Eaton Fuller Heavy Duty Transmissions Illustrated Parts List FRO-110C December 00 For the most current information, visit the Roadranger web site at www.roadranger.com
Contents How To Use The Illustrated Parts List... 4 Locating Transmission Tag and Identifying Model Designation... 5 Using Model Designation or Nomenclature... 5 AIR MODULE & RANGE CYL.... AUXILIARY DRIVE GEAR... CASE (AUX)... CASE (FRONT)...10 COUNTERSHAFT & BRGS(AUX)...1 COUNTERSHAFT ASSY...1 INPUT SHAFT & DRIVE GEAR...14 INTEGRAL OIL COOLER...15 INTEGRAL PUMP & COOLER...1 INTEGRAL OIL PUMP...1 INTEGRAL PUMP & COOLER...1 OIL COOLER...1 KITS & ASSEMBLIES...1 LEVERS/CONTROLS...0 ISOLATORS...0 LEVERS/CONTROLS...1 LEVERS/HOUSINGS...1 MAINSHAFT & SYNCHRO(AUX)... MAINSHAFT ASSY...4 MISC. THRU-SHAFT PTO...5 REAR HOUSING ASSY...5 MISCELLANEOUS... REVERSE IDLER... ROADRANGER VALVES... ROADRANGER VALVE... SHIFT BAR HOUSING (FRO)...9 Appendix...
How To Use The Illustrated Parts List Using Model Designation or Nomenclature This information provides a guideline to assist you in indentifying the transmission designation assigned to a transmission model - information vital to identifying and ordering parts. 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
Locating Transmission Tag and Identifying Model Designation Transmission model designation, and other transmission information, are stamped on the transmission tag. To identify the transmission model designation (nomenclature), locate the tag on the transmission and then locate the model designation number as shown. Using Model Designation or Nomenclature The model designation or nomenclature assigned to a transmission model provides information concerning transmission torque capacity, forward speeds, ratio set, shift bar housing and other provisions and options. Use the following guidelines to identify your transmission model designation. This information is useful when ordering parts. Every effort has been made to ensure the accuracy of this publication. However, Eaton Corporation makes no expressed or implied warranty or representation based on the information contained in this publication. Any errors or omissions may be reported to Eaton Roadranger Parts Marketing, Eaton Corporation, P.O. Box 401, Kalamazoo, MI 4900. Copyright Eaton Corporation, 00 All rights reserved. 5
Group: AIR MODULE & RANGE CYL. 11 1 1 9 10 1 5 4 101-9-94 AIR MODULE & RANGE CYL. 1 X--004M CAPSCREW 4 M X 1.5 X 0MM S-0,S-9,S-01,S-0 K-45 AIR MODULE ASSY A - 4 1 1419 -O- RING K-9,K-45,S-0,S-9,S-01 S-0 4 1559 -O- RING 1 K-45,S-0,S-9,S-01,S-0 5 04 -O- RING 1 K-9,S-0,S-9,S-01,S-0 K-19 BAR & RING KIT 4091 1 K-1 PISTON KIT 401 1 4000 SNAP RING 1 K-9,K-1,K-19,K-10,K-11 9 5550 -O- RING 1 K-9,S-0,S-9,S-01,S-0 10 145 -O- RING 1 K-9,S-0,S-9,S-01,S-0 11 1419 -O- RING 1 K-9,K-45,S-0,S-9,S-01 S-0 1 40140 COVER 1 S-0,S-9,S-01,S-0 1 X--004M CAPSCREW M X 1.5 X 0MM S-0,S-9,S-01,S-0
Group: AUXILIARY DRIVE GEAR 5 1 4 104-9-94 C AUXILIARY DRIVE GEAR 1 401 BEARING SPACER 1 5550 BEARING 55504 1 K-94,K-1 405 RETAINER 1 4 X--100M CAPSCREW M10 X 1.5 X 5MM K-51,S-4,S-4,S-91,S-9 S-4 5 4045 AUXILIARY DRIVE GEAR 4044 1 199 SNAP RING 1 K-91,K-94,K-1
Group: CASE (AUX) 1 4 OEM supplied adjustable speedometer sensor (Threaded) OEM supplied non-adjustable speedometer sensor (Non-Threaded) 5 4 1 1 5 Magnetic 0 1 Old Design Old Design 1 9 15 19 1 Mechanical 9 9 11 10 1 10414-9-94 14 Old Design 1 CASE (AUX) 1 S-501 SPEEDO ROTOR ASSY 404 1 MAGNETIC 55511 -O- RING 1 K-91,S-501,S-50,S-09 K-91 OIL SEAL KIT 40 40 1 MAGNETIC SPEEDO K-94 4 X--001M CAPSCREW M X 1.5 X 1MM S-0,S-9,S-01,S-0,S-09 S-44,S-45,S-4,S- 4 5 S-09 REAR BEARING COVER ASSY 40,40,4045 1 PUSH-IN/THREAD-IN MAGNETIC PICK- UP 404 GASKET 1 K-,K-91,K-91,S-50,S-09 S-59 X--1009M CAPSCREW M10 X 1.5 X 50MM USE W/40 AND 40 RBC X--100M HEX SCREW 4 M10 X 0.0MM USE W/4045 RBC S-09 X--1009M CAPSCREW M10 X 1.5 X 50MM USE W/4045 RBC X--100M CAPSCREW M10 X 1.5 X 5MM K-51,S-4,S-4,S-91,S-9 S-0,S-4,S-49 9 400 COVER 14 S-4,S-49 10 404 GASKET 145 K-91,S-4,S-49 11 K-05 SHIM KIT 145 K - 10 1 K-94, K-1,S-4,S-49 1 K-51 LIFTING EYE KIT A - 409 1 S-91 REAR HOUSING ASSY 4050 1 K-9 1 K-9 REAR HSG REPL KIT 404 1 14 404 GASKET 1 K-91,S-4,S-49
15 X--1005M CAPSCREW 1 M10 X 1.5 X 5MM 15 X--100M CAPSCREW M10 X 1.5 X 45MM 1 1559 -O- RING 1 K-45,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 4 1 A-15 RANGE BAR COVER ASSY A - 4 1 1 X--00M SCREW M X 1.5 X 0MM 19 104 SPEEDO DRIVE GEAR 1 0 S-50 SPEEDO SPACER ASSY 40590 1 MECHANICAL 1 K- OIL SEAL W/SLINGER 19109 00,00 1 MECHANICAL SPEEDO K-1 X--100M SCREW M10 X 1.5 X 5MM K-454 SPEED SENSOR KIT A - 9,A - 4 1 SINGLE PICK-UP ( PIN) K-455 SPEED SENSOR KIT, DUAL A - 04 1 DUAL PICK-UP (4 PIN) 4 4045 SLINGER 1 S-09 5 1414 -O- RING 1 S-59 REAR BRG COVER ASSY 40 1 MECHANICAL - :00 OPENING S-50 REAR BRG COVER ASSY 4004 1 MECHANICAL - 4:00 OPENING K-50 PLUG RETAINING KIT 40,4051 1,40519 015 LIFTING EYE 1105 K-51,S-4,S-4,S-91,S-9 S-0 9 X--100M CAPSCREW M10 X 1.5 X 5MM K-51,S-4,S-4,S-91,S-9 S-0,S-4,S-49 9
Group: CASE (FRONT) CASE (FRONT) 1 S-0 CASE ASSY 400 1 OPTIONAL - FOR USE W/INTEGRAL OIL COOLER 1 S-4 CASE ASSY 4001 1 W/INTEGRAL OIL PUMP X-1-00 PIPE PLUG X1 001 1 1-1/4" X-1-10 PIPE PLUG X1 101 1 /4" 4 4010 GASKET 199 1 K-91 5 4009 PTO COVER 159,40051 1 X--100M CAPSCREW M1 X 1.5 X 0MM 4014 GASKET 1 K-91 A-599 CLUTCH HOUSING ASSY 40110 1 #1 PULL ALUM. A-4 CLUTCH HOUSING ASSY A - 444,A - 41 1 # PUSH-PULL ALUM. A-04 CLUTCH HOUSING ASSY A - 44,A - 40,A - 1 #1 PUSH-PULL ALUM. 0,A - 0,A - 05 A-1 CLUTCH HOUSING ASSY A - 00 1 #1 PUSH-PULL IRON A- CLUTCH HOUSING ASSY A - 1,A - 1 # PUSH-PULL IRON 9 X-L-509 CAPSCREW 4 5/1"-1X1/" QUANTITY DEPENDENT ON DESIGN 10 4050 HAND HOLE COVER 1145 1 #1 PULL 11 5550 STUD 55505 M1 X X 0MM 1 X-10-1000 WASHER 5/" NOT REQUIRED WHEN USING X-1-105M NUT 1 X-1-105M NUT X 1 101M,X 1 10M M1 X 1.5 14 0550 FRONT BRG COVER 1 " PULL 15 X--1004M CAPSCREW M10 X 1.5 X 0MM 1 1411 GASKET 1 K-91 1 115 BUSHING 4 UPPER A-1,A-,A-4,A-599,A-04 10
19 BUSHING LOWER A-1,A-,A-4,A-04 0 X-C- CAPSCREW & WASHER M1 X 1.5 X 5MM IRON HOUSING 104M 0 X-C- 104M CAPSCREW & WASHER 4 M1 X 1.5 X 5MM ALUMINUM HOUSING 0 X-C- CAPSCREW & WASHER M1 X 1.5 X 90MM IRON HOUSING 10M 1 4040 PLUG 1 1-1/1" MAGNETIC S-4,S-0,S- 1 404 PLUG 1 1-1/1" - COMES WITH O-RING INSTALLED X--100M CAPSCREW M10 X 1.5 X 0MM 1455 PTO COVER 4054 1 4 14 GASKET 1 K-91 5 X-1-0 SELF-TAPPING SCREW X1 9 5/1" 5000 NAME PLATE 15 1 14 MAGNET S-4,S-0,S-0,S- 11 PIN 9 X-1-105M NUT X 1 101M,X 1 10M M1 X 1.5 0 55550 DOWEL PIN S-4,S-0 1 55504 STUD M1 X X 5MM K-51 LIFTING EYE KIT A - 409 X-1-0 PIPE PLUG X1 00 1 1/" S-0,S- 4 404 GASKET 1 K-910,K-91 5 4054 COVER 1 X--00M CAPSCREW 5 M X 1 X 0MM K-4 015 LIFTING EYE 1105 K-51,S-4,S-91,S-9,S-0 X--100M CAPSCREW M10 X 1.5 X 5MM K-51,S-4,S-91,S-9,S-0 S-4,S-49 11
Group: COUNTERSHAFT & BRGS(AUX) 1 1 10440-1/9 Aux CS Helical COUNTERSHAFT & BRGS(AUX) 1 4004 BEARING 14 4 K-94,K-1,S-4,S-49 A-4 WELDED COUNTERSHAFT A - 45,A - 44 D/G 10 - C/S 404 ASSY 90 SPACER K-91 1
Group: COUNTERSHAFT ASSY 9 11 10 Latest Design 1 5 Included w/item # 4 1 1 COUNTERSHAFT ASSY 1050-9-94 C 1 400 SNAP RING K-94,K-1 40400 BEARING 4040 4 K-94,K-1 K- CNTRSHFT KIT-W/REV & 1ST 4041 1 LOWER W/THRU SHAFT PTO & PUMP K-5 CNTRSHFT KIT-W/REV & 1ST 4040 LOWER & UPPER W/THRU SHAFT PTO K- CNTRSHFT KIT-W/REV & 1ST 4011,40119 STANDARD K-4 CNTRSHFT KIT-W/REV & 1ST 401,401 1 LOWER W/PUMP 4 401 KEY 5 X--1005 CAPSCREW INCLUDED WITH ITEM # K-,K-4,K-5,K-,K-, K-,K-9,K-0 40404 BEARING RETAINER INCLUDED WITH ITEM # K-,K-4,K-5,K-,K-, K-,K-9,K-0 4040 ND GEAR-CNTRSHFT 40404,4050 404 RD GEAR-CNTRSHFT 9 4014 OD GEAR-CNTRSHFT 409 10 1595 PTO GEAR - LOWER 1 10 040 PTO GEAR - UPPER 1595 1 11 4011 DRIVE GEAR-CNTRSHFT 40500 1 4001 SNAP RING 1 409 PUMP DRIVE GEAR 1 1
Group: INPUT SHAFT & DRIVE GEAR 9 5 1* * For Shipping Only Ñ Do Not Replace 104-9-94 C INPUT SHAFT & DRIVE GEAR 1 559 SHIPPING SEAL 1 NOT SOLD FOR SERVICE 190 SNAP RING 1 K-91 40141 BEARING 1 K-94,K-1 5 40 SNAP RING 1 USE W/4044 MAIN DRIVE GEAR K-91,K-94,K-1,K-41,K-419, K- 40 5 404 SNAP RING 1 USE W/404010 MAIN DRIVE GEAR K-91 404010 NLA-ORDER K-40 40400,404009 1 401 NLA-ORDER K-40 1 4044 MAIN DRIVE GEAR 40509 1 USE W/40 SNAP RING AND S- K-40 INPUT SHAFT S-95 NLA-ORDER K-40 4015 1 S- INPUT SHAFT ASSY 404 1 " PULL - USE W/4044 MAIN DRIVE K-41,K-419,K-40 GEAR 9 15 BUSHING 1 K-94,K-1,S-95,S- 14
Group: INTEGRAL OIL COOLER 1 4 5 9 1055-5-99 INTEGRAL OIL COOLER 1 K-4 INTEGRAL OIL COOLER KIT 1 S- OIL COOLER COVER ASSY 4099 1 STANDARD - /4-1 UNF B S-0 OIL COOLER COVER ASSY 4009 1 OPTIONAL - 1/-14 NPTF X--00M CAPSCREW M X 1 X 0MM K-4 4 14 MAGNET S-4,S-0,S-0,S- 5 4040 PLUG 1 1-1/1" MAGNETIC S-4,S-0,S- 5 404 PLUG 1 1-1/1" - COMES WITH O-RING INSTALLED X-1-0 PIPE PLUG X1 00 1 1/" S-0,S- 404 GASKET 1 K-91,S-0,S- 9 X--1004M CAPSCREW 1 M10 X 1.5 X 0MM 15
Group: INTEGRAL PUMP & COOLER Sub-Group: INTEGRAL OIL PUMP 1 105-9-94 C INTEGRAL PUMP & COOLER INTEGRAL OIL PUMP 1 A-4 INTEGRAL OIL PUMP 1 COMPONENT PARTS NOT SOLD SEPARATELY 1
Group: INTEGRAL PUMP & COOLER Sub-Group: OIL COOLER Oil Outlet 1 11 1 Oil Return 4 5 9 1 * *1 * 1 10 11 *14 *15 105-9-94 Cooler C *Adding Oil Filter and parts as shown is optional. INTEGRAL PUMP & COOLER OIL COOLER 1 105 OIL COOLER 1 K-195 1944 HOSE 1 5 FEET K-195 X--55 CAPSCREW 5/1"-1X-1/" K-195 4 X--50 LOCKWASHER 5/1" K-195 5 111 BRACKET 4 K-195 19419 CONNECTOR K-195,S-1404 19415 SWIVEL 4 K-195 X-10-501 WASHER 5/1" K-195 9 109 PLUG-RUBBER MOUNT K-195 10 1190 STRAP K-195 11 194 CLAMP 5 K-195 1 110 NUT K-195 1 194 ELBOW 4 K-195 14 S-1404 OIL FILTER 1 1 15 1 FILTER ELEMENT 1 S-1404 1
KITS & ASSEMBLIES K-495 REPL KIT-SLIDING CLUTCH K - 9 1 S-19 SHIFT LEVER HSG ASSY 1 LOW TOWER S-10 SHIFT LEVER HSG ASSY 1 HIGH TOWER S-49 RANGE SECTION ASSY 1 FOR "C" RATIOS S-09 REAR BEARING COVER ASSY 40,40,4045 1 PUSH-IN/THREAD-IN MAGNETIC PICK- UP K-195 COOLER INSTLN KIT 1 K-910 COVER & SCREW KIT 4054 1 K-14 SHIFT LEVER HSG 450,11,19,A - 1 LOW TOWER 44 K-9 SHIFT LEVER HSG KIT 11,40050,K - 1 HIGH TOWER 10 S-44 SHIFT BAR HSG ASSY (FRO) 40150,40445,40501,S - 9 1 COMPLETE - INCLUDES RANGE CYLINDER ASSY K-49 LEVER REPLACEMENT KIT 1 HIGH TOWER K-9 RANGE PISTON KIT 1 K-94,K-1 S-95 NLA - SEE GROUP NOTE 4015 1 K-9 LEVER REPLACEMENT KIT 1 MID TOWER S-54 ROADRANGER VALVE ASSY A - 504 1 RT - W/SHIFT DIAGRAM MEDALLION S-45 SHIFT BAR HSG ASSY (FRO) 40150,40445 1 COMPLETE - INCLUDES RANGE,40501,S - 95 CYLINDER ASSY AND OPTIONAL DETENT SPRING DESIGN DETENT SPRING. IT IS USED TO INCREASE SHIFTER DETENT FORCE. S-4 SHIFT BAR HSG ASY (FROF) 404,4044,4050,S - 91 1 COMPLETE - INCLUDES RANGE CYLINDER ASSY S-4 RANGE SECTION ASSY 1 FOR "B" RATIOS K-1 PISTON KIT 401 1 K-150 IDLER SHAFT KIT 401,X 1 100M 1 K-94 AIR SYSTEMS TOOL KIT 1 K-9 SHIFT LEVER HSG KIT 4011,A - 040 1 MID TOWER S-194 ISOLATOR ASSY 1 S-4 SHIFT BAR HSG ASY (FROF) 404,4044 1 COMPLETE - INCLUDES RANGE,4050,S - 94 CYLINDER ASSY AND OPTIONAL DETENT SPRING DESIGN DETENT SPRING. IT IS USED TO INCREASE SHIFTER DETENT FORCE. K-10 SHIFT YOKE KIT 4019 1 K-45 AIR MODULE ASSY A - 4 1 K-4 HOUSING UPDATE KIT (FRO) 40150,S - 94 1 HOUSING ONLY K-455 SPEED SENSOR KIT, DUAL A - 04 1 DUAL PICK-UP (4 PIN) S-501 SPEEDO ROTOR ASSY 404 1 MAGNETIC S-4 SHIFT BAR HOUSING (FROF) 4044 4050 1 HOUSING ONLY K-4 K-19 BAR & RING KIT 4091 1 K-40 REAR HSG REPL KIT 4054 1 THRU-SHAFT PTO K-4 INTEGRAL OIL COOLER KIT 1 K-419 GEAR UPDATE KIT 1 FRO/FROF - "B" RATIO K-4 HSG UPDATE KIT (FROF) 404,4044,S - 1 HOUSING ONLY 9 K-4 LEVER REPLACEMENT KIT 1 LOW TOWER K-99 ISOLATOR BUSHING KIT 144,11 1 K-50 PLUG RETAINING KIT 40,4051 1,40519 S-4 CASE ASSY 4001 1 W/INTEGRAL OIL PUMP S-0 OIL COOLER COVER ASSY 4009 1 OPTIONAL - 1/-14 NPTF S-59 REAR BRG COVER ASSY 40 1 MECHANICAL - :00 OPENING K-00 PIN & BUSHING KIT 1 K-104 ACTUATOR PIN KIT 40 1 K-1 BASIC REBUILD KIT 1 MECHANICAL SPEEDO FOR OVERHAUL KIT - ORDER THE REBUILD KIT AND THE REQUIRED INPUT SHAFT ASSY S-50 REAR BRG COVER ASSY 4004 1 MECHANICAL - 4:00 OPENING S-50 SPEEDO SPACER ASSY 40590 1 MECHANICAL 1
K-11 YOKE BAR KIT 400,401 1 K-49 SYNCHRONIZER KIT K - 44 1 S-519 SHIFT LEVER HSG ASSY S - 919 1 MID TOWER S-91 REAR HOUSING ASSY 4050 1 K-9 S-9 REAR HOUSING ASSY 40 1 THRU-SHAFT PTO K-40 S- OIL COOLER COVER ASSY 4099 1 STANDARD - /4-1 UNF B S- INPUT SHAFT ASSY 404 1 " PULL K-419,K-40 K-05 SHIM KIT 145 K - 10 1 K-94, K-1,S-4,S-49 K-91 OIL SEAL KIT 40 40 1 FOR MAGNETIC COVER K-94 K-91 SMALL PARTS KIT 1 K-4 COUNTERSHAFT KIT 401,401 1 "C" RATIO K-40 GEAR UPDATE KIT 1 FRO/FROF - "C" RATIO K-51 LIFTING EYE KIT A - 409 1 S-4 SHIFT BAR HOUSING (FRO) 40445 40501 1 HOUSING ONLY K-4 K-91 GASKET KIT 1 K-94,K-1 K-94 BASIC REBUILD KIT 1 ELECTRONIC SPEEDO FOR OVERHAUL KIT - ORDER THE REBUILD KIT AND THE REQUIRED INPUT SHAFT K-9 REAR HSG REPL KIT 404 1 K-5 COUNTERSHAFT KIT 4040 1 "C" RATIO K- COUNTERSHAFT KIT 4041 1 "C" RATIO K-454 SPEED SENSOR KIT A - 9,A - 4 1 SINGLE PICK-UP ( PIN) K-191 MASTER VALVE REPAIR KIT 1 FOR A-909 & A-5010 VALVES K- OIL SEAL W/SLINGER 19109 00,00 1 FOR MECHANICAL COVER K-1 K- COUNTERSHAFT KIT 4011,40119 1 "C" RATIO K- O-RING & WASHER KIT 40111 1 K-4 PIN REPLACEMENT KIT 145 1 S-1404 OIL FILTER 1 1 19
Group: LEVERS/CONTROLS Sub-Group: ISOLATORS 1 1 9 4 1 1 Indicates Part Of Item 10 10 1010-1/9 LEVERS/CONTROLS ISOLATORS 1 1914 -E- RING K-4 PIN REPLACEMENT KIT 145 1 14 BUSHING K-00,K-4,K-49,K-9,K-99 S-19,S-10,S-519 4 S-194 ISOLATOR ASSY 1 14 LEVER 1 STRAIGHT 1." 15 STUB LEVER 1 LOW TOWER K-4 1 STUB LEVER 1 HIGH TOWER K-49,S-10 4011 STUB LEVER 1 MID TOWER K-9 9 1 90 DEG LEVER 1 STRAIGHT " 10 K-99 ISOLATOR BUSHING KIT 144,11 1 11 X--50 SCREW 1 K-00,K-4,K-49,K-9,K-99, K- 4,S-19,S-10,S-519 1 X-9-50 NUT 1 K-00,K-4,K-49,K-9,K-99, K- 4,S-19,S-10,S-519 0
Group: LEVERS/CONTROLS Sub-Group: LEVERS/HOUSINGS 15 1 K-4 - Low K-9 - Mid K-49 - High 0 1 1 1 1 1 14 S-19 - Low S-519 - Mid S-10 - High 1004-9-94 Levers/Housings C LEVERS/CONTROLS LEVERS/HOUSINGS 1 K- O-RING & WASHER KIT 40111 1 199 PIN 1 K-14,K-9 X--1005M CAPSCREW 4 M10 X 1.5 X 5MM K-9 SHIFT LEVER HSG KIT 4011,A - 040 1 MID TOWER K-14 SHIFT LEVER HSG 450,11,19,A - 1 LOW TOWER 44 40594 GASKET 4041 1 K-14,K-9 1 4000 PIN 1 K-9,S-10 1 541 PIN 1 /" - USED W/11 ONLY 14 K-9 SHIFT LEVER HSG KIT 11,40050,K - 1 HIGH TOWER 10 15 104 BOOT 1 K-14,K-9,S-10 1 X-1-00 NUT 1 /"-4-N.F.PLAIN 1 X--00 LOCKWASHER 1 /" 0 100 GEAR SHIFT LEVER 1 STRAIGHT - LOW 1-1/" 0 14 GEAR SHIFT LEVER 1 STRAIGHT - HIGH 5" 1 5 RETAINER 1 K-14,K-9,S-10 5 SPRING 1 K-14,K-9,S-10 K-4 LEVER REPLACEMENT KIT 1 LOW TOWER K-49 LEVER REPLACEMENT KIT 1 HIGH TOWER K-9 LEVER REPLACEMENT KIT 1 MID TOWER S-19 SHIFT LEVER HSG ASSY 1 LOW TOWER S-10 SHIFT LEVER HSG ASSY 1 HIGH TOWER S-519 SHIFT LEVER HSG ASSY S - 919 1 MID TOWER 1
Group: MAINSHAFT & SYNCHRO(AUX) 9 11 9 9 9 Old Design 10 10 4 5 1 15 1 1 1 14 104-9-94 C MAINSHAFT & SYNCHRO(AUX) 1 149 SPRING K-91,K-94,K-1,K-49,K-495 A-1 SYNCHRONIZER ASSY 4049 4049 A - 1 HI RANGE K-49, K-495 591 40094 SLIDING CLUTCH 1 K-495 4 A-54 SYNCHRONIZER ASSEMBLY A - 49 A - 5 1 LO RANGE K-49, K-495 5 40 AUXILIARY MAINSHAFT 1 404 WASHER 1 K-91 K-11 YOKE BAR KIT 400,401 1 55550 PIN 1 NOT REQUIRED FOR 401 YOKE BAR 9 4000 SNAP RING K-9,K-1,K-19,K-10,K-11, K- 9,S-4,S-4 10 K-10 SHIFT YOKE KIT 4019 1 11 55519 NO LONGER AVAILABLE 1 NOT REQUIRED FOR 401 YOKE BAR 1 404 REDUCTION GEAR 4054 1 1 9 SPACER 1 K-91 14 55550 BEARING 1 K-94,K-1 15 401 NUT 1 S-4,S-49 1 550554 YOKE-10 FULL ROUND 1 1 550554 YOKE-110 HALF ROUND 1 1 5505545 YOKE-10 HALF ROUND 1 1 5505544 YOKE-110 FULL ROUND 1 1 550554 YOKE-110 HALF ROUND 1 1 550554 YOKE-110 FULL ROUND 1
Group: MAINSHAFT ASSY 1 1 11 10 9 1 5 4 10-9-94 C MAINSHAFT ASSY 1 401 MAINSHAFT 1 401 KEY 1 K-91 4014 SNAP RING 1 K-91 4 401 SPACER 1 K-91 5 4059 WASHER 1 K-91 400 REVERSE GEAR-MAINSHAFT 4011 1 405 SLIDING CLUTCH 405 WASHER K-91 9 40411 1ST GEAR-MAINSHAFT 4040 1 10 4041 ND GEAR-MAINSHAFT 40405 1 11 4050 RD GEAR-MAINSHAFT 404 1 1 404 NLA-ORDER K-40 1 1 40401 OD GEAR-MAINSHAFT 404011 40401 1 K-40 1 404014 SLIDING CLUTCH 1 K-41,K-419,K-40 1 4009 NLA-ORDER K-40 1 4
Group: MISC. THRU-SHAFT PTO Sub-Group: REAR HOUSING ASSY Old Design 9 10 4 5 4 9 10 10414A-10-95 Old Design MISC. THRU-SHAFT PTO REAR HOUSING ASSY 404 GASKET 1 K-91,S-4,S-49 K-40 REAR HSG REPL KIT 4054 1 S-9 REAR HOUSING ASSY 40 1 K-40 4 10 EXPANSION PLUG S-9 5 X-1-10 PIPE PLUG X1 101 1 /4" X-L- CAPSCREW & WASHER M10 X 1.5 101M K-51 LIFTING EYE KIT A - 409 K-50 PLUG RETAINING KIT 40,4051 1,40519 9 015 LIFTING EYE 1105 K-51,S-4,S-4,S-91,S-9 S-0 10 X--100M CAPSCREW M10 X 1.5 X 5MM K-51,S-4,S-4,S-91,S-9 S-0,S-4,S-49 5
MISCELLANEOUS 104 ADHESIVE SEALANT 1 0.5 CC (SINGLE APPLICATION SIZE) K-50 10 SILICONE LUBE 1 4 CC (SINGLE APPLICATION SIZE) K-4,K-49,K-9,K-9 0400 SHIFT DIAGRAM LABEL 1901 1 10 SILICONE LUBE 1 OZ (.59 CC)-FLEET SIZE 105 SEALANT 1 CC (SINGLE APPLICATION SIZE)
Group: REVERSE IDLER 5 1 4 10 5 Old Design 9 11 4 10 Latest Design Old Design 110-11-95 REVERSE IDLER 1 K-150 IDLER SHAFT KIT 401,X 1 100M 14 IDLER PLATE K-150 4041 WASHER K-150 4 14 BEARING 40500 K-94,K-1 5 4011 REVERSE IDLER GEAR 409 WASHER 14 K-150,S-4,S-4,S-0 K-150 IDLER SHAFT KIT 401,X 1 100M 4050 REVERSE IDLER SHAFT K-150 9 40 RETAINING RING K-150 10 14 NO LONGER AVAILABLE 11 X--100M CAPSCREW M1 X X 0MM K-150
Group: ROADRANGER VALVES Sub-Group: ROADRANGER VALVE 1 999 P S * * Old Design 11 See: Appendix / Air Line Tubing 5 1 1 * P S * 4 5 Valve Repair Kit *For Connector component information see Appendix. 10109-1-9 ROADRANGER VALVES ROADRANGER VALVE 1 55100 MEDALLION, LOGO 1 (LATEST DESIGN) FULLER LOGO ONLY A-909 1 5510 SHIFT DIAGRAM MEDALLION 1 FR/FRF/FRO/FROF S-54 K-191 MASTER VALVE REPAIR KIT 1 FOR A-909 & A-5010 VALVES 0495 LEVER 1 A-909 4 011 COVER 1 A-909 5 X--1 SCREW X 0 -X/" A-909 X-9-0 NUT 1 1/"-1 400 CONNECTOR ASSY 50 4 5/"TUBE-1/1"NPTF 4005 CONNECTOR ASSY 4 "PUSH-TO-CONNECT" 5/"TUBE- K-45 1/1"NPTF 11 410 UNION ASSY 1 5/" TUBING 11 410 UNION ASSY 1 "PUSH-TO-CONNECT" 5/" TUBING 1 010 SHEATHING 1 5/" - BLACK 50' 1 151 -O- RING CLAMP 999 A-909 ROADRANGER VALVE ASSY A - 5010,A - 510 1 STANDARD-W/LOGO 999 S-54 ROADRANGER VALVE ASSY A - 504 1 FR/FRF/FRO/FROF-W/MEDALLION
Group: SHIFT BAR HOUSING (FRO) 0 4 1 5 9 1 9 4 40 5 4 5 999 11 1 9 1 14 15 1 H 41 10 1 0 19 1 1 1 19 10-9-94 Old Design H Optional Design SHIFT BAR HOUSING (FRO) 1 K-4 HOUSING UPDATE KIT (FRO) 40150,S - 94 1 HOUSING ONLY 1 S-4 SHIFT BAR HOUSING (FRO) 40445 40501 1 HOUSING ONLY K-4 401 PIN 1 AFTER S/N 511091 S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 40 PIN 1 PRIOR TO S/N 511091 55504 -O- RING 1 TO BE USED WITH SWITCH ONLY 4 404 REVERSE SWITCH 1 5 4014 PLUG 1 M14 X HEX S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S-4 1419 -O- RING 1 TO BE USED WITH PLUG ONLY S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S-4 4015 GASKET 1 K-91,S-0,S-9,S-01,S-0 S-4,S-4,S-44,S- 45,S-4 S-4 51 ROLL PIN 51 1 S-44,S-45,S-4,S-4 9 4015 OIL TROUGH 1 S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 9
10 X--001M CAPSCREW M X 1.5 X 1MM S-0,S-9,S-01,S-0,S-09 S-44,S-45,S-4,S- 4 11 4041 PLUNGER 401 1 K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 4 1 4014 SPRING 1 STANDARD K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 4 1 4015 SPRING 1 S-9,S-0,S-45,S-4 14 X--101M SCREW 1 M10 X 1.5 X 0MM S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 15 400 SHIFT BLOCK 1 S-0,S-9,S-44,S-45 1 401 SHIFT YOKE 1 REVERSE/1ST S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 1 400 SHIFT SHAFT 1 CAN BE USED WITH EITHER 40501 OR 40445 SHIFT BAR HOUSING 1 40404 KEY 4015 1 SHIFT K-91,K-41,K-419,K-40 19 40159 INTERLOCK KEY 1 DETENT S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 0 401 SHIFT YOKE 1 ND/RD S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 1 4014 SHIFT BLOCK 1 USE W/40150 HOUSING 1 40444 SHIFT BLOCK 1 USE W/40445 HOUSING K-4,K-4,S-44,S-45,S-4 S-4 4010 SHIFT YOKE 1 4TH/5TH - USE W/40150 HOUSING 4044 SHIFT YOKE 1 4TH/5TH - USE W/40445 HOUSING K-4,K-4,S-44,S-45,S-4 S-4 40155 SHIFT BAR 1 S-44,S-45,S-4,S-4 4 4000 SNAP RING 1 K-104,K-4,K-4,S-44,S-45 S-4,S-4 5 405 ACTUATOR 1 USE W/40445 HOUSING K-4,K-4,S-44,S-45,S-4 S-4 5 4015 ACTUATOR 1 USE W/40150 HOUSING 401 SNAP RING 1 K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 4 401 BIAS PLATE 1 K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 4 X-1-0 PIPE PLUG X1 0 1 /" NPT S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S-4 9 4015 PIN 1 USE W/40150 HOUSING 9 K-104 ACTUATOR PIN KIT 40 1 USE W/40445 HOUSING 0 4040 BREATHER 05 1 1/4" - USE W/40445 HOUSING S-4,S-4,S-44,S-45,S-4 S-4 0 405 BREATHER 1 /" - USE W/40150 HOUSING 1 401 BIAS PLUNGER 1 K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 0
4 401 SPRING 1 OUTER K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 4 4019 SPRING 1 INNER K-91,S-0,S-9,S-01,S-0 S-44,S-45,S-4,S- 4 4 X-1-0 PIPE PLUG 1 1/" NPT S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 5 4015 PIN 1 S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 55510 -O- RING 1 USE WITH SWITCH OR PLUG S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S-4 4049 NEUTRAL SWITCH 1 4014 PLUG 1 M1 X 1.5 HEX S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S-4 9 X--1005M CAPSCREW 1 M10 X 1.5 X 5MM 40 X-1-404 PIPE PLUG 1 1/4" NPT - USE W/40445 HOUSING 40 X-1-0 PIPE PLUG X1 0 1 /" NPT - USE W/40150 HOUSING S-0,S-1,S-9,S-00,S-01 S-0,S-4,S-4,S- 44,S-45 S-4,S-4 41 4050 SHIFT SHAFT 1 CAN ONLY BE USED WITH 40501 SHIFT BAR HOUSING 999 S-44 SHIFT BAR HSG ASSY (FRO) 40150,40445,40501,S - 9 999 S-45 SHIFT BAR HSG ASSY (FRO) 40150,40445,40501,S - 95 1 COMPLETE - INCLUDES RANGE CYLINDER ASSY 1 COMPLETE - INCLUDES RANGE CYLINDER ASSY AND OPTIONAL DETENT SPRING DESIGN DETENT SPRING. IT IS USED TO INCREASE SHIFTER DETENT FORCE. S-0,S-9,S-01,S-0,S-44 S-45,S-4,S-4 1
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. 5/" Air Line and Harness Combinations Line Type Line Color Order Part No# Length Supply + Port Red (S) + Black (P) 501 50 ft Splitter + Deep Reduction Blue (SP) + Green (H/L) 501 50 ft Supply + Splitter + Port Red(S)+Blue(SP)+ Black(P) 401 50 ft 5/" Air Lines Line Type Line Color Order Part No# Length Supply Red (S) 510 50 ft Port Black (P) 50 50 ft Splitter Blue (SP) 50 50 ft Deep Reduction Green (H/L) 550 50 ft Sheathing 010 50 ft 1/" Air Lines Line Type Line Color Order Part No# Length Supply White 5 50 ft Port Black 01 50 ft Sheathing 0000 50 ft 1050-1/9 AL Chart
Copyright Eaton and Dana Corporation, 00. EATON AND DANA CORPORATION hereby grants its customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. THIS INFORMATION IS NOT INTENDED FOR SALE OR RE- SALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES. The Roadranger System is an unbeatable combination of the best products from Eaton and Dana partnering to provide you the most advanced, most trouble-free drivetrain in the industry. And it s backed by the Roadrangers the most experienced, most expert, most accessible drivetrain consultants in the business. For spec ing or service assistance, call 1-00--HELP (45) 4 hours a day, days a week, (Mexico: 001-00--HELP (45)) for more time on the road. Or visit our web site at www.roadranger.com. 4 FRO-110C 1/0 Printed in the USA