More time on the road Illustrated s List FS-5005A November 2012
Contents How To Use The Illustrated s List... CASE... 4 COUNTERSHAFT ASSY... 8 INPUT SHAFT... 10 KITS & ASSEMBLIES... 11 LEVER ASSY... 12 MAINSHAFT ASSY... 14 MISCELLANEOUS... 16 REMOTE CONTROL... 17 REVERSE IDLER GEAR ASSY... 19 SHIFT BAR HOUSING... 20 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 9 8 41 1 2 4 47 48 7 6 5 4 6 1 7 52 26 49 28 19 20 18 46 5 2 12 11 10 46 42 4 4 5 22 24 2 50 22 25 49 51 21 46 40 44 45 00181-6-94 CASE Item 1 S-1911 CASE ASSY 400218 1 1 S-1922 CASE ASSY 40098 1 METRIC BOSS HOLES 2 20548 CLUTCH HSG ASSY 20549 1 #2 PUSH-IRON W/10H25 FITTINGS 2 A-5205 CLUTCH HSG ASSY 21646 1 #2 ALUMINUM, BELOW CENTER LINE PUSH TYPE 2 A-564 CLUTCH HSG ASSY 2726,1626,1627,A - 562,A - 5771 1 #2 ALUMINUM, ABOVE CENTER LINE PULL TYPE 2 A-5751 CLUTCH HSG ASSY 400418 1 #2 ALUMINUM, BELOW CENTER LINE PUSH TYPE 2 A-751 CLUTCH HSG ASSY 1629 1 #2 ALUMINUM, PUSH TYPE (FORK) 4
Item 20198 PTO COVER 2 4 201400 GASKET 2 K-2085 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 15679 PLUG 1 K-212 11 15686 SNAP RING 1 K-212 12 10H25 FITTING-STRAIGHT 2 12 40001 FITTING-45 DEGREE 11H15 2 18 400121 OIL SEAL 1562 1 SHAFT 1.87, WIDTH.75, OD 2.68 K-212 18 400204 OIL SEAL 2594 1 SHAFT 1.87, WIDTH.75 K-212 18 400798 OIL SEAL 259 1 SHAFT 1.625, WIDTH.75 K-2121,K-2122 19 2147 FRONT BRG COVER- PULL 19 2557 FRONT BRG COVER- PUSH 19 2558 FRONT BRG COVER- PUSH 19 25650 FRONT BRG COVER- PULL 19 40054 FRONT BRG COVER- PUSH 19 40055 FRONT BRG COVER- PUSH 19 400882 FRONT BRG CVR- PUSH/PULL 1558 1 USE 400121 OIL SEAL 1 USE 400204 OIL SEAL 1 USE 400798 OIL SEAL 1 USE 400204 OIL SEAL 1 USE 400204 OR 400798 OIL SEAL 1 USE 400204 OIL SEAL 275 1 USE 400798 OIL SEAL 20 2540 SHIM.004 1 QUANTITY AS REQUIRED 20 25404 SHIM.007 1 QUANTITY AS REQUIRED 20 25405 SHIM.010 1 QUANTITY AS REQUIRED 20 25406 SHIM.020 1 QUANTITY AS REQUIRED 20 400979 SHIM.040 1 21 29614 SCREW 4 5/16-18X.81 22 22015 SHIM.004 1 QUANTITY AS REQUIRED 22 22016 SHIM.007 1 QUANTITY AS REQUIRED 22 22017 SHIM.010 1 QUANTITY AS REQUIRED 22 22018 SHIM.020 1 QUANTITY AS REQUIRED 5
Item 22 400982 SHIM.040 1 2 22011 NO LONGER AVAILABLE 1 24 9G416H SCREW 2 1/4"-20X1" 25 X-12-405 PIPE PLUG 1 26 2201 BEARING RETAINER 1 28 X-8C-604 CAPSCREW 4 /8"-16X1-1/4" 1 2261 SNAP RING 1 K-2121,K-2122,K- 212 2 21558 SPEEDO ROTOR 1 16 TEETH - 1.96 OUTPUT 2 14685 SPEEDO DRIVE GEAR 1 6 TEETH - 1.96 OUTPUT 400852 GASKET 2565 267 401096 1 K-2085,K-7041,K- 7042 4 241705 REAR BRG COVER 1 USE 400119 OIL SEAL 4 K-7041 REAR BRG COVER KIT 402617 1 USE 400119 OIL SEAL NOTE: PUSH-IN TYPE SPEEDO SENSOR 4 K-7042 REAR BRG COVER KIT 402618 1 USE 400119 OIL SEAL NOTE: PUSH-IN TYPE SPEEDO SENSOR 4 S-702 NLA-REAR BRG COVER ASSY 2247,401986 1 USE 40020 OIL SEAL NOTE: SENSOR SEAL REQUIRED 4 S-70 REAR BRG COVER ASSY 241,40202 1 USE 2484 OR 400119 OIL SEAL NOTE: SENSOR SEAL REQUIRED 4 S-704 REAR BRG COVER ASSY 21557,402000 1 USE 2484 OR 400119 OIL SEAL NOTE: SENSOR SEAL REQUIRED 5 294 STUD 4 1/2"-20X2-5/16" S-1922 6 2946 WASHER 4 1/2" 7 86D8 NUT 86D08 4 1/2"-20 8 2484 OIL SEAL 1 SHAFT 2.505, WIDTH.4 8 25655 OIL SEAL 1 SHAFT 2.75, WIDTH.5 K-2121,K-212 8 400119 OIL SEAL 1 SHAFT 2.75, WIDTH.5 K-2121,K-212 8 40020 OIL SEAL 229985,2798 1 SHAFT 2.50, WIDTH.5 9 2197 NUT 21605,25656,28026 1 1-1/4"-18 40 280 COVER 206466 1 A-5205,A-564,A- 5751,A-751 41 147 MAGNET 1 S-1911,S-1922 42 X--1000 LOCKWASHER 4 5/8" 4 X-8-1011 CAPSCREW 1C106 4 5/8"-11X2-1/4" 6
Item 44 X--400 LOCKWASHER 4E04 2 1/4" 45 1C408 CAPSCREW 2 1/4"-20 46 12815 BUSHING 4 A-564,A-5751 46 8677 BUSHING 2 A-5205 47 16225 SLEEVE 1 48 401954 SENSOR SEAL 1 S-702,S-70,S- 704 49 2870 LIFTING EYE 1 50 40160 BEARING RETAINER 1 51 X-8-688 CAPSCREW 4 /8"-16X1" 52 22014 GASKET 1 K-2085 7
Group: COUNTERSHAFT ASSY 5 4 1 1 6 6 Latest Design 0001-5/9 CS 52 COUNTERSHAFT ASSY Item 1 K-859 COUNTERSHAFT BRG KIT 654166, 79194 2 224024 SNAP RING 1 A-626,K-212 4 401181 DRIVE GEAR-CNTRSHFT 1 A-626 4 A-626 COUNTERSHAFT ASSY 1 8
Item 5 40118 4TH GEAR-CNTRSHFT 1 A-626 5 A-626 COUNTERSHAFT ASSY 1 6 401185 COUNTERSHAFT 1 A-626 6 A-626 COUNTERSHAFT ASSY 1 9
Group: INPUT SHAFT 4 5 6 1 2 00400-4/9 INPUT SHAFT Item 1 2551 INPUT SHAFT-1.50" PUSH 1 USE 400882 FRONT BRG COVER 1 255 NO LONGER AVAILABLE 1 USE 2558 FRONT BRG COVER 1 2554 INPUT SHAFT-1.50" PUSH 1 254 INPUT SHAFT-1.75" PUSH 1 25648 IN/SHAFT-1.75" PUSH/PUL 1 USE 2558 OR 40054 FRONT BRG COVER 1 USE 2557 FRONT BRG COVER 1 USE 2147 OR 25650 FRONT BRG COVER 1 40042 NO LONGER AVAILABLE 1 USE 40055 FRONT BRG COVER 1 400885 INPUT SHAFT-1.50" PUSH 2 K-415 BEARING KIT (INPUT SHAFT) 2 K-4154 BEARING KIT (INPUT SHAFT) 25417, 25418 1 1.75" INPUT 1 USE 400882 FRONT BRG COVER 114774, 11477 1 1.118",1.75" & 1.50" INPUT 4 25414 BEARING 14 K-2121,K-2122,K- 212 5 25415 WASHER 1 K-212 6 25416 SNAP RING 1 K-212 10
KITS & ASSEMBLIES Item K-2085 GASKET KIT 1 K-2121,K-2122,K- 212 K-211 SYNCHRONIZER KIT 1 K-2114 SYNCHRONIZER KIT 1 K-2121 BASIC REBUILD KIT 1 FOR UNITS W/1.50" INPUT SHAFT & 2.00" MAINSHAFT K-2122 BASIC REBUILD KIT 1 FOR UNITS W/1.50" INPUT SHAFT & 1.75" MAINSHAFT FOR UNITS W/1.75" INPUT SHAFT & 1.75" MAINSHAFT, IN ADDITION TO K- 2122 YOU MUST ORDER ONE 25417, 25418 & 400204 FOR 2.50" COVER BORE DIAMETER OR 400121 FOR 2.678" COVER BORE DIAMETER K-212 BASIC REBUILD KIT 1 FOR UNITS W/1.75" INPUT SHAFT & 2.00" MAINSHAFT K-212 SMALL PARTS KIT 1 K-2291 MAINSHAFT KIT 2016 1 1.96 SPLINE K-229 MAINSHAFT KIT 2118 1 2.00 SPLINE K-2294 MAINSHAFT KIT 2119 1 1.75 SPLINE K-859 COUNTERSHAFT BRG KIT 654166, 79194 1 K-7041 REAR BRG COVER KIT 402617 1 K-7042 REAR BRG COVER KIT 402618 1 K-7062 SHIFT LEVER HSG KIT 2080,402711,A - 6440 S-164 SHIFT LEVER ASSY- HIGH 1 ALUMINUM HOUSING HIGH - LEVER HEIGHT -1/2" 1 S-1911 CASE ASSY 400218 1 S-1922 CASE ASSY 40098 1 METRIC BOSS HOLES S-702 NLA-REAR BRG COVER ASSY 2247,401986 1 S-70 REAR BRG COVER ASSY 241,40202 1 S-704 REAR BRG COVER ASSY 21557,402000 1 11
Group: LEVER ASSY 9 6 5 Heigh 4 1 8 2 7 00170-8/9 Tur 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 12
Item 2 2180 PIN 2 FOR HSGS WITH PIN SLEEVES K-7062,S-164 400690 SPRING 2297 1 S-164 4 2181 WASHER 1 S-164 5 228648 SHIFT LEVER 1 USE WITH K-7062 STRAIGHT LEVER - "BEND TO SUIT" S-164 6 202484 DUST COVER 1 S-164 7 401958 GASKET 1 K-2085,K-7062 8 X-8C-604 CAPSCREW 4 /8"-16X1-1/4" 9 201401 SHIFT KNOB 1 /8"X24 THREAD S-164 1
Group: MAINSHAFT ASSY 11 12 1 4 5 6 7 9 8 10 16 12 17 18 15 10 1 14 24 25 26 27 19 20 21 22 2 1 2 1 12 00201-8/9 MAINSHAFT ASSY Item 1 K-704 BEARING & RACE KIT 2582,258 1 228296 SYNCHRONIZER CUP 2 K-211 4 A-5401 SYNCHRONIZER ASSY 4/5 1 K-211 5 2694 CLUTCH HUB 4/5 2165 1 K-2291,K-229,K- 2294 6 295 4TH GEAR-MAINSHAFT 1 7 29651 BEARING 1 K-2121,K-2122,K- 212 8 224069 SNAP RING 1 K-212,K-2291,K- 229,K-2294 9 40687 WASHER 2017 1 K-212,K-2291,K- 229,K-2294 14
Item 10 10J06 STEEL BALL 2 /16" K-212 11 2952 RD GEAR-MAINSHAFT 1 12 2965 BEARING K-2121,K-2122,K- 212 1 22806 SYNCHRONIZER CUP 1 K-2114 14 A-569 SYNCHRONIZER ASSY 2/ A - 5254 A - 554 1 K-2114 15 2696 MAINSHAFT 1 1.96 SPLINE K-2291 15 2697 MAINSHAFT 1 2.00 SPLINE K-229 15 2698 MAINSHAFT 1 1.75 SPLINE K-2294 15 K-2291 MAINSHAFT KIT 2016 1 1.96 SPLINE 15 K-229 MAINSHAFT KIT 2118 1 2.00 SPLINE 15 K-2294 MAINSHAFT KIT 2119 1 1.75 SPLINE 16 2566 2ND GEAR-MAINSHAFT 1 17 2578 SPLIT WASHER 2 K-212 18 2579 RETAINER 1 K-212 19 2565 REVERSE GEAR- MAINSHAFT 1 20 2571 CLUTCH HUB 1/REV 1 21 2572 SNAP RING 1 K-212 22 257 SLIDING CLUTCH 1 2 2541 SPACER 2 K-212 24 256 1ST GEAR-MAINSHAFT 1 25 2574 SPLIT WASHER 2 K-212 26 2575 RETAINER 1 K-212 27 K-4162 BEARING KIT (OUTPUT SHAFT) 27227, 25422 1 1 2576 BEARING 88 K-2121,K-2122,K- 212 15
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 7122 THREAD ADHESIVE 1 10 MILLILITER SIZE K-2121,K-2122,K- 212 16
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 1 1608 CONTROL HOUSING ASSY 22115 1609 1 2 12F100 PLUG 1" 1 12252 BUSHING 4 X-8C-604 CAPSCREW 4 /8"-16X1-1/4" 5 15948 BREATHER 1 6 21775 NO LONGER AVAILABLE 1 7 15272 SCREW 2 8 12745 WASHER 1 9 1587 SPRING 1 17
Item 10 12225 OIL SEAL 1 11 401958 GASKET 1 K-2085,K-7062 12 1402 BOOT 1 1 16288 NO LONGER AVAILABLE 1 LEVER HEIGHT 5-1/8" 1 A-527 SHAFT & LEVER ASSY 1 LEVER HEIGHT -/4" 1 A-5797 NO LONGER AVAILALBE 1 999 A-599 NO LONGER AVAILABLE 1 LEVER HEIGHT -/4" 999 A-5795 NO LONGER AVAILABLE 1 18
Group: REVERSE IDLER GEAR ASSY 4 2 1 5 1 2 2 6 7 00451-5/9 REVERSE IDLER GEAR ASSY Item 1 24002 WASHER 2 K-212 2 2541 SPACER K-212 25412 BEARING 52 K-2121,K-2122,K- 212 4 2592 IDLER GEAR 1 5 20609 IDLER SHAFT 1 6 201929 SHAFT LOCK 1 7 X-8C-600 CAPSCREW 29611 1 /8"-16X1" 19
Group: SHIFT BAR HOUSING 5 6 7 10 1512 * 16 17 18 8 9 11 1 11 11 1 11 1 14 1 2 28 0 19 29 7 * 7 24 9 2 40 27 27 1 2 19 8 5 6 26 * Neutral Switch Provision 4 25 21 20 22 20 40 999 00101-6/9 SBH 52 SHIFT BAR HOUSING Item 1 A-655 SHIFT BAR HSG ASSY 25626,402945 1 HOUSING ONLY REVERSE SWITCH POSITION - RIGHT FRONT 2 2280 GASKET 1 K-2085 10J14 STEEL BALL 11 7/16" 4 4099 SPRING 201045 5 25621 PLUG 1" 1 6 25622 GASKET 1 7 25620 SPACER 1 8 16218 SPRING 1 9 25619 PLUNGER 1 10 25052 CA PLUG 1 9/16-18 10 40656 PLUG 15917 1 9/16-18, THREADED 11 X-8C-600 CAPSCREW 29611 14 /8"-16X1" 1 2870 LIFTING EYE 14 5879 NO LONGER AVAILABLE 1 15 15900 GASKET 1 K-2085 20
Item 19 14J1818 PIN 2 20 204 CAPSCREW 4 /8"-16X1" 21 401277 SHIFT BAR RETAINER 1 FRONT 22 25609 SHIFT BAR RETAINER 1 REAR 2 25610 YOKE BAR 1ST/REV 1 24 21659 YOKE BAR 2ND/RD 1 25 21658 YOKE BAR 4TH/5TH 1 26 404465 YOKE BAR 1ST/REV 1 K-89 26 K-89 CLUTCH/BAR REPL KIT 25607,401712 1 27 14J1818 PIN 2 28 204756 SPACER 1 FRONT 29 284 SPACER 2 REAR 0 2561 SHIFT BLOCK 1ST/REV 1 1 25618 REVERSE BLOCK 1 2 25426 ACTUATOR 1 10658 PIN 1 5 206641 SPRING 1 6 25606 YOKE 1ST/REV 1 7 201044 PIN 1 8 A-5212 NO LONGER AVAILABLE 21660,22822 1 9 22824 NO LONGER AVAILABLE 22825 1 40 227675 INSERT - YOKE PAD 4 A-5212,K-212 999 S-7012 NO LONGER AVAILABLE 25626 1 21
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