Eaton Fuller: Mid-Range Transmissions

R R
Eaton Fuller
Mid-Range Transmissions
Service Manual
FS-4205/5205 Series
FS-6205/6305 Series
FS-5306/6306 Series
TRSM-0110
April 1993
Warning & Precautions
General Information
Model/Assembly Reference
External Parts
Shift Bar Housing
Main Section
Options
Every effort has been made to ensure the accuracy of all information in
this brochure. However, Eaton Transmission Division makes no
expressed or implied warranty or representation based on the enclosed
information. Any errors or omissions may be reported to Training and
Publications, Eaton Transmission Division, P.O. Box 4013, Kalamazoo, MI
49003.
2
Section 1: Warning and Precautions
Warning
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Precautions
Disassemble
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Snap Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
When using Tools to Move Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspection
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bearing Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Clutch Release Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Gear Shift Lever Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Gray Iron Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reverse Idler Gear Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Shift Bar Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Synchronizer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble
Axial Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Universal Joint Companion Flange or Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7
WARNING
Before starting a vehicle always be
seated in the drivers seat, place the
transmission in neutral, 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 or
disconnect the driveline to avoid
damage to the transmission during
towing.
9
Precautions
Disassemble
It is assumed in the detailed assembly instructions that the lubricant has
been drained from the transmission, the necessary linkage and the
transmission has been removed from vehicle chassis. Removal of the
gear shift lever housing assembly (or remote control assembly) is
included in the detailed instructions (External Parts/Shift Bar Housing/
How to Remove the Gear Shift Lever); however, this assembly MUST be
detached from the shift bar housing before transmission can be removed.
Follow closely each procedure in the detailed instructions, make use of
the text, illustrations, and photographs provided.
Assemblies
When disassembling the various assemblies, such as the
mainshaft, countershafts, and shift bar housing, lay all parts on a
clean bench in the same sequence as removed. This procedure will
simplify assembly and reduce the possibility of losing parts.
Bearings
Carefully wash and lubricate all usable bearings as removed and
protectively wrap until ready for use. Remove bearings planned to
be reused 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. Dirt is an abrasive and can
damage bearings. It is always good practice to clean the outside of
the unit before starting the planned disassembly.
Input Shaft
The input shaft can be removed from the transmission without
removing the countershaft or mainshaft.
Snap Rings
Remove snap rings with pliers designed for this purpose. Snap
rings removed in this manner can be reused, if they are not sprung
or loose.
When using Tools to Move Parts
Always apply force to shafts, housings, etc., with restraint.
Movement of some parts is restricted. Never apply force to driven
parts after they stop solidly. The use of soft hammers, soft bars,
and mauls for all disassembly work is recommended.
10
Precautions

Inspection
Before assembling the transmission, check each part carefully for
abnormal or excessive wear and damage to determine reuse or
replacement. When replacement is necessary, use only genuine Eaton®
Fuller® Transmission parts to assure continued performance and
extended life from your unit.
Since the cost of a new part is generally a small fraction of the total cost
of downtime and labor, avoid using a questionable part which could lead
to additional repairs and expense soon after assembly. To aid in
determining the reuse or replacement of any transmission part,
consideration should also be given to the unit’s history, mileage,
application, etc.
Recommended inspection procedures are provided in the following

checklist.
Bearings
1. Wash all bearings in clean solvent. Check balls, rollers, and
raceways for pitting, discoloration, and spalled areas. Replace
bearings that are pitted, discolored, spalled, or damaged during
disassembly.
2. Lubricate bearings that are not pitted, discolored, or spalled and
check for axial and radial clearances (per manufacturers
specifications).
3. Replace bearings with excessive clearances.
4. Check bearing fit. Bearing inner races should be tight to shaft; outer
races slightly tight to slightly loose in case bore. If bearing spins
freely in bore, case should be replaced.
Bearing Covers
1. Check covers for wear from thrust of adjacent bearing. Replace
covers damaged from thrust of bearing outer race.
2. Check cover bores for wear. Replace those worn or oversized.
Clutch Release Parts

1. Check clutch release parts. Replace yokes worn at cam surfaces
and bearing carrier worn at contact pads.
2. Check pedal shafts. Replace those worn at bushing surfaces.
continued on next page
11
Precautions
continued
Inspection
Gears
1. Check gear teeth for pitting. Frosting of gear teeth faces presents
no threat of transmission failure. Often in continued operation of
the unit, frosted gears “heal” and do not progress to the pitting
stage. In most cases, gears with light to moderate pitted teeth
have considerable gear life remaining and can be reused, but gears
in the advanced stage of pitting should be replaced.
2. Check for gears with clutching teeth abnormally worn, tapered, or
reduced in length from clashing during shifting. Replace gears
found in any of these conditions.
3. Check axial clearance of gears. Where excessive clearance is
found, check gear snap ring, split washer, clutch hub, and gear hub
for excessive wear.
Gear Shift Lever Housing Assembly

1. Check spring tension on shift lever. Replace tension spring if lever
moves too freely.
2. If housing is disassembled, check gear shift lever bottom end,
housing, and shift finger assembly for wear. Replace if excessively
worn.
Gray Iron Parts

1. Check all gray iron parts (case, covers) for cracks and breaks.
Replace parts found to be damaged.
Oil Seals
1. Check oil seal in input shaft and rear bearing cover. If sealing
action of lip has been destroyed, replace seal.
2. Check oil seal in rear bearing cover. If sealing action of lip has
been destroyed, replace seal.
12
Precautions

continued
Inspection
O-Rings
1. Check all O-rings for cracks or distortion. Replace if worn.
Reverse Idler Gear Assemblies

1. Check for excessive wear from action of roller bearings.
Shift Bar Housing Assembly

1. Check for wear on shift yokes and finger assembly at pads and lever
slot. Replace excessively worn parts.
2. Check yokes for correct alignment. Replace sprung yokes.
3. Check lockscrews in yoke assembly retainer plates. Tighten those
found loose. Replace shft bar housing if lockscrew holes are
damaged.
Splines
1. Check splines on all shafts for abnormal wear. If sliding clutches,
gears, clutch plates, companion flange, or clutch hub has worn
marks in the spline sides, replace the specific shaft affected.
Synchronizer Assembly
1. Check synchronizer friction surfaces for burrs, uneven and excessive
wear at contact surface, and metal particles.
2. Check blocker pins and pre-energizer springs for excessive wear or
looseness.
3. Check synchronizer contact surfaces on the synchronizer cups for
wear.
Washers
1. Check surfaces of all washers. Washer scored or reduced in
thickness should be replaced.
13
Precautions
Assemble
Make sure that case interiors and housings are clean. It is important that
dirt and other foreign materials are kept out of the transmission during
assembly. Dirt is an abrasive and can damage polished surfaces of
bearings and washers. Use certain precautions, as listed below, during
assemble.
Axial Clearances
Maintain recommended axial clearances for mainshaft gears.
Bearings
Use a sleeve type bearing driver for bearing installation. These
special drivers contacts the inner bearing inner race, preventing
damage to balls/rollers while maintaining correct bearing
alignment with shaft.
Capscrews
To prevent oil leakage and loosening, use Eaton/Fuller sealant
#71225 on all capscrews, if not precoated.
Gaskets
Use new gaskets throughout the transmission as it is being rebuilt.
Make sure all gaskets are installed. An omission of any gasket can
result in oil leakage or misalignment of bearing covers.
Initial Lubrication
Coat all thrust washers, synchronizers, and bearings with
transmission lubricant during assembly to prevent damage during
initial start up.
O-Rings
Lubricate all O-rings with silicon lubricant.
Shims
Apply a light coat of Eaton/Fuller sealant #71233 to both sides of
shims.
Universal Joint Companion Flange or Yoke
Pull the companion flange or yoke tightly into place with the output
shaft nut, using 300-350 Lbf·ft (407-475 Nm) of torque. Make
sure the speedometer drive gear or a replacement spacer has been
installed. Failure to properly torque the nut can result in damage
to the mainshaft rear bearing.
IMPORTANT: See the appropriate Illustrated Parts Lists (specified by
model series) to ensure that proper parts are used during assemble of
the transmission.
14
Section 2: General Information
General Information
How to Use This Manual 3
Model Designation 5
Lubrication 6
Maintenance Interval Chart 7
Power Flow 9
Tool Reference 10
Preventive Maintenance 11
Checks Before Transmission Removal 12
Checks With Drive Line Dropped 13
Inspection 14
Rear Seal Maintenance 15
Transmission appearance may differ, procedure is the same. 1

How to Use This Manual
This manual is designed to provide detailed information

necessary to service and repair the Eaton® Fuller®
General Information
transmissions listed in the Model Part Reference
section.
As outlined on the first page, the manual has been
divided into its main components: external parts, shift
bar housing, front section, auxiliary section, and
options (if applicable). Each component has its own
tabbed section. Each tabbed section has its own table
of contents and procedural flow charts. The table of
contents lists the procedures. The flow charts
represent the order in which the transmission should
be disassembled or assembled. The procedures have
two parts, disassembly or removal and reassembly or
installation.
The following is the general layout with descriptions.

1. Heading
Gives a general description of the topic covered. 1
2
2. Subhead
Gives a more specific description of the topic covered. 3 6
3. Special Instructions 4
Procedures that need to be done before performing the
topic covered. Hints that will make the procedure
easier to preform. 5
4. Special Tools 8
For most procedures typical service mechanic tools are 7
all that is required, but sometimes a "special" tool is
needed to prevent damaging the transmission.
5. The "How to"
The actual procedure to be performed.
6. Illustrations and pictures
To further help explain and illustrate the procedures.
7. Final Check
Must do's for proper performance. 8
8. Page Number/Section
Tells what page you are on and in what section.
How to Use This Manual
Remove As mentioned on the previous page, the flow charts

1 External
Parts represent the order in which the transmission should
be disassembled or assembled.
Input Shaft
2 Assembly
The following is an example of how to disassemble the
main section, specifically the countershaft assembly.
Mainshaft
Assembly
3 Disassemble Follow the flow chart "How to Disassemble the Main
Mainshaft
5 Section".
Reverse 1. Remove the external parts from the case.
Idler Gear
4 Assembly
2. Remove the input shaft assembly.
3. Remove the mainshaft assembly.
Countershaft
Assembly 4. Remove the countershaft assembly.
Disassemble
Countershaft
5. Disassemble the countershaft assembly.
Transmission Once the countershaft parts have been replaced,

Case
assemble the main section according to the "How to
Assemble Assemble the Main Section".
Countershaft
Countershaft
1. Install the reverse idler gear assembly.
1 Assembly 2
2. Assemble the countershaft assembly.
3. Install the countershaft assembly.
Reverse
3 Idler Gear 4. Continue following the chart.
Assembly 4
Assemble
Mainshaft
Mainshaft
Assembly
Input Shaft
Assembly
4 Transmission appearance may differ, procedure is the same.

Model Designation
Transmission model designation and other

transmission identification information are stamped on
General Information
the transmission tag. To identify the transmission
model designation and serial number, locate the tag on
the transmission and then locate the numbers as
shown.
Do not remove or destroy the transmission

identification tag.
PTO Codes
Eaton Fuller
Transmissions
FS-6306
Eaton Corporation
Transmission Div Made
Kalamazoo, MI 49003 in
F S - 6 3 0 6 A
Fuller Ratio Set
Synchronized Forward Speeds
Design Level
This (x) 100 = Nominal Torque Capacity

Lubrication
Proper lubrication procedures are the key to a good

all-around maintenance program.
Eaton® Fuller® Transmissions are designed so that the
internal parts operate in an oil circulating bath created
by the motion of the gears and shafts.
Thus, all parts are amply lubricated if these
procedures are closely followed:
1. Maintain oil level. Inspect regularly.
2. Follow maintenance interval chart.
3. Use the correct grade and type of oil.
4. Buy from a reputable dealer.
1. Maintain Proper Oil Level

Make sure oil is level with the filler opening. Because
Proper Oil Level
Improper Oil Level
you can reach oil with your finger does not mean oil is
at proper level. (One inch of oil level is about one
gallon of oil.)
When adding oil, types and brands of oil should not

be mixed because of possible incompatibility.

Lubrication
2. Maintenance Interval Chart
General Information
Eaton ® Roadranger® CD50 Transmission Fluid
HIGHWAY USE-Heavy Duty and Mid-Range
Initial Fill with Eaton® Roadranger® CD50 Transmission Fluid
Every 10,000 miles Check fluid level. Check for leaks.
Every 250,000 miles Change transmission fluid.
OFF-HIGHWAY USE
Every 40 hours Inspect lubricant level.
Check for leaks.
Every 500 hours Change transmission fluid where
severe dirt conditions exist.
Every 1,000 hours Change transmission fluid
(Normal off-highway use.)
HIGHWAY USE-Heavy Duty and Mid-Range

Initial Fill with Other Recommended Oil
First 3,000 to 5,000 miles Factory fill initial drain.
Refill with Eaton® Roadranger® CD50 Transmission Fluid;
thereafter follow maintenance intervals above.
Heavy Duty Engine Lubricant or

Mineral Gear Lubricant
HIGHWAY USE
First 3,000 to 5,000 miles Factory fill initial drain.
Every 10,000 miles Inspect lubricant level.

Check for leaks.
Every 50,000 miles Change transmission lubricant.
OFF-HIGHWAY USE
First 30 hours Change transmission
lubricant on new units.
Every 40 hours Inspect lubricant level. Check for leaks.
Change transmission lubricant where
Every 500 hours severe dirt conditions exist.
Change transmission lubricant
Every 1,000 hours (Normal off-highway use.)
If your vehicle has a transmission oil filter, you must

change the filter when fluid or lubricant is changed.
3. Recommended Lubricant Chart

Fahrenheit
Grade Ambient
Type (SAE) Temperature
Eaton® Roadranger®
CD50 Transmission 50 All
Fluid
Heavy Duty Engine Oil
MIL-L-2104B, C or D or 50 Above 10°F
API-SF or API-CD 40 Above 10°F
(Previous API designations 30 Below 10°F
acceptable)
Mineral Gear Oil with rust 90 Above 10°F
and oxidation inhibitor 80W Below 10°F
API-GL-1
Additives and friction modifiers must not be introduced.

Lubrication
4. Buy from a reputable dealer

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

If the transmission operating angle is more than +⁄-12°,
improper lubrication will occur. The operating angle is
the transmission mounting angle in the chassis plus
the percent of upgrade or downgrade (expressed in
degrees).

Power Flow
The transmission must efficiently transfer the engine's

power to the vehicle's driveline. Knowledge of what
General Information
takes place in the transmission is helpful when
troubleshooting and making repairs.
6 1. Power (torque) from the vehicle's engine is

transferred to the transmission's input shaft.
5
2 2. Torque is transferred to the countershaft drive
7 gear.
3. Torque is delivered along the countershaft to all
1 countershaft gears.
4. Torque is transferred to "engaged" mainshaft
gear. The cross section view illustrates a 1st
speed gear engagement.
5. The engaged mainshaft gear external clutching
teeth transfers torque to the mainshaft through
the synchronizer assembly or sliding clutch.
6. The mainshaft transfers torque directly to the
3 4 driveshaft through the output yoke.
FS-5205

Tool Reference
Some repair procedures pictured in this manual show

the use of specialized tools. Their actual use is
recommended as they make transmission repair
easier, faster, and prevent costly damage to critical
parts.
But for the most part, ordinary mechanic's tools such

as socket wrenches, screwdrivers, etc., and other
standard shop items such as a press, mauls and soft
bars are all that is needed to successfully disassemble
and reassemble any Eaton Fuller Transmission.
The specialized tools can be obtained from a tool

supplier or made from tool prints as required by the
individual user. Detailed Eaton Fuller Transmission
Tool Prints are available upon request by writing to:
Eaton Corporation
Transmission Division
Technical Service Dept.
P.O. Box 4013
Kalamazoo, Michigan 49003

Preventive Maintenance
Everyday there are countless vehicles operating over

the highways with transmissions in such a neglected
General Information
mechanical condition, they can be referred to as
failures looking for a place to break down. They lack a
proper and organized preventive maintenance program.
Preventive maintenance is a general term which applies

to all procedures necessary to have maximum life and
satisfactory service at the lowest possible cost, short of
removing and repairing the unit.
A number of conditions contrary to good preventive

maintenance can generally be pointed to when
inspecting a failed transmission. Taking a few minutes
every so many hours or miles to do a few simple
checks could help avoid eventual breakdown or reduce
the repair cost. If the transmission is not cared for, it
will breakdown.

Checks Before Transmission Removal

1 Clutch Housing Mounting
Check all capscrews of clutch housing flange for
looseness.
2 Clutch Release Bearing (Not Shown)

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.
3 Clutch Pedal Shaft and Bores

Pry upward on shafts to check wear.
If excessive movement is found, remove clutch
1 release mechanism and check bushings on bores
and wear on shafts. See OEM literature.
7 4 Lubricant
3 Change at specified service intervals.
Use only the types and grades as recommended.
See LUBRICANTS.
5 Filler and Drain Plugs

Remove filler plugs and check level of lubricant at
specified intervals. Tighten fill and drain plugs
securely.
6 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.
5
4
7 Gear Shift Lever

Check for looseness and free play in housing. If
General Information
lever is loose in housing, proceed with Check No.
8.
8 Gear Shift Lever Housing Assembly

Remove the gear shift lever housing assembly
from the transmission.
Check the tension spring and washer for set and
wear.
Check gear shift lever bottom end for wear in the
slots and check for wear of finger assembly and
housing.
Checks With Drive Line Dropped
9 Universal Joint Companion Flange or Yoke Nut 7 8
Check for tightness. Tighten to recommended
torque.
10 Output Shaft (Yoke Nut Tightened)

Pry upward against output shaft to check radial
clearance in mainshaft rear bearing.
9
Checks With Universal Joint Companion Flange or Yoke
Removed
NOTE: If necessary, use solvent and shop rag to
clean sealing surface of companion flange or
yoke. Do not use crocus cloth, emery paper,
or other abrasive materials that will mar 10
surface finish.
11 Splines on Output Shaft 11

Check for wear from movement and chucking
action of the universal joint companion flange or 12
yoke.
12 Mainshaft Rear Bearing Cover

Check oil seal for wear.

Inspection
Part to Inspect What to Check For Action to be Done
Speedometer Speedometer cables should not be loose. Applied hydraulic thread sealant #71208 to
Connections threads.
Torque speedometer sleeve to 35-50 Lbf·ft.
Should be an O-ring or gasket between the Replace the O-ring/gasket if damaged or

mating speedometer sleeve and the rear missing.
bearing cover.
Rear Bearing Check retaining nuts for tightness. Apply Eaton Sealant #71225 to the capscrew
Cover Nuts threads.
Torque nuts to 60-70 Lbf·ft.
Output Yoke Check the output yoke retaining nut for Torque the output yoke retaining nut to 300-
Retaining Nut tightness. 350 Lbf·ft. Do not over torque the output nut.
PTO Covers Check the capscrews for tightness. Apply Eaton Sealant #71225 to the capscrew
and Openings threads, if not precoated.
Tighten PTO capscrews to 10-20 Lb f·ft.
Front Bearing Check front bearing cover, front case, shift bar Replace parts found to be damaged.
Cover housing, rear bearing cover, and clutch
housing for cracks or breaks.
Check the capscrews for tightness. Tighten the capscrews to 15-25 Lb f·ft.
Oil Drain Plug, Check the oil drain plug and the oil fill plug for Torque the oil drain plug to 45-55 Lb f·ft.
Oil Fill Plug leakage. Torque the oil fill plug to 45-55 Lb f·ft.

Rear Seal Maintenance

Leakage in transmission rear seals is perhaps the most
common problem in truck transmissions. The problem
General Information
is more than a nuisance because if not repaired, a
leaking seal can lead to catastrophic transmission
failure. There have been strides in reducing leakage
through improved designs and the use of new seal
materials. However, the most important way to reduce
this problem continues to be through proper service
and installation procedures.
It can be very time consuming and expensive to replace

a rear seal system, then find the oil seal system was not
causing the oil leakage. Using the following checklist,
inspect the transmission to insure proper identification
of the leak path.
Before disassembling the rear seal system, clean the

rear bearing cover, the rear seal, and the output yoke.
DO NOT USE A HIGH PRESSURE SPRAY WASHER TO
CLEAN THE REAR SEAL SYSTEM. USE A CLEAN DRY
CLOTH. Run the vehicle, then inspect these areas for
oil leaks.
For more detailed information on rear seal

maintenance, order Form #193, "Rear Seal Maintenance
Guide." To receive a Literature Order Form, write to:
Eaton Corporation
P.O. Box 1368
Benton Harbor, MI 49022

Section 3: Model/Assembly Reference
FS-4205 3
FS-5205 4
FS-6205 5
FS-6305 6
FS-5306 7
FS-6306 8
1
FS-4205
Remove/ Install/
Disassemble Assemble
(page numbers)
External Parts
Shift Bar Housing
Gear Shift Lever 4 5
Shift Bar Housing 6 7
Output Yoke/Companion Flange 8 9
Endplay Setting Procedure 10
Clutch Housing 14 15
Shift Bar Housing

Yokes and Bars 6 7
Reverse Plunger 16 17
Main Section
Input Shaft Assembly 4 5
Mainshaft Assembly 6, 8 7, 10
Reverse Idler Gear Assembly 24 25
Countershaft Assembly 28, 30 29, 31
3
FS-5205
Remove/ Install/
(page numbers)
External Parts
Shift Bar Housing

Shift Bar Housing

Yokes and Bars 8 10
Main Section
4
FS-6205
Remove/ Install/
(page numbers)
External Parts
Shift Bar Housing
Shift Bar Housing

Yokes and Bars 12 13
Main Section
5
FS-6305
Remove/ Install/
(page numbers)
External Parts
Shift Bar Housing

Shift Bar Housing

Main Section
6
FS-5306
Remove/ Install/
(page numbers)
External Parts
Shift Bar Housing
Shift Bar Housing

Main Section
7
FS-6306
Remove/ Install/
(page numbers)
External Parts
Shift Bar Housing

Shift Bar Housing

Main Section
8
Section 4: External Parts
How to Disassemble the External Parts 2
How to Assemble the External Parts 3
Shift Bar Housing

How to Remove the Gear Shift Lever 4
How to Install the Gear Shift Lever 5
How to Remove the Shift Bar Housing 6
How to Install the Shift Bar Housing 7
Output Yoke/Companion Flange
External Parts
How to Remove the Output Yoke/Companion Flange 8
How to Install the Output Yoke/Companion Flange 9
Main Section
Setting End Play Procedure 10
Setting End Play Procedure For FS-5205 12
Clutch Housing
How to Remove the Clutch Housing 14
How to Install the Clutch Housing 15

How to Disassemble the External Parts
External
Parts
Gear Shift
Lever
Shift Bar
Housing
Output Yoke/
Companion
Flange
Clutch
Housing
How to Assemble the External Parts
External
Parts
Clutch
Housing
External Parts
Output Yoke/ Perform
Companion End Play
Flange Procedure
Shift Bar
Housing
Gear Shift
Lever
Shift Bar Housing
How to Remove the Gear Shift Lever

Special Instructions
Remote control housings are removed the same way
3 as gear shift levers.
2
1
Special Tools
Typical service mechanic tools needed
To Remove
1. From the gear shift lever base, remove the four
(4) retaining capscrews.
5005/27/8 2. To break the gasket seal, lightly jar the gear shift
housing.
3. Remove the gear shift lever housing.
4. Remove the gasket and clean all mounting
surfaces of gasket material.

Shift Bar Housing
How to Install the Gear Shift Lever

Remote control housings are installed the same way as
gear shift levers.
2
Make sure the shift block and yoke notches are aligned 4
in the neutral position.
Special Tools
Typical service mechanic tools needed 1
To Install
1. Position a new gear shift lever gasket on the gear 5005/27/8
shift lever mounting surface.
2. Fit the gear shift lever into the shift block.
External Parts
3. Apply Eaton/Fuller Sealant #71225 or equivalent to
the retaining capscrews, if not precoated.
4. Install the retaining capscrews, tighten to 20-25
Lbf·ft of torque.
Final Check
Make sure the capscrews are properly torqued.
Make sure you can shift the transmission.

Shift Bar Housing
How to Remove the Shift Bar Housing

3
2 There are two (2) lengths of capscrews. The 11⁄2"
capscrews are used with the lifting eyes. Note their
location.
Shift transmission into neutral position.
Special Tools
1 Typical service mechanic tools needed
To Remove
4005/1/2 1. From the shift bar housing rim, remove the
retaining capscrews.
2. To break the gasket seal, jar the shift bar
housing.
3. Remove the shift bar housing.
4. Remove the gasket and clean all mounting
surfaces of gasket material.

Shift Bar Housing
How to Install the Shift Bar Housing

There are two (2) lengths of capscrews. The 11⁄2" 2
capscrews are used with the lifting eyes.
Apply Eaton/Fuller gasket sealant #71233 or equivalent
to shift bar housing gasket before assembly.
Special Tools
To Install
1. Place the shift bars in the neutral position. 4005/37/4
2. Place the synchronizers in the neutral position

(refer to picture).
External Parts
3. Position a new shift bar housing gasket on the 4 3
shift bar housing mounting surface.
4. As you install the shift bar housing, make sure the
yokes fit onto the corresponding synchronizers.
the retaining capscrews, if not precoated.
6. Install the center rear retaining capscrew first and 4005/37/6
the center front retaining capscrew second,

tighten to 35-40 Lbf·ft of torque. 6
7. Install the remaining capscrews, tighten to 35-40

Lbf·ft of torque.
Final Check
4005/37/5
5005/21/1
How to Remove the Output Yoke/Companion Flange

1
You must remove the shift bar housing in order to lock
the transmission.
For proper cleaning and maintenance, see Form 193
“Rear Seal Maintenance Guide”.
Special Tools
Typical service mechanic tools are needed
A large breaker bar or air impact wrench
5005/15/5 To Remove
1. Engage two (2) mainshaft synchronizers into two
(2) mainshaft gears to lock the transmission.
2. Use a large breaker bar or air impact wrench to
remove the output shaft nut.
3. Pull the yoke or flange straight to the rear and off
the output shaft.
4005/37/2
4005/37/1

How to Install the Output Yoke/Companion Flange

1
You must remove the shift bar housing in order to lock
the transmission.
For proper cleaning and maintenance, see Form 193
“Rear Seal Maintenance Guide”.
Special Tools
A torque wrench with 500 Lbf·ft capacity
To Install 5005/15/5
1. Engage two (2) mainshaft synchronizers into two

(2) mainshaft gears to lock the transmission.
2 3
External Parts
2. Install the speedometer drive gear rotor or
replacement spacer on the output shaft inside the
rear bearing cover.
3. Slide the companion flange or yoke onto the
output shaft.
4. Install the output shaft nut, tighten to 300-350
Lbf·ft of torque.
4005/37/1
Final Check
Make sure the output shaft nut is properly torqued.
Unlock the transmission.

Main Section
Setting End Play Procedure

2, 3 Setting end play is done in the vertical position.
1 When setting end play the rear bearing cover, yoke
and output shaft nut will be installed, removed, and
installed again.
After end play is correct, apply a light coat of Eaton/
Fuller sealant #71233 or equivalent to both sides of
the shims, case, and cover before assembly.
Special Tools
4005/40/4 Typical service mechanic tools needed
Dial indicator
4
The Procedure
1. Place the transmission in the vertical position
with front end down.
2. Temporarily install the yoke and output shaft nut.
Tighten nut to 300-350 Lbf·ft of torque.
5 3. Rotate the output shaft and mainshaft six (6)

times clockwise and six (6) times
4005/40/2
counterclockwise to seat bearings and races.
Model Mainshaft End Play 4. Position the dial indicator on the output shaft
end.
FS-4205 .008-.012
5. Pry up on the output shaft to measure the end
FS-5205 .008-.012 play. End play must be set per chart below.
6. Remove shims for less end play, add shims for
FS-6205/6305 .006-.010 more end play.
FS-5306/6306 .006-.010 7. Remove output shaft nut, yoke and rear bearing
cover, coat the shims.
chart
8. Position shims and rear bearing cover on case,
rear bearing cover top is marked for proper
positioning.
9. Install the retaining nuts, tighten to 60-70 Lbf·ft of
torque.
8 Final Check
9 Make sure nuts are properly torqued.
Make sure the output shaft rotates.
4005/37/3 Make sure end play is within specification.
Main Section
Setting End Play Procedure For FS-5205

1
Setting end play is done in both the horizontal and
vertical position.
When setting end play the front bearing cover, rear
bearing cover, yoke and output shaft nut will be
installed, removed, and installed again.
2 After end play is correct, apply a light coat of Eaton/
Fuller sealant #71233 or equivalent to both sides of
the shims.
5005/35/2 Special Tools

Feeler gages
5
Dial indicator
The Procedure
1. Loosen the front bearing cover capscrews to 30
Lbf·in of torque.
6 2. At the capscrew locations, use two feeler gages
to record the gap between the front bearing cover
5005/21/8 and the case.
3. Average the two recorded measurements and add
0.016. This total gives you a shim pack thickness
to start the end play measurement. Combine the
shims to equal the total shim pack measurement.
4. Remove the front bearing cover and coat the
shim pack.
5. Position shims and front bearing cover on case.
6. Install the retaining nuts, tighten to 15-25 Lbf·ft of
torque.

Main Section
continued
Setting End Play Procedure For FS-5205
7. Place the transmission in the vertical position.
8. Install the yoke and output shaft nut. Tighten nut 8
to 300-350 Lbf·ft of torque.
9. Rotate the output shaft and mainshaft six (6)
times clockwise and six (6) times
counterclockwise to seat bearings and races. 9
7
10. Position the dial indicator on the output shaft end.
11. Pry up on the output shaft to measure the end
play. End play must be set per chart below.
5005/27/4
12. Add shims to the front bearing cover for more end
play or remove shims for less end play.
13. After the correct end play is set, remove the front 10
External Parts
bearing cover and shims. Coat both sides of the
shims with a light coat of Loctite #510 or
equilvalent.
14. Position the shims and the front bearing cover.
11
15. Install the cover capscrews, tighten to 15-20 Lbf·ft
of torque.
5005/27/2
Final Check
Make sure nuts and capscrews are properly torqued. Model Mainshaft End Play
Make sure the output shaft rotates.
FS-4205 .008-.012
FS-5205 .008-.012
FS-6205/6305 .006-.010
FS-5306/6306 .006-.010
chart
14
15
5005/21/8
Clutch Housing
How to Remove the Clutch Housing

2
Removal of the clutch housing is done in the
horizontal position.
The clutch release mechanism must be removed.
Special Tools
To Remove
1 1. From outside the clutch housing, remove the
4005/15/6 bolts.
2. Jar clutch housing to break gasket seal.
3
3. Pull the clutch housing from the transmission
case.
4005/15/7

Clutch Housing
How to Install the Clutch Housing

Installation of the clutch housing is done in the 1
horizontal position.
Special Tools
Typical service mechanic tools are needed.
To Install
1. Install the clutch housing on the transmission
case, align bolt holes with case holes.
2. Install the bolts, tighten to 90-100 Lbf·ft of torque
for the FS-4205 and 145-155 Lbf·ft of torque for all 4005/15/7
other models.
External Parts
Final Check
1
4005/15/6

Section 5: Shift Bar Housing
Functions of a Shift Bar Housing 3
Gear Shift Lever

How to Disassemble the Gear Shift Lever 4
How to Assemble the Gear Shift Lever 5
Shift Bar Housing

How to Disassemble the FS-4205 Yokes and Bars 6
How to Assemble the FS-4205 Yokes and Bars 7
How to Disassemble the FS-5205 Yokes and Bars 8
How to Assemble the FS-5205 Yokes and Bars 10
How to Disassemble the FS-6205/6305 Yokes and Bars 12
Shift Bar Housing

How to Assemble the FS-6205/6305 Yokes and Bars 13
How to Disassemble the FS-5306/6306 Yokes and Bars 14
How to Assemble the FS-5306/6306 Yokes and Bars 15
How to Disassemble the Reverse Plunger on FS-4205/5205 16
How to Assemble the Reverse Plunger on FS-4205/5205 17
How to Disassemble the Reverse Plunger On All Other Models 18
How to Assemble the Reverse Plunger On All Other Models 19

Functions of a Shift Bar Housing
Shift bar housings are a very important part of the

transmission. No matter what kind of shift bar housing
your transmission has, they all provide the same
functions:
√ Engage the transmission gearing,
√ Prevents the driver from shifting into 2 gears at
the same time,
√ Prevents shifting into reverse without force,
√ Actuates the back up lights,
√ Actuates the neutral switches.
Shift Bar Housing

Gear Shift Lever
How to Disassemble the Gear Shift Lever

For safety reasons, release the spring one coil at a
time.
2
Special Tools
A vise with brass jaws or wood blocks
To Disassemble
1. Remove the shift lever grip.
5106/5/1
2. Slide the boot up the shift lever shaft and remove.
3 3. With housing bottom facing up, secure the

4 assembly in a vise.
4. Use large screwdriver to twist between the spring
and housing, forcing the spring from under the
housing lugs.
5. From inside the housing tower, remove the
tension spring, washer, and gear shift lever.
6. From the housing tower spade pin bores, remove
5106/4/3 and inspect the spade pins, discard if damaged.
7. If housing tower spade pin bores are worn,
discard the housing tower and replace with a new
housing tower.
5106/4/5
6, 7
5106/4/6
Gear Shift Lever
How to Assemble the Gear Shift Lever

1
Inspect tension spring, washer, and spade pin bores for
wear.
2, 3
Apply oil to the shift lever pivot ball and housing socket
prior to assembly.
Seat the tension spring one coil at a time.
Special Tools
5106/4/7
Tension Spring Driver
To Assemble
1. With housing bottom facing up, secure the 4
assembly in a vise.
2. If housing tower spade pin bores are worn,
discard the housing tower and replace with a new
5
housing tower.
3. If the spade pins are damaged, replace and install
Shift Bar Housing

the spade pins in housing tower bore.
5106/4/8
4. Align the lever ball slot with the spade pin and
position the gear shift lever in the housing tower. 6
5. With dished-side up, install the washer over the
ball.
6. Use a tension spring driver to install the tension
spring under the housing lugs.
7. Remove the assembly from the vise.
8. Install a rubber boot over the gear shift lever and
against the housing. 5106/4/9
9. Install the shift lever grip.
Final Check 7
Make sure the gear shift lever can move.
8
5106/5/1
Shift Bar Housing
How to Disassemble the FS-4205 Yokes and Bars

1 3
The shift bar housing must be removed from the
transmission.
During disassembly, lay all parts on a clean bench in
2
order of removal to facilitate assembly.
Shift bars not being removed must be kept in the
neutral position or the interlocking parts lock the bars.
Start with 1st-reverse yoke assembly.
When removing the interlock balls, detent balls, and
springs, remove the interlock and detent balls before
4005/36/1-a
removing the springs.
Special Tools
To Disassemble
1. With the housing rear to the right, lay the
assembly on a flat surface.
2. In order to remove the front retaining capscrews,
4
shift 4th-5th yoke assembly into 4th gear position
4005/36/3 (rearward).
3. Remove capscrews and retainers.
4. Remove 1st-reverse yoke assembly.
5. Remove 2nd-3rd yoke assembly and interlock
pin.
6. Remove 4th-5th yoke assembly.
7. Inspect the yoke pad bushings. If the pads are
5 worn, remove worn pad from shift yoke, install
new pad and bend tabs over yoke top and
4005/36/4
bottom.
7 6 8. Inspect the yokes. If the yokes are damaged,

remove by driving the lock pin through the yoke
and rail with a punch and hammer. Install new
8 yoke by aligning shift yoke with shift bar
alignment hole and insert lock pin.
9. Remove the interlock balls, detent balls, and
9 springs.
4005/36/5
Shift Bar Housing
How to Assemble the FS-4205 Yokes and Bars

Interlock balls, detent balls, and springs can be used
interchangeably. e c
Lubricate yoke pads and inserts with oil before assembly.
Lubricate yoke bar grooves with grease before assembly.
Keep yoke bars in neutral while assembling.
The shift yoke retainer holes are not tapped on new shift bar a
housings. The capscrews that are used are "thread forming"
f d b
and can be reused if the shift bar housing is replaced.
It may be necessary to support the yoke bars in position
while installing the retainers.
Special Tools 4
To Assemble
1. Install the interlock balls, detent balls, and springs in
the following order:
a. Position three (3) balls in the reverse light switch
bore. 2 3
Shift Bar Housing

b. Install 1st-reverse detent spring and ball.
4005/15/3
c. Position two (2) balls in adjacent cross bore.
d. Install 2nd-3rd detent spring and ball.
e. Position two (2) balls in adjacent cross bore. 5
f. Install 4th-5th detent spring and ball.
2. Position 1st-reverse yoke in housing assembly.
3. Install interlock pin in 2nd-3rd yoke assembly.
4. Position 2nd-3rd yoke in housing assembly.
5. Position 4th-5th yoke in housing assembly.
6. Position retainers: front retainer in rear set of holes,
rear retainer in front set of holes. 4005/15/4
7. Install capscrews in rear retainer. Tighten to 20-25 6 7

Lbf·ft of torque.
8. Carefully shift the 4th-5th yoke into 4th gear position
(rearward).
9
9. Install the capscrews in front retainer. Tighten to
20-25 Lbf·ft of torque.
Final Check
8
Make sure interlocking system is working – can’t shift into 2
gears at the same time. 4005/36/1-a
Shift Bar Housing

1 3 Special Instructions
2 The shift bar housing must be removed from the
transmission.
Start with 4th-5th yoke assembly.
5005/22/3-a 5005/22/5-a
Special Tools
4 Magnet
To Disassemble
5005/22/6
(rearward).
pin.
5 6. Remove 1st-reverse bar assembly.
7. If necessary, remove 1st-reverse bar front
5005/22/7
spacer.
6
5005/22/8 5005/24/8
Shift Bar Housing
continued
8. From the 1st-reverse yoke assembly, remove the 8 9
1st-reverse lock pin.
9. Remove the 1st-reverse yoke assembly.
10. Remove the 1st-reverse actuator.
11. Remove the four (4) interlock balls, the three (3)
detent balls, the three (3) back up light switch
balls, and the three (3) springs.
worn, remove worn pad from shift yoke, install
new pad and bend tabs over yoke top and bottom. 5005/23/1
13. Inspect the yokes. If the yokes are damaged, 10

remove by driving the roll pin through the yoke
and rail.
11
Shift Bar Housing

5005/23/3
12
5005/25/3
13
5005/25/1
Shift Bar Housing

interchangeably.
e c Lubricate yoke pads and inserts with oil before
assembly.
Lubricate yoke bar grooves with grease before
assembly.
a Keep yoke bars in neutral while assembling.
b The shift yoke retainer holes are not tapped on new
f d
shift bar housings. The capscrews that are used are
"thread forming" and can be reused if the shift bar
3
housing is replaced.
It may be necessary to support the yoke bars in
position while installing the retainers.
Special Tools
2
To Assemble
1. Install the interlock balls, detent balls, and
5005/23/2 springs in the following order.
a. Position three (3) balls in the reverse light
switch bore.
d. Install 2nd-3rd detent spring and ball
e. Position two (2) balls in adjacent cross bore.
5 2. Over the actuator pivot pin, seat the 1st-reverse

actuator.
5005/22/8
3. Position 1st-reverse yoke assembly in the
housing.
4. Install the 1st-reverse lock pin in the yoke
assembly.
5. Position 1st-reverse bar assembly in the housing.

Shift Bar Housing
continued
6. Install the 2nd-3rd yoke interlock pin.
7. Position the 2nd-3rd yoke in the housing
assembly. 8
8. Position the 4th-5th yoke in the housing assembly.
9. Position retainers, front retainer in rear set of
holes. 7
10. Install the capscrews in rear retainer. Tighten to
20-25 Lbf·ft of torque. 6
11. Carefully shift the 4th-5th yoke into 4th gear
5005/22/7
position (rearward).
12. Install the capscrews in front retainer. Tighten to 9
20-25 Lbf·ft of torque.
Final Check
Make sure interlocking system is working – can’t shift
into 2 gears at the same time.
Shift Bar Housing

5005/22/6
10 11
12
5005/22/3-a
13
5005/22/4-a
Shift Bar Housing
How to Disassemble the FS-6205/6305 Yokes and Bars

1
2 3 The shift bar housing must be removed from the
transmission.
Start with 1st-reverse yoke assembly.
4
6105/2/4-a 6105/1/3
Special Tools
To Disassemble
6 1. With the housing rear to the right, lay the
5 assembly on a flat surface.
6105/1/4 6105/1/5 (rearward).
7 3. Remove capscrews and retainers.

4. Remove 1st-reverse yoke assembly.
8
pin.
worn, remove worn pad from shift yoke, install
5005/25/3 5005/25/1
bottom.
8. Inspect the yokes. If the yokes are damaged,
yoke by aligning shift yoke with shift bar
9 9. Remove the interlock balls, detent balls, and
springs.
6105/1/6
Shift Bar Housing
How to Assemble the FS-6205/6305 Yokes and Bars

interchangeably.
Lubricate yoke pads and inserts with oil before assembly. e c
The shift yoke retainer holes are not tapped on new shift bar
housings. The capscrews that are used are "thread forming"
and can be reused if the shift bar housing is replaced. a
It may be necessary to support the yoke bars in position f d b
Special Tools 4
Typical service mechanic tools needed 2
To Assemble
a. Position three (3) balls in the reverse light switch 3
bore.
Shift Bar Housing

6105/1/8 6105/1/9
d. Install 2nd-3rd detent spring and ball.
5 6 7
e. Position two (2) balls in adjacent cross bore.
2. Position 1st-reverse yoke in housing assembly.
3. Install interlock pin in 2nd-3rd yoke assembly.
4. Position 2nd-3rd yoke in housing assembly.
6. Position retainers, front retainer in rear set of holes.
6105/2/1 6105/2/3-a
7. Install the capscrews in the middle and rear
retainers. Tighten to 20-25 Lbf·ft of torque. 8
9
(rearward).
9. Install the remaining capscrews. Tighten to 20-25
Lbf·ft of torque.
Final Check
gears at the same time.
6105/2/5-a
Shift Bar Housing
How to Disassemble the FS-5306/6306 Yokes and Bars
1 Special Instructions
3 The shift bar housing must be removed from the
transmission.
Start with reverse shift bar.
2 4
5106/14/2 5106/14/3
7
Special Tools
To Disassemble
6
5
5106/14/4 5106/14/5 (rearward).
8
4. Remove reverse yoke assembly.
5. Remove 1st-2nd yoke assembly and interlock
9 pin.
6. Remove 3rd-4th yoke assembly and interlock pin.
5005/25/3 5005/25/1 worn, remove worn pad from shift yoke, install
bottom.
10 9. Inspect the yokes. If the yokes are damaged,
yoke by aligning shift yoke with shift bar
10. Remove the interlock balls, detent balls, and
springs.
5106/14/7
Shift Bar Housing
How to Assemble the FS-5306/6306 Yokes and Bars

interchangeably. c
Lubricate yoke pads and inserts with oil before assembly.
The shift yoke retainer holes are not tapped on new shift bar
housings. The capscrews that are used are "thread forming" a
and can be reused if the shift bar housing is replaced. b
It may be necessary to support the yoke bars in position
Special Tools
To Assemble
a. Position three (3) balls in the reverse light switch 4
bore. 2 3
Shift Bar Housing

b. Install reverse detent spring and ball.
c. Position two (2) balls in adjacent cross bore. 5106/14/8 5106/14/9
d. Repeat steps b and c for 1st-2nd position, 3rd-4th

position, and 5th-6th position. 7
5
2. Position reverse yoke in housing assembly.
3. Install interlock pin in 1st-2nd yoke assembly.
4. Position 1st-2nd yoke in housing assembly.
5. Install interlock pin in 3rd-4th yoke assembly.
6. Position 3rd-4th yoke in housing assembly.
6
8. Position retainer, front retainer in rear set of holes. 5106/15/1 5106/15/2
9. Install the capscrews in the middle and rear retainers. 9 10

Tighten to 20-25 Lbf·ft of torque. 8 11
(rearward).
11. Install the remaining capscrews. Tighten to 20-25
Lbf·ft of torque.
Final Check
gears at the same time. 5106/15/4-a 5106/15/7-a
Shift Bar Housing
How to Disassemble the Reverse Plunger on FS-4205/5205

Retainer is under spring pressure.
Special Tools
To Disassemble
1. Remove the reverse plunger retaining plug and
1 gasket.
2. Remove the reverse plunger spring.
5005/24/1
3. Remove the reverse plunger stop.
2 4. Remove the reverse plunger.
5. Inspect reverse plunger. Replace damaged parts.
5005/24/2
5005/24/3
5005/24/4
Shift Bar Housing
How to Assemble the Reverse Plunger on FS-4205/5205

With the reverse plunger bore up, place the shift bar 1
housing on its side.
Special Tools
To Assemble
1. Install the reverse plunger.
2. Install the reverse plunger spring.
5005/24/4
3. Install the reverse plunger stop.
4. Install the reverse plunger gasket and plug.
Tighten the plug to 8-12 Lbf·ft of torque. 2
Final Check
Make sure snap ring is securely in shift block groove.
Shift Bar Housing

5005/24/5
5005/24/6
5005/24/1
Shift Bar Housing
How to Disassemble the Reverse Plunger On All Other Models

Snap ring and retainer are under spring pressure.
1
Special Tools
Snap ring pliers
Vise with brass jaws or wood blocks
2
To Disassemble
1. Depress reverse plunger springs and retainer.
4005/41/3
2. Remove snap ring and spring retainer.
3. Remove reverse plunger springs.
4. Remove washer and plunger.
3
5. Inspect reverse plunger parts. Replace worn or
damaged parts.
4005/41/9
4005/41/7

Shift Bar Housing
How to Assemble the Reverse Plunger On All Other Models

Place the reverse yoke bar in a vise.
Special Tools 1
To Assemble
1. Install plunger and washer.
2. Install reverse plunger springs.
4005/41/6
3. Depress the reverse plunger retainer and springs.
4. Install the snap ring in the shift block groove.
Final Check 2
Make sure snap ring is securely in shift block groove.
Shift Bar Housing

4005/41/9
4005/41/3

Section 6: Main Section
How to Disassemble the Main Section 2
How to Assemble the Main Section 3
Input Shaft Assembly

How to Remove the Input Shaft Assembly 4
How to Install the Input Shaft Assembly 5
Mainshaft Assembly
How to Remove the Mainshaft Assembly 6
How to Install the Mainshaft Assembly 7
How to Disassemble the FS-4205 Mainshaft Assembly 8
How to Assemble the FS-4205 Mainshaft Assembly 10
How to Disassemble the FS-5205 Mainshaft Assembly 12
How to Assemble the FS-5205 Mainshaft Assembly 14
How to Disassemble the FS-6205/6305 Mainshaft Assembly 16
How to Assemble the FS-6205/6305 Mainshaft Assembly 18
How to Disassemble the FS-5306/6306 Mainshaft Assembly 20
How to Assemble the FS-5306/6306 Mainshaft Assembly 22
Reverse Idler Gear Assembly

How to Remove the Reverse Idler Gear Assembly 24
How to Install the Reverse Idler Gear Assembly 25
Main Section
How to Remove the FS-5306/6306 Reverse Idler Gear Assembly 26
How to Install the FS-5306/6306 Reverse Idler Gear Assembly 27
Countershaft Assembly
How to Remove the Countershaft Assembly 28
How to Install the Countershaft Assembly 29
How to Disassemble the FS-4205 Countershaft Assembly 30
How to Assemble the FS-4205 Countershaft Assembly 31
How to Disassemble the FS-5205 Countershaft Assembly 32
How to Assemble the FS-5205 Countershaft Assembly 33
How to Disassemble the FS-6205/6305 Countershaft Assembly 34
How to Assemble the FS-6205/6305 Countershaft Assembly 35
How to Disassemble the FS-5306/6306 Countershaft Assembly 36
How to Assemble the FS-5306/6306 Countershaft Assembly 37
How to Disassemble the Main Section
Remove
External
Parts
Input Shaft
Assembly
Mainshaft
Assembly
Disassemble
Mainshaft
Reverse
Idler Gear
Assembly
Countershaft
Assembly
Disassemble
Countershaft

How to Assemble the Main Section
Transmission
Case
Assemble
Countershaft
Countershaft
Assembly
Reverse
Idler Gear
Assembly
Assemble
Mainshaft
Mainshaft
Main Section
Assembly
Input Shaft
Assembly

How to Remove the Input Shaft Assembly

3
1
Special Tools
Typical service tools are needed
Rubber mallet
2
To Remove
1. Remove the front bearing capscrews.
4005/1/3 4005/8/6
2. Jar the front bearing cover with a rubber mallet.
3. Inspect the oil seal. Remove the oil seal if
damaged.
4 4. Remove the input shaft assembly from the case.
5. From the input shaft assembly, use a chisel and
hammer to remove the bearing cage and rollers.
6. Install a bearing puller to remove the bearing
race.
4005/1/6 7. For the FS-5205 model, if necessary, remove the
retention snap ring and the bearing retention ring.
Remove the fourteen (14) roller bearings from
the main drive gear bearing pocket.
5
4005/8/4
7 7
5005/34/7 5005/34/8
How to Install the Input Shaft Assembly

For the FS-5205 model, use a high quality grease on
the fourteen (14) needle bearings installed in the main
drive gear bearing pocket.
Do not heat the input shaft bearing above 275°F 1
(136°C). If possible, use a heat lamp as the source.
On stem type bearing caps, the oil seal and bearing
race must be installed from the rear.
The front and rear bearing covers are marked for
proper installation.
4005/8/5
Special Tools
Heat lamp
Sleeve type bearing driver
2
To Install
1. If input shaft is disassembled, install a new input
shaft bearing using a sleeve type bearing driver or
heat lamp. 5005/34/7
2. For the FS-5205 model, if removed, install the

fourteen (14) lubricated roller bearings in the main
drive gear bearing pocket. Install the retention
ring and the bearing retention snap ring. 3
Main Section
3. Install the input shaft in the case by aligning main
drive clutching teeth.
4. Coat input shaft bearing cover oil seal outer
diameter with Eaton/Fuller Sealant #71217 or
equivalent.
4005/1/6
5. Install the oil seal with flanged driver.
6. Install input shaft bearing race.
7
7. Position a new gasket on the front bearing
mounting surface. 8
8. Position the front bearing cover over the gasket.
6
the retaining capscrews, if not precoated. 9, 10
10. Install the retaining capscrews and tighten to 15-

25 Lbf·ft of torque. 4005/8/9 4005/1/3
Mainshaft Assembly
How to Remove the Mainshaft Assembly

2
3 When removing the rear bearing cover the shims may
come off with the cover.
1
Special Tools
Sling or 3 foot piece of rope
To Remove
1. Remove the speedometer sleeve and driven gear.
4005/38/3 5106/2/9
2. Remove the rear bearing cover retaining nuts and
lockwashers.
5 6
3. Using screwdrivers in cover notches, remove the
4 rear bearing cover.
7
4. Inspect the oil seal. Remove if damaged.
5. Inspect the rear bearing race inside the rear
bearing cover. Remove if damaged.
6. Remove any shims not removed with rear
bearing cover.
4005/7/8 4005/38/5
7. Remove speedometer drive gear or rotor.
8. For the FS-5205 model, tap on the mainshaft
front to move the mainshaft rearward about 1/4".
Use pry bars to remove the rear bearing cup and
locating snap ring.
8
9. Wrap sling or rope around the mainshaft and lift
the mainshaft front out of the case.
5005/28/9
4005/2/2
Mainshaft Assembly
How to Install the Mainshaft Assembly

The countershaft must be installed first. 1
Make sure the synchronizer cups on the mainshaft front
end stay in position as the mainshaft is lowered into the
case.
The rear bearing cover is marked for proper installation.
Special Tools
Typical service tools needed
Sling or 3' piece of rope
4005/1/9
To Install
1. Position a sling or rope around the mainshaft.
2. Carefully lower the mainshaft into the case while
guiding the output shaft through the rear case
bore.
3
3. For the FS-5205 model, install the mainshaft rear
outer bearing race in the output shaft bearing
bore.
4. Coat output shaft bearing cover oil seal outer 5005/34/9
diameter with Eaton/Fuller Sealant #71217 or
equivalent. 4, 5
5. If removed, install the oil seal with flanged driver.
6. If removed, install output shaft bearing race.
Main Section
7. Temporarily position shims on the rear bearing
mounting surface.
8. Position the rear bearing cover over the shims.
9. Install the retaining nuts and tighten to 60-70
Lbf·ft of torque. 4005/40/5
Final Check 7, 8
Make sure the mainshaft rotates freely.
9
4005/7/9 4005/1/7
Mainshaft Assembly
How to Disassemble the FS-4205 Mainshaft Assembly

10
2
Special Tools
11
3 To Disassemble
1. With mainshaft front facing up, install the
mainshaft assembly vertically in a vise.
12
2. Remove shift hub thrust bearing and bearing
race.
4 13
3. Remove 4th-5th speed synchronizer and cups.
4. Remove 4th-5th clutch hub.
5. Remove 4th gear and 4th gear bearing.
5 6. Remove 3rd gear retaining snap ring

7. Remove 3rd gear thrust washer and locating ball.
14
6 8. Remove 3rd gear and 3rd gear bearing.
7
9. Remove 2nd-3rd speed synchronizer and cups.
7
15 10. Remove snap ring and 2nd-3rd shift hub.
11. Remove 2nd gear and 2nd gear bearing.
12. Remove split ring retainer ring.
8 13. Separate split washers and remove half rings and
locating ball.
1 14. Remove 1st gear and 1st gear bearing.
15. Remove 1st-reverse clutch hub.
FS-4205-ms/front up
Mainshaft Assembly
continued
16. With mainshaft rear facing up, install the
17. Using a puller, remove reverse gear, washer, and
rear bearing. 17
18. Remove reverse gear bearing.
18
16
Main Section
FS-4205-ms/rear up

Mainshaft Assembly
How to Assemble the FS-4205 Mainshaft Assembly

5 Lubricate the gear bearing bores, gear hub faces, split
washers, synchronizer friction surfaces, synchronizer
cups and the mainshaft with transmission lube as the
4
mainshaft is assembled.
Special Tools
3 A sleeve type bearing driver
To Assemble
2 mainshaft assembly vertically in a vise.
2. Install reverse gear bearing.
3. With reverse gear clutching teeth down, install
reverse gear.
4. Install reverse gear washer. Washer can be
installed either way.
5. Use a sleeve type bearing driver and install the
1 rear mainshaft bearing.
FS-4205-ms/rear up

Mainshaft Assembly
continued
6. With mainshaft front facing up, install the 15
14
7. Install the 1st-reverse clutch hub.
25
8. Install 1st gear bearing.
13
9. With 1st gear clutching teeth down, install 1st
gear.
10. Install locating ball and split washer in mainshaft
groove, position split washer ends together at 24 12
locating ball.
11. Install retainer ring over split washer.
11
12. Install 2nd gear bearing.
13. With 2nd gear clutching teeth up, install 2nd gear. 23 10
14. With 2nd-3rd clutch hub stepped face up, install
2nd-3rd clutch hub. 22
9
15. Install snap ring in mainshaft groove.
16. Install 2nd-3rd speed synchronizer and cups. 21
17. Install 3rd gear bearing.
20 8
18. With 3rd gear clutching teeth down, install 3rd
gear. 19
19. Install locating ball and washer. Washer can be 7

18
Main Section
21. Install 4th gear bearing.
17
22. With 4th gear clutching teeth up, install 4th gear. 6
23. With 4th-5th clutch hub machined surface up,
install 4th-5th clutch hub.
24. Install 4th-5th speed synchronizer and cups.
25. Install the shift hub thrust bearing and bearing 16
race.
Final Check
Make sure the mainshaft gears rotate freely.
FS-4205-ms/front up
Mainshaft Assembly

2 Use caution when removing 1st gear, the needle
bearings are loose under 1st gear.
Special Tools
3 Vise with brass jaws or wood blocks
4 To Disassemble
5 2. Remove 4th-5th speed synchronizer and cups.

3. Remove shift hub thrust bearing and bearing
6 race.
4. Remove 4th-5th clutch hub.
7
5. Remove 4th gear and 4th gear bearing.
6. Remove 3rd gear retaining snap ring.
8 7. Remove 3rd gear thrust washer and locating ball.
8. Remove 3rd gear and 3rd gear bearing.
FS-5205-ms/front up
Mainshaft Assembly
continued
mainshaft assembly vertically in a vise. 11
11. Using a puller, remove mainshaft rear bearing. 12
12. Remove 1st gear split washer retaining ring. 13
13. Separate split washers and remove half rings.
14. Remove 1st gear and 1st gear bearing.
14
15. Remove 1st-reverse sliding clutch.
16. Remove 1st-reverse clutch hub snap ring.
15
17. Remove shift hub.
16
18. Remove reverse gear and reverse gear bearing.
17
19. Remove 2nd gear split washer retaining ring.
20. Remove 2nd gear split washer and locating ball.
21. Remove 2nd gear and 2nd gear bearing.
18
19
20
Main Section
21
10
FS-5205-ms/rear up

Mainshaft Assembly

14
13 mainshaft is assembled.
12 Special Tools
11
A sleeve type bearing driver
10 To Assemble
9
8 2. Install 2nd gear bearing.
3. With 2nd gear clutching teeth down, install 2nd
7 gear.
4. Install locating ball and split washer in mainshaft
6 groove, position split washer ends together at
locating ball.
5 5. Install 2nd gear split washer retaining ring.
6. Install reverse gear bearing.
4
7. Install reverse gear.
3 8. Install 1st-reverse clutch hub.
2 9. Install 1st-reverse clutch hub snap ring in

mainshaft groove.
10. Install 1st-reverse sliding clutch.
1
11. Install 1st gear bearing.
12. Install 1st gear.
13. Install 1st gear split washer in mainshaft groove,
position split washer ends together.
14. Install retainer ring over split washer.
15. Use a sleeve type bearing driver and install the
rear mainshaft bearing.
FS-5205-ms/rear up

Mainshaft Assembly
continued
17. Install 2nd-3rd speed synchronizer and cups.
26
18. Install 3rd gear bearing.
gear.
20. Install locating ball and 3rd gear thrust washer.
Align washer indent with ball. 25
21. Install snap ring in mainshaft groove. 24

22. Install 4th gear bearing.
23
23. With 4th gear clutching teeth up, install 4th gear.
24. With 4th-5th clutch hub machined surface up, 22
install 4th-5th clutch hub.
21
25. Install the clutch hub thrust bearing and bearing
race.
20
19
Final Check
18
Main Section
17
16
FS-5205-ms/front up
Mainshaft Assembly
How to Disassemble the FS-6205/6305 Mainshaft Assembly

3
8 order of removal to facilitate assembly.
Special Tools
2 Typical service tools are needed
To Disassemble
9 1. With mainshaft front facing up, install the
3 mainshaft assembly vertically in a vise.
3. Using a puller mounted behind 4th-5th clutch
hub, remove hub and bearing.
4 10
4. Remove 4th gear, bearings, and spacer.
5. Remove snap ring, thrust washer, and locating
ball.
5 6. Remove 3rd gear, bearings, and spacer.
8. Remove snap ring and 2nd-3rd shift hub.
11
9. Remove 2nd gear, bearings, and spacer.
6 12 ball.
11. Remove 1st gear, bearings, and spacer.
12. Remove 1st speed synchronizer.
1 continued on next page
FS-6205/6305-ms/front up
Mainshaft Assembly
continued
14
rear bearing.
15. Remove reverse gear bearings and spacer.
15
13
Main Section
FS-6205/6305-ms/rear up

Mainshaft Assembly
How to Assemble the FS-6205/6305 Mainshaft Assembly

4 mainshaft is assembled.
Special Tools
3
To Assemble
2. Install reverse gear bearings with spacer between
2 bearings.
3. With reverse gear clutching teeth down, install
reverse gear.
5. Use a sleeve type bearing driver or heat lamp and
install the rear mainshaft bearing.
1

Mainshaft Assembly
continued
6. With mainshaft front facing up, install the 15
7. Install the 1st-reverse synchronizer. 14
8. Install 1st gear bearings with spacer between the
bearings.
13
9. With 1st gear clutching teeth down, install 1st 24
gear.
10. Install locating ball and washer in mainshaft
groove. Washer can be installed either way. 12
12. Install 2nd gear bearings with spacer between 11
bearings. 22
13. With 2nd gear clutching teeth up, install 2nd gear. 10
14. With 2nd-3rd clutch hub stepped face up, install 9
2nd-3rd clutch hub. 21
16. Install 2nd-3rd speed synchronizer and cups.
19
17. Install 3rd gear bearings with spacer between
bearings. 18 8
gear. 7
19. Install locating ball and washer. Washer can be
Main Section
installed either way. 17
21. Install 4th gear bearings with spacer between 6
bearings.
23. With 4th-5th clutch hub shoulder end facing 16
down, install 4th-5th clutch hub.
25. Use a sleeve type driver and install the front
mainshaft bearing.
Final Check
Mainshaft Assembly

3 order of removal to facilitate assembly.
Special Tools
9
3 To Disassemble
10 1. With mainshaft front facing up, install the
3. Using a puller mounted behind 5th-6th clutch
hub, remove hub and bearing.
4 4. Remove 5th gear and bearings.
11
ball.
5 6. Remove 4th gear and bearings.
7. Remove 3rd-4th speed synchronizer and cups.
12 8. Remove snap ring and 3rd-4th clutch hub.
6 9. Remove 3rd gear and bearings.

ball.
11. Remove 2nd gear and bearings.
1 12. Remove 1st-2nd speed synchronizer and cups.
7
Mainshaft Assembly
continued
15
rear bearing.
16. Remove reverse gear bearings and sliding clutch.
17. Remove snap ring and clutch hub.
18. Remove 1st gear and bearings.
16
17
18
Main Section
14
Mainshaft Assembly

10 Lubricate the gear bearing bores, gear hub faces,
synchronizer friction surfaces, synchronizer cups and
9 the mainshaft with transmission lube as the mainshaft
is assembled.
Do not heat reverse bearing race over 320°F (160°C).
8
Special Tools
7
To Assemble
6 1. With mainshaft rear facing up, install the
5 2. Install 1st gear bearings.
4 3. With 1st gear clutching teeth down, install 1st
gear.
4. With reverse gear clutch hub notched teeth facing
3 down, install clutch hub.
5. Install snap ring.
2 6. With reverse gear sliding clutch counterbore up,

install sliding clutch.
7. Install reverse gear bearings.
8. With reverse gear clutching teeth facing down,
install reverse gear.
1
10. Use a sleeve type driver or heat lamp and install
the rear mainshaft bearing.
Mainshaft Assembly
continued
18
12. Install the 1st-2nd synchronizer and cps.
13. Install 2nd gear bearings.
14. With 2nd gear clutching teeth down, install 2nd 17
gear. 29
15. Install locating ball and washer in mainshaft 16

28
groove. Washer can be installed either way.
15
17. Install 3rd gear bearings. 14
18. With 3rd gear clutching teeth up, install 3rd gear. 27
19. With 3rd-4th clutch hub stepped face up, install

3rd-4th clutch hub. 26
21. Install 3rd-4th speed synchronizer and cups. 25
22. Install 4th gear bearings. 24

23. With 4th gear clutching teeth down, install 3rd 23
gear.
12
24. Install locating ball and washer. Washer can be
installed either way. 22
Main Section
26. Install 5th gear bearings.
11
28. With 5th-6th clutch hub flat surface facing up,
install 5th-6th clutch hub. 21
mainshaft bearing.
20
Final Check 19
How to Remove the Reverse Idler Gear Assembly

1 Special Tools
Rolling wedge bar
To Remove
1. Remove the reverse idler lock and retaining
capscrew.
4005/2/5
2. Use a rolling wedge bar and remove the reverse
idler shaft.
3. Remove reverse idler assembly and thrust
2 washers.
4. From inside the reverse idler assembly, remove
the needle bearings and spacer.
4005/2/8
4005/3/2

How to Install the Reverse Idler Gear Assembly

Use a high quality grease on the individual needle
bearings.
The reverse idler can be assembled in either the vertical
or horizontal case position.
Lubricate the idler shaft with oil before assembly.
Special Tools 1
To Install 4005/9/1
1. Coat reverse idler inside diameter with grease.

Insert the spacer in the reverse idler gear.
2. On both sides of the reverse idler spacer, install
the coated needle bearings.
3. Use grease on the reverse idler thrust washers to
hold in place.
4. Position washer tangs to align housing grooves
5. Install the reverse idler assembly in housing. 2
4005/9/2
6. Insert the idler shaft into the case bore, line up
idler shaft lock groove with lockscrew hole.
7. Position reverse idler retainer.
8. Install lockscrew retaining capscrew. Tighten the 3
Main Section
retainer to 20-25 Lbf·ft of torque.
Final Check
Make sure the retainer is tighten to torque rating.
Make sure the idler gear rotates freely. 4
4005/11/9
7 6 8
4005/12/4 4005/12/5
How to Remove the FS-5306/6306 Reverse Idler Gear Assembly

The reverse idler shaft has a locating ball just inside
the case wall, when removing the shaft make sure the
ball is not lost.
Special Tools
Slide hammer
1
To Remove
5106/3/7 1. Use the slide hammer and remove the reverse
idler shaft.
2. Remove the locating ball.
2
3. Remove reverse idler assembly and thrust
washers.
4. From the reverse idler assembly, remove the
bearings and spacer.
5106/3/8
5106/3/9

How to Install the FS-5306/6306 Reverse Idler Gear Assembly

The reverse idler can be assembled in either the vertical
or horizontal case position. 1
Lubricate the bearings and idler shaft with oil before 2
assembly.
Special Tools
To Install
1. Insert the spacer in the reverse idler gear. 5106/16/6
2. On either side of the reverse idler spacer, install

the bearings.
3. Use grease on the reverse idler thrust washers to 5
hold in place.
4. Position washer tangs to align housing grooves
5. Install the reverse idler assembly in housing. 3, 4
6. Insert the idler shaft into the case bore, line up
shaft notch with case notch. Do not install shaft
all the way. 5106/16/7
7. Install the locating ball.

8. Drive shaft into position.
6
Final Check
Main Section
Make sure the idler gear rotates freely.
5106/16/8
5106/16/9
How to Remove the Countershaft Assembly

When the rear bearing cover is removed, the
countershaft may slide to the rear and out of the
bearing bore.
Special Tools
1 To Remove
1. Remove the rear bearing capscrews, cover, and
4005/2/3
shims.
2. Remove the countershaft rear bearing cup.
3
3. Move the countershaft assembly to the rear and
lift the assembly from the case.
4. If the countershaft front bearing race is to be
replaced, drive bore plug through case front.
2 Drive the race rearward through the case.
5. Inspect the plug snap ring, remove if damaged.
6. Remove the transmission oil fill plug and the
4005/2/4 4005/3/1 drain plug from the transmission case.
7. Inspect the oil fill plug and drain plug for
damage.
4
4005/10/8 4005/10/9
4005/38/7 4005/38/8
How to Install the Countershaft Assembly

The front countershaft bore plug outer diameter must have a
coat of Eaton/Fuller Sealant #71233 or equivalent.
Setting end play is done in the vertical position.
When setting end play the rear bearing cover is installed,
removed, and installed again.
After end play is correct, apply a light coat of Eaton/Fuller 3
Sealant #71233 or equivalent to cover face and both sides of
the shims.
2
Special Tools
4005/11/1 4005/11/5
Dial indicator 5
To Install
1. If removed, install the oil fill plug and drain plug and 4
tighten to 45-55 Lbf·ft of torque.
2. If removed, install the front countershaft plug snap
ring, race (from inside the case), and coated bore plug.
3. Turn transmission case on end. Position assembly
into the front bearing race and case.
4. With tapered side toward case inside, install the
4005/12/6 4005/12/7
countershaft rear bearing cup.
5. Temporarily install new shims over the countershaft
Model Countershaft End Play
rear bearing cup.
6. Install the countershaft rear bearing cover and FS-4205 .002-.008
capscrews. Tighten the capscrews to 35-40 Lbf·ft of
Main Section
torque. FS-5205 .002-.008
7. Rotate the countershaft six (6) times clockwise and six
(6) times counterclockwise to seat bearings and races. FS-6205/6305 .006-.010
8. Position the dial indicator on one gear face.
FS-5306/6306 .006-.010
9. Pry up on the countershaft to measure end play. End
play must be set per chart. Add shims for less end chart
play, remove shims for more end play.
10. Remove the rear bearing retaining capscrews and
10, 11,
cover, coat the cover and shims. 6 12
11. Apply Eaton/Fuller Sealant #71225 or equivalent to the 7
retaining capscrews, if not precoated.
12. Install the retaining capscrews and tighten to 35-40
8
Lbf·ft of torque.
9
Final Check
Make sure the retaining capscrew are properly torqued.
Make sure the countershaft rotates freely. 4005/12/8 4005/12/9
How to Disassemble the FS-4205 Countershaft Assembly

The front countershaft bearing cage and rollers must
be removed in order to move the retaining snap ring
3 out of the snap ring groove.
2 The front bearing retaining snap ring must be
completely out of the snap ring groove.
1 As the individual countershaft gears are pressed from
the shaft, make sure to remove the corresponding
gear key.
4005/7/5 4005/7/6 Special Tools

Snap ring pliers
Press
4 To Disassemble
5
6 1. Position the countershaft in a vise with the front
bearing up.
2. Use a maul and chisel to remove the cage and
roller bearings from the front countershaft
4005/9/3 4005/9/4 bearing.
3. Use snap ring pliers and a screwdriver to move
the countershaft snap ring out of the snap ring
groove.
4. Use drive gear rear face as a base and press drive
7 gear from the countershaft assembly.
8
5. From the shaft, remove the drive gear locating
key.
6. Use 4th gear rear face as a base and press 4th
4005/9/5 gear from the countershaft assembly.
7. From the shaft, remove 4th gear locating key.
8. Use 3rd gear rear face as a base and press 3rd
gear from the countershaft assembly.
9 9. Use 2nd gear rear face as a base and press 2nd
10. If damaged, remove the rear countershaft
bearing.
4005/9/6
How to Assemble the FS-4205 Countershaft Assembly

Install the individual gear key just before installation of
the corresponding gear.
Special Tools 1 2
Snap ring pliers
Press
Sleeve type driver
To Assemble
1. With 2nd gear long hub to shaft front, position the 4005/9/7 4005/9/8
gear and shaft in the press. Press 2nd gear into

place.
2. With 3rd gear long hub to shaft rear, position the
gear and shaft in the press. Press 3rd gear into 4
place. 3 6
5
3. Install 4th gear key on countershaft.
4. With 4th gear long hub to shaft front, align 4th
gear keyway with shaft key, position the gear and
shaft in the press. Press 4th gear into place. 4005/10/2 4005/10/4
5. Install drive gear key on countershaft.
6. With drive gear long hub to shaft rear, align drive 7
shaft in the press. Press drive gear into place.
Main Section
7. Install the drive gear retaining snap ring in
countershaft front groove.
countershaft bearing.
9. Use a sleeve type driver and install the rear 4005/10/5
Final Check
Make sure all gears are pressed into place.
8
Make sure the countershaft bearings are installed.
4005/10/6
How to Disassemble the FS-5205 Countershaft Assembly

2
The front bearing retaining snap ring must be
completely out of the snap ring groove.
Special Tools
Snap ring pliers
Press
1
To Disassemble
5005/31/4 1. Position the countershaft in a vise with the front
bearing up.
2. Use snap ring pliers and a screwdriver to move
3
the countershaft snap ring out of the snap ring
groove.
gear, snap ring, and bearing from the
countershaft assembly.
5005/33/1
bearing.
4
5005/33/3-a

How to Assemble the FS-5205 Countershaft Assembly

Do not heat the bearings above 275°F (136°C). If
possible, use a heat lamp at the source.
Special Tools 1
Snap ring pliers
Press
Heat lamp
To Assemble
5005/33/6-a
shaft in the press. Press 4th gear into place.
2. With drive gear long hub to shaft rear, align drive
gear keyway with shaft key, position the gear and 2
shaft in the press. Press drive gear into place.
3. Install the drive gear retaining snap ring in groove.
4. Heat and install the front countershaft bearing.
5. If removed, heat and install the rear countershaft
bearing. 5005/33/7-a
Final Check 3
Main Section
5005/33/8
5
4
5005/31/3 5005/31/2
How to Disassemble the FS-6205/6305 Countershaft Assembly

As the individual countershaft gears are pressed from
2 the shaft, make sure to remove the corresponding
3 gear key.
Special Tools
Snap ring pliers
Press
Bearing puller
6105/8/7 6105/10/3
To Disassemble
bearing up.
2. Position puller jaws into the countershaft bearing
4
notches and remove the bearing.
3. Remove the drive gear retaining snap ring.
6105/8/9 6105/9/1 5. From the shaft, remove the drive gear locating
key and spacer.
6
9. Use 2nd gear rear face as a base and press 2nd
6105/9/2 6105/9/3
bearing.
8 9
6105/9/4 6105/9/5
How to Assemble the FS-6205/6305 Countershaft Assembly

1 2
Special Tools
Snap ring pliers
Press
Heat lamp
To Assemble
1. With 2nd gear long hub to shaft front, position the 6105/9/6 6105/9/7
gear and shaft in the press. Press 2nd gear into

place.
2. With 3rd gear long hub to shaft rear, position the 3
gear and shaft in the press. Press 3rd gear into
place. 4
3. Install 4th and drive gear keys on the countershaft.
5. Remove drive gear key from the countershaft.
Install the 4th-drive gear spacer.
8
6. Install drive gear key on the countershaft.
Main Section
gear keyway with shaft key, position the gear and 5
shaft in the press. Press the drive gear into place. 7
8. Install the drive gear retaining snap ring in
9. Use a sleeve type driver or heat lamp and install 6105/10/2 6105/10/4
the front countershaft bearing.
10. Use a sleeve type driver or heat lamp and install 9
the rear countershaft bearing.
10
Final Check
6105/10/5 6105/10/6
How to Disassemble the FS-5306/6306 Countershaft Assembly

3 As the individual countershaft gears are pressed from
2
the shaft, make sure to remove the corresponding
gear key.
Special Tools
Bearing puller
Snap ring pliers
1
Press
5106/12/1 5106/12/2
To Disassemble
5 bearing up.
2. Position puller jaws into the countershaft bearing
notches and remove the bearing.
3. Remove the drive gear retaining snap ring.
5106/12/3 5106/12/4 5. From the shaft, remove the drive gear locating
key and spacer.
6
5106/12/5 5106/12/6
bearing.
9
8
5106/12/7 5106/12/8
How to Assemble the FS-5306/6306 Countershaft Assembly

1 2
Special Tools
Snap ring pliers
Press
Sleeve type driver
To Assemble
1. With 3rd gear splined end hub to shaft front, 5106/12/9 5106/13/1
position the gear and shaft in the press. Press 3rd

gear into place.
2. With 4th gear long hub to shaft rear, position the
gear and shaft in the press. Press 4th gear into
3 4
place.
3. Install 5th and drive gear keys on the countershaft.
shaft in the press. Press the drive gear into place.
6. Install the drive gear retaining snap ring in 6
Main Section
5
8. Use a sleeve type driver and install the rear
5106/13/5 5106/13/6
Final Check
Make sure all gears are pressed into place. 8
Make sure the countershaft bearings are installed. 7
5106/13/7 5106/13/8

Eaton Fuller: Mid-Range Transmissions

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R R

Shift Bar Housing

Before working on a vehicle place

Before towing the vehicle place

Warning & Precautions

Recommended inspection procedures are provided in the following

Clutch Release Parts

Gear Shift Lever Housing Assembly

Gray Iron Parts

continued on next page

Warning & Precautions

Reverse Idler Gear Assemblies

Shift Bar Housing Assembly

Transmission appearance may differ, procedure is the same. 1

This manual is designed to provide detailed information

The following is the general layout with descriptions.

Remove As mentioned on the previous page, the flow charts

Transmission Once the countershaft parts have been replaced,

4 Transmission appearance may differ, procedure is the same.

Transmission model designation and other

Do not remove or destroy the transmission

Transmission appearance may differ, procedure is the same. 5

Proper lubrication procedures are the key to a good

1. Maintain Proper Oil Level

When adding oil, types and brands of oil should not

6 Transmission appearance may differ, procedure is the same.

2. Maintenance Interval Chart

Every 250,000 miles Change transmission fluid.

HIGHWAY USE-Heavy Duty and Mid-Range

Heavy Duty Engine Lubricant or

Every 10,000 miles Inspect lubricant level.

If your vehicle has a transmission oil filter, you must

3. Recommended Lubricant Chart

Additives and friction modifiers must not be introduced.

Transmission appearance may differ, procedure is the same. 7

4. Buy from a reputable dealer

Transmission Operating Angles

8 Transmission appearance may differ, procedure is the same.

The transmission must efficiently transfer the engine's

6 1. Power (torque) from the vehicle's engine is

Transmission appearance may differ, procedure is the same. 9

Some repair procedures pictured in this manual show

But for the most part, ordinary mechanic's tools such

The specialized tools can be obtained from a tool

10 Transmission appearance may differ, procedure is the same.

Everyday there are countless vehicles operating over

Preventive maintenance is a general term which applies

A number of conditions contrary to good preventive

Transmission appearance may differ, procedure is the same. 11

Checks Before Transmission Removal

2 Clutch Release Bearing (Not Shown)

3 Clutch Pedal Shaft and Bores

5 Filler and Drain Plugs

6 Capscrews and Gaskets

7 Gear Shift Lever

8 Gear Shift Lever Housing Assembly

10 Output Shaft (Yoke Nut Tightened)

11 Splines on Output Shaft 11

12 Mainshaft Rear Bearing Cover

Transmission appearance may differ, procedure is the same. 13

Should be an O-ring or gasket between the Replace the O-ring/gasket if damaged or

14 Transmission appearance may differ, procedure is the same.

Rear Seal Maintenance