More time on the road. Illustrated Parts List

Transcription

1 More time on the road Illustrated Parts List RT-909A-AT November 00

2 Contents How To Use The Illustrated Parts List... AIR SYS-POWER SYNCHRO... AIR SYS-RANGE... AUXILIARY DRIVE GEAR... BAR HOUSING ASSY... CASE (AUX)... CASE (FRONT)...9 CONVERTER HOUSING ASSY...0 COUNTERSHAFT & BRGS(AUX)... COUNTERSHAFT ASSY... ECU CONTROLS... AUTO SHIFTER ASSY... ECU CONTROLS... BAR HOUSING COVER ASSY... FILTER REGULATOR... HARNESSES & HARDWARE... HARNESS ASSY-TORQUE CONV... HARNESSES & HARDWARE...9 HARNESS ASY-AUTO SHIFTER...9 INPUT SHAFT & DRIVE GEAR...0 KITS & ASSEMBLIES... MAINSHAFT & SYNCHRO(AUX)... MAINSHAFT ASSY... MISCELLANEOUS... OIL LINE RETURN... OIL LINE RETURN/CURRENT... OIL LINE RETURN... OIL LINE RETURN/NON-CURR... OIL LINES-POWER SYNCHRO... POWER SYNCHRONIZER...9 RANGE CYLINDER...0 REVERSE IDLER... STATOR SUPPORT ASSY... TORQUE CONVERTER ASSY... Appendix...

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: AIR SYS-POWER SYNCHRO 0--9 AIR SYS-POWER SYNCHRO 0 ELBOW /" HOSE ASSY " HOSE ASSY 9" 9 HOSE CLAMP ELBOW /"

5 Group: AIR SYS-RANGE AIR SYS-RANGE K-99 RANGE VALVE KIT A - GASKET K-,K-99 9 PLUG 000 INSERT VALVE,0 X--00 LOCKWASHER /" X-- SCREW /"-X" 0 ELBOW /" 0 HOSE ASSY " 9 NO LONGER AVAILABLE -/" 0 0 ELBOW /" ELBOW /"

6 Group: AUXILIARY DRIVE GEAR 9 0-/9 Aux DG AUXILIARY DRIVE GEAR SNAP RING K-90,K-9 0 SNAP RING RETAINER RTO ONLY SNAP RING K-9 0- BEARING 0,0 K-90 BOX BEARING RETAINER X-- CAPSCREW X /"-X" -O- RING K-90,K-0,K- 9 K- NO LONGER AVAILABLE 009

7 Group: BAR HOUSING ASSY BAR HOUSING ASSY K- SHIFT BAR HSG ASSY 9 HOUSING ONLY 0 GASKET 9 K-,K-,S- 09 SPRING K-9,S- X--00 STEEL BALL /" 900 GASKET K-,S- 9 SHIFT SENSOR SWITCH K-,S- 9 ACTUATING SWITCH PIN S- X--9 CAPSCREW /"-X" 9 ROLL PIN S- 0 K-90 SENSOR UPDATE KIT,K - X--0 PLUG K- NEUTRAL SWITCH KIT 0 9 ACTUATING SHAFT 0 K-,S- SWITCH 0 SPRING S- 00 YOKE BAR LOW/REVERSE S- 0 LOCKSCREW S- YOKE LOW/REVERSE S- 9 YOKE BAR ST/ND S SHIFT YOKE 099 ST/ND S- SHIFT BLOCK ST/ND S- 9 YOKE BAR RD/TH S- 0 SHIFT BLOCK 0 RD/TH S- 90 SHIFT YOKE 0 RD/TH S- 999 S- SHIFT BAR HSG ASSY 9 COMPLETE

8 Group: CASE (AUX) * OEM supplied adjustable speedometer sensor OEM supplied non-adjustable speedometer sensor * Note Items & / Magnetic Speedometer Openings: Use 9 "O" ring w/ OEM supplied adjustable speedometer sensor and 0 "O" ring w/ OEM supplied non-adjustable speedometer sensor or Eaton part #0 Plug CASE (AUX) K- OIL SEAL TOOL KIT K- OIL SEAL W/SLINGER ,00 "FOR MECHANICAL COVER" K-90 X-L-0 CAPSCREW /"-X" S- NO LONGER AVAILABLE 00 LIFTING EYE GASKET K-,K- 0 PLUG-MAGNETIC 0 -O- RING USE W/0 PLUG OR OEM SUPPLIED NON-ADJUSTABLE SPEEDOMETER SENSOR NOT TO BE USED WITH 09 SEAL 09 SENSOR SEAL O-RING NOT REQUIRED 9 0 PLUG-MECHANICAL 0 -O- RING 99 BUSHING X-L-0 CAPSCREW /"-X-/" 9 REAR BEARING COVER 0 GASKET K- 00 REAR HOUSING GASKET K- X--0 CAPSCREW /"-X-/" X-L-09 CAPSCREW 0 /"-X-/" X-L- CAPSCREW /"-X" 909 COLLAR K-,K- 9 0 GASKET K-,K- 0 X-- CAPSCREW /"-X"

9 Group: CASE (FRONT) CASE (FRONT) S- CASE ASSY MAGNET S- X-- CAPSCREW /"-X/" PTO COVER GASKET K- X--00 NUT X 000 /"- X-0-00 WASHER X 000,X X.0,X0 00 STUD,9 /" X -/" 9 X-- CAPSCREW X /"-X/" PTO COVER 9,00 00 GASKET 00 K- 0 GASKET K-,K-0,K- X--0 PIPE PLUG X 00 /" 00 PLUG 0 -/" MAGNETIC, O-RING INCLUDED X--0 PIPE PLUG X 0,X 0 /" MAGNETIC 00 STUD 9 X-0-00 WASHER X 000,X X.0,X X--00 NUT X 000 /"- 0 9 STUD DOWEL X--0 CAPSCREW /"-X-/" X-0-0 NO LONGER AVAILABLE /" PLAIN 00 PLUG 0 -/" MAGNETIC, O-RING INCLUDED X--00 PIPE PLUG X 00 S- S- 9

10 Group: CONVERTER HOUSING ASSY A CONVERTER HOUSING ASSY X--9 CAPSCREW /"-X-/" X-L- CAPSCREW /"-X-/" X-L- CAPSCREW /"-X-/" A- VALVE ASSY X--0 PIPE PLUG /" GASKET K-,K-9R,K- NO LONGER AVAILABLE GASKET K-,K-9R,K- X--0 PIPE PLUG X 00 /" 00 ELBOW O- RING K-,K- 0 X-L- CAPSCREW /"-X" LIFTING EYE 90 DEG. K- ENG SPEED SENSOR KIT 9 0 -O- RING K-,K- INSTRUCTION TAG X--0 SCREW /"-0X" K-9 OIL PUMP KIT 00,0 X-C-0 CAPSCREW /"-X-/" 9 SEAL RING 0 K-0,K-,K O- RING K-0,K-,K FILTER BOWL X--0 SCREW X 0 /"-X-/" X--0 CONICAL WASHER /" 0 OIL FILTER K- 0 -O- RING K-,K- NIPPLE A- RELIEF VALVE ASSY K- 0

11 09 -O- RING K- 0 PLUG 9 GASKET K-,K-,K- 0,K- 0 X--0 CONICAL WASHER /" X--0 CAPSCREW /"-X" PT 00 OIL TRANSFER TUBE 00 K-0 MAGNET S- 00 OIL PAN 00 WASHER 00 DRAIN PLUG X--0 CONICAL WASHER 0 /" X--0 CAPSCREW 0 /"-X" PT O- RING K-,K- 0 CONNECTOR 000 OIL FILL TUBE STANDARD 000 DIPSTICK 000 STANDARD 09 -O- RING K- A- VALVE ASSY K- 00 CAP K- # CONVERTER HSG KIT SNAP RING K-9 0 PUMP GEAR 9 X--00 NUT /" SEAL RING K-,K-99,K-0 A-9 FILTER BYPASS VALVE A - 0 A - 9 K-9R,K- ASSY X--0 CAPSCREW /"-X/" 00 CLAMP K-,K-,K- X-0-0 WASHER /" X-9-0 NUT /"- 0 ELBOW /"

12 Group: COUNTERSHAFT & BRGS(AUX) 0-/9 Aux CS COUNTERSHAFT & BRGS(AUX) 9 BEARING K-90 A- WELDED A -,A - 9 C/S D/G 9 COUNTERSHAFT ASSY 0 BEARING 00 K-90 SNAP RING K-90,K-9

13 Group: COUNTERSHAFT ASSY /9 CS/RT COUNTERSHAFT ASSY SNAP RING K-90,K-9 BEARING K-90 K-9 CNTRSHFT-UPPER 99 K- CNTRSHFT-LOWER 00, 00, K-9 X--E KEY ROLL PIN 00 KEY 9 00 ST GEAR-CNTRSHFT 9,0 0 ND GEAR-CNTRSHFT RD GEAR-CNTRSHFT 90,9,09,00, PTO GEAR - LOWER 0 00 PTO GEAR - UPPER 0 DRIVE GEAR-CNTRSHFT 9,9,0,0,09 99 SNAP RING 099 BEARING 0 09 K RETAINER 9 ROLL PIN NO LONGER REQUIRED X--00 CAPSCREW /"-X-/"

14 Group: ECU CONTROLS Sub-Group: AUTO SHIFTER ASSY * 0 0 * * Indicates connection for Auto Shifter Harness Assembly ECU CONTROLS AUTO SHIFTER ASSY K-9 AUTO SHIFTER KIT A -,K - K-9R REMAN AUTOSHIFTER K - 00 KIT 9 -O- RING 90 GASKET 9 X-0-00 WASHER /" X--0 CAPSCREW /"-X-/" YOKE X--00 NUT /" SHIFT SENSOR SWITCH

15 D N P D N P Group: ECU CONTROLS Sub-Group: BAR HOUSING COVER ASSY 9 Option A Option B SOFTWARE NO. 9 Option C SOFTWARE NO. Eaton Eaton Note: Three bracket options are available for mounting shift cable item ECU CONTROLS BAR HOUSING COVER ASSY.00 AUTOSELECT ECU P/N CHART X--90 CAPSCREW /"-X" X-0-0 WASHER /" X--0 NUT /" SHIFT CONTROL LEVER / POSITION 000 SHIFT CONTROL LEVER POSITION 000 SHIFT INDICATOR PLATE POSITION 000 SHIFT INDICATOR PLATE POSITION 000 SHIFT INDICATOR PLATE POSITION WASHER WASHER X--0 NUT X BRACKET OPTION A - USE X--90 CAPSCREWS BRACKET OPTION C - USE X--90 CAPSCREWS BRACKET OPTION B - USE PCS 000 AND X--0 CAPSCREWS W/THIS BRACKET CLAMP U- BOLT X--00 CAPSCREW /"-X-/" X-- CAPSCREW 9 /"-X-/" 0 GASKET 9 BREATHER 9 BUSHING

16 X--0 PIPE PLUG 9 X-- CAPSCREW /"-X-/"

17 Group: FILTER REGULATOR NSS NSS Not Sold Separately FILTER REGULATOR K-9 -O- RING/ELEMENT KIT FOR FILTER REGULATOR 0 ELBOW X--0 PIPE PLUG /" NPT 0 ELBOW /" -O- RING K-0 9 A- FILTER REGULATOR - PSI K-0 ASSY 0 X--00 LOCKWASHER /" X--0 SCREW /"-0X-/"

18 NUTSIDE NUTSIDE Group: HARNESSES & HARDWARE Sub-Group: HARNESS ASSY-TORQUE CONV BYP INT Latest Design HARNESSES & HARDWARE HARNESS ASSY-TORQUE CONV A-9 HARNESS ASSY 009 SPACER 9 K-0 BRACKET KIT 00,0 0 X-L- CAPSCREW /"-X-/" CLAMP X--09 JAM NUT /"-0 X-0-0 WASHER /" K-0 BRACKET KIT 00,0

19 S S Group: HARNESSES & HARDWARE Sub-Group: HARNESS ASY-AUTO SHIFTER S P P P P HARNESSES & HARDWARE HARNESS ASY-AUTO SHIFTER K-9 AUTO SHIFTER KIT A -,K - 9

20 Group: INPUT SHAFT & DRIVE GEAR INPUT SHAFT & DRIVE GEAR 00 INPUT SHAFT OIL TUBE S- 90 SNAP RING 0 BEARING K-90 SPACER 0 SNAP RING K-90,K-9 0 DRIVE GEAR 90 PISTON RING K-99,K-0 0 PISTON RING K-99 9 S- INPUT SHAFT ASSY 0 0 BUSHING K-90,S- 0

21 KITS & ASSEMBLIES K-9 -O- RING/ELEMENT KIT FOR FILTER REGULATOR K- GASKET KIT K-90 K- OIL SEAL W/SLINGER ,00 "FOR MECHANICAL COVER" K-90 K-90 BASIC REBUILD KIT K-0 FILTER REGULATOR KIT K- OIL FILTER KIT K- AUTO-SHIFTER KIT K-9R REMAN HYDRA VALVE K - 0 KIT K-9R REMAN PWR SYNCHRO K - 0 A-RATIO KIT K-99 CONVERTOR SEAL KIT K-,K-R,K- 9R K-00R REMAN PWR SYNCHRO K - 0 B-RATIO KIT K-0 OIL PAN RETRO KIT STANDARD K-9 KEY & WASHER KIT CONTAINS -SIDED KEY K-0 OIL PUMP KIT K- POWER SYNCO LUBE KIT K- # CONVERTER HSG KIT 00 K-0 REPL KIT-DRIVE GEAR 00 B-RATIO K- ENG SPEED SENSOR KIT 9 K- BALL SWITCH KIT K- BOLT ROTATED LINE KIT K- BOLT OIL LINE KIT K- BOLT OIL LINE KIT K-R REMAN -B CNVTR KIT K - 0 K-9R REMAN -A CNVTR KIT K - K- SHIFT BAR HSG ASSY 9 HOUSING ONLY K-0 -O- RING KIT-RANGE K-90 K-9 SMALL PARTS KIT K- CYLINDER KIT-RANGE K- THROTTLE SENSOR KIT K - " CABLE K- THROTTLE SENSOR KIT K - 0 0" CABLE K- THROTTLE SENSOR KIT K - 0" CABLE K- SUMP TUBE RETURN KIT K - 0 K-9 OIL PUMP KIT 00,0 K-9 COUNTERSHAFT REPL 99 KIT K-90 SENSOR UPDATE KIT,K - K-9 AUTO SHIFTER KIT A -,K - K-9 AUTO-SHIFTER HARNESS K - 9 VOLT KI K-9 AUTO SHIFTER KIT A -,K - K-9R REMAN AUTOSHIFTER K - 00 KIT K- OIL SEAL TOOL KIT K- COUNTERSHAFT REPL 00,, 00, KIT K-9 S- INPUT SHAFT ASSY S- STATOR SUPPORT ASSY 9 S- CASE ASSY S- SHIFT BAR HSG ASSY 9 COMPLETE S- MAINSHAFT ASSY 00,09

22 Group: MAINSHAFT & SYNCHRO(AUX) Universal Joint Yoke MAINSHAFT & SYNCHRO(AUX) 9 SPRING K-90,K-9 A- SYNCHRONIZER ASSY 09,09,A - HI RANGE 9 9 SLIDING CLUTCH A- SYNCHRONIZER A - 9,A - LO RANGE ASSEMBLY 9 MAINSHAFT WASHER K WASHER K-9 9 NO LONGER AVAILABLE 9 SNAP RING K WASHER K-9 BEARING K SPACER NUT 9

23 Group: MAINSHAFT ASSY * * 9 * * 0 * Sided Key Design Hex (-Sided) Key Design * Updating to -Sided Key is Recommended. When Updating to -Sided Key Replace all Washers to Match Key Design Always Use Matching Key and Washer Sets (See Appendix - Mainshaft Washers) MAINSHAFT ASSY 0 -SIDED KEY 000 K-9 K-9 KEY & WASHER KIT CONTAINS -SIDED KEY S- MAINSHAFT ASSY 00,09 0 ROLL PIN S- 0 SNAP RING K-90,K-9 REVERSE GEAR- 0 MAINSHAFT 9 SPACER K-9 00 WASHER.9-WHITE K-9,K-9 00 WASHER.-GREEN OPTIONAL OR K-9,K USE ANY WASHERS. USE WITH -SIDED KEY 00 WASHER.9-ORANGE OPTIONAL OR K-9,K USE ANY WASHERS. USE WITH -SIDED KEY 00 WASHER.-PURPLE OPTIONAL OR 000 USE ANY WASHERS. USE WITH -SIDED KEY 00 WASHER.9-YELLOW OPTIONAL OR 000 USE ANY WASHERS. USE WITH -SIDED KEY 00 WASHER.-BLACK OPTIONAL OR 000 USE ANY WASHERS. USE WITH -SIDED KEY 000 WASHER.-BLUE K-9,K-9 SLIDING CLUTCH 9 LO GEAR-MAINSHAFT 0 09 ST GEAR-MAINSHAFT ND GEAR-MAINSHAFT 9 09 RD GEAR-MAINSHAFT 9

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25 MISCELLANEOUS 00 SHIFT DIAGRAM LABEL POS REVERSE FORWARD 00 SHIFT DIAGRAM LABEL POS REVERSE REARWARD 00 SHIFT DIAGRAM LABEL POS REVERSE FORWARD 00 SHIFT DIAGRAM LABEL POS REVERSE REARWARD 00 SHIFT DIAGRAM LABEL POS REVERSE FORWARD 0 SHIFT DIAGRAM LABEL POS REVERSE REARWARD 0 SILICONE LUBE OZ (.9 CC)-FLEET SIZE 0 ADHESIVE SEALANT 0. CC (SINGLE APPLICATION SIZE) 0 SEALANT CC (SINGLE APPLICATION SIZE) K-,K-90 0 SILICONE LUBE CC (SINGLE APPLICATION SIZE) K-,K-0,K-

26 Group: OIL LINE RETURN Sub-Group: OIL LINE RETURN/CURRENT OIL LINE RETURN OIL LINE RETURN/CURRENT 000 ELBOW 9 00 TUBE 9 CONNECTOR 09 -O- RING

27 Group: OIL LINE RETURN Sub-Group: OIL LINE RETURN/NON-CURR 0--9 OIL LINE RETURN OIL LINE RETURN/NON-CURR NO LONGER AVAILABLE ELBOW DEG. HOSE ASSY ELBOW 09 -O- RING

28 Group: OIL LINES-POWER SYNCHRO OIL LINES-POWER SYNCHRO HOSE ASSY K-,K- CONNECTOR STRAIGHT K-,K-,K- ELBOW 90 DEGREE K-,K-,K-,K- OIL RESTRICTOR K-,K-,K-,K- 9 CLAMP

29 Group: POWER SYNCHRONIZER POWER SYNCHRONIZER 0 K-9R REMAN PWR SYNCHRO K - 0 KIT 0 GASKET K-,K-9R,K- 00R ROLL PIN X-0-0 WASHER 9/" X-- CAPSCREW /"-0X-/" X-L- CAPSCREW /"-X-/" X-L- CAPSCREW /"-X" 9

30 Group: RANGE CYLINDER RANGE CYLINDER X-L-0 CAPSCREW /"-X-/" 990 CYLINDER COVER 9 GASKET K-,K-0,K- -O- RING K-0,K- PISTON K- X-L-0 CAPSCREW /"-X-/" X--00 NUT /"- -O- RING K-0,K YOKE BAR 0 BUSHING A- -O- RING K-0,K- A- RANGE CYLINDER ASSY K- GASKET K-,K-0,K- X-- CAPSCREW /"-X-/" 0 SHIFT YOKE BRACKET 0

31 Group: REVERSE IDLER Latest Design 9 0-/9 RI Old Design REVERSE IDLER X--00 NUT /"- WASHER K- 09 WASHER K-,S- BEARING 000 K-90 REVERSE IDLER GEAR 09 0 WASHER K- K- IDLER SHAFT REPL KIT 09 0 PLUG 9 NO LONGER AVAILABLE 0 RETAINING RING K- X--00 CAPSCREW /"-X-/

32 Group: STATOR SUPPORT ASSY 0A--9 STATOR SUPPORT ASSY 9 SEAL RING K-99,K-0 S- STATOR SUPPORT ASSY 9 GASKET K-,K-0,K-,S- X--00 STEEL BALL /" SPRING S- PLUG S- X-L- CAPSCREW X /"-X-/" X--0 PIPE PLUG /" NPT

33 Group: TORQUE CONVERTER ASSY TORQUE CONVERTER ASSY 0 X-- CAPSCREW X /"-X" 0 PILOT -O- RING K-99,K-0 9 SEAL RING K-99,K-0 9 SNAP RING K-99 K-R REMAN -B CNVTR KIT K - 0

34 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) 0 0 ft Splitter + Deep Reduction Blue (SP) + Green (H/L) 0 0 ft Supply + Splitter + Port Red(S)+Blue(SP)+ Black(P) 0 0 ft /" Air Lines Line Type Line Color Order Part No. Length Supply Red (S) 0 0 ft Port Black (P) 0 0 ft Splitter Blue (SP) 0 0 ft Deep Reduction Green (H/L) 0 0 ft Sheathing 00 0 ft /" Air Lines Line Type Line Color Order Part No. Length Supply White 0 ft Port Black 0 0 ft Sheathing ft 00-/9 AL Chart

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36 Copyright Eaton Corporation and Dana Limited, 00. 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 -00--HELP () hours a day, days a week (Mexico ), for more time on the road. Or visit our web site at 00 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.