More time on the road

Illustrated Parts List

FS-4005A
November 2008

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..............................................................................................................................................................................10
MISCELLANEOUS ..............................................................................................................................................................................11
REMOTE CONTROL...........................................................................................................................................................................12
REVERSE IDLER GEAR ASSY .........................................................................................................................................................13
SHIFT BAR HOUSING ........................................................................................................................................................................14

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

Group: CASE

33

32

30

34

31
29
28

35

36

26

37

27
2

6
7

24
22

4
23

1615
4

39

17

11
10
17

20
18
17
13

19

12
14

21
00180-4-93

CASE
Item

Current Part

Description

Replaced Part

Qty.

Notes

A-5205

CLUTCH HSG ASSY

21646

1
1

A-5629
A-5634

CLUTCH HSG ASSY

CLUTCH HSG ASSY

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 ,A - 5979
4300816 ,4301032
,4301099
4301033 ,A - 6001

13
14
15
16
17
17
18
18

1C408
4E04
X-8-903
4E09
12815
8677
4300121
4300204

CAPSCREW
LOCKWASHER
CAPSCREW
LOCKWASHER
BUSHING
BUSHING
OIL SEAL
OIL SEAL

X12 1206
X12 1202 X12 1206
206466

1C936

3315623
235394

1
2
2
12
1
1
1
1
1
2
2
4
4
4
2
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-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

A-5629,A-5634,A-5751
A-5205
K-2129

Item

Current Part

Description

Replaced Part

Qty.

Notes

18
19
19
19
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

4300798
22129
23147
237743
238104
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
4301985

OIL SEAL
NO LONGER AVAILABLE
FRONT BRG COVER-PULL
FRONT BRG COVER-PUSH
NO LONGER AVAILABLE
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
REAR BRG COVER
REAR BRG COVER
REAR BRG COVER
REAR BRG COVER
REAR BRG COVER
NO LONGER AVAILABLE

235393

SHAFT 1.625, WIDTH .375

USE 4300798 OIL SEAL
USE 4300121 OIL SEAL
USE 4300798 OIL SEAL
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
23246

1
1
1
1
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

31

K-7038

REAR BRG COVER KIT

4302614

31

K-7039

REAR BRG COVER KIT

4302615

31

S-7030

REAR BRG COVER ASSY

4300845 ,4302037

31

S-7031

REAR BRG COVER ASSY

4301677 ,4302039

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

3315538

237335

654166, 654137

216053 ,235656 ,238026

11H15
12H15

Kits/Assys Where
Needed
K-2120

K-2143
3/8"-16X3/4"
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"
K-2120,K-2129
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:
SENSOR SEAL REQUIRED
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-2120,K-2129

S-7030,S-7031
S-1923,S-1924

Group: COUNTERSHAFT ASSY

6
5

10

11

9
7

00300-4/93 CS 42

COUNTERSHAFT ASSY
Item

Current Part

Description

1
2
3
4
5
6
7
8
9
10
11

672070
675246
240767
241012
4301717
241016
241017
230292
241018
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

Replaced Part

22080

Qty.
1
1
1
1
1
1
1
2
1
1
1

Notes

Kits/Assys Where
Needed
K-2120,K-2129
K-2120,K-2129
K-2144

K-2144
K-2120,K-2129
K-2120,K-2129

Group: INPUT SHAFT

1
3

00400-4/93 IS 42

INPUT SHAFT
Item

Current Part

Description

Replaced Part

Qty.

Notes

23144

239802

INPUT SHAFT-1.50"
PUSH/PULL
INPUT SHAFT-1.50" PUSH

USE 23147 FRONT BRG COVER

USE 4300882 OR 238870 FRONT BRG

COVER
USE 4300882 OR 239821 FRONT BRG
COVER
USE 237743 FRONT BRG COVER

239803

INPUT SHAFT-1.50" PUSH

239813

3315857

4300414

INPUT SHAFT-1.375"
PUSH/PULL
INPUT SHAFT-1.75"
PUSH/PULL
NO LONGER AVAILABLE

1
1
2
2
3
3
4
5
6

4301050
4301051
1314774
235417
1314773
235418
235414
235415
235416

NO LONGER AVAILABLE
INPUT SHAFT-1.50" PUSH
BEARING CUP
BEARING CUP
BEARING CONE
BEARING CONE
BEARING
WASHER
SNAP RING

1
1
1
1
1
1
14
1
1

USE 23147 OR 3315538 FRONT BRG

COVER
USE 4300354 OR 4300355 FRONT
BRG COVER
USE 4300882 FRONT BRG COVER
USE 4300882 FRONT BRG COVER
1.375" & 1.50" INPUT
1.75" INPUT
1.375" & 1.50" INPUT
1.75" INPUT

Kits/Assys Where
Needed

K-2120
K-2129
K-2120
K-2129
K-2120,K-2129
K-2144
K-2144

KITS & ASSEMBLIES

Item

Current Part

Description

Replaced Part

K-2113
K-2114
K-2116
K-2120

SYNCHRONIZER KIT
SYNCHRONIZER KIT
SHIM KIT
BASIC REBUILD KIT

1
1
1
1

K-2129
K-2143
K-2144
K-3919
K-7038
K-7039
K-7061

BASIC REBUILD KIT

GASKET KIT
SMALL PARTS KIT
BEARING KIT
REAR BRG COVER KIT
REAR BRG COVER KIT
SHIFT LEVER HSG KIT

1
1
1
1
1
1
1

K-7062

SHIFT LEVER HSG KIT

S-1578

SHIFT LEVER ASSY-HIGH

S-1642

S-1874
S-1923

SHIFT LEVER ASSYMEDIUM

CASE ASSY
CASE ASSY

S-1924
S-7021

NO LONGER AVAILABLE
SHIFT BAR HSG ASSY

S-7022

SHIFT BAR HSG ASSY

4300878 ,A - 5979
4300816 ,4301032
,4301099
4301033 ,A - 6001
239834 ,240153
,4302944
4300336 ,4302956

S-7030
S-7031

REAR BRG COVER ASSY

REAR BRG COVER ASSY

4300845 ,4302037
4301677 ,4302039

654166, 654137
4302614
4302615
241075 ,4302711 ,A 6439
233080 ,4302711 ,A 6440

Qty.

Notes

FOR UNITS W/1.375" OR 1.50" INPUT

SHAFT
FOR UNITS W/1.75" INPUT SHAFT
K-2120,K-2129
K-2120,K-2129
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

1
1
1
1
1
1
1

Kits/Assys Where
Needed

COMPLETE REVERSE SWITCH

POSITION - RIGHT FRONT
COMPLETE - W/NEUTRAL SWITCH
PROVISION REVERSE SWITCH
POISTION - RIGHT REAR

Group: LEVER ASSY

9
6

Height

4
3
8

10

7
00170-4/93 LA

LEVER ASSY
Item

Current Part

Description

Replaced Part

Qty.

Notes

K-7062

SHIFT LEVER HSG KIT

233080 ,4302711 ,A 6440

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"

241076

SHIFT LEVER 27-1/2"

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

2
2
229337

241075 ,4302711 ,A 6439

1
1
1

USE WITH K-7062 STRAIGHT

LEVER - "BEND TO SUIT"
USE WITH K-7061 STRAIGHT
LEVER - "BEND TO SUIT"

Kits/Assys Where
Needed

K-7061,K-7062,S1578,S-1642
S-1578,S-1642
S-1578,S-1642
S-1578
S-1642
S-1578,S-1642
K-2143,K-7061,K7062,S-1578

3/8"-16X1-1/4"
3/8"X24 THREAD
ALUMINUM HOUSING MEDIUM LEVER HEIGHT 3-1/8"

S-1578

Group: MAINSHAFT ASSY

11
6
4

12

10

17

19

18

21
20

16
13

14

15

10
25

24

26

12

23
22
18

00200A-6-94 MS 40

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
228296
A-5401
23694
22079
239651
224069
23127
10J06
21546
239818
228306
A-5693
240037
21547
21545
239653
235379
235378
239787
239832
23695
239789

235382 ,235383

1
2
1
1
1
1
1
1
2
1
2
1
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

10

21635

A - 5254 A - 5543

654166, 654137

1
1

Notes

Kits/Assys Where
Needed
K-2113
K-2113
K-2120,K-2129

3/16"

K-2144
K-2144
K-2120,K-2129
K-2114
K-2114
K-2144
K-2120,K-2129
K-2144
K-2144

K-2144
K-2120,K-2129

MISCELLANEOUS
Item

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-2120,K-2129

11

Group: REMOTE CONTROL

14
3

5
Indicates part of item 1

6
9

11

999
10

12

* Use Lockwire at these positions

13

Lever Height

00151-2-94 RCH

REMOTE CONTROL
Item

Current Part

Description

Replaced Part

Qty.

3316284

3316285

A-5825

3316285

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
CONTROL HOUSING
ASSY
PLUG 1"
BUSHING
CAPSCREW
BREATHER
BREATHER
SHIFT FINGER
SCREW
WASHER
SPRING
OIL SEAL
GASKET

12
13
13
13
999
999

3314302
3316288
A-5312
A-5473
A-5497
A-6028

12

BOOT
NO LONGER AVAILABLE
SHAFT & LEVER ASSY
SHAFT & LEVER ASSY
NO LONGER AVAILABLE
M/R SLAVE CONTROL
ASSY

1
3
4
1
1
1
2
1
1
1
1
1
1
1
1
1
1

Notes

Kits/Assys Where
Needed

THREE DRILLED AND TAPPED

BOSS HOLES

A-6028
A-5825

3/8"-16X1-1/4"
USE WITH 3316284 HOUSING ASSY
A-5825
A-6028
A-6028
A-5825
K-2143,K-7061,K7062,S-1578
A-6028
LEVER HEIGHT 5-1/8"
LEVER HEIGHT 85MM (3.35")
LEVER HEIGHT 3-3/4"
LEVER HEIGHT 5-1/8"
LEVER HEIGHT 3-3/4"

A-6028

Group: REVERSE IDLER GEAR ASSY

23
20

22

26

21

26
25

24

20

00450-4/93 RI 42

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

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-2120,K-2129

13

Group: SHIFT BAR HOUSING

5
6

11

11

7
8

11

13

13

10
* 15

16 17

1
14
12 3

* Neutral Switch
Provision
4

3
26
* 25

33
32

999
30
32

22

33

27
23

3
25
3
29
24

27

28
21

31
20

21
31
20
00100A-4-94 SBH 42

SHIFT BAR HOUSING

Item

Current Part

Description

Replaced Part

Qty.

Notes

A-6534

SHIFT BAR HSG ASSY

239834 ,4302944

A-6538

SHIFT BAR HSG ASSY

4300336 ,4302956

HOUSING ONLY REVERSE SWITCH

POISTION - RIGHT FRONT
HOUSING ONLY - W/NEUTRAL
SWITCH PROVISION REVERSE
SWITCH POISTION - RIGHT REAR

2
3

240038
10J14

GASKET
STEEL BALL

3
4
5
6
7
8
9
10
10
11
12

10J14
4303939
235621
235622
240496
233794
23576
235052
4303656
X-8C-600
4301719

13
14
15
16
17

238370
15900
4303655
17179
4301718

20

233043

STEEL BALL
SPRING
PLUG 1"
GASKET
SPACER
SPRING
PLUNGER
CA PLUG
PLUG
CAPSCREW
BALL RETAINERREVERSE
LIFTING EYE
GASKET
PLUG
GASKET
BALL RETAINERNEUTRAL
CAPSCREW

20

233043

CAPSCREW

14

1
13
201045

15917
239611

17178

10
3
1
1
1
1
1
1
1
13
1

K-2143,S-7021,S-7022
7/16" - W/NEUTRAL SWITCH
PROVISION
7/16" - REVERSE SWITCH
K-2143

9/16 - 18
9/16 - 18, THREADED
3/8"-16X1"
S-7021

2
1
1
1
1
4
8

Kits/Assys Where
Needed

K-2143,S-7021,S-7022
S-7022
S-7022
3/8"-16X1" - USE W/4301277
RETAINER
3/8"-16X1" - USE W/235608
RETAINER

Item

Current Part

Description

21
21
22

235608
4301277
4300337

22

Replaced Part

Qty.

Notes

RETAINER
SHIFT BAR RETAINER
YOKE BAR 1ST/REV

2
2
1

4300400

YOKE BAR 1ST/REV

4 HOLE RETAINER
2 HOLE RETAINER
USE W/4300336, 4302956 OR A-6538
HOUSING
USE W/239834, 4302944 OR A-6534
HOUSING

23
24
25
25
26
27
28
29
30
31
32
33
999

21548
4300429
201044
201044
4300402
14J1818
240322
240324
4300401
227675
1JM6028
1JM3528
S-7021

YOKE BAR 2ND/3RD

YOKE BAR 4TH/5TH
PIN
PIN
SHIFT BLOCK 1ST/REV
PIN
YOKE ASSY 2ND/3RD
YOKE ASSY 4TH/5TH
SHIFT YOKE 1ST/REV
INSERT - YOKE PAD
PIN
PIN
SHIFT BAR HSG ASSY

999

S-7022

SHIFT BAR HSG ASSY

21637

240323
240325

239834 ,240153
,4302944
4300336 ,4302956

1
1
1
2
1
2
1
1
1
4
2
2
1
1

Kits/Assys Where
Needed

REVERSE SWITCH
W/NEUTRAL SWITCH PROVISION
INCLUDES (2) 227675
INCLUDES (2) 227675
K-2144
COMPLETE REVERSE SWITCH
POSITION - RIGHT FRONT
COMPLETE - W/NEUTRAL SWITCH
PROVISION REVERSE SWITCH
POISTION - RIGHT REAR

15

Copyright Eaton Corporation and

Dana Limited, 2008. Eaton and Dana
hereby grant their customers, vendors, or
distributors permission to freely copy,
reproduce and/or distribute this document
in printed format. It may be copied only in its
entirety without any changes or modifications.
THIS INFORMATION IS NOT INTENDED
FOR SALE OR RESALE, AND THIS NOTICE
MUST REMAIN ON ALL COPIES.

For specing or service assistance, call 1-800-826-HELP (4357) 24 hours a day, 7 days a week (Mexico
001-800-826-4357), for more time on the road. Or visit our web site at www.roadranger.com.
Roadranger: Eaton, Dana and other trusted partners providing the best
products and services in the industry, ensuring more time on the road.

16

2008 Eaton Corporation All rights reserved.

Eaton Corporation Truck Components Operations P.O. Box 4013 Kalamazoo, MI 49003 U.S.A. www.roadranger.com