Freightliner Cargo Maintenance Manual - part 10

Title of Maintenance Operation (MOP)

MOP Number

Allison Transmission Fluid and Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–05

Allison and Eaton/Fuller Transmission Breather Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–03

Eaton/Fuller Transmission Air Filter/Regulator Element Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–04

Manual Transmission Oil Change and Magnetic Plug Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–02

Manual Transmission Oil Level Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–01

Transmission

Index, Alphabetical

Cargo Maintenance Manual, January 2000

26–01 Manual Transmission Oil

Level Check

With the transmission at operating temperature,
and the vehicle on a level surface, check the oil
level in the transmission.

1.1

Clean the area around the fill plug. Re-
move the plug from the side of the case.

1.2

Using your finger or a bent pipe cleaner,
see if the oil is level with the lower edge
of the fill opening. See

Fig. 1

If needed, fill the transmission with oil until level
with the lower edge of the fill opening.

See

Table 1

for approved lubricants.

Approved Transmission Lubricants

Lubricant Type

Temperature: °F (°C)

SAE

Viscosity

Eaton/Fuller Transmissions

Heavy-Duty

Engine Oil API

Service

Classification SF

or CD

Above 10 (–12)

40 or 50

Below 10 (–12)

Allison AT and MD Series Transmissions

†

Dexron II

–25 to +120 (–32 to +48)

—

Allison MT Series Transmissions

Dexron

IIE

–10 to +120 (–23 to +48)

—

Dexron

III

–10 to +120 (–23 to +48)

—

Type C4

10 to 120 (–12 to +48)

SAE 10W

Type C4

32 to 120 (0 to 48)

SAE 30W

Lubricants listed in order of preference. Do not mix types of oil.

†

Factory filled with Dexron II. For off-highway operation or where ambient

temperature is consistently above 86°F (30°C) or below –25°F (–32°C), re-
fer to the manufacturer’s fluid recommendations.

Table 1, Approved Transmission Lubricants

CAUTION

Operating an Eaton/Fuller transmission with the
oil level higher or lower than recommended can
result in transmission damage. Do not overfill the
transmission. Overfilling the transmission will
force oil out of the case through the main shaft

openings. Oil overflow may also drain onto the
clutch or clutch brake causing additional prob-
lems.

IMPORTANT: Do not mix types of oil, because
of possible incompatibility. Do not use oil addi-
tives, friction modifiers, or synthetic lubricants.

Clean the fill plug. Install the fill plug in the trans-
mission. Tighten the plug:

•

20 to 25 lbf·ft (27 to 34 N·m) for a 3/4-inch
plug;

•

60 to 75 lbf·ft (81 to 102 N·m) for a 1-1/4-
inch plug.

26–02 Manual Transmission Oil

Change and Magnetic
Plug Clean

Draining

Clean the area around the fill plug.

Remove the fill plug from the side of the case.
Remove the drain plug(s) from the bottom of the
transmission case.

Drain the oil while the transmission is warm.

Clean the magnetic plug(s) before installing it.
(Use a piece of key stock, or any other conve-
nient steel slug, to short the two magnetic poles
and divert the magnetic field.) Install and tighten
the drain plug(s) 20 lbf·ft (27 N·m).

f260006b

10/05/94

A. Full

B. Low

Fig. 1, Transmission Oil Level Checking

Transmission

Cargo Maintenance Manual, January 2000

26/1

Filling

Add oil until it is level with the lower edge of the
fill opening. See

Fig. 1

. If the transmission has

two fill openings, add oil to the level of both fill
openings.

See

Table 1

for approved transmission lubri-

cants, and

Table 2

for lubricant capacities.

Transmission Lubricant Capacities

Transmission

Refill Capacity

quarts (liters)

Eaton/Fuller Models

FS-4205A/B

4.75 (4.5)

FS-5205A/B

5.25 (5.0)

FS-6305A/B

9.5 (9.0)

FS-5306A

9.0 (8.5)

FS-6306A

9.0 (8.5)

FS-8206A

10.0 (9.5)

RT-6609A

6.0 (5.7)

Allison Models

AT-545

16.0 (15.0)

17.5 (16.5)

MT-643
MT-653

15 (14)

Quantities listed are approximate. Fill the transmission until the lubricant

is level with the bottom of the fill hole (on Eaton/Fuller transmissions) with
the vehicle in normal operating position. On Allison transmissions, add the
recommended amount of fluid as listed under refill capacity. Perform a "hot
check" and add fluid as needed. Do not overfill.

Table 2, Transmission Lubricant Capacities

CAUTION

Operating a Eaton/Fuller transmission with the oil
level higher or lower than recommended can re-
sult in transmission damage. Do not overfill the
transmission. Overfilling the transmission will
force oil out of the case through the main shaft
openings. Oil overflow may also drain onto the
clutch or clutch brake causing additional prob-
lems.

IMPORTANT: Do not mix types of oil, because
of possible incompatibility. Do not use oil addi-
tives, friction modifiers, or synthetic lubricants.

NOTE: The correct oil capacity is established by
the fill plug opening.

Clean the fill plug. Install the fill plug. Tighten the
plug:

•

20 to 25 lbf·ft (27 to 34 N·m) for a 3/4-inch
plug;

•

60 to 75 lbf·ft (81 to 102 N·m) for a 1-1/4-
inch plug.

26–03 Allison and Eaton/Fuller

Transmission Breather
Check

Transmission housing breathers must remain clear. A
plugged breather could result in pressure build-up
which could cause oil leakage.

If the breather is plugged, clean or replace it. See

Fig. 2

. Check more often if the vehicle is operating

under very dusty conditions.

26–04 Eaton/Fuller

Transmission Air Filter/
Regulator Element Clean

Exhaust the air from the air reservoirs.

f260007a

05/27/93

Fig. 2, Transmission Breather (Eaton/Fuller shown)

Transmission

Cargo Maintenance Manual, January 2000

26/2

WARNING

Exhaust the air supply before servicing the air
filter/regulator; otherwise, serious personal injury
and component damage could result.

Clean the outside of the air filter/regulator with
cleaning solvent. Let it air dry. See

Fig. 3

Remove the end cap, large O-ring, and filter ele-
ment from the filter housing. See

Fig. 4

. Remove

the small O-ring from the end cap.

NOTE: Do not remove, disassemble, or adjust
the air regulator. If the air regulator is not keep-
ing the air pressure between 57 to 62 psi (396
to 431 kPa), replace the air filter/regulator,
which is not serviceable.

Clean the filter element.

4.1

Dip the filter element in alcohol or other
cleaning solvent. Blow compressed air
through the filter element (inside to out-
side) to loosen surface dirt and to dry the
element. The sintered metallic filter ele-

ment will last the life of the vehicle, pro-
vided it is not damaged.

4.2

Wipe out the filter housing with a clean,
dry, lint-free rag.

Clean and inspect the O-rings and the end cap.
Replace any parts that are damaged.

Install the large O-ring into the filter housing.

Install the filter element (small end first) into the
filter housing.

Install the small O-ring into the end cap. Install
the end cap on the filter housing. Tighten the end
cap 8 to 12 lbf·ft (11 to 16 N·m).

Start the engine and build up pressure in the air
system. Check for air leaks at the filter housing
and air line connections and repair any leaks.

CAUTION

Repair any air leaks. A leaking air filter or air lines
can cause slow or hard shifting of the transmis-
sion and eventual transmission damage.

f260037a

05/27/93

Fig. 3, Eaton/Fuller Transmission Air Filter/Regulator

Location

f260052a

10/17/2001

Air Regulator

Housing

Large O-Ring

Filter Element

Small O-Ring

End Cap

Plug

Fig. 4, Eaton/Fuller Transmission Air Filter/Regulator

Components

Transmission

Cargo Maintenance Manual, January 2000

26/3

Content .. 8 9 10 11 ..