Illustrated Parts List

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1 More time on the road Illustrated s List FRLO-540C-T November 0

2 Contents How To Use The Illustrated s List... CASE ASSY... 4 COUNTERSHAFT & BRGS(AUX)... COUNTERSHAFT ASSY... 8 ELECTRONIC CONTROL UNIT... 9 FILTER REGULATOR... 0 INPUT SHAFT & DRIVE GEAR... INTEGRAL OIL COOLER... ISOLATORS... 4 KITS & ASSEMBLIES... 5 LEVERS/HOUSINGS... MAINSHAFT & SYNCHRO(AUX)... 9 MAINSHAFT ASSY... MISCELLANEOUS... RANGE CYLINDER... REAR BEARING COVER... 4 REVERSE IDLER... 6 SHIFT KNOB... SHIFT SHAFT ASSY... 8 SPLITTER CYLINDER... 0

3 How To Use The Illustrated s List The information contained in this document is subject to frequent updates. Therefore, for the latest information available, please visit the interactive Electronic s Catalog at Model Designation or Nomenclature For information regarding Model Designation and Nomenclature, visit 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- numbers beginning with the letter 'A' are pre-assembled Production Assemblies K- numbers beginning with the letter 'K' are kits that are not assembled S- 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. numbers on illustrations correspond with parts listings on pages adjacent to the illustration. Notes are included on illustrations where additional information is needed. s Listing s listings are defined by parts groupings and are broken down by service assemblies. s listings identify a part for servicing with the following categories Number - corresponding with numbers on illlustrations for part identification. - indentifies part as it is available for service. Description - specifies part name or description. Replaced - 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 6 8 Group: CASE ASSY CASE ASSY Description Replaced Qty. Notes Kits/Assys Where LUBE TAG NOT PICTURED - LOCATED BY FILL PLUG 0 K-650 RTV SERVICE KIT FLANGE SEALANT K-6,S-8,S- 85 K-94 CLUTCH HOUSING 404,A-6 NON-NODAL MOUNT - ALUMINUM 4

5 Description Replaced Qty. Notes Kits/Assys Where SERVICE KIT S-6R REMAN CLUTCH HOUSING ASSY (SAU) S-R REMAN CLUTCH HOUSING ASSY (NAU) - HYDRAULIC 40548,A-4 STANDARD - ALUMINUM 4058,A-49 NODAL MOUNT - ALUMINUM 85 BUSHING 4 64 PLUG 44 DOWEL K OIL TROUGH K-94 5 X-8-080M CAPSCREW M8 X.5 X MM K BUSHING (SHIFT ROD) 0085 K OIL DAM PLATE K COVER SPRING BREATHER 605 /4" NPT X-8C- 04M X-8C- 0M CAPSCREW & WASHER 6 M0 X 5.0MM CAPSCREW & WASHER M0 X 55.0MM S-965 CASE ASSY - STANDARD STUD M6 X X 5MM 5 X--606M SELF LOCKING HEX NUT X 60M,X 60M,X--605M M6 X.5 6 X WASHER REVERSE SWITCH PIN PLUG 404 -/6" MAGNETIC, O-RING INCLUDED ONE FOR FILL OPENING ONE FOR DRAIN OPENING 4049 NEUTRAL SWITCH PIN OIL SEAL K-40,K-4 4 X--604M NUT 8 M8 X.5 5 X-8C- 05M CAPSCREW & WASHER 4 M0 X 0.0MM 6 X-8C- CAPSCREW & WASHER 8 M0 X 0MM 5

6 06M Description Replaced Qty. Notes Kits/Assys Where SCREW 4 M0 X M AUX COUNTERSHAFT COVER SIGHT PLUG (-5/8) SCREW 4 M0 X M8 455 PTO COVER MAGNET S-965 X--80 PIPE PLUG X 800 /" 4 X--08 PIPE PLUG /8" NPT PLUNGER 406 SPLITTER DETENT K COMPRESSION SPRING K-408,K-40,K O- RING PLUG 6

7 Group: COUNTERSHAFT & BRGS(AUX) COUNTERSHAFT & BRGS(AUX) Description Replaced Qty. Notes Kits/Assys Where BEARING - INNER RACE 4 K-40,K BEARING - OUTER RACE 4 K-40,K-4 A-68 WELDED COUNTERSHAFT ASSY C/S S/G BEARING K-40,K RETAINING RING K-40,K-4

8 Group: COUNTERSHAFT ASSY COUNTERSHAFT ASSY Description Replaced Qty. Notes Kits/Assys Where K-69 ROLLER BEARING KIT BEARING - INNER RACE K-40,K-4 A- WELDED COUNTERSHAFT ASSY 4049,4048,A - 66 C/S D/G TH/G

9 Group: ELECTRONIC CONTROL UNIT ELECTRONIC CONTROL UNIT Description Replaced Qty. Notes Kits/Assys Where X-8C- 0809M CAPSCREW & WASHER 9 M8 X 0.0MM S-88RX REMAN EXCHANGE LIGHTNING ECU 40498,A - 689,A - 699,A ,A ,S SEAL PLATE K-40,K WASHER 95 BREATHER 9

10 Group: FILTER REGULATOR NSS -O- Ring/Element Kit NSS - Not Sold Separately FILTER REGULATOR Description Replaced Qty. Notes Kits/Assys Where A-5 FILTER REGULATOR ASSY 6-8 PSI K-698 -O- RING/ELEMENT KIT FOR FILTER REGULATOR X-8C- 0604M CAPSCREW & WASHER M6 X 55.0MM 4 X--08 PIPE PLUG /8" NPT ELBOW 90 DEGREE O- RING 0

11 Group: INPUT SHAFT & DRIVE GEAR IMPORTANT DUE TO DESIGN CHANGES, PLEASE VERIFY THE PART NUMBER ON THE COMPONENT TO ENSURE PROPER PART REPLACEMENT INFORMATION INPUT SHAFT & DRIVE GEAR Description Replaced Qty. Notes Kits/Assys Where X-8C- 04M CAPSCREW & WASHER 6 M0 X 5.0MM K-64 CLUTCH INSTALLATION KIT 4040,4045,S - 968,K-654 UNITS BUILT PRIOR TO S/N K0004 S-99 FRONT BRG COVER ASSY 405 UNITS BUILT BEGINNING WITH S/N K0004 K NO LONGER AVAILABLE CAN ONLY BE USED WITH 404 FRONT BEARING COVER, ORDER S O-RING CAN ONLY BE USED WITH 405 FRONT BEARING COVER OIL SEAL 4045 UNITS BUILT BEGINNING WITH S/N K0004 K-55,S-99 K-40,K-4,S K-64 CLUTCH INSTALLATION KIT 4040,4045,S - 968,K-654 UNITS BUILT PRIOR TO S/N K K-55 SHIM KIT K - 40 K-64,K-40,K BEARING CUP K-40,K-4,S-

12 Description Replaced Qty. Notes Kits/Assys Where BEARING CONE K-64,K-40,K- 4 8 X M SCREW K-64,K ECCENTRIC PUMP ASSY K-64,K INPUT SHAFT 4040 UNITS BUILT BEGINNING WITH S/N K0004 K-64,K-40 0 K-64 CLUTCH INSTALLATION KIT 4040,4045,S - 968,K-654 UNITS BUILT PRIOR TO S/N K PISTON PUMP K-64,K SNAP RING MAIN DRIVE GEAR WASHER MAIN DRIVE GEAR BOX BOX BEARING 4048 K-40,K-4 SPHERICAL WASHER 404 K SNAP RING K-408,K-40,K- 4

13 Group: INTEGRAL OIL COOLER INTEGRAL OIL COOLER Description Replaced Qty. Notes Kits/Assys Where A-6899 FITTING ASSY /8" - INCLUDES ITEM & 085 -O- RING 4 A O- RING A OIL COOLER 5 X-8-080M CAPSCREW M8 X.5 X MM K-94

14 Group: ISOLATORS New Design New Design Isolator Indicates Of 0 ISOLATORS Description Replaced Qty. Notes Kits/Assys Where 94 -E- RING K-46 PIN REPLACEMENT KIT BUSHING K-48,K-98,K- 99,S-9,S-59 4 S-94 ISOLATOR ASSY 6 4 LEVER STRAIGHT 8.6" 5 STUB LEVER LOW TOWER K-48,S STUB LEVER MID TOWER K DEG LEVER STRAIGHT " 0 K-99 ISOLATOR BUSHING KIT 44, X SCREW X-9-50 NUT 4

15 KITS & ASSEMBLIES Description Replaced Qty. Notes Kits/Assys Where K-46 SHIFT LEVER HSG 450,6,898,404905,A - 44 LOW TOWER K-698 -O- RING/ELEMENT KIT FOR FILTER REGULATOR K-48 LEVER REPLACEMENT KIT K-9 SHIFT LEVER HSG KIT 406,40490,A K-98 LEVER REPLACEMENT KIT LOW TOWER MID TOWER MID TOWER K-6 O-RING & WASHER KIT 40 K-99 ISOLATOR BUSHING KIT 44, K-405 REPAIR KIT - RANGE K-406 REPAIR KIT - SPLITTER K-40 REPAIR KIT - RANGE/SPLITTER K-40,K-4 K-408 SMALL PARTS KIT K-454 SPEED SENSOR KIT A - 698,A - 64 SINGLE PICK-UP ( PIN) K-455 SPEED SENSOR KIT, DUAL A - 046,A - 58 DUAL PICK-UP (4 PIN) K-46 PIN REPLACEMENT KIT 45 K-49 SYNCHRONIZER KIT K K-49 SYNCHRONIZER REPLACEMENT KIT K - 00 SLIDING CLUTCH INCLUDED IN KIT K-5 SPEEDO PLUG KIT 400 K-55 SHIM KIT K - 40 K-64,K-40,K- 4 K-6 OIL SEAL KIT 40,40 K-40,K-4 K-650 RTV SERVICE KIT FLANGE SEALANT K-6,S-8,S- 85 K-64 CLUTCH INSTALLATION KIT 4040,4045,S - 968,K-654 UNITS BUILT PRIOR TO S/N K0004 K-94 CLUTCH HOUSING SERVICE KIT 404,A-6 NON-NODAL MOUNT - ALUMINUM - HYDRAULIC K-40 BASIC OVERHAUL KIT K - 409,K-65 K-4 BASIC REBUILD KIT K - 40,K-65 FOR UNITS BUILT PRIOR TO S/N K0004 YOU MUST ALSO ORDER A INPUT SHAFT, 5

16 Description Replaced Qty. Notes Kits/Assys Where FOR UNITS BUILT BEGINNING WITH S/N K0004 YOU ONLY NEED TO ORDER K-65 S-94 ISOLATOR ASSY S-9 SHIFT LEVER HSG ASSY LOW TOWER S-50 SPEEDO ROTOR ASSY 404 MAGNETIC S-59 SHIFT LEVER HSG ASSY S - 99 MID TOWER S-80 MAINSHAFT ASSY S-88RX REMAN EXCHANGE LIGHTNING ECU 40498,A - 689,A - 699,A ,A ,S-88 S-8 MAINSHAFT ASSY - AUX S-8 REAR BEARING COVER ASSY S-85 REAR BEARING COVER ASSY 40409,4048 ONE PUSH-IN SENSOR OPENING (0.00) TWO THREADED SENSOR OPENINGS (4:00/8:00) 4045 THREE PUSH-IN SENSOR OPENINGS (0:00/4:00/8:00) S-965 CASE ASSY - STANDARD 4046 S-99 FRONT BRG COVER ASSY 405 UNITS BUILT BEGINNING WITH S/N K0004 K-64 6

17 Group: LEVERS/HOUSINGS K-48 - Low K-98 - Mid S-6 - Low S-96 - Mid S-9 - Low S-59 - Mid LEVERS/HOUSINGS Description Replaced Qty. Notes Kits/Assys Where K-6 O-RING & WASHER KIT PIN K-46,K-9,S- 6 X-8C- 05M CAPSCREW & WASHER 4 M0 X 0.0MM K-46 SHIFT LEVER HSG 450,6,898,404905,A - 44 LOW TOWER GASKET 404 K-46,K-48,K- 9,K-98,S- 6,S-96,S- 9,S-59 9 K-9 SHIFT LEVER HSG KIT 406,40490,A MID TOWER 5 04 BOOT K-46,K-9,S- 6

18 Description Replaced Qty. Notes Kits/Assys Where GEAR SHIFT LEVER STRAIGHT - LOW -/" 58 RETAINER K-46,K-9,S SPRING K-46,K-9,S- 6 K-48 LEVER REPLACEMENT KIT K-98 LEVER REPLACEMENT KIT LOW TOWER MID TOWER 4 S-6 SHIFT TOWER ASSY LOW TOWER 4 S-96 SHIFT TOWER ASSY MID TOWER S-9 SHIFT LEVER HSG ASSY LOW TOWER S-59 SHIFT LEVER HSG ASSY S - 99 MID TOWER 8

19 Group: MAINSHAFT & SYNCHRO(AUX) MAINSHAFT & SYNCHRO(AUX) Description Replaced Qty. Notes Kits/Assys Where SLIDING CLUTCH 404- BOX BOX SPHERICAL WASHER 404 K-408 BEARING 4048 K-40,K AUXILIARY SPLITTER GEAR SPRING K-49,K-49,K- 40,K-4 6 A- SYNCHRONIZER ASSY A - 59 HI RANGE K-49,K SLIDING CLUTCH 4086 K-49 8 A-54 SYNCHRONIZER ASSEMBLY A - 49 A LO RANGE K-49,K-49 9 S-8 MAINSHAFT ASSY SPACER 4046 REDUCTION GEAR BEARING AVAILABLE FOR TRUCK DOWN ONLY 9

20 Description Replaced Qty. Notes Kits/Assys Where K-4 HEX FLANGE CRIMPED NUT KIT 40,

21 Group: MAINSHAFT ASSY MAINSHAFT ASSY Description Replaced Qty. Notes Kits/Assys Where 4046 SLIDING CLUTCH 4044 S-80 MAINSHAFT ASSY ROLL PIN S KEY K TH GEAR-MAINSHAFT ST GEAR-MAINSHAFT WASHER 6 K SLIDING CLUTCH AUXILIARY DRIVE GEAR REVERSE GEAR- MAINSHAFT 6980 SNAP RING

22 MISCELLANEOUS Description Replaced Qty. Notes Kits/Assys Where SHIFT DIAGRAM LABEL SILICONE LUBE 8 OZ (6.59 CC)-FLEET SIZE 04 ADHESIVE SEALANT 0.5 CC (SINGLE APPLICATION SIZE) 05 SEALANT CC (SINGLE APPLICATION SIZE) 06 SILICONE LUBE 4 CC (SINGLE APPLICATION SIZE) K-48,K-98,K- 405,K-406,K- 40,K-55,S-99 K-650 RTV SERVICE KIT FLANGE SEALANT K-6,S-8,S- 85

23 Group: RANGE CYLINDER RANGE CYLINDER Description Replaced Qty. Notes Kits/Assys Where X--00M NUT M0 X.5 HEX 404 PISTON K-405,K YOKE BAR 4 46 SNAP RING K-405,K WASHER O- RING K-405,K-406,K PIN 8 A-0 RANGE YOKE ASSY RETAINER A-0,A STEP WASHER A-0,A-0 X--0 SCREW

24 Group: REAR BEARING COVER OEM supplied adjustable speedometer sensor (Threaded) OEM supplied non-adjustable speedometer sensor (Non-Threaded) REAR BEARING COVER Description Replaced Qty. Notes Kits/Assys Where S-50 SPEEDO ROTOR ASSY 404 MAGNETIC O- RING K-6,S-50 K-6 OIL SEAL KIT 40,40 K-40,K-4 4 X-8-080M CAPSCREW M8 X.5 X MM USE W/S-8 OR USE W/S-85 K-94 5 S-8 REAR BEARING COVER ASSY 5 S-85 REAR BEARING COVER ASSY 40409,4048 ONE PUSH-IN SENSOR OPENING (0.00) TWO THREADED SENSOR OPENINGS (4:00/8:00) 4045 THREE PUSH-IN SENSOR OPENINGS (0:00/4:00/8:00) 6 X-8-008M HEX SCREW X 8C 04M 6 M0 X 80.0MM K-454 SPEED SENSOR KIT A - 698,A - 64 SINGLE PICK-UP ( PIN) K-455 SPEED SENSOR KIT, DUAL A - 046,A - 58 DUAL PICK-UP (4 PIN) 9 04 PLUG-THREADED USE W/S-8 S-8 9 K-5 SPEEDO PLUG KIT 400 USE W/S YOKE-0 HALF ROUND YOKE-60 HALF ROUND YOKE-80 HALF ROUND YOKE-RPL5 HALF 4

25 Description Replaced Qty. Notes Kits/Assys Where ROUND YOKE-SPL0 HALF ROUND YOKE-SPL50 HALF ROUND YOKE-9N HALF ROUND 5

26 Group: REVERSE IDLER REVERSE IDLER Description Replaced Qty. Notes Kits/Assys Where 4040 REVERSE IDLER SHAFT 4040 REVERSE IDLER GEAR 4040 BEARING 4 K-40,K WASHER SNAP RING K-406,K-40 6 X-8-004M CAPSCREW M0 X.5 X 0MM 6

27 Group: SHIFT KNOB SHIFT KNOB Description Replaced Qty. Notes Kits/Assys Where A-49 SHIFT KNOB ASSEMBLY 4044,4055,40508 X-9-80 NUT /"-

28 Group: SHIFT SHAFT ASSY SHIFT SHAFT ASSY Description Replaced Qty. Notes Kits/Assys Where A-69 SHIFT SHAFT ASSY 4046 ALL REQUIRED PINS INCLUDED 4040 KEY 8

29 Description Replaced Qty. Notes Kits/Assys Where YOKE ST & REV YOKE RD & DIRECT PLUG - HEX HEAD M8 X SPRING K SPRING PLUNGER K PLUG 404 COMPRESSION SPRING STANDARD K-408,K-40,K COMPRESSION SPRING OPTIONAL - HEAVY 4048 PLUNGER 406 K-408 9

30 Group: SPLITTER CYLINDER SPLITTER CYLINDER Description Replaced Qty. Notes Kits/Assys Where SNAP RING K-406,K O- RING 8899 K-406,K PISTON O- RING A-5,K-698,K- 406,K O- RING K-405,K-406,K PISTON 46 -O- RING K-406,K YOKE BAR PIN 0 A-0 SPLITTER YOKE ASSY 4049 X--0 SCREW STEP WASHER A-0,A RETAINER A-0,A-0 0

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