Fuller Transmissions TRTS0920: Troubleshooting Guide

Troubleshooting Guide
Fuller Transmissions
TRTS0920
July 2011
Warnings and Precautions
Warnings and Precautions
! WARNING
Before startinga vehicle always be seated in the driver’s seat, place the transmission in neutral, set the parking brakesand
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, remove the axle shafts,
or disconnect the driveline to avoiddamage to the transmission during towing.
The description and specifications contained in this service publication are current 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
timewithout 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 used throughout 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 indicated procedures 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 Contents
General Information RTLO-xxX610 Models ..............................................125

RTL-xx710 Speed Models ........................................129
RTL-xx710 Models ..................................................130
How to use this Troubleshooting/Operation Guide ...... 1 AT-1202 Auxillairy Transmission
Transmission Identification .........................................2 (with 2 Position Shift Valve) .............................134
Component Identification ............................................4 AT-1202 Auxiliary Housing (3 Position Valve) .........135
Lubricants and Sealants ..............................................6
Suggested Test Fixtures ..............................................7
System Components
Air System Troubleshooting A-4740 Air Filter/Regulator Assembly ......................137
A-5161/A-5454 Air Filter/Regulator Assembly .........138
8, 9, 10, 11, 13, 15, and 18-Speed Troubleshooting ... 8 A-3546 Range Valve ................................................139
RTLO 10-Speed Troubleshooting ..............................23 A-5010/A-6909 Roadranger Valve ...........................140
Combination Cylinder Troubleshooting .....................33 14651 Reduction Valve (Dash-Mounted) .................141
FR-1X210 Troubleshooting .......................................51 A-5015/A-6915 Roadranger Valve ...........................142
Two Position Selector Valve ....................................143
A-4900/A-6913 Roadranger Valve ...........................144
Operation A-5013/A-6913 Roadranger Valve ...........................145
Three Position Selector Valve ..................................147
A-5510/A-6910 Roadranger Valve ...........................148
Air Line Color Chart ................................................... 64 Range Actuator Valve (Old Design) ..........................150
Slave Valve Preselection System ............................... 65 Range Actuator Valve (Latest Design) .....................151
7,8,9 and 10-Speed Range Air Systems ....................66 19470 Poppet-Type Slave Valve ..............................152
7L,8,9 and 10-Speed (2-Speed auxiliary) .................. 67 A-4688 Slave Valve ..................................................153
RT & RTO-610,6610, 6609, and 8609 Models .......... 69 A-5000 Slave Valve ..................................................154
Deep Reduction Air System Range Cylinder ........................................................155
(with Dash Mounted Valve) ................................71 Range Cylinder for 610, 6610, 6609 and 8609 ........156
RT, RTO, & RTX xx607LL, Dash-Mounted Deep Reduction Cylinder .................157
xx608LL, and xx615 models .............................. 72 Deep Reduction Cylinder with Roadranger Valve .....158
Deep Reduction Air System RTLO-xx610 Model Range Cylinder Assembly ........160
(with A-6915 Roadranger Valve) ........................75 RTL-xx710 Model Range Cylinder Assembly ...........162
RT, RTO, & RTX xx607LL, Intermediate Shift Cylinder Assembly
xx608LL, and xx615 Models .............................. 76 613 and 6613, 3-Position Selector Valve ..........164
9 and 13-Speed Air Systems Intermediate Shift Cylinder Assembly
(Top 2 & Convertible) and 18-Speed (Top-2) .... 79 613 and 6613, A-5015 Roadranger Valve .........166
RT, RTO, & RTOOxx613 and xx813 Models ............. 83 Combination Cylinder Assembly ..............................168
RTLO-xx613 Models .................................................86 Splitter Cylinder Assembly .......................................171
RTLO-xx713 Models .................................................89 RTLO-xx610 Model Splitter Cylinder Assembly
RTLO-xx913 Models .................................................92 (Old Design) ....................................................173
RT0-15618 and RTLO-xx618 Models ........................95 RTLO-xx610 Model Splitter Cylinder Assembly
RTLO-xx718 Models .................................................99 (Latest Design) .................................................175
RTLO-xx918 Models ...............................................103 RTL-xx710 Model Splitter Cylinder Assembly ..........177
Combination Cylinder Air System ............................107 RTLO-xx613 Model Splitter Cylinder Assembly .......179
7LL/DLL/MLL, 8LL, 9MLL, and 15-Speed Models .. 108 RTLO-xx713 Model Splitter Cylinder Assembly .......181
Unique Air Systems .................................................111 RTLO-xx913 Model Splitter Cylinder Assembly .......183
RT &RTO613 and 6613 Models .............................112 RTO-15618 and RTLO-xx618 Model
RT & RTO 613 and 6613 Models Splitter Cylinder Assembly ...............................185
With A-6913 Roadranger Valve ....................... 115 RTLO-xx718 Model Splitter Cylinder Assembly .......187
RT & RTO 613 and 6613 Models ............................116 RTLO-xx918 Model Splitter Cylinder Assembly .......189
7608LL with A-6915 Roadranger Valve ................... 119
7608LL Models ....................................................... 120
RTLO-xx610 Speed Air System ...............................123
Table of Contents
Engineering Reference Drawings

Basic Air System Drawings -
6610,8609, and 6609 ....................................... 191
07L, 08, 08L, 09, and 10-Speed Models .......... 192
07LL, 08LL, and 15 Speed Models .................. 193
Basic Air System Drawings - 707LL, 7/908LL, 7/909LL,
and 7/915 Speed Models ................................. 194
Basic Air System Drawings - 11613, 14613, and 15613
Speed Models ..................................................195
Basic Air System Drawings - 6613, and 7608LL Speed
Models .............................................................196
18 Speed Models Left-Hand Drive ................... 197
18 Speed Right-Hand Drive .............................198
General Information
How to use this Troubleshooting/Operation Guide

The purpose of this manual is to assist in the diagnosis and repair of your air system. Use this manual in conjunction with other
service literature produced by Eaton®, including Service Bulletins, Illustrated Parts Lists, Service Manuals, and OEM service ma-
terial.
This guide provides four functions

• Troubleshooting Guide: Designed to isolate and resolve air system problems.
• System Operation and Schematics: Designed to explain a complete air system's operation.
• System Components: Designed to explain each component's function and operation.
• Engineering Reference Drawings: Detailed drawings with optional parts and part numbers.
Information
General
1
For parts or service call us
Pro Gear & Transmission, Inc.
1 (877) 776-4600
(407) 872-1901
parts@eprogear.com
906 W. Gore St.
Orlando, FL 32805
General Information
Transmission Identification
2-Speed Auxiliary/3-Speed and 2x2 Auxiliary
Roadranger
Valve
Air Lines
Range Cylinder
Air Filter/
Slave Regulator
Valve
2-Speed
Auxiliary
Air Hoses
Roadranger
Valve
Air Lines
Range Cylinder
Air Filter/
Slave Regulator
Valve
3-Speed
&
2X2 Auxiliary
Air Hoses
Deep Reduction or
Splitter Cylinder
2
General Information
Combination Cylinder / RTLO-10 Speeds
Roadranger
Valve
Combination
Air Lines Combination Cylinder
Cylinder
Air Filter/
Slave Regulator
Valve
Information
General
Air Hoses
Roadranger
Valve
RTLO-10 Speeds
Air Lines Range Cylinder
Range
Actuator Air Filter/
Valve Regulator
CYL
NO
NC
Air Hose
Splitter Cylinder
3
General Information
Component Identification
Air Filter/ Regulators
Control Valves - Old Production

A-3546 TwoPositionSelector ThreePositionSelector
DeepReductionValve A-5010 A-5015

14651
D Blue
SHIFTONLY
WHENINLOW
OUT RANGE IN
DONOT
PRE-SELECT
8, 9, and10 Speeds 8LL, 15, 6613 Speeds
A-5510 A-4900 A-5013
Gray Red Gray
RTLO-10 Speeds RT/RTLO13 Speeds RTLO-18 Speeds
4
General Information
Control Valves - Current Production

A-6909 A-6915
Blue
8, 9, and 10 Speeds 8LL, 15, 6613 Speeds
A-6910 A-6913 A-6918
Information
General
Gray Red Gray
RTLO-10 Speeds RT/RTLO 13 Speeds RTLO-18 Speeds
Slave Valves
19470 - Obsolete A-4688 - Old A-5000 - Current
Range Valves
23545 23545 - old design 4303110 - latest design
NO
S
S
CYL
EXH
NC
EX
H
P
5
General Information
Lubricants and Sealants

The use of improper sealants and lubricants during air system assembly can cause improper component operation and severe
transmission damage.
The following are the recommended sealants and lubricants to be used when assembling air system components:
Name: Eaton® Fuller® Silicone Lubricant

Part #: 71203 (8 oz. container)—Fleet size
Part #: 71206 (4 cc container)—Single application
Where Used: All O-rings and mating surfaces
Name: Eaton® Fuller® Sealant

Where Used: Air fittings and threads
6
General Information
Suggested Test Fixtures

Note: For the Automated transmission models, refer to their Troubleshooting Guides for air system diagnostics.
Test Fixture for Range Cylinder
5/32" Air Line
0-100 PSI Gauge
84006 - 5/32" Push-To-Connect

to 1/8" NPTF
Information
General
12881 - 1/8" Tee 12769 - 1/8" Nipple
Test fixture for 1/8" Air lines
0-100 PSI Gauge 5/32" Air Line

to 1/8" NPTF
84502 - Elbow
85002 - Elbow Assembly

12881 - 1/8" Tee
83501 - Grip Nut

1/8" Air Line
83001 - Compression Sleeve
Test Fixture For 5/32" Air Line
0-100 PSI Gauge

5/32" Air Line

to 1/8" NPTF
85003 - Elbow
85003 - Elbow
12881 - 1/8" Tee
5/32" Air Line
7
Air System Troubleshooting
8, 9, 10, 11, 13, 15, and 18-Speed Troubleshooting

Symptom
• Air Leak at Shift Knob
• Air Leak at Slave Valve
• Air Leak from Transmission Breather or Transmission Case is Pressurized
• Air Leak at Splitter Cylinder Cover Exhaust Port
• No or Slow Range Shift into Low
• No or Slow Range Shift into High
• Range Shifts with Shift Lever in Gear
WARNING: Use care when removing air lines or checking for air flow from disconnected lines. High pressure air may
exhaust suddenly. Wear safety glasses. Exhaust all air pressure from system before removing air filter/regulator or com-
bination cylinder cover.
Note: During all testing, the vehicle air pressure must be greater than 90 PSI (620 kPa). If during testing the pressure falls below
90 PSI (620 kPa), make sure the transmission is in neutral, start the engine, and let the pressure build to governor cutoff.
After the pressure reaches the governor cutoff, continue testing. The pressure is critical if the vehicle is equipped with a
Pressure Protection Valve that would shut off the air supply to certain air circuits if the system pressure dropped below a
preset level.
IMPORTANT: Use the following air system troubleshooting procedures for part replacement only if the symptom can be dupli-
cated. If the problem is intermittent, parts that are not defective could be replaced.
Instructions
1. Start at “Procedures” for Step A.
2. Based on the “Result” of the procedure, go to the corresponding “What To Do Next”.
8
Procedure 1: Symptom - Air Leak at Shift Knob

Normal Operation:
• Aburst of air will beexhaustedfrom theshift knob when moving therangeselector from low to high. This is the air being
exhausted from the “P” air line.
• A burst of air will be exhausted from the shift knob when moving the splitter button rearward (shifting to low split). This is
the air being exhausted from the “SP” air line.
Possible Causes:
• Incorrectly attached air lines
• Internal leak in slave valve
• Internal leak at insert valve
Troubleshooting
Air System
• Internal leak at shift knob
Table 10 Air Leak at Shift Knob
Procedure Result What to do next
Step A Remove lower skirt on shift knob. Leak found. Repair leaking fitting or air line.
Check for leaking fitting at the
shift knob.
No leak found. Go to Step B.
Step B Check air lines to make sure all lines Air lines are not connected to the Connect lines
properly. are connected to the proper ports on proper ports.
the shift knob.
A.) Reversal of “S” and “P” lines will Air lines are connected to the proper Go to
Step C. result in a constant leak from the ex- ports.
haust when high range is
selected. B.) Reversal of the
H/L and “SP” lines will result
in a constant leak when the
splitter button is rearward.
Step C Move the range selector lever down Constant air flow from the “E” port.
Replace
knob. to low range. Check for constant air
flow from the exhaust “E” port.
No air flow from “E” port. Go to Step D.
Step D Move the range selector up to high Constant air is leaking from the “P” Repair or replace the
shift knob. range. Disconnect the small air line port or the “E” port.
connected to the “P” port of the
shift knob. Check for air flow
from the port and air line.
Air is coming out of the disconnect- 1. Verify that the air line is
connected ed air line. to the slave valve “p” port.
2. If properly connected, replace
the slave valve.
Air is not leaking from either port or Go to
Step E. disconnected air line.
9

Step E Reattach the air line to the “P” port. Air is flowing from the SP line. 1. Check to make sure the “SP”
line Move the range selector down to low is connected to the splitter
cylinder
range and move the splitter button
cover
. rearward. Disconnect line from the
“SP” port. Check for air flowing
from the SP port on the shift
knob.
2.If the line is properly
attached, check that the insert
valve (old style) is properly
installed (stem facing inward)
and that the insert valve bore is
not defective.
3. Replace the insert
valve.
Air is not flowing from the line. Repair or replace the shift knob.
10
Procedure 2: Symptom - Air Leak at Slave Valve

Normal Operation:
A momentary exhaust of air at the slave valve occurs during a range shift. The air from the low side of the range cylinder is
exhausted as air pressure is applied to the high range side. Likewise, air from the high range side of the piston is exhausted as air
pressure is applied to the low range side. The exhaust port is located at the slave valve to transmission mounting interface.
Possible Causes:
• Internal leak in range cylinder.
• Internal leak in slave valve.
Table 11 Air Leak at Slave Valve
Troubleshooting
Air System
Step A Confirm that air is leaking from the ex- Air is leaking from fitting or air line. Repair or replace fitting
or air line. haust port on the slave valve and not a
fitting or air line.
Air is definitely leaking from slave Go to
Step B. valve exhaust port.
Step B Move range selector down to select low Air is flowing from high range sup- Remove range cylinder
cover and range. ply port on range cylinder. repair leaking range piston or
pis- Remove the 1/4" I.D. rubber air line at ton seal. After
repair, check for
the high range supply port on the range proper range
operation. cylinder.
Feel for air flow from the open port
on the range cylinder.
Notice if the air leak at the slave
valve only occurs when the
transmission is in high range.
Repeat the above test but remove
the low range air hose and check
with high range selected.
No air flow from high range port. Repair or replace slave valve.
11
Procedure 3: Symptom - Air Leak from Transmission Breather or Transmission Case is

Pressurized
Normal Operation:
There should be no measurable air flow from the transmission breather.
Possible Causes:
• Leak at range yoke bar O-ring
• Leak at splitter yoke bar O-ring
Table 12 Air Leak from Transmission Breather or Transmission Case is Pressurized
Step A Listen for the air leak with the Leak is only in low and Remove range cylinder and
transmission shifted to both range. inspect for damaged range yoke
low and high range. bar, yoke bar O- ring, or range
cylinder. Repair as necessary.
Remove splitter cylinder. Inspect
Leak is in both for damaged splitter yoke bar, O-
low high range. ring, or cylinder. Repair as
necessary.
12
Procedure 4: Symptom - Air Leak at Splitter Cylinder Cover Exhaust Port

Normal Operation:
A burst of air will exhaust from this port when shifting into low split (the splitter button is moved rearward while in low range).
Possible Causes:
• Damaged/defective insert valve
• Leak past insert valve external O-rings
• Leak past splitter cylinder piston
Table 13 Air Leak at Splitter Cylinder Cover Exhaust Port
Step A Remove insert valve. Check for contamination, dam- Contamination or damage Repair or
Troubleshooting
Air System
(old style) replace as neces- aged seals, or sticky movement. Check the insert found.
sary.
valve bore in the splitter cylinder cover for
contamination or damage which would result
in leakage past the insert valve O-rings.
No contamination or damage Go to
Step B. found.
Step B Remove the splitter cylinder cover and piston. Contamination or damage Repair or
replace as neces- Check the piston bore for contamination or damage. found.
sary.
Check the piston seals for damage.
NOTE: Early production transmissions used a
paper gasket to seal the splitter cover to
cylinder, if necessary, replace this
configuration with the spool valve design
which uses an O-ring.
13
Procedure 5: Symptom - No or Slow Range Shift into Low

Normal Operation:
When the range selector on the shift knob is moved down to select low range, air pressure will flow through the shift knob to the
"P" port on the slave valve. The slave valve will direct air pressure through the low range 1/4" rubber hose to the range cylinder to
shift the range. There will be a brief burst of air at the slave valve as the high range side of the range piston exhausts. Likewise,
when high range is selected, the air pressure in the "P" will be exhausted at the shift knob. This will cause the slave valve to direct
air to the rear side of the range cylinder piston. The air pressure on the low range side will be exhausted at the slave valve.
Possible Causes:
• Incorrect air line hook up
• Insufficient air supply to transmission
• Damaged or defective air filter / regulator assembly
• Damaged or defective shift knob master valve
• Damaged or defective slave valve
• Damaged or defective range cylinder
• Damaged or defective range yoke or yoke bar
• Damaged or defective range synchronizer
• Damaged or defective gearing in auxiliary section of transmission
Table 14 No or Slow Range Shift into Low
Step A Place the shift lever in neutral. Constant air leak is detected. Go to the other
corresponding symp- Check for constant air leakage at the shift tom first. See
beginning of Air System
knob, slave valve, and transmission case Troubleshooting
section. breather when both low and high range
have been selected.
No constant leak is detected. Go to Step B.
Step B Place shift lever in neutral. Air flows from the low range Remove range cylinder cover
and re- Move range selector up to high range port. pair leaking range piston or piston
seal. position. At the rear of the transmission,
disconnect the 1/4" rubber air line
from the low range supply port on
the range cylinder. Check for air
flow from the low range port.
No air flow from low range Go to
step C. port.
Step C Check for air flow from the disconnected Air flows from disconnected Go to
step F. air line. air line.
No air flow from disconnect- Go to

step D. ed line.
14

Step D Install a 100 PSI air gauge in the discon- The gauge
read 0 PSI. Go to step F. nected air line end. With
the shift lever in
neutral, move the range selector
down to select low range. Observe
the gauge.
The gauge reads pressure but Replace the filter/regulator
and check is lower than 58 PSI or higher for proper range
operation.
than 63 PSI.
Troubleshooting
Air System
The gauge reads between 58 - Go to
step E. 63 PSI.
Step E Confirm that shift lever is still in neutral. Pressure rapidly changes be- Air system appears to be
operating Have an assistant move the range selec- tween 58-63 PSI and 0 at the satisfactory. Go
to step R.
tor up and down between low and high
gauge. range. Does the pressure
measured at
the gauge respond rapidly when
going from high to low?
Pressure does not change 1. Check for a plugged or dirty
filter in rapidly at gauge. the filter/regulator assembly.
2.Check for a pinched or
obstructed 1/4" rubber air line
between the filter/ regulator and
slave valve.
between the slave valve and the
test gauge.
4. If all are satisfactory, go to step
F.
Step F Place shift lever in neutral. Air flows from the discon- 1. Confirm that the air lines are
con- At the shift knob, move the range selec- nected line. nected to the correct ports at the
shift tion lever up to select high range. knob.
At the slave valve, remove the air
line from the "P" port. (should be
a black line). Check for air flow from
the disconnected line.
2. If the lines are correct, replace
the shift knob.
No air flow from the discon- Go to
step G. nected line.
Step G Check for air flow from the "P" port on Air flows from this port. Replace the slave
valve. the slave valve.
No air flow from this port. Go to step H.
15

Step H Place the shift lever in neutral. Install a The gauge responds slowly. 1. Check for a
restricted line between 100 PSI pressure gauge in line with the the shift knob and slave valve.
"P" line. Move the range selector
back and forth from low to high
range. The gauge should show
rapid pressure change.
2.If the lines are correct, replace
the shift knob.
3.Check for a plugged or dirty filter
in the filter / regulator assembly.
slave valve.
5.Check for a pinched or obstructed
air line between the slave valve
and the "S" port on the shift knob.
6. If all are good, replace the shift
knob. The gauge rapidly moves be- Go to step I.
tween 58-63 PSI and 0 PSI.
Step I If possible, leave air lines attached to Actuating plunger pin does 1. Remove actuating
plunger pin and slave valve. Unbolt the slave valve from not move freely. check for damage.
transmission side. Check for free
movement of the plunger pin
protruding from the case under the
slave valve. The pin should extract
when the transmission is shifted into
gear and retract when shifted into
neutral.
NOTE: If desired, the slave valve
can be actuated and tested while
unbolted from the transmission
case. The air lines, of course, must
remain attached.
2. Check for missing or broken
spring.
Actuating plunger pin moves Repair or replace slave valve
and check freely. for proper range operation.
16

Step R If air system has been tested and
found to operate satisfactory, the
auxiliary section must be removed
to inspect for mechanical problem.
Remove auxiliary section and
inspect for:
•Binding of range yoke bar or piston
•Damaged or defective range yoke
•Damaged or defective range
synchronizer
•Cracked countershaft weld
Troubleshooting
Air System
resulting in gear turning on shaft
sliding clutch
•Auxiliary section gearing out of time
17
Procedure 6: Symptom - No or Slow Range Shift into High

Normal Operation:
'P" port on the slave valve. The slave valve will direct air pressure through the low range 1/4" rubber supply hose to the range
cylinder to shift the range. There will be a brief burst of air at the slave valve as the high range side of the range piston exhausts.
Likewise, when high range is selected,the air pressure in the "P"will be exhausted at the shift knob. This will causethe slave valve to
direct air to the rear side of the range cylinder piston. Theair pressure on the low range side will be exhausted at the slave valve.
Possible Causes:
• Plugged filter
• Incorrect regulator pressure
Table 15 No or Slow Range Shift into High
Step A Place the shift lever in neutral. Constant air leak is detected. Go to the other
corresponding symp- Check for constant air leakage at the shift tom first. See
beginning of Air System
knob, slave valve, and transmission case Troubleshooting
section. breather when both low and high range
have been selected.
No constant leak is detected. Go to Step B.
Step B Place shift lever in neutral. Air flows from the high range Remove range cylinder cover
and re- Move range selector down to low range port. pair leaking range piston or piston
seal.
position. After repair, check for proper range
op-
At the transmission rear, disconnect the
eration
. 1/4" rubber air line from the range cylin-
der high range supply port.
Check for air flow from the cylinder
high range port.
No air flow from high range Go to
step C. port.
Step C Check for air flow from the disconnected Air flows from disconnected Go to
step F. air line. air line.
No air flow from disconnect- Go to
step D. ed line.
18

Step D Install a 100 PSI air gauge in the discon- The gauge
reads 0 PSI. Go to step F. nected air line end. With
the shift lever in
neutral, move the range selector
up to select high range. Observe
the gauge.
The gauge reads pressure but Replace the filter/regulator
and check is lower than 58 PSI or higher for proper range
operation.
than 63 PSI.
Troubleshooting
Air System
The gauge reads between 58 - Go to
step E. 63 PSI.
Step E Confirm that shift lever is still in neutral. Pressure rapidly changes be- Air system appears to be
operating Have an assistant move the range selec- tween 58-63 PSI and 0 at the satisfactory. Go
to step R.
tor up and down between low and high
gauge. range. Does the pressure
measured at
the gauge respond rapidly when
going from high to low.
Pressure does not change 1. Check for a plugged or dirty
filter in rapidly at gauge. the filter/regulator assembly.
1/ 4" rubber air line between the
filter/regulator and slave valve.
1/ 4" rubber air line between the
slave valve and the test gauge.
4. If all are satisfactory, go to step
F.
Step F Place shift lever in neutral. Air flows from the discon- 1. Confirm that the air lines are
con- At the shift knob, move the range selec- nected line. nected to the correct ports at the
shift tion lever up to select high range. knob.
At the slave valve, remove the air
line from the "P" port. (should be
black line). Check for air flow from
the disconnected line.
the shift knob.
No air flow from the discon- Go to
step G. nected line.
Step G Check for air coming out of the slave Air flows from this port. Replace the slave
valve. valve "P" port.
No air flow from this port. Go to step H.
19

Step H Place the shift lever in neutral. Install a The gauge responds slowly. 1. Check for a
restricted line between 100 PSI pressure gauge in line with the the shift knob and slave valve.
"P" line. Move the range selector
back and forth from low to high
range. The gauge should show
rapid pressure change.
2.Check for a restricted exhaust
port on the shift knob.
in the filter/regulator assembly.
slave valve.
air line between the slave valve
and the "S" port on the shift knob.
6. If all are good, replace the shift
knob. The gauge rapidly moves be- Go to step I.
tween 58-63 PSI and 0 PSI.
Step I If possible, leave air lines attached to Actuating plunger pin does 1. Remove actuating
plunger pin and slave valve. not move freely. check for damage.
Unbolt the slave valve from
transmission side.
Check for free movement of the
plunger pin protruding from the
case under the slave valve. The pin
should extract when the
transmission is shifted into gear and
retract when shifted into neutral.
If desired, the slave valve can be
actuated and tested while
unbolted from the transmission
case. The air lines, of course,
must remain attached.
spring.
Actuating plunger pin moves Repair or replace slave valve
and check freely. for proper range operation.
20

Step R If air system has been tested and
found to operate satisfactory, the
auxiliary section must be removed
to inspect for mechanical problem.
Remove auxiliary section and
inspect for:
synchronizer
•Cracked countershaft weld
Troubleshooting
Air System
resulting in gear turning on shaft
sliding clutch
•Auxiliary section gearing out of time
21
Procedure 8: Symptom - Range Shifts with Shift Lever in Gear

Normal Operation:
Range shifts should only occur when the shift lever is in neutral. Therange selector can be moved up or down while the shift lever is
in a gear position, but the shift will not occur until the shift lever is moved to neutral.
Possible Causes:
• Worn or missing actuating pin or air valve shaft
• Worn shift rail
Procedure:
If the range has been confirmed to shift with the shift lever in gear, unbolt the slave valve from the side of the transmission. Con-
firm that the actuating pin is present and that it is the proper part number for the corresponding slave valve. If correct, remove the
shift bar housing assembly and check for a worn or damaged air valve shaft or worn shift rails. Replace necessary parts.
22
RTLO 10-Speed Troubleshooting
Confirm Correct Components and Plumbing

• A-5454 Air Filter/Regulator on the range cylinder cover.
• 1/4 inch air hose from the air filter/regulator to the splitter cylinder cover (iron port).
• A red air line from the air filter/regulator to the tee in the range actuator valve "S" port on the shift bar housing.
• A red air line from the tee to the A-5510/A-6910 Roadranger valve "S" port.
• A black air line from the range actuator valve "P" port to the range cylinder.
• A blue air line from the Roadranger A-5510/A-6910 valve "SP" port to the splitter cylinder cover (brass port.)
Troubleshooting
Air System
WARNING: Prior to removing the air module, exhaust the air from it. Failure to exhaust the air module may result in
personal injury or damage to parts from the sudden release of air.
WARNING: Use care when removing the test port pipe plugs. If air pressure is present on the plug, it can become a
projectile during removal. When removing the “L” plug or “H” plug, pressure can be shut off by selecting the opposite
range mode. If removing the “F” plug, exhaust the air to the module inlet.
Red Air Line

Red Air Line
Black Air Line
CYL
NO
NC
A-5454
Air Filter/
Regulator
Blue Air Line
Air Hose
23
Air Filter/ Regulator Test
Figure 1 Figure 2
Table 1 Air Filter/Regulator Test

Step Procedure Result What to do next
A Place the transmission shift
lever in neutral.
B Start the engine and wait for
the air system pressure to
reach governor cut off (90 to
125 PSI.)
C Turn the engine off.
If at any time during testing
the truck's air pressure falls
below 90 PSI; restart the
engine, wait for air pressure to
reach governor pressure,
turn the engine off, and con-
tinue testing.
D Make sure the splitter control
button is rearward.
E Remove the two (2) screws on
the Roadranger valve cover
and pull the cover down.
F Disconnect the blue air line
from the "SP" port.
G Install the correct test fixture
for your air line size in the "SP"
line.
24
Table 1 Air Filter/Regulator Test

H Move the splitter control button Air pressure is outside the 58 to Replace the A-5454
Filter/Regulator. forward to overdrive. The air pres- 63 PSI range and the truck's air
sure gauge should read between system pressure is 90 to
125 PSI. 58 and 63 PSI.
Air pressure slowly comes up to Inspect the red air line from the
filter/regulator between 58 and 63 PSI. to the range actuator
Troubleshooting
Air System
valve and the red air line
from the range actuator valve to the A-
5510/A- 6910 Roadranger valve for
restrictions
R Remove the test fixture.
Assemble the Roadranger
valve.
25
Range System Test

If water or oil is found in an insert valve, remove both insert valves, the filter/regulator, the range cylinder cover, and the range
piston. Clean everything and replace the range piston O-rings and range cylinder cover gasket. Apply silicone grease to the ex-
ternal range piston O-ring and the insert valve O-rings. Assemble and test.
Note: If you replace or repair any parts, return to Step A after completion
Figure 3 Figure 4
Table 2 Range System Test

A Move the transmission shift
lever in neutral away from the
driver to the top gear rail position.
B Remove the black air line from
the range cylinder cover.
C Check for air flow out of the black air There is no air flow from the black air Go to
step D. line. line.
There is air flow. Check the range actuator valve
retaining bolts. Tighten any
loose bolts and check again for air
flow. If air flow continues,
remove the range actuator
valve retaining bracket bolts. Push
the button all the way into the
valve. If air flow continues,
replace the range actuator valve.
If air flow stops when the range
actuator valve is manually oper-
ated, remove the actuating pin
(lift it out with a magnet). Check
the pin for wear. It should be 1.029
to 1.032 inches long. If it is not,
replace the pin. If the pin length
is correct, refer to the service
manual for shift bar housing
26 inspection.

D Check for air flow from the range cyl- There is no air flow from the port.Go to step
E. inder port.
There is air flow. Remove the insert valve retaining

plug from the range cylinder cover
bottom. The insert valve will be
blown out of the cover. Clean the
insert valve, using compressed
Troubleshooting
Air System
air and apply silicone grease to
the external O-rings. As-
semble and check for air flow from
the port. If air flow persists,
replace the insert valve.
E Install the correct test fixture, for
your air line size, in the range
cylinder port.
F Move the transmission shift lever to- Air pressure rapidly comes up to be- Remove the test fixture
and connect ward the driver (center rail.) The air tween 58 and 63 PSI. the black air line to the
range cylinder. pressure should rapidly be between 58 If air pressure does rapidly come
up to
and 63 PSI. between 58 and 63 PSI, remove
the
actuating pin (lift it out with a
magnet). The pin should be
between 1.029 and
1.032 inches long. If it is not,
replace it. If the pin length is
correct, refer to the service
manual for shift bar housing
inspection.
Air pressure does not rapidly come up Inspect the black air line
from the to between 58 and 63 PSI.range actuator valve "CYL" port
for re-
strictions.If there are no
restrictions, remove the range
actuator valve retaining bolt.
Push the button all the way into
the valve and release it. If air
pressure does not rapidly come 27
up to between 58 and 63 PSI,
replace the range actuator valve.

G Listen for a range shift while moving There is no range shift and there is Remove the range
cylinder cover. If the transmission shift lever from neu- momentary exhaust from both insert the piston
is stuck from rust and con- tral to the top gear rail and back toward valves. tamination, remove the
piston, clean
the driver into the center rail. If there is the cylinder, replace the O-rings,
and
no range shift, move the transmission assemble. Clean the insert valve,
use
shift lever back and forth again and compressed air and apply
silicone
check for a momentary exhaust from grease to the external O-rings.
As-
the insert valve retaining plug in the semble and
test. range cylinder cover bottom.
There is no momentary exhaust. Remove the insert valve retaining
plug
from the range cylinder cover
bottom. The insert valve will be
blown out of the cover. Clean the
insert valve, use compressed air
and apply silicone grease to the
external O-rings. Assem- ble and
test. If there is still no momentary
exhaust, replace the insert valve.
There is momentary exhaust. Move the transmission shift lever
in
neutral back and forth again and
check for momentary exhaust from
the insert valve retaining plug on
the range cylinder cover side.
Continue to step I.
I Move the transmission shift lever in There is air flow. Remove the insert valve retaining
plug. neutral toward the driver to the center The insert valve will be blown
out of
rail. Check both insert valve retaining the cover. Clean the insert valve,
use
plugs for continuous air flow from the compressed air and apply
silicone
exhaust port. grease to the external O-rings.
As-
semble and check for air flow. If
air flow persists, replace the insert
valve. If air flow persists with a
new insert valve, remove the
range cylinder cover and inspect
the range piston O-rings for
damage or contamination and the
range piston for cracks.
There is no air flow. Go to step J.

J Move the transmission shift lever in There is air flow. Remove the insert valve retaining
28 plug. neutral away from the driver to the top The insert valve will be blown
out of
gear rail. Check both insert valve re- the cover. Clean the insert valve,

K With the transmission shift lever in Air flow stopped. Refer to the service manual and
re- neutral, toward the driver in the center place the range piston shaft to
range
rail, remove the breather or breather cylinder O-
ring. hole plug on the shift bar housing.
Check for air flow from the hole in
the shift bar housing. If there is
airflow move the transmission
shift lever in neutral, away from
the driver, to the top gear rail.
Troubleshooting
Air System
Air flow did not stop. Refer to the service manual and
replace the splitter piston shaft to
splitter cylinder O-ring.
R If the insert valves were not
removed and cleaned during the
test, remove them now (remove
the insert valve retaining plugs.)
The insert valves will be blown
out the cover. Clean the insert
valve, use compressed air and ap-
ply silicone grease to the external
"O" rings. Assemble and test.
The range portion of the test is
now complete.
29
Splitter System Test

If you replace or repair any parts , return to Step A after completion
Ffigure 1 Figure 2
Figure 3
Table 3 Splitter System Test

A Wipe off the area around the
insert valve exhaust port.
B Move the control button back

and forth several times to clear
the exhaust port.
C Make sure the control button is
rearward. Loosen the control
air line retaining nut at the
splitter cylinder.
30

D Remove the loosened control air line There is no air flow. Go to step
E. and check for air flow from the cylin-
der fitting.
There is air flow. Remove the insert valve and
clean using compressed air.
Then apply silicone grease to
the o-rings and recheck for
airflow.
E Install, between the control line
and the cylinder fitting, the correct
test fixture for your air line size.
Troubleshooting
Air System
F Move the control button forward. Air pressure rapidly changes to be- Go to next step G.
tween 58 and 63 PSI and the
truck's air system is 90 to 125
PSI.
Air pressure does not change to be- Inspect the control air line for
restric- tween 58 and 63 PSI and the truck's tions.
air system is 90 to 125 PSI.
G Check the insert valve exhaust port for No leakage is detected. Go to next step
H. leakage.
Leakage is detected. Go to Step L.
H Move the control button rearward and There is a shift. Go to next step
I. listen for the shift.
There is no shift or a delayed shift. Go to Step L.
I Check the exhaust port for leakage.No leakage is detected. Go to next step J.
Leakage is detected. Go to Step L.

J Move the control button forward and There is a shift. Go to next step
K. listen for the shift.
There is no shift or a delayed shift. Go to Step L.
K If there is air pressure at the
control line, move the control
button rearward and remove the
test fixture. Connect the control
line to the cylinder.
L Remove the insert valve retaining There is no water and/or oil blown out. Go to
next step M. plug. The insert valve will be blown
out of the cover (note valve
orienta- tion.)
Water and/or oil is blown out. Remove the cylinder cover and
clean
the cover and cylinder. Replace
the cylinder cover gasket with a
new gasket. Install cover.
M Clean insert valve using
compressed air.
31

N Install the insert valve, as noted
in Step L, and replace the
retaining plug.
O Check the insert valve exhaust port for No leakage is Go to next step P.
detected. leakage.
Leakage is detected. Replace the insert valve.
P Move the control button forward and There is a Go to next step Q.

shift. listen for the shift.
There is no shift or a delayed shift. Replace the insert valve.
Q Check the insert valve exhaust port for No leakage is Go to next step R.
detected. leakage.
Leakage is detected. Replace the insert valve.
R Move the control button rearward and There is a Go to next step S.
shift. listen for the shift
There is no shift or a delayed shift. Replace the insert valve.
S Check the insert valve exhaust port for No leakage is Go to next step T.
detected. leakage.
Leakage is detected. Disassemble (see service
manual) and inspect
splitter/reduction piston O-ring
and piston to shaft seal.
T Move the control button forward and There is a Go to next step V.
shift. listen for the shift.
There is no shift or a delayed shift. Disassemble (see service
manual) and inspect
splitter/reduction piston O-ring
and piston to shaft seal.
V The air system test procedure is
now complete and the air system
has been confirmed to be
operating correctly. If
performance irregularities
persist, they are not caused by
the air system.
32
Combination Cylinder Troubleshooting

The symptoms listed below are covered on the following pages. Before beginning any of those troubleshooting procedures, place
the transmission in neutral and move the range selection lever from low to high. Listen for any constant air leak from the shift
knob, air module base (exhaust), or transmission breather. If a constant leak is heard, go to that particular leak troubleshooting
procedure first.
If you do not see the symptom you need to correct, refer to the General Troubleshooting chart.
Symptom
• Air Leak from Air Module Base (Exhaust Leak)
• No or Slow Range Shift into High (Shift into low range is good)
• No or Slow Range Shift into Low (Shift into high range is good)
Troubleshooting
Air System
• Constant Air Leak from Shift Knob
• Range Shifts in Gear
Note: Use the air system troubleshooting procedures for part replacement only if the symptom can be duplicated. If the problem is
intermittent, parts that are not defective could be replaced.
90 PSI (620 kPa), make sure the transmission is in neutral, start the engine and let the pressure build to governor cutoff.
After the pressure reaches the governor cutoff, continue testing. The pressure is critical if the vehicle is equipped with a ve-
hicle air system Pressure Protection Valve that would shut off the air supply to certain air circuits if the system pressure
dropped below a preset level.
Note: A 0-150 PSI (0-1034 kPa) air gauge with a 1/16” male pipe thread fitting attachment is required for some of the test proce-
dures.
33
Procedure 1: Symptom - Air Leak at Shift Knob

Normal operation:
Aburst of air will be exhaustedfrom the shift knob when moving the rangeselector from low to high. This is the air being exhaust-
ed from the "P" air line.
A burst of air will be exhausted from the shift knob when moving thedeep reduction button rearward (shifting out of deep reduc-
tion).This is the air being exhausted from the “SP” air line.
Possible causes:
• Incorrectly attached air lines
• Internal leak in slave valve
• Internal leak at insert valve
• Internal leak at shift knob
Step A Remove lower skirt on shift knob. Check Leak found. Repair leaking fitting or
air
for leaking fitting at the shift knob. line.
No leak found. Go to step B.
Step B Check air lines to make sure all lines are Air lines are not connected to the proper Connect
lines properly. connected to the proper ports on the shift ports.
knob. Reversal of “S” and “P” lines
will result in a constant leak from the
exhaust when high range is
selected. Reversal of the H/L and
“SP” lines will result in a constant
leak when the deep reduction but-
ton is rearward.
Air lines are connected to proper ports. Go to step C.
Step C Move the range selector lever down to Constant air flow from “E” port. Replace knob.
Low range. Check for constant air
flow from the exhaust “E” port.
No air flow from “E” port. Go to Step D.
Step D Move the range selector up to high range. Constant air is leaking from the “P” port Repair or replace
the shift Disconnect the small air line connected or the “E” port. knob.
to the “P” port of the shift knob.
Check for air flow from the port and
air line.
Air is coming out of the disconnected 1. Verify that the air
line is air line. connected to the slave
valve
“p” port.
2. If properly connected,
replace the slave valve.
Air is not leaking from either port or dis- Go to
Step E. connected air line.
34

Step E Reattach the air line to the “P” port. Move Air is flowing from the SP line. 1. Check to make sure
the the range selector down to low range and “SP” line is connected to
the
move the deep reduction button rear- deep reduction cylinder
cov-
ward. Disconnect the air line from the
er
. “SP” port. Check for air flowing from the
SP line.
2.If the line is properly
attached, check that the
Troubleshooting
Air System
insert valve is properly
installed (stem facing
inward) and that the
insert valve bore is not
defective.
3. Replace the insert valve.
Air is not flowing from the line. Repair or replace the
shift-
knob.
35
Procedure 2: Symptom - Air Leak at Slave Valve

Normal operation:
A momentary exhaust of air at the slave valve occurs during a range shift. The air from the low side of the range cylinder is ex-
hausted as air pressure is applied to the high range side. Likewise, air from the high range side of the piston is exhausted as air
pressure is applied to the low range side. The exhaust port is located at the slave valve to transmission mounting interface.
Possible Causes:
• Internal leak in range cylinder
• Internal leak in slave valve.
Table 2 Air Leak at Slave Valve
Step A Confirm that air is leaking from the Air is leaking from fitting or air line. Repair or replace fitting
or air line. exhaust port on the slave valve and
not a fitting or air line.
Air is definitely leaking from slave Go to
Step B. valve exhaust port.
Step B Move range selector down to select Air is flowing from high range sup- Remove range cylinder
cover and re- low range. Remove the 1/4” I.D. ply port on range cylinder. pair leaking range
piston or piston seal. rubber air line at the high range sup- After repair, check for proper range
op-
ply port on the range cylinder. Feel
eration
. for air flow from the open port on
the range cylinder. Note: If the
air leak at the slave valve only
occurs when the transmission
is in high range, repeat the
above test, but remove the
low range air hose and check
with high range selected.
No air flow from high range port. Repair or replace slave valve.
36
Procedure 3: Symptom - Air Leak from Transmission Breather or Transmission Case is

Pressurized
Normal Operation:
There should be no measurable air flow from the transmission breather.
Possible causes:
• Leak at range yoke bar O-ring
• Leak at deep reduction yoke bar O-ring
Table 3 Air Leak from Transmission Breather or Transmission Case is Pressurized
Step A Listen for the air leak with the trans- Leak is only in low range. Remove range cylinder and
Troubleshooting
Air System
inspect mission shifted to both low and high for damaged range yoke bar,
yoke bar
range. O-ring, or range cylinder. Repair
as
necessary.
Leak is in both low and high range. Remove deep reduction cylinder.
In-
spect for damaged deep
reduction yoke bar, O-ring, or
cylinder. Repair as necessary.
37
Procedure 4: Symptom: Air Leak at Deep Reduction Cylinder Cover Exhaust Port
Normal operation:
A burst of air will exhaust from this port when shifting into deep reduction (the deep reduction button is moved forward while in
low range).
Possible causes:
• Damaged/defective insert valve
• Leak past insert valve external O-rings
• Leak past deep reduction cylinder piston
Table 4 Air Leak at Deep Reduction Cylinder Cover Exhaust Port
Step A Remove insert valve. Check for con- Contamination or Repair or replace as necessary.
damage found. tamination, damaged seals, or sticky
movement. Check the insert
valve bore in the deep
reduction cylinder cover for
contamination or damage which
would result in leakage past
the insert valve O-rings.
Go to step B.
No contamination or damage
found.
Step B Remove the deep reduction cylinder Contamination or damage Repair or replace as necessary.
found. cover and piston. Check the piston
bore for contamination or
damage. Check the piston seals
for damage. NOTE: Early
production transmissions used
a paper gasket to seal the piston
to the yoke bar, if necessary,
replace this configuration with
the current design which uses
an O- ring.
38
Procedure 5: Symptom - No or Slow Range Shift into Low

Normal Operation:
When the range selector on the shift knob is moved down to select low range, air pressure will flow through the shift knob to the ‘P
port on the slave valve. The slave valve will direct air pressure through the low range 1/4” rubber hose to the range cylinder to shift
the range. There will be a brief burst of air at the slave valve as the high range side of the range piston exhausts. Likewise, when
high range is selected, the air pressure in the “P” will be exhausted at the shift knob. This will cause the slave valve to direct air to
the rear side of the range cylinder piston. The air pressure on the low range side will be exhausted at the slave valve.
Possible Causes:
• Damaged or defective air filter / regulator assembly
Troubleshooting
Air System
Step A Place the shift lever in neutral. Constant air leak is detected. Go to the other corresponding
Check for constant air leakage symptom first. See beginning of
at the shift knob, slave valve, Air System Troubleshooting
and transmission case breather section.
when both low and high range
have been selected.
No constant leak is detected.
Go to step B.
Step B Place shift lever in neutral. Air flows from the low range port. Remove range cylinder cover
Move range selector up to high and repair leaking range
range position. At the rear of piston or piston seal.
the transmission, disconnect the
1/4” rubber air line from the low
range supply port on the range
cylinder. Check for air flow
from the low range port.
No air flow from low range port. Go to step C.
Step C Check for air flow from the Air flows from disconnected air Go to step F.
disconnected air line. line.
Go to step D.
No air flow from disconnected
line.
39

Step D Install a 100 PSI air gauge in the dis- The gauge read 0 PSI. Go to step
F. connected air line end. With the shift
lever in neutral, move the range
selector down to select low
range and observe the gauge.
The gauge reads pressure but is low- Replace the filter/regulator

and check er than 58 PSI or higher than 63 PSI. for proper range
operation.
The gauge reads between 58 - 63
Go to step
E. PSI.
Step E Confirm that shift lever is still in neu- Pressure rapidly changes between Air system appears to be
operating tral. Have an assistant move the 58-63 PSI and 0 at the gauge. satisfactory. Go to
step R.
range selector up and down
between low and high range.
Does the pressure measured
at the gauge respond rapidly
when going from high to low.
Pressure does not change rapidly at 1. Check for a plugged or dirty
filter in gauge. thefilter/regulator assembly.
obstructed 1/4” rubber air line
slave valve.
obstructed 1/4” rubber air line
test gauge.
4. If all are satisfactory, go to
step F.
Step F Place shift lever in neutral. At the Air flows from the disconnected line. 1. Confirm that the air lines
are con- shift knob, move the range selection nected to the correct ports at the
shift
lever up to select high range. At the
knob
. slave valve, remove the air line from
the “P” port (should be black
line). Check for air flow from the
disconnected line.
the shift knob.
No air flow from the disconnected Go to
step G. line.
Step G Check for air flow from the “P” por- Air flows from this port. Replace the slave
valve. tion the slave valve.
40 No air flow from this port. Continue to step H.

Step H Place the shift lever in neutral. Install The gauge responds slowly. 1. Check for a restricted line
between a 100 PSI pressure gauge in line with the shift knob andslave valve.
the “P” line. Move the range
selector back and forth from
low to high range. The gauge
should show rapid pressure
change.
Troubleshooting
Air System
in the filter / regulator assembly.
obstructed 1/ 4” rubber air line
slave valve.
obstructed air line between the
slave valve and the “S” port on the
shift knob.
6.If all are good, replace the
shift knob.
The gauge rapidly moves between Go to
step I. 58-63 PSI and 0 PSI.
Step I If possible, leave air lines attached to Actuating plunger pin does not move 1. Remove actuating
plunger pin and slave valve. Unbolt the slave valve freely. check for damage.
from transmission side. Check
for free movement of the
plunger pin protruding from the
case under the slave valve. The
pin should extract when the
transmission is shifted into gear
and retract when shifted into
neutral.
spring.
Actuating plunger pin moves freely. Repair or replace
slave valve and
check for proper range operation.
41

Step R If air system has been tested
and found to operate
satisfactory, the auxiliary
section must be removed to
inspect for mechanical problem.
Re- move auxiliary section and
inspect for:
synchronizer
•Cracked c/s weld resulting in
gear turning on
shaft
sliding clutch
•Auxiliary section gearing out
of time.
42
Procedure 6: Symptom - No or Slow Range Shift into High

Normal Operation:
‘P” port on the slave valve. The slave valve will direct air pressure through the low range 1/4” rubber supply hose to the range
cylinder to shift the range. There will be a brief burst of air at the slave valve as the high range side of the range piston exhausts.
Likewise, when high range is selected, theair pressure in the “P” will be exhausted at the shift knob. This will cause the slave valve to
direct air to the rear side of the range cylinder piston. Theair pressure on the low range side will be exhausted at the slave valve.
Possible Causes:
• Plugged filter
Troubleshooting
Air System
• Incorrect regulator pressure
Step A Place the shift lever in neutral. Constant air leak is detected. Go to the above
Check for constant air leakage corresponding symptom first.
at the shift knob, slave valve, See beginning of Air System
and transmission case breather Troubleshooting section.
when both low and high range
have been selected.
No constant leak is detected.
Go to step B.
Step B Place shift lever in neutral. Air flows from the high range port. Remove range cylinder cover
Move range selector down to low and repair leaking range
range position. At the piston or piston seal. After
transmission rear, disconnect repair, check for proper range
the 1/4” rubber air line from the operation.
range cylinder high range supply
port. Check for air flow from the
cylinder high range port.
No air flow from high range port.
Go to step C.
Step C Check for air flow from the Air flows from disconnected air Go to step F.
disconnected air line. line.
No air flows from disconnected Go to step D.

line.
43

Step D Install a 100 PSI air gauge in the dis- The gauge reads 0 PSI. Go to step
F. connected air line end. With the shift
lever in neutral, move the range
selector up to select high
range. Observe the gauge.
The gauge reads pressure but is low- Replace the filter/regulator
and check er than 58 PSI or higher than 63 PSI. for proper range
operation.
The gauge reads between 58-63 PSI. Go to Step E.
Step E Confirm that a shift lever is still in Pressure rapidly changes between Air system appears to be
operating neutral. Have an assistant move the 58-63 PSI and O at the gauge. satisfactory. Go to
Step R.
range selector up and down
between low and high range.
Does the pressure measured
at the gauge respond rapidly
when going from low to high to
low.
Pressure does not respond rapidly at 1. Check for a plugged or dirty
filter in gauge. thefilter/regulatorassembly.
slave valve.
test gauge.
4. If all are satisfactory, Go to
Step F.
Step F Place shift lever in neutral. At the shift Air flows from the disconnected line. 1. Confirm proper air line
hook-up at knob, move the range selector up to the shift knob.
select high range. At the slave
valve, remove the air line from
the "P" port (should be black
line). Check for air flow from the
disconnected line.
2. If correct hook-up, replace the
shift knob.
No air flow from the disconnected Go to
Step G. line.
Step G Check for air coming out of the slave Air flows from this port. Replace the slave
valve. valve "P" port.
No air flow from this port. Continue to Step H.
44

Step H Place the shift lever in neutral. Install The gauge responds slowly. 1. Check for a restricted line
between a 100 PSI pressure gauge in line with theshiftknobandslavevalve.
the "P" line end. Move the range
selection lever back and forth
from low to high range. The
gauge should show rapid
pressure change.
3.Check for a plugged or dirty
Troubleshooting
Air System
filter in the filter/regulator
assembly.
slave valve.
obstructed air line between the
slave valve and the "S" port on
the shift knob.
6.If all are good, replace the
shift knob.
The gauge rapidly moves between Go to
Step I. 58-63 PSI and 0 PSI.
Step I If possible, leave air lines attached to Actuating plunger pin does not move 1. Remove actuating
plunger pin and slave valve. Unbolt the slave valve freely. check for damage.
from the transmission side. Check
for free movement of the plunger
pin protruding from the case
under the slave valve. The pin
should extract when the
transmission is shifted into gear
and retract when shifted into
neutral. NOTE: If desired, the
slave valve can be actuated and
tested while unbolted from the
transmission case. The air lines,
of course, must remain at-
tached.
2. Check for missing or
broken spring.
Actuating plunger pin moves freely. Repair or replace
slave valve and
check for proper range operation.
45

Step R If air system has been tested
and found to operate
satisfactory, the auxiliary section
must be removed to inspect for
mechanical problem. Re- move
auxiliary section and inspect
for:
synchronizer
•Cracked c/s weld resulting in
gear turning on
shaft
sliding clutch
•Auxiliary section gearing out of time.
46
Procedure 7: Symptom - No or Slow Shift into Deep Reduction

Normal Operation:
When the deep reduction button is moved forward to select deep reduction, air pressure is supplied through the “SP” air line to
the insert valve signal port. This air pressure causes the insert valve to exhaust the air pressure on the rear of the deep reduction
piston and the piston moves rearward. A burst of air occurs at the deep reduction cylinder exhaust port as this air is exhausted
from the piston back side. A burst of air also occurs at the shift knob when the deep reduction button is moved rearward. This is
the signal air being exhausted out of the “SP” line.
Possible causes:
• Incorrect air line hook up, Plugged filter.
• Incorrect regulator pressure. Insufficient air supply to transmission.
• Damaged or defective shift knob master valve.
Troubleshooting
Air System
• Damaged or defective deep reduction insert valve.
• Damaged or defective deep reduction piston or cylinder.
• Damaged or defective deep reduction yoke bar or yoke.
• Damaged or defective deep reduction sliding clutch or gearing.
Note: Before completing the following troubleshooting procedure, move the deep reduction button both rearward and forward an
check for constant exhaust air at either the shift knob or deep reduction cylinder exhaust port. If a constant leak is noticed,
go to that troubleshooting procedure first. In addition, confirm that the low and high range shifts are occurring properly. If
not, go to the appropriate range shift troubleshooting procedure before completing the following procedure.
Table 7 No or Slow Shift into Deep Reduction
Step A Move range selector down to select Air flows from the disconnected line. Go
to Step K. low range. Move the deep reduction
button rearward. At the deep
reduction cylinder on the
transmission back, remove the
small air line which provides the
signal to the insert valve (SP
line). Make sure this line was con-
nected to the proper port location
on the cylinder cover. Check for
air flow from the line.
No air flow from disconnected line. Go to Step B.
Step B Connect a 100 PSI pressure gauge to Gauge reads 0 PSI. Go to Step
F. the disconnected signal port line.
Move the deep reduction button
forward. Read the pressure on
the gauge.
Gauge reads pressure, but is lower than Replace filter / regulator
assembly. 58 PSI or higher than 63 PSI.
Gauge reads between 58 PSI and 63 Go to
Step C. PSI.
47

Step C Have an assistant move the deep re- Pressure rapidly changes between 58- Go
to Step D. duction button forward and rearward. 63 PSI and 0 PSI at the gauge.
Observe the pressure gauge.
Pressure does not respond rapidly at Go to

Step F. gauge.
Step D Remove the insert valve. NOTE: After Insert valve is contaminated, sticking, Replace insert valve,
reconnect air the insert valve plug has been re- or damaged. line, and check if deep
reduction
moved, cover the opening with a shop shifts
normally. rag and apply shop air to the signal
line port to blow the insert valve
out of it’s bore. Catch the valve
with the shop rag. If the vehicle
air pressure is still present,
constant air flow should be
blowing out of the insert valve
bore. Inspect the insert valve for
contamination or damage.
Make sure the small piston inside
the valve can freely move 1/32”.
Insert valve is clean and small internal Go to
step E. piston moves freely.
Step E Remove the deep reduction cylinder Deep reduction cylinder bore or piston Repair as necessary,
replace insert cover and deep reduction piston. In- is contaminated or damaged. valve
and air line. Check if deep re- spect piston and bore for contamina- duction shifts normally
tion or damage.
Deep reduction cylinder bore or piston 1. Remove deep reduction
cylinder is in good condition. assembly. Inspect for
contamination or damage causing deep reduc-
tion yoke bar to bind in
cylinder. Repair as necessary.
2. Remove auxiliary section
and inspect deep reduction
yoke, sliding clutch, and
gearing for damage which
would prevent deep reduc-
tion shift. Repair as necessary.
48

Step F At the shift knob, remove the two Air flows from “SP” Replace shift knob.
port. screws attaching the lower cover, and
slide the lower cover down to
access the fittings. Confirm that
the air lines are connected to
the proper ports. Make sure the
shift lever is in neutral. Move the
range selector down to select
low range, and move the deep re-
duction button rearward.
Disconnect the air line connected
Troubleshooting
Air System
to the “SP” port. Check for air flow
Go to Step G.
from the “SP” port.
No air flow from “SP” port.
Step G Move deep reduction button forward. Air flows 1.Check for proper air line
from “SP” port. Check for air flow from “SP” port. connec- tion from “SP” port on
shift knob to “SP port on deep
reduction cylinder.
2.Check for obstruction in “SP”
air line or fittings.
3.If clear, reconnect the air line
at the shift knob, go to step A.
No air flow from “SP” port. Go to step H.
Step H Disconnect air line H/L port on shift Air flows from Replace shift knob.
disconnected line. knob. Check for air flow from the dis-
connected line.
No air flow from 1.Check to make sure that the
disconnected line. shift lever is in neutral, the
range selector is down in low
range and the “H/ L” line is
properly connected to the
lowrangehoseattheslavevalve.
2.If no air pressure is available
on low range hose, perform low
range shift troubleshooting
procedure to correct this
problem.
49
Procedure 8: Symptom - Range Shifts with Shift Lever in Gear

Normal Operation:
Range shift should only occur when the shift lever is in neutral. The range selector can be moved up or down while the shift lever is
in a gear position, but the shift will not occur until the shift lever is moved to neutral.
Possible Causes:
• Worn or missing actuating pin or air valve shaft.
• Worn shift rail
Procedure:
If the range has been confirmed to shift with the shift lever in gear, unbolt the slave valve from the side of the transmission. Con-
firm that the actuating pin is present and that it is the proper P/N for the corresponding slave valve. If correct, remove the shift
bar housing assembly and check for a worn or damaged air valve shaft or worn shift rails. Replace necessary parts.
50
FR-1X210 Troubleshooting
The symptoms listed below are covered on the following pages. Before beginning any of those troubleshooting procedures, place
the transmission in neutral and move the range selection lever from low to high. Listen for any constant air leak from the shift
knob, air module base (exhaust), or transmission breather. If a constant leak is heard, go to that particular leak troubleshooting
procedure first. If you do not see the symptom you need to correct, refer to the General Troubleshooting chart at the beginning of
this section.
Symptom
• Air leak from Air Module Base (Exhaust leak)
• No or Slow Range Shift into High (Shift into low range is good)
• No or Slow Range Shift into Low (Shift into high range is good)
Troubleshooting
Air System
• Constant Air Leak from Shift Knob
• Range Shifts While Transmission is in Gear
Note: Use the air system troubleshooting procedures for part replacement only if the symptom can be duplicated. If the problem is
intermittent, parts that are not defective could be replaced.
90 PSI (620 kPa), make sure the transmission is in neutral, start the engine and let the pressure build to governor cutoff.
After the pressure reaches the governor cutoff, continue testing. The pressure is critical if the vehicle is equipped with a Pres-
sure Protection Valve that would shut off the air supply to certain air circuits if the system pressure dropped below a preset
level.
Note: A 0-150 PSI (0-1034 kPa) air gauge with a 1/16" male pipe thread fitting attachment is required for some of the test proce-
dures.
Note: Regulated air pressure is 75 to 85 PSI (517-586 kPa).
51
Air System Nomenclature

Figures 4-1 through 4-3 below show the air module, shift knob, and range alignment lock cover (earlier models) with their com-
ponents labeled. These are the primary components used during troubleshooting. If necessary, refer to these figures while trou-
bleshooting the air system.
52
Figure 4-4 below shows how to isolate the air module. If necessary, refer to this figure when isolating the air module.
Troubleshooting
Air System
Figure 4-4 Air Module Isolation
The table below shows which air lines connect to which ports on the shift knob and air module. If necessary, refer to this table
when connecting the air lines.
Port on Knob Port on Air Module Air Line Color (Typical)
S S Red
P P Black
53
Air System Symptom - Air Leak from Module Base (Exhaust)

Short bursts of air leakage from the module base (exhaust) are normal as the range system is shifted. The module base is defined as
both the interface of the module cover and module base and the extreme underside of the module. Leakage is a problem when it is
audible and constant. Air leakage from the module base may result from either a defective air module or a defective range
piston. The following procedure will identify the defective component.
Test Procedure:
1.Check for air leakage from the module base (exhaust) in each of the four following conditions. (Make sure the range is shifted
when the shift lever is in neutral.)
a. Range selection lever in Low and shift lever in neutral.
b. Range selection lever in Low and shift lever in gear.
c. Range selection lever in High and shift lever in neutral.
d. Range selection lever in High and shift lever in gear.
Record the findings (constant leak or no leak) in the following table.

Range Selector in LOW Range Selector in HIGH
Lever in Neutral
Lever in Gear
2. If the information you recorded at step 1 matches one of the following tables, replace the air module. If your table does not
match either of the tables, it will be necessary to isolate and test the air module separately, continue to step 3.
Lever in Neutral No Leak Constant Leak
Lever in Gear No Leak Constant Leak

Lever in Neutral Constant Leak Constant Leak
Lever in Gear Constant Leak Constant Leak
WARNING: Failure to exhaust the air pressure may cause personal injury or damage to parts.
3.Exhaust the air pressure from the air module. To do so, the vehicle’s air tanks may need to be exhausted.
4.Leaving all air lines connected to the module, remove the four capscrews attaching the air module to the shift bar housing. Lift the
air module and tilt it to gain access to the two air holes at the underside on the rear capscrew location. Do not damage or lose the
two o-rings used to seal the holes.
5.Block off the air ports on the underside of the module. Use a piece of gasket material or rubber material to seal the bottom of
the module as shown in Figure 4-1 under “Air System Nomenclature”.
6.Repressurize the air module with an inlet supply pressure of over 90 PSI (620 kPa). To repressurize the air module, the vehicle
may need to be started and air pressure allowed to build up.
7.Check for air leakage in both high and low range. If air continues to leak constantly from the exhaust, the air module is defective. If
air does not leak, a range cylinder piston or piston seal failure has occurred. Remove the shift bar housing to gain access to the
range shift cylinder.
54
Air System Symptom - No or Slow Range Shift into High (Shift into Low Range is Good)
This transmission contains a SynchroSaver feature to protect the high range synchronizer. When high range is selected and a front
section gear is engaged, air pressure is supplied to both sides of the range piston, which reduces synchronizer force. Therefore, if
the driver engages a front section gear before the high range synchronizer engages, the high range synchronizer will remain in
neutral. When a front section gear engages before the synchronizer shift completes, the driver must shift the lever back to neutral to
allow the high range synchronizer to complete its shift. Once the range shift is complete, the driver can complete the front section
shift.
If the high range synchronizer hangs up or is slow to synchronize, the front section may engage first. The driver complaint will be
that the transmission “neutralizes” on a shift to high range. If this condition occurs, perform the following test of the air system to
eliminate the air system as the source of the problem. If the air system performs properly, then the problem is internal to the
transmission range synchronizer system.
Troubleshooting
Air System
Note: The driver must preselect all range shifts.
Note: If a capscrew or stud is installed too far into the right side (air module side) rear support hole, the fastener can extend too
far into the transmission. The fastener may contact the range yoke and bind the range synchronizer assembly during the
range shift.
Test Procedure
1. Check the shift knob operation.
On the shift knob, remove the screws holding the plastic skirt. Slide the skirt down and out of the way. Move the range selection
lever up into high range. Disconnect the black line connected to the “P” port on the knob.
Question Result What to do next
Does air come out of the “P” port on Yes Repair or replace the knob.
the knob?
No Reconnect the air line to the knob, and
continue to the next step.
2. Test the regulator pressure. (Regulator pressure should be between 75 and 85 PSI (517-586 kPa).)
Reconnect the “P” line at the shift knob. Locate the two small pipe plugs on the rear of the air module. One is labeled “H" and the
other “L”. (See Figure 4-1 “Air System Nomenclature”). Install a 0-150 PSI (0-1034 kPa) air gauge in the port marked “H.”
Note: Prior to removing the pipe plug, turn off the air flow by flipping the range selector down into the low range position. The
transmission must be in neutral.
Move the range selector up to the high range position and record the pressure on the gauge. Match the pressure to one of those
on the chart on the next page, and follow the corresponding instructions.
Question Result What to do Next
What is the air pressure 75-85 PSI (517-586 Continue to the next step.
at the “H” port? kPa)
(to specification)
55

Less than 75 PSI On the top of the air module, remove the test port pipe plug
for fil- (517 kPa) tered vehicle air. (Marked “F” as shown in
Figure 4-1.)
Install the test gauge in the “F” port, and check the pressure.
If the pressure is less than 90 PSI (620 kPa), repair the
vehicle air system to achieve full vehicle air pressure at the
air module inlet, and repeat the test. If the pressures greater
than 90 PSI (620 kPa) and no external air leaks were
detected from the air module, shift knob, or transmission,
replace the air module.
Greater than 85 PSI Replace the air
module. (586 kPA)
3. Check the spool valve function.
With the shift lever in neutral, move the range selector from low to high several times. Answer the question on the chart below,
and follow the instructions corresponding to the result.
Does the gauge rapidly go from Yes Air system performs Go to
75- 85 PSI (517-586 kPa) in properly. step 5.
High to 0 PSI in Low?
No Continue to the next step.
4. Isolate and test the air module. Refer to Figure 4-1 “Air System Nomenclature” to see an example of an isolated air module.
WARNING: Failure to exhaust the air module may cause personal injury or damage to parts due to the rapid release of air.
Exhaust the air pressure from the air module. To do so, the vehicle air tanks may need to be exhausted. Remove the four capscrews
attaching the air module to the shift bar housing. Lift the air module and tilt it to gain access to the two air holes at the underside at
the rear capscrew location. Do not damage or lose the two O-rings used to seal the holes. Block off the air ports on the underside of
the module. Repressurize the air module with an inlet supply pressure of over 90 PSI (620 kPa). To repressurize the air module, the
vehicle may need to be started and the air pressure allowed to build. With the shift lever in neutral and the gauge still in the “H”
test port, move the range selection lever from high to low (down) position.
Answer the question on the chart below, and follow the instructions corresponding to the result.
Does the gauge rapidly go from Yes Continue to the next step.
75-85 PSI (517-586 kPa) in High
to) PSI in Low?
No Replace the air module.
5. Install the air module, and remove the range alignment lock cover (Figure 4-3). Then move the range selection lever from the
low to high (up) position. If range now shifts properly, inspect and correct the source of binding between lock cover and range
yoke bar.
Note: To prevent binding, range alignment lock cover capscrews must be tightened when transmission is in Low Range. If the
transmission does not shift properly, continue to Step 6.
56
6.Remove the auxiliary section and inspect the range synchronizer, range yoke, range yoke bar, range yoke snap ring, range slid-
ing clutch, and mating gears for excessive wear, binding, or damage. Repair as necessary. If these components do not need repair,
continue to Step 7.
7.Remove the shift bar housing and inspect the range piston, piston bar, and cylinder for excessive wear, binding, or damage.
Repair as necessary.
Troubleshooting
Air System
57
Air System Symptom - No or Slow Range Shift into Low (Shift into High is Good)
Test Procedure:
1. Check the shift knob operation.
On the shift knob, remove the two screws holding the plastic skirt. Slide the skirt down and out of the way. Move the range selector
up into high range. Disconnect the black line connected to the “P” port on the knob. Move the range selector down into low. An-
swer the question on the chart below and follow the instructions corresponding to the result.
Does air come out of the “P” port on Yes Go to Step 3.
the knob?
No Reconnect the air line to the knob, and
continue to the next step.
2. Check the air supply to the shift knob.
Disconnect the red line from the “S” port on the shift knob. Answer the question on the chart below and follow the instructions
corresponding to the result.
Is air coming out of the red line? Ye Repair or replace the shift knob.
s Loosen the air fitting for the line that

sup- plies vehicle air to the module
No inlet. If no air is available here, repair
the vehicle air to the air module. If air
is available at the inlet, check the red
line going from the air module to the
shift knob for obstructions or dam-
age. If the line is clear, replace the air
module.
3. Check the black line for obstruction.
Reconnect the black line at the shift knob. At the air module, disconnect the black air line from the “P” port. Answer the question on
the chart below and follow the instructions corresponding to the result.
Is air available on the line when the Yes Continue to next
step. range selector is in the Low position?
No Repair the black line for damage or
obstruction.
4. Check the regulator pressure.
Reconnect the “P” line at the air module. Locate the two small pipe plugs on the rear of the air module. One is labeled “H,” and
the other is labeled “L”. (See Figure 4-1 “Air System Nomenclature”). Install a 0-150 PSI (0-1034 kPa) air gauge in the port marked
“L”.
Note: Prior to removing the pipeplug, turn off theair flow by placing therangeselector up into the high range position. Thetrans-
mission must be in neutral.
58
Move the range selector down to the low position and record the pressure on the gauge. Match the air pressure to one of those
described on the chart on the next page, and follow the corresponding instructions.
What is the air pressure at the “L” port? 75-85 PSI (517-586 kPa) (To specifica- Continue to the next step.
tion.)
Less than 75 PSI (517 kPa) On the top or the air module, remove
the
test port pipe plug for filtered vehicle
air. (Marked “F” as shown in Figure
4-1 “Air System Nomenclature”)
Install the test gauge in the “F” port,
and check the pressure. If the
pressure is less than 90 PSI (620
Troubleshooting
Air System
kPa), repair the vehicle air system to
achieve full vehicle air pressure at the
module inlet, and repeat the test. If the
pressure is greater than 90 PSI
(620spa) and no external air leaks were
detected form the air module, shift
knob, or transmission, replace the air
module.
5. Check the spool valve function.
Greater than 85 PSI (586 kPa) Replace the air module.
With the shift lever in neutral, move the range selector from low to high several times. Answer the question on the chart below
and follow the instructions corresponding to the result.
Does the gauge rapidly go from Yes Air system performs properly. Go to
75- 85PSI (517-586 kPa) in Low to step 7.
0 PSI in High?
No
Continue to the next step.
6. Isolate the air module from the transmission. Refer to Figure 4-4 “Air System Nomenclature” to see an example of an isolated
air module.
Exhaust the air pressure from the air module. To do so, you may have to exhaust the vehicle air. Remove the four capscrews at-
taching the air module to the shift bar housing. Lift the air module and tilt it to gain access to the two air holes on the underside at
the rear capscrew location. Do not lose or damage the two small O-rings that seal the holes. Block off the air ports at the un-
derside of the module. Repressurize the air module with an inlet supply pressure of over 90 PSI (620 kPa). To repressurize the air
module, the vehicle may have to be started and the air pressure allowed to build. With the shift lever in neutral and the gauge still in
the “L” test port, move the range selector from low to high (up) position.
Answer the question on the chart below, and follow the corresponding instructions.
Does the gauge rapidly go from Yes Continue to next step.
75- 85PSI (517-586 kPa) in Low to
0 PSI in High?
59

No Replace the air module.
7.Install the air module, and remove range alignment lock cover (Figure 4-3 “Air System Nomenclature”). Then move the range
selector from low to high (up) position. If range now shifts properly, inspect and correct the source of binding between lock cover
and range yoke bar.
Note: To prevent binding, range alignment lock cover capscrew must be tightened when transmission is in Low Range. If trans-
mission does not shift properly, continue to Step 8
8.Remove the auxiliary section, and inspect range synchronizer, range yoke, range yoke bar, range yoke snap rings, range sliding
clutch, and mating gears for excessive wear, binding, or damage. Repair as necessary. If these components do not need repair,
continue to step 9.
9.Remove shift bar housing and inspect range piston, piston bar, and cylinder for excessive wear, binding, or damage. Repair as
necessary.
60
Air System Symptom - Constant Air Leak from Shift Knob

In normal operation, a burst of air will be exhausted from the shift knob when moving the range selector from low to high range.
If a constant air leak is detected, first check for a leaking fitting. If the leak occurs when both high and low range are selected and
the leak is from the exhaust “E” port on the shift knob. Repair or replace the shift knob.
If the leak only occurs in high range, check for reversed hook up of “P” and “S” air lines. If the air lines are connected properly,
repair or replace the shift knob.
Troubleshooting
Air System
61
Air System Symptom - Range Shift While Transmission is in Gear

The interlock mechanism allows the driver to move the range selection lever while still in gear (preselect). The range will then shift
when the shift lever moves into neutral. If the driver preselects a range shift and the shift occurs while the shift lever is in gear, a
problem is present.
Test Procedure:
1.Exhaust air pressure from the air module. To do so, the vehicle air may need to be exhausted.
2.Remove the four capscrews attaching the air module to the shift bar housing. Lift the air module and tilt it to gain access to the
module interlock finger. Do not lose or damage the two O-rings at the rear mounting capscrew.
3. Inspect the module interlock finger for excessive wear. Replace, if necessary.
4.Shine a bright light into the hole the interlock finger engages. Inspect the chamfer on the shift shaft for excessive wear. To
inspect the chamfer, the transmission may need to be shifted into gear so both the forward and rearward chamfers are visible. If
the chamfer is excessively worn, remove the shift bar housing, disassemble, and replace the worn parts.
5. If the shift shaft is not excessively worn, replace the air module.
62
Air System Symptom - Air Leak From Breather or Case is Pressurized

If the air leak occurs when the transmission is in high range, the problem is with the range cylinder in the transmission. Remove
the shift bar housing, and disassemble and inspect the range cylinder for worn or missing o-rings. Also, inspect the shift bar hous-
ing for cracks or porosity.
If the leak only occurs when the transmission is shifted to low range, the air module may be leaking into the transmission at the
interlock finger location. Prior to removing the shift bar housing, perform the following test to determine the problem.
Test Procedure:
Exhaust the air pressure from the air module. To do so, the vehicle air may need to be exhausted. Remove the four capscrews
Troubleshooting
Air System
attaching the air module to the shift bar housing. Lift the air module and tilt it to gain access to the two air holes at the underside at
the rear capscrew location. Do not lose or damage the two small o-rings near the rear capscrew location. Block off the air ports on
the underside of the module (Figure 4-4 “Air System Nomenclature”). Repressurize the air module with an inlet supply pressure of
over 90 PSI (620 kPa). Repressurizing the air module may require starting the vehicle and allowing the air pressure to build. Shift
the transmission into low range. Answer the question on the chart below, and follow the instructions corresponding to the result.

Can any air leakage be detected at the Yes Replace the air
module. module interlock finger?
No Air leak is at the range cylinder.
Remove the shift bar housing, and
disassemble and inspect the range
cylinder for worn or missing o-rings.
Also inspect the shift bar housing for
cracks or porosity.
63
Operation
Air Line Color Chart

Eaton® Fuller® 5/32" air lines are color codedfor easyidentification. Usethe follow chart along with the appropriate system sche-
matic when troubleshooting and repairing your air system.
Nomenclature Color
S- Supply Red
P-Pilot Black
H/L- Splitter or Deep reduction Green
A- Supply, Non-regulated Orange
SP- Splitter pilot Blue
B- Brake signal Yellow
E-Exhaust Brown
64
Operation
Slave Valve Preselection System

An air valve shaft protruding from the shift bar housing prevents the actuating piston in the slave valve from moving while the gear
shift lever is in a gear position and releases the piston when the lever is moved to or through neutral.
on
Operati
65
Operation
7, 8, 9 and 10-Speed Range Air Systems

Air is supplied to the system at the air supply port (1) by the vehicle's air system. The air filter (2) removes foreign matter from
the air then allows it to pass through the air regulator (3) where the pressure is adjusted for 58 to 63 PSI (4.0 daN/cm2). From
there the air passes through the supply air hose (4) and the slave valve supply port (5) through the supply air line (6) to the range
control valve (7). With the range control valve lever or knob down (LO range), air passes through the air line connected to the
slave valve "P" port (8). The slave valve then directs air to the LO range hose (9) and exhausts the HI range hose (10). With the
range control valve lever or knob up (HI range,) the air line connected to the slave valve "P" port (8) is exhausted. The slave valve
then directs air to the HI range hose (10) and exhausts the LO range hose (9).
Range Control
Valve
7
8 Range Cylinder
9
6
5 10
1
Slave Valve Air Filter/
Regulator
4
3
66
Operation
7L, 8, 9 and 10-Speed (2-SpeedAuxiliary)
on
Operati
67
Operation
Range—HI
A-3546Range A-6909 Roadranger
A-4688 Valve (old)
0R
19470 Valve (obsoleto)
A-4688 Slave Valve 19470or A-5000

ave Vave
0R
L0
t R t Range Oylinder
ss Asscmb
flo Air
Air from
Vehicle Source
Constant Air
68
Operation
RT & RTO-610, 6610, 6609, and 8609 Models
on
Operati
69
Operation
Range—III
A-3546Ra» &
\/a ve d9flt £6tl0h
A-4688 \!alve (old)
0R
A-5000 Valve (turrent)
A-4688 Slave \/alve 19470 or A-5000

Slave Valve
L0 0R
t
ss
L0
Air from
\/ehicle
Source
Constant Air
70
Operation
Deep ReductionAir System (with Dash Mounted Valve)

In addition to the components of the range air system, the deep reduction air system utilizes a reduction cylinder and a separate
dash mounted deep reduction valve. Air is supplied to the system at the air supply port (1) by the vehicle's air system. The air
filter (2) removes foreign matter from the air then allows it to pass through the air regulator (3) where the pressure is adjusted for
58 to 63 PSI. From there the air passes through the supply air hose (4) to the slave valve supply port (5) through the supply air
hose (6) to the deep reduction valve (7). Depending upon the position of the deep reduction valve lever, if air passes through the
air hose (8) connected to the reduction cylinder center port (9) then the deep reduction gearing is disengaged. If there is no air,
the constant air from the air filter/regulator assembly (10) moves the reduction piston rearward to engagedeepreduction gearing.
on
Operati
71
Operation
RT, RTO, & RTX xx607LL, xx608LL, and xx615 models
72
Operation
A-3546Ra« e A-6915 Roadranger
A-4688 Valve (old)
0R Down
• ' •
A-5000 Valve (tsrrent)
19470 \/alve (obsoleto)
A-4688S|a&Va|& 19470 or A-5000

Slave Valve
0R
L0
t Deep Redu¢tion Valve Range Cylinder Assembly

ss
Air to
L0
Air from
73
Operation
Rargs—HI
dentificat
A-4688 \/alve (old)
0R
A-5000 Valve (current)
A-4688 Slave \/alve 19470 orA-5000

ave Va ve
0R
L0
L0
Air f-ilter/Reg«lator Deep Reduction \/aIve Range OylinderAss‹rnbly

Assembly
flo Air
L0
Air from
Reduttioo
Assemb
Constant Air
74
Operation
Deep ReductionAir System (with A-6915 Roadranger Valve)

In addition to the range air system components, the deep reduction air system uses areduction cylinder and the Roadranger ValveA-
6915.
When the A-6915 Roadranger Valve is used, the deep reduction cover must be equipped with an insert valve.
the air and allows it to pass through the air regulator (3) where the pressure is adjusted for 58 to 63 PSI. From there, the air passes
through the supply air hose (4) to the slave valve supply port (5) through the supply air line to the Roadranger valve (6).
Depending upon the position of the Roadranger valve button (7), if air passes through the air line (8) connected to the reduction
cylinder center port (9), then the deep reduction gearing is engaged. If there is no air, the constant air from the air filter/regulator
assembly (10) moves the reduction piston rearward to disengage deep reduction gearing.
on
Operati
75
Operation
RT, RTO, & RTX xx607LL, xx608LL, and xx615 Models
76
Operation
Range—L0
A-6915 Roadranger \/alve
Rearward A-4688 \/alve (old)
19470\/alve (obsoleto)
H/L P 5 SP
A-4688 Slave Valve 19470 or A-5000

Slave Valve
0R
L0 H/L L0
Air Filter/Regulator Range Oylinder Asserrbly
Air to
L0 Housng
PON
Air from
Oonstant Air
77
Operation
Rarge—Hl
dentilicat
Rearnard A-4688 Valve (old)

II/L P 5 SP
A-4688 Slave Valve 19470 or A-5000
0R
L0 H/L L0
t R t Raagety|nde‹AssemNy
L0
Air from
NoAi
V& &
Vehicl
Oonstant Air Air to

Ü0V¢f
P0ft
78
Operation
9 and 13-Speed Air Systems (Top 2 & Convertible) and 18-Speed (Top-2)
In addition to the range air system components, the splitter air system uses a splitter cylinder and the Roadranger Valve A-4900/
A-6913 or the Two-Position Selector Valve.
Air is supplied to the system at the air supply port (1) by the vehicle’s air system. The air filter (2) removes foreign matter from
the air then allows it to pass through the air filter regulator (3) where the pressure is adjusted for 58 to 63 psi. From there, the air
passes through the supply air hose (4) to the slave valve supply port (5), through the supply air line (6) to the control valve.
Depending upon the position of the splitter button (7), if air passes through the air line (8) connected to the splitter cylinder center
port (9) then the underdrive/overdrive gearing is engaged. If there is no air, the constant air from the air filter/regulator assembly
(10) moves the splitter piston forward to disengage underdrive or overdrive gear.
18-Speed
on
Operati
79
Operation
13-Speed
80
Operation
9-Speed Top 2 Convertible
on
Operati
81
Operation
9-Speed Non-Top 2 Convertible
82
Operation
RT, RTO, & RTOOxx613 and xx813 Models
on
Operati
83
Operation
Range—HI/3pIitter—Direct

Jerlificat
A-4688 Valve (old)
IR
0R
Rearward
H/L ! 19470\/alve (obsoleto)
A-4688SW &VW & )947O o A-5OOO S|aveVa|ve

H/L
H/L
0R
L0
t R g Range Cylinder Assembly

b
L0
flo Air
Air from
Vehicl SP
3ource
Operation
Range—HI/Splitter—IJndsrdrivs orOvsrdrivs
A-3546 Rangs Sc|&cto
IJ.D./0.D. A-4688 Valve (old)
0R
Forward
II/L Ü 5! 19470 Valve (obsoleto)
A-4688 S|a &V&| &
0R
L0
d Range Cylinder Assembly

b
L0
Air from
Source
Operation
RTLO-xx613 Models
86
Operation
HIRargs L
A-6913 Roadranger Valve
A-5000 \/alve (current)

Rearward
19470 or A-5000 Slave Valve
tR Splitter Oylinder Range Cylinder Assembly

Assenbl/ §p
l o Air
flo Air
L0
Ai:fom
Vehit|
tomate
Constant Air
87
Operation
HI Range H

Forward
19470Valve (obsoleto)
H/L P SP
H/L
L0
Range Cylinder Assemóly
L0
Air from
Constant Air Airto Covcr

P0it
88
Operation
RTLO-xx713 Models
on
Operati
89
Operation
HIRargsL

Rearward
SP
H/L
L0
Air Filter/Regulator Spli4&:Cylinds Range Oylinder Assembly

Assembly Ass&mb|
' SP
ii NoAm×f
L0
Air from
Oonstant Air Air to Oover

Port
Operation
HIRange H
A-6913 Roadr3nger Valve
A-5000 Valve (Current)
H/L P S
H/L
R R3nge Cylinder Assembly

b Assemb|y
L0
Ai om
dift0 Ú0VR f
k0Ft
91
Operation
RTLO-xx913 Models
92
Operation
HI Range Low Split

deni calion

Rearward
A-5000 Slave \/alve
H/L
L0
Air Filter/Regulator Splitter Cylinder Range Cylinder Assembly

Assemb Assemb
Air from
\/ehicl
S0IJ/¢9
Constant Air
LO
93
Operation
Ul Rargs lJigl› Split


Forward
H?LP S SP
A-5000 Slave \/alve
H?L
L0
Air f-ilter/ReguIator tp
iRaftyDndcf
| Range Cylinder Assembly
Asssmby Assamb|y
NoAi:
Air frorr
94
Operation
RT0-15618 and RTLO-xx618 Models
on
Operati
95
Operation
L0 Range H
A-6918 Road aaja Vav&
Forward
Down
Sp|4ecty|nde Range Cylinder Assembly

Ass(mb|y
L0
Air from
96
Operation
HI Range L
Rearward
19470 Valve (obsolete)
Ai H4aQRage|a o: Splitter Oylinder Range Oylinder Assembly

Ass&mb|y sssmb SP
NoA
L0
Air from
Source
Constant Air
97
Operation
R
- 9 8R d
Forward
19470 \/aIve (obsoleto)
L0
Air Filter/Regulator Range Cylinder Assembly

Assembly
L0
Air from
\/ehicl
Constant Air Airto Govsr

Port
Operation
RTLO-xx718 Models
on
Operati
99
Operation
L0 Range H
Forward
A-5000 Slave Valve
L0
R t Range Oylinder Assembly

s
Air from
\/ehicle
Source
Constant Air flo Air
100
Operation
HI Rarge L
A-6918 R0ádf6h§üf VálVt
Rearward
A-5000 Slave \/alve
L0
Air Filter/Regulator d Range Oylinder Assembly

Assemóly
i
L0
Air from
101
Operation
HIRangeH
A-69)8Road aags
Forward
A-5000 Slave \/alve
Air Filter/Regulator Splitter Cylindsr Range Oylinder Assembly

Assemby
Air from
Oonstant Air Ai|

otova
102
Operation
RTLO-xx918 Models
on
Operati
103
Operation
L0 Rargs H
A-5000 Slave Valve
L0
Air Filter/Regulador Splitter Cylinder Range Cylinder Assembly

Assembly
SP
Ancho
Ú0VQf Ñ0U
Air from
L0
104
Operation
HI Rargs L
Rearward Jertificat
A-5000 Slave Valve
L0
Air Filter/Regulator SpliflerGylinder Range Cylinder Assembly
NoAi
V&hic|
SoDfO(
Air to HI L0
Ü0V9F Ñ0ft
105
Operation
R
-6918 R d
Forward
SP
A-5000 Slave Valve
L0
R Range Oylinder Asserrbly

s ssmb
NoAi
Air from
\/ehicl
Sorrce
106
Operation
Combination Cylinder Air System

The combination cylinder air system functions much like the other air systems except the range cylinder and the deep reduction
cylinder are located side by side in the same housing.
Air is supplied to the system at the air supply port (1) by the vehicle's air system. The air filter removes foreign matter from the
air then allows it to pass through the air regulator where the pressure is adjusted for 58 to 63 PSI (4.0 daN/cm2). From there the
air passes through the supply air hose (2) to the slavevalve supply port (3) through thesupply air line (4) to the Roadrangervalve.
Depending upon the position of the range lever (5), air passes through either the LO range air line (6) or the HI range air line (7) to
the range cylinder.
Depending upon the position of the splitter button (8), if air passes through the air line (9) connected to the deep reduction port
(10) then the deep reduction gearing is engaged. If there is no air, the constant air from the air filter/regulator assembly moves
the deep reduction piston forward to disengage deep reduction gear.
on
Operati
Roadranger Valve
8
5
9
4
3 2
Slave Valve
7
6 10
Combination
Cylinder with
Air Filter/
Regulator
1
107
Operation
7LL/DLL/MLL, 8LL, 9MLL, and 15-Speed Models
108
Operation
Rargs—L0
A-6915 9oadranger \/alve
Rearward
Down
A-5000 Valve (Current)
19470 Yalve (obsoleto)
19470 or A-5000 Slave \/alve
M/L L0
Oylinder Assembly
Range
Deep Reduction
Air Filter/Regulador
109
Operation
Rango—Hl
Rearward
19470 or A-5000 Slave \/alve
L0
flo Air ‹o
SP Air from
Range \/ehicl
S0urc9
Deep Reduction
tR
s b
110
Operation
Unique Air Systems

Note: Eaton recommends that you update using the latest air systems to prevent possible synchronizer failure.
RT & RTO 613 and 6613 Air Systems (With 3-Position Selector Valve)
This system consists of a 3-Position Selector valve and an intermediate shift cylinder in addition to the range cylinder. The inter-
mediate shift cylinder shifts the transmission between LO range and intermediate. The range cylinder shifts the transmission be-
tween intermediate and direct.
there the air passes through the supply air hose (4) to the slave valve supply port (5) through the supply air line to the control
valve (6).
Depending upon the position of the control button (7), if air passes through the air line (8) connected to the intermediate shift
on
Operati
cylinder center port (9) then the intermediate/direct gearing is disengaged. If there is no air, the constant air from the air filter/
regulator assembly (10) moves the intermediate piston forward to engage LO gearing.
Control Valve
7
7
8
2
6
1
Air Filter/ 4 5
Regulator
3
Intermediate
Shift Cylinder 10
Slave
Valve
9
Range Cylinder
111
Operation
RT & RTO 613 and 6613 Models
112
Operation
Intsrmsdiats
Selector Valve
A-4688 Valve (old)
A-4688 Slave \/alve 19470or A-5000

Slave Valve
0R
LO
L0
R t Range Cylinder Assembly

ss
Air to
H0uSÍng
Port
Air from
Oonstant Air
NoAi:
113
Operation
Selector \/alve
dentificat
DIR
A-4688 Valve (old)
A-4688 S|&&V&I &
OR
L0
Air Filter/Regulator
Assemb
L0
Air from
Vehicl
114
Operation
RT & RTO 613 and 6613 Models With A-6913 Roadranger Valve
This system consists of a A-6913 Roadranger valve and an intermediate shift cylinder in addition to the range cylinder. The inter-
mediate shift cylinder shifts the transmission between deep reduction and LO range, the range cylinder shifts the transmission
between LO and HI range.
there the air passes through the supply air hose (4) to the slave valve supply port (5) through the supply air line to the Roadranger
valve (6).
Depending upon the position of the splitter button (7), if air passes through the air line (8) connected to the intermediate shift
cylinder top port (9) then the deep reduction gearing is engaged. If there is no air, the constant air from the air filter/regulator
assembly (10) moves the intermediate piston rearward to disengage deep reduction gearing.
on
Operati
7
7 Roadranger Valve
Eaton ¨
Fuller ¨
Transmission
H/L P S SP
8
2
1 6
Air Filter/ 4 5
Regulator
3
10
Slave
9 Valve
Intermediate
Shift Cylinder
Range Cylinder
115
Operation
RT & RTO 613 and 6613 Models
116
Operation
A-6913 Boadranger \/alve
Rearward A-A688VW e(old)
H/L P SP
A-A688SW «V&N& 19470 or A-5000

H/L H/L
L0 0R
L0
Air Filter/Regslator Intermediate Cylinder Range Cylinder Assembly

Assemb Assemb
flo Air "
Air from
Vehicl
Source
Constant Air
117
Operation
Ra«g»—IJI
A-6913 R06dranger \/alve
Rearward A-4688 Valve (old)
A-4688S|a<&Va|<e 19470 or A-5000

H/L
0R
L0
áit Filler/Regulador Range Cylinder Asserrbly
klo Air
L0
f
h
OonstantAir
118
Operation
7608LL with A-6915 Roadranger Valve

This system consists of a A-6915 Roadranger valve and a deep reduction cylinder in addition to the range cylinder. The deep
reduction cylinder shifts the transmission between deep reduction and LO range. The range cylinder shifts the transmission be-
tween LO and HI range.
there the air passes through the supply air hose (4) to the slave valve supply port (5) through the supply air line to the Roadranger
valve(6).
Depending upon the position of the splitter button (7), if air passes through the air line (8) connected to the deep reduction cylinder
top port (9) then the deep reduction gearing is engaged. If there is no air, the constant air from the air filter/regulator assembly
(10) moves the piston forward to disengage deep reduction gearing.
on
Operati
7
Roadranger Valve
7
Eaton ¨
Fuller ¨
Transmission
H/L P S SP
8
2
1 6
Air Filter/ 5
4
Regulator
3
10
Slave
9 Valve
Range Cylinder
119
Operation
7608LL Models
120
Operation
d9flt 0áll0h
Rearward A-5000 \/alve (current)
H/L P 5 3P
19470 or A-5000
Slave \/alve
H/L
L0
Range Cylinder Assembly
AÍr t0
l-l0lJsing
L0
tio Air Port
Oonstant Air
121
Operation
Range—HI
Rearward A-5000 Valve (current)
19470 V ÍV9 (0bS0let9)
19470 or A-5000
L0
Air Filter/Regulator DaapR9duct0n Range Cylinder Assembly

Ú/|MdQ f4SSQ TMÜ|/
L0 " "’
Air from
Constant Air
Air to Comer
122
Operation
RTLO-xx610 Speed Air System

This system consists of a A-6910 Roadranger valve, range actuator valve, a splitter shift cylinder and a range cylinder. The splitter
cylinder shifts the transmission between odd and even numbered gear positions. The range cylinder shifts the transmission be-
the air then allows it to pass through the air regulator where the pressure is adjusted for 58 to 63 PSI (4.0 daN/cm2). From there
the air passes through the supply air hose (3) to the range actuator valve supply port through the supply air line (4) to the
Roadranger valve.
Depending upon the position of the splitter button (5), if air passes through the air line (6) connected to the splitter cylinder top
port (7) then the even numbered gear positions are engaged. If there is no air, the constant air from the air filter/regulator as-
sembly (8) moves the splitter piston rearward to engage odd numbered gear positions.
The transmission shift lever automatically activiates LO and HI range depending on gear position.
on
Operati
Latest Design
123
Operation
Old Design
124
Operation
RTLO-xxx610 Models
on
Operati
125
Operation
L0Raaj&—24,6Gaa:s
A-69)0Roadaoje:Va|ve
Forward
RangeActsator Yalve
(old style)
L0
Range Actuator Valve

(latsst design)
L0
Range Cylinder Assernbly
Air from
126
Operation
HI Rarge—7, 9Gears
Rsarward
Range Actuator Valve

(old style)
L0
R6fl§9 ÁCtLl6t0f Ü6ÍV9

(latest design)
L0
L0
f
indicó
127
Operation
HI Rargs—8, 10wars
RangeAc|ualoi Va|ve
0 d SÍ@B
|
L0
SP
(lstest design)
SP
L0
Air from
Sosrce
128
Operation
RTL-xx710 Speed Models

This system consists of a A-6910 Roadranger valve, range actuator valve, a splitter shift cylinder and a range cylinder. The splitter
cylinder shifts the transmission between odd and even numbered gear positions. The range cylinder shifts the transmission be-
the air then allows it to pass through the air regulator where the pressure is adjusted for 58 to 63 PSI (4.0 daN/cm2). From there
the air passes through the supply air hose (3) to the range actuator valve supply port through the supply air line (4) to the
Roadranger valve.
Depending upon the position of the splitter button (5), if air passes through the air line (6) connected to the splitter cylinder top
port (7) then the even numbered gear positions are engaged. If there is no air, the constant air from the air filter/regulator assem-
bly (8) moves the splitter piston forward to engage odd numbered gear positions.
The transmission shift lever automatical activiates LO and HI range depending on gear position.
on
Operati
129
Operation
RTL-xx710 Models
130
Operation
L0 Rargs—2, 4, 6 Gsars
A-69)0Rozd zoj& VzNa
RangeActuator Valve
Splitter Cylinder Assembly Range Cylinder Assembly
ÁÍf 10 h0lJSÍh§ Oft

L0
Air from
Socrce
131
Operation
HI Rargs—7, 9Gsars
A-69l0Roadanga VaNa
Rearward
Range Actuator Yalve
L0
Air from
Socrce
132
Operation
HlRange— 8, 10Gears
A-6910 Road aaj& Valva
Forward
SP
RangeActuator Valve
Splitter Cylinder Assembly R g d
SP
L0
Air from
133
Operation
AT-1202 Auxillairy Transmission (with 2 Position Shift Valve)

LORange
AUX. TRANS.
DIR RED
Constant air
from Air Filter/ SHIFTS AT
STANDSTILL
ONLY
Regulator
DIR RED
Constant air
from Slave V
LO
Breather HI
When the lever is moved to the Reduction (RED) position, air is shut off to piston rear side. The constant air moves the range
piston rearward and shifts the auxiliary transmission into Reduction.
High Range
AUX. TRANS.
DIR RED
Coons
sta
ant air SHIFTS AT
STANDSTILL
fro
om Air File
er/ ONLY
Reegula
ato
or DIR RED
Constant air
from Slave V
LO
Breather HI
When the lever is moved to the direct (DIR) position, the valve allows air to flow through to the piston rear side. Theconstant air
moves the range piston forward and shifts the auxiliary transmission into Direct.
134
Operation
AT-1202 Auxiliary Housing (3 Position Valve)

Neutral
Constant air
fromSlave Valve
Consstant air 1
from Air Filter/
Regulator
2 4
Lo
3
High
Neutral
on
Operati
The valve allows air to pass from #1 to #2 placing the auxiliary transmission in neutral.
#4 is connected to #3 to exhaust the air.
Reduction
Constant air
fromSlave Valve
Constant air 1
from Air Filter/
Regulator
2 4
Lo
3
High
Neutral
135
Operation
When the switch is moved to the LOW position, the valve closes and stops the air at #1 placing the auxiliary transmission in LO.
Direct
Constant air
fromSlave Valve
Consstant air 1
from Air Filter/
Reguulator
2 4
Lo
3
High
Neutral
When the switch is moved to the HIGH position, the valve opens and allows the air from #1 to pass to #4, placing the auxiliary
transmission in HI.
#2 is connected to #3 to exhaust the air.
136
System Components
A-4740 Air Filter/Regulator Assembly

The air filter removes foreign matter from the air then allows it to pass through the air regulator where the pressure is adjusted to
58 to 63 PSI. The output air pressure will not be in range if the truck's air pressure is incorrect.
End Cap
Components
System
O-Rings
Filter Element
Housing
Plug
Air Regulator
137
System Components
A-5161/A-5454 Air Filter/Regulator Assembly

The air filter removes foreign matter from the air then allows it to pass through the air regulator where the pressure is adjusted to
58 to 63 PSI. The output air pressure will not be in range if the truck's air pressure is incorrect.
End Cap
O-Rings
Filter Element
Housing
Plug
Air Regulator
O-Rings
138
System Components
A-3546 Range Valve

Constant air pressure is supplied from the slave valve to the Range valve inlet or "S" port (1).
In LO range (range knob down (2), air passes through the valve and out the range valve outlet or "P" port (3). This air returns to
the slave valve end port or "P" port depending on the slave valve used.
Components
System
In HI range (range knob up (2) the knob prevents the air from passing through the Range valve. Air pressure which was in the
outlet line (3) is exhausted out the bottom.
139
System Components
A-5010/A-6909 Roadranger Valve

Constant air pressure is supplied from the slave valve to the Roadranger valve inlet or "S" port (1).
In LOrange (range lever down( 2), air passes through the lever and out the Roadrangervalve outlet or "P"port (3). This air returns to
the slave valve end port or "P" port depending on the slave valve used.
In HI range (range lever up (2) the lever prevents the air from passing through the Roadranger valve. Air pressure which was in
the outlet line (3) is exhausted out the Roadranger valve "E" port.
140
System Components
14651 Reduction Valve (Dash-Mounted)

With the deep reduction lever in the "OUT" position (1), the valve is opened (2) and air is supplied to the deep reduction cylinder
cover center port, moving the reduction piston forward to disengagedeep reduction gearing.
Components
System
With the deep reduction lever in the "IN" position (1), the valve is closed (2) and no air is supplied to the deep reduction cylinder
cover center port. The constant air from the air filter/regulator assembly moves the reduction piston rearward to engage deep
reduction gearing.
141
System Components

Constant air pressure is supplied from the slave valve to the Roadranger valve “S” port and “H/L” port (for deep reduction and LO
range (1)).
For deep reduction (range lever down (2), deep reduction button forward (3), air flows out of the roadranger valve “P” port and
“SP” port (4).
For LO range (range lever down (2), deep reduction button rearward (3), air flows out of the roadranger valve “P” port (4).
For HI range (range lever up (2), deepreduction button rearward (3), the lever stops the air from passing through the Roadranger
valve. Air pressure which was in the outlet line is exhausted out the Roadranger valve bottom.
The Roadranger valve mechanical interlock prevents forward movement of the deep reduction button while in HI range.
142
System Components
Two Position Selector Valve

Constant air pressure is supplied from the slave valve to the A-3546 range valve “S” port (1).
For LO range (range knob down (2), selector valve button in the “DIR” position (3), air flows out of the range valve “P” port (4).
Components
System
For direct operation (range knob up (2), selector valve button in the “DIR” position (3), the knob prevents the air from passing
through the selector valve: air now flows through the “H” port and into the selector valve (5).
For Underdrive and Overdrive operation (range knob up (2), selector valve button in theforward position (3) air flows through the
selector valve “H” port (4) and out the “SP” port (5).
143
System Components

Constant air pressure is supplied from the slave valve to the Roadranger valve “S” port (1).
For LO range (range lever down (2), splitter button rearward (3), air flows out of the Roadranger valve “P” port (4).
For HI range (rangelever up (2), splitter button rearward( 3), thelever prevents theair from passing through the Roadrangervalve:
air now flows through the “H/L” port (4) into the Roadranger valve.
For splitter operation (range lever up (2), splitter button forward (3),air flows through the “H/L” port and air flows out of the
Roadranger valve “SP” port (4). Air pressure which was in the outlet line is exhausted out the bottom of the Roadranger valve.
The roadranger valve mechanical interlock prevents forward movement of the splitter button while in LO range.
144
System Components

Constant air pressure is supplied from the slave valve to the roadranger valve “S” port (1).
For LO range direct (range lever down (2), actuator button rearward (3),air flows out of the Roadranger valve “P” port (4).
Components
System
For LO range overdrive (range lever down (2), actuator button forward (3) air flows out of the roadranger valve “P” port and “SP”
port (4).
For HI range direct (range lever up (2), actuator button rearward (3),the lever prevents the air from passing through the Roadrang- er
valve (4).
145
System Components
For HI range overdrive (range lever up (2), actuator button forward (3),air flows out of the Roadranger valve “SP” port (4). Air
pressure which was in the outlet line is exhausted out the Roadranger valve bottom.
146
System Components
Three Position Selector Valve

For LO range (selector button in the “LO” position (2), the air is stopped from passing through the selector valve.
Components
System
For Intermediate range (selector button in the “INT” position (2),air flows out the “SP” port (3).
For HI range (selector button in the “DIR” position 2), air flows out the “P” port (3) and the “SP” port (4).
147
System Components

For LO range 1, 3, 5 gear positions (gear select button in the rearward position (2), the button prevents air from passing through
the Roadranger valve.
For LO range 2, 4, 6 gear positions (gear select button in the forward position (2), air flows out the roadranger “SP” port.
For HI range 7, 9 gear position (gear select button in the rearward position (2), air is again prevented from passing through the
Roadranger valve.
148
System Components
For HI range, 8 and 10 gear positions (gear select button in the forward (2) air flows out the roadranger valve “SP” port.
Components
System
149
System Components
Range Actuator Valve (Old Design)

Constant air pressure is supplied from the air filter/regulator to the range actuator valve "S" port tee (1).
For LO range (1, 2, 3, 4, 5, and 6 gear positions) the "S" port (2) is open and the air is allowed to pass through the range actuator
valve and out the LO range air line (3).
For HI range (7, 8, 9, and 10 gear positions) the "S" port (2) is closed and no air passes through the range actuator valve (3).
150
System Components
Range Actuator Valve (Latest Design)

Constant air pressure is supplied from the air filter/regulator to the range actuator valve "S" port tee (1).
For LOrange(1, 2, 3, 4, 5, and 6 gear positions) the "S"port is openand the air is allowed to pass through the range actuator valve
and out the LO range air line (2).
Components
System
For HI range (7, 8, 9, and 10 gear positions) the "S" port is closed and no air passes through the range actuator valve (2).
151
System Components
19470 Poppet-Type Slave Valve

The poppet-type slave valve is a non-serviceable valve. Should this valve prove to be defective replace the complete assembly
with A-5000. There are some preliminary checks to make before replacing the slave valve: check air fittings for restrictions, check
torque of the four (4) mounting capscrews (8-12 lbs. ft.), if valve continues to leak replace.
152
System Components
A-4688 Slave Valve

LO Range - Air pressure is supplied to the end cap (1) from the selector/master/Roadranger valve (2). The piston is held forward
since the surface area is larger on this end (3) than the surface area at the other end (4) and is exposed to constant air pressure.
The constant air flows through the piston center passage (5) which is aligned with the side cap LO range port (6). In normal op-
eration, exhaust occurs only for an instant as the range shift is made.
Components
System
HI Range - Noair pressure is supplied to the end cap(1) from the selector/master/Roadranger valve (2). Theconstant air pressure
entering the supply port (3) moves the piston to the rear position (4). The constant air flows through the piston center passage
(5) which is aligned with the sidecap HI range port (6). In normal operation, exhaust occurs only for an instant as the range shift is
made.
153
System Components
A-5000 Slave Valve

LO Range - Air pressure is supplied to the end cap (1) from the selector/master/Roadranger valve (2). The piston is held forward
since the surface area is larger on this end (3) than the surface area at the other end (4) and is exposed to constant air pressure.
The constant air flows through the piston center passage (5) which is aligned with the side cap LO range port (6). In normal op-
eration, exhaust occurs only for an instant as the range shift is made.
HI Range - Noair pressure is supplied to the end cap(1) from the selector/master/Roadranger valve (2). Theconstant air pressure
entering the supply port (3) moves the piston to the rear position (4). The constant air flows through the piston center passage
(5) which is aligned with theside cap HI range port (6) In normal operation, exhaust occurs only for an instant as the range shift is
made.
154
System Components
Range Cylinder
LO Range - With the control valve lever down, air is supplied from the slave valve to the range cylinder LOrange port (1). This air
pressure forces the range cylinder piston to the rear (2), engaging the LO range gearing. Air pressure on the piston back, and in
the HI range air hose (3), is exhausted out the slave valve.
Components
System
HI Range - With the control valve lever up, air is supplied from the slave valve to the range cylinder cover HI range port (1). This
air pressure forces the range cylinder piston forward (2), engaging the HI range gearing. Air pressure on the piston front side and in
the LO range air hose (3), during LO range operation, is exhausted out the slave valve.
155
System Components
Range Cylinder for 610, 6610, 6609 and 8609

LO Range - With the control valve lever down, air is supplied from the slave valve to the range cylinder LOrange port (1). This air
pressure forces the range cylinder piston to the rear (2), engaging the LO range gearing. Air pressure on the piston back, and in
the HI range air hose (3), is exhausted out the slave valve.
HI Range - With the control valve lever up, air is supplied from the slave valve to the range cylinder cover HI range port (1). This
air pressure forces the range cylinder piston forward (2), engaging the HI range gearing. Air pressure on the piston front side and in
the LO range air hose (3), during LO range operation, is exhausted out the slave valve.
156
System Components
Dash-Mounted Deep Reduction Cylinder

DeepReduction- With the deepreduction lever in the"IN" position, no air is supplied to thecylinder cover centerport (1). Constant
air from the air filter/regulator assembly (2) moves the reduction piston rearward (3), engaging deep reduction gearing.
Components
System
LO Range or HI Range - With the deep reduction lever in the "OUT"position, air is supplied to the cylinder cover center port (1),
moving the reduction piston forward (2), disengaging deep reduction gearing.
157
System Components
Deep Reduction Cylinder withRoadranger Valve

Deep Reduction - With the deep reduction button in the "forward" position, air is supplied to the deep reduction cylinder cover
center port (1), moving the reduction piston rearward, engaging deep reduction gearing (2).
LO or HI Range - With the deep reduction lever in the "rearward" position, no air is supplied to the deep reduction cylinder cover
center port (1). The constant air from the air filter/regulator assembly (2) moves the reduction piston forward, disengaging deep
reduction gearing (3).
158
System Components
Insert Valve
The insert valve is a self-contained 1-13/16" valve assembly located in the reduction cylinder cover. It cannot be disassembled
except for the three (3) o-rings on the outer diameter. The o-rings provide a stationary seal and do not move in the cylinder.
Insert valve piston travel is only 1/32". When air is applied to the valve piston top side through the signal line, the piston moves
down to cut off air supplied to the cylinder piston backside. This air is exhausted out the cover bottom port when constant air
supplied from the regulator is directed to the cylinder piston front side, moving the yoke bar rearward to engage deep reduction
gearing.
Deep Reduction
Air on
Signal Line
Components
System
Constant
Air
Constant
air sealed
off at this
point
Air exhausted through

bottom port from
piston back side
When no air is applied to the valve piston top side, constant air supplied from the air filter/regulator passes freely through the
insert valve and to the cylinder piston backside, moving the yoke bar forward to disengage deep reduction gearing.
LO Range and HI Range
No air on
Signal Line
Constant
Air
To piston back
side, yoke
bar forward
159
System Components
RTLO-xx610 Model Range Cylinder Assembly

Note: This is the Old design
LO Range - When the shift lever is moved laterally from 7th to 6th gear, air is supplied to the range cylinder housing port (1),
moving the piston rearward, engaging LO range gearing (2).
HI Range - When the shift lever is moved laterally from 6th to 7th gear, no air is supplied to the range cylinder housing port (1),
moving the piston forward, engaging HI range gearing (2).
160
System Components
Insert Valves
The insert valves are a self-contained 1-1/2" valve assembly located in the range cylinder cover. It cannot be disassembled except
for the three (3) o-rings on the outer diameter. The o-rings provide a stationary seal and do not move in the cylinder.
Insert valve piston travel is only 1/16". When air is applied to the valve piston top side, one piston moves down sealing off the
constant air supplied from the air filter/regulator, the other piston allows the constant air supplied from the air filter/regulator to
passfreely through theinsert valve, to thecylinder piston front side, moving theyoke bar rearward to engagetheLOrangegearing.
LO Range
Constant Air
from Air Valve
Constant Air from

Constant air sealed
Components
System
off at this point
To piston front
Exhaust from HI Yoke bar rearward
Side of Cylinder
When no air is applied to the signal line, the piston moves up allowing the constant air supplied from the air filter/regulator to pass
freely through one insert valve to the piston back side, moving the yoke bar forward to engage HI range gearing and sealing off
the constant air from the air filter/regulator to allow the air from the piston front side to exhaust.
HI Range
No Air on
Signal Line
Constant Air from
Constant Air
from Air Filter/
Regulator
Exhaust from
To piston back LO side of Cylinder
side, Yoke bar forward
161
System Components
RTL-xx710 Model Range Cylinder Assembly

LO Range - When the shift lever is moved laterally from 7th to 6th gear, air is supplied to the range cylinder housing port (1),
moving the piston rearward, engaging LO range gearing (2).
HI Range - When the shift lever is moved laterally from 6th to 7th gear, no air is supplied to the range cylinder housing port (1),
moving the piston forward, engaging HI range gearing (2).
162
System Components
Spool Valve
The spool valve components shown are part of a self-contained valve assembly, part number A-6864.
The spool valve piston travel is approximately 1/2". When filtered air is supplied from the 4303110 valve to the valve spool right
side (1), constant air from the filter/regulator (2) flows through the valve spool and seal plate to the range cylinder piston front
side moving the yoke bar rearwards. Air is exhausted from the range cylinder rear (3).
Components
System
When no filtered air is supplied from the 4303110 valve to the valve spool right side (1), constant air from the filter/regulator (2)
flows through the valve spool and seal plate to the range cylinder piston back side moving the yoke bar forward. Air is exhausted
from the range cylinder front (3).
163
System Components
Intermediate Shift Cylinder Assembly 613 and 6613, 3-Position Selector Valve
LO Range - With the Selector valve button in the "LO" position, no air is supplied to the Intermediate cylinder cover center port
(1). The constant air from the air filter/regulator assembly (2) moves the piston forward (3), disengaging underdrive/overdrive
gearing.
Intermediate or Direct Range - With the Selector valve button in the "INT" or "DIR" position, air is supplied to the Intermediate
cylinder cover center port (1), moving the piston rearward, engaging underdrive/overdrive gearing (2).
164
System Components
Insert Valve
The insert valve is a self-contained 1-13/16" valve assembly located in the intermediate cylinder cover. It cannot be disassembled
except for the three (3) O-rings on the outer diameter. The O-rings provide a stationary seal and do not move in the cylinder.
Insert valve piston travel is only 1/32". When no air is applied to the valve piston top side, constant air supplied from the air filter/
regulator passes freely through the insert valve and to the cylinder piston backside, moving the yoke bar forward to disengage
underdrive/overdrive gearing.
LO Range
No air on
Signal Line
Constant
Components
System
Air
To piston back
side, yoke
bar forward
When air is applied to the valve piston top side through the signal line, the piston moves down to cut off air supplied to the cylinder
piston backside. This air is exhausted out the cover bottom port when constant air supplied from the regulator is directed to the
cylinder piston front side, moving the yoke bar rearward to engage intermediate or direct gearing.
Intermediate Range and Direct Range
Air on
Signal Line
Constant
Air
Constant
air sealed
off at this
point

bottom port from
piston back side
165
System Components
Intermediate Shift Cylinder Assembly 613 and 6613, A-5015 Roadranger Valve
Deep Reduction - With the Roadranger valve lever in the up position, air is supplied to the Intermediate cylinder cover port (1),
moving the piston forward, engaging deep reduction gearing (2).
LOor HI Range - With the Roadranger valve lever in the down position, no air is supplied to the Intermediate cylinder cover port
(1). Theconstant air from the air filter/regulator assembly (2) moves the piston rearward (3), disengaging deepreduction gearing.
166
System Components
Insert Valve
Insert valve piston travel is only 1/32". When air is applied to the valve piston top side through the signal line, constant air supplied
from the air filter/regulator passes freely through the insert valve and to the cylinder piston backside, moving the yoke bar forward to
engage deep reduction gearing.
Components
System
When no air is applied to the valve piston top side, the piston moves up to cut off air supplied to the cylinder piston backside. This
air is exhausted out the cover back center bore, when constant air supplied from the cylinder is directed to the cylinder piston front
side, the yoke bar moves rearward to disengagedeep reduction gearing.
167
System Components
Combination Cylinder Assembly

The combination cylinder combines the range operation with the deep reduction operation. Each functions separately, but are
contained in the same housing.
Deep Reduction - With the range lever in the "down" position, air is supplied to the LO range port (1), moving the range piston
rearward to engage LO range gearing (2), and the deep reduction button is in the "forward" position. Air is supplied to the deep
reduction cylinder cover center port (3), moving the reduction piston rearward (4), and engaging deep reduction gearing.
LO Range - With the range lever in the "down" position, air is supplied to the LO range port (1), moving the range piston rearward
(2), engaging LO range gearing AND the deep reduction button is in the "rearward" position. No air is supplied to the deep reduction
cylinder cover center port (3). The constant air from the air filter/regulator assembly moves the reduction piston forward (4), dis-
engaging deep reduction gearing
168
System Components
HI Range - With the range lever in the "up" position, air is supplied to the HI range port (1), moving the range piston forward (2),
engaging HI range gearing AND the deep reduction button is in the "rearward" position. No air is supplied to the deep reduction
cylinder cover center port (3). The constant air from the air filter/regulator assembly moves the reduction piston forward (4), dis-
engaging deep reduction gearing.
Components
System
Insert Valve
Insert valve piston travel is only 1/32". When air is applied to the valve piston top side through the signal line, the piston moves
down to cut off air supplied to the cylinder piston backside. This air is exhausted out the cover bottom port when constant air,
supplied from the regulator, is directed to the cylinder piston frontside, moving the yoke bar rearward to engage deep reduction
gearing.
Deep Reduction
Air on
Signal Line
Constant
Air
Constant
air sealed
off at this
point

bottom port from
piston back side
169
System Components
When no air is applied to the valve piston top side, constant air supplied from the air filter/regulator passes freely through the
insert valve and to the cylinder piston backside, moving the yoke bar forward to disengage deep reduction gearing.
LO Range and HI Range

No air on
Signal Line
Constant
Air
To piston back
side, yoke
bar forward
170
System Components
Splitter Cylinder Assembly

LO Range or Direct - With the splitter button in the "rearward" position, no air is supplied to the splitter cylinder cover center port
(1). The constant air from the air filter/regulator assembly (2) moves the splitter piston forward, disengaging underdrive/overdrive
gearing (3).
Components
System
Underdrive/Overdrive - With the splitter button in the "forward" position, air is supplied to the splitter cylinder cover center port
(1), moving the splitter piston rearward, engaging underdrive/overdrive gearing (2).
171
System Components
Insert Valve
Insert valve piston travel is only 1/32”. When no air is applied to the valve piston top side, constant air supplied from the air filter/
regulator passes freely through the insert valve and to the cylinder piston backside, moving the yoke bar forward to disengage
underdrive/overdrive gearing.
LO Range
No air on
Signal Line
Constant
Air
To piston back
side, yoke
bar forward
piston backside. This air is exhausted out the cover bottom port when constant air supplied from the regulator is directed to the
cylinder piston front side, moving the yoke bar rearward to engage underdrive/overdrive gearing.
Intermediate Range and Direct Range
Air on
Signal Line
Constant
Air
Constant
air sealed
off at this
point

bottom port from
piston back side
172
System Components
RTLO-xx610 Model Splitter Cylinder Assembly (Old Design)

OddNumberedGear Positions (1, 3, 5, 7, 9) With the Roadranger valve button in the rearward position, no air is supplied to the
splitter cylinder cover port (1), moving the piston rearward, disengaging splitter gearing (2).
Components
System
Even Numbered Gear Positions (2, 4, 6, 8, 10) With the Roadranger valve button in the forward position, air is supplied to the
splitter cylinder cover port (1), moving the piston forward, engaging splitter gearing (2).
173
System Components
Insert Valve
The insert valve is a self-contained 1-13/16" valve assembly located in the splitter cylinder cover. It cannot be disassembled except
for the three (3) O-rings on the outer diameter. The O-rings provide a stationary seal and do not move in the cylinder.
Insert valve piston travel is only 1/32". When no air is applied to the valve piston top side through the signal line, constant air
supplied from the air filter/regulator moves the yoke bar rearward to engage the rear auxiliary drive gear (LO and HI range direct),
while air is exhausted out the insert valve.
No air on
Signal Line
Exhaust
From piston
backside, yoke Constant
bar rearward air sealed
off at this
point
Whenair is applied to the valve piston top side, the piston moves down passing air through the insert valve bottom to the cylinder
piston front and backside, moving the yoke bar forward to engage the front auxiliary drive gear (LO and HI range overdrive).
Air on
Signal Line
Constant
air sealed
off at this
To piston back point
side, yoke bar
forward
Constant Air
174
System Components
RTLO-xx610 Model Splitter Cylinder Assembly (Latest Design)

OddNumberedGear Positions (1, 3, 5, 7, 9) With the Roadranger valve button in the rearward position, no air is supplied to the
Components
System
Even Numbered Gear Positions (2, 4, 6, 8, 10) With the Roadranger valve button in the forward position, air is supplied to the
splitter cylinder cover port (1), moving the piston forward, engaging splitter gearing (2).
175
System Components
Spool Valve
The spool valve piston travel is approximately 1/2". When no air is supplied from the Roadranger valve to the valve spool left side
(1), constant air from the filter/regulator (2) is supplied to the splitter cylinder piston front side moving the yoke bar rearward. Air is
exhausted from the splitter cylinder rear (3) and from the breather situated on the valve assembly rear.
When air is supplied from the Roadranger valve to the valve spool left side (1), constant air from the filter/regulator (2) is supplied to
the splitter cylinder piston rear side moving the yoke bar forward. Air is exhausted from the splitter cylinder front (3) and from the
breather situated on the valve assembly rear.
176
System Components
RTL-xx710 Model Splitter Cylinder Assembly

Odd Numbered Gear Positions (1, 3, 5, 7, 9) With the Roadranger valve button in the forward position, air is supplied to the
Components
System
EvenNumbered Gear Positions (2, 4, 6, 8, 10) With the Roadranger valve button in the rearward position, no air is supplied to
the splitter cylinder cover port (1), moving the piston forward, engaging splitter gearing (2).
177
System Components
Spool Valve
The spool valve piston travel is approximately 1/2". When air is supplied from the Roadranger valve to the valve spool left side (1),
constant air from the filter/regulator (2) is supplied to the splitter cylinder piston front side moving the yoke bar rearward. Air is
exhausted from the splitter cylinder rear (3) and from the breather situated on the valve assembly rear.
When no air is supplied from the Roadranger valve to the valve spool left side (1), constant air from the filter/regulator (2) is sup-
plied to the splitter cylinder piston rear side moving the yoke bar forward. Air is exhausted from the splitter cylinder front (3) and
from the breather situated on the valve assembly rear.
178
System Components
RTLO-xx613 Model Splitter Cylinder Assembly

LO Range or HI Range L - With the splitter control button in the "rearward" position, no air is supplied to the splitter cylinder cover
left port (1). The constant air from the air filter/regulator assembly (2) moves the splitter piston rearward, disengaging the front
auxiliary gear (3).
Components
System
HI Range H - With the splitter control button in the "forward" position, air is supplied to the splitter cylinder cover left port (1),
moving the splitter piston forward, engaging the front auxiliary drive gear (2).
179
System Components
Insert Valve
The insert valve is a self-contained 1-13/16" valve assembly located in the intermediate shift cylinder cover. It cannot be disas-
sembled except for the three (3) O-rings on the outer diameter. The O-rings provide a stationary seal and do not move in the cyl-
inder.
supplied from the air filter/regulator moves the yoke bar rearward to engage the rear auxiliary drive gear (LO and HI range L), while
air is exhausted out the insert valve.
No air on
Signal Line
Exhaust
From piston Constant

backside, yoke air sealed
bar rearward off at this
point
piston front and backside, moving the yoke bar forward to engagethe front auxiliary drive gear (HI range H).
Air on
Signal Line
Constant
To piston back air sealed
side, yoke bar off at this
forward point
Constant Air
180
System Components

top port (1). The constant air from the air filter/regulator assembly (2) moves the splitter piston forward, disengaging the rear
auxiliary drive gear (3).
Components
System
HI Range H - With the splitter control button in the "forward" position, air is supplied to the splitter cylinder cover top port (1),
moving the splitter piston rearward, engaging the rear auxiliary drive gear (2).
181
System Components
Insert Valve
inder.
regulator passes freely through the insert valve and to the cylinder piston backside, moving the yoke bar forward to disengage the
rear auxiliary drive gear (LO range and HI range L).
No air on
Signal Line
To piston
backside, yoke
bar forward
piston backside. This air is exhausted out the cover bottom port as constant air supplied from the regulator is directed to the cyl-
inder piston front side, moving the yoke bar rearward to engage the rear auxiliary drive gear (HI range H).
Air on
Signal Line
Constant
From piston back air sealed
rearward point
182
System Components

LO Range or HI Range Low Split - With the splitter control button in the "rearward" position, no air is supplied to the splitter cyl-
inder cover top port (1). The constant air from the air filter/regulator assembly (2) moves the splitter piston rearward, disengaging
the rear auxiliary drive gear (3).
Components
System
HI Range High Split - With the splitter control button in the "forward"position, air is supplied to the splitter cylinder cover top port
(1), moving the splitter piston forward, engaging the rear auxiliary drive gear (2).
183
System Components
Spool Valve
The spool valve piston travel is approximately 1/2". When no air is supplied from the Roadranger valve to the valve spool left side
(1), constant air from the filter/regulator (2) is supplied to the splitter cylinder piston rear side moving the yoke bar forward.
the splitter cylinder piston front side moving the yoke bar rearward. Air is exhausted from the splitter cylinder rear (3) and from the
184
System Components
RTO-15618 and RTLO-xx618 Model Splitter Cylinder Assembly

LO or HI Range L - With the splitter control button in the "rearward" position, no air is supplied to the splitter cylinder cover left
port (1). The constant air from the air filter/regulator assembly (2) moves the splitter piston rearward, disengaging the front aux-
iliary drive gear (3).
Components
System
LO or HI Range H - With the splitter control button in the "forward" position, air is supplied to the splitter cylinder cover left port
(1), moving the splitter piston forward, engaging the front auxiliary drive gear (2).
185
System Components
Insert Valve
inder.
supplied from the air filter/regulator moves the yoke bar rearward to engage the rear auxiliary drive gear (LO and HI range L), while
air is exhausted out the insert valve.
No air on
Signal Line
Exhaust
From piston Constant

backside, yoke air sealed
bar rearward off at this
point
piston front and backside, moving the yoke bar forward to engagethe front auxiliary drive gear (LO range and HI range H).
Air on
Signal Line
Constant
To piston back air sealed
forward point
Constant Air
186
System Components

top port (1). The constant air from the air filter/regulator assembly (2) moves the splitter piston forward, disengaging the rear
auxiliary drive gear (3).
Components
System
LO Range or HI Range H - With the splitter control button in the "forward" position, air is supplied to the splitter cylinder cover
top port (1), moving the splitter piston rearward, engaging the rear auxiliary drive gear (2).
187
System Components
Insert Valve
inder.
regulator passes freely through the insert valve and to the cylinder piston backside, moving the yoke bar forward to disengage the
rear auxiliary drive gear (LO range and HI range L).
No air on
Signal Line
Constant
Air
To piston
backside, yoke
bar forward
piston backside. This air is exhausted out the cover bottom port as constant air supplied from the regulator is directed to the cyl-
inder piston front side, moving the yoke bar rearward to engage the rear auxiliary drive gear (LO range and HI range H).
Air on
Signal Line
Constant
From piston back air sealed
rearward point
Exhaust
188
System Components

LO Range or HI Range Low Split - With the splitter control button in the "rearward" position, no air is supplied to the splitter cyl-
inder cover top port (1). The constant air from the air filter/regulator assembly (2) moves the splitter piston forward, disengaging
the rear auxiliary drive gear (3).
Components
System
LORange or HI Range High Split - With the splitter control button in the"forward" position, air is supplied to the splitter cylinder
cover top port (1), moving the splitter piston rearward, engaging the rear auxiliary drive gear (2).
189
System Components
Spool Valve
The spool valve piston travel is approximately 1/2”. When no air is supplied from the Roadranger valve to the valve spool left side
(1), constant air from the filter/regulator (2) is supplied to the splitter cylinder piston rear side moving the yoke bar forward. Air is
exhausted from the splitter cylinder front (3) and from the breather situated on the valve assembly rear.
the splitter cylinder piston front side moving the yoke bar rearward. Air is exhausted from the splitter cylinder rear (3) and from the
190
BasicAir System Drawings - 6610, 8609, and 6609
Engineering
Drawings
Reference
191
BasicAir System Drawings - 07L, 08, 08L, 09, and 10-Speed Models
192
BasicAir System Drawings - 07LL, 08LL, and 15 Speed Models
Engineering
Drawings
Reference
193
BasicAir System Drawings - 707LL, 7/908LL, 7/909LL, and 7/915 Speed Models
194
BasicAir System Drawings - 11613, 14613, and 15613 Speed Models
Engineering
Drawings
Reference
195
BasicAir System Drawings - 6613, and 7608LLSpeed Models
196
BasicAir System Drawings - 18 Speed Models Left-Hand Drive
Engineering
Drawings
Reference
197
BasicAir System Drawings - 18 Speed Right-Hand Drive
198
Copyright Eaton Corporation, 2012.
Eaton hereby grant their customers,
vendors, or distributors permission
to freely copy, reproduce and/or
distribute this document in printed
format. It may be copied only in
its entirety without any changes or
modifications. THIS INFORMATION
IS NOT INTENDED FOR SALE OR
RESALE, AND THIS NOTICE MUST
REMAIN ON ALL COPIES.
Note: Features and specifications listed
in this document are subject to change
without notice and represent the
maximum capabilities of the software
and products with all options installed.
Although every attempt has been
made to ensure the accuracy of
information contained within, Eaton
makes no representation about the
completeness, correctness or accuracy
and assumes no responsibility for
any errors or omissions. Features and
functionality may vary depending on
selected options.
For spec’ing or service assistance,
call 1-800-826-HELP (4357) or visit
www.eaton.com/roadranger.
In Mexico, call 001-800-826-4357.
Roadranger: Eaton and trusted partners

providing the best products and services in the
industry, ensuring more time on the road.
Eaton Corporation
Vehicle Group
P.O. Box 4013
Kalamazoo, MI 49003 USA
800-826-HELP (4357)
www.eaton.com/roadranger
Printed in USA
For parts or service call us
Pro Gear & Transmission, Inc.
1 (877) 776-4600
(407) 872-1901
parts@eprogear.com
906 W. Gore St.
Orlando, FL 32805

Fuller Transmissions TRTS0920: Troubleshooting Guide

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Fuller Transmissions TRTS0920: Troubleshooting Guide

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Troubleshooting Guide

Warnings and Precautions

Always use genuine Eaton replacement parts.

General Information RTLO-xxX610 Models ..............................................125

Engineering Reference Drawings

How to use this Troubleshooting/Operation Guide

This guide provides four functions

2-Speed Auxiliary/3-Speed and 2x2 Auxiliary

Combination Cylinder / RTLO-10 Speeds

Air Filter/ Regulators

Control Valves - Old Production

DeepReductionValve A-5010 A-5015

8, 9, and10 Speeds 8LL, 15, 6613 Speeds

A-5510 A-4900 A-5013

Gray Red Gray

RTLO-10 Speeds RT/RTLO13 Speeds RTLO-18 Speeds

Control Valves - Current Production

8, 9, and 10 Speeds 8LL, 15, 6613 Speeds

A-6910 A-6913 A-6918

RTLO-10 Speeds RT/RTLO 13 Speeds RTLO-18 Speeds

Lubricants and Sealants

Name: Eaton® Fuller® Silicone Lubricant

Name: Eaton® Fuller® Sealant

Suggested Test Fixtures

Test Fixture for Range Cylinder

5/32" Air Line

0-100 PSI Gauge

84006 - 5/32" Push-To-Connect

0-100 PSI Gauge 5/32" Air Line

84006 - 5/32" Push-To-Connect

85002 - Elbow Assembly

83501 - Grip Nut

Test Fixture For 5/32" Air Line

0-100 PSI Gauge

84006 - 5/32" Push-To-Connect

5/32" Air Line

8, 9, 10, 11, 13, 15, and 18-Speed Troubleshooting

Procedure 1: Symptom - Air Leak at Shift Knob

Table 10 Air Leak at Shift Knob

Procedure 2: Symptom - Air Leak at Slave Valve

Procedure 3: Symptom - Air Leak from Transmission Breather or Transmission Case is

Procedure 4: Symptom - Air Leak at Splitter Cylinder Cover Exhaust Port

Procedure 5: Symptom - No or Slow Range Shift into Low

No air flow from disconnect- Go to

Table 14 No or Slow Range Shift into Low

Table 14 No or Slow Range Shift into Low

Table 14 No or Slow Range Shift into Low

Procedure 6: Symptom - No or Slow Range Shift into High

Table 15 No or Slow Range Shift into High

Table 15 No or Slow Range Shift into High

Table 15 No or Slow Range Shift into High

Procedure 8: Symptom - Range Shifts with Shift Lever in Gear

RTLO 10-Speed Troubleshooting

Confirm Correct Components and Plumbing

Red Air Line

Blue Air Line

Air Filter/ Regulator Test

Table 1 Air Filter/Regulator Test

Table 1 Air Filter/Regulator Test

Range System Test

Table 2 Range System Test

Table 2 Range System Test

There is air flow. Remove the insert valve retaining