FS-4205A

July 2011

............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7 KITS & ASSEMBLIES ................................................................................................ 15 2 ....................... 6 INPUT SHAFT ......................... 9 MAINSHAFT ASSY ............................................................... 12 REMOTE CONTROL...................Contents How To Use The Illustrated Parts List ........................................................... 8 LEVER ASSY .......................................................................... 14 SHIFT BAR HOUSING ..................................................................................................................................................................................................................................................................................................................... 4 COUNTERSHAFT ASSY ........................................ 13 REVERSE IDLER GEAR ASSY ................................................................................................................................................................................................................................................... 3 CASE ...................................................................................................................................................................................... 11 MISCELLANEOUS ...............................................................................................................................................................

Model Designation or Nomenclature • For information regarding Model Designation and Nomenclature. • Current Part .How To Use The Illustrated Parts List The information contained in this document is subject to frequent updates. • Description . • Notes . • Quantity . • Kits and Assemblies are shown with applicable parts groupings in the parts listings. • Item numbers on illustrations correspond with parts listings on pages adjacent to the illustration.Part numbers beginning with the letter 'K' are kits that are not assembled S.roadranger. • Kits/Assy's Where Used 3 . please visit the interactive Electronic Parts Catalog at www.defines unique characteristics or requirements. Parts Listing Parts listings are defined by parts groupings and are broken down by service assemblies. 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.com.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).Part numbers beginning with the letter 'A' are pre-assembled Production Assemblies K.indentifies part as it is available for service.corresponding with numbers on illlustrations for part identification. • Notes are included on illustrations where additional information is needed.com/epc.specifies part name or description.roadranger. • Replaced Part .indicates Kits or Assemblies that contain a particular part. Illustrations • Illustrations show parts in assembly groups. for the latest information available. Identifying Kits and Assemblies A.quantity quantity required for assembly. visit www. Therefore. Parts listings identify a part for servicing with the following categories • Item Number .

68 SHAFT 1. BELOW CENTER LINE PUSH TYPE #3 PUSH-IRON #2 ALUMINUM. PUSH TYPE (FORK) K-2143 3/8"-16X5/8" 3/4" MAGNETIC K-2144.A-7513 1/4"-20 1/4" 9/16"-12X2-1/4" 9/16" USE W/A-5205 CLUTCH HSG ASSY SHAFT 1.A-5751 A-5205 K-7000.K-7013 . WIDTH .5632 .A-5634.3316236 .873.Group: CASE CASE Item Current Part Description Replaced Part Qty.375 SHAFT 1.A .A-5751. 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 .625.A5634. BELOW CENTER LINE PUSH TYPE #2 ALUMINUM.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.A 5771 4300418 #2 ALUMINUM.873. WIDTH .375 USE 4300121 OIL SEAL A-5629.3316237 .K-7000. 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 .A-5629.K-7013 K-2144 A-5205. OD 2. WIDTH .375.229219 23726 .

007 SHIM .4302037 1 31 S-7031 REAR BRG COVER ASSY 4301677 .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.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 2.503.007 SHIM .S-7031 S-1923.020 SHIM .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. WIDTH .004 SHIM .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-1874.238026 11H15 12H15 Kits/Assys Where Needed K-2143 5/16-18X.004 SHIM .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 . 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 .S-1924 K-2116 K-2116 K-2116 K-2116 K-2116 K-7000.010 SHIM .235656 .010 SHIM .S-1924 5 .020 SHIM .040 CAPSCREW BEARING KIT SPEEDO ROTOR SPEEDO DRIVE GEAR SPEEDO DRIVE GEAR SPEEDO DRIVE GEAR STUD SHIM .K-7013 S-7030. 654137 216053 .

K-7013 .K-7013 K-7000.K-7013 K-2144 K-2144 K-7000.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.K-7013 K-7000. 1 1 1 1 1 1 1 2 1 1 1 Notes Kits/Assys Where Needed K-7000.

Notes 1 1 4301526 4301614 1 4301615 1 1 1 4301616 4301618 4301619 INPUT SHAFT-1.375" & 1.50" INPUT 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-1.375" 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 1.50" INPUT 1.1.K-7013 K-2144 K-2144 7 .Group: INPUT SHAFT INPUT SHAFT Item Current Part Description Replaced Part Qty.118".50"PUSH/PULL INPUT SHAFT-1.1.75" INPUT K-7000 K-7013 K-7000 K-7013 K-7000.75"PUSH/PULL IN/SHAFT1.50" PUSH IN/SHAFT1.375" & 1.75" INPUT 1.50" PUSH 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-1.118".

50 INPUT .75 INPUT SHAFT ALUMINUM HOUSING MEDIUM LEVER HEIGHT 3-1/8" ALUMINUM HOUSING HIGH LEVER HEIGHT 3-1/2" COMPLETE ASSY .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 .4302711 .LEVER HEIGHT 3-1/8" 27-1/2" STRAIGHT LEVER .LEVER HEIGHT 31/2" 27-1/2" STRAIGHT LEVER "BEND TO SUIT" 3/8" X 24 THREAD COMPLETE ASSY .W/NEUTRAL SWITCH PROVISION REVERSE SWITCH POISTION .4302711 ."BEND TO SUIT" 3/8" X 24 THREAD COMPLETE REVERSE SWITCH POSITION .RIGHT FRONT COMPLETE ."BEND TO SUIT" 3/8" X 24 THREAD COMPLETE ASSY .4302944 1 4300336 .7005 654166.4301099 4301033 4300845 . 654137 4302614 4302615 241075 .A 6440 Qty.00 OUTPUT 1.ALUMINUM HOUSING HIGH .4302037 4301677 . 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 239834 .LEVER HEIGHT 27/8" 33" STRAIGHT LEVER .7004 K .4302956 1 Notes 1.A 6439 233080 .4301032 .4302039 S-7077 SHIFT BAR HOUSING ASSY SHIFT BAR HSG ASSY S-7085 8 Replaced Part K .2.ALUMINUM HOUSING LOW .RIGHT REAR Kits/Assys Where Needed .ALUMINUM HOUSING MEDIUM .

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 . Notes 1 K-7062 SHIFT LEVER HSG KIT 233080 .Group: LEVER ASSY LEVER ASSY Item Current Part Description Replaced Part Qty.S-7045 S-1578."BEND TO SUIT" Kits/Assys Where Needed K-7061.S-7045 S-1578 9 ."BEND TO SUIT" USE WITH 233080 STRAIGHT LEVER .S-1827.4302711 .K-7062.K7065.S-1827.S-1827.S7045 S-1578.S-1578.

"BEND TO SUIT" USE WITH A-6448 STRAIGHT LEVER . Notes SHIFT LEVER 27-1/2" 1 4302823 SHIFT LEVER 33" 1 USE WITH K-7061 STRAIGHT LEVER .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.K-7065.A 6439 4302704 ."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 .S-1827.A 6448 1 Kits/Assys Where Needed S-1827 S-7045 S-1578.S-7045 K-2143.S-7045 .K7062.S-1578.S1827.Item Current Part Description 5 241076 5 Qty.K-7061.4302711 .4302711 .

K-7013 K-3421 K-3421 K-2144 K-7000.6137 654166.Group: MAINSHAFT ASSY MAINSHAFT ASSY Item Current Part Description Replaced Part Qty.K-7013 3/16" K-2144 K-2144 K-7000. 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 .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 .K-7013 K-2144 K-2144 K-2144 11 .235383 4301565 A . 654137 1 1 Notes Kits/Assys Where Needed K-3479 K-3479 K-7000.

K-7013 . Notes 1 1 1 1 1 1 8 OZ (236.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.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-7000.59 CC)-FLEET SIZE 0.

S-7045 LEVER HEIGHT 5-1/8" LEVER HEIGHT 85MM (3.K7062.35") LEVER HEIGHT 5-1/8" 13 .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.S-1578.K-7065.S1827.K-7061.

K-7013 .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.

4302944 OR A-6534 HOUSING USE W/4300336.USE W/4301277 RETAINER USE W/239834.S-7085 S-7085 S-7085 3/8"-16X1" .REVERSE SWITCH 7/16" . 4302956 OR A-6538 HOUSING W/NEUTRAL SWITCH PROVISION REVERSE SWITCH 15 .Group: SHIFT BAR HOUSING SHIFT BAR HOUSING Item Current Part Description Replaced Part Qty.18 9/16 .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. THREADED 3/8"-16X1" 2 1 1 1 1 4 Kits/Assys Where Needed K-2143.S-7085 7/16" .W/NEUTRAL SWITCH PROVISION K-2143 9/16 .18.4302944 1 1 A-6538 SHIFT BAR HSG ASSY 4300336 .S-7077.S-7077.RIGHT FRONT HOUSING ONLY .4302956 1 HOUSING ONLY REVERSE SWITCH POISTION . Notes 1 A-6534 SHIFT BAR HSG ASSY 239834 .

RIGHT REAR .4302944 2 1 1 1 4 2 2 1 4300336 .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.RIGHT FRONT COMPLETE .W/NEUTRAL SWITCH PROVISION REVERSE SWITCH POISTION .A-6146. 239834 .K-2144 COMPLETE REVERSE SWITCH POSITION .4302956 1 4301595 4301593 Notes Kits/Assys Where Needed A-6145.

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