TRANSMISSION PARTS LIST. Spicer ES43~5. Bulletin No. T210-ES43-5. March 2000

Transcription

1 TRANSMISSION PARTS LIST Spicer ES43~5 Bulletin No. T20-ES43-5 March 2000

2 For parts or service call us Pro Gear & Transmission, Inc. (877) (407) W. Gore St. Orlando, FL 32805

3 CONTENTS, RATIO TABLE and IDENTIFICATION T20 ES43 5 CONTENTS RATIO TABLE GEARS AND RELATED PARTS DRIVE GEAR GROUP MAINSHAFT GROUP COUNTERSHAFT GROUP REVERSE IDLER SHAFT GROUP DRIVE GEAR TABLE DRIVE GEAR BEARING CAP CHART WITH CLUTCH APPLICATIONS CLUTCH HOUSING & DRIVE GEAR BEARING CAP GROUP CLUTCH HOUSING DIMENSIONS CASE GROUP REAR BEARING CAP CHART WITH BRAKE APPLICATIONS... 0 REAR BEARING CAP GROUP AND RELATED PARTS REMOTE CONTROL ASSEMBLY COMPANION FLANGES AND END YOKES SHIFT BAR AND FORK ASSEMBLY SHIFT LEVER AND DOME ASSEMBLY CLUTCH RELEASE PARTS AND DIMENSIONS OVERHAUL KITS-MAJOR AND MINOR TABULATED BILLS OF MATERIALS BACK-TAPER CHANGEOVER KITS SPEEDS st 2nd 3rd 4th 5th Rev. RATIO TABLE MODELS ES43-5A ES43-5D n 6.77 Parts listed in this catalog may no longer be available. Use with transmission superseding list. IDENTIFICATION The Name Plate (NP-96} affixed to the RIGHT side of the Transmission is stamped with information: SERIAL I.,, B/M No... MODEL I., Abbreviations used in this parts list include: N.S. - Not Shown N.S.S. - Not Sold Separately N.R.- Not Required In requesting more information on these. transmissions, furnish the B/M No. and the Serial Number. LITHO IN U.S.A.

4 _--=.::.=:::~--- T 20-ES43-5 GEARS and RELATED PARTS \ ~ :::-...\ ~~» A 2 2

5 EASY SHIFT 5 SPEED MODELS (430 lb-ft) GEARS and RELATED PARTS T2 O ES43 5 Ref. Part No. Description Qty. No. Drive Gear Group A- See Tab Bills Drive Gear - Input (see table page 5) A Bearing - Mainshaft Pocket Mainshaft Group- Output B Main shaft B Pin -Thrust Washer Lock 2 B Gear- st Speed Mainshaft (45T) B Bearing - st Speed Needle B Washer - st & 2nd Speed Thrust B Snap Ring - st & 2nd Thrust Washer B Gear - 2nd Speed Mainshaft (38T)* or Gear - 2nd Speed Mainshaft (38T)** B Bearing - 2nd & Reverse Needle 2 B X Synchronizer - 2nd & 3rd Mainshaft* or 33764X Synchronizer - 2nd & 3rd Mainshaft** B Gear - 2nd & 3rd Mainshaft Clutch* or Gear - 2nd & 3rd Mainshaft Clutch** B Snap Ring - 2nd & 3rd Clutch Gear B Gear - 3rd Speed Mainshaft (34T)* or Gear- 3rd Speed Mainshaft (34T)** B Bearing - 3rd Speed Gear B Washer - 3rd & 4th Speed Thrust B Snap Ring - 3rd & 4th Thrust Washer B Gear- 4th Speed Mainshaft (22T) (for ES43-5A)* or Gear- 4th Speed Mainshaft (22T) (for ES43-5A)** or Gear- 4th Speed Mainshaft (2T) (for ES43-5D)* or Gear- 4th Speed Mainshaft (2T) (for ES43-5D)** B Bearing - 4th Speed Gear B X Synchronizer - 4th &5th Mainshaft* or 33n5x Synchonizer - 4th & 5th Mainshaft** B Gear- 4th & 5th Speed Clutch (33T)* or Gear - 4th & 5th Speed Clutch (33T)** B Snap Ring - 4th & 5th Speed Clutch Gear B Clutch Collar - st & Rev. B Gear - Reverse {42T) B Washer - Reverse Thrust B-24 See Tab Bills Gear - Speedometer Drive B-25 See Tab Bills Companion Flange or End Yoke B Washer - Mainshaft Nut B Nut- Mainshaft ( //- 8) *-Back-Tapered Clutching Teeth Version (After Serial No. J ) -Straight Clutching Teeth Version (Before Serial No. J ) N.S.S. - Not Sold Separately 'ftll'fllt'ftll'flll//taportant 3

6 T2 O-ES43-5 GEARS and RELATED PARTS 4

7 Ref. No. C- C-2 C-3 C-4 C-5 Part No EASY SHIFT 5 SPEED MODELS (430 lb.. ft) CASE GROUP and RELATED PARTS Description Countershaft Group Countershaft (without P.T.O. drive) Cone - Bearing - Countershaft Rear Gear- 2nd Speed Countershaft {20T) Spacer - 2nd & 3rd Speed Countershaft Gear Gear - 3rd Speed Countershaft (32T) T2 O-ES43-5. Qty. C-6 or C-7 C-8 C-9 C-0 C Gear 4th Speed, Countershaft (32T) for ES43-5A Gear - 4th Speed, Countershaft (34T) for ES43-5D Snap Ring - 4th Speed Countershaft Gear Gear- Drive (44T) Countershaft Snap Ring - Countershaft Drive Gear Cone - Bearing - Countershaft Front Cup - Bearing - Countershaft Front D- D-2 D-3 D Reverse Idler Group Gear - Reverse Idler ( 7T) Spacer - Bearing Reverse Idler Gear Bearing - Reverse Idler Shaft - Idler Gear 2 A Input Shaft length 6.40" 9.93" 7.22" 7.99" 9.93" 6.40" 9.93" 7.22" 9.87" 9.93" 7.99" 9.93" DRIVE GEAR TABLE B Spline Dia. & No. of Teeth.375" - 0 spline.500" - o spline.500"-0 spline.25"-0 spline.500" - 0 spline.375"- 0 spline.500"- 0 spline.500" - 0 spline.750"-0 spline.750"-0 spline.25"- 0 spline.500"- 0 spline c Pilot Size.9837".9837''.9837".5900".80".9837".9837".9837".80".9837".5900".80" Drive Gear Sub-Assembly (Includes ) X** X** X** X** X** X* X* X* X* X* X* X* *-Back-Tapered Clutching Teeth Version {After Serial No. J ) **-Straight Clutching Teeth Version (Before Serial No. J ) N.S.S.- Not Sold Separately <fttt<fllt<fttt<fltt/mportant 5

8 CLUTCH HOUSING and DRIVE GEAR BEARING CAP GROUP T2 O ES43 5 E- E-0 E-3 ~- F-2 E-4 F-4 DRIVE GEAR BEARING CAP CHART A B c D Drive Gear Front Bearing Cap Brg. Cap Outside Stem Inside Dia. Casting Sub-Assembly Includes Oil Seal Diameter Diameter Length for Oil Seal Number Part Number F-3 FLAT TYPE- For Pull Type Clutches Pull Type Release 5 /a".260" 2.562" C X X STEM TYPE - For Push Type Clutches Pull Type Release 5 /a".745" 4.34" 2 /s" C X X 5 /a".87" 4.375" 2 /,s" C X X 5 /a".940" 6.260" 2 /,s" C X X 5 /e".87" 5.669" 2 /s" C X X 5 /a".87" 6.654" 2 /,s" C X X 5 /a".87" 6.654" 2 /s" C X X 5 /a".372" 5.360" 2 /s" C X X 6

9 CLUTCH HOUSING and DRIVE GEAR BEARING CAP GROUP T2 O-ES43 5 Ref. Part No. Description Qty. No. Clutch Housing E-2 See Tab Bills Clutch Housing Assembly (see page 20) N.S.S. Clutch Housing (see dimension table below) E-3 28C-20 Bushing - Clutch Release Shaft 2 E X Hand Hole Cover Assembly E Oil Trough E Pin - Drive Oil Trough 2 E Lift Hook E Bolt - Clutch Housing to Case ( x. 25) 6 E Dowel Pin- Case Front 2 E Support - Front Shift Bar E Bolt- Shift Bar Support ( x 2.25) 2 N.S Nipple - Clutch Release Shaft 2 E Spacer - Front Bar Support 2 F- See Tab Bills Cap & Seal Assembly (see table page 6) F-2 N.S.S. Cap F X Seal - Drive Gear Bearing Cap (stem only) or X Seal - Drive Gear Bearing Cap (flat only) F Cap Screw- Drive Gear Bearing Cap ( x.00 self-locking) 8 F Snap Ring - Bearing Drive Gear Front F Bearing- Drive Front F Return Spring Bracket (Navistar only) F Oil Ring N.S.S. Not Sold Separately SAE A Size Pilot B No. Diameter O.D. 20 /a" 2 %" 2 7 %" 9 // 3 6 /a" 7 3 h" Assembly No. E-2 Casting No. CLUTCH HOUSING s A E c Length Shaft Hole Dia. D C/L to Front Face Upper Hole RELEASE SHAFT HOLE E 0 Above C/Lto C/L Front Face Upper Hole Lower Hole F Below C/L Lower Hole 4g..5s-g..2x ++4g X ++4g..S8--2X C C4g..58- C /64".00" 8 35 /64".00" 8 35 /64".00" 3 3 /i' 3 3 /4" 3 3 /4" /2" /2" /2" 2 9 /a" 3 9 /32" 2 9 /s" 3.00" 2.50" 3.00" ++ - Housings Have (2) Tapped Holes Either Side of the Shaft Hole. 7

10 CASE GROUP G-0 G-3 )p 8

11 Ref. No. G- G-2 N.S. N.S. N.S. N.S. N.S. G-3 G-5 G-6 G-7 G-0 or N.S. Part No. EASY SHIFT 5 SPEED MODELS (430 lb-ft) CASE GROUP and RELATED PARTS Description Case Group See Tab Bills Case Assembly (includes G- thru G-6) N.S.S. Case (casting number C49-5-7) NP-96 Name Plate NP-96 Patent Plate 252-SP Pin - Name Plate Magnet - Ceramic Plug- Side Hole(%"- 6 x %") Plug - Filler/Drain ( 3 //- 4 N.P.I.F.) Breather Insert- Poppet Spring & Plunger X Plunger Assy. (includes 3 springs and 3 poppets) Switch - Back-Up Light (Navistar only) Switch- Back-Up Light (Ford) Sleeve Back-Up Light (shipping) T2 O-ES43~5 Qty G- G Pin - st & Reverse Select Plunger Spring - st & Reverse Shift Finger Plunger or Spring- st & Reverse Shift Finger Plunger (white) (A. V.I.) or Spring - st & Reverse Shift Finger Plunger G Plug - st & Reverse Plunger G Cover - PTO Aperture (6 bolt) 2 N.S Anaerobic Sealant AIR G Screw - PTO Aperture Cover ( x. 750) 2 *-Back-Tapered Clutching Teeth Version (AfterSerial No. J )..,ll.. lfl.. lll.. **-Straight Clutching Teeth Version (Before Serial No. J ) N.S.S. - Not Sold Separately N.S. - Not Shown AIR - As Required llf IMPORTANT 9

12 REAR BEARING CAP GROUP and RELATED PARTS T2 O ES43-5 / MAINSHAFT REAR BEARING CAP TABLE Part Number Includes Part Oil Speedo Number Seal Casting Bush. Gasket H- H-2 Number H-5 H-6 Ty(!e & Description Used By X C x4 DCM, Mech. Speedo Navistar X C x3/0x3 Bend. Mech. Speedo All X C Air Cap, Mech. Speedo Ford & Std X C Air Cap, Elec/Mech Speedo Nav.&GM X C x4 Elect. Speedo Only Navistar X C x3 Elect. Speedo Only Navistar X C Air Cap, Elect. Speedo Only Navistar X C Air Cap, Elect. Speedo (Metric) Volvo 0

13 Ref. No. MODEL ES43 5 REAR BEARING CAP GROUP and RELATED PARTS Part No. H- See Tab Bills H H-3 See Page 0 H-4 N.S.S. H-5 See Page 0 Description T2 O-ES43-5 Mainshaft Rear Bearing Cap Group Cap Assembly - Mainshaft Bearing Rear Oil Seal - Mainshaft Rear Bearing Cap Cap Sub Assembly - Mainshaft Rear Cap - Mainshaft Rear Bearing Bushing - Speedometer Qty. H or H H-8 See Tab Bills H ~2-X N.S N.S N.S H N.S H H or J J or or J J ~ J M M and M M N N N ~ N N N N Gasket - Mainshaft Rear Bearing Cap Gasket - Mainshaft Rear Bearing Cap (brake only} Bolt - Rear Bearing Cap ( x.25) 4 Gear - Speedometer Drive Sleeve & Oil Seal Cap - Speedometer Dust Plug- Speedometer (used without driven gear) Plug- Speedometer Outlet (electronic} Bearing - Mainshaft Rear Plug - Electronic Speedometer (Ford) Tube- Vent (assembly to front of transmission) Bolt- Cap (D.C.M. brake) 2 Plug- Case (rear holes) 2 Countershaft Rear Bearing Cap Group Cap - Countershaft Rear Bearing Shim- Countershaft Rear Bearing (.0055/.0045} Shim- Countershaft Rear Bearing (.00/.0090) Shim - Countershaft Rear Bearing (.065/.035) Cup - Countershaft Rear Bearing Lift Hook Bolt- Countershft Rear Bearing Cap ( x i.co} 4 Interlock Group Plate - Interlock Retainer Gasket - Case to Interlock Plate (bottom} Gasket- Case to Interlock Plate (top) Screw - Drive {interlock retainer} 2 Plate - Interlock Rear Shaft Bar Support Group Support - Rear Shift Bar Cap - Rear Shift Bar Lift- Hook Screw- Shift Bar Cap ( x.00) 4 Screw- Shift Bar Support ( x 2.250) 2 Gasket - Shift Bar Cover Spacer - Rear Bar Support 2 N.S.S. - Not Sold Separately N.S.- Not Shown

14 T2 O-ES43-5 REMOTE CONTROL ASSEMBLY Ref. No. Part No. Description X -3X -6X See Tab Bills X L- N.S.S. L L-3 28P-9 N.S X L L L L L N.S. LW-3-9 L or L L X L L L L L L L L L X L Remote Control Assembly Remote Control Cover Assembly Remote Control Cover Bushing - Remote Control Cover Seal - Remote Control Rod Inner Shifter Shaft, Finger and Key Key - Shift Bracket Shaft - Remote Control Finger - Shift Set Screw- 7 /a"- 20 x.72" Square Head Boot - Shift Rod Lockwire Control Lever Control Lever Set Screw- 7 /s"- 4 x 7 /a Square Head Shift Rod Rod End (/2" 20UNF) Bolt- Control Lever (/2"- 3 x 2 // hex head) Spacer - Control Lever Bolt Nut - Control Lever and Rod End (/2" - 3 hex) Nut - Tie Rod Assembly Mounting Bolt (%" - 6 hex) Spacer - Tie Rod Assembly Mounting Bolt Bolt - Tie Rod Assembly (%" - 6 x. 75 hex hed) Bracket - Tie Rod Tie Rod Assembly NUT - Control Shift Rod N.S.S.- Not Sold Separately N.S. - Not Shown 2

15 COMPANION FLANGES and END YOKES T2 O ES43 5 COMPANION FLANGE Companion Flanges Part No. G c A Companion Part No. End of Hub Pilot Diameter Flange Flange Companion to Flange F-Female Brake Joint Series Diameter Assembly Flange Face Length M-Male Size 480/550 Rectangular F-3%" 9 x 3 or 2 x 4 FULL ROUND U-BOLT-BRG. STRAP-HALF ROUND End Yoke End of Hub to Series Yoke Style Part Number Center Line Length Joint Angle Brake Size 480 U-Bolt fe/ 22 /2 480 Brg. Strap** / /2 550 U-Bolt /s/ 2 /2 550 Brg. Strap* /s/ Brg. Strap** /s/ 2 /2 550 U-Bolt /s/ 22 2 X U-Bolt /s/ 22 /2 550 Brg. Strap* /s/ 22 /2 550 Brg. Strap** fs/ 22 /2 550 Half Rnd. (A) X 7 /32" 22 2 x4 60 Full Rnd " 9 60 Half Rnd " 9 60 Full Rnd /s/ 22 J20 60 Half Rnd fs/ 22 /2 60 Full Rnd /32" 22 2 X 4 60 Half Rnd. (A) X 7 9 /s" 22 2 X 4 70 Full Rnd // Half Rnd // 33 /z 0 (A) Assembly Includes Brake Drum *With Tapped Holes **With Thru Holes s 3

16 T2 O-ES43-5 EASY SHIFT 5 SPEED MODELS (430 lb-ft) SHIFT BAR and FORK ASSEMBLY Ref. Part No. Description No. Shift Bar and Fork Assembly R X Fork and Bar Assembly - st and Reverse (includes R-2, poppet plunger, and spring) R X Kit - Shift Fork Clip (includes (2) clips) (included in R-, R-3, and R-4) R X Fork and Bar Assembly - 2nd and 3rd* (includes R-2, poppet plunger, and spring) or X Fork and Bar Assembly - 2nd and 3rd** (includes R-2, poppet plunger, and spring) R X Fork and Bar Assembly- 4th and 5th* (includes R-2, poppet plunger, and spring) or 3376-X Fork and Bar Assembly- 4th and 5th** (includes R-2, poppet plunger, and spring) *-Back-Tapered Clutching Teeth Version (After Serial No. J ) **-Straight Clutching Teeth Version (Before Serial No. J ) Qty..lll.lll.Cll.lCl/MPORTANT 3 4

17 SHIFT LEVER and DOME ASSEMBLY T2 O ES43 5 Ref. Part No. Description No. -28X -29X X Sub-Assy.- Shift Knob (includes P- thru P-5) P- 39Q-35 Handle - Shift Lever P Insert - Shift Lever Handle (ES43-5 & ES53-5} P Insert- Shift Lever Handle (ES52-7 & ES066-7B} P Nut - Shift Knob Retaining P-3a Washer- Shift Lever Retaining (lock type) P Washer - Shift Knob P Pin - Shift Knob N.S X Sub Assy.- Shift Tower (includes P-6 thru P-3) P Boot - Shift Tower and Lever P-7 53Q-20 Pin- Pivot (Gimbal} P-8 48Q-60 Yoke - Shift (Gimbal) P Tower - Shift (Gimbal) P-0 33Q-5- Tie Cable - Upper P- 33Q-5-2 Tie Cable - Lower P X Kit- Trunion Screws (includes (2) Trunion screws) P Screw - Shift Tower 4 4 P-4 25Q Shift Lever (26.400ff long) Straight - 25Q Shift Lever (30. 72" long) Straight Bulletin - Installation Shift Knob Parts Not Included In Tower Assemblies N.S Boot - Floorboard (oval) N.S Boot- Floorboard (rectangular) N.S Boot - Internal (UPS) N.S. - Not Shown N.S.S. - Not Sold Separately 5

18 T20-ES43.-5 MODEL ES43 5 CLUTCH RELEASE CODE TABLE PEDAL ADJUSTING ARM RIGHT SIDE X PEDAL ADJUSTING ARM LEFT SIDE-30233X Part No. 06C-42 06C-85 06C-26 06C C C C Part No. 06C C-67 06C C C C C C C-047 Length 6.25" 5.750" 4.750" 4.82" 5.32" 6.78" 6.500" 6.250" CR-2 LONG SHAFT Type RS-5 RS-8 RS-8 RS-8 RS-8 RS-8 RS-8 RS-8 RS-8 Length 4.000" 0.469".469" 0.000" 9.750".968" 8.79" 8.968" 9.469" CR- LONG SHAFT (Cont'd) Part No. Type Length 06C-083 RS " 06C- 094 RS " 06C-23 RS " 06C-35 RS " 06C-367 RS " 06C-375 RS " 06C-47 RS " 06C-422 RS " 06C-490 RS " 06C-55 RS-5.375" 06C-529 RS " RS " RS " RS " CR-6 PEDAL ADJ. ARM 30233X For Left Side Mtg X For Right Side Mtg X Lever Type 7 /4" 30873X lever Type 7 /4" Lever type can be used on either right or left side. THRU SHAFT (used with push type clutch) Type Splined Splined Keyed Splined Length 9.25"" 9.500" 9.20" 9.33" CLUTCH RELEASE YOKES CR 7 Forging No. Used With Type J K M 05C-64 F05C64 Spicer 5 / 2 SP Pull 8.000" 6.500" 4.895" 05C-68 F05C99 Spicer 4" SP Pull 7.25" 5.750" 4.32" OSC-7 F05C8 Spicer & Others Push 8.375" 7.000" 4.885" 05C-24 F05C25 Spicer AL & AR Push 3.750" 2.25" 2.885" 05C-32 2 F05C8 Spicer & Others Push 8.375" 7.000" 4.885" 05C-37 F05C38 Spicer 3" and Pull 8.000" 6.500" 4.895" C05C38 4" 2P F05C8 Spicer & Others Push 8.375" 7.000" 4.885" 'Machined washer surface on yoke front 2 Machined washer surface on yoke rear (for clearance) 3 Same as ' above except contains spring holes in lugs Use 7743X Clutch Release Bearing and (2) 230C 2 Springs * CLUTCH RELEASE YOKE ATTACHING PARTS- Use one KEY 0 30, two SCREWS and two LOCK WASHERS NOTE: When changing from a two plate to single plate clutch or vice versa, a different bearing cap wil be required. 6

19 Rei. Code See Tab Bill CR 7 Yoke* 05C C C C C C C C C C-68 05C C C C C-68 5A 05C C C C C C C C C C C C C C C C C C C C-7 35A 05C C C C C C C C C C C C-7 46A 05C C C C C-24 52A 05C C C C C C C C 37 MODEL ES43 5 CLUTCH RELEASE CODE TABLE ShaH D Rei. Code ShaH CR CR 2 Adjustable Dim. See CR 7 CR CR 2 Short Long Arm (ln.) Tab Bill Yoke* Short Long 06C-42 06C X C-37 06C 85 06C C-85 06C C-37 06C 85 06C C-85 06C X C-37 06C-85 06C C-85 06C X C-37 06C 85 06C C-85 06C X C-37 06C-85 06C C-85 06C HX OSC-37 06C-85 06C C C X C-37 06C-85 06C C-42 06C C-37 06C-85 06C C 42 06C C-37 06C-85 06C C-42 06C X C-37 06C-85 06C C-42 06C X C-37 06C-85 06C-23 06C-42 06C X C-37 06C-85 06C-23 06C-42 06C X C-37 06C-85 06C C-42 06C X C-37 06C-85 06C C C C-37 06C-85 06C C C X C-37 06C-85 t06c-55 06C C X C-37 06C-85 06C C-42 06C X C-37 06C C-85 06C A 05C-37 06C C-85 06C X C-37 06C-26 06C 67 06C-85 06C HX C-37 06C C C-85 06C X C-37 06C-278 OSC-67 06C-85 06C X C-37 06C C C 85 06C X A 05C-37 06C C C-85 06C X C-37 06C C C 85 06C X C-37 06C C C-85 06C C-37 06C C C 85 06C X C-37 06C C C-85 06C X C-37 06C C C-85 06C X C-37 06C C C-85 06C X C-37 06C C C-85 06C X.875 9A 05C-37 06C C C-85 06C C-37 06C C C-85 06C X A 05C-37 06C C-35 06C-85 06C X C-37 06C C C-85 06C X C-37 06C C C-85 06C X C-37 06C C C-85 06C X C-37 06C C C-85 06C X A 05C-37 06C C-47 06C C X C-37 06C C C C X C-37 06C C C C X C-37 06C C C C X C-37 06C C-67 06C C X C-37 06C C-67 06C C X C-37 06C C C C X C-37 06C C C C X C-37 06G C C C-37 06C C C-85 06C C-37 06C C-046 Thru Shaft 05C X 07 05C-37 06C C-047 Thru Shaft 06C X 08 05C-37 06C C-047 Thru Shaft 06C X 09 05C-37 06C C-083 Thru Shaft X C-37 06C C C-85 06C X C C C-85 05C X A C C C-85 06C X C C-47 06C Thru Shaft 06C C A Thru Shaft 06C C-85 06C Thru Shaft 06C C-85 06C X Thru Shaft T2 O-ES43-5 Adjustable Arm D Dim. (ln.) 30233X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X - - Use n43x Clutch Release Bearing and (2) 23QC-2 Springs 7

20 T2 O-ES43-5 OVERHAUL KITS Part No. Description Qty. Major Overhaul Kit X Major Overhaul Kit Nut - Mainshaft Output Washer - Mainshaft Nut X Thrust Washer Kit X Shifter Housing Small Parts Kit X Minor Overhaul Kit Minor Overhaul Kit (included in major overhaul kit) X Minor Overhaul Kit Bearings Mainshaft Pocket Mainshaft Rear Cone Drive Gear Front Mainshaft 2nd & Reverse Reverse Idler Gear Countershaft Front- Cone Countershaft Front - Cup Countershaft Rear - Cone Countershaft Rear - Cup Mainshaft 3rd Needle Mainshaft st Speed Mainshaft 4th Speed Clip - Shift Fork X Seal - Drive Gear (flat type) X Seal- Drive Gear (stem type) Seal - Mainshaft Rear #2 Moly Grease (packet) Loctite - Threadlock Adhesive (vial) X Gasket Kit X Shim Kit - Countershaft Rear X Snap Ring - Kit Service Manual 2770 Bulletin - Bearing Lube Instruction 2783 Bulletin - Loctite Application for Mainshaft Nut X Thrust Washer Kit (included in major overhaul kit) Mainshaft - 3rd & 4th Speed Mainshaft - st & 2nd Speed Mainshaft - Reverse Pin- Lock X Shifter Housing Small Parts (included in major overhaul kit) 2823 Bulletin - Shift Bar Assembly & Poppet Plunger Plunger - Poppet Insert- Poppet Spring and Ball Pin - st and Reverse Select Plunger Spring - Shift Bar Poppet Spring - st & Reverse Shift Finger Plunger 8

21 Part No X X X X Description OVERHAUL KITS Gasket Kit (included in minor overhaul kit) Mainshaft Rear Bearing Cap Mainshaft Rear Bearing Cap (D.C.M. brake) Tower Tower Anaerobic Sealant Gasket - Shift Bar Cover Bulletin - Liquid Gasket Snap Ring Kit (included in minor overhaul kit) Mainshaft 3rd & 4th Thrust Washer Countershaft Head End Gear Mainshaft 2nd & 3rd Clutch Gear Mainshaft st & 2nd Speed Thrust Washer Countershaft 4th Gear Mainshaft Front Bearing 4th & 5th Gear Shim Kit (included in minor overhaul kit) Countershaft Rear Bearing Cap (.065/.035) Countershaft Rear Bearing Cap (.00/.0090) Countershaft Rear Bearing Cap (.055/.0045) Bulletin - Countershaft Shim Kit Breakdown of Oil Seals in the Minor Overhaul Kit Sub Assembly - Oil Seal & Installation Sleeve (flat cap) Seal - Drive Gear Bearing Cap Sleeve- Oil Seal Installation (.75 diameter shaft) Sleeve- Oil Seat Installation (.50 diameter shaft) Bulletin - Oil Seal Installation Instruction T2 O-ES43-5 Qty X Sub Assembly- Oil Seal & Installation Sleeve (stem cap) Seat - Drive Gear Bearing Cap Sleeve- Oil Seal Installation (.500 diameter shaft) Sleeve- Oil Seal Installation {.375 diameter shaft) Bulletin - Oil Seal Installation THE ANAEROBIC SEALANT SHOULD BE APPLIED AS FOLLOWS: Approx. (4)cc for C/S Bearing Caps Approx. (4)cc for Rear Shift Bar Support Approx. (6)cc for Drive Gear Bearing Cap A 50cc tube is supplied in the Minor Overhaul Kit 9

22 T2 O-ES43-5 Tab No. Used By Model ES43-5A Never Released -2 Navistar -3 Navistar -4 Navistar -5 Navistar -6 Canadian Foremost -7 GMC- (UPS) -8 Mercedes Benz -9 Mercedes Benz -0 Hino Motors - Cummins -2 DPD Aust -3 OshKosh -4 TSP Dina -5 TSP Dina -6 TSP MBM -7 Navistar -8 Navistar -9 Navistar -20 Navistar -2 OshKosh -22 Ford -23 TSP -24 General Motors -25 Navistar -26 Navistar -27 Navistar -28 GMC UPS -29 GMC UPS -30 Navistar -3 Ford -32 Never Released -33 Franklin -34 Terra Flex -35 TSP -36 OshKosh -37 Ted-Trans. -38 OshKosh -39 J.L.G. -40 HI CO -4 Freightliner -42 TSP -43 American Transport -44 Rolligon Corp. TABULATED BILLS OF MATERIAL CLUTCH HOUSING For Use s Assembly Rei. Main With A No. Code Drive Clutch E E- Pages Gear Push Type X X Push Type X X Push Type X X Push Type X X Push Type X X Push Type X** X Push Type X X Push Type X X Push Type X X Push X X Push X Push X X Pull X X Pull X X Pull X X Push X X Push X X Push X X Push X X Push X X Push X X Push X X Push X X Push X X Push X X Push 2' X X Push X X Push X X Push X X Push X X Push X X Push X X Pull X X Push X X Push X X Push X X Push X X Push X X Push X X Push X X Push X X Push X X Drive Gear Bearing Case Cap Assembly F- G X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 49-9"6- X X X X X X X X X X X X X X X X X X X X X X X X X X 20

23 Main shaft Rear Brg. Cap Tab Assembly No. H- Model ES43-5A X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X TABULATED BILLS OF MATERIAL Speedometer Drive Gear End Yoke or Signal Driven or Gear Gear Companion Housing B-24 H-7 Flange Assembly X X X X X X X X X X X X X T2 O-ES43-5 Shifter Lever & Dome Remote Assembly Control Pages Pages X X X X ox X X X X X X X X X X X 2

24 T2 O-ES43-5 Tab No. Used By Model ES43-5D TABULATED BILLS OF MATERIAL CLUTCH HOUSING For Use s Assembly Rei. Main With A No. Code Drive Clutch E E- Pages Gear Drive Gear Bearing Case Cap Assembly F- G- - Never Released -2 Never Released -3 Navistar -4 Navistar -5 Navistar -6 Navistar -7 Ford -8 Navistar -9 Direcspicer TSP -0 Service - Spicer Dr.Tr. -2 OshKosh -3 Navis tar -4 Navistar -5 Navistar -6 Ford -7 Navistar -8 Ford -9 Navistar -20 Ford -2 Ford -22 Spicer Dr.Tr. -23 Spicer Dr. Tr Navistar -26 Navistar Push Type X X Push Type X X Push Type X X Push Type X X Push Type X** X Push Type X X Push Type X X Push Type X X Pull Type X X Push Type X X Push Type X X Push Type X X Push Type X X Push Type X X Push Type X X Push Type ~ 0- X X Push Type X 49~ X Pull Type X X Pull Type X X Pull Type X X Pull Type X X Push Type X X Push Type X X 49w9-9- X X X X X IX X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 22

25 Mainshaft Rear Brg. Cap Tab Assembly No. H- Model ES43-5D Never Released -2 Never Released X X X X X X X X X X X X X X X X X X X X X TABULATED BILLS OF MATERIAL Speedometer Drive Gear End Yoke or Signal Driven or Gear Gear Companion Housing B-24 H-7 Flange Assembly X T2 O-ES43-5 Shifter Lever & Dome Remote Assembly Control Pages Pages X X 23

26 BACK-TAPER CHANGEOVER KITS FOR ES43-5 TRANSMISSIONS Kits will be available November 25, 996 ES43-5, A Ratio, 4/5 Shift Rail, Kit X Drive Gear MIS 4th Gear Synchronizer X Clutch Gear Shift Rail Assembly X Poppet Plunger Poppet Spring Identification Tag NP-204 Old Drive Gear New Drive Gear Order Kit# X X X X X X X X Above Kits are the same except for the Drive Gear. See Kit part llst left. ES43-5, 0 Ratio, 4/5 Shift Rail, Kit X Drive Gear M/S 4t~ Gear Synchronizer X Clutch Gear _ Shift Rail Assembly X Poppet Plunger Poppet Spring Identification Tag NP-204 Old Drive Gear New Drive Gear Order Kit# X X X X X X X X Above Kits are the same except for the Drive Gear. See Kit part list left. ES43-5, A & 0 Ratio, 2/3 Shift Rail, Kit X M/S 3rd Gear MIS 2nd Gear Synchronizer X Clutch Gear Shift Rail Assembly X Poppet Plunger Poppet Spring Identification Tag NP-204 Note: Due to the nature of back-tapered clutching teeth, the straight toothed parts are not interchangeable with back-tapered parts. The entire kit must be installed so that a given rail has parts that have either straight toothed clutching teeth or back-tapered clutching teeth. Do not mix straight toothed parts with back-tapered parts. Printed in U.S.A. 24

27 For parts or service call us Pro Gear & Transmission, Inc. (877) (407) W. Gore St. Orlando, FL 32805