Fuller Ultrashift 2009 Unique Problem

Discussion in 'Heavy Duty Diesel Truck Mechanics Forum' started by jaxwinner, Feb 2, 2019.

  1. jaxwinner

    jaxwinner Light Load Member

    83
    79
    Sep 6, 2017
    Barton Arkansas
    0
    I'm having a problem with my transmission. (2009 KW T660 with a Cat C-15 Acert and a Fuller 10-sp Ultrashift.

    Two months ago I broke down in an intersection because the truck would not go into gear. It had previously stalled a few times where it would not go into gear after coming to a stop at a stop sign or intersection. I would wait 15-45 min and it would then go back into gear usually near the end of the day. I had to have it towed to Crowe's Truck Center near Memphis.

    They looked at it and said the clutch was burnt up and replaced the clutch and rear seal for $6000. (motor mounts and an exhaust leak also)

    I drove it three weeks and then one day pulled into a receiver at the end of the day moved it to line it up with the dock and it would not go into gear after I put it in neutral to open my doors. If I put it in drive or reverse it would only flash the down arrow and gear but would not move (disconnecting the batteries didn't help). I let it set for a couple of hours and it went into gear again and over the next few hours I was able to wiggle it into the dock to be unloaded the next morning. After getting unloaded I drove it to a shipper and checked in and when I came out the same problem it would not go into gear but only flash the down arrow and show the gear. No error codes on the transmission.

    I took it to a shop near Atlanta but the guy didn't sound convincing that he knew what the problem was and lied in that he would have me in the shop first thing in the morning so at 1 pm I drove it 5.5 hours to Batesville MS. I got to an intersection to make a left turn and it went into neutral on its own and then would not go into gear. I sat there an hour and a half with the Batesville MS police blocking the intersection waiting on a tow truck. Just as the tow got there the truck went into gear and I moved it to the shoulder which was on an incline. Luckily I didn't get a tow bill or a ticket. It wouldn't go into gear again off the shoulder but i let it roll back just a little and it went into gear.

    I drove it to Crowe's the next morning on the 31st day after them replacing the transmission clutch. They looked at it and said they couldn't find anything they did that was wrong but there was a J1939 problem that they didn't have the equipment to read. I then took it to Rush Truck Center in Memphis where it is now.

    Rush replaced the batteries, fixed brakes and brake drums, and an intermittent abs issue and said it was fixed. I asked them to test drive it again and it wasn't fixed. They replaced the transmission harness and said it was fixed. I drive the hour and a half over there and drive it around Memphis and nothing was fixed. I took it back to Rush and asked for the mechanic that did the work and the manager came out to the truck. I told him to get in the drivers seat and put it in gear. He did and the truck did not go. He put it in reverse and it would not go. He put it in drive and it would not go. So there it sits now while the manager tries to talk to Eaton Fuller Monday.

    So the issues:
    intermittent abs
    being knocked out of cruise
    truck won't go into gear when transmission warms up after being put in neutral on a flat surface
    if the truck is on a hill and can roll slightly forward or reverse it will go into gear
    truck idles rough if idled up to 1000 rpm
    no transmission codes (Rush says they rode around in it Friday and had fixed it being knocked out of cruise because the brake pedal was loose and that they had the computer hooked up and there were no codes)

    Things that have been fixed:
    transmission harness
    complete new batteries
    new transmission clutch
    two computer updates on the transmission
    rear seal on transmission
    motor mounts
    exhaust leak
    new drums and brakes
    cab leveling valves both replaced
    rear vehicle speed sensor

    Questions: My home mechanic found a bit of oil in the line when he replaced the cab leveling valves and said that both the abs and the transmission have an air governor. Crowe's also said there was some oil in the air tanks when they took the transmission out to put in the clutch. Would a fault in the air governor cause these issues because as I understand it the transmission needs about 90 psi of air to function correctly?

    With it going into gear when on an incline could this be a clutch brake issue and would it have anything to do with the clutch being replaced?

    Does an Fuller Ultrashift work like a car transmission... could simply changing the fluid and the filter (isnt there a filter inside the oil pan) fix the problem?

    Sorry for the long post but I hope I've been thorough.
     
    Last edited: Feb 2, 2019
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  3. QUALITYTRUCK

    QUALITYTRUCK Road Train Member

    1,817
    1,783
    Jun 14, 2009
    romulus,mi
    0
    Eaton ServiceRanger diagnostic program is one of, if not the best, of all the OEM programs. The one issue from all that you have posted that they should be concentrating on is the j1939 data link issues. A "dirty" or broken data link signal will cause operational issues with whatever module is using it to communicate. In your case the engine,ABS,transmssion and CECU (interior dash) all use j1939. First and easiest thing to try is to unplug ABS module (under center console cup holder) go for test drive and see if problem is corrected. If not, second would be to follow proper j1939 diagnostic testing procedures. I would be betting on a datalink wiring problem with OEM Kenworth transmission harness (from truck to transmission ECU) they probably replaced the Eaton harness(transmission ECU to all trans.components)
     
    BoxCarKidd and Heavyd Thank this.
  4. Truckrazy

    Truckrazy Light Load Member

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    55
    Jun 4, 2019
    Illinois
    0
    A bit of an old thread but any update on what the issue was, and remedy?!
     
    gerardo1961 Thanks this.
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