Fuller Ultrashift 2009 Unique Problem Cont

mustang190 · Feb 4, 2019

Welcome to the brave new world.

25(2)+2 · Feb 4, 2019

Manual mode is just operator control of the automated process.

It won't 'allow' the operator to abuse it, I would have been stuck on mud covered ice Saturday night in that farmyard had I still had the automatic disaster sold by Eaton.

The truck in this thread is about 10 years old, seriously, I'd be turning it into a manual right about now.

Makeajump · Feb 4, 2019

Makeajump said: ↑

Thank You Lazer! If I ever see one of these Ultrashift in a truck, I'll run the other way fast! But that would be the fix, Just put it back to manual mode......
Click to expand...

Ya I didn’t mean with a selector switch, I meant removing all the electric controls and going back with manual controls as described by Lazer......

32awalker · Apr 8, 2022

The problem is your o-rings in the range cylinder have gone bad. It’s a $20 kit that will save you a lot of headaches trust me!!! I’ve been going through this problem for awhile especially on cold mornings,truck wouldn’t change range or wouldn’t go into 2nd gear at stop signs. I threw all kinds of parts at the problem only for it work for a little and go back to the same thing.It’s located on the the upper right corner corner inside the housing for the air regulator and hi-lo range solenoid.Easy fix for any mechanically incline person,diagrams online to show you exactly how it fits together.Also this may help if you’re getting a code 41.Try this first trust me,before you go down the parts rabbit hole.

32awalker · Apr 8, 2022

jaxwinner said: ↑

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.
Click to expand...

32awalker · Apr 8, 2022

The problem is the o-rings in your range cylinder,truck would do the same thing especially on cold mornings and wouldn’t go into 2nd at stops especially on flat land.The kit is only $20 and comes with everything to solve the problem the part #K-3484.Anyone going through this,try doing this before throwing money at it . It’s a simple fix,it’s located on the back in the upper right corner behind the air regulator and hi-lo solenoid inside a housing that controls the piston to change from high to low.If the o-rings go bad it affects your shifting.Also this is definitely the problem if you get code 41. Hopefully this helps

dorlia2 · Oct 6, 2022

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