (47-60 N m) using a cross pattern.
49
Service Procedure
3.
WARNING
The Inertia Brake is heavy. Be prepared to handle the weight of the Inertia Brake until the mounting bolts are installed. 1. Install the Inertia Brake, gaskets, and spacer (depending on model) being careful to align the Inertia Brake gear with the drive gear.
Using a 7/8 wrench, reconnect the Inertia Brake lubricant supply line to the transmission and tighten to 20-22 lbs. ft. (27-29 N m).
Note: The spacer and extra gasket are used on all transmission ratios except the N.
4.
Using a 3/8 wrench, install the Input Shaft Speed Sensor and tighten to 8-12 lbs. ft. (11-16 N m).
Service Procedure
2.
Using a 9/16 socket, install the (6) mounting bolts. Tighten mounting bolts to 35-45 lbs. ft. (47-60 N m) using a cross pattern.
5.
Reconnect the Transmission Harness to the Input Shaft Speed Sensor and the Inertia Brake Coil.
50
Service Procedure
Electric Shifter Removal

None
Special Tools
Basic Hand Tools
1. Capscrew 2. Electric Shifter 3. Gasket
51
Service Procedure
1.
Remove nylon cable ties from the motor wires. Disconnect the Transmission Harness from the Rail Select Sensor and the Gear Select Sensor.
WARNING
Possible Pinch Point - Make sure battery is disconnected before removal of Electric Shifter. 4. Remove the Electric Shifter and gasket.
2.
Disconnect the Rail Select and Gear Select Motors from the Transmission ECU.
Service Procedure
3.
Using a 9/16 socket, remove the four (4) mounting capscrews.
52
Service Procedure
Electric Shifter Installation

None
Special Tools
Basic Hand Tools
1. Capscrew 2. Electric Shifter 3. Gasket
53
Service Procedure
1.
Check to ensure the shift blocks are in the neutral position, then move the shift finger to the center (neutral) location.
4.
Position the Electric Shifter on the Shift Bar Housing. Then using a 9/16 socket, install the mounting capscrews and tighten in a cross pattern as follows: 5, and 6-Speed (Aluminum Housing)- Tighten to 2025 lbs. ft. (27-33 N m). 10, 13, and 18-Speed (Cast Iron Housing) Tighten to 34-45 lbs. ft. (45-60 N m).
Note: If the shift finger is not properly aligned, the Electric Shifter will not fit properly at its mounting location.
2.
Clean and remove old gasket material from the Shift Bar Housing. Then, install the new gasket on the Shift Bar Housing. 5. Reconnect the Rail Select Sensor and Gear Select Sensor.
Note: Apply Eaton sealant #71205 or equivalent to the mounting capscrews before installing.
Service Procedure
3.
The Dowel pin on the Electric Shifter must be aligned with the hole in the Shift Bar Housing (used on 10 and 13 & 18-Speed models only).
6.
Reconnect the Transmission Harness to the Rail Select and Gear Select motors. Using nylon ties, secure the motor wires to the transmission in their previous position.
54
Service Procedure
IMPORTANT
The Electric Shifter must be calibrated before the vehicle is placed into operation. 7. To operate properly, the system must be calibrated as follows: Turn the ignition switch on and allow the transmission to power up. Turn the ignition switch to off and wait two minutes.
55
Service Procedure
Transmission Controller Removal

None
Special Tools
Basic Hand Tools
Heavy Duty
Medium Duty
Service Procedure
1. Nut 2. Bracket 3. Transmission ECU 4. 38-Way Connectors 5. Capscrew (Located inside 38-Way connectors)
1. Capscrew 2. Transmission ECU 3. 38-Way Connectors 4. Capscrew (Located inside 38-Way connectors)
56
Service Procedure
3.
Remove the Transmission Controller retaining bracket.
CAUTION
The battery negative must be disconnected prior to unhooking the Transmission ECU 38-Way connectors. Do not allow contamination into the Transmission ECU or connectors. 1. Disconnect the following connectors: Using a 5/32 allen wrench, unscrew and disconnect the Transmission Harness 38-way connector and Vehicle Interface 38-way connector.
4.
Remove the Transmission Controller assembly from the locating studs.
2.
Using a 7/16 socket, remove the three (3) mounting nuts.
57
Service Procedure
3.
Remove the Transmission Controller assembly from the locating studs.
CAUTION
Service Procedure
2.
Using a 7/16 socket, remove the three (3) mounting bolts.
58
Service Procedure
Transmission Controller Installation

Special Tools
Basic Hand Tools
Heavy Duty
Medium Duty
1. Nut 2. Bracket 3. Transmission ECU 4. 38-Way Connectors
1. Capscrew 2. Transmission ECU 3. 38-Way Connectors
59
Service Procedure

CAUTION
Battery negative must remain disconnected until the Transmission ECU 38-Way connectors are installed. Do not allow contamination into the Transmission ECU or connectors. 1. Position the Transmission Controller on the locating studs.
3.
Using a 7/16 socket, install the three (3) Transmission Controller mounting nuts and tighten to 7 - 9 lbs. ft. (9.5 12.2 Nm).
CAUTION
Do not exceed the torque on the Transmission Harness or Vehicle Harness connector or bolt failure will occur. 4. Reconnect the following connectors: Using a 5/32 wrench, reconnect the Transmission Harness 38-way connector and tighten to 25 +/- 3 lbs. in. (2.82 +/- .33 Nm). Using a 5/32 wrench, reconnect the Vehicle Interface 38-way connector and tighten to 25 +/- 3 lbs. in. (2.82 +/- .33 Nm). Reconnect the negative battery cable.
Service Procedure
2.
Place the Transmission Controller retaining bracket over the Transmission ECU.
60
Service Procedure
IMPORTANT
The Electric Shifter must be calibrated before the vehicle is placed in operation. 5. To operate properly, the system must be calibrated as follows: Turn the ignition switch on and allow the transmission to power up. Turn the ignition off and wait two minutes.
CAUTION
Do not exceed the torque on the Transmission Harness or Vehicle Harness connector or bolt failure will occur. 3. Reconnect the following connectors: Using a 5/32 wrench, reconnect the Transmission Harness 38-way connector and tighten to 25 +/- 3 lbs. in. (2.82 +/- .33 Nm). Using a 5/32 wrench, reconnect the Vehicle Interface 38-way connector and tighten to 25 +/- 3 lbs. in. (2.82 +/- .33 Nm). Reconnect the negative battery cable.

CAUTION
Battery negative must remain disconnected until the Transmission ECU 38-Way connectors are installed. Do not allow contamination into the Transmission ECU or connectors. 1. Position the Transmission Controller on the locating studs.
IMPORTANT
The Electric Shifter must be calibrated before the vehicle is placed in operation. 4. To operate properly, the system must be calibrated as follows: 2. Using a 7/16 socket, install the three (3) Transmission Controller mounting bolts and tighten to 7 - 9 lbs. ft. (9.5 - 12.2 Nm). Turn the ignition switch on and allow the transmission to power up. Turn the ignition off and wait two minutes.
Note: UltraShift AW3- Perform clutch calibration: (see page 75).
61
Service Procedure
Transmission Harness Removal

None
Special Tools
Basic Hand Tools
Heavy Duty
Medium Duty
10 3 7 2 5 1 11 8 4
2 3
9 4
Service Procedure
7
9
6
6
1. Transmission ECU 38-way connector 2. Gear Sensor connector 3. Rail Sensor connector 4. 4-way Transmission Diagnostic connector 5. Input Shaft Speed Sensor connector 6. Inertia Brake connector (DM3 models) 7. Range Solenoid connector 8. Output Shaft Speed Sensor connector 9. Splitter Solenoid connector (13,18-speeds only) 10. Mainshaft Speed Sensor connector 11. Electric Shifter connector
1. Transmission ECU 38-way connector 2. Gear Sensor connector 3. Rail Sensor connector 4. (Future position of 4-way Transmission Diagnostic connector 5. Input Shaft Speed Sensor connector 6. Inertia Brake connector 7. WetClutch Solenoid connector (AW3 only) 8. Output Shaft Speed Sensor connector 9. Electric Shifter connector
62
Service Procedure
CAUTION
CAUTION
The battery negative must be disconnected prior to unhooking the Transmission ECU 38-Way connectors. Do not allow contamination into the Transmission ECU or connectors. 1. Using a 5/32 allen wrench, disconnect the Transmission Harness 38-way connector.
2. 2. Disconnect the following harness connectors: Inertia Brake Coil (if equipped) Input Shaft Speed Sensor Main Shaft Speed Sensor Gear Select Sensor and Rail Select Sensor Output Shaft Speed Sensor Range and Splitter Valve Solenoids 4-Way Transmission Diagnostic connector Electric Shifter [see page 1]
Disconnect the following harness connectors: Inertia Brake Coil (if equipped) Input Shaft Speed Sensor Gear Select Sensor and Rail Select Sensor WetClutch solenoid (AW3 only) Output Shaft Speed sensor (location may vary) 4-way Transmission Diagnostic connector Electric Shifter [see page 1]
63
Service Procedure
Transmission Harness Installation

None
Special Tools
Basic Hand Tools
Heavy Duty
Medium Duty
10 3 7 2 5 1 11 8 4
2 3
9 4
Service Procedure
7
9
6
6
1. Transmission ECU 38-way connector 2. Gear Sensor connector 3. Rail Sensor connector 4. 4-way Transmission Diagnostic connector 5. Input Shaft Speed Sensor connector 6. Inertia Brake connector (DM3 models) 7. Range Solenoid connector 8. Output Shaft Speed Sensor connector 9. Splitter Solenoid connector (13,18-speeds only) 10. Mainshaft Speed Sensor connector 11. Electric Shifter connector
1. Transmission ECU 38-way connector 2. Gear Sensor connector 3. Rail Sensor connector 4. (Future position of) 4-way Transmission Diagnostic connector 5. Input Shaft Speed Sensor connector 6. Inertia Brake connector 7. WetClutch Solenoid connector (AW3 only) 8. Output Shaft Speed Sensor connector 9. Electric Shifter connector
64
Service Procedure
CAUTION
Do not allow contamination into the Transmission ECU connectors. Do not over tighten ty-raps. You need to leave a service loop in the Transmission Harness. Do not put sharp bends in the Transmission Harness. The battery negative must be disconnected, while installing the Transmission ECU connectors. 1. Reconnect the following harness connectors: Gear Select and Rail Select Sensor Main Shaft Speed Sensor Input Shaft Speed Sensor Inertia Brake Coil (if equipped) Output Shaft Speed Sensor 4-way Transmission Diagnostic connector Electric Shifter Range and Splitter Valve Solenoids [see page 1]
CAUTION
Do not allow contamination into the Transmission ECU connectors. Do not over tighten ty-raps. You need to leave a service loop in the Transmission Harness. Do not put sharp bends in the Transmission Harness. The battery negative must be disconnected, while installing the Transmission ECU connectors. 1. Reconnect the following harness connectors: Gear Select and Rail Select Sensor Input Shaft Speed Sensor Inertia Brake Coil Output Shaft Speed Sensor 4-way Transmission Diagnostic connector Electric Shifter WetClutch solenoid (AW3 only) [see page 1]
CAUTION CAUTION
Do not exceed the torque on the Transmission Harness or Vehicle harness connector or bolt failure will occur. Using a 5/32 allen wrench, reconnect the Transmission Harness 38-way connector and tighten to 25 +/- 3 lbs. in. (2.82 +/ - .33 Nm). Do not exceed the torque on the Transmission Harness or Vehicle harness connector or bolt failure will occur. 2. Using a 5/32 allen wrench, reconnect the Transmission Harness 38-way connector and tighten to 25 +/- 3 lbs. in. (2.82 +/- .33 Nm).
65
Service Procedure
Shift Control Removal

The exact location varies depending on vehicle manufacturer.
Special Tools
Basic Hand Tools
4
Service Procedure
1. Nut 2. Washer 3. Push Button Shift Control 30-Way Connector 4. Backing Plate 5. Push Button Shift Control
66
Service Procedure
1.
Using a 1/4 socket, loosen the retaining bolt and disconnect the 30-way connector from the back of the Shift Control.
2.
Using a 11/32 wrench, remove the two (2) nuts and lock washers from the back of the Shift Control and remove the Shift Control.
Note: Shift Control location and use varies with each truck.
67
Service Procedure
Shift Control Installation

Special Tools
Basic Hand Tools
4
Service Procedure
1. Nut 2. Washer 3. Push Button Shift Control 30-Way Connector 4. Backing Plate 5. Push Button Shift Control
68
Service Procedure
1.
Install the Shift Control in its mounting location. Then, using a 11/32 wrench, install the two (2) lock washers and nuts and tighten to 14-16 lbs. in. (1.6-1.8 N m).
2.
Using a 1/4 wrench, reconnect the 30-way connector to the back of the Shift Control and tighten to 7.1 - 13.3 lbs. in. [0.8 - 1.5 N m]
69
Service Procedure
Cobra Lever Removal

None
Special Tools
Basic Hand Tools
Service Procedure
3 2
1. Tower 2. Screw 3. 8-Way Cobra Lever Harness Connector
70
Service Procedure
1.
Using a phillips screwdriver remove the four screws from the Cobra Lever Housing.
2.
Disconnect the 8-Way Cobra Lever harness connector and remove the Cobra Lever from the Housing.
71
Service Procedure
Cobra Lever Installation

None
Special Tools
Basic Hand Tools
Service Procedure
3 2
1. Tower 2. Screw 3. 8-Way Cobra Lever Harness Connector
72
Service Procedure
1.
Connect the 8-Way Cobra Lever harness connector and place the Cobra Lever into the tower.
1.
Using a phillips screwdriver install the four screws into the Cobra Lever Housing.
73
Appendix
Operation
For more detailed information on transmission operation and shifting go to the Roadranger.com Literature Center (www.roadranger.com) and look for the drivers manual on your model transmission. Generation III UltraShift - TRDR-0940 Generation III AutoShift - TRDR-0930
Appendix
74
Appendix
Lubrication Specifications 5,6,10,13, and 18-Speed UltraShift DM3 and 10,18-Speed AutoShift
CAUTION
Never mix engine oils and synthetic transmission oils in the same transmission. When switching between types of lubricants, all areas of each affected component must be thoroughly drained. Do not introduce additives and friction modifiers. Do not mix lubricants of different grades. Note: For a list of Eaton Approved Synthetic Lubricants, see TCMT-0021 or call 1-800-826-HELP (4357). Note: The use of lubricants not meeting these requirements will affect warranty coverage. Note: For lubrication change and inspection intervals see TCMT-0021.
Buy from a reputable dealer

For a complete list of approved and reputable dealers, write to: Eaton Corporation, Worldwide Marketing Services, P.O. Box 4013, Kalamazoo, MI 49003
Transmission Operating Angles

If the transmission operating angle is more than 12 degrees, improper lubrication will occur. The operating angle is the transmission mounting angle in the chassis plus the percent of upgrade (expressed in degrees). For operating angles over 12 degrees, the transmission must be equipped with an oil pump or cooler kit to insure proper lubrication.
Operating Temperatures with Oil Coolers

The transmission must not be operated consistently at temperatures above 250 F. Operation at temperatures above 250F [121C] causes loaded gear tooth temperatures to exceed 350F [177C] which will ultimately destroy the heat treatment of the gears. If the elevated temperature is associated with an unusual operating condition that will reoccur, a cooler should be added, or the capacity of the existing cooling system increased. The following conditions in any combination can cause operating temperatures of over 250 F [121C]: Operating consistently at slow speed. High ambient temperatures. Restricted air flow around transmission. Use of engine retarder. High horsepower operation.
Note: Transmission coolers must be used to reduce the operating temperatures when the above conditions are encountered.
75
Appendix
Oil Cooler Chart

Transmission Oil Coolers are: Recommended With engines of 350 H.P. and above. Required With engines 399 H.P. and above and GCWs over 90,000 lbs. With engines 399 H.P. and above and 1400 lbs. ft. or greater torque. With engines 1500 lbs. ft. and above 18-speed AutoShift transmissions require use of an Eaton supplied oil-to-water cooler or approved equivalent. With engines 450 H.P. and above.
Appendix
76
Appendix
UltraShift ASW Models

CAUTION
Never mix engine oils and synthetic transmission oils in the same transmission. When switching between types of lubricants, all areas of each affected component must be thoroughly drained. Do not introduce additives and friction modifiers. Do not mix lubricants of different grades. Note: For a list of Eaton Approved Synthetic Lubricants, see TCMT-0021 or call 1-800-826-HELP (4357). Note: The use of lubricants not meeting these requirements will affect warranty coverage. Note: For lubrication change and inspection intervals see TCMT-0021.
Buy from a reputable dealer

For a complete list of approved and reputable dealers, write to: Eaton Corporation, Worldwide Marketing Services, P.O. Box 4013, Kalamazoo, MI 49003
Synthetic Dextron III ATF

Synthetic Dextron III ATF must be used in the WetClutch portion of the transmission.
CD-50
CD-50 must be used in the gearbox portion of the transmission.
Maintenance/Lubricant Change Intervals

Transmission inspections and lubricant changes are outlined below. For a list of Eaton Roadranger approved lubricants, order publication TCMT-0020.
Table 1: Lubricant Inspection and Change Interval (On-highway)

Interval First 1,000 to 1,500 miles Every 2,500 miles Every 3 years or 150,000 miles, whichever occurs first Description Inspect oil levels. Check for leaks. Inspect lubricant level. Perform Transmission Inspection. Change WetClutch oil and filters.
77
Appendix
Checking WetClutch Lubricant

The WetClutch portion is checked using a dipstick located in the engine compartment.
Proper WetClutch Lubricant Level

WetClutch lubricant level should be checked when idling in neutral, with the transmission temperature between 60 F and 120 F (15.5 C and 48.8 C) and when the vehicle has been idling in neutral for at least two (2) minutes. Proper lubricant level is obtained when the lubricant is between the cold ADD mark and the cold FULL marks on the dipstick. Due to thermal expansion of the lubricant, it is not recommended to check the level when the transmission is above 120 F (48.8 C).
Checking Gearbox Lubricant

The gearbox portion is checked at the lubricant fill plug located on the right side of the gear case.
Cooler
A transmission clutch cooler must be used with the Eaton UltraShift AW3 transmission. The cooler sizing must meet the requirements specified in this TRIG-0930
Proper Gearbox Lubricant Level

The gearbox lubricant is at the proper level when it is even with bottom of the fill hole. When you remove the plug to check the lubricant level, lubricant should seep out. Do not use your finger to feel for the lubricant. Even if you can touch the lubricant, it may not be at the proper level. In a transmission, one inch of lubricant level equals about one gallon of lubricant.
Actual Lube Level Actual Lube Level
Appendix
78
Appendix
Drain the Transmission Gearbox and WetClutch Housing

1. 2. 3. 4. 5. 6. Locate the drain plugs at the bottom of the transmission gear case and on the clutch housing oil pan. Place a drain pan under each drain plug. Remove both drain plugs and allow the lubricants to drain completely. Disconnect both cooler lines at the WetClutch housing. Pressurize one line with 20 PSI until all lubricant is forced out of the cooler. Reconnect both cooler lines.
Change WetClutch Filters

Change the lubricant filters when the transmission lubricant is changed. Detailed information can be found on removal and replacement of the oil filters in this service manual.
Fill the Transmission

1. 2. 3. 4. 5. 6. Install the transmission gearbox drain plug and tighten to 45-55 lbs. ft. (60-73 Nm). Sealant is not required on the drain plug threads. Install the clutch housing oil pan drain plug and torque to 34-48 lbs. ft. (45-64 Nm). Sealant is not required on the drain plug thread. Fill the transmission gearbox with the recommended lubricant until the lubricant seeps out of the fill hole. Install the fill plug and torque to 25-35 lbs. ft. (33-47 Nm). Slowly fill the clutch through the dipstick tube with an initial fill of 18 pints (8.5 liters) of the recommended lubricant. Place the transmission in neutral position apply the parking brakes. Start the engine and let idle for five (5) minutes, (this allows oil to fill the WetClutch system and cooling system), add oil as needed to obtain a level at the proper temperature range. Total oil quantity at this time varies depending on the cooling system capacity. Increase the engine idle slowly to 1500 RPM for two (2) minutes. Now, recheck the oil level at normal idle speed in neutral, again adding oil to obtain a level at the proper temperature range. Install the dipstick and tighten securely.
7. 8.
79
Appendix
Clutch Calibration
The ASW system automatically provides for clutch wear. The system will initiate a clutch calibration once per vehicle power up, when certain vehicle conditions are right. Of these conditions, the most important ones include: when the engine is running at idle speed, during normal operating temperature, when the vehicle is stopped, and when neutral is selected on the Shift Control. During the calibration, the clutch is partially engaged until the engine begins to slightly lug down. It will then disengage the clutch and repeat this process several times. The calibration process usually takes as little as thirty seconds but can take as long as two(2) minutes. The calibration will be aborted when any position other than neutral is selected on the Shift Control. If it appears that the vehicle is not engaging smoothly from a stop, it is possible that the clutch needs to be re-calibrated. If it has not been previously calibrated during the current power up, stop the vehicle with the engine idling at its normal operating temperature and place the Shift Control in neutral and wait two(2) minutes. If the calibration is being performed you should hear the engine slightly lug down and then return to its no load condition several times. If calibration does not occur a Power Down/Power Up will initiate a calibration.
Appendix
80
Appendix
Inspection Procedures
For all inspection procedures on assembly and disassembly refer to the service manual covering the base box procedures. These manuals can be found on roadranger.com under the Literature Center.
Appendix
Basic Troubleshooting
For all Basic Troubleshooting questions refer to the appropriate service manual covering the base box procedures. These manuals can be found on roadranger.com under the Literature Center.
Appendix
82
Appendix
Air System Operation and Troubleshooting

For all air system operation and troubleshooting questions refer to the "Gen III Troubleshooting Guide" TRTS-0930, which is found on Roadranger.com under the Literature Center.
83
Appendix
Tool Specifications General Tools

The following General Tools are available from several tool manufacturers such as Snap-On, OTC, and many others.
Table 5 General Tools

TOOL PURPOSE 0 - 100 lbs. ft. (0-135 Nm) 1/2" (12.7mm) drive Torque General torquing of fasteners (Typically 15-80 lbs. ft. (20-108 Wrench Nm)) 0 - 600 lbs. ft. (0-810 Nm) 3/4" or 1" (19mm or 25.4mm) Torquing of Output Nut drive Torque Wrench 0 - 50 lb. in. (0-5.62 Nm) 3/8" (9.52mm) drive Torque General torquing of fasteners Wrench 2 3/4" (70mm) or Socket - Standard Depth Large Brass Drift 3/4" x 12" (19mm x 304.8mm) Large Dead Blow Hammer or Maul 32 ounces (2) Air Pressure Gauges (0-150 PSI) 0-10.34 BAR To remove the Output Yoke/Flange Nut Used to protect shafts and bearings during removal To provide force for shaft and bearing removal To troubleshoot and verify correct operation of air system
3/8" Drive Deepwell socket set 3/8"- 1" (9.5mm - 25.4mm) To remove/install capscrews and nuts 3/8" Drive Shallow socket set 3/8" - 1" (9.5mm - 25.4mm) Snap Ring Pliers - Large Standard External Feeler Gauges Open-end wrench set 3/8" - 1" (9.52mm -25.4mm) To remove/install capscrews and nuts To remove the snap rings at the auxiliary drive gear, input shaft bearing, and countershaft bearings To set mainshaft washer endplay and auxiliary tapered bearing endplay To remove certain airline connections
Appendix
84
Appendix
Torque Specifications
Correct torque application is extremely important to assure long transmission life and dependable performance. Overtightening 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 capscrews. Do not torque capscrews dry. Description Transmission-to-Engine capscrews Clutch-to-Flywheel capscrews 7/16 x 2.25 x 14 3/8 x 2.25 x 16 M10 x 1-3/8 M10 x 1-3/4 6 (Small PTO Cover Capscrews) 8 (Large PTO Cover Capscrews) 4 Electric Shifter Capscrews 40 - 50 lbs. ft. 7/16 x 2.25 x 14 40 - 50 lbs. ft. [54 - 68 Nm] [54 - 68 Nm] 30 - 35 lbs. ft. 3/8 x 2.25 x 16 [41 - 47 Nm] 26 - 35 lbs. ft. M10 x 1-3/8 [35 - 47 Nm] 26 - 35 lbs. ft. M10 x 1-3/4 [35 - 47 Nm] 20 - 25 lbs. ft. 3/8"-16 [27 - 34 Nm] 50 - 65 lbs. ft. 7/16"-14 [68 - 88 Nm] 30 - 45 lbs. ft. 3/8" - 16 [48 - 61 Nm] cast and 20 - 25 lbs. ft. [27 - 34 Nm] aluminum 20 - 25 lbs. ft. 9/16"-18 [27 - 34 Nm] 20 - 25 lbs. ft. [27 - 34 Nm] 3/4"-16 30 - 35 lbs. ft. [41 - 47 Nm] 26 - 35 lbs. ft. [35 - 47 Nm] 26 - 35 lbs. ft. [35 - 47 Nm] Apply Loctite 242 to threads. Apply Loctite 242 to threads. Torque Value Thread size lbs. ft. [Nm] Refer to OEM for specification Additional Comments
1 Reverse switch 1 Neutral switch/cap 3 ECU Capscrews (Medium Duty) 3 ECU Nuts (Heavy Duty)
7 - 9 lbs. ft. (9.5 1/4" - 20 - 12.2 Nm) 7 - 9 lbs. ft. [9.5 1/4" - 20 - 12.2 Nm]
2 Transmission ECU 38-Way Connectors Cap- 25 +/- 3 lbs. in. M5 - .8 screws [2.82 +/- .33 Nm] 3 ECU Bracket Nuts 3 ECU Bracket Studs 2 Harness Bracket Capscrews 20 - 25 lbs. ft. .3125" - 18 [27 - 34 Nm] 35 - 45 lbs. ft. 3/8" - 16 [48 - 61 Nm] 20-25 lbs. ft. .3125-18 [27-34 Nm]
85
Appendix
1 Push Button Shift Controller 30-Way Connec- 10 +/- 3 lbs. in. tor Capscrew [14 +/- 4 N m] 2 Push Button Shift Controller Backing Plate 14-16 lbs. in. nuts and lockwashers [1.6-1.8 N m] 6 Inertia Brake Capscrews 2 Inertia Brake Hose Fittings 4 Splitter Solenoid Capscrews 4 Range Solenoid Capscrews 1 Output Shaft Speed Sensor Capscrew (MD) 40-45 lbs. ft. 3/8"-16 [54- 61.0 Nm] 30-40 lbs. ft. 3/4"-16 [41-54 Nm] 21-27 lbs. in. #10-24 [2.4-3.1 Nm] 21-27 lbs. in. #10-24 [2.4-3.1 Nm] 8-10 lbs. [10.8-13.6 Nm] 8-10 lbs. [10.8-13.6 Nm] 8-10 lbs. [10.8-13.6 Nm] ft. 1/4"-20 Apply Loctite 242 to threads.
1 Main Shaft Speed Sensor Capscrew
ft. 1/4"-20
1 Input Shaft Speed Sensor Capscrew
ft. 1/4"-20
2 Rail Sensor Capscrews 2 Gear Sensor Capscrews 2 Air Filter Regulator Capscrews
21-27 lbs. in. [2.4-3.1 Nm] 21-27 lbs. in. [2.4-3.1 Nm] 8-12 lbs. ft. 1/4"-20 [10.8-16.02 Nm] 45 - 55 lbs. ft. 3/4-NPT [61 - 75 Nm] 60 - 75 lbs. ft. 1-NPT [47 - 61 Nm] Apply Loctite 242 to threads.
1 Lubricant fill plug (6-Speed) 1 Lubricant fill plug (13,10,18-speed) 2 Lifting Bracket Capscrews Transmission Nodal (10,13,18-Speed) Mount
Appendix
35 - 45 lbs. ft. 3/8"-16 [47 - 61 Nm] Capscrews Refer to OEM for Specification
2 Transmission Rear Mount Nuts (10,13,18- Refer to OEM Speed) for Specification 6 - Speed AW3 Specific Oil cooler line fitting Oil cooler line nut 50 - 60 lbs. ft. [68 - 81 Nm] 50 - 60 lbs. ft. [68 - 81 Nm]
86
Appendix
2 Dipstick tube fitting 1 WetClutch drain plug 12 Flywheel to Drive Coupler Capscrews High Pressure Oil Filter Low Pressure Oil Filter
60 - 70 lbs. ft. 1 5/8"-12 [81 - 95 Nm] 34 - 48 lbs. ft. [46 - 65 Nm] 3/8 x 16 x 1-1/4 35 - 40 lbs. ft. [47 - 55 Nm] 25 - 35 lbs. ft. [34-41 Nm] Turn until seal touches, then tighten with a 1/2" drive 3/4 to 1 full turn.
87
Appendix
Torque Overview
Heavy Duty
ECU Bracket Nuts & Studs
Input Shaft Speed Sensor Capscrew
Electric Shifter Capscrews Gear Select Sensor Capscrews Main Shaft Speed Sensor Capscrew Rail Select Sensor Capscrews
Splitter Valve Solenoid Capscrew
Range Valve Solenoid Air Filter Requlator
Output Shaft Speed Sensor Capscrew Transmission ECU Nuts
Appendix
Inertia Brake Capscrews
88
Appendix
Medium Duty
Electric Shifter Capscrews Gear Select Sensor Capscrews Rail Select Sensor Capscrews
Output Shaft Speed Sensor Capscrew Input Shaft Speed Sensor Capscrew
Transmission ECU Nuts
Oil Pan Capscrews Inertia Brake Capscrews
Oil Pan Drain Plug
89
Copyright Eaton and Dana Corporation, 2002. EATON AND DANA CORPORATION hereby grants its customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.
The Roadranger System is an unbeatable combination of the best products from Eaton and Dana -- partnering to provide you the most advanced, most trouble-free drivetrain in the industry. And it's backed by the Roadrangers -- the most experienced, most expert, most accessible drivetrain consultants in the business. Visit our web site at www.roadranger.com. For spec'ing or service assistance, call 1-800-826-HELP (4357) 24 hours a day, 7 days a week, (Mexico: 001-800-826-HELP (4357)) for more time on the road.
TRSM-0930 Printed in USA

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Eaton Fuller Automated Transmissions

RTO-1X910X-AS3 RTO-1X910X-DM3 RTLO-1X913X-DM3 RTLO-1X918X-AS3 RTOM-1X910X-DM3 FX-X405X-DM3 FX-X406X-AW3 FX-X406X-DM3

Service Manual TRSM-0930 September 2005

Warnings & Cautions

Warnings & Cautions

Input Shaft Speed Sensor Electric Shifter

Gear Select Sensor

Main Shaft Speed Sensor

Rail Select Sensor

Range Valve Solenoid Splitter Valve Solenoid Air Filter Requlator

Output Shaft Speed Sensor

Inertia Brake (13-Speed DM3 Only)

Heavy Duty 10-Speed AS3 & DM3

Input Shaft Speed Sensor Electric Shifter

Gear Select Sensor

Main Shaft Speed Sensor Output Shaft Speed Sensor

Rail Select Sensor

Range Valve Solenoid Air Filter Regulator

Inertia Brake (10-Speed DM3 Only)

Medium Duty 6 & 5-Speed DM3

Gear Select Sensor

Rail Select Sensor

Output Shaft Speed Sensor

Input Shaft Speed Sensor Location Transmission Harness Transmission ECU

Medium Duty 6-Speed AW3

Electric Shifter Gear Select Sensor

Rail Select Sensor

Output Shaft Speed Sensor Input Shaft Speed Sensor Location

Transmission Harness Transmission ECU

Wetclutch Solenoid Connector

Oil Pan and Filters Inertia Brake

How to use this Manual

Serial Tag Information and Model Nomenclature

Do not remove or destroy the transmission identification tag!

Eaton Corporation Transmission Div. Kalamazoo, MI. 49003

Generation 3 Electronics AutoShift Gear Ratio Forward Speeds

Lubricant Filter Removal (AW3 Models Only)

Remove the WetClutch oil pan and gasket.

Lubricant Filter Installation (AW3 Models Only)

Install a new gasket and the WetClutch oil pan.

Gear Select Sensor Removal

1. Capscrew 2. Sensor 3. Gasket

Disconnect the Transmission Harness from the Gear Select Sensor.

Gear Select Sensor Installation

1. Capscrew 2. Sensor 3. Gasket

Reconnect the Transmission Harness to the Gear Select Sensor.

Rail Select Sensor Removal

1. Capscrew 2. Sensor 3. Gasket

Disconnect the Transmission Harness from the Rail Select Sensor.

Rail Select Sensor Installation

1. Capscrew 2. Sensor 3. Gasket

Reconnect the Transmission Harness to the Rail Select Sensor.

Input Shaft Speed Sensor Removal

1. Capscrew 2. Sensor 3. O-ring

Input Shaft Speed Sensor Installation

1. Capscrew 2. Sensor 3. O-ring

Heavy Duty Procedure

Medium Duty Procedure

Reconnect the Transmission Harness to the Input Shaft Speed Sensor.

Reconnect the Transmission Harness to the Input Shaft Speed Sensor.

Note: Fill the transmission with lubricant (see page 75).

Main Shaft Speed Sensor Removal

1. Capscrew 2. Sensor 3. O-ring