Group 2 Power Train 204 CARY-LIFT PARTS BOOK

Transcription

1 Group 2 Power Train 204 CARY-LIFT POWER TRAIN ASSEMBLY, FL ENGINE AND TORQUE CONVERTER INSTALLATION, FL TORQUE CONVERTER (FRONT COVER GROUP, LL ), LL TRANSMISSION INSTALLATION, FL FUNK TRANSMISSION, LL TRANSMISSION PLUMBING CIRCUIT (FUNK TRANSMISSION), FL AXLE AND CRADLE INSTALLATION, FL FRONT AXLE ASSEMBLY (CARRIER ASSEMBLY), LL REAR AXLE ASSEMBLY (CARRIER ASSEMBLY), LL CYLINDER ASSEMBLY, FL STEERING CYLINDER ASSEMBLY, FL FRONT CRADLE INSTALLATION, FL REAR CRADLE ASSEMBLY, FL SWAY CYLINDER ASSEMBLY, AL DRIVE SHAFT INSTALLATION, FL ENGINE DRIVE SHAFT ASSEMBLY, BL DRIVE SHAFT ASSEMBLY, BL REAR AXLE DRIVESHAFT ASSEMBLY, BL AIR CLEANER INSTALLATION, FL AIR CLEANER ASSY, LL AIR INTAKE PRECLEANER AND DASH INSTALLATION, FL AIR INTAKE WITH PRECLEANER, FL EXHAUST INSTALLATION, FL RADIATOR SHROUD INSTALLATION, FL COOLING CIRCUIT, FL FUEL SYSTEM CIRCUIT, FL FUEL TANK ASSEMBLY, FL PAGE 2-1

2 POWER TRAIN ASSEMBLY, FL PAGE 2-2

3 POWER TRAIN ASSEMBLY, FL ITEM PART NUMBER DESCRIPTION REQ D 1 FL COOLING CIRCUIT 204 W/QSB FL FUEL SYSTEM CIRCUIT TIER FL FUNK TRANS PLUMBING CIRCUIT 1 4 FL INST-AXLE/CRADLE 1 5 FL INST-DRIVE SHAFT 1 6 FL INST-ENGINE & TORQUE CONVERTER 1 7 FL INST-EXHAUST 1 8 FL INST-RAD-SHROUD 1 9 FL INST-TRANSMISSION 1 10 FL INST.-AIR CLEANER 1 PAGE 2-3

4 ENGINE AND TORQUE CONVERTER INSTALLATION, FL PAGE 2-4

5 ENGINE AND TORQUE CONVERTER INSTALLATION, FL ITEM PART NUMBER DESCRIPTION REQ D 1 0LT ADPT 2MNPT-2FNPT-2FNPT TEE 1 2 LL ASSY PUMP LLB BUSHING 1 4 LL CAPSCR-HEX -.38 NF X 1.75 LG. 8 5 LL CAPSCR-HEX-.50NCX LL CAPSCR-HEX-M10-1.5X100MM 4 7 LL CAPSCR-HEX-M10X1.5 X LL CAPSCR-HEX-M16X2X70MM LG. 1 9 LL CENTER BUSHING MOUNT LL CPSCR-M12X1.75X40MM LL ENGINE OIL SENDER 1 12 LL ENGINE-QSB HP 1 13 LL FAN-SUCKER-24IN_DIA 1 14 LL FUNK DF3R2A 1 15 LL NUT-NYLOCK-.50 NC 4 16 LL SENDER 1 17 LLH WASH-FL-.50_HARD LL WASH-FL-M LL WASH-LOCK-16MM 1 20 LLS WASH-LOCK-M LLS WASH-LOCK-SPLIT_SPG A WASHER-FLAT 1 23 LLS WASHER-LK-SPG-M LL WATER & OIL TEMP SENDER 1 25 FL WLDMT-MNT ENGINE REAR 2 PAGE 2-5

6 TORQUE CONVERTER (FRONT COVER GROUP, LL ), LL PAGE 2-6

7 TORQUE CONVERTER (FRONT COVER GROUP, LL ), LL ITEM PART NUMBER DESCRIPTION REQ D 1 LL FRONT COVER ASSEMBLY (CONSISTS OF A-T) REF A LL HOUSING, INPUT, SAE #3 1 B LL SHAFT, IDLER 2 C LL GEAR, DRIVEN 36T 2 D LL GEAR, IDLER 2 E LL SEAL, OIL (VITON) 1 F LL BEARING, BALL 4 G LL BEARING, BALL 1 H LL BEARING 3 I LL BEARING 1 J LL SNAP RING 1 K LL SPACER, BEARING 1 L LL O-RING, ARP219 2 M LL PACKING, O-RING 2 N LL SENSOR, MAGNETIC PICK-UP 1 O LL COVER, MAGNETIC PICK-UP 1 P LL CAPSCREW, M6 X 20 (GRD 8.8) 2 Q LL O-RING 1 R LL WASHER, HELICAL SPRING LOCK, RGLR 2 S LL WASHER, METALLIC, ROUND HOLE 2 T LL PLUG, HEX SOC. 1 2 LL TUBE, STATOR SUPPORT 1 3 LL GEAR, SPUR 38T 1 4 LL SHAFT, TURBINE 1 5 LL PIN, COTTER 1 6 LL THRUST RACE 1 7 LL BEARING, NEEDLE THRUST 1 8 LL CAPSCREW, M12 X 110 (GRD 8.8) 5 9 LL DEFLECTOR 1 10 LL O-RING, ARP LL CAPSCREW, M8 X 50 (GRD 10.0) 7 12 LL HOUSING ASSEMBLY, CONVERTER REMOTE 1 13 LL SEAL, RING LL BEARING 1 16 LL SNAP RING LL SCREW, SOCKET HD, M12 X LL PLUG, 1 5/8 W/O-RING 2 20 LL PLUG 1 21 LL O-RING, ARP LL PLUG, SHIPPING 1 24 LL PLUG, SHIPPING 2 25 LL IDENTIFICATION PLATE 1 26 LL SCREW, DRIVE 2 27 LL O-RING, ARP904 1 PAGE 2-7

8 CONVERTER HOUSING ASSEMBLY, LL (LL TORQUE CONVERTER) ITEM PART NUMBER DESCRIPTION REQ D 1 LL HOUSING, CONVERTER REMOTE 1 2 LL BALL, STEEL, 9/32 1 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-8

9 NOTES PAGE 2-9

10 CHARGE PUMP ASSEMBLY, LL (LL TORQUE CONVERTER) ITEM PART NUMBER DESCRIPTION REQ D 1 LL PUMP, OIL 1 2 LL O-RING 1 4 LL SCREW, SET 1 5 LL CUP, PLUG 1 6 LL PLUG, SHIPPING 1 7 LL CAPSCREW, M16X65 (GR 8) 3 N.S. LL SEAL KIT-SERVICE 1 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-10

11 DRIVE PLACE ASSEMBLY, LL (LL TORQUE CONVERTER) ITEM PART NUMBER DESCRIPTION REQ D 1 LL PLATE, DRIVE (INCLUDES NUT PLATES (8) 1 2 LL RING 1 3 LL CAPSCREW 12 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-11

12 FRONT COVER GROUP, LL (LL TORQUE CONVERTER) PAGE 2-12

13 FRONT COVER GROUP, LL (LL TORQUE CONVERTER) ITEM PART NUMBER DESCRIPTION REQ D 1 LL HOUSING, INPUT 1 2 LL SHAFT, IDLER 2 3 LL GEAR, DRIVEN 36T 2 4 LL GEAR, IDLER 37T 2 5 LL SEAL, OIL (VITON) 1 6 LL BEARING, BALL 4 7 LL BEARING, BALL 1 8 LL BEARING 3 9 LL BEARING 1 10 LL SNAP RING 1 11 LL SPACER, BEARING 1 12 LL O-RING 2 13 LL PACKING, O-RING 2 14 LL SENSOR, MAGNETIC PICKUP 1 15 LL COVER, MAGNETIC PICKUP 1 16 LL CAPSCREW, M6X20 (GR 8) 2 17 LL O-RING 1 18 LL WASHER, HELICAL SPRING LOCK, RGLR 2 19 LL WASHER, METALLIC, RND HOLE 2 20 LL PLUG, HEX SOC. 1 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-13

14 COVER PLATE ASSEMBLY, LL (LL TORQUE CONVERTER) ITEM PART NUMBER DESCRIPTION REQ D 1 LL PLATE, COVER, C 1 2 LL O-RING 1 3 LL CAPSCREW, M12 X 20 (GRD 8.8) 4 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-14

15 YOKE GROUP, LL (LL TORQUE CONVERTER) ITEM PART NUMBER DESCRIPTION REQ D 1 LL YOKE, 6C 1 2 LL O-RING 1 3 LL WASHER, YOKE 1 4 LL CAPSCREW, M16 X 35 (GR 8.8) 1 5 LL OIL SEAL 1 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-15

16 TRANSMISSION INSTALLATION, FL PAGE 2-16

17 TRANSMISSION INSTALLATION, FL ITEM PART NUMBER DESCRIPTION REQ D 1 LL CAPSCR-HEX.75NC X LL CAPSCR-HEX-.25NCX LL CAPSCR-HEX-M16X2X45MM LG. 8 4 LL CPSCR-HEX HD M16 X 2 X LL DF150 TRANSMISSION 1 6 FL PL-PARK BRAKE SOLENOID MOUNT 1 7 BL TRANSMISSION MOUNT - FUNK 2 8 LLH WASH-FL-.25_HARD 3 9 LLH WASH-FL-.75_HARD 4 10 LLS WASH-LOCK-SPLIT_SPG LLS WASH-LOCK-SPLIT_SPG LLS WASHER-LK SPG M16 10 PAGE 2-17

18 FUNK TRANSMISSION, LL ITEM NO. PART NUMBER DESCRIPTION SER. # AFFECTED LL REMOTE MOUNT INPUT GROUP ALL LL GEAR RATIO GROUP ALL LL SHAFT 1ST STAGE ALL LL CLUTCH 2ND STAGE ALL LL CLUTCH 3RD STAGE ALL LL CLUTCH 4TH STAGE ALL LL SHAFT 6TH STAGE ALL LL OUTPUT GROUP 5281, 5396 LL OUTPUT GROUP 5422 AND UP LL WET BRAKE ASSEMBLY 5281, 5396 LL WET BRAKE ASSEMBLY 5422 AND UP LL MAIN CASE GROUP ALL LL CONTROL VALVE GROUP 5281, 5396 LL CONTROL VALVE GROUP 5422 AND UP LL VALVE ASSEMBLY 5281, 5396 LL VALVE ASSEMBLY 5422 AND UP LL MAIN REGULATOR ASSEMBLY 5281, 5396 LL MAIN REGULATOR ASSEMBLY 5422 AND UP LL VOLT PROPORTIONAL SOLENOID ASSY ALL LL VOLT PROPORTIONAL SOLENOID ASSY ALL LL C YOKE GROUP ALL LL ST STAGE COVER GROUP ALL MISCELLANEOUS ITEMS ALL NOTE: ALL SERIAL NUMBERS ARE MACHINE SERIAL NUMBERS, NOT TRANSMISSION SERIAL NUMBERS. PAGE 2-18

19 NOTES PAGE 2-19

20 REMOTE MOUNT INPUT GROUP (LL TRANSMISSION), LL PAGE 2-20

21 ITEM PART NUMBER DESCRIPTION REQ'D SER. # AFFECTED 204 CARY-LIFT REMOTE MOUNT INPUT GROUP (LL TRANSMISSION), LL LL RETAINER, REMOTE INPUT BEARING 1 ALL 2 LL YOKE, 6C , LL YOKE, 6C AND UP 3 LL O-RING 1 ALL 4 LL SHAFT, INPUT 1 ALL 5 LL SCREW, HEX CAP 16 X 35 MM , LL SCREW, HEX CAP 16 X 35 MM AND UP 6 LL WA, YOKE 1 ALL 7 LL OIL SEAL , LL OIL SEAL AND UP 8 LL SNAP RING 1 ALL 9 LL GASKET, INPUT (REMOTE MOUNT) 1 ALL 10 LL RING, SEAL 1 ALL 11 LL BEARING 1 ALL 12 LL SCREW, CAP M8 X 75 7 ALL 13 LL SCREW, HEX CAP 12 X 190 MM , LL SCREW, HEX CAP 12 X 200 MM AND UP NOTE: ALL SERIAL NUMBERS ARE MACHINE SERIAL NUMBERS, NOT TRANSMISSION SERIAL NUMBERS. PAGE 2-21

22 GEAR RATIO GROUP (LL TRANSMISSION), LL PAGE 2-22

23 GEAR RATIO GROUP (LL TRANSMISSION), LL ITEM PART NUMBER DESCRIPTION REQ'D 1 LL SHAFT, 1ST STAGE ASSY 1 2 LL CLUTCH, 2ND STAGE ASSY 1 3 LL CLUTCH, 3RD STAGE ASSY 1 4 LL CLUTCH, 4TH STAGE ASSY 1 5 LL SHAFT, 6TH STAGE ASSY 1 PAGE 2-23

24 SHAFT 1ST STAGE (LL TRANSMISSION), LL PAGE 2-24

25 SHAFT 1ST STAGE (LL TRANSMISSION), LL ITEM PART NUMBER DESCRIPTION REQ'D 1 LL SHAFT, 1ST STAGE 27T 1 2 LL BEARING 1 3 LL RING, SEAL 1 4 LL BEARING 1 5 LL PLUG, LL GEAR, 41T 1 PAGE 2-25

26 CLUTCH 2ND STAGE (LL TRANSMISSION), LL PAGE 2-26

27 CLUTCH 2ND STAGE (LL TRANSMISSION), LL ITEM PART NUMBER DESCRIPTION REQ'D SER. # AFFECTED 1 LL SHAFT, ASM 2ND/ 3RD STAGE 1 ALL 2 0LA SEAL, PISTON OUTER 2 ALL 3 LL O-RING 2 ALL 4 LL PISTON, CLUTCH 2 ALL 5 LL WASHER, LUBE SHUTOFF 2 ALL 6 LL SPRING, CLUTCH RETAINING 12 ALL 7 LL RETAINING RING 2 ALL 8 LL RETAINER, SNAP RING 2 ALL 9 0LA PLATE CLUTCH SEP. 20 ALL 10 LL PLATE CLUTCH 20 ALL 11 LL RETAINER, CLUTCH PLATE 2 ALL 12 LL RING SNAP 2 ALL 13 LL GEAR, CLUTCH 2ND 47T 1 ALL 14 LL GEAR, CLUTCH 2ND 61T 1 ALL 15 LL BEARING 2 ALL 16 LL BEARING 2 ALL 17 LL BEARING 2 ALL 18 LL RETAINING RING 2 ALL 19 LL SEAL RING , LL SEAL RING AND UP 20 LL O-RING 2 ALL NOTE: ALL SERIAL NUMBERS ARE MACHINE SERIAL NUMBERS, NOT TRANSMISSION SERIAL NUMBERS. PAGE 2-27

28 CLUTCH 3RD STAGE ASSEMBLY (LL TRANSMISSION), LL PAGE 2-28

29 CLUTCH 3RD STAGE ASSEMBLY (LL TRANSMISSION), LL ITEM PART NUMBER DESCRIPTION REQ'D SER. # AFFECTED 1 LL SHAFT ASM 2ND/ 3RD STAGE 1 ALL 2 0LA SEAL, PISTON OUTER 2 ALL 3 LL O-RING 2 ALL 4 LL PISTON, CLUTCH 2 ALL 5 LL WASHER, LUBE SHUTOFF 2 ALL 6 LL SPRING, CLUTCH RETAINING 12 ALL 7 LL RETAINING RING 2 ALL 8 LL RETAINER, SNAP RING 2 ALL 9 0LA PLATE CLUTCH SEP. 20 ALL 10 LL PLATE CLUTCH 20 ALL 11 LL REAINER, CLUTCH PLATE 2 ALL 12 LL RING, SNAP 2 ALL 13 LL GEAR, CLUTCH 3RD 47T 1 ALL 14 LL GEAR, CLUTCH 3RD 61T 1 ALL 15 LL BEARING 2 ALL 16 LL BEARING 2 ALL 17 LL BEARING 2 ALL 18 LL SNAP RING 2 ALL 19 LL SEAL RING , LL SEAL RING AND UP 20 LL O-RING 2 ALL NOTE: ALL SERIAL NUMBERS ARE MACHINE SERIAL NUMBERS, NOT TRANSMISSION SERIAL NUMBERS. PAGE 2-29

30 CLUTCH 4TH STAGE ASSEMBLY (LL TRANSMISSION), LL PAGE 2-30

31 CLUTCH 4TH STAGE ASSEMBLY (LL TRANSMISSION), LL ITEM PART NUMBER DESCRIPTION REQ'D SER. # AFFECTED 1 LL SHAFT, ASM 4TH AND 5TH STAGE 1 ALL 2 0LA SEAL, PISTON OUTER 2 ALL 3 LL O-RING 2 ALL 4 LL PISTON, CLUTCH 2 ALL 5 LL WASHER, LUBE SHUTOFF 2 ALL 6 LL SPRING, CLUTCH RETAINING 12 ALL 7 LL RETAINING RING 2 ALL 8 LL RETAINER, SNAP RING 2 ALL 9 0LA PLATE CLUTCH SEP. 20 ALL 10 LL PLATE CLT. 20 ALL 11 LL RETAINER, CLUTCH PLATE 2 ALL 12 LL RING, SNAP 2 ALL 13 LL GEAR, CLUTCH 4TH 68T 1 ALL 14 LL GEAR, CLUTCH 4TH 38T 1 ALL 15 LL BEARING 2 ALL 16 LL BEARING 2 ALL 17 LL RETAINING RING 2 ALL 18 LL BEARING 1 ALL 19 LL BEARING 1 ALL 20 LL SEAL RING , LL SEAL RING AND UP NOTE: ALL SERIAL NUMBERS ARE MACHINE SERIAL NUMBERS, NOT TRANSMISSION SERIAL NUMBERS. PAGE 2-31

32 SHAFT 6TH STAGE ASSY. (LL TRANS.), LL ITEM PART NUMBER DESCRIPTION REQ'D 1 LL SHAFT, ASSY 6TH STAGE (HAS 25T, 33T, & 1 55T GEARS) 2 LL BEARING 1 3 LL BEARING 1 PAGE 2-32

33 NOTES PAGE 2-33

34 OUTPUT GROUPS (LL TRANSMISSION), LL AND LL PAGE 2-34

35 OUTPUT GROUP (LL TRANSMISSION), LL (MACHINE SER. #'S 5281, 5396) ITEM PART NUMBER DESCRIPTION REQ'D 1 LL SHAFT OUTPUT ASSY. 1 4 LL BEARING CONE 2 5 LL WET BRAKE ASSY. 1 6 LL HUB, BRAKE 1 7 LL GASKET 1 8 LL SCREW, HEX CAP 12 X 140 MM 10 9 LL SWITCH, PRESSURE 1 10 LL PLUG, SHIPPING 1 11 LL O-RING, PACKING 1 12 LL RETAINER, BEARING 1 13 LL SCREW, CAP M8 X LL SHIM, LL SHIM, LL SHIM, LL WIRING, BRAKE JUMPER (NOT SHOWN) 1 OUTPUT GROUP (LL TRANSMISSION), LL (MACHINE SER. #'S 5422 AND UP) ITEM PART NUMBER DESCRIPTION REQ'D 1 LL SHAFT OUTPUT ASSY. 1 4 LL BEARING CONE 2 5 LL WET BRAKE ASSY. 1 6 LL HUB, BRAKE 1 7 LL GASKET 1 8 LL SCREW, HEX CAP 12 X 140 MM 10 9 LL SWITCH, PRESSURE 1 10 LL PLUG, SHIPPING 1 11 LL O-RING, PACKING 1 12 LL RETAINER, BEARING 1 13 LL SCREW, CAP M8 X LL SHIM, LL SHIM, LL SHIM, LL WIRING, BRAKE JUMPER (NOT SHOWN) 1 PAGE 2-35

36 WET BRAKE ASSEMBLY (LL TRANSMISSION), LL AND LL PAGE 2-36

37 WET BRAKE ASSEMBLY (LL TRANSMISSION), LL (MACHINE SER. #'S 5281, 5396) ITEM PART NUMBER DESCRIPTION REQ'D 1 LL COVER 1 2 LL HOUSING, BRAKE 1 3 LL PISTON, BRAKE 1 4 LL SPRING, BELLEVILLE 1 5 LL O-RING 1 6 LL SEAL, POLYHONE OUTER 1 7 LL SEAL, POLYHONE INNER 1 8 LL PLATE, SEPERATOR 9 9 LL DISK, BRAKE 8 10 LL CAPSCREW 12 X 110 MM 4 WET BRAKE ASSEMBLY (LL TRANSMISSION), LL (MACHINE SER. #'S 5422 AND UP) ITEM PART NUMBER DESCRIPTION REQ'D 1 LL COVER 1 2 LL HOUSING, BRAKE 1 3 LL PISTON, BRAKE 1 4 LL SPRING, BELLEVILLE 1 5 LL O-RING 1 6 LL SEAL, POLYHONE OUTER 1 7 LL SEAL, POLYHONE INNER 1 8 LL PLATE, SEPERATOR 9 9 LL DISK, BRAKE 8 10 LL CAPSCREW 12 X 110 MM 4 PAGE 2-37

38 MAIN CASE GROUP (LL TRANSMISSION), LL PAGE 2-38

39 MAIN CASE GROUP (LL TRANSMISSION), LL ASSEMBLY PROCEDURE FOR GASKETING USING ANAEROBIC SEALANT CLEANING CLEAN BOTH SURFACE THAT WILL BE JOINED USING 100% ISOPROPYL ALCOHOL. FROM A PUMP DISPENSER OR SIMILAR DEVICE, WIPING EXCESS OFF WITH A CLEAN CLOTH. LOCTITE 7070 ODC-FREE CAN BE USED AS A SUBSTITUTE FOR THE ISOPROPYL ALCOHOL. PRIMER THE USE OF PRIMER TO EXPEDITE CURING TIME IS PERMISSIBLE. THE USE OF PRIMER REQUIRES IMMEDIATE JOINING OF FLANGES AFTER APPLICATION OF THE SEALANT. USE LOCTITE PRIMER -N- #7649 OR EQUIVALENT. EQUIVALENT PRIMERS MUST MEET ENVIRONMENTAL AND SAFETY STANDARD OF FUNK MFG. CO. DISPENSING / APPLYING / ASSEMBLING DISPENSE APPROXIMATELY 1/2 OZ. OF LOCTITE SEALANT ON A PLASTIC SHEET OR TABLETOP. LOCTITE 518 OR 510 MAY BE SUBSTITUTED. AVOID USING EXCESSIVE AMOUNTS THAT MAY BE EXPOSED FOR LONG PERIODS OF TIME. THIS WILL HELP PREVENT CONTAMINATION FROM THE SURROUNDING ATMOSPHERE SUCH AS DUST WITH METAL CONTENT. USING AN INK ROLLER OR SIMILAR DEVICE (RUBBER ROLLER WITH A HANDLE) APPLY TO ONE SURFACE OF THE JOINT BY LOADING THE ROLLER FROM THE PLASTIC SHEET AND TRANSFERRING THE MATERIAL IN A THIN FILM TO THE JOINT. THE APPLICATION SHOULD BE THE THINNEST FILM POSSIBLE BUT PROVIDE COMPLETE COVERAGE. THIS CAN BE JUDGED BY THE APPEARANCE OF THE JOINT ONCE IT IS PUT TO- GETHER. EXCESSIVE AMOUNTS WILL CAUSE RUNOFF OF THE MATERIAL. A SMALL BEAD OR BUILDUP AT THE JOINT IS PERMISSIBLE AND INDICATES GOOD DISPERSION THROUGH THE JOINT. EXCESS CAN BE WIPED FROM THE JOINT, JOINING SHOULD TAKE PLACE WITHIN 3 MINUTES AFTER SEALANT APPLICATION. APPLY THE PROPER BOLT TORQUE AND ALLOW MINIMUM OF MINUTES BEFORE ADDING OIL FOR TEST STAND USAGE. DISASSEMBLY CURED MATERIAL CAN BE REMOVED WITH A WIRE BRUSH OR SCRAPPER. CHEMICAL CLEANERS ARE AVAILABLE FOR CUSTOMER USE SHOULD THEY BE DEEMED NECES- SARY. PAGE 2-39

40 MAIN CASE GROUP (LL TRANSMISSION), LL ITEM PART NUMBER DESCRIPTION REQ'D MACHINE SER. # AFFECTED 1 LL HOUSING, REAR 1 ALL 2 LL HOUSING, 4 SPEED W/ DIPSTICK 1 ALL 3 LL GASKET, CENTER HOUSING 1 ALL 4 LL MANIFOLD, SUCTION 1 ALL 5 LL SCREEN, SUCTION ASSEMBLY 1 ALL 6 LL PLUG, SHIPPING 1 ALL 8 LL CAPSCREW , LL CAPSCREW AND UP 9 LL DIPSTICK 1 ALL 10 LL TUBE, DIPSTICK ASSY. 1 ALL 11 LL HOSE, 1/2" ID 6 ALL 14 LL O-RING 1 ALL 15 LL PIN, DOWEL 2 ALL 16 LL SCREW, HEX CAP 12 X 120 MM 18 ALL 18 LL SENSOR, MAGNETIC PLUG 2 ALL 19 LL O-RING 2 ALL 20 LL COVER, MAGNETIC PICKUP 2 ALL 21 LL SCREW, HEX CAP , LL SCREW, HEX CAP AND UP 22 LL WASHER, LOCK 2 ALL 23 LL WASHER 2 ALL 24 LL BUSHING, INPUT 1 ALL 25 LL TROUGH, OIL ASSEMBLY 1 ALL 26 LL CAPSCREW 2 ALL 27 LL SLV, BORE 3 ALL 28 LL PLUG, 1 5/8 STD W/ O-RING 2 ALL 29 LL BAFFLE SUCTION TUBE 1 ALL 30 LL GASKET 1 ALL 31 LL BEARING CUP 2 ALL 32 LL VALVE, RELIEF , LL VALVE, RELIEF AND UP 33 LL PLATE, IDENT , LL PLATE, IDENT AND UP 34 LL SCREW, DRIVE 2 ALL 35 LL PLUG, HEX SOC 9/ ALL 38 LL BRACKET 1 ALL 39 LL ELBOW, PIPE 3/8 1 ALL 40 LL CLAMP, HOSE 2 ALL 41 LL /8 NPT COUPLING 1 ALL 42 LL NIPPLE 3/8 X 1" 1 ALL 43 LL SNAP RING 1 ALL 44 LL CAPSCREW, M8 X 80MM 2 ALL 45 LL O-RING 1 ALL 46 LL WASHER, FLAT 1 ALL NOTE: ALL SERIAL NUMBERS ARE MACHINE SERIAL NUMBERS, NOT TRANSMISSION SERIAL NUMBERS. PAGE 2-40

41 NOTES PAGE 2-41

42 CONTROL VALVE GROUP (LL TRANSMISSION), LL AND LL PAGE 2-42

43 CONTROL VALVE GROUP (LL TRANSMISSION), LL (MACHINE S/N'S 5281, 5396) ITEM PART NUMBER DESCRIPTION REQ'D 1 LL VALVE ASSEMBLY 1 2 LL GASKET 1 3 LL PLATE 1 4 LL GASKET 1 5 LL SCREW, CAP M8 X LL SCREW, CAP M8 X LL SCREW, CAP M8 X LL SENSOR, TEMPERATURE 1 9 LL PACKING, O-RING 1 CONTROL VALVE GROUP (LL TRANSMISSION), LL (MACHINE S/N'S 5422 AND UP) ITEM PART NUMBER DESCRIPTION REQ'D 1 LL VALVE ASSEMBLY 1 2 LL GASKET 1 3 LL PLATE 1 4 LL GASKET 1 5 LL SCREW, CAP M8 X LL SCREW, CAP M8 X LL SCREW, CAP M8 X LL SENSOR, TEMPERATURE 1 9 LL PACKING, O-RING 1 PAGE 2-43

44 VALVE ASSEMBLY (LL TRANSMISSION), LL AND LL PAGE 2-44

45 VALVE ASSEMBLY (LL TRANSMISSION), LL (MACHINE S/N'S 5281, 5396) ITEM PART NUMBER DESCRIPTION REQ'D 1 LL HOUSING, VALVE 1 2 LL MAIN REGULATOR ASSEMBLY 1 3 LL VALVE, RELIEF LL VALVE, PROP. 12 VOLT 6 5 LL PLUG 1 6 LL PLUG, HEX SOC 7/ LL PLUG, HEX SOC. 9/ LL STEEL BALL 9/ LL PLUG, PROP SOLENOID 2 12 LL O-RING 2 14 LL O-RING 2 16 LL O-RING (NOT SHOWN) 12 VALVE ASSEMBLY (LL TRANSMISSION), LL (MACHINE S/N'S 5422 AND UP) ITEM PART NUMBER DESCRIPTION REQ'D 1 LL HOUSING, VALVE 1 2 LL MAIN REGULATOR ASSEMBLY 1 3 LL VALVE, RELIEF LL VALVE, PROP. 12 VOLT 6 5 LL PLUG 1 6 LL PLUG, HEX SOC 7/ LL PLUG, HEX SOC. 9/ LL STEEL BALL 9/ LL PLUG, PROP SOLENOID 2 12 LL O-RING 2 14 LL O-RING 2 16 LL O-RING (NOT SHOWN) 12 PAGE 2-45

46 7C YOKE GROUP (LL TRANSMISSION), LL ITEM PART NUMBER DESCRIPTION REQ'D 1 LL YOKE, 7C 1 2 LL WASHER, YOKE 1 3 LL SCREW, HEX CAP 16 X 35MM 1 4 LL OIL SEAL 1 5 LL SEAL, V-RING 1 6 LL O-RING 1 PAGE 2-46

47 NOTES PAGE 2-47

48 MAIN REGULATOR (LL TRANSMISSION) ASSEMBLY, LL PAGE 2-48

49 MAIN REGULATOR (LL TRANSMISSION) ASSEMBLY, LL ITEM PART NUMBER DESCRIPTION REQ D 1 LL BACKUP RING 2 4 LL O-RING 1 5 LL O-RING 1 6 LL O-RING 1 7 0LA O-RING 1 8 LL O-RING 1 11 LL SNAP RING 1 12 LL SHIM 3 PAGE 2-49

50 12 VOLT PROPORTIONAL SOLENOID (LL TRANSMISSION) ASSEMBLY, LL AND LL PAGE 2-50

51 12 VOLT PORPORTIONAL SOLENOID (LL TRANSMISSION) ASSEMBLY, LL (MACHINE SER. #'S 5281, 5396) ITEM PART NUMBER DESCRIPTION REQ D 2 LL VOLT COIL, SOLENOID 1 5 LL O-RING 1 6 LL O-RING 1 7 LL O-RING 1 12 VOLT PORPORTIONAL SOLENOID (LL TRANSMISSION) ASSEMBLY, LL (MACHINE SER. #'S 5422 AND UP) ITEM PART NUMBER DESCRIPTION REQ D 2 LL VOLT COIL, SOLENOID 1 5 LL O-RING 1 6 LL O-RING 1 7 LL O-RING 1 PAGE 2-51

52 1ST STAGE COVER GROUP (LL TRANSMISSION.), LL ST STAGE COVER GROUP (LL TRANSMISSION.), LL ITEM PART NUMBER DESCRIPTION REQ'D 1 LL COVER, 1ST STAGE 1 2 LL O-RING 1 3 LL SCREW, HEX CAP 12 X 20 MM 6 4 LL HANGER, LIFT 1 PAGE 2-52

53 MISCELLANEOUS ITEMS FOR LL TRANSMISSION ITEM PART NUMBER DESCRIPTION REQ'D SER. # AFFECTED LL CONTROL MODULE 1 ALL LL BUMP SHIFTER, 12 VOLT 1 ALL LL FILTER ASSEMBLY , 5396 LL FILTER ASSEMBLY AND UP LL HEAD FILTER , 5396 LL HEAD FILTER AND UP LL FILTER ELEMENT , 5396 LL FILTER ELEMENT AND UP LL KIT, PRESSURE SWITCH 1 ALL LL VOLT BRK. CONTROL VALVE 1 ALL LL TVP 12 VOLT MODULE 1 ALL LL GEAR DISPLAY ASSEMBLY , 5396 LL GEAR DISPLAY ASSEMBLY AND UP LL WIRING HARNESS , 5396 LL WIRING HARNESS AND UP NOTE: ALL SERIAL NUMBERS ARE MACHINE SERIAL NUMBERS, NOT TRANSMISSION SERIAL NUMBERS. PAGE 2-53

54 TRANSMISSION PLUMBING CIRCUIT (FUNK TRANSMISSION), FL PAGE 2-54

55 TRANSMISSION PLUMBING CIRCUIT (FUNK TRANSMISSION), FL ITEM PART NUMBER DESCRIPTION REQ D 1 LL ADAPTER-MALE TEE 1 2 LL ADAPTER-STR 16 MORING-12 MFJIC 2 3 LL ADPT 20MORB-16MJIC 1 4 LL ADPT 2FNPT-4MJIC 1 5 LL-6041 ADPT 45 16FJIC-16MJIC LH 1 6 LL ADPT 90 20MORB-20MJIC 1 7 LL ADPT-16FJIC-12MJIC 1 8 LL ADPT-16FJIC-16MJIC-16MJIC_RUN 1 9 LL ADPT-16MORB-16MJIC 6 10 LL ADPT-6MORB-4MJIC 1 11 LL ADPT-90-12MORB-12MJIC 1 12 LL ADPT-90-16MORB-16MJIC 2 13 LL ADPT-STR-12MORB-12MJIC 2 14 LL ADPT-STR-20MORB-20MJIC 1 15 LL ASSY 12HOSE-12FJIC-12FJIC X LL ASSY 12HOSE-12FJIC90-12FJICX LL ASSY 12HOSE-12FJIC90-12FJICX LL ASSY 16HOSE-16FJIC-16FJICX LL ASSY 16HOSE-16FJIC45-16FJICX LL ASSY 16HOSE-16FJIC90-16FJICX LL ASSY 16HOSE-16FJIC90-16FJICX LL ASSY 16HOSE-16FJIC90-16FJICX LL ASSY 20HOSE-20FJIC90-20FJICX LL ASSY 4HOSE-4FJIC90-4FJIC X LL FITTING-STR 16MORING-16FJIC 1 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-55

56 AXLE AND CRADLE INSTALLATION, FL PAGE 2-56

57 AXLE AND CRADLE INSTALLATION, FL PAGE 2-57

58 AXLE AND CRADLE INSTALLATION, FL PAGE 2-58

59 AXLE AND CRADLE INSTALLATION, FL ITEM PART NUMBER DESCRIPTION REQ D 1 AL ASSY-CYL 4.5 BORE-2.0 SFT 2 2 FL WLDMT-PIN 1.5 OD X FL ASSY-CYL-4.00 BORE-2.00 SFT 2 4 FL INST-CRADLE FRONT AXLE 1 5 FL GUARD-STEERING CYLINDER 1 6 FL ASSY-REAR AXLE CRADLE 1 7 FL ASSY-CYL-4.00 BORE-2.00 SFT 2 8 FL PIN - 2 X 10-1/8 LG. 2 9 FL FRONT_CRADLE_PIN 1 10 FL PIN - 2 X 7-1/8 LG FL WLDMT-MAIN FRAME 1 12 FL-8351 WLDMT-PIN-STEERING_CYL LL AXLE-FRONT 1 14 LL AXLE-REAR 1 15 LL NUT-BUD WHEEL LL ASSY-HOSE GREASE-.12 X LL FTG-LUBE-1/8NPT-STR 4 18 LL CAPSCR-HEX-.50NF X LL CAPSCR-HEX-.75 NC X 1.25 LG 6 20 LL CAPSCRW-HEX-.75 NC_X_ LL CAPSCRW-HEX-.75 NC X LL CAPSCR-HEX.75NC X LL CAPSCR-HEX-1NC X LL CAPSCR-HEX-1NCX LL CAPSCR-HEX-.50NCX LL CAPSCRW-.50 NC X 3.5 LG 4 27 LL-6416 CRADLE PIN 2 28 LL NUT-NYLOCK-.50 NC 4 29 LL NUT-NYLOCK-.75 NC 3 30 LL NUT-HEX-NYLOCK-1UNC LL FTG-2NPTF-2NPTM-STR 2 32 LL FTG-2NPTF_SW-2NPTM LLH WASH-FL-.50_HARD 8 34 LLH WASH-FL-1.00 HARD LLS WASH-LOCK-SPLIT_SPG LLS WASH-LOCK-SPLIT_SPG PAGE 2-59

60 FRONT AXLE ASSEMBLY (CARRIER ASSEMBLY), LL LL SERVICE KIT-RS145 CARRIER (CON- SISTS OF ITEMS 3, 6, 7, 13-18, 23 & 41) PAGE 2-60

61 FRONT AXLE ASSEMBLY (CARRIER ASSEMBLY), LL ITEM PART NUMBER DESCRIPTION REQ D 1 LL CARRIER ASSEMBLY, 5.86 RATIO (INCLUDES ITEMS 2-41) N.A. 2 LL DIFFERENTIAL CARRIER AND CAP ASSEMBLY 1 3 LL KIT-SHIM 1 4 LL WASHER, FLAT 8 5 LL CAP SCREW M12 X 17.5 X LL CONE-BEARING 2 7 LL CUP-BEARING 2 8 LL BEARING ADJ. RING 2 9 LL SCREW-SPECIAL 2 10 LL THRUST SCREW 1 11 LL JAM NUT 1 12 LL PINION CAGE ASSEMBLY (ALSO INCLUDES ITEMS 13 & 14) 1 13 LL INNER BEARING CUP 1 14 LL OUTER BEARING CUP 1 15 LL SEAL ASSEMBLY, OIL 1 16 LL INNER BEARING CONE 1 17 LL SPACER KIT 1 18 LL OUTER CONE BEARING 1 19 LL KIT, BOLT (INCLUDES 12 EACH OF ITEMS 20, 21 & 22) 1 20 LL CAP SCREW LL WASHER, HARDENED LL NUT LL ROLLER BEARING 1 24 LL ASSEMBLY-GEAR & PINION (INCLUDES RING & PINION ALONG WITH ITEMS 25 & 26) 1 25 LL WASHER 1 26 LL LOCK NUT 1 27 LL CASE-DIFF/NEST ASSEMBLY (SPIDERS AND CASE HALVES, INCLUDES ITEMS 28 & 33) 1 28 LL DIFFERENTIAL CASE ASSEMBLY (CASE HALVES W/O SPIDERS, INCLUDES ITEMS 29 & 32) 1 29 CASE, DIFF, FLANGE HALF N.S.S. 30 CASE, DIFF, PLAIN HALF N.S.S. 31 LL WASHER, FLAT LL CAP SCREW LL KIT-DIFFERENTIAL (INCLUDES ITEMS 34-38) 1 34 LL THRUST WASHER 2 35 LL GEAR, DIFF. SIDE N.S.S. 36 LL DIFFERENTIAL SPIDER N.S.S. 37 LL PINNION, DIFF. N.S.S. 38 LL THRUST WASHER 4 39 LL YOKE ASSEMBLY, INPUT (INCLUDES YOKE & ITEM 40) 1 40 LL DEFLECTOR 1 41 LL PILOT BEARING SNAP RING 1 PAGE 2-61

62 FRONT AXLE ASSEMBLY (HOUSING ASSEMBLY), LL ITEM PART NUMBER DESCRIPTION REQ D 1 LL ASSEMBLY-AXLE HOUSING (ALSO INCLUDES ITEMS 2-12) N.A. 2 LL CAPSCREW.62-11X LL CAPSCREW X LL MAGNET 6 5 LL BUSHING 4 6 LL UNIVERSAL JOINT BUSHING 2 7 LL OIL SEAL 2 8 LL OIL FILLER PLUG 3/4 X 14 PTF 1 9 LL PLUG 1 10 LL BREATHER ASSEMBLY 1 11 LL HARDENED WASHER 12 PAGE 2-62

63 NOTES PAGE 2-63

64 FRONT AXLE ASSEMBLY (SHAFT HUB AND STEERING ASSEMBLY), LL PAGE 2-64

65 FRONT AXLE ASSEMBLY (SHAFT HUB AND STEERING ASSEMBLY), LL PAGE 2-65

66 FRONT AXLE ASSEMBLY (SHAFT HUB AND STEERING ASSEMBLY), LL ITEM PART NUMBER DESCRIPTION REQ D 1 LL KNUCKLE, STEERING (RH) 1 2 LL KNUCKLE, STEERING (LH) 1 3 LL STEERING KNUCKLE CAP 4 4 LL SEAL, GREASE 4 5 LL SHIM (.003) 12 6 LL SHIM (.005) 8 7 LL SHIM (.020) 4 8 LL CAPSCREW 16 9 LL WASHER, HARDENED LL GREASE FITTING 4 11 LL UNIVERSAL JOINT ASSEMBLY (RH) 1 12 LL KIT, CENTER PARTS 2 13 LL OUTER AXLE SHAFT 2 14 LL INNER AXLE SHAFT (RH) 1 15 LL UNIVERSAL JOINT ASSEMBLY (LH) 1 16 LL INNER AXLE SHAFT (LH) 1 17 LL STOP SCREW 2 18 LL JAM NUT 4 19 LL SPINDLE ASSEMBLY (INCLUDES ITEMS 20 & 21) 2 20 LL BUSHING 2 21 LL OIL SEAL 2 22 LL WASHER LL CAPSCREW, SPINDLE TO KNUCKLE LL CAPSCREW, BRAKE DISC TO HUB LL WASHER, FLAT LL BRAKE DISC 2 27 LL OIL SEAL 2 28 LL WHEEL HUB INNER BEARING CONE 2 29 LL WHEEL HUB (INCLUDES ITEMS 30 & 31) 2 30 LL WHEEL HUB INNER BEARING CUP 2 31 LL WHEEL HUB OUTER BEARING CUP 2 32 LL STUD, WHEEL LL WHEEL HUB OUTER BEARING CONE 2 34 LL HUB, PLANETARY RING GEAR 2 35 LL PLANETARY RING GEAR (55T) 2 36 LL NUT, SPINDLE (NSS, SEE LL ) 2 37 LL RETAINING SCREW, SPINDLE NUT 2 38 LL WASHER 2 39 LL GEAR, PLANETARY SUN 2 40 LL SNAP RING 2 41 LL PLANETARY SPIDER, PINION, SHAFT & THRUST WASHER SERVICE ASSEMBLY (INCLUDES ITEMS 42 & 45-48) 2 42 LL PLANETARY SPIDER & THRUST BUTTON ASSEMBLY (INCLUDES ITEMS 43 & 44) 2 43 LL THRUST BUTTON 6 44 LL THRUST BUTTON 2 PAGE 2-66

67 FRONT AXLE ASSEMBLY (SHAFT HUB AND STEERING ASSEMBLY), LL ITEM PART NUMBER DESCRIPTION REQ D 45 LL THRUST WASHER 6 46 LL PLANETARY PINION (19T) 6 47 LL THRUST WASHER 6 48 LL SHAFT & O-RING SERVICE ASSEMBLY, PLANET PINION (INCLUDES ITEMS 49 & 50) 6 49 N.A. SHAFT, PINION (NSS, SEE ITEM 48) N.S.S. 50 LL O-RING 6 51 LL SET SCREW 6 52 LL WASHER LL CAPSCREW, PLANET SPIDER T. HUB LL PLUG 2 55 LL ASSEMBLY TIE ROD (CONSISTS OF ITEMS 56-58) 1 56 LL ASSEMBLY TIE ROD TUBE AND CLAMPS 1 57 LL TIE ROD END-RH SIDE 1 58 LL TIE ROD END-LH SIDE 1 59 LL COTTER, TIE ROD END 2 60 LL NUT, SLOTTED 2 PAGE 2-67

68 FRONT AXLE ASSEMBLY (CALIPER ASSEMBLY), LL ITEM PART NUMBER DESCRIPTION REQ D 1 LL BRAKE CALIPER ASSEMBLY 2 2 LL WASHER, HARDENED 8 3 LL CAPSCREW 8 PAGE 2-68

69 NOTES PAGE 2-69

70 FRONT AXLE ASSEMBLY (BRAKE CALIPER ASSEMBLY, LL ), LL PAGE 2-70

71 FRONT AXLE ASSEMBLY (BRAKE CALIPER ASSEMBLY, LL ), LL ITEM PART NUMBER DESCRIPTION REQ D LL HOUSING, BRAKE LL RING, BACKUP LL O-RING LL DUST SEAL LL PISTON LL O-RING LL CAP, FIN LL ASSEMBLY-BRAKE PAD (STD + 2 MM) LL PLATE, FIN LL BOLT/CAPSCREW LL PLUG LL SCREW, BLEEDER 2 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-71

72 REAR AXLE ASSEMBLY (CARRIER ASSEMBLY), LL LL SERVICE KIT-RS145 CARRIER (CON- SISTS OF ITEMS 3, 6, 7, 13-18, 23 & 41) PAGE 2-72

73 REAR AXLE ASSEMBLY (CARRIER ASSEMBLY), LL ITEM PART NUMBER DESCRIPTION REQ D 1 LL CARRIER ASSEMBLY, 6.83 RATIO (INCLUDES ITEMS 2-41) N.A. 2 LL DIFFERENTIAL CARRIER AND CAP ASSEMBLY 1 3 LL KIT-SHIM 1 4 LL WASHER, FLAT 8 5 LL CAP SCREW M12 X 17.5 X LL CONE-BEARING 2 7 LL CUP-BEARING 2 8 LL BEARING ADJ. RING 2 9 LL SCREW-SPECIAL 2 10 LL THRUST SCREW 1 11 LL JAM NUT 1 12 LL PINION CAGE ASSEMBLY (ALSO INCLUDES ITEMS 13 & 14) 1 13 LL INNER BEARING CUP 1 14 LL OUTER BEARING CUP 1 15 LL SEAL ASSEMBLY, OIL 1 16 LL INNER BEARING CONE 1 17 LL SPACER KIT 1 18 LL OUTER CONE BEARING 1 19 LL KIT, BOLT (INCLUDES 12 EACH OF ITEMS 20, 21 & 22) 1 20 LL CAP SCREW LL WASHER, HARDENED LL NUT LL ROLLER BEARING 1 24 LL ASSEMBLY-GEAR & PINION (INCLUDES RING & PINION ALONG WITH ITEMS 25 & 26) 1 25 LL WASHER 1 26 LL LOCK NUT 1 27 LL CASE-DIFF/NEST ASSEMBLY (SPIDERS AND CASE HALVES, INCLUDES ITEMS 28 & 33) 1 28 LL DIFFERENTIAL CASE ASSEMBLY (CASE HALVES W/O SPIDERS, INCLUDES ITEMS 29 & 32) 1 29 CASE, DIFF, FLANGE HALF N.S.S. 30 CASE, DIFF, PLAIN HALF N.S.S. 31 LL WASHER, FLAT LL CAP SCREW LL KIT-DIFFERENTIAL (INCLUDES ITEMS 34-38) 1 34 LL THRUST WASHER 2 35 GEAR, DIFF. SIDE N.S.S. 36 DIFFERENTIAL SPIDER N.S.S. 37 PINNION, DIFF. N.S.S. 38 LL THRUST WASHER 4 39 LL YOKE ASSEMBLY, INPUT (INCLUDES YOKE & ITEM 40) 1 40 LL DEFLECTOR 1 41 LL PILOT BEARING SNAP RING 1 PAGE 2-73

74 REAR AXLE ASSEMBLY (HOUSING ASSEMBLY), LL ITEM PART NUMBER DESCRIPTION REQ D 1 LL ASSEMBLY-AXLE HOUSING (ALSO INCLUDES ITEMS 2-12) N.A. 2 LL CAPSCREW.62-11X LL CAPSCREW X LL MAGNET 6 5 LL BUSHING 4 6 LL UNIVERSAL JOINT BUSHING 2 7 LL OIL SEAL 2 8 LL OIL FILLER PLUG 3/4 X 14 PTF 1 9 LL PLUG 1 10 LL BREATHER ASSEMBLY 1 11 LL HARDENED WASHER 12 PAGE 2-74

75 NOTES PAGE 2-75

76 REAR AXLE ASSEMBLY (SHAFT HUB AND STEERING ASSEMBLY), LL PAGE 2-76

77 REAR AXLE ASSEMBLY (SHAFT HUB AND STEERING ASSEMBLY), LL PAGE 2-77

78 REAR AXLE ASSEMBLY (SHAFT HUB AND STEERING ASSEMBLY), LL ITEM PART NUMBER DESCRIPTION REQ D 1 LL KNUCKLE, STEERING (RH) 1 2 LL KNUCKLE, STEERING (LH) 1 3 LL STEERING KNUCKLE CAP 4 4 LL SEAL, GREASE 4 5 LL SHIM (.003) 12 6 LL SHIM (.005) 8 7 LL SHIM (.020) 4 8 LL CAPSCREW 16 9 LL WASHER, HARDENED LL GREASE FITTING 4 11 LL UNIVERSAL JOINT ASSEMBLY (RH) 1 12 LL KIT, CENTER PARTS 2 13 LL OUTER AXLE SHAFT 2 14 LL INNER AXLE SHAFT (RH) 1 15 LL UNIVERSAL JOINT ASSEMBLY (LH) 1 16 LL INNER AXLE SHAFT (LH) 1 17 LL STOP SCREW 2 18 LL JAM NUT 2 19 LL SPINDLE ASSEMBLY (INCLUDES ITEMS 20 & 21) 2 20 LL BUSHING 2 21 LL OIL SEAL 2 22 LL WASHER LL CAPSCREW, SPINDLE TO KNUCKLE LL CAPSCREW, BRAKE DISC TO HUB LL WASHER, FLAT LL BRAKE DISC 2 27 LL OIL SEAL 2 SEE NOTE 28 LL WHEEL HUB INNER BEARING CONE 2 29 LL WHEEL HUB (INCLUDES ITEMS 30 & 31) 2 SEE NOTE 30 LL WHEEL HUB INNER BEARING CUP 2 31 LL WHEEL HUB OUTER BEARING CUP 2 32 LL STUD, WHEEL LL WHEEL HUB OUTER BEARING CONE 2 34 LL HUB, PLANETARY RING GEAR 2 35 LL PLANETARY RING GEAR (52T) 2 36 LL NUT, SPINDLE (NSS, SEE LL ) 2 37 LL RETAINING SCREW, SPINDLE NUT 2 38 LL WASHER 2 39 LL GEAR, PLANETARY SUN 2 40 LL SNAP RING 2 41 LL PLANETARY SPIDER, PINION, SHAFT & THRUST WASHER SERVICE ASSEMBLY (INCLUDES ITEMS 42 & 45-48) 2 42 LL PLANETARY SPIDER & THRUST BUTTON ASSEMBLY (INCLUDES ITEMS 43 & 44) 2 43 LL THRUST BUTTON 6 44 LL THRUST BUTTON 2 PAGE 2-78

79 REAR AXLE ASSEMBLY (SHAFT HUB AND STEERING ASSEMBLY), LL ITEM PART NUMBER DESCRIPTION REQ D 45 LL THRUST WASHER 6 46 LL PLANETARY PINION (16T) 6 47 LL THRUST WASHER 6 48 LL SHAFT & O-RING SERVICE ASSEMBLY, PLANET PINION (INCLUDES ITEMS 49 & 50) 6 49 LL SHAFT, PINION (NSS, SEE ITEM 48) N.S.S. 50 LL O-RING 6 51 LL SET SCREW 6 52 LL WASHER LL CAPSCREW, PLANET SPIDER T. HUB LL PLUG 2 55 LL ASSEMBLY TIE ROD (CONSISTS OF ITEMS 56-58) 1 56 LL ASSEMBLY TIE ROD TUBE AND CLAMPS 1 57 LL TIE ROD END-RH SIDE 1 58 LL TIE ROD END-LH SIDE 1 59 LL COTTER, TIE ROD END 2 60 LL NUT, SLOTTED 2 NOTE: EARLY MODELS USED A DIFFERENT HUB AND OIL SEAL THAN THE ONES SHOWN HERE. THIS NEWER HUB AND SEAL WILL WORK ON THESE AXLES. THE OLD SEAL AND HUB ARE NO LONGER AVAILABLE. PAGE 2-79

80 REAR AXLE ASSEMBLY (CALIPER ASSEMBLY), LL ITEM PART NUMBER DESCRIPTION REQ D 1 LL BRAKE CALIPER ASSEMBLY 2 2 LL WASHER, HARDENED 8 3 LL CAPSCREW 8 PAGE 2-80

81 NOTES PAGE 2-81

82 REAR AXLE ASSEMBLY (BRAKE CALIPER ASSEMBLY, LL ), LL PAGE 2-82

83 REAR AXLE ASSEMBLY (BRAKE CALIPER ASSEMBLY, LL ), LL ITEM PART NUMBER DESCRIPTION REQ D LL HOUSING, BRAKE LL RING, BACKUP LL O-RING LL DUST SEAL LL PISTON LL O-RING LL CAP, FIN LL ASSEMBLY-BRAKE PAD (STD + 2 MM) LL PLATE, FIN LL BOLT/CAPSCREW LL PLUG LL SCREW, BLEEDER 2 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-83

84 CYLINDER ASSEMBLY, FL PAGE 2-84

85 CYLINDER ASSEMBLY, FL ITEM PART NUMBER DESCRIPTION REQ D 1 FL-8959 COLLAR-4.00 BORE 1 2 LL FTG-GREASE ZERK 1 3 BL-9963 HEAD 1 4 LL INNER RACE-1.50IDX1.75ODX1.0W 2 5 LL INNER RACE-1.50IDX1.75ODX1.25W 1 6 LL MODULAR BACK-UP 1 7 LL NUT-NYLOCK_HEX-1.25NF 1 8 LL O RING - HEAD 1 9 LL O-RING-1.25 ID X.12W 1 10 BL-9929 PISTON-4.0 BORE-1.25X3.75 STUB 1 11 LL PLUG-PROTECTIVE 2 12 LL RING-BACK UP 1 13 LL SEAL-POLYHONE-PISTON 1 14 LL SEAL-POLYPAK ROD 1 15 LL SET SCREW.38NC X FL SPACER-2.875ODX.375WX2.125LG 1 17 LL WEAR RING-PISTON 2 18 LL WEAR RING-ROD 1 19 LL WIPER-ROD DIA ROD 1 20 FL WLDMT-CYL-SFT2.0X18.00LG 1 21 FL WLDMT-CYL-TUBE-4.00 BORE X LL COMPLETE SEAL KIT (CONSISTS OF ITEMS 6, 8, 9, 12, 13, 14, 17, 18, & 19) SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-85

86 STEERING CYLINDER ASSEMBLY, FL PAGE 2-86

87 STEERING CYLINDER ASSEMBLY, FL ITEM PART NUMBER DESCRIPTION REQ D 1 FL-8959 COLLAR-4.00 BORE 1 2 LL FTG-LUBE-1/8NPT-STR 1 3 BL-9963 HEAD 1 4 LL INNER RACE-1.50IDX1.75ODX1.0W 2 5 LL INNER RACE-1.50IDX1.75ODX1.25W 1 6 LL MODULAR BACK-UP 1 7 LL NUT-NYLOCK_HEX-1.25NF 1 8 LL O RING - HEAD 1 9 LL O-RING-1.25 ID X.12W 1 10 BL-9929 PISTON-4.0 BORE-1.25X3.75 STUB 1 11 LL PLUG-PROTECTIVE 2 12 LL RING-BACK UP 1 13 LL SEAL-POLYHONE-PISTON 1 14 LL SEAL-POLYPAK ROD 1 15 LL SET SCREW.38NC X FL SPACER-2.875ODX.375WX9.875LG 1 17 LL WEAR RING-PISTON 2 18 LL WEAR RING-ROD 1 19 LL WIPER-ROD DIA ROD 1 20 LL WIPER-ROD-CANNED-1.50SFT 2 21 FL WLDMT-CYL-SFT2.0X25.75LG 1 22 FL WLDMT-CYL-TUBE-4.00 BORE X LL SEAL KIT (CONSISTS OF ITEMS 6, 8, 9, 12, 13, 14, 17, 18, & 19) SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-87

88 FRONT CRADLE INSTALLATION, FL PAGE 2-88

89 FRONT CRADLE INSTALLATION, FL ITEM PART NUMBER DESCRIPTION REQ D 1 LL BUSH-BRONZE 5.0 OD X.25W X LL WIPER-CANNED ROD-J SERIES 4 3 FL WLDMT-FRONT CRADLE 1 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-89

90 REAR CRADLE ASSEMBLY, FL PAGE 2-90

91 REAR CRADLE ASSEMBLY, FL ITEM PART NUMBER DESCRIPTION REQ D 1 LL BUSH-BRZ-3.50ODX.25X LL WIPER-CANNED ROD-3 ID 4 3 FL WLDMT-REAR CRADLE 1 PAGE 2-91

92 SWAY CYLINDER ASSEMBLY, AL PAGE 2-92

93 SWAY CYLINDER ASSEMBLY, AL ITEM PART NUMBER DESCRIPTION REQ D 1 LL BUSH.-2.5 OD X 2.0 ID X FL-8548 COLLAR-4.5 CYL BORE 1 3 LL FTG-LUBE-1/8NPT-STR 2 4 BL-9990 HEAD-4.5BORE CYL/2.0SFT 1 5 LL MODULAR BACK-UP 1 6 LL O-RING-1.25 ID X.12W 1 7 LL O-RING-HEAD 1 8 LL PIN-COTTER 1/4 X 2.50 LG 1 9 BL-9871 PISTON-4.5BORE 1 10 LL PROTECTIVE PLUG 2 11 LL RING-BACK-UP-HEAD 1 12 LL SEAL-POLYHONE 1 13 LL SEAL-POLYPAK ROD 1 14 LL SET SCREW.38NC X LL WEAR RING-PISTON 2 16 LL WEAR RING-ROD 1 17 LL WIPER-CANNED ROD-J SERIES 2 18 LL WIPER-ROD DIA ROD 1 19 AL WLDMT-CYL TUBE 4.50 BORE X BL WLDMT-SFT CYL 2.00 OD X FL WLDMT-STOPPER_1.25 STUB 1 LL COMPLETE SEAL KIT CONSISTS OF ITEMS 5, 6, 7, 11, 12, 13, 15, 16, & 18 PAGE 2-93

94 DRIVE SHAFT INSTALLATION, FL PAGE 2-94

95 DRIVE SHAFT INSTALLATION, FL ITEM PART NUMBER DESCRIPTION REQ D 1 BL ASSY-DRIVE SFT 6C 3 OD X BL ASSY-DRIVE SFT 7C 3.5OD X BL ASSY-DRIVESFT 7C 3.5OD X PAGE 2-95

96 ENGINE DRIVE SHAFT ASSEMBLY, BL ITEM PART NUMBER DESCRIPTION REQ D 1 LL CROSS & BEARING ASSEMBLY 1 1A LL SEAL, BEARING 4 1B* BEARING (BLOCK TYPE), 2 EA. ASSY N. S. S. 1C* BEARING(WING TYPE), 2 EA. ASSY N. S. S. 1D* CROSS N. S. S. 1E FITTING, ALEMITE GREASE, 1/4 NFT 1 2 LL CROSS & BEARING ASSY 1 2A LL SEAL, BEARING 4 2B* BEARING (WING TYPE), 4 EA. ASSY N. S. S. 2C* CROSS N. S. S. 2D FITTING, ALEMITE GREASE, 1/4 NFT 1 3 LOCKWASHER, 7/ LL CAPSCREW 8 5 FL DRIVE SHAFT 1 6 LL SLIP YOKE ASSY 1 7 LL CAP, RETAINER 1 8 LL WASHER, RETAINER 2 9 LL WASHER, FELT 1 10 LL YOKE, SLIP 1 11* FITTING, ALEMITE GREASE, 1/8 NPT 1 12 LL CAPSCREW 4 * CROSS & BEARING NOT SOLD SEPARATEL, EXCEPT FOR BEARING SEALS * CHECK FOR PIPE PLUG - BEFORE ASSY, BE SURE IT HAS ALEMITE FITTINGS IN PLACE OF PLUG. PAGE 2-96

97 DRIVE SHAFT ASSEMBLY, BL ITEM PART NUMBER DESCRIPTION REQ D BL UNIVERSAL DRIVE SHAFT ASSEMBLY REF 1 LL CROSS & BEARING ASSEMBLY 1 1A LL SEAL, BEARING 4 1B* BEARING (BLOCK TYPE), 4 EA ASSEMBLY NSS 1C* CROSS NSS 1D* LL FITTING, ALEMITE GREASE, 1/4 NPT 1 2 LL CROSS & BEARING ASSEMBLY 1 2A LL SEAL, BEARING 4 2B* BEARING (BLOCK TYPE), 4 EA ASSEMBLY NSS 2C* CROSS NSS 2D* LL FITTING, ALEMITE GREASE, 1/4 NPT 1 3 LL SLIP YOKE ASSEMBLY 1 4 BL DRIVE SHAFT 1 5 LL CAPSCREW 16 6 LL LOCKWASHER, 1/ LL YOKE, SLIP 1 9 LL WASHER, RETAINER 2 10 LL WASHER, FELT 1 11 LL CAP, RETAINER 1 16 LL FITTING, ALEMITE GREASE 1/8 NPT 1 PAGE 2-97

98 REAR AXLE DRIVESHAFT ASSEMBLY, BL ITEM PART NUMBER DESCRIPTION REQ D 1 LL CROSS & BEARING ASSEMBLY 1 1A* LL SEAL BEARING 4 1B* BEARING (BLOCK TYPE) 4 EA. ASSY N. S. S. 1C* CROSS N. S. S. 1D* FITTING, ALEMITE GREASE 1/4 NFT 1 2 LL CROSS & BEARING ASSEMBLY 1 2A LL SEAL, BEARING 4 2B* BEARING, (BLOCK TYPE) 4 EA ASSY N. S. S. 2C* CROSS N. S. S. 2D* FITTING, ALEMITE GREASE, 1/4 NFT 1 3 LOCKWASHER, 7/ LL CAPSCREW 8 5 BL DRIVE SHAFT 1 6 LL SLIP YOKE ASSEMBLY 1 7 LL CAP, RETAINER 1 8 LL WASHER, RETAINER 2 9 LL WASHER, FELT 1 10 LL YOKE, SLIP 1 11* FITTING, ALEMITE GREASE, 1/8 NPT 1 12 LL CAPSCREW 8 * CROSS & BEARING NOT SOLD SEPARATELY, EXCEPT FOR BEARING SEALS #CHECK FOR PIPE PLUG - BEFORE ASSEMBLY, BE SURE IT HAS ALEMITE GREASE FITTING IN PLACE OF PLUG. PAGE 2-98

99 AIR CLEANER INSTALLATION, FL ITEM PART NUMBER DESCRIPTION REQ D 1 0L INDICATOR-AIR RESTRICTOR 1 2 0LA SCR-DRILL & TAP_10-16X FL TUBE-AIR 4.00 OD X 16GA 1 4 LL CAPSCR-HEX-.38NCX LL NIPPLE-CLOSE-1/8NPT-SCH_ LL-6429 TUBE-AIR CLEANER EXTENSION 1 7 LL NUT-NYLOCK HEX-.38NC 4 8 LL ELBOW-5-4 REDUCING LL CLAMP T-BOLT LL CLAMP T-BOLT LL INLET-HOOD 1 12 LL ASSY-AIR CLEANER 1 13 LL BAND-AIR CLEANER 2 14 LL HOSE-4 HUMP-STR LLH WASH-FL-.38_HARD 4 PAGE 2-99

100 AIR CLEANER ASSY, LL ITEM PART NUMBER DESCRIPTION REQ D 1 LL BAND-AIR CLEANER 2 2 LL COVER-AIR CLEANER 1 3 LL FILTER-ELEMENT-PRIMARY 1 4 LL FILTER-ELEMENT-SAFETY 1 5 LL GASKET-COVER 1 6 NSS HOUSING 1 7 LL VLV-VACUATOR 1 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-100

101 NOTES PAGE 2-101

102 AIR INTAKE PRECLEANER AND DASH INSTALLATION, FL PAGE 2-102

103 AIR INTAKE PRECLEANER AND DASH INSTALLATION, FL ITEM PART NUMBER DESCRIPTION REQ D 1 0L INDICATOR-AIR RESTRICTOR 1 2 0LA SCR-DRILL & TAP_10-16X FL TUBE-AIR 4.00 OD X 16GA 1 4 FL WLDMT-TUBE-AIR-INTAKE 1 5 FL MTG HOLES-REMOTE INDICATOR MNT 1 6 LL CENTRI_PRECLEANER 1 7 LL CAPSCR-HEX-.25NC X LL CAPSCR-HEX-.38NCX LL NUT-NYLOCK HEX-.38NC 4 10 LL NUT-NYLOCK HEX-.25NC 2 11 LL ELBOW-5-4 REDUCING LL ASSY-HOSE REMOTE FILT IND 1 13 LL CLAMP T-BOLT LL CLAMP T-BOLT LL ADPT-ELL 90 2MNPT-4MJIC 1 16 LL ADPT-45 1/8MNPT-4MJIC 1 17 LL ASSY-AIR CLEANER 1 18 LL BAND-AIR CLEANER 2 19 LL FLG-REMOTE INDICATOR MNT 1 20 LL HOSE-4 HUMP-STR LLH WASH-FL-.25_HARD 4 22 LLH WASH-FL-.38_HARD 4 PAGE 2-103

104 AIR INTAKE WITH PRECLEANER, FL PAGE 2-104

105 AIR INTAKE WITH PRECLEANER, FL ITEM PART NUMBER DESCRIPTION REQ D 1 0L INDICATOR-AIR RESTRICTOR 1 2 0LA SCR-DRILL & TAP_10-16X FL TUBE-AIR 4.00 OD X 16GA 1 4 FL WLDMT-TUBE-AIR-INTAKE 1 5 LL CENTRI_PRECLEANER 1 6 LL CAPSCR-HEX-.38NCX LL NIPPLE-CLOSE-1/8NPT-SCH_ LL NUT-NYLOCK HEX-.38NC 4 9 LL ELBOW-5-4 REDUCING LL CLAMP T-BOLT LL CLAMP T-BOLT LL ASSY-AIR CLEANER 1 13 LL BAND-AIR CLEANER 2 14 LL HOSE-4 HUMP-STR LLH WASH-FL-.38_HARD 4 PAGE 2-105

106 EXHAUST INSTALLATION, FL PAGE 2-106

107 EXHAUST INSTALLATION, FL ITEM PART NUMBER DESCRIPTION REQ D 1 0LA SCR-DRILL & TAP_10-16X FL TUBE-ELBOW EXHAUST 4 X 90 DEG. 1 3 LL CLAMP-MUFFLER-3.0IN 1 4 LL ASSY-CLMP-EXHAUST-4IN 2 5 LL CAPSCR-HEX-.38NCX LL-6624 PIPE-TAIL 1 7 LL WASH-.38 X 1.5 X LL ASSY- MNT EXH ISOLATION 4 9 LL NUT-NYLOCK HEX-.38NC 4 10 LL MUFFLER-4.0 INLET 1 11 LL CLMP-BAND MUFFLER 2 12 LL REDUCER-EXHAUST ALUMINIZED 1 13 LLH WASH-FL-.38_HARD 4 14 LLH WASH-FL-.75_HARD 4 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-107

108 RADIATOR SHROUD INSTALLATION, FL PAGE 2-108

109 RADIATOR SHROUD INSTALLATION, FL ITEM PART NUMBER DESCRIPTION REQ D 1 FL BRKT-RAD MNT 2 2 FL BAFFLE-FOAM 1 3 FL RUBBER PAD 2 4 FL SHROUD-RAD 1 5 LL ASSY-RAD 1 6 LL CAPSCR-HEX-.31NC X LL CAPSCR-HEX-.38NCX LL NUT-NYLOCK HEX-.38NC 10 9 LLH WASH-FL-.31-HARD 8 10 LLH WASH-FL-.38_HARD 10 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-109

110 COOLING CIRCUIT, FL PAGE 2-110

111 COOLING CIRCUIT, FL ITEM PART NUMBER DESCRIPTION REQ D 1 LL ADAPTER-90 DEG MNPT-1.0 OD HOSE BARB 1 2 LL ADAPTER-PIPE.75 MNPT-.75 MNPT 2 3 LL ADAPTER-PIPE 90 DEG.75 MNPT-.75 FNPT 1 4 LL ADPT-1/4MNPT-6MIJC 1 5 LL ASSY-04 HOSE-NONE-04FJIC X LL ASSY-06 HOSE-NONE-06FJIC X LL BOOT-CHARGE AIR COOLER 4 8 FL BRACE-CHARGE AIR COOLING 4 9 LL BRASS REDUCER BUSH 1/4-1/8NPT 1 10 LL CLMP-CAC 8 11 LL CLMP-HOSE LL CLMP-HOSE LL CLMP-HOSE LL CONNECTOR-HOSE 1.0 ID 1 15 LL HOSE-1.0 X LL HOSE-1.0 X LL HOSE-1.75 X LL HOSE-2.25 X LL HOSE-RADIATOR 1.0 ID 1 20 LL NUT-HEX-.25UNF 8 21 LL NUT-NYLOCK HEX-.25NF 8 22 LL PETCOCK 1 23 LL SLEEVE-HOSE 2.86 ID X LL SLEEVE-HOSE 2.86 ID X LL SLEEVE-HOSE 2.86 ID X FL TUBE-ENGINE AIR IN 1 27 FL TUBE-ENGINE AIR OUT 1 SERVICE BULLETIN REFERENCE NUMBER DATE SUBJECT CHANGE PAGE 2-111