More time on the road. Illustrated Parts List

Transcription

1 More time on the road Illustrated Parts List RTO-090B-AS November 008

2 Contents How To Use The Illustrated Parts List... AUXILIARY DRIVE GEAR... CASE (AUX)... CASE (FRONT)...7 CONTROLLER ECU & HARNESS...9 COUNTERSHAFT & BRGS (AUX)...0 COUNTERSHAFT ASSY... FILTER REGULATOR... GEAR DISPLAY MODULE... INPUT SHAFT & DRIVE GEAR... INTEGRAL OIL PUMP... KITS & ASSEMBLIES...7 MAINSHAFT & SYNCHRO(AUX)...8 MAINSHAFT ASSY...9 MISCELLANEOUS...0 OIL COOLER... RANGE CYLINDER... REVERSE IDLER... SHIFT BAR HOUSING... SHIFT CONTROLS...6 X-Y SHIFTER MODULE...7 Appendix...8

3 How To Use The Illustrated Parts List The information contained in this document is subject to frequent updates. Therefore, for the latest information available, please visit the interactive Electronic Parts 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- 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 Group: AUXILIARY DRIVE GEAR /9 Aux DG AUXILIARY DRIVE GEAR 676 SNAP RING K-,K- 0 SNAP RING RETAINER K-,K- 668 SNAP RING BEARING 660,6607 K-,K- BOX 68 BEARING RETAINER 6 X-8-6 CAPSCREW X /8"-6X" 7 9 AUXILIARY DRIVE GEAR

5 Group: CASE (AUX) OEM supplied adjustable speedometer sensor (Threaded) OEM supplied non-adjustable speedometer sensor (Non-Threaded) CASE (AUX) S-0 SPEEDO ROTOR ASSY 0 MAGNETIC 68 -O- RING K-98,S-0,S- 9,S-96 K-98 OIL SEAL KIT 0 0 "FOR MAGNETIC COVER" K-,K- X-8-080M CAPSCREW M8 X. X MM S-9 REAR BEARING COVER ASSY GASKET - RED EDGE MOLDED 6 07 GASKET - PURPLE EDGE MOLDED 6967,06,08 RED EDGE MOLDED GASKET - UNCOMPRESSED THICKNESS NOT INTERCHANGEABLE WITH ANY OTHER GASKET NON EDGE MOLDED GASKET - UNCOMPRESSED THICKNESS NOT INTERCHANGABLE K-98,K-8,S-9 K-98,K-8 WITH ANY OTHER GASKET 7 X-8L-6 CAPSCREW /8"-6X-/" 7 X-8L-6 CAPSCREW /8"-6X" 8 X-8L-60 CAPSCREW 6 /8"-6X-/" 8 X-8L-6 CAPSCREW /8"-6X" 8 X-8L-66 CAPSCREW X 8 66 /8"-6X-/" 9 00 COVER 6 S GASKET 06 K-8,S-96 K-80 SHIM KIT K - 06 K-,K-,S-96 GASKET K-8,S REAR HOUSING 08 LIFTING EYE 70 S-96 6 X-8L-600 CAPSCREW 8 /8"-6X" K- SPEED SENSOR KIT A - 698,A - 67 SINGLE PICK-UP ( PIN) K- SPEEDO PLUG KIT SHIELD S-9

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7 Group: CASE (FRONT) Latest Design 0 * * D * Bushing quantity requirements: # Housing Upper bore use #8 / Lower bore use #8677. # Housing Upper bore use #8 and #8677 / Lower bore use #8677. Note: Some part requirements are specific to # or # Aluminum or Iron Clutch Housings and Push or Pull type Clutch. CASE (FRONT) S-996 CASE ASSY 0,0766,S S-998 CASE ASSY 08,076,S - FOR USE W/INTEGRAL PUMP 07 X--007 PIPE PLUG X PLUG 077 -/6" MAGNETIC, O-RING S-996,S-998 INCLUDED USE WITH 0766 CASE X--07 PIPE PLUG X 0,X 06 /" MAGNETIC USE WITH 0 & 08 CASES 00 GASKET 080 K PTO COVER 696,007 6 X-8-7 CAPSCREW X /6"-X7/8" GASKET 08 K-8 8 A-7 CLUTCH HOUSING ASSY A # PUSH-PULL IRON 8 A-7 CLUTCH HOUSING ASSY A - 7,A - 7 # PUSH-PULL IRON 8 A-77 CLUTCH HOUSING ASSY A -,A - 77 # PUSH-PULL ALUM. 8 A-606 CLUTCH HOUSING ASSY A -,A - 770,A - # PUSH-PULL ALUM. 606,A - 606,A X-8L-09 CAPSCREW /6"-8X/" QUANTITY DEPENDENT ON DESIGN 0 06 HAND HOLE COVER # PUSH 0 07 HAND HOLE COVER # PULL 0 00 HAND HOLE COVER # PULL 0 0 HAND HOLE COVER 6 # PUSH 0708 STUD X-0-00 WASHER X 000,X X 6.60,X0 00 X--00 NUT X /8"-8 00 FRONT BRG COVER " PULL K-68 7

8 X-8L-60 CAPSCREW 6 /8"-6X-/" 6 09 FRONT BRG COVER " PUSH 7 GASKET K BUSHING FOR # HOUSING UPPER A-7,A-7,A- 77,A-606,K BUSHING FOR # HOUSING UPPER A-7,A-7,A- 77,A-606,K BUSHING FOR # HOUSING UPPER A-7,A-7,A- 77,A BUSHING FOR # AND # HOUSING LOWER A-7,A-7,A- 77,A X-8C-8 CAPSCREW X 8 8,X 8L 8 /- X -/ - FOR IRON HOUSING 0 X-8C-86 CAPSCREW 6,X 8 809,X 8L 809,X 8L 86 /- X -7/6 - FOR IRON HOUSING 0 X-8C-86 CAPSCREW 6,X 8 809,X 8L 809,X 8L 86 /- X -7/6 - FOR ALUMINUM HOUSING 00 PLUG 077 -/6" MAGNETIC, O-RING S-996,S-998 INCLUDED X CAPSCREW 6 /8"-6X/" 7 PTO COVER GASKET 68 K HEX HEAD PLUG S-996,S MAGNET S-996,S PIN 9 X--00 NUT X 000 /8"-8 0 X-0-00 WASHER X 000,X X 6.60,X0 00 STUD 6,679 /8" X -/6" 6 0 PLUG 7 7 X-8-00 CAPSCREW /8"-X-/" 8 08 SPACER 9 X--80 PIPE PLUG X 800 /" 0 X--07 PIPE PLUG X 0,X 06 /" MAGNETIC 697 PIN S-996,S-998 8

9 Group: CONTROLLER ECU & HARNESS 0 9 Range Solenoid A Shift Bar Housing Speed Sensor B Shift Bar Housing Speed Sensor Splitter Solenoid (8 Speeds Only) Blank Rear Bearing Cover CONTROLLER ECU & HARNESS 00 BRACKET 98 TY-RAP 8 K-7,K MOUNTING PAD 078 DOWEL PIN S-90 K-RX REMAN EXCHANGE K-, K-R TRANSMISSION CONTROLLER KIT SLEEVE 7 0 WASHER 8 X-8- SCREW /6"-8X-/" 9 K-68 RANGE/SPLITTER VALVE 680,680,K - KIT K-908 -O- RING KIT FOR SOLENOID VALVE X-8-6 HEX FLANGE HEAD X 8 9 #0- X / SCREW X--0 LOCKWASHER #0 PLAIN K-7 TRANSMISSION HARNESS KIT

10 Group: COUNTERSHAFT & BRGS (AUX) 00-/9 Aux CS Helical COUNTERSHAFT & BRGS (AUX) 007- BEARING,007 K-,K- BOX A-68 WELDED A - 66 C/S D/G 60 COUNTERSHAFT ASSY SPACER 0

11 Group: COUNTERSHAFT ASSY /9 CS/RT COUNTERSHAFT ASSY 7 SNAP RING K-,K- 66 BEARING K-,K- 06 CNTRSHFT-W/REV & ST 069 X-6-E KEY 6 ROLL PIN KEY ND GEAR-CNTRSHFT 97, RD GEAR-CNTRSHFT OD GEAR-CNTRSHFT 96,96,08,0, PTO GEAR - LOWER PTO GEAR - UPPER DRIVE GEAR-CNTRSHFT 90,9,09,0087, SNAP RING 099 BEARING K-,K- 060 RETAINER 98 ROLL PIN NO LONGER REQUIRED X-7-00 CAPSCREW /8"-8X-/"

12 Group: FILTER REGULATOR NSS -O- Ring/Element Kit 0--9 AFR/AS NSS - Not Sold Separately FILTER REGULATOR K-70 FILTER REG KIT A - K-698 -O- RING/ELEMENT KIT FOR FILTER REGULATOR X-8C- CAPSCREW X 8S /"-0X-/" -O- RING K-70,K-6 X--08 PIPE PLUG /8" NPT

13 Group: GEAR DISPLAY MODULE GEAR DISPLAY MODULE K-99 DRIVER DISPLAY MODULE 060

14 Group: INPUT SHAFT & DRIVE GEAR * * 070-/9 IS * For Shipping Only -- Do Not Replace INPUT SHAFT & DRIVE GEAR 9 SHIPPING SEAL NOT SOLD FOR SERVICE 6980 SNAP RING K-68,K- 80 BEARING K-68,K-,K- 66 SPACER 70 SNAP RING K-68,K-,K MAIN DRIVE GEAR 00,0086,08 8 S-69 INPUT SHAFT " PULL - USE W/FBC 00 K-68,K- 8 S-660 INPUT SHAFT 06,67 " PUSH - USE W/FBC BUSHING K-,S-69,S-660

15 Group: INTEGRAL OIL PUMP Indicates part of item Oil Pump INTEGRAL OIL PUMP X-8C-09 CAPSCREW /"-0X/8" K-0 COVER & SCREW KIT 0,007 0 GASKET K-0 08 PLUG 76 -O- RING K-8 6 X-8-8 SCREW X 8 /"-0X-/" 7 08 WASHER K DOWEL PIN RETAINER 0 K-67 OIL PUMP KIT 089,098,0776,09,07 A - 696,A - 77 K-67 OIL PUMP KIT 089,098,0776,09,07 A - 696,A KEY 8 SNAP RING 077 PUMP DRIVE GEAR 0880 K-67 OIL PUMP KIT 089,098,0776,09,07 A - 696,A X--700 STEEL BALL 7/6" SPRING 8 07 SUCTION TUBE 068 O-RING INCLUDED ON SUCTION K-67 TUBE PLUG 0668 GASKET 08 K-8

16 S-998 CASE ASSY 08,076,S - FOR USE W/INTEGRAL PUMP 07 7 MAGNET S-996,S X-8-7 SCREW 7 0 -O- RING 999 K-67 OIL PUMP KIT 089,098,0776,09,07 A - 696,A

17 KITS & ASSEMBLIES K-698 -O- RING/ELEMENT KIT FOR FILTER REGULATOR K-96 COOLER INSTLN KIT K-70 FILTER REG KIT A - K-0 COVER & SCREW KIT 0,007 K-68 CLUTCH INSTALLATION KIT FOR USE WITH S-69 INPUT SHAFT ASSY AND 80 INPUT SHAFT BEARING K-80 SHIM KIT K - 06 K-,K-,S-96 K-908 -O- RING KIT FOR SOLENOID VALVE K-98 OIL SEAL KIT 0 0 "FOR MAGNETIC COVER" K-,K- K-9 COUNTERSHAFT REPL 0,0 KIT K- SPEED SENSOR KIT A - 698,A - 67 SINGLE PICK-UP ( PIN) K-6 RANGE CYL COVER KIT 69 K-67 OIL PUMP KIT 089,098,0776,09,07 A - 696,A - 77 K-6 XY SHIFTER KIT 698,A - 70 K-8 POSITION SENSOR KIT 69,6996 K-RX REMAN EXCHANGE TRANSMISSION CONTROLLER KIT K-, K-R K-8 O-RING KIT - RANGE K-,K- K-9 SYNCHRONIZER KIT K - 6 K-9 SYNCHRONIZER REPLACEMENT KIT K - 8 SLIDING CLUTCH INCLUDED IN KIT K-8 GASKET KIT K-,K- K- BASIC REBUILD KIT K- SPEEDO PLUG KIT 0707 K- BASIC OVERHAUL KIT K-7 TRANSMISSION 6966 HARNESS KIT K-6 OIL SEAL TOOL KIT K-680 COBRA SHIFT LEVER KIT A - 78 (LEFT HAND DRIVE) K-68 RANGE/SPLITTER VALVE 680,680,K - KIT 907 S-0 OIL FILTER 78 S-69 INPUT SHAFT " PULL - USE W/FBC 00 K-68,K- S-660 INPUT SHAFT 06,67 " PUSH - USE W/FBC 09 S-0 SPEEDO ROTOR ASSY 0 MAGNETIC S-688 MAINSHAFT ASSY 00,09 S-90 SHIFT BAR HOUSING 69 COMPLETE ASSY S-9 REAR BEARING COVER 6967,06 ASSY,08 S-9 SHIFT BAR HOUSING ASSY 69 HOUSING ONLY (DOES NOT INCLUDE SPEED SENSORS) S-96 RANGE SECTION ASSY "B" RATIO S-989 PUSHBUTTON S - 98 ASSEMBLY S-990 PUSHBUTTON FOR USE WITH REMOTE LEVER ASSEMBLY S-996 CASE ASSY 0,0766,S S-998 CASE ASSY 08,076,S - 07 FOR USE W/INTEGRAL PUMP 7

18 Group: MAINSHAFT & SYNCHRO(AUX) 8 7 Universal Joint Yoke 0 0A-0-0 MAINSHAFT & SYNCHRO(AUX) 897 SPRING K-9,K-9,K-,K- A-7 SYNCHRONIZER ASSY A - HI RANGE K-9,K SLIDING CLUTCH K-9 A-7 SYNCHRONIZER A - 97 A LO RANGE K-9,K-9 ASSEMBLY 076 AUXILIARY MAINSHAFT WASHER REDUCTION GEAR SPACER 60- BEARING 60 K-,K- BOX 0 NUT 8

19 Group: MAINSHAFT ASSY B-0-96 MAINSHAFT ASSY S-688 MAINSHAFT ASSY 00,09 60 ROLL PIN S SIDED KEY SNAP RING K-68,K-,K- 6 REVERSE GEAR- MAINSHAFT 6 79 SPACER SLIDING CLUTCH 007 K ST GEAR-MAINSHAFT WASHER ND GEAR-MAINSHAFT 0 08 RD GEAR-MAINSHAFT OD GEAR-MAINSHAFT 08, WASHER.-BLUE 098 WASHER 0996 SLIDING CLUTCH 699 9

20 MISCELLANEOUS 8660 SHIFT DIAGRAM LABEL S SILICONE LUBE 8 OZ (6.9 CC)-FLEET SIZE 70 ADHESIVE SEALANT 0. CC (SINGLE APPLICATION SIZE) 70 SEALANT CC (SINGLE APPLICATION SIZE) K- 706 SILICONE LUBE CC (SINGLE APPLICATION SIZE) K-8 0

21 Group: OIL COOLER 6 7 Flow Oil Return Oil Pump Outlet * *6 Outlet * Fuller 77 *6 Inlet * Return Outlet 0-/9 Cooler *Adding Oil Filter and parts as shown is optional. Return / Outlet Location OIL COOLER 80 OIL COOLER K-96 9 HOSE FEET K-96 X-8- CAPSCREW /6"-6X-/" X--06 LOCKWASHER /6" 8 BRACKET K CONNECTOR 6 K-96,S SWIVEL K-96 8 X-0-0 WASHER /6" PLUG-RUBBER MOUNT K STRAP 8 K-96 9 CLAMP K NUT K-96 9 ELBOW K-96 S-0 OIL FILTER FILTER ELEMENT S-0

22 Group: RANGE CYLINDER RANGE CYLINDER A-7 SHIFT YOKE ASSY 7 GASKET K RANGE CYLINDER 76 -O- RING K-8 PISTON 6 -O- RING K-8 7 -O- RING K-8 8 X--00 NUT /8" GASKET 690 K-6,K-8,K-8 0 K-6 RANGE CYL COVER KIT 69 X-8-67 CAPSCREW /8"-6X-/" X-8L-60 CAPSCREW /8"-6X" X--600 LOCKWASHER /8" X--08 PIPE PLUG /8" NPT

23 Group: REVERSE IDLER Latest Design RI REVERSE IDLER X CAPSCREW /8"-8X-/ 8 WASHER 098 WASHER 8 K-09,S-996,S BEARING 000 K-,K- 677 REVERSE IDLER GEAR 09 6 K-09 IDLER SHAFT REPL KIT 60,098, RETAINING RING K RETAINING RING K IDLER SHAFT K-09

24 Group: SHIFT BAR HOUSING SHIFT BAR HOUSING S-9 SHIFT BAR HOUSING ASSY 69 HOUSING ONLY (DOES NOT INCLUDE SPEED SENSORS) 0676 GASKET 98 K-8,S-90,S OIL TROUGH S-90 0 AIR VALVE SHAFT 777 S-90 6 X-8- CAPSCREW /"-0X/" 7 X--60 PIPE PLUG X 60 /8" NPT DOWEL PIN S PLUNGER 07 SPRING 779 GASKET S-90,S-9 06 PLUG 778 S-90,S-9 9 NEUTRAL LIGHT SWITCH 69 SWITCH NORMALLY CLOSED 08 LIFTING EYE 70 S-96 6 X-8L-60 CAPSCREW /8"-6X-/" 6 X-8L-60 CAPSCREW 6 /8"-6X-/"- OR USE PCS OF X- 8L-60 WITH PCS OF X-8L PIN GASKET S-90,S REVERSE LIGHT SWITCH 680 SWITCH NORMALLY OPEN PLUG 97 S-90,S COMPRESSION SPRING S-90 X--800 STEEL BALL /" 697 SHIFT YOKE 076 REVERSE/ST S-90 X--00 STEEL BALL /" 68 SHIFT BLOCK ND/RD S LOCKSCREW S INTERLOCK PIN S SHIFT BLOCK TH/TH S SHIFT YOKE 0 TH/TH S-90

25 0 066 YOKE BAR TH/TH S SHIFT YOKE 099 ND/RD S YOKE BAR ND/RD S YOKE BAR REVERSE/ST S-90 K- SPEED SENSOR KIT A - 698,A - 67 SINGLE PICK-UP ( PIN) -O- RING S-90 6 X-8C-09 CAPSCREW /"-0X/8" PLUG 97 S-90,S GASKET S-90,S S-90 SHIFT BAR HOUSING ASSY 69 COMPLETE

26 Group: SHIFT CONTROLS VOLUME CONTROL R N SERVICE D SHIFT MANUAL EATON FULLER TRANSMISSIONS LOW PUSHBUTTON ASSEMBLY COBRA LEVER 009B-0-07 COBRA RETROFIT ASSEMBLIES SHIFT CONTROLS S-989 PUSHBUTTON S - 98 ASSEMBLY S-990 PUSHBUTTON FOR USE WITH REMOTE LEVER ASSEMBLY K-680 COBRA SHIFT LEVER KIT 07 (LEFT HAND DRIVE) S-987 COBRA RETROFIT ASSEMBLY AUTOSHIFT (LEFT HAND DRIVE) COBRA LEVER & SHIFT TOWER ASSY, NARROW BASE W/TONE S-997 COBRA RETROFIT ASSEMBLY 00 SHIFT LEVER POSITION STRIP 0 SHIFT LEVER KNOB DECAL AND HARNESS AUTOSHIFT (RIGHT HAND DRIVE) COBRA LEVER & SHIFT TOWER ASSY, NARROW BASE W/TONE AND HARNESS 6

27 Group: X-Y SHIFTER MODULE Items not included in X-Y SHIFTER MODULE 0 GASKET 098 K-6 X-8C-6 CAPSCREW 060 BREATHER 60 /" NPT 98 TY-RAP K-7,K-68 K-8 POSITION SENSOR KIT 69, K-6 XY SHIFTER KIT 698,A

28 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. /" Air Line and Harness Combinations Line Type Line Color Order Part No. Length Supply + Port Red (S) + Black (P) 60 0 ft Splitter + Deep Reduction Blue (SP) + Green (H/L) 70 0 ft Supply + Splitter + Port Red(S)+Blue(SP)+ Black(P) ft /" Air Lines Line Type Line Color Order Part No. Length Supply Red (S) 70 0 ft Port Black (P) 70 0 ft Splitter Blue (SP) ft Deep Reduction Green (H/L) 70 0 ft Sheathing ft /8" Air Lines Line Type Line Color Order Part No. Length Supply White ft Port Black 80 0 ft Sheathing ft 060-/9 AL Chart 8

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30 Copyright Eaton Corporation and Dana Limited, 008. Eaton and Dana hereby grant their customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. It may be copied only in its entirety without any changes or modifications. THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES. For spec ing or service assistance, call HELP (7) hours a day, 7 days a week (Mexico ), for more time on the road. Or visit our web site at Eaton Corporation All rights reserved. Roadranger: Eaton, Dana and other trusted partners providing the best products and services in the industry, ensuring more time on the road. Eaton Corporation Truck Components Operations P.O. Box 0 Kalamazoo, MI 900 U.S.A.