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

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. 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

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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)

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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

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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

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