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Eaton FullerLight Duty Transmissions
Ed. 07/04
FSO-4305/4405Service Manual
Transmission
General Information
3
1
2
3
4
5
Input Shaft Bearing Cover
Gear Shift Lever Housing
Main Section
Shifting System
FSO-4305/4405 Ed. 07/04
4 Ed. 07/04 FSO-4305/4405
5
Table of Contents
1
FSO-4305/4405 Ed. 07/04
General Information
Foreword .................................................. 7
How to Use This Manual .......................... 8
Identification and Specifications ............... 9
Exploded View........................................ 11
Housing ............................................ 11
Engagement ..................................... 13
Shifting System................................. 15
Gear Shift Lever Housing ................. 16
Lubrication.............................................. 18
Operation................................................ 20
Power Flow ............................................. 21
Sealant Application ................................ 25
Torque Recommendation ....................... 26
Precautions ............................................ 29
Troubleshooting ...................................... 33
Special Tools .......................................... 39
6 Ed. 07/04 FSO-4305/4405
7
Foreword
1
FSO-4305/4405 Ed. 07/04 General Information
Eaton Ltda. - Transmission DivisionAftermarket and Service
Rua Clark, 2061 - P.O.Box 30413270 - Valinhos - So Paulo - Brazil
Phone: (19) 3881-9590Fax: (19) 3881-9687
This manual is designed to provide detailed information necessary to service and repair theEaton transmission FSO-4305/FSO-4405.
Disassembly and assembly instructions in this manual make use of a typical FSO-4305/FSO-4405 transmission. Illustrations and pictures show parts that may differ from one transmissionmodel to another, according to its application and serial number.
In addition, it is also assumed that the transmission has been removed from the vehicle andthe lubricant has been drained.
The manual has been divided into two main groups as follows:
1. Information and technical references, placed all together into one section.
2. Disassembly and assembly instructions, divided into sections gathering specific componentassemblies.
For more detailed information on product improvement, repair procedures and other subjectsrelated to service, please contact:
8
How to Use This Manual
1
Informaes Gerais Ed. 07/04 FSO-4305/4405
27. Install the rear thrust ring of the 3rdspeed gear rollers.
28. Lubricate and install the rollers of the3rd speed gear, using a light coat ofgrease to keep the rollers in theirposition.
NOTE: Use transmission oil to lubricatethe bearing.
29. Install the front thrust ring of the 3rdspeed gear.
30. Install the 3rd speed gear on therollers, with the cone side facing up(towards the synchronizer ring).
31. Install the 3rd speed synchronizer ring.
WARNING! The 3rd speedsynchronizer ring HAS EFM coating.See Shifting System, SynchronizerAssemblies.
26. Install the 2nd gear snap ring.
Assembly
89
Main Shaft
Ed. 07/04 FSO-4305/4405 Main Section
4
1
2
3
7
8 9
5
6
4FSO-4405A/108
FSO-4405A/132
FSO-4405A/133
FSO-4405A/134
26
2928
27
30
31
To disassemble and assemble the entire transmission, follow the manual in its normal sequence.
However, if the problem involves one specific component, refer to the table of contents of itsrelated section, for the page number showing that component.
Example
Component: Main Shaft End Play
Location: Main Section, Engagement
From the table of contents: Main Shaft End Play Adjustment, page 88.
General page layout description
1. Heading of the topic covered in the section.
2. Subheading with a more specificdescription of the topic covered.
3. Number and description of operations ofthe procedure.
4. Illustration or photograph showing theprocedures. Reference numbers indicatethe respective operations.
5. WARNING! Information requiring specialattention as it represents risks of personalinjury or product damage.
6. NOTE: Useful information to perform theoperation.
7. Manuals section number.
8. Manuals section description.
9. Page number.
9
Identification and Specifications
1
FSO-4305/4405 Ed. 07/04 General Information
Eaton FullerSynchronizedOverdrive
FSO - 4405AGear ratio
FSO-4405A/152
FSO-4405A/17
FSO - 4305A
Identification and Specifications
Identification
Model designation
Forward synchronizedspeeds
Design level
Nominal torque capacity(x100 lb.ft)
All Eaton transmissions are identified by the modeldesignation and serial number. This information isstamped on the identification tag fixed to thetransmission case.
WARNING! Do not remove or destroy thetransmission identification tag.
NOTE: When ordering parts or consulting forservice assistance, please inform datacontained on the identification tag.
10
Identification and Specifications
1
General Information Ed. 07/04 FSO-4305/4405
FSO-4405A FSO-4405B FSO-4405CFSO-4305A FSO-4305B FSO-4305C
Torque lb.ft 427 427 427
N.m 580 580 580
NT Gear Ratio NT Gear Ratio NT Gear Ratio
Output Shaft 28 28 28
Countershaft 44 44 44
1st Speed (CS) 12 5.762 17 5.084 12 5.762(MS) 44 55 44
2nd Speed (CS) 20 2.829 25 2.640 25 2.640(MS) 36 42 42
3rd Speed (CS) 36 1.528 36 1.528 36 1.528(MS) 35 35 35
4th Speed (CS) 1.000 1.000 1.000(MS)
5th Speed (CS) 49 0.770 49 0.770 49 0.770(MS) 24 24 24
Reverse Speed (CS) 125.238
174.714
125.238Reverse Idler Gear 28 35 28
(MS) 40 51 40
NT = Number of teeth CS = Countershaft MS = Main shaft
Specifications
NOTE: The transmission specifications may be modified at any time. The data on tableis provided for reference purposes only.
Weight
Cable shifting = 92.0 kg
Rod shifting = 73.5 kg
Direct shifting = 79.0 kg
NOTE: Weight includes transmission lubricant filled up to the correct level.
11
Exploded View
1
FSO-4305/4405 Ed. 07/04 General Information
1 - Capscrew
2 - Input shaft bearing cover
3 - Oil seal
4 - Oil baffle
5 - Bearing cup
6 - Adjusting shim
7 - Plug
8 - Filling plug
9 - PTO cover
10 - Capscrew
11 - Sphere (or spherical pin)
12 - Spring
13 - Cover
14 - Bracket
15 - Capscrew
16 - Dowel pin
17 - Lifting hook
18 - Capscrew
19 - Oil seal
20 - Baffle
21 - Yoke
22 - Nut
23 - Sphere
24 - Countershaft rear cover
25 - Capscrew
26 - Neutral switch
27 - Speedometer sensor
28 - Rear housing
29 - Reverse speed light switch
30 - Washer
31 - Plug
32 - Drain plug
33 - Front housing
34 - Adjusting shim
35 - Countershaft front cover
36 - Capscrew
FSO-4405A/176
Housings
Main Section
12
Exploded View
1
General Information Ed. 07/04 FSO-4305/4405
Housings
Clutch
1 - Capscrew
2 - Clutch collar
3 - Clutch housing
4 - Capscrew
5 - Dust protector
6 - Connection
7 - Bleed valve
8 - Connection
9 - Cover
10 - Capscrew
11 - Washer
FSO-4405A/177
13
Exploded View
1
FSO-4305/4405 Ed. 07/04 General Information
1 - Bearing cone
2 - Input shaft
3 - Oil baffler
4 - Bearing cone
5 - 4th synchronizer ring
6 - Lock ring
7 - Key
8 - 3rd/4th synchronizer hub
9 - 3rd/4th synchronizer sleeve
10 - 3th synchronizer ring
11 - 3rd/4th synchronizer assy
12 - 3rd speed gear
13 - Spacer washer
14 - Rollers
15 - Spacer washer
16 - Snap ring
17 - Thrust washer
18 - Sphere
19 - 2nd speed gear
20 - Rollers
21 - Spacer washer
22 - Snap ring
23 - 2nd synchronizer ring
24 - Lock ring
25 - Key
26 - Hub insert
27 - Sleeve insert
28 - 1st/2nd synchronizer hub
29 - 1st/2nd synchronizer sleeve
30 - 1st synchronizer ring
31 - 1st/2nd synchronizer assy(Booster)
32 - 1st speed gear
33 - Needle bearing
34 - Snap ring
35 - Thrust washer
36 - Sphere
37 - Reverse speed gear
38 - Needle bearing
39 - Snap ring
40 - Reverse speed synchronizer ring
41 - Lock ring
42 - Key
43 - 5th/reverse synchronizer hub
44 - 5th/reverse synchronizer sleeve
45 - 5th synchronizer ring
46 - 5th/reverse synchronizer assy
47 - Main shaft
48 - 5th speed gear
49 - Rollers
50 - Thrust washer
51 - Rear bearing cone
52 - Rear bearing cup
53 - Speedometer rotor
FSO-4405A/178
Engagement
Input Shaft and Main Shaft
14
Exploded View
1
General Information Ed. 07/04 FSO-4305/4405
Engagement
Countershaft and Reverse Idler Gear
1 - Front bearing cup
2 - Front bearing cone
3 - Snap ring
4 - Driving gear (4th speed)
5 - 3rd speed gear
6 - Key
7 - Countershaft
8 - 5th speed gear
9 - Snap ring
10 - Rear bearing cone
11 - Rear bearing cup
12 - Reverse idler gear shaft
13 - Capscrew
14 - Needle bearing
15 - Reverse speed idler gear
FSO-4405A/179
15
Exploded View
1
FSO-4305/4405 Ed. 07/04 General Information
Shifting System
Shift Yoke and Bars
FSO-4405A/180
1 - 1st/2nd speed shift yoke
2 - Pad
3 - Roll pin (diam. 5 mm)
4 - 1st/2nd speed shift bar
5 - Sphere
6 - Interlock pin
7 - 3rd/4th speed shift bar
8 - Roll pin (diam. 4 mm)
9 - 3rd/4th speed shift block
10 - 3rd/4th speed shift yoke
11 - 5th/reverse speed shift block
12 - 5th/reverse speed shift yoke
13 - 5th/reverse speed shift bar
16
Exploded View
1
General Information Ed. 07/04 FSO-4305/4405
Gear Shift Lever Housing
Remote
FSO-4405A/181
1 - Shaft and lever assy
2 - Lever
3 - Boot
4 - Oil seal
5 - Bushing
6 - 5th speed locator plug (offset)
7 - Capscrew
8 - Plug
9 - Breather
10 - Lifting hook
11 - Capscrew
12 - Spring rear plug
13 - Outer spring
14 - Retainer
15 - Inner spring
16 - Thrust washer
17 - Housing
18 - Locating spring (offset)
19 - Locating sphere (offset)
20 - Capscrew
21 - Lock wire
22 - Internal shift selector
23 - Gasket
24 - Retainer
25 - Washer
26 - Lever
27 - Bearing
28 - Shaft
29 - Bracket
30 - Nut
31 - Shaft
32 - Capscrew
33 - Spherical pin
34 - Counterweight
35 - Bushing
36 - Washer
37 - Snap ring
38 - Bracket
17
Exploded View
1
FSO-4305/4405 Ed. 07/04 General Information
Gear Shift Lever Housing
Direct
FSO-4405A/182
1 - Capscrew
2 - Gear shift lever
3 - Pin
4 - Thrust washer
5 - Ball joint
6 - Cover
7 - Boot
8 - Capscrew
9 - Housing
10 - Capscrew
11 - Capscrew
12 - Plunger
13 - Spring
14 - Plug
15 - Torsion spring
16 - Guide pin
17 - Cam plate
18 - Stop pin
19 - Spring
20 - Ball
18
Lubrication
1
General Information Ed. 07/04 FSO-4305/4405
Highway use
After first 50,000 km Change transmission oil
Every 25,000 km Inspect oil level and check for leaks
Every 100,000 km Change transmission oil
Off-highway use
After first 25,000 km Change transmission oil
Every 12,500 km Inspect oil level and check for leaks
Every 50,000 km Change transmission oil
Proper lubrication procedure is the key to a good and complete maintenance program. If theoil is not doing its job, or if the oil level is ignored, all the other possible maintenance procedureswill not be enough to keep the transmission running or to assure long transmission life.
Eaton transmissions are designed so that all the internal parts operate in oil circulating bath,created by the motion of gears and shafts. Thus, all parts are correctly lubricated if theseprocedures are closely followed:
1. Maintain proper oil level, inspecting it regularly.
2. Change oil regularly following maintenance interval chart.
3. Use the recommended grade and type of oil.
4. Buy oil from a reputable dealer.
Oil change and level inspection
Periodic transmission oil change eliminates possible bearing failures, ring wear and seizures,since the products of normal wear in service (tiny metal particles), which circulate in thetransmission oil, are harmful to these parts. In addition, the oil changes its chemicalcharacteristics due to the repeated heating and cooling cycles of a transmission in use.
As a general guide, the following chart provides maintenance interval recommendation tolevel inspection and oil change.
WARNING! Always follow the vehicle manufacturer maintenance recommendation,that prevails over this chart.
Recommended lubricant oil: SAE 80W90 API GL3 or API GL4
19
Lubrication
1
FSO-4305/4405 Ed. 07/04 General Information
FSO-2405/87
Correct Oil Level Incorrect Oil Level
Draining
It is important to drain the transmission while it is warm. To drain the oil, remove the magneticdrain plug. Clean the drain plug before reinstalling it.
Refilling
Clean the case around the oil fill plug, remove the plug and refill the transmission to the levelof the filler opening.
Oil quantify necessary to refill the transmission depends on the transmission angle. So, refillthe transmission with the vehicle on a flat and leveled surface.
Do not fill the transmission above the recommended level. This will cause oil to be forced outof the case through the front bearing cover, the control cover, the shift lever housing, etc.
Lubricant capacity
4.6 liters
NOTE: The supplied oil volume may vary according to engine and transmission operatingangle. Always refill the transmission with proper grade and type of lubricant up to thelevel of the filler plug opening.
Oil level inspection
Every time the oil level is being checked, clean the area around the filler plug and, if necessary,add sufficient oil to maintain the proper oil level.
WARNING! Do not mix oils of different types and brands, as they might not becompatible.
20
Operation
1
General Information Ed. 07/04 FSO-4305/4405
FSO-4405A/151
Gear shift lever pattern
FSO-4305/FSO4405 transmissions have 5 forwardspeeds and one reverse, all of them synchronized.
To shift the speeds follow the shift pattern shownby the illustration aside.
A reverse gear shifting interlocking system preventsfrom accidental transmission shifting from 5th toreverse gear.
Tips for the driver
Always use the clutch to change the gears. The incorrect use of the clutch may cause prematurefailures of the synchronizer assembly.
Always select a starting gear that will provide sufficient reduction (torque) for the vehicles loadand working conditions (terrain).
Never slam or jerk the gear shift lever to complete gear engagement.
Never leave the shift lever in the neutral position while going down hill.
21
Power Flow
1
FSO-4305/4405 Ed. 07/04 General Information
1st Speed
FSO-4405A/162
The transmission must efficiently transfer the engines power or torque to the vehicles driveline.It is essential to know what takes place in the transmission during torque transfer whentroubleshooting or repairs are required.
1st, 2nd, 3rd and 5th Speeds
1. Torque from the engine is transferred to the transmissions input shaft.
2. The torque is transferred from the input shaft to the countershaft, through its drive gear. Inthis way, input shaft and countershaft always run together.
3. The torque from the countershaft is delivered to all main shaft gears, assembled on bearings.These gears rotate free unless one of the gears is shifted.
4. When a gear is shifted, the torque is transferred from the corresponding engaged mainshaft gear to the clutching teeth of the synchronizer assembly and then to the synchronizerhub, that runs together with the main shaft. Torque is, then, delivered along the main shaftto the driveline components through output yoke.
22
Power Flow
1
General Information Ed. 07/04 FSO-4305/4405
2nd Speed
FSO-4405A/163
5th Speed
FSO-4405A/165
3rd Speed
FSO-4405A/164
23
Power Flow
1
FSO-4305/4405 Ed. 07/04 General Information
4th Speed
FSO-4405A/166
4th Speed
The 4th speed gear is also named direct speed gear.
Torque comes from the input shaft, which transfers the torque directly to the main shaft, despiteof moving the counter shaft at the same time. This torque is transferred through the input shaftclutching teeth, which are engaged to the 4th speed synchronizer hub, directly connected tothe main shaft.
The transmissions noise level in this speed is really low, since torque is delivered directly fromone shaft to another and there are no gears under load.
24
Power Flow
1
General Information Ed. 07/04 FSO-4305/4405
Reverse Speed
FSO-4405A/167
Reverse Speed
When the reverse speed gear is shifted, torque is transferred from countershaft to the reverseidler gear, that changes the rotating direction, and then, from that gear to the main shaftreverse speed gear.
25
Sealant Application
1
FSO-4305/4405 Ed. 07/04 General Information
The correct application of sealing compounds is important to assure a suitable assemblyand to avoid leakages.
FSO-4405A/200
Apply Eaton E680 to mounting surfaces of front and rear covers of the countershaft
Apply Eaton E679 to expanded plugs
Apply Eaton E680 to mounting surface of the PTO cover
* Silicone sealant
Apply Eaton E680 to mounting surfaces of front and rear housings
Apply Eaton E679 to gear shift lever housing plugs
Apply Eaton E679 to mounting surfaces of the input shaft bearing cover and adjusting shims
26
Torque Recommendation
1
General Information Ed. 07/04 FSO-4305/4405
Tightening capscrews, plugs and nuts to the proper torque is important to prevent oil leakageand loosening of components, assuring a long working life to the transmission. Additionally,always apply sealant to the threads whenever recommended.
WARNING! Always use a torque wrench to tight to the recommended torque.
Item Description Thread Torque N.m (lb.ft) Sealant
1 Reverse light switch 9/16" - 18 UNF 13.6-20.3 (10-15) Eaton E677
2 Neutral light switch 5/8" - 18 UNF 13.6-20.3 (10-15) Eaton E677
3 Speedometer sensor 3/4" - 16 UNF 9.5-16.3 (7-12) Eaton E677
4 Reverse idler gear M8 19-25.7 (14-19) Eaton E677mounting capscrews
5 Countershaft rear M10 19.0-25.7 (14-19) Eaton E677bearing cover capscrews
FSO-4405A/154
1 2 3
54
27
Torque Recommendation
1
FSO-4305/4405 Ed. 07/04 General Information
FSO-4405A/155
Item Description Thread Torque N.m (lb.ft) Sealant
6 Housing capscrews M8
7 Clutch housing M14
19-25.7 (14-19) Eaton E677
108.6-121.7 (80-90) Eaton E677capscrews
8 Input shaft bearing cover M8 9.5-16.3 (7-12) Eaton E677
9 Yoke nut 1-1/4" - 18 UNF 407-475 (300-350) Eaton E677
10 PTO cover capscrews 3/8" - 16 UNC 19-25.7 (14-19) Eaton E677
11 Oil filling plug 3/4" - 14 NPTF 13.6-20.3 (10-15) Eaton E677
12 Clutch inspection M5 1.4-6.8 (1-5) Eaton E677cover capscrews
13 Countershaft front bearing M8 9.5-16.3 (7-12) *1 Eaton E677cover capscrews 24.4-31-2 (18-23) *2
14 Oil drain plug *3 3/4" - 14 NPTF 13.6-20.3 (10-15) Eaton E677
9
*1 Stamped sheet cover *2 Cast iron cover *3 Not shown
6
10 11 12
7 8
13
28
Torque Recommendation
1
General Information Ed. 07/04 FSO-4305/4405
FSO-4405A/156
Item Description Thread Torque N.m (lb.ft) Sealant
15 Boot retaining M5 2.0-7.0 (1.5-5) Eaton E677cover capscrews *5
16 Internal shift lever 3/8" - 24 UNF 34-41 (25-30) Eaton E677mounting capscrews *4
17 Gear shift lever M10 19.0-25.7 (14-19) Eaton E677housing capscrews
18 5th gear positioning M16 13.6-20.3 (10-15) Eaton E679spring plug (offset) *4
19 Plunger spring M18 10.5-20.3 (8-15) Eaton E679retainer plug *5
20 Gear shift lever M12 9.5-16.3 (7-12) Eaton E677retaining capscrews *5
21 Shift positioning device M8 9.5-16.3 (7-12) Eaton E677cover capscrews
22 Shift shaft spring 1-1/4" - 12 UNF 34-41 (25-30) Eaton E679plugs *4
*4 Remote Gear Shift Lever Housing *5 Direct Gear Shift Lever Housing
20 21 22 21
16 17 18
1917
15
29
Precautions
1
FSO-4305/4405 Ed. 07/04 General Information
Precautions during disassembly and assembly
WARNING! When assembling the transmission, it is important to lubricate gearbearings, needle bearings, non-sealed bearings and all other parts under frictionconditions, with the same transmission lubricant oil, in order to prevent damageto transmission parts during initial gears movement.
Cleaning and handling
In order to completely clean the parts, wash them into a solvent bath (kerosene, for instance),moving every part slowly up and down until all the old lubricant and foreign material havebeen dissolved.
WARNING! Care must be taken to avoid skin rasher, fire hazard and vaporinhalation when using solvents.
Non-sealed bearings
Immerse the bearings in clean solvent. Move them slowly up and down in order to loosen thedeposits. Dry the bearings with moisture free compressed air, avoiding the direct air flow tothe bearing in order not to rotate it in high speed. Repeat the above mentioned operation untilthe bearings are thoroughly clean.
WARNING! Never drive the air jet directly to bearing in order to rotate it in highspeed. That can damage the bearing.
Synchronizer assemblies
Avoid bad handling of synchronizer assemblies. Either drops or bumps when disassemblingor assembling may lock them.
30
Precautions
1
General Information Ed. 07/04 FSO-4305/4405
Housings
Clean thoroughly the interior and exterior of cases, covers, etc. Cast parts may be cleaned inmild alkaline solution baths (a 7% soluble degreasing oil solution is recommended). The partsare to remain in the bath for the time required to become completely clean. The parts cleanedin alkaline solutions should be rinsed with clean water to remove any alkaline trace aftercleaning process.
WARNING! Care must to be taken to avoid vapor inhalation and skin rashes whenusing alkaline solutions. Every cleaned part must be totally dried at once by meansof moisture free compressed air, or else, by means of a lint free soft cloth, free ofany abrasive material such as metal filings, contaminated oil or polishingcompounds.
Inspection
A thorough and careful inspection of every part is very important for the transmission life. Thereplacement of parts showing either wear or fatigue will avoid future expensive and foreseenfailures.
Gears, shafts and synchronizer assemblies
Whenever magna-flux is available, this process should be used to check the parts.
Check carefully gear teeth for wear, pitting, chipping and cracks. If gear teeth show areaswhere the hardening layer is worn out or cracked, the gear should be replaced by a new one.
Check shafts for warping and excessive wear or damaged splines.
Cases, covers, etc.
Make sure cases, covers, etc. are completely clean and that mounting surfaces and bearingbores are free from chips or burrs. Check carefully every part for cracks, excessive wear or forany other condition that may cause oil leak or a future failure.
Needle bearings
Check carefully every needle roller for wear, pitting or cracked areas to determine whetherthey are suitable for reuse or should be replaced. After inspection, dip the needle bearings inan oil bath and then wrap them in a lint free cloth or paper, so as to protect them until they areto be reassembled.
31
Precautions
1
FSO-4305/4405 Ed. 07/04 General Information
FSO-2405/98
This side out
Oil seals and snap rings
Any oil seal, snap ring, etc. damaged during maintenance, should be replaced by a new one.Replacement of oil seals and snap rings is cheaper when unit is disassembled than a prematureoverhaul to replace these parts in a future time.
An oil leakage through a worn seal may result in failures of other more expensive componentsof the transmission. The sealing elements should be handled carefully, particularly duringassembly. Cuts, scratches or rolled up seal lips decrease the sealing efficiency.
WARNING! Snap rings have proper assembling position due to the angle of theiropening ends. The side with shorter opening should be faced outwards to facilitatethe installation with pliers.
32
Precautions
1
General Information Ed. 07/04 FSO-4305/4405
FSO-2405/140
Parts replacement
When it is necessary to replace parts, use only genuine Eaton transmission spare parts toassure continued performance and extended life of the transmission. The use of either nongenuine or remanufactured spare parts, besides not having the factorys warranty, may lead tosevere damage of the unit.
Since the cost of a new part is generally a small fraction of the total cost of downtime andservice labor, do not reuse a questionable part which could lead to additional repairs andexpenses soon after assembly.
To aid in determining the reuse or replacement of any transmission part, considerations shouldalso be given to the units history, mileage, application, etc.
33
Troubleshooting
1
FSO-4305/4405 Ed. 07/04 General Information
Problem Probable cause Possible solution Reference
Transmission Incorrect idle speed Adjust idle speed Instructions onnoise when in adjustment vehicles manualneutral
Improper or Replace disc Instructions ondamaged clutch vehicles manualdisc
Loose or damaged Replace and/or Instructions onengine or tighten mounts vehicles manualtransmission mounts
Worn or damaged Replace yoke Instructions onyoke vehicles manual
Warped or Repair or replace Requires specificunbalanced drive drive shaft procedureshaft
Low lubricant level Fill with recommended Recommendedoil to the proper level lubricant - page 18
Contaminated Drain and clean Recommendedlubricant transmission and refill lubricant - page 18
with recommended oil
Worn or damaged Replace damaged parts Instructions on thisgears and/or manualbearings
Misalignment due Retighten capscrews Instructions onto loose tightening vehicles manualcapscrews
Transmission Improper or Replace disc Instructions onnoise with damaged clutch vehicles manualshifted gears disc
Low lubricant level Fill with recommended Recommendedoil to the proper level lubricant - page 18
The following chart presents some transmission malfunctions with their most common causesand possible solutions.
34
Troubleshooting
1
General Information Ed. 07/04 FSO-4305/4405
Problem Probable cause Possible solution Reference
Transmission Worn or damaged Replace damaged parts Instructions onnoise with flywheel bushing vehicles manualshifted gears or bearing(continued)
Vibration from Verify and repair as Instructions onother vehicle per vehicles manual vehicles manualcomponents (driveshaft, mounts, yoke)
Misalignment Realign Instructions onbetween engine vehicles manualand transmission
Worn or Replace damaged parts Instructions on thisdamaged gears manualand/or bearings
Warped main Replace warped shaft Instructions on thisshaft or manualcountershaft
Hard shifting Malfunction of Verify and adjust Instructions onclutch (not clutch driving system vehicles manualreleasing)
Wrong adjustment Adjust pedal stroke Instructions onof clutch pedal vehicles manual
Worn or damaged Replace damaged parts Instructions onflywheel bushing or vehicles manualbearing
Improper lubricant Drain and refill with Recommendedrecommended oil lubricant - page 18
Low lubricant level Fill with recommended Recommendedoil to the proper level lubricant - page 18
Worn or damaged Replace damaged parts Gear shift levergear shift lever housing - page 49components
35
Troubleshooting
1
FSO-4305/4405 Ed. 07/04 General Information
Problem Probable cause Possible solution Reference
Hard shifting Worn or damaged Replace rings Synchronizer(continued) synchronizer rings assemblies -
page 119
Excessively worn Replace synchronizer Synchronizeror damaged assemblies assemblies -synchronizer page 119assemblies (keys,sleeve or hub)
Improper Readjust synchronizer Synchronizeradjustment of assemblies assemblies -synchronizer page 119assemblies sleeveor hub
Worn or damaged Replace damaged parts Instructions on thisshifting system manualcomponents (yokes,nylon pads, bars,shift blocks)
Improper end play Adjust end play Main shaft andon main shaft or countershaft endcountershaft play adjustment -
pages 88 and 85
Gear shift Malfunction of clutch Verify and adjust clutch Instructions onrubbing (not releasing) driving system vehicles manual
Wrong adjustment Adjust pedal stroke Instructions onof clutch pedal vehicles manualstroke
Malfunction of Verify and adjust system Instructions onclutch driving vehicles manualsystem
Worn or damaged Replace damaged parts Instructions onflywheel bushing vehicles manualor bearing
Incorrect idle Adjust idle speed Instructions onspeed adjustment vehicles manual
36
Troubleshooting
1
General Information Ed. 07/04 FSO-4305/4405
Problem Probable cause Possible solution Reference
Gear shift Worn or damaged Replace rings Synchronizerrubbing synchronizer rings assemblies -(continued) page 119
Worn or damaged Replace gear Instructions on thisgear clutching teeth manual
Worn shift yokes Replace nylon pads Shift bars - pagenylon pads 117
Transmission Misalignment Realign Instructions onslips out of between engine vehicles manualgear and transmission
Incomplete gear Shift gear properlyshifting
Excessive vibration Replace and/or Instructions onon gear shift lever tighten mounts vehicles manualdue to loose ordamaged engineor transmissionmounts
Gear shift lever Adjust console Instructions onconsole out of vehicles manualposition, forcingthe lever
Worn or damaged Replace synchronizer Synchronizersynchronizer assemblies assemblies - pageassemblies 119
Excessive axial Adjust clearance Main shaft end playclearance on main adjustment - pageshaft gears 88
Worn or damaged Replace gear Instructions on thisclutching gear teeth manual
Worn or damaged Replace damaged parts Instructions on thisshifting system manual(gear shifting leverhousing, yokes,bars, etc.)
37
Troubleshooting
1
FSO-4305/4405 Ed. 07/04 General Information
Problem Probable cause Possible solution Reference
Oil leak Lubricant above Correct to proper level Recommendedproper level lubricant - page 18
Clogged breather Verify and unclogbreather
Worn or damaged Replace damaged Instructions on thisoil seals seals manual
Housing capscrews Reassemble with proper Instructions on thisnot properly sealant and tightening manual - pages 25tightened or lack torque and 26of sealant
Cracked housing Replace or repair Requires specificor covers damaged parts procedure
Warped or Replace or repair Requires specificdamaged mounting damaged parts proceduresurfaces of housingsand covers
Bearings failures Low lubricant level Fill with recommended Recommendedoil to the proper level lubricant - page 18
Contaminated or Drain and clean Recommendednot recommended transmission and lubricant - page 18lubricant refill with
recommended oil
Improper assembly Reassemble transmission Instructions on thisof transmission manualcomponents
Improper end play Adjust end play Main shaft andon main shaft or countershaft end play adjustment - pagescountershaft 88 and 85
Bearings were not Replace damaged parts. Instructions on thislubricated prior to Reassemble following manual - page 29assembly right procedure
38
Troubleshooting
1
General Information Ed. 07/04 FSO-4305/4405
Problem Probable cause Possible solution Reference
Double shifting Double gear Reassemble system Instructions on thisshifting interlock manual - page 76system assembledimproperly
39
Special Tools
1
FSO-4305/4405 Ed. 07/04 General Information
Ref. Description
To properly service the Eaton FSO-4305/FSO-4405 transmission, the following specializedtools are recommended:
These special tools should be ordered directly from the approved tools supplier:
40 Ed. 07/04 FSO-4305/4405
41
Table of Contents
2
FSO-4305/4405 Ed. 07/04
Input Shaft Bearing Cover
Removal ................................................. 43
Disassembly ........................................... 45
Assembly ................................................ 46
Installation .............................................. 47
42 Ed. 07/04 FSO-4305/4405
43
Input Shaft Bearing Cover
2
FSO-4305/4405 Ed. 07/04 Input Shaft Bearing Cover
FSO-4405A/01
1
FSO-4405A/03
4
FSO-4405A/02
2
3
5
Removal
1. Remove bleed plug and inlet connection.
2. Remove the three mounting capscrews of theclutch collar.
3. Remove the clutch collar.
4. Remove the four mounting capscrews of theclutch housing.
5. Remove the clutch housing.
44
Input Shaft Bearing Cover
2
Input Shaft Bearing Cover Ed. 07/04 FSO-4305/4405
FSO-4405A/06
FSO-4405A/04
6
FSO-4405A/05
7
6
6. Remove the six mounting capscrews (inner orouter hexagon head, depending on thetransmission model) from the input shaftbearing cover.
Removal
7. Placing two pry bars under the slots existenton the input shaft bearing cover, remove thecover and the main shaft end play adjustingshims.
45
Input Shaft Bearing Cover
2
FSO-4305/4405 Ed. 07/04 Input Shaft Bearing Cover
FSO-4405A/07
FSO-4405A/08
1
2
3
Disassembly
1. Remove the main shaft front bearing cup withthe special puller. See Special Tools, Reference?????.
2. Remove the oil baffle.
3. Remove input shaft bearing cover oil seal.
NOTE: The oil seal removed should not bereused.
46
Input Shaft Bearing Cover
2
Input Shaft Bearing Cover Ed. 07/04 FSO-4305/4405
FSO-4405A/09
3
FSO-4405A/08
2
1
Assembly
1. Install the new oil seal, hitting it carefully withthe special installer of the proper diameter. SeeSpecial Tools, Reference ???.
2. Install the oil baffle, observing its correctassembly position.
3. Install the main shaft front bearing cup, hittingit carefully with the special installer until it isproperly seated on the oil baffle. See SpecialTools, Reference ???.
47
Input Shaft Bearing Cover
2
FSO-4305/4405 Ed. 07/04 Input Shaft Bearing Cover
FSO-2405/77
3
2, 3
FSO-4405A/86
1, 2
FSO-4405A/04
A
3
Installation
NOTE: Thoroughly clean the parts andremove any remaining sealant from themounting surfaces prior to installation.
WARNING! The main shaft end play isadjusted by using a shim pack,positioned under the input shaft bearingcover.
1. Use the same original shim pack if the mainshaft end play is within the specified range, orelse add or remove shims as needed, followingthe main shaft end play measurement. SeeMain Section Assembly, Main Shaft End PlayAdjustment.
NOTE: Main shaft end play = 0.025 mm to0.100 mm (0.01 to 0.04 in)
2. Apply sealant to both sides of shims of theselected pack and to the mounting surface ofthe input shaft bearing cover.
NOTE: Apply Eaton E679 sealant to both sides of shims and cover surface.
3. Install the shim pack and the input shaft bearingcover. Observe the position of the lubricatingslots on both cover and shims. Slots should beturned toward the upper side of thetransmission (A).
WARNING: Lubricant slots on both coverand shims must be turned toward theupper side of the transmission (A).
NOTE: Place shims with highest thicknesson the extremities of the pack.
48
Input Shaft Bearing Cover
2
Input Shaft Bearing Cover Ed. 07/04 FSO-4305/4405
Installation
5
FSO-4405A/01
6
FSO-4405A/04
44. Apply sealant to the threads of the six mounting
capscrews of the input shaft bearing cover andtighten them to the proper torque.
NOTE: Apply Eaton E677 sealant to the threads.Torque = 9.5 to 16.3 N.m (7 to 12 lb.ft)
5. Install the clutch housing and collar followingthe inverse order of the removal.
NOTE: Clutch housing, torque = 108.6 to121.7 N.m (80 to 90 lb.ft)Clutch collar, torque = ??? N.m (??? lb.ft)
6. Install the bleed valve and the inlet connection.
49
3
FSO-4305/4405 Ed. 07/04
Table of Contents
Gear Shift Lever Housing
Direct Gear Shift Lever Housing............. 51
Removal............................................ 51
Disassembly ..................................... 52
Assembly .......................................... 55
Installation ........................................ 58
Remote Gear Shift Lever Housing ......... 59
Removal............................................ 59
Disassembly ..................................... 60
Assembly .......................................... 62
Installation ........................................ 64
50 Ed. 07/04 FSO-4305/4405
51
3
FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing
Direct Gear Shift Lever Housing
1. Place transmission gear shifting mechanism inNEUTRAL.
2. Remove the four mounting capscrews of thegear shift lever housing to the transmissioncase.
3. Remove the gear shift lever housing from thetransmission case.
Removal
FSO-4405A/183
2
3
52
3
Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405
Direct Gear Shift Lever Housing
1. Secure the gear shift lever housing in a vise,with the gear shift lever facing up.
2. From the cover, remove the four retainingcapscrews and remove the cover.
3. Remove the boot.
4. Remove the two gear shift lever retainingcapscrews and remove the lever.
5. Remove the two nylon thrust washers.
Disassembly
FSO-4405A/184
12
FSO-4405A/185
3
4
FSO-4405A/186
5
53
3
FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing
Direct Gear Shift Lever Housing
Disassembly
6. From the gear shift lever positioning system,remove the two retaining plugs.
A - Plug
B - Plunger spring
C - Plunger
D - Ball
E - Ball Spring
7. Remove the plunger spring, the plunger andthe ball from both sides of the gear shift leverhousing.
8. Using a screw driver, remove the ball springfrom its housing on both gear shift lever housingsides.
9. Using a pin punch, remove the stop pin of the5th/reverse gear shift inhibitor mechanism, frominside to outside of the gear shift lever housing.
FSO-4405A/187
FSO-4405A/188
AB
C
D
E
FSO-4405A/189
8
FSO-4405A/190
9
6
54
3
Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405
Direct Gear Shift Lever Housing
10. Remove the 5th/reverse gear shift inhibitormechanism.
A - Torsion spring
B - Cam plate
C - Stop pin
Disassembly
11. Remove the pivot pin of the gear shift lever balljoint, the ball joint itself and the two nylon thrustwashers.
FSO-4405A/191
A
B
C
FSO-4405A/192
11
55
3
FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing
Direct Gear Shift Lever Housing
1. Install the torsion spring of the 5th/reverse gearshift inhibitor mechanism by inserting one endinto the existing gear shift lever housing hole.
2. Position the cam plate on the housing by fittingthe guide pin and the free torsion spring end.Holding the cam plate in place, install the stoppin and press it into place.
3. Place the ball joint on the gear shift lever withthe two nylon thrust washers and install thepivot pin.
Assembly
FSO-4405A/193
FSO-4405A/194
1
2
FSO-4405A/192
3
56
3
Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405
Direct Gear Shift Lever Housing
4. Insert the gear shift lever with the two nylonthrust washers into the gear shift lever housing,placing the gear shift lever upper end towardthe same side as the 5th/reverse gear shiftinhibitor mechanism.
Assembly
5. Install the two gear shift lever retainingcapscrews.
NOTE: Apply Eaton E677 sealant to the threads.Torque = 9,5 to 16,3 N.m (7 to 12 lb.ft)
6. Install the gear shift lever positioning systemplunger, springs, ball and the retaining plug onboth gear shift lever housing sides. Tighten theplugs to the recommended torque.
A - Plug
B - Plunger spring
C - Plunger
D - Ball
E - Ball Spring
NOTE: Apply Eaton E679 sealant to the plug threads.Torque = 10,5 to 20,3 N.m (8 to 15 lb.ft)
FSO-4405A/195
FSO-4405A/196
FSO-4405A/197
FSO-4405A/188
AB
C
D
E
5
4
4
6
57
3
FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing
Direct Gear Shift Lever Housing
Assembly
7. Install the boot.
8. Install the cover and the four retainingcapscrews.
NOTE: Apply Eaton E677 sealant to the threads.Torque = 2,0 to 7,0 N.m (1,5 to 5,0 lb.ft)
FSO-4405A/198
7
8
58
3
Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405
Direct Gear Shift Lever Housing
1. Place transmission gear shifting mechanism inNEUTRAL.
Installation
2. Apply the recommended sealant to gear shiftlever housing contact surface with thetransmission case.
NOTE: Apply Eaton E680 sealant to gear shift lever housing face.
3. Install the gear shift lever housing on thetransmission case with the housing boss facingthe input shaft.
4. Install the four gear shift lever housing retainingcapscrews and tighten to the recommendedtorque.
NOTE: Apply Eaton E677sealant to the threads.Torque = 19,0 to 25,7 N.m (14 to 19 lb.ft)
FSO-4405A/199
FSO-4405A/198
FSO-4405A/183
3
4
1
2
59
3
FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing
Remote Gear Shift Lever Housing
FSO-4405A/10
2
3
4
Removal
1. Place the gear shift lever in NEUTRAL.
2. Remove the four mounting capscrews of thegear shift lever housing to the transmissioncase.
3. Depending on the model of the transmission,remove the lateral mounting capscrew of thegear shift lever linkage and remove its bracketto enable removal of the gear shift leverhousing.
4. Remove the gear shift lever housing and itsgasket.
60
3
Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405
Remote Gear Shift Lever Housing
FSO-4405A/11
FSO-4405A/12
1
5
2
3
FSO-4405A/79
6
7
7
FSO-4405A/158
4
Disassembly
1. Position and hold the gear shift lever housingin a vise, with the lower part facing up.
2. On the front side of the housing, remove the5th speed locator plug (offset) and then removethe spring and the locating ball.
3. Remove the plug from the opposite side.
NOTE: Some transmission models also mayhave a spring and a ball in this side of thegear shift lever housing.
4. Remove the lock wire from the two mountingcapscrews of the internal shift selector.
5. Remove the two mounting capscrews of theinternal shift selector.
WARNING! Springs are assembled underpressure. Be careful while removing theplug and the snap ring that retains thespring.
6. Remove rear plug of the shifting shaft and theouter spring (1st and 2nd speeds shifting).
7. Remove the retainer and the inner spring (5thand reverse speeds shifting) and the thrustwasher.
61
3
FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing
Remote Gear Shift Lever Housing
FSO-4405A/14
9
FSO-4405A/12
8
Disassembly
8. Remove the shifting shaft, boot and lever bypulling them outwards.
9. Remove the gear shift lever housing oil seal.
NOTE: In case of worn housing bushings,replace the whole gear shift lever housing.
62
3
Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405
Remote Gear Shift Lever Housing
FSO-4405A/79
4
FSO-4405A/15
2
FSO-4405A/16
3
FSO-4405A/14
1
Assembly
1. Install the new oil seal, hitting it carefully with aspecial device of the proper diameter until itrests against its seat. See Special Tools,Reference ???.
2. Place the boot on the shifting shaft and installthe shaft on the housing, passing it throughthe first hole. Next, position the internal shiftselector and push the shaft until it reaches theother hole.
3. Install the thrust washer and then install theinner spring and the retainer.
4. Install the external spring and the rear plug,after applying a light sealant coat on themounting surface of the plug. DO NOT applysealant to the plugs thread. Press the plugagainst the spring to allow it to be installed.
NOTE: Apply Eaton E679 sealant to the mounting surface of the plug.Torque = 34 to 41 N.m (25 to 30 lb.ft)
63
3
FSO-4305/4405 Ed. 07/04 Gear Shift Lever Housing
Remote Gear Shift Lever Housing
Assembly
5. Align the holes on the internal shift selector withthe holes on the shaft and tighten the twomounting capscrews.
NOTE: Torque = 34 to 41 N.m (25 to 35 lb.ft)
6. Lock the two mounting capscrews with the wire.
FSO-4405A/12
5
FSO-4405A/11
8
7
FSO-4405A/158
6
7. On the rear side of the housing, install the plugopposite to the 5th speed locator (offset).
NOTE: Some transmission models also mayhave a spring and a ball in this side of thegear shift lever housing.
8. On the front side of the housing, install the 5thspeed locating ball, its spring and the plug.
NOTE: Apply Eaton E679 sealant to the mounting surfaces of the plugs. DO NOT apply sealant to the plugs threadsTorque = 13.6 to 20.3 N.m (10 to 15 lb.ft)
64
3
Gear Shift Lever Housing Ed. 07/04 FSO-4305/4405
Remote Gear Shift Lever Housing
FSO-4405A/10
3
2
11. Place a new gasket and the gear shift lever
housing assembly on the transmission case.
2. Depending on the model of the transmission,install the shift lever linkage bracket and tightenits mounting capscrew.
3. Apply sealant to the threads of the fourmounting capscrews of the gear shaft leverhousing and tighten them to the proper torque.
NOTE: Apply Eaton E677 sealant to the threads.Torque = 19 to 25.7 N.m (14 to 19 lb.ft)
Installation
65
Table of Contents
4
FSO-4305/4405 Ed. 07/04
Main Section
Engagement ........................................... 67
Disassembly ..................................... 67
Assembly .......................................... 75
Countershaft End PlayAdjustment .................................. 85
Main Shaft End PlayAdjustment .................................. 88
Final Assembly............................ 91
Input Shaft .............................................. 93
Disassembly ..................................... 93
Assembly .......................................... 94
Main Shaft .............................................. 95
Disassembly ..................................... 95
Assembly ........................................ 102
Countershaft ......................................... 108
Disassembly ................................... 108
Assembly ........................................ 111
66 Ed. 07/04 FSO-4305/4405
67
Engagement
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/17
1
FSO-4405A/19
3
FSO-4405A/18
2
FSO-4405A/80
2
AB
C
D
Disassembly
1. Remove the clutch housing and collar and theinput shaft bearing cover. See Input ShaftBearing Cover, Removal.
2. Remove the cover of the shift bar locatingdevice, by loosing the two mounting capscrews.Depending on the model of the transmission,the cover of the locating device can be arectangular plate or the shifting cable bracketitself, used simultaneously as a cover, as shownon the illustration aside.
3. Remove the three springs and balls (orspherical pins) of the shift locating device.
A = 1st and 2nd speeds locator
B = 3rd and 4th speeds locator
C = 5th and reverse speeds locator
D = Not used
68
Engagement
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/22
FSO-4405A/10
5
FSO-4405A/21
6
8
9
7
6
FSO-4405A/20
4
4. Remove the reverse speed light switch and thewasher.
Disassembly
5. Remove the gear shift lever housing. See GearShift Lever Housing, Removal.
6. Remove the neutral switch and the two balls.
7. Remove the speedometer sensor.
8. Lock the shaft with a special tool and removethe output yoke nut. See Special Tools,Reference ???.
9. Remove the output yoke. If necessary, removethe yokes baffler.
69
Engagement
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/24
FSO-4405A/25
FSO-4405A/23
11
12 13
10
FSO-4405A/160
B
A
Disassembly
10. To replace only the rear oil seal, it is not requiredto disassemble the rear case. It is possible toremove the oil seal at this stage, by pulling itfrom its housing. Install a new seal with theproper special tool. See Special Tools,Reference ?.
11. Remove the eighteen mounting capscrews ofthe rear case.
NOTE: Depending on the transmissionmodel, one capscrew (A) is used also to holdthe bracket of the gear shift lever linkage andother two capscrews (B) are used to holdthe counterweight of that shifting system.These three capscrews are different from theothers and differ one from each other as well.
12. Place the transmission with the input shaftfacing up.
13. Remove the three mounting capscrews of thecountershaft front cover and remove the cover.
NOTE: Depending on the countershaft frontcover type, these three capscrews might beouter or inner hexagon head type.
70
Engagement
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/28
FSO-4405A/29
16
17
FSO-4405A/27
15
FSO-4405A/26
1414. Remove the countershaft end play adjusting
shims.
Disassembly
15. Remove the two reverse idler gear mountingcapscrews.
16. Using two pry bars, separate the front case fromthe rear case.
17. Remove the front case by lifting it.
71
Engagement
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/32
FSO-4405A/31
19
21
22
20
FSO-4405A/30
18
Disassembly
18. With the recommended special device, removethe countershaft front bearing cup by hitting itcarefully from either inside or outside the case.See Special Tools, Reference ???.
19. Lift and remove the reverse idler gear shaft.
20. Remove the reverse idler gear shaft togetherwith the needle bearing, paying specialattention not to drop the bearing.
21. Move the countershaft slightly and remove theinput shaft.
22. Remove the 4th speed synchronizer ring.
23. Remove the roll pin of the 5th and reversespeed shift yoke, using a pin punch.
NOTE: Use a 5 mm diameter pin punch.
WARNING! To avoid damage to either theshift bar or its bore on the case, or toboth, place a wooden block between thegears and the bar.
24. Make sure that the transmission is onNEUTRAL position and remove the 5th andreverse speed shift bar together with the shiftcontrol block. The 5th and reverse speed shiftyoke will be removed later, together with themain shaft.
FSO-4405A/33
23
24
72
Engagement
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/35
FSO-4405A/36
26
28
FSO-4405A/34
25
27
FSO-4405A/37
29
30
25. Remove the roll pin of the 3rd and 4th speedshift yoke, using a pin punch.
NOTE: Use a 5 mm diameter pin punch.
WARNING! To avoid damage to either theshift bar or its bore on the case, or toboth, place a wooden block between thegears and the bar.
Disassembly
26. Lift the 1st and 2nd speed shift yoke and shiftto 2nd speed.
27. Remove the roll pin of the 3rd and 4th speedshift control block, using a pin punch.
NOTE: Use a 4 mm diameter pin punch.
WARNING! To avoid damage to either theshift bar or its bore on the case, or toboth, place a wooden block between thegears and the bar.
28. Disengage the 2nd speed and return the 1stand 2nd speed shift yoke to NEUTRAL. Thenremove the 3rd and 4th speed shift bar togetherwith its yoke and shift control block.
29. Remove the roll pin of the 1st and 2nd speedshift yoke, using a pin punch.
NOTE: Use a 5 mm diameter pin punch.
WARNING! To avoid damage to either theshift bar or its bore on the case, or toboth, place a wooden block between thegears and the bar.
30. Remove the 1st and 2nd speed shift bar andyoke.
73
Engagement
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/38
FSO-4405A/39
31
33
FSO-4405A/40
34
FSO-4405A/41
35
32
36
Disassembly
31. Move the countershaft slightly to enableremoval of the main shaft.
32. Remove the main shaft from its housing on therear case, lifting the shaft together with the 5thand reverse speed shift yoke. Next, remove the5th and reverse speed shift yoke from the mainshaft assembly.
33. Remove the countershaft from thetransmission case.
34. Remove the four balls of the double gearshifting interlocking system.
35. Remove the main shaft rear oil seal, by hittingit from the inside to the outside of the case.
NOTE: The oil seal removed should not bereused.
36. Remove the main shaft rear bearing cup, byhitting it with a special device from the outsideto the inside of the case. See Special Tools,Reference ???.
74
Engagement
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/42
37
FSO-4405A/43
38
Disassembly
37. Remove the countershaft rear cover, byloosening its four mounting capscrews.
38. Remove the countershaft rear bearing cup, byhitting it with a special device from the outsideto the inside of the case. See Special Tools,Reference ???.
75
Engagement
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/44
FSO-4405A/45
1
4
2
3
Assembly
NOTE: Thoroughly clean the parts andremove any remaining sealant from themounting surfaces prior to installation.
1. Properly place the rear case with its internalside facing up.
2. Carefully clean the bearings cups and housingsprior to installation.
3. Install the countershaft rear bearing cup, bypressing it with a special device until it restsproperly against its housing. See Special Tools,Reference ???.
4. Install the main shaft rear bearing cup, bypressing it with a special device until it restsproperly against its housing. See Special Tools,Reference ???.
76
Engagement
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/48
10
FSO-4405A/46
FSO-4405A/47
5
7
FSO-4405A/39
9
6
8
5. Turn the rear case over and properly place itwith the internal side facing down.
6. Manually align the rear oil seal and install it onthe case, by hitting it with a special device untilit rests properly against its housing. See SpecialTools, Reference ???.
Assembly
7. Return the rear case to the position with theinternal side facing up.
8. Install the four balls of the double gear shiftinginterlocking system, placing two balls in eachof the housings. Apply a light grease coat tokeep the balls in the housings during assembly.
9. Install the countershaft in its housing on therear case, with the rear bearing cone facingup.
10. Install the speedometer rotor on the rear endof the main shaft, after applying a grease coatto the rotor hole in order to avoid it to fall duringinstallation of the shaft.
77
Engagement
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/38
11
12
FSO-4405A/51
16
17
Assembly
11. Place the 5th and reverse speed shift yoke onthe slot of the corresponding synchronizersleeve on the main shaft.
12. Tilt the countershaft slightly and install the mainshaft on its housing on the rear case, with therear bearing cone facing down. Once the mainshaft has been placed, the countershaft willreturn to its correct position.
13. Insert the 5th and reverse speed shift bar withthe shift control block already assembledthrough its respective shift yoke.
14. With a light grease coat, install the neutralswitch driving pin on the 5th and reverse speedshift bar.
15. Push the 5th and reverse shift bar inside itsbore on the case, making sure that the bar isproperly installed on the ball of the double gearshifting interlocking system.
NOTE: Be careful not to misplace the ballsof the double gear shifting interlockingsystem from their housings.
16. Place the 3rd and 4th speed shift yoke on theslot of the corresponding synchronizer sleeveand install the respective shift bar through theyoke.
17. With a light grease coat, install the interlockpin in the 3rd and 4th speed shift bar.
FSO-4405A/49
13
FSO-4405A/50
15
14
78
Engagement
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/55
22
FSO-4405A/52
18
FSO-4405A/53
19
FSO-4405A/54
21
20
18. Install the 3rd and 4th speed shift control blockon the shift bar and push the shift bar to itsbore on the case, assuring that the bar isproperly installed on the ball of the double gearshifting interlocking system.
NOTE: Be careful not to misplace the ballsof the double gear shifting interlockingsystem from their housings.
Assembly
19. Place the 1st and 2nd speed shift yoke on theslot of the corresponding synchronizer sleeveand install its shift bar through the yoke.
20. Push the 1st and 2nd speed shift bar to its boreon the case, making sure that the bar is properlyinstalled on the ball of the double gear shiftinginterlocking system.
NOTE: Be careful not to misplace the ballsof the double gear shifting interlockingsystem from their housings.
21. Align the mounting hole on the 3rd and 4thspeed shift bar with the hole on the shift yokeand install a new roll pin.
NOTE: Use a 5 mm diameter pin punch.
WARNING! To avoid damage to either theshift bar or its bore on the case, or toboth, place a wooden block between thegears and the bar.
22. Align the mounting hole on the 3rd and 4thspeed shift control block with the hole on theshift bar and install a new roll pin.
NOTE: Use a 4 mm diameter pin punch.
WARNING! To avoid damage to either theshift bar or its bore on the case, or toboth, place a wooden block between thegears and the bar.
79
Engagement
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FSO-4405A/57
24
FSO-4405A/58
25
FSO-4405A/59
27
Assembly
23. Align the mounting hole on the 5th and reversespeed shift bar with the hole on the shift yokeand install a new roll pin.
NOTE: Use a 5 mm diameter pin punch.
WARNING! To avoid damage to either theshift bar or its bore on the case, or toboth, place a wooden block between thegears and the bar.
24. Align the mounting hole on the 1st and 2ndspeed shift bar with the hole on the shift yokeand install a new roll pin.
NOTE: Use a 5 mm diameter pin punch.
WARNING! To avoid damage to either theshift bar or its bore on the case, or toboth, place a wooden block between thegears and the bar.
25. At the end of assembling the shift bars, yokesand control blocks, all bars must have theirupper end aligned and the control blocks mustbe aligned in neutral position.
26. Test the functionality of the double shiftinginterlocking system, trying to shift two gears atthe same time: shift to any gear and then tryshifting another one.
27. Install the 4th speed synchronizer ring on themain shaft.
WARNING! The 4th speed synchronizerring DOES NOT have EFM coating. SeeShifting System, SynchronizerAssemblies.
FSO-4405A/56
23
80
Engagement
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/83
30
FSO-4405A/32
28
FSO-4405A/82
29
FSO-4405A/60
29
28. Slightly move the countershaft and install theinput shaft assembly.
Assembly
29. Install the reverse idler gear with the needlebearing in its shaft on its housing on the rearcase.
NOTE: Lubricate the needle bearing with thesame recommended lubricating oil of thetransmission.
30. Align the lower hole of the reverse idler gearshaft with the hole on the rear case and installthe mounting capscrew.
NOTE: Apply Eaton E677 sealant to the thread.Torque = 19 to 25.7 N.m (14 to 19 lb.ft)
81
Engagement
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/61
31, 33
FSO-4405A/29
34
32
FSO-4405A/62
35
Assembly
31. Remove any residual sealant form the mountingsurfaces on the front and rear transmissioncases.
32. Remove any residual sealant from thecapscrew holes on the cases, using proper tapsor specially prepared capscrews.
33. Apply recommended sealant on the mountingsurface of the rear case with the front case,spreading it homogeneously over all the surfaceto avoid leakages.
NOTE: Apply Eaton E680 sealant to the mounting surface of the cases.
NOTE: Make sure that all shift bars andassemblies are in NEUTRAL position.
34. Place the front case over the rear case,observing the correct positioning of the dowelpins.
35. Apply sealant to the threads of the eighteenrear case mounting capscrews.
NOTE: Apply Eaton E677 sealant to the threads.
82
Engagement
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/27
37
FSO-4405A/26
38
FSO-4405A/84
36
FSO-4405A/160
B
A
36. Place the lifting hook and install the eighteenmounting capscrews. Tighten the capscrewscrosswise to the appropriate torque.
NOTE: Torque = 19 to 25.7 N.m (14 to 19lb.ft)
Assembly
NOTE: Depending on the transmissionmodel, one capscrew (A) is used also to holdthe bracket of the gear shift lever linkage andother two capscrews (B) are used to holdthe counterweight of that shifting system.These three capscrews are different from theothers and differ one from each other as well.
37. Install the second mounting capscrew of thereverse idler gear shaft on the front case.
NOTE: Apply Eaton E677 sealant to the thread.Torque = 19 to 25.7 N.m (14 to 19 lb.ft)
38. Install the countershaft end play adjustingshims.
NOTE: Use the same original shim packremoved during disassembly. Place shimswith highest thickness on the extremities ofthe pack.
83
Engagement
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FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/63
39
FSO-4405A/64
40
41
Assembly
NOTE: At this stage, DO NOT apply anysealant to the mounting surface of thecountershaft front cover with thetransmission case or in the threads of thecover mounting capscrews.
39. Temporarily install the countershaft front coverand the three mounting capscrews. Tighten thecapscrews to the appropriate torque.
NOTE: Depending on the countershaft frontcover type, these three capscrews might beouter or inner hexagon head type.Stamped sheet cover, torque = 9.5 to 16.3N.m (7 to 12 lb.ft)Cast iron cover, torque = 24.4 to 31.2 N.m(18 to 23 lb.ft)
40. Install the main shaft end play adjusting shimspack and temporarily install the input shaftcover. Observe the position of the lubricatingslots on both cover and shims. Slots should beturned toward the upper side of thetransmission. See Input Shaft Bearing Cover,Installation.
NOTE: Use the same original shim packremoved during disassembly. Place shimswith highest thickness on the extremities ofthe pack.At this stage, DO NOT apply any sealant tothe mounting surface of the input shaft coveror in the threads of the cover mountingcapscrews.
41. Install the six mounting capscrews of the inputshaft bearing cover and tighten the capscrewsto the appropriate torque.
NOTE: Torque = 9.5 to 16.3 N.m (7 to 12lb.ft)
84
Engagement
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Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/65
42
4344, 45
42. Place the transmission with the rear side facingup.
43. Install the output yoke on the splines of the mainshaft.
NOTE: If necessary, replace the yoke baffler.
44. Apply sealant to the threads of the new yokenut and tighten the nut.
WARNING! The output yoke nut must bereplaced with a new one each time it isdisassembled.
45. Lock the shaft with a special tool and tightenthe yoke nut to the appropriate torque. SeeSpecial Tools, Reference ???.
NOTE: Apply Eaton E677sealant to the yoke nut threads.Torque = 407 to 475 N.m (300 to 350 lb.ft)
46. Check the countershaft end play. SeeCountershaft End Play Adjustment next in thismanual.
Assembly
85
Engagement
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FSO-4405A/66
47
FSO-4405A/67
50
FSO-4405A/63
52
48
49
51
53
Countershaft End Play Adjustment
NOTE: The transmission must be positionedwith the rear side facing up.
47. Invert the mounting position of the countershaftrear cover in one of the mounting holes anduse the cover itself as a base to support themagnetic base of the dial indicator.
48. Rotate the countershaft several times, bothclockwise and counterclockwise, to guaranteethat it is completely seated on the bearing.
49. Place the tip of the dial indicator on the end ofthe countershaft. Set the pointer to zero.
50. Remove the lateral cover of the power take off(PTO) opening.
51. Insert a pry bar through the PTO opening andforce the countershaft upwards at once. Readthe countershaft end play on the dial indicator.
52. Invert the position of the transmission case,placing it with the input shaft facing up.
53. Remove the countershaft front cover andremove the end play adjusting shims.
86
Engagement
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/26
54, 55
FSO-4405A/63
56
57
54. If necessary, add or remove shims to set theend play within the specified range, preferablycloser to the lower limit.
NOTE: Add shims to reduce end play andremove shims to increase end play.Place shims with highest thickness on theextremities of the pack.Countershaft end play = 0.025 mm to 0.100mm (0.01 to 0.04 in)
55. Install the selected shim pack.
NOTE: Apply Eaton E679 sealant to both sides of shims.
Countershaft End Play Adjustment
56. Apply sealant to mounting surface of thecountershaft front cover with the transmissioncase and install the cover.
NOTE: Apply Eaton E680 sealant to the mounting surface of the countershaft front cover.
57. Apply sealant to the threads of the threemounting capscrews of the countershaft frontcover and tighten them to the proper torque.
NOTE: Depending on the countershaft frontcover type, these three capscrews might beouter or inner hexagon head type.Stamped sheet cover, torque = 9.5 to 16.3N.m (7 to 12 lb.ft)Cast iron cover, torque = 24.4 to 31.2 N.m(18 to 23 lb.ft)
87
Engagement
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FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/85
58
59
Countershaft End Play Adjustment
58. Install the lateral PTO opening cover.
NOTE: Apply Eaton E680sealant to the mounting surface of the PTO cover.
Apply Eaton E677 sealant to the threads. Torque = 19 to 25.7 N.m (14 to 19 lb.ft)
59. Check the main shaft end play. See Main ShaftEnd Play Adjustment next in this manual.
88
Engagement
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/68
60
FSO-4405A/64
64
6162
63
65
Main Shaft End Play Adjustment
NOTE: The transmission must be positionedwith the rear side facing up.
60. Invert the mounting position of the countershaftrear cover in one of the mounting holes anduse the cover itself as a base to support themagnetic base of the dial indicator.
61. Rotate the main shaft several times, bothclockwise and counterclockwise, to guaranteethat it is completely seated on the bearing.
62. Place the tip of the dial indicator on the end ofthe main shaft. Set the pointer to zero.
63. Place two pry bars under the output yoke andforce the main shaft upwards at once. Readthe main shaft end play on the dial indicator.
64. Invert the position of the transmission case,placing it with the input shaft facing up.
65. Remove the input shaft bearing cover andremove the end play adjusting shims.
89
Engagement
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FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/86
66, 67
FSO-4405A/64
69
FSO-2405/77
68
67, 68
FSO-4405A/04
A
68
Main Shaft End Play Adjustment
66. If necessary, add or remove shims to set theend play within the specified range, preferablycloser to the lower limit.
NOTE: Add shims to reduce end play andremove shims to increase end play.Place shims with highest thickness on theextremities of the pack.Main shaft end play = 0.025 mm to 0.100mm (0.01 to 0.04 in)
67. Apply sealant to both sides of shims of theselected pack and to the mounting surface ofthe input shaft bearing cover.
NOTE: Apply Eaton E679 sealant to both sides of shims and cover surface.
68. Install the shim pack and the input shaft bearingcover. Observe the position of the lubricatingslots on both cover and shims. Slots should beturned toward the upper side of thetransmission (A).
WARNING: Lubricant slots on both coverand shims must be turned toward theupper side of the transmission (A).
NOTE: Place shims with highest thicknesson the extremities of the pack.
69. Apply sealant to the threads of the six mountingcapscrews of the bearing cover and tightenthem to the proper torque.
NOTE: Apply Eaton E677sealant to the threads.Torque = 9.5 to 16.3 N.m (7 to 12 lb.ft)
90
Engagement
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/87
7071
72
70. Invert the position of the transmission again,placing it with the rear side facing up.
71. Apply sealant to mounting surface of thecountershaft rear cover with the transmissioncase and install the cover.
NOTE: Apply Eaton E680 sealant to the mounting surface of the countershaft rear cover.
72. Apply sealant to the threads of the threemounting capscrews of the countershaft rearcover and tighten them to the proper torque.
NOTE: Apply Eaton E677sealant to the threads.Torque = 19 to 25.7 N.m (14 to 19 lb.ft)
Main Shaft End Play Adjustment
91
Engagement
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/20
76
FSO-4405A/19
77AB
C
FSO-4405A/10
75
FSO-4405A/21
74
73
74
D
Final Assembly
73. Install the speedometer sensor.
74. Install the neutral switch and the two balls.
75. Install the gear shift lever housing. See GearShift Lever Housing, Installation.
76. Install the reverse speed light switch and thewasher.
77. Install the three springs and balls (or sphericalpins) of the shift bar locating device.
A = 1st and 2nd speeds locator
B = 3rd and 4th speeds locator
C = 5th and reverse speeds locator
D = Not used
92
Engagement
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Main Section Ed. 07/04 FSO-4305/4405
Final Assembly
FSO-4405A/17
79
FSO-4405A/18
78
FSO-4405A/80
78
78. Install the cover of the shift locating device andtighten its two mounting capscrews. Dependingon the model of the transmission, the cover ofthe locating device can be a rectangular plateor the shifting cable support itself, usedsimultaneously as a cover, as shown on theillustration aside.
NOTE: Apply Eaton E677sealant to the threads.Torque = 9.5 to 16.3 N.m (7 to 12 lb.ft)
79. Install the clutch collar and housing. See InputShaft Bearing Cover, Installation.
93
Input Shaft
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/168
FSO-4405A/169
Disassembly
1. Remove the input shaft bearing cone with thespecial puller. See Special Tools, Reference???.
2. Hold the input shaft in a vise with the rear sidefacing up. Remove the oil baffler with ascrewdriver.
94
Input Shaft
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/170
FSO-4405A/171
Assembly
1. Install the new oil baffler with a special device.See Special Tools, Reference ???.
2. Place the input shaft in a press with the frontend facing up.
WARNING! Place the tubular tool on theinner race of the bearing. NEVER supportit on the bearing cage.
3. Install the front bearing cone using a specialtubular tool. See Special Tools, Reference ???.
95
Main Shaft
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/48
1
FSO-4405A/106
2
FSO-4405A/107
3
FSO-4405A/108
4
5
Disassembly
2. From the front end of the shaft, place the specialpuller on the 3rd speed gear and remove thegear together with the 3rd and 4th speedssynchronizer assembly, the 3rd speedsynchronizer ring and the front bearing cone.See Special Tools, Reference ???.
3. Remove front and rear spacer rings of the 3rdspeed gear rollers and then remove the rollers.
4. Place the main shaft in vertical position in avise, with the front end facing up.
5. Remove the 2nd speed gear snap ring.
1. Manually remove the speedometer rotor fromthe end of the main shaft.
96
Main Shaft
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/109
6
FSO-4405A/110
7
FSO-4405A/111
8
FSO-4405A/112
9
6. Remove the thrust washer.
Disassembly
7. Remove the thrust washer locating ball.
8. Remove the 2nd speed gear.
9. Remove the 2nd speed gear rollers.
97
Main Shaft
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FSO-4405A/113
10
FSO-4405A/114
12
FSO-4405A/115
13
FSO-4405A/172
Disassembly
10. Remove the spacer ring of 2nd speed gearrollers.
11. Remove the 2nd speed synchronizer rings(Tricone) (only FSO-4305 transmission).
12. Remove the snap ring of the 1st and 2nd speedsynchronizer assembly.
13. Remove the 1st and 2nd speed synchronizerassembly.
98
Main Shaft
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/117
16
FSO-4405A/118
17
18
FSO-4405A/116
15
FSO-4405A/173
14. Remove the 1st speed synchronizer rings(Tricone) (only FSO-4305 transmission).
Disassembly
15. Remove the 1st speed gear.
16. Remove the 1st gear needle bearing.
17. Remove the reverse speed gear snap ring.
18. Remove the reverse speed gear thrust washer.
99
Main Shaft
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/119
19
FSO-4405A/120
20
FSO-4405A/121
21
FSO-4405A/122
22
Disassembly
19. Remove the thrust washer locating ball.
20. Remove the reverse speed gear.
21. Remove the two reverse speed needlebearings.
22. Remove the reverse speed synchronizer ring.
100
Main Shaft
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/125
25
FSO-4405A/126
27
FSO-4405A/123
23
FSO-4405A/124
24
23. Remove the snap ring of the 5th and reversespeed synchronizer assembly.
Disassembly
24. Remove the 5th and reverse speedsynchronizer assembly.
25. Remove the 5th speed synchronizer ring.
26. Remove the main shaft from the vise.
27. From the rear end of the main shaft, placespecial puller behind the rear bearing thrustwasher and remove the bearing together withthe washer. See Special Tools, Reference ???.
101
Main Shaft
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/127
2829
Disassembly
28. Remove the 5th speed gear.
29. Remove the 5th gear rollers.
102
Main Shaft
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/128
4
FSO-4405A/127
32
5
6
FSO-4405A/125
8
7
1
FSO-4405A/124
9
1. Place the main shaft in vertical position in avise, with the rear end facing up.
2. Lubricate and position the rollers of the 5thspeed gear on the shaft, using a light coat ofgrease to keep the rollers in their position.
NOTE: Use transmission oil to lubricate therollers.
3. Manually install the 5th speed gear, with thecone side facing down, until it seats on theshaft.
Assembly
4. Place the main shaft in vertical position in apress, with the rear end facing up and supportit properly.
5. Install the thrust ring of the main shaft rearbearing.
WARNING! Place the tubular tool on theinner race of the bearing. NEVER supportit on the bearing cage.
6. Use a tubular tool and press the rear bearing,with the smaller side of the cone facing up, untilit seats on the shaft. See Special Tools,Reference ???.
7. Place the main shaft in vertical position in avise, with the front end facing up.
8. Install the 5th speed synchronizer ring, with theflat side facing down (towards the 5th speedgear).
9. Install the 5th and reverse speed synchronizerassembly with its wider side facing up (towardsthe reverse speed gear).
103
Main Shaft
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/123
10
FSO-4405A/122
11
FSO-4405A/121
12
FSO-4405A/120
13
Assembly
10. Install the 5th speed gear snap ring.
11. Install the reverse speed synchronizer ring, withthe flat side facing up (towards the reversespeed gear).
12. Lubricate and install the two needle bearingsof the reverse speed gear, using a light coat ofgrease to keep the bearings in their position.
NOTE: Use transmission oil to lubricate thebearings.
13. Install the reverse speed gear with the coneside facing down.
104
Main Shaft
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/130
17
FSO-4405A/116
18
FSO-4405A/118
16
FSO-4405A/119
14
15
14. Install the locating ball of the reverse speedgear thrust washer.
Assembly
15. Install the reverse speed gear thrust washer.
16. Install the reverse gear snap ring.
17. Lubricate and install the needle bearing of the1st speed gear, using a light coat of grease tokeep the bearing in its position.
NOTE: Use transmission oil to lubricate thebearing.
18. Install the 1st speed gear with the cone sidefacing up.
105
Main Shaft
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/112
2324
FSO-4405A/131
20
21
FSO-4405A/172
FSO-4405A/173
Assembly
19. Install the 1st speed synchronizer rings(Tricone) (only FSO-4305 transmission).
20. Install the 1st and 2nd speed synchronizerassembly.
21. Install the synchronizer assembly snap ring.
22. Install the 2nd speed synchronizer rings(Tricone) (only FSO-4305 transmission).
23. Install the spacer ring of the 2nd speed gearrollers.
24. Lubricate and install the rollers of the 2nd speedgear, using a light coat of grease to keep therollers in their position.
NOTE: Use transmission oil to lubricate thebearing.
106
Main Shaft
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/132
31
FSO-4405A/108
27
28
3029
FSO-4405A/111
25
FSO-4405A/110
26
25. Install the 2nd speed gear on the rollers, withthe cone side facing the synchronizer assembly.
Assembly
26. Install the locating ball of the 2nd speed gearthrust washer.
27. Install the 2nd speed thrust washer.
28. Install the 2nd gear snap ring.
29. Install the rear spacer ring of the 3rd speedgear rollers.
30. Lubricate and install the rollers of the 3rd speedgear, using a light coat of grease to keep therollers in their position.
NOTE: Use transmission oil to lubricate thebearing.
31. Install the front spacer ring of the 3rd speedgear.
107
Main Shaft
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FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/136
35
FSO-4405A/135
34
36
FSO-4405A/133
32
FSO-4405A/134
33
Assembly
32. Install the 3rd speed gear on the rollers, withthe cone side facing up (towards thesynchronizer ring).
33. Install the 3rd speed synchronizer ring.
WARNING! The 3rd speed synchronizerring HAS EFM coating. See ShiftingSystem, Synchronizer Assemblies.
34. Install the 3rd and 4th speed synchronizerassembly with its hub wider surface facing down(towards the 3rd speed gear).
35. Place the main shaft in a press, with the frontend facing up and support it properly.
WARNING! Place the tubular tool on theinner race of the bearing. NEVER supportit on the bearing cage.
36. Using a tubular tool, press the front bearingwith the smaller side of the cone facing up, untilit seats on the shaft. See Special Tools,Reference ???.
108
Countershaft
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/137
1
FSO-4405A/138
2
FSO-4405A/139
FSO-4405A/140
5
3, 4
Disassembly
1. Place the countershaft in vertical position in avise, with the front end facing up, and removethe front bearing using a special puller. SeeSpecial Tools, Reference ???.
2. Remove the 4th speed gear snap ring.
3. Place the countershaft in vertical position in apress, with the front end facing up and usingthe 4th speed gear as a base.
4. Press the countershaft and remove the 4thspeed gear.
5. Turn the countershaft over on the press anduse the 3rd speed gear as a base. Then pressthe countershaft and remove the 3rd speedgear.
109
Countershaft
4
FSO-4305/4405 Ed. 07/04 Main Section
6
FSO-4405A/141
6
FSO-4405A/142
7
FSO-4405A/143
Disassembly
8, 9
6. Place the countershaft in vertical position in avise, with the rear end facing up and removethe rear bearing using a special puller. SeeSpecial Tools, Reference ???.
7. Remove the 5th speed gear snap ring.
8. Place the countershaft in vertical position in apress, with the rear end facing up and usingthe 5th speed gear as a base.
9. Press the countershaft and remove the 5thspeed gear.
110
Countershaft
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/144
10
FSO-4405A/145
10
10. Using a punch, remove the rear key and thetwo front keys, carefully tapping to not damagethe shaft and keys.
Disassembly
111
Countershaft
4
FSO-4305/4405 Ed. 07/04 Main Section
FSO-4405A/146
2
FSO-4405A/144
1
FSO-4405A/145
1
FSO-4405A/142
4
3
Assembly
1. Using a hammer, install the rear key and thetwo front keys.
2. Place the countershaft in vertical position in apress, with the rear end facing up and usingthe 2nd speed gear as a base.
3. Using a tubular tool, press the 5th speed geardown the countershaft, with the most prominentside of the gear flange facing down. Make sureto keep the correct alignment of the gear slotwith the shaft key prior to pressing the geardown. See Special Tools, Reference ???.
4. Install the 5th speed gear snap ring.
112
Countershaft
4
Main Section Ed. 07/04 FSO-4305/4405
FSO-4405A/147
5
FSO-4405A/149
8
FSO-4405A/148
7
6
FSO-4405A/138
9
WARNING! Place the tubular tool on theinner race of the bearing. NEVER supportit on the bearing cage.
5. Using a tubular tool, press the rear bearing withthe smaller side of the cone facing up, until itseats on the shaft. See Special Tools,Reference ???.
Assembly
6. Turn the countershaft over on the press, so thatits front end will be facing up. Use the 5th speedgear as a base.
7. Using a tubular tool, press the 3rd speed geardown the countershaft with the most prominentside of the gear flange facing up (towards the4th speed gear). Make sure to keep the correctalignment of the gear slot with the two shaftkeys prior to pressing the gear down. SeeSpecial Tools, Reference ???.
8. Using a tubular