TRTS0920 0711-Branding PDF

Troubleshooting Guide
Fuller Transmissions
TRTS0920
July 2011
Warnings and Precautions

Warnings and Precautions
WARNING
Before starting a vehicle always be seated in the drivers seat, place the transmission in neutral, set the parking brakes and
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 avoid damage 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
time without notice.
Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use
and should not be considered an endorsement. Equivalents may be used.
This symbol is 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
How to use this Troubleshooting/Operation Guide ...... 1
Transmission Identification ......................................... 2
Component Identification ............................................ 4
Lubricants and Sealants .............................................. 6
Suggested Test Fixtures .............................................. 7
RTLO-xxX610 Models ..............................................125

RTL-xx710 Speed Models ........................................129
RTL-xx710 Models ..................................................130
AT-1202 Auxillairy Transmission
(with 2 Position Shift Valve) .............................134
AT-1202 Auxiliary Housing (3 Position Valve) .........135
System Components
Air System Troubleshooting
8, 9, 10, 11, 13, 15, and 18-Speed Troubleshooting ... 8
RTLO 10-Speed Troubleshooting .............................. 23
Combination Cylinder Troubleshooting ..................... 33
FR-1X210 Troubleshooting ....................................... 51
Operation
Air Line Color Chart ................................................... 64
Slave Valve Preselection System ............................... 65
7,8,9 and 10-Speed Range Air Systems .................... 66
7L,8,9 and 10-Speed (2-Speed auxiliary) .................. 67
RT & RTO-610,6610, 6609, and 8609 Models .......... 69
Deep Reduction Air System
(with Dash Mounted Valve) ................................ 71
RT, RTO, & RTX xx607LL,
xx608LL, and xx615 models .............................. 72
Deep Reduction Air System
(with A-6915 Roadranger Valve) ........................ 75
RT, RTO, & RTX xx607LL,
xx608LL, and xx615 Models .............................. 76
9 and 13-Speed Air Systems
(Top 2 & Convertible) and 18-Speed (Top-2) .... 79
RT, RTO, & RTOO xx613 and xx813 Models ............. 83
RTLO-xx613 Models ................................................. 86
RTLO-xx713 Models ................................................. 89
RTLO-xx913 Models ................................................. 92
RT0-15618 and RTLO-xx618 Models ........................ 95
RTLO-xx718 Models ................................................. 99
RTLO-xx918 Models ............................................... 103
Combination Cylinder Air System ............................ 107
7LL/DLL/MLL, 8LL, 9MLL, and 15-Speed Models .. 108
Unique Air Systems ................................................. 111
RT &RTO 613 and 6613 Models ............................. 112
RT & RTO 613 and 6613 Models
With A-6913 Roadranger Valve ....................... 115
RT & RTO 613 and 6613 Models ............................ 116
7608LL with A-6915 Roadranger Valve ................... 119
7608LL Models ....................................................... 120
RTLO-xx610 Speed Air System ............................... 123
A-4740 Air Filter/Regulator Assembly ......................137

A-5161/A-5454 Air Filter/Regulator Assembly .........138
A-3546 Range Valve ................................................139
A-5010/A-6909 Roadranger Valve ...........................140
14651 Reduction Valve (Dash-Mounted) .................141
Two Position Selector Valve ....................................143
Three Position Selector Valve ..................................147
Range Actuator Valve (Old Design) ..........................150
Range Actuator Valve (Latest Design) .....................151
19470 Poppet-Type Slave Valve ..............................152
A-4688 Slave Valve ..................................................153
A-5000 Slave Valve ..................................................154
Range Cylinder ........................................................155
Range Cylinder for 610, 6610, 6609 and 8609 ........156
Dash-Mounted Deep Reduction Cylinder .................157
Deep Reduction Cylinder with Roadranger Valve .....158
RTLO-xx610 Model Range Cylinder Assembly ........160
RTL-xx710 Model Range Cylinder Assembly ...........162
Intermediate Shift Cylinder Assembly
613 and 6613, 3-Position Selector Valve ..........164
Intermediate Shift Cylinder Assembly
613 and 6613, A-5015 Roadranger Valve .........166
Combination Cylinder Assembly ..............................168
Splitter Cylinder Assembly .......................................171
RTLO-xx610 Model Splitter Cylinder Assembly
(Old Design) ....................................................173
(Latest Design) .................................................175
RTL-xx710 Model Splitter Cylinder Assembly ..........177
RTLO-xx613 Model Splitter Cylinder Assembly .......179
RTO-15618 and RTLO-xx618 Model
Splitter Cylinder Assembly ...............................185
Table of Contents
Engineering Reference Drawings
Basic Air System Drawings 6610,8609, and 6609 ....................................... 191
Basic Air System Drawings 07L, 08, 08L, 09, and 10-Speed Models .......... 192
Basic Air System Drawings 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
Basic Air System Drawings 18 Speed Models Left-Hand Drive ................... 197
Basic Air System Drawings 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 material.
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.
General Information
1
General Information
Transmission Identification
2-Speed Auxiliary/3-Speed and 2x2 Auxiliary
Roadranger
Valve
Air Lines
Range Cylinder
Air Filter/
Regulator
Slave
Valve
2-Speed
Auxiliary
Air Hoses
Roadranger
Valve
Air Lines
Range Cylinder
Slave
Valve
Air Filter/
Regulator
3-Speed
&
2X2 Auxiliary
Air Hoses
Deep Reduction or
Splitter Cylinder
General Information
Combination Cylinder / RTLO-10 Speeds
Roadranger
Valve
Combination
Air Lines
Cylinder
Combination
Cylinder
Air Filter/
Regulator
Slave
Valve
General Information
Air Hoses
Roadranger
Valve
RTLO-10 Speeds
Air Lines
Range Cylinder
Range
Actuator
Valve
CYL
NC
NO
Air Filter/
Regulator
Air Hose
Splitter Cylinder
General Information
Component Identification
Air Filter/ Regulators
Control Valves - Old Production

A-3546
Three Position Selector
A-5010
A-5015
DO
WN-
LOW
UP
-HIG
H
Deep Reduction Valve

14651
E DUCT
PR
I
E E SHIFT ONLY O
OUT
WHEN IN LOW
RANGE
Blue
Two Position Selector
IN
DO NOT
PRE-SELECT
8, 9, and 10 Speeds
A-5510
RTLO-10 Speeds
A-5013
A-4900
Gray
8LL, 15, 6613 Speeds
Red
RT/RTLO 13 Speeds
Gray
RTLO-18 Speeds
General Information
Control Valves - Current Production
A-6909
A-6915
Blue
8, 9, and 10 Speeds
A-6910
8LL, 15, 6613 Speeds
A-6918
A-6913
RTLO-10 Speeds
Gray
Red
RT/RTLO 13 Speeds
General Information
Gray
RTLO-18 Speeds
Slave Valves
19470 - Obsolete
A-4688 - Old
A-5000 - Current
23545 - old design
4303110 - latest design
Range Valves
EXH
EXH
NC
CYL
NO
23545
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
Part #:
Part #:
Where Used:
Air fittings and threads
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
General Information
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
1/8" Air Line
83501 - Grip Nut

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

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 combination 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 duplicated. 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.

Procedure 1: Symptom - Air Leak at Shift Knob
Normal Operation:
A burst of air will be exhausted from the shift knob when moving the range selector 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
Internal leak at shift knob
Table 10 Air Leak at Shift Knob

Procedure
Step A
Result
Remove lower skirt on shift knob. Leak found.

Check for leaking fitting at the shift
knob.
No leak found.
Step B
What to do next
Repair leaking fitting or air line.
Go to 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.
to low range. Check for constant air
flow from the exhaust E port.
No air flow from E port.
Step D
Replace knob.
Go to 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.

Procedure
Step E
Result
Reattach the air line to the P port. Air is flowing from the SP line.
Move the range selector down to low
range and move the splitter button
rearward. Disconnect line from the
SP port. Check for air flowing from
the SP port on the shift knob.
What to do next
1. Check to make sure the SP line
is connected to the splitter cylinder
cover.
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.
10
Repair or replace the shift knob.

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

Procedure
What to do next
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 supply port on range cylinder.
range.
Remove the 1/4" I.D. rubber air line at
the high range supply port on the range
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.
Remove range cylinder cover and

repair leaking range piston or piston seal. After repair, check for
proper range operation.
Repair or replace slave valve.
11
Step A
Result

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

Procedure
Step A
Result
Listen for the air leak with the trans- Leak is only in low range.
mission shifted to both low and
high range.
Leak is in
high range.
12
What to do next
both
low
Remove range cylinder and inspect for

damaged range yoke bar, yoke bar Oring, or range cylinder. Repair as necessary.
and Remove splitter cylinder. Inspect for
damaged splitter yoke bar, O-ring, or cylinder. Repair as necessary.

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

Procedure
Result
or
damage Repair or replace as necessary.
No contamination or damage Go to Step B.

found.
Step B
Remove the splitter cylinder cover and piston. Contamination

Check the piston bore for contamination or damage. found.
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.
or
damage Repair or replace as necessary.
13
Step A (old Remove insert valve. Check for contamination, dam- Contamination
style)
aged seals, or sticky movement. Check the insert found.
valve bore in the splitter cylinder cover for contamination or damage which would result in leakage past
the insert valve O-rings.
What to do next

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

Procedure
Step A
Result
Constant air leak is detected.

Place the shift lever in neutral.
Check for constant air leakage at the shift
knob, slave valve, and transmission case
breather when both low and high range
have been selected.
No constant leak is detected.
Step B
What to do next
Go to the other corresponding symptom first. See beginning of Air System
Troubleshooting section.
Go to Step B.
Air flows from the low range Remove range cylinder cover and rePlace shift lever in neutral.
pair leaking range piston or piston seal.
Move range selector up to high range port.
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
Procedure
Result
What to do next
Install a 100 PSI air gauge in the disconnected air line end. With the shift lever in
neutral, move the range selector down to
select low range. Observe the gauge.
The gauge read 0 PSI.
Go to step F.
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.
The gauge reads between 58 - Go to step E.
63 PSI.
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.
1/4" rubber air line between the slave
valve and the test gauge.
4. If all are satisfactory, go to step F.
Step F
Air flows from the discon- 1. Confirm that the air lines are conPlace shift lever in neutral.
nected to the correct ports at the shift
At the shift knob, move the range selec- nected line.
knob.
tion lever up to select high range.
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.
the slave valve.
No air flow from this port.
Replace the slave valve.

Go to step H.
15
Step E

Procedure
Step H
Result
Place the shift lever in neutral. Install a The gauge responds slowly.
100 PSI pressure gauge in line with the
"P" line. Move the range selector back
and forth from low to high range. The
gauge should show rapid pressure
change.
What to do next
1. Check for a restricted line between
the shift knob and slave valve.

shift knob.
3. Check for a plugged or dirty filter in
the filter / regulator assembly.
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
check for damage.
slave valve. Unbolt the slave valve from not move freely.
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

Procedure
Step R
Result
What to do next
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
Cracked countershaft weld resulting in
gear turning on shaft
Damaged or defective range 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 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:
Plugged filter
Incorrect regulator pressure
Table 15 No or Slow Range Shift into High

Procedure
Step A
Result
Constant air leak is detected.

Place the shift lever in neutral.
Check for constant air leakage at the shift
knob, slave valve, and transmission case
breather when both low and high range
have been selected.
Step B
Air flows from the high range

Place shift lever in neutral.
Move range selector down to low range port.
position.
At the transmission rear, disconnect the
1/4" rubber air line from the range cylinder high range supply port.
Check for air flow from the cylinder high
range port.
What to do next
Go to Step B.
Remove range cylinder cover and repair leaking range piston or piston seal.
After repair, check for proper range operation.
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
Procedure
Result
What to do next
Install a 100 PSI air gauge in the disconnected air line end. With the shift lever in
neutral, move the range selector up to
select high range. Observe the gauge.
The gauge reads 0 PSI.
Go to step F.
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.
The gauge reads between 58 - Go to step E.
63 PSI.
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.
2. Check for a pinched or obstructed 1/
4" rubber air line between the filter/regulator and slave valve.
4" rubber air line between the slave
Step F
Air flows from the discon- 1. Confirm that the air lines are conPlace shift lever in neutral.
nected to the correct ports at the shift
At the shift knob, move the range selec- nected line.
knob.
tion lever up to 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.
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.
valve "P" port.

Go to step H.
19
Step E

Procedure
Step H
Result
Place the shift lever in neutral. Install a The gauge responds slowly.
100 PSI pressure gauge in line with the
"P" line. Move the range selector back
and forth from low to high range. The
gauge should show rapid pressure
change.
What to do next
2. Check for a restricted exhaust port

on the shift knob.
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
not move freely.
check for damage.
slave valve.
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.
Actuating plunger pin moves Repair or replace slave valve and check
freely.
for proper range operation.
20

Procedure
Step R
Result
What to do next
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:
Cracked countershaft weld resulting in
gear turning on shaft
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. 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. Confirm 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.)
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
CYL
NC
NO
Black Air Line

A-5454
Air Filter/
Regulator
Blue Air Line
Air Hose
23
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.

Air Filter/ Regulator Test
Figure 1
Figure 2
Table 1 Air Filter/Regulator Test

Step
Procedure
Place the transmission shift lever

in neutral.
Start the engine and wait for the

air system pressure to reach governor cut off (90 to 125 PSI.)
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 continue testing.
Make sure the splitter control button is rearward.
Remove the two (2) screws on the

Roadranger valve cover and pull
the cover down.
Disconnect the blue air line from

the "SP" port.
Install the correct test fixture for

your air line size in the "SP" line.
24
Result
What to do next

Table 1 Air Filter/Regulator Test
Step
Procedure
Result
What to do next
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.
Remove the test fixture. Assemble

the Roadranger valve.
25
Air pressure slowly comes up to Inspect the red air line from the filter/regulator
between 58 and 63 PSI.
to the range actuator valve and the red air line
from the range actuator valve to the A-5510/A6910 Roadranger valve for restrictions

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 external 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

Step
Procedure
Result
Move the transmission shift lever in

neutral away from the driver to the top
gear rail position.
Remove the black air line from the

range cylinder cover.
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.
26
What to do next
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 operated, 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
inspection.

Step
Procedure
Result
Check for air flow from the range cyl- There is no air flow from the port.
inder port.
There is air flow.
What to do next
Go to step E.
Install the correct test fixture, for your

air line size, in the range cylinder port.
Move the transmission shift lever to- Air pressure rapidly comes up to be- Remove the test fixture and connect
the black air line to the range cylinder.
ward the driver (center rail.) The air tween 58 and 63 PSI.
If air pressure does rapidly come up to
pressure should rapidly be between 58
between 58 and 63 PSI, remove the
and 63 PSI.
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 restrictions.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 up to
between 58 and 63 PSI, replace the
range actuator valve.
27
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 air and apply silicone
grease to the external O-rings. Assemble and check for air flow from the
port. If air flow persists, replace the
insert valve.

Step
Procedure
Listen for a range shift while moving There is no range shift and there is
the transmission shift lever from neu- momentary exhaust from both insert
tral to the top gear rail and back toward valves.
the driver into the center rail. If there is
no range shift, move the transmission
shift lever back and forth again and
check for a momentary exhaust from
the insert valve retaining plug in the
range cylinder cover bottom.
Result
Remove the insert valve retaining plug

from the range cylinder cover bottom.
the cover. Clean the insert valve, use
grease to the external O-rings. Assemble 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.
Move the transmission shift lever in There is air flow.

neutral toward the driver to the center
rail. Check both insert valve retaining
plugs for continuous air flow from the
exhaust port.
Move the transmission shift lever in There is air flow.

neutral away from the driver to the top
gear rail. Check both insert valve retaining plugs for continuous air flow
from the exhaust port.
There is no air flow.
28
Remove the range cylinder cover. If

the piston is stuck from rust and contamination, remove the piston, clean
the cylinder, replace the O-rings, and
assemble. Clean the insert valve, use
grease to the external O-rings. Assemble and test.
There is no momentary exhaust.
There is no air flow.

J
What to do next
Remove the insert valve retaining plug.

grease to the external O-rings. Assemble 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.
Go to step J.
Remove the insert valve retaining plug.
grease to the external O-rings. Assemble and check for air flow. If air
flow persists, replace the insert valve.
Go to step K.

Step
Procedure
Result
With the transmission shift lever in Air flow stopped.

neutral, toward the driver in the center
rail, remove the breather or breather
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.
Refer to the service manual and replace the range piston shaft to range
cylinder O-ring.
Refer to the service manual and replace the splitter piston shaft to splitter
cylinder O-ring.
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 apply silicone grease to the external "O"
rings. Assemble and test. The range
portion of the test is now complete.
29
Air flow did not stop.
What to do next

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

Step
Procedure
Wipe off the area around the insert

valve exhaust port.
Move the control button back and

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

Step
Procedure
Result
Remove the loosened control air line There is no air flow.

and check for air flow from the cylinder fitting.
There is air flow.
Install, between the control line and

the cylinder fitting, the correct test fixture for your air line size.
Move the control button forward.
Go to step E.
Remove the insert valve and clean using compressed air. Then apply silicone grease to the o-rings and
recheck for airflow.
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 restrictween 58 and 63 PSI and the truck's tions.
air system is 90 to 125 PSI.
Check the insert valve exhaust port for No leakage is detected.

leakage.
Leakage is detected.
Move the control button rearward and There is a shift.

listen for the shift.
Check the exhaust port for leakage.
Go to next step H.
Go to Step L.
Go to next step I.
There is no shift or a delayed shift.
Go to Step L.
No leakage is detected.
Go to next step J.
Go to Step L.
Move the control button forward and There is a shift.

Go to next step K.
Go to Step L.
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.
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 orientation.)
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.
Clean insert valve using compressed

air.
31
What to do next

Step
Procedure
Result
Install the insert valve, as noted in

Step L, and replace the retaining plug.

leakage.


leakage.
Move the control button rearward and There is a shift.

listen for the shift

leakage.

32
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.
What to do next
Go to next step P.
Replace the insert valve.
Go to next step Q.
Go to next step R.
Go to next step S.
Go to next step T.
Disassemble (see service manual)
and inspect splitter/reduction piston
O-ring and piston to shaft seal.
Go to next step V.
Disassemble (see service manual)
and inspect splitter/reduction piston
O-ring and piston to shaft seal.

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)
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 vehicle 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 procedures.
33

Procedure 1: Symptom - Air Leak at Shift Knob
Normal operation:
A burst of air will be exhausted from the shift knob when moving the range selector 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 deep reduction button rearward (shifting out of deep reduction).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

Procedure
Step A
Result
Remove lower skirt on shift knob. Check Leak found.

for leaking fitting at the shift knob.
No leak found.
Step B
What to do next
Repair leaking fitting or air
line.
Go to 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 button 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.
Low range. Check for constant air flow
from the exhaust E port.
No air flow from E port.
Step D
Replace knob.
Go to Step D.
Move the range selector up to high range. Constant air is leaking from the P port Repair or replace the shift
knob.
Disconnect the small air line connected or the E port.
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

Procedure
Step E
Result
Reattach the air line to the P port. Move Air is flowing from the SP line.
the range selector down to low range and
move the deep reduction button rearward. Disconnect the air line from the
SP port. Check for air flowing from the
SP line.
What to do next
1. Check to make sure the
SP line is connected to the
deep reduction cylinder cover.
3. Replace the insert valve.

Air is not flowing from the line.
Repair or replace the shiftknob.
35
2. If the line is properly attached, check that the insert

valve is properly installed
(stem facing inward) and
that the insert valve bore is
not defective.

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 2 Air Leak at Slave Valve

Procedure
Step A
Result
What to do next
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 repair leaking range piston or piston seal.
low range. Remove the 1/4 I.D. ply port on range cylinder.
After repair, check for proper range oprubber air line at the high range superation.
ply port on the range cylinder. Feel
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.
36
Repair or replace slave valve.

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

Procedure
Listen for the air leak with the trans- Leak is only in low range.
mission shifted to both low and high
range.
Leak is in both low and high range.
What to do next
Remove range cylinder and inspect
for damaged range yoke bar, yoke bar
O-ring, or range cylinder. Repair as
necessary.
Remove deep reduction cylinder. Inspect for damaged deep reduction
yoke bar, O-ring, or cylinder. Repair
as necessary.
37
Step A
Result

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

Procedure
Step A
Result
Remove insert valve. Check for con- Contamination or 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.
No contamination or damage found.
Step B
38
Remove the deep reduction cylinder Contamination or damage 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 Oring.
What to do next
Repair or replace as necessary.
Go to step B.
Repair or replace as necessary.

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

Procedure
Step A
Result
Place the shift lever in neutral. Check Constant air leak is detected.
for constant air leakage at the shift
knob, slave valve, and transmission
case breather when both low and
high range have been selected.
Step B
Place shift lever in neutral. Move Air flows from the low range port.
range selector up to high range 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 port.
Step C
Check for air flow from the discon- Air flows from disconnected air line.
nected air line.
No air flow from disconnected line.
What to do next
Go to step B.
Remove range cylinder cover and repair leaking range piston or piston
seal.
Go to step C.
Go to step F.
Go to step D.
39

Procedure
Step D
Result
Install a 100 PSI air gauge in the dis- The gauge read 0 PSI.
connected air line end. With the shift
lever in neutral, move the range selector down to select low range and
observe the gauge.
What to do next
Go to step F.
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.
Step E
Go to step E.
Confirm that shift lever is still in neu- Pressure rapidly changes between Air system appears to be operating
satisfactory. Go to step R.
tral. Have an assistant move the 58-63 PSI and 0 at the gauge.
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.
1/4 rubber air line between the filter/
1/4 rubber air line between the slave
Step F
Place shift lever in neutral. At the Air flows from the disconnected line.
shift knob, move the range selection
lever up to 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.
1. Confirm that the air lines are connected to the correct ports at the shift
knob.

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.
tion the slave valve.
40

Continue to step H.

Procedure
Step H
Result
Place the shift lever in neutral. Install The gauge responds slowly.
a 100 PSI pressure gauge in line with
the P line. Move the range selector
back and forth from low to high
range. The gauge should show rapid
pressure change.
What to do next

on the shift knob.

4 rubber air line between the filter/
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
check for damage.
slave valve. Unbolt the slave valve freely.
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.
Actuating plunger pin moves freely.
Repair or replace slave valve and

check for proper range operation.
41

the filter / regulator assembly.

Procedure
Step R
42
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:
Cracked c/s weld resulting in gear
turning
on
shaft
clutch
Auxiliary section gearing out of
time.
Result
What to do next

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 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:
Plugged filter
Incorrect regulator pressure

Procedure
Step A
Result
Place the shift lever in neutral. Check Constant air leak is detected.
for constant air leakage at the shift
knob, slave valve, and transmission
case breather when both low and high
range have been selected.
Step B
Place shift lever in neutral. Move Air flows from the high range port.
range selector down to low range position. At the transmission rear, disconnect the 1/4 rubber air line from
the range cylinder high range supply
port. Check for air flow from the cylinder high range port.
Step C
Check for air flow from the discon- Air flows from disconnected air line.
nected air line.
What to do next
Go to the above corresponding
symptom first. See beginning of Air
System Troubleshooting section.
Go to step B.
Remove range cylinder cover and repair leaking range piston or piston
seal. After repair, check for proper
range operation.
Go to step C.
Go to step F.
No air flows from disconnected line. Go to step D.
43

Procedure
Step D
Result
Install a 100 PSI air gauge in the dis- The gauge reads 0 PSI.
connected air line end. With the shift
lever in neutral, move the range selector up to select high range. Observe
the gauge.
What to do next
Go to step F.
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
satisfactory. Go to Step R.
neutral. Have an assistant move the 58-63 PSI and O at the gauge.
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.
1/4" rubber air line between the slave
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
the shift knob.
knob, move the range selector up to
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.
valve "P" port.
44
Continue to Step H.

Procedure
Step H
Result
Place the shift lever in neutral. Install The gauge responds slowly.
a 100 PSI pressure gauge in line with
the "P" line end. Move the range selection lever back and forth from low to
high range. The gauge should show
rapid pressure change.
What to do next

on the shift knob.

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
check for damage.
slave valve. Unbolt the slave valve freely.
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 attached.
2. Check for missing or broken
spring.
Actuating plunger pin moves freely.
Repair or replace slave valve and

check for proper range operation.
45


Procedure
Step R
46
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:
Cracked c/s weld resulting in gear
turning
on
shaft
clutch
Auxiliary section gearing out of time.
Result
What to do next

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.
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

Procedure
Step A
Result
Move range selector down to select Air flows from the disconnected line.
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 connected to the proper port location on
the cylinder cover. Check for air flow
from the line.
No air flow from disconnected line.
Step B
Connect a 100 PSI pressure gauge to Gauge reads 0 PSI.

the disconnected signal port line.
Move the deep reduction button forward. Read the pressure on the gauge.
What to do next
Go to Step K.
Go to Step B.
Go to Step F.
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

Procedure
Step C
Result
What to do next
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
line, and check if deep reduction
the insert valve plug has been re- or damaged.
shifts normally.
moved, cover the opening with a shop
rag and apply shop air to the signal
line port to blow the insert valve out of
its 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
valve and air line. Check if deep recover and deep reduction piston. In- is contaminated or damaged.
duction shifts normally
spect piston and bore for contamination 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 reduction 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 reduction shift. Repair as necessary.
48

Procedure
Step F
At the shift knob, remove the two Air flows from SP 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 reduction button rearward. Disconnect
the air line connected to the SP port.
Check for air flow from the SP port.
Move deep reduction button forward.

Check for air flow from SP port.
What to do next
Replace shift knob.
No air flow from SP port.
Go to Step G.
Air flows from SP port.
1. Check for proper air line connection 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.

Step H
Disconnect air line H/L port on shift Air flows from disconnected line.
knob. Check for air flow from the disconnected line.
No air flow from disconnected
line.
Go to step H.
Replace shift knob.
1. Check to make sure that the shift

lever is in neutral, the range selector is down in low range and the H/
L line is properly connected to the
low range hose at the slave valve.
2. If no air pressure is available on
low range hose, perform low range
shift troubleshooting procedure to
correct this problem.
49
Step G
Result

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. Confirm 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)
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 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 procedures.
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 components labeled. These are the primary components used during troubleshooting. If necessary, refer to these figures while troubleshooting 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.
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)
Red
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 vehicles 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.
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 the Yes

knob?
Repair or replace 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 at 75-85 PSI (517-586 kPa) Continue to the next step.
the H port?
(to specification)
55
Note: The driver must preselect all range shifts.

Question
Result
What to do Next
Less than
(517 kPa)
Greater than
(586 kPA)
75
85
PSI On the top of the air module, remove the test port pipe plug for filtered 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.
PSI Replace the air module.
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.
Question
Result
Does the gauge rapidly go from 75- Yes

85 PSI (517-586 kPa) in High to 0
PSI in Low?
No
What to do Next
Air system performs properly. Go to
step 5.
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.
Question
Result
Does the gauge rapidly go from 75-85 Yes

PSI (517-586 kPa) in High to) PSI in
Low?
No
What to do Next
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 sliding 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.
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. Answer the question on the chart below and follow the instructions corresponding to the result.
Question
Result
Does air come out of the P port on the Yes

knob?
No
What to do Next
Go to Step 3.
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.
Question
Result
What to do Next
Is air coming out of the red line?
Yes
Repair or replace the shift knob.
No
Loosen the air fitting for the line that supplies vehicle air to the module 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 damage. 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.
Question
Result
Is air available on the line when the Yes

range selector is in the Low position?
No
What to do Next
Continue to next step.
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 pipe plug, turn off the air flow by placing the range selector up into the high range position. The transmission 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.
Question
Result
What to do Next
What is the air pressure at the L port? 75-85 PSI (517-586 kPa) (To specifica- Continue to the next step.
tion.)
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 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.
Greater than 85 PSI (586 kPa)
5. 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.
Question
Result

85PSI (517-586 kPa) in Low to 0 PSI in
High?
No
What to do Next
Air system performs properly. Go to step 7.
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 attaching 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 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 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.
Question
Result

85PSI (517-586 kPa) in Low to 0 PSI in
High?
What to do Next
Continue to next step.
59
Less than 75 PSI (517 kPa)

Question
Result
What to do Next
No
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 transmission 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.
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 housing 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:
Question
Result
Can any air leakage be detected at the Yes

module interlock finger?
No
What to do Next
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
Exhaust the air pressure from the air module. To do so, the vehicle air 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 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.
Operation
Air Line Color Chart
Eaton Fuller 5/32" air lines are color coded for easy identification. Use the follow chart along with the appropriate system schematic 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.
Operation
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
Range Cylinder
9
6
5
10
2
1
Slave Valve
66
Air Filter/
Regulator
Operation
7L, 8, 9 and 10-Speed (2-Speed Auxiliary)
Operation
67
Operation
68
Operation
RT & RTO-610, 6610, 6609, and 8609 Models
Operation
69
Operation
70
Operation
Deep Reduction Air 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 engage deep reduction gearing.
Operation
71
Operation
RT, RTO, & RTX xx607LL, xx608LL, and xx615 models
72
Operation
Operation
73
Operation
74
Operation
Deep Reduction Air System (with A-6915 Roadranger Valve)
In addition to the range air system components, the deep reduction air system uses a reduction cylinder and the Roadranger Valve
A-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.
Operation
75
Operation
RT, RTO, & RTX xx607LL, xx608LL, and xx615 Models
76
Operation
Operation
77
Operation
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 vehicles 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
Operation
79
Operation
13-Speed
80
Operation
9-Speed Top 2 Convertible
Operation
81
Operation
9-Speed Non-Top 2 Convertible
82
Operation
RT, RTO, & RTOO xx613 and xx813 Models
Operation
83
Operation
84
Operation
Operation
85
Operation
RTLO-xx613 Models
86
Operation
Operation
87
Operation
88
Operation
RTLO-xx713 Models
Operation
89
Operation
90
Operation
Operation
91
Operation
RTLO-xx913 Models
92
Operation
Operation
93
Operation
94
Operation
RT0-15618 and RTLO-xx618 Models
Operation
95
Operation
96
Operation
Operation
97
Operation
98
Operation
RTLO-xx718 Models
Operation
99
Operation
100
Operation
Operation
101
Operation
102
Operation
RTLO-xx918 Models
Operation
103
Operation
104
Operation
Operation
105
Operation
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 slave valve supply port (3) through the supply air line (4) to the Roadranger valve.
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.
Operation
Roadranger Valve
9
4
2
Slave Valve
7
10
Combination
Cylinder with
Air Filter/
Regulator
107
Operation
7LL/DLL/MLL, 8LL, 9MLL, and 15-Speed Models
108
Operation
Operation
109
Operation
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 intermediate shift cylinder shifts the transmission between LO range and intermediate. The range cylinder shifts the transmission between 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).
Control Valve
7
7
8
2
1
Air Filter/
Regulator
3
Intermediate
Shift Cylinder
10
Slave
Valve
Range Cylinder
111
Operation
Depending upon the position of the control button (7), if air passes through the air line (8) connected to the intermediate shift
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.
Operation
112
Operation
Operation
113
Operation
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 intermediate 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.
Operation
Roadranger Valve
Eaton
Fuller
Transmission
H/L P S SP
8
2
6
1
Air Filter/
Regulator
3
10
Slave
Valve
9
Intermediate
Shift Cylinder
Range Cylinder
115
Operation
116
Operation
Operation
117
Operation
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 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 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.
Operation
Roadranger Valve
7
Eaton
Fuller
Transmission
H/L P S SP
8
2
6
1
Air Filter/
Regulator
4
3
10
Slave
Valve
Range Cylinder
119
Operation
7608LL Models
120
Operation
Operation
121
Operation
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 between LO and HI range.
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 assembly (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.
Operation
Latest Design
123
Operation
Old Design
124
Operation
RTLO-xxx610 Models
Operation
125
Operation
126
Operation
Operation
127
Operation
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 between LO and HI range.
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 assembly (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.
Operation
129
Operation
RTL-xx710 Models
130
Operation
Operation
131
Operation
132
Operation
Operation
133
Operation
AT-1202 Auxillairy Transmission (with 2 Position Shift Valve)
LO Range
DIR
Constant air
from Air Filter/
Regulator
SHIFTS AT
STANDSTILL
ONLY
RED
DIR
Constant air
from Slave V
LO
Breather
AUX. TRANS.
RED
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
Constant air
from Air Filer/
DIR
Regulator
Constant air
from Slave V
SHIFTS AT
STANDSTILL
ONLY
RED
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. The constant 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
from Slave Valve
Constant air
from Air Filter/
Regulator
2
Lo
3
High
Neutral
Operation
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
from Slave Valve
Constant air
from Air Filter/
Regulator
2
Lo
Neutral
3
High
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
from Slave Valve
Constant air
from Air Filter/
Regulator
2
Lo
Neutral
3
High
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
System Components
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.
System Components
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 LO range (range lever down( 2), air passes through the lever and out the Roadranger valve 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 disengage deep reduction gearing.
141
System Components
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.
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), deep reduction 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).
For Underdrive and Overdrive operation (range knob up (2), selector valve button in the forward position (3) air flows through the
selector valve H port (4) and out the SP port (5).
143
System Components
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).
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 (range lever up (2), splitter button rearward( 3), the lever prevents the air from passing through the Roadranger valve:
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).
For HI range direct (range lever up (2), actuator button rearward (3),the lever prevents the air from passing through the Roadranger valve (4).
145
System Components
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).
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.
System Components
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.
System Components
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 LO range (1, 2, 3, 4, 5, and 6 gear positions) the "S" port is open and the air is allowed to pass through the range actuator valve
and out the LO range air line (2).
System Components
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 operation, exhaust occurs only for an instant as the range shift is made.
System Components
HI Range - No air pressure is supplied to the end cap (1) from the selector/master/Roadranger valve (2). The constant 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 side cap 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 operation, exhaust occurs only for an instant as the range shift is made.
HI Range - No air pressure is supplied to the end cap (1) from the selector/master/Roadranger valve (2). The constant 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 side 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 LO range 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.
System Components
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 LO range 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
Deep Reduction - With the deep reduction lever in the "IN" position, no air is supplied to the cylinder cover center port (1). Constant
air from the air filter/regulator assembly (2) moves the reduction piston rearward (3), engaging deep reduction gearing.
System Components
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 with Roadranger 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
System Components
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
pass freely through the insert valve, to the cylinder piston front side, moving the yoke bar rearward to engage the LO range gearing.
LO Range
Constant Air
from Air Valve
Constant Air from
Air Filter/Regulator
System Components
Constant air sealed

off at this point
To piston front
Yoke bar rearward
Exhaust from HI
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
Air Filter/Regulator
Constant Air
from Air Filter/
Regulator
To piston back
side, Yoke bar forward
Exhaust from
LO side of Cylinder
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).
System Components
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
System Components
Constant
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).
LO or HI Range - With the Roadranger valve lever in the down position, no air is supplied to the Intermediate cylinder cover port
(1). The constant air from the air filter/regulator assembly (2) moves the piston rearward (3), disengaging deep reduction 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.
System Components
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 disengage deep 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), disengaging 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), disengaging deep reduction gearing.
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, 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).
System Components
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)
Odd Numbered Gear 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).
System Components
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
bar rearward
Constant
air sealed
off at this
point
When air 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
To piston back
side, yoke bar
forward
Constant Air
174
Constant
air sealed
off at this
point
System Components
RTLO-xx610 Model Splitter Cylinder Assembly (Latest Design)
Odd Numbered Gear Positions (1, 3, 5, 7, 9) With the Roadranger valve button in the rearward position, no air is supplied to the
System Components
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
System Components
Even Numbered 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 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.
178
System Components
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).
System Components
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 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.
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
Constant
air sealed
off at this
point
From piston
backside, yoke
bar rearward
piston front and backside, moving the yoke bar forward to engage the front auxiliary drive gear (HI range H).
Air on
Signal Line
To piston back
side, yoke bar
forward
Constant Air
180
Constant
air sealed
off at this
point
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).
System Components
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
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 cylinder piston front side, moving the yoke bar rearward to engage the rear auxiliary drive gear (HI range H).
Air on
Signal Line
From piston back

side, yoke bar
rearward
182
Constant
air sealed
off at this
point
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 cylinder 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).
System Components
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.
to the splitter cylinder piston front side moving the yoke bar rearward. Air is exhausted from the splitter cylinder rear (3) and from
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 auxiliary drive gear (3).
System Components
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
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
Constant
air sealed
off at this
point
From piston
backside, yoke
bar rearward
piston front and backside, moving the yoke bar forward to engage the front auxiliary drive gear (LO range and HI range H).
Air on
Signal Line
To piston back
side, yoke bar
forward
Constant Air
186
Constant
air sealed
off at this
point
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).
System Components
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
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 cylinder 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
From piston back

side, yoke bar
rearward
Exhaust
188
Constant
air sealed
off at this
point
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 cylinder 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).
System Components
LO Range 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.
to the splitter cylinder piston front side moving the yoke bar rearward. Air is exhausted from the splitter cylinder rear (3) and from
190

Basic Air System Drawings - 6610, 8609, and 6609
Engineering Reference
Drawings
191

Basic Air System Drawings - 07L, 08, 08L, 09, and 10-Speed Models
192

Basic Air System Drawings - 07LL, 08LL, and 15 Speed Models
Drawings
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
Drawings
195

Basic Air System Drawings - 6613, and 7608LL Speed Models
196

Basic Air System Drawings - 18 Speed Models Left-Hand Drive
Drawings
197

Basic Air 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 specing 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

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Troubleshooting Guide

Warnings and Precautions

RTLO-xxX610 Models ..............................................125

A-4740 Air Filter/Regulator Assembly ......................137

This guide provides four functions

Troubleshooting Guide: Designed to isolate and resolve air system problems.

System Components: Designed to explain each component's function and operation.

Control Valves - Old Production

Three Position Selector

Deep Reduction Valve

Two Position Selector

8LL, 15, 6613 Speeds

8LL, 15, 6613 Speeds

23545 - old design

4303110 - latest design

Eaton Fuller Silicone Lubricant

71203 (8 oz. container)Fleet size

71206 (4 cc container)Single application

All O-rings and mating surfaces

Eaton Fuller Sealant

71205 (2 cc container)Single application

71206 (4 cc container)Single application

Air fittings and threads

Test Fixture for Range Cylinder

84006 - 5/32" Push-To-Connect

12881 - 1/8" Tee

12769 - 1/8" Nipple

Test fixture for 1/8" Air lines

0-100 PSI Gauge

5/32" Air Line

85002 - Elbow Assembly

83501 - Grip Nut

Test Fixture For 5/32" Air Line

0-100 PSI Gauge

5/32" Air Line

Air System Troubleshooting

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

Start at Procedures for Step A.

Based on the Result of the procedure, go to the corresponding What To Do Next.

Air System Troubleshooting

Internal leak in slave valve

Internal leak at insert valve

Internal leak at shift knob

Air System Troubleshooting

Table 10 Air Leak at Shift Knob

Remove lower skirt on shift knob. Leak found.

Air System Troubleshooting

2. If the line is properly attached,

Repair or replace the shift knob.

Air System Troubleshooting

Internal leak in range cylinder.

Internal leak in slave valve.

Table 11 Air Leak at Slave Valve

Remove range cylinder cover and

Repair or replace slave valve.

Air System Troubleshooting

Air System Troubleshooting