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FSO-4305/4405

Service Manual
Transmission

Eaton® Fuller®
Light Duty Transmissions

Ed. 07/04
General Information
1
Input Shaft Bearing Cover
2
Gear Shift Lever Housing
3
Main Section
4
Shifting System
5
FSO-4305/4405 Ed. 07/04 3
4 Ed. 07/04 FSO-4305/4405
Table of Contents

General Information

Foreword .................................................. 7
1
How to Use This Manual .......................... 8
Identification and Specifications ............... 9
Exploded View ........................................ 11
Housing ............................................ 11
Engagement ..................................... 13
Shifting System................................. 15
Gear Shift Lever Housing ................. 16
Lubrication.............................................. 18
Operation................................................ 20
Power Flow ............................................. 21
Sealant Application ................................ 25
Torque Recommendation ....................... 26
Precautions ............................................ 29
Troubleshooting ...................................... 33
Special Tools .......................................... 39

FSO-4305/4405 Ed. 07/04 5


6 Ed. 07/04 FSO-4305/4405
Foreword

This manual is designed to provide detailed information necessary to service and repair the
Eaton transmission FSO-4305/FSO-4405.

Disassembly and assembly instructions in this manual make use of a typical FSO-4305/FSO-
4405 transmission. Illustrations and pictures show parts that may differ from one transmission
model to another, according to its application and serial number.
1
In addition, it is also assumed that the transmission has been removed from the vehicle and
the lubricant has been drained.

The manual has been divided into two main groups as follows:
1. Information and technical references, placed all together into one section.
2. Disassembly and assembly instructions, divided into sections gathering specific component
assemblies.

For more detailed information on product improvement, repair procedures and other subjects
related to service, please contact:

Eaton Ltda. - Transmission Division


Aftermarket and Service
Rua Clark, 2061 - P.O.Box 304
13270 - Valinhos - São Paulo - Brazil
Phone: (19) 3881-9590
Fax: (19) 3881-9687

FSO-4305/4405 Ed. 07/04 General Information 7


How to Use This Manual

To disassemble and assemble the entire transmission, follow the manual in its normal sequence.
However, if the problem involves one specific component, refer to the table of contents of its

1 related section, for the page number showing that component.

Example
• Component: Main Shaft End Play
• Location: Main Section, Engagement
• From the table of contents: Main Shaft End Play Adjustment, page 88.

General page layout description


1. Heading of the topic covered in the section.
1
2. Subheading with a more specific Main Shaft

description of the topic covered. 2 Assembly


26. Install the 2nd gear snap ring.

3. Number and description of operations of 26

the procedure.
4
4. Illustration or photograph showing the FSO-4405A/108

procedures. Reference numbers indicate 3 27. Install the rear thrust ring of the 3rd
speed gear rollers. 29
28
the respective operations. 28. Lubricate and install the rollers of the
3rd speed gear, using a light coat of 27
grease to keep the rollers in their
position.
5. WARNING! Information requiring special NOTE: Use transmission oil to lubricate

attention as it represents risks of personal the bearing. 6 FSO-4405A/132


29. Install the front thrust ring of the 3rd

injury or product damage. speed gear.


30
30. Install the 3rd speed gear on the
rollers, with the cone side facing up
6. NOTE: Useful information to perform the (towards the synchronizer ring).
7
operation.
7. Manual’s section number. 31. Install the 3rd speed synchronizer ring.
FSO-4405A/133 4
WARNING! The 3rd speed 31
8. Manual’s section description. 5
synchronizer ring HAS EFM coating.
See Shifting System, Synchronizer
Assemblies.
9. Page number.
FSO-4405A/134
Ed. 07/04 FSO-4305/4405 Main Section 89

8 9

8 Informações Gerais Ed. 07/04 FSO-4305/4405


Identification and Specifications

Identification and Specifications


Identification
Model designation

FSO - 4305A
1
FSO - 4405A
Eaton Fuller Gear ratio
Synchronized
Overdrive Forward synchronized
speeds

Design level

Nominal torque capacity


(x100 lb.ft)

All Eaton transmissions are identified by the model


designation and serial number. This information is
stamped on the identification tag fixed to the
transmission case.
WARNING! Do not remove or destroy the
transmission identification tag.
NOTE: When ordering parts or consulting for
service assistance, please inform data
contained on the identification tag.

FSO-4405A/17

FSO-4405A/152

FSO-4305/4405 Ed. 07/04 General Information 9


Identification and Specifications

Specifications

1
FSO-4405A FSO-4405B FSO-4405C
FSO-4305A FSO-4305B FSO-4305C
lb.ft 427 427 427
Torque
N.m 580 580 580
NT Gear Ratio NT Gear Ratio NT Gear Ratio
Output Shaft 28 28 28
Countershaft 44 44 44
1st Speed (CS) 12 17 12
5.762 5.084 5.762
(MS) 44 55 44
2nd Speed (CS) 20 25 25
2.829 2.640 2.640
(MS) 36 42 42
3rd Speed (CS) 36 36 36
1.528 1.528 1.528
(MS) 35 35 35
4th Speed (CS)
1.000 1.000 1.000
(MS)
5th Speed (CS) 49 49 49
0.770 0.770 0.770
(MS) 24 24 24
Reverse Speed (CS) 12 17 12
Reverse Idler Gear 28 5.238 35 4.714 28 5.238
(MS) 40 51 40

NT = Number of teeth CS = Countershaft MS = Main shaft

NOTE: The transmission specifications may be modified at any time. The data on table
is provided for reference purposes only.

Weight
Cable shifting = 92.0 kg
Rod shifting = 73.5 kg
Direct shifting = 79.0 kg
NOTE: Weight includes transmission lubricant filled up to the correct level.

10 General Information Ed. 07/04 FSO-4305/4405


Exploded View

Housings
Main Section

13
14
15
17 18 7 21 22
1
19

16
24
12 20
10
11
9
8 26 25
7 23

7 27
6
2 5 28
4 16
3

29
31 30
33
32
1 34

2 35
36

FSO-4405A/176

1- Capscrew 13 - Cover 25 - Capscrew


2- Input shaft bearing cover 14 - Bracket 26 - Neutral switch
3- Oil seal 15 - Capscrew 27 - Speedometer sensor
4- Oil baffle 16 - Dowel pin 28 - Rear housing
5- Bearing cup 17 - Lifting hook 29 - Reverse speed light switch
6- Adjusting shim 18 - Capscrew 30 - Washer
7- Plug 19 - Oil seal 31 - Plug
8- Filling plug 20 - Baffle 32 - Drain plug
9- PTO cover 21 - Yoke 33 - Front housing
10 - Capscrew 22 - Nut 34 - Adjusting shim
11 - Sphere (or spherical pin) 23 - Sphere 35 - Countershaft front cover
12 - Spring 24 - Countershaft rear cover 36 - Capscrew

FSO-4305/4405 Ed. 07/04 General Information 11


Exploded View

Housings

1
Clutch

3 4

1 5 6 7

5 8

11

9
10

FSO-4405A/177

1- Capscrew 5- Dust protector 9- Cover


2- Clutch collar 6- Connection 10 - Capscrew
3- Clutch housing 7- Bleed valve 11 - Washer
4- Capscrew 8- Connection

12 General Information Ed. 07/04 FSO-4305/4405


Exploded View

Engagement
Input Shaft and Main Shaft

8
11

9 6 10 12 13 14 15
16 17
19 20
21 22
1
5 6 7
3 4
2
1 18

45
42 44 41
40 41
39
38 43
35 37
33 34
32
29 30
25 28
23 24

46

36
27
26
31

53
52
51
49 50
48
47
FSO-4405A/178

1- Bearing cone 19 - 2nd speed gear 36 - Sphere


2- Input shaft 20 - Rollers 37 - Reverse speed gear
3- Oil baffler 21 - Spacer washer 38 - Needle bearing
4- Bearing cone 22 - Snap ring 39 - Snap ring
5- 4th synchronizer ring 23 - 2nd synchronizer ring 40 - Reverse speed synchronizer ring
6- Lock ring 24 - Lock ring 41 - Lock ring
7- Key 25 - Key 42 - Key
8- 3rd/4th synchronizer hub 26 - Hub insert 43 - 5th/reverse synchronizer hub
9- 3rd/4th synchronizer sleeve 27 - Sleeve insert 44 - 5th/reverse synchronizer sleeve
10 - 3th synchronizer ring 28 - 1st/2nd synchronizer hub 45 - 5th synchronizer ring
11 - 3rd/4th synchronizer assy 29 - 1st/2nd synchronizer sleeve 46 - 5th/reverse synchronizer assy
12 - 3rd speed gear 30 - 1st synchronizer ring 47 - Main shaft
13 - Spacer washer 31 - 1st/2nd synchronizer assy 48 - 5th speed gear
14 - Rollers (Booster) 49 - Rollers
15 - Spacer washer 32 - 1st speed gear 50 - Thrust washer
16 - Snap ring 33 - Needle bearing 51 - Rear bearing cone
17 - Thrust washer 34 - Snap ring 52 - Rear bearing cup
18 - Sphere 35 - Thrust washer 53 - Speedometer rotor

FSO-4305/4405 Ed. 07/04 General Information 13


Exploded View

Engagement

1
Countershaft and Reverse Idler Gear

5
4
3
2
1

11
10
9
8
6
7
6

15
14
12

13

FSO-4405A/179

1- Front bearing cup 6- Key 11 - Rear bearing cup


2- Front bearing cone 7- Countershaft 12 - Reverse idler gear shaft
3- Snap ring 8- 5th speed gear 13 - Capscrew
4- Driving gear (4th speed) 9- Snap ring 14 - Needle bearing
5- 3rd speed gear 10 - Rear bearing cone 15 - Reverse speed idler gear

14 General Information Ed. 07/04 FSO-4305/4405


Exploded View

Shifting System
Shift Yoke and Bars

5 5
1
6 5
4 6
7
5
8
1 5
9

3
3
3
3
13

2
12
2
11
2 10

FSO-4405A/180

1- 1st/2nd speed shift yoke 6- Interlock pin 11 - 5th/reverse speed shift block
2- Pad 7- 3rd/4th speed shift bar 12 - 5th/reverse speed shift yoke
3- Roll pin (diam. 5 mm) 8- Roll pin (diam. 4 mm) 13 - 5th/reverse speed shift bar
4- 1st/2nd speed shift bar 9- 3rd/4th speed shift block
5- Sphere 10 - 3rd/4th speed shift yoke

FSO-4305/4405 Ed. 07/04 General Information 15


Exploded View

Gear Shift Lever Housing

1
Remote

24

25

24 26

11 25
27
10 27
9 31
28

8 29
5
30
12 32 34
7
13
14
33
15 6
16
35 36
17 37

38
5 35
19 4
3
18
22
6 2
23
21 20
1

FSO-4405A/181

1- Shaft and lever assy 14 - Retainer 27 - Bearing


2- Lever 15 - Inner spring 28 - Shaft
3- Boot 16 - Thrust washer 29 - Bracket
4- Oil seal 17 - Housing 30 - Nut
5- Bushing 18 - Locating spring (offset) 31 - Shaft
6- 5th speed locator plug (offset) 19 - Locating sphere (offset) 32 - Capscrew
7- Capscrew 20 - Capscrew 33 - Spherical pin
8- Plug 21 - Lock wire 34 - Counterweight
9- Breather 22 - Internal shift selector 35 - Bushing
10 - Lifting hook 23 - Gasket 36 - Washer
11 - Capscrew 24 - Retainer 37 - Snap ring
12 - Spring rear plug 25 - Washer 38 - Bracket
13 - Outer spring 26 - Lever

16 General Information Ed. 07/04 FSO-4305/4405


Exploded View

Gear Shift Lever Housing


Direct

1
1
2 6

3 4 7

4 9 10

4 5 14
11
13
12
12
13
4
14
10
15
20
16
19 17

18

FSO-4405A/182

1- Capscrew 8- Capscrew 15 - Torsion spring


2- Gear shift lever 9- Housing 16 - Guide pin
3- Pin 10 - Capscrew 17 - Cam plate
4- Thrust washer 11 - Capscrew 18 - Stop pin
5- Ball joint 12 - Plunger 19 - Spring
6- Cover 13 - Spring 20 - Ball
7- Boot 14 - Plug

FSO-4305/4405 Ed. 07/04 General Information 17


Lubrication

Proper lubrication procedure is the key to a good and complete maintenance program. If the
oil is not doing its job, or if the oil level is ignored, all the other possible maintenance procedures

1
will not be enough to keep the transmission running or to assure long transmission life.
Eaton transmissions are designed so that all the internal parts operate in oil circulating bath,
created by the motion of gears and shafts. Thus, all parts are correctly lubricated if these
procedures are closely followed:
1. Maintain proper oil level, inspecting it regularly.
2. Change oil regularly following maintenance interval chart.
3. Use the recommended grade and type of oil.
4. Buy oil from a reputable dealer.

Oil change and level inspection


Periodic transmission oil change eliminates possible bearing failures, ring wear and seizures,
since the products of normal wear in service (tiny metal particles), which circulate in the
transmission oil, are harmful to these parts. In addition, the oil changes its chemical
characteristics due to the repeated heating and cooling cycles of a transmission in use.
As a general guide, the following chart provides maintenance interval recommendation to
level inspection and oil change.
WARNING! Always follow the vehicle manufacturer maintenance recommendation,
that prevails over this chart.

Recommended lubricant oil: SAE 80W90 API GL3 or API GL4

Highway use
After first 50,000 km Change transmission oil
Every 25,000 km Inspect oil level and check for leaks
Every 100,000 km Change transmission oil

Off-highway use
After first 25,000 km Change transmission oil
Every 12,500 km Inspect oil level and check for leaks
Every 50,000 km Change transmission oil

18 General Information Ed. 07/04 FSO-4305/4405


Lubrication

Draining
It is important to drain the transmission while it is warm. To drain the oil, remove the magnetic
drain plug. Clean the drain plug before reinstalling it.

Refilling
1
Correct Oil Level Incorrect Oil Level
FSO-2405/87

Clean the case around the oil fill plug, remove the plug and refill the transmission to the level
of the filler opening.
Oil quantify necessary to refill the transmission depends on the transmission angle. So, refill
the transmission with the vehicle on a flat and leveled surface.
Do not fill the transmission above the recommended level. This will cause oil to be forced out
of the case through the front bearing cover, the control cover, the shift lever housing, etc.

Lubricant capacity
4.6 liters
NOTE: The supplied oil volume may vary according to engine and transmission operating
angle. Always refill the transmission with proper grade and type of lubricant up to the
level of the filler plug opening.

Oil level inspection


Every time the oil level is being checked, clean the area around the filler plug and, if necessary,
add sufficient oil to maintain the proper oil level.
WARNING! Do not mix oils of different types and brands, as they might not be
compatible.

FSO-4305/4405 Ed. 07/04 General Information 19


Operation

Gear shift lever pattern

1
FSO-4305/FSO4405 transmissions have 5 forward
speeds and one reverse, all of them synchronized.
To shift the speeds follow the shift pattern shown
by the illustration aside.
A reverse gear shifting interlocking system prevents
from accidental transmission shifting from 5th to
reverse gear.

FSO-4405A/151

Tips for the driver


Always use the clutch to change the gears. The incorrect use of the clutch may cause premature
failures of the synchronizer assembly.
Always select a starting gear that will provide sufficient reduction (torque) for the vehicle’s load
and working conditions (terrain).
Never slam or jerk the gear shift lever to complete gear engagement.
Never leave the shift lever in the neutral position while going down hill.

20 General Information Ed. 07/04 FSO-4305/4405


Power Flow

The transmission must efficiently transfer the engine’s power or torque to the vehicle’s driveline.
It is essential to know what takes place in the transmission during torque transfer when

1
troubleshooting or repairs are required.

1st, 2nd, 3rd and 5th Speeds


1. Torque from the engine is transferred to the transmission’s input shaft.
2. The torque is transferred from the input shaft to the countershaft, through its drive gear. In
this way, input shaft and countershaft always run together.
3. The torque from the countershaft is delivered to all main shaft gears, assembled on bearings.
These gears rotate free unless one of the gears is shifted.
4. When a gear is shifted, the torque is transferred from the corresponding engaged main
shaft gear to the clutching teeth of the synchronizer assembly and then to the synchronizer
hub, that runs together with the main shaft. Torque is, then, delivered along the main shaft
to the driveline components through output yoke.

1st Speed

FSO-4405A/162

FSO-4305/4405 Ed. 07/04 General Information 21


Power Flow

2nd Speed

FSO-4405A/163

3rd Speed

FSO-4405A/164

5th Speed

FSO-4405A/165

22 General Information Ed. 07/04 FSO-4305/4405


Power Flow

4th Speed
The 4th speed gear is also named direct speed gear.
Torque comes from the input shaft, which transfers the torque directly to the main shaft, despite
of moving the counter shaft at the same time. This torque is transferred through the input shaft
clutching teeth, which are engaged to the 4th speed synchronizer hub, directly connected to
the main shaft.
1
The transmission’s noise level in this speed is really low, since torque is delivered directly from
one shaft to another and there are no gears under load.

4th Speed

FSO-4405A/166

FSO-4305/4405 Ed. 07/04 General Information 23


Power Flow

Reverse Speed
When the reverse speed gear is shifted, torque is transferred from countershaft to the reverse

1 idler gear, that changes the rotating direction, and then, from that gear to the main shaft
reverse speed gear.

Reverse Speed

FSO-4405A/167

24 General Information Ed. 07/04 FSO-4305/4405


Sealant Application

The correct application of sealing compounds is important to assure a suitable assembly


and to avoid leakages.

Apply Eaton E679 to mounting


surfaces of the input shaft bearing
cover and adjusting shims
Apply Eaton E679 to
gear shift lever
housing plugs
1
Apply Eaton E679 to
expanded plugs

Apply Eaton E680 to


mounting surfaces of front
and rear housings

Apply Eaton E680 to


Apply Eaton E680 to
mounting surfaces of front
mounting surface of the PTO
and rear covers of the
cover
countershaft
* Silicone sealant
FSO-4405A/200

FSO-4305/4405 Ed. 07/04 General Information 25


Torque Recommendation

Tightening capscrews, plugs and nuts to the proper torque is important to prevent oil leakage
and loosening of components, assuring a long working life to the transmission. Additionally,

1
always apply sealant to the threads whenever recommended.
WARNING! Always use a torque wrench to tight to the recommended torque.

1 2 3

FSO-4405A/154

4 5

Item Description Thread Torque N.m (lb.ft) Sealant


1 Reverse light switch 9/16" - 18 UNF 13.6-20.3 (10-15) Eaton E677
2 Neutral light switch 5/8" - 18 UNF 13.6-20.3 (10-15) Eaton E677
3 Speedometer sensor 3/4" - 16 UNF 9.5-16.3 (7-12) Eaton E677
4 Reverse idler gear M8 19-25.7 (14-19) Eaton E677
mounting capscrews
5 Countershaft rear M10 19.0-25.7 (14-19) Eaton E677
bearing cover capscrews

26 General Information Ed. 07/04 FSO-4305/4405


Torque Recommendation
6 7 8

FSO-4405A/155

9 10 11 12 13

Item Description Thread Torque N.m (lb.ft) Sealant


6 Housing capscrews M8 19-25.7 (14-19) Eaton E677
7 Clutch housing M14 108.6-121.7 (80-90) Eaton E677
capscrews
8 Input shaft bearing cover M8 9.5-16.3 (7-12) Eaton E677
9 Yoke nut 1-1/4" - 18 UNF 407-475 (300-350) Eaton E677
10 PTO cover capscrews 3/8" - 16 UNC 19-25.7 (14-19) Eaton E677
11 Oil filling plug 3/4" - 14 NPTF 13.6-20.3 (10-15) Eaton E677
12 Clutch inspection M5 1.4-6.8 (1-5) Eaton E677
cover capscrews
13 Countershaft front bearing M8 9.5-16.3 (7-12) *1 Eaton E677
cover capscrews 24.4-31-2 (18-23) *2
14 Oil drain plug *3 3/4" - 14 NPTF 13.6-20.3 (10-15) Eaton E677
*1 *2 *3
Stamped sheet cover Cast iron cover Not shown

FSO-4305/4405 Ed. 07/04 General Information 27


Torque Recommendation
15 16 17 18

FSO-4405A/156

17 19 20 21 22 21
Item Description Thread Torque N.m (lb.ft) Sealant
15 Boot retaining M5 2.0-7.0 (1.5-5) Eaton E677
cover capscrews *5
16 Internal shift lever 3/8" - 24 UNF 34-41 (25-30) Eaton E677
*4
mounting capscrews
17 Gear shift lever M10 19.0-25.7 (14-19) Eaton E677
housing capscrews
18 5th gear positioning M16 13.6-20.3 (10-15) Eaton E679
spring plug (offset) *4
19 Plunger spring M18 10.5-20.3 (8-15) Eaton E679
retainer plug *5
20 Gear shift lever M12 9.5-16.3 (7-12) Eaton E677
retaining capscrews *5
21 Shift positioning device M8 9.5-16.3 (7-12) Eaton E677
cover capscrews
22 Shift shaft spring 1-1/4" - 12 UNF 34-41 (25-30) Eaton E679
plugs *4
*4 *5
Remote Gear Shift Lever Housing Direct Gear Shift Lever Housing

28 General Information Ed. 07/04 FSO-4305/4405


Precautions

Precautions during disassembly and assembly

1
WARNING! When assembling the transmission, it is important to lubricate gear
bearings, needle bearings, non-sealed bearings and all other parts under friction
conditions, with the same transmission lubricant oil, in order to prevent damage
to transmission parts during initial gears movement.

Cleaning and handling


In order to completely clean the parts, wash them into a solvent bath (kerosene, for instance),
moving every part slowly up and down until all the old lubricant and foreign material have
been dissolved.
WARNING! Care must be taken to avoid skin rasher, fire hazard and vapor
inhalation when using solvents.

Non-sealed bearings
Immerse the bearings in clean solvent. Move them slowly up and down in order to loosen the
deposits. Dry the bearings with moisture free compressed air, avoiding the direct air flow to
the bearing in order not to rotate it in high speed. Repeat the above mentioned operation until
the bearings are thoroughly clean.
WARNING! Never drive the air jet directly to bearing in order to rotate it in high
speed. That can damage the bearing.

Synchronizer assemblies
Avoid bad handling of synchronizer assemblies. Either drops or bumps when disassembling
or assembling may lock them.

FSO-4305/4405 Ed. 07/04 General Information 29


Precautions

Housings
Clean thoroughly the interior and exterior of cases, covers, etc. Cast parts may be cleaned in

1 mild alkaline solution baths (a 7% soluble degreasing oil solution is recommended). The parts
are to remain in the bath for the time required to become completely clean. The parts cleaned
in alkaline solutions should be rinsed with clean water to remove any alkaline trace after
cleaning process.
WARNING! Care must to be taken to avoid vapor inhalation and skin rashes when
using alkaline solutions. Every cleaned part must be totally dried at once by means
of moisture free compressed air, or else, by means of a lint free soft cloth, free of
any abrasive material such as metal filings, contaminated oil or polishing
compounds.

Inspection
A thorough and careful inspection of every part is very important for the transmission life. The
replacement of parts showing either wear or fatigue will avoid future expensive and foreseen
failures.

Gears, shafts and synchronizer assemblies


Whenever magna-flux is available, this process should be used to check the parts.
Check carefully gear teeth for wear, pitting, chipping and cracks. If gear teeth show areas
where the hardening layer is worn out or cracked, the gear should be replaced by a new one.
Check shafts for warping and excessive wear or damaged splines.

Cases, covers, etc.


Make sure cases, covers, etc. are completely clean and that mounting surfaces and bearing
bores are free from chips or burrs. Check carefully every part for cracks, excessive wear or for
any other condition that may cause oil leak or a future failure.

Needle bearings
Check carefully every needle roller for wear, pitting or cracked areas to determine whether
they are suitable for reuse or should be replaced. After inspection, dip the needle bearings in
an oil bath and then wrap them in a lint free cloth or paper, so as to protect them until they are
to be reassembled.

30 General Information Ed. 07/04 FSO-4305/4405


Precautions

Oil seals and snap rings


Any oil seal, snap ring, etc. damaged during maintenance, should be replaced by a new one.
Replacement of oil seals and snap rings is cheaper when unit is disassembled than a premature
overhaul to replace these parts in a future time.
An oil leakage through a worn seal may result in failures of other more expensive components
of the transmission. The sealing elements should be handled carefully, particularly during
assembly. Cuts, scratches or rolled up seal lips decrease the sealing efficiency.
1
WARNING! Snap rings have proper assembling position due to the angle of their
opening ends. The side with shorter opening should be faced outwards to facilitate
the installation with pliers.

This side out

FSO-2405/98

FSO-4305/4405 Ed. 07/04 General Information 31


Precautions

Parts replacement

1
When it is necessary to replace parts, use only genuine Eaton transmission spare parts to
assure continued performance and extended life of the transmission. The use of either non
genuine or remanufactured spare parts, besides not having the factory’s warranty, may lead to
severe damage of the unit.

Since the cost of a new part is generally a small fraction of the total cost of downtime and
service labor, do not reuse a questionable part which could lead to additional repairs and
expenses soon after assembly.

To aid in determining the reuse or replacement of any transmission part, considerations should
also be given to the unit’s history, mileage, application, etc.

FSO-2405/140

32 General Information Ed. 07/04 FSO-4305/4405


Troubleshooting

The following chart presents some transmission malfunctions with their most common causes
and possible solutions.

Problem

Transmission
noise when in
Probable cause Possible solution

Incorrect idle speed Adjust idle speed


adjustment
Reference

Instructions on
vehicle’s manual
1
neutral

Improper or Replace disc Instructions on


damaged clutch vehicle’s manual
disc

Loose or damaged Replace and/or Instructions on


engine or tighten mounts vehicle’s manual
transmission mounts

Worn or damaged Replace yoke Instructions on


yoke vehicle’s manual

Warped or Repair or replace Requires specific


unbalanced drive drive shaft procedure
shaft

Low lubricant level Fill with recommended Recommended


oil to the proper level lubricant - page 18

Contaminated Drain and clean Recommended


lubricant transmission and refill lubricant - page 18
with recommended oil

Worn or damaged Replace damaged parts Instructions on this


gears and/or manual
bearings

Misalignment due Retighten capscrews Instructions on


to loose tightening vehicle’s manual
capscrews

Transmission Improper or Replace disc Instructions on


noise with damaged clutch vehicle’s manual
shifted gears disc

Low lubricant level Fill with recommended Recommended


oil to the proper level lubricant - page 18

FSO-4305/4405 Ed. 07/04 General Information 33


Troubleshooting

Problem Probable cause Possible solution Reference

1 Transmission
noise with
shifted gears
(continued)
Worn or damaged
flywheel bushing
or bearing
Replace damaged parts Instructions on
vehicle’s manual

Vibration from Verify and repair as Instructions on


other vehicle per vehicle’s manual vehicle’s manual
components (drive
shaft, mounts, yoke)

Misalignment Realign Instructions on


between engine vehicle’s manual
and transmission

Worn or Replace damaged parts Instructions on this


damaged gears manual
and/or bearings

Warped main Replace warped shaft Instructions on this


shaft or manual
countershaft

Hard shifting Malfunction of Verify and adjust Instructions on


clutch (not clutch driving system vehicle’s manual
releasing)

Wrong adjustment Adjust pedal stroke Instructions on


of clutch pedal vehicle’s manual

Worn or damaged Replace damaged parts Instructions on


flywheel bushing or vehicle’s manual
bearing

Improper lubricant Drain and refill with Recommended


recommended oil lubricant - page 18

Low lubricant level Fill with recommended Recommended


oil to the proper level lubricant - page 18

Worn or damaged Replace damaged parts Gear shift lever


gear shift lever housing - page 49
components

34 General Information Ed. 07/04 FSO-4305/4405


Troubleshooting

Problem Probable cause Possible solution Reference

Hard shifting
(continued)
Worn or damaged
synchronizer rings

Excessively worn
Replace rings

Replace synchronizer
Synchronizer
assemblies -
page 119

Synchronizer
1
or damaged assemblies assemblies -
synchronizer page 119
assemblies (keys,
sleeve or hub)

Improper Readjust synchronizer Synchronizer


adjustment of assemblies assemblies -
synchronizer page 119
assemblies sleeve
or hub

Worn or damaged Replace damaged parts Instructions on this


shifting system manual
components (yokes,
nylon pads, bars,
shift blocks)

Improper end play Adjust end play Main shaft and


on main shaft or countershaft end
countershaft play adjustment -
pages 88 and 85

Gear shift Malfunction of clutch Verify and adjust clutch Instructions on


rubbing (not releasing) driving system vehicle’s manual

Wrong adjustment Adjust pedal stroke Instructions on


of clutch pedal vehicle’s manual
stroke

Malfunction of Verify and adjust system Instructions on


clutch driving vehicle’s manual
system

Worn or damaged Replace damaged parts Instructions on


flywheel bushing vehicle’s manual
or bearing

Incorrect idle Adjust idle speed Instructions on


speed adjustment vehicle’s manual

FSO-4305/4405 Ed. 07/04 General Information 35


Troubleshooting

Problem Probable cause Possible solution Reference

1 Gear shift
rubbing
(continued)
Worn or damaged
synchronizer rings

Worn or damaged
Replace rings

Replace gear
Synchronizer
assemblies -
page 119

Instructions on this
gear clutching teeth manual

Worn shift yokes Replace nylon pads Shift bars - page


nylon pads 117

Transmission Misalignment Realign Instructions on


slips out of between engine vehicle’s manual
gear and transmission

Incomplete gear Shift gear properly


shifting

Excessive vibration Replace and/or Instructions on


on gear shift lever tighten mounts vehicle’s manual
due to loose or
damaged engine
or transmission
mounts

Gear shift lever Adjust console Instructions on


console out of vehicle’s manual
position, forcing
the lever

Worn or damaged Replace synchronizer Synchronizer


synchronizer assemblies assemblies - page
assemblies 119

Excessive axial Adjust clearance Main shaft end play


clearance on main adjustment - page
shaft gears 88

Worn or damaged Replace gear Instructions on this


clutching gear teeth manual

Worn or damaged Replace damaged parts Instructions on this


shifting system manual
(gear shifting lever
housing, yokes,
bars, etc.)

36 General Information Ed. 07/04 FSO-4305/4405


Troubleshooting

Problem Probable cause Possible solution Reference

Oil leak Lubricant above


proper level

Clogged breather
Correct to proper level

Verify and unclog


breather
Recommended
lubricant - page 18
1
Worn or damaged Replace damaged Instructions on this
oil seals seals manual

Housing capscrews Reassemble with proper Instructions on this


not properly sealant and tightening manual - pages 25
tightened or lack torque and 26
of sealant

Cracked housing Replace or repair Requires specific


or covers damaged parts procedure

Warped or Replace or repair Requires specific


damaged mounting damaged parts procedure
surfaces of housings
and covers

Bearings failures Low lubricant level Fill with recommended Recommended


oil to the proper level lubricant - page 18

Contaminated or Drain and clean Recommended


not recommended transmission and lubricant - page 18
lubricant refill with
recommended oil

Improper assembly Reassemble transmission Instructions on this


of transmission manual
components

Improper end play Adjust end play Main shaft and


on main shaft or countershaft end play adjustment - pages
countershaft 88 and 85

Bearings were not Replace damaged parts. Instructions on this


lubricated prior to Reassemble following manual - page 29
assembly right procedure

FSO-4305/4405 Ed. 07/04 General Information 37


Troubleshooting

Problem Probable cause Possible solution Reference

1 Double shifting Double gear


shifting interlock
system assembled
improperly
Reassemble system Instructions on this
manual - page 76

38 General Information Ed. 07/04 FSO-4305/4405


Special Tools

To properly service the Eaton FSO-4305/FSO-4405 transmission, the following specialized


tools are recommended:

Ref. Description
1

These special tools should be ordered directly from the approved tools supplier:

FSO-4305/4405 Ed. 07/04 General Information 39


40 Ed. 07/04 FSO-4305/4405
Table of Contents

Input Shaft Bearing Cover

Removal ................................................. 43
Disassembly ........................................... 45
Assembly ................................................ 46
Installation .............................................. 47
2

FSO-4305/4405 Ed. 07/04 41


42 Ed. 07/04 FSO-4305/4405
Input Shaft Bearing Cover
Removal
1. Remove bleed plug and inlet connection.

1
FSO-4405A/01

2
2. Remove the three mounting capscrews of the
clutch collar.
2
3. Remove the clutch collar.

FSO-4405A/02

4. Remove the four mounting capscrews of the


clutch housing. 4
5. Remove the clutch housing.

5
FSO-4405A/03

FSO-4305/4405 Ed. 07/04 Input Shaft Bearing Cover 43


Input Shaft Bearing Cover
Removal
6. Remove the six mounting capscrews (inner or
outer hexagon head, depending on the 6
transmission model) from the input shaft
bearing cover.

FSO-4405A/04

2
6
FSO-4405A/05

7. Placing two pry bars under the slots existent


on the input shaft bearing cover, remove the 7
cover and the main shaft end play adjusting
shims.

FSO-4405A/06

44 Input Shaft Bearing Cover Ed. 07/04 FSO-4305/4405


Input Shaft Bearing Cover
Disassembly

1. Remove the main shaft front bearing cup with


the special puller. See Special Tools, Reference
?????.

FSO-4405A/07

2
2. Remove the oil baffle.
2
3. Remove input shaft bearing cover oil seal.
NOTE: The oil seal removed should not be 3
reused.

FSO-4405A/08

FSO-4305/4405 Ed. 07/04 Input Shaft Bearing Cover 45


Input Shaft Bearing Cover
Assembly

1. Install the new oil seal, hitting it carefully with


the special installer of the proper diameter. See 2
Special Tools, Reference ???.
1
2. Install the oil baffle, observing its correct
assembly position.

FSO-4405A/08

2
3. Install the main shaft front bearing cup, hitting
it carefully with the special installer until it is 3
properly seated on the oil baffle. See Special
Tools, Reference ???.

FSO-4405A/09

46 Input Shaft Bearing Cover Ed. 07/04 FSO-4305/4405


Input Shaft Bearing Cover
Installation
NOTE: Thoroughly clean the parts and
remove any remaining sealant from the 1, 2
mounting surfaces prior to installation.
WARNING! The main shaft end play is
adjusted by using a shim pack,
positioned under the input shaft bearing
cover.
1. Use the same original shim pack if the main
shaft end play is within the specified range, or
else add or remove shims as needed, following
the main shaft end play measurement. See FSO-4405A/86

2
Main Section Assembly, Main Shaft End Play
Adjustment. 3
NOTE: Main shaft end play = 0.025 mm to
0.100 mm (0.01 to 0.04 in)
2. Apply sealant to both sides of shims of the
selected pack and to the mounting surface of
the input shaft bearing cover.
NOTE: Apply Eaton E679 sealant to both
sides of shims and cover surface. 2, 3
3. Install the shim pack and the input shaft bearing FSO-2405/77
cover. Observe the position of the lubricating
slots on both cover and shims. Slots should be
A
turned toward the upper side of the
transmission (A).
3
WARNING: Lubricant slots on both cover
and shims must be turned toward the
upper side of the transmission (A).
NOTE: Place shims with highest thickness
on the extremities of the pack.

FSO-4405A/04

FSO-4305/4405 Ed. 07/04 Input Shaft Bearing Cover 47


Input Shaft Bearing Cover
Installation

4. Apply sealant to the threads of the six mounting


capscrews of the input shaft bearing cover and 4
tighten them to the proper torque.
NOTE: Apply Eaton E677 sealant to the
threads.
Torque = 9.5 to 16.3 N.m (7 to 12 lb.ft)

FSO-4405A/04

2
5. Install the clutch housing and collar following
the inverse order of the removal.
NOTE: Clutch housing, torque = 108.6 to
121.7 N.m (80 to 90 lb.ft)
Clutch collar, torque = ??? N.m (??? lb.ft)
6. Install the bleed valve and the inlet connection.

5
6
FSO-4405A/01

48 Input Shaft Bearing Cover Ed. 07/04 FSO-4305/4405


Table of Contents

Gear Shift Lever Housing

Direct Gear Shift Lever Housing ............. 51


Removal............................................ 51
Disassembly ..................................... 52
Assembly .......................................... 55
Installation ........................................ 58
Remote Gear Shift Lever Housing ......... 59
Removal............................................ 59
Disassembly ..................................... 60
Assembly .......................................... 62 3
Installation ........................................ 64

FSO-4305/4405 Ed. 07/04 49


50 Ed. 07/04 FSO-4305/4405
Direct Gear Shift Lever Housing
Removal
1. Place transmission gear shifting mechanism in
NEUTRAL. 3
2. Remove the four mounting capscrews of the
gear shift lever housing to the transmission 2
case.
3. Remove the gear shift lever housing from the
transmission case.

FSO-4405A/183

FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing 51


Direct Gear Shift Lever Housing
Disassembly
1. Secure the gear shift lever housing in a vise,
with the gear shift lever facing up.
1
2
2. From the cover, remove the four retaining
capscrews and remove the cover.

FSO-4405A/184

3. Remove the boot.


3
4. Remove the two gear shift lever retaining
capscrews and remove the lever.
4

3 5. Remove the two nylon thrust washers.


5
FSO-4405A/185

FSO-4405A/186

52 Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405


Direct Gear Shift Lever Housing
Disassembly
6. From the gear shift lever positioning system,
remove the two retaining plugs. 6
A - Plug
B - Plunger spring
C - Plunger
D - Ball
E - Ball Spring
7. Remove the plunger spring, the plunger and
the ball from both sides of the gear shift lever FSO-4405A/187
housing.
C

B
A
D

8. Using a screw driver, remove the ball spring


from its housing on both gear shift lever housing
sides.
FSO-4405A/188

3
8

FSO-4405A/189

9. Using a pin punch, remove the stop pin of the


5th/reverse gear shift inhibitor mechanism, from
9
inside to outside of the gear shift lever housing.

FSO-4405A/190

FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing 53


Direct Gear Shift Lever Housing
Disassembly
10. Remove the 5th/reverse gear shift inhibitor
mechanism. A
A - Torsion spring B
B - Cam plate
C - Stop pin C

FSO-4405A/191

11. Remove the pivot pin of the gear shift lever ball
joint, the ball joint itself and the two nylon thrust
washers.

11

3 FSO-4405A/192

54 Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405


Direct Gear Shift Lever Housing
Assembly
1. Install the torsion spring of the 5th/reverse gear
shift inhibitor mechanism by inserting one end
into the existing gear shift lever housing hole.

FSO-4405A/193

2. Position the cam plate on the housing by fitting


the guide pin and the free torsion spring end.
Holding the cam plate in place, install the stop
pin and press it into place.

3. Place the ball joint on the gear shift lever with


the two nylon thrust washers and install the
pivot pin.
FSO-4405A/194

3
3
FSO-4405A/192

FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing 55


Direct Gear Shift Lever Housing
Assembly
4. Insert the gear shift lever with the two nylon
thrust washers into the gear shift lever housing,
placing the gear shift lever upper end toward
the same side as the 5th/reverse gear shift
inhibitor mechanism.
4

FSO-4405A/195

3 5. Install the two gear shift lever retaining


capscrews.
NOTE: Apply Eaton E677 sealant to the
6
FSO-4405A/196

threads.
Torque = 9,5 to 16,3 N.m (7 to 12 lb.ft)
6. Install the gear shift lever positioning system
plunger, springs, ball and the retaining plug on
both gear shift lever housing sides. Tighten the
plugs to the recommended torque.
A - Plug
FSO-4405A/197

B - Plunger spring
C - Plunger C
D - Ball
B
E - Ball Spring A
NOTE: Apply Eaton E679 sealant to the D
plug threads.
Torque = 10,5 to 20,3 N.m (8 to 15 lb.ft)

E
FSO-4405A/188

56 Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405


Direct Gear Shift Lever Housing
Assembly
7. Install the boot.
7
8. Install the cover and the four retaining
capscrews. 8
NOTE: Apply Eaton E677 sealant to the
threads.
Torque = 2,0 to 7,0 N.m (1,5 to 5,0 lb.ft)

FSO-4405A/198

FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing 57


Direct Gear Shift Lever Housing
Installation
1. Place transmission gear shifting mechanism in
NEUTRAL. 1

FSO-4405A/199

2. Apply the recommended sealant to gear shift


lever housing contact surface with the
transmission case.
NOTE: Apply Eaton E680 sealant to gear
shift lever housing face. 2
3. Install the gear shift lever housing on the
transmission case with the housing boss facing
the input shaft.
4. Install the four gear shift lever housing retaining

3 capscrews and tighten to the recommended


torque.
NOTE: Apply Eaton E677sealant to the
threads.
Torque = 19,0 to 25,7 N.m (14 to 19 lb.ft)
FSO-4405A/198

FSO-4405A/183

58 Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405


Remote Gear Shift Lever Housing
Removal
1. Place the gear shift lever in NEUTRAL.
4 2
2. Remove the four mounting capscrews of the
gear shift lever housing to the transmission
case.
3. Depending on the model of the transmission,
remove the lateral mounting capscrew of the
gear shift lever linkage and remove its bracket 3
to enable removal of the gear shift lever
housing.
4. Remove the gear shift lever housing and its
FSO-4405A/10
gasket.

FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing 59


Remote Gear Shift Lever Housing
Disassembly
1. Position and hold the gear shift lever housing 3
in a vise, with the lower part facing up. 1
2. On the front side of the housing, remove the
5th speed locator plug (offset) and then remove
the spring and the locating ball.
3. Remove the plug from the opposite side. 2
NOTE: Some transmission models also may
have a spring and a ball in this side of the
gear shift lever housing.
FSO-4405A/11

4. Remove the lock wire from the two mounting


capscrews of the internal shift selector. 4

3 5. Remove the two mounting capscrews of the


internal shift selector.
5
FSO-4405A/158

FSO-4405A/12

WARNING! Springs are assembled under


pressure. Be careful while removing the
plug and the snap ring that retains the
spring. 7
6. Remove rear plug of the shifting shaft and the 6
outer spring (1st and 2nd speeds shifting).
7. Remove the retainer and the inner spring (5th
and reverse speeds shifting) and the thrust
washer. 7
FSO-4405A/79

60 Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405


Remote Gear Shift Lever Housing
Disassembly
8. Remove the shifting shaft, boot and lever by
pulling them outwards.
8

FSO-4405A/12

9. Remove the gear shift lever housing oil seal.


9
NOTE: In case of worn housing bushings,
replace the whole gear shift lever housing.

FSO-4405A/14

FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing 61


Remote Gear Shift Lever Housing
Assembly
1. Install the new oil seal, hitting it carefully with a
special device of the proper diameter until it 1
rests against its seat. See Special Tools ,
Reference ???.

FSO-4405A/14

2. Place the boot on the shifting shaft and install


the shaft on the housing, passing it through 2
the first hole. Next, position the internal shift
selector and push the shaft until it reaches the
other hole.

3 3. Install the thrust washer and then install the


inner spring and the retainer. 3
FSO-4405A/15

FSO-4405A/16

4. Install the external spring and the rear plug,


after applying a light sealant coat on the
mounting surface of the plug. DO NOT apply
sealant to the plug’s thread. Press the plug
against the spring to allow it to be installed.
4
NOTE: Apply Eaton E679 sealant to
the mounting surface of the plug.
Torque = 34 to 41 N.m (25 to 30 lb.ft)

FSO-4405A/79

62 Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405


Remote Gear Shift Lever Housing
Assembly
5. Align the holes on the internal shift selector with 5
the holes on the shaft and tighten the two
mounting capscrews.
NOTE: Torque = 34 to 41 N.m (25 to 35 lb.ft)

FSO-4405A/12

6. Lock the two mounting capscrews with the wire.


6

7. On the rear side of the housing, install the plug


opposite to the 5th speed locator (offset).
NOTE: Some transmission models also may
7
FSO-4405A/158

3
have a spring and a ball in this side of the
gear shift lever housing.
8. On the front side of the housing, install the 5th 8
speed locating ball, its spring and the plug.
NOTE: Apply Eaton E679 sealant to the
mounting surfaces of the plugs. DO NOT
apply sealant to the plugs’ threads FSO-4405A/11
Torque = 13.6 to 20.3 N.m (10 to 15 lb.ft)

FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing 63


Remote Gear Shift Lever Housing
Installation
1. Place a new gasket and the gear shift lever
housing assembly on the transmission case. 1 3
2. Depending on the model of the transmission,
install the shift lever linkage bracket and tighten
its mounting capscrew.
3. Apply sealant to the threads of the four
mounting capscrews of the gear shaft lever 2
housing and tighten them to the proper torque.
NOTE: Apply Eaton E677 sealant to the
threads.
FSO-4405A/10
Torque = 19 to 25.7 N.m (14 to 19 lb.ft)

64 Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405


Table of Contents

Main Section

Engagement ........................................... 67
Disassembly ..................................... 67
Assembly .......................................... 75
Countershaft End Play
Adjustment .................................. 85
Main Shaft End Play
Adjustment .................................. 88
Final Assembly............................ 91
Input Shaft .............................................. 93
Disassembly ..................................... 93
Assembly .......................................... 94
Main Shaft .............................................. 95
Disassembly ..................................... 95
Assembly ........................................ 102
4
Countershaft ......................................... 108
Disassembly ................................... 108
Assembly ........................................ 111

FSO-4305/4405 Ed. 07/04 65


66 Ed. 07/04 FSO-4305/4405
Engagement
Disassembly
1. Remove the clutch housing and collar and the
input shaft bearing cover. See Input Shaft
Bearing Cover, Removal.

1
FSO-4405A/17

2. Remove the cover of the shift bar locating


device, by loosing the two mounting capscrews. 2
Depending on the model of the transmission,
the cover of the locating device can be a
rectangular plate or the shifting cable bracket
itself, used simultaneously as a cover, as shown
on the illustration aside.

FSO-4405A/18

3. Remove the three springs and balls (or


FSO-4405A/80
4
spherical pins) of the shift locating device.
A = 1st and 2nd speeds locator C
B
B = 3rd and 4th speeds locator A 3
C = 5th and reverse speeds locator D
D = Not used

FSO-4405A/19

FSO-4305/4405 Ed. 07/04 Main Section 67


Engagement
Disassembly
4. Remove the reverse speed light switch and the
washer.

FSO-4405A/20

5. Remove the gear shift lever housing. See Gear


Shift Lever Housing, Removal. 5

FSO-4405A/10

6. Remove the neutral switch and the two balls.


7. Remove the speedometer sensor.
6

4
6
7
FSO-4405A/21

8. Lock the shaft with a special tool and remove


the output yoke nut. See Special Tools , 8
Reference ???.
9
9. Remove the output yoke. If necessary, remove
the yoke’s baffler.

FSO-4405A/22

68 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Disassembly
10. To replace only the rear oil seal, it is not required
to disassemble the rear case. It is possible to 10
remove the oil seal at this stage, by pulling it
from its housing. Install a new seal with the
proper special tool. See Special Tools ,
Reference ?.

FSO-4405A/23

11. Remove the eighteen mounting capscrews of


the rear case.

11
FSO-4405A/24

NOTE: Depending on the transmission


model, one capscrew (A) is used also to hold
the bracket of the gear shift lever linkage and
other two capscrews (B) are used to hold
the counterweight of that shifting system. A
These three capscrews are different from the
others and differ one from each other as well.

12. Place the transmission with the input shaft


B
FSO-4405A/160
4
facing up. 12 13
13. Remove the three mounting capscrews of the
countershaft front cover and remove the cover.
NOTE: Depending on the countershaft front
cover type, these three capscrews might be
outer or inner hexagon head type.

FSO-4405A/25

FSO-4305/4405 Ed. 07/04 Main Section 69


Engagement
Disassembly
14. Remove the countershaft end play adjusting
shims. 14

FSO-4405A/26

15. Remove the two reverse idler gear mounting


capscrews.

15
FSO-4405A/27

16. Using two pry bars, separate the front case from
the rear case.
16

4 17. Remove the front case by lifting it.


FSO-4405A/28

17

FSO-4405A/29

70 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Disassembly
18. With the recommended special device, remove
the countershaft front bearing cup by hitting it
carefully from either inside or outside the case. 18
See Special Tools, Reference ???.

FSO-4405A/30

19. Lift and remove the reverse idler gear shaft.


19
20. Remove the reverse idler gear shaft together
with the needle bearing, paying special 20
attention not to drop the bearing.

FSO-4405A/31

21. Move the countershaft slightly and remove the


input shaft.
21
22. Remove the 4th speed synchronizer ring.

23. Remove the roll pin of the 5th and reverse


speed shift yoke, using a pin punch.
NOTE: Use a 5 mm diameter pin punch.
22

FSO-4405A/32
4
WARNING! To avoid damage to either the
shift bar or its bore on the case, or to
both, place a wooden block between the
gears and the bar.
24
24. Make sure that the transmission is on
NEUTRAL position and remove the 5th and 23
reverse speed shift bar together with the shift
control block. The 5th and reverse speed shift
yoke will be removed later, together with the
main shaft.
FSO-4405A/33

FSO-4305/4405 Ed. 07/04 Main Section 71


Engagement
Disassembly
25. Remove the roll pin of the 3rd and 4th speed
shift yoke, using a pin punch. 25
NOTE: Use a 5 mm diameter pin punch.
WARNING! To avoid damage to either the
shift bar or its bore on the case, or to
both, place a wooden block between the
gears and the bar.

FSO-4405A/34

26. Lift the 1st and 2nd speed shift yoke and shift
to 2nd speed. 26
27. Remove the roll pin of the 3rd and 4th speed
shift control block, using a pin punch.
27
NOTE: Use a 4 mm diameter pin punch.
WARNING! To avoid damage to either the
shift bar or its bore on the case, or to
both, place a wooden block between the
gears and the bar.
FSO-4405A/35

28. Disengage the 2nd speed and return the 1st


and 2nd speed shift yoke to NEUTRAL. Then
remove the 3rd and 4th speed shift bar together
with its yoke and shift control block. 28

4 29. Remove the roll pin of the 1st and 2nd speed
FSO-4405A/36

shift yoke, using a pin punch.


30
NOTE: Use a 5 mm diameter pin punch.
WARNING! To avoid damage to either the
shift bar or its bore on the case, or to
both, place a wooden block between the 29
gears and the bar.
30. Remove the 1st and 2nd speed shift bar and
yoke.
FSO-4405A/37

72 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Disassembly
31. Move the countershaft slightly to enable
removal of the main shaft.
32. Remove the main shaft from its housing on the
rear case, lifting the shaft together with the 5th
and reverse speed shift yoke. Next, remove the
31 32
5th and reverse speed shift yoke from the main
shaft assembly.

FSO-4405A/38

33. Remove the countershaft from the


transmission case.
33

FSO-4405A/39

34. Remove the four balls of the double gear


shifting interlocking system.

35. Remove the main shaft rear oil seal, by hitting


34
FSO-4405A/40
4
it from the inside to the outside of the case.
36
NOTE: The oil seal removed should not be
reused. 35
36. Remove the main shaft rear bearing cup, by
hitting it with a special device from the outside
to the inside of the case. See Special Tools,
Reference ???.

FSO-4405A/41

FSO-4305/4405 Ed. 07/04 Main Section 73


Engagement
Disassembly
37. Remove the countershaft rear cover, by
37
loosening its four mounting capscrews.

FSO-4405A/42

38. Remove the countershaft rear bearing cup, by


hitting it with a special device from the outside 38
to the inside of the case. See Special Tools,
Reference ???.

FSO-4405A/43

74 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Assembly
NOTE: Thoroughly clean the parts and
remove any remaining sealant from the 1 3
mounting surfaces prior to installation.
1. Properly place the rear case with its internal 2
side facing up.
2. Carefully clean the bearings cups and housings
prior to installation.
3. Install the countershaft rear bearing cup, by
pressing it with a special device until it rests
properly against its housing. See Special Tools,
FSO-4405A/44
Reference ???.

4. Install the main shaft rear bearing cup, by


pressing it with a special device until it rests 4
properly against its housing. See Special Tools,
Reference ???.

FSO-4405A/45
4

FSO-4305/4405 Ed. 07/04 Main Section 75


Engagement
Assembly
5. Turn the rear case over and properly place it
with the internal side facing down.
6
6. Manually align the rear oil seal and install it on
the case, by hitting it with a special device until
it rests properly against its housing. See Special
Tools, Reference ???. 5

FSO-4405A/46

7. Return the rear case to the position with the


7
internal side facing up.
8
8. Install the four balls of the double gear shifting
interlocking system, placing two balls in each
of the housings. Apply a light grease coat to
keep the balls in the housings during assembly.

FSO-4405A/47

9. Install the countershaft in its housing on the


rear case, with the rear bearing cone facing
up. 9

4 10. Install the speedometer rotor on the rear end


FSO-4405A/39

of the main shaft, after applying a grease coat


10
to the rotor hole in order to avoid it to fall during
installation of the shaft.

FSO-4405A/48

76 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Assembly
11. Place the 5th and reverse speed shift yoke on
the slot of the corresponding synchronizer
12
sleeve on the main shaft.
12. Tilt the countershaft slightly and install the main
shaft on its housing on the rear case, with the
rear bearing cone facing down. Once the main
shaft has been placed, the countershaft will
return to its correct position.

11
FSO-4405A/38

13. Insert the 5th and reverse speed shift bar with
the shift control block already assembled
through its respective shift yoke. 13
14. With a light grease coat, install the neutral
switch driving pin on the 5th and reverse speed
shift bar.
14

FSO-4405A/49

15. Push the 5th and reverse shift bar inside its
bore on the case, making sure that the bar is
properly installed on the ball of the double gear 15
shifting interlocking system.
NOTE: Be careful not to misplace the balls
of the double gear shifting interlocking
system from their housings.

16. Place the 3rd and 4th speed shift yoke on the
FSO-4405A/50
4
slot of the corresponding synchronizer sleeve
and install the respective shift bar through the
yoke.
16
17. With a light grease coat, install the interlock
pin in the 3rd and 4th speed shift bar.

17

FSO-4405A/51

FSO-4305/4405 Ed. 07/04 Main Section 77


Engagement
Assembly
18. Install the 3rd and 4th speed shift control block
on the shift bar and push the shift bar to its
bore on the case, assuring that the bar is
properly installed on the ball of the double gear
shifting interlocking system.
NOTE: Be careful not to misplace the balls
of the double gear shifting interlocking
system from their housings.
18

FSO-4405A/52

19. Place the 1st and 2nd speed shift yoke on the
slot of the corresponding synchronizer sleeve
and install its shift bar through the yoke. 20
20. Push the 1st and 2nd speed shift bar to its bore 19
on the case, making sure that the bar is properly
installed on the ball of the double gear shifting
interlocking system.
NOTE: Be careful not to misplace the balls
of the double gear shifting interlocking
system from their housings.
FSO-4405A/53

21. Align the mounting hole on the 3rd and 4th


speed shift bar with the hole on the shift yoke
and install a new roll pin. 21
NOTE: Use a 5 mm diameter pin punch.
WARNING! To avoid damage to either the
shift bar or its bore on the case, or to
both, place a wooden block between the

4 gears and the bar.

22. Align the mounting hole on the 3rd and 4th


FSO-4405A/54

speed shift control block with the hole on the


shift bar and install a new roll pin. 22
NOTE: Use a 4 mm diameter pin punch.
WARNING! To avoid damage to either the
shift bar or its bore on the case, or to
both, place a wooden block between the
gears and the bar.

FSO-4405A/55

78 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Assembly
23. Align the mounting hole on the 5th and reverse
speed shift bar with the hole on the shift yoke
and install a new roll pin.
NOTE: Use a 5 mm diameter pin punch.
WARNING! To avoid damage to either the
shift bar or its bore on the case, or to 23
both, place a wooden block between the
gears and the bar.

FSO-4405A/56

24. Align the mounting hole on the 1st and 2nd


speed shift bar with the hole on the shift yoke 24
and install a new roll pin.
NOTE: Use a 5 mm diameter pin punch.
WARNING! To avoid damage to either the
shift bar or its bore on the case, or to
both, place a wooden block between the
gears and the bar.

FSO-4405A/57

25. At the end of assembling the shift bars, yokes


and control blocks, all bars must have their 25
upper end aligned and the control blocks must
be aligned in neutral position.
26. Test the functionality of the double shifting
interlocking system, trying to shift two gears at
the same time: shift to any gear and then try
shifting another one.

27. Install the 4th speed synchronizer ring on the


FSO-4405A/58
4
main shaft. 27
WARNING! The 4th speed synchronizer
ring DOES NOT have EFM coating. See
Shifting System, Synchronizer
Assemblies.

FSO-4405A/59

FSO-4305/4405 Ed. 07/04 Main Section 79


Engagement
Assembly
28. Slightly move the countershaft and install the
input shaft assembly. 28

FSO-4405A/32

29. Install the reverse idler gear with the needle


bearing in its shaft on its housing on the rear
case.
29
NOTE: Lubricate the needle bearing with the
same recommended lubricating oil of the
transmission.

FSO-4405A/82

29

4 30. Align the lower hole of the reverse idler gear


FSO-4405A/60

shaft with the hole on the rear case and install


the mounting capscrew.
NOTE: Apply Eaton E677 sealant to the
thread.
Torque = 19 to 25.7 N.m (14 to 19 lb.ft)
30

FSO-4405A/83

80 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Assembly
31. Remove any residual sealant form the mounting
surfaces on the front and rear transmission
cases.
32. Remove any residual sealant from the
capscrew holes on the cases, using proper taps 31, 33
or specially prepared capscrews.
33. Apply recommended sealant on the mounting
surface of the rear case with the front case,
spreading it homogeneously over all the surface 32
to avoid leakages.
NOTE: Apply Eaton E680 sealant to the
FSO-4405A/61

mounting surface of the cases.

NOTE: Make sure that all shift bars and


assemblies are in NEUTRAL position. 34
34. Place the front case over the rear case,
observing the correct positioning of the dowel
pins.

35. Apply sealant to the threads of the eighteen


FSO-4405A/29
4
rear case mounting capscrews. 35
NOTE: Apply Eaton E677 sealant to
the threads.

FSO-4405A/62

FSO-4305/4405 Ed. 07/04 Main Section 81


Engagement
Assembly
36. Place the lifting hook and install the eighteen
mounting capscrews. Tighten the capscrews 36
crosswise to the appropriate torque.
NOTE: Torque = 19 to 25.7 N.m (14 to 19
lb.ft)

FSO-4405A/84

NOTE: Depending on the transmission


model, one capscrew (A) is used also to hold
the bracket of the gear shift lever linkage and
other two capscrews (B) are used to hold
the counterweight of that shifting system. A
These three capscrews are different from the
others and differ one from each other as well.

B
FSO-4405A/160

37. Install the second mounting capscrew of the


reverse idler gear shaft on the front case.
NOTE: Apply Eaton E677 sealant to the
thread.
Torque = 19 to 25.7 N.m (14 to 19 lb.ft)

4 38. Install the countershaft end play adjusting


37
FSO-4405A/27

shims.
38
NOTE: Use the same original shim pack
removed during disassembly. Place shims
with highest thickness on the extremities of
the pack.

FSO-4405A/26

82 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Assembly
NOTE: At this stage, DO NOT apply any
sealant to the mounting surface of the
countershaft front cover with the 39
transmission case or in the threads of the
cover mounting capscrews.
39. Temporarily install the countershaft front cover
and the three mounting capscrews. Tighten the
capscrews to the appropriate torque.
NOTE: Depending on the countershaft front
cover type, these three capscrews might be
outer or inner hexagon head type. FSO-4405A/63

Stamped sheet cover, torque = 9.5 to 16.3


N.m (7 to 12 lb.ft)
Cast iron cover, torque = 24.4 to 31.2 N.m
(18 to 23 lb.ft)

40. Install the main shaft end play adjusting shims


40
pack and temporarily install the input shaft
cover. Observe the position of the lubricating 41
slots on both cover and shims. Slots should be
turned toward the upper side of the
transmission. See Input Shaft Bearing Cover,
Installation.

4
NOTE: Use the same original shim pack
removed during disassembly. Place shims
with highest thickness on the extremities of
the pack. FSO-4405A/64
At this stage, DO NOT apply any sealant to
the mounting surface of the input shaft cover
or in the threads of the cover mounting
capscrews.
41. Install the six mounting capscrews of the input
shaft bearing cover and tighten the capscrews
to the appropriate torque.
NOTE: Torque = 9.5 to 16.3 N.m (7 to 12
lb.ft)

FSO-4305/4405 Ed. 07/04 Main Section 83


Engagement
Assembly
42. Place the transmission with the rear side facing
up.
43
44, 45
43. Install the output yoke on the splines of the main
shaft.
NOTE: If necessary, replace the yoke baffler. 42
44. Apply sealant to the threads of the new yoke
nut and tighten the nut.
WARNING! The output yoke nut must be
replaced with a new one each time it is
disassembled. FSO-4405A/65

45. Lock the shaft with a special tool and tighten


the yoke nut to the appropriate torque. See
Special Tools, Reference ???.
NOTE: Apply Eaton E677sealant to the
yoke nut threads.
Torque = 407 to 475 N.m (300 to 350 lb.ft)
46. Check the countershaft end play. See
Countershaft End Play Adjustment next in this
manual.

84 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Countershaft End Play Adjustment
NOTE: The transmission must be positioned 49
with the rear side facing up.
47. Invert the mounting position of the countershaft
rear cover in one of the mounting holes and 47
use the cover itself as a base to support the
magnetic base of the dial indicator.
48. Rotate the countershaft several times, both
clockwise and counterclockwise, to guarantee
48
that it is completely seated on the bearing.
49. Place the tip of the dial indicator on the end of
FSO-4405A/66
the countershaft. Set the pointer to zero.

50. Remove the lateral cover of the power take off


(PTO) opening.
51. Insert a pry bar through the PTO opening and
force the countershaft upwards at once. Read
the countershaft end play on the dial indicator.

52. Invert the position of the transmission case,


50
51
FSO-4405A/67
4
placing it with the input shaft facing up. 53
53. Remove the countershaft front cover and
remove the end play adjusting shims. 52

FSO-4405A/63

FSO-4305/4405 Ed. 07/04 Main Section 85


Engagement
Countershaft End Play Adjustment
54. If necessary, add or remove shims to set the
end play within the specified range, preferably 54, 55
closer to the lower limit.
NOTE: Add shims to reduce end play and
remove shims to increase end play.
Place shims with highest thickness on the
extremities of the pack.
Countershaft end play = 0.025 mm to 0.100
mm (0.01 to 0.04 in)
55. Install the selected shim pack.
FSO-4405A/26
NOTE: Apply Eaton E679 sealant to both
sides of shims.

56. Apply sealant to mounting surface of the


countershaft front cover with the transmission
56
case and install the cover.
57
NOTE: Apply Eaton E680 sealant to the
mounting surface of the countershaft
front cover.
57. Apply sealant to the threads of the three

4 mounting capscrews of the countershaft front


cover and tighten them to the proper torque.
NOTE: Depending on the countershaft front
cover type, these three capscrews might be
outer or inner hexagon head type.
FSO-4405A/63

Stamped sheet cover, torque = 9.5 to 16.3


N.m (7 to 12 lb.ft)
Cast iron cover, torque = 24.4 to 31.2 N.m
(18 to 23 lb.ft)

86 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Countershaft End Play Adjustment
58. Install the lateral PTO opening cover.
NOTE: Apply Eaton E680sealant to the
mounting surface of the PTO cover.
Apply Eaton E677 sealant to the threads.
Torque = 19 to 25.7 N.m (14 to 19 lb.ft)
59. Check the main shaft end play. See Main Shaft 59
End Play Adjustment next in this manual.
58

FSO-4405A/85

FSO-4305/4405 Ed. 07/04 Main Section 87


Engagement
Main Shaft End Play Adjustment
NOTE: The transmission must be positioned
62
with the rear side facing up.
61
60. Invert the mounting position of the countershaft
rear cover in one of the mounting holes and 60
use the cover itself as a base to support the
magnetic base of the dial indicator.
61. Rotate the main shaft several times, both
clockwise and counterclockwise, to guarantee
that it is completely seated on the bearing.
63
62. Place the tip of the dial indicator on the end of
FSO-4405A/68
the main shaft. Set the pointer to zero.
63. Place two pry bars under the output yoke and
force the main shaft upwards at once. Read
the main shaft end play on the dial indicator.

64. Invert the position of the transmission case,


placing it with the input shaft facing up. 64
65. Remove the input shaft bearing cover and 65
remove the end play adjusting shims.

4 FSO-4405A/64

88 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Main Shaft End Play Adjustment
66. If necessary, add or remove shims to set the
end play within the specified range, preferably 66, 67
closer to the lower limit.
NOTE: Add shims to reduce end play and
remove shims to increase end play.
Place shims with highest thickness on the
extremities of the pack.
Main shaft end play = 0.025 mm to 0.100
mm (0.01 to 0.04 in)
67. Apply sealant to both sides of shims of the
selected pack and to the mounting surface of FSO-4405A/86

the input shaft bearing cover.


68
NOTE: Apply Eaton E679 sealant to both
sides of shims and cover surface.
68. Install the shim pack and the input shaft bearing
cover. Observe the position of the lubricating
slots on both cover and shims. Slots should be
turned toward the upper side of the
transmission (A).
WARNING: Lubricant slots on both cover 67, 68
and shims must be turned toward the
FSO-2405/77
upper side of the transmission (A).
NOTE: Place shims with highest thickness A
on the extremities of the pack.
68

69. Apply sealant to the threads of the six mounting


FSO-4405A/04
4
capscrews of the bearing cover and tighten 69
them to the proper torque.
NOTE: Apply Eaton E677sealant to the
threads.
Torque = 9.5 to 16.3 N.m (7 to 12 lb.ft)

FSO-4405A/64

FSO-4305/4405 Ed. 07/04 Main Section 89


Engagement
Main Shaft End Play Adjustment
70. Invert the position of the transmission again,
placing it with the rear side facing up. 71
71. Apply sealant to mounting surface of the 70
countershaft rear cover with the transmission 72
case and install the cover.
NOTE: Apply Eaton E680 sealant to the
mounting surface of the countershaft rear
cover.
72. Apply sealant to the threads of the three
mounting capscrews of the countershaft rear
FSO-4405A/87
cover and tighten them to the proper torque.
NOTE: Apply Eaton E677sealant to the
threads.
Torque = 19 to 25.7 N.m (14 to 19 lb.ft)

90 Main Section Ed. 07/04 FSO-4305/4405


Engagement
Final Assembly
73. Install the speedometer sensor.
74. Install the neutral switch and the two balls.
74

74
73
FSO-4405A/21

75. Install the gear shift lever housing. See Gear 75


Shift Lever Housing, Installation.

FSO-4405A/10

76. Install the reverse speed light switch and the


washer.

77. Install the three springs and balls (or spherical


76

FSO-4405A/20
4
pins) of the shift bar locating device.
A = 1st and 2nd speeds locator C
B
B = 3rd and 4th speeds locator A 77
C = 5th and reverse speeds locator D
D = Not used

FSO-4405A/19

FSO-4305/4405 Ed. 07/04 Main Section 91


Engagement
Final Assembly
78. Install the cover of the shift locating device and
tighten its two mounting capscrews. Depending 78
on the model of the transmission, the cover of
the locating device can be a rectangular plate
or the shifting cable support itself, used
simultaneously as a cover, as shown on the
illustration aside.
NOTE: Apply Eaton E677sealant to the
threads.
Torque = 9.5 to 16.3 N.m (7 to 12 lb.ft)
FSO-4405A/18

78

FSO-4405A/80

79. Install the clutch collar and housing. See Input


Shaft Bearing Cover, Installation.

4 79
FSO-4405A/17

92 Main Section Ed. 07/04 FSO-4305/4405


Input Shaft
Disassembly
1. Remove the input shaft bearing cone with the
special puller. See Special Tools, Reference
???.

FSO-4405A/168

2. Hold the input shaft in a vise with the rear side


facing up. Remove the oil baffler with a
screwdriver.

FSO-4405A/169

FSO-4305/4405 Ed. 07/04 Main Section 93


Input Shaft
Assembly
1. Install the new oil baffler with a special device.
See Special Tools, Reference ???.

FSO-4405A/170

2. Place the input shaft in a press with the front


end facing up.
WARNING! Place the tubular tool on the
inner race of the bearing. NEVER support
it on the bearing cage.
3. Install the front bearing cone using a special
tubular tool. See Special Tools, Reference ???.

FSO-4405A/171

94 Main Section Ed. 07/04 FSO-4305/4405


Main Shaft
Disassembly
1. Manually remove the speedometer rotor from
the end of the main shaft.
1

FSO-4405A/48

2. From the front end of the shaft, place the special


puller on the 3rd speed gear and remove the 2
gear together with the 3rd and 4th speeds
synchronizer assembly, the 3rd speed
synchronizer ring and the front bearing cone.
See Special Tools, Reference ???.

FSO-4405A/106

3. Remove front and rear spacer rings of the 3rd


speed gear rollers and then remove the rollers.

4. Place the main shaft in vertical position in a


3

FSO-4405A/107
4
vise, with the front end facing up. 4
5. Remove the 2nd speed gear snap ring.
5

FSO-4405A/108

FSO-4305/4405 Ed. 07/04 Main Section 95


Main Shaft
Disassembly
6. Remove the thrust washer.
6

FSO-4405A/109

7. Remove the thrust washer locating ball.


7

FSO-4405A/110

8. Remove the 2nd speed gear.


8

4 9. Remove the 2nd speed gear rollers.


FSO-4405A/111

FSO-4405A/112

96 Main Section Ed. 07/04 FSO-4305/4405


Main Shaft
Disassembly
10. Remove the spacer ring of 2nd speed gear
rollers.

10

FSO-4405A/113

11. Remove the 2nd speed synchronizer rings


(Tricone) (only FSO-4305 transmission).

FSO-4405A/172

12. Remove the snap ring of the 1st and 2nd speed
synchronizer assembly.
12

13. Remove the 1st and 2nd speed synchronizer


FSO-4405A/114
4
assembly.
13

FSO-4405A/115

FSO-4305/4405 Ed. 07/04 Main Section 97


Main Shaft
Disassembly
14. Remove the 1st speed synchronizer rings
(Tricone) (only FSO-4305 transmission).

FSO-4405A/173

15. Remove the 1st speed gear.


15

FSO-4405A/116

16. Remove the 1st gear needle bearing.


16

4 17. Remove the reverse speed gear snap ring.


FSO-4405A/117

18. Remove the reverse speed gear thrust washer. 17

18

FSO-4405A/118

98 Main Section Ed. 07/04 FSO-4305/4405


Main Shaft
Disassembly
19. Remove the thrust washer locating ball.
19

FSO-4405A/119

20. Remove the reverse speed gear.


20

FSO-4405A/120

21. Remove the two reverse speed needle


bearings. 21

22. Remove the reverse speed synchronizer ring.


FSO-4405A/121
4
22

FSO-4405A/122

FSO-4305/4405 Ed. 07/04 Main Section 99


Main Shaft
Disassembly
23. Remove the snap ring of the 5th and reverse
speed synchronizer assembly.

23

FSO-4405A/123

24. Remove the 5th and reverse speed


synchronizer assembly.
24

FSO-4405A/124

25. Remove the 5th speed synchronizer ring.


26. Remove the main shaft from the vise.
25

4 27. From the rear end of the main shaft, place


FSO-4405A/125

27
special puller behind the rear bearing thrust
washer and remove the bearing together with
the washer. See Special Tools, Reference ???.

FSO-4405A/126

100 Main Section Ed. 07/04 FSO-4305/4405


Main Shaft
Disassembly
28. Remove the 5th speed gear.
29. Remove the 5th gear rollers.

28
29

FSO-4405A/127

FSO-4305/4405 Ed. 07/04 Main Section 101


Main Shaft
Assembly
1. Place the main shaft in vertical position in a
1
vise, with the rear end facing up.
2. Lubricate and position the rollers of the 5th
speed gear on the shaft, using a light coat of
grease to keep the rollers in their position.
NOTE: Use transmission oil to lubricate the
rollers. 3
3. Manually install the 5th speed gear, with the 2
cone side facing down, until it seats on the
shaft.
FSO-4405A/127

4. Place the main shaft in vertical position in a


press, with the rear end facing up and support
it properly.
5. Install the thrust ring of the main shaft rear
bearing. 6
WARNING! Place the tubular tool on the 4
inner race of the bearing. NEVER support
5
it on the bearing cage.
6. Use a tubular tool and press the rear bearing,
with the smaller side of the cone facing up, until
FSO-4405A/128
it seats on the shaft. See Special Tools ,
Reference ???.
7
7. Place the main shaft in vertical position in a
vise, with the front end facing up. 8
8. Install the 5th speed synchronizer ring, with the
flat side facing down (towards the 5th speed
gear).

4 9. Install the 5th and reverse speed synchronizer


FSO-4405A/125

assembly with its wider side facing up (towards


the reverse speed gear). 9

FSO-4405A/124

102 Main Section Ed. 07/04 FSO-4305/4405


Main Shaft
Assembly
10. Install the 5th speed gear snap ring.

10

FSO-4405A/123

11. Install the reverse speed synchronizer ring, with


the flat side facing up (towards the reverse
speed gear). 11

FSO-4405A/122

12. Lubricate and install the two needle bearings


of the reverse speed gear, using a light coat of 12
grease to keep the bearings in their position.
NOTE: Use transmission oil to lubricate the
bearings.

13. Install the reverse speed gear with the cone


FSO-4405A/121
4
side facing down. 13

FSO-4405A/120

FSO-4305/4405 Ed. 07/04 Main Section 103


Main Shaft
Assembly
14. Install the locating ball of the reverse speed
gear thrust washer. 14

FSO-4405A/119

15. Install the reverse speed gear thrust washer.


16. Install the reverse gear snap ring. 16

15

FSO-4405A/118

17. Lubricate and install the needle bearing of the


1st speed gear, using a light coat of grease to
keep the bearing in its position.
NOTE: Use transmission oil to lubricate the 17
bearing.

4 18. Install the 1st speed gear with the cone side
FSO-4405A/130

facing up. 18

FSO-4405A/116

104 Main Section Ed. 07/04 FSO-4305/4405


Main Shaft
Assembly
19. Install the 1st speed synchronizer rings
(Tricone) (only FSO-4305 transmission).

FSO-4405A/173

20. Install the 1st and 2nd speed synchronizer


assembly. 21
21. Install the synchronizer assembly snap ring.

20

FSO-4405A/131

22. Install the 2nd speed synchronizer rings


(Tricone) (only FSO-4305 transmission).

23. Install the spacer ring of the 2nd speed gear


FSO-4405A/172
4
rollers.
24. Lubricate and install the rollers of the 2nd speed 24
gear, using a light coat of grease to keep the 23
rollers in their position.
NOTE: Use transmission oil to lubricate the
bearing.

FSO-4405A/112

FSO-4305/4405 Ed. 07/04 Main Section 105


Main Shaft
Assembly
25. Install the 2nd speed gear on the rollers, with
the cone side facing the synchronizer assembly. 25

FSO-4405A/111

26. Install the locating ball of the 2nd speed gear


thrust washer. 26

FSO-4405A/110

27. Install the 2nd speed thrust washer.


28. Install the 2nd gear snap ring.

28

27

4 29. Install the rear spacer ring of the 3rd speed


FSO-4405A/108

gear rollers.
30. Lubricate and install the rollers of the 3rd speed
31
gear, using a light coat of grease to keep the 30
29
rollers in their position.
NOTE: Use transmission oil to lubricate the
bearing.
31. Install the front spacer ring of the 3rd speed
gear.
FSO-4405A/132

106 Main Section Ed. 07/04 FSO-4305/4405


Main Shaft
Assembly
32. Install the 3rd speed gear on the rollers, with
the cone side facing up (towards the
synchronizer ring).
32

FSO-4405A/133

33. Install the 3rd speed synchronizer ring.


WARNING! The 3rd speed synchronizer
ring HAS EFM coating. See Shifting
33
System, Synchronizer Assemblies.

FSO-4405A/134

34. Install the 3rd and 4th speed synchronizer


assembly with its hub wider surface facing down
(towards the 3rd speed gear). 34

35. Place the main shaft in a press, with the front


FSO-4405A/135
4
end facing up and support it properly.
36
WARNING! Place the tubular tool on the
inner race of the bearing. NEVER support
it on the bearing cage.
35
36. Using a tubular tool, press the front bearing
with the smaller side of the cone facing up, until
it seats on the shaft. See Special Tools ,
Reference ???.

FSO-4405A/136

FSO-4305/4405 Ed. 07/04 Main Section 107


Countershaft
Disassembly
1. Place the countershaft in vertical position in a
vise, with the front end facing up, and remove
the front bearing using a special puller. See
Special Tools, Reference ???.
1

FSO-4405A/137

2. Remove the 4th speed gear snap ring.

FSO-4405A/138

3. Place the countershaft in vertical position in a


press, with the front end facing up and using 3, 4
the 4th speed gear as a base.
4. Press the countershaft and remove the 4th
speed gear.

4 5. Turn the countershaft over on the press and


FSO-4405A/139

use the 3rd speed gear as a base. Then press


the countershaft and remove the 3rd speed
gear. 5

FSO-4405A/140

108 Main Section Ed. 07/04 FSO-4305/4405


Countershaft
Disassembly
6. Place the countershaft in vertical position in a
vise, with the rear end facing up and remove
the rear bearing using a special puller. See
Special Tools, Reference ???. 6

FSO-4405A/141

7. Remove the 5th speed gear snap ring.


7

FSO-4405A/142

8. Place the countershaft in vertical position in a


press, with the rear end facing up and using
the 5th speed gear as a base.
9. Press the countershaft and remove the 5th
speed gear. 8, 9

FSO-4405A/143
4

FSO-4305/4405 Ed. 07/04 Main Section 109


Countershaft
Disassembly
10. Using a punch, remove the rear key and the
two front keys, carefully tapping to not damage 10
the shaft and keys.

FSO-4405A/144

10

FSO-4405A/145

110 Main Section Ed. 07/04 FSO-4305/4405


Countershaft
Assembly
1. Using a hammer, install the rear key and the
two front keys. 1

FSO-4405A/144

FSO-4405A/145

2. Place the countershaft in vertical position in a


press, with the rear end facing up and using 3
the 2nd speed gear as a base.
3. Using a tubular tool, press the 5th speed gear
down the countershaft, with the most prominent
side of the gear flange facing down. Make sure
to keep the correct alignment of the gear slot
with the shaft key prior to pressing the gear 2
down. See Special Tools, Reference ???.

4. Install the 5th speed gear snap ring.


FSO-4405A/146
4
4

FSO-4405A/142

FSO-4305/4405 Ed. 07/04 Main Section 111


Countershaft
Assembly
WARNING! Place the tubular tool on the
inner race of the bearing. NEVER support 5
it on the bearing cage.
5. Using a tubular tool, press the rear bearing with
the smaller side of the cone facing up, until it
seats on the shaft. See Special Tools ,
Reference ???.

FSO-4405A/147

6. Turn the countershaft over on the press, so that


its front end will be facing up. Use the 5th speed 7
gear as a base.
7. Using a tubular tool, press the 3rd speed gear
down the countershaft with the most prominent
side of the gear flange facing up (towards the
4th speed gear). Make sure to keep the correct
alignment of the gear slot with the two shaft
keys prior to pressing the gear down. See
Special Tools, Reference ???. 6
FSO-4405A/148

8. Using a tubular tool, press the 4th speed gear


down the countershaft with the most prominent
side of the gear hub facing down (towards the
3rd speed gear). Make sure to keep the correct
alignment of the gear slot with the shaft key 8
prior to pressing the gear down. See Special
Tools, Reference ???.

4 9. Install the 4th speed gear snap ring.


FSO-4405A/149

FSO-4405A/138

112 Main Section Ed. 07/04 FSO-4305/4405


Countershaft
Assembly
WARNING! Place the tubular tool on the
inner race of the bearing. NEVER support 10
it on the bearing cage.
10. Using a tubular tool, press the front bearing
with the smaller side of the cone facing up, until
it seats on the shaft. See Special Tools ,
Reference ???.

FSO-4405A/150

FSO-4305/4405 Ed. 07/04 Main Section 113


114 Ed. 07/04 FSO-4305/4405
Table of Contents

Shifting System

Shift Yoke and Bars .............................. 117


Disassembly ................................... 117
Assembly ........................................ 118
Synchronizer Assemblies ..................... 119
Characteristics ................................ 119
1st and 2nd Speed “Booster”
Synchronizer Assembly .................. 121
Disassembly.............................. 121
Assembly .................................. 122
Regular Synchronizer
Assemblies ..................................... 125
Disassembly.............................. 125
Assembly .................................. 126

5
FSO-4305/4405 Ed. 07/04 115
116 Ed. 07/04 FSO-4305/4405
Shift Yoke and Bars
Disassembly
1. With an exception made to the shift control
block of the 5th and reverse speed shift bar
assembly and to the yoke nylon pads, all A
other components of the shifting system are
disassembled with the transmission main
section. See Main Section, Disassembly.
B
A = 1st and 2nd speed shift bar
B = 3rd and 4th speed shift bar
C = 5th and reverse speed shift bar C
FSO-4405A/71

2. Remove the 5th and reverse speeds shift


control block roll pin. 3
NOTE: Use a 5 mm diameter pin punch.
3. Remove the 5th and reverse speed shift
control block.

FSO-4405A/72

4. Remove the nylon pads on both ends of the


shift yokes.

FSO-4405A/73

5
FSO-4305/4405 Ed. 07/04 Shifting System 117
Shift Yoke and Bars
Assembly
1. Position the 5th and reverse speed shift
control block in its corresponding shift bar, 1
observing its mounting position related to
the slots for the locating balls on both ends
of the shift bar.
2. Align the roll pin hole on the shift control
block with the hole on the shift bar and install 2
a new roll pin.
NOTE: Use a 5 mm diameter pin punch.

FSO-4405A/72

3. Install the nylon pads on both ends of the


shift yokes.
4. Shift yokes, bars and shift blocks other than
the above mentioned, are assembled with
the transmission main section. See Main
Section, Assembly. 3

FSO-4405A/73

5
118 Shifting System Ed. 07/04 FSO-4305/4405
Synchronizer Assemblies
Characteristics
There are four synchronizer assemblies used
in the FSO-4305 and FSO-4405 transmissions: A B
A = 1st and 2nd speed synchronizer assembly,
used with “Tricone” synchronizer rings in the
FSO-4305 transmission.
B = 1st and 2nd speed “Booster” synchronizer
assembly, used with self contained C D
synchronizer rings in the FSO-4405
transmission.
C =3rd and 4th speed synchronizer assembly
FSO-4405A/174
D =5th and reverse speed synchronizer
assembly
C
NOTE: In an eventual repair to a
synchronizer assembly, do not replace
parts separately. Always replace the
entire assembly. B D

FSO-4405A/74

Types of synchronizer rings


E
E = “Tricone” synchronizer ring, used with a
regular synchronizer on 1st and 2nd speed
gears in the FSO-4305 transmission.

FSO-4405A/175

F = Regular synchronizer ring, without EFM II


coating, used on 4th, 5th and reverse speed F
gears.
G =Regular synchronizer ring, with EFM II
coating, used on 3rd speed gear.

G
5
FSO-4405A/75

FSO-4305/4405 Ed. 07/04 Shifting System 119


Synchronizer Assemblies
Characteristics
H =Self contained ring, with EFM II coating,
used with the “Booster” synchronizer on 1st
and 2nd speed gears in the FSO-4405
transmission.

FSO-4405A/88

5
120 Shifting System Ed. 07/04 FSO-4305/4405
Synchronizer Assemblies
1st and 2nd Speed “Booster” Synchronizer Assembly
This type of synchronizer (Booster) is used on
1st and 2nd speed gears in the FSO-4405 1
transmission.

Disassembly
1. Manually remove the synchronizer sleeve
from the hub. The entire assembly will
practically disassemble alone.
A = Synchronizer hub
FSO-4405A/76
B = Hub insert
C = Sleeve insert G B D
D = Synchronizer ring D
E = Synchronizer sleeve A
F = Key
G = Lock ring (spring)
C
F
E
FSO-4405A/89

5
FSO-4305/4405 Ed. 07/04 Shifting System 121
Synchronizer Assemblies
1st and 2nd Speed “Booster” Synchronizer Assembly
Assembly
1. Place one of the booster’s synchronizer ring
on a working bench, with its most prominent
side facing up.
2. Install the hub over the synchronizer ring,
with its most prominent side facing down.
Be careful to centralize the biggest slot on 2
the hub with the smallest slot on the ring.
1
FSO-4405A/90

3. Install the second synchronizer ring, with


its most prominent side facing down. Again,
be careful to centralize the bigger slot on
the hub with the smallest slot on the ring.

FSO-4405A/91

4. Insert the three keys on the smallest slots


on the hub, placing them between the two 4
synchronizer rings, so that the rings will be
supported by the keys.

FSO-4405A/92

5. Install the three hub inserts, fitting them on


the biggest slots on hub and on the 5
synchronizer rings slots.

5
FSO-4405A/93

122 Shifting System Ed. 07/04 FSO-4305/4405


Synchronizer Assemblies
1st and 2nd Speed “Booster” Synchronizer Assembly
6. From the inside of the sleeve, install the
three sleeve inser ts on its slots and
centralize the inserts visually.

6
FSO-4405A/94

FSO-4405A/95

WARNING! The matching marks on


the hub and on the sleeve of the 1st
and 2nd speeds synchronizer
assembly (Booster) must coincide
during the assembly.
7. Install the sleeve over the hub and the
synchronizer rings, fitting the sleeve inserts
on the hub inserts, paying attention to
coincide the matching marks on both hub
and sleeve. 7
FSO-4405A/96

8. Insert the hook shaped end of the lock ring


into its fitting hole on the hub, and insert 8
the other ring end under the synchronizer
ring.

5
FSO-4405A/97

FSO-4305/4405 Ed. 07/04 Shifting System 123


Synchronizer Assemblies
1st and 2nd Speed “Booster” Synchronizer Assembly
WARNING! Make sure that the hook
9
shaped end of the lock ring is really
attached to the fitting hole.
9. Invert the position of the synchronizer
assembly and install the other lock ring,
repeating the procedure described above.

FSO-4405A/161

5
124 Shifting System Ed. 07/04 FSO-4305/4405
Synchronizer Assemblies
Regular Synchronizer Assemblies
This type of synchronizer assembly is used on
1st and 2nd speed gears(only in the FSO-4305 B A
transmission) and on 3rd, 4th, 5th and reverse
speed gears (FSO-4305 and FSO-4405
transmissions).
Disassembly
C
A = Synchronizer hub
D
B = Synchronizer sleeve
C = Lock ring (spring)
FSO-4405A/98
D = Key
1. Remove the lock rings from the keys on both
sides of the synchronizer assembly. 1

FSO-4405A/99

2. Manually remove the synchronizer sleeve 2


from the hub, pulling it upwards.

FSO-4405A/100

3. Remove the three keys.


3

5
FSO-4405A/101

FSO-4305/4405 Ed. 07/04 Shifting System 125


Synchronizer Assemblies
Regular Synchronizer Assemblies
Assembly
1. Place the hub of the synchronizer assembly
on a working bench, with the matching mark
facing up.
2. Insert the three keys on their slots.

2
1
FSO-4405A/102

NOTE: The sleeve of 5th and reverse


speed synchronizer assembly is nort
symmetric and must be assembled with
the wider side of its outside face facing
the same side as the most prominent hub
side.

FSO-4405A/105

WARNING! The matching marks on


both the hub and the sleeve of the 3rd 3
and 4th speed and the 5th and reverse
speed synchronizer assemblies must
coincide during the assembly.
3. Align the inner lugs of the sleeve with their
slots on the hub, making sure that the
matching marks on both the sleeve and the
hub are aligned.

FSO-4405A/103

4. Install the sleeve on the hub, forcing it 4


downwards.

5
FSO-4405A/100

126 Shifting System Ed. 07/04 FSO-4305/4405


Synchronizer Assemblies
Regular Synchronizer Assemblies
5. Install the lock rings, fitting them on the key
slots and holding the hook shaped ends on 5
the outermost keys.
WARNING! Make sure that the hook
shaped end of the spring is really
attached to the key.

FSO-4405A/104

5
FSO-4305/4405 Ed. 07/04 Shifting System 127
128 Ed. 07/04 FSO-4305/4405
Eaton® Fuller®
Light Duty Transmissions