Eaton Fuller Heavy Duty Transmissions Illustrated Parts List FS-5005C March 2003

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1 Eaton Fuller Heavy Duty Transmissions Illustrated Parts List FS-00C March 00 For the most current information, visit the Roadranger web site at

2

3 Contents How To Use The Illustrated Parts List...4 Locating Transmission Tag and Identifying Model Designation... Using Model Designation or Nomenclature... CASE...6 COUNTERSHAFT ASSY...8 INPUT SHAFT...9 KITS & ASSEMBLIES...0 LEVER ASSY... MAINSHAFT ASSY... MISCELLANEOUS...4 REMOTE CONTROL... REVERSE IDLER GEAR ASSY...6 SHIFT BAR HOUSING...7

4 How To Use The Illustrated Parts List Using Model Designation or Nomenclature This information provides a guideline to assist you in indentifying the transmission designation assigned to a transmission model - information vital to identifying and ordering parts. 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 4

5 Locating Transmission Tag and Identifying Model Designation Transmission model designation, and other transmission information, are stamped on the transmission tag. To identify the transmission model designation (nomenclature), locate the tag on the transmission and then locate the model designation number as shown. Eaton Fuller Transmissions FS-606 PTO Codes Eaton Corporation Transmission Div Kalamazoo, MI 4900 Made in Using Model Designation or Nomenclature The model designation or nomenclature assigned to a transmission model provides information concerning transmission torque capacity, forward speeds, ratio set, shift bar housing and other provisions and options. Use the following guidelines to identify your transmission model designation. This information is useful when ordering parts. Every effort has been made to ensure the accuracy of this publication. However, Eaton Corporation makes no expressed or implied warranty or representation based on the information contained in this publication. Any errors or omissions may be reported to Eaton Roadranger Parts Marketing, Eaton Corporation, P.O. Box 40, Kalamazoo, MI Copyright Eaton Corporation, 00 All rights reserved.

6 Group: CASE CASE S-9 CASE ASSY 4008 S-9 CASE ASSY METRIC BOSS HOLES A-0 CLUTCH HSG ASSY 646 # ALUMINUM, BELOW CENTER LINE PUSH TYPE A-64 CLUTCH HSG ASSY 76,66,67,A - 6,A # ALUMINUM, ABOVE CENTER LINE PULL TYPE A-7 CLUTCH HSG ASSY # ALUMINUM, BELOW CENTER LINE PUSH TYPE A-7 CLUTCH HSG ASSY 69 # ALUMINUM, PUSH TYPE (FORK) 048 CLUTCH HSG ASSY 049 # PUSH-IRON W/0H FITTINGS 098 PTO COVER GASKET K CAPSCREW /8"-6X/8" 6 X--0 PIPE PLUG X 06 S-9 7 X--07 PIPE PLUG X 0 /4" MAGNETIC S SCREW NAME PLATE PLUG K- 686 SNAP RING K FITTING-4 DEGREE H 0H FITTING-STRAIGHT OIL SEAL 6 SHAFT.87, WIDTH.7, OD.68 K OIL SEAL 94 SHAFT.87, WIDTH.7 K OIL SEAL 9 SHAFT.6, WIDTH.7 K-,K-,K FRONT BRG COVER-PULL 8 USE 400 OIL SEAL 9 60 FRONT BRG COVER-PULL USE OIL SEAL FRONT BRG COVER-PUSH USE OR OIL SEAL FRONT BRG COVER-PUSH USE OIL SEAL

7 9 7 FRONT BRG COVER-PUSH USE OIL SEAL 9 8 FRONT BRG COVER-PUSH USE OIL SEAL FRONT BRG CVR- 7 USE OIL SEAL PUSH/PULL 0 40 SHIM.004 QUANTITY AS REQUIRED SHIM.007 QUANTITY AS REQUIRED 0 40 SHIM.00 QUANTITY AS REQUIRED SHIM.00 QUANTITY AS REQUIRED SHIM SCREW 4 /8"-6X/4" 0 SHIM.004 QUANTITY AS REQUIRED 06 SHIM.007 QUANTITY AS REQUIRED 07 SHIM.00 QUANTITY AS REQUIRED 08 SHIM.00 QUANTITY AS REQUIRED SHIM PTO ADAPTER 4 9G46H SCREW /4"-0X" X--40 PIPE PLUG 6 0 BEARING RETAINER 7 E7H WASHER 4 8 C60H CAPSCREW 4 /8"X-/4" 0 4 BEARING ASSY INCLUDES 6 SNAP RING 6 SNAP RING K-,K-,K-,K- 468 SPEEDO DRIVE GEAR 6 TEETH -.96 OUTPUT 8 SPEEDO ROTOR 6 TEETH -.96 OUTPUT 48 SPEEDO ROTOR 6 TEETH -.7 OUTPUT 4008 GASKET K-08,K-704,K S-70 NLA-REAR BRG COVER ASSY 47,40986 USE 4000 OIL SEAL NOTE: SENSOR SEAL REQUIRED REAR BRG COVER USE 4009 OIL SEAL 4 S-70 REAR BRG COVER ASSY 4,400 USE 484 OR 4009 OIL SEAL NOTE: SENSOR SEAL REQUIRED 4 S-704 REAR BRG COVER ASSY 7,40000 USE 484 OR 4009 OIL SEAL NOTE: SENSOR SEAL REQUIRED 4 K-704 REAR BRG COVER KIT 4067 USE 4009 OIL SEAL NOTE: PUSH- IN TYPE SPEEDO SENSOR 4 K-704 REAR BRG COVER KIT 4068 USE 4009 OIL SEAL NOTE: PUSH- IN TYPE SPEEDO SENSOR 94 STUD 4 /"-0X-/6" S WASHER 4 /" 7 86D8 NUT 86D08 4 /" OIL SEAL SHAFT.0, WIDTH OIL SEAL SHAFT.7, WIDTH. K-,K-,K OIL SEAL SHAFT.7, WIDTH. K-,K-,K OIL SEAL 998,798 SHAFT.0, WIDTH NUT 60,66,806 -/4" COVER A-64,A-7,A MAGNET S-9,S-9 4 X--000 LOCKWASHER 4 /8" 4 X-8-0 CAPSCREW C06 4 /8"-X-/4" 44 4E04 LOCKWASHER /4" 4 C408 CAPSCREW /4" BUSHING 4 A-64,A BUSHING A SLEEVE SENSOR SEAL S-70,S-70,S BRACKET BEARING RETAINER C66R CAPSCREW 4 /8"-4X" 04 GASKET K-08 7

8 Group: COUNTERSHAFT ASSY Latest Design 000-/9 CS COUNTERSHAFT ASSY 6466 BEARING CUP K-,K-,K-,K BEARING CONE K-,K-,K-,K- 404 SNAP RING A-66,A-67,A- 68,K- 4 A-68 COUNTERSHAFT ASSY DRIVE GEAR-CNTRSHFT A-67,A TH GEAR-CNTRSHFT A-68 A-68 COUNTERSHAFT ASSY COUNTERSHAFT A-68 6 A-68 COUNTERSHAFT ASSY 8

9 Group: INPUT SHAFT 4 6 INPUT SHAFT /9 649 IN/SHAFT-.7" PUSH/PULL USE 47 OR 60 FRONT BRG COVER 4 INPUT SHAFT-.0" PUSH USE 8 FRONT BRG COVER 44 INPUT SHAFT-.0" PUSH USE FRONT BRG COVER INPUT SHAFT-.0" PUSH USE FRONT BRG COVER NO LONGER AVAILABLE USE 400 FRONT BRG COVER 7608 NO LONGER AVAILABLE USE 47 OR 60 FRONT BRG COVER 4774 BEARING CUP.0" INPUT K-,K-,K- 47 BEARING CUP.7" INPUT K- 477 BEARING CONE.0" INPUT K-,K-,K- 48 BEARING CONE.7" INPUT K BEARING 4 K-,K-,K-,K- 4 WASHER K SNAP RING K- 9

10 KITS & ASSEMBLIES K- BASIC REBUILD KIT FOR UNITS W/.0" INPUT SHAFT &.00" MAINSHAFT K- BASIC REBUILD KIT FOR UNITS W/.0" INPUT SHAFT &.7" MAINSHAFT FOR UNITS W/.7" INPUT SHAFT &.7" MAINSHAFT, IN ADDITION TO K- YOU MUST ORDER ONE 47, 48 & FOR.0" COVER BORE DIAMETER OR 400 FOR.678" COVER BORE DIAMETER K- BASIC REBUILD KIT FOR UNITS W/.7" INPUT SHAFT &.00" MAINSHAFT S-9 CASE ASSY 4008 S-9 CASE ASSY METRIC BOSS HOLES K-08 GASKET KIT K-,K-,K-,K- K-9 MAINSHAFT KIT SPLINE K-9 MAINSHAFT KIT 8.00 SPLINE K-94 MAINSHAFT KIT 9.7 SPLINE S-70 NLA-REAR BRG COVER 47,40986 ASSY S-70 REAR BRG COVER ASSY 4,400 S-704 REAR BRG COVER ASSY 7,40000 K-704 REAR BRG COVER KIT 4067 K-704 REAR BRG COVER KIT 4068 K- REBUILDER KIT S-70 SHIFT BAR HSG ASSY 66 S-64 SHIFT LEVER ASSY-HIGH K-706 SHIFT LEVER HSG KIT 080,407,A ALUMINUM HOUSING HIGH - LEVER HEIGHT -/" K- SMALL PARTS KIT K- K- SYNCHRONIZER KIT K-4 SYNCHRONIZER KIT 0

11 Group: LEVER ASSY 9 6 Height /9 LEVER ASSY K-706 SHIFT LEVER HSG KIT 080,407,A ALUMINUM HOUSING HIGH - LEVER HEIGHT -/" 004 PIN FOR HSGS WITHOUT PIN SLEEVES 80 PIN FOR HSGS WITH PIN SLEEVES K-706,S SPRING 97 S WASHER S SHIFT LEVER USE WITH K-706 STRAIGHT S-64 LEVER - "BEND TO SUIT" DUST COVER S GASKET K-08,K X-8C-604 CAPSCREW 4 /8"-6X-/4" KNOB /8"X4 THREAD S-64

12 Group: MAINSHAFT ASSY /9 MAINSHAFT ASSY 8 BEARING RACE K-,K-,K-,K- 8 BEARING K-,K-,K-,K- 896 SYNCHRONIZER CUP K-,K- 4 A-40 SYNCHRONIZER ASSY 4/ K-,K- 694 CLUTCH HUB 4/ 6 K-9,K-9,K TH GEAR-MAINSHAFT 7 96 BEARING K-,K-,K-,K SNAP RING K-,K-9,K- 9,K WASHER 07 K-,K-9,K- 9,K J06 STEEL BALL /6" K- 946 RD GEAR-MAINSHAFT 96 BEARING K-,K-,K-,K- 806 SYNCHRONIZER CUP K-4,K- 4 A-69 SYNCHRONIZER ASSY / A - 4 A - 4 K-4,K- 696 MAINSHAFT.96 SPLINE K MAINSHAFT.00 SPLINE K MAINSHAFT.7 SPLINE K-94 K-9 MAINSHAFT KIT SPLINE K-9 MAINSHAFT KIT 8.00 SPLINE K-94 MAINSHAFT KIT 9.7 SPLINE 6 66 ND GEAR-MAINSHAFT 7 78 SPLIT WASHER K RETAINER K-

13 9 6 REVERSE GEAR- MAINSHAFT 0 7 CLUTCH HUB /REV 7 SNAP RING K- 7 SLIDING CLUTCH 4 SPACER K ST GEAR-MAINSHAFT 74 SPLIT WASHER K- 6 7 RETAINER K BEARING CONE K-,K-,K- 76 BEARING 88 K-,K-,K-,K-

14 MISCELLANEOUS 704 ADHESIVE SEALANT 0. CC (SINGLE APPLICATION SIZE) 7 GASKET SEALANT 8 MILLILITER SIZE K-8 70 SEALANT CC (SINGLE APPLICATION SIZE) 706 SILICONE LUBE 4 CC (SINGLE APPLICATION SIZE) 70 SILICONE LUBE 8 OZ (6.9 CC)-FLEET SIZE 7 THREAD ADHESIVE 0 MILLILITER SIZE 4

15 Group: REMOTE CONTROL 4 4 Indicates part of item 7 * * * Use Lockwire at these positions Lever Height REMOTE CONTROL 684 CONTROL HOUSING 68 ASSY 608 CONTROL HOUSING 609 A-99 A-79 ASSY F00 PLUG " BUSHING 4 X-8C-604 CAPSCREW 4 /8"-6X-/4" 948 BREATHER 6 77 INNER SHIFT LEVER A-99,A SCREW A-99,A WASHER 9 87 SPRING 0 OIL SEAL 4098 GASKET K-08,K BOOT A-99,A-79 A-797 NO LONGER AVAILALBE A-79 A-7 SHAFT & LEVER ASSY LEVER HEIGHT -/4" A SHAFT & LEVER ASSY LEVER HEIGHT -/8" 999 A-99 M/R SLAVE CONTROL LEVER HEIGHT -/4" ASSY 999 A-79 NO LONGER AVAILABLE

16 Group: REVERSE IDLER GEAR ASSY /9 REVERSE IDLER GEAR ASSY 400 WASHER K- 4 SPACER K- 4 BEARING K-,K-,K-,K- 4 9 IDLER GEAR 0609 IDLER SHAFT SHAFT LOCK 7 X-8C-600 CAPSCREW 96 /8"-6X" 6

17 Group: SHIFT BAR HOUSING * * Neutral Switch Provision * /9 SBH SHIFT BAR HOUSING A-6 SHIFT BAR HSG ASSY 66,4094 HOUSING ONLY REVERSE SWITCH POSITION - RIGHT FRONT 80 GASKET K-08,S-70 0J4 STEEL BALL 7/6" SPRING PLUG " 6 6 GASKET 7 60 SPACER 8 68 SPRING 9 69 PLUNGER 0 0 CA PLUG 9/ PLUG 97 9/6-8, THREADED X-8C-600 CAPSCREW 96 4 /8"-6X" 870 BRACKET PLUG 900 GASKET K-08,S J88 PIN 0 04 CAPSCREW 4 /8"-6X" 4077 SHIFT BAR RETAINER FRONT 609 SHIFT BAR RETAINER REAR 60 YOKE BAR ST/REV 4 69 YOKE BAR ND/RD 68 YOKE BAR 4TH/TH YOKE BAR ST/REV J88 PIN SPACER FRONT 9 84 SPACER REAR 0 6 SHIFT BLOCK ST/REV 68 REVERSE BLOCK 46 ACTUATOR 068 PIN 0664 SPRING YOKE ST/REV PIN 8 A- YOKE ND/RD 660, YOKE 4TH/TH BUSHING 4 A-,K- 999 S-70 SHIFT BAR HSG ASSY 66 7

18 Copyright Eaton and Dana Corporation, 00. EATON AND DANA CORPORATION hereby grants its customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. THIS INFORMATION IS NOT INTENDED FOR SALE OR RE- SALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES. The Roadranger System is an unbeatable combination of the best products from Eaton and Dana partnering to provide you the most advanced, most trouble-free drivetrain in the industry. And it s backed by the Roadrangers the most experienced, most expert, most accessible drivetrain consultants in the business. For spec ing or service assistance, call HELP (47) 4 hours a day, 7 days a week, (Mexico: HELP (47)) for more time on the road. Or visit our web site at 8 FS-00C /0 Printed in the USA

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