Eaton Fuller Heavy Duty Transmissions Illustrated Parts List RTLO-18918B Feb 2006

Transcription

1 Eaton Fuller Heavy Duty Transmissions Illustrated Parts List RTLO-9B Feb 00 For the most current information, visit the Roadranger web site at

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3 Contents How To Use The Illustrated Parts List... Locating Transmission Tag and Identifying Model Designation...5 Using Model Designation or Nomenclature...5 AUXILIARY DRIVE GEAR... CASE (AUX)... CASE (FRONT)...9 CASE (FRONT) FORCED LUBE... COUNTERSHAFT & BRGS(AUX)... COUNTERSHAFT ASSY... FILTER REGULATOR...5 H & C W/A-5000 VALVE... HEAT EXCHANGER... INPUT SHAFT & DRIVE GEAR...9 ISOLATORS...0 KITS & ASSEMBLIES... LEVERS/HOUSINGS... MAINSHAFT & SYNCHRO(AUX)...5 MAINSHAFT ASSY... MISCELLANEOUS... OIL COOLER... OIL PUMP...9 OIL PUMP (FORCED LUBE)... RANGE CYLINDER... REVERSE IDLER... ROADRANGER VALVE...5 SHIFT BAR HOUSING... SLAVE VALVE - A SPLITTER CYLINDER...9 Appendix...0

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

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 0, Kalamazoo, MI 900. Copyright Eaton Corporation, 00 All rights reserved. 5

6 Group: AUXILIARY DRIVE GEAR 5 0-/9 Aux DG / AUXILIARY DRIVE GEAR 099 SPACER 5550 BEARING K-9,K-0 09 RETAINER X--0 CAPSCREW /"-X-/" SPACER K-0 K-0 REPL KIT - DRIVE GEAR WASHER 0090 K-0 05 SNAP RING K-,K-9,K- 0,K-0

7 Group: CASE (AUX) OEM supplied adjustable speedometer sensor (Threaded) OEM supplied non-adjustable speedometer sensor (Non-Threaded) 5 5 Magnetic 0 9 Mechanical CASE (AUX) S-50 SPEEDO ROTOR ASSY 0 MAGNETIC 555 -O- RING K-9,S-50,S-50,S-,S-09 K-9 OIL SEAL KIT 0 0 MAGNETIC SPEEDO K-9,K-0,K- 5 X--00M CAPSCREW M X.5 X MM S-09 5 S-09 REAR BEARING COVER ASSY 0,0,05,050 PUSH-IN/THREAD-IN MAGNETIC PICK-UP 0 GASKET NON EDGE MOLDED GASKET - UNCOMPRESSED THICKNESS NOT INTERCHANGABLE WITH ANY OTHER GASKET GASKET - RED EDGE MOLDED RED EDGE MOLDED GASKET - UNCOMPRESSED THICKNESS NOT INTERCHANGEABLE WITH ANY OTHER GASKET K-,K-9,K- K-,K-9,K-,S-50,S-09 S-59 X-L- CAPSCREW /"-X" USE W/0 RBC X-L- CAPSCREW /"-X-/" S-09 X-L- CAPSCREW /"-X" X-L-0 CAPSCREW /"-X-/" X-L- CAPSCREW /"-X" 9 00 COVER S GASKET 0 K-,S- K-05 SHIM KIT 5 K - 0 K-9,K-0,K- 5,S- 5 GASKET K-,S- 05 REAR HOUSING 05 SLINGER S LIFTING EYE 05 S- X-L-0 CAPSCREW /"-X-/" S-

8 9 0 SPEEDO DRIVE GEAR 0 S-50 SPEEDO SPACER ASSY 0590 MECHANICAL K- OIL SEAL W/SLINGER 909,00,00 MECHANICAL SPEEDO X-L- CAPSCREW X /"-X-/" K-5 SPEED SENSOR KIT A - 9,A - SINGLE PICK-UP ( PIN) K-55 SPEED SENSOR KIT, A - 0,A - 5 DUAL PICK-UP ( PIN) DUAL 99 BUSHING S-50,S O- RING S- S-50 REAR BRG COVER ASSY 00,05 MECHANICAL - :00 OPENING S-59 REAR BRG COVER ASSY 0,05 MECHANICAL - :00 OPENING

9 Group: CASE (FRONT) Dipstick components 0 Latest Design * * A--9 Iron/Alum Hsg *Bushing quantity requirements: # Housing Upper bore use #5 / Lower bore use #. # Housing Upper bore use #5 and # / Lower bore use #. Note : Some part requirements are specific to # or # Aluminum or Iron Clutch Housings and Push or Pull type Clutch. CASE (FRONT) S-0 CASE ASSEMBLY 09,050,S - 5 X--00 PIPE PLUG X 00 X--0 PIPE PLUG X 0,X 0 /" MAGNETIC 050 GASKET 00 K PTO COVER 59,005 X--5 CAPSCREW X /"-X/" 05 GASKET 05 K-,K-,K-,K-,K- A- CLUTCH HOUSING ASSY A -,A - # PUSH-PULL ALUM. A- CLUTCH HOUSING ASSY A -,A - # PUSH-PULL IRON A-599 CLUTCH HOUSING ASSY 00 # PULL ALUM.(SPECIAL-LIGHTER WEIGHT) A- CLUTCH HOUSING ASSY A - 00 # PUSH-PULL IRON 9 X-L-509 CAPSCREW 5/"-X/" QUANTITY DEPENDENT ON DESIGN 0 50 HAND HOLE COVER # PULL HAND HOLE COVER 5 # PULL 0 05 HAND HOLE COVER 55 # PUSH 0 50 HAND HOLE COVER # PUSH 00 STUD 59 X WASHER X 000,X X.0,X0 00 X--005 NUT X 000 5/" FRONT BEARING COVER " PULL K- 5 X-L-0 CAPSCREW /"-X-/" S- 059 FRONT BEARING COVER " PUSH GASKET K- 5 BUSHING FOR # HOUSING UPPER A-,A-,A-,A-599,K- 9

10 BUSHING FOR # HOUSING UPPER A-,A-,A- 5 BUSHING FOR # HOUSING UPPER A-,A-,A-,A-599,K- 9 BUSHING FOR # AND # HOUSING LOWER A-,A-,A- 0 X-C- CAPSCREW X 09 X L /- X -/ - FOR ALUMINUM K-,K-,K- 09 X L HOUSING 0 X-C- CAPSCREW X 09 X L /- X -/ - FOR IRON 09 X L HOUSING 0 X-C- CAPSCREW X,X L /- X -/ 00 PLUG 0 -/" MAGNETIC, O-RING INCLUDED,K- K-,K-,K-,K- S-00,S-0 X-- CAPSCREW /"-X/" 55 PTO COVER GASKET K- MAGNET S-00,S-0 PIN 9 X--005 NUT X 000 5/"- 0 X WASHER X 000,X X.0,X STUD,59 5/" X -/" X-L-0 CAPSCREW /"-X-/" 0 TUBE 0 ELBOW 5 0 DIPSTICK 0 PLUG X--005 CAPSCREW 5/"-X-/" 0 SPACER 9 X--0 PIPE PLUG X 00 /" 0 00 BUSHING 0

11 Group: CASE (FRONT) FORCED LUBE Dipstick components Alum Hsg CASE (FRONT) FORCED LUBE S-00 CASE ASSEMBLY 0590,050,S PLUG 0 -/" MAGNETIC, O-RING S-00,S-0 INCLUDED A- EXTENDED LUBE TUBE ASSY 059 CAN ONLY BE USED W/0590 CASE A-9 LUBE TUBE ASSY 09,A - CAN BE USED W/0590 OR 09 CASE 050 GASKET 00 K PTO COVER 59,005 X--5 CAPSCREW X /"-X/" 05 GASKET 05 K-,K-,K-,K-,K- K- FORCED LUBE CL HSG KIT A - # PULL ALUMINUM - NODAL MOUNT K- FORCED LUBE CL HSG A - 9,A - 50 # PULL IRON - NODAL MOUNT KIT K- FORCED LUBE CL HSG A - 5 # PULL ALUMINUM KIT K- FORCED LUBE CL HSG A - # PULL IRON KIT 9 X-L-509 CAPSCREW 5/"-X/" QUANTITY DEPENDENT ON DESIGN HAND HOLE COVER 5 # PULL 0 05 HAND HOLE COVER 55 # PUSH 00 STUD 59 X WASHER X 000,X X.0,X0 00 X--005 NUT X 000 5/" FRONT BEARING COVER " PULL K-

12 5 X-L-0 CAPSCREW /"-X-/" S- 059 FRONT BEARING COVER " PUSH GASKET K- 5 BUSHING A-,A-,A-,A-599,K- 0 X-C- CAPSCREW X 09 X L 09 X L /- X -/ - FOR IRON HOUSING K-,K-,K-,K- 0 X-C- CAPSCREW X 09 X L 09 X L /- X -/ - FOR ALUMINUM HOUSING K-,K-,K-,K- 0 X-C- CAPSCREW X,X L /- X -/ - FOR IRON HOUSING X-- CAPSCREW /"-X/" 55 PTO COVER GASKET K- MAGNET S-00,S-0 PIN 9 X--005 NUT X 000 5/"- 0 X WASHER X 000,X X.0,X STUD,59 5/" X -/" X-L-0 CAPSCREW /"-X-/" 0 TUBE 0 ELBOW 5 0 DIPSTICK 0 PLUG X--005 CAPSCREW 5/"-X-/" 0 SPACER 9 X--0 PIPE PLUG X 00 /" 0 00 BUSHING 5 -O- RING A-9,A-,K- 5 -O- RING A-9,A-,K-,K O- RING A-9,A-,K-

13 Group: COUNTERSHAFT & BRGS(AUX) 0-5/9 CS Helical COUNTERSHAFT & BRGS(AUX) 05 BEARING K-5,K-5 K-0 COUNTERSHAFT REPLT 09,09,A - KIT,A - 0,A SPACER 009 K-0

14 Group: COUNTERSHAFT ASSY CS/RT COUNTERSHAFT ASSY 00 SNAP RING K-,K-9,K- 0 0 BEARING K-9,K-0 K-9 CNTRSHFT W/REV & LO 05 X--E KEY 5 5 ROLL PIN 00 KEY 9 05 ST GEAR-CNTRSHFT 00, ND GEAR-CNTRSHFT OD GEAR-CNTRSHFT 0, PTO GEAR - LOWER 0 00 PTO GEAR - UPPER DRIVE GEAR-CNTRSHFT 99 SNAP RING K BEARING K-9,K RETAINER 95 5 X--005 CAPSCREW 5/"-X-/"

15 Group: FILTER REGULATOR NSS -O- Ring/Element Kit NSS - Not Sold Separately FILTER REGULATOR A-0 FILTER/REGULATOR 900 K-9 -O- RING/ELEMENT KIT FOR FILTER REGULATOR X-C- CAPSCREW X S /"-0X-/" 5

16 Group: H & C W/A-5000 VALVE 9 H 5 H L P From RRV 9 Range Cylinder From RRV S L 0 S 5 Splitter Cylinder 0 00I-/9 SP H & C W/A-5000 VALVE A-5000 SLAVE VALVE ASSY GASKET K O- RING 0 K-99 K-99 SLEEVE KIT,90, FOR SLAVE VALVES 5 SPRING PIN ELBOW /" X-C- CAPSCREW /"-0X-/" HOSE ASSY " HOSE ASSY " A-0 FILTER/REGULATOR 900 X--0 PIPE PLUG /" NPT X-L-0 CAPSCREW /"-X-/" HOSE CLAMP 5 5 STRAP BRACKET HOSE CLAMP X-L-0 CAPSCREW /"-X-/" HOSE ASSY 5" 5 -O- RING A-5000,K-95

17 Group: HEAT EXCHANGER Connect to Hose From Oil Pump "B" Port Connect to Hose From Oil Pump "A" Port Connect to Hose Connect to Hose From Oil Pump From Oil Pump "A" Port "A" Port Connect to Hose Connect to Hose From Oil Pump From Oil Pump "B" Port "B" Port Top Right Side Mount Top Right Side Mount Top Left Side Mount 9 To Oil Pump "A" Port To Oil Pump "B" Port 0 Connect to Hose From Oil Pump "A" Port 5 Connect to Hose From Oil Pump "B" Port Connect to Hose From Oil Pump "B" Port 5 Connect to Hose From Oil Pump "A" Port Bottom Mount Top Right Side Mount HEAT EXCHANGER 555 HEAT EXCHANGER (") 55 /" PORTS K-0 K-0 HEAT EXCHANGER KIT 5500 MUST USE WHEN REPLACING 5500 HEAT EXCHANGER WITH 5/" PORTS, 5/" TO /" ADAPTERS ARE INCLUDED IN THIS KIT 55 HEAT EXCHANGER (") 55 /" PORTS K- K- HEAT EXCHANGER KIT 550,K - MUST USE WHEN REPLACING 550 HEAT EXCHANGER WITH 5/" PORTS, 5/" TO /" ADAPTERS ARE INCLUDED IN THIS KIT 55 HEAT EXCHANGER (") 555 /" PORTS K- K- HEAT EXCHANGER KIT 550 MUST USE WHEN REPLACING 550 HEAT EXCHANGER WITH 5/" PORTS, 5/" TO /" ADAPTERS ARE INCLUDED IN THIS KIT 559 HEAT EXCHANGER (") 555 /" PORTS K- K- HEAT EXCHANGER KIT 550 MUST USE WHEN REPLACING 550 HEAT EXCHANGER WITH 5/" PORTS, 5/" TO /" ADAPTERS ARE INCLUDED IN THIS KIT 5 55 HEAT EXCHANGER (") 550 /" PORTS K-5 5 K-5 HEAT EXCHANGER KIT 5505,K - 0 MUST USE WHEN REPLACING 5505 HEAT EXCHANGER WITH 5/" PORTS, 5/" TO /" ADAPTERS ARE INCLUDED IN THIS KIT 5 STRAP K- 550 OIL HOSE ASSEMBLY " 5509 OIL HOSE ASSEMBLY " 550 OIL HOSE ASSEMBLY " 550 OIL HOSE ASSEMBLY "

18 550 OIL HOSE ASSEMBLY " K OIL HOSE ASSEMBLY " 5505 OIL HOSE ASSEMBLY " 550 OIL HOSE ASSEMBLY " 9 00 ELBOW FOR OIL PUMP "A" PORT 0 0 ELBOW FOR OIL PUMP "B" PORT X-C-09 CAPSCREW /"-X-/" X-L-0 CAPSCREW /"-X-/" X-C-09 CAPSCREW /"-X-/" X-L-0 CAPSCREW /"-X-/" 5 X-C- SCREW /"-X/" 05 MOUNTING BRACKET 0 BRACKET 0 HOSE CLAMP

19 Group: INPUT SHAFT & DRIVE GEAR 9 5 * 00-/9 IS * For Shipping Only Do Not Replace INPUT SHAFT & DRIVE GEAR 559 SHIPPING SEAL NOT SOLD FOR SERVICE 90 SNAP RING K-5,K-5 50 BEARING K-5,K-5 SPACER 5 50 SNAP RING K-5,K MAIN DRIVE GEAR 095,0 S-59 INPUT SHAFT 055 5,0 " PULL - USE W/FBC 0550 K-5 S-0 INPUT SHAFT 05,5 " PUSH - USE W/FBC BUSHING K-5,S-59,S-0 9

20 Group: ISOLATORS 9 Indicates Part Of Item /9 ISOLATORS 9 -E- RING K- PIN REPLACEMENT KIT 5 BUSHING K-00,K-,K- 9,K-9,K-99 S-9,S-0,S-59 S-9 ISOLATOR ASSY LEVER STRAIGHT." 5 STUB LEVER LOW TOWER K- STUB LEVER HIGH TOWER K-9,S-0 0 STUB LEVER MID TOWER K DEG LEVER STRAIGHT " 0 K-99 ISOLATOR BUSHING KIT, X--50 SCREW K-00,K-,K- 9,K-9,K-99,K-,S-9,S- 0,S-59 X-9-50 NUT K-00,K-,K- 9,K-9,K-99,K-,S-9,S- 0,S-59 0

21 KITS & ASSEMBLIES K-0 ACTUATOR PIN KIT 0 K-9 K-9 AIR SYSTEMS TOOL KIT K-9 BASIC OVERHAUL KIT K-0 BASIC REBUILD KIT S-5 CAP ASSY 05,05 S-00 CASE ASSEMBLY 0590,050,S - 9 S-0 CASE ASSEMBLY 09,050,S - 5 K- CLUTCH INSTALLATION KIT USE FOR UNITS BUILT WITH THE FORCED LUBRICATION SYSTEM DESIGN USE FOR UNITS BUILT PRIOR TO THE FORCED LUBRICATION SYSTEM DESIGN FOR USE WITH S-59 INPUT SHAFT ASSY AND 50 INPUT SHAFT BEARING K-9 COUNTERSHAFT REPL 05 KIT K-0 COUNTERSHAFT REPLT 09,09,A - KIT,A - 0,A - 0 K- FORCED LUBE CL HSG A - 9,A - 50 # PULL IRON - NODAL MOUNT KIT K- FORCED LUBE CL HSG A - # PULL IRON KIT K- FORCED LUBE CL HSG KIT A - # PULL ALUMINUM - NODAL MOUNT K- FORCED LUBE CL HSG KIT A - 5 # PULL ALUMINUM K- GASKET KIT K-9,K-0,K- 9 S-59 INPUT SHAFT 5 " PULL - USE W/FBC 0550 K-,K-9,K- 9 S-0 INPUT SHAFT 5 " PUSH - USE W/FBC 059 S-9 ISOLATOR ASSY K-99 ISOLATOR BUSHING KIT, K-9 LEVER REPLACEMENT MID TOWER KIT K-9 LEVER REPLACEMENT HIGH TOWER KIT K- LEVER REPLACEMENT KIT LOW TOWER S-50 MAINSHAFT ASSY 05,00,S - K-9 MASTER REBUILDER KIT USE TO REBUILD RTLO-9B W/NON-SELECTIVE WASHERS AND FORCED LUBE ONLY K-9 MASTER VALVE REPAIR FOR A-9 VALVE KIT K-9 -O- RING/ELEMENT KIT FOR FILTER REGULATOR S-0 OIL FILTER K- OIL PUMP KIT 09,09,0,059,05 A - 9,A - K-9 OIL SEAL KIT 0 0 K-9,K-0,K- 9 K- OIL SEAL W/SLINGER 909,00,00 K- O-RING KIT K-9,K-0,K- 9 K-00 PIN & BUSHING KIT K- PIN REPLACEMENT KIT 5 S- RANGE SECTION ASSY S-09 REAR BEARING COVER ASSY 0,0,05,050 PUSH-IN/THREAD-IN MAGNETIC PICK-UP S-50 REAR BRG COVER ASSY 00,05 MECHANICAL - :00 OPENING S-59 REAR BRG COVER ASSY 0,05 MECHANICAL - :00 OPENING K-95 REPAIR KIT-SLAVE FOR A-5000 VALVE VALVE K-0 REPL KIT - DRIVE GEAR 009 K-9 REPL KIT-SLIDING CLUTCH K - 00

22 S-5 ROADRANGER VALVE ASSY S-0 SHIFT BAR HSG 05 HOUSING ONLY (RTLO) S-9 SHIFT BAR HSG 09 HOUSING ONLY (RTLOF) S-90 SHIFT BAR HSG ASSY 05 COMPLETE (RTLO) FOR UNITS BUILT WITH THE FORCED LUBRICATION SYSTEM DESIGN S- SHIFT BAR HSG ASSY 09 COMPLETE (RTLOF) FOR UNITS BUILT PRIOR TO THE FORCED LUBRICATION SYSTEM DESIGN S- SHIFT BAR HSG ASSY 05 COMPLETE (RTLO) FOR UNITS BUILT PRIOR TO THE FORCED LUBRICATION SYSTEM DESIGN S-9 SHIFT BAR HSG ASSY 09 COMPLETE (RTLOF) FOR UNITS BUILT WITH THE FORCED LUBRICATION SYSTEM DESIGN K- SHIFT LEVER HSG 50,,9 LOW TOWER,0905,A - S-0 SHIFT LEVER HSG ASSY S - 05 HIGH TOWER S-59 SHIFT LEVER HSG ASSY S - 99 MID TOWER S-9 SHIFT LEVER HSG ASSY LOW TOWER K-9 SHIFT LEVER HSG KIT,,0050 HIGH TOWER,090,K - 0 K - 9 K-9 SHIFT LEVER HSG KIT 0,090,A - MID TOWER 00 K-05 SHIM KIT 5 K - 0 K-9,K-0,K- 9,S- K-99 SLEEVE KIT 90, FOR SLAVE VALVES K-9 K- SMALL PARTS KIT S-50 SPEEDO ROTOR ASSY 0 MAGNETIC S-50 SPEEDO SPACER ASSY 0590 K- SPLITTER VLV REPL KIT 009,00,00,A - K-9 SYNCHRONIZER KIT K -

23 Group: LEVERS/HOUSINGS K- - Low K-9 - Mid K-9 - High 0 5 S-9 - Low S-59 - Mid S-0 - High LEVERS/HOUSINGS K- O-RING & WASHER KIT 0 99 PIN K-,K-9 X-C-0 CAPSCREW /"-X-/" X--00 NUT /"--N.F.PLAIN 5 X--00 LOCKWASHER /" 9 STUD K- SHIFT LEVER HSG 50,,9 LOW TOWER,0905,A GASKET 0 K-,K-99,K-,K-9,K-9,K-9,K-9,S- 9,S-0,S- S-,S-59 9 K-9 SHIFT LEVER HSG KIT 0,090,A - MID TOWER 00 5 PIN /" - USED W/ ONLY 000 PIN K-9,S-0 K-9 SHIFT LEVER HSG KIT,,0050 HIGH TOWER,090,K - 0 K BOOT K-,K-9,K- 9,S-0 X--00 NUT /"--N.F.PLAIN X--00 LOCKWASHER /" 0 00 GEAR SHIFT LEVER STRAIGHT - LOW -/" 0 GEAR SHIFT LEVER STRAIGHT - HIGH 5" 5 RETAINER K-,K-9,K- 9,S-0 5 SPRING K-,K-9,K- 9,S-0

24 K-9 LEVER REPLACEMENT MID TOWER KIT K-9 LEVER REPLACEMENT HIGH TOWER KIT K- LEVER REPLACEMENT LOW TOWER KIT S-9 SHIFT LEVER HSG ASSY LOW TOWER S-0 SHIFT LEVER HSG ASSY S - 05 HIGH TOWER S-59 SHIFT LEVER HSG ASSY S - 99 MID TOWER

25 Group: MAINSHAFT & SYNCHRO(AUX) Universal Joint Yoke Aux MS MAINSHAFT & SYNCHRO(AUX) 0090 SLIDING CLUTCH X--00 SCREW 5/"-X-/" 0 RETAINER 0 SPLITTER GEAR 0, TAPERED ROLLER BRG K-5,K-55 0 BEARING SLEEVE 0 SNAP RING K-5,K SPRING K-,K-5,K- 55,K-9,K-9 0 A- SYNCHRONIZER ASSY A - HI RANGE K-9,K SLIDING CLUTCH 0 K-9 A-5 SYNCHRONIZER A - 9 A - 5 LO RANGE K-9,K-9 ASSEMBLY 005 MAINSHAFT 0 WASHER REDUCTION GEAR SPACER BEARING K-5,K ROTOR 9 0 NUT K-,S- 5

26 Group: MAINSHAFT ASSY B-0-9 MAINSHAFT ASSY S-50 MAINSHAFT ASSY 05,00,S - 50 ROLL PIN S SIDED KEY SNAP RING K-,K-,K- 9,K REVERSE GEAR- 0 MAINSHAFT 00 SPACER K- SLIDING CLUTCH 009 LO GEAR-MAINSHAFT WASHER 09 K ST GEAR-MAINSHAFT 00 ND GEAR-MAINSHAFT 05 OD GEAR-MAINSHAFT 0,09,0 00 WASHER.9-WHITE K- 09 WASHER K- 5 0 SLIDING CLUTCH 0 K-9

27 MISCELLANEOUS 0 ADHESIVE SEALANT 0.5 CC (SINGLE APPLICATION SIZE) 05 SEALANT CC (SINGLE APPLICATION SIZE) K-,K-5 SHIFT DIAGRAM LABEL SILICONE LUBE OZ (.59 CC)-FLEET SIZE 0 SILICONE LUBE CC (SINGLE APPLICATION SIZE) K-,K-9,K- 9,K-,K-,K-5

28 Group: OIL COOLER Flow 5 9 Oil Return 0 Oil Pump Outlet * 055-/9 Cooler * Outlet * Fuller Inlet *Adding Oil Filter and parts as shown is optional. * *5 Return Outlet Return / Outlet Location OIL COOLER 05 OIL COOLER K-95 9 HOSE 5 FEET K-95 X--55 CAPSCREW 5/"-X-/" K-95 X--50 LOCKWASHER 5/" K-95 5 BRACKET K CONNECTOR K-95,S-0 95 SWIVEL K-95 X-0-50 WASHER 5/" K PLUG-RUBBER MOUNT K STRAP K-95 9 CLAMP 5 K-95 0 NUT K-95 9 ELBOW K-95 S-0 OIL FILTER 5 FILTER ELEMENT S-0

29 Group: OIL PUMP Indicates part of item Oil Pump 5 OIL PUMP 0 PLUG 5 5 -O- RING K- X-- SCREW X 5 /"-0X-/" 0 WASHER K- 05 DOWEL PIN 9 0 RETAINER 0509 KEY 5 SNAP RING 0 PUMP DRIVE GEAR 00 5 K- OIL PUMP KIT 09,09,0,059,05 A - 9,A - X--00 STEEL BALL /" 05 SPRING 05 SUCTION TUBE 0 O-RING INCLUDED ON SUCTION K- TUBE 9 K- OIL PUMP KIT 09,09,0,059,05 A - 9,A PLUG K- X-- CAPSCREW /"-X/" 055 SPLITTER LUBE TUBE A GASKET 05 K-,K-,K-,K-,K- S-0 CASE ASSEMBLY 09,050,S MAGNET S-00,S-0 X-- SCREW 9

30 05 -O- RING K- OIL PUMP KIT 09,09,0,059,05 A - 9,A - 9 K- OIL PUMP KIT 09,09,0,059,05 A - 9,A K- OIL PUMP KIT 09,09,0,059,05 A - 9,A - 0

31 Group: OIL PUMP (FORCED LUBE) Indicates part of item Oil Pump 5 OIL PUMP (FORCED LUBE) 0 PLUG 5 5 -O- RING K- X-- SCREW X 5 /"-0X-/" 0 WASHER K- 05 DOWEL PIN 9 0 RETAINER 0 K- OIL PUMP KIT 09,09,0,059,05 A - 9,A - K- OIL PUMP KIT 09,09,0,059,05 A - 9,A KEY 5 SNAP RING 0 PUMP DRIVE GEAR 00 5 K- OIL PUMP KIT 09,09,0,059,05 A - 9,A - X--00 STEEL BALL /" 05 SPRING 05 SUCTION TUBE 0 O-RING INCLUDED ON SUCTION K- TUBE 9 09 PLUG X-- CAPSCREW /"-X/" 055 SPLITTER LUBE TUBE A GASKET 05 K-,K-,K-,K-,K-

32 S-00 CASE ASSEMBLY 0590,050,S MAGNET S-00,S-0 X-- SCREW 05 -O- RING 999 K- OIL PUMP KIT 09,09,0,059,05 A - 9,A -

33 Group: RANGE CYLINDER RANGE CYLINDER GASKET K-,K- SHIFT YOKE 5 X--09 BOLT X 0,X /"-0X-/" A-90 RANGE CYLINDER ASSY X-L-0 CAPSCREW X 0 /"-X-/" 5 -O- RING K- 059 YOKE BAR PISTON O- RING K- 0 -O- RING K- X--00 NUT 5/"- K- GASKET K-,K- 09 COVER

34 Group: REVERSE IDLER 5 9 Latest Design RI REVERSE IDLER X--00 CAPSCREW 5/"-X-/ IDLER PLATE 09 WASHER K-09,S-0 BEARING REVERSE IDLER GEAR 09 K-09 IDLER SHAFT REPL KIT 05,09,055 0 RETAINING RING K-09 0 RETAINING RING K IDLER SHAFT K-09

35 Group: ROADRANGER VALVE 999 P S SP * * * Old Design See: Appendix / Airline Tubing 5 P * 0 S * 0 SP * 0 Splitter Cylinder 5 00B-5-9 *For Connector and Elbow Assy component information see Appendix. ROADRANGER VALVE 5500 MEDALLION, LOGO (LATEST DESIGN) FULLER LOGO A-9 ONLY 55 SHIFT DIAGRAM RTLO-W/SHIFT PATTERN S-5 MEDALLION K-9 MASTER VALVE REPAIR FOR A-9 VALVE KIT 095 LEVER A-9 0 COVER A-9 5 X-- SCREW X 0 -X/" A-9 X-9-0 NUT /"- 00 CONNECTOR ASSY 50 5/"TUBE-/"NPTF 005 CONNECTOR ASSY "PUSH-TO-CONNECT" 5/"TUBE- S-5 /"NPTF 00 CONNECTOR ASSY 50 /"TUBE-/"NPTF ELBOW ASSY 50 /"TUBE-/"NPTF K-,K ELBOW ASSY "PUSH-TO-CONNECT" 5/"TUBE- /"NPTF ELBOW ASSY 50 5/"TUBE-/"NPTF 0 UNION ASSY /" TUBING 0 UNION ASSY 5/" TUBING 0 UNION ASSY "PUSH-TO-CONNECT" 5/" TUBING 5 -O- RING CLAMP 999 A-9 ROADRANGER VALVE A - 50 STANDARD-W/LOGO ASSY 999 S-5 ROADRANGER VALVE ASSY RTLO-W/SHIFT PATTERN K-9,K-,K- 0,K-,K-9,K-5 5

36 Group: SHIFT BAR HOUSING SHIFT BAR HOUSING S-0 SHIFT BAR HSG 05 HOUSING ONLY (RTLO) 0 GASKET 9 K-,S-9,S-0,S-,S- S-90,S-9 00 BREATHER 05 /" NPT X--0 PIPE PLUG /" NPT S-9,S-0,S-,S-,S-90 S OIL TROUGH WILL CAUSE INTERFERENCE ON S-,S- UNITS BUILT WITH THE FORCED LUBRICATION SYSTEM. 5 0 AIR VALVE SHAFT S-,S-,S-90 X-- CAPSCREW NOT TO BE USED ON UNITS BUILT WITH THE FORCED LUBRICATION SYSTEM.,S-9 S-,S- X--0 PIPE PLUG X 0 /" NPT S-,S-,S-90,S-9 X-L-09 CAPSCREW /"-X-/" 9 GASKET S-9,S-0,S-,S-,S-90 S PLUG S-9,S-0,S-,S-,S-90 S-9 9 NEUTRAL LIGHT SWITCH 9 SWITCH NORMALLY CLOSED 5 05 LIFTING EYE 05 S- X-C-09 CAPSCREW /"-X-/" USE TO ATTACHED COOLER TO SHIFT BAR HOUSING X-L-0 CAPSCREW /"-X-/" X-L-0 CAPSCREW /"-X-/" OR USE PCS OF X- L-0 WITH PCS OF X-L PIN S-9,S-0,S-,S-,S-90 S GASKET S-9,S-0,S-,S-,S-90 S REVERSE LIGHT SWITCH 0 SWITCH NORMALLY OPEN 0 05 PLUG 59 S-9,S-0,S-,S-,S-90 S-9 59 SPRING K-,K-9,S-,S-,S-90 S-9 S-

37 X--00 STEEL BALL /" K-,S-,S-,S-90,S-9 K-0 ACTUATOR PIN KIT 0 SHIFT YOKE REVERSE/LO S-,S-90 X--00 STEEL BALL /" S-,S-,S-90,S-9 5 SHIFT BLOCK ST/ND S-,S LOCKSCREW 5 S-,S-,S-90,S-9 0 INTERLOCK PIN K-,S-,S-,S-90,S-9 90 SHIFT BLOCK RD/OD S-,S SHIFT BLOCK 9 RD/OD S-,S-,S-90,S-9 9 YOKE BAR 00 RD/OD S-,S-90 9 SHIFT YOKE ST/ND S-,S-,S-90,S YOKE BAR ST/ND S-,S SNAP RING K-0,S-,S-,S-90,S-9 05 ACTUATOR S-,S-,S-90,S SHIFT YOKE 050 RD/OD S-,S-,S-90,S YOKE BAR REVERSE/LO S-,S PLUNGER S-,S-,S-90,S-9 9 SPRING K-,S-,S-,S-90,S-9 9 PLUG S-,S-,S-90,S S-90 SHIFT BAR HSG ASSY 05 COMPLETE (RTLO) FOR UNITS BUILT WITH THE FORCED LUBRICATION SYSTEM DESIGN 999 S- SHIFT BAR HSG ASSY 05 COMPLETE (RTLO) FOR UNITS BUILT PRIOR TO THE FORCED LUBRICATION SYSTEM DESIGN

38 Group: SLAVE VALVE - A Repair Kit SLAVE VALVE - A-5000 A-5000 SLAVE VALVE ASSY 050 K-9,K- K-95 REPAIR KIT-SLAVE FOR A-5000 VALVE VALVE 055 PLUG A PISTON A CAP 5 A-,A-5000 S-5 CAP ASSY 05,05 X-C- CAPSCREW /"-0X-/" A-5000

39 Group: SPLITTER CYLINDER 5 Indicates part of item SPLITTER CYLINDER A-0 SPLITTER YOKE ASSY A - 0,A GASKET K-59,K SPLITTER CYLINDER 0 -O- RING K PISTON 5 -O- RING K-,K-59 X--05 NUT 09 -O- RING K O- RING K- 5 -O- RING K-,K-59 X00 BREATHER 95 5 K- SPLITTER VLV REPL KIT 009,00,00,A - X-L-50 CAPSCREW 5/"-X-/" 999 K- SPLITTER VLV REPL KIT 009,00,00,A - 9

40 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) 0 50 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 /" Air Lines Line Type Line Color Order Part No# Length Supply White 5 50 ft Port Black 0 50 ft Sheathing ft 050-/9 AL Chart 0

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42 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 -00--HELP (5) hours a day, days a week, (Mexico: HELP (5)) for more time on the road. Or visit our web site at RTLO-9B /0 Printed in the USA