FS-4205A July 2011
Contents How To Use The Illustrated Parts List .................................................................................................................................................. 3 CASE......................................................................................................................................................................................................... 4 COUNTERSHAFT ASSY ....................................................................................................................................................................... 6 INPUT SHAFT......................................................................................................................................................................................... 7 KITS & ASSEMBLIES ........................................................................................................................................................................... 8 LEVER ASSY .......................................................................................................................................................................................... 9 MAINSHAFT ASSY .............................................................................................................................................................................. 11 MISCELLANEOUS .............................................................................................................................................................................. 12 REMOTE CONTROL........................................................................................................................................................................... 13 REVERSE IDLER GEAR ASSY ......................................................................................................................................................... 14 SHIFT BAR HOUSING ........................................................................................................................................................................ 15
2
How To Use The Illustrated Parts List The information contained in this document is subject to frequent updates. Therefore, for the latest information available, please visit the interactive Electronic Parts 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- 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
3
Group: CASE
CASE Item
Current Part
Description
Replaced Part
Qty.
Notes
1
A-5205
CLUTCH HSG ASSY
21646
1
1 1
A-5629 A-5634
CLUTCH HSG ASSY CLUTCH HSG ASSY
1 1
1
A-5751
CLUTCH HSG ASSY
23721 ,229219 23726 ,3316236 ,3316237 ,A - 5632 ,A 5771 4300418
#2 ALUMINUM, BELOW CENTER LINE PUSH TYPE #3 PUSH-IRON #2 ALUMINUM, ABOVE CENTER LINE PULL TYPE
1 2 2
A-7513 S-1874 S-1923
CLUTCH HSG ASSY CASE ASSY CASE ASSY
1 1 1
2 3 4 5 6 7 10 11 12
S-1924 201398 201400 239613 X-12-1210 X-12-1207 239783 240040 23380
NO LONGER AVAILABLE PTO COVER GASKET CAPSCREW PIPE PLUG PIPE PLUG PLUG SNAP RING COVER
3316239 4300878 4300816 ,4301032 ,4301099 4301033
13 14 15 16 17 17 18 18 18 19
1C408 X-3-400 X-8-903 4E09 12815 8677 4300121 4300204 4300798 23147
CAPSCREW LOCKWASHER CAPSCREW LOCKWASHER BUSHING BUSHING OIL SEAL OIL SEAL OIL SEAL FRONT BRG COVER-PULL
4
X12 1206 X12 1202 X12 1206
206466
4E04 1C936
3315623 235394 235393 3315538
1
1 2 2 12 1 1 1 1 1 2 2 4 4 4 2 1 1 1 1
Kits/Assys Where Needed
#2 ALUMINUM, BELOW CENTER LINE PUSH TYPE #2 ALUMINUM, PUSH TYPE (FORK)
K-2143 3/8"-16X5/8" 3/4" MAGNETIC K-2144,K-7000,K-7013 K-2144 A-5205,A-5629,A5634,A-5751,A-7513 1/4"-20 1/4" 9/16"-12X2-1/4" 9/16" USE W/A-5205 CLUTCH HSG ASSY SHAFT 1.873, WIDTH .375, OD 2.68 SHAFT 1.873, WIDTH .375 SHAFT 1.625, WIDTH .375 USE 4300121 OIL SEAL
A-5629,A-5634,A-5751 A-5205
K-7000,K-7013
Item
Current Part
Description
19 19 19 19 19 19 20 21 22 23 23 23 23 23 24 26 27 27 27 27 28 29 29 29 29 29 30 30 31 31 31 31 31 31 31
237743 238870 239821 4300354 4300355 4300882 240321 239614 4300261 240017 240018 240019 240020 4300980 X-8-688 K-3919 21555 3314356 3314448 86301 239433 240329 240330 240331 240332 4300981 208385 4300203 4300846 4300849 4300877 4300970 4300972 4301053 K-7038
FRONT BRG COVER-PUSH FRONT BRG COVER-PUSH FRONT BRG COVER-PUSH FRONT BRG COVER-PUSH FRONT BRG COVER-PUSH FRONT BRG COVER-PUSH GASKET SCREW C/S REAR BRG COVER SHIM .004 SHIM .007 SHIM .010 SHIM .020 SHIM .040 CAPSCREW BEARING KIT SPEEDO ROTOR SPEEDO DRIVE GEAR SPEEDO DRIVE GEAR SPEEDO DRIVE GEAR STUD SHIM .004 SHIM .007 SHIM .010 SHIM .020 SHIM .040 OIL SEAL OIL SEAL REAR BRG COVER NO LONGER AVAILABLE REAR BRG COVER REAR BRG COVER REAR BRG COVER REAR BRG COVER REAR BRG COVER KIT
31
K-7039
31
Replaced Part
Qty.
Notes USE 4300798 OIL SEAL USE 4300798 OIL SEAL USE 4300798 OIL SEAL USE 4300204 OR 4300798 OIL SEAL USE 4300204 OIL SEAL USE 4300798 OIL SEAL
229985 237983 241101 241615 241099 3315498 241102 241100 4302614
1 1 1 1 1 1 1 4 1 1 1 1 1 1 4 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1
REAR BRG COVER KIT
4302615
1
S-7030
REAR BRG COVER ASSY
4300845 ,4302037
1
31
S-7031
REAR BRG COVER ASSY
4301677 ,4302039
1
32 33 34 35 36 37 39 39
86D8 239436 21937 4301954 86016 14373 4300301 4872
NUT WASHER NUT SENSOR SEAL SLEEVE MAGNET FITTING-45 DEGREE FITTING-90 DEGREE
86D08
4 4 1 1 1 1 2 2
237335
654166, 654137
216053 ,235656 ,238026
11H15 12H15
Kits/Assys Where Needed
K-2143 5/16-18X.81 QUANTITY AS REQUIRED QUANTITY AS REQUIRED QUANTITY AS REQUIRED QUANTITY AS REQUIRED
K-2116 K-2116 K-2116 K-2116 K-2116
3/8"-16X1"
5 TEETH 6 TEETH 5 TEETH 1/2"-20X2-5/16" QUANTITY AS REQUIRED QUANTITY AS REQUIRED QUANTITY AS REQUIRED QUANTITY AS REQUIRED
SHAFT 2.503, WIDTH .5 USE 4300203 OIL SEAL USE 4300203 OIL SEAL USE 4300203 OIL SEAL USE 208385 OIL SEAL USE 4300203 OIL SEAL USE 4300203 OIL SEAL USE 4300203 OIL SEAL NOTE: PUSHIN TYPE SPEEDO SENSOR USE 4300203 OIL SEAL NOTE: PUSHIN TYPE SPEEDO SENSOR USE 4300203 OIL SEAL NOTE: SENSOR SEAL REQUIRED USE 4300203 OIL SEAL NOTE: SENSOR SEAL REQUIRED 1/2"-20 1/2" 1-1/4"-18
S-1874,S-1924 K-2116 K-2116 K-2116 K-2116 K-2116 K-7000,K-7013
S-7030,S-7031 S-1923,S-1924
5
Group: COUNTERSHAFT ASSY
COUNTERSHAFT ASSY Item
Current Part
Description
1 2 3 4 5 6 7 8 9 10 11
672070 675246 240767 241012 4301535 4301536 241017 230292 4301537 666554 730362
BEARING CUP BEARING CONE SNAP RING DRIVE GEAR-CNTRSHFT 4TH GEAR-CNTRSHFT 3RD GEAR-CNTRSHFT 2ND GEAR-CNTRSHFT KEY COUNTERSHAFT BEARING CONE BEARING CUP
6
Replaced Part
Qty. 1 1 1 1 1 1 1 2 1 1 1
Notes
Kits/Assys Where Needed K-7000,K-7013 K-7000,K-7013 K-2144
K-2144 K-7000,K-7013 K-7000,K-7013
Group: INPUT SHAFT
INPUT SHAFT Item
Current Part
Description
Replaced Part
Qty.
Notes
1 1
4301526 4301614
1
4301615
1 1 1
4301616 4301618 4301619
INPUT SHAFT-1.50" PUSH IN/SHAFT1.75"PUSH/PULL IN/SHAFT1.50"PUSH/PULL INPUT SHAFT-1.50" PUSH INPUT SHAFT-1.50" PUSH NO LONGER AVAILABLE
1 1
USE 4300882 FRONT BRG COVER USE 23147 OR 4300882 FRONT BRG COVER USE 23147 FRONT BRG COVER
1 1 1
1
4301620
INPUT SHAFT-1.50" PUSH
1
1
4301622
1
2 2 3 3 4 5 6
1314774 235417 1314773 235418 235414 235415 235416
INPUT SHAFT-1.375" PUSH BEARING CUP BEARING CUP BEARING CONE BEARING CONE BEARING WASHER SNAP RING
1
1 1 1 1 14 1 1
Kits/Assys Where Needed
USE 4300882 FRONT BRG COVER USE 4300882 FRONT BRG COVER USE 239821 OR 4300882 FRONT BRG COVER USE 4300354 OR 4300355 FRONT BRG COVER USE 237743 FRONT BRG COVER 1.118",1.375" & 1.50" INPUT 1.75" INPUT 1.118",1.375" & 1.50" INPUT 1.75" INPUT
K-7000 K-7013 K-7000 K-7013 K-7000,K-7013 K-2144 K-2144
7
KITS & ASSEMBLIES Item
Current Part
Description
K-2116 K-2143 K-2144 K-3421 K-3479 K-3919 K-7000 K-7013 K-7038 K-7039 K-7061
SHIM KIT GASKET KIT SMALL PARTS KIT SYNCHRONIZER KIT SYNCHRONIZER KIT BEARING KIT BASIC REBUILD KIT BASIC REBUILD KIT REAR BRG COVER KIT REAR BRG COVER KIT SHIFT LEVER HSG KIT
K-7062
SHIFT LEVER HSG KIT
S-1578
SHIFT LEVER ASSY 3-1/2"
S-1827
SHIFT LEVER ASSY 3-1/8"
S-7079
1
S-1874 S-1923
CASE ASSY CASE ASSY
1 1
S-1924 S-7030 S-7031 S-7045
NO LONGER AVAILABLE REAR BRG COVER ASSY REAR BRG COVER ASSY SHIFT LEVER ASSY 2-7/8"
4300878 4300816 ,4301032 ,4301099 4301033 4300845 ,4302037 4301677 ,4302039
S-7077
SHIFT BAR HOUSING ASSY SHIFT BAR HSG ASSY
S-7085
8
Replaced Part
K - 7004 K - 7005 654166, 654137
4302614 4302615 241075 ,4302711 ,A 6439 233080 ,4302711 ,A 6440
Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1
239834 ,4302944
1
4300336 ,4302956
1
Notes
1.50 INPUT - 2.00 OUTPUT 1.75 INPUT SHAFT
ALUMINUM HOUSING MEDIUM LEVER HEIGHT 3-1/8" ALUMINUM HOUSING HIGH LEVER HEIGHT 3-1/2" COMPLETE ASSY - ALUMINUM HOUSING HIGH - LEVER HEIGHT 31/2" 27-1/2" STRAIGHT LEVER "BEND TO SUIT" 3/8" X 24 THREAD COMPLETE ASSY - ALUMINUM HOUSING MEDIUM - LEVER HEIGHT 3-1/8" 27-1/2" STRAIGHT LEVER - "BEND TO SUIT" 3/8" X 24 THREAD
COMPLETE ASSY - ALUMINUM HOUSING LOW - LEVER HEIGHT 27/8" 33" STRAIGHT LEVER - "BEND TO SUIT" 3/8" X 24 THREAD COMPLETE REVERSE SWITCH POSITION - RIGHT FRONT COMPLETE - W/NEUTRAL SWITCH PROVISION REVERSE SWITCH POISTION - RIGHT REAR
Kits/Assys Where Needed
Group: LEVER ASSY
LEVER ASSY Item
Current Part
Description
Replaced Part
Qty.
Notes
1
K-7062
SHIFT LEVER HSG KIT
233080 ,4302711 ,A 6440
1
2 2
201054 23180
PIN PIN
ALUMINUM HOUSING HIGH LEVER HEIGHT 3-1/2" FOR HSGS WITHOUT PIN SLEEVES FOR HSGS WITH PIN SLEEVES
3 4 5
4300690 23181 21722
SPRING WASHER SHIFT LEVER 27-1/2"
5
228648
GEAR SHIFT LEVER
2 2
229337
1 1 1 1
USE WITH K-7062 STRAIGHT LEVER - "BEND TO SUIT" USE WITH 233080 STRAIGHT LEVER - "BEND TO SUIT"
Kits/Assys Where Needed
K-7061,K-7062,K7065,S-1578,S-1827,S7045 S-1578,S-1827,S-7045 S-1578,S-1827,S-7045 S-1578
9
Item
Current Part
Description
5
241076
5
Qty.
Notes
SHIFT LEVER 27-1/2"
1
4302823
SHIFT LEVER 33"
1
USE WITH K-7061 STRAIGHT LEVER - "BEND TO SUIT" USE WITH A-6448 STRAIGHT LEVER - "BEND TO SUIT"
6 7
202484 4301958
DUST COVER GASKET
1 1
8 9 10
X-8C-604 201401 K-7061
CAPSCREW SHIFT KNOB SHIFT LEVER HSG KIT
4 1 1
11
K-7065
SHIFT LEVER HSG KIT
10
Replaced Part
241075 ,4302711 ,A 6439 4302704 ,4302711 ,A 6448
1
Kits/Assys Where Needed S-1827 S-7045 S-1578,S-1827,S-7045 K-2143,K-7061,K7062,K-7065,S-1578,S1827,S-7045
3/8"-16X1-1/4" 3/8"X24 THREAD ALUMINUM HOUSING MEDIUM LEVER HEIGHT 3-1/8" ALUMINUM HOUSING LOW LEVER HEIGHT 2-7/8"
S-1578,S-7045
Group: MAINSHAFT ASSY
MAINSHAFT ASSY Item
Current Part
Description
Replaced Part
Qty.
1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
K-3704 3001435 A-6609 4303689 4303796 239651 224069 23127 10J06 4301528 239818 4301467 A-6608 240037 4301533 4301529 239653 235379 235378 4301530 4301566 4301532 4301531
235382 ,235383 4301565 A - 6144 4301534 4301527
1 2 1 1 1 1 1 1 2 1 2 2 1 1 1 1 2 1 2 1 1 1 1
25 26
240026 K-3919
BEARING & RACE KIT SYNCHRONIZER CUP SYNCHRONIZER ASSY 4/5 CLUTCH HUB 4/5 4TH GEAR-MAINSHAFT BEARING SNAP RING WASHER STEEL BALL 3RD GEAR-MAINSHAFT BEARING SYNCHRONIZER CUP SYNCHRONIZER ASSY 2/3 SNAP RING CLUTCH HUB 2/3 2ND GEAR-MAINSHAFT BEARING RETAINER SPLIT WASHER 1ST GEAR-MAINSHAFT SLIDING CLUTCH MAINSHAFT REVERSE GEARMAINSHAFT WASHER BEARING KIT
A - 6137
654166, 654137
1 1
Notes
Kits/Assys Where Needed K-3479 K-3479
K-7000,K-7013
3/16"
K-2144 K-2144 K-7000,K-7013 K-3421 K-3421 K-2144
K-7000,K-7013 K-2144 K-2144
K-2144
11
MISCELLANEOUS Item
12
Current Part
Description
71203 71204 71205 71206 71231 71232
SILICONE LUBE ADHESIVE SEALANT SEALANT SILICONE LUBE GASKET SEALANT THREAD ADHESIVE
Replaced Part
Qty.
Notes
1 1 1 1 1 1
8 OZ (236.59 CC)-FLEET SIZE 0.5 CC (SINGLE APPLICATION SIZE) 2 CC (SINGLE APPLICATION SIZE) 4 CC (SINGLE APPLICATION SIZE) 8 MILLILITER SIZE 10 MILLILITER SIZE
Kits/Assys Where Needed
K-2116 K-7000,K-7013
Group: REMOTE CONTROL
REMOTE CONTROL Item
Current Part
Description
Replaced Part
Qty.
1
3316284
3316285
1
2 3 4 5 5 6 7 8 9 10 11
12F100 3312252 X-8C-604 3315948 4300217 3316290 3315272 3312745 3315837 3312225 4301958
CONTROL HOUSING ASSY PLUG 1" BUSHING CAPSCREW BREATHER BREATHER SHIFT FINGER SCREW WASHER SPRING OIL SEAL GASKET
12 13 13 999
3314302 3316288 A-5312 A-5497
BOOT NO LONGER AVAILABLE SHAFT & LEVER ASSY NO LONGER AVAILABLE
1 3 4 1 1 1 2 1 1 1 1
1 1 1 1
Notes
Kits/Assys Where Needed
3/8"-16X1-1/4" USE WITH 3316284 HOUSING ASSY
K-2143,K-7061,K7062,K-7065,S-1578,S1827,S-7045 LEVER HEIGHT 5-1/8" LEVER HEIGHT 85MM (3.35") LEVER HEIGHT 5-1/8"
13
Group: REVERSE IDLER GEAR ASSY
REVERSE IDLER GEAR ASSY Item
Current Part
Description
20 21 22 23 24 25 26
240023 240024 4301592 240022 201929 X-8C-600 235376
WASHER SPACER IDLER GEAR IDLER SHAFT SHAFT LOCK CAPSCREW BEARING
14
Replaced Part
239799
239611
Qty. 2 1 1 1 1 1 52
Notes
Kits/Assys Where Needed K-2144 K-2144
3/8"-16X1" K-7000,K-7013
Group: SHIFT BAR HOUSING
SHIFT BAR HOUSING Item
Current Part
Description
Replaced Part
Qty.
Notes
1
A-6534
SHIFT BAR HSG ASSY
239834 ,4302944
1
1
A-6538
SHIFT BAR HSG ASSY
4300336 ,4302956
1
HOUSING ONLY REVERSE SWITCH POISTION - RIGHT FRONT HOUSING ONLY - W/NEUTRAL SWITCH PROVISION REVERSE SWITCH POISTION - RIGHT REAR
2 3 3
240038 10J14 10J14
GASKET STEEL BALL STEEL BALL
4 5 6 7 8 9 10 10 11 12
4303939 235621 235622 240496 233794 23576 235052 4303656 X-8C-600 4301719
13 14 15 16 17
238370 15900 4303655 17179 4301718
20
233043
SPRING PLUG 1" GASKET SPACER SPRING PLUNGER CA PLUG PLUG CAPSCREW BALL RETAINERREVERSE LIFTING EYE GASKET PLUG GASKET BALL RETAINERNEUTRAL CAPSCREW
21 22
4301277 4301541
SHIFT BAR RETAINER YOKE BAR 1ST/REV
2 1
22
4302656
YOKE BAR 1ST/REV
1
23 24 25 25 26
4301540 4301539 201044 201044 4300402
YOKE BAR 2ND/3RD YOKE BAR 4TH/5TH PIN PIN SHIFT BLOCK 1ST/REV
1 1 2 1 1
1 10 13 201045
15917 239611
17178
3 1 1 1 1 1 1 1 13 1
K-2143,S-7077,S-7085 7/16" - REVERSE SWITCH 7/16" - W/NEUTRAL SWITCH PROVISION
K-2143
9/16 - 18 9/16 - 18, THREADED 3/8"-16X1"
2 1 1 1 1 4
Kits/Assys Where Needed
K-2143,S-7077,S-7085 S-7085 S-7085
3/8"-16X1" - USE W/4301277 RETAINER USE W/239834, 4302944 OR A-6534 HOUSING USE W/4300336, 4302956 OR A-6538 HOUSING
W/NEUTRAL SWITCH PROVISION REVERSE SWITCH
15
Item
Current Part
Description
27 28 29 30 31 32 33 999
14J1818 A-6146 A-6145 4300401 227675 1JM6028 1JM3528 S-7077
999
S-7085
PIN YOKE ASSY 2ND/3RD YOKE ASSY 4TH/5TH SHIFT YOKE 1ST/REV INSERT - YOKE PAD PIN PIN SHIFT BAR HOUSING ASSY SHIFT BAR HSG ASSY
16
Replaced Part
Qty.
239834 ,4302944
2 1 1 1 4 2 2 1
4300336 ,4302956
1
4301595 4301593
Notes
Kits/Assys Where Needed
A-6145,A-6146,K-2144
COMPLETE REVERSE SWITCH POSITION - RIGHT FRONT COMPLETE - W/NEUTRAL SWITCH PROVISION REVERSE SWITCH POISTION - RIGHT REAR
17
18
