Eaton Fuller RTLO Series Heavy Duty Transmission Service Repair Manual PDF

Description

Eaton Fuller RTLO Series Heavy Duty Transmission Service Repair Manual

This Eaton Fuller RTLO Series Heavy Duty Transmission Service Repair Manual is the complete workshop reference for technicians servicing Roadranger twin countershaft transmissions from the RTLO-11610B through the RTLO-18610B family. Published under document number TRSM0550 (July 2010), it walks through every major overhaul procedure on these units — external parts, shift bar housing, front section, auxiliary section, and the integral oil pump option — with photographs, exploded illustrations, and torque values printed alongside each step.

Whether you are rebuilding a worn RTLO-14610B, resealing an auxiliary section, replacing an input shaft without pulling the whole gearbox apart, or timing countershafts after a bearing change, this Eaton Fuller RTLO Series service repair manual gives you the exact sequence and the exact numbers. The procedures are written for the technician working on the bench, not for a classroom — each section assumes the transmission is out of the chassis and ready for teardown.

File Details

• Manual type: Heavy duty transmission service repair manual
• Brand: Eaton Fuller
• Series: RTLO (Roadranger Twin Countershaft, Low Inertia, Overdrive)
• Document number: TRSM0550
• Publication date: July 2010
• Language: English
• Page count: 179 pages
• File format: PDF

Models Covered

This manual applies to the following Eaton Fuller RTLO Series heavy duty transmissions:

• RTLO-11610B, RTLO-11610B-T2
• RTLO-12610B, RTLO-12610B-T2
• RTLO-13610B, RTLO-13610B-T2
• RTLO-14610A, RTLO-14610B, RTLO-14610B-T2
• RTLO-15610B, RTLO-15610B-T2
• RTLO-16610B, RTLO-16610B-T2
• RTLO-17610B, RTLO-17610B-T2
• RTLO-18610B, RTLO-18610B-T2

Chapters Covered

• General Information — general service practices and part inspection, how to use this manual, model designation, power flow (1st, 2nd, 7th, 8th gear), timing procedures, tool reference
• Preventive Maintenance — lubrication, preventive maintenance schedule, inspection, rear seal maintenance
• External Parts — disassembly and assembly of external components, air lines and hose removal/installation, air filter/regulator, Roadranger valve, range actuator valve, Top 2 valve assembly, gear shift lever, shift bar housing, output yoke/companion flange, auxiliary section (with and without tapered bearings), shimming procedure for tapered bearings, clutch housing, input shaft removal and installation without disassembling the transmission
• Shift Bar Housing — identification, gear shift lever disassembly/assembly, standard shift bar housing disassembly/assembly, standard shift bar housing with Super 10 on cover, forward shift bar housing with Super 10 on cover, new forward shift bar housing with Super 10 on cover
• Front Section — disassembly and assembly of the front section, auxiliary drive gear assembly, reverse idler gear assembly, countershaft bearings, mainshaft assembly, countershaft assemblies, input shaft assembly, countershaft assembly disassembly/assembly, mainshaft assembly disassembly/assembly
• Auxiliary Section — auxiliary section disassembly and assembly, front auxiliary drive gear, countershaft assemblies with tapered bearings, countershaft assemblies with ball bearings (A Series), rear auxiliary drive gear, range cylinder assembly, output shaft assembly, splitter cylinder assembly, synchronizer assembly
• Options — integral oil pump removal, installation, disassembly, and assembly

What This Eaton Fuller RTLO Series Service Repair Manual Gives You

The RTLO Series is a twin countershaft design, and getting one back together correctly depends on details that are easy to miss — timing marks on the countershaft drive gears, the shimming procedure for tapered auxiliary bearings, and axial clearances on the mainshaft gears. This manual documents all of it. The timing procedure chapter explains how to mark the countershaft drive teeth stamped with an “O” and the paired teeth on the main drive gear, and how to mesh them correctly so the mainshaft gears stay centred under load. Skip that step and the gears climb out of equilibrium and destroy themselves.

The auxiliary section coverage is equally detailed, with separate procedures for units running tapered bearings versus ball bearings on the A Series. The shimming chart for tapered bearings lists feeler gauge measurements, shim thicknesses, part numbers, and colour codes so you can select the right shim the first time rather than guessing and re-pulling the cover.

Torque values appear throughout the procedures as they are needed — output yoke retaining nut at 450–500 lb-ft, shift bar housing retaining capscrews at 35–45 lb-ft, clutch housing nuts at 175 lb-ft, countershaft retaining capscrews at 90–120 lb-ft, PTO cover capscrews by bolt count, range piston retaining nut at 70–85 lb-ft, and many more. Sealant and lubricant callouts are specified by Eaton part number (#71205, #71206, #71208, #71209, #71210, #71212, #71213, #71214, #71215) so you use the correct product on each joint.

Detailed Procedures Included

Overhauling a heavy duty Roadranger transmission is a sequence job. Remove the wrong part first and you create extra work. The flow charts at the start of each tabbed section show the order in which the unit should be disassembled and reassembled, and the procedures follow that order step by step. Inside this Eaton Fuller RTLO Series heavy duty transmission repair manual you will find:

• Removing and installing the auxiliary section in both horizontal and vertical positions, with and without tapered bearings
• The complete shimming procedure for tapered auxiliary bearings, including the feeler gauge measurement method and shim selection chart
• Disassembling and assembling the standard, forward, and new forward shift bar housings, including the Super 10 on cover variants
• Interlock system assembly so the transmission cannot be shifted into two gears at once
• Mainshaft assembly stack-up with axial clearance checks using feeler gauges and limit washer selection
• Countershaft assembly pressing sequence with gear keyway alignment and bearing inner race installation
• Input shaft replacement without disassembling the transmission — useful when only the input shaft or its bearing needs attention
• Range cylinder and splitter cylinder assembly, including insert valve orientation and piston O-ring installation
• Synchronizer assembly with spring compression and pin alignment
• Integral oil pump removal, disassembly, assembly, and installation, including retainer plate part number notes for maincases machined after April 1995
• Air system components: air filter/regulator, Roadranger valve, range actuator valve, Top 2 valve assembly, and air line/hose routing

Specifications and Service Data

Beyond the step-by-step teardown, the manual carries the service data you need to judge whether a part goes back in or gets replaced. Bearing inspection criteria cover pitting, discoloration, spalling, and axial/radial clearance. Gear inspection covers frosting, pitting stages, clutching teeth wear, and axial clearance. Inspection checklists for bearing covers, clutch release parts, gray iron castings, O-rings, reverse idler gear assemblies, shift bar housings, sliding clutches, splines, synchronizer assemblies, and washers are all included.

Operating limits are documented as well: transmission operating angle must not exceed 12° without an oil pump or cooler kit, continuous operating temperature must stay below 250°F with intermittent peaks to 300°F, and the oil cooler chart specifies when cooling is recommended versus required based on engine horsepower and GCW.

Who This Manual Is For

This is a bench manual for transmission technicians, fleet maintenance shops, and experienced owner-operators who pull their own gearboxes. The procedures assume the transmission has been removed from the chassis, the lubricant drained, and the linkage and air lines disconnected. If you are doing clutch work, a rear seal, an auxiliary section reseal, a bearing replacement, or a full overhaul on any RTLO-11610B through RTLO-18610B unit, this is the reference that matches the hardware in front of you.

Get Your Eaton Fuller RTLO Series Transmission Manual Today

With this Eaton Fuller RTLO Series Heavy Duty Transmission Service Repair Manual on hand you can tear down and rebuild your Roadranger transmission to factory procedure, torque every fastener to spec, time the countershafts correctly, and shim the auxiliary bearings properly the first time. That means fewer comebacks, less downtime, and a gearbox that shifts cleanly through every range.

Correct procedures and correct specifications are what separate a transmission that lasts from one that fails again in 20,000 miles. The manual delivers both, in the order you need them.

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