More time on the road Illustrated s List FRWF-520B November 202
Contents How To Use The Illustrated s List... 3 AIR MODULE & RANGE CYL.... 4 AUXILIARY DRIVE GEAR... 6 CASE (AUX)... 7 CASE (FRONT)... 9 COUNTERSHAFT & BRGS(AUX)... COUNTERSHAFT ASSY... 2 INPUT SHAFT & DRIVE GEAR... 4 ISOLATORS... 5 KITS & ASSEMBLIES... 6 LEVERS/HOUSINGS... 8 MAINSHAFT & SYNCHRO(AUX)... 20 MAINSHAFT ASSY... 22 MISCELLANEOUS... 24 REVERSE IDLER... 25 ROADRANGER VALVE... 27 SHIFT BAR HOUSING (FRF)... 29 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 3
Group: AIR MODULE & RANGE CYL. 2 3 7 8 9 0 2 4 5 6 3 4 036-9-94 AIR MODULE & RANGE CYL. Item X-8-0804M CAPSCREW 4 M8 X.25 X 30MM 2 K-3245 AIR MODULE ASSY A - 6342 3 497 -O- RING 2 K-2923,K-3245,S- 270 4 5569 -O- RING K-3245,S-270 5 20423 -O- RING K-2923,S-270 4
Item 6 K-329 BAR & RING KIT 430298 7 K-328 PISTON KIT 430277 8 4302080 SNAP RING K-2923,K-328,K- 329,K-330,K-33 9 5568507 -O- RING K-2923,S-270 0 4765 -O- RING K-2923,S-270 497 -O- RING K-2923,K-3245,S- 270 2 430240 COVER S-270 3 X-8-0804M CAPSCREW 2 M8 X.25 X 30MM 4 5554902 CONNECTOR ASSY, ELBOW 4 84005 CONNECTOR ASSY, STRAIGHT 2 "PUSH-TO-CONNECT" 5/32"TUBE- /6"NPTF 2 "PUSH-TO-CONNECT" 5/32"TUBE- /6"NPTF K-3245 K-3245 5
Group: AUXILIARY DRIVE GEAR 3 5 6 2 4 0486-9-94 C2 AUXILIARY DRIVE GEAR Item 430233 BEARING SPACER 2 5566507- BOX BEARING 5566504,5566507 K-2924 3 4302257 RETAINER 4 X-8-003M CAPSCREW 6 M0 X.5 X 25MM 5 4302435 AUXILIARY DRIVE GEAR 4302434 6 7399 SNAP RING K-2924 6
Group: CASE (AUX) OEM supplied adjustable speedometer sensor (Threaded) OEM supplied non-adjustable speedometer sensor (Non-Threaded) 23 25 2 5 5 4 6 7 3 8 9 0 3 044B-05-09 4 CASE (AUX) Item S-250 SPEEDO ROTOR ASSY 4302242 MAGNETIC 2 55685 -O- RING K-298,S-250,S- 2809 3 K-298 OIL SEAL KIT 4302322 4302323 "FOR MAGNETIC COVER" K-2924 4 X-8-080M CAPSCREW 2 M8 X.25 X 2MM 5 S-2809 REAR BEARING COVER ASSY 4302332,4303872,4304652,4305830 PUSH-IN/THREAD-IN MAGNETIC PICK-UP 6 00955 GASKET - RED EDGE MOLDED RED EDGE MOLDED GASKET - UNCOMPRESSED THICKNESS.043 -.05 - NOT INTERCHANGEABLE WITH ANY OTHER GASKET K-298,K-292,S- 2809 7 X-8-009M CAPSCREW 6 M0 X.5 X 50MM 8 X-8-003M CAPSCREW 8 M0 X.5 X 25MM 7
Item 9 4302320 COVER 2346 2 0 4305978 GASKET 4302246 2 K-292 K-2805 SHIM KIT 2452 K - 206 K-2924 3 S-269 REAR HOUSING ASSY 4303750 4 4302248 GASKET K-292 5 X-8C- 036M 5 X-8C- 037M CAPSCREW X-8-005M 7 M0 X.5 X 38MM CAPSCREW X-8-006M 2 M0 X.5 X 49MM 23 K-3454 SPEED SENSOR KIT A - 6398,A - 6724 SINGLE PICK-UP (2 PIN) 23 K-3455 SPEED SENSOR KIT, DUAL A - 7046,A - 758 DUAL PICK-UP (4 PIN) 25 442 -O- RING 8
Group: CASE (FRONT) 37 38 26 27 28 29 3 30 23 24 22 2 8 33 4 3 20 8 7 6 5 5 4 7 3 2 0 9 8 304-05-09 CASE (FRONT) Item S-2348 CASE ASSY 4302645 3 X-2-207 PIPE PLUG X2 202 X2 206 3/4" MAGNETIC 4 430530 GASKET 430280 K-292 5 4302809 PTO COVER 6596,430057 6 X-8-200M CAPSCREW 8 M2 X.75 X 20MM 7 4306584 GASKET 430234 K-292,K-4054 8 A-5992 CLUTCH HOUSING ASSY 43003 # PULL ALUM. 9 23964 CAPSCREW X-8L-509 2 5/6-8X.8 9
Item 0 4305230 HAND HOLE COVER 453 # PULL 5577509 STUD 5577505,5577503 6 M6 X 60MM 2 X-0-005 WASHER X 3 000,X0 000,X0 004 3 X--606M SELF LOCKING HEX NUT X 60M,X 603M,X--605M 6.23 X 6.60 K-4054 6 M6 X.5 K-4054 4 20550 FRONT BRG COVER 2" PULL K-3600,K-424 5 X-8-004M CAPSCREW 6 M0 X.5 X 30MM 7 43 GASKET K-292 8 285 BUSHING 4 A-5992,K-3600 20 X-8C- 209M SCREW, HEX HD/WASHER ASSY X-8C-204M 4 M2X.75 K-4054 2 4304023 PLUG 4303747 -/6" MAGNETIC, O-RING INCLUDED S-2348 22 X-8-002M CAPSCREW 6 M0 X.5 X 20MM 23 4575 PTO COVER 4302254 24 4305309 GASKET 684 K-292 26 5575503 DOWEL PIN 2 S-2348 27 4373 MAGNET 3 S-2348 28 828 PIN 2 29 X--606M SELF LOCKING HEX NUT X 60M,X 603M,X--605M 2 M6 X.5 K-4054 30 X-0-005 WASHER 2 K-4054 3 5577504 STUD 2 M6 X 2 X 52MM 33 X-2-802 PIPE PLUG X2 800 /2" 37 X-8-003M CAPSCREW 2 M0 X.5 X 25MM 38 2085 LIFTING EYE 705 2 S-2348,S-269 0
Group: COUNTERSHAFT & BRGS(AUX) 2 3 0440-/92 Aux CS Helical COUNTERSHAFT & BRGS(AUX) Item 4302074- BOX BEARING 2343,4302074 4 K-2924 2 A-6434 WELDED COUNTERSHAFT ASSY A - 6433,A - 6552 2 D/G 2360 - C/S 430242 3 2342 SPACER 22903 2
Group: COUNTERSHAFT ASSY 9 0 5 6 2 2 4 3 2 8 7 0369-05-09 COUNTERSHAFT ASSY Item 4302082 SNAP RING 2 K-2924 2 4304080 BEARING 4302240 4 K-2924 3 4303877 COUNTERSHAFT 2 4 430237 KEY 2 5 X-7-005 CAPSCREW 2 6 4304024 BEARING RETAINER 2 7 4302420 2ND GEAR-CNTRSHFT 4302404,4302530 2 8 430449 3RD GEAR-CNTRSHFT 4302402 2 9 4305879 4TH GEAR-CNTRSHFT 2 0 5953 PTO GEAR - LOWER 0 20840 PTO GEAR - UPPER 5952 4306033 DRIVE GEAR-CNTRSHFT 2 2 430208 SNAP RING 2 2
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Group: INPUT SHAFT & DRIVE GEAR 6 9 8 3 5 * 2 0 Clutch Installation Kit * For Shipping Only - Do Not Replace 0374-9-94 C2 INPUT SHAFT & DRIVE GEAR Item 23559 SEAL NOT SOLD FOR SERVICE 2 6980 SNAP RING K-3600,K-424 3 43047 BEARING 8504 K-2924,K-3600,K- 424 5 4303362 SNAP RING K-2924,K-3600,K- 424 6 4306450 MAIN DRIVE GEAR 8 S-2822 INPUT SHAFT ASSY 4304633 2" PULL - USE W/4304635 MAIN DRIVE GEAR K-3600,K-424 9 6566 BUSHING K-2924,S-2822 0 K-3600 CLUTCH INSTALLTION KIT 0 K-424 CLUTCH INSTALLATION KIT (FR), HYDRAULIC RELEASE STANDARD FR INPUT SHAFT AND YOKE FOR HYDRAULIC CLUTCH RELEASE 4
Group: ISOLATORS New Design 2 3 6 2 3 9 3 4 7 2 3 New Design 2 0 020--92 Isolator Indicates Of Item 0 ISOLATORS Item 924 -E- RING 2 2 K-3467 PIN REPLACEMENT KIT 2245 3 2246 BUSHING 2 K-2003,K-2428,K- 2429,K-2978,K- 3399,S-229,S- 230,S-259 4 S-794 ISOLATOR ASSY 6 2247 LEVER STRAIGHT 8.67" 7 2235 STUB LEVER LOW TOWER K-2428,S-677 7 2236 STUB LEVER HIGH TOWER K-2429,S-579,S- 230 7 43068 STUB LEVER MID TOWER K-2978 9 2767 90 DEG LEVER STRAIGHT 33" 0 K-3399 ISOLATOR BUSHING KIT 2244,233 X-8-560 SCREW K-2003 2 X-9-503 NUT K-2003 5
KITS & ASSEMBLIES Item K-476 SHIFT LEVER HSG 4530,763,8298,4304905,A - 4437 K-92 MASTER VALVE REPAIR KIT LOW TOWER FOR A-6909 & A-500 VALVES K-2003 PIN & BUSHING KIT K-2394 AIR SYSTEMS TOOL KIT K-2428 LEVER REPLACEMENT KIT K-2429 LEVER REPLACEMENT KIT LOW TOWER HIGH TOWER K-2805 SHIM KIT 2452 K - 206 K-2924 K-292 GASKET KIT K-2924 K-2923 RANGE PISTON KIT K-2924 K-2924 BASIC REBUILD KIT ELECTRONIC SPEEDO FOR OVERHAUL KIT - ORDER THE REBUILD KIT AND THE REQUIRED INPUT SHAFT K-2973 SHIFT LEVER HSG KIT 766,767,4303050,430490,K - 630 K - 94 K-2977 SHIFT LEVER HSG KIT 43067,4304907,A - 6040 K-2978 LEVER REPLACEMENT KIT HIGH TOWER MID TOWER MID TOWER K-328 PISTON KIT 430277 K-329 BAR & RING KIT 430298 K-330 SHIFT YOKE KIT 430279 K-33 YOKE BAR KIT 4302780,430383 K-3245 AIR MODULE ASSY A - 6342 K-3376 O-RING & WASHER KIT 4302 K-3399 ISOLATOR BUSHING KIT 2244,233 K-3454 SPEED SENSOR KIT A - 6398,A - 6724 SINGLE PICK-UP (2 PIN) K-3455 SPEED SENSOR KIT, DUAL A - 7046,A - 758 DUAL PICK-UP (4 PIN) K-3467 PIN REPLACEMENT KIT 2245 K-3492 SYNCHRONIZER KIT K - 2446 6
Item K-3495 SYNCHRONIZER REPLACEMENT KIT K-3600 CLUTCH INSTALLTION KIT K-4054 FR CLUTCH HOUSING SERVICE KIT K-424 CLUTCH INSTALLATION KIT (FR), HYDRAULIC RELEASE K - 2922 SLIDING CLUTCH INCLUDED IN KIT STANDARD FR INPUT SHAFT AND YOKE FOR HYDRAULIC CLUTCH RELEASE S-579 SHIFT TOWER ASSY HIGH TOWER S-677 SHIFT TOWER ASSY LOW TOWER S-794 ISOLATOR ASSY S-967 SHIFT TOWER ASSY MID TOWER S-229 SHIFT LEVER HSG ASSY LOW TOWER S-230 SHIFT LEVER HSG ASSY S - 2053 HIGH TOWER S-2348 CASE ASSY 4302645 S-250 SPEEDO ROTOR ASSY 4302242 MAGNETIC S-259 SHIFT LEVER HSG ASSY S - 299 MID TOWER S-2543 ROADRANGER VALVE ASSY A - 5043 W/SHIFT DIAGRAM MEDALLION S-269 REAR HOUSING ASSY 4303750 S-2700 SHIFT BAR HSG (FRF) S-270 SHIFT BAR HSG ASSY (FRF) S-2809 REAR BEARING COVER ASSY 4302332,4303872,4304652,4305830 PUSH-IN/THREAD-IN MAGNETIC PICK-UP S-2822 INPUT SHAFT ASSY 4304633 2" PULL K-3600,K-424 7
Group: LEVERS/HOUSINGS 6 7 3 5 7 2 3 6 2 3 3 4 3 8 8 8 23 24 33 20 2 22 0204-9-94 K-2428 - Low K-2978 - Mid K-2429 - High S-677 - Low S-967 - Mid S-579 - High S-229 - Low S-259 - Mid S-230 - High LEVERS/HOUSINGS Item K-3376 O-RING & WASHER KIT 4302 2 8299 PIN K-476,K-2977,S- 677 3 X-8C- 036M CAPSCREW X-8-005M 4 M0 X.5 X 38MM 6 K-2977 SHIFT LEVER HSG KIT 43067,4304907,A - 6040 7 K-476 SHIFT LEVER HSG 4530,763,8298,4304905,A - 4437 MID TOWER LOW TOWER 8 4305294 GASKET 430343 K-476,K-2428,K- 2429,K-292,K- 2973,K-2977,K- 2978,S-579,S- 677,S-967,S- 229,S-230,S- 8
Item 259,S-270 3 4303030 PIN K-2973,S-579,S- 230 3 654 PIN 3/8" - USED W/767 ONLY 4 K-2973 SHIFT LEVER HSG KIT 766,767,4303050,430490,K - 630 K - 94 HIGH TOWER 5 0427 BOOT K-476,K-2973,K- 2977,S-579,S- 677,S-230 6 X--600 NUT 3/8"-24-N.F.PLAIN 7 X-3-600 LOCKWASHER 3/8" 20 7600 GEAR SHIFT LEVER STRAIGHT - LOW 2-/2" 20 8482 GEAR SHIFT LEVER STRAIGHT - HIGH 35" 2 2538 RETAINER K-476,K-2973,K- 2977,S-579,S- 677,S-230 22 2536 SPRING K-476,K-2973,K- 2977,S-579,S- 677,S-230 23 K-2428 LEVER REPLACEMENT KIT 23 K-2429 LEVER REPLACEMENT KIT 23 K-2978 LEVER REPLACEMENT KIT LOW TOWER HIGH TOWER MID TOWER 24 S-579 SHIFT TOWER ASSY HIGH TOWER 24 S-677 SHIFT TOWER ASSY LOW TOWER 24 S-967 SHIFT TOWER ASSY MID TOWER 33 S-229 SHIFT LEVER HSG ASSY LOW TOWER 33 S-230 SHIFT LEVER HSG ASSY S - 2053 HIGH TOWER 33 S-259 SHIFT LEVER HSG ASSY S - 299 MID TOWER 9
Group: MAINSHAFT & SYNCHRO(AUX) 3 4 5 2 9 7 9 5 0 2 3 Universal Joint Yoke 6 4 0433B-05-09 MAINSHAFT & SYNCHRO(AUX) Item 4897 SPRING 3 K-2924,K-3492,K- 3495 2 A-733 SYNCHRONIZER ASSY 4304396 4304397 A - 597 HI RANGE K-3492,K-3495 3 4300924 SLIDING CLUTCH K-3495 4 A-7254 SYNCHRONIZER ASSEMBLY A - 4937 A - 5876 LO RANGE K-3492,K-3495 5 4302276 AUXILIARY MAINSHAFT 6 4302243 WASHER 7 K-33 YOKE BAR KIT 4302780,430383 20
Item 9 4302080 SNAP RING 2 K-2923,K-328,K- 329,K-330,K-33 0 K-330 SHIFT YOKE KIT 430279 2 430243 REDUCTION GEAR 4302409 3 22898 SPACER 4 5556503- BOX BEARING 5556503 K-2924 5 K-422 HEX FLANGE CRIMPED NUT KIT 430232,4306520 2
Group: MAINSHAFT ASSY 3 8 2 8 8 0 8 9 8 7 7 8 2 6 5 4 3 0327-9-94 C2 MAINSHAFT ASSY Item 430467 MAINSHAFT 430238 2 430236 KEY 3 430284 SNAP RING 4 430232 SPACER 5 4302259 WASHER 6 4303033 REVERSE GEAR- MAINSHAFT 43036 7 4302265 SLIDING CLUTCH 2 8 4302258 WASHER 6 22
Item 9 4303880 ST GEAR-MAINSHAFT 4304494,430374 0 430242 2ND GEAR-MAINSHAFT 4302405 4302529 3RD GEAR-MAINSHAFT 4302403 2 4306449 4TH GEAR-MAINSHAFT 3 430404 SLIDING CLUTCH 23
MISCELLANEOUS Item 20400 SHIFT DIAGRAM LABEL 930 7203 SILICONE LUBE 8 OZ (236.59 CC)-FLEET SIZE 7204 ADHESIVE SEALANT 0.5 CC (SINGLE APPLICATION SIZE) 7205 SEALANT 2 CC (SINGLE APPLICATION SIZE) 7206 SILICONE LUBE 4 CC (SINGLE APPLICATION SIZE) K-2428,K-2429,K- 2923,K-2978 24
Group: REVERSE IDLER 5 6 2 8 8 3 4 385-05-09 REVERSE IDLER Item 3 430224 WASHER 2 4 4287 BEARING 4305020 2 K-2924 5 43037 REVERSE IDLER GEAR 2 6 4302982 WASHER 4282 2 S-2348 8 4303336 RETAINING RING 4 2 430552 REVERSE IDLER SHAFT 2 25
Group: ROADRANGER VALVE 2 2 2 2 999 Old Design 2 2 2 2 3 2 5 4 5 P 6 S 2 Valve Repair Kit * 7 7 * See: Appendix / Air Line Tubing 2 * 7 7 * 3 P S 009--97 RRV C2 *For Connector component information see Appendix. 26
ROADRANGER VALVE Item 558600 MEDALLION, LOGO FULLER LOGO ONLY A-6909 558606 SHIFT DIAGRAM MEDALLION 2 K-92 MASTER VALVE REPAIR KIT S-2543 3 20495 LEVER A-6909 4 202 COVER A-6909 5 X-8-23 SCREW X 8 202 2 8-32X3/8" 6 X-9-802 NUT /2"-3 7 84003 CONNECTOR ASSY 82503 4 5/32"TUBE-/6"NPTF 7 84005 CONNECTOR ASSY 4 "PUSH-TO-CONNECT" 5/32"TUBE- /6"NPTF K-3245 8402 UNION ASSY 5/32" TUBING 8403 UNION ASSY "PUSH-TO-CONNECT" 5/32" TUBING 2 8020 SHEATHING (50 FT ROLL) 5/32" - BLACK 50' 3 357 -O- RING CLAMP 2 999 A-6909 ROADRANGER VALVE ASSY 999 S-2543 ROADRANGER VALVE ASSY A - 500,A - 530 STANDARD-W/LOGO A - 5043 STANDARD-W/MEDALLION 27
Group: SHIFT BAR HOUSING (FRF) 30 28 37 38 34 33 32 3 36 35 39 2 3 4 29 7 6 5 999 2 9 2 4 5 3 * 0 6 40 20 9 2 26 27 28 0238-07-09
SHIFT BAR HOUSING (FRF) Item S-2700 SHIFT BAR HSG (FRF) 4302642,4305077 HOUSING ONLY 2 430273 PIN S-270 3 5568504 -O- RING TO BE USED WITH SWITCH ONLY 4 4302748 REVERSE SWITCH 5 430242 PLUG M4 X 2 HEX S-2700,S-270 6 492 -O- RING TO BE USED WITH PLUG ONLY S-2700,S-270 7 430256 GASKET K-292,S-270 9 430275 OIL TROUGH S-270 0 X-8-080M CAPSCREW 2 M8 X.25 X 2MM 430438 PLUNGER 430262 S-270 2 430234 SPRING STANDARD S-270 3 430335 SPRING 4 X-8-03M SCREW M0 X.5 X 20MM 5 4303039 SHIFT BLOCK S-270 6 430268 SHIFT YOKE REVERSE/LO S-270 9 430259 INTERLOCK KEY DETENT S-270 20 430266 SHIFT YOKE ST/2ND S-270 2 430264 SHIFT YOKE 3RD/4TH S-270 26 430283 SNAP RING S-270 27 430272 BIAS PLATE S-270 28 X-2-404 PIPE PLUG /4" NPT 29 X-2-603 PIPE PLUG 3/8" NPT 30 4304602 BREATHER 23605 /4" NPT 3 430233 BIAS PLUNGER S-270 32 430238 SPRING OUTER S-270 33 430239 SPRING INNER S-270 34 X-2-208 PIPE PLUG /8" NPT 35 430253 PIN S-270 36 556850 -O- RING USE WITH SWITCH OR PLUG S-2700,S-270 37 4302749 NEUTRAL SWITCH 38 430243 PLUG M6 X.5 HEX S-2700,S-270 29
Item 39 X-8C- 036M CAPSCREW X-8-005M 6 M0 X.5 X 38MM 40 4305078 SHIFT SHAFT S-270 999 S-270 SHIFT BAR HSG ASSY (FRF) 4302642,4305077 COMPLETE - INCLUDES RANGE CYLINDER ASSY 30
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