It is assumed in the detailed assembly instructions that the lubricant has been drained from transmission, the necessary linkage and air lines disconnected and the transmission has been removed from vehicle chassis. Re- moval of the gear shift lever housing assembly (or remote control assembly) is included in the detailed instruc- tions (Disassembly and Reassembly - Shifting Controls); however, this assembly MUST be detached from shift bar housing before transmission can be removed.
FOLLOW CLOSELY EACH PROCEDURE IN THE DETAILED INSTRUCTIONS, MAKING USE OF THE TEXT, ILLUS- TRATIONS AND PHOTOGRAPHS PROVIDED.
BEARINGS - Carefully wash and relubricate all reusable bearings as removed and protectively wrap until ready for use. Remove bearings planned to be reused with pullers designed for this pur- pose.
ASSEMBLIES - When disassembling the various assemblies, such as the mainshaft, countershaft, and shift bar housing, lay all parts on a clean bench in the same sequence as removed. This pro- cedure will simplify reassembly and reduce the possibility of losing parts.
SNAP RINGS - Remove snap rings with pliers de- signed for this purpose. Snap rings removed in this manner can be reused, if they are not sprung or loose.
tershafts, mainshaft, or main drive gear. Special procedures are required and provided in this man- ual.
5 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.
6 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 the part being driven after it stops solidly. The use of soft hammers, bars and mauls for all disassembly work is recommended.
4. INPUT SHAFT - The input shaft can be removed from transmission without removing the coun-
Before reassembling 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 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 reus- ing a questionable part which could lead to additional repairs and expense soon after initial reassembly. To aid in determining the reuse or replacement of any transmission part, consideration should also be given to the un- it’s history, mileage, application, etc.
Recommended inspection procedures are provided in the following checklist.
Check gear teeth for frosting and pitting. Frosting of gear tooth faces present no threat of transmission failure. Often in continued operation of the unit, frosted gears will “heal” and not progress to the pitting stage. And in most cases, gears with light to moderate pit- ted teeth have considerable gear life remain- ing and can be reused. But gears with advanced stage pitting should be replaced.
Check for gears with clutching teeth abnor- mally worn, tapered, or reduced in length from clashing in shifting. Replace gears found in any of these conditions.
Wash all bearings in clean solvent. Check balls, rollers and raceways for pitting, discol- oration, and spalled areas. Replace bearings that are pitted, discolored, or spalled.
Lubricate bearings that are not pitted, discol- ored, or spalled and check for axial and radial clearances.
Replace bearings with excessive clearances.
Check bearing fits. Bearing inner races should be tight to shaft; outer races slightly tight to slightly loose in case bore. If bearing spins freely in bore, however, the case should be replaced