Service Bulletin — Process

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Subject: Lightning to FRO/RT 13-Speed Conversion Instructions
Document Number: TMIB0176
Date: June 17, 2009 Updated: October 18, 2012

Issue Description:

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.

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 an 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 1-800-826-4357.

Listed at the bottom of this service bulletin are conversion kit part numbers. These kits

do not include transmissions or oil coolers. Special applications may require ordering of
additional clutch housings.

Page 1 of 8
Service Bulletin — Process

Best Transmission Options for a Lightning Conversion Chart

Current Lightning | Optional Part Number

Model Transmission Model

FRLO-XX410C FRO-16210C TA-D60-10R — Reman w/ internal cooler
(preferred option)

TA-D60-12R — Reman w/ internal pump
w/o internal cooler

RTLO-16913A TA-F04-50R — Reman RTLO-16913A
(internal pump model)
FRLOF-XX410C FROF-16210C TA-D61-10R — Reman w/ internal cooler

TA-D61-12R — Reman w/ internal pump
w/o internal cooler

RTLOF-16913A TA-F05-50R — Reman RTLOF-16913A
(internal pump model)

Note: Dependent on chassis model and configuration, a “Forward” or “Standard” shift
bar housing model needs to be utilized.

An Warning: Internal cooler FRO models cannot be used with a hydraulic clutch release
system application

AY 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 responsible for any costs associated with the PTO conversion

Page 2 of 8
Service Bulletin — Process

Clutch Housing Options Chart

Note: Reman transmissions come standard with an upper and lower bushed clutch housing.
Note: Hydraulic actuator clutch housings for hydraulic actuated clutch applications needs to

be ordered separately

Lightning CL HSG

| FRO/F-10 Speed CL HSG | RTLO/F 13 Speed CL HSG

TA-D66/75-SAU-10 A-5992 K-3676

Standard aluminum (#1, Pull, Alum) (#1, Pull, Alum)

upper cross shaft Forced Lube CL HSG Kit
bushing location

TA-D84-SAL-10 A-7665 A-7664

Standard aluminum
(non-nodal) lower cross

(#1, Pull, Alum, Below
Centerline, Non-Nodal)

(#1, Pull, Alum, Below
Centerline, Forced Lube, Non-

shaft bushing location Nodal)
TA-D66/75-NAU-10 A-4456 K-3673

Nodal aluminum upper (#1, Pull, Alum) (#1, Pull, Alum, Nodal)
cross shaft bushing Forced Lube CL HSG Kit
location

TA-D66/75-NAL-10 A-4550 A-7589

Nodal aluminum lower
cross shaft bushing
location

(#1, Pull, Lower, Alum)

(#1, Alum, Nodal)

TA-D66/75-HA-10
Hydraulic actuator
housing

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: Clutch housing replacement may be necessary on 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.

Page 3 of 8

Service Bulletin — Process

Master Control Valve Replacement
Note: See “Air System Troubleshooting Guide” TRTS0902, available on
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, orientate to the correct
position and tighten jam nut.

3. Install °/3." air line fittings into the master control valve. Install the 5/30" air line from
the master control valve on the shift lever to the air module/slave valve/splitter
cylinder on the transmission.

4. Secure all air lines to prevent chaffing.

5. Install skirt for master control valve.

Oil Cooler/Heat Exchanger
Installing an internal cooler FRO model:

4. Install the existing Lightning oil cooler lines to correct “In” and “Out” oil cooler ports
on the FRO model transmission.

Note: Alter coolant lines for correct fit.
2. Secure all oil lines to prevent chaffing.
Installing a non-internal cooled FRO model:

4. Several cooler options are available for this conversion. The facility initiating the
conversion must choose the type and part number of cooler that best fits the
cab/chassis configuration. The available options are:

Oil to Water Heat Exchanger Options | at ae

Top, Rear Mount, Oil-Water Heat Exchanger K-4121
Front Mount, Shift Bar Housing, Oil-Water Heat Exchanger K-4000
Left Mount, Shift Bar Housing, Oil-Water Heat Exchanger K-3740

Note: The Bottom, Rear Mount, Oil-Air Type Heat Exchanger kit may interfere with
some PTO applications.

Page 4 of 8
Service Bulletin — Process

Installing a RT 13-speed model:
External air to oil cooler kit: K-1956

Oil to Water Heat Exchanger Options for RT-13 speed model:

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?modellD=373&group|ID=1095 for
heat exchanger mounting configurations to fit applicable vehicle model and chassis
configurations.

Heat Exchanger Installation
1. Install oil cooler/neat 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 to 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 are
installed onto the correct ports of the heat exchanger and transmission ports.

5. Secure all oil lines to prevent chaffing.

A Important: Engine coolant level and transmission oil level must be checked after
heat exchanger installation is completed.

/\ Important: Check for any leaks after operation of vehicle.

Page 5 of 8
Service Bulletin — Process

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. Decals are included in conversion kits:

Transmission Model _| Shift Label Part Number

FRO/F 10-Speed 20400
RTLO/F 13-Speed 4300764

Lightning 18-Way Harness Connector Cap Installation

1. After the original Lightning 18-way harness connector is removed from the
transmission ECU (Electronic Control Module), install the supplied 18-way harness
connector cover (K-3756).

2. Secure harness in area that will prevent any future harness damage.

VSS (Vehicle Speed Sensor) Installation/Program

Some Lightning transmission ECUs broadcast speed information over the J1939 data
link to the vehicle and engine. This can be identified 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 will no longer be able to be broadcasted on
the J1939 data link. The FRO model transmission will require the installation of a VSS in
this case. For the vehicle/engine VSS:

4. Install speed sensor into the 12 o'clock position of the rear bearing cover.
Note: Refer to engine manufacture specifications for correct VSS application.
2. Hard wire the VSS to the chassis electrical system.

Note: Refer to OEM wiring diagrams and harness specifications. Most OEMs
already have the harness in-place on the chassis somewhere and would just
need routed to the newly installed VSS.

3. | Reprogram the VSS engine parameter to reflect a “Manual” VSS application.
Note: Refer to engine manufacture parameter setting specifications.
4. Ensure VSS is reading correctly during vehicle operation.

Driveshaft Modification
4... 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 an RT
13-speed installation. The shaft should be modified by a reputable driveshaft
repair facility.

Page 6 of 8
Service Bulletin — Process

Conversion Kits

Part Number: K-3998 Description: Kit, Conversion Lightning, FRO/F

Comments: Kit used with the conversion from Lightning to FRO/F Series
Transmission

Quantity | Part Number Description

1 K-3756 Harness Cap

1 S-2543 Master Valve

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 Clt 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

Page 7 of 8
Service Bulletin — Process

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

Part Number: K-4003 Description: Kit, Conversion Lightning Hydraulic CLT
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 product improvement information. Eaton Corporation is not committed to, or
liable for, canvassing existing products. FSUD: 2005-FSUD-597

Page 8 of 8