Before reassembling the transmission, check each part carefully for abnormal wear, excessive wear or damage to determine if the part is suitable for reuse. 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 reusing a questionable part. This could lead to additional repairs and expense soon after assembly. Consideration should also be given to the history of the unit, mileage, application, etc., when determining the reuse or replacement of any transmission part.

Bearings

• 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
• Lubricate bearings that are not pitted, discolored or spalled and check for axial and radial clearances.
• Replace bearings with excessive clearances.
• Check bearing fit. Bearing inner races should be tight to shaft; outer races slightly tight to slightly loose in case bore. If the bearing spins freely in the bore, the case should be replaced.

Bearing Covers

• Check covers for wear from thrust of adjacent bearing. Replace covers damaged from thrust of bearing outer race.
• Check cover bores for wear. Replace those worn or oversized.

Clutch Release Parts

• Replace yokes worn at cam surfaces and bearing carrier worn at contact pads.
• Check pedal shafts. Replace those worn at bushing surfaces.

Gears

• Check gear teeth for frosting and 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.
• Check gears with clutching teeth abnormally worn, tapered or reduced in length from clashing during shifting. Replace gears found in any of these conditions.
• Check axial clearance of gears.

Gear Shift Lever Housing Assembly

• Check spring tension on Shift Lever. Replace tension spring if lever moves too freely. If housing is disassembled, check the Gear Shift Lever bottom end and shift finger assembly for wear.

Gray Iron Parts

• Check all gray iron parts for cracks and breaks.
• Replace damaged parts.

Oil Return Threads and Seals

• Check oil return threads on the Input Shaft. If return action of threads has been destroyed, replace the Input Shaft.
• Check oil seal in Rear Bearing Cover. If sealing action of lip has been destroyed, replace seal.

O-Rings

• Check all O-rings for cracks or distortion. Replace if worn.

Reverse Idler Gear Assemblies

• Check for excessive wear from action of roller bearings.

Shift Bar Housing Assembly

• Check for wear on shift yokes and block at pads and lever slot. Replace excessively worn parts.
• Check yokes for correct alignment. Replace sprung yokes.
• If housing has been disassembled, check shift shaft and all related parts for wear.

Sliding Clutches

• Check all shift yokes and yoke slots in sliding clutches for extreme wear or discoloration from heat.
• Check engaging teeth of sliding clutches for partial engagement pattern.

Splines

• Check splines on all shafts for abnormal wear. If sliding clutch gears, companion flange or clutch hub has wear marks in the spline sides, replace the specific shaft affected.

Synchronizer Assembly

• Check Synchronizer for burrs, uneven and excessive wear at contact surface, and metal particles.
• Check blocker pins for excessive wear or looseness.
• Check Synchronizer contact surfaces on the Synchronizer cups for wear.

Washers

• Check surfaces of all washers. Washers scored or reduced in thickness should be replaced.