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Eaton UltraShift PLUS Service Manual

Eaton UltraShift PLUS
266 pages
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Service Manual
UltraSh
ift PLUS
Automated Transmissions
TRSM0940 EN-US
October 2022
Linehaul Active Shifting (LAS)
Vocational Active Shifting (VAS)
Multipurpose Extreme Performance (MXP)
Multipurpose High Performance (MHP)
Vocational Construction Series (VCS)
Vocational High Performance (VHP)
Vocational Multipurpose Series (VMS)
Vocational Extreme Performance (VXP)

Table of Contents

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Eaton UltraShift PLUS Specifications

General IconGeneral
BrandEaton
ModelUltraShift PLUS
CategoryMicrophone system
LanguageEnglish

Summary

General Information

Warnings & Cautions

Safety warnings and cautions for operating and servicing the transmission. Includes important precautions.

Timing Procedures

Essential steps for timing transmission gears to ensure proper mesh and function.

Preventive Maintenance

Routine checks and maintenance to ensure transmission longevity and reliability.

Assembly and Disassembly Precautions

Crucial guidelines for safe and correct transmission assembly and disassembly.

Assembly Precautions

General guidelines and specific precautions for assembling transmission components.

Disassembly Precautions

General guidelines and specific precautions for disassembling transmission components.

Auxiliary Section Service Procedures

LAS/VAS Auxiliary Section Removal and Disassembly – In Chassis

Procedure for removing the LAS/VAS auxiliary section while the transmission is in the chassis.

LAS/VAS Auxiliary Section Removal and Disassembly

Detailed procedure for removing and disassembling the LAS/VAS auxiliary section.

LAS/VAS Auxiliary Section Removal

Procedure for removing the LAS/VAS auxiliary section from the main case.

LAS/VAS Auxiliary Section Assembly and Installation

Procedure for assembling and installing the LAS/VAS auxiliary section.

LAS/VAS Auxiliary Section Assembly

Procedure for assembling the LAS/VAS auxiliary section onto the transmission.

LAS/VAS Auxiliary Counter Shaft Installation and Timing

Instructions for installing and timing the auxiliary counter shafts.

LAS/VAS Auxiliary Counter Shaft Shimming

Procedure for shimming and installing auxiliary counter shafts for correct endplay.

VCS/VMS Auxiliary Section Removal and Disassembly – In Chassis

Procedure for removing the VCS/VMS auxiliary section while the transmission is in the chassis.

VCS/VMS Auxiliary Section Removal and Disassembly

Detailed procedure for removing and disassembling the VCS/VMS auxiliary section.

Auxiliary Mainshaft Assembly Disassembly

Procedure for disassembling the auxiliary mainshaft assembly.

VCS/VMS Auxiliary Section Assembly and Installation

Procedure for assembling and installing the VCS/VMS auxiliary section.

VCS/VMS Auxiliary Section Assembly

Procedure for assembling the VCS/VMS auxiliary section.

Auxiliary Countershaft Assembly and Timing

Instructions for assembling and timing auxiliary countershafts.

MHP/MXP/VHP/VXP Auxiliary Section Removal and Disassembly

Procedure for removing and disassembling the MHP/MXP/VHP/VXP auxiliary section.

Auxiliary Section Removal

Procedure for removing the MHP/MXP/VHP/VXP auxiliary section.

Auxiliary Section Disassembly

Procedure for disassembling the MHP/MXP/VHP/VXP auxiliary section.

Auxiliary Mainshaft Disassembly

Procedure for disassembling the auxiliary mainshaft assembly.

MHP/MXP/VHP/VXP Auxiliary Section Assembly and Installation

Procedure for assembling and installing the MHP/MXP/VHP/VXP auxiliary section.

MHP/MXP/VHP/VXP Auxiliary Mainshaft Assembly

Procedure for assembling the auxiliary mainshaft assembly.

MHP/MXP/VHP/VXP Auxiliary Countershaft Installation

Instructions for installing MHP/MXP/VHP/VXP auxiliary countershafts.

Range Cylinder and Piston Installation

Procedure for installing the range cylinder and piston.

Splitter Cylinder Installation

Procedure for installing the splitter cylinder.

Auxiliary Countershaft Shimming

Procedure for shimming and installing auxiliary counter shafts for correct endplay.

Removal and Installation

Input Shaft

Procedures for removing, installing, and servicing the input shaft.

Replacing Input Shaft without Disassembling the Main Case or Removing Clutch Housing

Procedure for replacing the input shaft without full transmission disassembly.

Input Shaft Installation

Procedure for installing the input shaft assembly into the transmission.

Clutch Housing

Procedures for removing, installing, and servicing the clutch housing.

Clutch Housing Removal

Step-by-step procedure for removing the clutch housing.

Clutch Housing Installation

Step-by-step procedure for installing the clutch housing.

Shift Bar Housing Removal

Procedure for removing the shift bar housing from the transmission.

Shift Bar Housing Installation - Cast Iron

Instructions for installing the cast iron shift bar housing.

Shift Bar Housing Installation - Aluminum

Instructions for installing the aluminum shift bar housing.

Electronic Clutch Actuator (ECA)

Procedures for removing and installing the electronic clutch actuator.

ECA Removal

Procedure for removing the electronic clutch actuator from the transmission.

ECA Installation

Procedure for installing the electronic clutch actuator onto the transmission.

Transmission Electronic Control Unit (TECU)

Procedures for removing and installing the TECU.

TECU Removal

Procedure for removing the transmission electronic control unit.

TECU Installation

Procedure for installing the transmission electronic control unit.

X-Y Shifter

Procedures for removing and installing the X-Y shifter.

X-Y Shifter Removal

Procedure for removing the X-Y shifter from the transmission.

X-Y Shifter Installation

Procedure for installing the X-Y shifter onto the transmission.

Oil Pump and Lube Tube Installation

Procedures for installing the oil pump and lubrication tubes.

Oil Pump Installation

Procedure for installing the oil pump into the transmission.

Lubrication Tubes Installation

Procedure for installing the transmission lubrication tubes.

Main Case Gear Timing and Assembly

Procedure for timing and assembling gears within the main case.

Main Case Counter Shaft Installation

Procedure for installing the counter shafts into the main case.

Auxiliary Section Installation

Procedure for installing the auxiliary section onto the main case.

VCS/VMS Combination Cylinder

Procedures for disassembling and assembling the VCS/VMS combination cylinder.

VCS/VMS Combination Cylinder Disassembly

Procedure for disassembling the VCS/VMS combination cylinder.

Procedure – Combination Cylinder Assembly - VCS, VMS

Procedure for assembling the VCS/VMS combination cylinder.

Range Cylinder LAS/VAS Model

Procedures for disassembling and assembling the LAS/VAS range cylinder.

Range Cylinder Disassembly

Procedure for disassembling the MHP/MXP/VHP/VXP range cylinder.

Shift Bar Housing

Procedures for disassembling and assembling the shift bar housing.

Main Case Main Shaft without Low Force Gearing Disassembly

Procedure for disassembling the main case main shaft without low force gearing.

Main Case Main Shaft without Low Force Gearing Assembly

Procedure for assembling the main case main shaft without low force gearing.

Main Case Main Shaft with Low Force Gearing Disassembly

Procedure for disassembling the main case main shaft with low force gearing.

Main Case Main Shaft with Low Force Gearing Assembly

Procedure for assembling the main case main shaft with low force gearing.

Main Case Disassembly and Lubrication Tube Removal

Procedures for disassembling the main case and removing lubrication tubes.

Appendix

Oil Leak Inspection Process

Flowchart and steps for inspecting and identifying transmission oil leaks.

Torque Specifications

List of torque values for various fasteners and components.

Torque Specifications LAS/VAS

List of torque values for various fasteners and components specific to LAS/VAS models.

Lubrication Specifications

Guidelines for transmission lubrication, including cautions, operating angles, and temperatures.

Recommended Lubrication

Recommends specific grease types and ratings for release bearing lubrication.

Grade Sensor Calibration

Procedures for calibrating the transmission's grade sensor.

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