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Eaton 4106B PDF
Eaton 4106B PDF
Eaton 4106B PDF
Eaton Transmissions
TRSM0080
October 2009
FS-4106A
FS-4206B
FSO-4206B
FS-5206A
FS-5206B
FS-5206F
FSO-5206B
Table of Contents
Introduction
Model Information
Serial Tag Information and Model Nomenclature .........................................................................................5
Model Number ..............................................................................................................................................5
Serial Number................................................................................................................................................5
Specifications
Technical Data...............................................................................................................................................6
Torque Rating ...............................................................................................................................................7
Gear End Floats ............................................................................................................................................8
Synchroniser Ring to Synchroniser Flange Clearance .................................................................................8
Lubrication Information
Lubrication ....................................................................................................................................................9
Recommended Lubricants.............................................................................................................................10
Tool Information
Recommended Tools ...................................................................................................................................13
Special Tools Manufacturers .........................................................................................................................14
Locally Made Tools........................................................................................................................................15
Preventive Maintenance
Preventive Maintenance ...............................................................................................................................16
Checks Before Transmission Removal .........................................................................................................16
Checks With Drive Line Dropped ..................................................................................................................17
Checks With Universal Joint Companion Flange or Yoke Removed.............................................................17
Rear Seal Maintenance .................................................................................................................................17
Table of Contents
Power Flow
Power Flow ...................................................................................................................................................18
Layshaft Assembly
Exploded View ..............................................................................................................................................39
How to Disassemble Layshaft ......................................................................................................................40
How to Assemble Layshaft ............................................................................................................................41
Selector Assembly
Exploded View ..............................................................................................................................................72
How to Disassemble Selector Assembly ......................................................................................................73
How to Assemble Selector Assembly............................................................................................................74
Before starting a ve hicle always be s eated in the driver’s seat, place the transmission in ne utral, set the
parking brakes and disengage the clutch.
Before working on a vehicle place the transmission in neutral, set the parking brakes and block the wheels.
Before towing the vehicle place the transmission in neutral, and lift the rear wheels off the ground, remove
the axle shafts, or disconnect the driveline to avoid damage to the transmission during towing.
The description and specifications contained in this service publication are current at the time of printing.
Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifi-
cations at any time without notice.
Any reference to brand name in this publication is made as an example of the types of tools and materials recom-
mended for use and should not be considered an endorsement. Equivalents may be used.
This symbol is used throughout this manual to call attention to procedures where carelessness or failure
to follow specific instructions may result in personal injury and/or component damage.
Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may
jeopardize the personal safety of the service technician or vehicle operator.
Warning: Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician.
Caution: Failure to follow indicated procedures may cause component damage or malfunction.
Note: Additional service information not covered in the service procedures.
Tip: Helpful removal and installation procedures to aid in the service of this unit.
1
Introduction
Introduction
look at the heading at the top and outside edge of each
page until you find the one that contains the procedure Assemblies
you need. When disassembling the various assemblies, such as
the mainshaft, layshaft and remote control housing, lay
Transmission Overhaul Procedures follow the general all parts on a clean bench in the same sequence as
steps for complete disassembly and then assembly of removed. This procedure will simplify reassembly and
the transmission. reduce the possibility of losing parts. When pulling off
synchroniser hubs follow the procedures detailed in
Note: In some instances the transmission appearance ‘Disassembly’ using a suitable puller of adequate
may be different from the illustrations, but the pro- capacity. Failure to adhere to the recommended proce-
cedure is the same. dures may cause irreparable damage.
Bearings
Carefully wash and relubricate all bearings as removed
and protectively wrap until ready for use. Remove
bearings with pullers designed for this purpose.
Cleanliness
Provide a clean place to work. It is important that no dirt
or foreign material enters the unit during repairs. The
outside of the unit should be carefully cleaned before
starting the disassembly. Dirt is abrasive and can dam-
age bearings.
Snap rings
Remove snap rings with pliers designed for this pur-
pose. New selective fit snap rings must be fitted as
specified in ‘Reassembly’.
When Pressing
Apply force to shafts, housings etc. with restraint.
Movement of some parts is restricted. Do not apply
force after the part being driven stops solidly. Use soft
hammers for all disassembly work.
2
Introduction
Bearings Splines
• Wash all bearings in clean solvent. Check roll- • Check splines on all shafts for wear. If synchro-
ers and races for pits and spalled areas. niser hubs, output drive flange or clutch hub
Renew damaged bearings. have worn into the sides of the splines, the
shafts in this condition must be renewed.
• Lubricate undamaged bearings and check for
axial and radial clearances. Renew bearings Thrust Washers
with excessive clearances.
• Check surfaces of all thrust washers. Washers
• Check fits of bearings in housing bores. If outer scored or reduced in thickness should be
races turn too freely in the bores, the housing renewed.
should be renewed. Check housing bores for
signs of wear prior to taking this action. Only Reverse Idler Gear
replace housing if wear is seen as a result of
bearing spin. • Check bearings and shaft for wear from action
of roller bearings.
Gears
Clutch Release Parts
• Check gear teeth for pitting of the tooth faces.
Gears with pitted teeth should be renewed. • Check clutch release parts, yokes and bearing
Check the reverse gear dog engagement teeth carrier. Check pedal shafts. Renew worn shafts
for freedom from damage. and bearings.
• Check the internal bearing surfaces for wear of Gear Selector Shaft Assembly
the effects of overheating. • Check forks and keys for wear at contact
• Check axial clearances of gears. Where points. Renew worn parts.
excessive clearance is found, check gear and • Check forks for excessive and uneven wear,
hub for excessive wear. renew worn forks.
• Maintain the specified axial clearance on main- • Check lockscrew in selector block. A lockscrew
shaft forward gears. with worn taper must be renewed.
Bearing Sleeve — Mainshaft • Check condition and fit of selector key and
interlock key in shift shaft. Worn or damaged
• Sleeves with groove formation, pits or which keys must be renewed.
have either been overheated or worn out must
be renewed.
3
Introduction
Introduction
outer race.
• Check bores of covers for wear. Renew those Capscrews
worn oversize. Use thread sealant (Loctite 641) on all capscrews.
Refer section ’Specification’ for torque ratings.
Oil Return Threads and Seals
‘O’ Rings
• Check oil seal in front bearing cover for dam- Lubricate all ‘O’ rings lightly with silicone lubricant.
age and wear, renew if necessary.
Initial Lubrication
• Check oil seal in speedometer housing for Lubricate bearings with gearbox oil during reassembly.
damage or wear, renew if necessary. Renew
grit shield if worn or loose on flange. Axial Clearances
Refer section ’Specification’ to maintain the end float
• Check oil seal journals for wear and renew if of mainshaft gears.
worn or grooved.
Bearings
O-Rings Use of flange-end bearing drivers is recommended for
the installation of bearings. These drivers apply equal
• Renew all O-rings. force to both races of the bearing, preventing damage
to balls and races and maintaining correct bearing
alignment with shaft and bore. A tubular type driver, if
used, will apply force only to the inner race. Heating the
bearing inner tracks will aid installation.
Output Shaft Drive Flange
Tighten the nut to the correct torque.
Synchroniser Hubs
All synchroniser hubs are an interference fit on the
mainshaft splines and must be heated to approximately
85°C (180°F) before installation.
Layshaft
The layshaft gears are a shrink and press fit on the lay-
shaft body. The gears must be heated to 150°C (300°F)
before assembly.
4
Model Information
Model Information
Identification plate on front case is showing;
1. Transmission serial number
2. Transmission model
3. Manufacturing date code
4. Trasmission specification number
The transmission specification number is unique to each customer and gives precise details of the transmission
design level. This number must be quoted when ordering replacement parts.
Model Number
The model number gives basic information about the transmission and is explained above. Use this number when
calling for service assistance or replacement parts.
Serial Number
The serial number is the sequential indentification number of the transmission. Before calling for service assis-
tance, write number down. It may be needed.
5
Specifications
Technical Data
Models FS 4106A, FS 4206B, FSO 4206B, FS 5106A, FS 5206B, FSO 5206B, FS 5206 F
Nominal Input Torque Weight (a) Length (b)
FS 4106A 640 Nm 117 Kg NA
FS 4206B 700 Nm 117 Kg NA
FSO 4206B 750 Nm 117 Kg NA
FS 5206A 700 Nm 117 Kg NA
FS 5206B 750 Nm 117 Kg NA
FSO 5206B 825 Nm 117 Kg NA
Oil Capacity Vertical 7.5 lit
Horizontal 6.5 lit
Vertical (Special) 8.5 lit
Clutch Housing SAE Standard
Power Take-off Vertical Installtion - Left side
Openings Horizontal Installation - Bottom right
PTO Drive Gears (c) Rotation to Engine
Driven from the reverse idler Driven from the layshaft front gear
gear
FS 4106A Engine speed x 0.226 Engine speed x 0.434
FS 4206B Engine speed x 0.271 Engine speed x 0.519
Specifications
FSO 4206B Engine speed x0.336 Engine speed x 0.644
FS 5206A Engine speed x 0.226 Engine speed x 0.434
FS 5206B Engine speed x 0.271 Engine speed x 0.519
FSO 5206B Engine speed x0.336 Engine speed x 0.644
Gear FS 4106A % step FS 4106B % step FSO 4106B % step FS 5206F % step
FS 5206A FS 5206B FSO 5206B
6 1.00 38 1.00 30 0.79 27 1.00 21
5 1.38 45 1.30 44 1.00 35 1.21 24
4 2.00 55 1.87 50 1.35 55 1.50 50
3 3.10 69 2.80 57 2.09 69 2.26 57
2 5.25 72 4.38 72 3.53 72 3.53 72
1 9.03 7.54 6.08 6.08
Reverse 8.07 6.74 5.43
6
Specifications
Torque Rating
Correct torque application is extremely important to assure long transmission life and dependable performance.
Overtightening or under-tightening can result in a loose installation and, in many instances, eventually cause
damage to transmission gears, shafts or bearings. Use of a thread sealer/locking compound is recommended for
all capscrews. Do not torque capscrews dry.
7
Specifications
Mainshaft Gear
Minimum 0.5
Maximum 1.9
Specifications
8
Lubrication Information
Lubrication
Proper Oil Level
Before checking the oil level or refilling, vehicle should be on level ground. Make sure that the oil is level with the
filler opening.
Draining Oil
Drain transmission while oil is warm. To drain oil remove the drain plug at the bottom if case. Clean the drain plug
before re-installing.
Lubrication Information
Refilling
Clean area around filler plug. Fill transmission to the level of the filler opening. The exact amount of oil depends on
the transmission inclination. In every instance, fill to the level of the filler opening. Do not overfill — this causes oil
to be forced out of the case past the mainshaft and input shaft seals.
Adding Oil
It is recommended that different types and brands of oil are not intermixed because of possible incompatibility.
Operating Temprature
It is important that the transmission operating temperature does not exceed 120°C (250°F) for an extended period
of time. Operating temperatures above 120°C (250°F) cause breakdown of the oil and shorten transmission life.
The following conditions in any combination can cause operating temperatures of over 120°C (250°F):
1. Operating consistently at road speeds under 32 km/h (20m.p.h.).
2. High engine RPM.
3. High ambient temperature.
4. Restricted air flow around transmission.
5. Exhaust system too close to transmission.
6. High horsepower, over-drive operation.
7. High power PTO operation for extensive periods while stationary.
Towing
When towing the vehicle, the propeller shaft between the axle and transmission must be disconnected.
9
Lubrication Information
Recommended Lubricants
Mineral Oils
Recommended Lubricants
Type Grade (SAE) Ambient Temperature
Heavy Duty Engine Oil API-CD 50 Above - 12°C
40 Above - 12°C
30 Below - 12°C
Mild EP Gear Oil 90 -12°C to 38°C
API-GL-4 80W -26°C to 21°C
• Multi-viscosity engine oils (such as 15W40) are not recommended without consultation with with Eaton.
• Do not mix engine oil and gear oils in the same transmission.
• Eaton does not approve mineral lubricants by brand name.
• Additives or friction modifiers which are not part of the original lubricants are not recommended.
IMPORTANT: Refer ’Lubrication Manual’ on following web address for more details:
http://www.roadranger.com/Roadranger/servicesalesliterature/LiteratureCenterResults
10
Lubrication Information
The following brands of semi-synthetic oils are now approved for use in Eaton transmissions;
1. TEXACO MULTIGEAR MTF 75W80W
2. ELF TRANSELF 75W80W, (also known as RVI Longevia)
3. MOBIL MOBILUBE XHP
4. BP ENERGEAR XHP 75W80
Lubrication Information
5. KUWAIT Q8 T 60
6. FUCHS DEA DEAGEAR LD & TITAN CYTRAC LD
7. FIAT LUBRICANTI TUTELA TRUCK GEAR FE
8. DE OLIEBRON TOR MT/LD GEAR OIL
9. OMV AKTIENGESELLCHAFT OMVLDL 75W80
10. PAKELO MOTOR OIL PAKELO GOLDENGEAR LD
11. YACCO BVX Z-500 SAE 75W80
12. REPSOL CARTAGO CAJAS FE LD
11
Lubrication Information
Synthetic Oils
The following brands of semi-synthetic oils are now approved for use in Eaton transmissions:
1. COGNIS ROADRANGER SAE 50
12
Tools Information
Recommended Tools
Some repair procedures pictured in this manual show But for the most part, ordinary mechanic's tools such
the use of specialized tools. Their actual use is recom- as socket wrenches, screwdrivers, etc., and other stan-
mended as they make transmission repair easier, dard shop items such as a press, mauls and soft bars
faster, and prevent costly damage to critical parts. are all that is needed to successfully disassemble and
reassemble any Eaton Transmission.
13
Tools Information
Tool Information
Genoa House
Below are the addresses and phone numbers of the Everdon Park
companies that make tools specifically for Eaton trans- Heartlands Business Park
missions. Daventry
Northamptonshire NN11 8YH
SPX England Phone: + 44 (01327) 303400
Global Headquarters Web site:
3515 Ballantyne Corporate Place http://www.spxuk.co.uk/
Charlotte, North Carolina 28277
United States The following general purpose pullers are available
Phone: +1 (704) 752-4400 from Sykes-Pickavant Ltd., or through their Dealers.
Web site: http://www.spx.com/en/products-and-ser-
vices/diagnostics.aspx
14
Tools Information
15
Preventive Maintenance
Preventive Maintenance
Everyday there are countless vehicles operating over Clutch Pedal Shaft and Bores
the highways with transmissions in such a neglected
• Pry upward on shafts to check wear.
mechanical condition, they can be referred to as fail-
ures looking for a place to break down. They lack a • If excessive movement is found, remove clutch
proper and organized preventive maintenance pro- release mechanism and check bushings on
gram. bores and wear on shafts. See OEM literature.
Preventive Maintenance
life and satisfactory service at the lowest possible cost,
short of removing and repairing the unit. • Use only the types and grades as recom-
mended. Refer section ’Lubrication Informa-
tion’.
Checks Before Transmission Removal
Filler and Drain Plugs
• Remove filler plugs and check level of lubricant
at specified intervals. Tighten fill and drain
plugs securely.
Capscrews and Gaskets
• Check all capscrews, especially those on PTO
covers and rear bearing covers for looseness
which would cause oil leakage.
• Check PTO opening and rear bearing covers
for oil leakage due to faulty gasket.
A number of conditions contrary to good preventive Gear Shift Lever
maintenance can generally be pointed to when inspect-
ing a failed transmission. Taking a few minutes every • Check for looseness and free play in housing.
so many hours or miles to do a few simple checks If lever is loose in housing, check Direct Con-
could help avoid eventual breakdown or reduce the trol Assembly.
repair cost. If the transmission is not cared for, it will Direct Control Assembly
breakdown.
• Remove the direct control assembly from the
Note: Transmission appearance may differ, the proce- transmission.
dure is the same.
• Check the tension spring for set and wear.
Clutch Housing Mounting
• Check gear shift lever bottom end for wear in
• Check all capscrews of clutch housing flange the slots and check for wear of finger assembly
for looseness. and housing.
Clutch Release Bearing
• Remove hand hole cover and check radial and
axial clearance in release bearing.
• Check relative position of thrust surface of
release bearing with thrust sleeve on push-
type clutches.
16
Preventive Maintenance
17
Power Flow
Power Flow
The transmission must efficiently transfer the engine's 3. Torque is delivered along layshaft to all lay-
power, in terms of torque, to the vehicle's rear wheels. shaft gears.
Knowledge of what takes place in the transmission dur-
4. Torque is transferred to "engaged" mainshaft
ing torque transfer is essential when trouble-shooting
gear.
and when making repairs become necessary.
5. The engaged mainshaft gear external clutching
teeth transfer torque to the mainshaft through
1. Power (torque) from the engine is transferred
the synchronizer assembly or sliding gear.
to the transmission input shaft.
6. The mainshaft transfers torque directly to
2. Torque is transferred to layshaft drive gear.
driveshaft through the output yoke.
18
Direct Control Assembly
Exploded View
DIRECT CONTROL ASSEMBLY
19
Direct Control Assembly
Special Instructions
Special Tools
Snap ring plier
20
Direct Control Assembly
21
Direct Control Assembly
Special Instructions
Check spring tension before installing.
Special Tools
Snap ring plier
22
Direct Control Assembly
6. Install conical spring and spring retainer. 10. Apply Loctite 5900 to the mating faces. Fit the
plunger, spring and detent cover. Install screws
IMPORTANT: Ensure that the smaller diameter of and washers. Tighten the screws to 20 -24 Nm.
the spring sits against the seating.
23
Remote Control Assembly
Exploded View
REMOTE CONTROL ASSEMBLY
Remote Control
Assembly
1. Bolt 21. Screw
2. Outer Lever 22. Spring Washer (if fitted)
3. Nut 23. End Cover
4. Boot 24. Gasket (if fitted)
5. Oil Seal 25. ‘O’ Ring
6. Bush 26. ‘O’ Ring (If fitted)
7. LRC Housing 27. Plug (if fitted)
8. Seal 28. Switch Activator Pin
9. Plunger 29. Neutral Switch
10. Spring 30. Breather
11. Gasket 31. Expansion Plug
12. Cover 32. Plug (if fitted)
13. Spring Washer (if fitted) 33. Elbow (if fitted)
14. Screw 34. Shift Rod
15. Circlip 35. Inner Striking Lever
16. Spring Retainer - Booster 36. Grooved Pin
17. Spring - Booster (If fitted) 37. Plain Washer (if fitted)
18. Spring - Bias 38. Spring Washer (if fitted)
19. Spring Retainer - Bias 39. Bolt (if fitted)
20. Reaction Rod Mounting Bracket (If fitted)
24
Remote Control Assembly
Special Instructions
Special Tools
1. Ensure the control assembly is in neutral. 8. Remove reverse detent cover and pull out the
spring and plunger (if fitted).
2. Remove bolts, washers and lifting eye (if fitted).
9. Remove gasket.
3. Remove the control assembly, dowels and seal.
Note: The position of the outer lever is marked on 12. Remove end cover and ‘O’ ring or gasket (if fitted).
the shaft. Check before removal.
13. Remove the circlip from the shift rod and remove
the bias spring retainer.
25
Remote Control Assembly
16. Invert the housing and carefully drift out the expan-
sion plug.
Remote Control
inner striking lever with the expansion plug hole.
Assembly
18. Drift out the grooved pin. Remove the shift rod and
inner stricking lever.
26
Remote Control Assembly
Special Instructions
Special Tools
4. Install the shift rod from the right hand side of the
housing.
27
Remote Control Assembly
5. Align the inner striking lever on the shift rod and 10. Fit a new ‘O’ ring or gasket (if fitted) and secure the
install the new grooved pin. end cover to the housing by screws and washers (if
fitted).
Note: Inner striking lever should be supported
whilst driving grooved pin, to prevent damage 11. Install the reaction bracket (if fitted).
to bushes.
12. Tighten the screws to 20 -24 Nm.
6. Fit the inner circlip onto the shift rod. Install the
booster spring retainer.
13. Install the spring and reverse detent plunger (if fit-
ted).Install gasket and detent cover.
Remote Control
Assembly
7. Insert the booster spring (if fitted) and bias spring.
15. Fit the rubber boot onto the housing. Align the
outer lever with the timing mark on the shift rod.
Tighten the capscrew and nut to 35 -39 Nm.
28
Remote Control Assembly
29
Pneumatic Power Assist
Assembly
Exploded View
PPA ASSEMBLY
30
Pneumatic Power Assist
Assembly
How to remove Pneumatic Power Assist How to install Pneumatic Power Assist
(PPA) Assembly (PPA) Assembly
Procedure - Procedure -
1. Remove screws and lifting eye. 1. Install breather, new 'O' ring (if fitted) and neutral
switch (if fitted). Tighten neutral switch to 24 - 30
2. Remove PPA from housing and seal (if fitted). Nm.
3. Remove breather, 'O' ring (if fitted) and neutral 2. Install seal (if fitted) and PPA on housing.
switch (if fitted).
3. Install screws and lifting eye.
31
Transmission Case Disassembly
Exploded View
TRANSMISSION CASE
32
Transmission Case Disassembly
Special Instructions
Special Tools
Transmission Case
and refit the drain and filler plugs.
Note: The transmission illustrated in this section is a
standard ratio horizontally installed unit. The pro-
cedure is the same for all transmissions but the
physical size and number of teeth on some of the
gears will vary from those illustrated on overdrive
and alternative ratio models. Vertically installed
units have the remote control on the side of the
transmission and alternative filler and drain plug
positions. 3. Remove the reverse switch and ‘O’ ring (if fitted).
1. IMPORTANT: Secure the adaptor plates to the
transmission case rear mounting flanges.
33
Transmission Case Disassembly
34
Transmission Case Disassembly
10. Position the transmission forward end upper most 13. Remove the half case flange bolts and nuts.
on the stand or wooden cradle. Remove the
screws and washers (if fitted). Remove the neutral Note: Mark the position of the shorter bolts
detent cover, gasket, spring and plunger or detent threaded into the case.
assembly (if fitted).
Transmission Case
mounted) or right (horizontally mounted) so that
the case will not foul the selector block on removal.
15. Remove the outer circlip from the input shaft bear-
ing.
35
Transmission Case Disassembly
17. Using a soft face mallet break the seal and sepa- 21. Assemble lifting fixtures to the mainshaft under
rate the front case from the rear case. Lift off the 5th / 6th synchronizer. Raise the shaft by approx.
front case, leaving the input shaft and bearing 20 mm. This allows the layshaft to lift clear.
inplace.
23. Lift off the input shaft with 6th gear flange. Remove
the 6th gear synchroniser ring.
19. Using a suitable long drift drive out the reverse idler
shaft from the case. Remove the ‘O’ ring from the
reverse idler shaft (old design).
24. Raise the hoist and lift out the mainshaft and selec-
tor assembly. Carefully lower on to a clean bench
and remove the lifting fixture. Separate selector
assembly from the mainshaft.
20. Remove the reverse idler gear and the thrust
washers. Remove the bearing and spacer from the
gear.
36
Transmission Case Disassembly
25. Invert the rear case on the stand. Remove the cap- 28. Invert the casing on the stand and remove the lay-
screws securing the speedo housing. shaft rear bearing cover and spacer.
29. Drift out layshaft rear bearing outer cup using the
special tool.
Transmission Case
and graded spacer from the front case.
37
Transmission Case Disassembly
34. Invert the case halves and using the special tool or
a suitable (25 mm dia.) mandrel drive the selector
shaft bushes out of the cases.
38
Layshaft Assembly
Exploded View
LAYSHAFT ASSEMBLY
Layshaft Assembly
1. Layshaft 4. Graded Circlip Pack
2. Bearing 5. Shim Pack
3. Distance Piece 6. Spacer
39
Layshaft Assembly
Special Instructions
Special Tools
Procedure -
1. Support the shaft assembly and remove the
graded circlip retaining the front taper roller bear-
ing.
40
Layshaft Assembly
Special Instructions
Special Tools
Bearing heater
Hot plate OR Temperature controlled oven
Bearing installer - E 109-11
Snap ring pliers
Refer section ‘Tools Information’
Procedure - Note: Refer IPL for circlip size and part numbers.
1. Heat the layshaft taper rooler bearing inner races 3. Fit the circlip.
to 85° C (180° F), using bearing heater or hot plate
or temprature controlled oven. Support the shaft
assembly forward end uppermost and place the
heated inner cone and roller assembly onto the
shaft. Use a bearing installer E 109-11 to make
sure bearing is fully home.
Layshaft Assembly
4. Invert the layshaft assembly and fit the heated rear
taper roller bearing inner race onto the shaft. Make
sure the bearing is fully home using a bearing
installer E 109-11.
41
Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
Exploded View
MAINSHAFT ASSEMBLY
Mainshaft Assembly
1. Mainshaft 25. Needle Roller Brg.
2. Needle Roller Brg. 26. Needle Roller Brg.
3. Gear Mainshaft 3rd 27. Gear Mainshaft 2nd
4a. Synchro Flange 3rd/4th 28. Synchro Flange 1st/2nd
4. Ring Synchro 29. Ring Synchro
5. Roller 30. Spring
6. Plunger 31. Plunger
7. Spring 32. Roller
8. Fixed Hub 3rd/4th 33. Fixed Hub 1st/2nd
9. Sliding Sleeve 3rd/4th 34. Sliding Sleeve 1st/2nd
10. Ring Synchro 35. Ring Synchro
10a. Synchro Flange 3rd/4th 36. Synchro Flange 1st/2nd
11. Gear Mainshaft 4th 38. Graded Circlip Pack
12. Needle Roller Brg. 39. Gear Mainshaft 1st
13. Sleeve Mainshaft Brg. 40. Needle Roller Brg.
14. Circlip Assy. 41. Fixed Hub Reverse
15. Needle Roller Brg. 42. Graded Circlip Pack
16. Gear Mainshaft 5th 43. Needle Roller Brg.
17a. Synchro Flange 5th/6th 44. Gear Mainshaft Reverse
17. Ring Synchro 45. Mainshaft Output Brg.
18. Roller 46. Speedo Drive Gear OR
19. Plunger 46. Tachograph Rotor
20. Spring 47. Dirt Shield
21. Fixed Hub 5th/6th 48. Flange Coupling
22. Sliding Sleeve 5th/6th 49. Mainshaft Locknut
23. Ring Synchro 50. Spacer Tachograph Rotor
24. Graded Circlip Pack
42
Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
43
Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
Special Instructions
Special Tools
Vice
Snap ring plier
Puller kit - Series 1500 with hydraulic ram
Three legged puller - Series 1500 with hydraulic ram
Refer section ‘Tools Information’
Mainshaft Assembly
and theree springs from the synchoniser hub.
may be neccessary to engage the puller over the
6th gear also.
44
Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
5. Carefully remove 4th gear bearing sleeve reatining 9. Lift off steel cage bearing and 1st gear synchro-
snap ring. niser ring.
6. Invert the shaft assembly and using a suitable 10. Slide the 1st/2nd gear synchroniser sleeve, care-
three legged puller (Series 1500 with hydraulic fully rearwards until the three rollers are clear off
ram) under the reverse gear, remove the gear, the groove in the sleeve. Remove the roller, sleeve,
thrust washer, bearing track. Remove the reverse theree plungers and three springs from the syn-
gear needle roller bearing. chroniser hub.
7. Remove the reverse gear fixed hub retaining snap 11. Remove the 1st/2nd synchroniser hub retaining
ring. snap ring.
8. Using a press or three legged puller (Series 1500 12. Assmeble the puller kit (Series 1500 with hydraulic
with hydraulic ram), pull off the 1st gear assembly ram) over the 2nd gear and pull off 2nd gear, syn-
and the reverse gear fixed hub. chroniser ring , flange, hub and bearing.
45
Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
13. Support the shaft on the press under the 3rd gear. Check clearance between synchro-
Note: It is imperative that 3rd gear is supported niser ring and flange
and that the flange on the shaft does not foul Before assembling the synchroniser assemblies onto
the supporting blocks or press bed when the the mainshaft, check the fit of each synchroniser ring to
shaft is being pressed through. the relevant synchroniser flange.
Press or pull the shaft through 3rd gear, 3rd/4th
gear synchroniser hub and 4th gear bearing
sleeve.
Mainshaft Assembly
in the same relative position.
The gears and flanges are then treated as one assem-
bly.
46
Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
Special Instructions
Special Tools
Vice
Snap ring plier
Hot plate or Temperature controlled oven
Driver E 108
Dial gauge
Feeler gauge
Refer section ‘Tools Information’
IMPORTANT: The following parts must be heated to 2. Lubricate the bearing with clean gear oil and fit the
the 85°C prior to assembly. Place the parts on a hot 2nd gear assembly over the bearing.
plate or in temperature controlled oven for not less than
30 minute to make sure that parts are thoroughly
heated placing them in position. Once fitted and cooled
the parts will shrink to an interference fit.
• 4th gear bearing sleeve
• Reverse fixed hub
• Mainshaft rear bearing inner track
• Synchroniser hubs
3. Then fit the synchroniser ring.
Procedure -
47
Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
4. Take the heated 1st/2nd synchroniser hub and 8. Assemble the three springs and plungers into the
place it over the splines of the mainshaft ensuring synchroniser hub. Place the synchroniser sleeve
that the large slots in the hub align with the large over the synchroniser hub and support it with the
shoulders on the synchroniser ring. Use a soft drift internal grooves just above the synchroniser hub.
or driver E 108 to ensure the hub is fully home after Position the three rollers as shown, retsing on the
cooling for 4-5 minutes. heads of the plungers and press downward on the
synchroniser sleeve. This compress the springs
allowing the synchroniser sleeve to centralise in
the neutral position.
Mainshaft Assembly
6. Install the snap ring in the groove.
48
Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
11. Take the heated reverse gear fixed hub and fit it 15. Lubricate the reverse gear bearing. Install the
over the splines, boss uppermost, onto the main- bearing and reverse gear onto the mainshaft.
shaft.
13. From the range of the graded snap rings select the 17. Take the heated inner tarck of the mainshaft rear
thickest one which fits into the groove with the min- bearing and fit it over the shaft, flange inner most
imum free play. Install the snap ring in the groove. against the spacer. Use a soft drift or driver E 108 if
neccessary to ensure that the bearing is fully home
Note: Taking care not to damage mainshaft bear- against the shoulder.
ing surface.
Note: When cooled, the bearing track should be
sufficiently tight on the shaft to retain the
reverse gear on the shaft.
14. Check that the 1st gear end float is within specified
tolerance.
49
Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
18. Invert the mainshaft in the vice. Lubricate and 22. Assemble the three springs and plungers into the
install the 3rd gear bearing and 3rd gear assembly. synchroniser hub. Place the synchroniser sleeve
over the synchroniser hub and support it with the
internal grooves just above the synchroniser hub.
Position the three rollers as shown, retsing on the
heads of the plungers, and press downward on the
synchroniser sleeve. This compress the springs
allowing the synchroniser sleeve to centralise in
the neutral position.
23. Place the 4th gear synchroniser ring into the syn-
chroniser hub assembly.
Mainshaft Assembly
place it over the splines of the mainshaft ensuring
that the large slots in the hub align with the large
shoulders on the synchroniser ring. Use a soft drift
or driver E 108 to ensure the hub is fully home after
cooling for 4-5 minutes. Recheck that the shoul-
ders are in the correct slots.
24. Lubricate the 4th gear and bearing. Position the
gear into the synchroniser ring and the bearing into
the gear.
21. Check that the 3rd gear end float is within specified
tolerance.
50
Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
25. Take the heated 4th gear bearing sleeve and 29. Position 5th gear synchroniser ring onto the syn-
locate it inside the bearing and over the shaft. Use chroniser flange.
soft drift or flange driver if neccessary, to ensure
the sleeve is firmly home against the synchroniser CAUTION: Ensure that when fitting the synchro-
hub. niser flange on the 5th gear, the correct flange is
used. on overdrive transmission it is possible to fit
the overdrive flange to the 5th gear.
27. Check that the 4th gear end float is within the spec-
ified tolerance.
51
Mainshaft Assembly - W/o 1st-2nd
Double Cone Synch.
33. Check that the 5th gear end float is within the spec-
ified tolerance.
Mainshaft Assembly
34. Assemble the three springs and plungers into the
synchroniser hub. Place the synchroniser sleeve
over the synchroniser hub and support it with the
internal grooves just above the synchroniser hub.
Position the three rollers as shown, retsing on the
heads of the plungers, and press downward on the
synchroniser sleeve. This compress the springs
allowing the synchroniser sleeve to centralise in
the neutral position.
52
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
Exploded View
MAINSHAFT ASSEMBLY
Mainshaft Assembly
1. Mainshaft 20. Spring
2. Needle Roller Brg. 21. Fixed Hub 5th/6th
3. Gear Mainshaft 3rd 22. Sliding Sleeve 5th/6th
4a. Synchro Flange 3rd/4th 23. Ring Synchro
4. Ring Synchro 24. Graded Circlip Pack
5. Roller 25. Needle Roller Brg.
6. Plunger 26. Needle Roller Brg.
7. Spring 27. Gear Mainshaft 2nd
8. Fixed Hub 3rd/4th 28. Synchro Pack D.C. 1st/2nd
9. Sliding Sleeve 3rd/4th 29. Gear Mainshaft 1st
10. Synchro Flange 3rd/4th 30. Needle Roller Brg.
10a. Ring Synchro 31. Fixed Hub Reverse
11. Gear Mainshaft 4th 32. Graded Circlip Pack
12. Needle Roller Brg. 33. Needle Roller Brg.
13. Sleeve Mainshaft Brg. 34. Gear Mainshaft Reverse
14. Circlip Assy. 35. Mainshaft Output Brg.
15. Needle Roller Brg. 36. Speedo Drive Gear OR
16. Gear Mainshaft 5th 36. Tachograph Rotor
17a. Synchro Flange 5th/6th 37. Spacer Tachograph Rotor
17. Ring Synchro 38. Dirt Shield
18. Roller 39. Flange Coupling
19. Plunger 40. Mainshaft Locknut
53
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
54
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
Special Instructions
Special Tools
Vice
Snap ring plier
Press
1st / 2nd synchroniser assembly retaining tool
Puller kit - Series 1500 with hydraulic ram
Three legged puller - Series 1500 with hydraulic ram
Refer section ‘Tools Information’
Mainshaft Assembly
the groove in the synchroniser sleeve. Remove the
three rollers, synchroniser sleeve, three plungers
and theree springs from the synchoniser hub.
55
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
5. Using a press or suitable puller remove the reverse 8. To prevent the synchroniser assembly from sepa-
gear fixed hub and 1st speed gear. rating during removal, fit the retaining tool. The tool
fits onto the mainshaft , boss down, with the three
retainers located underneath 2nd speed gear.
Adjust the retainers so that there is no free play
between 2nd speed gear and synchroniser assem-
bly.
56
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
11. Invert the mainshaft . As the 5th/6th synchroniser 14. Using a suitable press or puller support the main-
hub is not symmetrical identify its orientation. Using shaft assembly underneath 3rd speed gear.
a press or Puller kit (Series 1500 with hydraulic
ram), remove the 5th/6th gear synchroniser hub, Note: It is imperactive that the flange, which is part
synchroniser ring and 5th speed gear assembly. of the mainshaft, does not foul the press or
puller legs as this may result in damage to
Note: Care must be taken to ensure that the dam- the mainshaft. Press or pull the 4th speed
age to the teeth on the synchroniser flange gear bearing sleeve, 4th speed needle roller
does not occur. On an overdrive tranmission bearing , 4th speed gear assembly, 3rd/4th
it may be neccessary to engage the press/ synchroniser assembly and 3rd speed gear
puller also over the gear. assembly off. Remove the 3rd speed gear
needle roller bearing from the mainshaft.
12. Remove the 5th speed gear needle roller bearing. 15. Place the assembly onto a suitable work surface,
On overdrive transmissions this will be 6th gear. 4th speed gear, uppermost. Remove the bearing
Mainshaft Assembly
sleeve, needle roller bearing and 4th gear assem-
bly.
57
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
17. Lift off synchroniser hub and synchroniser ring. Check clearance between synchroniser
ring and flange (Only for 3rd & 4th, 5th &
6th speed synchroniser assemblies)
Before assembling the synchroniser assemblies onto
the mainshaft, check the fit of each synchroniser ring to
the relevant synchroniser flange.
58
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
Check clearance between synchroniser 5. Fit the synchroniser inner ring, tangs uppermost,
onto the synchroniser flange.
ring and flange (Only for 1st & 2nd Double
Cone Synchroniser Assembly)
Procedure -
Mainshaft Assembly
niser friction ring locate into the slots on the
synchroniser flange.
59
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
60
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
How to disassemble 1st and 2nd Double 4. Remove the synchroniser inner ring.
Cone Synchroniser Assembly
Note: The synchroniser is supplied as an assembly.
Parts that are used to make the complete assem-
bly are not available separately.
Procedure -
Mainshaft Assembly
6. Remove the synchroniser ring.
2. Push the synchroniser sleeve downwards.
61
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
8. Taking care not to loose the balls or springs, lift the 12. Remove the synchroniser ring.
detent poppets to release the balls. Once the balls
have been removed it is possible to remove the
detent poppets and springs.
62
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
How to assemble 1st and 2nd Double Cone 4. Fit the synchroniser ring ensuring that the under-
Synchroniser Assembly cuts (1) line up with the tabs (2) of the sybchroniser
inner ring and that bosses (3) of the synchroniser
ring are to the left hand side of tabs (2) of the syn-
Procedure - chroniser inner ring as shown.
Mainshaft Assembly
6. Fit the synchroniser hub ensuring that the narrow
slots are in line with the bosses of the synchroniser
ring.
63
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
8. Take the synchroniser sliding sleeve, stepped side 12. Place the synchroniser ring onto the synchronsier
uppermost, and fit it to the synchroniser hub ensur- hub so that the three bosses enagge with the three
ing that the three internal bosses of the synchro- narrow slots on the synchroniser hub.
niser sleeve locate in the slots of the synchroniser
hub.
10. Place the detent balls onto the springs and then
using suitable tool push against the detent ball to 14. Place the synchroniser inner ring into position
compress spring. ensuring that the three tabs align with the legs of
the blocks.
64
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
Mainshaft Assembly
65
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
Special Instructions
Special Tools
Vice
Snap ring plier
Press
1st / 2nd synchroniser assembly retaining tool
Hot plate or Temperature controlled oven
Dial gauge
Feeler Gauge
Refer section ‘Tools Information’
IMPORTANT: The following parts must be heated to 2. Place 1st/2nd speed synchroniser assembly onto
the 85°C prior to assembly. Place the parts on a hot the retaining tool ensuring that the chamfer on the
plate or in temperature controlled oven for not less than synchroniser sleeve is uppermost.
30 minute to make sure that parts are thoroughly
heated placing them in position. Once fitted and cooled
the parts will shrink to an interference fit.
• 4th gear bearing sleeve
• Reverse fixed hub
• Mainshaft rear bearing inner track
• Synchroniser hubs
66
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
4. Fit the 2nd speed gear to the synchroniser assem- 7. Lubricate and install the 3rd gear needle roller
bly ensuring that the splines on the gear engage bearing and 3rd gear assembly.
into the splines on the synchroniser assembly. Fit
and lubricate the needle roller bearing.
Mainshaft Assembly
shaft ensuring that the large slots in the synchro-
niser hub align with the large shoulders on the
synchroniser ring. Press the synchroniser fully
home.
67
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
11. Assemble the three srpings and plungers into the 14. Heat the 4th speed gear bearing sleeve to 85°C.
synchroniser hub. Place the synchroniser sleeve Locate it onto the mainshaft and inside the needle
over the synchroniser hub and support it with the roller bearing. Press the bearing sleeve into posi-
internal grooves just above the synchroniser hub. tion.
Position the three rollers as shown, retsing on the
heads of the plungers, and press downward on the
synchroniser sleeve. This compress the springs
allowing the synchroniser sleeve to centralise in
the neutral position.
15. Fit a new snap ring into the mainshaft groove tak-
ing care not to damage the mainshaft bearing sur-
face.
12. Place the 4th gear synchroniser ring onto the syn-
chroniser assembly ensuring that the shoulders on
the synchroniser rings locate into the slots of the
synchroniser hub. Lubricate synchroniser ring.
16. Check that the 4th gear end float is within the spec-
ified tolerance.
68
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
18. Lubricate the 5th gear synchroniser flange and 22. Invert the mainshaft and then remove the retaining
synchroniser ring. tool.
Mainshaft Assembly
20. From the range of graded circlips select the one
which fits into the mainshaft groove with the least
amount if free play. Fit the ciclip into the groove.
24. Check that the 2nd gear end float is within the
specified tolerance.
21. Using feeler gauges check that the 5th gear end
float is within the specified tolerance.
69
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
25. Fit and lubricate needle roller bearing. Fit the 1st 28. Check that the 1st gear end float is within the spec-
speed gear ensuring that the splines on the 1st ified tolerance.
speed gear engage into the the splines of the syn-
chroniser flange.
70
Mainshaft Assembly - With 1st-2nd
Double Cone Synch.
32. Place the 6th gear synchroniser ring onto the syn-
chroniser assembly ensuring that the shoulders on
the synchroniser rings locate into the slots of the
synchroniser hub. Lubricate synchroniser ring.
Mainshaft Assembly
71
Selector Assembly
Exploded View
SELECTOR ASSEMBLY - DIRECT DRIVE SELECTOR ASSEMBLY - OVERDRIVE
Selector Assembly
6. Fork 3rd/4th 6. Fork 3rd/4th
7. Dowel 7. Dowel
8. Screw 8. Screw
9. Selector Block 9. Selector Block
10. Fork 5th/6th 10. Selector Overdrive
11. Fork Overdrive
12. Overdrive Shift Pad
72
Selector Assembly
Procedure -
Note: Tapered screw fitted on opposite side on hori-
zontal transmission.
1. Place selector assembly on bench with the selector
block to the left. Mark the front of the shaft and key
to aid reassembly.
73
Selector Assembly
Selector Assembly
3. Place the forks in their respective positions on the
selector shaft.
74
Transmission Case Assembly
Special Instructions
Special Tools
Transmission Case
Mainshaft rear seal replacer E 108-6
Flange holding wrench LC 113A
Reverse idler shaft retaining pin installer E 117
Refer section ‘Tools Information’
75
Transmission Case Assembly
2. Using special tool E 109-8 with E 109 to install the 6. Apply Loctite 5900 to the housing, install the lay-
selector shaft bushes into the cases. Drive it until shaft rear bearing cover to the case. Install the cap-
fully home. screws and washers (if fitted). Tighten the
capscrews evenly to 69 -78 Nm.
76
Transmission Case Assembly
10. Locate the selector assembly to the mainshaft. 13. Lower the hoist to allow the mainshaft, layshaft and
Support the mainshaft using lifting fixture E 116A selector shaft to seat into their respective bearing
with adaptor E 116-2 and hoist. Lower the main- or bushes. Remove the lifting fixture and adaptor.
shaft and selector assembly into the case, making
sure the selector shaft enters the rear bush. Sup- IMPORTANT: Ensure the selector block is posi-
port the mainshaft and selectors approximately 20 tioned so it does not foul front case.
mm above the fully installed position.
Transmission Case
15. Apply Loctite 5900 sealant to the mating flange on
12. Locate the layshaft into mesh with the mainshaft. the rear case and install the front case. Install the
capscrews and nuts.
77
Transmission Case Assembly
17. When aligning right hand pin, use a screw driver 19. Fit the bearing thrust washer. Place the origional
and lift the selector through the remote control spacer against the bearing and check thet the snap
aperture. Install screw and washers. Tighten the ring will fit into its groove without free play. Check
screws to 20 -40 Nm. at several places around the diameter of ths shaft.
If there is a free play, or the snap ring will not fit into
the groove, a new thicker or thinner spacer respec-
tively will be required in place of the origional.
18. Fit the input shaft bearing ensuring oil feed hole is 20. If removed, install a new oil seal into the input shaft
kept clear. bearing front cover using the special tool E 109-7.
Press the seal firmly down to the shoulder ensuring
the seal is not damaged.
78
Transmission Case Assembly
22. Select a shim pack and place it against the layshaft 24. Back off the four screws. Press the cover by hand
bearing cup. Place the spacer on the top of the (approx. 200N) in the middle, just sufficiently to nip
shim. the bearing cover plate. Using feeler gauges, mea-
sure the clearance between the cover plate and
Note: The shim pack must be proud of the front the case at several points. From the range of the
face of the case when the bearing cup is fully graded spacers select the thickness which give the
seated against the bearing cone and roller required preload to the layshaft bearing of 0.01 to
assembly. 0.15 mm with new bearings or 0.03 to 0.08 with
used bearings.
Note: Refer IPL for, shims thickness and part num-
bers.
Transmission Case
while rotating the input shaft backwards and
forwards to settle the bearings. Continue to
tighten the screws until some resistance can
be felt on the input shaft.
79
Transmission Case Assembly
27. Install the bearing thrust spacer onto the mainshaft, 30. Apply flange sealer Loctite 5900 and install the
over the shoulder against the rear bearing. Ensure speedo hosuing.
the oil groove is against the rollers.
Note: Install the longer screws at right position on
speedo housing.
Tighten screws to 35 - 39 Nm.
31. Apply a light grease to the oil seal lips and install
the drive flange.
80
Transmission Case Assembly
33. If not already installed, install the sender unit or Reverse Idler - Old Design
speedo drive pinion using a new sealing washer.
Tighten it to 24 - 30 Nm. 36. Ensure the thrust washer and gear correctly posi-
tioned and that the parallel groove pin holes are in
alignment and install the reverse idler gear shaft,
with new ‘O’ ring into the case. Take care to ensure
that the components are not dislodged as shaft is
driven home with a soft mallet.
Transmission Case
35. Install the bearing and spacer into the reverse idler
gear. Locate the assembled gear between the
thrust washers and into mesh with the layshaft and 38. Install the reverse idler gear/PTO cover plate.
the mainshaft reverse gear. Install screws and washers (if fitted). Tighten
screws to 35 - 39 Nm.
IMPORTANT: Ensure the tab of thrust washer
locates into recess of case.
81
Transmission Case Assembly
Reverse Idler - New Design 44. Install the neutral detent punger and spring. Install
gasket and cover plate with screws and washers (if
40. Ensure the thrust washer and gear correctly posi- fitted). Tighten screws to 19 -24 Nm. Or install neu-
tioned. Drive the shaft into the position ensuring tral detent assembly and tighten to 32 -37 Nm.
that the end of the shaft is just below the surface of
the case.
41. Install circlip into the reverse idler bore. Apply seal-
ant to the expansion plug and fit into the reverse
idler bore.
82
Transmission Case Assembly
48. Check manually using the shift lever that all gears
Transmission Case
can be engaged. It may be neccessary to rotate
input shaft to obtain full gear engagement.
83
Copyright Eaton Corporation, 2009.
Eaton hereby grants their customers,
vendors, or distributors permission to
freely copy, reproduce and/or distribute
this document in printed format. It may
be copied only in its entirety without
any changes or modifications. THIS
INFORMATION IS NOT INTENDED FOR
SALE OR RESALE, AND THIS NOTICE
MUST REMAIN ON ALL COPIES.
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