Description

NAVISTAR FULLER 10 SPEED TRANSMISSIONS SERVICE MANUAL

What does this catalog contain?

NAVISTAR FULLER 10 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.

NAVISTAR FULLER 10 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.

What will you get when you get this service catalog?

• After payment has been received, a few minutes later.
• Lifetime PDF and Access To Download (By Request).
• Compatible With Windows, Mac, IOS, Android and Other Systems.
• Searchable Text and Built-in Index For Instant Information Search Bookmarks.
• Printable – Pages Or Entire Manual.
• Zoomable – Detailed Exploded Diagrams, Picture.

TABLE OF CONTENT OF THE NAVISTAR FULLER 10 SPEED SERVICE MANUAL

1. IDENTIFICATION………………………………………………………………………………………….1
1.1. MODEL NUMBER………………………………………………………………………………1
1.2. SERIAL NUMBER………………………………………………………………………………1
2. PREVENTIVE MAINTENANCE……………………………………………………………………………2
2.1. TRANSMISSION OIL……………………………………………………………………………2
2.2. AIR SYSTEM……………………………………………………………………………………2
2.3. MASTER CLUTCH SYSTEM……………………………………………………………………3
2.4. DRIVETRAIN……………………………………………………………………………………3
2.5. OVERALL INSPECTION………………………………………………………………………..3
3. INSPECT…………………………………………………………………………………………………..3
3.1. GEARS………………………………………………………………………………………….3
3.2. BEARINGS……………………………………………………………………………………..3
3.3. SPLINED SHAFTS………………………………………………………………………………4
3.4. THRUST WASHERS…………………………………………………………………………….4
3.5. SNAP RINGS……………………………………………………………………………………4
3.6. HOUSINGS……………………………………………………………………………………..4
3.7. SLIDING CLUTCHES……………………………………………………………………………4
3.8. RANGE SYNCHRONIZER………………………………………………………………………4
3.9. CLUTCH HOUSING…………………………………………………………………………….4
3.10. O-RINGS AND SEALS…………………………………………………………………………5
3.11. SHIFTING MECHANISM……………………………………………………………………….5
3.12. RANGE CYLINDER ASSEMBLY………………………………………………………………5
3.13. SHIFT LEVER………………………………………………………………………………….5
3.14. INPUT SHAFT SEAL…………………………………………………………………………..5
3.15. FRONT BEARING COVER…………………………………………………………………….5
3.16. GASKET SURFACES………………………………………………………………………….5
3.17. OUTPUT SEAL SYSTEM………………………………………………………………………5
4. AIR FITTINGS……………………………………………………………………………………………..6
4.1. COMPRESSION TYPE FITTING………………………………………………………………..6
Remove……………………………………………………………………………………..6
Install………………………………………………………………………………………..6
4.2. PUSH-TO-CONNECT TYPE FITTING…………………………………………………………..7
Remove……………………………………………………………………………………..7
Install………………………………………………………………………………………..7
5. SPECIAL PROCEDURES…………………………………………………………………………………8
5.1. INPUT SHAFT (WITHOUT MAIN CASE DISASSEMBLY)………………………………………8
5.2. AUXILIARY SECTION IN CHASSIS…………………………………………………………..10
6. REMOVE…………………………………………………………………………………………………12
6.1. SHIFT KNOB (ROADRANGER VALVE) ………………………………………………………12
6.2. SHIFT LEVER/REMOTE SHIFT CONTROL……………….. …………………………….. ….13
6.3. DETENT SPRING……………………………………………………………………………..14
6.4. NEUTRAL SWITCH……………………………………………………………………………15

6.5. NEUTRAL SWITCH TROUBLESHOOTING.. ……………………….. ……………………….17
6.6. AIR MODULE………………………………………………………………………………….18
6.7. OUTPUT SHAFT OIL SEAL …………………………………………………………………..20
6.8. SHIFT BAR HOUSING…………………………………………………………………………22
6.9. AUXILIARY SECTION (BENCH PROCEDURE)……………………………………………….23
6.10. CLUTCH HOUSING………………………………………………………………………….25
6.11. OIL PUMP (IF PRESENT)…………………………………………………………………….26
6.12. AUXILIARY DRIVE GEAR ASSEMBLY ……………………………………………………..27
6.13. UPPER REVERSE IDLER SHAFT……………………………………………………………29
6.14. MAINSHAFT ASSEMBLY…………………………………………………………………….30
6.15. INPUT SHAFT ……………………………………………………………………………….34
6.16. COUNTERSHAFT…………………………………………………………………………….36
6.17. LOWER REVERSE IDLER SHAFT…………………………………………………………..36
6.18. AUXILIARY COUNTERSHAFT BEARING RACE… ….. ….. ….. …. ….. ….. ….. ….. ….. ….37
7. DISASSEMBLE…………………………………………………………………………………………..38
7.1. SHIFT BAR HOUSING…………………………………………………………………………38
7.2. RANGE CYLINDER……………………………………………………………………………42
7.3. SHIFT LEVER………………………………………………………………………………….44
7.4. AUXILIARY SECTION…………………………………………………………………………45
7.5. SYNCHRONIZER………………………………………………………………………………48
7.6. RANGE YOKE…………………………………………………………………………………49
7.7. OUTPUT SHAFT………………………………………………………………………………49
7.8. AUXILIARY COUNTERSHAFT………………………………………………………………..50
7.9. MAINSHAFT…………………………………………………………………………………..51
7.10. COUNTERSHAFT…………………………………………………………………………….53
8. ASSEMBLE………………………………………………………………………………………………54
8.1. SHIFT BAR HOUSING…………………………………………………………………………54
8.2. RANGE CYLINDER …………………………………………………………………………..60
8.3. SHIFT LEVER………………………………………………………………………………….62
8.4. AUXILIARY COUNTERSHAFT………………………………………………………………..63
8.5. OUTPUT SHAFT (AUXILIARY MAIN SHAFT)…………………………………………………63
8.6. RANGE YOKE…………………………………………………………………………………65
8.7. SYNCHRONIZER………………………………………………………………………………66
8.8. AUXILIARY SECTION…………………………………………………………………………67
8.9. COUNTERSHAFT……………………………………………………………………………..73
8.10. MAINSHAFT …………………………………………………………………………………75
9. INSTALL………………………………………………………………………………………………….78
9.1. MAIN CASE PREPARATION FOR REASSEMBLY……………………………………………78
9.2. LOWER REVERSE IDLER GEAR……………………………………………………………..78
9.3. COUNTERSHAFT……………………………………………………………………………..79
9.4. LOWER COUNTERSHAFT BEARING ………………………………………………………..80
9.5. INPUT SHAFT AND MAIN DRIVE GEAR……………………………………………………..83
9.6. MAINSHAFT…………………………………………………………………………………..85
9.7. UPPER COUNTERSHAFT BEARING…………………………………………………………87
9.8. AUXILIARY DRIVE GEAR……………………………………………………………………..89
9.9. UPPER REVERSE IDLER SHAFT ……………………………………………………………90
9.10. AUXILIARY COUNTERSHAFT BEARING RACE… ….. ….. ….. …. ….. ….. ….. ….. ….. ….92
9.11. OIL PUMP (IF EQUIPPED)……………………………………………………………………92
9.12. INPUT BEARING COVER……………………………………………………………………93
9.13. CLUTCH HOUSING ………………………………………………………………………….94
9.14. AUXILIARY SECTION………………………………………………………………………..95
9.15. AUXILIARY COUNTERSHAFT BEARING SHIM PROCEDURE……………………………..98
9.16. OUTPUT SHAFT OIL SEAL…………………………………………………………………100
9.17. SHIFT BAR HOUSING………………………………………………………………………102
9.18. DETENT SPRING …………………………………………………………………………..103
9.19. NEUTRAL SWITCH…………………………………………………………………………104
9.20. REVERSE SWITCH…………………………………………………………………………104
9.21. AIR MODULE……………………………………………………………………………….104
9.22. GEAR SHIFT LEVER/REMOTE SHIFT CONTROL…………………………………………106
9.23. SHIFT KNOB (ROADRANGER VALVE)…………………………………………………….107
10. TROUBLESHOOTING…………………………………………………………………………………108
10.1. GENERAL TROUBLESHOOTING………………………………………………………….109
10.2. AIR SYSTEM TROUBLESHOOTING……………………………………………………….112
10.2.1 Symptom — Air Leak From Module Base (Exhaust)…………………………….115
10.2.2. Symptom — No or Slow Range Shift Into High (Shift Into Low Range is
Good)…………………………………………………………………………………116
10.2.3. Symptom — No Or Slow Range Shift Into Low (Shift Into High Range Is
Good)…………………………………………………………………………………119
10.2.4. Symptom — Constant Air Leak From Shift Knob………………………………121
10.2.5. Symptom — Range Shift While Transmission Is In Gear. ……………… ……..121
10.2.6. Symptom — Air Leak From Transmission Breather or Transmission Case is
Pressurized…………………………………………………………………………..122
11. TORQUE CHART………………………………………………………………………………………123

Moreover

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle.
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