Fuller

Fuller® Heavy-Duty FR/FRO Transmissions

More time on the road®

Service Manual
Fuller Heavy-Duty FR/FRO Transmissions
TRSM2400

February 2009
FR-11210B FR-12210B FR-13210B FR-14210B FR-15210B FR-9210B FRF-11210B FRF-12210B FRF-13210B FRF-14210B FRF-15210B FRF-9210B FRO-11210B FRO-11210C FRO-12210B FRO-12210C FRO-13210B FRO-13210C FRO-14210B FRO-14210C FRO-15210B FRO-15210C FRO-16210BFRO-16210C FRO-17210C FRO-18210C FROF-11210B FROF-11210C FROF-12210B FROF-12210C FROF-13210B FROF-13210C FROF-14210B FROF-14210C FROF-15210B FROF-15210C FROF-16210B FROF-16210C FRW-15210B

Warnings and Precautions
Warnings and Precautions

!

WARNING

Before starting a vehicle always be seated in the driver’s seat, place the transmission in neutral, set the parking brakes and disengage theclutch. Before working on a vehicle place the transmission in neutral, set the parking brakes and block the wheels. Before towing the vehicle place the transmission in neutral, and lift the rear wheels off the ground, remove the axle shafts, or disconnect the driveline to avoid damage to the transmission during towing. The description and specifications contained in this service publication arecurrent at the time of printing. Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice. Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents may be used. This symbol is usedthroughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and/or component damage. Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technican or vehicle operator.
WARNING

Failure to follow indicatedprocedures creates a high risk of personal injury to the service technician.
CAUTION

Failure to follow indicated procedures may cause component damage or malfunction. Note: Additional service information not covered in the service procedures. Tip: Helpful removal and installation procedures to aid in the service of this unit. Always use genuine Eaton replacement parts.

Table of ContentsGeneral Information
Purpose and Scope of Manual .................................... 1 Serial Tag Information and Model Nomenclature ........ 5 Lubrication Specifications ........................................... 8 Oil Leak Inspection Process ....................................... 10 Transmission Operation ............................................ 11 Tool Specifications.................................................... 15 Torque Specifications ................................................ 19 Power Flow Diagrams ............................................... 21 Air System Troubleshooting ...................................... 31 General Troubleshooting Chart ................................. 42 Air System Overview ................................................. 45 TimingProcedures .................................................... 60

Transmission Overhaul Procedures-Bench Service
How to Disassemble the Gear Shift Lever ................102 How to Assemble the Gear Shift Lever ....................104 How to Remove the Shift Bar Housing ....................106 How to Install the Shift Bar Housing ........................107 How to Disassemble the Shift Bar Housing.............108 How to Disassemble the Range Cylinder .................111 How Assemble the Range Cylinder ..........................112 How to Assemble the Shift Bar Housing ..................114 How to Remove the Input Shaft Assembly (without main case disassembly) .....................118 How to Install the Input Shaft Assembly (without main case disassembly) .....................120 How to...