Control Lever and/or Boot Replacement

Control Lever and/or Boot Replacement

Removal Procedure




1. Exhaust all air pressure from the system, if equipped.
2. If equipped, with the Eaton Fuller(R) 9 or 10 speed transmission, remove the screws from the control lever shift sheath.
3. Slide the sheath down the shift lever.
4. If equipped with the 9 speed transmission, disconnect the following tubes:

* Red tube (1) from the "S" port
* Black tube (2) from the "P" port




5. If equipped with the 10 speed transmission, disconnect the following tubes:

* Blue tube (1) from the "SP" port
* Black tube (2) from the "P" port
* Red tube (3) from the "S" port
* Green tube (4) from the "H" port to "L" port

6. Cap the tube openings.
7. Perform the following steps in order to remove the air shift control lever:

1. Loosen the shift knob lock nut.
2. Unscrew the shift knob.
3. Slide off the sheath, if necessary.




8. If equipped, with the Eaton Fuller(R) 9 or 10 speed transmission, remove the control lever retainer bolts and retainer.
9. Remove the control lever boot retainer plate bolts and plate.
10. Remove the control lever boot bolts and boot.




11. If equipped, with the Eaton Fuller(R) transmission, loosen the shift knob lock nut.
12. Unscrew the shift knob.




13. If equipped, with the 6.6/7.2L (1) or 8.1L (2) engine, and regular production options (RPOs) MSC/MSG, remove the retainer and bushing.
14. Remove the retaining pin, and bushing.
15. Remove the control lever.




16. If equipped, with the 6.6/7.2L engine without RPOs MSC/MSG remove the retainer and bushing.
17. Remove the retaining pin, and bushing.
18. Remove the control lever.




19. If equipped with the Spicer(R) transmission, RPOs MK8/MK9, remove the control lever boot retainer bolts and retainer.
20. Remove the control lever boot bolts.
21. Lift up the control lever boot.




22. If equipped with the Spicer(R) transmission, RPOs MK8/MK9, loosen the set screw (1).
23. Remove the control lever and boot.

Installation Procedure




1. If equipped with the Spicer(R) transmission, RPOs MK8/MK9, install the control lever and boot.
Notice: Refer to Fastener Notice in Cautions and Notices.

2. Tighten the control lever set screw (1).

Tighten the control lever set screw to 39 Nm (28 lb ft).

3. Push down the control lever boot.




4. If equipped with the Spicer(R) transmission, RPOs MK8/MK9, install the control lever boot bolts.

Tighten the control lever boot bolts to 2 Nm (18 lb in).

5. Install the control lever boot retainer and bolts.

Tighten the control lever retainer bolts to 2 Nm (18 lb in).




6. If equipped, with the 6.6/7.2L engine without RPOs MSC/MSG, install the control lever.
7. Install the retaining pin, and bushing.
8. Install the retainer and bushing.




9. If equipped, with the 6.6/7.2L (1) or 8.1L (2) engine, and RPOs MSC/MSG, install the control lever.
10. Install the retaining pin, and bushing.
11. Install the retainer and bushing.




12. If equipped, with the Eaton Fuller(R) transmission, screw the shift knob on.
13. Tighten the shift knob lock nut.

Tighten the shift knob lock nut to 25 Nm (18 lb ft).




14. If equipped, with the Eaton Fuller(R) 9 or 10 speed transmission, install the control lever boot and boot bolts.
15. Install the control lever boot retainer plate and bolts.

Tighten the control lever boot retainer plate bolts to 2 Nm (18 lb in).

16. Install the control lever retainer and bolts.

Tighten the control lever retainer bolts to 2 Nm (18 lb in).




17. Perform the following steps in order to install the air shift control lever:

1. Slide on the sheath, if necessary.
2. Screw on the shift knob.
3. Tighten the shift knob lock nut.

Tighten the shift knob lock nut to 25 Nm (18 lb ft).

18. Remove the caps from the tube openings.
19. If equipped with the 10 speed transmission, connect the following tubes:

* Blue tube (1) to the "SP" port
* Black tube (2) to the "P" port
* Red tube (3) to the "S" port
* Green tube (4) to the "H" port to "L" port




20. If equipped with the 9 speed transmission, connect the following tubes:

* Red tube (1) to the "S" port
* Black tube (2) to the "P" port

21. Slide the sheath up the shift lever.
22. If equipped, with the Eaton Fuller(R) 9 or 10 speed transmission, install the screws to the control lever shift sheath.

Tighten the control lever shift sheath screws to 5 Nm (44 lb in).

23. Pressurize the air system, if equipped.
24. Operate the shift control lever to check for leaks, if equipped.