Eaton Fuller Heavy Duty Transmissions Illustrated Parts List RTO-9109B-AT Jun 2005

Eaton Fuller Heavy Duty Transmissions Illustrated Parts List RTO-9109B-AT Jun 2005 For the most current information, visit the Roadranger web site at www.roadranger.com

2

Contents How To Use The Illustrated Parts List... Locating Transmission Tag and Identifying Model Designation... 5 Using Model Designation or Nomenclature... 5 AUXILIARY DRIVE GEAR... BAR HOUSING ASSY... CASE (AUX)... CASE (FRONT)... 9 CONVERTER HOUSING ASSY...11 COUNTERSHAFT & BRGS(AUX)...13 COUNTERSHAFT ASSY...1 ECU CONTROLS...15 AUTO SHIFTER ASSY...15 ECU CONTROLS...1 BAR HOUSING COVER ASSY...1 FILTER REGULATOR...1 FRONT SECTION MISC...1 OIL LINES-POWER SYNCHRO...1 HARNESSES & HARDWARE...19 HARNESS ASSY-TORQUE CONV...19 HARNESSES & HARDWARE...20 HARNESS ASY-AUTO SHIFTER...20 INPUT SHAFT & DRIVE GEAR...21 KITS & ASSEMBLIES...22 MAINSHAFT & SYNCHRO(AUX)...23 MAINSHAFT ASSY...2 MISCELLANEOUS...2 OIL LINE RETURN...2 OIL LINE RETURN/CURRENT...2 OIL LINE RETURN...2 OIL LINE RETURN/NON-CURR...2 POWER SYNCHRONIZER...29 RANGE CYLINDER...30 REVERSE IDLER...31 STATOR SUPPORT ASSY...32 TORQUE CONVERTER ASSY...33 VALVES...3 AIR SYS-POWER SYNCHRO...3 VALVES...35 AIR SYS-RANGE...35 Appendix...3 3

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

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 013, Kalamazoo, MI 9003. Copyright Eaton Corporation, 2005 All rights reserved. 5

Group: AUXILIARY DRIVE GEAR 9 1 5 2 3 1 102-12/92 Aux DG AUXILIARY DRIVE GEAR 1 13 SNAP RING 2 K-230,K-2902,K-2903,K-290,K-2905 2 21320 SNAP RING RETAINER 1 RTO ONLY K-230 3 12 SNAP RING 1 K-230 5550 BEARING 5550 1 K-2902,K-2903,K-290,K-2905 5 113 BEARING RETAINER 1 X--5 CAPSCREW 3/"-1X1" 153 -O- RING 2 K-22,K-230,K-2902,K-2903,K-290,K- 2905 9 K-230 REPL KIT-DRIVE GEAR 3005 1

Group: BAR HOUSING ASSY 10 5 11 12 9 3 10 1 13 1 1 9 15 1 1 2 22 19 1 1 23 25 2 1 1 999 20232-11-93 BAR HOUSING ASSY 1 K-25 SHIFT BAR HSG ASSY 2259 1 HOUSING ONLY 2 302 GASKET 191 1 K-212,K-25,S-1 3 109 SPRING 3 K-2,K-229,S-1 X-1-00 STEEL BALL 3 1/2" A-532,K-229,S-1 5 15900 GASKET 2 K-233,S-1 91 SHIFT SENSOR SWITCH 2255 2 K-233,S-1 9131 ACTUATING SWITCH PIN 23112 1 S-1 X--91 CAPSCREW 3 3/"-1X1" 9 251 ROLL PIN 2521 2 S-1 10 K-290 SENSOR UPDATE KIT 225,K - 231 2 11 X-12-102 PLUG 1 S-1 12 K-321 NEUTRAL SWITCH KIT 2203 1 13 9131 ACTUATING SHAFT SWITCH 2201 1 K-321,S-1 1 220 SPRING 1 S-1 15 2200 YOKE BAR 1 LOW/REVERSE S-1 1 3220 LOCKSCREW 5 S-1 1 223 YOKE 1 LOW/REVERSE S-1 1 22593 YOKE BAR 1 1ST/2ND S-1 19 9100 SHIFT YOKE 30299 1 1ST/2ND S-1 22 15 SHIFT BLOCK 1 1ST/2ND S-1 23 2259 YOKE BAR 1 3RD/TH S-1 2 30323 SHIFT BLOCK 2202 1 3RD/TH S-1 25 9101 SHIFT YOKE 302212 1 3RD/TH S-1 999 S-1 SHIFT BAR HSG ASSY 2259 1 COMPLETE

Group: CASE (AUX) * 1 15 OEM supplied adjustable speedometer sensor 1 13 12 9 10 11 OEM supplied non-adjustable speedometer sensor 3 19 20 1 1 5 1 2 * Note Items & / Magnetic Speedometer Openings: Use 139 "O" ring w/ OEM supplied adjustable speedometer sensor and 20225 "O" ring w/ OEM supplied non-adjustable speedometer sensor or Eaton part #2022 Plug 20500-11-93 CASE (AUX) 1 K-351 OIL SEAL TOOL KIT 1 2 K-222 OIL SEAL W/SLINGER 19109 200 200 1 K-2290,K-23 3 X-L-05 CAPSCREW 5 3/"-1X3" S-21 NO LONGER AVAILABLE 302015 1 5 23 LIFTING EYE 1 15532 GASKET 1 K-212,K-222,S-21 2022 PLUG-MAGNETIC 2 S-21,S-21,S-219 20225 -O- RING 2 USE W/2022 PLUG OR OEM SUPPLIED NON-ADJUSTABLE SPEEDOMETER SENSOR NOT TO BE USED WITH 30195 SEAL 30195 SEAL 2 O-RING NOT REQUIRED S-21 9 2022 PLUG-MECHANICAL 223 1 S-21,S-21,S-219 10 112 -O- RING 1 S-21,S-21,S-219 11 992 BUSHING 1 S-21 12 X-L-02 CAPSCREW 3/"-1X1-1/2" 13 2219 REAR BEARING COVER 1 1 2220 GASKET 1 K-212 15 2200 REAR HOUSING 1 1 1335 GASKET 1 K-212,S-21,S-219 1 X-L-09 CAPSCREW 10 3/"-1X1-3/" 1 X-L-1 CAPSCREW 3/"-1X2" 1 X--101 CAPSCREW 2 3/"-1X1-1/2" 1 1909 COLLAR 1 K-212,K-222,S-21 19 110 GASKET 1 K-212,K-222,S-21 20 X--2 CAPSCREW 1 3/"-1X3"

Group: CASE (FRONT) 2 1 15 5 1 21 3 19 1 20 22 23 1 13 11 12 10 9 1 205-11-93 19 1 CASE (FRONT) 1 S-15 CASE ASSY 2353 1 2 133 MAGNET 3 S-15 3 X-- CAPSCREW 3/"-1X3/" 155 PTO COVER 30225 1 5 305309 GASKET 1 1 K-212,K-23 X-1-1005 NUT X 1 1000 2 5/"-1 K-250,K-225 X-10-1005 WASHER X 3 1000,X10 1000,X10 2 1.23 X.0 100 155 STUD 132,59 2 5/" X 2-3/1" 9 X--25 CAPSCREW X 2 /1"-1X/" 10 30209 PTO COVER 159,30051 1 11 305310 GASKET 30210 1 K-212 12 2250 GASKET 1 K-212,K-23,K-250,K-225 13 X-12-02 PIPE PLUG X12 00 1 1/2" K-322 1 X-12-120 PIPE PLUG X12 1202,X12 120 1 3/" MAGNETIC 1 30023 PLUG 303 1 1-1/1" MAGNETIC, O-RING INCLUDED S-15 1 3020 STUD 59 1 X-10-1005 WASHER X 3 1000,X10 1000,X10 1.23 X.0 100 19 X-1-1005 NUT X 1 1000 5/"-1 K-250,K-225 20 2291 STUD 2 21 133 DOWEL 2 22 X--0 CAPSCREW 1/2"-13X1-1/" 23 X-10-02 NO LONGER AVAILABLE 1/2" PLAIN 2 X-12-200 PIPE PLUG X12 200 1 2 30023 PLUG 303 1 1-1/1" MAGNETIC, O-RING INCLUDED S-15 9

10

Group: CONVERTER HOUSING ASSY 0 2 3 5 3 9 10 11 12 10 13 11 1 1 1 15 1 1 51 50 9 19 23 2 25 2 21 22 20 22 2 55 5 5 5 29 2002A-1-9 5 1 0 39 3 3 32 3 30 31 33 3 35 3 CONVERTER HOUSING ASSY 1 X-L-2 CAPSCREW 2 3/"-1X2-1/" 1 X--93 CAPSCREW 2 3/"-1X2-1/" 1 X-L-1 CAPSCREW 3/"-1X2-3/" 2 A-5552 VALVE ASSY 1 3 X-12-210 PIPE PLUG 1/" 22532 GASKET 1 K-212,K-2393R,K- 22 5 22533 NO LONGER AVAILABLE 1 2253 GASKET 1 K-212,K-2393R,K- 22 X-12-02 PIPE PLUG X12 00 1 1/2" 300315 ELBOW 1 9 23109 -O- RING 1 K-22,K-2 10 X-L-5 CAPSCREW 2 3/"-1X1" 11 235 LIFTING EYE 2 90 DEG. 12 K-232 ENG SPEED SENSOR KIT 2259 1 13 2250 -O- RING 1 K-22,K-232 1 2353 INSTRUCTION TAG 3 15 X--1202 SCREW 3 3/"-10X1" 1 K-2911 OIL PUMP KIT 300,3021 1 1 X-C-0 CAPSCREW 2 3/"-1X1-1/" K-250,K-2911 1 9132 SEAL RING 55503 1 K-250,K-22,K-2911 19 2230 -O- RING 1 K-250,K-22,K-2911 20 23220 FILTER BOWL 1 21 X--105 SCREW X 10 3 3/"-1X1-1/" K-231 22 X-3-0 CONICAL WASHER 3 3/" K-231 23 22510 OIL FILTER 1 K-231 11

2 2310 -O- RING 1 K-231,K-22 25 22512 NIPPLE 1 2 A-532 RELIEF VALVE ASSY 1 K-22 2 23029 -O- RING 1 K-22 2 2302 PLUG 1 29 22 GASKET 1 K-212,K-231,K-203,K-22 30 X-3-50 CONICAL WASHER 2 5/1" 31 X--550 CAPSCREW 2 5/1"-1X1" 12 PT 32 30101 OIL TRANSFER TUBE 3003 1 K-203 33 133 MAGNET 1 S-15 3 30032 OIL PAN 1 35 300 WASHER 1 3 3003 DRAIN PLUG 1 3 X-3-50 CONICAL WASHER 20 5/1" 3 X--550 CAPSCREW 20 5/1"-1X1" 12 PT 39 23109 -O- RING 1 K-22,K-2 0 2231 CONNECTOR 1 1 5500503 OIL FILL TUBE 1 STANDARD 2 5501020 DIPSTICK 5501003 1 STANDARD 3 23029 -O- RING 1 K-22 A-55 VALVE ASSY 1 K-22 5 30052 CAP 1 K-22 #2 CONVERTER HSG KIT 30032 1 302219 SNAP RING 1 K-2911 30221 PUMP GEAR 1 9 X-1-100 NUT 1 5/"-1 K-250,K-22 50 2299 SEAL RING 1 K-212,K-2399,K-250 51 A-119 FILTER BYPASS VALVE ASSY A - 0 A - 393 1 K-2393R,K-22 55 X--01 CAPSCREW 1 3/"-1X3/" 5 3002 CLAMP 1 K-2,K-25,K-2 5 X-10-05 WASHER 1 3/" K-290,K-291,K-292,K-293,K-293R,K- 3201 5 X-9-0 NUT 1 3/"-1 0 125 ELBOW 2 1/" 12

Group: COUNTERSHAFT & BRGS(AUX) 3 2 1 102-/92 Aux CS COUNTERSHAFT & BRGS(AUX) 1 9 BEARING 2 K-223,K-235,K-21,S-19 2 A-535 WELDED COUNTERSHAFT A - 2,A - 5051 2 C/S 30032 - D/G 192 ASSY 3 1052 BEARING 100 2 K-223,K-235,K-21 123 SNAP RING 2 K-190,K-223,K-235,K-21 13

Group: COUNTERSHAFT ASSY 11 13 12 5 15 1 9 10 2 1 5 3 1031-1/92 CS/RT COUNTERSHAFT ASSY 1 131 SNAP RING 2 K-229,K-2290,K-25,K-2,K-2,K- 2,K-229,K-230 2 13 BEARING 2 K-229,K-2290,K-25,K-2,K-2 3 K-2935 CNTRSHFT-LOWER 200,2211 1 3 K-293 CNTRSHFT-UPPER 1959 1 X--E KEY 2 5 2511 ROLL PIN 300 KEY 193 2 21025 1ST GEAR-CNTRSHFT 1929 2 212 2ND GEAR-CNTRSHFT 1923 2 9 2122 OD GEAR-CNTRSHFT 1939,2102 2 10 15953 PTO GEAR - LOWER 1 10 200 PTO GEAR - UPPER 1 11 30509 DRIVE GEAR-CNTRSHFT 2101 2 12 1919 SNAP RING 2 13 30599 BEARING 302 3059 2 K-229,K-2290,K-25,K-2,K-2,K- 2 1 3005 RETAINER 195 2 ROLL PIN NO LONGER REQUIRED 15 X--1005 CAPSCREW 2 5/"-1X1-3/" 1

Group: ECU CONTROLS Sub-Group: AUTO SHIFTER ASSY 5 * 2 5 50 50 * 2 50 25 2 2 2022-11-93 ECU CONTROLS * Indicates connection for Auto Shifter Harness Assembly AUTO SHIFTER ASSY 2 K-293 AUTO SHIFTER KIT A - 551,K - 235 1 2 K-293R REMAN AUTOSHIFTER KIT K - 300 1 25 119 -O- RING 1 K-233,K-293 2 91303 GASKET 22592 1 K-212,K-235,K-233,K-293,S-1 2 X-10-00 WASHER 3/" 2 X--101 CAPSCREW 3/"-1X1-1/2" 5 22 YOKE X-1-00 NUT /1"-20 50 91 SHIFT SENSOR SWITCH 2255 3 K-233,S-1 15

ECU CONTROLS BAR HOUSING COVER ASSY 2.002 AUTOSELECT ECU P/N CHART 1 30111 GASKET 1 K-212,K-235,K-233,K-25,K-290,K- 291,K-292,K-293,S-1 935 BREATHER 1 9332 BUSHING 1 X-12-05 PIPE PLUG 1 X--15 CAPSCREW 2 3/"-1X-1/" 1 X--90 CAPSCREW 3 3/"-1X5" 2 X-10-05 WASHER 2 3/" K-290,K-291,K-292,K-293,K-293R,K- 3201 3 X-1-0 NUT 1 3/"-2 30009 SHIFT CONTROL LEVER 1 5/ POSITION 3000 SHIFT CONTROL LEVER 1 POSITION 5 30002 SHIFT INDICATOR PLATE 1 5 POSITION 5 3000 SHIFT INDICATOR PLATE 1 POSITION 5 30005 SHIFT INDICATOR PLATE 1 POSITION 233 WASHER 15 K-235,K-233,K-290,K-291,K-292,K- 293,S-1 225 WASHER 1 X-1-05 NUT X 9 02 2 K-25 9 30005 BRACKET 1 OPTION A - USE X--90 CAPSCREWS 9 300055 BRACKET 1 OPTION C - USE X--90 CAPSCREWS 9 30005 BRACKET 1 OPTION B - USE 2 PCS 300051 AND X- -103 CAPSCREWS W/THIS BRACKET 10 300053 CLAMP 1 K-25 11 300092 -U- BOLT 1 K-25 12 X--100 CAPSCREW 1 3/"-1X-1/" 13 X-- CAPSCREW 9 3/"-1X-3/" 1

Group: FILTER REGULATOR NSS 2 2 2 11 5 10 9 2015-11-93 NSS Ð Not Sold Separately FILTER REGULATOR 2 K-19 -O- RING/ELEMENT KIT 1 FOR FILTER REGULATOR 5 230 ELBOW 1 X-12-20 PIPE PLUG 2 1/" NPT A-55 120 ELBOW 1 1/" 1511 -O- RING 2 K-2301 9 A-533 FILTER REGULATOR ASSY 22 1-2 PSI K-2301 10 X-3-00 LOCKWASHER 2 1/" 11 X--0 SCREW 2 1/"-20X2-1/" 1

Group: FRONT SECTION MISC. Sub-Group: OIL LINES-POWER SYNCHRO 5 9 2055-11-93 FRONT SECTION MISC. OIL LINES-POWER SYNCHRO 5 222 HOSE ASSY 1 K-221,K-23 23 CONNECTOR 1 STRAIGHT K-221,K-22,K-23 222 ELBOW 1 90 DEGREE K-221,K-22,K-23,K-2 222 OIL RESTRICTOR 1 K-221,K-22,K-23,K-2 9 115 CLAMP 1 1

Group: HARNESSES & HARDWARE Sub-Group: HARNESS ASSY-TORQUE CONV 12 BYP 225 NUTSIDE INT 225 NUTSIDE 11 13 10 9 11 10 9 Latest Design 20310-11-93 HARNESSES & HARDWARE HARNESS ASSY-TORQUE CONV A-5519 HARNESS ASSY 1 3009 SPACER 2 9 K-3201 BRACKET KIT 30025,3033 1 10 X-L-1 CAPSCREW 2 3/"-1X2-3/" 11 115 CLAMP 2 12 X-1-09 JAM NUT 2 1/2"-20 13 X-10-05 WASHER 1 3/" K-290,K-290,K-291,K-292,K-293,K- 293R,K-3201 1 K-3201 BRACKET KIT 30025,3033 1 19

Group: HARNESSES & HARDWARE Sub-Group: HARNESS ASY-AUTO SHIFTER S3 S2 5 55 P S2 P3 P1 P2 20300-11-93 5 HARNESSES & HARDWARE HARNESS ASY-AUTO SHIFTER K-291 AUTO SHIFTER KIT A - 551,K - 23 1 20

Group: INPUT SHAFT & DRIVE GEAR 1 3 5 2 10 9 205-11-93 INPUT SHAFT & DRIVE GEAR 1 22500 INPUT SHAFT OIL TUBE 1 S-1 2 190 SNAP RING 1 K-23 3 150 BEARING 1 K-2290,K-23 13 SPACER 1 5 150 SNAP RING 1 K-2290,K-229,K-23 19239 DRIVE GEAR 21019,3025 1 222 PISTON RING 2 K-2399,K-250 2250 PISTON RING 3 K-2399 9 S-1 INPUT SHAFT ASSY 223 1 K-23 10 2011 BUSHING 1 K-2290,S-1 21

KITS & ASSEMBLIES K-22 #2 CONVERTER HSG KIT 30032 1 K-23 BOLT OIL LINE KIT 1 K-22 BOLT ROTATED LINE KIT 1 K-2 BOLT OIL LINE KIT 1 K-291 AUTO SHIFTER KIT A - 551,K - 23 1 K-293 AUTO SHIFTER KIT A - 551,K - 235 1 K-292 AUTO-SHIFTER HARNESS KI K - 239 1 2 VOLT K-235 AUTO-SHIFTER KIT 1 K-233 BALL SWITCH KIT 1 K-23 BASIC OVERHAUL KIT 1 K-2290 BASIC REBUILD KIT 1 K-25 BRACKET KIT 1 S-15 CASE ASSY 2353 1 K-2399 CONVERTOR SEAL KIT 1 K-22,K-2R,K- 29R K-293 COUNTERSHAFT REPL KIT 1959 1 K-2935 COUNTERSHAFT REPL KIT 200,2211 1 K-231 CYLINDER KIT-RANGE 1 K-232 ENG SPEED SENSOR KIT 2259 1 K-2301 FILTER REGULATOR KIT 1 K-212 GASKET KIT 1 K-2290,K-23 S-1 INPUT SHAFT ASSY 223 1 K-23 K-239 KEY & WASHER KIT 1 CONTAINS 3-SIDED KEY S-2 MAINSHAFT ASSY 3030,303913 1 K-23 NO LONGER AVAILABLE 30059 1 A-RATIO S-21 NO LONGER AVAILABLE 302015 1 S-219 NO LONGER AVAILABLE 1 B-RATIO S-21 NO LONGER AVAILABLE 1 A-RATIO K-202 -O- RING KIT-RANGE 1 K-2290,K-23 K-19 -O- RING/ELEMENT KIT 1 FOR FILTER REGULATOR K-231 OIL FILTER KIT 1 K-203 OIL PAN RETRO KIT 1 STANDARD K-250 OIL PUMP KIT 1 K-2911 OIL PUMP KIT 300,3021 1 K-351 OIL SEAL TOOL KIT 1 K-222 OIL SEAL W/SLINGER 19109 200 200 1 K-2290,K-23 K-221 POWER SYNCO LUBE KIT 1 K-29R REMAN 1-A CNVTR KIT K - 311 1 K-2R REMAN 1-B CNVTR KIT K - 301 1 K-293R REMAN AUTOSHIFTER KIT K - 300 1 K-2393R REMAN HYDRA VALVE KIT K - 30 1 K-200R REMAN PWR SYNCHRO KIT K - 30 1 B-RATIO K-239R REMAN PWR SYNCHRO KIT K - 30 1 A-RATIO K-230 REPL KIT-DRIVE GEAR 3005 1 B-RATIO K-290 SENSOR UPDATE KIT 225,K - 231 1 S-1 SHIFT BAR HSG ASSY 2259 1 COMPLETE K-25 SHIFT BAR HSG ASSY 2259 1 HOUSING ONLY K-229 SMALL PARTS KIT 1 S-153 STATOR SUPPORT ASSY 229 1 K-2 SUMP TUBE RETURN KIT K - 220 1 K-25 THROTTLE SENSOR KIT K - 2505 1 0" CABLE K-2 THROTTLE SENSOR KIT K - 232 1 30" CABLE K-2 THROTTLE SENSOR KIT K - 2325 1 5" CABLE 22

Group: MAINSHAFT & SYNCHRO(AUX) 1 2 3 5 Universal Joint Yoke 13 12 9 10 11 20531-11-93 MAINSHAFT & SYNCHRO(AUX) 1 19 SPRING 3 K-229,K-2290,K-25,K-2,K-2,K- 2,K-229,K-230 2 A-331 SYNCHRONIZER ASSY 3039,3039,A - 1 HI RANGE 591 3 22915 SLIDING CLUTCH 1 A-25 SYNCHRONIZER ASSEMBLY A - 93,A - 5 1 LO RANGE 5 1921 MAINSHAFT 1 1332 WASHER 1 K-229 23099 WASHER 1 K-229 2309 NO LONGER AVAILABLE 1 9 132 SNAP RING 1 K-229 10 19 WASHER 1 K-229 11 13 BEARING 1 K-2290,K-2 12 135 SPACER 1 13 2225 NUT 1195 1 S-215,S-219 23

Group: MAINSHAFT ASSY * 12 11 * 9 * * 10 * 5 3 1 2 10321-12-93 3-Sided Key Design Hex (-Sided) Key Design * Updating to 3-Sided Key is Recommended. When Updating to 3-Sided Key Replace all Washers to Match Key Design Always Use Matching Key and Washer Sets (See Appendix - Mainshaft Washers) MAINSHAFT ASSY 1 3015 3-SIDED KEY 300120 1 K-239,K-230 1 K-239 KEY & WASHER KIT 1 CONTAINS 3-SIDED KEY 2 S-2 MAINSHAFT ASSY 3030,303913 1 3 250 ROLL PIN 1 S-2 150 SNAP RING 5 K-229,K-2290,K-25,K-2,K-2,K- 2,K-229,K-230 5 15 REVERSE GEAR-MAINSHAFT 220 1 19 SPACER K-229,K-230 30030 WASHER.2-BLUE 5 K-239,K-229,K-230 30032 WASHER.29-WHITE 5 K-239,K-229,K-230 30033 WASHER.25-GREEN 5 OPTIONAL 30032-3003 OR K-239,K-229,K-230 30030 USE ANY 5 WASHERS. USE WITH 3-SIDED KEY 3003 WASHER.259-ORANGE 5 OPTIONAL 30032-3003 OR K-239,K-229,K-230 30030 USE ANY 5 WASHERS. USE WITH 3-SIDED KEY 30035 WASHER.2-PURPLE 5 OPTIONAL 30032-3003 OR 30030 USE ANY 5 WASHERS. USE WITH 3-SIDED KEY 3003 WASHER.29-YELLOW 5 OPTIONAL 30032-3003 OR 30030 USE ANY 5 WASHERS. USE WITH 3-SIDED KEY 3003 WASHER.2-BLACK 5 OPTIONAL 30032-3003 OR 30030 USE ANY 5 WASHERS. USE WITH 3-SIDED KEY 2212 SLIDING CLUTCH 3 K-25,K-2,K-2 2

9 15 LO GEAR-MAINSHAFT 1 10 2102 1ST GEAR-MAINSHAFT 192 1 11 1922 2ND GEAR-MAINSHAFT 2123,3002 1 12 2121 OD GEAR-MAINSHAFT 193 1 25

MISCELLANEOUS 120 ADHESIVE SEALANT 1 0.5 CC (SINGLE APPLICATION SIZE) 1205 SEALANT 1 2 CC (SINGLE APPLICATION SIZE) K-231,K-23,K-290 30105 SHIFT DIAGRAM LABEL 1 5 POS REVERSE FORWARD 3010 SHIFT DIAGRAM LABEL 1 POS REVERSE REARWARD 3010 SHIFT DIAGRAM LABEL 1 POS REVERSE FORWARD 301121 SHIFT DIAGRAM LABEL 1 POS REVERSE REARWARD 3010 SHIFT DIAGRAM LABEL 1 5 POS REVERSE REARWARD 301120 SHIFT DIAGRAM LABEL 1 POS REVERSE FORWARD 1203 SILICONE LUBE 1 OZ (23.59 CC)-FLEET SIZE 120 SILICONE LUBE 1 CC (SINGLE APPLICATION SIZE) K-231,K-202,K-231 2

Group: OIL LINE RETURN Sub-Group: OIL LINE RETURN/CURRENT 1 2 3 200-11-93 OIL LINE RETURN OIL LINE RETURN/CURRENT 1 301100 ELBOW 2359 1 K-2 2 301101 TUBE 23 1 K-2 3 2359 CONNECTOR 1 K-2 23109 -O- RING 1 K-22,K-2 2

Group: OIL LINE RETURN Sub-Group: OIL LINE RETURN/NON-CURR 1 2 3 5 201-1-9 OIL LINE RETURN OIL LINE RETURN/NON-CURR 1 13 NO LONGER AVAILABLE 1 2 11 ELBOW 1 5 DEG. 3 2251 HOSE ASSY 1 2213 ELBOW 1 5 23109 -O- RING 1 K-22,K-2 2

Group: POWER SYNCHRONIZER 30 35 31 33 3 32 3 2051-11-93 POWER SYNCHRONIZER 30 K-200R REMAN PWR SYNCHRO KIT K - 30 1 31 220 GASKET 1 K-212,K-2392R,K- 239R,K-200R,K- 21R 32 2525 ROLL PIN 2 33 X-10-01 WASHER 2 9/32" 3 X--13 CAPSCREW 2 1/"-20X1-1/2" 35 X-L-3 CAPSCREW 3/"-1X3-3/" 3 X-L-21 CAPSCREW 1 3/"-1X5" 29

Group: RANGE CYLINDER 2 1 5 3 12 13 1 15 9 2053-11-93 1 11 10 RANGE CYLINDER 1 X-L-0 CAPSCREW 3/"-1X1-1/" 2 1990 CYLINDER COVER 1 3 139 GASKET 1 K-212,K-202,K-231 13 -O- RING 1 K-202,K-231 5 131 PISTON 23353 1 K-231 X-L-0 CAPSCREW 3/"-1X1-1/" X-1-1010 NUT 1 5/"-1 K-202,K-231 135 -O- RING 1 K-202,K-231 9 1993 YOKE BAR 1 10 2252 BUSHING 1 A-531 11 15 -O- RING 1 K-202,K-231 12 A-531 RANGE CYLINDER ASSY 2253 1 K-231 13 13 GASKET 1 K-212,K-202,K-231 1 X--25 CAPSCREW 2 1/2"-13X2-3/" 15 3012 SHIFT YOKE 22 1 1 221 BRACKET 1 30

Group: REVERSE IDLER 5 11 Latest Design 12 2 3 5 1 2 3 9 1031-11/92 RI Old Design REVERSE IDLER 1 X-1-100 NUT 2 5/"-1 2 123 IDLER PLATE 2 K-321 3 30292 WASHER 122 2 K-321,S-112 12 BEARING 305020 2 K-1,K-190 5 15 REVERSE IDLER GEAR 2209 2 103 WASHER 2 K-321 K-321 IDLER SHAFT REPL KIT 30291 2 5202 PLUG 2 9 122 NO LONGER AVAILABLE 2 11 30333 RETAINING RING 2 K-321 12 X--100 CAPSCREW 2 5/"-1X1-1/ K-321 31

Group: STATOR SUPPORT ASSY 3 2 1 5 2021A-1-9 STATOR SUPPORT ASSY 1 229 SEAL RING 1 K-2399,K-250 2 S-153 STATOR SUPPORT ASSY 229 1 3 22 GASKET 1 K-212,K-250,K-22,S-153 X-1-00 STEEL BALL 1 /1" S-153 5 22 SPRING 1 S-153 231 PLUG 1 S-153 X-L-1 CAPSCREW X 1 3/"-1X2-3/" X-12-20 PIPE PLUG 2 1/" NPT S-153 32

Group: TORQUE CONVERTER ASSY 3 33 32 35 30 31 2030-11-93 TORQUE CONVERTER ASSY 30 X--5 CAPSCREW X 12 3/"-1X1" 31 3012 PILOT 1 32 223 -O- RING 1 K-2399,K-250 33 229 SEAL RING 2 K-2399,K-250 3 2229 SNAP RING 1 K-2399 35 K-2R REMAN 1-B CNVTR KIT K - 301 1 33

Group: VALVES Sub-Group: AIR SYS-POWER SYNCHRO 1 1 15 13 1 1 2012-11-93 VALVES AIR SYS-POWER SYNCHRO 13 120 ELBOW 2 1/" 1 5552 HOSE ASSY 1 2" 15 55523 HOSE ASSY 1 29" 1 19 HOSE CLAMP 12152 1 1 125 ELBOW 2 1/" 3

Group: VALVES Sub-Group: AIR SYS-RANGE 3 9 2 1 5 10 11 3 20100-11-93 VALVES AIR SYS-RANGE 1 K-299 RANGE VALVE KIT A - 533 1 2 22551 GASKET 1 K-212,K-299 3 2239 PLUG 2 30010 INSERT VALVE 221,30315 2 5 X-3-500 LOCKWASHER 5/1" X--5 SCREW 5/1"-1X2" 120 ELBOW 2 1/" 55505 HOSE ASSY 1 1" 9 55533 HOSE ASSY 1 1-1/2" 10 120 ELBOW 1 1/" 11 125 ELBOW 1 1/" 35

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. 5/32" Air Line and Harness Combinations Line Type Line Color Order Part No# Length Supply + Port Red (S) + Black (P) 5201 50 ft Splitter + Deep Reduction Blue (SP) + Green (H/L) 5201 50 ft Supply + Splitter + Port Red(S)+Blue(SP)+ Black(P) 01 50 ft 5/32" Air Lines Line Type Line Color Order Part No# Length Supply Red (S) 5120 50 ft Port Black (P) 5320 50 ft Splitter Blue (SP) 520 50 ft Deep Reduction Green (H/L) 5520 50 ft Sheathing 0120 50 ft 1/" Air Lines Line Type Line Color Order Part No# Length Supply White 52 50 ft Port Black 2013 50 ft Sheathing 0000 50 ft 1050-1/92 AL Chart 3

3

Copyright Eaton and Dana Corporation, 2002. 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 1-00-2-HELP (35) 2 hours a day, days a week, (Mexico: 001-00-2-HELP (35)) for more time on the road. Or visit our web site at www.roadranger.com. 3 RTO-9109B-AT /05 Printed in the USA