|Title||Publication Date||Type||Size||Publication Number|
|Service Bulletin - ServiceRanger 3.x Database Updates - All
This document contains all ServiceRanger Database update information. The most recent version is 51. This document has been created as a reference for the information included in each database update only. Generally ServiceRanger 3.x database updates are released in conjunction with an application software updates. For application software update information reference the appropriate bulletin for the complete software build.
|Improved Sliding Clutches for “Hard Shift” Complaint
Newly designed main shaft sliding clutches are being released to improve shift quality in the RT and FR model products. The sliding clutches have an increased backlash to allow the operator an increased synchronous window. The sliding clutch part numbers have changed but all main shaft gearing part numbers will remain the same.
|Vehicle Vibration Analysis Process
Customer complaints of vehicle vibration concerns are often difficult to isolate and identify root cause.
|Updated Heavy-Duty Solo Clutch In-Vehicle Resetting Procedure
The Eaton Heavy-Duty Solo Clutch Technical Support Team worked with truck dealership technicians to identify confusion with the current published process of the product’s In-Vehicle Resetting Procedure.
|Heat Exchanger Failure Causing Transmission Lube Contamination / Flush Procedure
Heat exchanger failure causes engine coolant to enter the transmission case and mix with the lubricant. A flush procedure is required to clean contamination from the transmission as a part of the heat exchanger replacement.
|UltraShift PLUS Operation with Paving Machine
Fleets request additional driver information for paving machine operation with the UltraShift PLUS Transmission.
|2/11/2013||30 KB||TAIB0845 EN-US|
|Changes to Slots in Cast 14" Clutch Intermediate Plate
Eaton Clutch is implementing a change to all Heavy-Duty Cast 14" Easy Pedal and 14" Value twin plate clutches. This change reduces the number of Intermediate plate slots from 12 down to 6. There is not impact to fit, form or function relative to the installation of this product.
|UltraShift® PLUS Driver Instructions for Winter Driving
Fleets are requesting additional driver information regarding winter driving with the UltraShift® PLUS.
|2/01/2013||29 KB||TAIB0844 EN-US|
|Service Bulletin - ServiceRanger 3.x Software Manager Update Utility
In order to keep the ServiceRanger program up-to-date with the latest fixes, database updates and enhancements, an internet update utility has been included in the ServiceRanger Version 184.108.40.206 installation.
|New Push-In Style Speed Sensors
A redesigned speed sensor has been released into production and service. External changes include a sensor body designed to minimize corrosion seizing and integrated retaining clip that will not distort the sensor when the retaining cap screw is tightened. Sensor output signal, harness connector interface and 14142 O-ring are all interchangeable with current design sensors.
|Coating Change on XY Shifter Motor End Caps
The varnish coating currently used on XY Shifter motor end caps is being phased out by the supplier.
|ServiceRanger Database 47: Cannot See UltraShift PLUS Software 5569906
After updating to Database 47, the current production UltraShift® PLUS ECU software 5569906 is no longer available in the Product Programming function of ServiceRanger; no new software is displayed.
|Out-of-Vehicle Reset Procedure for Heavy-Duty Solo Advantage Clutches Without Using an Arbor Press
The Out-of-Vehicle Reset Procedure is for vehicle repairs where the Heavy-Duty Solo Advantage clutch is removed without installing the 4 shipping bolts and the clutch is reusable. For a smoother reinstallation of the clutch it is best to reset the clutch prior to reinstalling into the vehicle. The published procedure requires the use of an arbor press to complete, but not all technicians have an arbor press available, so this revised procedure is needed.
|HLA Version 28 Production Software Released and APF Revision
Version 28 software for HLA has been released. The HLA advanced product function (APF) has also been revised with calibration updates to support changes in v28 software.
|Roadranger HLA High Performance Hydraulic Oil
Roadranger HLA fluid is now available through Sea-Land for direct purchase.
|Transmission Upshift Complaints with No Transmission Fault Codes
Eaton Automated Transmission will not make an upshift in auto mode until the throttle is released or transmission is upshifted manually. During the concern, the gear display will indicate a solid current gear and with no upshift or downshift arrows, as well as no flashing “F” or transmission service light. Engine may also be unresponsive to throttle input. The Transmission ECU (TECU) may not log fault codes. These complaints are shifting related, but vehicle systems can contribute to the concern.
|Reman Transmissions Assembled Without Splitter Snap Ring
A number of Reman transmissions have failed due to not installing the splitter gear snap ring (4303424).
|Loose ECA Connectors in UltraShift PLUS models
Instances of loose ECA connectors have been discovered in some UltraShift PLUS models.
|HLA Accumulator Thermal Relief Cap
There have been accumulator thermal relief caps found in the field to be out of tolerance. The pin in the cap is extended further than should be allowing contact to push on the gas valve venting nitrogen from the accumulator at a slow rate.
|Clutch Lubrication Requirements for UltraShift® PLUS Transmission
Unlike the Eaton UltraShift® automated transmission, Eaton UltraShift® PLUS transmission does require greasing during vehicle servicing. The UltraShift PLUS transmission has grease zerk locations for lubricating the clutch release bearing and cross-shaft bushing of the ECA motor in addition to the clutch release bearing and the bushing for the shaft of the ECA motor. Over lubricating these components may contribute to a slipping clutch by getting too much grease into the clutch environment.
|1/24/2012||453 KB||CLIB0020, CLIB-0022, CLIB 0022|
|HLA Accumulator Sensor Torque
Sensors on HLA accumulators have loosened during operation in the field.
|Cummins Engine Software Update for HLA System
Update pre 2010 Cummins engine calibration to allow HLA system to torque limit the engine command during economy mode launch.
|Recommended Dealer Stocking List
Eaton Corporation recommends this dealer stocking list for all automated transmission models. The list covers parts needed for a wide variety of failure modes that can be repaired in hours when parts are on hand, rather than the possibility of keeping a vehicle “down” for many days while waiting for parts.
|Oil Leak Around the Filter, Filter Housing and Cooler Lines on UltraShift® PLUS Models
UltraShift PLUS transmissions have been reported with oil leaking around the filter, filter housing and cooler lines.
|ServiceRanger Version 2.80 Released – Final Build
ServiceRanger version 2.80 is intended to be a final replacement for all previous ServiceRanger 2.x versions.
|Worn Shift Fork and Sliding Clutch Wear on Automated Transmissions
Wear of the direct/ overdrive shift yoke and sliding clutch on automated transmissions. Various shifting complaints, 70 series fault codes (prior to s/w version 860) and/or fault code 81 (sw version 860 and higher).
|Transmission Output Shaft Nut Loosening
The heavy-duty transmission output shaft nuts have been loosening.
|MY09 Power Electronics Carrier (PEC) Air Filter Cover Change
Initial production of the MY09 PEC air filter cover A-8128 did not adequately crush the PEC air filter 4306115 allowing contaminants to enter the PEC.
|Effects from Improper Removal of the UltraShift PLUS ECA Clutch
The UltraShift PLUS ECA Clutch is being removed without being properly caged. This is either from no shipping (caging) bolts used or bolts not meeting length specifications. This will result in permanent damage to the clutch and it should not be reinstalled or reused. The intent of the shipping bolts is to retain the pressure plate in the installed position.
|Eaton Clutch Performance Evaluation and Set-up
The purpose of communicating this information is to provide details as to how to evaluate the below list of topics relating to Eaton clutch products
|FR/FRO Series 10-Speed Transmission Built With Nonconforming Input Shaft
FR/FRO Series 10-Speed Transmission Built With Nonconforming Input Shaft
|Elimination of 15.5” Solo and Easy-Pedal XL Clutch Product
15.5” Solo and Easy-Pedal XL Clutch Product
|Heavy-Duty DM Clutch Returns
Heavy-Duty DM Clutch Returns
|FR Internal Cooler Cover
FR series internal cooler covers may be mis-machined causing a coolant leak at the cooler line fitting.
|Lightning to FRO/RT 13-Speed Conversion Instructions
Due to the Lightning model transmissions no longer available for 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 to FRO or RT 13-speed models. The following instructions will help guide the customer/technician through the conversion process.
|Nonconforming 4303119 Countershaft Used In FRO-15210C & FRO-16210C
We have identified an issue with FRO-15210C and FRO-16210C transmissions built at our Mexico facility from July 31, 2009 through August 17, 2009. The countershaft journal can be .010-.030 oversized which can cause a bearing failure.
|Hybrid MY09 Power Electronics Carrier (PEC) Decals
The MY09 (Metal Enclosure) PEC top service cover decals are becoming delaminated, faded, and or peeling.
|Service Bulletin - Transmission, Hybrid Components, and Clutch Warranty Returns Shipping Instructions
The intent of this FSUD is to communicate shipping (routing) instructions for warranty part, units, and clutch returns for Eaton products; where Eaton is responsible for inbound freight. Eaton requires these instructions be followed to avoid any additional freight costs incurred by using non-Eaton approved carriers or a denied acceptance of a shipment. Part return procedures and requirements are documented in the Eaton Warranty Manual (TCWY0600) available on Roadranger.com; found under the Customer Support tab, then select Warranty.
This bulletin is to clarify the maximum allowable PTO torque on Eaton HD transmissions. Previously Eaton published a 500 lb.-ft limit for the PTO drive gear on the countershaft. Following the PTO manufactures differentiation between continuous and intermittent (less than 5 out of 15 minutes) operation, it was assumed that this limit would be considered only for intermittent operation.
|Eaton Advantage and non-Eaton Advantage Lube Hose Assemblies
With the introduction of the Eaton HD Solo Advantage clutch in the fall of 2010. The attachment of the lube hose assembly used with catapult style hydraulic clutch release systems the attachment of the lube hose assembly has changed.
|ServiceRanger Version 220.127.116.117 with Database Version 30 released
ServiceRanger software version 18.104.22.1687 with database version 30 has been released.
|Cannot See New Gen 2 Transmission ECU Software in ServiceRanger 3.x
The AutoShift/UltraShift Gen 2 transmissions have two ECUs, the shift controller and transmission controller each with its own application software.
|Serviceability of MY09 (Metal Enclosure) Power Electronics Carrier (PEC)
Full OEM integration of the MY09 (Metal enclosure) PEC was completed March 2010. The MY09 PEC was designed to be serviceable by trained and registered technicians.
|UltraShift PLUS Product Enhancements
UltraShift PLUS Product Enhancements
|ServiceRanger 3.x Approved Vehicle Link Adapter Settings
Incorrect ServiceRanger 3.x data link settings can result in loss of ECU communication. Communication loss during a download attempt may result in the ECU being “stuck in programming mode”. Proper setting of each data link connection in ServiceRanger is required to ensure reliable and stable communication.
|Worn XY Shifter Center Shaft Bushing
Warranty parts review has identified wear on the XY Shifter center shaft bushing on XY’s built prior to October 2009.
|Installing Clutch Inspection Hand-Hole Cover
Over the years it has been the practice in the trucking service industry when servicing Eaton clutch products the hand-hole inspection cover is not being reinstalled. Not reinstalling the clutch inspection cover after servicing of the clutch will leave a large opening which will allow contamination to be ingested into the clutch housing and the clutch itself.
|Clutch Housing Hand Hole Cover Fasteners
Clutch Housing Hand Hole Cover Fasteners
|Hazmat Shipping Requirements (U.S. DOT)
Hydraulic Hybrid Accumulators
|ServiceRanger Version 22.214.171.12407 with Database Version 27 released
ServiceRanger software version 126.96.36.19907 with database version 27 has been released
Bulletin for untrained personnel working on Hybrid units, revised training process
|Clutch Housing Gasket and Fastener Improvements – RT Series
Clutch housing gasket leaks on RT series transmissions.
|FR Model Clutch Housing Gasket and Fastener Improvements
Upgraded components for FR series transmission clutch housings.
|Gen 3 Transmission Harness Chafing
An emerging trend has been identified on the Gen 3 transmission wiring harness. Harness is chafing on the edge of harness bracket causing a short. The failure causes a wide range of customer complaints, as well as active and inactive codes depending on specific shorted wires.
|New UltraShift PLUS Prognostic Grease Interval Driver Notification
The heavy-duty UltraShift PLUS has an optional prognostic feature that notifies the operator when the Clutch Release Bearing needs greasing (lubrication).
|Roadranger Warranty Guide TCWY0900 – January 2010 Update
The purpose of this document is to communicate the most recent Updates to the Roadranger Warranty Guide TCWY0900.
| Eaton Cobra Lever Kit K-3980
A potential interference condition can exist between the shift inhibit bar on the Cobra Lever and the lever mounting bracket in the Kenworth chassis and Eaton shift tower.
|FR/FRF/FRO/FROF Gear Update Kit
The kits listed below are intended ONLY for updating FR series transmissions built prior to 3-1-1999. These kits are not intended for current production models. Repair parts for current models are to be purchased separately.
|Service Bulletin - Output (Speedometer) Speed Sensor Inspection Procedure
As a result of a significant percentage of returned speed sensors tested being found to have no verifiable failure, Eaton Corporation is implementing a test procedure to all. This test is a very simple and quick test to determine if a warrantable failure has occurred. The equipment involved is simply an ohm meter which is a standard item at all repair facilities.
|Freightliner M2 and Cascadia Chassis with Buss Traffic Error Prior to Downloading
Communication error on ServiceRanger will appear prior to downloading the transmission ECU or Pushbutton. ServiceRanger will display this error ýThe following device: 249- is still activeý. The vehicle Multiplex controller is sending messages on the J-1587 data link if the vehicle doors are open, vehicle lights are on, or if the brake pedal is applied.
|Nonconforming A-5000 Slave Valve / Service Parts Only
Nonconforming slave valves were discovered at the Shenandoah facility. The valve was assembled incorrectly by our supplier and caused a gross air leak in low range. The failure was detected at final test as the transmission was unable to perform a range shift. All service parts A-5000 slave valves with the date code of 9I1 are suspect.
|Reman FR/FRO 10-Speed Transmission Built With Plastic Plugs
A population of Reman transmissions was built by Shenandoah and Kings Mountain with plastic plugs instead of studs or threaded plugs in the transmission rear support pad location. The right rear support location on FR/FRO transmissions is a through hole and can cause a leak if not plugged. This could lead to a low lube failure.
|HD UltraShift Clutch Broken Pressure Plate Ears
Warranty is seeing a small number of the ears on the pressure plate of the DM UltraShift clutch broken due to the use of the jackscrew. Cases have been observed where the clutch has been operated and caused progressive damage to the clutch housing.
| FC12 with GEN3 Automated Transmissions
GEN3 transmissions are reporting an active or inactive FC12 Mid 130 SID 254 FMI 13. This should be confirmed with ServiceRanger Software.
Environmental conditions permit rust to form in the speed sensor bore and damage the sensor housing. This corrosion can cause the sensor to permanently affix itself to the bore (rust weld) making removal exceedingly difficult.
|Input Shaft Breakage Service Bulletin
The input shaft is broken, preventing torque from being transferred from the engine to the transmission.
|Hazmat Shipping Requirements (U.S. DOT)
Medium-Duty Hybrid Batteries
|The Role of Real Time Warranty (RTW)
A misconception exists among some OEM dealerships concerning the Real Time Warranty (RTW) program. This notification was created to restate and clarify the role of RTW.
|RT Clutch Housing Gasket on SAE #2 Clutch Housings
When using the new RT clutch housing gasket (4306584), the edge molding may protrude between the clutch housing and case surface on some SAE #2 clutch housings.
|Heavy Duty DM Clutch Fails to Disengage (False Brinelling)
Complaint of truck has urge to pull at idle. Clutch data max energy is less than 3000 BTU with active and /or inactive fault code 27 and no indication of secondary failure (i.e. FC16, 35. 93).
|New Integral Hydraulic Clutch Release Production Release
Eaton Corporation is releasing an Integral Hydraulic Clutch system for manual and AutoShift transmissions. This system replaces the currently available multi-piece hydraulic clutch release system for models using the current HD 15 ½” two plate clutches.
|Hydraulic Actuated Clutches Equipped with Easy Pedal Clutch
When utilizing a Heavy Duty Easy Pedal with a hydraulic assist clutch actuator, the cab pedal cannot be used to indicate when clutch adjustments are required. Drivers may not notice the need for clutch adjustment and continue driving in such condition.
|Driving instructions for AT-1202/2A92
Instructions on how to shift an AT-1202 or 2A92 transmission
|Synthetic Lube Supply – Production and Service
Sales control and supply allocation measures have recently been instituted by the primary suppliers of high viscosity polyalphaolefin (PAO) used in Roadranger SAE 50 Synthetic Transmission Lubricant.
|FR-XX210 Rear Housing, Shift Bar Housing and Shift Tower Capscrews
Due to a fastener style change in 2007 there is the possibility of transmissions having one of two different style fasteners.
| Low Lube Transmission Failures Caused by Radiator Repair or Replacement
There have been several instances of transmission failures caused by lack of lubricant. Root cause has been linked to a prior repair of the vehicles engine radiator.
|Service Bulletins: New Pre-Authorized Warranty Repair Guidelines
Based on dealer feedback, 18 Pre-Authorized Warranty Repair Guidelines have now been posted in the Warranty section of Roadranger.com.
| Push-to-Connect 5/32” tube fittings (airline)
The National Highway Safety Administration has made significant revisions to the Department of Transportation Federal Motor Vehicle Safety Standard FMVSS-106; Brake Hoses.
|MD-200\PC-Link Software Update; version 2.02
This update summarizes the various enhancements incorporated to address issues for some of the MD-200\PC-Link tool functions. Version 2.02 adds the MD-Logger functionality.
|14" Heat Exchangers
Failures of the 14ý heat exchanger which include internal leaks causing transmission oil and engine coolant to mix and broken mounting brackets causing external oil leak. High transmission sump temperatures and/or coolant GPM (gallons per minute) levels less than that required by Eaton will put the heat exchanger at a higher risk of internal failures.
|Power Up-No Crank (Delivery of Vehicle)
The gear display will register an (-) instead of an (N) Neutral. During transit one of the shift blocks has dropped into gear preventing the XY Shifter from confirming Neutral.
|Upgrade - UltraShift® Heavy-Duty “DM Clutch” Warranty in Linehaul Applications
This coverage is for applications that fit the linehaul definition in the Roadranger Warranty guide (TCWY0900).
|Mechanical Transmission Hard Shift Analysis
Mechanical transmission hard shift complaints may be diagnosed as a transmission problem but may actually be an OEM related issue. Potential causes may be OEM shift boots, levers, or controls. This has been known to drive un-necessary transmission repairs and costs to the customer.
|Inspection/Repair of Flood Damaged Vehicles with Roadranger Components
This document provides guidance on the proper inspection of Eaton components partially or fully submerged by flood water conditions.
|Auxilary Countershaft Bearing Cover Gasket
A New gasket has been released to address possible Auxiliary Countershaft Bearing Cover gasket leaks.
|Transmission 'Extended Drain Lubricants'
Transmission Division has revised the Lubrication Specification for E500 lubricants (PS-164 Rev 7). This new specification was sent to all lubricant suppliers in October 2004. Any ýcurrent approved supplierý of Eaton ýextended drain lubricantý must comply with the new specification by April 1, 2006. Failure to comply will result in removal from the approved supplier list, and will not qualify for extended drain/extended warranty.
|Spicer Life Series Zerk Cover
Spicer Life Series, Zerk Cover, Dana, Universal Joints
|MD-200\PC-Link Software Update; version 2.00
MD-200, Mobile Diagnostics, Software update, version 2.00
|Transmission Oil Leak Inspection Process
In effort to properly diagnose transmission oil leaks, reduce customer downtime, and eliminate second repair attempts; a formal transmission oil leak inspection process has been developed.
|Eaton MD Tools Support for Windows 95, 98, and ME Operating Systems
Effective February 2006, MD Tools will remove support for Windows 95, 98, and ME operating systems. Microsoft will remove external support of Windows 98 and ME operating systems on July 1, 2006. Microsoft has already removed support for Windows 95 on December 31, 2001. Without support from Microsoft it is impossible for the MD Tools product line to continue a high level of support that our customers expect.
|Lightning Input Shaft Removal / Installation
Using the incorrect removal/installation procedure can cause breakage of the small set-screw that holds the lube pump stationary in the front bearing cover.
Internal contamination caused by transmission failures can be categorized into three groups: Level A, B, & C
|Auxiliary Drive Gear Bearing
The auxiliary drive gear bearing can become pitted, loose and ultimately fail. Worst-case scenario is when the bearing cage breaks up. This can allow the Auxiliary Drive Gear to be thrust fore and aft causing additional damage to the main or auxiliary sections.
|Output Bearing Flange Breakage/Bearing Cover Oil Leakage
The rear bearing cover dimensional stack up allows for possible interference or lack of gasket clamp. If interference occurs between the rear bearing cover and bearing flange, the gasket clamp is compromised and leakage could occur. In the event the stack up allows for endplay between the bearing race and rear bearing cover, the result could be a broken output-bearing flange. A broken output-bearing flange may cause noise and/or vibration that will increase or decrease with road speed along with possible range shift issues. Most failures result in a failed synchronizer and are brought in with a raking complaint.
|Lightning 18-way ECU Connector
It is possible that the 18-way connector on the Lightning transmission ECU may exhibit ýFretting Corrosioný build up between the female connector terminals and the ECU pins. The tin coating of the female terminals and ECU pins may oxidize through heat cycles and vibration possibly causing ýFretting Corrosioný build up. The fretting corrosion build up may cause resistance levels to increase between the terminals and ECU pins. This may result with the ECU possibly logging an active/inactive fault code or to have an intermittent symptom.
|Lube Line Fitting Wear Causes Premature Clutch Failure
Wear of the clutch release bearing lube-line fitting at the clutch housing. In some cases the fitting wears through allowing the grease to escape, preventing it from reaching the clutch release bearing. This results in failure of the clutch release bearing. See photos for failure description.
|New Splitter and Range Kits for Heavy-Duty Fuller Transmissions
Eaton Roadranger Parts Marketing has released several splitter and range valve replacement kits for heavy-duty Fuller transmissions. These new kits incorporate an advanced engineering design that is much less susceptible to vehicle air system contamination.
|Roadranger Lube (Transmission). Elimination of 250,000 mi. Drain
Transmission Division has revised the specification for Extended Drain lubricants and has eliminated the 250,000 mile drain category, effective January 1, 2005. Affected lubricants are no longer approved for extended drain / extended warranty. This action impacts one lubricant ý Chevron Delo Trans Fluid ESI. Lubricant suppliers, including Chevron Texaco, were contacted early in 2005.
|AutoShift Operation With Paving Machines
AutoShift Operation with paving machines
|Correct Timing Procedure for the FR or RT Auxiliary Section
Concern with the transmission Auxiliary section being timed incorrectly after a service repair, causing shifting problems, and premature component wear.