More time on the road Illustrated s List FRLO-440C November 0
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
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 www.roadranger.com/epc. Model Designation or Nomenclature For information regarding Model Designation and Nomenclature, visit www.roadranger.com. 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
5 6 8 Group: CASE ASSY 8 5 4 6 4 5 8 4 4 0 0 9 9 8 0 5 6 6 4 5 0 6 0 4 8 9 08-6-99 CASE ASSY 0 406899 LUBE TAG 404885 NOT PICTURED - LOCATED BY FILL PLUG 0 K-650 RTV SERVICE KIT 556455 556455 FLANGE SEALANT K-6,S-8,S- 85 K-94 CLUTCH HOUSING 404,A-6 NON-NODAL MOUNT - ALUMINUM 4
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-94 4 40485 OIL TROUGH K-94 5 X-8-080M CAPSCREW M8 X.5 X MM K-94 6 4050 BUSHING (SHIFT ROD) 0085 K-94 4048 OIL DAM PLATE K-94 8 4049 COVER 9 40499 SPRING 0 40460 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 4046 4 55504 STUD M6 X X 5MM 5 X--606M SELF LOCKING HEX NUT X 60M,X 60M,X--605M M6 X.5 6 X-0-005 WASHER 8 4048 REVERSE SWITCH 9 40465 PIN 0 4040 PLUG 404 -/6" MAGNETIC, O-RING INCLUDED ONE FOR FILL OPENING ONE FOR DRAIN OPENING 4049 NEUTRAL SWITCH 40405 PIN 40489 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
06M 40496 SCREW 4 M0 X M8 8 4049 AUX COUNTERSHAFT COVER 9 405550 SIGHT PLUG (-5/8) 404 0 4040 SCREW 4 M0 X M8 455 PTO COVER 4054 4 MAGNET S-965 X--80 PIPE PLUG X 800 /" 4 X--08 PIPE PLUG /8" NPT 5 4048 PLUNGER 406 SPLITTER DETENT K-408 6 404 COMPRESSION SPRING K-408,K-40,K- 4 556850 -O- RING 8 4049 PLUG 6
Group: COUNTERSHAFT & BRGS(AUX) 4 5 0455-6-99 COUNTERSHAFT & BRGS(AUX) 40485 BEARING - INNER RACE 4 K-40,K-4 40484 BEARING - OUTER RACE 4 K-40,K-4 A-68 WELDED COUNTERSHAFT ASSY C/S 40459 - S/G 404 4 4044 BEARING K-40,K-4 5 404 RETAINING RING K-40,K-4
Group: COUNTERSHAFT ASSY 066-6-99 COUNTERSHAFT ASSY K-69 ROLLER BEARING KIT 4058 404 BEARING - INNER RACE K-40,K-4 A- WELDED COUNTERSHAFT ASSY 4049,4048,A - 66 C/S 40458 - D/G 4045 4TH/G - 4048 8
Group: ELECTRONIC CONTROL UNIT 5 6 05-6-99 ELECTRONIC CONTROL UNIT X-8C- 0809M CAPSCREW & WASHER 9 M8 X 0.0MM S-9RX REMAN EXCHANGE LIGHTNING ECU A - 699,A - 6999,S- 9 5 40486 SEAL PLATE K-40,K-4 6 4045 WASHER 95 BREATHER 9
Group: FILTER REGULATOR NSS -O- Ring/Element Kit 5 4 4 04-6-99 6 NSS - Not Sold Separately FILTER REGULATOR 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 5 4048 ELBOW 90 DEGREE 6 54 -O- RING 0
Group: INPUT SHAFT & DRIVE GEAR IMPORTANT DUE TO DESIGN CHANGES, PLEASE VERIFY THE PART NUMBER ON THE COMPONENT TO ENSURE PROPER PART REPLACEMENT INFORMATION 5 4 6 9 8 0 4 5 6 0-6-99 INPUT SHAFT & DRIVE GEAR 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-64 5568545 O-RING K-55,S-99 4 40565 OIL SEAL 4045 UNITS BUILT BEGINNING WITH S/N K0004 K-40,K-4,S- 99 4 K-64 CLUTCH INSTALLATION KIT 4040,4045,S - 968,K-654 UNITS BUILT PRIOR TO S/N K0004 5 K-55 SHIM KIT K - 40 K-64,K-40,K- 4 6 55550 BEARING CUP K-40,K-4,S- 99 555005 BEARING CONE K-64,K-40,K- 4 8 X-- SCREW K-64,K-40
0400M 9 4040 ECCENTRIC PUMP ASSY K-64,K-40 0 40564 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 K0004 4040 PISTON PUMP K-64,K-40 4044 SNAP RING 40554 MAIN DRIVE GEAR WASHER 4048 4 40466 MAIN DRIVE GEAR 4040 5 4048- BOX 6 404- BOX BEARING 4048 K-40,K-4 SPHERICAL WASHER 404 K-408 4040 SNAP RING K-408,K-40,K- 4
Group: INTEGRAL OIL COOLER 4 5 056-6-99 INTEGRAL OIL COOLER A-6899 FITTING ASSY 40440 /8" - INCLUDES ITEM & 085 -O- RING 4 A-6899 556858 -O- RING A-6899 4 404 OIL COOLER 5 X-8-080M CAPSCREW M8 X.5 X MM K-94
Group: ISOLATORS New Design 6 9 4 New Design 0 00--9 Isolator Indicates Of 0 ISOLATORS 94 -E- RING K-46 PIN REPLACEMENT KIT 45 46 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-6 4068 STUB LEVER MID TOWER K-98 9 6 90 DEG LEVER STRAIGHT " 0 K-99 ISOLATOR BUSHING KIT 44, X-8-560 SCREW X-9-50 NUT 4
KITS & ASSEMBLIES 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 - 6040 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 - 446 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 556455 556455 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 40564 INPUT SHAFT, 5
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 40404 S-8 MAINSHAFT ASSY - AUX. 40456 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-9RX REMAN EXCHANGE LIGHTNING ECU A - 699,A - 6999,S- 9 S-99 FRONT BRG COVER ASSY 405 UNITS BUILT BEGINNING WITH S/N K0004 K-64 6
Group: LEVERS/HOUSINGS 5 9 8 8 4 0 K-48 - Low K-98 - Mid S-6 - Low S-96 - Mid S-9 - Low S-59 - Mid 008-6-99 LEVERS/HOUSINGS K-6 O-RING & WASHER KIT 40 899 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 8 40594 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 - 6040 MID TOWER 5 04 BOOT K-46,K-9,S- 6
0 600 GEAR SHIFT LEVER STRAIGHT - LOW -/" 58 RETAINER K-46,K-9,S- 6 56 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
Group: MAINSHAFT & SYNCHRO(AUX) 6 5 8 4 9 0 049-6-99 MAINSHAFT & SYNCHRO(AUX) 40440 SLIDING CLUTCH 404- BOX 4048- BOX SPHERICAL WASHER 404 K-408 BEARING 4048 K-40,K-4 4 4046 AUXILIARY SPLITTER GEAR 5 489 SPRING K-49,K-49,K- 40,K-4 6 A- SYNCHRONIZER ASSY 40496 4049 A - 59 HI RANGE K-49,K-49 40840 SLIDING CLUTCH 4086 K-49 8 A-54 SYNCHRONIZER ASSEMBLY A - 49 A - 586 LO RANGE K-49,K-49 9 S-8 MAINSHAFT ASSY 40456 0 4049 SPACER 4046 REDUCTION GEAR 5556505 BEARING AVAILABLE FOR TRUCK DOWN ONLY 9
K-4 HEX FLANGE CRIMPED NUT KIT 40,40650 0
Group: MAINSHAFT ASSY 6 5 4 08-6-99 8 0 9 MAINSHAFT ASSY 4046 SLIDING CLUTCH 4044 S-80 MAINSHAFT ASSY 40404 6504 ROLL PIN S-80 4 4044 KEY K-408 5 4046 4TH GEAR-MAINSHAFT 6 40480 ST GEAR-MAINSHAFT 404 4048 WASHER 6 K-408 8 404 SLIDING CLUTCH 9 4040 AUXILIARY DRIVE GEAR 0 4040 REVERSE GEAR- MAINSHAFT 6980 SNAP RING
MISCELLANEOUS 55860 SHIFT DIAGRAM LABEL 55865 0 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 556455 556455 FLANGE SEALANT K-6,S-8,S- 85
Group: RANGE CYLINDER 8 6 5 4 9 0 46-6-99 RANGE CYLINDER X--00M NUT M0 X.5 HEX 404 PISTON K-405,K-40 404 YOKE BAR 4 46 SNAP RING K-405,K-40 5 40449 WASHER 6 556858 -O- RING K-405,K-406,K- 40 40458 PIN 8 A-0 RANGE YOKE ASSY 404 9 404 RETAINER A-0,A-0 0 40488 STEP WASHER 40466 A-0,A-0 X--0 SCREW
Group: REAR BEARING COVER OEM supplied adjustable speedometer sensor (Threaded) OEM supplied non-adjustable speedometer sensor (Non-Threaded) 5 4 9 4 6 40-6-99 REAR BEARING COVER S-50 SPEEDO ROTOR ASSY 404 MAGNETIC 55685 -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-85 550554 YOKE-0 HALF ROUND 5505545 YOKE-60 HALF ROUND 550554 YOKE-80 HALF ROUND 550555 YOKE-RPL5 HALF 4
ROUND 55055 YOKE-SPL0 HALF ROUND 55055 YOKE-SPL50 HALF ROUND 550558 YOKE-9N HALF ROUND 5
Group: REVERSE IDLER 5 4 6 84-6-99 REVERSE IDLER 4040 REVERSE IDLER SHAFT 4040 REVERSE IDLER GEAR 4040 BEARING 4 K-40,K-4 4 40406 WASHER 5 40080 SNAP RING K-406,K-40 6 X-8-004M CAPSCREW M0 X.5 X 0MM 6
Group: SHIFT KNOB 099-6-99 SHIFT KNOB A-49 SHIFT KNOB ASSEMBLY 4044,4055,40508 X-9-80 NUT /"-
Group: SHIFT SHAFT ASSY 4 9 5 8 6 5-6-99 SHIFT SHAFT ASSY A-69 SHIFT SHAFT ASSY 4046 ALL REQUIRED PINS INCLUDED 4040 KEY 8
4 4058 YOKE ST & REV 5 40465 YOKE RD & DIRECT 6 405 PLUG - HEX HEAD M8 X.5 40455 SPRING K-408 8 404 SPRING 9 4045 PLUNGER K-408 4049 PLUG 404 COMPRESSION SPRING STANDARD K-408,K-40,K- 4 40450 COMPRESSION SPRING OPTIONAL - HEAVY 4048 PLUNGER 406 K-408 9
Group: SPLITTER CYLINDER 6 5 4 8 0 9 466-6-99 SPLITTER CYLINDER 40080 SNAP RING K-406,K-40 556859 -O- RING 8899 K-406,K-40 4046 PISTON 4 995 -O- RING A-5,K-698,K- 406,K-40 5 556858 -O- RING K-405,K-406,K- 40 6 40494 PISTON 46 -O- RING K-406,K-40 8 40404 YOKE BAR 9 40458 PIN 0 A-0 SPLITTER YOKE ASSY 4049 X--0 SCREW 40488 STEP WASHER 40466 A-0,A-0 404 RETAINER A-0,A-0 0