More time on the road Illustrated s List FS-4205A November 2012
Contents How To Use The Illustrated s List... CASE... 4 COUNTERSHAFT ASSY... 8 INPUT SHAFT... 9 KITS & ASSEMBLIES... 11 LEVER ASSY... 1 MAINSHAFT ASSY... 15 MISCELLANEOUS... 17 REMOTE CONTROL... 18 REVERSE IDLER GEAR ASSY... 20 SHIFT BAR HOUSING... 21 2
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. Item 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 Item 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
Group: CASE 1 2 0 4 29 1 5 4 7 6 7 2 28 26 16 15 27 2 24 22 5 6 20 18 19 17 17 1 9 12 14 11 10 17 4 5 21 00180-4-9 CASE Item 1 A-5205 CLUTCH HSG ASSY 21646 1 #2 ALUMINUM, BELOW CENTER LINE PUSH TYPE 1 A-5629 CLUTCH HSG ASSY 2721,229219 1 # PUSH-IRON 1 A-564 CLUTCH HSG ASSY 2726,1626,1627,A - 562,A - 5771 1 #2 ALUMINUM, ABOVE CENTER LINE PULL TYPE 1 A-5751 CLUTCH HSG ASSY 400418 1 #2 ALUMINUM, BELOW CENTER LINE PUSH TYPE 1 A-751 CLUTCH HSG ASSY 1629 1 #2 ALUMINUM, PUSH TYPE (FORK) 2 S-1874 CASE ASSY 400878 1 2 S-192 CASE ASSY 400816,40102,401099 1 2 S-1924 NO LONGER AVAILABLE 4010 1 20198 PTO COVER 2 4
Item 4 201400 GASKET 2 K-214 5 2961 CAPSCREW 12 /8"-16X5/8" 6 X-12-1210 PIPE PLUG X12 1206 1 7 X-12-1207 PIPE PLUG X12 1202 X12 1206 1 /4" MAGNETIC 10 2978 PLUG 1 K-2144,K-7000,K- 701 11 240040 SNAP RING 1 K-2144 12 280 COVER 206466 1 A-5205,A-5629,A- 564,A-5751,A-751 1 1C408 CAPSCREW 2 1/4"-20 14 X--400 LOCKWASHER 4E04 2 1/4" 15 X-8-90 CAPSCREW 1C96 4 9/16"-12X2-1/4" 16 4E09 LOCKWASHER 4 9/16" 17 12815 BUSHING 4 A-5629,A-564,A- 5751 17 8677 BUSHING 2 USE W/A-5205 CLUTCH HSG ASSY A-5205 18 400121 OIL SEAL 1562 1 SHAFT 1.87, WIDTH.75, OD 2.68 18 400204 OIL SEAL 2594 1 SHAFT 1.87, WIDTH.75 18 400798 OIL SEAL 259 1 SHAFT 1.625, WIDTH.75 K-7000,K-701 19 2147 FRONT BRG COVER- PULL 19 2774 FRONT BRG COVER- PUSH 19 28870 FRONT BRG COVER- PUSH 19 29821 FRONT BRG COVER- PUSH 19 40054 FRONT BRG COVER- PUSH 19 40055 FRONT BRG COVER- PUSH 19 400882 FRONT BRG COVER- PUSH 1558 1 USE 400121 OIL SEAL 1 USE 400798 OIL SEAL 1 USE 400798 OIL SEAL 1 USE 400798 OIL SEAL 1 USE 400204 OR 400798 OIL SEAL 1 USE 400204 OIL SEAL 275 1 USE 400798 OIL SEAL 20 24021 GASKET 1 K-214 21 29614 SCREW 4 5/16-18X.81 22 400261 C/S REAR BRG COVER 1 2 240017 SHIM.004 1 QUANTITY AS REQUIRED K-2116 5
Item 2 240018 SHIM.007 1 QUANTITY AS REQUIRED K-2116 2 240019 SHIM.010 1 QUANTITY AS REQUIRED K-2116 2 240020 SHIM.020 1 QUANTITY AS REQUIRED K-2116 2 400980 SHIM.040 1 K-2116 24 X-8-688 CAPSCREW 4 /8"-16X1" 26 K-919 BEARING KIT 654166, 65417 1 27 21555 SPEEDO ROTOR 1 27 1456 SPEEDO DRIVE GEAR 1 5 TEETH 27 14448 SPEEDO DRIVE GEAR 1 6 TEETH 27 8601 SPEEDO DRIVE GEAR 1 5 TEETH 28 294 STUD 4 1/2"-20X2-5/16" S-1874,S-1924 29 24029 SHIM.004 1 QUANTITY AS REQUIRED K-2116 29 2400 SHIM.007 1 QUANTITY AS REQUIRED K-2116 29 2401 SHIM.010 1 QUANTITY AS REQUIRED K-2116 29 2402 SHIM.020 1 QUANTITY AS REQUIRED K-2116 29 400981 SHIM.040 1 K-2116 0 20885 OIL SEAL 1 0 40020 OIL SEAL 229985 2798 1 SHAFT 2.50, WIDTH.5 K-7000,K-701 1 400846 REAR BRG COVER 241101 1 USE 40020 OIL SEAL 1 400849 NO LONGER AVAILABLE 241615 1 USE 40020 OIL SEAL 1 400877 REAR BRG COVER 241099 1 USE 40020 OIL SEAL 1 400970 REAR BRG COVER 15498 1 USE 20885 OIL SEAL 1 400972 REAR BRG COVER 241102 1 USE 40020 OIL SEAL 1 40105 REAR BRG COVER 241100 1 USE 40020 OIL SEAL 1 K-708 REAR BRG COVER KIT 402614 1 USE 40020 OIL SEAL NOTE: PUSH-IN TYPE SPEEDO SENSOR 1 K-709 REAR BRG COVER KIT 402615 1 USE 40020 OIL SEAL NOTE: PUSH-IN TYPE SPEEDO SENSOR 1 S-700 REAR BRG COVER ASSY 400845,40207 1 USE 40020 OIL SEAL NOTE: SENSOR SEAL REQUIRED 1 S-701 REAR BRG COVER ASSY 401677,40209 1 USE 40020 OIL SEAL NOTE: SENSOR SEAL REQUIRED 2 86D8 NUT 86D08 4 1/2"-20 2946 WASHER 4 1/2" 6
Item 4 2197 NUT 21605,25656,28026 1 1-1/4"-18 5 401954 SENSOR SEAL 1 S-700,S-701 6 86016 SLEEVE 1 7 147 MAGNET 1 S-192,S-1924 9 40001 FITTING-45 DEGREE 11H15 2 9 4872 FITTING-90 DEGREE 12H15 2 7
Group: COUNTERSHAFT ASSY 8 4 1 6 5 10 9 7 0000-4/9 COUNTERSHAFT ASSY Item 1 K-4156 BEARING KIT (C/S FRONT) 672070, 675246 1 240767 SNAP RING 1 K-2144 4 241012 DRIVE GEAR-CNTRSHFT 1 5 40155 4TH GEAR-CNTRSHFT 1 6 40156 RD GEAR-CNTRSHFT 1 7 241017 2ND GEAR-CNTRSHFT 1 8 20292 KEY 2 K-2144 9 40157 COUNTERSHAFT 1 10 K-4157 BEARING KIT (C/S REAR) 666554, 7062 1 8
Group: INPUT SHAFT 4 5 6 1 2 00400-4/9 INPUT SHAFT Item 1 401526 INPUT SHAFT-1.50" PUSH 1 401614 IN/SHAFT- 1.75"PUSH/PULL 1 401615 IN/SHAFT- 1.50"PUSH/PULL 1 401616 INPUT SHAFT-1.50" PUSH 1 401618 INPUT SHAFT-1.50" PUSH 1 USE 400882 FRONT BRG COVER 1 USE 2147 OR 400882 FRONT BRG COVER 1 USE 2147 FRONT BRG COVER 1 USE 400882 FRONT BRG COVER 1 USE 400882 FRONT BRG COVER 1 401619 NO LONGER AVAILABLE 1 USE 29821 OR 400882 FRONT BRG COVER 1 401620 INPUT SHAFT-1.50" PUSH 1 401622 INPUT SHAFT-1.75" PUSH 2 K-415 BEARING KIT (INPUT SHAFT) 2 K-4154 BEARING KIT (INPUT SHAFT) 25417, 25418 1 1.75" INPUT 1 USE 40054 OR 40055 FRONT BRG COVER 1 USE 2774 FRONT BRG COVER 114774, 11477 1 1.118",1.75" & 1.50" INPUT 4 25414 BEARING 14 K-7000,K-701 5 25415 WASHER 1 K-2144 6 25416 SNAP RING 1 K-2144 9
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KITS & ASSEMBLIES Item K-2116 SHIM KIT 1 K-214 GASKET KIT 1 K-2144 SMALL PARTS KIT 1 K-421 SYNCHRONIZER KIT K - 7004 1 K-479 SYNCHRONIZER KIT K - 7005 1 K-919 BEARING KIT 654166, 65417 1 K-7000 BASIC REBUILD KIT 1 1.50 INPUT - 2.00 OUTPUT K-701 BASIC REBUILD KIT 1 1.75 INPUT SHAFT K-708 REAR BRG COVER KIT 402614 1 K-709 REAR BRG COVER KIT 402615 1 K-7061 SHIFT LEVER HSG KIT 241075,402711,A - 649 K-7062 SHIFT LEVER HSG KIT 2080,402711,A - 6440 S-1578 SHIFT LEVER ASSY - 1/2" 1 ALUMINUM HOUSING MEDIUM - LEVER HEIGHT -1/8" 1 ALUMINUM HOUSING HIGH - LEVER HEIGHT -1/2" 1 COMPLETE ASSY - ALUMINUM HOUSING HIGH - LEVER HEIGHT -1/2" 27-1/2" STRAIGHT LEVER - "BEND TO SUIT" /8" X 24 THREAD S-1827 SHIFT LEVER ASSY - 1/8" S-7079 1 COMPLETE ASSY - ALUMINUM HOUSING MEDIUM - LEVER HEIGHT -1/8" 27-1/2" STRAIGHT LEVER - "BEND TO SUIT" /8" X 24 THREAD S-1874 CASE ASSY 400878 1 S-192 CASE ASSY 400816,40102,401099 1 S-1924 NO LONGER AVAILABLE 4010 1 S-700 REAR BRG COVER ASSY 400845,40207 1 S-701 REAR BRG COVER ASSY 401677,40209 1 S-7045 SHIFT LEVER ASSY 2-7/8" S-7077 SHIFT BAR HOUSING ASSY 1 COMPLETE ASSY - ALUMINUM HOUSING LOW - LEVER HEIGHT 2-7/8" " STRAIGHT LEVER - "BEND TO SUIT" /8" X 24 THREAD 2984,402944 1 COMPLETE REVERSE SWITCH POSITION - RIGHT FRONT S-7085 SHIFT BAR HSG ASSY 4006,402956 1 COMPLETE - W/NEUTRAL SWITCH PROVISION REVERSE SWITCH POISTION - RIGHT REAR 11
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Group: LEVER ASSY 9 6 5 Height 4 8 8 8 1 10 2 2 11 2 7 00171--94 LA LEVER ASSY Item 1 K-7062 SHIFT LEVER HSG KIT 2080,402711,A - 6440 1 ALUMINUM HOUSING HIGH - LEVER HEIGHT -1/2" 2 201054 PIN 2 FOR HSGS WITHOUT PIN SLEEVES 1
Item 2 2180 PIN 2 FOR HSGS WITH PIN SLEEVES K-7061,K-7062,K- 7065,S-1578,S- 1827,S-7045 400690 SPRING 2297 1 S-1578,S-1827,S- 7045 4 2181 WASHER 1 S-1578,S-1827,S- 7045 5 21722 SHIFT LEVER 27-1/2" 1 USE WITH K-7062 STRAIGHT LEVER - "BEND TO SUIT" S-1578 5 228648 GEAR SHIFT LEVER 1 USE WITH 2080 STRAIGHT LEVER - "BEND TO SUIT" 5 241076 SHIFT LEVER 27-1/2" 1 USE WITH K-7061 STRAIGHT LEVER - "BEND TO SUIT" 5 40282 SHIFT LEVER " 1 USE WITH A-6448 STRAIGHT LEVER - "BEND TO SUIT" S-1827 S-7045 6 202484 DUST COVER 1 S-1578,S-1827,S- 7045 7 401958 GASKET 1 K-214,K-7061,K- 7062,K-7065,S- 1578,S-1827,S-7045 8 X-8C-604 CAPSCREW 4 /8"-16X1-1/4" 9 201401 SHIFT KNOB 1 /8"X24 THREAD S-1578,S-7045 10 K-7061 SHIFT LEVER HSG KIT 241075,402711,A - 649 11 K-7065 SHIFT LEVER HSG KIT 402704,402711,A - 6448 1 ALUMINUM HOUSING MEDIUM - LEVER HEIGHT -1/8" 1 ALUMINUM HOUSING LOW - LEVER HEIGHT 2-7/8" 14
Group: MAINSHAFT ASSY 11 12 1 1 14 4 1 5 15 16 17 6 7 18 8 9 10 19 20 10 21 12 24 25 26 2 18 22 00200-4/9 MS 42 MAINSHAFT ASSY Item 1 K-704 BEARING & RACE KIT 2582,258 1 00145 SYNCHRONIZER CUP 401565 2 K-479 4 A-6609 SYNCHRONIZER ASSY 4/5 A - 6144 1 K-479 5 40689 CLUTCH HUB 4/5 40154 1 6 40796 4TH GEAR-MAINSHAFT 401527 1 7 29651 BEARING 1 K-7000,K-701 8 224069 SNAP RING 1 9 2127 WASHER 1 K-2144 10 10J06 STEEL BALL 2 /16" K-2144 11 401528 RD GEAR-MAINSHAFT 1 12 29818 BEARING 2 K-7000,K-701 15
Item 1 401467 SYNCHRONIZER CUP 2 K-421 14 A-6608 SYNCHRONIZER ASSY 2/ A - 617 1 K-421 15 24007 SNAP RING 1 K-2144 16 4015 CLUTCH HUB 2/ 1 17 401529 2ND GEAR-MAINSHAFT 1 18 2965 BEARING 2 K-7000,K-701 19 2579 RETAINER 1 K-2144 20 2578 SPLIT WASHER 2 K-2144 21 40150 1ST GEAR-MAINSHAFT 1 22 401566 SLIDING CLUTCH 1 2 40152 MAINSHAFT 1 24 40151 REVERSE GEAR- MAINSHAFT 1 25 240026 WASHER 1 K-2144 26 K-919 BEARING KIT 654166, 65417 1 16
MISCELLANEOUS Item 7120 SILICONE LUBE 1 8 OZ (26.59 CC)-FLEET SIZE 71204 ADHESIVE SEALANT 1 0.5 CC (SINGLE APPLICATION SIZE) 71205 SEALANT 1 2 CC (SINGLE APPLICATION SIZE) 71206 SILICONE LUBE 1 4 CC (SINGLE APPLICATION SIZE) 7121 GASKET SEALANT 1 8 MILLILITER SIZE K-2116 7122 THREAD ADHESIVE 1 10 MILLILITER SIZE K-7000,K-701 17
Group: REMOTE CONTROL 2 14 5 4 1 Indicates part of item 1 6 11 7 * * 9 8 10 12 999 * Use Lockwire at these positions 1 Lever Height 00151-2-94 RCH REMOTE CONTROL Item 1 16284 NO LONGER AVAILABLE 16285 1 2 12F100 PLUG 1" 1 12252 BUSHING 4 X-8C-604 CAPSCREW 4 /8"-16X1-1/4" 5 15948 BREATHER 1 USE WITH 16284 HOUSING ASSY 5 400217 BREATHER 1 6 16290 SHIFT FINGER 1 7 15272 SCREW 2 8 12745 WASHER 1 9 1587 SPRING 1 18
Item 10 12225 OIL SEAL 1 11 401958 GASKET 1 K-214,K-7061,K- 7062,K-7065,S- 1578,S-1827,S-7045 12 1402 BOOT 1 1 16288 NO LONGER AVAILABLE 1 LEVER HEIGHT 5-1/8" 1 A-512 SHAFT & LEVER ASSY 1 LEVER HEIGHT 85MM (.5") 999 A-5497 NO LONGER AVAILABLE 1 LEVER HEIGHT 5-1/8" 19
Group: REVERSE IDLER GEAR ASSY 22 20 2 20 26 21 26 24 25 00450-4/9 RI 42 REVERSE IDLER GEAR ASSY Item 20 24002 WASHER 2 K-2144 21 240024 SPACER 1 K-2144 22 401592 IDLER GEAR 29799 1 2 240022 IDLER SHAFT 1 24 201929 SHAFT LOCK 1 25 X-8C-600 CAPSCREW 29611 1 /8"-16X1" 26 2576 BEARING 52 K-7000,K-701 20
Group: SHIFT BAR HOUSING 5 6 7 8 9 11 1 11 11 1 * 25 22 2 26 0 2 27 * 15 16 17 10 14 12 1 2 24 25 29 2 27 1 28 20 21 * Neutral Switch Provision 21 4 1 20 999 00100-4/9 SHIFT BAR HOUSING Item 1 A-654 SHIFT BAR HSG ASSY 2984,402944 1 HOUSING ONLY REVERSE SWITCH POISTION - RIGHT FRONT 1 A-658 SHIFT BAR HSG ASSY 4006,402956 1 HOUSING ONLY - W/NEUTRAL SWITCH PROVISION REVERSE SWITCH POISTION - RIGHT REAR 2 24008 GASKET 1 K-214,S-7077,S- 7085 10J14 STEEL BALL 10 7/16" - REVERSE SWITCH 10J14 STEEL BALL 1 7/16" - W/NEUTRAL SWITCH PROVISION 4 4099 SPRING 201045 5 25621 PLUG 1" 1 6 25622 GASKET 1 K-214 7 240496 SPACER 1 8 2794 SPRING 1 9 2576 PLUNGER 1 10 25052 CA PLUG 1 9/16-18 10 40656 PLUG 15917 1 9/16-18, THREADED 21
Item 11 X-8C-600 CAPSCREW 29611 1 /8"-16X1" 12 401719 BALL RETAINER- REVERSE 1 1 2870 LIFTING EYE 2 14 15900 GASKET 1 K-214,S-7077,S- 7085 15 40655 PLUG 17178 1 S-7085 16 17179 GASKET 1 S-7085 17 401718 BALL RETAINER- NEUTRAL 1 20 204 CAPSCREW 4 /8"-16X1" - USE W/401277 RETAINER 21 401277 SHIFT BAR RETAINER 2 22 401541 YOKE BAR 1ST/REV 1 USE W/2984, 402944 OR A-654 HOUSING 22 402656 YOKE BAR 1ST/REV 1 USE W/4006, 402956 OR A- 658 HOUSING 2 401540 YOKE BAR 2ND/RD 1 24 40159 YOKE BAR 4TH/5TH 1 25 201044 PIN 2 W/NEUTRAL SWITCH PROVISION 25 201044 PIN 1 REVERSE SWITCH 26 400402 SHIFT BLOCK 1ST/REV 1 27 14J1818 PIN 2 28 A-6146 YOKE ASSY 2ND/RD 401595 1 29 A-6145 YOKE ASSY 4TH/5TH 40159 1 0 400401 SHIFT YOKE 1ST/REV 1 1 227675 INSERT - YOKE PAD 4 A-6145,A-6146,K- 2144 2 1JM6028 PIN 2 1JM528 PIN 2 999 S-7077 SHIFT BAR HOUSING ASSY 2984,402944 1 COMPLETE REVERSE SWITCH POSITION - RIGHT FRONT 999 S-7085 SHIFT BAR HSG ASSY 4006,402956 1 COMPLETE - W/NEUTRAL SWITCH PROVISION REVERSE SWITCH POISTION - RIGHT REAR 22
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