TMIB-0176B
Service Bulletin Details
Public Details for: TMIB-0176B
Speed conversion instructions.
- 9999 -
Models from 9999
9999 EATON EATON |
More time on the road- Bulletin: TMIB-0176 Date: March 18, 2011 Bulletin Type: Service Topic: Lightning to FRO/RT-13 Speed Conversion Instructions Issue Description: Due to the Lightning transmission model no longer in new production some customers may want to move away from the Lightning product. Remanufactured Lightning transmissions are available through the Eaton authorized distributors. Customers have the option of moving into a "FRO" or "RT-13" speed models. The following instructions will help guide the customer/technician through the conversion process. Current Process: Real Time Warranty assists customers on a one-on-one basis. Revised Process: The instructions listed below cover the process of removing a Lightning transmission and the reinstallation of a "FRO" or "RT-13" speed model transmission. These instructions cover most of the vehicle configurations in the marketplace. If any additional information is needed please contact the Roadranger Call Center at 800-826-4357. Listed at the bottom of this communication are conversion kit part numbers. These kits do not include transmissions or oil coolers . Additional clutch housings may also need to be ordered for special applications . - Continued below Page 1 of 7 . conversion : Th e fo II owinq transmission o ::>t1ons wou Id best app1y I f or a L'IQ htninQ Current Lightning Model Optional Transmission Model Part# TA-060-10R - Reman w/ FRLO-XX41 OC FR0-16210C interna l cooler (preferred option) TA-060-12R - Reman w/ internal pump w/o internal cooler RTL0-16913A TA-F04-50R - Reman RTL0-16913A (interna l pump model) TA-061-10R - Reman w/ FRLOF-XX41 QC FROF-16210C internal cooler TA-061-12R- Reman w/ internal pump w/o internal cooler TA-F05-50R - Reman RTLOF-16913A RTLOF-16913A (interna l pump model) Note: Dependent on chassis model and configuration a " Forward" or " Standard" shift bar housing model will need to be utilized. Warning: Internal cooler "FRO" models can not be used with a hydraulic clutch release system application Caution : Lightning PTO configurations are not directly transferable to " FRO " or " RT-13" speed model transmissions . Consult the PTO manufacturer for PTO fit up requirements. The customer is respons ible for any costs associated with the PTO conversion Clutch Housing Options Chart (Reman transmissions come with a standard upper and lower bushed clutch housing) (A hydraulic actuator clutch housing for hydraulic actuated clutch applications will need to be ordered separately) Lightning CL HSG FRO/F-10 Spd CL HSG RTLO/F 13 Spd CL HSG TA-066/75-SAU-10 A-5992 K-3676 Standard Aluminum Upper (#1 , Pull, Alum) (#1 , Pull, Alum) cross shaft bush ing location Forced lube CL Hsg kit TA-084-SAL-10 Standard A-7665 A-7664 Alumin um (Non Nodal) (#1, Pull, Alum , Below (#1 , Pull, Alum , Below Lowe r cross shaft bushing Centerline, Non Nodal) Centerline, Forced Lube, location Non Nodal) A-4456 K-3673 TA- 066/75-NAU-10 Nodal Aluminum Upper cross (#1, Pull, Alum) (#1 , Pull, Alum , Nodal) shaft bushinQ location Forced lube CL HsQ kit TA-066/75-NAL-10 Nodal A-4550 A-7589 Page 2of7 Aluminum Lower cross shaft bushinq location TA-066/75-HA-10 Hydraulic Actuator housing (#1 , Pull, lower, Alum) (#1 , Alum, nodal) K-3759 (#1 , Alum) 4305781 (#1 , Alum , Nodal) K-3760 (#1 , Forced Lube, Hydraulic) Transmission Removal & Installation 1. Refer to OEM service manual for proper removal and installation of transmission Note: Replacement of clutch housing may be necessary on the remanufactured FRO or RT-13 speed model transmissions if the Lightning transmission was equipped with a hydraulic clutch release system. Note: Ensure replacement transmission is filled with lube to the correct level before vehicle is operated. Master Control Valve Replacement See "Air System Troubleshooting Guide" TRTS0902 available on www.roadranger.com for proper air line installation of the applicable model transmission . 1. Remove Lightning shift control knob from shift lever. 2. Install supplied master control valve and skirt onto shift lever and orientate to the correct position and tighten jam nut. 3. Install 5/32" air line fittings into the master control valve. Install the 5/32" air line from the master control valve on the shift lever to the air module/slave valve/splitter cylinder on the transmission 4. Secure air lines to prevent chaffing . 5. Install skirt for master control valve. Oil Cooler/Heat Exchanger If installing an internal cooler "FRO" model 1. Install the existing Lightning oil cooler lines to the correct "in" and "out" oil cooler ports on the "FRO" model transmission . Coolant lines may need to be altered for correct fit. 2. Ensure oil lines are fastened securely to prevent oil lines from chaffing . If installing a non-internal cooled "FRO" model 1. A number or cooler options are available for this conversion . The facility that is initiating the conversion must choose the type and part number of cooler that best fits the cab/chassis configuration . Listed below are the available options. Oil to Water Heat Exchanger Options Bottom, Rear Mount, Oil-Water Heat Exchanqer Front Mount, Shift Bar Housinq, Oil-Water Heat Exchanger Left Mount, Shift Bar Housing , Oil-Water Heat Exchanger Page 3of7 Part# K-3357 K-4000 K-3740 Note: Bottom, Rear Mount, Oil-Air type heat exchanger kit may interfere with some PTO applications. If installing a RT-13 speed model External air to oil cooler kit: K-1956 O'II to W ater Heat Exc h anger 0 1prion s for RT-13 speed models Heat Exchanger Kit Part Numbers K-3952 K-3963 K-3954 K-3965 K-3955 K-3966 K-3956 K-3967 K-3699 K-3959 K-3972 Note : See "www.inforanger.roadranger.com/epc/index.asp?model lD=373&grouplD=1095 " for heat exchanger mounting configurations to fit applicable vehicle model and chassis configurations. Heat Exchanger Installation Steps 1. Install oil cooler/heat exchanger onto transmission 2. Connect coolant lines to newly installed oil cooler/heat exchanger. If the cooler is an oil-water type cooler. Coolant lines may need to be altered for correct fit. 3. Install transmission cooler line fittings into transmission oil pump ports and heat exchanger if applicable. 4. Install oil lines from heat exchanger to oil pump port fittings . Ensure the oil lines or installed onto the correct ports of the heat exchanger and transmission ports. 5. Ensure oil lines are fastened securely to prevent oil lines from chaffing . Note: Engine coolant level and transmission oil level need to be checked after heat exchanger installation is completed. Note: Check for any leaks after operation of vehicle. Shift Decal Replacement 1. Remove the original "Lightning" model shift decal from the cab area. 2. Install the new "FRO" or "RT-13" speed model shift decal in place of the removed shift decal. (These are included in the conversion kits listed below) Page 4of7 Shift Label Part# 20400 4300764 Transmission Model FRO/F-10 speed RTLO/F-13 speed Lightning 18-way Harness Connector Cap Installation 1. After the original Lightning 18-way harness connector is removed from the ECU (Electronic Control Module) of transmission install the supplied 18-way harness connector cover (K-3756). 2. Retain harness in area that will prevent any future harness damage. VSS (Vehicle Speed Sensor) Installation/Program 1. Some Lightning transmission ECU 's broadcasted speed information over the J-1939 data link to the vehicle and engine. This can be indentified by the presence of only 1 VSS on the rear bearing cover of the transmission . When converting to the "FRO" model transmission this type of speed information w ill no longer be able to be broadcasted on the J-1939 data link. The "FRO" model transmission will require the installation of a VSS in this case. Below is a list of items that need to be done for the vehicle/engine VSS: a. Install speed sensor into the 12:00 o'clock position of the rear bearing cover. Note: Refer to engine manufactures specifications for correct VSS application. b. Hard wire the VSS to the chassis electrical system. Refer to OEM wiring diagrams and harness specifications. Most OEM 's already have the harness in-place on the chassis somewhere and would just need routed to the newly installed VSS. c. Reprogram the VSS engine parameter to reflect a "Manual" VSS application . Refer to engine manufactures parameter setting specifications. d. Ensure VSS is reading correctly during vehicle operation . Driveshaft Modification 1. The main driveshaft attached to the transmission must be shortened 1.8" to be compatible with the installation of the "FRO" model transmission or 5.0" for a RT-13 speed installation. The shaft should be modified by a reputable driveshaft repair facility. Conversion Kits Part Number: K-3998 I Description: Kit , Conversion Lightning , FRO/F Comments: Kit used with the conversion from Lightning to FRO/F series Transm ission Quantity Part Number Description 1 K-3756 Harness Cap 1 S-2543 Master Valve Page 5of7 1 20400 Shift Label 2 84005 Connector, STR 2 52622 Harness Tubing (48 in .) 1 L-2009-03 L-Letter Part Number: K-3999 Description: Kit, Conversion Lightning Hydraulic Cit Hsg, FRO/F Comments: Kit used with the conversion from Lightning with Hydraulic Clutch Housing to FRO/F series Transmission Quantity Part Number Description 1 K-3756 Harness Cap 1 S-2543 Master Valve 1 4301180 Skirt, Valve 1 20400 Shift Label 1 K-3759 Hydraulic Clutch Housing for FRO Series 2 84005 Connector, STR 2 52622 Harness Tubing (48 in.) 1 L-2009-03 L-Letter Part Number: K-4002 Description: Kit, Conversion Lightning, RTLO/F-13 Speed Comments: Kit used with the conversion from Lightning to RTLO/F-13 speed series Transmission Quantity Part Number Description 1 K-3756 Harness Cap 1 S-2578 Master Valve (includes fittings) 1 4300764 Shift Label 4 52622 Harness Tubing (48 in .) 1 22940 Switch , Reverse 1 L-2009-03 L-Letter Page 6 of7 Part Number: K-4003 Description: Kit, Conversion Lightning Hydraulic Cit Hsg , RTLO/F-13 Speed Comments: Kit used with the conversion from Lightning with Hydraulic Clutch Housing to RTLO/F-13 speed series Transmission Quantity Part Number Description 1 K-3756 Harness Cap 1 S-2578 Master Valve (includes fittings) 1 4300764 Shift Label 1 K-3760 Hydraulic Clutch Housing for FRO Series 1 22940 Switch, Reverse 4 52622 Harness Tubing (48 in.) 1 L-2009-03 L-Letter The material contained in this bulletin is process improvement information. Eaton and Dana Corporation are not committed to, or liable for, canvassing existing products. FSUD: 2005-FSUD-597 Page 7of7