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EATON 8 SPEED-9 SPEED-13 SPEED SERVICE MANUAL

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EATON 8 SPEED-9 SPEED-13 SPEED SERVICE MANUAL contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your machine. This document is printable, without restrictions, contains searchable text and bookmarks for easy navigation.

EATON 8 SPEED-9 SPEED-13 SPEED SERVICE MANUAL includes:

Numbered table of contents easy to use so that you can find the information you need fast.
Detailed sub-steps expand on repair procedure information.
Numbered instructions guide you through every repair procedure step by step.
Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
Notes, cautions and warnings throughout each chapter pinpoint critical information.
Bold figure number help you quickly match illustrations with instructions.
Detailed illustrations, drawings and photos guide you through every procedure.
Enlarged inset helps you identify and examine parts in detail.

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TABLE OF CONTENT OF THE EATON 8 SPEED-9 SPEED-13 SPEED SERVICE MANUAL

1. IDENTIFICATION………………………………………………………………………………………….1
2. MAINTENANCE……………………………………………………………………………………………2
3. PRECAUTIONS………………………………………………………………………………………….3
3.1. DISASSEMBLY……………………………………………………………………………………3
3.2. INSPECTION……………………………………………………………………………………..4
3.3. REASSEMBLY…………………………………………………………………………………….6
4. CHANGING THE INPUT SHAFT…………………………………………………………………………6
4.1. SPECIAL PROCEDURE…………………………………………………………………………..6
4.2. DISASSEMBLY……………………………………………………………………………………7
4.3. REASSEMBLY…………………………………………………………………………………….7
5. AIR SYSTEM…………………………………………………………………………………………….8
5.1. TROUBLESHOOTING…………………………………………………………………………….8
5.2. AIR FILTER/REGULATOR ASSEMBLY…………………………………………………………..11
5.3. SLAVE VALVES………………………………………………………………………………….11
5.4. RANGE VALVE A-3546…………………………………………………………………………..13
Removal and Disassembly……………………………………………………………………….13
Reassembly and Installation……………………………………………………………………..14
5.5. RANGE VALVE A-5010…………………………………………………………………………..14
Removal and Disassembly……………………………………………………………………….15
Reassembly and Installation……………………………………………………………………..15
5.6. DEEP REDUCTION AIR SYSTEM: 8-SPEED “LL” MODELS ONLY……………………………..15
Troubleshooting………………………………………………………………………………….15
For Models Equipped with the Deep Reduction Valve……………………………………………15
For Models Equipped with the Master Control Valve A-5015……………………………………..16
5.7. ROADRANGER VALVE A-5015………………………………………………………………….19
Removal and Disassembly……………………………………………………………………….19
Reassembly and Installation……………………………………………………………………..20
5.8. SPLITTER SHIFT AIR SYSTEM: 13-SPEED SPLITTER MODELS ONLY.. …. … … … … …. … …20
Troubleshooting………………………………………………………………………………….20
5.9. INSERT VALVE: 8-SPEED “LL” MODELS (EQUIPPED WITH ROADRANGER VALVE A-5015) AND
13-SPEED SPLITTER MODELS…………………………………………………………………23
5.10. SELECTOR VALVE………………………………………………………………………………23
Removal and Disassembly……………………………………………………………………….23
Reassembly and Installation……………………………………………………………………..24
5.11. ROADRANGER VALVE A-4900………………………………………………………………….24
Removal and Disassembly……………………………………………………………………….25
Reassembly and Installation……………………………………………………………………..26
6. REMOVE………………………………………………………………………………………………..26
6.1. SHIFTING CONTROLS………………………………………………………………………….26
Air Control………………………………………………………………………………………..27
Air Filter/Regulator Assembly…………………………………………………………………….29
Slave Valve………………………………………………………………………………………30
6.2. GEAR SHIFT LEVER ASSEMBLY……………………………………………………………….32
6.3. SHIFTER HOUSING……………………………………………………………………………..32
6.4. UNIVERSAL JOINT COMPANION FLANGE OR YOKE………………………………………….33

6.5. AUXILIARY SECTION……………………………………………………………………………34
6.6. CLUTCH HOUSING……………………………………………………………………………..36
6.7. AUXILIARY SECTION (8-SPEED “LL” MODELS)………………………………………………..37
Range Cylinder Assembly………………………………………………………………………..37
Auxiliary Countershaft Assembly…………………………………………………………………41
Synchronizer Assembly…………………………………………………………………………..43
Low Range Gear…………………………………………………………………………………43
Deep Reduction Cylinder Assembly………………………………………………………………45
Range Mainshaft Assembly………………………………………………………………………47
Output Shaft and Rear Bearing Assemblies………………………………………………………49
6.8. AUXILIARY SECTION (9-SPEED AND RT-8608L MODELS)…………………………………….52
Range Cylinder Assembly………………………………………………………………………..52
Auxiliary Countershaft Assembly…………………………………………………………………55
Synchronizer Assembly…………………………………………………………………………..57
Output Shaft and Rear Bearing Assemblies………………………………………………………58
6.9. AUXILIARY SECTION (13-SPEED SPLITTER MODELS)…. ……… …….. ……… …….. ……..58
Range Cylinder Assembly………………………………………………………………………..58
Auxiliary Countershaft Assembly…………………………………………………………………62
Synchronizer Assembly (13-Speed Models)……………………………………………………..64
Low Range Gear…………………………………………………………………………………65
Splitter Cylinder Assembly……………………………………………………………………….67
Range Mainshaft Assembly………………………………………………………………………69
Output Shaft and Rear Bearing Assemblies………………………………………………………72
6.10. FRONT BEARING COVER AND INPUT SHAFT NUT……………………………………………72
6.11. AUXILIARY DRIVE GEAR……………………………………………………………………….74
6.12. LEFT REVERSE IDLER GEAR ASSEMBLY……………………………………………………..75
6.13. COUNTERSHAFT BEARINGS…………………………………………………………………..78
6.14. MAINSHAFT ASSEMBLY………………………………………………………………………..81
6.15. MAIN DRIVE GEAR ASSEMBLY…………………………………………………………………82
6.16. COUNTERSHAFT ASSEMBLIES………………………………………………………………..84
7. DISASSEMBLE…………………………………………………………………………………………85
7.1. GEAR SHIFT LEVER ASSEMBLY……………………………………………………………….85
7.2. SHIFTER HOUSING……………………………………………………………………………..86
7.3. AUXILIARY SECTION……………………………………………………………………………89
Synchronizer Assembly (8, 9 and 13-Speed Models)…………………………………………….89
Output Shaft and Rear Bearing Assemblies (8-Speed “LL” Models)… .. … … … .. … … … .. … … ..90
Output Shaft and Rear Bearing Assemblies (9-Speed and RT-8608 Models)…………………….91
Output Shaft and Rear Bearing Assemblies (13-Speed Models). … .. … … … .. … … … … .. … … ..95
7.4. MAINSHAFT ASSEMBLY………………………………………………………………………..97
7.5. COUNTERSHAFT ASSEMBLIES………………………………………………………………101
7.6. RIGHT REVERSE IDLER GEAR ASSEMBLY…………………………………………………..103
7.7. AUXILIARY DRIVE GEAR ASSEMBLY…………………………………………………………103
8. REASSEMBLE………………………………………………………………………………………..104
8.1. GEAR SHIFT LEVER ASSEMBLY………………………………………………………………104
8.2. SHIFTER HOUSING……………………………………………………………………………106
8.3. AUXILIARY SECTION (8-SPEED “LL” MODELS)………………………………………………110
Range Mainshaft Assembly……………………………………………………………………..110
Output Shaft and Rear Bearing Assemblies…………………………………………………….112

Low Range Gear………………………………………………………………………………..121
Synchronizer Assembly…………………………………………………………………………123
Auxiliary Countershaft Assemblies and Timing………………………………………………….125
Range Cylinder Assembly………………………………………………………………………127
8.4. AUXILIARY SECTION (9-SPEED MODELS)……………………………………………………130
Output Shaft and Rear Bearing Assemblies…………………………………………………….130
Synchronizer Assembly…………………………………………………………………………136
Auxiliary Countershaft Assemblies and Timing………………………………………………….138
Range Cylinder Assembly………………………………………………………………………141
8.5. AUXILIARY SECTION (13-SPEED MODELS)………………………………………………….144
Range Mainshaft Assembly……………………………………………………………………..144
Output Shaft and Rear Bearing Assemblies…………………………………………………….146
Auxiliary Countershaft Assemblies and Timing………………………………………………….153
Splitter Cylinder Assembly………………………………………………………………………155
Low Range Gear………………………………………………………………………………..158
Synchronizer Assembly…………………………………………………………………………160
Auxiliary Countershaft Rear Bearings…………………………………………………………..162
Range Cylinder Assembly………………………………………………………………………163
8.6. AUXILIARY DRIVE GEAR ASSEMBLY…………………………………………………………166
8.7. COUNTERSHAFT ASSEMBLIES………………………………………………………………167
8.8. MAINSHAFT ASSEMBLY……………………………………………………………………….171
9. INSTALL……………………………………………………………………………………………….187
9.1. RIGHT REVERSE IDLER GEAR ASSEMBLY…………………………………………………..187
9.2. COUNTERSHAFT ASSEMBLIES………………………………………………………………190
Left Countershaft Assembly…………………………………………………………………….190
9.3. MAIN DRIVE GEAR ASSEMBLY……………………………………………………………….193
9.4. RIGHT COUNTERSHAFT ASSEMBLY…………………………………………………………196
9.5. LEFT REVERSE IDLER GEAR ASSEMBLY……………………………………………………198
9.6. MAINSHAFT ASSEMBLY……………………………………………………………………….198
9.7. MAINSHAFT AUXILIARY DRIVE GEAR ASSEMBLIES….. …….. …….. ……. …….. …….. …200
9.8. DRIVE GEAR NUT AND FRONT BEARING COVER…………………………………………..203
9.9. CLUTCH HOUSING…………………………………………………………………………….206
9.10. AUXILIARY SECTION………………………………………………………………………….207
9.11. UNIVERSAL JOINT COMPANION FLANGE OR YOKE……. ……. …….. ……. …….. ……. …209
9.12. SHIFTER HOUSING……………………………………………………………………………210
9.13. GEAR SHIFT LEVER HOUSING ASSEMBLY…………………………………………………..211
9.14. SLAVE VALVE………………………………………………………………………………….212
10. LUBRICATION…………………………………………………………………………………………214
10.1. PROPER OIL LEVEL……………………………………………………………………………214
10.2. DRAINING OIL………………………………………………………………………………….214
10.3. REFILLING……………………………………………………………………………………..214
10.4. OPERATING TEMPERATURES………………………………………………………………..215
11. SPECIFICATIONS……………………………………………………………………………………..216
TORQUE…………………………………………………………………………………………………..217

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