Eaton Fuller Heavy Duty Transmissions Illustrated Parts List FRO-16210C December 2002

Transcription

1 Eaton Fuller Heavy Duty Transmissions Illustrated Parts List FRO-110C December 00 For the most current information, visit the Roadranger web site at

2

3 Contents How To Use The Illustrated Parts List... 4 Locating Transmission Tag and Identifying Model Designation... 5 Using Model Designation or Nomenclature... 5 AIR MODULE & RANGE CYL.... AUXILIARY DRIVE GEAR... CASE (AUX)... CASE (FRONT)...10 COUNTERSHAFT & BRGS(AUX)...1 COUNTERSHAFT ASSY...1 INPUT SHAFT & DRIVE GEAR...14 INTEGRAL OIL COOLER...15 INTEGRAL PUMP & COOLER...1 INTEGRAL OIL PUMP...1 INTEGRAL PUMP & COOLER...1 OIL COOLER...1 KITS & ASSEMBLIES...1 LEVERS/CONTROLS...0 ISOLATORS...0 LEVERS/CONTROLS...1 LEVERS/HOUSINGS...1 MAINSHAFT & SYNCHRO(AUX)... MAINSHAFT ASSY...4 MISC. THRU-SHAFT PTO...5 REAR HOUSING ASSY...5 MISCELLANEOUS... REVERSE IDLER... ROADRANGER VALVES... ROADRANGER VALVE... SHIFT BAR HOUSING (FRO)...9 Appendix...

4 How To Use The Illustrated Parts List Using Model Designation or Nomenclature This information provides a guideline to assist you in indentifying the transmission designation assigned to a transmission model - information vital to identifying and ordering parts. Kits and Assemblies (K/A's) Kits and Assemblies contain groups of individual or assembled parts developed for optimal replacement or repair of a service problem. Kits and Assemblies are shown with applicable parts groupings in the parts listings. Identifying Kits and Assemblies A- Part numbers beginning with the letter 'A' are pre-assembled Production Assemblies K- Part numbers beginning with the letter 'K' are kits that are not assembled S- Part numbers beginning with the letter 'S' are pre-assembled Service Assemblies Note: Some Production Assemblies do not begin with a letter prefix (Midrange only). Illustrations Illustrations show parts in assembly groups. Item numbers on illustrations correspond with parts listings on pages adjacent to the illustration. Notes are included on illustrations where additional information is needed. Parts Listing Parts listings are defined by parts groupings and are broken down by service assemblies. Parts listings identify a part for servicing with the following categories Item Number - corresponding with numbers on illlustrations for part identification. Current Part - indentifies part as it is available for service. Description - specifies part name or description. Replaced Part - quantity quantity required for assembly. Quantity - defines unique characteristics or requirements. Notes - indicates Kits or Assemblies that contain a particular part. Kits/Assy's Where Used 4

5 Locating Transmission Tag and Identifying Model Designation Transmission model designation, and other transmission information, are stamped on the transmission tag. To identify the transmission model designation (nomenclature), locate the tag on the transmission and then locate the model designation number as shown. Using Model Designation or Nomenclature The model designation or nomenclature assigned to a transmission model provides information concerning transmission torque capacity, forward speeds, ratio set, shift bar housing and other provisions and options. Use the following guidelines to identify your transmission model designation. This information is useful when ordering parts. Every effort has been made to ensure the accuracy of this publication. However, Eaton Corporation makes no expressed or implied warranty or representation based on the information contained in this publication. Any errors or omissions may be reported to Eaton Roadranger Parts Marketing, Eaton Corporation, P.O. Box 401, Kalamazoo, MI Copyright Eaton Corporation, 00 All rights reserved. 5

6 Group: AIR MODULE & RANGE CYL AIR MODULE & RANGE CYL. 1 X--004M CAPSCREW 4 M X 1.5 X 0MM S-0,S-9,S-01,S-0 K-45 AIR MODULE ASSY A O- RING K-9,K-45,S-0,S-9,S-01 S O- RING 1 K-45,S-0,S-9,S-01,S O- RING 1 K-9,S-0,S-9,S-01,S-0 K-19 BAR & RING KIT K-1 PISTON KIT SNAP RING 1 K-9,K-1,K-19,K-10,K O- RING 1 K-9,S-0,S-9,S-01,S O- RING 1 K-9,S-0,S-9,S-01,S O- RING 1 K-9,K-45,S-0,S-9,S-01 S COVER 1 S-0,S-9,S-01,S-0 1 X--004M CAPSCREW M X 1.5 X 0MM S-0,S-9,S-01,S-0

7 Group: AUXILIARY DRIVE GEAR C AUXILIARY DRIVE GEAR BEARING SPACER BEARING K-94,K RETAINER 1 4 X--100M CAPSCREW M10 X 1.5 X 5MM K-51,S-4,S-4,S-91,S-9 S AUXILIARY DRIVE GEAR SNAP RING 1 K-91,K-94,K-1

8 Group: CASE (AUX) 1 4 OEM supplied adjustable speedometer sensor (Threaded) OEM supplied non-adjustable speedometer sensor (Non-Threaded) Magnetic 0 1 Old Design Old Design Mechanical Old Design 1 CASE (AUX) 1 S-501 SPEEDO ROTOR ASSY MAGNETIC O- RING 1 K-91,S-501,S-50,S-09 K-91 OIL SEAL KIT MAGNETIC SPEEDO K-94 4 X--001M CAPSCREW M X 1.5 X 1MM S-0,S-9,S-01,S-0,S-09 S-44,S-45,S-4,S- 4 5 S-09 REAR BEARING COVER ASSY 40,40, PUSH-IN/THREAD-IN MAGNETIC PICK- UP 404 GASKET 1 K-,K-91,K-91,S-50,S-09 S-59 X--1009M CAPSCREW M10 X 1.5 X 50MM USE W/40 AND 40 RBC X--100M HEX SCREW 4 M10 X 0.0MM USE W/4045 RBC S-09 X--1009M CAPSCREW M10 X 1.5 X 50MM USE W/4045 RBC X--100M CAPSCREW M10 X 1.5 X 5MM K-51,S-4,S-4,S-91,S-9 S-0,S-4,S COVER 14 S-4,S GASKET 145 K-91,S-4,S K-05 SHIM KIT 145 K K-94, K-1,S-4,S-49 1 K-51 LIFTING EYE KIT A S-91 REAR HOUSING ASSY K-9 1 K-9 REAR HSG REPL KIT GASKET 1 K-91,S-4,S-49

9 15 X--1005M CAPSCREW 1 M10 X 1.5 X 5MM 15 X--100M CAPSCREW M10 X 1.5 X 45MM O- RING 1 K-45,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 4 1 A-15 RANGE BAR COVER ASSY A X--00M SCREW M X 1.5 X 0MM SPEEDO DRIVE GEAR 1 0 S-50 SPEEDO SPACER ASSY MECHANICAL 1 K- OIL SEAL W/SLINGER ,00 1 MECHANICAL SPEEDO K-1 X--100M SCREW M10 X 1.5 X 5MM K-454 SPEED SENSOR KIT A - 9,A SINGLE PICK-UP ( PIN) K-455 SPEED SENSOR KIT, DUAL A DUAL PICK-UP (4 PIN) SLINGER 1 S O- RING 1 S-59 REAR BRG COVER ASSY 40 1 MECHANICAL - :00 OPENING S-50 REAR BRG COVER ASSY MECHANICAL - 4:00 OPENING K-50 PLUG RETAINING KIT 40,4051 1, LIFTING EYE 1105 K-51,S-4,S-4,S-91,S-9 S-0 9 X--100M CAPSCREW M10 X 1.5 X 5MM K-51,S-4,S-4,S-91,S-9 S-0,S-4,S-49 9

10 Group: CASE (FRONT) CASE (FRONT) 1 S-0 CASE ASSY OPTIONAL - FOR USE W/INTEGRAL OIL COOLER 1 S-4 CASE ASSY W/INTEGRAL OIL PUMP X-1-00 PIPE PLUG X /4" X-1-10 PIPE PLUG X /4" GASKET K PTO COVER 159, X--100M CAPSCREW M1 X 1.5 X 0MM 4014 GASKET 1 K-91 A-599 CLUTCH HOUSING ASSY #1 PULL ALUM. A-4 CLUTCH HOUSING ASSY A - 444,A # PUSH-PULL ALUM. A-04 CLUTCH HOUSING ASSY A - 44,A - 40,A - 1 #1 PUSH-PULL ALUM. 0,A - 0,A - 05 A-1 CLUTCH HOUSING ASSY A #1 PUSH-PULL IRON A- CLUTCH HOUSING ASSY A - 1,A - 1 # PUSH-PULL IRON 9 X-L-509 CAPSCREW 4 5/1"-1X1/" QUANTITY DEPENDENT ON DESIGN HAND HOLE COVER #1 PULL STUD M1 X X 0MM 1 X WASHER 5/" NOT REQUIRED WHEN USING X-1-105M NUT 1 X-1-105M NUT X 1 101M,X 1 10M M1 X FRONT BRG COVER 1 " PULL 15 X--1004M CAPSCREW M10 X 1.5 X 0MM GASKET 1 K BUSHING 4 UPPER A-1,A-,A-4,A-599,A-04 10

11 19 BUSHING LOWER A-1,A-,A-4,A-04 0 X-C- CAPSCREW & WASHER M1 X 1.5 X 5MM IRON HOUSING 104M 0 X-C- 104M CAPSCREW & WASHER 4 M1 X 1.5 X 5MM ALUMINUM HOUSING 0 X-C- CAPSCREW & WASHER M1 X 1.5 X 90MM IRON HOUSING 10M PLUG 1 1-1/1" MAGNETIC S-4,S-0,S PLUG 1 1-1/1" - COMES WITH O-RING INSTALLED X--100M CAPSCREW M10 X 1.5 X 0MM 1455 PTO COVER GASKET 1 K-91 5 X-1-0 SELF-TAPPING SCREW X1 9 5/1" 5000 NAME PLATE MAGNET S-4,S-0,S-0,S- 11 PIN 9 X-1-105M NUT X 1 101M,X 1 10M M1 X DOWEL PIN S-4,S STUD M1 X X 5MM K-51 LIFTING EYE KIT A X-1-0 PIPE PLUG X /" S-0,S GASKET 1 K-910,K COVER 1 X--00M CAPSCREW 5 M X 1 X 0MM K LIFTING EYE 1105 K-51,S-4,S-91,S-9,S-0 X--100M CAPSCREW M10 X 1.5 X 5MM K-51,S-4,S-91,S-9,S-0 S-4,S-49 11

12 Group: COUNTERSHAFT & BRGS(AUX) /9 Aux CS Helical COUNTERSHAFT & BRGS(AUX) BEARING 14 4 K-94,K-1,S-4,S-49 A-4 WELDED COUNTERSHAFT A - 45,A - 44 D/G 10 - C/S 404 ASSY 90 SPACER K-91 1

13 Group: COUNTERSHAFT ASSY Latest Design 1 5 Included w/item # COUNTERSHAFT ASSY C SNAP RING K-94,K BEARING K-94,K-1 K- CNTRSHFT KIT-W/REV & 1ST LOWER W/THRU SHAFT PTO & PUMP K-5 CNTRSHFT KIT-W/REV & 1ST 4040 LOWER & UPPER W/THRU SHAFT PTO K- CNTRSHFT KIT-W/REV & 1ST 4011,40119 STANDARD K-4 CNTRSHFT KIT-W/REV & 1ST 401,401 1 LOWER W/PUMP KEY 5 X CAPSCREW INCLUDED WITH ITEM # K-,K-4,K-5,K-,K-, K-,K-9,K BEARING RETAINER INCLUDED WITH ITEM # K-,K-4,K-5,K-,K-, K-,K-9,K ND GEAR-CNTRSHFT 40404, RD GEAR-CNTRSHFT OD GEAR-CNTRSHFT PTO GEAR - LOWER PTO GEAR - UPPER DRIVE GEAR-CNTRSHFT SNAP RING PUMP DRIVE GEAR 1 1

14 Group: INPUT SHAFT & DRIVE GEAR 9 5 1* * For Shipping Only Ñ Do Not Replace C INPUT SHAFT & DRIVE GEAR SHIPPING SEAL 1 NOT SOLD FOR SERVICE 190 SNAP RING 1 K BEARING 1 K-94,K SNAP RING 1 USE W/4044 MAIN DRIVE GEAR K-91,K-94,K-1,K-41,K-419, K SNAP RING 1 USE W/ MAIN DRIVE GEAR K NLA-ORDER K , NLA-ORDER K MAIN DRIVE GEAR USE W/40 SNAP RING AND S- K-40 INPUT SHAFT S-95 NLA-ORDER K S- INPUT SHAFT ASSY " PULL - USE W/4044 MAIN DRIVE K-41,K-419,K-40 GEAR 9 15 BUSHING 1 K-94,K-1,S-95,S- 14

15 Group: INTEGRAL OIL COOLER INTEGRAL OIL COOLER 1 K-4 INTEGRAL OIL COOLER KIT 1 S- OIL COOLER COVER ASSY STANDARD - /4-1 UNF B S-0 OIL COOLER COVER ASSY OPTIONAL - 1/-14 NPTF X--00M CAPSCREW M X 1 X 0MM K MAGNET S-4,S-0,S-0,S PLUG 1 1-1/1" MAGNETIC S-4,S-0,S PLUG 1 1-1/1" - COMES WITH O-RING INSTALLED X-1-0 PIPE PLUG X /" S-0,S- 404 GASKET 1 K-91,S-0,S- 9 X--1004M CAPSCREW 1 M10 X 1.5 X 0MM 15

16 Group: INTEGRAL PUMP & COOLER Sub-Group: INTEGRAL OIL PUMP C INTEGRAL PUMP & COOLER INTEGRAL OIL PUMP 1 A-4 INTEGRAL OIL PUMP 1 COMPONENT PARTS NOT SOLD SEPARATELY 1

17 Group: INTEGRAL PUMP & COOLER Sub-Group: OIL COOLER Oil Outlet Oil Return * *1 * *14 * Cooler C *Adding Oil Filter and parts as shown is optional. INTEGRAL PUMP & COOLER OIL COOLER OIL COOLER 1 K HOSE 1 5 FEET K-195 X--55 CAPSCREW 5/1"-1X-1/" K X--50 LOCKWASHER 5/1" K BRACKET 4 K CONNECTOR K-195,S SWIVEL 4 K-195 X WASHER 5/1" K PLUG-RUBBER MOUNT K STRAP K CLAMP 5 K NUT K ELBOW 4 K S-1404 OIL FILTER FILTER ELEMENT 1 S

18 KITS & ASSEMBLIES K-495 REPL KIT-SLIDING CLUTCH K S-19 SHIFT LEVER HSG ASSY 1 LOW TOWER S-10 SHIFT LEVER HSG ASSY 1 HIGH TOWER S-49 RANGE SECTION ASSY 1 FOR "C" RATIOS S-09 REAR BEARING COVER ASSY 40,40, PUSH-IN/THREAD-IN MAGNETIC PICK- UP K-195 COOLER INSTLN KIT 1 K-910 COVER & SCREW KIT K-14 SHIFT LEVER HSG 450,11,19,A - 1 LOW TOWER 44 K-9 SHIFT LEVER HSG KIT 11,40050,K - 1 HIGH TOWER 10 S-44 SHIFT BAR HSG ASSY (FRO) 40150,40445,40501,S COMPLETE - INCLUDES RANGE CYLINDER ASSY K-49 LEVER REPLACEMENT KIT 1 HIGH TOWER K-9 RANGE PISTON KIT 1 K-94,K-1 S-95 NLA - SEE GROUP NOTE K-9 LEVER REPLACEMENT KIT 1 MID TOWER S-54 ROADRANGER VALVE ASSY A RT - W/SHIFT DIAGRAM MEDALLION S-45 SHIFT BAR HSG ASSY (FRO) 40150, COMPLETE - INCLUDES RANGE,40501,S - 95 CYLINDER ASSY AND OPTIONAL DETENT SPRING DESIGN DETENT SPRING. IT IS USED TO INCREASE SHIFTER DETENT FORCE. S-4 SHIFT BAR HSG ASY (FROF) 404,4044,4050,S COMPLETE - INCLUDES RANGE CYLINDER ASSY S-4 RANGE SECTION ASSY 1 FOR "B" RATIOS K-1 PISTON KIT K-150 IDLER SHAFT KIT 401,X 1 100M 1 K-94 AIR SYSTEMS TOOL KIT 1 K-9 SHIFT LEVER HSG KIT 4011,A MID TOWER S-194 ISOLATOR ASSY 1 S-4 SHIFT BAR HSG ASY (FROF) 404, COMPLETE - INCLUDES RANGE,4050,S - 94 CYLINDER ASSY AND OPTIONAL DETENT SPRING DESIGN DETENT SPRING. IT IS USED TO INCREASE SHIFTER DETENT FORCE. K-10 SHIFT YOKE KIT K-45 AIR MODULE ASSY A K-4 HOUSING UPDATE KIT (FRO) 40150,S HOUSING ONLY K-455 SPEED SENSOR KIT, DUAL A DUAL PICK-UP (4 PIN) S-501 SPEEDO ROTOR ASSY MAGNETIC S-4 SHIFT BAR HOUSING (FROF) HOUSING ONLY K-4 K-19 BAR & RING KIT K-40 REAR HSG REPL KIT THRU-SHAFT PTO K-4 INTEGRAL OIL COOLER KIT 1 K-419 GEAR UPDATE KIT 1 FRO/FROF - "B" RATIO K-4 HSG UPDATE KIT (FROF) 404,4044,S - 1 HOUSING ONLY 9 K-4 LEVER REPLACEMENT KIT 1 LOW TOWER K-99 ISOLATOR BUSHING KIT 144,11 1 K-50 PLUG RETAINING KIT 40,4051 1,40519 S-4 CASE ASSY W/INTEGRAL OIL PUMP S-0 OIL COOLER COVER ASSY OPTIONAL - 1/-14 NPTF S-59 REAR BRG COVER ASSY 40 1 MECHANICAL - :00 OPENING K-00 PIN & BUSHING KIT 1 K-104 ACTUATOR PIN KIT 40 1 K-1 BASIC REBUILD KIT 1 MECHANICAL SPEEDO FOR OVERHAUL KIT - ORDER THE REBUILD KIT AND THE REQUIRED INPUT SHAFT ASSY S-50 REAR BRG COVER ASSY MECHANICAL - 4:00 OPENING S-50 SPEEDO SPACER ASSY MECHANICAL 1

19 K-11 YOKE BAR KIT 400,401 1 K-49 SYNCHRONIZER KIT K S-519 SHIFT LEVER HSG ASSY S MID TOWER S-91 REAR HOUSING ASSY K-9 S-9 REAR HOUSING ASSY 40 1 THRU-SHAFT PTO K-40 S- OIL COOLER COVER ASSY STANDARD - /4-1 UNF B S- INPUT SHAFT ASSY " PULL K-419,K-40 K-05 SHIM KIT 145 K K-94, K-1,S-4,S-49 K-91 OIL SEAL KIT FOR MAGNETIC COVER K-94 K-91 SMALL PARTS KIT 1 K-4 COUNTERSHAFT KIT 401,401 1 "C" RATIO K-40 GEAR UPDATE KIT 1 FRO/FROF - "C" RATIO K-51 LIFTING EYE KIT A S-4 SHIFT BAR HOUSING (FRO) HOUSING ONLY K-4 K-91 GASKET KIT 1 K-94,K-1 K-94 BASIC REBUILD KIT 1 ELECTRONIC SPEEDO FOR OVERHAUL KIT - ORDER THE REBUILD KIT AND THE REQUIRED INPUT SHAFT K-9 REAR HSG REPL KIT K-5 COUNTERSHAFT KIT "C" RATIO K- COUNTERSHAFT KIT "C" RATIO K-454 SPEED SENSOR KIT A - 9,A SINGLE PICK-UP ( PIN) K-191 MASTER VALVE REPAIR KIT 1 FOR A-909 & A-5010 VALVES K- OIL SEAL W/SLINGER ,00 1 FOR MECHANICAL COVER K-1 K- COUNTERSHAFT KIT 4011, "C" RATIO K- O-RING & WASHER KIT K-4 PIN REPLACEMENT KIT S-1404 OIL FILTER

20 Group: LEVERS/CONTROLS Sub-Group: ISOLATORS Indicates Part Of Item /9 LEVERS/CONTROLS ISOLATORS E- RING K-4 PIN REPLACEMENT KIT BUSHING K-00,K-4,K-49,K-9,K-99 S-19,S-10,S S-194 ISOLATOR ASSY 1 14 LEVER 1 STRAIGHT 1." 15 STUB LEVER 1 LOW TOWER K-4 1 STUB LEVER 1 HIGH TOWER K-49,S STUB LEVER 1 MID TOWER K DEG LEVER 1 STRAIGHT " 10 K-99 ISOLATOR BUSHING KIT 144, X--50 SCREW 1 K-00,K-4,K-49,K-9,K-99, K- 4,S-19,S-10,S X-9-50 NUT 1 K-00,K-4,K-49,K-9,K-99, K- 4,S-19,S-10,S-519 0

21 Group: LEVERS/CONTROLS Sub-Group: LEVERS/HOUSINGS 15 1 K-4 - Low K-9 - Mid K-49 - High S-19 - Low S Mid S-10 - High Levers/Housings C LEVERS/CONTROLS LEVERS/HOUSINGS 1 K- O-RING & WASHER KIT PIN 1 K-14,K-9 X--1005M CAPSCREW 4 M10 X 1.5 X 5MM K-9 SHIFT LEVER HSG KIT 4011,A MID TOWER K-14 SHIFT LEVER HSG 450,11,19,A - 1 LOW TOWER GASKET K-14,K PIN 1 K-9,S PIN 1 /" - USED W/11 ONLY 14 K-9 SHIFT LEVER HSG KIT 11,40050,K - 1 HIGH TOWER BOOT 1 K-14,K-9,S-10 1 X-1-00 NUT 1 /"-4-N.F.PLAIN 1 X--00 LOCKWASHER 1 /" GEAR SHIFT LEVER 1 STRAIGHT - LOW 1-1/" 0 14 GEAR SHIFT LEVER 1 STRAIGHT - HIGH 5" 1 5 RETAINER 1 K-14,K-9,S-10 5 SPRING 1 K-14,K-9,S-10 K-4 LEVER REPLACEMENT KIT 1 LOW TOWER K-49 LEVER REPLACEMENT KIT 1 HIGH TOWER K-9 LEVER REPLACEMENT KIT 1 MID TOWER S-19 SHIFT LEVER HSG ASSY 1 LOW TOWER S-10 SHIFT LEVER HSG ASSY 1 HIGH TOWER S-519 SHIFT LEVER HSG ASSY S MID TOWER 1

22

23 Group: MAINSHAFT & SYNCHRO(AUX) Old Design C MAINSHAFT & SYNCHRO(AUX) SPRING K-91,K-94,K-1,K-49,K-495 A-1 SYNCHRONIZER ASSY A - 1 HI RANGE K-49, K SLIDING CLUTCH 1 K A-54 SYNCHRONIZER ASSEMBLY A - 49 A LO RANGE K-49, K AUXILIARY MAINSHAFT WASHER 1 K-91 K-11 YOKE BAR KIT 400, PIN 1 NOT REQUIRED FOR 401 YOKE BAR SNAP RING K-9,K-1,K-19,K-10,K-11, K- 9,S-4,S-4 10 K-10 SHIFT YOKE KIT NO LONGER AVAILABLE 1 NOT REQUIRED FOR 401 YOKE BAR REDUCTION GEAR SPACER 1 K BEARING 1 K-94,K NUT 1 S-4,S YOKE-10 FULL ROUND YOKE-110 HALF ROUND YOKE-10 HALF ROUND YOKE-110 FULL ROUND YOKE-110 HALF ROUND YOKE-110 FULL ROUND 1

24 Group: MAINSHAFT ASSY C MAINSHAFT ASSY MAINSHAFT KEY 1 K SNAP RING 1 K SPACER 1 K WASHER 1 K REVERSE GEAR-MAINSHAFT SLIDING CLUTCH 405 WASHER K ST GEAR-MAINSHAFT ND GEAR-MAINSHAFT RD GEAR-MAINSHAFT NLA-ORDER K OD GEAR-MAINSHAFT K SLIDING CLUTCH 1 K-41,K-419,K NLA-ORDER K

25 Group: MISC. THRU-SHAFT PTO Sub-Group: REAR HOUSING ASSY Old Design A Old Design MISC. THRU-SHAFT PTO REAR HOUSING ASSY 404 GASKET 1 K-91,S-4,S-49 K-40 REAR HSG REPL KIT S-9 REAR HOUSING ASSY 40 1 K EXPANSION PLUG S-9 5 X-1-10 PIPE PLUG X /4" X-L- CAPSCREW & WASHER M10 X M K-51 LIFTING EYE KIT A K-50 PLUG RETAINING KIT 40,4051 1, LIFTING EYE 1105 K-51,S-4,S-4,S-91,S-9 S-0 10 X--100M CAPSCREW M10 X 1.5 X 5MM K-51,S-4,S-4,S-91,S-9 S-0,S-4,S-49 5

26 MISCELLANEOUS 104 ADHESIVE SEALANT CC (SINGLE APPLICATION SIZE) K SILICONE LUBE 1 4 CC (SINGLE APPLICATION SIZE) K-4,K-49,K-9,K SHIFT DIAGRAM LABEL SILICONE LUBE 1 OZ (.59 CC)-FLEET SIZE 105 SEALANT 1 CC (SINGLE APPLICATION SIZE)

27 Group: REVERSE IDLER Old Design Latest Design Old Design REVERSE IDLER 1 K-150 IDLER SHAFT KIT 401,X 1 100M 14 IDLER PLATE K WASHER K BEARING K-94,K REVERSE IDLER GEAR 409 WASHER 14 K-150,S-4,S-4,S-0 K-150 IDLER SHAFT KIT 401,X 1 100M 4050 REVERSE IDLER SHAFT K RETAINING RING K NO LONGER AVAILABLE 11 X--100M CAPSCREW M1 X X 0MM K-150

28 Group: ROADRANGER VALVES Sub-Group: ROADRANGER VALVE P S * * Old Design 11 See: Appendix / Air Line Tubing * P S * 4 5 Valve Repair Kit *For Connector component information see Appendix ROADRANGER VALVES ROADRANGER VALVE MEDALLION, LOGO 1 (LATEST DESIGN) FULLER LOGO ONLY A SHIFT DIAGRAM MEDALLION 1 FR/FRF/FRO/FROF S-54 K-191 MASTER VALVE REPAIR KIT 1 FOR A-909 & A-5010 VALVES 0495 LEVER 1 A COVER 1 A X--1 SCREW X 0 -X/" A-909 X-9-0 NUT 1 1/" CONNECTOR ASSY /"TUBE-1/1"NPTF 4005 CONNECTOR ASSY 4 "PUSH-TO-CONNECT" 5/"TUBE- K-45 1/1"NPTF UNION ASSY 1 5/" TUBING UNION ASSY 1 "PUSH-TO-CONNECT" 5/" TUBING SHEATHING 1 5/" - BLACK 50' O- RING CLAMP 999 A-909 ROADRANGER VALVE ASSY A ,A STANDARD-W/LOGO 999 S-54 ROADRANGER VALVE ASSY A FR/FRF/FRO/FROF-W/MEDALLION

29 Group: SHIFT BAR HOUSING (FRO) H Old Design H Optional Design SHIFT BAR HOUSING (FRO) 1 K-4 HOUSING UPDATE KIT (FRO) 40150,S HOUSING ONLY 1 S-4 SHIFT BAR HOUSING (FRO) HOUSING ONLY K PIN 1 AFTER S/N S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 40 PIN 1 PRIOR TO S/N O- RING 1 TO BE USED WITH SWITCH ONLY REVERSE SWITCH PLUG 1 M14 X HEX S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S O- RING 1 TO BE USED WITH PLUG ONLY S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S GASKET 1 K-91,S-0,S-9,S-01,S-0 S-4,S-4,S-44,S- 45,S-4 S-4 51 ROLL PIN 51 1 S-44,S-45,S-4,S OIL TROUGH 1 S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 9

30 10 X--001M CAPSCREW M X 1.5 X 1MM S-0,S-9,S-01,S-0,S-09 S-44,S-45,S-4,S PLUNGER K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S SPRING 1 STANDARD K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S SPRING 1 S-9,S-0,S-45,S-4 14 X--101M SCREW 1 M10 X 1.5 X 0MM S-0,S-9,S-01,S-0,S-44 S-45,S-4,S SHIFT BLOCK 1 S-0,S-9,S-44,S SHIFT YOKE 1 REVERSE/1ST S-0,S-9,S-01,S-0,S-44 S-45,S-4,S SHIFT SHAFT 1 CAN BE USED WITH EITHER OR SHIFT BAR HOUSING KEY SHIFT K-91,K-41,K-419,K INTERLOCK KEY 1 DETENT S-0,S-9,S-01,S-0,S-44 S-45,S-4,S SHIFT YOKE 1 ND/RD S-0,S-9,S-01,S-0,S-44 S-45,S-4,S SHIFT BLOCK 1 USE W/40150 HOUSING SHIFT BLOCK 1 USE W/40445 HOUSING K-4,K-4,S-44,S-45,S-4 S SHIFT YOKE 1 4TH/5TH - USE W/40150 HOUSING 4044 SHIFT YOKE 1 4TH/5TH - USE W/40445 HOUSING K-4,K-4,S-44,S-45,S-4 S SHIFT BAR 1 S-44,S-45,S-4,S SNAP RING 1 K-104,K-4,K-4,S-44,S-45 S-4,S ACTUATOR 1 USE W/40445 HOUSING K-4,K-4,S-44,S-45,S-4 S ACTUATOR 1 USE W/40150 HOUSING 401 SNAP RING 1 K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S BIAS PLATE 1 K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 4 X-1-0 PIPE PLUG X1 0 1 /" NPT S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S PIN 1 USE W/40150 HOUSING 9 K-104 ACTUATOR PIN KIT 40 1 USE W/40445 HOUSING BREATHER /4" - USE W/40445 HOUSING S-4,S-4,S-44,S-45,S-4 S BREATHER 1 /" - USE W/40150 HOUSING BIAS PLUNGER 1 K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 0

31 4 401 SPRING 1 OUTER K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S SPRING 1 INNER K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 4 4 X-1-0 PIPE PLUG 1 1/" NPT S-0,S-9,S-01,S-0,S-44 S-45,S-4,S PIN 1 S-0,S-9,S-01,S-0,S-44 S-45,S-4,S O- RING 1 USE WITH SWITCH OR PLUG S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S NEUTRAL SWITCH PLUG 1 M1 X 1.5 HEX S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S-4 9 X--1005M CAPSCREW 1 M10 X 1.5 X 5MM 40 X PIPE PLUG 1 1/4" NPT - USE W/40445 HOUSING 40 X-1-0 PIPE PLUG X1 0 1 /" NPT - USE W/40150 HOUSING S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S SHIFT SHAFT 1 CAN ONLY BE USED WITH SHIFT BAR HOUSING 999 S-44 SHIFT BAR HSG ASSY (FRO) 40150,40445,40501,S S-45 SHIFT BAR HSG ASSY (FRO) 40150,40445,40501,S COMPLETE - INCLUDES RANGE CYLINDER ASSY 1 COMPLETE - INCLUDES RANGE CYLINDER ASSY AND OPTIONAL DETENT SPRING DESIGN DETENT SPRING. IT IS USED TO INCREASE SHIFTER DETENT FORCE. S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 1

32 Appendix Air Line Tubing Choosing nylon tubing for air lines Use the following chart to specify the Eaton Fuller nylon tube appropriate to your vehicle's air system. 5/" Air Line and Harness Combinations Line Type Line Color Order Part No# Length Supply + Port Red (S) + Black (P) ft Splitter + Deep Reduction Blue (SP) + Green (H/L) ft Supply + Splitter + Port Red(S)+Blue(SP)+ Black(P) ft 5/" Air Lines Line Type Line Color Order Part No# Length Supply Red (S) ft Port Black (P) ft Splitter Blue (SP) ft Deep Reduction Green (H/L) ft Sheathing ft 1/" Air Lines Line Type Line Color Order Part No# Length Supply White 5 50 ft Port Black ft Sheathing ft /9 AL Chart

33

34 Copyright Eaton and Dana Corporation, 00. EATON AND DANA CORPORATION hereby grants its customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. THIS INFORMATION IS NOT INTENDED FOR SALE OR RE- SALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES. The Roadranger System is an unbeatable combination of the best products from Eaton and Dana partnering to provide you the most advanced, most trouble-free drivetrain in the industry. And it s backed by the Roadrangers the most experienced, most expert, most accessible drivetrain consultants in the business. For spec ing or service assistance, call HELP (45) 4 hours a day, days a week, (Mexico: HELP (45)) for more time on the road. Or visit our web site at 4 FRO-110C 1/0 Printed in the USA