FO-5406B-DM3

July 2011
 For parts or service call us
Pro Gear & Transmission, Inc.

1 (877) 776-4600
(407) 872-1901
[email protected]

906 W. Gore St.

Orlando, FL 32805
Contents
How To Use The Illustrated Parts List .................................................................................................................................................. 3
CASE ......................................................................................................................................................................................................... 4
CONTROLLER ECU & HARNESS...................................................................................................................................................... 6
COUNTERSHAFT ASSY ....................................................................................................................................................................... 7
INERTIA BRAKE ASSEMBLY ............................................................................................................................................................ 8
INPUT SHAFT ......................................................................................................................................................................................... 9
KITS & ASSEMBLIES ......................................................................................................................................................................... 10
MAINSHAFT ASSY .............................................................................................................................................................................. 11
REVERSE IDLER GEAR ASSY ......................................................................................................................................................... 13
SHIFT BAR HOUSING ........................................................................................................................................................................ 14
SHIFT CONTROLS .............................................................................................................................................................................. 16
X-Y SHIFTER MODULE ..................................................................................................................................................................... 17

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 Kits/Assys Where
Needed
TA-C38-01 FO-5406B-DM3 SERVICE 1 COMPLETE UNIT
UNIT
1 A-7636 CLUTCH HSG ASSY 4305882 1
2 A-7635 CASE ASSY 4305847 1
4 201398 PTO COVER 1
6 239613 CAPSCREW 6 3/8"-16X5/8"
7 4303692 HAND HOLE COVER 1 A-7636
8 3315679 PLUG 1 K-3440
9 4305309 GASKET 1684 1 K-3648,K-3738
4
Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
10 X-8L-408 SCREW & WASHER ASSY 2
11 X-3-1000 LOCKWASHER 4 5/8"
12 X-8-1013 HEX HEAD SCREW 4 .625-11 X 3.00
15 3315659 GASKET 1 K-3738
16 4300888 FRONT BRG COVER-PULL 1
17 4300121 OIL SEAL 3315623 1 SHAFT 1.873, WIDTH .375, OD 2.68 K-3440
18 239614 SCREW 6 5/16-18X.81
21 3315681 SHIM .004 1 K-2183
21 3315682 SHIM .007 1 K-2183
21 3315683 SHIM .010 1 K-2183
21 3315684 SHIM .020 1 K-2183
21 4300977 SHIM .040 1
23 X-12-1209 PIPE PLUG 1
24 X-12-1207 PIPE PLUG X12 1202 ,X12 1206 2 3/4" MAGNETIC
27 4301607 C/S REAR BRG COVER 1
30 3316160 SPEEDO ROTOR 1 16 TEETH
31 711123 BEARING CUP 1 K-3440
32 3315662 SHIM .004 1 K-2183
32 3315663 SHIM .007 1 K-2183
32 3315664 SHIM .010 1 K-2183
32 3315665 SHIM .020 1 K-2183
32 4300978 SHIM .040 1
33 S-2864 REAR BRG COVER ASSY 691423 ,691666 1
34 4300119 OIL SEAL 1 SHAFT 2.753, WIDTH .5 K-3440,S-2864
36 K-3411 NUT KIT 21937 ,4301920 1
,4304690
37 239436 WASHER 4 1/2"
38 86D8 NUT 86D08 4 1/2"-20
44 X-8C-604 CAPSCREW 4 3/8"-16X1-1/4"
47 14373 MAGNET 2 A-7635
49 239433 STUD 4 1/2"-20X2-5/16"
50 X-12-405 PIPE PLUG 1
52 238370 LIFTING EYE 2
53 K-3231 SPEED SENSOR KIT A - 6398 ,A - 6724 1 SINGLE PICK-UP (2 PIN)
54 X-8C-409 CAPSCREW 1 1/4"-20X5/8"
55 14142 -O- RING 1 K-3125,K-3638,S-2864
56 K-3125 SPEEDO PLUG KIT 4302707 2
57 X-8C-409 CAPSCREW 2 1/4"-20X5/8"

5
Group: CONTROLLER ECU & HARNESS

CONTROLLER ECU & HARNESS

Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
1 K-3711 TRANS CONTROLLER KIT 1
2 K-3743 TRANS HARNESS KIT 4306024 1
3 X-8C-455 HEX HEAD 3
WASHER/SCREW

6
Group: COUNTERSHAFT ASSY

COUNTERSHAFT ASSY
Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
1 3315686 SNAP RING 1 K-3440
2 3315687 WASHER 1
3 K-3795 COUNTERSHAFT BRG KIT 1313645, 791943 1
5 3315752 SNAP RING 3315751 1
6 4304541 DRIVE GEAR-CNTRSHFT 1
7 4304542 5TH GEAR-CNTRSHFT 1
8 4304097 4TH GEAR-CNTRSHFT 4304099 1
9 4304056 3RD GEAR-CNTRSHFT 4304062 1
10 230292 KEY 2
11 4303868 COUNTERSHAFT 1
12 658981 BEARING CONE 1 K-3440
13 660181 BEARING CUP 1 K-3440

7
Group: INERTIA BRAKE ASSEMBLY

INERTIA BRAKE ASSEMBLY

Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
1 K-3648 INERTIA BRAKE KIT A - 7434 ,K - 3508, A- 1
7828
2 X-8C-409 CAPSCREW 1 1/4"-20X5/8"
3 X-8C-690 CAPSCREW 6
4 4303677 ELBOW 1
5 5588207 OIL HOSE ASSY (12.70") 1
6 691651 ELBOW, 90 DEG MALE 2
7 691517 FILTER FITTING 1
8 4305309 GASKET 1684 2 K-3648,K-3738
9 K-3231 SPEED SENSOR KIT A - 6398 ,A - 6724 1 SINGLE PICK-UP (2 PIN)
10 691519 PLATE-ADAPTER 6 BOLT 1
PTO
11 K-3638 I-BRAKE CONNECTOR 691499 1
KIT

8
Group: INPUT SHAFT

INPUT SHAFT
Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
1 675250 BEARING CUP 1 1.75" INPUT K-3440
2 742259 BEARING CONE 1 1.75" INPUT K-3440
3 4304539 INPUT SHAFT-1.75" PULL 1 PILOT 30MM

9
KITS & ASSEMBLIES
Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
K-2183 SHIM KIT 1 K-3440
K-3125 SPEEDO PLUG KIT 4302707 1
K-3231 SPEED SENSOR KIT A - 6398 ,A - 6724 1 SINGLE PICK-UP (2 PIN)
K-3411 NUT KIT 21937 ,4301920 1
,4304690
K-3438 POSITION SENSOR KIT 691551 ,691926 1
K-3440 BASIC REBUILD KIT 1
K-3638 I-BRAKE CONNECTOR 691499 1
KIT
K-3648 INERTIA BRAKE KIT A - 7434 ,K - 3508 1
K-3711 TRANS CONTROLLER KIT 1
K-3738 GASKET KIT 1 K-3440
K-3743 TRANS HARNESS KIT 4306024 1
K-3784RX REMAN EXCH GEN 3 X-Y A - 7670, A - 7856,K- 1
SHIFTER KIT 3784
K-3795 COUNTERSHAFT BRG KIT 1313645, 791943 1
S-2864 REAR BRG COVER ASSY 691423 ,691666 1
S-2865 SHIFT BAR HOUSING 691655 ,A - 7053 1
ASSY
TA-C38-01 FO-5406B-DM3 SERVICE 1 COMPLETE UNIT
UNIT

10
Group: MAINSHAFT ASSY

MAINSHAFT ASSY
Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
4 710787 BEARING CONE 1 K-3440
6 691415 SLIDING CLUTCH 1
(5TH/6TH)
7 4301476 CLUTCH HUB 5/6 1
8 4304543 5TH GEAR-MAINSHAFT 1
9 3315737 BEARING 2 K-3440
10 3315728 SNAP RING 3315729 1
11 3315727 WASHER 1
12 4304098 4TH GEAR-MAINSHAFT 4304401 1
13 4124075 BEARING 4 K-3440
15 3315725 SNAP RING 2 K-3440
16 691414 SLIDING CLUTCH 1
(3RD/4TH)
17 4301475 CLUTCH HUB 3/4 1
18 4304057 3RD GEAR-MAINSHAFT 4304063 1
19 3315722 BEARING 2 K-3440
20 3315717 SNAP RING 3315718 1
21 3315719 WASHER 1
22 4303231 2ND GEAR-MAINSHAFT 4301482 1
23 4301852 SLIDING CLUTCH 1
1ST/REV

11
Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
24 4303298 1ST GEAR-MAINSHAFT 1
25 4303301 REVERSE GEAR- 1
MAINSHAFT
26 4301474 CLUTCH HUB-REV 1
27 4301473 SLIDING CLUTCH-REV 1
28 10J06 STEEL BALL 2 3/16"
31 3315703 BEARING 4 K-3440
33 4301468 MAINSHAFT 1
34 4301492 WASHER 1
35 5557003 BEARING CONE 1 K-3440

12
Group: REVERSE IDLER GEAR ASSY

REVERSE IDLER GEAR ASSY

Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
15 3315674 BEARING 2 K-3440
16 3315676 SPACER 1
18 3315672 REVERSE IDLER SHAFT 1
19 10J06 STEEL BALL 1 3/16"
20 4304319 REVERSE IDLER GEAR 1

13
Group: SHIFT BAR HOUSING

SHIFT BAR HOUSING

Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
1 S-2865 SHIFT BAR HOUSING 691655 ,A - 7053 1

14
Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
ASSY
2 4300854 GASKET 3315678 1 K-3738,S-2865
3 X-8C-600 CAPSCREW 239611 12 3/8"-16X1"
4 691644 SPRING 4 K-3440
5 10J14 STEEL BALL 13 7/16"
6 201044 PIN 2
7 4301719 BALL RETAINER- 1
REVERSE
26 691526 SHIFT BLOCK - REVERSE 1
27 691654 YOKE BAR - REVERSE 691422 1
28 3315897 SHIFT YOKE ASSY 1
29 691522 SHIFT BLOCK (1ST/2ND) 1
30 691419 YOKE BAR (1ST/2ND) 1
31 3315772 SHIFT YOKE ASSY 3315770 1
32 691420 YOKE BAR (3RD/4TH) 1
33 A-7038 YOKE ASSY (3RD/4TH) 691524 1
34 1JM6028 PIN 6
35 1JM3528 PIN 6
36 691421 YOKE BAR (5TH/6TH) 1
37 A-7039 YOKE ASSY (5TH/6TH) 691525 1
39 4301279 SHIFT BAR RETAINER 3315756 2
40 3315757 SHIFT BAR RETAINER 1
41 233043 CAPSCREW 8 3/8"-16X1"
43 227675 INSERT - YOKE PAD 6 A-7038,A-7039
44 235052 CA PLUG 1 9/16 - 18
44 4303656 PLUG 15917 1 9/16 - 18, THREADED
45 15900 GASKET 1 K-3738,S-2865
46 X-8-688 CAPSCREW 3 3/8"-16X1"
47 238370 LIFTING EYE 3
999 S-2865 SHIFT BAR HOUSING 691655 ,A - 7053 1
ASSY

15
Group: SHIFT CONTROLS

SHIFT CONTROLS
Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
1 4306043 PUSHBUTTON ASSY A - 7466,S-3007 1

16
Group: X-Y SHIFTER MODULE

X-Y SHIFTER MODULE

Item Current Part Description Replaced Part Qty. Notes Kits/Assys Where
Needed
1 K-3784RX REMAN EXCH GEN 3 X-Y A - 7670, A - 7856,K- 1
SHIFTER KIT 3784
2 4305452 GASKET 4301958 1 K-3738,K-4009
3 K-3438 POSITION SENSOR KIT 691551 ,691926 2
4 X-8C-615 CAPSCREW 4
5 4304602 BREATHER 23605 1 1/4" NPT
6 5559348 TY-RAP 6 K-3743
7 K-4009 XY SHIFTER REPAIR KIT 1

17
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