JD 7200R Series Repair Manual PDF

John Deere Agriculture
7200R, 7215R, 7230R, 7260R and 7280R

Tractors
REPAIR TECHNICAL MANUAL

(SN: 000101-080000) models 7200R, 7215R,
7230R, 7260R, 7280R
TM110119, May 2013

TM110119-REPAIR TECHNICAL MANUAL (g) by Belgreen
Table of contents
FOREWORD
DEALER PREDELIVERY INFORMATION FORM
Section 10 - GENERAL INFORMATION
Group 05 - Safety
Group 10 - General Information
Section 20 - ENGINE
Group 00 - Component Removal and Installation
Group 05 - Engine Repair
Section 30 - FUEL AND COOLING SYSTEMS
Group 10 - Diesel Fuel System
Group 15 - Air Intake System
Group 20 - Auxiliary Drive System
Group 25 - Radiator and Coolers
Group 30 - Exhaust System
Section 40 - ELECTRICAL
Group 05 - Connectors
Group 10 - Wiring Harness Routings
Group 15 - Charging Circuit
Group 20 - Starting Circuit
Group 25 - Relays, Fuses, Solenoids, and Switches
Group 30 - Monitoring System
Group 35 - Armrest Control
Group 40 - Implement and Accessory Connectors
Group 45 - Convenience and Accessory Components
Section 50 - AUTOQUAD/COMMANDQUAD TRANSMISSION
Group 05 - Transmission Shifting Mechanisms
Group 10 - PowrQuad-Plus™ Module
Group 20 - Range Box (PowrQuad™ and AutoQuad™)
Group 30 - Range Box (CommandQuad™)
Section 51 - AUTOPOWR/IVT TRANSMISSION
Group 05 - General Repair Procedures
Group 20 - Transmission Repair
Group 30 - Assemble Transmission
Section 56 - DRIVE SYSTEMS
Group 10 - Rear Differential
Group 20 - Final Drive
Group 30 - Rear PTO
Group 35 - Front PTO
Group 40 - Primary Brakes
Group 45 - Pump Drive Housing
Section 57 - 1100 SERIES MFWD AXLE
Group 00 - Component Removal And Installation
Group 05 - Final Drives
Group 10 - Axle Housing
Group 15 - Differential
<- Go to Global Table of contents TM110119-REPAIR TECHNICAL MANUAL


Section 59 - SUSPENDED MFWD AXLE
Group 20 - Suspension Components
Section 60 - STEERING AND BRAKES
Group 05 - Steering Column
Group 10 - Steering Control Assembly
Group 15 - Steering Cylinders
Group 20 - Service Brakes
Group 30 - Hydraulic Trailer Brake
Group 35 - Air Trailer Brake
Section 70 - HYDRAULICS
Group 15 - Integrated Hydraulic Pump
Group 25 - Hitch Valve, Selective Control Valves and Couplers
Group 30 - Rear Hitch
Group 35 - Front Hitch
Section 80 - MISCELLANEOUS
Group 05 - Hood
Group 10 - Front Axle (Two-Wheel Drive)
Group 20 - Rear Wheels
Group 25 - Wagon And Pick-Up Hitch
Section 90 - OPERATOR STATION
Group 05 - Heating, Ventilating, and Air Conditioning (HVAC)
Group 10 - Air Conditioning System
Group 15 - Air Suspension Seat
Group 16 - ComfortCommand™ Seat
Group 20 - ActiveSeat™
Group 25 - Armrest
Group 30 - Cab Door and Windshield
Group 35 - Cab Suspension
Section 99 - DEALER TOOLS
Group 05 - Dealer Fabricated Tools
Group 10 - Essential And Recommended Tools

Foreword
This manual is written for an experienced technician. Essential and recommended tools
required in performing certain service work are identified in this manual.
Live with safety: Read the safety messages in the introduction of this manual and the
cautions presented throughout the text of the manual.
CAUTION:
This is the safety-alert symbol. When you see this symbol on the machine or in this manual,
be alert to the potential for personal injury.
Technical manuals are used to provide service information. The Repair Technical Manual tells
how to repair the components. The Operation and Test Technical Manual helps you quickly
identify the majority of failures.
Information is organized in groups for the various components requiring service instruction.
At the beginning of each group are summary listings of all applicable essential and
recommended tools, other material needed to do the job, service parts kits, specifications,
wear tolerances, and torque values.
Technical manuals are concise guides for specific machines. They are on-the-job guides
containing only the vital information needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of
operation, fundamentals of troubleshooting, general maintenance, and basic type of failures
and their causes.

GENERAL INFORMATION (g) by Belgreen
Dealer Predelivery Information Form

The John Deere Predelivery Form, when properly filled out and signed by dealer, verifies
predelivery and delivery services were satisfactorily performed.
Because of the shipping factors involved, plus extra finishing touches necessary to promote
customer satisfaction, there are certain predelivery services that must be performed by the
dealer. These services are listed on the predelivery form with the tractor.
Perform all services listed and check each job off as it is completed. Fill form out completely
and sign it.

Section 10 - GENERAL INFORMATION

Table of contents
Group 05 - Safety ...................................................................................................................... 1
Recognize Safety Information ................................................................................................ 1
Understand Signal Words ....................................................................................................... 1
Follow Safety Instructions ...................................................................................................... 2
Wear Protective Clothing ....................................................................................................... 2
Service Machines Safely ......................................................................................................... 3
Stay Clear of Rotating Drivelines ........................................................................................... 4
Handle Fluids Safely—Avoid Fires .......................................................................................... 5
Prevent Battery Explosions .................................................................................................... 5
Prepare for Emergencies ........................................................................................................ 6
Remove Paint Before Welding or Heating .............................................................................. 6
Avoid Heating Near Pressurized Fluid Lines ........................................................................... 7
Handle Starting Fluid Safely ................................................................................................... 8
Avoid Hot Exhaust .................................................................................................................. 8
Clean Exhaust Filter Safely .................................................................................................. 10
Prevent Acid Burns ............................................................................................................... 13
Handle Agricultural Chemicals Safely .................................................................................. 15
Clean Vehicle of Hazardous Pesticides ................................................................................. 16
Handling Batteries Safely ..................................................................................................... 17
Avoid Harmful Asbestos Dust ............................................................................................... 19
Dispose of Waste Properly ................................................................................................... 20
Avoid High-Pressure Fluids ................................................................................................... 21
Wait Before Opening High-Pressure Fuel System ................................................................. 21
Service Accumulator Systems Safely ................................................................................... 22
Protect Against High Pressure Spray .................................................................................... 23
Service Cooling System Safely ............................................................................................. 23
Prevent Machine Runaway ................................................................................................... 24
Keep ROPS Installed Properly ............................................................................................... 24
Avoid Backover Accidents .................................................................................................... 25
Park Machine Safely ............................................................................................................. 25
Support Machine Properly .................................................................................................... 26
Work in Clean Area .............................................................................................................. 27
Work In Ventilated Area ....................................................................................................... 27
Illuminate Work Area Safely ................................................................................................. 28
Use Proper Lifting Equipment ............................................................................................... 28
Service Tires Safely .............................................................................................................. 28
Instructional Seat ................................................................................................................. 30
Service Front-Wheel Drive Tractor Safely ............................................................................ 30
Use Steps and Handholds Correctly ..................................................................................... 31
Transport Tractor Safely ...................................................................................................... 31
Practice Safe Maintenance ................................................................................................... 32
Use Proper Tools .................................................................................................................. 33
Construct Dealer-Made Tools Safely .................................................................................... 33
Replace Safety Signs ............................................................................................................ 34
Install All Guards .................................................................................................................. 34
Live With Safety ................................................................................................................... 35

Group 10 - General Information ............................................................................................ 36

List of References ................................................................................................................ 36
Trademarks .......................................................................................................................... 37
Sealants and Adhesives Cross-Reference Chart ................................................................... 40
Metric Bolt and Screw Torque Values ................................................................................... 42
Unified Inch Bolt and Screw Torque Values .......................................................................... 43
Face Seal Fittings Assembly and Installation—All Pressure Applications .............................. 45
Metric Face Seal And O-Ring Stud End Fitting Torque Chart—Standard Pressures .............. 46
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications
....................................................................................................................................... 48
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures .................. 50
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications ....... 51
Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications ................... 52
SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications .............. 53
SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications ..................... 54
External Hexagon Port Plug Torque Chart ............................................................................ 55
Prevent Hydraulic System Contamination ............................................................................ 55
Check Oil Lines and Fittings ................................................................................................. 57
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer
Controlled Systems ....................................................................................................... 59
Identify Zinc-Flake Coated Fasteners ................................................................................... 59
Use Torque Wrench Adapter ................................................................................................ 61
Servicing and Connecting Snap to Connect STC™ Fittings .................................................. 62
Glossary of Terms ................................................................................................................ 64

Section 10 - GENERAL INFORMATION Group 05: Safety
Group 05 - Safety
Recognize Safety Information
This is a safety-alert symbol. When you see this symbol on your machine or in this manual,
be alert to the potential for personal injury.
Follow recommended precautions and safe operating practices.
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol.

DANGER identifies the most serious hazards.
DANGER or WARNING safety signs are located near specific hazards. General precautions are
listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this
<- Go to Section TOC Section 10 page 1 TM110119-REPAIR TECHNICAL MANUAL
manual.
Follow Safety Instructions
Carefully read all safety messages in this manual and on your machine safety signs. Keep
safety signs in good condition. Replace missing or damaged safety signs. Be sure new
equipment components and repair parts include the current safety signs. Replacement safety
signs are available from your John Deere dealer.
There can be additional safety information contained on parts and components sourced from
suppliers that is not reproduced in this operator′s manual.
Learn how to operate the machine and how to use controls properly. Do not let anyone
operate without instruction.
Keep your machine in proper working condition. Unauthorized modifications to the machine
may impair the function and/or safety and affect machine life.
If you do not understand any part of this manual and need assistance, contact your John
Deere dealer.
Wear Protective Clothing

Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or
music headphones while operating machine.
Service Machines Safely

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when
you work near machine tools or moving parts. If these items were to get caught, severe injury
could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving
parts.
Stay Clear of Rotating Drivelines
Entanglement in rotating driveline can cause serious injury or death.
Keep all shields in place at all times. Make sure rotating shields turn freely.
Wear close-fitting clothing. Stop the engine and be sure that all rotating parts and drivelines
are stopped before making adjustments, connections, or performing any type of service on
engine or machine driven equipment.

Handle Fluids Safely—Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn spontaneously.
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can
explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near
your telephone.
Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a
torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint
cannot be removed, wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before
welding. Remove solvent or paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
Avoid Heating Near Pressurized Fluid Lines
Flammable spray can be generated by heating near pressurized fluid lines, resulting in
severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally
burst when heat goes beyond the immediate flame area.

Handle Starting Fluid Safely
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep starting fluid away from batteries and
cables.
To prevent accidental discharge when storing the pressurized can, keep the cap on the
container, and store in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
Avoid Hot Exhaust

Servicing machine or attachments with engine running can result in serious personal injury.
Avoid exposure and skin contact with hot exhaust gases and components.
Exhaust parts and streams become very hot during operation. Exhaust gases and
components reach temperatures hot enough to burn people, ignite, or melt common
materials.

Clean Exhaust Filter Safely

During exhaust filter cleaning operations, the engine may run at elevated idle and hot
temperatures for an extended period of time. Exhaust gases and exhaust filter components
reach temperatures hot enough to burn people, or ignite or melt common materials.
Keep machine away from people, animals, or structures which may be susceptible to harm or
damage from hot exhaust gases or components. Avoid potential fire or explosion hazards
from flammable materials and vapors near the exhaust. Keep exhaust outlet away from

people and anything that can melt, burn, or explode.
Closely monitor machine and surrounding area for smoldering debris during and after
exhaust filter cleaning.
Adding fuel while an engine is running can create a fire or explosion hazard. Always stop
engine before refueling machine and clean up any spilled fuel.
Always make sure that engine is stopped while hauling machine on a truck or trailer.
Contact with exhaust components while still hot can result in serious personal injury.
Avoid contact with these components until cooled to safe temperatures.
If service procedure requires engine to be running:
Only engage power-driven parts required by service procedure

Ensure that other people are clear of operator station and machine
Keep hands, feet, and clothing away from power-driven parts.
Always disable movement (neutral), set the parking brake or mechanism and disconnect
power to attachments or tools before leaving the operator’s station.
Shut off engine and remove key (if equipped) before leaving the machine unattended.

Prevent Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
3. Get medical attention immediately.

Handle Agricultural Chemicals Safely
Chemicals used in agricultural applications such as fungicides, herbicides, insecticides,

pesticides, rodenticides, and fertilizers can be harmful to your health or the environment if
not used carefully.
Always follow all label directions for effective, safe, and legal use of agricultural chemicals.
Reduce risk of exposure and injury:
Wear appropriate personal protective equipment as recommended by the

manufacturer. In the absence of manufacturer′s instructions, follow these general
guidelines:
Chemicals labeled′Danger′ : Most toxic. Generally require use of goggles,
respirator, gloves, and skin protection.
Chemicals labeled′Warning′ : Less toxic. Generally require use of goggles, gloves,
and skin protections.

Chemicals labeled′Caution′ : Least toxic. Generally require use of gloves and skin
protection.
Avoid inhaling vapor, aerosol or dust.
Always have soap, water, and towel available when working with chemicals. If chemical
contacts skin, hands, or face, wash immediately with soap and water. If chemical gets
into eyes, flush immediately with water.
Wash hands and face after using chemicals and before eating, drinking, smoking, or
urination.
Do not smoke or eat while applying chemicals.
After handling chemicals, always bathe or shower and change clothes. Wash clothing
before wearing again.
Seek medical attention immediately if illness occurs during or shortly after use of
chemicals.
Keep chemicals in original containers. Do not transfer chemicals to unmarked
containers or to containers used for food or drink.
Store chemicals in a secure, locked area away from human or livestock food. Keep
children away.
Always dispose of containers properly. Triple rinse empty containers and puncture or
crush containers and dispose of properly.
Clean Vehicle of Hazardous Pesticides
CAUTION:
During application of hazardous pesticides, pesticide residue can build up

on the inside or outside of the vehicle. Clean vehicle according to use
instructions of hazardous pesticides.
When exposed to hazardous pesticides, clean exterior and interior of vehicle daily to keep
free of the accumulation of visible dirt and contamination.
[1] - Sweep or vacuum the floor of cab.

[2] - Clean headliners and inside cowlings of cab.
[3] - Wash entire exterior of vehicle.
[4] - Dispose of any wash water with hazardous concentrations of active or non-active
ingredients according to published regulations or directives.

Handling Batteries Safely

Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to
check battery electrolyte level.
Never check battery charge by placing a metal object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (-) battery clamp first and replace grounded clamp last.
Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into eyes.
Avoid hazards by:
Filling batteries in a well-ventilated area

Wearing eye protection and rubber gloves
Avoiding use of air pressure to clean batteries

Avoiding breathing fumes when electrolyte is added
Avoiding spilling or dripping electrolyte
Using correct battery booster or charger procedure.
If acid is spilled on skin or in eyes:
1. Flush skin with water.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush eyes with water for 15—30 minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 qt.).
3. Get medical attention immediately.
WARNING: Battery posts, terminals, and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and reproductive
harm.Wash hands after handling.
Avoid Harmful Asbestos Dust
Avoid breathing dust that may be generated when handling components containing asbestos
fibers. Inhaled asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers are brake pads, brake band and
lining assemblies, clutch plates, and some gaskets. The asbestos used in these components
is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding

material containing asbestos. When servicing, wear an approved respirator. A special vacuum
cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the
material containing asbestos.
Keep bystanders away from the area.
Dispose of Waste Properly
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful
waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid,
filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that
may mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere.
Government regulations may require a certified air conditioning service center to recover and
recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or
recycling center, or from your John Deere dealer.

Avoid High-Pressure Fluids
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts,
cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or
damage.
Replace worn or damaged hose assemblies immediately with John Deere approved
replacement parts.
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this
type of injury should reference a knowledgeable medical source. Such information is
available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by
calling 1-800-822-8262 or +1 309-748-5636.
Wait Before Opening High-Pressure Fuel System

High-pressure fluid remaining in fuel lines can cause serious injury. Only technicians familiar
with this type of system should perform repairs. Before disconnecting fuel lines, sensors, or
any other components between the high-pressure fuel pump and nozzles on engines with
High Pressure Common Rail (HPCR) fuel system, wait a minimum of 15 minutes after engine
is stopped.
Service Accumulator Systems Safely
Escaping fluid or gas from systems with pressurized accumulators that are used in air
conditioning, hydraulic, and air brake systems can cause serious injury. Extreme heat can
cause the accumulator to burst, and pressurized lines can be accidentally cut. Do not weld or
use a torch near a pressurized accumulator or pressurized line.
Relieve pressure from the pressurized system before removing accumulator.
Relieve pressure from the hydraulic system before removing accumulator. Never attempt to
relieve hydraulic system or accumulator pressure by loosening a fitting.
Accumulators cannot be repaired.
Protect Against High Pressure Spray
Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray
from contacting hands or body.
If an accident occurs, see a doctor immediately. Any high pressure spray injected into the
skin must be surgically removed within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a knowledgeable medical source. Such
information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
Service Cooling System Safely

Explosive release of fluids from pressurized cooling system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure before removing completely.
Prevent Machine Runaway
Avoid possible injury or death from machinery runaway.
Do not start engine by shorting across starter terminals. Machine will start in gear if normal
circuitry is bypassed.
NEVER start engine while standing on ground. Start engine only from operator’s seat, with
transmission in neutral or park.
Keep ROPS Installed Properly

Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is
loosened or removed for any reason. Tighten mounting bolts to proper torque.
The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way altered by welding, bending, drilling, or
cutting. A damaged ROPS should be replaced, not reused.
The seat is part of the ROPS safety zone. Replace only with John Deere seat approved for
your tractor.
Any alteration of the ROPS must be approved by the manufacturer.
Avoid Backover Accidents
Before moving machine, be sure that all persons are clear of machine path. Turn around and
look directly for best visibility. Use a signal person when backing if view is obstructed or when
in close quarters.
Do not rely on a camera to determine if personnel or obstacles are behind the machine. The
system can be limited by many factors including maintenance practices, environmental
conditions, and operating range.
Park Machine Safely

Before working on the machine:
Lower all equipment to the ground.

Stop the engine and remove the key.
Disconnect the battery ground strap.
Hang a "DO NOT OPERATE" tag in operator station.
Support Machine Properly
Always lower the attachment or implement to the ground before you work on the machine. If
the work requires that the machine or attachment be lifted, provide secure support for them.
If left in a raised position, hydraulically supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under
continuous load. Do not work under a machine that is supported solely by a jack. Follow
recommended procedures in this manual.

When implements or attachments are used with a machine, always follow safety precautions
listed in the implement or attachment operator′s manual.
Work in Clean Area
Before starting a job:
Clean work area and machine.

Make sure you have all necessary tools to do your job.
Have the right parts on hand.
Read all instructions thoroughly; do not attempt shortcuts.
Work In Ventilated Area
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an
enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the
area.
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside
or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or oil.
Use Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.

Service Tires Safely
CAUTION:
Explosive separation of a tire and rim parts can cause serious injury or
death.
Do not attempt to mount a tire unless you have the proper equipment and
experience to perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended
pressure.
Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure
resulting in a tire explosion. Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to
stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
Instructional Seat
The instructional seat, if so equipped, has been provided only for training operators or
diagnosing machine problems.
Service Front-Wheel Drive Tractor Safely

When servicing front-wheel drive tractor with the rear wheels supported off the ground and
rotating wheels by engine power, always support front wheels in a similar manner. Loss of
electrical power or transmission hydraulic system pressure will engage the front driving
wheels, pulling the rear wheels off the support if front wheels are not raised. Under these
conditions, front drive wheels can engage even with switch in disengaged position.
Use Steps and Handholds Correctly
Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with
steps, handholds, and handrails.
Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean
and free of grease or oil. Never jump when exiting machine. Never mount or dismount a
moving machine.
Transport Tractor Safely
A disabled tractor is best transported on a flatbed carrier. Use chains to secure the tractor to
the carrier. The axles and tractor frame are suitable attachment points.

Before transporting the tractor on a low-loader truck or flatbed rail wagon, make sure that
the hood is secured over the tractor engine and that doors, roof hatch (if equipped) and
windows are properly closed.
Never tow a tractor at a speed greater than 10 km/h (6 mph). An operator must steer and
brake the tractor under tow.
Practice Safe Maintenance
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing
from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower
equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace
worn or broken parts. Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments
on electrical systems or welding on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical
system components or welding on machine.
Use Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners.
For loosening and tightening hardware, use the correct size tools. DO NOT use U.S.
measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. When constructing tools, use proper,
quality materials, and good workmanship.
Do not weld tools unless you have the proper equipment and experience to perform the job.
Replace Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct
safety sign placement.
Install All Guards

Section 10 - GENERAL INFORMATION Group 10: General Information
Rotating cooling system fans, belts, pulleys, and drives can cause serious injury.
Keep all guards in place at all times during engine operation.
Wear close-fitting clothes. Stop the engine and be sure fans, belts, pulleys, and drives are
stopped before making adjustments, connections, or cleaning near fans and their drive
components.
Live With Safety
Before returning machine to customer, make sure machine is functioning properly, especially
the safety systems. Install all guards and shields.

Group 10 - General Information

List of References
Below is a list of all items within this group.
Trademarks
Sealants and Adhesives Cross-Reference Chart
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Face Seal Fittings Assembly and Installation—All Pressure Applications
Metric Face Seal And O-Ring Stud End Fitting Torque Chart—Standard Pressures
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications
Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications
SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications
SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications
External Hexagon Port Plug Torque Chart
Prevent Hydraulic System Contamination
Check Oil Lines and Fittings
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer
Controlled Systems
Identify Zinc-Flake Coated Fasteners
Use Torque Wrench Adapter
Servicing and Connecting Snap to Connect STC™ Fittings
Glossary of Terms

Trademarks
Trademarks
AccuDepth™ Trademark of Deere and Company
ACS™ Trademark of Deere and Company
ActiveSeat™ Trademark of Deere and Company
AMBLYGON™ Trademark of Kluber Lubrication
AMPSEAL 16™ Trademark of Tyco Electronics
AutoLoad™ Trademark of Deere and Company
AutoPowr™ Trademark of Deere and Company
AutoPowr™/IVT™ Trademark of Deere and Company
AutoQuad™ II Trademark of Deere and Company
AutoQuad™ PLUS Trademark of Deere and Company
AutoTrac™ Trademark of Deere and Company
Avdel™ Trademark of Avdel UK Limited
Bio Hy-Guard™ Trademark of Deere and Company
Break-In™ Trademark of Deere and Company
Break-In PLUS™ Trademark of Deere and Company
CINCH™ Trademark of Cinch Inc.
ClimaTrak™ Trademark of Deere and Company
ComfortCommand™ Trademark of Deere and Company
ComfortGard™ Trademark of Deere and Company
ComfortGard Deluxe™ Trademark of Deere and Company
CommandARM™ Trademark of Deere and Company
CommandCenter™ Trademark of Deere and Company
CommandQuad™ Trademark of Deere and Company
CommandView™ Trademark of Deere and Company
COOL-GUARD™ II Trademark of Deere and Company
CoolScan™ Trademark of Deere and Company
CPC™ Trademark of AMP Incorporated
Deere™ Trademark of Deere and Company
DEUTSCH™ Trademark of Deutsch Company
DURABUILT™ Trademark of Camoplast Inc.
Efficiency Manager™ Trademark of Deere and Company
FieldCruise™ Trademark of Deere and Company
Field Doc™ Trademark of Deere and Company
Field Office™ Trademark of Deere and Company

Trademarks
GreenStar™ Trademark of Deere and Company
HY-GARD™ Trademark of Deere and Company
ILS™ Trademark of Deere and Company
iPhone® Trademark of Apple, Inc.
iPod® Trademark of Apple, Inc.
iPod Touch® Trademark of Apple, Inc.
iTEC™ Trademark of Deere and Company
iTEC™ Pro Trademark of Deere and Company
IVT™ Trademark of Deere and Company
IVT Selector™ Trademark of Deere and Company
JDLink™ Trademark of Deere and Company
JDOffice™ Trademark of Deere and Company
John Deere™ Trademark of Deere and Company
Loctite™ Trademark of Henkel Corporation
MATE-N-LOC™ Trademark of AMP Incorporated
METRIMATE™ Trademark of AMP Incorporated
METRI-PACK™ Trademark of Delphi Packard Electric Systems
NEVER-SEEZ™ Trademark of Bostik-Findley Inc.
Oilscan™ Trademark of Deere and Company
Parallel Tracking™ Trademark of Deere and Company
PLUS-50™ II Trademark of Deere and Company
PowrQuad™ Trademark of Deere and Company
PowrQuad™ PLUS Trademark of Deere and Company
PowerTech™ Trademark of Deere and Company
PowerTech™ Plus Trademark of Deere and Company
Power Zero™ Trademark of Deere and Company
QUICK METAL™ Trademark of Henkel Corporation
QuickTatch™ Trademark of Deere and Company
Row-Trak™ Trademark of Deere and Company
ServiceADVISOR™ Trademark of Deere and Company
SERVICEGARD™ Trademark of Deere and Company
StarFire™ Trademark of Deere and Company
StarFire™ iTC Trademark of Deere and Company
STC™ Trademark of Aeroquip Corporation
StellarSupport™ Trademark of Deere and Company
SUMITOMO™ Trademark of Sumitomo Corporation

Trademarks
TEFLON™ Trademark of DuPont Co.
TIA™ Trademark of Deere and Company
TLS™ Trademark of Deere and Company
TLS™ Plus Trademark of Deere and Company
TouchSet™ Trademark of Deere and Company
Tractor-Implement Automation™ Trademark of Deere and Company
Vari-Cool™ Trademark of Deere and Company
Weather Pack™ Trademark of Packard Electric
YAZAKI™ Trademark of Yazaki Corporation

Sealants and Adhesives Cross-Reference Chart

Canadian Part LOCTITE ™

U.S. Part Number Color Size Description
Number /Permatex Number
Bonding
PM37513 PM38606 BLACK AND WHITE 4 g Epoxy Adhesive 21425
PM37391 PM38615 CLEAR 2g Gel Super Glue 454
PM37532 — BLACK 5 oz Weatherstrip Adhesive 30540
— PM38603 YELLOW 147 ml Weatherstrip Adhesive 30537
Gasketing
PM38655 PM38625 PURPLE 50 ml Flexible Form-in-Place Gasket 515
— PM38600 BROWN 118 ml Liquid Gasket Maker 30524
General Purpose Gasket Dressing (Aviation Gasket

PM37559 PM38600 BROWN 4 oz 30517
Sealant)
PM38657 PM38628 BLUE 50 ml High-Flex Form-in-Place Gasket 17430
PM37463 PM37463 CLEAR 80 g RTV Clear Silicone 59530
PM37521 CLEAR 30 g RTV Clear Silicone 59575
— PM38618 CLEAR 300 g RTV Clear Silicone
PM37465 PM38616 METALLIC BLUE 80 ml Ultra Blue RTV Silicone 58730
PM37553 PM37553 BURGUNDY 16 oz High Tack Gasket Dressing 30525
PM37555 PM38607 BURGUNDY 9 oz aerosol Hi-Tack Gasket Sealant 30524
PM37469 PM38609 RED 80 g Hi-Temp RTV Silicone 59630
PM37529 — RED 7.25 aerosol Hi-Temp RTV Silicone 30541
PM37512 PM37512 — — Flexible Flange Sealant 5900
PM37616 — — 20 g Stick Copper Anti-Seize Stick —
PM37617 — — 20 g Stick Silver-Grade Anti-Seize Stick —
TY24810 TY24810 — 12.5 aerosol NEVER-SEEZ ™ —
TY24811 TY24811 — 8 oz can with brush NEVER-SEEZ ™ —
H154379 — GREEN Sealant —
Priming
PM37509 PM38611 GREEN 4.5 oz Cure Primer 7649
Retaining
PM38651 PM38612 SILVER 50 ml QUICK METAL ™ 660
PM37485 — GREEN 36 ml Maximum Strength 680
— PM38626 GREEN 50 ml Maximum Strength 62083
PM38652 — GREEN 36 ml High-Temperature 620
Thread Locking and Sealing
PM38653 — PURPLE 6 ml Low Strength 222
— PM38645 PURPLE 2g Superglue Instant Adhesive 22200
PM37418 PM38621 BLUE 6 ml Medium Strength 242
PM37477 PM38622 BLUE 36 ml Medium Strength 242
PM37643 — BLUE 9 g Stick Blue Stick Threadlocker (medium-strength) —
PM37614 — BLUE 19 g Stick Blue Stick Threadlocker (medium-strength) —
PM37615 — — 19 g Stick PST Thread Sealant Stick —
271 (usually red in

PM37421 PM38623 RED 6 ml High Strength
color)
PM38654 PM38623 RED 36 ml High Strength 271
— PM38624 RED 50 ml High Strength 27140
PM38656 PM38627 RED 36 ml High Strength 277
PM37700 — RED 19 g Stick Red Stick Threadlocker (High-Strength) —
PM37701 — RED 9 g Stick Red Stick Threadlocker (High-Strength) —
PM37398 PM38613 WHITE 6 ml Pipe Sealant with TEFLON ™ 592
PM37397 PM38613 WHITE 50 ml Pipe Sealant with TEFLON 592

Metric Bolt and Screw Torque Values
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Lubricated Lubricated Lubricated Lubricated

[ “Lubricated” [ “Lubricated” [ “Lubricated” [ “Lubricated”
means coated means coated means coated means coated
Dry Dry Dry Dry
with a with a with a with a
[ “Dry” means [ “Dry” means [ “Dry” means [ “Dry” means
lubricant such lubricant such lubricant such lubricant such
plain or zinc plain or zinc plain or zinc plain or zinc
Bolt as engine oil,
plated without
as engine oil,
plated without
as engine oil,
plated without
as engine oil,
plated without
or fasteners with fasteners with fasteners with fasteners with
any any any any
phosphate phosphate phosphate phosphate
Screw lubrication, or lubrication, or lubrication, or lubrication, or
and oil and oil and oil and oil
Size M6 to M18 M6 to M18 M6 to M18 M6 to M18
coatings, or coatings, or coatings, or coatings, or
fasteners with fasteners with fasteners with fasteners with
M20 and M20 and M20 and M20 and
JDM F13B, JDM F13B, JDM F13B, JDM F13B,
larger larger larger larger
F13E or F13H F13E or F13H F13E or F13H F13E or F13H
fasteners with fasteners with fasteners with fasteners with
zinc flake zinc flake zinc flake zinc flake
JDM F13C, JDM F13C, JDM F13C, JDM F13C,
coating. ] coating. ] coating. ] coating. ]
F13F or F13J F13F or F13J F13F or F13J F13F or F13J
zinc flake zinc flake zinc flake zinc flake
coating. ] coating. ] coating. ] coating. ]
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N˙m lb.-ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the
Shear bolts are designed to fail under predetermined loads. Always
strength of the bolt or screw. DO NOT use these values if a
replace shear bolts with identical property class. Replace fasteners
different torque value or tightening procedure is given for a
with the same or higher property class. If higher property class
specific application. For stainless steel fasteners or for nuts
fasteners are used, tighten these to the strength of the original. Make
on U-bolts, see the tightening instructions for the specific
sure fastener threads are clean and that you properly start thread
application. Tighten plastic insert or crimped steel type lock
engagement. When possible, lubricate plain or zinc plated fasteners
nuts by turning the nut to the dry torque shown in the chart,
other than lock nuts, wheel bolts or wheel nuts, unless different
unless different instructions are given for the specific
instructions are given for the specific application.
application.

Unified Inch Bolt and Screw Torque Values
SAE Grade 2
[ Grade 2 applies for hex cap
screws (not hex bolts) up to 6
in. (152 mm) long. Grade 1
SAE Grade 1 SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
applies for hex cap screws
over 6 in. (152 mm) long, and
for all other types of bolts and
screws of any length. ]
Lubricated Lubricated
[ [
[ “Lubricated” [ “Lubricated”
Bolt “Lubricated” “Lubricated”
means coated means coated
or means coated Dry means coated Dry Dry Dry
with a with a
with a [ “Dry” means with a [ “Dry” means [ “Dry” means [ “Dry” means
Screw lubricant such lubricant such
lubricant such plain or zinc lubricant such plain or zinc plain or zinc plain or zinc
Size as engine oil, as engine oil,
as engine oil, plated without as engine oil, plated without plated without plated without
fasteners with fasteners with
fasteners with any fasteners with any any any
phosphate phosphate
phosphate lubrication, or phosphate lubrication, or lubrication, or lubrication, or
and oil and oil
and oil 1/4 to 3/4 in. and oil 1/4 to 3/4 in. 1/4 to 3/4 in. 1/4 to 3/4 in.
coatings, or coatings, or
coatings, or fasteners with coatings, or fasteners with fasteners with fasteners with
7/8 in. and 7/8 in. and
7/8 in. and JDM F13B, 7/8 in. and JDM F13B, JDM F13B, JDM F13B,
larger larger
larger F13E or F13H larger F13E or F13H F13E or F13H F13E or F13H
fasteners with zinc flake fasteners with zinc flake zinc flake zinc flake
JDM F13C, JDM F13C,
JDM F13C, coating. ] JDM F13C, coating. ] coating. ] coating. ]
F13F or F13J F13F or F13J
zinc flake zinc flake
coating. ] coating. ]
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N˙m lb.-ft. N˙m lb.-ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N˙m lb.-ft. N˙m lb.-ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N˙m lb.-ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

SAE Grade 2
[ Grade 2 applies for hex cap
screws (not hex bolts) up to 6
in. (152 mm) long. Grade 1
SAE Grade 1 SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
applies for hex cap screws
over 6 in. (152 mm) long, and
for all other types of bolts and
screws of any length. ]
[ [
[ “Lubricated” [ “Lubricated”
Bolt “Lubricated” “Lubricated”
means coated means coated
or means coated Dry means coated Dry Dry Dry
with a with a
with a [ “Dry” means with a [ “Dry” means [ “Dry” means [ “Dry” means
Screw lubricant such lubricant such
lubricant such plain or zinc lubricant such plain or zinc plain or zinc plain or zinc
Size as engine oil, as engine oil,
as engine oil, plated without as engine oil, plated without plated without plated without
fasteners with any fasteners with any any any
phosphate phosphate
phosphate lubrication, or phosphate lubrication, or lubrication, or lubrication, or
and oil and oil
and oil 1/4 to 3/4 in. and oil 1/4 to 3/4 in. 1/4 to 3/4 in. 1/4 to 3/4 in.
coatings, or coatings, or
coatings, or fasteners with coatings, or fasteners with fasteners with fasteners with
7/8 in. and 7/8 in. and
7/8 in. and JDM F13B, 7/8 in. and JDM F13B, JDM F13B, JDM F13B,
larger larger
larger F13E or F13H larger F13E or F13H F13E or F13H F13E or F13H
fasteners with zinc flake fasteners with zinc flake zinc flake zinc flake
JDM F13C, JDM F13C,
JDM F13C, coating. ] JDM F13C, coating. ] coating. ] coating. ]
Torque values listed are for general use only, based on the strength Replace fasteners with the same or higher grade. If higher
of the bolt or screw. DO NOT use these values if a different torque grade fasteners are used, tighten these to the strength of the
value or tightening procedure is given for a specific application. For original. Make sure fastener threads are clean and that you
plastic insert or crimped steel type lock nuts, for stainless steel properly start thread engagement. When possible, lubricate
fasteners, or for nuts on U-bolts, see the tightening instructions for plain or zinc plated fasteners other than lock nuts, wheel
the specific application. Shear bolts are designed to fail under bolts or wheel nuts, unless different instructions are given for
predetermined loads. Always replace shear bolts with identical grade. the specific application.

Face Seal Fittings Assembly and Installation—All

Pressure Applications
Face Seal O-Ring to Stud End Installation
[1] - Inspect the fitting surfaces. They must be free of dirt and/or defects.
[2] - Inspect the O-ring. It must be free of damage and/or defects.
[3] - Lubricate O-rings and install into groove using petroleum jelly to hold in place.
[4] - Push O-ring into groove with petroleum jelly so O-ring is not displaced during assembly.
[5] - Index angle fittings and tighten by hand pressing joint together to insure O-ring remains
in place.
[6] - Tighten fitting or nut to torque value shown on the chart per dash size stamped on the
fitting. DO NOT allow hoses to twist when tightening fittings.
Face Seal Adjustable Stud End O-Ring Installation
[1] - Back off lock nut (jam nut) and washer to full exposed turned down section of the
fitting.
[2] - Install a thimble over the fitting threads to protect the O-ring from nicks.
[3] - Slide the O-ring over the thimble into the turned down section of the fitting.
[4] - Remove thimble.
Face Seal Straight Stud End O-Ring Installation
[1] - Install a thimble over the fitting threads to protect the O-ring from nicks.
[2] - Slide the O-ring over the thimble into the turned down section of the fitting.
[3] - Remove thimble.
Fitting Installation
[1] - Install fitting by hand until snug.

[2] - Position adjustable fittings by unscrewing the fitting no more than one turn.
[3] - Apply assembly torque per table.
Assembly Torque
[1] - Use one wrench to hold the connector body and one wrench to tighten nut.
[2] - For a hydraulic hose, it may be necessary to use three wrenches to prevent twist; one
on the connector body, one on the nut, and one on the body of the hose fitting.

Metric Face Seal And O-Ring Stud End Fitting

Torque Chart—Standard Pressures
LEGEND:
A Straight Stud and Tube Nut
B Bulkhead Union and Bulkhead Jam Nut
C 90° Swivel Elbow and Tube Nut
D 90° Adjustable Stud Elbow
E Port Plug
F Stud End
G Tube Nut
H Swivel Nut
I Jam Nut
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressure-Below 27.6 MPA (4,000 PSI)
Nominal Tube OD O-Ring Face Seal/ Bulkhead Jam O-Ring Straight, Adjustable, and External Port
A A
Hose ID Tube Swivel Nut Nut Torque Plug Stud Ends
Adj
Swivel Tube Jam Steel Aluminum
Metric Straight Lock
Thread Nut Nut/Swivel Nut Jam Nut Thread or or
Tube Inch Tube OD Hex Nut
Size Hex Nut Hex Torque Size B Gray Iron Brass
OD Size Hex C
Size Torque Size Torque Torque
Size
Dash
mm in. mm in. mm N˙m lb-ft mm N˙m lb-ft mm mm mm N·m lb-ft N˙m lb-ft
Size
4 -2 0.125 3.18 — — — — — — — M8 X 1 12 12 8 6 5 4
M10 X
5 -3 0.188 4.76 — — — — — — — 14 14 15 11 10 7
1
M12 X
6 -4 0.250 6.35 9/16-18 17 16 12 22 32 24 17 17 25 18 17 12
1.5
M14 X
8 -5 0.312 7.92 — — — — — — — 19 19 40 30 27 20
1.5
M16 X
10 -6 0.375 9.53 11/16-16 22 24 18 27 42 31 22 22 45 33 30 22
1.5
M18 X
12 -8 0.500 12.70 13/16-16 24 50 37 30 93 69 24 24 50 37 33 25
1.5
M22 X
16 -10 0.625 15.88 1-14 30 69 51 36 118 87 27 27 69 51 46 34
1.5
M27 X
20 -12 0.750 19.05 1-3/16-12 36 102 75 41 175 129 32 32 100 74 67 49
2
M30 X
22 -14 0.875 22.23 1-3/16-12 36 102 75 41 175 129 36 36 130 96 87 64
2
M33 X
25 -16 1.000 25.40 1-7/16-12 41 142 105 46 247 182 41 41 160 118 107 79
2
M38 x
28 — — — — — — — — — — 46 46 176 130 117 87
2

M42 X
32 -20 1.250 31.75 1-11/16-12 50 190 140 50 328 242 50 50 210 155 140 103
2
M48 X
38 -24 1.500 38.10 2-12 60 217 160 60 374 276 55 55 260 192 173 128
2
M60 X
50 -32 2.000 50.80 — — — — — — — 65 65 315 232 210 155
2
A
Tolerance is +15%, minus 20% of mean tightening torque unless otherwise specified.
B
The straight hex wrench sizes listed apply to connectors only and may not be the same as the corresponding plug of the same
thread size.
C
These torques were established using steel plated connectors in aluminum and brass.

Metric Face Seal and O-Ring Stud End Fitting

Torque Chart—High Pressure Applications
LEGEND:
A Stud Straight and Tube Nut
B Bulkhead Union and Bulkhead Lock Nut
E Port Plug
F Stud End
G Tube Nut
H Swivel Nut
I Lock Nut
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure-Above 27.6 MPA (4,000 PSI),
Working Pressure-41.3 MPA (6,000 PSI)
Bulkhead Jam
Nominal Tube OD O-Ring Face Seal/ O-Ring Straight, Adjustable, and
Nut
Hose ID Tube Swivel Nut External Port Plug Stud Ends A
Torque A
Adj
Swivel Tube Jam Steel
Thread Nut Nut/Swivel Nut Jam Nut Thread or
Size Hex Nut Hex Torque Size Gray Iron
OD Size B Hex
Size Torque Size Torque
Size
Dash
mm in. mm in. mm N˙m lb-ft mm N˙m lb-ft mm. mm mm N·m lb-ft
Size
4 -2 0.125 3.18 — — — — — — — M8 X 1 12 12 8 6
M10 X
5 -3 0.188 4.76 — — — — — — — 14 14 15 11
1
M12 X
6 -4 0.250 6.35 9/16-18 17 24 18 22 32 24 17 17 35 26
1.5
M14 X
8 -5 0.312 7.92 — — — — — — — 19 19 45 33
1.5
M16 X
10 -6 0.375 9.53 11/16-16 22 37 27 27 42 31 22 22 55 41
1.5
M18 X
12 -8 0.500 12.70 13/16-16 24 63 46 30 93 69 24 24 70 52
1.5
M22 X
16 -10 0.625 15.88 1-14 30 103 76 36 118 87 27 27 100 74
1.5
M27 X
20 -12 0.750 19.05 1-3/16-12 36 152 112 41 175 129 32 32 170 125
2
M30 X
22 -14 0.875 22.23 1-3/16-12 36 152 112 41 175 129 36 36 215 159
2

M33 X
25 -16 1.000 25.40 1-7/16-12 41 214 158 46 247 182 41 41 260 192
2
M38 x
28 — — — — — — — — — — 46 46 320 236
2
M42 X
32 -20 1.250 31.75 1-11/16-12 — 286 211 50 328 242 50 50 360 266
2
M48 X
38 -24 1.500 38.10 2-12 — 326 240 60 374 276 55 55 420 310
2
A
B
The straight hex wrench sizes listed apply to connectors only and may not be the same as the corresponding plug of the
same thread size.

SAE Face Seal and O-Ring Stud End Fitting Torque

Chart—Standard Pressures
LEGEND:
E Port Plug
F Stud End
G Tube Nut
H Swivel Nut
I Lock Nut
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressure-Below 27.6 MPA (4,000 PSI)
Nominal Tube OD O-Ring Face Seal/ Bulkhead Jam Nut O-Ring Straight, Adjustable, and External Port Plug
A A
Hose ID Tube Swivel Nut Torque Stud Ends
Adj
Swivel Jam Steel Aluminum
Metric Tube Nut Straight Lock
Thread Nut Nut Jam Nut Thread or or
Tube Inch Tube OD Swivel Nut Hex Nut
Size Hex Hex Torque Size Gray Iron Brass
OD Torque Size B Hex
Size Size Torque Torque C
Size
Dash
mm in. mm in. in. N˙m lb-ft N˙m lb-ft in. in. in. N·m lb-ft N˙m lb-ft
Size
5 -3 0.188 4.78 — — — — — — — 3/8-24 5/8 9/16 12 9 8 6
6 -4 0.250 6.35 9/16-18 11/16 16 12 13/16 32 24 7/16-20 5/8 5/8 16 12 11 8
8 -5 0.312 7.92 — — — — — — — 1/2-20 3/4 11/16 24 18 16 12
10 -6 0.375 9.53 11/16-16 13/16 24 18 1 42 31 9/16-18 3/4 3/4 37 27 25 18
12 -8 0.500 12.70 13/16-16 15/16 50 37 1-1/8 93 69 3/4-16 7/8 15/16 50 37 33 25
16 -10 0.625 15.88 1-14 1-1/8 69 51 1-5/16 118 87 7/8-14 1-1/16 1-1/16 69 51 46 34
20 -12 0.750 19.05 1-3/16-12 1-3/8 102 75 1-1/2 175 129 1-1/16-12 1-1/4 1-3/8 102 75 68 50
22 -14 0.875 22.23 1-3/16-12 — 102 75 — 175 129 1-3/16-12 1-3/8 1-1/2 122 90 81 60
25 -16 1.000 25.40 1-7/16-12 1-5/8 142 105 1-3/4 247 182 1-5/16-12 1-1/2 1-5/8 142 105 95 70
32 -20 1.25 31.75 1-11/16-12 1-7/8 190 140 2 328 242 1-5/8-12 1-3/4 1-7/8 190 140 127 93
38 -24 1.50 38.10 2-12 2-1/4 217 160 2-3/8 374 276 1-7/8-12 2-1/8 2-1/8 217 160 145 107
50.8 -32 2.000 50.80 — — — — — — — 2-1/2-12 2-3/4 2-3/4 311 229 207 153
A
B
The straight hex wrench sizes listed apply to connectors only and may not be the same as the corresponding plug of the same thread size.
C
These torques were established using steel plated connectors in aluminum and brass.

SAE Face Seal and O-Ring Stud End Fitting Torque

Chart—High Pressure Applications
LEGEND:
E Port Plug
F Stud End
G Tube Nut
H Swivel Nut
I Lock Nut
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure - Above 27.6 MPA (4,000 PSI), Working
Pressure-41.3 MPA (6,000 PSI)
Nominal Tube OD O-Ring Face Seal/ Bulkhead Jam Nut O-Ring Straight, Adjustable, and External
Hose ID Tube Swivel Nut Torque A Port Plug Stud Ends A
Adj
Swivel Tube Jam Steel
Thread Nut Nut/Swivel Nut Jam Nut Thread or
Size Hex Nut Hex Torque Size B Gray Iron
OD Size Hex
Size Torque Size Torque
Size
Dash
mm in. mm in. in. N˙m lb-ft N˙m lb-ft in. in. in. N·m lb-ft
Size
5 -3 0.188 4.78 — — — — — — — 3/8-24 5/8 9/16 18 13
6 -4 0.250 6.35 9/16-18 11/16 24 18 13/16 32 24 7/16-20 5/8 5/8 24 18
8 -5 0.312 7.92 — — — — — — — 1/2-20 3/4 11/16 30 22
10 -6 0.375 9.53 11/16-16 13/16 37 27 1 42 31 9/16-18 3/4 3/4 37 27
12 -8 0.500 12.70 13/16-16 15/16 63 46 1-1/8 93 69 3/4-16 7/8 15/16 75 55
16 -10 0.625 15.88 1-14 1-1/8 103 76 1-5/16 118 87 7/8-14 1-1/16 1-1/16 103 76
20 -12 0.750 19.05 1-3/16-12 1-3/8 152 112 1-1/2 175 129 1-1/16-12 1-1/4 1-3/8 177 131
22 -14 0.875 22.23 1-3/16-12 — 152 112 — 175 129 1-3/16-12 1-3/8 1-1/2 231 170
25 -16 1.000 25.40 1-7/16-12 1-5/8 214 158 1-3/4 247 182 1-5/16-12 1-1/2 1-5/8 270 199
32 -20 1.25 31.75 1-11/16-12 1-7/8 286 211 2 328 242 1-5/8-12 1-3/4 1-7/8 286 211
38 -24 1.50 38.10 2-12 2-1/4 326 240 2-3/8 374 276 1-7/8-12 2-1/8 2-1/8 326 240
A
B
The straight hex wrench sizes listed apply to connectors only and may not be the same as the corresponding plug of the same
thread size.

Four Bolt Flange Fittings Assembly and

Installation—All Pressure Applications
[1] - Inspect the sealing surfaces for nicks or scratches, roughness or out-of-flat condition.
Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If
these defects cannot be polished out, replace the component.
[2] - Install the correct O-ring (and back-up washer if required) into the groove using
petroleum jelly to hold it in place.
[3] - For split flange; loosely assemble split flange halves, being sure that the split is
centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in
place. Do not pinch O-ring.
[4] - For single piece flange; put hydraulic line in the center of the flange and install four cap
screws. With the flange centrally located on the port, hand tighten cap screws to hold it in
place. Do not pinch O-ring.
[5] - For both single piece flange and split flange, be sure the components are properly
positioned and cap screws are hand tight. Tighten one cap screw, then tighten the diagonally
opposite cap screw. Tighten the two remaining cap screws. Tighten all cap screws within the
specified limits shown in the chart.
DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others.
DO NOT overtighten.

SAE Four Bolt Flange Cap Screw Torque

Values—Standard Pressure Applications
SAE Four Bolt Flange Cap Screw Torque Values—27,600 KPA (4,000 PSI) Pressure Applications
Torque
Newton Meters Foot Pounds
Screw Size
Nominal Flange Size [ JDM A17D, SAE Grade 5 or better cap screws with plated hardware. ] Min Max Min Max
[ 1.5.1.2 Lock washers are permissible but not recommended. ]
1/2 5/16-18 UNC 20 31 15 23
3/4 3/8-16 UNC 28 54 21 40
1 3/8-16 UNC 37 54 27 40
1-1/4 7/16-14 UNC 47 85 35 63
1-1/2 1/2-13 UNC 62 131 46 97
2 1/2-13 UNC 73 131 54 97
2-1/2 1/2-13 UNC 107 131 79 97
3 5/8-11 UNC 187 264 138 195
3-1/2 5/8-11 UNC 158 264 117 195
4 5/8-11 UNC 158 264 117 195
5 5/8-11 UNC 158 264 117 195

SAE Four Bolt Flange Cap Screw Torque

Values—High Pressure Applications
SAE Four Bolt Flange Cap Screw Torque Values—41,400 KPA (6,000 PSI) Pressure Applications
Torque
Newton Meters Foot Pounds
Screw Size
Nominal Flange Size [ JDM A17D, SAE Grade 5 or better cap screws with plated hardware. ] Min Max Min Max
[ 1.5.1.2 Lock washers are permissible but not recommended. ]
1/2 5/16-18 UNC 20 31 15 23
3/4 3/8-16 UNC 34 54 25 40
1 7/16-14 UNC 57 85 42 63
1-1/4 1/2-13 UNC 85 131 63 63
1-1/2 5/8-11 UNC 159 264 117 195
2 3/4-10 UNC 271 468 200 345

External Hexagon Port Plug Torque Chart
Port or Stud End Thread Size Torque

[ Port to JDS-G173.1; stud end to JDS-G173.3. ] +15%/-20%
M8 x 1 10 N·m (89 lb-in)
M10 x 1 17 N·m (150 lb-in)
M12 x 1.5 28 N·m (20.6 lb-ft)
M14 x 1.5 39 N·m (28.7 lb-ft)
M16 x 1.5 48 N·m (35.4 lb-ft)
M18 x 1.5 60 N·m (44.2 lb-ft)
M20 x 1.5 60 N·m (44.2 lb-ft)
M22 x 1.5 85 N·m (62.7 lb-ft)
M27 x 2 135 N·m (99.6 lb-ft)
M30 x 2 165 N·m (121.7 lb-ft)
M33 x 2 235 N·m (173.3 lb-ft)
M38 x 2 245 N·m (180.7 lb-ft)
M42 x 2 260 N·m (191.8 lb-ft)
M48 x 2 290 N·m (213.9 lb-ft)
M60 x 2 330 N·m (243.4 lb-ft)
Prevent Hydraulic System Contamination

IMPORTANT:
Cleanliness is very important when working on the hydraulic system.

Prevent contamination by assembling the cylinders, hoses, couplers, and
valves in a clean area of the shop.
Leave protective caps on the fluid openings until ready to make the
connection. When charging the system, use a tractor or other source that
contains clean oil, free of abrasive materials. Keep couplers clean. Abrasive
particles, like sand or metal fragments, can damage seals, barrels and
pistons, causing internal leakage.

Check Oil Lines and Fittings
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious
injury. Avoid the hazard by relieving pressure before disconnecting
hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from
high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the
skin must be surgically removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of injury may call Deere &
Company Medical Department in Moline, Illinois or other knowledgeable
medical source.
Check all oil lines, hoses and fittings regularly for leaks or defects. Make sure all clamps are
in position and tight. Make sure hoses are not twisted or touching machine parts which are
moving. Replace damaged parts.
IMPORTANT:
Tighten fittings as specified in torque chart.

If necessary, use two wrenches to prevent hoses from twisting, bending or breaking tubing
and fittings.

Basic Electrical Component Handling / Precautions

For Vehicles Equipped With Computer Controlled
Systems
Electrical Precautions To Take:
Never disconnect the batteries while the key switch is running. Why: This can cause electrical
voltage spikes that can damage electronic components.
Do not connect jumper cables while the key switch is on. Why: This can cause electrical
voltage spikes that can damage electronic components.
Disconnect batteries prior to recharging (if possible). Why: Electrical loads in the combine can
slow the recharging process. Battery chargers can cause electrical voltage spikes that can
damage electronic components.
Never jump start the machine with a voltage higher than the machine is designed to operate
on. Why: This can damage electronic components.
Do not connect or disconnect electrical connectors while the key switch is on or the combine
is running. Why: This can cause computer system errors from interrupting a computer
program while it is running and electrical voltage spikes that are produced can damage
electronic components.
Do not apply power or ground to any component as a test unless specifically instructed to do
so. Why: Connecting the wrong voltage to the wrong point of an electronic system can cause
electronic component failures.
When welding on the machine, make sure to connect ground lead to the parts being welded.
For maximum protection, disconnect all electronic controller connectors before welding. Why:
High currents associated with welding can damage wiring harnesses that are involved in the
ground path. Welding can also cause electrical voltage spikes that can damage electronic
components.
Identify Zinc-Flake Coated Fasteners

LEGEND:
A Standard Cap Screws
B Zinc-plated Cap Screw
C Zinc-Flake Cap Screw (16 mm and larger)
Standard cap screws (A) are a reflective silver color.
Zinc plated cap screws (B) are a reflective gold color.
Zinc-Flake Coated cap screws (C) are a dull silver color.
→NOTE:
Zinc-Flake Coated fasteners are tightened to lubricated specifications,

unless otherwise noted. (See Torque Value Charts in this group.)

Use Torque Wrench Adapter
Tw = Torque setting on the torque wrench
Ta = Torque actually being applied to the nut or cap screw
L = Length from the point of force (center of the wrench handle) to the center of head of torque wrench
A = Application distance from center of torque wrench head to the center of adapter

Servicing and Connecting Snap to Connect STC™

Fittings
LEGEND:
A JDG1885
B Release Ring
C Retaining Ring
D Backup Ring

E O-ring
CAUTION:
Do NOT disconnect STC™ fitting when under pressure. Failure to relieve

pressure before disconnecting fitting may result in personal injury,
damage to equipment or both.
IMPORTANT:
Do not use tool to pry fitting apart, it is used only as a spacer to move
release ring (B) inward to release retaining ring (C).
→NOTE:
Snap to Connect fittings are used on steel lines, hose connections and
come in various sizes. JDG1885 STC Tools (A) are designed as a spacer to
move release ring (B) inward which releases retaining ring (C). JDG1885
STC™ tools can be purchased through SERVICEGARD.
[1] - For disassembly, perform the following: Insert correct JDG1885 STC™ tool (A)
between releasing ring (B) and fitting.
[2] - Remove hose or line pulling parallel from connector.
→NOTE:
If retaining ring, backup ring (D) or O-ring (E) are damaged, replace all
three parts.
Before connecting Snap to Connect fitting:
[1] - Check mating surfaces for nicks, scratches, or flat spots.

[2] - Check O-ring, backup ring, and retaining ring for wear or damage. Replace as needed.
[3] - Ensure that both female and male ends are clean and free of contaminates.
[4] - Push fitting connections parallel together until a definite snap and solid stop is felt.
[5] - Pull parallel back on hose to ensure that fitting connections are locked together.

Glossary of Terms

ENGINE (g) by Belgreen
ITEM ABBREVIATION DESCRIPTION
Accessory ACC Secondary electrical system
AutoQuad-Plus Transmission AQ+ Abbreviation
Automatic Powershift APS Transmission feature
Active Seat ™ Control Unit ASU Computerized system used to control the ActiveSeat™
Air Conditioning A/C System used conditioning the air in the cab
Air Quality System AQS System used to control conditioned air in the cab
Alternating Current AC Electrical current that reverses its direction at regularly recurring intervals
Armrest Control Unit ACU Armrest control used to control tractor functions
Auto-Temperature Control ATC Automatically controlled air quality system
Battery Bat A device used to furnish electrical current
Brakes BR Abbreviation
Brake Control Unit BRC Computerized system for brake control
Brake Load Sense BRL Reference—Brake load sense
Cab Control Unit CAB Computerized system for controlling cab electronic functions
Controller Area Network CAN A communication system linking on-board electronics
Chassis Control Unit CCU Computerized system for tractor monitoring
Circuit CCT A complete path of an electrical current
Circulation Motor Symbols for circulation motor speeds
O Medium Speed
+ Fastest Speed
Cab Load Center CLC Computerized system for controlling cab electrical functions
Clean Oil Reservoir COR Reservoir used to contain oil for the tractor hydraulic system
ClimaTrak ™ Automatically controlled air quality system
Clockwise CW Direction in which the hands of a clock rotate
Cold Cranking Amperes CCA Refers to a battery′s capability to perform during cold-weather operation
Component Technical Manual CTM Technical manual developed for the servicing of major components
Counterclockwise CCW Direction opposite the rotation of the hands of a clock
Control Flow (Steering Pressure) CF Reference—Steering pressure control flow
Control Flow DR CFD Reference—Control flow diagnostic receptacle
Corner Post Display CPD Display for system control units
Diagnostic Receptacle DR A connection where hydraulic pressure can be measured
Digital Multimeter DMM An electrical multifunctional measuring device
Direct Current DC Electrical current flowing in one direction only
Displacement Control Valve DCV Controls hydraulic pump stroke
Economy Mode ECO Abbreviation
Electronic Displacement Control EDC Senses and communicates to the displacement control valve demand for hydraulic pump stroke
Electrohydraulic EH Refers to a hydraulic valve function that is controlled electrically
Electrohydraulic Depth Control EHDC Abbreviation
Electro-hydraulic Option Control Unit EHO Computerized system used to control the independent link suspension axle
Electrohydraulic Selective Control Valve EH SCV Selective control valve operated with electrical solenoids
Electronic Components Relay ELX Refers to the relay powering most of the electronic components
Engine Control Unit ECU Computerized system used to govern engine speed
Electronically Programmable Read-Only Memory EPROM Abbreviation
Evacuation Diagnostic Receptacle EVAC Diagnostic receptacle port used for pre-lubrication of the pump drive gears
Excess Flow (SCV/Hitch Flow) EF Reference—SCV/Hitch flow
Excess Flow Load Sense (SCV/Hitch Flow) EFL Reference—SCV/Hitch load sense
Forward-Neutral-Reverse FNR Abbreviation
Forward FWD Refers to direction of movement
Gallons Per Minute gpm Amount of fluid over a period of one minute
GreenStar™ System GSS Part of John Deere Precision Farming Systems
Ground-Driven Pump GDP Pump used to operate steering and brakes during emergency conditions
Global Positioning System GPS Abbreviation
Heating-Ventilating and Air Conditioning HVAC Abbreviation
High-Intensity Discharge Light HID Abbreviation
High Pressure - Common Rail HPCR Fuel injected engine that utilizes high pressure fuel injection and a common pressure rail
Hitch Control Unit HCU Computerized system used to control hitch functions
Hitch Slip Command HSC System to compensate for traction changes
Housing Hsg Abbreviation
Ignition IGN Control for starting and stopping the tractor
Implement Management System IMS Control for operating equipment
Independent Link Suspension ILS Front axle with an active suspension system that is electrohydraulic controlled
Inside Diameter ID Abbreviation
Instrument Control Unit ICU Computerized system controlling tractor warning functions
International Standards Organization ISO Standards organization
Infinitely Variable Transmission IVT A hydro-mechanical transmission with infinitely variable speeds
Joint Industry Council Organization JIC Standards organization
Lateral Hitch Position LHP Refers to hitch positioning for a row guidance hitch application
Left-Hand LH or L-H Abbreviation
Liquid Crystal Display LCD A technology used for displaying information
Manifold Air Pressure MAP Abbreviation
Mechanical Front Wheel Drive MFWD A mechanically powered front axle
Negative Neg (—) Refers to a part of an electrical circuit
Number No. Abbreviation
ORFS
O-Ring Face Seal A type of seal used in making hydraulic connections
ORS
Outside Diameter OD Abbreviation
Perf Mon
Performance Monitor Abbreviation
(PrF)
Positive Pos (+) Refers to a part of an electrical circuit
Potentiometer POT A device used to vary electrical voltage
PowerQuad-Plus Transmission PQ+ Abbreviation
Powershift Transmission PST Abbreviation
IVT Transmission Control Unit PTI Computerized system used to control IVT transmission shift functions
Power Take-Off PTO Abbreviation
Powershift Transmission Control Unit PTP Computerized system used to control powershift transmission shift functions
Pressure Control Valve PCV Valve used to control pressure within a system
Pressure Regulating Valve PRV A device used to regulate pressure in a system
Product Identification Number PIN Serial number relating to tractor identification
Pulse-Width-Modulation PWM Method of controlling electrical signals
Pump DR PD Reference—Pump diagnostic receptacle
Pump Load Sense PLD Reference—Pump load sense
Reverse Rev Refers to direction of movement
Revolutions Per Minute rpm Abbreviation
RH or
Right-Hand Abbreviation
R-H
Rockshaft RS Abbreviation
Selective Control Option SCo Control unit for selective control valves 4 and 5
Selective Control Unit SCU Computerized system used to control selective control valve functions for selective control valves 1, 2, and 3
Selective Control Valve SCV Device used to control remote hydraulic functions
Steering Control Unit SSU Computerized system controlling tractor steering
Setup Panel SUP Operator control panel used to set selective control valve function
Slow Moving Vehicle SMV Warning sign on the rear of the tractor
Society of Automotive Engineers SAE Engineering Standards Organization
Specification SPEC Abbreviation
Suspended Front Axle SFA Front axle with an active suspension system that is electronically controlled
Tracks Tractor Steering System Control Unit SST Computerized system controlling tractor steering for tracks tractors
Wheel Tractor Steering System Control Unit SSU Computerized system controlling tractor steering for wheel tractors equipped with AutoTrac™
Steering Load Sense STL Reference—Steering load sense
Switch SW Abbreviation
Tachometer Tach Abbreviation
Terrain Compensation Module TCM Electronic module that corrects for vehicle dynamics such as roll on side-slopes and rough terrain
Tail Light TL Abbreviation
Tractor Control Unit - Vehicle TEC Electronic system for communicating between vehicle and implement
Tractor Control Unit - Implement TEI Electronic system for communicating between implement and vehicle
Temperature Temp Abbreviation
Transmission Trans Abbreviation
TouchSet Depth Control TSDC Abbreviation-Same as EHDC
Transient Voltage Protection TVP An electrical device used to protect a circuit from voltage surge
Voltage (Volts) V Abbreviation
Voltage Detector V Det Abbreviation
Vehicle Load Center VLC Computerized system for controlling vehicle electrical functions
Warning Lamp WL Abbreviation
Without W/O Abbreviation
Wide-Open Throttle WOT Full throttle
Two Wheel Drive 2WD Vehicle where only one pair of wheels is powered

ENGINE (g) by Belgreen

Section 20 - ENGINE
Table of contents
Group 00 - Component Removal and Installation ................................................................ 1
List of References .................................................................................................................. 1
Essential, Recommended, and Fabricated Tools .................................................................... 1
Other Material ........................................................................................................................ 1
Specifications ......................................................................................................................... 2
Remove and Install 6.8L Engine ............................................................................................. 3
Remove and Install 9.0L Engine ........................................................................................... 16
Group 05 - Engine Repair ....................................................................................................... 27
Essential, Recommended, and Fabricated Tools .................................................................. 27
Specifications ....................................................................................................................... 27
Repair Engine—Use CTM ...................................................................................................... 28
Remove and Install 6.8L Engine Rocker Arm Cover ............................................................. 29
Remove and Install 9.0L Engine Rocker Arm Cover ............................................................. 39
Replace Flywheel Dampener ................................................................................................ 47

Section 20 - ENGINE Group 00: Component Removal and Installation

List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Remove and Install 6.8L Engine
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD™

Catalog or from the European Microfiche Tool Catalog (MTC).
Below are tools listed in this group.
JDG19 Lifting Eyes
JDG820 Flywheel Rotation Tool
JDG11252 Front Lifting Bracket
JDG11258 Rear Lifting Bracket
JDG11260 Lifting Bracket
JT07336 Lift Sling
Other Material
Number Name Use
• PM38657 (us)
• TY9484 (canadian) High Flex Form-In-Place Gasket Used to seal surfaces.
• 17430 Loctite ™ (loctite)

Specifications
Item Measurement Specification
Engine Lifting Brackets Cap Screws Torque 170 N·m
(125 lb.-ft.)
6.8L Torque Turn Cap Screws (1—10) Torque Turn 30 N·m + 90° Turn
(265 lb.-in.+ 90° Turn)
(265 lb.-in.+ 90° Turn)
6.8L Torque Turn Cap Screws (25 and 26) Torque Turn 50 N·m + 120° Turn
(37 lb.-ft. + 120° Turn)
6.8L Cap Screws Torque (27—36) Torque 35 N·m
26 lb.-ft.
Drive Shaft Yoke-to-Engine Cap Screws Torque 70 N·m
(52 lb.-ft.)
(103 lb.-ft...+ 90° Turn)
(148 lb.-ft.+ 90° Turn)
9.0L Torque Turn Cap Screws (21 —24) Torque Turn 45 N·m + 120° Turn
(33 lb.-ft. + 120° Turn)


[1] - Remove hood and side shields.
[2] - Disconnect battery ground (—) cable at batteries.
[3] - Discharge air conditioning system. (See Discharge Air Conditioning System in Section 90
Group 10.)
[4] - Drain engine coolant from radiator and engine block.
[5] - Disconnect starter wiring harness.

[6] -
LEGEND:
A Upper Radiator Hose
B Deaeration Tank
C Left-Hand Air-to-Air Cooler Pipe
D Air Cleaner Pipe
E Bracket
F Rear Heat Shield
Disconnect upper radiator hose (A).
[7] - Remove deaeration tank (B).
[8] - Remove clamps and remove left-hand air-to-air cooler pipe (C).
[9] - Disconnect air cleaner pipe (D).
[10] - Remove bracket (E).
[11] - Remove heat shield (F).

[12] -
LEGEND:
A Fuel Cooler Lines
B Lower Radiator Hose
C Right-Hand Air-to-Air Cooler Pipe
D Harness Cover
E Heat Shields
F Bracket
G Exhaust Pipes
H Cap Screw (2 used)
Disconnect fuel cooler lines (A) to line bundle.
[13] - Remove lower radiator hose (B).
[14] - Remove right-hand air-to-air cooler pipe (C).
[15] - Remove harness cover (D).
[16] - Remove heat shield (E).

[17] - Remove bracket (F).

[18] - Remove exhaust pipes (G). (See Service Exhaust System in Section 30, Group 30.)
[19] - Remove cap screws (H) from line bundle support.
[20] -
LEGEND:
A Cap Screw (6 used)
B Auxiliary Drive Shaft
Remove cap screws (A).
[21] - Pry auxiliary drive shaft (A) forward away from engine.

[22] -
LEGEND:
A Line Bundle Mounting Cap Screws (2 used)
B Cap Screws (2 used)
C Cap Screws (4 used)
D Hood Support
Remove line bundle mounting cap screws (A).
[23] - Remove line bundle mounting cap screws (B).
[24] - Remove any line and harness clamps from hood support (D).
[25] - Remove mounting cap screws (C) at frame and remove hood support (D) out left-hand
side.
[26] -


LEGEND:
A Clamps (2 used)
B Receiver Dryer
D Exhaust Filter Sensor Harness Connector
E Line Bundle
F Cap Screws (5 used)
Remove clamps (A).
[27] - Disconnect receiver dryer (B).
[28] - Remove cap screws (C and F).
[29] - Disconnect exhaust filter sensor harness connector (D).
[30] - Remove any line and harness clamps from hood support.
[31] - Tilt line bundle (E) to the right-hand side of tractor.

[32] -
LEGEND:
A Lift Straps (2 used)
B Exhaust Filter and Bracket
Install lift straps (A) as shown around exhaust filter.
[33] - Remove exhaust filter and bracket (B) with hoist.
[34] -
IMPORTANT:
Lift straps must be tightened to prevent damage to injection lines and
other engine components during engine removal.

LEGEND:
A JDG11260 Rear Lift Brackets
B JDG11260 Front Lift Brackets
C JT07336 Lifting Sling
Attach JDG11260 Lifting Bracket (A and B) with cap screws and tighten cap screws to the
following specifications.
Engine Lifting Brackets Cap Screws Torque 170 N·m
(125 lb.-ft.)
[35] - Disconnect drive shaft from engine using JDG820 Flywheel Rotation Tool to rotate
drive shaft for access to cap screws.

[36] -
CAUTION:
The only recommended method for lifting the engine is with JT07336
Engine Lifting Sling and safety approved lifting straps. Use extreme
caution when lifting and NEVER permit any part of the body to be
positioned under an engine being lifted or suspended.
IMPORTANT:
Lift engine with longitudinal loading on lifting sling and lifting brackets
only. Angular loading greatly reduces lifting capacity of sling and brackets.
Lift spacing on sling is adjustable. Position each lifting point so that engine
hangs level when lifted.
Attach the JT07336 Lift Sling (C) to JDG11260 Lift brackets (A and B) and overhead hoist or
floor crane.
[37] - Remove oil pan cap screws.
[38] -
IMPORTANT:
Move the engine control unit with wiring harness toward the engine to
prevent interference during engine removal.
Carefully remove engine, rotating the front end upward and forward as engine is being
removed.
Refer to engine CTM for procedure to install engine in repair stand.

[1] - Install engine noting the following instructions:
LEGEND:
A Sealant
Remove any gasket or oil residue from mating parts.
[2] - Apply sealant (A)
Number Name Use
• PM38657 (us)
at the jointed edges created by the flywheel housing, front plate, and timing gear cover.

[3] -
LEGEND:
A Cap Screws (1—10)
B Cap Screws (11—24)
C Cap Screws (25 and 26)
D Cap Screws (27—36)
IMPORTANT:
Tighten all cap screws using sequence and torque turn strategy.
Tighten cap screws (A) to the following specifications.

(265 lb.-in.+ 90° Turn)
[4] - Tighten cap screws (B) to the following specifications.

(265 lb.-in.+ 90° Turn)
[5] - Tighten cap screws (C) to the following specifications.

6.8L Torque Turn Cap Screws (25 and 26) Torque Turn 50 N·m + 120° Turn
(37 lb.-ft. + 120° Turn)

[6] - Tighten cap screws (D) to the following specifications.

6.8L Cap Screws Torque (27—36) Torque 35 N·m
26 lb.-ft.
[7] - Tighten drive shaft yoke cap screws to specification.

(52 lb.-ft.)


[2] - Discharge air conditioning system. (See Discharge Air Conditioning System in Section 90
Group 10.)
[4] - Drain engine coolant from radiator.
[5] -
LEGEND:
B Left-Hand Air-to -Air Cooler Pipe
C Air Cleaner Pipe
D Starter Wiring
E Exhaust Pipe
F Rear Heat Shields
[6] - Remove clamps and remove left-hand air-to-air cooler pipe (B).
[7] - Disconnect air cleaner pipe (C).
[8] - Disconnect starter wiring harness (D).
[10] - Remove rear heat shields (F).

[11] -
LEGEND:
B Auxiliary Drive Shaft
[12] - Pry auxiliary drive shaft (A) forward away from engine.
[13] -
LEGEND:
A Fuel Cooler Lines
C Harness Cover
D Hood Spreader Bracket
E Exhaust Pipes
F Line Bundle Mounting Cap Screw (2 used)


[15] - Remove harness cover (C).
[18] - Remove cap screws (F) from line bundle support.
[19] -
LEGEND:
A Hoses
B Sensor Connectors
D Deaeration Tank
E Clamps (2 used)
F Charge Air Hose
Disconnect hoses (A).
[20] - Disconnect sensor connectors (B).
[21] - Remove cap screws (C) and deaeration tank (D).

[22] - Remove clamps (E) and charge air hose (F).

[23] -
LEGEND:
A Cap Screws (2 used)
B Heater Hoses (2 used)
C Line Bundle
D Cap Screws (4 used)
E Cap Screws (2 used)
F Hood Support
[24] - Disconnect heater hoses (B).

[25] - Tilt line bundle (C) to right-hand side of tractor.

[27] - Remove cap screws (D) from both sides.
[28] - Remove cap screws (E) and remove hood support (F) out left-hand side.
[29] -
LEGEND:
A Exhaust Filter Sensor Harness Connector
B Receiver Dryer Lines
E Exhaust Filter Support Frame
Disconnect exhaust filter sensor harness connector (A).
[30] - Disconnect receiver dryer lines (B).
[31] - Remove cap screws (C).

[32] - Remove remaining harness and hose clamps from exhaust filter support frame.
[33] - Remove cap screws (D) under exhaust filter support frame (E).
[34] - Disconnect heater return hose from steel line on exhaust filter support frame (E).
[35] -
LEGEND:
A JDG19 Lifting Eye
B Lift Straps (2 used)
C Exhaust Filter and Support Frame
Install JDG19 Lifting Eyes (A) as shown.
[36] - Install lift straps (B) as shown around exhaust filter and lift eye.
[37] - Remove exhaust filter and support frame (C) with hoist.
[38] - Disconnect drive shaft from engine using JDG820 Flywheel Rotation Tool to rotate
drive shaft for access to cap screws.
[39] -
IMPORTANT:
Lift straps must be tightened to prevent damage to injection lines and

LEGEND:
A JDG11252 Front Lift Bracket
B Cap Screw
Attach JDG11252 Front Lifting Bracket (A) with cap screw (B) and tighten.
[40] -
IMPORTANT:
Lift bracket must be tightened to prevent damage to injection lines and
LEGEND:
A Bracket of JDG11258 Rear Lift Bracket
B Cap Screw M20 X 70 mm (2 used)
C Upright Strap of JDG11258 Rear Lift Bracket
D Cap Screw (4 used)
Attach bracket (A) of JDG11258 Rear Lifting Bracket with cap screws (B) to rear of engine
block and tighten.
[41] - Attach upright strap (C) of JDG11258 Rear Lift Strap with special cap screw (D) to
bracket and tighten.
[42] -
CAUTION:
The only recommended method for lifting the engine is with JT07336
Engine Lifting Sling and safety approved lifting straps. Use extreme
caution when lifting and NEVER permit any part of the body to be
positioned under an engine being lifted or suspended.
IMPORTANT:
Lift engine with longitudinal loading on lifting sling and lifting brackets
only. Angular loading greatly reduces lifting capacity of sling and brackets.
Lift spacing on sling is adjustable. Position each lifting point so that engine
hangs level when lifted.
LEGEND:
A JDG11252 Front Lift Bracket
B JDG11258 Rear Lift Bracket
C JT07336 Lifting Sling
Attach JT07336 Lift Sling (C) to overhead hoist or floor crane and JDG11252 front lift bracket
(A) and JDG11258 rear lift bracket (B).
[43] - Remove oil pan cap screws.

[44] -
IMPORTANT:
Move engine control unit with wiring harness toward the engine to prevent
interference during engine removal.
Carefully remove engine, rotating the front end upward and forward as engine is being
removed.
Refer to engine CTM for procedure to install engine in repair stand.

[1] - Install engine noting the following instructions:
LEGEND:
A High Flex Form-In-Place Gasket Location (4 used)
B Front of Pan Gasket
C Rear of Pan Gasket
Remove any gasket or oil residue from mating parts.

[2] -
IMPORTANT:
High Flex Form-In-Place Gasket is used on block side of gasket to seal area
created by the flywheel housing, front plate, and timing gear cover.
Apply
Number Name Use
• PM38657 (us)
high flex form-in-place gasket in location (A) on block side of gasket at front of pan gasket (B)
and rear of pan gasket (C).
[3] -
LEGEND:
A Cap Screws (1—18)
B Cap Screws (19 and 20)
C Cap Screws (21 —24)
IMPORTANT:
Tighten all cap screws using sequence and torque turn strategy.
Tighten cap screws (A) to the following specifications.

(103 lb.-ft...+ 90° Turn)

Section 20 - ENGINE Group 05: Engine Repair
[4] - Tighten cap screws (B) to the following specifications.

(148 lb.-ft.+ 90° Turn)
[5] - Tighten cap screws (C) to the following specifications.

9.0L Torque Turn Cap Screws (21 —24) Torque Turn 45 N·m + 120° Turn
(33 lb.-ft. + 120° Turn)
[6] - Tighten drive shaft yoke cap screws to specification.

(52 lb.-ft.)

Group 05 - Engine Repair

List of References
Specifications
Repair Engine—Use CTM
Remove and Install 6.8L Engine Rocker Arm Cover
Replace Flywheel Dampener
→NOTE:

JDG861 Torque Wrench Adapter
JDG879A Differential and Pinion Lifting Fixture
Specifications
Baffle-to-Rocker Arm Cover Cap Screw Torque 10 N·m
(86 lb.-in.)
Rocker Arm Cover-to-Cylinder Head Cap Screw Torque 35 N·m
(26 lb.-ft.)
OCV Filter Mounting Cap Screws Torque 70 N·m
(52 lb.-ft.)
Inlet Tube Cap Screw Torque 15 N·m

(133 lb.-in.)
Rocker Arm Cover-to-Cylinder Head Cap Screw Torque 35 N˙•m
(26 lb.-ft.)
Inertia Ring/Dampener-to-Flywheel Cap Screws Torque 70 N·m
(52 lb.-ft.)
Transmission Drive Hub-to-Flywheel Dampener Cap Screws Torque 125 N·m
(92 lb.-ft.)
Repair Engine—Use CTM
For complete repair information, component technical manual is also required.
Use the component manual in conjunction with this machine manual.


[3] - Discharge air conditioning system. (See Discharge Air Conditioning System in Section
90—Group 10.)

[6] -
LEGEND:
B Deaeration Tank
D Air Cleaner Pipe
E Bracket
F Rear Heat Shield

[12] -
LEGEND:
A Fuel Cooler Lines
D Harness Cover
E Heat Shields
F Bracket
G Exhaust Pipes


[20] -
LEGEND:
D Hood Support
side.
[24] -


LEGEND:
A Clamps (2 used)
B Receiver Dryer
E Line Bundle
Remove clamps (A).

[30] -
LEGEND:
[32] -
LEGEND:
A Breather Hose
B Cap Screws
C Rocker Arm Cover
Disconnect wiring harness from sensors to allow rocker arm cover removal.
[33] - Remove breather hose (A) and cap screws (B) from rocker arm cover.
[34] - Remove rocker arm cover (C).
[35] - Check valve clearance. (See Check Valve Clearance in CTM.)

[36] -
Install Baffle
LEGEND:
A Cap screw (2)
B Baffle
If removed, assemble baffle (B) to the bottom face of the rocker arm cover. Install cap screws
(A) and tighten to given specifications.
Baffle-to-Rocker Arm Cover Cap Screw Torque 10 N·m
(86 lb.-in.)
[37] -

Install Rocker Arm Cover
Rocker Arm Cap Screws Tightening Sequence

LEGEND:
A Rocker Arm Cover Gasket
B Rocker Arm Cover
C Cap Screw (15)
D Rocker Arm Cover-to-OCV Filter Housing Tube
E OCV Filter Housing
F O-Ring
G Cap Screw
H Oil Fill Cap Seal
I Cap Screw (2)

Check rocker arm cover gasket (A) for its condition. If damaged, install a new gasket.
[38] - Install rocker arm cover (B) and gasket (A). Tighten rocker arm cover cap screws (C) to
specifications, in the sequence as shown.
Rocker Arm Cover-to-Cylinder Head Cap Screw Torque 35 N·m
(26 lb.-ft.)
[39] - Install OCV filter (E) to intake manifold using two cap screws (I). Tighten cap screws to
specifications:
OCV Filter Mounting Cap Screws Torque 70 N·m
(52 lb.-ft.)
[40] - Connect rocker arm cover-to-OCV filter housing tube (D) to rocker arm cover (B) using
a new O-ring (F). Install cap screw (G) and tighten it to specification:
Inlet Tube Cap Screw Torque 15 N·m
(133 lb.-in.)
[41] - If applicable, check for condition of oil fill cap seal (H). Replace if necessary.
[42] - Reinstall clamps holding wiring harness and coolant lines. Reconnect wiring harness.


90, Group 10.)

[6] -
LEGEND:
B Deaeration Tank
D Air Cleaner Pipe
E Bracket
F Rear Heat Shield

[12] -
LEGEND:
A Fuel Cooler Lines
D Harness Cover
E Heat Shields
F Bracket
G Exhaust Pipes


[20] -
LEGEND:
D Hood Support
side.
[24] -


LEGEND:
A Clamps (2 used)
B Receiver Dryer
E Line Bundle
Remove clamps (A).

[30] -
LEGEND:
[32] -
LEGEND:
A Breather Hose
C Rocker Arm Cover
Remove breather hose (A) and cap screws (B) from rocker arm cover.
[33] - Remove rocker arm cover (C).
[34] - Check valve clearance. (See Check Valve Clearance in CTM.)
[35] -
IMPORTANT:
Always use a new rocker arm cover gasket when reinstalling cover.
Rocker Arm Cover
Rocker Arm Cover Torque Sequence

Install rocker arm cover gasket and cover. Tighten rocker arm cover cap screws to
specifications, in sequence as shown.
Rocker Arm Cover-to-Cylinder Head Cap Screw Torque 35 N˙•m
(26 lb.-ft.)
[36] - Install vent hose to elbow on rocker arm cover.

[37] - Install any wiring harness connections removed from sensors.
Replace Flywheel Dampener

[1] - Remove exhaust pipe. (See Service Exhaust System in Section 30, Group 30.)
[2] - Remove intake assembly. (See Remove and Install Intake Housing in Section 30, Group
15.)
[3] - Drain cooling system. (See Draining, Flushing, and Refilling Cooling System in Section
30, Group 25.)
[4] -
LEGEND:
A Clamps (4 used)
C Support
Remove clamps (A), cap screws (B), and support (C).

[5] -
LEGEND:
B Line Bundle
Remove cap screws (A) and move line bundle (B) aside.
[6] -
LEGEND:
B Hood Bracket
C Coolant Lines (2 used)
D Bracket
Remove cap screws (A) and hood bracket (B).
[7] - Disconnect coolant lines (C).
[8] - Remove bracket (D) and overflow tank.

[9] -
LEGEND:
A Battery Cable
B Ground Points (2 used)
C Harness
D Coolant Hose
Remove battery cable (A).
[10] - Disconnect ground points (B).
[11] - Remove harness (C) and coolant hose (D).
[12] -
LEGEND:
A Clamp
B Fuel Line
Remove clamp (A) and fuel line (B).

[13] -
LEGEND:
[14] -
LEGEND:
B Shields (2 used)
Remove cap screws (A) and shields (B).

[15] -
→NOTE:
Hood support needs to be removed from left-hand side of tractor.
LEGEND:
A DPF Support
Support DPF support (A) using a suitable lifting device.
[16] - Remove hood support (B).
[17] -
LEGEND:
Remove cap screws (A) using JDG820 Flywheel Rotation Tool to rotate engine, and slide
transmission coupler rearward.
[18] -
CAUTION:
Damper and inertia ring weigh 38 kg (83 lb.). Use proper lifting equipment
when handling.

LEGEND:
B M12 Cap Screw
C JDG879A Differential and Pinion Lifting Fixture
[19] - Attach handles from JDG879A Differential and Pinion Lifting Fixture (C) to inertia ring
with an M12 cap screw (B).
[20] - Remove dampener with inertia ring.
[21] -
IMPORTANT:
Ensure that dampener is fully seated in inertia ring.
→NOTE:
Two nylon tie bands may be used to hold dampener (A) to inertia ring (B)
during handling.

LEGEND:
A Dampener
B Inertia Ring
Replace dampener (A).
[22] - Inspect parts and replace as necessary. Install in reverse order.
[23] -
Install dampener with inertia ring. Tighten cap screws to specification.

Inertia Ring/Dampener-to-Flywheel Cap Screws Torque 70 N·m
(52 lb.-ft.)

FUEL AND COOLING SYSTEMS (g) by Belgreen
[24] -
→NOTE:
Keep torque wrench straight when used with JDG861 Torque Wrench
Adapter . Calculate proper torque wrench setting if other torque wrench
adapters are used. (See Use Torque Wrench Adapter in Group 10.)
LEGEND:
Install and tighten transmission drive hub-to-flywheel dampener cap screws (A).
Transmission Drive Hub-to-Flywheel Dampener Cap Screws Torque 125 N·m
(92 lb.-ft.)
[25] - Install intake assembly. (See Remove and Install Intake Housing in Section 30, Group
15.)
[26] - Install exhaust. (See Service Exhaust System in Section 30, Group 30.)
[27] - Fill cooling system. (See Draining, Flushing, and Refilling Cooling System in Section 30,
Group 25.)

Section 30 - FUEL AND COOLING SYSTEMS

Table of contents
Group 10 - Diesel Fuel System ................................................................................................ 1
Specifications ......................................................................................................................... 2
Remove and Install Left-Hand Fuel Tank ................................................................................ 3
Remove and Install Right-Hand Fuel Tank ............................................................................. 8
Replace Fuel Filter, Fuel Pump, and Bleed Fuel System ....................................................... 16
Group 15 - Air Intake System ................................................................................................ 18
Specifications ....................................................................................................................... 19
Air Intake Pipe Connections ................................................................................................. 21
Remove and Install Intake Housing ...................................................................................... 26
Remove and Install Aspirator Hose ...................................................................................... 34
Remove and Install Charge Air Cooler Pipes—6.8 L ............................................................. 37
Remove and Install Charge Air Cooler Pipes—9.0 L ............................................................. 39
Group 20 - Auxiliary Drive System ........................................................................................ 41
Specifications ....................................................................................................................... 41
Remove and Install Fan Belt ................................................................................................ 43
Remove and Install Water Pump Drive Belt—6.8L ............................................................... 46
Inspect Belt Tensioner .......................................................................................................... 48
Remove and Install Electronic Fan Drive .............................................................................. 49
Group 25 - Radiator and Coolers ........................................................................................... 53
Other Material ...................................................................................................................... 54
Specifications ....................................................................................................................... 54
Draining, Flushing, and Refilling Cooling System ................................................................. 55
Test Radiator and Deaeration Tank ...................................................................................... 65
Test Radiator Cap ................................................................................................................ 66
Remove and Install Charge Air Cooler .................................................................................. 67
Remove and Install Fan Shroud ........................................................................................... 69
Remove and Install Radiator ................................................................................................ 71
Remove and Install Fuel Coolers .......................................................................................... 77
Remove and Install Air Conditioning Condenser .................................................................. 78
Remove and Install Hydraulic Oil Cooler .............................................................................. 80
Leak Test Hydraulic Oil Cooler ............................................................................................. 80
Group 30 - Exhaust System .................................................................................................... 82
Other Material ...................................................................................................................... 82
Specifications ....................................................................................................................... 83
Service Exhaust System ....................................................................................................... 84

Section 30 - FUEL AND COOLING SYSTEMS Group 10: Diesel Fuel System
Group 10 - Diesel Fuel System

List of References
Specifications
Remove and Install Left-Hand Fuel Tank
Remove and Install Right-Hand Fuel Tank
Replace Fuel Filter, Fuel Pump, and Bleed Fuel System

Specifications
Specificatio
Item Measurement
n
Upper Step Assembly Cap Screws Torque 125 N·m
(92 lb.-ft.)
Lower Step Assembly Cap Screws Torque 70 N·m
(52 lb.-ft.).
Fuel Tank Strap Mounting Cap Screws Torque 73 N·m
(54 lb.-ft).
Rear Fuel Tank Support Mounting Cap Screw Torque 128 N·m
(94 lb.-ft)
Center Section of Fuel Tank to Transmission Cap Screw Torque 73 N·m
(54 lb.-ft.)
(54 lb.-ft.).
Rear Support Mounting Cap Screw Torque 128 N·m
(94 lb.-ft.)
Fuel Tank Centering Cap Screw Torque 73 N·m
(54 lb.-ft.)

Remove and Install Left-Hand Fuel Tank

[1] - Disconnect and remove batteries.
[2] -
LEGEND:
A Drain Valve
Open drain valve (A) and drain fuel tanks into a suitable container.
[3] - Remove air intake and air cleaner housing. (See Remove and Install Intake Housing in
Section 30, Group 15.)
[4] -
LEGEND:
C Debris Shield
Remove cap screws (A—B) and debris shield (C).

[5] -
LEGEND:
A Upper Step Assembly Cap Screws (4 used)
B Lower Step Assembly Cap Screws (2 used)
C Left Hand Step Assembly
E Power Relay Module Cover
Remove cap screws (A—B) and step assembly (C).
[6] - Remove cap screws (D) to remove power relay module cover (E).
[7] - Identify, label, and disconnect wiring harness from junction block and relay.
[8] - Identify, label, and disconnect window washer harnesses and hoses.
[9] - Remove washer reservoir.

[10] -
Upper Crossover Hose
Lower Crossover Hose

LEGEND:
A Hose Clamp (4 Used)
B Crossover Hose (2 used)
Loosen hose clamps (A) and disconnect crossover hoses (B).

[11] -
LEGEND:
B Support Bracket
C Clamp
Remove cap screws (A), cable support bracket (B), and clamp (C) from tank.
[12] -
CAUTION:
Fuel tank weighs approximately 18 kg (40 lb.).
Remove fuel tank.

[13] - Inspect and replace parts as needed.

[14] -
LEGEND:
A Upper Step Assembly Cap Screws (4 used)
B Lower Step Assembly Cap Screws (2 used)
Install in reverse order.
[15] - Tighten step assembly cap screws (A and B) to specification.
Upper Step Assembly Cap Screws Torque 125 N·m
(92 lb.-ft.)
Lower Step Assembly Cap Screws Torque 70 N·m
(52 lb.-ft.).
[16] - Add fuel and bleed fuel system. (See Bleeding Fuel System in Operator′s Manual or
CTM.)
[17] - Check all connections for leaks.

Remove and Install Right-Hand Fuel Tank

[1] -
LEGEND:
A Drain Valve
[2] - Remove rear wheels. (See Remove Rear Wheels in Section 80, Group 20.)
[3] - Remove cab. (See Remove Cab in Section 90, Group 00.)
[4] -
LEGEND:
B Step Cover
Remove cap screws (A) and step cover (B).

[5] -
LEGEND:
B Step Assembly
Remove cap screws (A) and step assembly (B).
[6] -
LEGEND:
B Tool Box Mounting Bracket
D Upper Right-Hand Step
Remove cap screws (A) and tool box mounting bracket (B).
[7] - Remove cap screws (C) and upper right-hand step (D).

[8] -
LEGEND:
A Harness Connector
B Fuel Supply Line
C Fuel Return Line
Identify, label, and disconnect harness connector (A) and fuel lines (B—C) from sending unit;
then plug fuel lines.

[9] -
LEGEND:
A Hose Clamps (4 used)
B Crossover Hoses (2 used)
Loosen hose clamps (A) and remove crossover hoses (B).

[10] -
LEGEND:
A Vent Hose
B Cap Screw (3 used)
C Fuel Tank Centering Cap Screw
D Vehicle Control Unit
Disconnect vent hose (A) from fuel tank.
[11] - Remove cap screws (B).
[12] - Disconnect harness from fuel tank and move vehicle control unit (D) aside.
[13] - Remove cap screw, washer, and spacer (C) from center of fuel tank.
[14] -

LEGEND:
C Strap
Remove cap screws (A—B) and strap (C).
[15] -
LEGEND:
A Cap Screw
B Rear Support Strap
Remove cap screw (A) and rear support strap (B).

[16] -
CAUTION:
Fuel tank weighs approximately 38 kg (84 lb.).
Remove fuel tank.

[17] - Inspect parts and replace as necessary.
[18] -
LEGEND:
C Fuel Tank Strap
Install fuel tank in reverse order.
[19] - Install strap (C) and cap screws (A and B). Tighten to specification.
(54 lb.-ft.).
[20] -
LEGEND:
A Cap Screw
B Rear Support Strap
Install rear support strap (B) and cap screw (A). Tighten to specification.
Rear Support Mounting Cap Screw Torque 128 N·m
(94 lb.-ft.)

[21] -
LEGEND:
A Cap Screw
Install center cap screw (A), washer, and spacer. Tighten to specification.
Fuel Tank Centering Cap Screw Torque 73 N·m
(54 lb.-ft.)
[22] - Install harnesses and control unit to top of fuel tank; then connect fuel lines and vent
hose.
[23] - Install cab. (See Install Cab in Section 90, Group 00.)
[24] - Install rear wheels. (See Install Rear Wheels in Section 80, Group 20.)
[25] - Add fuel and bleed fuel system. (See Bleeding Fuel System in Operator′s Manual or
CTM.)
Replace Fuel Filter, Fuel Pump, and Bleed Fuel

System

Section 30 - FUEL AND COOLING SYSTEMS Group 15: Air Intake System
See Operator′s Manual or CTM for repair.

Group 15 - Air Intake System

List of References
Specifications
Air Intake Pipe Connections
Remove and Install Intake Housing
Remove and Install Aspirator Hose
Remove and Install Charge Air Cooler Pipes—6.8 L

Specifications
Coupling Hose Clamps Torque 10 N·m
(88 lb.-in.)
Flange Clamps Torque 20 N·m
(178 lb.-in.)
Hose Clamp Torque 10 N·m
(89 lb.-in.)
Air Cleaner to Step Cap Screws Torque 25 N·m
(221 lb.-in.)
Air Cleaner bracket to Cab Support Cap Screws Torque 35 N·m
(26 lb.-ft.)
Hose Clamp Torque 10 N·m
(89 lb.-ft.)
Precleaner Mounting Cap Screws Torque 25 N·m
(221 lb.-in.)
Hose Clamp Torque 6.5 N·m
(58 lb.-in.)
Aspirator Hose Clamp Torque 10 N·m
(89 lb.-in.)
Hose Clamps Torque 10 N·m
(88 lb.-in.)
Flange Clamp Torque 10 N·m
(88 lb.-in.)
Air Intake Flange Clamps Torque 20 N·m
(178 lb.-in.)
Intake Tube Hose Clamp Torque 10 N·m
(89 lb.-in.)
Air Cleaner-to-Step Cap Screws Torque 25 N·m
(221 lb.-in.)
Air Cleaner bracket-to-Cab Support Cap Screws Torque 35 N·m
(26 lb.-ft.)
Air Cleaner hose Clamp Torque 10 N·m
(89 lb.-ft.)
Precleaner Hose Clamp Torque 6.5 N·m
(58 lb.-in.)
Aspirator Hose Clamps Torque 10 N·m
(88 lb.-in.)
Charge Air Cooler Hose Clamps-6.8L Torque 10 N·m

(88 lb.-in.)
Charge Air Cooler Flange Clamp-6.8L Torque 10 N·m
(88 lb.-in.)
(88 lb.-in.)
(88 lb.-in.)

Air Intake Pipe Connections
IMPORTANT:
Ensure that coupling hose is fully pushed over pipe ribs and hose clamps
DO NOT sit on ribs.
Ensure at least 2 mm of hose extends past clamps.

[1] -
LEGEND:
A Coupling Hose Clamp
B Single Rib Pipe
C Double Rib Pipe
For single rib pipe: Assemble coupling hose with clamp (A) positioned completely behind
pipe rib (B).
[2] - For double rib pipe: Assemble coupling hose with clamp (A) positioned between pipe
ribs (C).
[3] - Tighten coupling hose clamps to specification.
(88 lb.-in.)

[4] -
IMPORTANT:
Pipe rib (A) MUST NOT be positioned in hose ribs (C).
Ensure that coupling hose is fully pushed over pipe ribs and hose clamps
DO NOT sit on ribs.
Ensure at least 2 mm of hose extends past clamps.
LEGEND:
A Pipe Rib
B Hose Clamp
C Hose Ribs
For flex-coupling hoses: Assemble with pipe rib (A) positioned as shown.
(88 lb.-in.)

[5] -
IMPORTANT:
LEGEND:
A Flange Clamp
B Gasket
C Pipes
Flange pipe coupling MUST have gaskets (B) replaced between pipe
flanges.
For flange clamp coupling perform the following:
a. Connecting pipe must have new gasket (B) positioned over pilot to keep gasket in place
while assembling clamp.
IMPORTANT:
Do not extend clamp over pipes.
Slip the clamp over connecting pipe ensuring the proper orientation.
c. Align pipes (C) with pilot engaged and pipe faces flat to each other.
d. Continue to hold pipes together while sliding the clamp over the flange.
e. Tighten flange clamp (A) enough to hold pipes. Verify proper alignment and tighten to
specification.
Air Intake Flange Clamps Torque 20 N·m
(178 lb.-in.)

Remove and Install Intake Housing

[1] -
LEGEND:
A Battery Compartment Cover
Remove battery compartment cover (A).
[2] - Remove cap screws (B) and shield.
[3] - Disconnect batteries.

[4] -
LEGEND:
A Hose Clamp
B Cap Screw
C Aspirator Hose
D Hose Clamp
F Intake Air Sensor
Loosen aspirator hose clamp (A) and remove cap screw (B).
[5] - Remove aspirator hose (C) from precleaner housing.
[6] - Loosen hose clamp (D).
[7] - Remove cap screws (E) and remove precleaner housing.
[8] - Disconnect harness connector from intake air sensor (F).

[9] -
LEGEND:
A Air Compressor Inlet Hose
For tractors equipped with air trailer brakes: Disconnect hose (A).

[10] -
LEGEND:
C Hose Clamp
Remove cap screws (A and B).
[11] - Loosen hose clamp (C) and remove air filter housing.
[12] -

LEGEND:
B Heat Shield
C Hose Clamp
D Intake Tube
Remove cap screws (A) and heat shield (B).
[13] - Loosen hose clamp (C) and remove intake tube (D).
[15] - Install intake tube and tighten hose clamp (C) to specification.
Intake Tube Hose Clamp Torque 10 N·m
(89 lb.-in.)
[16] - Install heat shield and cap screws (A).

[17] -
LEGEND:
C Hose Clamp
Install air filter housing using cap screws (A and B). Tighten to specification.
Air Cleaner-to-Step Cap Screws Torque 25 N·m
(221 lb.-in.)
Air Cleaner bracket-to-Cab Support Cap Screws Torque 35 N·m
(26 lb.-ft.)
[18] - Tighten hose clamp (C) to specification

Air Cleaner hose Clamp Torque 10 N·m
(89 lb.-in.)

[19] - Install precleaner housing, cap screws (E), and hose clamp (D). Tighten to
specification.
Precleaner Mounting Cap Screws Torque 25 N·m
(221 lb.-in.)
Precleaner Hose Clamp Torque 6.5 N·m
(58 lb.-in.)
LEGEND:
A Hose Clamp
B Cap Screw
C Aspirator Hose
D Hose Clamp
F Intake Air Sensor
[20] - Install aspirator hose (C) and hose clamp (A). Tighten to specification.
Aspirator Hose Clamp Torque 10 N·m
(89 lb.-in.)
[21] - Connect wiring harness to intake air sensor (F).

[22] -
LEGEND:
A Battery Compartment Cover
Install cover and install cap screws (B).
[23] - Connect batteries and install battery compartment cover (A).

Remove and Install Aspirator Hose

[1] -
LEGEND:
A Cover
Remove battery compartment cover (A).
[2] - Remove cap screws (B) and remove shield.

[3] -
LEGEND:
B Aspirator Hose
C Aspirator Check Valve
D Cap Screw
Loosen hose clamps (A).
[4] - Remove aspirator hose (B).
[5] - Remove cap screw (D) and aspirator check valve (C).
[6] - Remove check valve.
[7] -
CAUTION:
LEGEND:
B Step
D Shield
Exhaust pipe may be hot. Let machine cool off before removing hose.

Remove cap screws (A) and step (B).

[8] - Remove cap screws (C) and shield (D).
[9] -
LEGEND:
A Hose Clamp
B Aspirator hose
Loosen hose clamp (A) and remove aspirator hose (B).
[11] - Assemble in reverse order.
[12] - Tighten hose clamps to specification.
Aspirator Hose Clamps Torque 10 N·m
(88 lb.-in.)


[1] -
→NOTE:
Note location and orientation of hose clamps (B) for reassembly.
Position Hood forward. (See Position Hood Forward in Section, 80 Group 05.)
[2] -
LEGEND:
B Coupling Hoses (2 used)
C Right-Hand Charge Air Cooler Pipe
LEGEND:
B Coupling Hose
C Charge Air Cooler Pipe
D Flange Clamp
E Gasket
Remove hose clamps (A) and flange clamp (D).
[3] - Remove coupling hoses (B) and charge air pipes (C).


[5] -
IMPORTANT:
New gasket (E) must be used every time flange pipe coupling is serviced.
Install in reverse order. (See Air Intake Pipe Connections in this group.)
[6] - Tighten clamps to specification.
(88 lb.-in.)
(88 lb.-in.)


[1] -
→NOTE:
Note location and orientation of hose clamps (B) for reassembly.
Position Hood forward. (See Position Hood Forward in Section 80, Group 05.)
[2] -
LEGEND:
B Coupling Hose
C Right Hand Charge Air Cooler Pipe
LEGEND:
B Coupling Hose
C Left-Hand Charge Air Cooler Pipe
D Flange Clamp
E Gasket
Remove hose clamps (A) and flange clamp (D).
[3] - Remove coupling hoses (B) and charge air pipes (C).

Section 30 - FUEL AND COOLING SYSTEMS Group 20: Auxiliary Drive System

[5] -
IMPORTANT:
New gasket (E) must be used every time flange pipe coupling is serviced.
Install in reverse order. (See Air Intake Pipe Connections in this group.)
[6] - Tighten clamps (A and D) to specification.
(88 lb.-in.)
(88 lb.-in.)

Group 20 - Auxiliary Drive System

List of References
Specifications
Remove and Install Fan Belt
Remove and Install Water Pump Drive Belt—6.8L
Inspect Belt Tensioner
Remove and Install Electronic Fan Drive
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™

D01300AA Slide Hammer Puller
Specifications
Input Shaft-to-Engine Cap Screws Torque 70 N·m
(52 lb.-ft.)
Bearing Support Mounting Cap Screws Torque 70N·m
(52 lb.-ft.)
Pulley-to-Input Shaft Cap Screws Torque 35 N·m
(26 lb.-ft.)
Tension Arm Torque 18—23 N·m
(159—204 lb-in.)
Electronic Fan Drive-to-Drive Shaft Torque 100 N·m
(74 lb.-ft.)
Drive Pulley-to-Shaft Cap Screws Torque 35 N·m

(26 lb.-ft.)

Remove and Install Fan Belt

[1] -
→NOTE:
LEGEND:
A Hood Release Loop
B Cap Screws
Fan drive belt is equipped with an automatic tensioner which does not
require adjustment.
Pull hood release loop (A) and raise hood.

[2] - Remove cap screws (B) and belt cover.
[3] -

LEGEND:
A Long-Handle 1/2 in. Drive Tool

B Belt Tensioner
Release tension on belt using long-handle 1/2 in. drive tool (A) on tensioner pulley (B).
[4] - Remove belt.
[6] - Install in reverse order.

Remove and Install Water Pump Drive Belt—6.8L
LEGEND:
B Drive Pulley
[1] - For tractors equipped without FPTO perform the following:
Remove fan belt. (See Remove and Install Fan Belt in this group.)
Remove cap screws (A) and drive pulley (B).
Remove cap screws (C).
[2] - For all tractors perform the following: Remove cap screws (D) and slide input shaft
forward.
[3] - Release tension on belt using long-handle 1/2 in. drive tool on tensioner pulley.
[4] - Remove belt.

[6] - Install in reverse order. Tighten to specification.

Input Shaft-to-Engine Cap Screws Torque 70 N·m
(52 lb.-ft.)
Bearing Support Mounting Cap Screws Torque 70N·m
(52 lb.-ft.)
Pulley-to-Input Shaft Cap Screws Torque 35 N·m
(26 lb.-ft.)

Inspect Belt Tensioner

[1] - Remove fan belt. (See Remove and Install Fan Belt in this group.)
[2] -
LEGEND:
A Scribe Line
B Scribe Line
Measure 21 mm (13/16 in.) from (A) and put a scribe line (B) on mounting bracket.
[3] - Rotate tension arm with torque wrench until marks (A and B) align.
Tension Arm Torque 18—23 N·m
(159—204 lb-in.)
[4] - Replace tensioner if torque wrench measurement is not within specification.

[5] - Install fan belt. (See Remove and Install Fan Belt in this Section.

Remove and Install Electronic Fan Drive

[1] - Remove hood. (See Remove and Install Hood in Section 80, Group 05.)
[2] - Remove lower side panels.
[3] - Remove fan belt. (See Remove and Install Fan Belt in this group.)
[4] -
LEGEND:
C Shield
D Fuel Coolers (2 used)
Remove cap screws (A) and remove shield (C).
[5] - Remove cap screws (B) and lay fuel coolers (D) on right-hand front tire.

[6] -
LEGEND:
B Pulley
Remove cap screws (A) and pulley (B).
[7] -
LEGEND:
A Snap Ring
Remove snap ring (A).

[8] -
LEGEND:
A Cap Screw
B Fan Drive Harness
Remove cap screw (A) and disconnect harness (B).
[9] -
LEGEND:
A Shaft Flats
B Fan Drive
Hold shaft flats (A) with wrench and using another wrench remove fan drive (B).
[10] -
→NOTE:
D01300AA Slide Hammer Puller may be used to aid in shaft and bearing
removal.

Section 30 - FUEL AND COOLING SYSTEMS Group 25: Radiator and Coolers
Remove shaft and bearings from housing.

[11] -
LEGEND:
B Fan and Shroud
[12] - Rotate fan and shroud (B) out to the left-hand side of the tractor.
[15] - Install electronic fan drive to shaft. Tighten to specification.
Electronic Fan Drive-to-Drive Shaft Torque 100 N·m
(74 lb.-ft.)
Drive Pulley-to-Shaft Cap Screws Torque 35 N·m
(26 lb.-ft.)

Group 25 - Radiator and Coolers

List of References
Other Material
Specifications
Draining, Flushing, and Refilling Cooling System
Test Radiator and Deaeration Tank
Test Radiator Cap
Remove and Install Charge Air Cooler
Remove and Install Fan Shroud
Remove and Install Radiator
Remove and Install Fuel Coolers
Remove and Install Air Conditioning Condenser
Remove and Install Hydraulic Oil Cooler
Leak Test Hydraulic Oil Cooler
→NOTE:

D05104ST Radiator Pressure Tester
D05361ST Rubber Stopper and Leak Detector Kit
JDG19 Lifting Eyes

JDG1885 STC Tools
JDG10539 Radiator Pressure Tester Adapter
JT05412 Universal Pressure Test Kit
Other Material
Number Name Use
• PM37463 (us)
• PM37463 (canadian) Clear RTV Silicone Seals contacting surfaces.
• 59530 LOCTITE ™ (loctite)
Specifications
Thermostat Housing Cap Screws Torque 48 N·m
(35 lb.-ft.)
Radiator Pressure Pressure Test 90 kPa (0.9 bar)
(13 psi)
Radiator Cap Pressure Test 103 kPa (1.03 bar)
(15 psi)
Oil Cooler Air Pressure 700—1000 kPa (7—10 bar)
(100—150 psi)

Draining, Flushing, and Refilling Cooling System
Standard HVAC Shown

LEGEND:
A Run Position
B Temperature Knob
C Deaeration Cap
CAUTION:
Explosive release of fluids from pressurized cooling system can cause

serious burns.
Shut off engine. Only remove cap when cool enough to touch with bare
hands. Slowly loosen cap to first stop to relieve pressure before removing
completely.
IMPORTANT:
Thermostat(s) and thermostat gasket must be replaced whenever system is

flushed.

→NOTE:
When service is performed on cooling system, ensure that coolant is

checked daily for the next three days of operation. Check coolant level
when tractor is cool. If coolant is low, fill deaeration tank to mark on tank.
[1] - Park tractor, turn ignition key to off and allow radiator to cool.
[2] - Open hood and remove lower side panels.
[3] - Turn key to RUN position (A), then turn temperature knob (B) to highest setting.
→NOTE:
Throughout the draining, flushing, and filling procedure, turn temperature
knob to highest setting and leave set to the highest setting to ensure that
fluids are drained from heating/air conditioning unit. If either temperature
knob is not set to highest setting or ignition key is not in Run position,
system will not completely drain.
[4] - Remove deaeration tank cap (C).

[5] -

Engine Drain Valve—9.0 L
LEGEND:
A Radiator Drain Valve
B Engine Drain Valve—9.0L

C Engine Drain Plug—6.8L
Open radiator drain valve (A) and drain coolant into suitable container.
[6] - Open engine drain valve (B) or drain plug (C) and drain coolant into suitable container.
[7] -
6.8 L Shown
6.8 L Thermostats
LEGEND:
A Hose Clamp
B Radiator Hose
C Cap Screws
D Support Bracket
E Hose Clamp
F Radiator Hose
G Venturi Line
H Turbo Actuator Line
I Cap Screws
J Support Bracket
K EGR Line
L Cap Screws
M Thermostat Housing
N Thermostats
O Seals
Remove 6.8 L Engine Thermostats:
a. Remove hose clamp (A) and slide radiator hose (B) off thermostat housing (M).
b. Remove cap screws (C) and support bracket (D).
→NOTE:
It may be necessary to remove adapter fitting, located beneath
radiator hose, to allow access to all thermostat housing connections.
Remove hose clamp (E) and radiator hose (F).
d. Remove venturi line (G), turbo actuator line (H), and EGR line (K).
e. Remove cap screws (I) and support bracket (J).
f. Remove cap screws (L) and thermostat housing (M).
g. Remove old thermostats (N), seals (O), and clean sealing area.
→NOTE:
Thermostats are not installed during flushing procedure.
[8] -
9.0 L Shown

9.0 L Thermostat
LEGEND:
A Hose Clamp
B Radiator Hose
C Cap Screws
D Coolant Bypass Tube
E Cap Screws
F Thermostat Housing
G Thermostat
H Seal
I Thermostat Housing
Remove 9.0 L Engine Thermostat:
a. Loosen hose clamp (A) and slide radiator hose (B) off thermostat housing (F).
b. Remove cap screw (C) and coolant bypass tube (D).
c. Remove cap screws (E) and thermostat housing (F).
d. Remove old thermostat (G) and seal (H) from housing (I).
→NOTE:
During flushing, coolant system will not have thermostat installed.
e. Clean sealing area.

[9] - For All Engines: Install new seal (H) and housing (I). Tighten cap screws to
specifications.
(35 lb.-ft.)
[10] - Replace previously removed hoses, brackets, and cap screws.

[11] - Close engine and radiator drain valves.
[12] - Fill coolant system with cleaning solution at deaeration tank.
[13] - Install deaeration cap.
[14] - Start engine and run at a minimum of 1500 rpm for 15 minutes.
[15] - Shut off engine and allow cleaning solution to cool.
[16] - Ensure temperature knob is turned to highest setting, then turn key to RUN position.
[17] - Open radiator drain valve and remove/open engine drain plug/valve. Drain into
suitable container.
CAUTION:
serious burns.
Only remove cap when cool enough to touch with bare hands. Slowly
[18] - Allow cooling system to completely drain.

[19] - Close engine and radiator drain valves.
[20] - Fill coolant system with clean water at deareation tank.
[21] - Install deaeration cap.
[22] - Start engine and run for a minimum of 1500 rpm for 15 minutes.
[23] - Shut off engine and allow clean water to cool.
[24] - Ensure that temperature knob is turned to highest setting, then turn key to RUN
position.
[25] - Remove deaeration cap, then drain radiator and engine block into suitable container.
CAUTION:
serious burns.
Only remove cap when cool enough to touch with bare hands. Slowly
[26] - Allow radiator to drain completely.

[27] - Remove hose clamp, hoses, cap screws, thermostat housing, and seal.
[28] - Inspect sealing area to Ensure it is clean and free of debris.
[29] - Apply light coat of PM37463 Clear RTV Silicone sealant to new seal.
Number Name Use
• PM37463 (us)
• PM37463 (canadian) Clear RTV Silicone Seals contacting surfaces.
[30] - Install new thermostat(s), new seal, and housing.
[31] - Tighten cap screws to specifications.
(35 lb.-ft.)
[32] - Install previously removed hoses, clamps, cap screws, and brackets.
[33] - Close engine and radiator drain valve.
[34] - Fill high-pressure coolant system at deaeration tank with new coolant solution.
IMPORTANT:
Ensure that side panel is installed and hood is closed before starting
engine.
[35] - Ensure that temperature knob is turned to highest setting, then turn key to RUN
position.

[36] - Start engine and run at a minimum of 1500 rpm for 15 minutes.
→NOTE:
Coolant may seep out of the deaeration tank overflow vent as air is purged
from the coolant system.
Level may change when tractor is running or during the next few starts.
[37] - Monitor coolant level, check for leaks, and refill deaeration tank as required.

Test Radiator and Deaeration Tank
LEGEND:
A Hose
B Plug
C JDG10539-1 Tank Adapter
D JDG11244 Adapter
E D05104ST Pressure Tester
[1] - Raise hood.

[2] - Visually check radiator for leaks or damage.
[3] -
→NOTE:
JDG10539-1 tank adapter and Plug (B) are part of JDG10539 Radiator
Pressure Tester Adapter .
Remove hose (A) and install plug (B) on tank.

[4] - Remove pressure cap from deaeration tank and attach JDG10539-1 tank adapter (C) to
filler neck.
[5] - Attach JDG11244 Radiator Pressure Tester Adapter (D) to D05104ST Radiator Pressure
Tester (E).
[6] - Pressurize system.
Radiator Pressure Pressure Test 90 kPa (0.9 bar)
(13 psi)
[7] - Repair system if pressure drops.

Test Radiator Cap
LEGEND:
A Radiator Cap
B JDG10539-2 Threaded Adapter
C JDG11244 Adapter
D D05104ST Pressure Tester
[1] -
→NOTE:
JDG10539-2 treaded adapter is part of JDG10539 Radiator Pressure Tester
Adapter .
Install radiator cap (A) on JDG10539-2 threaded adapter (B).

[2] - Install JDG11244 Radiator Pressure Tester Adapter (C) on JDG10539-2 threaded adapter.
[3] - Install D05104ST Radiator Pressure Tester (D) on JDG11244 Radiator Pressure Tester
Adapter .
[4] -
→NOTE:
Cap should hold pressure within specifications. Relief occurs at the top of
the range.
Pressurize cap.
Radiator Cap Pressure Test 103 kPa (1.03 bar)
(15 psi)
[5] - Replace cap if pressure drops.

Remove and Install Charge Air Cooler

[2] - Remove fan drive. (See Remove and Install Electronic Fan Drive in Section 30, Group
20.)
[3] - Remove fan shroud. (See Remove and Install Fan Shroud in this group.)
[4] - Remove air conditioning condenser. (See Remove and Install Air Conditioning
Condenser in this group.)
[5] - Remove charge air cooler pipes. (See Remove and Install Charge Air Cooler Pipes—6.8 L
or Remove and Install Charge Air Cooler Pipes—9.0 L in Section 30, Group 15.)
[6] -
LEGEND:
B Coolant Tank
D Upper Radiator Support
Remove cap screws (A) and move coolant tank (B) aside.
[7] - Remove cap screws (C) and support (D).

[8] -
LEGEND:
B Charge Air Cooler
Remove cap screws (A) and charge air cooler (B).

Remove and Install Fan Shroud

20.)
[3] -

LEGEND:
B Fan Shroud
Remove cap screws (A) and fan shroud (B).

Remove and Install Radiator
CAUTION:

serious burns.
Shut off engine. Only remove filler cap when cool enough to touch with
bare hands. Slowly loosen cap to first stop to relieve pressure before
removing completely.
[1] - Remove charge air cooler. (See Remove and Install Charge Air Cooler in this group.)
[2] - Remove hydraulic oil cooler. (See Remove and Install Hydraulic Oil Cooler in this group.)
[3] - Drain coolant. (See Draining, Flushing, and Refilling Cooling System in this group.)
[4] -

LEGEND:
A Line Clamps
B Hoses (2 used)
C Deaeration Hose
Disconnect line clamps (A).
[5] - Remove hoses (B) and deaeration hose (C).
[6] -
CAUTION:
Radiator assembly weighs approximately 37 kg (82 lb.).

LEGEND:
A Lifting Eyes (2 used)
Install JDG19 Lifting Eyes (A) to slots on each side of radiator support and attach to an
overhead hoist.
[7] -

LEGEND:
B Cap screws (3 used)
Remove cap screws (A and B), and radiator assembly.
[8] -

LEGEND:
B Clips (2 used)
C Pin (2 used)

D Supports (4 used)
Remove cap screws (A), clips (B), and pins (C).
[9] - Remove supports (D) from radiator.
[11] -
→NOTE:
Use only lubricant such as diluted soap or antifreeze to aid in assembly of
hoses.

[12] - Fill coolant system at deaeration tank.
[13] - Ensure that temperature knob is turned to highest setting and turn key to RUN
position.
[14] - Install deaeration cap and close hood.
[15] - Start engine and run for 15 minutes at a minimum of 1500 rpm.
[16] -
→NOTE:
Coolant may seep out of the deaeration tank overflow vent as air is purged
from the coolant system.
Level may change when tractor is running or during the next few starts.
Monitor coolant level, check for leaks, and refill deaeration tank as required.

Remove and Install Fuel Coolers

[1] -
LEGEND:
A Line Clamps (2 used)
B Hose Clamps (8 used)
C Hoses (4 used)
E Fuel Coolers (2 used)
Remove clamps (A).
[2] - Remove hose clamps (B).
[3] - Disconnect hoses (C).
[4] - Remove cap screws (D) and fuel coolers (E).
[7] - Bleed fuel system. (See Bleeding Fuel System in Operator′s Manual or CTM).

LEGEND:
A Lines (2 used)
B Condenser
D Latches (2 used)

20.)
90, Group 10.)
[4] - Disconnect lines (A) from condenser (B). Cap lines to prevent contamination.
[6] - Release latches (D) to remove condenser.
[8] - Install condenser.
[9] - Inspect O-rings on condenser connectors and replace as necessary.
[10] - Connect air conditioner lines.
[11] - Evacuate air conditioning system. (See Evacuate Air Conditioning System in Section
90, Group 10.)
[12] - Charge air conditioning system. (See Charge Air Conditioning System in Section 90,
group 10.)
[13] - Install fan shroud. (See Remove and Install Fan Shroud in this group.)
[14] - Install fan drive. (See Remove and Install Electronic Fan Drive in Section 30, Group
20.)

Remove and Install Hydraulic Oil Cooler
LEGEND:
A Hydraulic Oil Lines (2 used)
C Mounting Latches (2 used)
20.)
[3] - Use JDG1885 STC Tools to disconnect hydraulic oil cooler lines (A). (See Servicing and
Connecting Snap to Connect STC™ Fittings in Section 10, Group 10.)
[4] - Remove cap screws (B)
[5] - Disconnect latches (C) and remove hydraulic oil cooler.
Leak Test Hydraulic Oil Cooler

[1] - Cap one side of cooler with 62H1032 plug.
[2] - Apply air pressure using 62M1013 adapter and JT05412 Universal Pressure Test Kit .
Oil Cooler Air Pressure 700—1000 kPa (7—10 bar)
(100—150 psi)
[3] - Spray surface using a 50—50 mixture of liquid soap and water to check for leaks.

Section 30 - FUEL AND COOLING SYSTEMS Group 30: Exhaust System
[4] -
→NOTE:
Minor leaks may be repaired, but components should be replaced if there is
a major leak or restriction.
Repair or replace oil cooler as necessary.

Group 30 - Exhaust System

List of References
Other Material
Specifications
Service Exhaust System
Other Material
Number Name Use
• PT569 (us)
NEVER-SEEZ™ Anti-Seize Lubricant Used as a lubricant.
• TY6332 (canadian)

Specifications
Exhaust Pipe-to-Cab Mounting Cap Screws Torque 130 N·m
(96 lb.-ft.)
Clamp-to-Support Cap Screw Torque 37 N·m
(27 lb.-ft.)
Flange Clamp Torque 20 N·m
(177 lb.-in.)
Band Clamp Torque 70 N·m
(52 lb.-ft.)
Band Clamps Torque 17 N·m
(150 lb.-in.)
(150 lb.-in.)
Band Clamps Torque 40 N·m
(30 lb.-ft.)
Front Diesel Exhaust Filter Support Cap Screws—9.0 L Torque 250 N·m
(184 lb.-ft.)
Exhaust Elbow Flange Clamp Torque 20 N·m
(177 lb.-in.)
Exhaust Elbow Band Clamp Torque 70 N·m
(52 lb.-ft.)
DPF Band Clamps Torque 17 N·m
(150 lb.-in.)
DOC Flange Clamps Torque 17 N·m
(150 lb.-in.)
DPF Mounting Band Clamps Torque 40 N·m
(30 lb.-ft.)

Service Exhaust System

[1] -
LEGEND:
B Step
D Shield
Remove and Install Exhaust Pipe:
a. Remove hood. (See Remove and Install Hood in section 80, group 05).
b. Remove cap screws (A) and step (B).
c. Remove cap screws (C) and shield (D).
d.

LEGEND:
B Heat Shield
Remove cap screws (A) and heat shield (B).
e.
LEGEND:
B Bracket
Remove cap screws (A) and bracket (B).
IMPORTANT:
Scribe a line at each exhaust pipe connection flange for proper
alignment during reassembly.
Make a scribe line at each exhaust pipe connection flange.

IMPORTANT:
LEGEND:
A Heat Shield
B Clamp
C Heat Shield
D Flange Clamp
E Exhaust Elbow
Visually check that flanges are aligned and clamp is sitting evenly
around flanges of exhaust pipes.
Remove heat shield (A) and clamp (B).
h. Loosen heat shield (C) and slide up to remove clamp (D).

i. Remove elbow (E).
j.
LEGEND:
A Clamp
C Exhaust Pipe

Remove clamp (A), cap screws (B), and exhaust pipe (C).
k. Assemble in reverse order.
l. Install exhaust pipe, cap screws, and clamp. Tighten to specification.
Exhaust Pipe-to-Cab Mounting Cap Screws Torque 130 N·m
(96 lb.-ft.)
Clamp-to-Support Cap Screw Torque 37 N·m
(27 lb.-ft.)
m.
LEGEND:
A Heat Shield
B Clamp
C Heat Shield
D Flange Clamp
E Exhaust Elbow
Install exhaust elbow (E) and tighten clamps to specification.
Exhaust Elbow Flange Clamp Torque 20 N·m
(177 lb.-in.)
Exhaust Elbow Band Clamp Torque 70 N·m
(52 lb.-ft.)
[2] -

LEGEND:
A Clamps (4 used)
C Support
Remove Diesel Exhaust Filter:
a. Remove clamps (A), cap screws (B), and support (C).
b.
LEGEND:
A Cap Screws
B Line Bundle
Remove cap screws (A) and move line bundle (B) aside.

→NOTE:
9.0 L Sensor Location

LEGEND:
A Lines (2 used)
B Sensors (3 used)
6.8 L lines and sensors are located on opposite side of filter.
Disconnect lines (A).
d. Disconnect sensors (B).

IMPORTANT:
6.8 L Exhaust Elbow
9.0 L Exhaust Elbow

LEGEND:
A Flange Clamps (2 used)
B Gaskets (2 used)
C Exhaust Elbow
Scribe a line at each exhaust pipe connection flange for proper
alignment during reassembly.
Remove flange clamps (A), gaskets (B), and exhaust elbow (C).

IMPORTANT:
Diesel Exhaust Filter weighs approximately 65 kg (143 lb.).
Support diesel exhaust filter with lifting strap and overhead hoist.
g.
9.0 L Mounts

6.8 L Mounts
LEGEND:
A Band Clamps
B Cap Screws—9.0L (3 used)
Remove band clamps (A) and cap screws (B).
h. Remove diesel exhaust filter from engine.
[3] -
LEGEND:
A Scribe Lines
B Scribe Lines
C Flange Clamps
D Outlet Cone
E Gaskets
F Diesel Particulate Filter (DPF)
G Diesel Oxidation Catalyst (DOC)
Remove Diesel Particulate Filter:
IMPORTANT:
Handle the diesel oxidation catalyst (DOC) and diesel particulate filter
(DPF) with care and do not drop.
Mark exhaust filter with scribe lines (A) at each clamped joint for reassembly alignment.
b. Mark scribe line (B) at each clamp connection flange for reassembly alignment.

c. Apply NEVER-SEEZ™ to clamp stud threads.

Number Name Use
⚬ PT569 (us)
⚬ TY6332 (canadian)
d. Remove band clamps (C) and outlet cone (D).

e. Remove diesel particulate filter (DPF) (F) from diesel oxidation catalyst (DOC) (G).
IMPORTANT:
Replace sealing gaskets each time filter is disassembled.
Discard gaskets (E).
IMPORTANT:
Check components for burrs, sharp edges, or contamination. Inspect
clamp for thread damage and replace as needed.
Inspect diesel particulate filter (DPF). (See Engine CTM Group 115)

[4] -
IMPORTANT:
LEGEND:
A Scribe Lines
B Scribe Lines
C Flange Clamps
D Outlet Cone
E Gaskets
F Diesel Particulate Filter (DPF)
G Diesel Oxidation Catalyst (DOC)
Assemble DPF and outlet cone to DOC assembly when the unit is oriented
vertically to verify joint alignment.
Install Diesel Particulate Filter:
a. Installnew gasket (E) into groove in face of DOC assembly (G).

b. Align scribe lines (A and B).
c. Carefully install DPF (F) to DOC assembly.
d. Apply NEVER-SEEZ™ to clamp stud threads.
Number Name Use
⚬ PT569 (us)
NEVER-SEEZ™ ™ Anti-Seize Lubricant Used as a lubricant.
⚬ TY6332 (canadian)

IMPORTANT:
Visually check that flanges are aligned and clamp is sitting evenly
around flanges of exhaust pipes.
Install clamps (C) to joint and tighten to specification.

DPF Band Clamps Torque 17 N·m
(150 lb.-in.)
f. Using a rubber mallet, gently tap both clamps at several points around joint
circumference to ensure that clamp is seated.
g. Tighten clamps to specification.
DOC Flange Clamps Torque 17 N·m
(150 lb.-in.)
[5] -
Install Diesel Exhaust Filter:
a. Use lifting straps and overhead hoist to install DPF on engine.

b.
6.8 L Mounts
9.0 L Mounts
LEGEND:
A Band Clamps
Install cap screws (B) and band clamp (A), but do not tighten.
IMPORTANT:

6.8 L Exhaust Elbow
9.0 L Exhaust Elbow

LEGEND:
A Flange Clamp (2 used)
B Gasket (2 used)
C Exhaust Elbow
Connecting flange MUST have gasket positioned over it to keep gasket
in place while assembling clamp.
Install exhaust elbow (C) usingnew gaskets (B).
IMPORTANT:
Align scribe lines at each exhaust pipe connection flange.
Install flange clamps (A) and tighten to specification.

(150 lb.-in.)
e. Using a rubber mallet, gently tap both clamps at several points around joint
circumference to ensure that clamp is seated, then retighten to specification.
f.
6.8 L Mounts
9.0 L Mounts
LEGEND:
A Band Clamps
Tighten DPF mounting band clamps (A) and cap screws (B) to specification.
DPF Mounting Band Clamps Torque 40 N·m
(30 lb.-ft.)
Front Diesel Exhaust Filter Support Cap Screws—9.0 L Torque 250 N·m
(184 lb.-ft.)

→NOTE:
6.8 L lines and sensors are located on opposite side of filter.
LEGEND:
A Harness
B Inlet Pressure Line
C Outlet Pressure Line
D 12 mm Temperature Sensor
E 14 mm Temperature Sensor
F 16 mm Temperature Sensor
Install temperature sensors (D—F) and orientate as illustrated.
IMPORTANT:
Torque value must be calculated for all torque wrench adapters. (See
Use Torque Wrench Adapter in Section 10, Group 10.)
Tighten temperature sensors to specification using a torque wrench and open ended
adapter.
12 mm Temperature Sensor Torque 35 N·m
(26 lb.-ft.)
14 mm and 16 mm Temperature Sensors Torque 45 N·m
(33 lb.-ft.)
i. Install outlet pressure line (C) and inlet pressure line (B).

IMPORTANT:
Torque value must be calculated for all torque wrench adapters. (See
Use Torque Wrench Adapter in Section 10, Group 10.)
Use backup wrench on fittings when tightening lines.
Tighten lines to specification using a torque wrench and open ended adapter.
Outlet Pressure Line Fittings Torque 49 N·m
(36 lb.-ft.)
Inlet Pressure Line Fittings Torque 24 N·m
(216 lb.-in.)
k.
LEGEND:
A Cap Screws
B Line Bundle
Move line bundle into position and install cap screws (A).

ELECTRICAL (g) by Belgreen
l.
LEGEND:
A Clamps (4 used)
C Support
Install support (C), cap screws (B), and clamps (A).

Section 40 - ELECTRICAL
Table of contents
Group 05 - Connectors .............................................................................................................. 1
Other Material ........................................................................................................................ 4
Use Electrical Insulating Compound ....................................................................................... 4
Using High-Pressure Washers ................................................................................................ 4
Repair AMP Connector ............................................................................................................ 5
Repair AMPSEAL 16™ Connectors .......................................................................................... 8
CAN Controlled SCV Connectors ........................................................................................... 14
Remove Connector Body from Blade Terminals ................................................................... 16
CINCH™ Wedgebox Connectors ........................................................................................... 18
Exploded View—CINCH™ Flexbox Connectors ..................................................................... 26
CINCH™ Flexbox Connectors ............................................................................................... 28
Repair CPC™ Blade Type Connectors ................................................................................... 33
Repair CPC™, Large MATE-N-LOC™, and METRIMATE™ Pin Type Connectors ..................... 35
Repair DEUTSCH™ Connectors ............................................................................................ 37
Repair DEUTSCH™ Implement Connectors .......................................................................... 41
Repair ITT Connector ........................................................................................................... 44
Repair Small MATE-N-LOC™ Socket Connector .................................................................... 48
Repair Small MATE-N-LOC™ Pin Connector .......................................................................... 49
Repair (Pull Type) METRI-PACK™ Connectors ....................................................................... 50
Repair (Push Type) METRI-PACK™ Connectors ..................................................................... 52
Repair Molex™ Control Unit Connectors .............................................................................. 55
Repair Molex Connector ....................................................................................................... 62
Repair SUMITOMO™ Connectors .......................................................................................... 65
Repair Tyco Fuel Injector Connector .................................................................................... 68
Repair Weather Pack™ Connector ....................................................................................... 70
Repair YAZAKI™ Connectors ................................................................................................ 72
Group 10 - Wiring Harness Routings .................................................................................... 75
Wire Number and Color Codes ............................................................................................. 80
Convenience Outlet #2 Harness (Eur Only) ......................................................................... 80
Convenience Outlet #2 Harness (NA Only) .......................................................................... 81
Convenience Outlet #1 Harness (Eur Only) ......................................................................... 82
Convenience Outlet #1 Harness (NA Only) .......................................................................... 83
Roof Control Unit Power Cable ............................................................................................. 84
Cab Control Unit Power Cable .............................................................................................. 85
Alternator Harness ............................................................................................................... 86
Positive Battery Cable .......................................................................................................... 87
Negative Battery Cable ........................................................................................................ 88
Cab and Rear Chassis Control Unit Power Cable .................................................................. 89
Auxiliary Power Strip ............................................................................................................ 89
Power Module Relay Harness ............................................................................................... 90
Hood Light Harness .............................................................................................................. 91
Dual Power Mirror Harness ................................................................................................... 92
Extremity Light Harness (NA Only) ....................................................................................... 93

Front Console Harness (PowrQuad-Plus™/AutoQuad-Plus™) ................................................ 94

Front Console Harness (AutoPowr™/IVT™/CommandQuad™) .............................................. 95
Front Console Harness (ACS™) (AutoPowr™/IVT™/CommandQuad™) ................................. 96
Steering Column Harness ..................................................................................................... 97
ATC Roof Harness ................................................................................................................. 99
Manual HVAC Roof Harness ............................................................................................... 101
Auxiliary Audio Harness ..................................................................................................... 102
Microphone Harness ........................................................................................................... 102
Left Extended Fender Harness ........................................................................................... 103
Right Extended Fender Harness ......................................................................................... 104
Key Switch Control Harness (EUR Only) ............................................................................. 105
Rear Implement Lighting and Accessory Harenss (NA Only) .............................................. 106
Rear Implement Lighting and Accessory Harness (Eur Only) ............................................. 107
Front Implement Lighting and Accessory Harness (NA Only) ............................................. 108
Front Implement Lighting and Accessory Harness (Eur Only) ............................................ 109
Optional Roof Lighting Harness .......................................................................................... 110
Radar Harness .................................................................................................................... 111
2WD Chassis Harness ........................................................................................................ 113
MFWD Chassis Harness ...................................................................................................... 116
MFWD Chassis Harness (Hydraulic Backup Pump) ............................................................. 119
TLS™ Plus Chassis Harness ................................................................................................ 122
TLS™ Plus Chassis Harness (Front Hitch) ........................................................................... 125
TLS™ Plus Chassis Harness (Hydraulic Backup Pump) ....................................................... 129
TLS™ Plus Chassis Harness (Hydraulic Backup Pump, Front Hitch) ................................... 133
ACS™ Chassis Harness ....................................................................................................... 137
ACS™ Chassis Harness (Front Hitch) .................................................................................. 141
Rear Chassis Harness ......................................................................................................... 145
Rear Chassis Harness (Cab Suspension) ............................................................................ 147
PowrQuad-Plus™/AutoQuad-Plus™ Transmission Harness ................................................. 148
CommandQuad™ Transmission Harness ........................................................................... 150
AutoPowr™/IVT™ Transmission Harness ............................................................................ 152
Front Chassis Harness (Mid-Stack SCVs) ............................................................................ 153
Front Chassis Harness (TLS™ Plus) .................................................................................... 153
Front Chassis Harness (TLS™ Plus and Mid-Stack SCVs) .................................................... 154
Front Chassis Harness (TLS™ Plus and Front Hitch) ........................................................... 156
Engine Coolant Sensors Harness ........................................................................................ 156
PowrQuad-Plus™ Cab Harness (NA Only) ........................................................................... 158
AutoQuad-Plus™ Cab Harness (EUR Only) ......................................................................... 160
AutoPowr™/IVT™ and CommandQuad™ Cab Harness (NA Only) ....................................... 162
AutoPowr™/IVT™ and CommandQuad™ Cab Harness (Eur Only) ...................................... 164
SCV Controls Harness (PowrQuad-Plus™/AutoQuad-Plus™) ............................................... 165
Hitch Controls Harness (PowrQuad-Plus™/AutoQuad-Plus™) ............................................. 166
Right Hand Console Harness (PowrQuad-Plus™/AutoQuad-Plus™) .................................... 166
Power Assisted PTO Control Unit Harness .......................................................................... 167
Power Assisted PTO Valve Harness .................................................................................... 168
Rear PTO Shaft Identifier Switch Harness .......................................................................... 169
Rear PTO Shaft Identifier Switch Extension Harness .......................................................... 170
Main Armrest Control Unit Harness .................................................................................... 171
Standard Armrest Control Unit Harness ............................................................................. 173
Armrest Control Unit Harness ............................................................................................ 173

Armrest Control Unit Harness (CommandQuad™) ............................................................. 174

Armrest Control Unit Harness—CommandQuad™ .............................................................. 175
Armrest Control Unit Harness (AutoPowr™/IVT™) .............................................................. 176
Single Lever Control Assembly Harness (AutoPowr™/IVT™) .............................................. 177
Single Single Lever Control Assembly Harness (PowrQuad-Plus™/AutoQuad-Plus™) ......... 177
Mid-Stack SCV Controls Harness ........................................................................................ 178
Mid-Stack SCV Controls Backlighting Extension Harness ................................................... 179
CommandCenter™ Display Programming Harness ............................................................ 179
Mid-Stack SCV Harness ...................................................................................................... 180
Draft Sensor Harness ......................................................................................................... 181
Wheel Angle Sensor Harness (Non ACS™) ......................................................................... 182
Wheel Angle Sensors Harness (ACS™) ............................................................................... 182
Front Brake Valve Harness ................................................................................................. 183
Front PTO Harness ............................................................................................................. 184
Center Hitch Switch Harness .............................................................................................. 185
TLS™ Plus and Mid-Stack SCV Extension Harness .............................................................. 185
TLS™ Plus Harness ............................................................................................................. 186
Backup Hydraulic Pump Harness ....................................................................................... 187
Secondary Brake Valve Harness ........................................................................................ 188
Front ISO Implement Connector Harness ........................................................................... 189
JDLink™ (MTG) Harness ..................................................................................................... 189
JDLink™ (MTG) w/Satellite Harness .................................................................................... 190
Roof Lighting Harness (NA Only) ........................................................................................ 192
Roof Lighting Harness (Eur Only) ....................................................................................... 194
ISO 11786 Cornerpost Harness .......................................................................................... 195
Air Trailer Brake Harness ................................................................................................... 195
ActiveSeat™ Harness ......................................................................................................... 196
Standard Seat Harness ...................................................................................................... 197
Heated Seat Power Harness ............................................................................................... 198
Heated Seat Switch Harness .............................................................................................. 199
Heated Seat Heater Element Harness ................................................................................ 200
Power Standard Mirror Harness .......................................................................................... 201
Power Extend Mirror Harness ............................................................................................. 202
Group 15 - Charging Circuit ................................................................................................. 204
List of References .............................................................................................................. 204
Repair Alternator—Use CTM ............................................................................................... 204
Exploded View—Alternator ................................................................................................. 204
Remove and Install Alternator ............................................................................................ 207
Replace Alternator Master Fuse ......................................................................................... 209
Group 20 - Starting Circuit ................................................................................................... 211
Essential, Recommended, and Fabricated Tools ................................................................ 211
Specifications ..................................................................................................................... 211
Repair Starter—Use CTM .................................................................................................... 211
Remove and Install Starter Motor ...................................................................................... 213
Replace Starter Circuit Relay ............................................................................................. 214
Replace Starter Master Fuse .............................................................................................. 216
Group 25 - Relays, Fuses, Solenoids, and Switches ........................................................ 219
Specifications ..................................................................................................................... 219

General Repair Procedures—Solenoids and Switches ........................................................ 220

Load Center Fuses and Relays ........................................................................................... 221
Remove and Install Backup Pump Master Fuse .................................................................. 226
Remove and Install Backup Pump Relay ............................................................................ 228
Replace Staring Aid Switch ................................................................................................ 229
Replace Ignition Switch ...................................................................................................... 231
Replace Seat Raise/Lower Switch ....................................................................................... 233
Replace Seat Firmness Switch—ActiveSeat™ .................................................................... 235
Replace Heated Seat Switch .............................................................................................. 237
Replace Operator Presence Seat Switch ............................................................................ 239
Replace Differential Lock Switch ........................................................................................ 241
Replace Differential Lock and Rear PTO Solenoids ............................................................. 243
Replace Hitch Position Potentiometer Assembly ................................................................ 244
Replace Clutch Pedal Position Sensor ................................................................................ 245
Remove and Install CommandQuad™, AutoQuad™, and PowrQuad™ Transmission Solenoids
and Switches ............................................................................................................... 247
Remove and Install AutoPowr™ and IVT™ Transmission Solenoids and Switches ............. 247
Replace Transmission Control (AutoPowr™/IVT™) ............................................................. 248
Group 30 - Monitoring System ............................................................................................ 250
Specifications ..................................................................................................................... 252
Essential, Recommended and Fabricated Tools ................................................................. 252
Other Material .................................................................................................................... 252
General Information—Monitoring Systems ......................................................................... 252
Control Units Identification ................................................................................................. 254
Replace Control Units ......................................................................................................... 257
Replace Cab Switch Module (CSM) Control Unit ................................................................. 258
Replace Engine Coolant Temperature Sensor .................................................................... 259
Replace Engine Coolant Level Sensor ................................................................................ 260
Replace Air Filter Restriction Indicator Sensor ................................................................... 260
Replace Fuel Level Sensor ................................................................................................. 262
Replace Foot Throttle Sensor ............................................................................................. 264
Replace Hydraulic Oil Filter Restriction Sensor .................................................................. 264
Remove and Install CommandQuad™, AutoQuad™, and PowrQuad™ Transmission Sensors
..................................................................................................................................... 266
Remove and Install AutoPowr™ and IVT™ Transmission Sensors ...................................... 266
Replace Draft Sensing Sensor ............................................................................................ 267
Adjust Draft Link Sensor ..................................................................................................... 269
Replace Rear PTO Speed Sensor ........................................................................................ 272
Replace Power Assisted PTO Shift Electromagnets ............................................................ 272
Replace Radar Sensor—CommandQuad™, AutoQuad™, and PowrQuad™ Transmissions
..................................................................................................................................... 273
Replace Radar Sensor—IVT™ Transmissions ..................................................................... 278
Remove and Install MFWD Speed Sensor ........................................................................... 283
Replace Wheel Angle Sensor .............................................................................................. 284
Replace Steering Input Device ........................................................................................... 288
Replace Gyroscope Sensor ................................................................................................. 294
Group 35 - Armrest Control .................................................................................................. 296
Specifications ..................................................................................................................... 296

Armrest Test Procedures .................................................................................................... 296

Remove and Install CommandARM™ Assembly ................................................................. 297
Replace Armrest Interface Control Unit (AIC) ..................................................................... 300
Replace Engine Speed Control ........................................................................................... 301
Replace Transmission Control ............................................................................................ 303
Replace SCV Control Lever ................................................................................................. 305
Replace Hitch Control ........................................................................................................ 306
Replace Rear PTO Switch ................................................................................................... 307
Replace Front PTO Switch .................................................................................................. 308
Replace ITEC Sequence Switch .......................................................................................... 309
Replace Resume Switch ..................................................................................................... 310
Disassemble Right-Hand Console ....................................................................................... 312
Assemble Right-Hand Console ........................................................................................... 318
Group 40 - Implement and Accessory Connectors ........................................................... 324
Replace Seven-Terminal Outlet Socket .............................................................................. 325
Replace GreenStar™ Terminal Connector .......................................................................... 326
Replace Auxiliary Power Strip ............................................................................................ 328
Replace Three-Pin Accessory Outlet—Right-Hand Console ................................................ 329
Replace Three-Pin Accessory Outlet—Storage Box ............................................................ 330
Replace and Adjust Field Lights ......................................................................................... 331
Group 45 - Convenience and Accessory Components ...................................................... 332
Replace Wiper Motor .......................................................................................................... 332
Replace Windshield Washer Pumps ................................................................................... 334
Replace Circulation Blower Motor ...................................................................................... 335
Replace Heating, Ventilating, and Air Conditioning (HVAC) Pressurizer Blower Motor ....... 337
Test Ground-Fault Circuit Interrupter ................................................................................. 338
Replace Hydraulic Charge Pump Heater ............................................................................ 339
Remove Radio and Speakers ............................................................................................. 341

Section 40 - ELECTRICAL Group 05: Connectors
Group 05 - Connectors
List of References
Other Material
Use Electrical Insulating Compound
Using High-Pressure Washers
Repair AMP Connector
Repair AMPSEAL 16™ Connectors
CAN Controlled SCV Connectors
Remove Connector Body from Blade Terminals
CINCH™ Wedgebox Connectors
Exploded View—CINCH™ Flexbox Connectors
CINCH™ Flexbox Connectors
Repair CPC™ Blade Type Connectors
Repair CPC™, Large MATE-N-LOC™, and METRIMATE™ Pin Type Connectors
Repair DEUTSCH™ Connectors
Repair DEUTSCH™ Implement Connectors
Repair ITT Connector
Repair Small MATE-N-LOC™ Socket Connector
Repair Small MATE-N-LOC™ Pin Connector
Repair (Pull Type) METRI-PACK™ Connectors
Repair (Push Type) METRI-PACK™ Connectors
Repair Molex™ Control Unit Connectors
Repair Molex Connector

Repair SUMITOMO™ Connectors
Repair Tyco Fuel Injector Connector
Repair Weather Pack™ Connector
Repair YAZAKI™ Connectors

→NOTE:

JDG141 Extraction Tool
JDG155 Electrical Repair Tool Kit
JDG359 DEUTSCH Electrical Repair Tool Kit
JDG707 Crimping Tool
JDG708 AMP Crimping Tool
JDG783 Weather Pack Crimping Tool
JDG948 Terminal Extractor Tool
JDG1727 Terminal Crimping Tool
JDG1744 Master Repair Kit
JDG10353 DEUTSCH Crimp and Extractor Tool Set
JDG10927 Terminal Extraction Tool
JDG11016 Die Assembly
JDG11228 Die Set

JDG11229 Die Set
JDG11230 Die Set
JT07195B Technician’s Electrical Repair Kit
Other Material
Number Name Use
• AT66865 (us) Lubricant Used to insulate electrical connectors.
Use Electrical Insulating Compound

Apply AT66865 Compound directly to the terminals between the wire seal and connector
body. This provides a moisture barrier, especially in wet and humid conditions.
Number Name Use

• AT66865 (us) Lubricant Used to insulate electrical connectors.
Using High-Pressure Washers
IMPORTANT:
Directing pressurized water at electronic/electrical components or

connectors, bearings and hydraulic seals, fuel injection pumps or other
sensitive parts and components may cause product malfunctions. Reduce
pressure, and spray at a 45 to 90 degree angle.

Repair AMP Connector
Using AMP Crimping Tool
LEGEND:
A Locator Assembly
B Locator
C Wire
D Crimping Slot
E Crimping Slot
F Terminal
G Insulation Barrel
H Wire Barrel
[1] - Press JDG948 Terminal Extractor Tool into face of connector and remove wire and
terminal from back of connector.
→NOTE:
Verify wire stripping length and crimp height before using AMP crimping
tool. See instructions provided with tool.
[2] - Strip new wire (C) to length indicated in tool instructions. Do not nick or cut wire
strands.
[3] - Hold JDG708 AMP Crimping Tool so that back (wire side) is facing you. Squeeze tool
handles together and allow them to open fully.
→NOTE:
See instructions provided with tool to determine which crimping slot (D or
E) to use of locator assembly.

[4] - Hold terminal (F) by mating end and insert insulation barrel (G) through front of tool into
appropriate crimp slot (D or E).
IMPORTANT:
Make sure that both sides of the insulation barrel (G) are started evenly
into crimping section. Do NOT attempt to crimp an improperly positioned
contact.
[5] - Position terminal so that open ”U” of wire and insulation barrels (H and G) face top of
tool. Place terminal into nest so that movable locator (B) drops into slot in terminal as shown.
Butt front end of wire barrel (H) against movable locator.
[6] - Hold terminal (F) in position and squeeze tool handles together until ratchet engages
sufficiently to hold terminal in position. DO NOT deform insulation barrel or wire barrel.
[7] - Insert stripped wire into terminal insulation and wire barrels until it is butted against
wire stop.
Crimp Terminal
LEGEND:
A Wire and Terminal

[8] - Hold wire and terminal (A) in place. Squeeze tool handles together until ratchet
releases. Allow tool handles to open and remove crimped terminal.
→NOTE:
The crimped terminal may stick in the crimping area. It can be easily
removed by pushing downward on the top of the locator.
[9] - Install wire in connector.

Repair AMPSEAL 16™ Connectors

[1] -
LEGEND:
A Connector Lock
B Latch
Remove terminal from connector body: Slide connector lock (A) rearward.
[2] - Depress latch (B) and separate connector.

[3] -
LEGEND:
A Extraction Tool
B Terminal Locator
C Cap Assembly
Insert JDG11019 Extraction Tool (A) as shown.
[4] - Remove terminal locator (B) from cap assembly (C).

[5] -
LEGEND:
A Terminal Locator
B Plug Assembly
C Extractor Tool
Pry terminal locator (A) from plug assembly (B) using JDG11019 Extraction Tool (C).

[6] -
Plug Assembly Shown

LEGEND:
A JDG11019 Extraction Tool
B Terminal Retention Finger
C Wire
D Terminal
Insert tip of JDG11019 Extraction Tool (A) into terminal cavity and deflect terminal retention
finger (B).
[7] - Gently pull wire (C) until terminal (D) is free from housing.
[8] -
→NOTE:
Items (A—D) are part of JDG11016 Die Assembly .
→NOTE:
Items (E—K) are part of JDG11017 Crimping Tool .

LEGEND:
A Insulation Anvil Die
B Insulation Crimper Die
C Wire Anvil Die
D Wire Crimper Die
E Nut
F Locator Assembly
G Tool Frame
H Upper Die Retaining Pins
I Long Die Retaining Screw
J Lower Die Retaining Pins
K Short Die Retaining Screw
Assemble Crimper: Install insulation anvil die (A) and wire anvil die (C) into tool frame (G).
[9] - Insert lower die retaining pins (J).
[10] - Install short die retaining screw (K) but do not tighten completely.
[11] - Install insulation crimper die (B) and wire crimper die (D) into tool frame (G).
[12] - Insert upper die retaining pins (H).
[13] - Install long die retaining screw (I) but do not tighten completely.
[14] - Carefully close tool handles making sure anvil and crimper dies align properly.
[15] - Tighten both die retaining screws.
[16] - Place locator assembly (F) over long die retaining screw (I) and against tool frame (G).

[17] -
→NOTE:
Nut (E) should be tight enough to hold locator assembly against tool and
still allow locator to move up and down.
Install and tighten nut (E) onto retaining screw.

[18] -
LEGEND:
A Terminal
B Wire Locator
C Wire Stop Slot
D Wire
Replace terminal: Strip 3.81 mm (.150 in) of insulation from wire.
[19] - Insert terminal (A) into JDG11017 Crimping Tool and lower wire locator (B) into wire
stop slot (C).
[20] - Insert stripped wire (D) into terminal until it is against wire locator (B).
[21] - Holding wire in place squeeze crimper tool handles together until ratchet releases.
[22] -
→NOTE:
Crimped terminal may stick in crimping area of tool but can be removed by
pushing downward on wire locator.
Allow handles to open and remove crimped terminal from tool.

CAN Controlled SCV Connectors

[1] -
LEGEND:
A Connector Boot
B Wire Guide
Remove terminal from connector body: Remove connector boot (A) from connector.
[2] - Remove wire guide (B) from connector.
[3] -
→NOTE:
JDG10927 Terminal Extraction Tool is part of JDG10663 CAN Controlled SCV
Essential Tool Kit.

LEGEND:
B Wire
Insert JDG10927 Terminal Extraction Tool (A) into connector body and then pull wire (B) from
back of connector.
[4] - Replace terminal:

LEGEND:
A Seal
B JDG10519 Terminal Crimping Tool
C Terminal
D Wire
Remove old terminal.
[5] - Install seal (A) onto wire.
[6] - Strip 6 mm (0.250 in.) of insulation from wire then slide seal to edge of insulation.
[7] - Grip JDG10519 Terminal Crimping Tool (B) securely and squeeze ratcheting mechanism
completely. Then allow it to open.
[8] - Insert terminal (C) into 16-14 slot of crimper with crimp wings facing down.
[9] - Squeeze handles enough to retain terminal.
[10] - Insert stripped wire (D) into terminal until seal contacts terminal.
[11] - Hold wire stationary and squeeze tool together until ratchet releases.
[12] - Remove wire from tool.
[13] - Push terminal into connector body until fully seated (an audible click should be heard).
[14] - Pull on wire slightly to ensure that terminal is locked in position.
[15] - Reinstall wire guide and boot onto connector.
Remove Connector Body from Blade Terminals

[1] -
LEGEND:
A Locking Tang
B Locking Tang Original Position
Depress locking tang (A) on terminal using small screwdriver. Remove connector body.
[2] - Bend locking tang back to original position (B) before installing connector body.

CINCH™ Wedgebox Connectors

[1] - Remove terminal from connector body:
LEGEND:
A Latches
B Secondary Lock
Locate latches (A) locking secondary lock (B) into connector.
[2] -
→NOTE:
JDG1869 Secondary Lock Extraction Tool is part of JDG1744 Master Repair
Kit .
LEGEND:
A JDG1869 Secondary Lock Extraction Tool
B Latches
C Connector Wall
Insert JDG1869 Secondary Lock Extraction Tool (A) between latches (B) and outside
connector wall (C) as shown.

[3] -
LEGEND:
A JDG1869 Secondary Lock Extraction Tool
B Secondary Lock
C Latches
Lightly squeeze and rotate JDG1869 Secondary Lock Extraction Tool (A) to place secondary
lock (B) into pre-staged position.
[4] - Manually press latches (C) and remove secondary lock (B) from connector.

[5] -
→NOTE:
JDG1868 Terminal Extraction Tool (A) is designed so longer spring loaded
finger (B) lifts latch out of terminal locking window and shorter stationary
finger (C) pushes terminal out of connector body.
JDG1868 Terminal Extraction Tool is part of JDG1744 Master Repair Kit
LEGEND:
A JDG1868 Terminal Extraction Tool
B Spring Loaded Finger
C Stationary Finger
D Ceiling
Insert JDG1868 Terminal Extraction Tool (A) into connector body window so that longer spring
loaded finger (B) slides on ceiling (D) of window.
[6] -
→NOTE:
JDG1868 Terminal Extraction Tool (A) should be flush with face of connector
body when fully inserted and terminal should be unlatched.

LEGEND:
B Wire
Push JDG1868 Terminal Extraction Tool (A) into connector body until it stops.
[7] - Remove JDG1868 Terminal Extraction Tool and pull wire (B) from back of connector.

[8] -
→NOTE:
LEGEND:
A Terminal Receptacle
B JDG1866 Terminal Receptacle
C JDG1727 Terminal Crimping Tool
16, 18, 20 gauge terminal receptacle has three terminal windows and
JDG1866, 16, 18 gauge terminal receptacle has two terminal windows.
JDG1866 Terminal Receptacle and JDG1727 are part of JDG1744 Master
Repair Kit .
Install Crimper Jaw Set: Remove 16, 18, 20 gauge terminal receptacle (A) and install
JDG1866 Terminal Receptacle (B) on JDG1727 Terminal Crimping Tool (C).
[9] -

LEGEND:
A Socket-head Screws
B Three Terminal Jaw Set
C JDG1866 Two Terminal Jaw Set
D Mechanism Release Screw
Squeeze handle on JDG1727 Terminal Crimping Tool to expose socket-head screws (A).
[10] - Remove socket-head screws (A).

[11] -
→NOTE:
If ratcheting mechanism does not release when handle is completely
squeezed, rotate mechanism release screw (D) to release.
Squeeze handle on JDG1727 Terminal Crimping Tool completely and release to allow tool to
open wide.
[12] - Remove three terminal jaw set (B) from crimping tool.
[13] - Install JDG1866 two terminal jaw set (C) into crimping tool.
[14] - Install socket-head screws (A).
[15] - Replace terminal:

LEGEND:
A CINCH Terminal Crimping Tool
B Terminal Receptacle
C Terminal
D Wire
Remove old terminal and strip 4.85 mm (0.191 in.) of insulation from wire.
[16] - Grip JDG1727 Terminal Crimping Tool (A) securely, and squeeze ratcheting mechanism
completely. Then allow it to open completely.
[17] - With tool in ready position (open handle), open terminal receptacle (B).
[18] - Insert terminal (C) into proper wire gauge window, crimp wings facing up.
[19] - Close terminal receptacle (B).
[20] - Squeeze handle until two clicks are heard.
[21] - Insert stripped wire (D) into terminal.
[23] - Remove terminated wire from tool.
[24] -
→NOTE:
Make sure cavity identification letters (A) on back of connector and
terminal wings (B) are facing up.

LEGEND:
A Cavity Identification Letters
B Terminal Wings
C Secondary Lock
Install terminal into connector body: Grasp terminated wire closely behind crimped
terminal making sure terminal wings (B) are facing up.
[25] - Push terminal into connector body until fully seated (an audible click should be heard).
[26] - Pull on wire slightly to ensure that terminal is locked in position.
[27] - Install and push secondary lock (C) closed.
Exploded View—CINCH™ Flexbox Connectors

LEGEND:
A Connnector Locking Cam
B Cover
C Cover Locks
D Connector Body
E Terminal Lock
F Cavity Seal Plug
G Terminal Removal Tool Opening
H Terminal Opening
I 0.6 mm (0.02 in.) Terminal
J 1.5 mm (0.06 in.) Terminal
K Seal

CINCH™ Flexbox Connectors

[1] -
LEGEND:
A Tab
B Locking Cam
C Cover Locks
D Cover
Press tab (A) and rotate locking cam (B) 90° to disconnect connector from flexbox.
[2] - Move cover locks (C) slightly outward with a small screwdriver.

[3] - Remove cover (D) away from wires.

[4] -
LEGEND:
A Terminal Lock
Pull terminal lock (A) out as far as it will go, but do not force its removal.
[5] -
→NOTE:
JDG1725 Terminal Extractor Tool has two different sizes of pins, 0.6 for
smaller 20 gauge holes (A), and 1.5 for larger 16 and 18 gauge holes (B).
JDG1725 Terminal Extractor Tool and JDG1727 Terminal Crimping Tool are
part of JDG1744 Master Repair Kit .

LEGEND:
A 20 Gauge Holes
B 16 & 18 Gauge Holes
C Holes
D Terminal Opening
E JDG1725 Terminal Extractor Tool
[ Included in JDG1744 Master Kit ]
F Terminal
Insert JDG1725 Terminal Extractor Tool (E) into holes (C) next to terminal opening (D) to
unlock terminal.
[6] - Pull wire and terminal (F) from connector body.
[7] -

LEGEND:
A JDG1727 Terminal Crimping Tool
[ Included in JDG1744 Master Kit ]
B Terminal Receptacle
C Terminal
D Wire
Remove old terminal and strip 4.85 mm (0.191 in.) of insulation from wire.
[8] - Grip JDG1727 Terminal Crimping Tool (A) securely, and squeeze ratcheting mechanism
[9] - With tool in ready position (open handle), open terminal receptacle (B).

[10] - Insert terminal (C) into proper wire gauge window, crimp wings facing up.
[11] - Close terminal receptacle (B).
[13] - Insert stripped wire (D) into terminal.
[16] - Push terminal into connector body until fully seated. Pull on wire slightly to ensure that
terminal is locked in position.
[17] - Push terminal lock closed.
[18] - Install cover.
[19] - Install connector to control unit and close connector body locking cam.

Repair CPC™ Blade Type Connectors
IMPORTANT:
Move extraction tool back and forth ONLY in direction illustrated to fully
seat tool in connector.
[1] -
→NOTE:
JDG141 Extraction Tool is included in JDG155 Electrical Repair Tool Kit and
JT07195B Technician’s Electrical Repair Kit .
→NOTE:
JDG145 Universal Electrical Pliers and JDG144 Crimping Pliers are included
in JDG155 Electrical Repair Tool Kit .
LEGEND:
A Tip
Push tip (A) of JDG141 Extraction Tool
[ Included in JDG155 Electrical Repair Tool Kit and JT07195B Technician′s Electrical Repair Kit ]
into terminal offsets until tips bottom in connector.
[2] - Pull wire to remove contact from connector.
[3] - Remove old contact and strip 6 mm (1/4 in.) of insulation from wire using JDG145
Universal Electrical Pliers
[ Included in JDG155 Electrical Repair Tool Kit ]
.
[4] - Crimp new contact on wire using JDG144 Crimping Pliers
[ Included in JDG155 Electrical Repair Tool Kit ]
.
[5] - Insert wire in correct terminal of new connector.

[6] - Transfer remaining wires to correct terminal on new connector.

Repair CPC™, Large MATE-N-LOC™, and

METRIMATE™ Pin Type Connectors
LEGEND:
A Tool Sleeve
B Tool Handle
C Tool Push Rod
D Push Rod Button
[1] -
→NOTE:
JDG140 Extraction Tool is included in JDG155 Electrical Repair Tool Kit and
JT07195B Technician’s Electrical Repair Kit .
→NOTE:
JDG143 Extraction Tool and JDG144 Crimping Pliers are included in JDG155
Electrical Repair Tool Kit .
Select correct size JDG140 Extraction Tool or JDG143 Extraction Tool to remove contact.
→NOTE:
Allow tool push rod (C) to back out during insertion.
[2] - Insert tool sleeve (A) over contact until tool bottoms.
[3] - Rotate tool handle (B) to ensure release of contact locking lances.
[4] - Hold tool sleeve firmly seated in connector and press push rod button (D). Remove
contact from connector.

Universal Electrical Pliers.
[6] - Crimp new contact on wire using JDG144 Crimping Pliers.
[7] - Spread contact locking lances and insert wire in correct terminal of new connector.
[8] - Transfer remaining wires to correct terminal of new connector.

Repair DEUTSCH™ Connectors
LEGEND:
A Handle
[1] - Select correct size extractor tool for size of wire to be removed:
→NOTE:
JDG361, JDG362, and JDG363 are part of JDG359 DEUTSCH Electrical Repair
Tool Kit .
JDG361 Extractor Tool - 12—14 Gauge Wire

JDG362 Extractor Tool - 16—18 Gauge Wire
JDG363 Extractor Tool - 20 Gauge Wire
[2] - Start correct size extractor tool over wire at handle (A).
[3] - Slide extractor tool rearward along wire until tool tip snaps onto wire.
IMPORTANT:
DO NOT twist tool when inserting in connector.
[4] - Slide extractor tool along wire into connector body until tool is positioned over terminal
contact.

[5] - Pull wire from connector body using extractor tool.
LEGEND:
A Selector
B Lock Nut
C Adjusting Screw
[6] - Strip 6 mm (1/4 in.) insulation from wire.

[7] -
→NOTE:
JDG360 Crimping Tool is part of JDG359 DEUTSCH Electrical Repair Tool Kit .
Adjust selector (A) on JDG360 Crimping Tool for correct wire size.
[8] - Loosen lock nut (B) and turn adjusting screw (C) in until screw stops.
[9] -
IMPORTANT:
Select correct size contact sleeve or pin to fit connector body.
LEGEND:
A Contact
B Cover
C Lock Nut
D Adjusting Screw
Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B).
[10] - Tighten lock nut (C).

[11] -
IMPORTANT:
Contact must remain centered between indenters while crimping.
Insert wire in contact and crimp until handle contacts stop.

[12] - Release handle and remove contact.
IMPORTANT:
If all wire strands are not crimped into contact, cut off wire at contact and
repeat contact installation procedures.
→NOTE:
Readjust crimping tool for each crimping procedure.

[13] - Inspect contact to ensure that all wires are in crimped barrel.
IMPORTANT:
Install contact in correct location using correct size grommet.
[14] - Push contact straight into connector body until positive stop is felt.
[15] - Pull on wire slightly to ensure that contact is locked in position.
[16] - Transfer remaining wires to correct terminal in new connector.

Repair DEUTSCH™ Implement Connectors

[1] -
LEGEND:
A Connector
B Seal
Disconnect connector (A).
[2] - Remove seal (B).

[3] -
LEGEND:
A Tabs
B Terminal Retainer
C Terminal
D Connector Body
Lift tabs (A) and remove terminal retainer (B).
[4] - Push Terminal (C) from connector body (D).
[5] -
→NOTE:
JDG145 Electrician′s Pliers are included in JDG155 Electrical Repair Tool Kit .
Remove terminal and strip wire using JDG145 Electricians Pliers.

[6] -
→NOTE:
JDG10353P1 Crimper Tool is part of JDG10353 DEUTSCH Crimp and
Extractor Tool Set .

LEGEND:
A Terminal
B Crimper Tool
C Hole
D Wire
Insert new terminal (A) into JDG10353P1 Crimper Tool (B) with hole (C) in terminal facing up.
[7] - Insert wire (D) into terminal and crimp.
[8] - Open crimp tool.
[9] - Rotate terminal and wire 90°.
[10] - Close tool and crimp.
[11] - Remove terminal from crimp tool.
[12] - Assemble connector in reverse order.

Repair ITT Connector

[1] -
LEGEND:
A Seal Retainer
B Seal
Remove terminal from connector body: Remove seal retainer (A) from connector.
[2] - Slide seal (B) rearward on wires.
[3] -
→NOTE:
JDG140 Extraction Tool and JDG145 Universal Electrical Pliers are included
in JDG155 Electrical Repair Tool Kit .
Allow tool push rod (C) to back out during insertion.

LEGEND:
A Tool Sleeve
B Tool Handle
C Tool Push Rod
D Push Rod Button
Insert JDG140 Extraction Tool sleeve (A) over terminal until tool bottoms.
[4] - Rotate tool handle (B) to ensure release of terminal locking lances.
[5] - Hold tool sleeve firmly seated in connector and press push rod button (D). Remove
terminal from connector.

[6] -
LEGEND:
A Locator Blade
B Terminal
C Crimp Wings
D Notch
Replace terminal: Remove old terminal and strip 3 mm (1/8 in.) of insulation from wire
using JDG145 Universal Electrical Pliers.
[7] - Grip JDG10198 Terminal Crimping Tool securely, and squeeze ratcheting mechanism
[8] - With tool in ready position (open handle), lift locator blade (A).
[9] - Insert terminal (B) into JDG10198 Crimping Tool, crimp wings (C) facing up.
[10] -
→NOTE:
Locator blade (A) should be inserted into notch (D) of terminal when
closed.
Close locator blade (A).

[11] - Insert stripped wire into terminal (B) until it contacts locator blade (A).

[14] - Install terminal into connector body: Spread terminal locking lances and insert
terminal into connector.
[15] -
LEGEND:
A Seal Retainer
B Seal
Install seal (B) into connector.
[16] - Install seal retainer (A).

Repair Small MATE-N-LOC™ Socket Connector
LEGEND:
A Contact
B Contact Seam
[1] - Push contact (A) from wire side into connector as far as possible.
IMPORTANT:
DO NOT pry on extraction tool.
[2] -
→NOTE:
JDG142 Extraction Tool, JDG144 Crimping Pliers and JDG145 Universal
Electrical Pliers are part of JDG155 Electrical Repair Tool Kit .
Align tip of JDG142 Extraction Tool opposite contact seam (B).

[3] - Push extraction tool in connector until tool bottoms.
[4] - Pull wire to remove contact from connector.
Universal Electrical Pliers.
[7] - Insert wire in correct terminal of new connector.
[8] - Transfer remaining wires to correct terminal on new connector.

Repair Small MATE-N-LOC™ Pin Connector
LEGEND:
A Contact Pin
B Locking Lance
[1] - Push contact pin (A) from wire side into connector as far as possible.
IMPORTANT:
DO NOT pry on extraction tool.
[2] - Pull wire to remove contact from connector body.

[3] -
→NOTE:
JDG142 Extraction Tool, JDG144 Crimping Pliers and JDG145 Universal
Electrical Pliers are part of JDG155 Electrical Repair Tool Kit .
Remove old contact and strip 6 mm (1/4 in.) of insulation from wire using JDG145 Universal
Electrical Pliers.
[4] - Put tip of JDG142 Extraction Tool against locking lance (B) and depress lance.
[6] - Spread contact pin locking lance and insert wire in correct terminal of new connector.
[7] - Remove remaining wires and install in correct terminal of new connector.

Repair (Pull Type) METRI-PACK™ Connectors
LEGEND:
A Connector
B JDG777 Terminal Extraction Tool
C Body Socket
D Locking Tab
E Terminal
[1] - Disconnect Metri-Pack connector (A). Remove tie bands and tape.

[2] - Angle tip so tip slides close to plastic socket edge pushing inward on terminal locking
tab (D).
[3] -
→NOTE:
JDG777 Terminal Extraction Tool is included in JT07195B Technician’s
Electrical Repair Kit .
Insert JDG777 Terminal Extraction Tool (B) 6 mm (1/4 in.) into connector body socket (C).
[4] -
→NOTE:
JDG144 Crimping Pliers and JDG145 Electrician′s Pliers are included in
JDG155 Electrical Repair Tool Kit .
Remove terminal and strip wire using JDG145 Electrician′s Pliers.
[5] - Remove JDG777 Terminal Extraction Tool and push terminal (E) from socket.
[6] -
LEGEND:
A Crimping Pliers
Crimp new terminal on wire through connector using JDG144 Crimping Pliers (A).
→NOTE:
Terminal will seat only one way. If terminal does not pull into the connector
body socket, check for correct terminal alignment.
[7] - Check to ensure that locking tab on new terminal is in outward position, then pull on
wire until terminal locks in connector body socket.

Repair (Push Type) METRI-PACK™ Connectors
LEGEND:
A Connector Lock
B Extraction Tool
C Connector Body Socket
D Terminal
[1] - Disconnect Metri-Pack connector. Remove tie bands and tape.

[2] - Remove connector lock (A), and mark wire colors for identification.
[3] - Identify wire color locations with connector terminal letters.
→NOTE:
Use JDG776 Extraction Tool with 56, 280, and 630 Series Metri-Pack
terminals. Use JDG777 Extraction Tool with 150 Series Metri-Pack
terminals.
JDG145 Universal Electrical Pliers, JDG776 and JDG777 Terminal Extraction
Tools are included in JT07195B Technician’s Electrical Repair Kit .
[4] - Insert JDG776 or JDG777 Terminal Extraction Tool (B) into connector body socket (C)
pushing terminal locking tab inward.
[5] - Remove extraction tool and pull terminal (D) out of socket.
[6] -
Remove old contact from wire using JDG145 Universal Electrical Pliers.

[7] -
IMPORTANT:
The seal must fit snug over the cable insulation, without a gap between the
cable seal and the insulation.
→NOTE:
Cable seals are color coded for three sizes of wire:
Green - 18—20 Gauge Wire

Gray - 14—16 Gauge Wire
Blue - 10—12 Gauge Wire
Push correct size cable seal on wire.

[8] - Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of
insulation.
[9] - Install correct size contact on wire.
[10] -
LEGEND:
A Contact
B Crimping Tool
Crimp contact (A) in position with a ”W” type crimp using JDG865 Crimping Tool (B).

[11] -
LEGEND:
A Cable Seal
B Crimping Tool
Crimp cable seal (A) on contact using JDG865 Crimping Tool (B).
[12] -
LEGEND:
A Locking Tab
Make sure locking tab (A) on new terminal is in outward position.
[13] - Push terminal into connector body socket until terminal locks.

Repair Molex™ Control Unit Connectors

[1] -
LEGEND:
A Tab
B Locking Cam
C Cover Locks
D Cover
Press tab (A) and rotate locking cam (B) 90° to disconnect connector from control unit.
[2] - Move cover locks (C) slightly outward with a small screwdriver.

[3] - Remove cover (D) away from wires.

[4] -
LEGEND:
A Terminal Lock
Pull terminal lock (A) out but do not force its removal.
[5] -
→NOTE:
JDG1725 Terminal Extractor Tool has two different sizes of pins, 0.6 for
smaller 20 gauge holes (A), and 1.5 for larger 16, 18 (B), and 10, 12 (C)
gauge holes.
JDG1725 Terminal Extractor Tool and JDG1727 Terminal Crimping Tool are
part of JDG1744 Master Repair Kit .

LEGEND:
A 20 Gauge Holes
B 16 & 18 Gauge Holes
C 10 & 12 Gauge Holes
D Holes
E Terminal Opening
F JDG1725 Terminal Extractor Tool
G Terminal
Insert JDG1725 Terminal Extractor Tool (F) into holes (D) next to terminal opening (E) to
unlock terminal.
[6] - Pull wire and terminal (G) from connector body.
[7] -
→NOTE:
JDG1727 Terminal Crimping Tool part of JDG1744 Master Repair Kit or
JDG11255 Terminal Crimping Tool can be used.
Use JDG11228 Die Set for 10 - 12 gauge wire, JDG11229 Die Set for 14-16
gauge wire, and JDG11230 Die Set for 18-20 gauge wire.

LEGEND:
A Insulation Anvil Die
B Insulation Crimper Die
C Wire Anvil Die
D Wire Crimper Die
E Short Die Retaining Screw
F Long Die Retaining Screw
G Tool Frame
Assemble Crimper: Install insulation anvil die (A) and wire anvil die (C) into tool frame (G).
[8] - Install short die retaining screw (E) but do not tighten completely.
[9] - Install insulation crimper die (B) and wire crimper die (D) into tool frame (G).
[10] - Install long die retaining screw (F) but do not tighten completely.
[11] - Carefully close tool handles making sure that anvil and crimper dies align properly.
[12] - Tighten both die retaining screws.

[13] -
LEGEND:
A Locator
B Pivot Shaft
Install locator (A) onto pivot shaft (B).
[14] - Remove locator by pressing down on pivot shaft (B) and lifting on locator (A).

[15] -
LEGEND:
A Locator
B Wire Stop
C Terminal
Replace terminal: Remove old terminal and strip 4.90—5.10 mm (.193—.201 in.) of
insulation from wire.
[16] - Grip JDG1727 Terminal Crimping Tool or JDG11255 Terminal Crimping Tool securely
and squeeze ratcheting mechanism completely. Then allow it to open completely.
[17] -
→NOTE:
Terminals with large insulation grips have to be inserted into locator with
locator in closed position.
With tool in ready position (open handle), open locator (A).

[18] - Open wire stop (B).
[19] - Insert terminal (C) into locator.
[20] - Close locator (A).

[22] -
LEGEND:
A Wire
B Seal (if needed)
C Wire Stop
D Terminal
Insert stripped wire (A) with seal (B) (if needed) into terminal (D) against wire stop (C).
[24] - Press down on wire stop and remove terminated wire from tool.
[25] - Push terminal into connector body until fully seated. Pull on wire slightly to ensure that
terminal is locked in position.
[26] - Push terminal lock closed.
[27] - Install cover.
[28] - Install connector to control unit and close connector body locking cam.

Repair Molex Connector

[1] -
LEGEND:
A Terminal Lock
Remove terminal from connector body: Remove terminal lock (A) (if equipped) from
connector using a suitable push tool.
[2] -
→NOTE:
Be sure that tool is inserted with blades (B) of tool between connector body
and terminal.
LEGEND:
B Blades
Insert JDG10146 Extraction Tool (A) into connector as shown.
[3] - Squeeze tool to release terminal locking lances.
[4] - Pull wire to remove terminal from connector.

[5] -
LEGEND:
A Locator Blade
B Terminal
C Crimp Wings
D Notch
Replace terminal: Remove old contact and strip 3 mm (1/8 in.) of insulation from wire using
JDG145 Universal Electrical Pliers.
[6] - Grip JDG10145 Terminal Crimping Tool securely, and squeeze ratcheting mechanism
[7] - With tool in ready position (open handle), lift locator blade (A).
[8] - Insert terminal (B) into JDG10145 Crimping Tool, crimp wings (C) facing up.
[9] -
→NOTE:
Locator blade (A) should be inserted into notch (D) of terminal when
closed.
Close locator blade (A).

[10] - Insert stripped wire into terminal (B) until it contacts locator blade (A).

[13] - Install terminal into connector body: Spread contact locking lances and insert
terminal into connector.
[14] - Install terminal lock (if equipped).

Repair SUMITOMO™ Connectors
LEGEND:
B Locking Tab
[1] - Disconnect SUMITOMO™ connector.

[2] - Identify wire color location with terminal position.
[3] -
→NOTE:
JDG777 Terminal Extraction Tool is part of JT07195B Technician’s Electrical
Repair Kit .
Insert JDG777 Terminal Extraction Tool (A) into connector body socket pushing terminal
locking tab (B) upward.
[4] - Remove extraction tool and pull terminal out of socket.
[5] -
→NOTE:
JDG145 Universal Electrical Pliers is part of JDG155 Electrical Repair Tool Kit

IMPORTANT:
[6] - Push correct size cable seal on wire.

insulation.
[8] -
LEGEND:
A Cable Seal
B JDG707 Crimping Tool
Crimp contact on cable seal (A) using JDG707 Crimping Tool (B).

[9] -
LEGEND:
A Terminal
Make sure terminal (A) is positioned correctly for locking tab inside connector.

Repair Tyco Fuel Injector Connector

[1] -
LEGEND:
A Locking Tab
Disconnect connector from engine: Pull locking tab (A) outward.
[2] - Rotate connector counterclockwise and remove from engine.
[3] -
→NOTE:
For replacement of wire terminals, see procedure in engine CTM for
PowerTech Plus™ 9.0 L Diesel Engines—Level 14 Electronic Fuel System
with Denso HPCR.

LEGEND:
A Inner Part
B Outer Part
C Green Marks
Install connector to engine: Grasp inner part (A) of connector.
[4] - Rotate outer part (B) of connector counterclockwise until green marks (C) are aligned.
[5] - Install connector on engine with green marks (C) at approximately the seven o′clock
position.
[6] -
→NOTE:
Green marks will no longer be aligned.
LEGEND:
A Locking Tab
Rotate outer part of connector clockwise until locking tab (A) is at 12 o′clock position.
[7] - Push in locking tab (A).

Repair Weather Pack™ Connector
IMPORTANT:
Identify wire color locations with connector terminal letters.
[1] - Open connector body.

[2] -
→NOTE:
JDG364 Extraction Tool is part of JT07195B Technician’s Electrical Repair Kit
.
Insert JDG364 Extraction Tool over terminal contact in connector body.

→NOTE:
If terminal cannot be removed, insert wire or nail through extractor tool
handle and push terminal contact from connector.
[3] - Hold extractor tool fully seated and pull wire from connector body.
→NOTE:
Cable seals are color coded for three sizes of wire:
Green - 18—20 Gauge Wire

Gray - 14—16 Gauge Wire
Blue - 10—12 Gauge Wire

IMPORTANT:

insulation.
→NOTE:
Contacts have numbered identification for two sizes of wire:
#15 - 14—16 Gauge Wire

#19 - 18—20 Gauge Wire
[6] - Put correct size contact on wire and crimp in position with W—type crimp using JDG783
Weather Pack Crimping Tool .
LEGEND:
A Sleeve
B Pin
IMPORTANT:
Contact lances must be carefully spread to ensure good seating on
connector body.
→NOTE:
Connector bodies are ”keyed” for correct contact. Ensure that contacts are
correctly aligned.
Correct contact installation for sleeve (A) and pin (B) is illustrated.
[7] - Push contact into new connector body until fully seated.
[8] - Pull on wire slightly to ensure that contact is locked in position.
[9] - Transfer remaining wires to correct terminal in new connector.
[10] - Close connector body.

Repair YAZAKI™ Connectors
LEGEND:
B Locking Tab
[1] - Disconnect YAZAKI™ connector.

[2] - Identify wire color location with terminal position.
[3] -
→NOTE:
JDG777 Terminal Extraction Tool is part of JT07195B Technician’s Electrical
Repair Kit .
Insert JDG777 Terminal Extraction Tool (A) into connector body socket pushing terminal
locking tab (B) upward.
[4] - Remove extraction tool and pull terminal out of socket.
[5] -
→NOTE:
JDG145 Universal Electrical Pliers is part of JDG155 Electrical Repair Tool Kit
.

IMPORTANT:
Seal must fit snug over cable insulation, without a gap between cable seal
and insulation.

insulation.
[8] -
LEGEND:
A Cable Seal
B JDG707 Crimping Tool
Crimp contact on cable seal (A) using JDG707 Crimping Tool (B).

Section 40 - ELECTRICAL Group 10: Wiring Harness Routings
[9] -
LEGEND:
A Terminal
Make sure terminal (A) is positioned correctly for locking tab inside connector.

Group 10 - Wiring Harness Routings

List of References
Wire Number and Color Codes
Convenience Outlet #2 Harness (Eur Only)
Convenience Outlet #2 Harness (NA Only)
Roof Control Unit Power Cable
Cab Control Unit Power Cable
Alternator Harness
Positive Battery Cable
Negative Battery Cable
Cab and Rear Chassis Control Unit Power Cable
Auxiliary Power Strip
Power Module Relay Harness
Hood Light Harness
Dual Power Mirror Harness
Extremity Light Harness (NA Only)
Front Console Harness (PowrQuad-Plus™/AutoQuad-Plus™)
Front Console Harness (AutoPowr™/IVT™/CommandQuad™)
Front Console Harness (ACS™) (AutoPowr™/IVT™/CommandQuad™)
Steering Column Harness
ATC Roof Harness
Manual HVAC Roof Harness

Auxiliary Audio Harness
Microphone Harness
Left Extended Fender Harness
Right Extended Fender Harness
Key Switch Control Harness (EUR Only)
Rear Implement Lighting and Accessory Harenss (NA Only)
Rear Implement Lighting and Accessory Harness (Eur Only)
Front Implement Lighting and Accessory Harness (NA Only)
Front Implement Lighting and Accessory Harness (Eur Only)
Optional Roof Lighting Harness
Radar Harness
2WD Chassis Harness
MFWD Chassis Harness
MFWD Chassis Harness (Hydraulic Backup Pump)
TLS™ Plus Chassis Harness
TLS™ Plus Chassis Harness (Front Hitch)
TLS™ Plus Chassis Harness (Hydraulic Backup Pump)
TLS™ Plus Chassis Harness (Hydraulic Backup Pump, Front Hitch)
ACS™ Chassis Harness
ACS™ Chassis Harness (Front Hitch)
Rear Chassis Harness
Rear Chassis Harness (Cab Suspension)
PowrQuad-Plus™/AutoQuad-Plus™ Transmission Harness
CommandQuad™ Transmission Harness
AutoPowr™/IVT™ Transmission Harness

Front Chassis Harness (Mid-Stack SCVs)
Front Chassis Harness (TLS™ Plus)
Front Chassis Harness (TLS™ Plus and Mid-Stack SCVs)
Front Chassis Harness (TLS™ Plus and Front Hitch)
Engine Coolant Sensors Harness
PowrQuad-Plus™ Cab Harness (NA Only)
AutoQuad-Plus™ Cab Harness (EUR Only)
AutoPowr™/IVT™ and CommandQuad™ Cab Harness (NA Only)
AutoPowr™/IVT™ and CommandQuad™ Cab Harness (Eur Only)
SCV Controls Harness (PowrQuad-Plus™/AutoQuad-Plus™)
Hitch Controls Harness (PowrQuad-Plus™/AutoQuad-Plus™)
Right Hand Console Harness (PowrQuad-Plus™/AutoQuad-Plus™)
Power Assisted PTO Control Unit Harness
Power Assisted PTO Valve Harness
Rear PTO Shaft Identifier Switch Harness
Rear PTO Shaft Identifier Switch Extension Harness
Main Armrest Control Unit Harness
Standard Armrest Control Unit Harness
Armrest Control Unit Harness
Armrest Control Unit Harness (CommandQuad™)
Armrest Control Unit Harness—CommandQuad™
Armrest Control Unit Harness (AutoPowr™/IVT™)
Single Lever Control Assembly Harness (AutoPowr™/IVT™)
Single Single Lever Control Assembly Harness (PowrQuad-Plus™/AutoQuad-Plus™)
Mid-Stack SCV Controls Harness

Mid-Stack SCV Controls Backlighting Extension Harness
CommandCenter™ Display Programming Harness
Mid-Stack SCV Harness
Draft Sensor Harness
Wheel Angle Sensor Harness (Non ACS™)
Wheel Angle Sensors Harness (ACS™)
Front Brake Valve Harness
Front PTO Harness
Center Hitch Switch Harness
TLS™ Plus and Mid-Stack SCV Extension Harness
TLS™ Plus Harness
Backup Hydraulic Pump Harness
Secondary Brake Valve Harness
Front ISO Implement Connector Harness
JDLink™ (MTG) Harness
JDLink™ (MTG) w/Satellite Harness
Roof Lighting Harness (NA Only)
Roof Lighting Harness (Eur Only)
ISO 11786 Cornerpost Harness
Air Trailer Brake Harness
ActiveSeat™ Harness
Standard Seat Harness
Heated Seat Power Harness
Heated Seat Switch Harness
Heated Seat Heater Element Harness

Power Standard Mirror Harness
Power Extend Mirror Harness

Wire Number and Color Codes

Two methods of coding circuits are numbers and colors.
A three-digit number is used to identify each wire circuit. This code is printed on each
harness wire every 25 mm (1 in.). Circuit numbers and corresponding functional usage are
noted in Table 1.
TABLE 1 - WIRE NUMBERS
Circuit No. Function
000-099 Power
100-199 Lighting
200-299 Accessories
300-499 Engine
500-699 Transmission
700-799 Hydraulics
800-899 Hitch
900-999 Other
Wire insulation colors are determined by the last digit of the wire circuit number. Circuit
numbers, corresponding wire colors and number color code are noted in Table 2.
TABLE 2 - WIRE COLORS
Color Code
Circuit No. Circuit Wire Color
Printed Numbers
XX0 Black White
XX1 Brown White
XX2 Red White
XX3 Orange Black
XX4 Yellow Black
XX5 Dark Green White
XX6 Light Blue Black
XX7 Purple White
XX8 Gray Black
XX9 White Black

LEGEND:
1 Cab to Convenience Outlet #2 Harness Interconnect
2 Convenience Outlet #2 (Eur Only)

LEGEND:
1 Cab to Convenience Outlet #2 Harness Interconnec
2 Convenience Outlet #2 (NA Only)

LEGEND:
1 Convenience Outlet #1 (Eur Only)

LEGEND:
1 Convenience Outlet #1 (NA Only)
Roof Control Unit Power Cable

LEGEND:
1 Master Fuse
2 Roof Control Unit Connector
Cab Control Unit Power Cable

LEGEND:
1 Cab Control Unit Connector
2 Master Fuse
Alternator Harness

LEGEND:
1 Alternator/Battery Relay
1 Master Fuse
2 Alternator
Positive Battery Cable

LEGEND:
1 Starter Motor
2 Battery
3 Battery
4 Master Fuse
5 Battery Charging Post
Negative Battery Cable

LEGEND:
1 Single Point Ground
2 Battery
3 Alternator
Cab and Rear Chassis Control Unit Power Cable
LEGEND:
1 Master Fuse
2 Rear Chassis Control Unit Connector
3 Battery Power Junction Block

LEGEND:
1 Auxiliary Power Strip
2 Right Junction Block
Power Module Relay Harness

LEGEND:
1 Chassis to Power Module Relay Harness Interconnect
2 Starter Relay
3 Alternator/Battery Relay Diode 2
4 Alternator/Battery Relay Diode 1
5 Alternator/Battery Relay
6 Backup Hydraulic Pump Relay
Hood Light Harness

LEGEND:
1 Left Low-Beam Driving Light
2 Left High-Beam Driving Light
3 Left Front Inner Flood Light
4 Left Front Outer Flood Light
5 Right Front Outer Flood Light
6 Right Front Inner Flood Light
7 Right Low-Beam Driving Light
8 Right High-Beam Driving Light
9 Chassis to Hood Light Harness Interconnect
Dual Power Mirror Harness

LEGEND:
1 Right Power Mirror Interconnect
2 Inner Roof Harness to Dual Power Mirror Harness Interconnect
3 Mirror Heat Switch
4 Mirror Extend Switch
5 Mirror Adjustment Switch
6 Left Power Mirror Interconnect
Extremity Light Harness (NA Only)

Extremity Light Harness
LEGEND:
1 Right Extremity Transport Light
2 Right Extremity Light Interconnect
3 Left Extremity Light Interconnect
4 Left Extremity Transport Light
Front Console Harness (PowrQuad-Plus™/AutoQuad-

Plus™)

LEGEND:
1 Cab to Front Console Harness Interconnect 1
3 Foot Throttle
4 Clutch Pedal Position Sensor
5 Steering Wheel Module (ACS™)
6 Key Switch
7 Front Console to Steering Column Harness Interconnect
8 Left-Hand Reverser
9 Start Aid Switch
10 Differential Lock Switch
11 Chassis to Front Console Harness Interconnect
12 Brake Pedal Sensor Module
Front Console Harness

(AutoPowr™/IVT™/CommandQuad™)

LEGEND:
3 Foot Throttle
6 Key Switch
9 Start Aid Switch
Front Console Harness (ACS™)


LEGEND:
3 Foot Throttle
6 Key Switch
9 Start Aid Switch
11 Chassis to Front Console Harness Interconnect (ACS™)

LEGEND:
1 Road Light Switch
2 Inverter Backlighting Steering Column
3 Front Wiper Switch
4 Turn Signal Switch Assembly

ATC Roof Harness
LEGEND:
1 Cab to Roof HVAC Harness Interconnect
2 Roof HVAC to Roof Lighting Harness Interconnect
3 Water Valve Motor
4 Business Band Connector
5 Radio Connector
6 Right-Hand Console Lamp
7 Map Lamp Switch
8 Vehicle CAN Bus Active Terminator Connector
8 Vehicle CAN Bus Active Terminator
9 Roof Cab Ground
10 Map Lamp
11 Rear Wiper Switch
12 Automatic Temperature Control Unit (ATC) Connector
14 Right Front Speaker
15 Air Flow Mode Motor
16 Left Front Speaker
17 Dome Lamp Switch
18 Pressurizer Blower Motor
19 ATC Blower Motor Driver Connector

20 Left Rear Speaker

21 Door Switch
22 Outlet Air Temperature Sensor
23 Refrigerant Pressure Sensor
24 Cab Temperature Sensor
25 Evaporator Temperature Sensor
26 Right Rear Speaker
27 Ambient Temperature Sensor

Manual HVAC Roof Harness
LEGEND:
3 Business Band Connector
4 Inverter Backlighting Roof
5 Radio Connector
6 Right-Hand Console Lamp
7 Map Lamp Switch
8 Vehicle CAN Bus Active Terminator Connector
8 Vehicle CAN Bus Active Terminator
9 Map Lamp
10 Blower Motor Switch
11 A/C On / Off Switch
12 Rear Wiper Switch
13 Manual HVAC Circulation Blower Motor Relay
15 Right Front Speaker
16 Left Front Speaker
17 Dome Lamp Switch
18 Pressurizer Blower Motor
19 Manual HVAC Circulation Blower Motor

20 Left Rear Speaker

21 Blower Motor Resistor
22 Door Switch
23 A/C De-Icing Switch
24 A/C Dual Pressure Switch
25 Right Rear Speaker
LEGEND:
1 Auxiliary Audio Jack
2 Radio Connector
3 Radio Connector
Microphone Harness

LEGEND:
1 Radio Connector
2 Microphone
Left Extended Fender Harness

LEGEND:
1 Cab to Left Fender Harness Interconnect 2
3 Left Rear Fender Flood Light
4 Left Fender Turn Signal
5 Left Tail/Brake Light
6 Rear PTO Left External Switch (Eur Only)
7 Rear Hitch Left External Switch
8 SCV Left External Switch
Right Extended Fender Harness

LEGEND:
1 Cab to Right Fender Harness Interconnect 2
3 Right Rear Fender Flood Light
4 Right Fender Turn Signal
5 Right Tail/Brake Light
6 Rear PTO Right External Switch (Eur Only)
7 Rear Hitch Right External Switch
8 SCV Right External Switch
Key Switch Control Harness (EUR Only)

LEGEND:
1 Cab to Key Switch Control Harness Interconnect 2 (Eur Only)
3 Key Switch Control
Rear Implement Lighting and Accessory Harenss

(NA Only)

LEGEND:
1 Rear Chassis to Rear Trailer Light Extension Harness
2 Rear Implement Lighting and Accessory Connector (NA Only)
Rear Implement Lighting and Accessory Harness

(Eur Only)

LEGEND:
1 Front Chassis to Front Trailer Light Extension Harness
2 Front Implement Flood Light Connector (Eur Only)
3 Front Implement Lighting and Accessory Connector (Eur Only)
Front Implement Lighting and Accessory Harness

(NA Only)

LEGEND:
2 Front Implement Lighting and Accessory Connector (NA Only)
Front Implement Lighting and Accessory Harness

(Eur Only)

LEGEND:
2 Rear Implement Flood Light Connector (Eur Only)
3 Front Implement Lighting and Accessory Connector (Eur Only)
Optional Roof Lighting Harness

LEGEND:
1 Left Loader Flood Light
2 Left Front Inner Roof Flood Light
3 Roof Lighting to Optional Roof Lighting Harness Interconnect
4 Right Loader Flood Light
5 Right Front Inner Roof Flood Light
Radar Harness

LEGEND:
1 Radar Sensor
2 Transmission to Radar Harness Interconnect

2WD Chassis Harness


LEGEND:
1 Chassis Ground
2 Starter Motor
3 Fuel Level Sensor
5 Exhaust Filter Temperature Module
6 Glow Plug Relay Power Interconnect
7 Chassis to Engine Harness Interconnect
8 Horn
9 Front Load Center Panel—Fuses
10 Vehicle CAN Bus Passive Terminator Connector
11 A/C Compressor Clutch
12 Alternator
13 Electronically Controlled Viscous Fan Clutch
14 Engine Control Unit Connector
15 Chassis to Front Chassis Harness Interconnect 1
16 Chassis to Engine Coolant Sensors Harness Interconnect
17 Differential Pressure Sensor
18 Chassis to TLS™ Plus and Mid-Stack Extension Harness Interconnect
20 Cab to Chassis Harness Interconnect
21 Chassis to Rear Chassis Harness Interconnect 1
22 Chassis to Transmission Harness Interconnect
23 Rear PTO Solenoid
24 Rear PTO Oil Temperature
25 Rear Differential Lock Solenoid
26 Backup Alarm
27 Chassis to Power Assisted PTO Control Unit Harness Interconnect
28 Rear PTO Speed Sensor
29 Chassis to Rear PTO Shaft Select Switch Extension Harness Interconnect
30 Axle Lube Pressure Sensor
31 Hydraulic Oil Filter Restriction Sensor
32 Starter Relay
33 Rear Washer Pump
34 Front Washer Pump

MFWD Chassis Harness


LEGEND:
1 Chassis Ground
2 Starter Motor
3 Fuel Level Sensor
8 Ether Solenoid
10 Horn
13 Chassis to Wheel Angle Sensor Harness Interconnect
14 Alternator
24 Steering System Control Unit Connector
31 Backup Alarm
36 Starter Relay
37 Rear Washer Pump
39 AutoTrac™ Steer Right Solenoid (Non ACS™)
40 AutoTrac™ Steer Left Solenoid (Non ACS™)
41 AutoTrac™ Steer Enable Solenoid (Non ACS™)

MFWD Chassis Harness (Hydraulic Backup Pump)


LEGEND:
1 Chassis Ground
2 Starter Motor
3 Fuel Level Sensor
8 Ether Solenoid
10 Horn
14 Alternator
33 Backup Alarm
37 Chassis to Secondary Brake Valve Harness Interconnect
39 Main Hydraulic Pump Pressure Sensor 2
41 Backup Hydraulic Pump Pressure Sensor
43 Starter Relay
45 Rear Washer Pump

TLS™ Plus Chassis Harness


LEGEND:
1 Chassis Ground
2 Starter Motor
3 Fuel Level Sensor
8 Ether Solenoid
10 Horn
14 Alternator
24 Chassis to Air Trailer Brake Harness Interconnect
35 Backup Alarm
41 Left Rear Brake Pressure Sensor
42 Right Rear Brake Pressure Sensor
43 Chassis to Front Brake Valve Harness Interconnect
45 Starter Relay
46 Rear Washer Pump

TLS™ Plus Chassis Harness (Front Hitch)


LEGEND:
1 Chassis Ground
2 Starter Motor
3 Fuel Level Sensor
8 Ether Solenoid
10 Horn
14 Alternator
37 Backup Alarm
47 Starter Relay
48 Rear Washer Pump



TLS™ Plus Chassis Harness (Hydraulic Backup

Pump)


LEGEND:
1 Chassis Ground
2 Starter Motor
3 Fuel Level Sensor
8 Ether Solenoid
10 Horn
14 Alternator
35 Backup Alarm
48 Starter Relay
50 Rear Washer Pump



TLS™ Plus Chassis Harness (Hydraulic Backup

Pump, Front Hitch)


LEGEND:
1 Chassis Ground
2 Starter Motor
3 Fuel Level Sensor
8 Ether Solenoid
10 Horn
14 Alternator
37 Backup Alarm
45 Implement CAN Bus Passive Terminator Connector

51 Starter Relay
53 Rear Washer Pump

ACS™ Chassis Harness


LEGEND:
1 Chassis Ground
2 Starter Motor
3 Fuel Level Sensor
8 Ether Solenoid
10 Horn
14 Alternator
26 ActiveCommand Steering B-Box Connector
29 ActiveCommand Steering A-Box Connector
38 Backup Alarm

51 Starter Relay
53 Rear Washer Pump
55 Steer Right Valve 2 Position Sensor (ACS™)
56 Steer Left Valve 2 Position Sensor (ACS™)
59 Steer Right Solenoid 1 (ACS™)
60 Steer Left Solenoid 1 (ACS™)
61 Steer Enable Solenoid 1 (ACS™)

ACS™ Chassis Harness (Front Hitch)


LEGEND:
1 Chassis Ground
2 Starter Motor
3 Fuel Level Sensor
8 Ether Solenoid
10 Horn
14 Alternator
40 Backup Alarm


54 Starter Relay
56 Rear Washer Pump

Rear Chassis Harness
LEGEND:
2 Implement Power Relay Module
3 Implement Switched Power Fuse
6 Option Configuration Connector
7 Cab to Rear Chassis Harness Interconnect
8 ISO Implement Connector
9 Implement CAN Bus Active Terminator
10 Implement Switch
11 Rear Hitch Position Sensor
12 Rear Chassis to Draft Sensor Extension Harness Interconnect
14 Rear Chassis Ground
15 Selective Control Valve Unit I (SV1)
16 Selective Control Valve Unit II (SV2)
17 Selective Control Valve Unit III (SV3)
18 Hitch Control Valve Unit
19 Selective Control Valve Unit IV (SV4)
20 Selective Control Valve Unit V (SV5)

21 Selective Control Valve Unit VI (SV6)

Rear Chassis Harness (Cab Suspension)
LEGEND:
2 Implement Power Relay Module
3 Implement Switched Power Fuse
6 Option Configuration Connector
9 Implement CAN Bus Active Terminator
10 Implement Switch
11 Rear Hitch Position Sensor
14 Rear Chassis Ground
15 Selective Control Valve Unit I (SV1)
16 Selective Control Valve Unit II (SV2)
17 Selective Control Valve Unit III (SV3)
18 Hitch Control Valve Unit
19 Selective Control Valve Unit IV (SV4)
20 Selective Control Valve Unit V (SV5)
21 Selective Control Valve Unit VI (SV6)
22 Cab Suspension Position Sensor
23 Cab Suspension Lower Solenoid
24 Cab Suspension Raise Solenoid
25 Cab Suspension Dampening Solenoid

PowrQuad-Plus™/AutoQuad-Plus™ Transmission
Harness
LEGEND:
System 1 Pressure Sensor (PowrQuad-Plus™/AutoQuad-
2
Plus™/CommandQuad™)
3 Hydraulic Oil Temperature Sensor
4 Clutch Enable Pressure Sensor
5 Hydraulic Oil Cooler Control Solenoid
6 Diagnostic Hydraulic Pressure Connector
7 Reverse Brake Solenoid
8 Forward Clutch Solenoid
Clutch Enable Solenoid ((PowrQuad-Plus™/AutoQuad-
9
11 Four-Speed Solenoid 2
Transmission Primary Speed Sensor (PowrQuad-Plus™/AutoQuad-
13
14 Top Shaft Speed Sensor
15 MFWD Solenoid


CommandQuad™ Transmission Harness
LEGEND:
System 1 Pressure Sensor (PowrQuad-Plus™/AutoQuad-
2
4 Transmission Oil Boost Solenoid
8 Reverse Brake Solenoid
9 Forward Clutch Solenoid
Clutch Enable Solenoid ((PowrQuad-Plus™/AutoQuad-
10
Transmission Secondary Speed Sensor
14
Transmission Primary Speed Sensor (PowrQuad-Plus™/AutoQuad-
15
16 Top Shaft Speed Sensor

17 E Rail Position Sensor

18 C/D Rail Position Sensor
19 A/B Rail Position Sensor
20 Range Solenoid 1
21 Range Solenoid 2
22 Range Solenoid 3
23 MFWD Solenoid
24 Park Sump Block Solenoid
25 Park Brake Supply Solenoid
26 Park Brake Pressure Sensor
28 Cab to CommandQuad™ Transmission Harness Interconnect

AutoPowr™/IVT™ Transmission Harness
LEGEND:
2 Ring Gear 2 Primary Speed Sensor
3 Transmission Primary Speed Sensor (AutoPowr™/IVT™)
Transmission Secondary Speed Sensor
4
8 Loop Flush Cutoff Solenoid
11 Transmission Oil Boost Solenoid
12 System 1 Pressure Sensor (AutoPowr™/IVT™)
13 Hydro Control Solenoid
15 Mode 1/3 Selector Solenoid
16 Mode 1/3 Solenoid
18 Park Sump Block Solenoid
19 Park Brake Pressure Sensor

20 Forward Synchronizer Solenoid

21 Reverse Synchronizer Solenoid
22 MFWD Solenoid
23 Mode 2 Solenoid
24 Clutch Enable Solenoid
25 Park Brake Supply Solenoid
26 MFWD Speed Sensor
27 Synchronizer Position Sensor
Front Chassis Harness (Mid-Stack SCVs)
LEGEND:
1 Front Chassis Control Unit Connector
5 Front Option Configuration Connector
Front Chassis Harness (TLS™ Plus)

LEGEND:
5 Front Suspension Position Sensor
6 Front Suspension Dampening Solenoid
Front Chassis Harness (TLS™ Plus and Mid-Stack

SCVs)

LEGEND:

Front Chassis Harness (TLS™ Plus and Front Hitch)
LEGEND:
8 Front PTO Diagnostic Pressure Connector
9 Front Chassis Ground
12 Front Chassis to Front PTO Harness Interconnect
13 Front Hitch Position Sensor
16 Front Chassis to Front ISO Implement Harness Interconnect
17 Front Hitch External Switch
18 Front PTO External Switch (Eur Only)

Engine Coolant Sensors Harness
LEGEND:
2 Engine Coolant Level Sensor
3 Engine Coolant Loss Sensor

PowrQuad-Plus™ Cab Harness (NA Only)
LEGEND:
1 Reconfigurable Display Connector
2 Cab to ISO 11786 Cornerpost Harness Interconnect
3 Corner Post Display Connector
6 Cab Implement Connector (4 pin)
7 Wheel Speed Signal Connector
Cab to Right Hand Console Harness Interconnect (PowrQuad-
11
Plus™/AutoQuad-Plus™)
12 Wheel Speed Signal Connector (Radar)
13 Wheel Speed Signal Connector (GPS)
15 Service ADVISOR™ Connector
18 Secondary Brake Lever Sensor
20 ISO 11783 Console Connector
21 ISO 11783 Relay Box
Cab to Hitch Controls Harness Interconnect (PowrQuad-Plus™/AutoQuad-
22
Plus™)
Cab to SCV Operator Controls Harness Interconnect (PowrQuad-
23

Cab to Single Lever Control Assembly Harness (PowrQuad-

24
25 Seat to Cab Harness Interconnect
26 Cab Ground 1
29 Cab to Video Camera Harness Interconnect
32 Subwoofer
33 Circuit 050 Splice Connector 2
37 Cab to MTG System Harness Interconnect
38 Cab to Power Assisted PTO Control Unit Harness Interconnect
43 Load Center Panel—Fuses
43 Load Center Panel—Relays
44 Lighter

AutoQuad-Plus™ Cab Harness (EUR Only)
LEGEND:
13
24
Plus™)


25
Cab to Single Lever Control Assembly Harness (PowrQuad-
26
28 Cab Ground 1
34 Subwoofer
46 Lighter

AutoPowr™/IVT™ and CommandQuad™ Cab Harness

(NA Only)
LEGEND:
15 Lighter #1 (AutoPowr™/IVT™/CommandQuad™)
19 Gyro (ACS™ Only)
22 Cab to Main Armrest Harness Interconnect
24 Cab Ground 1


30 Subwoofer
42 Lighter

AutoPowr™/IVT™ and CommandQuad™ Cab Harness

(Eur Only)
LEGEND:
17 Lighter #1 (AutoPowr™/IVT™/CommandQuad™)
21 Gyro (ACS™ Only)
26 Cab Ground 1
32 Subwoofer
44 Lighter
SCV Controls Harness (PowrQuad-Plus™/AutoQuad-

Plus™)
LEGEND:


1
2
3 Up/Down Shift Switch (PowrQuad-Plus™/AutoQuad-Plus™)
4 SCV III Control Lever Sensor (PowrQuad-Plus™/AutoQuad-Plus™)
5 SCV II Control Lever Sensor (PowrQuad-Plus™/AutoQuad-Plus™)
6 SCV IV Control Lever Sensor (PowrQuad-Plus™/AutoQuad-Plus™)
7 SCV I Control Lever Sensor (PowrQuad-Plus™/AutoQuad-Plus™)
Hitch Controls Harness (PowrQuad-

LEGEND:
1 Linear Rear Hitch Control Lever (PowrQuad-Plus™/AutoQuad-Plus™)
2
Plus™)
SCV Operator Controls Harness to Hitch Controls Harness Interconnect
3
(PowrQuad-Plus™/AutoQuad-Plus™)
4 Front PTO Switch (PowrQuad-Plus™/AutoQuad-Plus™)
5 Rear PTO Switch (PowrQuad-Plus™/AutoQuad-Plus™)
Right Hand Console Harness (PowrQuad-


LEGEND:
1
2 Up/Down and Autoshift Switches (AutoQuad-Plus™)
3 Hand Clutch Switch (AutoQuad-Plus™)
4 Range Lever Park Switch (PowrQuad-Plus™/AutoQuad-Plus™)
5 Hand Throttle Position Sensor (PowrQuad-Plus™/AutoQuad-Plus™)
6 CommandCenter™ Connector
7 Cab Switch Module Connector (PowrQuad-Plus™/AutoQuad-Plus™)
8 Lighter #1 (PowrQuad-Plus™/AutoQuad-Plus™)
Power Assisted PTO Control Unit Harness

LEGEND:
2 Power Assisted PTO Control Unit Connector
5 Power Assisted PTO Chassis Ground
Power Assisted PTO Control Unit to Power Assisted PTO Valve Harness
7
Interconnect
Power Assisted PTO Valve Harness

LEGEND:
1 Rear PTO Shaft Identifier Switch
Power Assisted PTO Control Unit to Power Assisted PTO Valve Harness
2
Interconnect
3 Power Assisted PTO Shift Valve Assembly
Rear PTO Shaft Identifier Switch Harness

LEGEND:
1 Rear PTO Shaft Identifier Switch
Rear PTO Shaft Select Switch Extension to Rear PTO Shaft Select Switch
2
Harness Interconnect
Rear PTO Shaft Identifier Switch Extension Harness

LEGEND:
Rear PTO Shaft Select Switch Extension to Rear PTO Shaft Select Switch
2
Main Armrest Control Unit Harness

LEGEND:
3 Neutral Start Switch
4 Cab Switch Module Connector (AutoPowr™/IVT™/CommandQuad™)
6 Inverter Backlighting Armrest
7 Armrest Control Unit Connector (14 Pin)

Standard Armrest Control Unit Harness
LEGEND:
3 Rear PTO Switch (AutoPowr™/IVT™/CommandQuad™)
4 Hand Throttle Position Sensor (AutoPowr™/IVT™/CommandQuad™)
5 SCV IV Control Lever Sensor (AutoPowr™/IVT™/CommandQuad™)
6 iTEC™ Sequence Switch 1
7 iTEC™ Sequence Switch 2
8 Rear Hitch Control Lever Sensor (AutoPowr™/IVT™/CommandQuad™)
9 SCV I Control Lever Sensor (AutoPowr™/IVT™/CommandQuad™)
10 SCV II Control Lever Sensor (AutoPowr™/IVT™/CommandQuad™)
11 SCV III Control Lever Sensor (AutoPowr™/IVT™/CommandQuad™)
Armrest Control Unit Harness

LEGEND:
2 SCV V Control Lever Sensor (AutoPowr™/IVT™/CommandQuad™)
3 SCV VI Control Lever Sensor (AutoPowr™/IVT™/CommandQuad™)
4 Front PTO Switch (AutoPowr™/IVT™/CommandQuad™)
Armrest Control Unit Harness (CommandQuad™)

LEGEND:
1 CommandQuad™ Shift Lever
3 Speed Control Lever Sensor (CommandQuad™)
5 AutoTrac™ Resume Switch (AutoPowr™/IVT™/CommandQuad™)
Armrest Control Unit Harness—CommandQuad™

LEGEND:
1 CommandQuad™ Range Selector
2 Armrest Control Unit Connector (16 pin)
Armrest Control Unit Harness (AutoPowr™/IVT™)
LEGEND:

3 AutoTrac™ Resume Switch (AutoPowr™/IVT™/CommandQuad™)
4 Speed Control Lever Sensor (AutoPowr™/IVT™)
5 Right-Hand Reverser (AutoPowr™/IVT™)
Single Lever Control Assembly Harness

(AutoPowr™/IVT™)
LEGEND:
1 Cab Switch Module Connector
2 Transport Lock Switch
3 Single Lever Control Assembly
Single Single Lever Control Assembly Harness

(PowrQuad-Plus™/AutoQuad-Plus™)

LEGEND:
1 Single Lever Control Assembly
Cab to Single Lever Control Assembly Harness (PowrQuad-Plus™/AutoQuad-
2
Plus™)
Mid-Stack SCV Controls Harness
LEGEND:
1 Cab Switch Module Connector

Mid-Stack SCV Controls Backlighting Extension to Mid-Stack SCV Controls
2
3 Mid-Stack SCV Controls Backlighting
4 Mid-Stack SCV Left Control Lever Sensor
5 Mid-Stack SCV Middle Control Lever Sensor
6 Mid-Stack SCV Right Control Lever Sensor
Mid-Stack SCV Controls Backlighting Extension

Harness
LEGEND:
Mid-Stack SCV Controls Backlighting Extension to Mid-Stack SCV Controls
1
Secondary Brake Lever Backlighting to Mid-Stack SCV Controls Backlighting
2
Extension Harness Interconnect
3 Secondary Brake Lever Backlighting

LEGEND:
2 CommandCenter™ Programming Connector
Mid-Stack SCV Harness

LEGEND:
1 TLS™ Plus and Mid-Stack Extension to Mid-Stack Harness Interconnect
2 Mid-Stack Selective Control Valve Unit (SVK)
3 Mid-Stack Selective Control Valve Unit (SVL)
4 Mid-Stack/Front Hitch Selective Control Valve Unit (SVM/SVJ)
Draft Sensor Harness
LEGEND:


2 Rear Hitch Draft Sensor
Wheel Angle Sensor Harness (Non ACS™)
LEGEND:
1 Left Wheel Angle Sensor
Wheel Angle Sensors Harness (ACS™)

LEGEND:
1 Left Wheel Angle Sensor
3 Right Wheel Angle Sensor (ACS™ Only)
Front Brake Valve Harness

LEGEND:
2 Front Brake Pressure Sensor
3 Front Brake Enable Solenoid
4 Front Brake Solenoid
Front PTO Harness
LEGEND:

1 Front Chassis to Front PTO Harness Interconnect

2 Front PTO Speed Sensor
3 Front PTO Clutch Pressure Sensor
4 Front PTO Oil Temperature Sensor
5 Front PTO Solenoid
Center Hitch Switch Harness
LEGEND:
3 Rear Hitch Center External Switch
TLS™ Plus and Mid-Stack SCV Extension Harness

LEGEND:
2 TLS™ Plus and Mid-Stack Extension to TLS™ Plus Harness Interconnect
3 TLS™ Plus and Mid-Stack Extension to Mid-Stack Harness Interconnect
TLS™ Plus Harness

LEGEND:
1 TLS™ Plus and Mid-Stack Extension to TLS™ Plus Harness Interconnect
2 Front Suspension Spring Rate Decrease Solenoid
3 Front Suspension Spring Rate Increase Solenoid
4 Front Suspension Pressure Sensor
5 Front Suspension Raise Solenoid
6 Front Suspension Lower Solenoid
Backup Hydraulic Pump Harness

LEGEND:
1 Backup Hydraulic Pump Relay
2 Chassis Ground
3 Backup Hydraulic Pump Motor
Secondary Brake Valve Harness
LEGEND:
2 Secondary Brake Pressure Sensor (Eur Only)

3 Secondary Brake Enable Solenoid
4 Secondary Brake Solenoid
Front ISO Implement Connector Harness
LEGEND:
1 Front Chassis to Front ISO Implement Harness Interconnect
2 Front ISO Implement Connector
3 Front Implement CAN Bus Active Terminator

LEGEND:
1 JDLink™ (MTG) Control Unit
JDLink™ (MTG) w/Satellite Harness
LEGEND:
1 JDLink™ (MTG) Control Unit

3 Intelligent Vehicle Systems Connector

6 JDLink™ (MTG) Satellite Control Unit

Roof Lighting Harness (NA Only)
LEGEND:
1 Right Mid Body Flood Light
2 Right Front Clearance and Warning Light (Eur Only)
3 Vehicle CAN Bus Passive Terminator
4 Left Front Side Roof Flood Light
5 Left Front Roof Warning (NA Only)
6 Beacon Light
8 GPS Receiver Connector
9 Front Wiper Ground
10 Front Wiper Motor
13 Right Front Roof Warning (NA Only)
14 Right Front Side Roof Flood Light
15 Roof Cab Ground
17 Right Rear Side Roof Flood Light
18 Right Rear Roof Warning (NA Only)
19 Right Rear Inner Roof Flood Light

20 Rear Wiper Motor

21 Rear Wiper Ground
22 Left Rear Inner Roof Flood Light
23 Left Rear Roof Warning (NA Only)
24 Left Rear Side Roof Flood Light

Roof Lighting Harness (Eur Only)
LEGEND:
1 Right Mid Body Flood Light
2 Right Front Clearance and Warning Light (Eur Only)
3 Vehicle CAN Bus Passive Terminator
4 Left Mid Body Flood Light
5 Left Front Clearance and Warning Light (Eur Only)
6 Left Front Side Roof Flood Light
7 Left Front Corner Roof Light (Eur Only)
8 Beacon Light
10 GPS Receiver Connector
11 Front Wiper Ground
12 Front Wiper Motor
15 Right Front Corner Roof Light (Eur Only)
16 Right Front Side Roof Flood Light
17 Roof Cab Ground
19 Right Rear Side Roof Flood Light

20 Right Rear Corner Roof Light (Eur Only)

21 Right Rear Inner Roof Flood Light
22 Right License Plate Light (Eur Only)
23 Left License Plate Light (Eur Only)
24 Rear Wiper Motor
25 Rear Wiper Ground
26 Left Rear Inner Roof Flood Light
27 Left Rear Corner Roof Light (Eur Only)
28 Left Rear Side Roof Flood Light
LEGEND:
1 ISO 11786 Cornerpost Connector
Air Trailer Brake Harness

LEGEND:
2 Air Trailer Pre-Brake Enable Solenoid
3 Air Trailer Pre-Brake Pressure Sensor
4 Air Trailer Brake Enable Solenoid
5 Air Trailer Pre-Brake Solenoid
6 Air Trailer Brake Pressure Sensor

LEGEND:
1 ActiveSeat™ Pressure Control Solenoid
2 ActiveSeat™ Raise / Lower Solenoid
4 Seat Position Sensor
5 ActiveSeat™ Compressor Assembly
6 ActiveSeat™ Compressor Relay
7 Seat Accelerometer Sensor
8 Seat to Heated Seat Harness Interconnect
9 Operator Presence Switch
10 ActiveSeat™ Height Control Switch
11 ActiveSeat™ Firmness Control Switch

LEGEND:
1 Standard Seat Height Control Switch
4 Standard Seat Compressor Motor
5 Standard Seat Diode

LEGEND:
2 Heated Seat Power Connector

LEGEND:
1 Heated Seat Switch
2 Heated Seat Switch Connector

LEGEND:
1 Heated Seat Heater Elements Connector
2 Backrest Heating Element
Power Standard Mirror Harness

LEGEND:
1 Power Standard Right Mirror Motor
4 Power Standard Left Mirror Motor
Power Extend Mirror Harness

Section 40 - ELECTRICAL Group 15: Charging Circuit
LEGEND:
1 Power Extend Right Mirror Motors
4 Power Extend Left Mirror Motors

Group 15 - Charging Circuit

List of References
Repair Alternator—Use CTM
Exploded View—Alternator
Remove and Install Alternator
Replace Alternator Master Fuse
Repair Alternator—Use CTM
For complete repair information on alternator, component technical manual is also required.
Use component technical manual in conjunction with this machine manual.
Exploded View—Alternator

LEGEND:
1 Seal
2 Rear End Frame
3 Seal
4 Rectifier
5 "S" Terminal Insulator
6 Transient Voltage Protector
7 Brush Holder
8 Brush
9 Seal
10 Rear End Cover
11 Nut
12 Pulley
13 Drive End Frame
14 Stator
15 Bearing
16 Stud Bolt
17 Retainer Plate
18 Rotor

19 Bearing
20 Bearing Cover

Remove and Install Alternator

[1] -
IMPORTANT:
The alternator is designed with a Transient Voltage Protector to protect
tractor electronics. A regular alternator without transient voltage protector
damages electronics.
LEGEND:
B Auxiliary Drive Shield
C Alternator wires (3 used)

Disconnect battery ground (-) cable.
[2] - Open hood and remove front right-hand side panel.
[3] - Remove cap screws (A) and auxiliary drive shield (B).
[4] - Remove belt from alternator pulley.
[5] - Identify, label, and disconnect alternator wires (C).
[6] - Remove mounting cap screws (D) and alternator.

Replace Alternator Master Fuse
LEGEND:
A Cover
B Nuts (2 used)
C Alternator Master Fuse
IMPORTANT:
Only tractors equipped with backup pumps have an alternator master fuse.
→NOTE:
Alternator master fuse is located behind the cab steps on the left-hand side
of the tractor.
[1] - Disconnect battery ground (-) cable.

[2] - Remove cover (A).
[3] - Remove nuts (B) and alternator master fuse (C).

Section 40 - ELECTRICAL Group 20: Starting Circuit
[4] -
IMPORTANT:
Alternator master fuse (250 Amp) has been specifically designed. Do not
substitute parts or damage could result to the electrical system.
Inspect parts and replace as necessary.


Group 20 - Starting Circuit

List of References
Specifications
Repair Starter—Use CTM
Remove and Install Starter Motor
Replace Starter Circuit Relay
Replace Starter Master Fuse
→NOTE:

JDG2046 Starter Wrench
Specifications
Starter Motor Cap Screws Torque 48 N·m
(35 lb.-ft.)
Repair Starter—Use CTM

For complete repair information on starter, component technical manual is also required.
Use component technical manual in conjunction with this machine manual.

Remove and Install Starter Motor

[1] -
LEGEND:
A Battery Cable
B Solenoid Cover and Wire
D Nut
Open hood and remove rear left-hand side panel.
[3] - Remove battery cable (A).
[4] - Remove solenoid cover and wire (B).
[5] - Remove cap screws (C) and nut (D) using JDG2046 Starter Wrench .
[7] - Install in reverse order and tighten to specification.
Starter Motor Cap Screws Torque 48 N·m
(35 lb.-ft.)

Replace Starter Circuit Relay
→NOTE:
Starter relay (B) is located behind the cab steps on the left-hand side of the
tractor.
Starter Relay Without Back Up Pump

Starter Relay With Back Up Pump
LEGEND:
A Cover
B Starter Relay
C Nuts (2 used)

[3] - Identify, label, and disconnect wires from starter relay (B).
[4] - Remove nuts (C) and starter relay.

Replace Starter Master Fuse

[1] -

→NOTE:
Starter Master Fuse Without Back Up Pump
Starter Master Fuse With Back Up Pump

LEGEND:
A Cover
B Starter Master Fuse
C Nuts (2 used)
Starter master fuse is located behind steps on the left-hand side of the
tractor.

Section 40 - ELECTRICAL Group 25: Relays, Fuses, Solenoids, and Switches

[3] - Remove nuts (C) and starter master fuse (B).
[4] -
IMPORTANT:
Starter master fuse (250 Amp) has been specifically designed. Do not


Group 25 - Relays, Fuses, Solenoids, and Switches

List of References
Specifications
General Repair Procedures—Solenoids and Switches
Load Center Fuses and Relays
Remove and Install Backup Pump Master Fuse
Remove and Install Backup Pump Relay
Replace Starting Aid Switch
Replace Ignition Switch
Replace Seat Raise/Lower Switch
Replace Seat Firmness Switch—ActiveSeat™
Replace Heated Seat Switch
Replace Operator Presence Seat Switch
Replace Differential Lock Switch
Replace Differential Lock and Rear PTO Solenoids
Replace Hitch Position Potentiometer Assembly
Replace Clutch Pedal Position Sensor
Remove and Install CommandQuad™, AutoQuad™, and PowrQuad™ Transmission Solenoids

and Switches
Remove and Install AutoPowr™ and IVT™ Transmission Solenoids and Switches
Replace Transmission Control (AutoPowr™/IVT™)

Specifications
MFWD Solenoid
Solenoid Plate Cap Screws Torque 10 N·m
(86 lb-in.)
Differential Lock and Rear PTO Solenoids

Retaining Plate Cap Screw Torque 10 N·m
(86 lb-in.)
Hitch Solenoids
Return and Pressure Solenoid CapScrews Torque 2 N·m
(18 lb-in.)
Brake Pedal Stop Screws and Switch Clearance 0.20—0.60 mm
(0.008—0.024 in.)
General Repair Procedures—Solenoids and Switches
IMPORTANT:
Absolute cleanliness is essential when working on the electro-hydraulic

system. Contamination can result in serious damage or inadequate
operation. The solenoid area MUST BE THOROUGHLY CLEANED before
removing the solenoid.
→NOTE:
Replacement or repair of sensors, switches, and solenoids not mentioned in

this group are described in the group or CTM dealing with the
corresponding component.
→NOTE:
Before beginning repair, review the following guidelines. These are

provided to emphasize the need for attention to detail and care when
servicing the solenoids.
Disassembly and Assembly:
Clean, inspect, disassemble, and assemble electro-hydraulic valve.

Disconnect battery ground (-) at battery.
Replace all O-rings.
Replace damaged connectors.
Fasteners must be tightened to the specified torque.

Load Center Fuses and Relays
→NOTE:
Fold seat backrest down to allow easier access, and allow cab lighting to
shine on load center when fuses are being inspected or replaced.
Load center is found directly behind the operator′s seat and just below the cab rear window.
To access load center, lift on Operator′s Manual holder (A).
LEGEND:
A Operator′s Manual Holder
The illustration to the right explains how to read the load center diagram.

LEGEND:
A Fuse Location Number
B Fuse Size
IMPORTANT:
LEGEND:
K1 ISO Implement Connector Power Relay
K2 Electronics Relay (If Equipped)
K3 Electronics Relay (If Equipped)
K4 Implement Accessory Relay
K5 AC Switch/Blower Relay
K6 Accessories Relay
K7 Warning Horn Relay
K8 Implement Flood Relay
K9 Not Used
K10 Not Used
1 Key Switch
3 Air Conditioner
4 PAPTOS (If Equipped)
5 Cab Switch Module
6 PAPTOS (If Equipped)
7 Module Telematics Gateway
8 Armrest Control Unit
9 Not Used
10 Implement Flood Lights
11 Implement Accessory
12 Not Used

13 ActiveCommand Steering (If Equipped)

14 Not Used
15 Convenience Outlet Battery
16 Not Used
17 Not Used
18 Park Break Release
19 Seat Controls
20 Not Used
21 Spare
22 Park Brake Release
23 Convenience Outlet Battery
24 Video Camera Power (If Equipped)
25 Spare
26 Spare
27 Convenience Outlet Switched
28 Rear Chassis Control Unit
29 Spare
31 Remote Mirror
32 Come Home Mode (IVT™ only)
33 Accessories Power
34 Blower Motor
35 Not Used
36 Not Used
Replacement Fuses must be the same rating as the original.
Ensure both negative (-) and positive (+) battery connections are
disconnected fromboth batteries before fuse inspection or replacement.
Open hood to locate front load center located in front of cowl. Remove cover (A).

LEGEND:
A Cover
B Front Load Center Panel
C Not Used
D Not Used
E Not Used
F Not Used
G Not Used
H Not Used

I Key Switch
J ACS Control Unit
K Front Chassis Control Unit 2
L Front Chassis Control Unit 1
M Not Used
N Not Used
O Not Used
P Not Used
Q Not Used
R Not Used
S Not Used
T ECU 1
U Dosing Pump
V Fuel Transfer Pump

Remove and Install Backup Pump Master Fuse

[1] -
→NOTE:
Backup pump master fuse is located behind the cab steps on the left-hand
side of the tractor.
LEGEND:
A Cover
B Backup Pump Master Fuse
C Nuts (2 used)
[3] - Remove nuts (C) and backup pump master fuse (B).
[4] -
IMPORTANT:
Backup pump master fuse (150 Amp) has been specifically designed. Do not


Remove and Install Backup Pump Relay
→NOTE:
Backup pump relay (B) is located behind the cab steps on the left-hand side
of the tractor.
LEGEND:
A Cover
B Backup Pump Relay
C Nuts (2 used)

[3] - Identify, label, and disconnect wires from backup pump relay (B).
[4] - Remove nuts (C) and backup pump relay (B).

Replace Staring Aid Switch

[1] -
LEGEND:
A Tray
B Screws (2 used)
C Upper Cowl
D Alignment Pins (2 used)
E Clips (2 used)
Remove tray (A) and screws (B) from upper cowl (C).
[2] - Pull upper cowl (C) rearward off alignment pins (D) and clips (E).

[3] -
LEGEND:
A Harness
B Start Aid Switch
C Jam Nut
D Washer
E Rubber Cover
Disconnect harness (A) from start aid switch (B).
[4] - Loosen jam nut (C).
[5] - Remove rubber cover (E).
[6] - Remove start aid switch and washer (D).

Replace Ignition Switch

[1] -
LEGEND:
A Tray
B Screws (2 used)
C Upper Cowl
E Clips (2 used)
Remove tray (A) and screws (B) from upper cowl (C).

[3] -
LEGEND:
A Harness Connector
B Ignition Switch
C Jam Nut
Disconnect harness connector (A) from ignition switch (B).
[4] - Remove jam nut (C).
[5] - Remove switch.

Replace Seat Raise/Lower Switch

[1] -
LEGEND:
A Screw
B Armrest Pad
C Connector
D Tabs
Remove screw (A) and armrest pad (B).
[2] - Disconnect connector (C).
[3] - Depress tabs (D) and remove switch from armrest.

[4] -
LEGEND:
A Tab
B Notch
C Screw
Install new switch into armrest.
[5] - Connect connector.
[6] - Insert tab (A) into notch (B) on armrest.
[7] - Install screw (C).

Replace Seat Firmness Switch—ActiveSeat™

[1] -
LEGEND:
A Screw
B Armrest Pad
C Connector
D Tabs
[2] - Disconnect connector (C).

[4] -
LEGEND:
A Tab
B Notch
C Screw
[5] - Connect connector.

Replace Heated Seat Switch

[1] -
LEGEND:
A Screw
B Armrest Pad
C Connector (3 Used)
D Tabs
[2] -
→NOTE:
Mark wires for identification.
Disconnect connectors (C) from switch.


[4] -
LEGEND:
A Tab
B Notch
C Screw
[5] - Connect previously marked wires to switch.

Replace Operator Presence Seat Switch
LEGEND:
A Harness Connector
B Screws (2 used)
C Switch Connector
D Tabs
→NOTE:
Seat switch is located under seat cushion.

[1] - Disconnect harness connector (A) located at rear of seat.

[2] - Remove screws (B) and seat cushion.
[3] - Disconnect switch connector (C) from seat.
[4] - Depress tabs (D) and remove presence switch from seat.
[5] - Replace parts as necessary.

Replace Differential Lock Switch

[1] -
LEGEND:
A Floor Mat
B Floor Plate
C Wiring Harness Connector
D Switch
Remove floor mat (A).
[2] - Remove floor plate (B).

[3] - Disconnect wiring harness connector (C).

[4] - Remove switch (D) from floor plate.

Replace Differential Lock and Rear PTO Solenoids

[1] -
→NOTE:
Differential lock solenoid (B) is located on top of differential case behind
rear PTO solenoid (A).
LEGEND:
A Rear PTO Solenoid
B Differential Lock Solenoid
Disconnect connector from PTO solenoid (A) or differential lock solenoid (B).
[2] - Remove cap screws, retaining plate, and valve assembly.
[3] - Install solenoid.
[4] - Tighten solenoid retaining plate cap screws.
Differential Lock and Rear PTO Solenoids

Retaining Cap Screw Torque 10 N·m
(86 lb.-in.)

Replace Hitch Position Potentiometer Assembly

[1] -
LEGEND:
A Connector
B Linkage
C Cap Screw (2 Used)
D Snap Ring
E Nut and Cap Screw (2 Used)
[2] - Remove linkage (B) from rockshaft lift arm.
[3] - Remove cap screws (C) and remove potentiometer assembly.
[4] - Remove snap ring (D), nuts, cap screws (E) and potentiometer.

[5] -
IMPORTANT:
LEGEND:
A Potentiometer
B Nut and Cap Screw (2 Used)
C Snap Ring
Do not forcibly rotate sensor arm. This will damage potentiometer.
Removing hitch position potentiometer will require hitch recalibration.
Install potentiometer (A) to bracket. Rotate sensor counterclockwise until mounting holes line
up.
[6] - Install cap screws and nuts (B) and snap ring (C).
[7] - Install assembly on tractor.
[8] - Calibrate hitch control circuit. (See OPERATION AND TEST TM—Section 245, Group
HCU).
Replace Clutch Pedal Position Sensor

[1] -
→NOTE:
Clutch pedal position sensor is located on lower right-hand side of steering
column.

LEGEND:
A Connector
B Nut (2 Used)
C Sensor
Remove lower front console.
[2] - Test and replace if necessary. (See OPERATION AND TEST TM—Section 245, Group
CAB.)
[3] - Disconnect connector (A).
[4] - Remove nuts (B).
[5] - Remove sensor (C).

Remove and Install CommandQuad™, AutoQuad™,

and PowrQuad™ Transmission Solenoids and
Switches
Reference the following:
See Remove, Recondition, and Install Cooler Bypass Valve in Section 50, Group 10.
See Remove, Recondition, and Install Shift Valve Housing in Section 50, Group 10.
See Remove, Recondition, and Install Transmission Front Cover in Section 50, Group 10.
See Repair Shift Control Housing in Section 50, Group 20.
See Exploded View—Valve Assembly in Section 50, Group 30
See Repair Valve Assembly in Section 50, Group 30.
See Exploded View—Shift Control Housing in Section 50, Group 30.
See Repair Shift Control Housing in Section 50, Group 30
Remove and Install AutoPowr™ and IVT™

Transmission Solenoids and Switches
See Exploded View—Front Valve Housing in Section 51, Group 20.

See Repair Front Valve Housing in Section 51, Group 20.
See Exploded View—Rear Valve Housing in Section 51, Group 20.
See Repair Rear Valve Housing in Section 51, Group 20.

Replace Transmission Control (AutoPowr™/IVT™)

[1] -
→NOTE:
When removing transmission control assembly, remove engine speed
control assembly at the same time.
LEGEND:
A Shifter Knob
B Cap
C Support
D Nut
E Speed Selector Knob
F Sensor
G Strap
H Screw (2 Used)
I Sensor Housing
J Sensor Connector
K Control Assembly
L Potentiometer
M Circuit Board
Remove armrest control assembly (See Remove and Install CommandARM™ Assembly in
Group 35.)
[2] - Remove shifter knob (A).
[3] - Remove screws (H).

Section 40 - ELECTRICAL Group 30: Monitoring System
[4] - Separate sensor housing (I).

[5] - Disconnect sensor connector (J) from sensor (F).
[6] - Remove mounting cap screws from transmission and engine speed control.
[7] - Disconnect control harness from armrest control unit.
[8] - Remove controls from armrest control assembly.
[10] - Calibrate control. (See OPERATION AND TEST TM2234—Section 245, Group ACU-001.)

Group 30 - Monitoring System

List of References
Specifications
Essential, Recommended and Fabricated Tools
Other Material
General Information—Monitoring Systems
Control Units Identification
Replace Control Units
Replace Cab Switch Module (CSM) Control Unit
Replace Engine Coolant Temperature Sensor
Replace Engine Coolant Level Sensor
Replace Air Filter Restriction Indicator Sensor
Replace Fuel Level Sensor
Replace Foot Throttle Sensor
Replace Hydraulic Oil Filter Restriction Sensor
Remove and Install CommandQuad™, AutoQuad™, and PowrQuad™ Transmission Sensors
Remove and Install AutoPowr™ and IVT™ Transmission Sensors
Replace Draft Sensing Sensor
Adjust Draft Link Sensor
Replace Rear PTO Speed Sensor
Replace Power Assisted PTO Shift Electromagnets
Replace Radar Sensor—CommandQuad™, AutoQuad™, and PowrQuad™ Transmissions
Replace Radar Sensor—IVT™ Transmissions
Remove and Install MFWD Speed Sensor

Replace Wheel Angle Sensor
Replace Steering Input Device
Replace Gyroscope Sensor

Specifications
Draft Sensor Cover Plate Cap Screws Torque 70 N·m
(51 lb.-ft.)
Draft Link Sensor Source Voltage

Source Voltage Range 4.8—5.2 V
Draft Link Sensor Voltage Plunger Fully Extended 0.25—0.90 V
Plunger Fully Retracted 3.95—4.75 V
Draft Sensor Voltage Range 2.0—2.3 V
Bracket Cap Screws Torque 37 N·m
(28 lb.-ft.)
Bracket-to-Frame Cap Screws Torque 70 N·m
(52 lb.-ft.)
Shield-to-Bracket Cap Screws Torque 37 N·m
(28 lb.-ft.)
Kingpin-to-Knuckle Housing Cap Screws Torque 545 N·m
(402 lb.-ft.)
→NOTE:

DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses
Other Material
Number Name Use
• PM38655 (us)
Flexible Form-in-Place
• PM38625 (canadian) Used to seal surfaces.
Gasket
Lubricate wheel-speed sensor end
• TY6311 (us) Grease
cap
General Information—Monitoring Systems

Replacement or repair of sensors, switches, and solenoids not mentioned in this group are
described in the group or CTM dealing with the corresponding component.

Control Units Identification
AutoPowr™/IVT™/CommandQuad™ Cab Control Unit Locations
LEGEND:
1 CommandCenter™ Display Unit (VTI, VTV)
2 Corner Post Display Unit (PDU)
3 Roof Control Unit (RLC, SMV, TEC)
4 Automatic Temperature Control Unit (ATC)
5 Cab Switch Module (CSM)
6 Cab Control Unit (AIC, ASU, CLC, EIC, FCC, OIC, TII, TIQ)
7 JDLink™ Control Unit (MTG)
8 Armrest Control Unit (AIC)

PowrQuad™/AutoQuad™ Cab Control Unit Locations
LEGEND:
1 CommandCenter™ Display Unit (VTI, VTV)
2 Corner Post Display Unit (PDU)
3 Roof Control Unit (RLC, SMV, TEC)
4 Automatic Temperature Control Unit (ATC)
5 Cab Switch Module (CSM)
6 Cab Control Unit (AIC, ASU, CLC, EIC, FCC, OIC, TII, TIQ)
7 JDLink™ Control Unit (MTG)

Chassis Control Unit Locations
LEGEND:
1 Engine Control Unit (ECU)
2 Front Chassis Control Unit (SFA, SCO, PTF)
3 Rear Chassis Control Unit (VLC. CCU, PTI, PTQ, HCC, CSC, SCC, RPT)
4 Steering System Control Unit (XMC, XSC)
4 ActiveCommand Steering A-Box Control Unit (XMA/XSA)
5 ActiveCommand Steering B-Box Control Unit (XMB/XSB)
6 Power Assisted PTO Control Unit (PAP)

Replace Control Units

[1] -
→NOTE:
Refer to Control Units Identification in this group for controller locations.
Record engine hours on cover of new CCU being installed, before replacing CCU. Enter hours
when calibrating new CCU.
[2] - Disconnect battery ground (—).
[3] - Disconnect electrical connectors from control unit(s).
[4] - Remove control unit(s) mounting screws.
[5] - Disassemble control unit being replaced.
[6] - Install in reverse order and calibrate control unit.
FOR CALIBRATION AND TEST PROCEDURES SEE APPROPRIATE SECTION IN OPERATION AND TEST TM
AIC .......... Section 245
ATC .......... Section 245
CCU .......... Section 245
CLC .......... Section 245
CSM .......... Section 245
EIC .......... Section 245
HCC .......... Section 245
JDL .......... Section 245
OIC .......... Section 245
PAP .......... Section 245
PDU .......... Section 245
PTI .......... Section 245
RLC .......... Section 245
RPT .......... Section 245
SCC .......... Section 245
SCO .......... Section 245
SFA .......... Section 245
SMV .......... Section 245
TEC .......... Section 245
TII .......... Section 245
VLC .......... Section 245
VTI .......... Section 245
XMA .......... Section 245
XMB .......... Section 245
XMC .......... Section 245
XSA .......... Section 245
XSB .......... Section 245
XSC .......... Section 245

Replace Cab Switch Module (CSM) Control Unit
[1] - For tractors equipped with Right-Hand Console, perform the following:
Pull up on control unit (A) to remove from console.

Disconnect electrical connector (B).
Calibrate control unit (See Operation and Test TM Section 245, Group CSM.)

[2] -
For tractors equipped with CommandARM™, perform the following:
Remove knob (A).

Identify, label, and disconnect harnesses and remove cab switch module (B).
Calibrate control unit (See Operation and Test TM Section 245, Group CSM.)
Replace Engine Coolant Temperature Sensor

[1] -
CAUTION:
Engine coolant may be hot. Be sure to let coolant cool before removing
sensor.
→NOTE:
The engine coolant temperature sensor (A) is located in the engine
thermostat housing.
LEGEND:
A Sensor

Disconnect sensor harness and remove sensor (A).

[2] - Apply teflon sealant tape to threads and install replacement sensor.
Replace Engine Coolant Level Sensor

[1] -
LEGEND:
A Sensor
Drain coolant from tractor.
[2] - Open hood and remove left side shield.
[3] - Disconnect sensor harness from sensor.
[4] - Remove sensor (A) from coolant reservoir.
Replace Air Filter Restriction Indicator Sensor
LEGEND:
A Air Intake Sensor
B Cap Screws

→NOTE:
Sensor (A) is located on air intake duct.
[1] - Disconnect wiring harness from air intake sensor (A).

[2] - Remove cap screws (B) and air intake sensor (A).

Replace Fuel Level Sensor

[1] -
→NOTE:
Fuel level sender is located on top right-hand side of fuel tank.
LEGEND:
B Cover
C Sensor Wire
D Mounting Screws
E Sensor Unit
Fold back cab floor mat on right-hand side of cab.
[2] - Remove four cap screws (A).
[3] - Remove floor plate (B) and gasket covering fuel sender.
[4] -

LEGEND:
A Hoses
B Connector
D Retaining Plate
E Sensor
Disconnect and plug hoses (A).
[5] - Disconnect sensor wire connector (B).
[6] - Remove cap screws (C) and sensor retaining plate (D).
[7] - Remove sensor (E).
[8] -
→NOTE:
Use a new gasket between floor plate and floor.

→NOTE:
Verify operation of gauge after replacement by observing fuel level gauge
operation. If gauge is not operating correctly, check address CCU 013 to
check sensor voltage. (See OPERATION AND TEST TM—Section 245, Group
CCU.)
Replace Foot Throttle Sensor

[1] -
LEGEND:
A Screw (2 Used)
B Sensor
C Notch
D Bushing
Lift floor mat up over foot throttle.
[2] - Disconnect harness (A) from foot throttle sensor.
[3] - Remove screws (B).
[4] - Remove sensor (C).
Replace Hydraulic Oil Filter Restriction Sensor

LEGEND:
A Hydraulic Oil Restriction Sensor
→NOTE:
Sensor (A) is located on left-hand side of tractor on hydraulic filter base.
[1] - Disconnect connector.

[2] - Replace sensor (A) as required.

Remove and Install CommandQuad™, AutoQuad™,

and PowrQuad™ Transmission Sensors
See Remove, Recondition, and Install Transmission Boost Valve in Section 50, Group 10.
See Remove, Recondition, and Install Transmission Front Cover in Section 50, Group 10.
See Install Sensors for AutoQuad™ and PowrQuad™ in Section 50, Group 20.
See Exploded View—Valve Assembly in Section 50, Group 30.
See Repair Valve Assembly in Section 50, Group 30.
See Exploded View—Shift Control Housing in Section 50, Group 30.
See Repair Shift Control Housing in Section 50, Group 30.
See Install Sensors for CommandQuad™ in Section 50, Group 30.
Remove and Install AutoPowr™ and IVT™

Transmission Sensors
See Exploded View—Front Valve Housing in Section 51, Group 20.

See Repair Front Valve Housing in Section 51, Group 20.
See Exploded View—Rear Valve Housing in Section 51, Group 20.
See Repair Rear Valve Housing in Section 51, Group 20.
See Install Sensors in Section 51, Group 30.

Replace Draft Sensing Sensor

[1] -
→NOTE:
Draft sensing sensor is located under rear axle housing.
LEGEND:
A Cap Screws
B Harness Shield
C Cover Plate
D Sensor Connector
E Sensing Strap
Disconnect battery ground cable.
[2] - Remove drawbar.
[3] - Remove cap screws (A), harness shield (B), and cover plate (C).
[4] - Disconnect sensor at connector (D).
[5] - Remove sensing strap (E).

[6] -
LEGEND:
A Sensor Retainer
B Sensor
Remove sensor retainer (A) and sensor (B) replace as required.
[7] - Adjust draft sensing sensor. (See ADJUST DRAFT SENSING SENSOR in this group.)
[8] - Remove old gasket material from cover plate and mating surface.
[9] - Apply RE62967 Liquid Adhesive Gasket to cover plate. Sealant must encircle all holes on
cover.
Number Name Use
• RE62967 (us) Liquid Adhesive Gasket Install cover draft sensor cover
[10] - Connect sensor harness.
[11] - Install cover plate and sensor harness shield.
Draft Sensor Cover Plate Cap Screws Torque 70 N·m
(51 lb.-ft.)


Check Source Voltage
[1] -
→NOTE:
Key switch inOFF position and hitch fully down.
→NOTE:
See DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses
in Section 99, Group 05 to fabricate DFRW65 Tap-Out Harness.
LEGEND:
A Connector (To Hitch Power Harness)
B Connector (To Sensor)
C Connector (For Volt Meter)
Install connector (A) of DFRW65 Tap-Out Harness to hitch power harness.
[2] - Install connector (B) of Tap-Out Harness to draft link sensor harness.
[3] - Connect voltage meter to connector (C) of Tap-Out Harness (red lead from volt meter to
terminal “A” and black lead to terminal “C”).
[4] - Turn key switch toON position but do NOT start engine.

[5] - Check voltage.

Draft Link Sensor Source Voltage

Source Voltage Range 4.8—5.2 V
Check Draft Sensor Voltage
[1] -
→NOTE:
LEGEND:
A Connector (To Hitch Power Harness)
B Connector (To Sensor)

C Connector (For Volt Meter)

D Sensor Strap
E Sensor Plunger
Connect voltage meter to connector (C) of Tap-Out Harness (red lead from volt meter to
terminal “B” and black lead to terminal “C”).
[3] -
→NOTE:
Check voltage with sensor strap (D) disconnected. Sensor plunger must
move smoothly and voltage readings must show no sudden changes or
hesitation.
Depress and release sensor plunger (E) and observe voltage.

Draft Link Sensor Voltage Plunger Fully Extended 0.25—0.90 V
Plunger Fully Retracted 3.95—4.75 V
[1] -
→NOTE:
LEGEND:
A Sensor Strap
B Adjustment Screw
C Lock Nut
Install sensor strap (A).

[3] - Adjust sensor strap adjustment screw (B) until correct voltage is obtained.
Draft Sensor Voltage Range 2.0—2.3 V
[4] - Lock adjustment screw (B) with lock nut (C) and recheck voltage.
[5] - Calibrate draft sensor. (See OPERATION AND TEST TM— Section 245, Group HCU.)
Replace Rear PTO Speed Sensor

[1] -
LEGEND:
A Sensor
Disconnect wiring harness.
[2] - Remove sensor (A).
Replace Power Assisted PTO Shift Electromagnets

Replace Power Assisted PTO Shift electromagnets (See Recondition Power Assisted PTO
Shifter in Section 56, Group 30.)

Replace Radar Sensor—CommandQuad™,

AutoQuad™, and PowrQuad™ Transmissions
Remove Radar Sensor
[1] -
LEGEND:
A Radar Connector
B Cap Screw (2 Used)
C Shield
Disconnect battery ground (-) cable at battery.
[3] - Loosen cap screws (B) and lower radar assembly.
[4] - Remove shield (C).
[5] -
IMPORTANT:
If isolators (B) or (C) are exposed to oil, they stiffen and become less
effective and must be replaced.


LEGEND:
A Cap Screw (4 Used)
B Isolator (4 Used)
C Isolator (4 Used)
D Washer (4 Used)
E Nut (4 Used)
Remove cap screws (A), washers (D), and nuts (E) from radar assembly.
Install Radar Sensor
[1] -
IMPORTANT:
Install isolator (B) with chamfer down.
→NOTE:
Apply a soap solution to small end of isolator (C), for ease when installing
through holes in bracket (F).
LEGEND:
B Isolator
C Isolator
D Washer
E Nut (4 Used)
F Bracket
G Radar Assembly
Install isolator (C) into bracket (F) with small end pointing up through bracket holes.
[2] - Install donut isolators (B), four washers (F) on (G).
[3] - Install radar assembly (G). to base bracket (D) with cap screws (G) and nuts (B) and
tighten.
[4] - Install cap screws (A), washers (D), and nuts (E).

[5] - Tighten to specification.

(28 lb.-ft.)
[6] -
LEGEND:
A Harness
Attach radar jumper wiring harness (A) to radar assembly.

[7] -
LEGEND:
A Connector
B Cap Screws
C Shield
Install radar assembly onto tractor.
[8] - Tighten radar bracket mounting cap screws (B).
(52 lb.-ft.)
[9] - Install shield (C).

[10] - Connect radar harness connector (A).
[11] - Connect battery ground (-) cable.

Replace Radar Sensor—IVT™ Transmissions

Remove Radar Sensor

[1] -
LEGEND:
A Radar Connector
C Cap Screw (2 Used)
D Shield
[3] - Loosen cap screws (B).

[4] - Remove cap screws (C) and lower radar assembly.

[5] - Remove shield (D).
[6] -
IMPORTANT:
If isolators (B) or (C) are exposed to oil, they stiffen and become less
effective and must be replaced.
LEGEND:
B Isolator (4 Used)
C Isolator (4 Used)
D Washer (4 Used)
E Nut (4 Used)
Remove cap screws (A), washers (D), and nuts (E) from radar assembly.
Install Radar Sensor
[1] -
IMPORTANT:
Install isolator (B) with chamfer down.
→NOTE:
Apply a soap solution to small end of isolator (C), for ease when installing
through holes in bracket (F).

LEGEND:
B Isolator
C Isolator
D Washer
E Nut (4 Used)
F Bracket
G Radar Assembly
Install isolator (C) into bracket (F) with small end pointing up through bracket holes.
[2] - Install donut isolators (B).
[3] - Install radar assembly (G) onto bracket (F) with cap screws (A), washers (D), and nuts
(E).
(28 lb.-ft.)

[5] -
LEGEND:
A Shield
C Nut (3 Used)
Install shield (A) using cap screws (B) and nuts (C).
Shield-to-Bracket Cap Screws Torque 37 N·m
(28 lb.-ft.)

[7] -
LEGEND:
A Radar Assembly
B Cap Screws
C Connector
Install radar assembly (A) onto tractor.
[8] - Tighten radar bracket mounting cap screws (B).
(52 lb.-ft.)
[9] - Connect radar harness connector (C).

[10] - Connect battery ground (-) cable.
Remove and Install MFWD Speed Sensor

See Install Sensors in Section 51, Group 30.

Replace Wheel Angle Sensor

[1] -
LEGEND:
A Sensor Shield
B Connector
Remove front fender.
[2] - Remove sensor shield (A).
[3] - Disconnect harness (B).

[4] -
LEGEND:
A Upper Kingpin
Support axle and remove upper kingpin (A).
[5] -

LEGEND:
A Sensor Screws (2 used)
B Sensor
C O-Ring
D Adapter
E Sensor Rod
F Rod Guide Screws (2 used)
G Seal
H Rod Guide
Remove parts (A—H).
[6] - Inspect and replace parts as necessary.
[7] -
→NOTE:
Make sure 0-ring (C) is installed on sensor.
Assemble in reverse order.

[8] -
IMPORTANT:
Locator (A) on sensor rod must align with notch (B) in rod guide when
installing kingpin.

LEGEND:
A Locator
B Notch
Install upper kingpin.
(402 lb.-ft.)
[9] - Connect harness.

[10] - Install sensor shield.
[11] - Install fender.
[12] - Calibrate sensor:
For tractors equipped with ACS see Diagnostic Technical Manual--Section 245, Group
XSA, Address 022
For tractors equipped with AutoTrac see Diagnostic Technical Manual--Section 245,
Section XSC, Address 022

Replace Steering Input Device

[1] -
LEGEND:
A Emblem
B O-Ring
C Nut
D Special Washers
E Knob
F Large Nut
G Retainer
H Snap Ring
Remove parts (A—G) to remove steering wheel.
[2] - Remove snap ring (H) from steering shaft.

[3] -
LEGEND:
A Tray
B Screws (2 used)
C Upper Cowl
E Clips (2 used)
F Module
Remove tray (A) and screws (B).
[5] - Remove cowl (C) over module (F).

[6] -
LEGEND:
B Support Bracket
D Lower Cowl
E Ignition Switch Connector
F Either Aid Switch Connector
G Module Harness Connector
H Lever Cover
Remove cap screws (A) and support bracket (B).
[7] - Disconnect harness connectors from ignition switch (E) and either aid switch (F).
[8] - Remove cap screws (C) and remove lower cowl (D).
[9] - Disconnect module harness connector (G).
[10] - Remove lever cover (H).

[11] -
LEGEND:
B Steering Module
C Guide
D Top Cover
E Harness
[12] - Remove steering module (B), guide (C), and top cover (D) noting how harness (E) is
routed.

[13] -
LEGEND:
A Connector
B Cap Screw
C Washer
D Input Device
[14] - Remove caps screw (B) and washer (C).
[15] - Remove steering input device (D) from steering column.
[16] - Assemble and install steering column in reverse order.
Steering Input Device Cap Screw Torque 15 N·m
133 lb.-in.
[17] -
IMPORTANT:
Use care to prevent breaking the tabs when installing covers.
Install covers.

[18] - Install steering wheel and tighten nut.

Steering Wheel Nut Torque 32 N·m
(25 lb-ft)

Replace Gyroscope Sensor

[1] -
LEGEND:
A Screws (3 used)
Remove cup holder and tray inserts.
[2] - Pull back rear upholstery and remove screws (A).
[3] - Carefully remove right-hand console from under rear cab post cover and set aside.

Section 40 - ELECTRICAL Group 35: Armrest Control
[4] -
LEGEND:
A Harness Connector
B Screws (3 used)
Disconnect harness connector (A).
[5] - Remove screws (B) and gyroscope sensor.

Group 35 - Armrest Control

List of References
Specifications
Armrest Test Procedures
Remove and Install CommandARM™ Assembly
Replace Armrest Interface Control Unit (AIC)
Replace Engine Speed Control
Replace Transmission Control
Replace SCV Control Lever
Replace Hitch Control
Replace Rear PTO Switch
Replace Front PTO Switch
Replace ITEC Sequence Switch
Replace Resume Switch
Disassemble Right-Hand Console
Assemble Right-Hand Console
Specifications
Display Mounting Bracket Cap Screws Torque 8 N·m
(70 lb.-in.)
Armrest Test Procedures

Armrest control test procedures. (SeeDiagnostic Technical Manual—Section 245, Group AIC.)

Remove and Install CommandARM™ Assembly

[1] -
LEGEND:
A Harness
B Cap Screws
Disconnect armrest control harness (A) from main harness.
[2] - Remove two cap screws (B) to remove armrest control from seat.
[3] -

LEGEND:
A Knob
B Cab Switch Module
C Covers
D Harness
E CommandCenter™
Remove knob (A) disconnect harness and remove cab switch module (B).
[4] - Remove cover (C).
[5] - Disconnect harness (D) from CommandCenter™ (E).

[6] -
LEGEND:
A Screws
B Tie Bands
C Top Cover
Remove five screws (A).
[7] - Remove harness from tie bands (B).
[8] - Remove top cover (C) to access armrest controls.
[9] -
IMPORTANT:
Be careful not to pinch wires during assembly of armrest cover to armrest
body.

Replace Armrest Interface Control Unit (AIC)

[1] -
LEGEND:
A Harnesses
B Screws (2 used)
C AIC
Remove CommandARM™ assembly from seat. (See Remove and Install CommandARM™
Assembly in this group.)
[2] -
IMPORTANT:
AIC board is easily damaged by static electricity. Use a grounding strap
when handling circuit boards. Only handle edges of circuit board. Bending
circuit board will cause damage to chips and circuits.
Disconnect harnesses (A) from AIC.

[3] - Remove screws (B).
[4] - Remove AIC (C) from armrest cover.

Replace Engine Speed Control

[1] -
LEGEND:
1 Knob
2 Control Lever
3 Special Washer
4 Friction Washer
5 Special Washer
6 Bracket
7 Washer
8 Spring
9 Nut
10 Cap Screw
11 Washer
12 Sensor
13 Gear
14 Cap Screw
15 Cap Screw
Remove CommandARM™ assembly (See Remove and Install CommandARM™ Assembly in
this group).
[3] - Remove mounting cap screws from engine speed control.
[4] - Replace control as necessary.
[5] - Tighten nut (9) until friction spring (8) height is 5.0—5.5 mm.

Replace Transmission Control

[1] -
→NOTE:
When removing transmission control assembly, remove engine speed
control assembly at the same time.
LEGEND:
1 Special Screw
2 Circuit Board Cover
3 Shift Lever Guide
4 Spring
5 Circuit Board
6 Transmission Control Bracket
7 Selector

8 Knob
9 E-Clip
10 Washer
11 Spring (Lateral Detent)
12 Pin
13 Pivot Pin
14 Plastic Cover
15 Screws
16 Spring (Lateral Return)
17 Shift Lever Pivot
18 E-Clip
19 Spring (Shift Lever Return)
20 Neutral Start Switch
21 E-Clip
22 Sector Centering Spring
this group).
[3] - Remove mounting cap screws from transmission and engine speed control.
[4] - Remove controls from armrest control assembly.

Replace SCV Control Lever

[1] -
→NOTE:
Potentiometer (I) snaps together with housing (C) for assembly and
disassembly. Use care when removing to prevent damage to potentiometer
and housing.
LEGEND:
A Control Lever
B Tab
C Housing
D Mounting Screw
E Arm
F Spring
G Spring
H Spring
I Potentiometer
J Locking Tab
this group) to access SCV Control Lever.
[2] - Disconnect SCV control harness from armrest control unit.

[3] - Remove mounting cap screws from SCV control.

[4] - Remove control from armrest control assembly.
[5] - Disengage locking tabs (J) and remove potentiometer (I) from housing (C).
[6] - Separate housing (C) at tab (B). Remove control lever (A) through top of housing.
[7] - Remove spring (H).
[8] - Remove spring (G).
[9] - Remove spring (F) and arm (E).
[10] - Assemble in reverse order using the following special instructions:
IMPORTANT: Spring must be installed with correct orientation. Spring

leg with two bends must be installed toward housing (C). If spring is
installed backwards, spring will rub housing.
Install spring (H) as shown.
Install potentiometer. Ensure that guide pin on potentiometer arm is seated in slot of
control lever.
Operate control lever in each direction to verify proper assembly.
[11] - Install switch into armrest control assembly.
Replace Hitch Control

[1] -
LEGEND:
A Hitch Control
this group), to access hitch control.
[2] - Disconnect hitch control harness from armrest control unit.
[3] - Remove mounting cap screws from hitch control.
[4] - Remove switch (A) from armrest control assembly.
Replace Rear PTO Switch

[1] -
LEGEND:
A Rear PTO Switch
this group), to access rear PTO switch.
[2] - Disconnect switch harness from armrest control unit.
[3] - Remove mounting cap screws from switch.
Replace Front PTO Switch

[1] -
→NOTE:
For tractors equipped with right-hand console, see Disassemble Right-Hand
Console in this group.

LEGEND:
A Front PTO Switch
this group), to access front PTO switch.
[3] - Depress tabs and remove switch (A) from armrest control assembly.
Replace ITEC Sequence Switch

[1] -
LEGEND:
A ITEC Sequence Switch
this group), to access ITEC sequence switch.
Replace Resume Switch

[1] -
LEGEND:
A Resume Switch
this group), to access resume switch.

Disassemble Right-Hand Console

[1] -
LEGEND:
A Cab Switch Module
B Connector
[2] - Pull up on control unit (A) to remove from console.
[3] - Disconnect electrical connector (B).

[4] -
LEGEND:
A SCV Control
Remove SCV control (A) and disconnect harness.

[5] -
LEGEND:
A Screws (3 used)
B CommandCenter
C Mount Shield
D Cab Switch Module Extension
Remove screws (A), command center (B), and mount shield (C).
[6] - Remove cab switch module extension (D).

[7] -
LEGEND:
A Cup Holder
B Ash Tray
C Power Plug
Remove cup holder (A), ash tray (B), and power plug (C).
[8] -
LEGEND:
A Screws (8 used)
Remove screws (A) and raise right-hand console (RHC) top panel slightly.
[9] - Remove lower RHC upholstery.
[10] - Identify, label, and disconnect wiring harnesses and remove RHC top panel.

[11] -
LEGEND:
A Screws (4 used)
B Linear Rear Hitch Control Lever
C Gear Shift Toggle Switch
D Front and Rear PTO Switches (2 used)
Remove screws (A) and linear rear hitch control lever (B).
[12] - Depress tabs and remove gearshift toggle switch (C).
[13] - Depress tabs and remove front and rear PTO switches (D), if equipped.
[14] -
LEGEND:
B Bracket Assembly
Remove cap screws (A) and bracket assembly (B).

[15] -
LEGEND:
A Cap Screws and Nuts (4 used)
B Shifting Assembly
Remove cables from shifting assembly. (See Remove and Install Shift Cables in Section 50,
Group 05.)
[16] - Remove cap screws and nuts (A) and shifting assembly (B).

Assemble Right-Hand Console

[1] -
LEGEND:
A Cap Screws and Nuts (4 used)
B Shifting Assembly
Install shifting assembly (B) and cap screws and nuts (A).
[2] - Install shift cables. (See Remove and Install Shift Cables in Section 50, Group 05.)
[3] - Check and adjust shift cables. (See Check And Adjust Shift Cables (PowrQuad™ and
AutoQuad™ Transmissions) in Section 50, Group 05.)

[4] -
LEGEND:
B Bracket Assembly
Install bracket assembly (B) and cap screws (A). Tighten to specification.
Display Mounting Bracket Cap Screws Torque 8 N·m
(70 lb.-in.)
[5] -
LEGEND:
A Screws (4 used)
B Linear Rear Hitch Control Lever
C Gear Shift Toggle Switch
D Front and Rear PTO Switches (2 used)
Install front and rear PTO switches (D), if equipped.
[6] - Install gearshift toggle switch (C).
[7] - Install linear rear hitch control lever (B) and screws (A).

[8] -
LEGEND:
A Screws (8 used)
Ensure that all wiring harnesses are connected.
[9] - Install right-hand console (RHC) lower upholstery.
[10] - Install RHC top panel and screws (A).
[11] -
LEGEND:
A Cup Holder
B Ash Tray
C Power Plug
Install cup holder (A), ash tray (B), and power plug (C).

[12] -
LEGEND:
A Screws (3 used)
B CommandCenter
C Mount Shield
D Cab Switch Module Extension
Install cab switch module extension (D).
[13] - Install mount shield (C), command center (B), and screws (A).

[14] -
LEGEND:
A SCV Control
Connect wiring harness and install SCV control (A).
[15] -
LEGEND:
A Cab Switch Module
B Harness Connector
Connect harness connector (B) and install cab switch module (A).

Section 40 - ELECTRICAL Group 40: Implement and Accessory Connectors
[16] - Calibrate control unit (See Operation and Test TM Section 245, Group CSM.)
[17] - Connect battery ground (-) cable at battery.

Group 40 - Implement and Accessory Connectors

List of References
Replace Seven-Terminal Outlet Socket
Replace GreenStar™ Terminal Connector
Replace Auxiliary Power Strip
Replace Three-Pin Accessory Outlet—Right-Hand Console
Replace Three-Pin Accessory Outlet—Storage Box
Replace and Adjust Field Lights

Replace Seven-Terminal Outlet Socket

[1] -
North American
European
LEGEND:

A Socket
B Terminal
Remove socket (A) from mounting bracket.
[2] - Slide the rubber boot back and disconnect wires by loosening setscrews.
[3] - Attach wires to socket and tighten setscrews. Be sure wires are attached to correct
terminals (B).
[4] - Check power to outlet socket terminals.
North American
Terminal Function Wire Number & Color
1 Ground 010 White
2 Flood Light 109 Black
3 Left Turn 126 Yellow
4 Implement Brake Lights 196 Red
5 Right Turn 195 Red
6 Tail Light 118 Brown
7 Accessory 222 Blue
EUROPEAN
Terminal Function Wire Number & Color
1 Left Turn 126 Lt. Blue
2 Accessory 222 Red
3 Ground 010 Black
4 Right Turn 195 Green
5 Left Tail 128 Gray
6 Brakes 196 Lt. Blue
7 Right Tail 118 Gray
Replace GreenStar™ Terminal Connector

[1] -
LEGEND:
A Implement Connector
B CAN Implement Active Connector
C GREENSTAR™ Terminal Connector
Disconnect connectors (A and B) from GREENSTAR™ Terminal Connector (C).
[2] - Remove connector (C) from bracket.

Replace Auxiliary Power Strip

[1] -
LEGEND:
A Dust Cap
B Retaining Nut
C Screws
D Mounting Plate
[2] - Remove dust cap (A), retaining nut (B), and screws (C).
[3] - Remove mounting plate (D).
[4] -
→NOTE:
Pin (A) provides battery power, pin (B) provides switched power, and pin
(C) is ground.

LEGEND:
A Battery (Circuit 262)
B Switched Power (Circuit 192)
C Ground (Circuit 090)
Replace Three-Pin Accessory Outlet—Right-Hand

Console

[1] -
LEGEND:
A Trim
B Accessory Outlet
[2] - Remove trim (A).
[4] - Remove accessory outlet (B) as necessary.
Replace Three-Pin Accessory Outlet—Storage Box

Section 40 - ELECTRICAL Group 45: Convenience and Accessory Components
[1] -
LEGEND:
A Storage Box
B Accessory Outlet
[2] - Remove storage box (A).
[4] - Remove accessory outlet (B) as necessary.
Replace and Adjust Field Lights

Refer to the Operator′s Manual for the adjustment and replacement of lights.

Group 45 - Convenience and Accessory Components

List of References
Replace Wiper Motor
Replace Windshield Washer Pumps
Replace Circulation Blower Motor
Replace Heating, Ventilating, and Air Conditioning (HVAC) Pressurizer Blower Motor
Test Ground-Fault Circuit Interrupter
Replace Hydraulic Charge Pump Heater
Remove Radio and Speakers
Replace Wiper Motor

[1] -
IMPORTANT:
Sliding roof back too far could damage antenna connections.
→NOTE:
Wiper motor is not repairable.

LEGEND:
A Connector
B Hex Screw
C Mounting Cap Screw
D Motor Shield
E Hex Nut
F Wiper Motor
Remove roof back to access wiper motor.
[2] - Disconnect connector (A) and hex screw (B).
[3] - Remove mounting cap screws (C) and pull wiper assembly through opening in
headliner.
[4] - Remove parts (D—F) and remove wiper motor from linkage assembly.
[5] - Install motor and seal roof.
Replace Windshield Washer Pumps

[1] -
→NOTE:
Washer pumps and reservoir (B) are located behind the battery cover in the
front left-hand corner of cab.
LEGEND:
B Washer Reservoir
C Front Washer Pump
D Rear Washer Pump
Remove battery cover.
[2] - Remove cap screws (A) and washer reservoir (B).
[3] - Disconnect harness and fluid lines from pumps.
White Wire #239W Rear Washer

Gray Wire #238W Front Washer
[4] - Remove and replace pumps (C and D) as necessary.


Replace Circulation Blower Motor

[1] -
→NOTE:
Circulation blower motor is located under green roof on top of cab.
LEGEND:
A Screws
B Green Roof
C Antenna Cable
Remove all screws (A) from top of cab green roof (B).
[2] - Disconnect antenna cable (C).
[3] - Remove green roof (B).
[4] -
LEGEND:
A Blower Motor Connector
B Thermostat Probe
C Socket Head Screw (12 Used)
D Cover
Disconnect blower motor connector (A).

[5] - Disconnect and remove thermostat probe (B).

[6] - Remove socket head screws (C).
[7] - Remove cover (D) with blower motor.
[8] -
LEGEND:
A Tie Bands (2 Used)
B Grommet
C Nuts (4 Used)
D Motor Assembly
E Cover
Remove tie bands (A).
[9] - Remove grommet (B) from cover (E) and remove wire harness from grommet.
[10] - Remove nuts (C).
[11] - Remove motor assembly (D) from cover (E).
[12] - Install parts in reverse order.

Replace Heating, Ventilating, and Air Conditioning

(HVAC) Pressurizer Blower Motor
[1] -
→NOTE:
Pressurizer blower motor is located under green roof on top of cab.
LEGEND:
A Screws
B Green Roof
C Antenna Cable
Remove all screws (A) from top of cab green roof (B).
[3] - Remove green roof (B).
[4] -
LEGEND:
A Harness
B Screws (9 Used)
Disconnect blower motor harness (A).

[5] - Remove screws (B) from cover.

[6] - Remove blower motor assembly from tractor.
[7] -
LEGEND:
A Screws (4 Used)
B Nuts (4 Used)
C Plate
D Grommet
E Blower Motor Assembly
Remove screws (A).
[9] - Remove plate (C) from cover.
[10] - Remove grommet (D).
[11] - Remove blower motor assembly (E).
[12] - Assemble parts in reverse order.
Test Ground-Fault Circuit Interrupter

[1] -
CAUTION:
Use at least a 15-amp extension cord when plugging into ground fault
interrupter to apply power to heaters.
IMPORTANT:
A 110-volt alternating current for ground-fault interrupter must be
grounded correctly.
→NOTE:
All heaters are 110-volt. Ground-fault circuit interrupter (A) senses current
flow, and protects from electrical shock or hazards.
Fault is detected when indicator light continues to go off.
LEGEND:
A Ground-Fault Interrupter
Depress test button before each use. Indicator light should go off.
[2] - Reset interrupter by depressing reset button.
Replace Hydraulic Charge Pump Heater

[1] -
→NOTE:
Charge pump heater is located on lower right-hand side of charge pump
next to hydraulic oil filter near the front of transmission.

LEGEND:
A Heater
Locate and disconnect harness from heater.
[2] - Remove heater (A).
[3] - Replace as necessary.

Remove Radio and Speakers

Remove and Install Radio:
[1] -
LEGEND:
A Assembly
B Connectors
C Nut
D Antenna
Pull bezel assembly (A) towards center of cab.
[2] - Disconnect connectors to courtesy light, remote mirror switch, and rear wiper switch if
equipped.
[3] - Remove bezel.
[4] - Disconnect radio connectors (B).
[5] - Remove nut (C).
[6] - Disconnect antenna (D).

[7] -
→NOTE:
Radio removal tools (A) are supplied with replacement radios.
LEGEND:
A Radio Removal Tools
Install radio removal tools (A) into radio and pull out radio.
Radio Nut Torque 3 N·m
26 lb.-in.
Remove and Install Speakers:

[1] -
LEGEND:
A Bezel Cover
B Mirror
C Sun shade
D Dome Light Assembly
E Coat Hook
F Resonator Port Bezels
G Filter Cover
H Screws
I Headliner
Remove four cab post covers.
[2] -
→NOTE:
Bezel assembly is held in place with clips. Pull straight out on assembly
when removing.
Remove bezel assembly (A) and disconnect switches.

[3] - Remove mirror (B).
[4] - Remove sun shade (C).
[5] - Remove dome light assembly (D) and disconnect light.
[6] - Remove coat hook (E).
[7] - Remove resonator port bezels (F).
[8] - Remove filter cover (G).
[9] - Remove four headliner-to-inner roof screws (H).
[10] - Remove headliner (I).

AUTOQUAD/COMMANDQUAD TRANSMISSION (g) by Belgreen
[11] -
Radio Speakers Installed

LEGEND:
A Speakers
B Screws, M5 x 20
Disconnect cab harness connectors from speakers (A).
[12] - Remove screws (B) and lower speakers from inner roof.

Section 50 - AUTOQUAD/COMMANDQUAD
TRANSMISSION
Table of contents
Other Material ........................................................................................................................ 2
Specifications ......................................................................................................................... 3
Remove Transmission ............................................................................................................ 5
Install Transmission ............................................................................................................. 26
Remove PowrQuad™ ............................................................................................................ 47
Install PowrQuad™ ............................................................................................................... 50
Remove Range Box .............................................................................................................. 54
Install Range Box ................................................................................................................. 57
Remove MFWD Clutch .......................................................................................................... 61
Install MFWD Clutch ............................................................................................................. 67
Group 05 - Transmission Shifting Mechanisms .................................................................. 79
Other Material ...................................................................................................................... 79
Reconditioning Shift Lever ................................................................................................... 80
Repair Range Shift Linkage (PowrQuad™ and AutoQuad™ Transmissions) ......................... 82
Remove and Install Shift Cables ........................................................................................... 84
Check and Adjust Shift Cables (PowrQuad™ and AutoQuad™ Transmissions) ..................... 86
Group 10 - PowrQuad-Plus™ Module .................................................................................... 92
Other Material ...................................................................................................................... 93
Specifications ....................................................................................................................... 94
Remove, Recondition, and Install Transmission Boost Valve ............................................... 99
Remove, Recondition, and Install Cooler Bypass Valve ...................................................... 105
Remove And Install Front Transmission Cover Valves ........................................................ 110
Remove, Recondition, and Install Shift Valve Housing ....................................................... 115
Remove, Recondition, and Install Transmission Front Cover .............................................. 121
Exploded View—Transmission Oil Pump ............................................................................ 129
Remove, Recondition, and Install Transmission Oil Pump .................................................. 131
Exploded View—Planetary Drive ........................................................................................ 138
Remove, Recondition, and Install Gear-Shift Planetary Drive ............................................ 140
Remove, Recondition, and Install B1, B2 Brakes ................................................................ 149
Remove, Recondition, and Install B3 Brakes ...................................................................... 153
Exploded View—C4 Clutch ................................................................................................. 156
Remove, Recondition, and Install C4 Clutch ....................................................................... 158
Exploded View—Reverse Brake .......................................................................................... 168
Remove, Recondition, and Install Reverse Brake ............................................................... 170
Exploded View—Forward Clutch with Planetary Drive ........................................................ 174
Cross Sectional View—Forward Clutch with Planetary Drive .............................................. 176
Remove, Recondition, and Install Forward Clutch With Planetary Drive ............................ 178
Exploded View—Output Shaft ............................................................................................ 188
Replace Output Shaft ......................................................................................................... 189

Group 20 - Range Box (PowrQuad™ and AutoQuad™) .................................................... 191

Other Material .................................................................................................................... 192
Specifications ..................................................................................................................... 193
Install Range Box In Repair Stand ...................................................................................... 195
Disassemble Range Box ..................................................................................................... 197
Repair MFWD Clutch .......................................................................................................... 205
Repair Park Pawl ................................................................................................................ 219
Exploded View—Input Shaft 30 km/h (18 mph) .................................................................. 227
Exploded View—Input Shaft 40 km/h (25 mph) .................................................................. 228
Repair Input Shaft .............................................................................................................. 229
Exploded View—Output Shaft 30 km/h (18 mph) ............................................................... 235
Exploded View—Output Shaft 40 km/h (25 mph) ............................................................... 236
Repair Output Shaft ........................................................................................................... 237
Repair Shift Control Housing .............................................................................................. 242
Repair Rear Cover .............................................................................................................. 246
Install Bearing Cups ........................................................................................................... 252
Install Input/Output Assembly ............................................................................................ 253
Install Shift Forks ................................................................................................................ 257
Install MFWD Clutch ........................................................................................................... 262
Install Rear Cover ............................................................................................................... 268
Install Shift Control Housing ............................................................................................... 268
Install Sensors .................................................................................................................... 269
Group 30 - Range Box (CommandQuad™) ......................................................................... 271
Other Material .................................................................................................................... 272
Specifications ..................................................................................................................... 273
Install Range Box In Repair Stand ...................................................................................... 275
Disassemble Range Box ..................................................................................................... 277
Repair Park Brake .............................................................................................................. 299
Repair Rear Cover .............................................................................................................. 307
Exploded View—Input Shaft 40 km/h (25 mph) ECO and 50 km/h (31mph) ....................... 313
Repair Input Shaft .............................................................................................................. 315
Exploded View—Output Shaft 40 km/h (25 mph) ECO and 50 km/h (31mph) .................... 320
Repair Output Shaft ........................................................................................................... 322
Exploded View—Valve Assembly ........................................................................................ 325
Repair Valve Assembly ....................................................................................................... 327
Exploded View—Shift Control Housing ............................................................................... 331
Repair Shift Control Housing .............................................................................................. 333
Install Bearing Cups ........................................................................................................... 335
Install Input/Output Assembly ............................................................................................ 336
Install Shift Forks ................................................................................................................ 340
Install MFWD Clutch ........................................................................................................... 343
Install Rear Cover ............................................................................................................... 349
Install Valve Assembly ....................................................................................................... 351
Install Sensors .................................................................................................................... 352

Group 00: Component Removal and Installation
TRANSMISSION

List of References
Other Material
Specifications
Remove Transmission
Install Transmission
Remove PowrQuad™
Install PowrQuad™
Remove Range Box
Install Range Box
Remove MFWD Clutch
Install MFWD Clutch
→NOTE:

JDG19 Lifting Eyes
JDG909 Lifting Eyes
JDG2061 Front Adapter
JDG11217 Splitting Stand

TRANSMISSION
JT07211 Rear Differential Support Stand
KJD10539 Support Stand Adapter
Other Material
Number Name Use
• PM38657 (us)
• 17430 Loctite™ (loctite)
• PM37477 (us)
Thread Lock and Sealer (Medium Used to retain cap screws
• PM38621 (canadian)
Strength) and seal surfaces.
• 242Loctite™ (us)

TRANSMISSION
Specifications
Mid-Frame-to-Range Box Cap Screws Torque 500 N·m
(370 lb.-ft.)
Drive Shaft Cap Screws Torque 125 N·m
(92 lb.-ft.)
Front Frame-to-Mid-Frame Crossbar Cap Screws Torque 500 N·m
(370 lb.-ft.)
Mid-Frame-to-Front Frame Cap Screws Torque 500 N·m
(370 lb.-ft.)
Coupler Cap Screws Torque 125 N·m
(92 lb.-ft.)
Rear Hood Support-to-Mid-Frame Cap Screws Torque 320 N·m
(236 lb.-ft.)
Air Trailer Brake Assembly Cap Screws Torque 125 N·m
(92 lb.-ft.)
Air Compressor Cap Screws Torque 128 N·m
(94 lb.-ft.)
Steering Line Bracket Cap Screws Torque 73 N·m
(54 lb.-ft.)
SCV/TLS™ Support Plate Cap Screws Torque 73 N·m
(54 lb.-ft.)
Front Cab Support Cap Screws Torque 600 N·m
(443 lb.-ft.)
Fuel Tank Support Cap Screws Torque 73 N·m
(54 lb.-ft.)
Transmission Drain Plugs Torque 102 N·m
(75 lb.-ft.)
Stabilizer Hitch-to-Differential Case Cap Screws Torque 430 N·m
(317 lb.-ft.)
Drawbar Pin Retainer Cap Screw Torque 70 N·m
(52 lb.-ft.)
Drawbar Front Support-to-Differential Case Cap Screws Torque 430 N·m
(317 lb.-ft.)
Radar Assembly Cap Screw Torque 70 N·m
(52 lb.-ft.)
Shield-to-Chassis Cap Screw Torque 73 N·m
(54 lb.-ft.)
PowrQuad™-to-Range Box Cap Screws Torque 50 N·m

TRANSMISSION
(37 lb.-ft.)
Differential Case-to-Range Box Cap Screws Torque 500 N·m
(370 lb.-ft.)
MFWD Cap Screws Torque 73 N·m
(54 lb.-ft.)
MFWD Clutch End Play 0.013—0.08 mm
(0.0005—0.003 in.)
Retaining Clip Cap Screw Torque 20 N·m
(180 lb.-in.)
U-Joint Cap Screws Torque 60 N·m
(45 lb.-ft.)

TRANSMISSION
Remove Transmission
[1] - Remove front weights or front hitch, if equipped. (See Remove and Install Front 3-Point
Hitch in Section 70, Group 00.)
[2] - For tractors equipped with cab suspension, perform the following:
Relieve cab suspension pressure. (See Depressurize Cab Suspension System in Section
90, Group 35.)
[3] - For tractors equipped with TLS™, perform the following:
Relieve TLS pressure. (See Relieve Pressure From Suspended MFWD Axle Hydraulic
System in Section 59, Group 20.)
[4] - With engine off, depress brake pedals ten times fully releasing between depressions.
[5] - Bleed air brakes. (See Bleed Air from Air Trailer Brake Reservoirs in Section 60, Group
35.)
[6] -
LEGEND:
A Cap Screw
B Cap Screws (2 Used)
If equipped with radar, perform the following:
Loosen cap screw (A).

Remove cap screws (B) and lower radar assembly.
Disconnect connector.

TRANSMISSION
[7] -
LEGEND:
A Retainer Cap Screw
B Retainer
C Pin
Remove parts (A—C).
[8] -
CAUTION:
Drawbar weighs over 28 kg (62 lb.). Use proper lifting equipment to avoid
personal injury.
LEGEND:
A Drawbar
Remove drawbar (A).

TRANSMISSION
[9] -
LEGEND:
A Drawbar Front Support-to-Differential Case Cap Screws (4 used)
B Bracket
C Spacers (2 used)

TRANSMISSION
[10] -
LEGEND:
A Cotter Pin (2 used)
B Pin (2 used)
C Retainer Cap Screw
D Retainer
E Pin
F Drawbar
G Stabilizer-to-Differential Case Cap Screws (14 used)
H Stabilizer Hitch
For tractors equipped with stabilizers, perform the following:
a. Remove cotter pins (A) and pins (B).

b. Remove cap screw (C), retainer (D), and pin (E).
c. Remove drawbar (F).
d. Remove cap screws with washers (G) and stabilizer hitch (H).

TRANSMISSION
[11] -
LEGEND:
A Plugs (3 used)
Remove plugs (A) and drain hydraulic oil.
[12] -
→NOTE:
JDG11217P1 Long Nose Stand, JDG11217P2 Rear Outrigger Support Stand,
and JDG11217P3 Jack Screw are part of JDG11217 Splitting Stand .
Do not tighten cap screws when assembling.
LEGEND:
A JDG11217P3 Jack Screw
B JDG11217P2 Rear Outrigger Support Stand
C JDG2061 Front Adapter
D JDG11217P1 Long Nose Stand

TRANSMISSION
Install JDG11217P3 Jack Screw (A), JDG11217P2 Rear Outrigger Support Stand (B), and
JDG2061 Front Adapter (C) to JDG11217P1 Long Nose Stand (D).
[13] -
→NOTE:
Splitting Stand must be brought in from right side of tractor.
LEGEND:
Attach JDG11217P2 Rear Outrigger Support Stand to the differential case using M20 x 70 mm
cap screws (A).
[14] -
LEGEND:
A Jack Screw
Adjust JDG11217P3 Jack Screw (A) to drawbar support.
[15] - Position JDG2061 Front Adapter under the mid-frame.
[16] - Tighten cap screws on JDG11217 Splitting Stand and JDG2061 Front Adapter.

TRANSMISSION
[17] - Remove intake housing and aspirator. (See Remove and Install Intake Housing and
Remove and Install Aspirator Hose in Section 30, Group 15.)
[19] - Remove rear wheels. (See Operator’s Manual.)
[20] -
→NOTE:
Fuel tank removed for illustration only.
LEGEND:
A Park Lock Cable
B E Range Shift Cable (40K Tractors)
C A—B Range Shift Cable
D C—D Range Shift Cable
For tractors equipped with PowrQuad™ or AutoQuad™ transmissions, perform the
following: Remove cables (A—D).

TRANSMISSION
[22] -
LEGEND:
A Drain Valve
C Shield
Open drain valve (A) and drain fuel into suitable catch container.
[23] - Remove cap screws (B) and shield (C).

TRANSMISSION
[24] -
LEGEND:
B Left-Hand Fuel Tank Support
Remove fuel tanks. (See Remove and Install Left-Hand Fuel Tank and Remove and Install
Right-Hand Fuel Tank in Section 30, Group 10.)
[25] - Remove cap screws (A) and left-hand fuel tank support plate (B).
[26] -
LEGEND:
B Right-Hand Fuel Tank Support
Remove cap screws (A) and right-hand fuel tank support (B).

TRANSMISSION
[27] -
LEGEND:
B Front Cab Support
Remove any wiring harness brackets and clamps attached to front cab support.
[28] - Remove cap screws (A) and front cab support (B).

TRANSMISSION
[29] -
LEGEND:
B Line
C Lines (2 used)
D Front Differential Lock Line
E Lines (2 used)
F Hoses (6 used)
G Cap Screws (2 used)
Remove line clamps (A).
[30] - For tractors equipped with mid-mount SCV, perform the following:
Remove lines (C).

Disconnect hoses (F).

TRANSMISSION
Remove line (B).

Disconnect lines (E).
CAUTION:
Support plate with mid-mount SCVs and TLS™ valves weighs
approximately 22 kg (48.5 lb.).
Remove cap screws (G) and mid-mount SCV/TLS™ support plate.
[32] - For tractors equipped with front differential lock, perform the following:
Remove front differential lock line (D).
[33] -
Steering Line Clamp and Bracket

LEGEND:
B Bracket
Remove cap screws (A) from bracket (B).
[34] -

TRANSMISSION
Air Compressor
LEGEND:
A Hose
B Lines (3 used)

TRANSMISSION
D Lines (5 used)
F Hanger Bolt
G Air Trailer Brake Assembly
For tractors equipped with air trailer brakes, perform the following:
Remove hose (A).

Remove lines (B).
Remove cap screws (C) and compressor.
Identify, label, and disconnect harness from air trailer brake assembly (G).
Disconnect lines (D).
Remove cap screws (E).
Loosen hanger bolt (F).
Lift air trailer brake assembly (G) off hanger bolt and remove.
[35] - If equipped, perform the following:
Remove front brake valve. (See Remove and Install Front Brake Valve in Section 60,
Group 20.)
Remove hydraulic trailer brake valve. (See Remove and Install Hydraulic Trailer Brake
Valve in Section 60, Group 30.)
Remove ActiveCommand Steering (ACS™) valve. (See Remove and Install
ActiveCommand Steering (ACS™) Valve in Section 60, Group 10.)
Remove AutoTrac™ valve. (See Remove and Install AutoTrac™ Valve in Section 60,
Group 10.)
[36] -
LEGEND:
A JT07211 Rear Differential Support Stands (2 used)
B KJD10539 Support Stand Adapter (2 used)
Attach JT07211 Rear Differential Support Stand (A) and KJD10539 Support Stand Adapter (B).

TRANSMISSION
[37] -
LEGEND:
A Rear Hood Support-to-Mid-frame Cap Screws (4 used)
B Shields (2 used)
Remove rear hood support-to-mid-frame cap screws with washers (A) and shields (B).
[38] -
LEGEND:
A Drive Shaft-to-Engine Cap Screws (9 used)
Remove drive shaft-to-engine cap screws (A).

TRANSMISSION
[39] - Remove pump drive housing. (See Remove and Install Pump Drive Housing Section 56,
Group 45.)
[40] - Identify, label, and disconnect remaining wiring harnesses and hydraulic lines.
[41] -

TRANSMISSION
LEGEND:
A Mid-Frame-to-Front Frame Cap Screws (12 used)
B Mid-Frame Cap Screws (2 used)
For tractors not equipped with front hitch, perform the following: Remove cap
screws (B).
[42] - Remove cap screws and washers (A).
[43] -
IMPORTANT:
When tractor is separated MFWD drive shaft remains with engine when
tractor is split. Ensure that drive shaft does not fall or catch while splitting
tractor.
Carefully roll JDG11217 splitting stand rearward.

TRANSMISSION
[44] -
LEGEND:
A Coupler
B Lines (2 used)
C Elbow Fittings (3 used)
[45] -
CAUTION:
Mid-Frame weighs over 176 kg (388 lb.). Use proper lifting equipment to
avoid personal injury.
LEGEND:
A JDG909 Lifting Eyes (4 used)

TRANSMISSION
Attach JDG909 Lifting Eyes (A).

[46] - Use overhead hoist to suspend mid-frame.
[47] -
LEGEND:
A JDG2061 Front Adapter
Position JDG2061 Front Adapter (A) under range box.

TRANSMISSION
[48] -
LEGEND:
Remove all cap screws with washers (A).

TRANSMISSION
[49] -
LEGEND:
A Mid-Frame
Remove mid-frame (A).

TRANSMISSION
Install Transmission
[1] - Install range box. (See Install Range Box in this group.)
[2] - Install PowrQuad™. (See Remove PowrQuad™ in this group.)
[3] -
CAUTION:
Mid-Frame weighs over 176 kg (388 lb.). Use proper lifting equipment to
avoid personal injury.
→NOTE:
Fabricate guide pins as needed by removing heads from M20 x 120 mm cap
screws.
LEGEND:
A Mid-Frame
B Guide Pins (2 used)
Install guide pins (B) to assist with lining up mid-frame.
[4] - Using an overhead hoist, install mid-frame (A).
[5] -

TRANSMISSION
LEGEND:
Install cap screws and washers (A). Tighten to specification.
Mid-Frame-to-Range Box Cap Screws Torque 500 N·m
(370 lb.-ft.)

TRANSMISSION
[6] -
LEGEND:
Use overhead hoist to suspend mid-frame and position JDG2061 Front Adapter (A) under mid-
frame.
[7] -
LEGEND:
Lower mid-frame and detach from overhead hoist.
[8] - Remove JDG909 Lifting Eyes (A).

TRANSMISSION
[9] -
LEGEND:
A Drive Shaft
B Lines (2 used)
C Elbow Fittings (3 used)
Install elbow fittings (C), lines (B), and drive shaft (A). Tighten to specification.
(92 lb.-ft.)
[10] -
Align mid-frame and front frame of tractor.If equipped with MFWD: install MFWD drive
shaft.
[11] -

TRANSMISSION
LEGEND:
Install cap screws and washers (A).

TRANSMISSION
[12] - For tractors not equipped with front hitch, perform the following: Install cap
screws and washers (B) and tighten to specification.
Front Frame-to-Mid-Frame Crossbar Cap Screws Torque 500 N·m
(370 lb.-ft.)
[13] - Tighten cap screws (A) to specification.

(370 lb.-ft.)
[14] -
IMPORTANT:
New torque value must be calculated for use with torque wrench adapters.
(See Use Torque Wrench Adapter in Section 10, Group 10).
LEGEND:
A Coupler Cap Screws (9 used)
Tighten coupler cap screws (A) to specification using JDG861 Torque Wrench Adapter .
Coupler Cap Screws Torque 125 N·m
(92 lb.-ft.)

TRANSMISSION
[15] -
LEGEND:
B Shields (2 used)
Install shields (B) and cap screws with washers (A). Tighten to specification.
Rear Hood Support-to-Mid-Frame Cap Screws Torque 320 N·m
(236 lb.-ft.)

TRANSMISSION
[16] -
LEGEND:
A JT07211 Rear Differential Support Stands (2 used)
B KJD10539 Support Stand Adapter (2 used)
Remove JT07211 Rear Differential Support Stand (A) and KJD10539 Support Stand Adapter
(B).
[17] - Install pump drive housing. (See Remove and Install Pump Drive Housing Section 56,
Group 45.)
Install AutoTrac™ valve. (See Remove and Install AutoTrac™ Valve in Section 60, Group
10.)
Install ActiveCommand Steering (ACS™) valve. (See Remove and Install
Install front brake valve. (See Remove and Install Front Brake Valve in Section 60,
Group 20.)
Install hydraulic trailer brake valve. (See Remove and Install Hydraulic Trailer Brake
[19] -

TRANSMISSION
Air Compressor
LEGEND:
A Hose
B Lines (3 used)

TRANSMISSION
D Lines (5 used)
F Hanger Cap Screw
Install air trailer brake assembly (G) onto hanger cap screw (F).
Install cap screws (E).
Tighten cap screws (E and F) to specification.
(92 lb.-ft.)
Connect lines (D).

Connect harness to air trailer brake assembly.
Install compressor and cap screws (C).
Tighten cap screws to specification.
(94 lb.-ft.)
Install lines (B).

Install hose (A).
[20] -

LEGEND:
B Bracket
Install bracket (B) and cap screws (A).
(54 lb.-ft.)

TRANSMISSION
[22] -
CAUTION:
LEGEND:
B Line
C Lines (2 used)
E Lines (2 used)
F Hoses (6 used)
For tractors equipped with TLS™, perform the following:
Install mid-mount SCV/TLS™ support plate and cap screws (G).


TRANSMISSION
(54 lb.-ft.)
Install line (B).

Connect lines (E).
Install lines (C).

Connect hoses (F).
Install line clamps (A).
Install front differential lock line (D).
[25] -
LEGEND:
B Line
For tractors equipped with a backup pump, perform the following:
Install line (B).

Route backup pump cables forward.
Install shield and cap screws (A).

TRANSMISSION
[26] -
LEGEND:
B Front Cab Support
Attach wiring harness brackets and clamps to front cab support.
[27] - Install front cab support (B) and cap screws (A). Tighten to specification.
(443 lb.-ft.)
[28] - Install hydraulic lines and wiring harnesses.

[29] -
LEGEND:
Install left-hand fuel tank support plate (B) and cap screws (A). Tighten to specification.
(54 lb.-ft.)

TRANSMISSION
[30] -
LEGEND:
Install right-hand fuel tank support (B) and cap screws (A). Tighten to specification.
(54 lb.-ft.)
[31] - Install fuel tanks. (See Remove and Install Left-Hand Fuel Tank and Remove and Install
[33] -
→NOTE:
Fuel tank removed for illustration only.
LEGEND:
A Park Lock Cable
TRANSMISSION

For tractors equipped with PowrQuad™ or AutoQuad™ transmissions, perform the
following: Install cables (A—D).
[34] - Install rear wheels. (See Operator’s Manual.)
[35] -
LEGEND:
Adjust JDG11217P3 jack screw (A) to the lowest position.
[36] -
→NOTE:
Splitting Stand must be removed from the right-hand side of tractor.
JDG11217P2 Rear Outrigger Support Stand is part of JDG11217 Splitting
Stand.
LEGEND:
TRANSMISSION

Remove cap screws (A), JDG11217 Splitting Stand , and JDG2061 Front Adapter from the
drawbar support.
[37] -
LEGEND:
A Transmission Drain Plugs (3 used)
Install plugs (A) and tighten to specification.
(75 lb.-ft.)
[38] -

TRANSMISSION
LEGEND:
A Cotter Pins (2 used)
B Pins (2 used)
D Retainer
E Pin
F Drawbar
H Stabilizer Hitch
a. Install stabilizer hitch (H) and cap screws with washers (G). Tighten to specification.
Stabilizer Hitch-to-Differential Case Cap Screws Torque 430 N·m
(317 lb.-ft.)
b. Install drawbar (F).

c. Install pin (E), retainer (D), and cap screw (C). Tighten to specification.
(52 lb.-ft.)
d. Install pins (B) and cotter pins (A).

TRANSMISSION
[39] -
LEGEND:
B Bracket
C Spacers (2 used)
Install spacers (C), bracket (B), and cap screws (A). Tighten to specification.
Drawbar Front Support-to-Differential Case Cap Screws Torque 430 N·m
(317 lb.-ft.)
[40] -
CAUTION:
Drawbar weighs over 28 kg (62 lb.). Use proper lifting equipment to avoid
personal injury.
LEGEND:
A Drawbar
Install drawbar (A).

TRANSMISSION
[41] -
LEGEND:
A Cap Screw
B Retainer
C Pin
Install pin (C), retainer (B), and cap screw (A). Tighten to specification.
(52 lb.-ft.)

TRANSMISSION
[42] -
LEGEND:
A Cap Screw
Connect radar harness connector.

Install radar assembly and cap screws (B).
Tighten cap screws (A and B) to specification.
Radar Assembly Cap Screw Torque 70 N·m
(52 lb.-ft.)

TRANSMISSION
[43] -
LEGEND:
A Drain Valve
C Shield
Close drain valve (A).
[44] - Install shield (C) and cap screws (B). Tighten to specification.
Shield-to-Chassis Cap Screw Torque 73 N·m
(54 lb.-ft.)
[45] - Install intake housing and aspirator. (See Remove and Install Intake Housing and
Remove and Install Aspirator Hose in Section 30, Group 15.)
[46] - Install exhaust pipe. (See Service Exhaust System in Section 30, Group 30.)
[47] - Install front weights or front hitch, if equipped. (See Remove and Install Front 3-Point
[48] - Fill tractor with hydraulic oil. (See Fill Hydraulic System in Section 70, Group 05.)

TRANSMISSION
Remove PowrQuad™
[1] - Remove transmission. (See Remove Transmission in this group.)
[2] -
Identify, label, and disconnect remaining hydraulic lines.

[3] -
CAUTION:
Module weighs over 181 kg (400 lb.). Use proper lifting equipment when
handling to avoid personal injury.
LEGEND:
A Spacer
B JDG19 Lifting Eyes (2 used)
Install 72 mm (2.835 in.) spacer (A), JDG19 Lifting Eyes (B), and cap screws (C). Attach to
overhead hoist.

TRANSMISSION
[4] -
IMPORTANT:
Do not remove cap screws (B) or plug (C).
LEGEND:
TRANSMISSION

B Support Cap Screws (2 used)
C Plug
[5] -
LEGEND:
A PowrQuad™ Module
B Gasket
Remove PowrQuad™ module (A) and gasket (B).

TRANSMISSION
Install PowrQuad™
[1] - Attach range box to rear differential. (See Install Range Box in this group.)
[2] -
CAUTION:
Module weighs over 181 kg (400 lb.). Use proper lifting equipment when
handling to avoid personal injury.
LEGEND:
A Spacer
Install 72 mm (2.835 in.) spacer (A), JDG19 Lifting Eyes (B), and cap screws (C). Attach to
overhead hoist.

TRANSMISSION
[3] -
LEGEND:
A PowrQuad™
B Gasket
InstallNEW gasket (B).
[4] -
IMPORTANT:
Do not tighten cap screws until PowrQuad™ module is completely installed
onto dowel pins.
Install PowrQuad™ module (A).

[5] -
IMPORTANT:
Do not tighten cap screws (B) or plug (C).

TRANSMISSION
LEGEND:
B Support Cap Screws (2 used)
C Plug
Install cap screws (A) and tighten to specification.
PowrQuad™-to-Range Box Cap Screws Torque 50 N·m
(37 lb.-ft.)

TRANSMISSION
[6] -
LEGEND:
A Spacer
Remove cap screws (C), JDG19 Lifting Eyes (B), and spacer (A).

TRANSMISSION
Remove Range Box

[1] - Remove the PowrQuad™ transmission. (See Remove Transmission and Remove
PowrQuad™ in this group.)
[2] -
LEGEND:
A Coupler
B PTO Shaft
Remove coupler (A) and PTO shaft (B).
[3] -
CAUTION:
Range box weighs over 450 kg (992 lb.). Use proper lifting equipment
when handling to avoid personal injury.

TRANSMISSION
LEGEND:
Install JDG909 lifting eyes (A), JDG19 lifting eyes (B), and attach to overhead hoist.
[4] -
LEGEND:
Remove all cap screws with washers (A).

TRANSMISSION
[5] -
Use overhead hoist to remove range box from rear differential.

TRANSMISSION
Install Range Box

[1] - Clean sealing surfaces and apply PM38657 High Flex Form-In-Place Gasket.
Number Name Use
• PM38657 (us)
[2] -
→NOTE:
Fabricate guide pins as needed by removing heads from M20 x 120 mm cap
screws.
LEGEND:
A Guide Pins (2 used)
Install guide pins (A) to assist in lining up range box.
[3] - Using overhead hoist, install range box to rear differential.

TRANSMISSION
[4] -
LEGEND:
Install cap screws with washers (A) and tighten to specification.
Differential Case-to-Range Box Cap Screws Torque 500 N·m
(370 lb.-ft.)

TRANSMISSION
[5] -
LEGEND:
Detach from overhead hoist and remove lifting eyes (A and B).

TRANSMISSION
[6] -
LEGEND:
A Coupler
B PTO Shaft
Install PTO shaft (B) and coupler (A).

TRANSMISSION
Remove MFWD Clutch
LEGEND:
A Drain Plug
[1] - Disconnect battery ground (—) cable.

[2] - Drain hydraulic oil from drain plug (A).

TRANSMISSION
[3] -
LEGEND:
D Drive Shaft
Remove cap screws (C) and drive shaft (D).

TRANSMISSION
[4] -
LEGEND:
A Line
Remove line (A).

TRANSMISSION
[5] -
MFWD Clutch Cover (Frame Removed for Illustration only)

LEGEND:
B Threaded Studs (2 used)
D Jack Screw Hole Location (2 used)
E MFWD Clutch Cover
F Lines (2 used)
[6] - Remove threaded studs (B) with two nuts tightened together on stud.
[7] - Remove cap screws (C) from cover (E).
[8] - Support MFWD clutch cover (E) and insert cap screws in threaded holes (D) to separate
cover from transmission case.
[9] -
IMPORTANT:
Removing cover requires a second person.
→NOTE:
MFWD clutch and shaft must stay in tractor while removing cover.
Push lines (F) upward and move MFWD clutch cover (E) forward off shaft.

TRANSMISSION
[10] -
LEGEND:
A MFWD Clutch Cover
B Fuel Crossover Hose
C Mid-Frame
Tilt MFWD Clutch cover (A) forward, over fuel crossover hose (B) and tilt out of mid-frame (C).
[11] -
IMPORTANT:
Removing MFWD clutch and shaft requires a second person.
→NOTE:
MFWD clutch and shaft are removed as an assembly.

TRANSMISSION
LEGEND:
A MFWD Clutch Assembly
C Mid-Frame
With assistance, move MFWD clutch assembly (A) over fuel crossover hose (B) and remove
from mid-frame (C).

TRANSMISSION
Install MFWD Clutch
LEGEND:
A MFWD Clutch Assembly
C Mid-Frame
IMPORTANT:
Installing MFWD clutch and shaft requires a second person.
→NOTE:
MFWD clutch and shaft are installed as an assembly.

TRANSMISSION
[1] - With assistance, install MFWD clutch assembly (A) and over fuel crossover hose (B)
through mid-frame (C).
[2] -
LEGEND:
A O-ring
B Cover
Replace O-ring (A) in cover (B).
[3] - Clean sealing surface of differential drive case and apply PM38657 High Flex Form-In-
Place Gasket.
Number Name Use
• PM38657 (us)
Used to seal transmission
• PM38628 (canadian) High Flex Form-In-Place Gasket
housings.
• 17430 Loctite™ (us)
[4] -
IMPORTANT:
Installing cover requires a second person.

TRANSMISSION
LEGEND:
A MFWD Clutch Cover
C Mid-Frame
With assistance, install MFWD Clutch cover (A) through mid-frame (C) and over fuel crossover
hose (B).

TRANSMISSION
[5] -
MFWD Clutch Cover (Frame Removed for Illustration only)

LEGEND:
A Lines (2 used)
B MFWD Clutch Cover
C Shaft
Push lines (A) upward and install MFWD clutch cover (B) over shaft (C).
[6] - Apply PM37477 Thread Lock and Sealer (Medium Strength) to cap screws (D).
Number Name Use
• PM37477 (us)
Thread Lock and Sealer (Medium Used to retain cap screws and
Strength) seal surfaces.
[7] - Install cap screws (D) and tighten to specification.
(54 lb.-ft.)

TRANSMISSION
[8] -
LEGEND:
A Bearing Cup
B Seal Sleeve
C Adjusting Ring
Install bearing cup (A), seal sleeve (B), and adjusting ring (C).
[9] -

TRANSMISSION
LEGEND:
A Cap Screw and Washer
B Pry Bar
C Dial Indicator
D Adjusting Ring
Install cap screw and washer (A) in end of shaft.
[10] - Install Dial indicator (C) on end of shaft.
[11] - Using pry bar (B) force shaft in and out to check end play.
[12] -
IMPORTANT:
Install shim under adjusting ring (D) if end play cannot be adjusted to
specification.
Adjust end play to specification using a brass drift on adjusting ring (D).
MFWD Clutch End Play 0.013—0.08 mm
(0.0005—0.003 in.)

TRANSMISSION
[13] -
LEGEND:
A Cap Screw
B Retainer Clip
C Adjusting Ring
Clean threads and apply PM37477 Thread Lock and Sealer (Medium Strength) to cap screw
(A).
Number Name Use
• PM37477 (us)
[14] - Install retainer clip (B) and cap screw. Tighten to specification.
(180 lb.-in.)

TRANSMISSION
[15] -
LEGEND:
A Line
Replace O-ring at fitting ends and install line (A).

TRANSMISSION
[16] -
LEGEND:
A Drain Plug
Install drain plug (A).
[17] - Fill hydraulic oil. (See Fill Hydraulic System in Section 70, Group 05.)

TRANSMISSION
[18] -
LEGEND:
A Threaded Studs
B Line Clamp
Install threaded studs (A) and line clamps (B).
[19] -

TRANSMISSION
LEGEND:
A Radar Harness Connector
B Radar and Bracket
D Drive Shaft
Install drive shaft (D) and tighten cap screws (C) to specification.
U-Joint Cap Screws Torque 60 N·m
(45 lb.-ft.)
[20] - Install radar and bracket (B) and connect radar harness connector (A).

Group 05: Transmission Shifting Mechanisms
TRANSMISSION
[21] -
LEGEND:
B Skid Plate
Install skid plate (B).
[22] - Connect battery ground (—) cable.

TRANSMISSION
Group 05 - Transmission Shifting Mechanisms

List of References
Reconditioning Shift Lever
Repair Range Shift Linkage (PowrQuad™ and AutoQuad™ Transmissions)
Remove and Install Shift Cables
Check And Adjust Shift Cables (PowrQuad™ and AutoQuad™ Transmissions)
Other Material
Number Name Use
• TY6341 (us) Multi-Purpose SD Polyurea
Used to lubricate synchronizers.
• CXTY6341 (canadian) Grease

TRANSMISSION
Reconditioning Shift Lever

[1] -
PowrQuad™
AutoQuad™
Service procedures are the same for PowrQuad™ and AutoQuad™ shift levers.

TRANSMISSION
[2] -
LEGEND:
A Screws (3 used)
Remove screws (A) and remove half of the grip.
[3] -
LEGEND:
A Circuit Board
B Screws (2 used)
C Grip
Carefully disconnect circuit board (A) from connector.
[4] - Remove screws (B) and pull off grip (C).
[5] - Inspect parts and replace as necessary. Assemble in reverse order.

TRANSMISSION
Repair Range Shift Linkage (PowrQuad™ and

AutoQuad™ Transmissions)
LEGEND:
1 Lever Gear switch
2 Screw
3 Clamp

TRANSMISSION
4 Spring Pins (2 used)

5 Bushings (8 used)
6 Bushings (4 used)
7 Bushings (4 used)
8 Pins (2 used)
9 Snap Rings (8 used)
10 Levers (4 used)
11 Cam Follower
12 Beam (2 used)
13 Bearing Pin
14 Side Walls
15 Extension Springs (4 used)
16 Washers (4 used)
17 Cap Screws (4 used)
18 Washers (2 used)
19 Pin Fastener
20 Retaining Washer
21 Shift Quadrant, Ranges C and D
22 Lever
23 Shift Quadrant, Ranges A and B
24 Washers (2 used)
25 Shift Quadrant (Park Lock) and Park Lock Switch
26 Rivet
27 Cam Follower
[1] - Repair or assemble parts of shift mechanism as required, using illustration as a guide.
[2] -
IMPORTANT:
Tractors equipped with E Range will have an additional lever and shift
quadrant.
For tractors with E range, perform the following: Install additional lever (22) and
quadrant (21).
[3] - Apply TY6341 Multi-Purpose SD Polyurea Grease to all moving parts on bearing pin (13).
Number Name Use
• TY6341 (us) Multi-Purpose SD Polyurea
Used to lubricate synchronizers.
• CXTY6341 (canadian) Grease

TRANSMISSION
Remove and Install Shift Cables

[1] -
LEGEND:
A Park Lock Cable
B A-B Range Shift Cable
C C-D Range Shift Cable
D E-Range Shift Cable (40K Tractors)
E Clips (4 used)
IMPORTANT:
When removing and installing shift cables, be careful not to bend. When
routing cables, be careful that they do not chafe and are not subjected to
tension.
[2] - Shift transmission to NEUTRAL position and remove shift console lower upholstery.

TRANSMISSION
[3] - Identify and label shift cables for reassembly.

[4] - Disconnect cables (A—D) at yoke ends.
[5] - Remove clips (E).
[6] -
Fuel tanks removed for illustration purposes

LEGEND:
A Park Lock Cable
Attach cables (A—D) to transmission as illustrated.

TRANSMISSION
Check and Adjust Shift Cables (PowrQuad™ and

AutoQuad™ Transmissions)
[1] -
CAUTION:
Never adjust shift linkage with engine running. Unexpected tractor
movement may cause injury or death. Switch off ignition and remove key.
→NOTE:
Spring (A) will hold park lever (B) in position during adjustment.
Adjust Quadrants (4-Range Shifter Shown)

LEGEND:
A Spring
B Park Lever
C Shift Quadrants
Checking and Adjusting Range Shifter:
a. Identify and label shift cables.

b. Shift transmission to NEUTRAL position and disconnect shift cables.
c. Loosen cap screws (D).
d. Push quadrants (C) up to end of travel, then move downward 1.5 mm (1/16 in.)
(measured at outer cable pin hole). Tighten cap screws (D).

TRANSMISSION
e.
LEGEND:
A Shift Lever
Move shift lever (A) back and forth in neutral zone (see arrow).
→NOTE:
Additional adjustments may be necessary once cables are
reconnected.
If it is difficult to move shift lever across neutral gate, move shift quadrants down
slightly to improve lateral movement.
[2] -

TRANSMISSION
LEGEND:
A Shift Lever Alignment
B Cable Hole, Range E (Center Hole)
C Cable Hole, Range C and D (Center Hole)
D Cable Hole, Range A and B (Inner Hole)
E Cable Hole, Park Lock (Outer Hole)
F Jam Nut
TRANSMISSION
G Retaining Pin
H Cable Yoke
I Park Lock Lever
J Range A and B Lever
K Range C and D Lever
L Range E Lever
Check and Adjust Shift Cables:
a. Loosen jam nuts (F).

b. Adjust all cable yokes (H) to proper length to align with holes (B—E) while keeping
range levers (I—L) in alignment (A).
c. Tighten jam nuts (F).
→NOTE:
It may be necessary to move shift lever in order to install spring clips.
Spring clips can only be installed in one hole on each lever.

TRANSMISSION
LEGEND:
A Park Lock Cable (Yellow)
B A—B Range Shift Cable (Blue)
C C—D Range Shift Cable (Green)
D E Range Shift Cable (40K Tractors) (Red)
E Clips (4 used)
Install shift cables (A—D).
(A) Yellow—Park Lock, 1st Hole
(B) Blue—A—B Range, 3rd Hole
(C) Green—C—D Range, 2nd Hole
(D) Red—E Range (40K Tractors), 2nd Hole
e. Install clips (E).

f. Check movement of shift lever.
g. Adjust park lock.
[3] -
Park Lock at Transmission

Group 10: PowrQuad-Plus™ Module
TRANSMISSION
Cable in Cab
LEGEND:
A Park Lock Rod
B Castle Nut
C Cotter Pin
D Shift Quadrant (Park Lock)
E Park Lock Cable
F Spring
G Park Lock Stop
H Jam Nut
Adjusting Park Lock:
a. Adjust castle nut (B) until cotter pin (C) can be installed in park lock rod (A) at
transmission.
b. Ensure shift lever is in neutral.
c. Check to ensure spring (F) is pulling shift quadrant (D) to park lock stop (G).
d. Disconnect park lock cable (E).
e. Pull gently on cable yoke so that free play, before actuation of park lock rod, is removed
from cable.
f. Hold cable in this position (free of play) and turn yoke until yoke hole and shift quadrant
(D) are precisely aligned; then install retaining pin and tighten jam nut (H).
g. Check adjustment again.
[4] -
CAUTION:
Ensure there are no persons around or in front of tractor when performing
park brake check.
Checking Park Lock:
a. Drive tractor onto an incline or an uphill slope and stop it there.

b. Shift lever to "PARK" position.
c. Slowly release brake pedal.
CAUTION:
If park lock does not hold, further range box repairs are necessary.
Park lock must engage and tractor must not roll away.

TRANSMISSION
Group 10 - PowrQuad-Plus™ Module

List of References
Other Material
Specifications
Remove, Recondition, and Install Transmission Boost Valve
Remove, Recondition, and Install Cooler Bypass Valve
Remove And Install Front Transmission Cover Valves
Remove, Recondition, and Install Shift Valve Housing
Remove, Recondition, and Install Transmission Front Cover
Exploded View—Transmission Oil Pump
Remove, Recondition, and Install Transmission Oil Pump
Remove, Recondition, and Install Gear-Shift Planetary Drive
Remove, Recondition, and Install B1, B2 Brakes
Remove, Recondition, and Install B3 Brakes
Exploded View—C4 Clutch
Remove, Recondition, and Install C4 Clutch
Exploded View—Reverse Brake
Remove, Recondition, and Install Reverse Brake
Cross Sectional View—Forward Clutch with Planetary Drive
Exploded View—Forward Clutch with Planetary Drive
Remove, Recondition, and Install Forward Clutch With Planetary Drive
Exploded View—Output Shaft
Replace Output Shaft

TRANSMISSION
→NOTE:

D01045AA Disk Set
D01048AA 17-1/2 Ton Hydraulic Puller Set
D01173AA 17-1/2 Ton Mechanical Puller Set
JDG765 Bushing Installer
JDG772 Input Planetary Installation Tool
Other Material
Number Name Use
• PM37477 (us)
Thread Lock and Sealer Used to retain cap screws and seal
(Medium Strength) surfaces.
• L64500 (us) Used to retain cap screws and seal
Thread Lock and Sealer
• 574 Loctite™ (loctite) surfaces.

TRANSMISSION
Specifications
Transmission Oil Temperature Sensor Torque 16 N·m
(142 lb.-in.)
Pressure Regulating Valve Plug Torque 30 N·m
(22 lb.-ft)
Cooling Oil Control Valves And Cooling Valve Plug Torque 20 N·m
(177 lb.-in.)
Front Transmission Cover Cap Screws Torque 15 N·m
(133 lb.-in.)
Transmission Oil Pump-to-Front Transmission Cover Cap Screw Torque 25 N·m
(221 lb.-in.)
C4 Clutch Cover Cap Screw Torque 40 N·m
(29 lb.-ft)
Reverse Brake Housing Cap Screw Torque 50 N·m
(37 lb.-ft)
Boost Control Solenoid Valve Spring Free Length 45.2 mm
(1.77 in.)
Test Length 35 mm at 40—60 N
(1.38 in. at 9—13.5 lb.-force)
Test Length 25 mm at 99 N
(1 in. at 22.3 lb.-force)
Boost Control Valve Solenoid Cap Screw Torque 15 N·m
(133 lb.-in.)
Pressure Regulating Valve Spring Free Length 48 mm
(1.89 in.)
Test Length 35.2 mm at 45—55 N
(1.39 in. at 10—12.4 lb.-force)
(34 lb.-ft.)
Transmission Boost Valve Cap Screw Torque 15 N·m
(133 lb.-in.)
Cooler Control Solenoid Valve Spring Free Length 45.2 mm
(1.77 in.)
(1.38 in. at 9—13.5 lb.-force)
Cooler Control Solenoid Valve Torque 35 N·m

TRANSMISSION
(26 lb.-ft.)
Cooler Bypass Pressure Regulating Valve Spring Free Length 48 mm
(1.89 in.)
(1.39 in. at 10—12.4 lb.-force)
Cooler Bypass Pressure Regulating Valve Plug Torque 33 N·m
(292 lb.-in.)
Cooler Bypass Valve-to-Transmission Cap Screw Torque 50 N·m
(37 lb.-ft.)
Gear-To-Gear Modulation Valve Cover Cap Screw Torque 12 N·m
(106 lb.-in.)
Pressure Regulating Valve Spring Free Length 182.77 mm
(7.20 in.)
Test Length 157.17 mm at 476.8—536.8 N
(6.20 in.) at (107—121 lb.-force)
Clutch Cooling Valve Outer Spring Free Length 28 mm
(1.102 in.)
(.965 in.) at (53—64 lb.-force)
Clutch Cooling Valve Inner Spring Free Length 34.474 mm
(1.36 in.)
(1.39 in.) at (7—9.2 lb.-force)
(.965 in.) at (17.2—21 lb.-force)
Clutch Cooling Valve Plug Torque 20 N·m
(177 lb.-in.)
Pressure Regulating Valve Inner Spring Free Length 50.054 mm
(1.970 in.)
Test Length 32 mm at 15—18.4 N
(1.26 in.) at (3.37—4.14 lb.-force)
Pressure Regulating Valve Outer Spring Free Length 50 mm
(1.97 in.)
(1.26 in.) at (6.74—8.22 lb.-force)
Shift Valve Plate-to-Shift Valve Cap Screw Torque 15 N·m
(133 lb.-in.)
Shift Valve Housing-to-Front Cover Cap Screw Torque 15 N·m
(133 lb.-in.)

TRANSMISSION
Transmission Oil Pump Spring Free Length 43.5 mm
(1.71 in.)
Test Length 21.5 mm at 81.47 N
(.846 in.) at (18.32 lb.-force)
Transmission Oil Pump-to-Front Transmission Cover Screw Torque 25 N·m
(221 lb-in.)
Ring Gear Shield Cap Screw Torque 10 N·m
(89 lb.-in.)
B1 Brake Housing Cap Screw Torque 60 N·m
(44 lb.-ft.)
B3 Piston Plate Socket-head Screw Torque 6 N·m
(53 lb-in.)
C4 Clutch Cover Screw Torque 25 N·m
(221 lb.-in.)
Reverse Brake Housing Cap Screw Torque 50 N·m
(37 lb.-ft.)
Forward Clutch Drum Cap Screw Torque 50 N·m
(37 lb.-ft.)
(7.20 in.)
(6.20 in. at 107—121 lb.-force)
Clutch Cooling Outer Spring Free Length 28 mm
(1.102 in.)
(.965 in. at 53—64 lb.-force)
Clutch Cooling Inner Spring Free Length 34.474 mm
(1.36 in.)
(1.39 in. at 7—9.2 lb.-force)
(.965 in. at 17.2—21 lb.-force)
Four Speed Solenoid 1 Inner Spring Free Length 50 mm
(1.97 in.)
(1.26 in. at 3.37—4.14 lb.-force)
Four Speed Solenoid 1 Outer Spring Free Length 50 mm
(1.97 in.)

TRANSMISSION
(1.26 in. at 6.74—8.22 lb.-force)
Four Speed Solenoid 1 Torque 35 N·m
(26 lb.-ft.)
(1.97 in.)
(1.26 in. at 3.37—4.14 lb.-force)
(1.97 in.)
(1.26 in. at 6.74—8.22 lb.-force)
(26 lb.-ft.)
B3-C4 Shift Valve Spring Free Length 50 mm
(1.97 in.)
(1.26 in. at 3.37—4.14 lb.-force)
B3-C4 Shift Valve Outer Spring Free Length 50 mm
(1.97 in.)
(1.26 in. at 6.74—8.22 lb.-force)
B3-C4 Shift Valve Plug Torque 35 N·m
(26 lb.-ft.)
System 2 Pressure Sensor Torque 16 N·m
(142 lb.-in.)
Clutch Enable Pressure Sensor Torque 16 N·m
(142 lb.-in.)
Clutch Enable Solenoid Cap Screw Torque 25 N·m
(221 lb.-in.)
Forward Clutch Control Valve Spring Free Length 34 mm
(1.34 in.)
(1.02 in. at 10—13.3 lb.-force)
Forward Clutch Control Solenoid Valve Torque 35 N·m
(26 lb.-ft.)
Reverse Brake Valve Spring Free Length 34 mm
(1.34 in.)
(1.02 in. at 10—13.3 lb.-force)

TRANSMISSION
Reverse Brake Solenoid Valve Torque 35 N·m
(26 lb.-ft.)
Lube Surge Relief Valve Spring Free Length 48 mm
(1.89 in.)
(1.50 in. at 21.4—32.6 lb.-force)
(1.18 in. at 48.6 lb.-force)
Lube Surge Relief Valve Plug Torque 33 N·m
(292 lb.-in.)
Cooler Relief Valve Spring Free Length 92.5 mm
(3.64 in.)
(3.22 in. at 40.5—49.5 lb.-force)
Cooler Relief Valve Plug Torque 46 N·m
(34 lb.-ft.)
Front Transmission Cover Cap Screw Torque 15 N·m
(133 lb.-in.)

TRANSMISSION
Remove, Recondition, and Install Transmission

Boost Valve
[1] -
LEGEND:

TRANSMISSION
[2] -
LEGEND:
A Boost Valve Housing
B Gasket
Remove boost valve housing (A) and gasket (B).
[3] -
IMPORTANT:
Repair valve in a clean work area free of dust and dirt. Absolute cleanliness
is essential when working on hydraulic components.
Replace and lubricate all O-rings with clean hydraulic oil when installing
plugs, sensors, and valves.

TRANSMISSION
LEGEND:
A Temperature Sensor
Remove temperature sensor (A).
[4] - Inspect temperature sensor and replace as needed.
[5] - Install temperature sensor and tighten to specification.
(142 lb.-in.)
[6] -
LEGEND:
B Solenoid Valve
C Clamp
D Spool Valve
E Spring
Remove parts (A—E).

TRANSMISSION

Boost Control Solenoid Valve Spring Free Length 45.2 mm
(1.77 in.)
(1.38 in. at 9—13.5 lb.-force)
[8] - Install parts (A—E) and tighten to specification.

Boost Control Valve Solenoid Cap Screws Torque 15 N·m
(133 lb.-in.)
[9] -
LEGEND:
A Plug
B Poppet Valve
C Spring
Remove plug (A), poppet valve (B), and spring (C).

TRANSMISSION

Pressure Regulating Valve Spring Free Length 48 mm
(1.89 in.)
(1.39 in. at 10—12.4 lb.-force)
[11] - Install parts (A—C) and tighten to specification.

(34 lb.-ft.)
[12] -
LEGEND:
A Boost Valve Housing
B Gasket
Install boost valve housing (A) andNEW gasket (B).

TRANSMISSION
[13] -
LEGEND:
Transmission Boost Valve Cap Screws Torque 15 N·m
(133 lb.-in.)

TRANSMISSION
Remove, Recondition, and Install Cooler Bypass

Valve
[1] -
LEGEND:
[2] -
LEGEND:
A Cooler Bypass Valve
B Oil Cooler Lines (2 used)
Remove cooler bypass valve (A) and oil cooler lines (B).

TRANSMISSION
[3] -
IMPORTANT:
Repair valve in a clean work area free of dust and dirt. Absolute cleanliness
is essential when working on hydraulic components.
Replace and lubricate all O-rings when installing plugs, sensors and valves.
LEGEND:
A Solenoid Valve
B Valve Spool
C Spring
Remove solenoid valve (A), valve spool (B), and spring (C).
[4] - Inspect parts and replace as needed.
Cooler Control Solenoid Valve Spring Free Length 45.2 mm
(1.77 in.)
(1.38 in. at 9—13.5 lb.-force)

Cooler Control Solenoid Valve Torque 35 N·m
(26 lb.-ft.)

TRANSMISSION
[6] -
LEGEND:
A Plug
B Spring
C Valve
Remove plug (A), spring (B), and valve (C).
Cooler Bypass Pressure Regulating Valve Spring Free Length 48 mm
(1.89 in.)
(1.39 in. at 10—12.4 lb.-force)

Cooler Bypass Pressure Regulating Valve Plug Torque 33 N·m
(292 lb.-in.)

TRANSMISSION
[9] -
LEGEND:
A Cooler Bypass Valve
B Oil Cooler Lines (2 used)
Lubricate oil cooler lines (B) with clean hydraulic oil and install.
[10] - Install cooler bypass valve (A).

TRANSMISSION
[11] -
LEGEND:
Cooler Bypass Valve-to-Transmission Cap Screw Torque 50 N·m
(37 lb.-ft.)

TRANSMISSION
Remove And Install Front Transmission Cover

Valves
Repair Gear-To-Gear Modulator Valve and Return Valve

TRANSMISSION
[1] -
LEGEND:
B Cover
C Accumulator
D Return Valve
E Spring
F Spring
G Pin
H Modulator Valve
I Spring
J Gasket
Remove cap screws (A—J).

TRANSMISSION
[3] -
→NOTE:
Before installing parts, check that bores are clean and allow through
passage.
Keep all screws and screw holes clean, dry, and free of oil and grease.
Install return valve and cover. Tighten cap screws to specification.

Gear-To-Gear Modulation Valve Cover Cap Screws Torque 12 N·m
(106 lb.-in.)
Repair Pressure Regulating Valve
[1] -
LEGEND:
A Plug
B Shims
C Spring
D Pressure Regulating Valve
Remove parts (A—D).
(7.20 in.)
(6.20 in. at 107—121 lb.-force)
[3] -
→NOTE:
Before installing valve, check that bore is clean and allows through
passage.

TRANSMISSION
Install parts (A—D) and tighten plug (A) to specification.

(34 lb.-ft.)
[4] - Adjust pressure regulating valve (See Diagnostic Manual Section 250, Group 50B.)
Repair Clutch Cooling Valve
[1] -
LEGEND:
A Plug
B Clutch Cooling Spool Valve
C Clutch Cooling Inner Springs (2 used)
D Middle Clutch Cooling Spool Valve
E Clutch Cooling Outer Springs (2 used)
F Reverse Clutch Cooling Spool Valve
Remove parts (A—F).

TRANSMISSION

Clutch Cooling Outer Spring Free Length 28 mm
(1.102 in.)
(.965 in. at 53—64 lb.-force)
Clutch Cooling Inner Spring Free Length 34.474 mm
(1.36 in.)
(1.39 in. at 7—9.2 lb.-force)
(.965 in. at 17.2—21 lb.-force)
[3] -
→NOTE:
passage.
Install parts (A—F) and tighten plug (A) to specification.

Clutch Cooling Valve Plug Torque 20 N·m
(177 lb.-in.)

TRANSMISSION
Remove, Recondition, and Install Shift Valve

Housing
[1] -
LEGEND:
B Valve Housing
Remove cap screws (A) and shift valve housing (B).

TRANSMISSION
[2] -
LEGEND:
A Shift Valve Solenoid
B Shift Valve
C Outer Spring
D Inner Spring
For four speed solenoid 1 perform the following: Remove parts (A—D).
(1.97 in.)
(1.26 in. at 3.37—4.14 lb.-force)
(1.97 in.)
(1.26 in. at 6.74—8.22 lb.-force)
[4] -
→NOTE:
passage.
Install parts (A—E) and tighten to specification.

TRANSMISSION
(26 lb.-ft.)
[5] -
LEGEND:
B Shift Valve
C Outer Spring
D Inner Spring
For four speed solenoid 2 perform the following: Remove parts (A—D).
(1.97 in.)
(1.26 in. at 3.37—4.14 lb.-force)
(1.97 in.)
(1.26 in. at 6.74—8.22 lb.-force)

TRANSMISSION
[7] -
→NOTE:
Before installing solenoid, check that bore is clean and allows through
passage.
Install parts (A—D) and tighten to specification.

(26 lb.-ft.)
[8] -
LEGEND:
B Shift Valve
C Outer Spring
D Inner Spring
E Plug
For B3-C4 shift valve perform the following: Remove parts (A—E).

TRANSMISSION

B3-C4 Shift Valve Spring Free Length 50 mm
(1.97 in.)
(1.26 in. at 3.37—4.14 lb.-force)
B3-C4 Shift Valve Outer Spring Free Length 50 mm
(1.97 in.)
(1.26 in. at 6.74—8.22 lb.-force)
[10] -
→NOTE:
passage.
Install parts (A—E) and tighten to specification.

B3-C4 Shift Valve Plug Torque 35 N·m
(26 lb.-ft.)
[11] -
→NOTE:
Clean all sealing faces and install NEW gaskets.
Keep all screws and bores clean, dry, and free of oil and grease.

TRANSMISSION
LEGEND:
A Housing
B Gasket
C Plate
D Mounting Gasket
Assemble housing (A), gasket (B), and plate (C) with three cap screws (E) and tighten evenly
to specification.
Shift Valve Plate-to-Shift Valve Cap Screw Torque 15 N·m
(133 lb.-in.)
[12] - Install shift valve housing andnew mounting gasket (D). Tighten cap screws evenly to
specification.
Shift Valve Housing-to-Front Cover Cap Screw Torque 15 N·m
(133 lb.-in.)

TRANSMISSION
Remove, Recondition, and Install Transmission

Front Cover
[1] - For CommandQuad™ Transmissions: Remove boost valve housing. (See Remove,
Recondition, and Install Transmission Boost Valve in this group.)
[2] -
LEGEND:
B Front Valve Housing
C Gasket
For PowrQuad™ and AutoQuad™ Transmissions: Remove cap screws (A), front valve
housing (B), and gasket (C).
[3] - Remove cooler bypass valve (See Remove, Recondition, and Install Cooler Bypass Valve
in this group.)

TRANSMISSION
[4] -
LEGEND:
A Front Transmission Cover
B Gasket
For all transmissions perform the following: Remove front transmission cover (A) and
gasket (B).
[5] -
LEGEND:
A Oil seal
Remove oil seal (A).
[7] -
→NOTE:
Driver disk is part of D01045AA Disk Set .
Use 64 mm (2-1/2 in.) driver disk to install oil seal until fully seated.

TRANSMISSION
[8] -
LEGEND:
A System 2 Pressure Sensor
B Clutch Enable Pressure Sensor
Remove system 2 pressure sensor (A) and clutch enable pressure sensor (B).
[10] - Install sensors and tighten to specification.
System 2 Pressure Sensor Torque 16 N·m
(142 lb.-in.)
(142 lb.-in.)
[11] -
LEGEND:
A Cap Screw
B Clamp
C Valve
D O-ring
Remove cap screw (A), clamp (B), valve (C), and O-ring (D).

TRANSMISSION

[13] - Install O-ring (D), valve (C), clamp (B), and cap screw (A). Tighten to specification.
Clutch Enable Solenoid Cap Screw Torque 25 N·m
(221 lb.-in.)
[14] -
LEGEND:
A Solenoid Valve
B Spool
C Spring
Remove forward clutch control solenoid valve (A), spool (B), and spring (C).
Forward Clutch Control Valve Spring Free Length 34 mm
(1.34 in.)
(1.02 in. at 10—13.3 lb.-force)
[16] - Install parts (A—C).

Forward Clutch Control Solenoid Valve Torque 35 N·m
(26 lb.-ft.)

TRANSMISSION
[17] -
LEGEND:
A Solenoid Valve
B Spool
C Spring
Remove reverse brake solenoid valve (A), spool (B), and spring (C).
Reverse Brake Valve Spring Free Length 34 mm
(1.34 in.)
(1.02 in. at 10—13.3 lb.-force)
[19] - Install parts (A—C).

Reverse Brake Solenoid Valve Torque 35 N·m
(26 lb.-ft.)

TRANSMISSION
[20] -
LEGEND:
A Plug
B Spring
C Valve
Lube Surge Relief Valve Spring Free Length 48 mm
(1.89 in.)
(1.50 in. at 21.4—32.6 lb.-force)
(1.18 in. at 48.6 lb.-force)

Lube Surge Relief Valve Plug Torque 33 N·m
(292 lb.-in.)

TRANSMISSION
[23] -
LEGEND:
A Plug
B Spring
C Valve
Cooler Relief Valve Spring Free Length 92.5 mm
(3.64 in.)
(3.22 in. at 40.5—49.5 lb.-force)

Cooler Relief Valve Plug Torque 46 N·m
(34 lb.-ft.)

TRANSMISSION
[26] -
LEGEND:
A Temperature Sensor
For PowrQuad™ and AutoQuad™ Tractors: Remove, inspect, and replace temperature
sensor (A). Tighten to specification.
(142 lb.-in.)
[27] -
LEGEND:
A Front Transmission Cover
B Gasket
For all transmissions perform the following: Install aNEW gasket (B) and front
transmission cover (A).
[28] - Loosely install front transmission cover cap screws.
[29] - Install cooler bypass valve. (See Remove, Recondition, and Install Cooler Bypass Valve
in this group.)

TRANSMISSION
[30] -
LEGEND:
B Temperature Sensor Housing
C Gasket
For PowrQuad™ and AutoQuad™ Transmissions perform the following: Install gasket
(C), temperature sensor housing (B).
[31] - Loosely install cap screws (A).
[32] - For CommandQuad™ Transmissions perform the following: Install transmission
boost valve. (See Remove, Recondition, and Install Transmission Boost Valve in this group.)
[33] - For all transmissions perform the following: Tighten front cover cap screws to
specification in a clockwise direction, starting in the center.
Front Transmission Cover Cap Screws Torque 15 N∙m
(133 lb.-in.)
[34] - After 5 minutes, retighten all cap screws evenly to specification.
Exploded View—Transmission Oil Pump

TRANSMISSION
LEGEND:
A Bushing
B Input Shaft
C Bearing
D Screws (6 used)
E Pump Housing
F Dowel Pins (2 used)
G Drive Gear
H Idler gear
I Air Pump Operating Pin
J Pump Piston
K Rubber Ball
L Lower Spring Retainer
M Spring
N Upper Spring Retainer with O-Ring
O Snap Ring
P Front Transmission Cover

TRANSMISSION
Remove, Recondition, and Install Transmission Oil

Pump
[1] -
LEGEND:
A Snap Ring
[2] -
LEGEND:
Remove screws (A) from transmission oil pump.

TRANSMISSION
[3] -
LEGEND:
A Snap Ring
B Upper Spring Retainer with O-Ring
C Spring
D Lower Spring Retainer
E Rubber Ball
F Piston
G Input Shaft
H Pump Gears
Remove parts (A—H).
[4] - Check parts for wear. Replace as necessary.
Transmission Oil Pump Spring Free Length 43.5 mm
(1.71 in.)
(.846 in.) at (18.32 lb.-force)

TRANSMISSION
[5] -
LEGEND:
A Air Pump Operating Pin
Remove air pump operating pin (A).
[6] -
LEGEND:
A Input Shaft
Check input shaft (A) for wear.

TRANSMISSION
[7] -
LEGEND:
A Bushing
Check bearing bushing (A) of input shaft. Replace as necessary.
[8] - Install new bushing using JDG765 Bushing Installer .
[9] -
→NOTE:
D01045AA Disk Set , D01048AA 17-1/2 Ton Hydraulic Puller Set and
D01173AA 17-1/2 Ton Mechanical Puller Set may be used to replace
bearings.

TRANSMISSION
LEGEND:
A Bearing
Replace bearing (A) as necessary, using a handle and 82.6 mm (3-1/4 in.) pilot disk and
93.7 mm (3-11/16 in.) driver disk. Do not press bearing more than 0.5 mm (0.020 in.) below
surface.

TRANSMISSION
[10] -
LEGEND:
A Air Pump Operating Pin
Install air pump operating pin (A) into manifold.

TRANSMISSION
[11] -
LEGEND:
A Snap Ring
B Upper Spring Retainer with O-Ring
C Spring
D Lower Spring Retainer
E Rubber ball
F Piston
G Input Shaft
H Pump Gears
Install input shaft (G) into manifold.
[12] - Install parts (A—F).
[13] -
IMPORTANT:
Install gears with "Up" facing away from housing. (Chamfered side of gears
toward housing).
Install oil pump gears (H).

TRANSMISSION
[14] -
LEGEND:
A Seal
Install seal (A) until fully seated.
[15] -
LEGEND:
A Screws (6 used)
Install transmission oil pump on front transmission cover. Tighten cap screws (A) to
specification.
Transmission Oil Pump-to-Front Transmission Cover Screw Torque 25 N·m
(221 lb-in.)
[16] - Install front transmission cover. (See Remove, Recondition, and Install Transmission
Front Cover in this group.)
Exploded View—Planetary Drive

TRANSMISSION
LEGEND:
A B1 Brake Housing
B Bushing
C 3rd Sun Gear
D Thrust Washer
E Bushing
F 2nd Sun Gear
G Thrust Washer
H 1st Sun Gear
I Thrust Washer
J Planetary Carrier
K Thrust Washer
L Ring Gear
M Shield
N Thrust Washers (6 used)
O Bearings (6 used)
P Retaining Pins (3 used)
Q Planetary Gears (3 used)
R Spacers (3 used)
S Planetary Shafts (3 used)

TRANSMISSION
Remove, Recondition, and Install Gear-Shift

Planetary Drive
[1] -
LEGEND:
A Shield
B Ring Gear
C Thrust Washer
D Planetary Carrier Assembly
Remove front transmission cover. (See Remove, Recondition, and Install Transmission Front
Cover in this group.)

TRANSMISSION
[2] - Remove shield (A).

[3] - Remove ring rear (B) and thrust washer (C).
[4] - Remove planetary carrier assembly (D).
[5] -
LEGEND:
A Thrust Washer
B 1st Sun Gear
C Thrust Washer
D 2nd Sun Gear
E Thrust Washer
F 3rd Sun Gear
G Thrust Washer
Remove parts (A—G).
[6] - Inspect thrust washers and replace as necessary.
[7] -
→NOTE:
Handle and driver disks are part of D01045AA Disk Set

TRANSMISSION
LEGEND:
A 3rd Sun Gear Bushing
B 2nd Sun Gear Bushing
C Gear Surface
If necessary, replace bushing (A).
[8] - Install bushing (A) flush with surface of gear using a handle, 93.7 mm (3-13/16 in.) pilot
disk, and 109.5 mm (4-5/16 in.) driver disk.
[9] - If necessary, replace bushing (B).
[10] - Install bushing 11.6 mm (.453 in.) below gear surface (C) using a handle and 74.6 mm
(2-15/16 in.) driver disk.

TRANSMISSION
[11] -
LEGEND:
A 1st Sun Gear
B Thrust Washer
Inspect 1st sun gear (A) and thrust washer (B). Replace parts as necessary.
[12] -
IMPORTANT:
Ensure oil passages in planetary shafts (A) are not blocked.
LEGEND:
A Planetary Shafts (3 used)
B Thrust Washers (6 used)
C Bearings (6 used)

TRANSMISSION
D Spacers (3 used)
E Planetary Gears (3 used)
F Retaining Pins (3 used)
G Planetary Carrier
To disassemble planetary shaft (A), first drive retaining pins (F) into shaft (A).
[13] - Remove planetary shafts (A), planetary gears (E), and thrust washers (B) from
planetary carrier (G).
[14] - Remove retaining pins (F) from shafts (A).
[15] - Remove bearings (C) and spacers (D) from planetary gears (E).
[16] - Check individual parts for wear. Replace as necessary.
[17] -
IMPORTANT:
Install retaining pins (F) flush with planetary carrier (G).

[18] -

TRANSMISSION
LEGEND:
A Timing Mark on Planetary Gear
B Timing Mark on Ring Gear
Install planetary carrier assembly into ring gear so timing marks (A and B) are aligned.
[19] -
Turn planetary carrier and ring gear over, ensuring that timing marks remain aligned.
[20] - Install JDG772 Input Planetary Installation Tool (A).
[21] -
IMPORTANT:
Thrust washer (G) must be installed on 1st sun gear. If this washer is
missing, sun gear must be replaced.

TRANSMISSION
LEGEND:
A Thrust Washer
B 3rd Sun Gear
C Thrust Washer
D 2nd Sun Gear
E Thrust Washer
F 1st Sun Gear
G Thrust Washer
Install parts (A—G).
[22] -

TRANSMISSION
LEGEND:
A Ring Gear
B Shield
C Cap Screws
Install ring gear (A) and remove JDG772 Input Planetary Installation Tool .
[23] - Install shield (B).

TRANSMISSION
[24] - Coat threads of cap screws (C) with PM37477 Thread Lock and Sealer (Medium
Strength) and install.
Number Name Use
• PM37477 (us)
[25] - Tighten cap screws to specification.
Ring Gear Shield Cap Screw Torque 10 N·m
(89 lb.-in.)
[26] - Install front transmission cover. (See Remove, Recondition, and Install Transmission
Front Cover in this group.)

TRANSMISSION
Remove, Recondition, and Install B1, B2 Brakes

[1] -
LEGEND:
B Brake Housing
Remove gear-shift planetary drive. (See Remove, Recondition, and Install Gear-Shift
Planetary Drive in this group.)
[2] - Remove cap screws (A).
[3] - Remove brake housing (B).
[4] -
LEGEND:
A Brake Piston
Remove B1 brake piston (A). Replace as necessary.

TRANSMISSION
[5] -
LEGEND:
A B1 Piston Plate
B B1 Disks (2 used)
C B1 Plate
D B1-B2 Separator Plates (2 used)
E B2 Disk
F B2 Piston Plate
G B2 Brake Piston
H Springs (4 used)
Remove, inspect, and replace parts (A—H) as necessary.
[6] -

TRANSMISSION
LEGEND:
A Seal
B O-rings (9 used)
C Oil Return Ports
Remove, inspect, and replace seal (A) and O-rings (B).
[7] - Apply L64500 thread lock and sealer around two oil return ports (C).

TRANSMISSION
[8] -
LEGEND:
Install B1 brake housing and tighten cap screws (A) to specification.
B1 Brake Housing Cap Screw Torque 60 N·m
(44 lb.-ft.)
[9] - Install gear-shift planetary drive. (See Remove, Recondition, and Install Gear-Shift

TRANSMISSION
Remove, Recondition, and Install B3 Brakes

[1] -
LEGEND:
A B2-B3 Brake Housing
Remove B1 brake housing. (See Remove, Recondition, and Install B1, B2 Brakes in this
group.)
[2] - Remove B2-B3 brake housing (A).
[3] -
LEGEND:
A B3 Brake Piston
Remove B3 brake piston (A). Replace as necessary.

TRANSMISSION
[4] -
LEGEND:
A Socket-head Screw (2 used)
B B3 Piston Plate
C B3 Disk
D B3 Plate
E Springs (4 used)
Remove, inspect, and replace parts (A—E) as necessary.
B3 Piston Plate Socket-head Screw Torque 6 N·m
(53 lb.-in.)

TRANSMISSION
[5] -
LEGEND:
A Seal
B O-rings (7 used)
Remove, inspect, and replace seal (A) and O-rings (B).
[6] -
LEGEND:
A Oil Return Port
Apply L64500 thread lock and sealer around oil return port (B).
Number Name Use
• L64500 (us) Used to retain cap screws and seal
Thread Lock and Sealer
• 574 Loctite™ (loctite) surfaces.

TRANSMISSION
[7] -
LEGEND:
B Oil Return Port (2)
Install B2-B3 brake housing (A).
[8] - Apply L64500 thread lock and sealer around two oil return ports (B).
[9] - Install B1 brake housing. (See Remove, Recondition, and Install B1, B2 Brakes in this
group.)
Exploded View—C4 Clutch

TRANSMISSION
LEGEND:
A Thrust Washer
B Bushing
C C4 Clutch Drum
D Pins (6 used)
E Inner Packing
F Outer Packing
G C4 Clutch Piston
H Piston Plate
I Springs (6 used)
J Thrust Washer
K Clutch Hub
L Disk (4 used)
M Clutch Cover
N Cap Screws (6 used)
O Thrust Washer
P Separator Plate
Q Ball (2 used)
R Retainer (2 used)

TRANSMISSION
Remove, Recondition, and Install C4 Clutch

[1] -
LEGEND:
Remove B1 brake housing. (See Remove, Recondition, and Install B1, B2 Brakes in this
group.)
[2] - Remove B2-B3 brake housing (A).
[3] -

TRANSMISSION
LEGEND:
A C4 Clutch
B Thrust Washer
C Sealing Rings (2 used)
Remove C4 clutch (A).
[4] - Remove, inspect, replace, thrust washer (B) and sealing rings (C).
[5] -
IMPORTANT:
Ends of seal rings (A) must be together and staggered from each other.

TRANSMISSION
LEGEND:
A Sealing Rings (2 used)
B Thrust Washer
Install sealing rings (A) and thrust washer (B).
[6] -
LEGEND:
B Cover
Remove cap screws (A) and clutch cover (B).

TRANSMISSION
[7] -
LEGEND:
A Outer Thrust Washer
B Clutch Hub
C Inner Thrust Washer
D Disks (4 used)
E Separator Plates (3 used)
Remove, inspect, and replace parts (A—E) as necessary.

TRANSMISSION
[8] -
LEGEND:
A Springs (6 used)
B Piston Plate
C Pins (6 used)
Remove, inspect, and replace springs (A), piston plate (B), and pins (C) as necessary.

TRANSMISSION
[9] -
LEGEND:
A Piston
B Outer Piston Packing
C Inner Piston Packing
Remove piston (A), outer piston packing (B), and inner piston packing (C) inspect and replace
packings as necessary.
[10] -
→NOTE:
Check valve consists of ball and retainer.
LEGEND:
A Check Valves

TRANSMISSION
Inspect piston check valves (A).

[11] -
LEGEND:
A Bushing
Inspect bushing (A) and replace as necessary.
[12] -
→NOTE:
Handle and driver disks are part of D01045AA Disk Set .
Install bushing flush with surface using a handle, 57 mm (2-1/4 in.) pilot disk, and 67 mm

TRANSMISSION
[13] -
LEGEND:
A Inner Piston Packing
B Outer Piston Packing
C Piston
Install inner piston packing (A) and outer piston packing (B), and inspect and replace
packings as necessary.
[14] - Lightly lubricate packings with clean hydraulic oil and install piston (C).

TRANSMISSION
[15] -
LEGEND:
A Pins (6 used)
B Piston Plate
C Springs (6 used)
Install pins (A), piston plate (B), and springs (C).

TRANSMISSION
[16] -
LEGEND:
A Disks (4 used)
B Separator Plates (3 used)
C Inner Thrust Washer
D Clutch Hub
E Outer Thrust Washer
Install parts (A—E).
[17] -
LEGEND:
B Cover
Install clutch cover (B).

TRANSMISSION
[18] - Apply PM37477 Thread Lock and Sealer (Medium Strength) to cap screws (A).
Number Name Use
• PM37477 (us)
[19] - Install cap screws and tighten to specification.
C4 Clutch Cover Screw Torque 25 N·m
(221 lb.-in.)
[20] -
LEGEND:
A C4 Clutch
Install C4 clutch (A).
[21] - Install B2-B3 brake housing. (See Remove, Recondition, and Install B1, B2 Brakes in
this group.)
[22] - Install B1 brake housing. (See Remove, Recondition, and Install B1, B2 Brakes in this
group.)
Exploded View—Reverse Brake

TRANSMISSION
LEGEND:
A Dowel Pin
B Bearing Bushing
C Seal Ring
D Mounting Cap Screws (6 used)
E Reverse Brake Housing
F Gasket
G Reverse Brake Piston
H Piston Plate
I Reverse Brake Disks (5 used)
J Springs (8 used)
K Separator Plates (4 used)
L Ring Gear
M Pressure Plate

TRANSMISSION
Remove, Recondition, and Install Reverse Brake

[1] -
LEGEND:
B Housing
Remove cap screws (A) and reverse brake housing (B).

TRANSMISSION
[2] -
LEGEND:
A Piston Return Plate
B Brake Disks (5 used)
C Separator Plates (4 used)
Remove piston return plate (A), brake disks (B), and separator plates (C) inspect and replace
as necessary.
[3] -
LEGEND:
A Pressure Plate
B Springs (8 used)
Remove pressure plate (A) and springs (B).

TRANSMISSION
[4] -
LEGEND:
A Brake Piston
Remove brake piston (A) from housing.
[5] - Repair or assemble reverse brake as required. (See Exploded View—Reverse Brake in
this group.)
[6] -
LEGEND:
A Bushing
Check bushing (A) in reverse brake housing. Replace as necessary.
[7] - When installing, turn bushing (A) so that its hole is aligned with hole in housing (see
arrow).

TRANSMISSION
[8] -
→NOTE:
Install new bushing (A) flush using a handle, 94 mm (3-11/16 in.) pilot disk, and 100 mm
[9] -
LEGEND:
Clean sealing surfaces and installnew gasket.
[10] - Install reverse brake housing and tighten cap screws (A) to specification.
Reverse Brake Housing Cap Screws Torque 50 N·m
(37 lb.-ft.)

TRANSMISSION
Exploded View—Forward Clutch with Planetary

Drive
LEGEND:
1 Thrust Washer
2 Planetary Carrier
3 Disk (5 used)
4 Clutch Plate (4 used)
5 Piston Return Spring (12 used)
6 Piston Plate
7 Pin (12 used)
8 Clutch Hub
9 Clutch Piston
10 Seal Ring
11 Seal Ring
12 Thrust Washer
13 Bushing
14 Clutch Drum
15 Screw (6 used)
16 Input Shaft
17 Planetary Drive Housing
18 Thrust Washer
19 Seal Ring (2 used)
20 Snap Ring
21 Bushing
22 Retainer (2 used)
23 Spring (2 used)

TRANSMISSION
24 Ball (2 used)
25 Thrust Washer (12 used)
26 Planetary Gear (6 used)
27 Needle Bearing (12 used)
28 Retaining Pin (6 used)
29 Planetary Shaft (6 used)

TRANSMISSION
Cross Sectional View—Forward Clutch with

Planetary Drive
LEGEND:
A Piston Plate
B Disk (5 used)
C Clutch Plate (4 used)
D Planetary Carrier
E Retaining Pin (6 used)
F Thrust Washer (12 used)
G Planetary Gear (6 used)
H Planetary Shaft (6 used)
I Clutch Hub
J Thrust Washer
K Needle Bearing (12 used)
L Bushing

TRANSMISSION
M Piston Return Spring (12 used)

N Pin (12 used)
O Seal Ring
P Clutch Piston
Q Seal Ring
R Bushing
S Input Shaft
T Snap Ring
U Thrust Washer
V Clutch Drum
W Ball Outlet Valve (2 used)

TRANSMISSION
Remove, Recondition, and Install Forward Clutch

With Planetary Drive
[1] -
LEGEND:
A Ring Gear
Remove reverse brake. (See Remove, Recondition, and Install Reverse Brake in this group.)
[2] - Remove ring gear (A).
[3] -
CAUTION:
LEGEND:
A Forward Clutch
Forward clutch and planetary drive are heavy. Proceed with care and use
proper lifting equipment to avoid injury and damage to parts when lifting
them out.
Remove forward clutch (A) with planetary drive.

TRANSMISSION
[4] -
IMPORTANT:
It is not necessary to remove input shaft unless it is damaged. If shaft is
removed snap ring (A) will be damaged .
LEGEND:
A Snap Ring
Force shaft to rear of clutch and remove snap ring (A).
[5] - Remove input shaft through carrier assembly.
[6] -
LEGEND:
A Snap Ring
Install snap ring (A) on drive shaft.
[7] -
→NOTE:
There is a chamfer on front end of splines in clutch drum to allow shaft with
snap ring to be installed into correct position.

TRANSMISSION
LEGEND:
A Shaft
B Drum Assembly
Force shaft with snap ring (A) into clutch drum assembly (B) from front.
[8] -
LEGEND:
B Planetary Carrier
C Clutch Drum
Remove cap screws (A) from clutch drum.
[9] - Separate planetary carrier (B) from clutch drum (C).

TRANSMISSION
[10] -
LEGEND:
A Clutch Hub
B Return Springs (12 used)
C Bushing
D Snap Ring
Remove clutch hub (A) and return springs (B).
[11] -
→NOTE:
Install bushing (C) flush using a handle and 75 mm (2-15/16 in.) driver disk.
Remove, inspect, and replace bushing (C) and snap ring (D) as necessary.

TRANSMISSION
[12] -
LEGEND:
A Disks (5 used)
B Separator Plates (4 used)
C Piston Plate
D Pins (12 used)
[13] -
LEGEND:
A Spring
Remove traction disk spring (A).

TRANSMISSION
[14] -
LEGEND:
A Clutch Piston
B Outer Packing
C Thrust Washer
D Inner Packing
[15] - Inspect and replace thrust washer (C) and packings (B) and (D) as necessary.
[16] -
→NOTE:
Ball outlet valve consists of ball (A), spring (B), and retainer (C).
LEGEND:
A Balls (2 used)
B Springs (2 used)
C Retainers (2 used)
Remove, inspect, and replace ball outlet valves as necessary.

TRANSMISSION
[17] -
LEGEND:
A Retaining Pins (6 used)
B Shafts (6 used)
Remove planetary shaft retaining pins (A) by driving pins through carrier and into shafts.
[18] - Remove shafts (B).
[19] - Remove retaining pins from shafts.
[20] - Remove planetary gears, thrust washers, and needle bearings from carrier.
[21] - Check individual parts for wear. Replace as necessary.
[22] -
→NOTE:
Install retaining pins (A) flush with planetary carrier.
Reassemble planetary carrier in reverse order.

TRANSMISSION
[23] -
LEGEND:
A Bushing
B Carrier Surface
Inspect ID of bushing (A). Replace as necessary.
[24] -
→NOTE:
Install bushing flush with carrier surface (B) using a handle, 57 mm (2-1/4 in.) pilot disk, and
67 mm (2-5/8 in.) driver disk.
[25] -
IMPORTANT:
Springs (A) must sit in spring recesses (B) when reassembling.

TRANSMISSION
LEGEND:
A Return Springs (12 used)
B Springs Recesses
C Planetary Drive
D Clutch Housing
Assemble clutch in reverse order.
[26] - Install planetary drive (C) onto clutch housing (D).
[27] - Coat threads of cap screws (E) with L41475 (Medium Strength) Thread Lock and
Sealer.
Number Name Use
• L41475 (us)
Oil Resistant Threadlocker (Medium Used to retain cap screws and
• 243 Loctite™
(loctite)
Forward Clutch Drum Cap Screw Torque 50 N·m
(37 lb.-ft.)

TRANSMISSION
[29] -
LEGEND:
A Seal Rings (2 used)
B Thrust Washer
Ensure that seal rings (A) and thrust washer (B) are positioned correctly.
[30] -
CAUTION:
LEGEND:
A Forward Clutch
Assembly is heavy. Use proper lifting equipment to avoid injury and
damage to parts.
IMPORTANT:
Avoid damaging sealing rings.
Install forward clutch (A) with planetary drive.

TRANSMISSION
[31] -
LEGEND:
A Ring Gear
Install ring gear (A).
[32] - Install reverse brake. (See Remove, Recondition, and Install Reverse Brake in this
group.)
Exploded View—Output Shaft
LEGEND:
A Seal Ring
B Transmission Output Shaft
C Bearing Bushing
D O-Ring
E Snap Ring
F Sleeve
G Rear PTO Drive Shaft

Group 20: Range Box (PowrQuad™ and AutoQuad™)
TRANSMISSION
Replace Output Shaft

[1] - Check transmission output shaft, rear PTO drive shaft, sleeve and all components for
wear. Replace as necessary.
LEGEND:
A Sleeve
B Rear PTO Drive Shaft
C Transmission Output Shaft
[2] -
→NOTE:
LEGEND:
A Seal Ring
B O-Ring
C Bushing
D Oil Passage
Press in bushing (C) to a depth of 2 mm (0.079 in.) beneath base of chamfer in transmission
output shaft using a handle, 94 mm (3-11/16 in.) pilot disk, and 100 mm (3-15/16 in.) driver
disk.
[3] - Ensure oil passages (D) of transmission output shaft are open.
TRANSMISSION

TRANSMISSION
Group 20 - Range Box (PowrQuad™ and

AutoQuad™)
List of References
Other Material
Specifications
Install Range Box In Repair Stand
Disassemble Range Box
Repair MFWD Clutch
Repair Park Pawl
Exploded View—Input Shaft 30 km/h (18 mph)
Repair Input Shaft
Exploded View—Output Shaft 30 km/h (18 mph)
Repair Output Shaft
Repair Shift Control Housing
Repair Rear Cover
Install Bearing Cups
Install Input/Output Assembly
Install Shift Forks
Install MFWD Clutch
Install Rear Cover
Install Shift Control Housing

TRANSMISSION
Install Sensors
→NOTE:

D01045AA Disk Set
D05223ST Engine Rollover Stand
JDG754 Spring Compressor
JDG1413 Bearing Cone Installer
JDG11149 IVT Transmission Mounting Fixture
JDG11190 MFWD Adjusting Ring Tool
JDG11240 Mounting Fixture
JDG11241 Lift Fixture Tool
JDG11320 Output Shaft Adjusting Ring Tool
Other Material
Number Name Use
• PM37477 (us)
Thread Lock and Sealer (Medium Used to retain cap screws and seal
Strength) surfaces.
• PM38654 (us)
Thread Lock and Sealer (High Used to retain cap screws and seal
Strength) surfaces.
• PM38657 (us)
• TY6341 (us)
Multi-Purpose SD Polyurea Grease Used to lubricate synchronizers.
• CXTY6341 (canadian)

TRANSMISSION
Specifications
Park Pawl Spring Free Length 62 mm
(2.44 in.)
(1.94 in. at 21—25 lb.-force)
(1.62 in. at 34.2—40.2 lb.-force)
Shaft Retaining Plug Torque 50 N·m
(37 lb.-ft.)
Plug Torque 50 N·m
(37 lb.-ft.)
Valve Cap Screws Torque 10 N·m
(89 lb.-in.)
Rear Cover Lock Nut Torque 150 N·m
(111 lb.-ft.)
Bearing Support Cap Screws Torque 318 N·m
(235 lb.-ft.)
Lubrication Tube Cap Screw Torque 10 N·m
(89 lb.-in.)
Gear Assemblies End Play 0.05—0.20 mm
(0.002—0.007 in.)
Retaining Clip Cap Screws Torque 20 N·m
(180 lb.-in.)
Set Screws Torque 40 N·m
(30 lb.-ft.)
Socket Head Screws Torque 20 N·m
(180 lb.-in.)
MFWD Cover Cap Screws Torque 73 N·m
(54 lb.-ft.)
MFWD Clutch Assembly End Play 0.013—0.08 mm
(0.0005—0.003 in.)
(180 lb.-in.)
Rear Cover Cap Screws Torque 73 N·m
(54 lb.-ft.)
Shift Control Housing Cap Screws Torque 70 N·m
(52 lb.-ft.)
Range Box Speed Sensors Torque 23 N·m

TRANSMISSION
(204 lb.-in.)
Scavenge Inlet Manifold Cap Screw Torque 37 N·m
(27 lb.-ft.)

TRANSMISSION

[1] - Remove transmission from tractor. (See Remove Transmission in Group 00.)
[2] - Remove PowrQuad™. (See Remove PowrQuad™ in this group.)
[3] - Remove range box from differential housing. (See Remove Range Box in this group.)
[4] -
→NOTE:
JDG11149P5 Main Plate is part of JDG11149 IVT Transmission Mounting
Fixture .
Install JDG11149P5 Main Plate to D05223ST Engine Rollover Stand .

[5] -
→NOTE:
JDG11240P1 and JDG11240P2 Attaching Adapters are part of JDG11240
Mounting Fixture .
LEGEND:
B JDG11240P1 Attaching Adapter
C JDG11240P2 Attaching Adapter
D JDG11149P5 Main Plate

TRANSMISSION
Install JDG11240P1 Attaching Adapter (B) and JDG11240P2 Attaching Adapter (C) to
JDG11149P5 Main Plate (D) using cap screws (A).
[6] -
LEGEND:
A JDG11240 Mounting Fixture
Install transmission in JDG11240 Mounting Fixture (A) using overhead hoist.

TRANSMISSION

[1] -
CAUTION:
Range Box weighs over 544 kg (1200 lb.). Use proper lifting equipment
Install range box in stand. (See Install Range Box in Repair Stand in this group.)
[2] -
LEGEND:
A PTO Shaft
Remove PTO shaft (A).
[3] -
LEGEND:
A Differential Drive Shaft Coupler
Remove differential drive shaft coupler (A).

TRANSMISSION
[4] -
LEGEND:
A Range Box Speed Sensors (2 used)
B Cap Screw
C Scavenge Inlet Manifold
Remove range box speed sensors (A), cap screw (B), and scavenge inlet manifold (C).
[5] -
LEGEND:
B Rear Cover
Remove cap screws (A) and rear cover (B).

TRANSMISSION
[6] -
LEGEND:
B MFWD Cover
Remove cap screws (A) and MFWD cover (B).
[7] -
LEGEND:
A O-Ring
B Scavenge Screen
Remove O-ring (A) and scavenge screen (B).

TRANSMISSION
[8] -
LEGEND:
A MFWD Shaft
Remove MFWD shaft (A).
[9] -
LEGEND:
A MFWD Clutch
Remove MFWD clutch (A).

TRANSMISSION
[10] -
LEGEND:
A Thrust Washer
B Bearing Cone
Remove thrust washer (A) and bearing cone (B).
[11] -
LEGEND:
A Socket Head Screws (2 used)
B MFWD Baffle
Remove socket head screws (A) and MFWD baffle (B).

TRANSMISSION
[12] -
LEGEND:
B Shift Control Housing
C Gasket
Remove cap screws (A), shift control housing (B), and gasket (C).
[13] -
LEGEND:
A Springs (3 used)
B Balls (3 used)
C Set Screws (4 used)
Remove springs (A), balls (B), and set screws (C).

TRANSMISSION
[14] -
→NOTE:
Steel balls may fall out when removing shift rails (A).
LEGEND:
A Shift Rails (3 used)
B Shift Forks (3 used)
Remove shift rails (A) and shift forks (B).
[15] -
LEGEND:
A Balls (4 used)
Remove balls (A).

TRANSMISSION
[16] -
LEGEND:
B Bearing Support
Remove cap screws (A) and bearing support (B)..
[17] -
LEGEND:
A JDG11241 Lift Fixture Tool
Install JDG11241 Lift Fixture Tool (A).
[18] - Use overhead hoist to remove gear assemblies and lubrication tube.

TRANSMISSION
Repair MFWD Clutch
LEGEND:
B O-rings (2 used)
C Bearing Cone
[1] - Remove sealing rings (A), O-rings (B), and bearing cone (C).
[2] - Use press to install new bearing cone (C).
[3] - Install sealing rings (A) and O-rings (B).
[4] -
LEGEND:
A Gear
Remove gear (A).

TRANSMISSION
[5] -
LEGEND:
A Bushings (2 used)
Remove bushings (A).
[6] -
→NOTE:
Install bushings (A) flush with outside of gear.
Driver disks are part of D01045AA Disk Set .
LEGEND:
A Bushings (2 used)
Use 57 mm (2-1/4 in.) driver disk to install bushings (A).

TRANSMISSION
[7] -
LEGEND:
A Thrust Washer
B Seal
Remove seal (B) and thrust washer (A).
[8] -
LEGEND:
A JDG754 Spring Compressor
B Snap Ring
Using a press and JDG754 Spring Compressor (A), compress spring and remove snap ring (B).

TRANSMISSION
[9] -
LEGEND:
A Retainer
Remove retainer (A).
[10] -
LEGEND:
A Springs (3 used)
Remove springs (A).

TRANSMISSION
[11] -
LEGEND:
A Piston
Remove piston (A).
[12] -
LEGEND:
A Snap Ring

TRANSMISSION
[13] -
LEGEND:
A Backing Plate
B Clutch Plates (7 used)
C Clutch Disks (8 used)
D Pressure Plate
Remove backing plate (A), clutch plates (B), clutch disks (C), and pressure plate (D).
[14] -
LEGEND:
A Packings (2 used)
Replace packings (A).

TRANSMISSION
[15] -
IMPORTANT:
Clutch plates and disks are a matched set. DO NOT mix plates and disks
with other clutch sets.
→NOTE:
Ensure correct orientation of backing plate (A) and pressure plate (D).
LEGEND:
A Backing Plate
D Pressure Plate
Install backing plate (A), clutch plates (B), clutch disks (C), and pressure plate (D).

TRANSMISSION
[16] -
LEGEND:
A Snap Ring
Install snap ring (A).
[17] -
IMPORTANT:
Install seal with spring side of seal away from gear.
→NOTE:
LEGEND:
A Thrust Washer
B Seal
Install thrust washer (A) and seal (B) flush using a 114 mm (4-1/2 in.) driver disk.

TRANSMISSION
[18] -
LEGEND:
A Gear
Install gear (A).
[19] -
LEGEND:
A Packings (2 used)
B Piston
Lubricate packings (A) with clean hydraulic oil and install piston (B).

TRANSMISSION
[20] -
→NOTE:
Verify springs (A) are indexed properly.
LEGEND:
A Springs (3 used)
Install springs (A).

TRANSMISSION
[21] -
LEGEND:
A Retainer
B JDG754 Spring Compressor
C Snap Ring
Install retainer (A).
[22] - Use JDG754 Spring Compressor (B) and press to install snap ring (C).
[23] -
LEGEND:
A Cap Screw
B Retainer
C Adjusting Ring
Remove cap screw (A) and retainer (B).
[24] - Using a brass drift, remove adjusting ring (C).

TRANSMISSION
[25] -
LEGEND:
A Oil Seal Assembly
Remove oil seal assembly (A).
[26] -
LEGEND:
A Bearing Cup
Remove bearing cup (A).

TRANSMISSION
[27] -
LEGEND:
A Oil Seal
B Seal Carrier Tube
C O-ring
Using a hydraulic press and 65 mm (2-9/16 in.) driver disk, remove oil seal (A) from seal
carrier tube (B).
[28] - Replace O-ring (C).
[30] -
→NOTE:
Install oil seal with spring side down.
LEGEND:
A 65 mm (2-9/16 in.) Driver Disk
B Oil Seal
Using a hydraulic press and 65 mm (2- 9/16 in.) driver disk (A), install oil seal (B).

TRANSMISSION
[31] -
LEGEND:
A Oil Seal Assembly
Lubricate O-ring with clean hydraulic oil and install oil seal assembly (A).
[32] -
LEGEND:
A Bearing Cup
Install bearing cup (A).

TRANSMISSION
Repair Park Pawl

[1] -
LEGEND:
A Plug
B Park Pawl Spring
Remove plug (A) and spring (B).
Park Pawl Spring Free Length 62 mm
(2.44 in.)
(1.94 in. at 21—25 lb.-force)
(1.62 in. at 34.2—40.2 lb.-force)
[3] -
LEGEND:
A Shaft Retaining Plug
Remove shaft retaining plug (A).

TRANSMISSION
[4] -
LEGEND:
A Shaft
Remove shaft (A).
[5] -
LEGEND:
A Parking Pawl
Remove parking pawl (A).

TRANSMISSION
[6] -
LEGEND:
A Bushings (2 used)
[7] -
LEGEND:
A Spring Pin
B Park Arm
C Seal Ring
Remove spring pin (A).
[8] - Remove park arm (B) and seal ring (C).

TRANSMISSION
[9] -
LEGEND:
A Lock Cam
B Thrust Bearing Races (2 used)
C Needle Thrust Bearing
Remove lock cam (A), thrust bearing races (B), and needle thrust bearing (C).
[10] -
LEGEND:
A Spring Pin

TRANSMISSION
[11] -
LEGEND:
A Roller Pin
B Roller
Remove roller pin (A) and roller (B).
[12] - Inspect all parts and replace as necessary.
[13] - Install roller and roller pin.
[14] -
LEGEND:
A Spring Pin
Install spring pin (A).

TRANSMISSION
[15] -
LEGEND:
A Lock Cam
B Thrust Bearing Races (2 used)
C Needle Thrust Bearing
Install thrust bearing races (B) and needle thrust bearing (C).
[16] - Lubricate O-ring with clean hydraulic oil and install lock cam (A).
[17] -
LEGEND:
A Spring Pin
B Park Arm
C Seal Ring
Install park arm (B) and seal ring (C).
[18] - Install spring pin (A).

TRANSMISSION
[19] -
LEGEND:
A Bushings (2 used)
Install bushings (A).
[20] -
LEGEND:
A Parking Pawl
Install parking pawl (A).

TRANSMISSION
[21] -
LEGEND:
A Shaft
Install shaft (A).
[22] -
LEGEND:
A Shaft Retaining Plug
Lubricate O-ring and install shaft retaining plug (A). Tighten to specification.
Shaft Retaining Plug Torque 50 N·m
(37 lb.-ft.)

TRANSMISSION
[23] -
LEGEND:
A Plug
B Spring
Install spring (B).
[24] - Lubricate O-ring and install plug (A). Tighten to specification.
Plug Torque 50 N·m
(37 lb.-ft.)
LEGEND:
1 Seal
TRANSMISSION
2 Snap Ring
3 Bearing Cone
4 Thrust Washer
5 C-Range Gear
6 Sleeve
7 Synchronizer
8 D-Range Gear
9 Sleeve
10 Spacer
11 Input Shaft
12 Bearing Cone
LEGEND:
1 Seal
2 Snap Ring
3 Bearing Cone
4 Thrust Washer
5 C-Range Gear
6 Sleeve
7 Synchronizer
8 D-Range Gear
9 Sleeve
10 Synchronizer
11 E-Range Gear
12 Input Shaft
13 Bearing Cone

TRANSMISSION
Repair Input Shaft

[1] -
→NOTE:
Use exploded view illustrations as a guide to inspect, repair, and assemble
drive shaft as required. (See Exploded View—Input Shaft 30 km/h (18 mph)
or Exploded View—Input Shaft 40 km/h (25 mph) in this group.)
LEGEND:
A Seal
B Snap Ring
Remove seal (A) and snap ring (B).
[2] -
→NOTE:

TRANSMISSION
LEGEND:
B Bearing Cone
Use press and 62 mm (2-7/16 in.) driver disk (A) to remove bearing cone (B) and
components.
[4] -
→NOTE:
Apply TY6341 Multi-Purpose SD Polyurea Grease to synchronizer surfaces
before installation.
Number Name Use
• TY6341 (us)
Multi-Purpose SD Polyurea Used to lubricate
• CXTY6341
Grease synchronizers.
(canadian)

TRANSMISSION
LEGEND:
A Bearing Cone
Use hydraulic press and spacer to install bearing cone (A).
[5] -
LEGEND:
A Spacer
For 30 km/h (18 mph) tractors: Install spacer (A)

TRANSMISSION
[6] -
LEGEND:
A E-Range Gear
For 40 km/h (25 mph) tractors: Install E-range gear (A).
[7] -
LEGEND:
A Synchronizer
For 40 km/h (25 mph) tractors: Install synchronizer (A).

TRANSMISSION
[8] -
LEGEND:
A D-Range Gear
Install D-range gear (A) with sleeve.
[9] -
LEGEND:
A Synchronizer
Install synchronizer (A).

TRANSMISSION
[10] -
LEGEND:
A D-Range Gear
B Thrust Washer
Install D-range gear (A) with sleeve and thrust washer (B).
[11] -
LEGEND:
A Bearing Cone
Use press to install bearing cone (A) until fully seated.
[12] -
→NOTE:
Snap rings (B) are available in various thicknesses. Use thickest snap ring
that fits in groove.

TRANSMISSION
LEGEND:
A Seal
B Snap Ring
Install snap ring (B) and seal (A).
LEGEND:
1 Bearing Cone
2 Spacer
3 C-Range Gear
4 D-Range
5 MFWD Drive Gear
6 Spacer
7 B-Range Gear

TRANSMISSION
8 Sleeve
9 Synchronizer
10 A-Range Gear
11 Output Shaft
12 Bearing Cone
LEGEND:
1 Bearing Cone
2 Spacer
3 C-Range Gear
4 D-Range
5 MFWD Drive Gear
6 E-Range Gear
7 B-Range Gear
8 Sleeve
9 Synchronizer
10 A-Range Gear
11 Output Shaft
12 Bearing Cone

TRANSMISSION
Repair Output Shaft

[1] -
IMPORTANT:
Ensure correct orientation of gears and synchronizer during reassembly.
→NOTE:
Use exploded view illustrations as a guide to inspect, repair, and assemble
drive shaft as required. (See Exploded View—Output Shaft 30 km/h (18
mph) or Exploded View—Output Shaft 40 km/h (25 mph) in this group.)
Use hydraulic press to remove bearing cone and components.

TRANSMISSION
[2] -
LEGEND:
A Bearing Cone
Use press to remove bearing cone (A).
[3] - Inspect and replace bearing cone as necessary.
[4] - Install bearing cone using JDG1413 Bearing Cone Installer and hydraulic press.
[5] -
→NOTE:
Number Name Use
• TY6341 (us)
• CXTY6341
(canadian)
LEGEND:
A A-Range Gear
Install A-range gear (A)

TRANSMISSION
[6] -
LEGEND:
A Synchronizer
[7] -
LEGEND:
A B-Range Gear
Install B-range gear (A) with sleeve.

TRANSMISSION
[8] -
LEGEND:
A Spacer
B MFWD Gear
C D-Range Gear
For 30 km/h (18 mph) tractors: Install spacer (A), MFWD gear (B), and D-range gear (C).
[9] -
LEGEND:
A E-Range Gear
B MFWD Gear
C D-Range Gear
For 40 km/h (25 mph) tractors: Install E-range gear (A), MFWD gear (B), and D-range gear
(C).

TRANSMISSION
[10] -
LEGEND:
A C-Range Gear
Install C-range gear (A).
[11] -
LEGEND:
A Spacer
B Bearing Cone
Install spacer (A).
[12] - Use press to install bearing cone (B) until fully seated.

TRANSMISSION

[1] -
LEGEND:
B Valve
Remove cap screws (A) and valve (B).
[2] -
LEGEND:
A Spring Pins (3 used)
Remove spring pins (A).

TRANSMISSION
[3] -
LEGEND:
A Inner Shift Arms (3 used)
Remove inner shift arms (A).
[4] -
LEGEND:
A Outer Shift Arms (3 used)
B O-Rings (3 used)
Remove outer shift arms (A).
[5] - Replace O-rings (B).
[6] - Lubricate O-rings with clean hydraulic oil and install outer shift arms.

TRANSMISSION
[7] -
LEGEND:
A Inner Shift Arms (3 used)
Install inner shift arms (A).
[8] -
LEGEND:
A Spring Pins (3 used)
Install spring pins (A).

TRANSMISSION
[9] -
LEGEND:
B Valve
Lubricate O-rings with clean hydraulic oil and install valve (B).
[10] - Install cap screws (A) and tighten to specification.
Valve Cap Screws Torque 10 N·m
(89 lb.-in.)

TRANSMISSION
Repair Rear Cover

[1] -
LEGEND:
A Slot
Remove lock nut tab from slot (A).
[2] -
LEGEND:
A Lock Nut
Remove lock nut (A).

TRANSMISSION
[3] -
LEGEND:
A Gear
B Bearing Cone
C Spacer
[4] -
LEGEND:
A Bearing Cone
Remove bearing cone (A).

TRANSMISSION
[5] -
LEGEND:
A Bearing Cups (2 used)
Remove bearing cups (A).
[6] -
→NOTE:
Cones, cups, snap ring, and spacer are a matched set. DO NOT mix with
other bearing sets.

TRANSMISSION
LEGEND:
A Snap Ring
[8] - Install snap ring (A).
[9] -
→NOTE:
LEGEND:
A 76 mm (3 in.) Driver Disk
B Bearing Cups (2 used)
Use 76 mm (3 in.) driver disk (A) to install bearing cups (B) until fully seated.

TRANSMISSION
[10] -
LEGEND:
A Gear
B Bearing Cone
C Spacer
Install parts (A—C).
[11] -
LEGEND:
A Bearing Cone
Install bearing cone (A).

TRANSMISSION
[12] -
LEGEND:
A Lock Nut
Install lock nut (A) and tighten to specification.
Rear Cover Lock Nut Torque 150 N·m
(111 lb.-ft.)
[13] -
LEGEND:
A Slot
Drive lock nut tab into slot (A).

TRANSMISSION

[1] -
LEGEND:
[2] -
→NOTE:
Use 110 mm (4-5/16 in.) and 92 mm (3-5/8 in.) driver disks to install new bearing cups until
fully seated.
[3] -
LEGEND:
A Bearing Cup
[4] - Use 62 mm (2-7/16 in) driver disk to install new bearing cup until fully seated.

TRANSMISSION

[1] -
LEGEND:
Install JDG11241 Lift Fixture Tool (A) to input shaft, output shaft, and lubrication tube.
[2] - Use overhead hoist to install gear assemblies and lubrication tube.
[3] - Remove JDG11241 Lift Fixture Tool.
[4] -
→NOTE:
Bearing cups are slip fit.
LEGEND:
Install bearing cups (A).

TRANSMISSION
[5] -
LEGEND:
A Bearing Support
C Lubrication Tube Cap Screw
Install bearing support (A).
[6] - Apply Loctite™ 242 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (us)
to cap screws (B).
(235 lb.-ft.)
Number Name Use
• PM37477 (us)
to lubrication tube cap screw (C).
[9] - Install lubrication tube cap screw and tighten to specification.
(89 lb.-in.)

TRANSMISSION
[10] -
LEGEND:
A Adjusting Rings (2 used)
B JDG11320 Output Shaft Adjusting Ring Tool
C JDG11190 MFWD Adjusting Ring Tool
Install adjusting rings (A).
[11] - Rotate shafts several revolutions in each direction to seat bearings.
[12] - Install dial indicator as illustrated and record end play.
[13] - Using JDG11320 Output Shaft Adjusting Ring Tool (B) and JDG11190 MFWD Adjusting
Ring Tool (C), adjust end play to specification.
(0.0005—0.003 in.)

TRANSMISSION
[14] -
LEGEND:
A Retainers (2 used)
Apply Loctite™ 242 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (us)
to cap screws (B).
[15] - Install retainers (A) and cap screws (B). Tighten to specification.
(180 lb.-in.)
[16] - Verify end play is within specification.

(0.0005—0.003 in.)

TRANSMISSION
Install Shift Forks

[1] -
LEGEND:
A Shift Fork Clips (2 used)
B A-B Range Shift Fork
Install shift fork clips (A) and A-B range shift fork (B).
[2] -
LEGEND:
A Shift Fork Clips (2 used)
B C-D Range Shift Fork
Install shift fork clips (A) and C-D range shift fork (B).

TRANSMISSION
[3] -
LEGEND:
A E Range Shift Fork
For 40 km/h (25 mph) tractors: Install E range shift fork (A).
[4] -
LEGEND:
A A-B Range Shift Rail
Install A-B range shift rail (A).

TRANSMISSION
[5] -
LEGEND:
A Balls (2 used)
Install balls (A).
[6] -
LEGEND:
A Pin
B C-D Range Shift Rail
For 40 km/h (25 mph) tractors: Install pin (A) into C-D range shift rail (B).
[7] - Install C-D range shift rail.

TRANSMISSION
[8] -
LEGEND:
A Balls (2 used)
For 40 km/h (25 mph) tractors: Install balls (A).
[9] -
LEGEND:
A E Range Shift Rail
For 40 km/h (25 mph) tractors: Install E range shift rail (A).

TRANSMISSION
[10] -
LEGEND:
A Set Screws (4 used)
Number Name Use
• PM38654 (us)
Thread Lock and Sealer (High Used to retain cap screws and
to set screws (A).
[11] - Install set screws (A) and tighten to specification.
(30 lb.-ft.)

TRANSMISSION
Install MFWD Clutch
LEGEND:
B MFWD Baffle
[1] - Install MFWD baffle (B).

[2] - Apply PM37477 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (us)
to socket head screws (A).
[3] - Install socket head screws and tighten to specification.
(180 lb.-in.)

TRANSMISSION
[4] -
LEGEND:
A Thrust Washer
B Bearing Cone
Install bearing cone (B) and thrust washer (A).
[5] -
LEGEND:
A MFWD Clutch
Install MFWD clutch (A).

TRANSMISSION
[6] -
LEGEND:
A MFWD Shaft
Install MFWD shaft (A).
[7] -
LEGEND:
A O-ring
B Scavenge Screen
Install O-ring (A).
[8] - Install scavenge screen (B).

TRANSMISSION
[9] -
LEGEND:
B MFWD Cover
Clean sealing surfaces and apply PM38657 High Flex Form-In-Place Gasket.
Number Name Use
• PM38657 (us)
[10] - Install MFWD cover (B).
Number Name Use
• PM37477 (us)
to cap screws (A).
MFWD Cover Cap Screws Torque 73 N·m
(54 lb.-ft.)

TRANSMISSION
[13] -
LEGEND:
A Adjusting Ring
Install adjusting ring (A) using a brass drift.
[14] - Rotate shaft several revolutions in each direction to seat bearings.
[16] - Using a brass drift, adjust end play to specification.
(0.0005—0.003 in.)

TRANSMISSION
[17] -
LEGEND:
A Cap Screw
B Retainer
C Adjusting Ring
Clean threads and apply PM37477 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (us)
to cap screw (A).
[18] - Align notches of retainer (B) with adjusting ring (C).
[19] - Install cap screw (A) and tighten to specification.
(180 lb.-in.)
[20] - Verify that end play is within specification.

(0.0005—0.003 in.)

TRANSMISSION
Install Rear Cover

[1] -
LEGEND:
A Rear Cover
C Seals (2 used)
Number Name Use
• PM38657 (us)
[2] - Install rear cover (A).
Number Name Use
• PM37477 (us)
to cap screws (B).
[4] - Install cap screws (B) and tighten to specification.
(54 lb.-ft.)
[5] - Replace seals (C).
Install Shift Control Housing

TRANSMISSION
[1] -
LEGEND:
B Shift Control Housing
C Gasket
Install gasket (C) and shift control housing (B).
Shift Control Housing Cap Screws Torque 70 N·m
(52 lb.-ft.)
Install Sensors

Group 30: Range Box (CommandQuad™)
TRANSMISSION
[1] -
LEGEND:
B Cap Screw
C Scavenge Inlet Manifold
Inspect range box speed sensors (A) and replace as needed.
[2] - Install range box speed sensors (A) and tighten to specification.
(204 lb.-in.)
[3] - Install scavenge inlet manifold (C) and cap screw (B). Tighten to specification.
Scavenge Inlet Manifold Cap Screw Torque 37 N·m
(27 lb.-ft.)

TRANSMISSION
Group 30 - Range Box (CommandQuad™)

List of References
Other Material
Specifications
Repair MFWD Clutch
Repair Park Brake
Repair Rear Cover
Exploded View—Input Shaft 40 km/h (25 mph) ECO and 50 km/h (31mph)
Repair Input Shaft
Exploded View—Output Shaft 40 km/h (25 mph) ECO and 50 km/h (31mph)
Repair Output Shaft
Exploded View—Valve Assembly
Repair Valve Assembly
Exploded View—Shift Control Housing
Install Shift Forks
Install MFWD Clutch
Install Rear Cover
Install Valve Assembly

TRANSMISSION
Install Sensors
→NOTE:

D01045AA Disk Set
JDG11219 Park Brake Installation Tool
Other Material
Number Name Use
• PM37477 (us)
Thread Lock and Sealer (Medium Used to retain cap screws and seal
Strength) surfaces.
• PM38654 (us)
Thread Lock and Sealer (High Used to retain cap screws and seal
Strength) surfaces.
• PM38657 (us)
• TY6341 (us)
Multi-Purpose SD Polyurea Grease Used to lubricate synchronizers.

TRANSMISSION
Specifications
Park Brake Cap Screws Torque 318 N·m
(235 lb.-ft.)
Lock Nut Torque 150 N·m
(111 lb.-ft.)
Valve Mounting Plate Cap Screws Torque 10 N·m
(89 lb.-in.)
Transmission Oil Pressure Sensor Torque 16 N·m
(142 lb.-in.)
Valve Assembly Drain Plug Spring Free Length 18.5 mm
(0.73 in.)
(0.63 in. at 1 lb.-force)
Valve Assembly Drain Plug Torque 20 N·m
(177 lb.-in.)
Shift Valve Springs Free Length 50 mm
(2 in.)
Test Length 32 mm at 16.7 N
(1.3 in. at 3.8 lb.-force)
Outer Springs Free Length 50 mm
(2 in.)
(1.3 in. at 6.7—8.2 lb.-force)
Range Solenoid Valve Torque 35 N·m
(26 lb.-ft.)
(89 lb.-in.)
(235 lb.-ft.)
(89 lb.-in.)
(0.0005—0.003 in.)
(180 lb.-in.)
Actuator Plug Torque 130 N·m
(96 lb.-ft.)

TRANSMISSION
(30 lb.-ft.)
(180 lb.-in.)
(54 lb.-ft.)
(0.0005—0.003 in.)
(180 lb.-in.)
(54 lb.-ft.)
Valve Manifold Cap Screws Torque 35 N·m
(26 lb.-ft.)
(204 lb.-in.)

TRANSMISSION

[1] - Remove range box from differential housing. (See Remove Range Box in Group 00.)
[2] -
→NOTE:
JDG11149P5 Main Plate is part of JDG11149 IVT Transmission Mounting
Fixture .

[3] -
→NOTE:
JDG11240P1 and JDG11240P2 Attaching Adapters are part of JDG11240
Mounting Fixture .
LEGEND:
B JDG11240P1 Attaching Adapter
C JDG11240P2 Attaching Adapter
Use cap screws (A) to install JDG11240P1 Attaching Adapter (B) and JDG11240P2 Attaching
Adapter (C) to JDG11149P5 Main Plate (D).

TRANSMISSION
[4] -
LEGEND:
A JDG11240 Mounting Fixture
Use overhead hoist to install transmission in JDG11240 Mounting Fixture (A).

TRANSMISSION

[1] -
CAUTION:
Range Box weighs over 544 kg (1200 lb.). Use proper lifting equipment
Install range box in stand. (See Install Range Box in Repair Stand in this group.)
[2] -
LEGEND:
Remove range box speed sensors (A).
[3] -
LEGEND:
B Valve Manifold
C Gasket
Remove cap screws (A), range box valve manifold (B), and valve gasket (C).

TRANSMISSION
[4] -
LEGEND:
B Valve Cover
C Packing
Remove cap screws (A), valve cover (B), and packing (C).
[5] -
LEGEND:
A PTO Shaft
Remove PTO shaft (A).

TRANSMISSION
[6] -
LEGEND:
B MFWD Cover
Remove cap screws (A) and MFWD cover (B).
[7] -
LEGEND:
A O-Ring
B Scavenge Screen
Remove O-ring (A) and scavenge screen (B).

TRANSMISSION
[8] -
LEGEND:
A MFWD Shaft
Remove MFWD shaft (A).
[9] -
LEGEND:
A MFWD Clutch
Remove MFWD clutch (A).

TRANSMISSION
[10] -
LEGEND:
A Thrust Washer
B Bearing Cone
Remove thrust washer (A) and bearing cone (B).
[11] -
LEGEND:
B MFWD Baffle
Remove socket head screws (A) and MFWD baffle (B).

TRANSMISSION
[12] -
LEGEND:
B Rear Cover
Remove cap screws (A) and rear cover (B).
[13] -
LEGEND:
Remove set screws (A).

TRANSMISSION
[14] -
LEGEND:
A Plug
B A-B Shift Rail Assembly
C Shift Fork
Remove actuator plug (A), A-B shift rail assembly (B), and shift fork (C).
[15] -
LEGEND:
A Plugs (2 used)
B C-D Shift Rail Assembly
C E Shift Rail Assembly
D Shift Forks (2 used)
Remove actuator plugs (A).
[16] - Remove C-D shift rail assembly (B) and E shift rail assembly (C).
[17] - Remove shift forks (D).

TRANSMISSION
[18] -
LEGEND:
B Bearing Support
Remove cap screws (A) and bearing support (B).
[19] -
LEGEND:
Install JDG11241 Lift Fixture Tool (A).
[20] - Use overhead hoist to remove gear assemblies and lubrication tube.

TRANSMISSION
Repair MFWD Clutch
LEGEND:
B O-rings (2 used)
C Bearing Cone
[1] - Remove sealing rings (A) and O-rings (B).

[2] - Remove bearing cone (C).
[4] - Use press to install new bearing cone (C).
[5] - Install sealing rings (A) and O-rings (B).
[6] -
LEGEND:
A Gear
Remove gear (A).

TRANSMISSION
[7] -
LEGEND:
A Bushings (2 used)
[8] -
→NOTE:
Install bushings (A) flush with outside of gear.
LEGEND:
A Bushings (2 used)
Use 57 mm (2-1/4 in.) driver disk to install bushings (A).

TRANSMISSION
[9] -
LEGEND:
A Thrust Washer
B Seal
Remove thrust washer (A) and seal (B).
[10] -
LEGEND:
B Snap Ring
Use JDG754 Spring Compressor (A) and press to remove snap ring (B).

TRANSMISSION
[11] -
LEGEND:
A Retainer
Remove retainer (A).
[12] -
LEGEND:
A Springs (3 used)
Remove springs (A).

TRANSMISSION
[13] -
LEGEND:
A Piston
Remove piston (A).
[14] -
LEGEND:
A Snap Ring

TRANSMISSION
[15] -
LEGEND:
A Backing Plate
D Pressure Plate
Remove backing plate (A), clutch plates (B), clutch disks (C), and pressure plate (D).
[16] -
LEGEND:
A Seals (2 used)
Replace seals (A).

TRANSMISSION
[17] -
IMPORTANT:
→NOTE:
Ensure correct orientation of backing plate (A) and pressure plate (D).
LEGEND:
A Backing Plate
D Pressure Plate
Install backing plate (A), clutch plates (B), clutch disks (C), and pressure plate (D).

TRANSMISSION
[18] -
LEGEND:
A Snap Ring
[19] -
LEGEND:
A Thrust Washer
Install thrust washer (A).

TRANSMISSION
[20] -
LEGEND:
A Gear
Install gear (A).
[21] -
LEGEND:
A Seals (2 used)
B Piston
Lubricate seals (A) with clean hydraulic oil and install piston (B).

TRANSMISSION
[22] -
→NOTE:
Ensure correct orientation of springs (A).
LEGEND:
A Springs (3 used)

TRANSMISSION
[23] -
LEGEND:
A Retainer
B JDG754 Spring Compressor
C Snap Ring
Install retainer (A).
[24] - Use JDG754 Spring Compressor (B) and press to install snap ring (C).
[25] -
LEGEND:
A Cap Screw
B Retainer
C Adjusting Ring
Remove cap screw (A) and retainer (B).
[26] - Using a brass drift, remove adjusting ring (C).

TRANSMISSION
[27] -
LEGEND:
A Oil Seal Assembly
Remove oil seal assembly (A).
[28] -
LEGEND:
A Bearing Cup

TRANSMISSION
[29] -
LEGEND:
A Oil Seal
B Seal Carrier Tube
C O-ring
Use hydraulic press and 65 mm (2-9/16 in.) driver disk to remove oil seal (A).
[30] -
LEGEND:
B Oil Seal
Use hydraulic press and 65 mm (2- 9/16 in.) driver disk (A) to install oil seal (B).
[31] - Replace O-ring (C).

TRANSMISSION
[33] -
LEGEND:
A Oil Seal Assembly
Install oil seal assembly (A).
[34] -
LEGEND:
A Bearing Cup
Install bearing cup (A).

TRANSMISSION
Repair Park Brake

[1] -
CAUTION:
Park brake is under spring tension. Use caution when removing cap
screws.
LEGEND:
B Park Brake Assembly
Evenly remove cap screws (A) and park brake assembly (B).
[2] -
LEGEND:
A Spacer
Remove park brake spacer (A).

TRANSMISSION
[3] -
LEGEND:
A Springs (2 used)
Remove springs (A).
[4] -
LEGEND:
A Gear
B Thrust Washer
Remove gear (A) and thrust washer (B).

TRANSMISSION
[6] -
LEGEND:
A Pressure Plate
Remove pressure plate (A), clutch plates (B), and clutch disks (C).
[7] -
LEGEND:
A Piston
Remove piston (A).
[9] - Lubricate with clean hydraulic oil and install piston.

TRANSMISSION
[10] -
LEGEND:
A Gear
Install gear (A).
[11] -
IMPORTANT:
LEGEND:
A Pressure Plate

TRANSMISSION
Install pressure plate (A), clutch plates (B), and clutch disks (C).
[12] -
IMPORTANT:
Ensure correct orientation of springs (A).
LEGEND:
A Springs (2 used)
[13] -
IMPORTANT:
Ensure both dowel pins (B) contact spring surfaces (C) to prevent spring
tabs from rotating away from each other.

TRANSMISSION
LEGEND:
A Park Brake Spacer
B Dowel Pins (2 used)
C Spring Surfaces
Install park brake spacer (A).
[14] -
LEGEND:
A JDG11219 Park Brake Tool
Install JDG11219 Park Brake Installation Tool (A).

TRANSMISSION
[15] -
LEGEND:
A Park Brake Assembly
Install park brake assembly (A).
[16] - Apply Loctite™ 271 Thread Lock and Sealer (High Strength)
Number Name Use
• PM38654 (us)
to cap screws (B).
[17] - Install cap screws (B) and tighten to specification.
Park Brake Cap Screws Torque 318 N·m
(235 lb.-ft.)

TRANSMISSION
[18] -
LEGEND:
A JDG11219 Park Brake Installation Tool
Remove JDG11219 Park Brake Installation Tool (A).

TRANSMISSION
Repair Rear Cover

[1] -
→NOTE:
Remove Parking Brake before beginning. Refer to Repair Park Brake in this
group, for removal and installation procedures.
LEGEND:
A Slot
[2] -
LEGEND:
A Lock Nut
Remove lock nut (A).

TRANSMISSION
[3] -
LEGEND:
A Gear
B Bearing Cone
C Spacer
Remove gear (A), bearing cone (B), and spacer (C).
[4] -
LEGEND:
A Bearing Cone

TRANSMISSION
[5] -
LEGEND:

TRANSMISSION
[6] -
LEGEND:
A Snap Ring
[8] -
→NOTE:
Cones, cups, snap ring, and spacer are a matched set. DO NOT mix with
other bearing sets.
LEGEND:
A Snap Ring
[9] -
→NOTE:

TRANSMISSION
LEGEND:
A 76 mm (3 in.) Driver Disk
Use 76 mm (3 in.) driver disk (A) to install bearing cups (B) until fully seated.

TRANSMISSION
[10] -
LEGEND:
A Gear
B Bearing Cone
C Spacer
Install spacer (C), bearing cone (B), and gear (A).
[11] -
LEGEND:
A Bearing Cone

TRANSMISSION
[12] -
LEGEND:
A Lock Nut
Install lock nut (A) and tighten to specification.
Lock Nut Torque 150 N·m
(111 lb.-ft.)
[13] -
LEGEND:
A Slot
Drive lock nut tab into slot (A).
Exploded View—Input Shaft 40 km/h (25 mph) ECO

and 50 km/h (31mph)

TRANSMISSION
LEGEND:
1 Seal
2 Snap Ring
3 Bearing Cone
4 Thrust Washer
5 C-Range Gear
6 Sleeve
7 Synchronizer
8 D-Range Gear
9 Sleeve
10 Synchronizer
11 E-Range Gear
12 Input Shaft
13 Bearing Cone

TRANSMISSION
Repair Input Shaft

[1] -
LEGEND:
A Seal
B Snap Ring
[2] -
→NOTE:
LEGEND:

TRANSMISSION
B Bearing Cone
Use press and 62 mm (2-7/16 in.) driver disk (A) to remove bearing cone (B) and
components.
[4] -
→NOTE:
Number Name Use
• TY6341 (us)
• CXTY6341
(canadian)
LEGEND:
A Bearing Cone
Use press to replace bearing cone (A).

TRANSMISSION
[5] -
LEGEND:
A E-Range Gear
Install E-range gear (A).
[6] -
LEGEND:
A Synchronizer

TRANSMISSION
[7] -
LEGEND:
A D-Range Gear
Install D-range gear (A) with sleeve.
[8] -
LEGEND:
A Synchronizer

TRANSMISSION
[9] -
LEGEND:
A D-Range Gear
B Thrust Washer
Install D-range gear (A) with sleeve and thrust washer (B).
[10] -
LEGEND:
A Bearing Cone
[11] -
→NOTE:
Snap ring (B) is available in various thicknesses. Use thickest snap ring
that fits in groove.

TRANSMISSION
LEGEND:
A Seal
B Snap Ring
Install snap ring (B) and seal (A).
Exploded View—Output Shaft 40 km/h (25 mph) ECO

and 50 km/h (31mph)
LEGEND:
1 Bearing Cone
2 Spacer
3 C-Range Gear
4 D-Range
5 MFWD Drive Gear
6 E-Range Gear
TRANSMISSION
7 B-Range Gear
8 Sleeve
9 Synchronizer
10 A-Range Gear
11 Output Shaft
12 Bearing Cone

TRANSMISSION
Repair Output Shaft

[1] -
IMPORTANT:
Ensure correct orientation of gears and synchronizer during reassembly.
Remove bearing cone and components using hydraulic press.

[2] -
LEGEND:
A Bearing Cone
[3] - Use press to install bearing cone (A).

TRANSMISSION
[4] -
→NOTE:
Number Name Use
• TY6341 (us)
• CXTY6341
(canadian)
LEGEND:
A A-Range Gear
Install A-range gear (A).
[5] -
LEGEND:
A Synchronizer

TRANSMISSION
[6] -
LEGEND:
A B-Range Gear
Install B-range gear (A) with sleeve.
[7] -
LEGEND:
A E-Range Gear
B MFWD Gear
C D-Range Gear
Install E-range gear (A), MFWD gear (B), and D-range gear (C).

TRANSMISSION
[8] -
LEGEND:
A C-Range Gear
Install C-range gear (A).
[9] -
LEGEND:
A Spacer
B Bearing Cone
Install spacer (A).
[10] - Use press to install bearing cone (B) until fully seated.
Exploded View—Valve Assembly

TRANSMISSION
LEGEND:
1 Pressure Sensor
2 Plug
3 Spring
4 Ball
5 Valve Seat
6 Valve Body
7 Valve Mounting Plate
9 Solenoid Valves (2 used)
10 Sump Solenoid Valve
11 Inner Springs (3 used)
12 Outer Springs (3 used)
13 Valve Spools (3 used)
14 Valves (3 used)

TRANSMISSION
Repair Valve Assembly

[1] -
LEGEND:
B Valve Mounting Plate
C MFWD Solenoid Valve
D Park Brake Sump Solenoid Valve
E Park Brake Supply Solenoid Valve
Remove parts (A—E).
[2] -
LEGEND:
A O-Rings (6 used)
B MFWD Solenoid Valve
C Park Brake Sump Solenoid Valve
D Park Brake Supply Solenoid Valve
Replace O-rings (A) on MFWD solenoid valve (B), park brake sump solenoid valve (C), and
park brake supply solenoid valve (D).
[3] - Lubricate O-rings (A) with clean hydraulic oil.

TRANSMISSION
[4] -
LEGEND:
B Valve Mounting Plate
C MFWD Solenoid Valve
D Park Brake Sump Solenoid Valve
E Park Brake Supply Solenoid Valve
Install solenoid valves (C—E).
[5] - Install valve mounting plate (B).
Valve Mounting Plate Cap Screws Torque 10 N·m
(89 lb.-in.)
[7] -
LEGEND:
A Transmission Oil Pressure Sensor
Remove transmission oil pressure sensor (A).
[8] - Inspect pressure sensor and replace as necessary.

TRANSMISSION
[9] - Install transmission oil pressure sensor and tighten to specification.

Transmission Oil Pressure Sensor Torque 16 N·m
(142 lb.-in.)
[10] -
LEGEND:
A Plug
B Spring
C Ball
D Valve Seat
Remove plug (A), spring (B), ball (C), and valve seat (D).
Valve Assembly Drain Plug Spring Free Length 18.5 mm
(0.73 in.)
[12] - Install parts (A—D) and tighten plug to specification.

Valve Assembly Drain Plug Torque 20 N·m
(177 lb.-in.)

TRANSMISSION
[13] -
LEGEND:
A Solenoid Valves (3 used)
B Valve Spools (3 used)
C Outer Springs (3 used)
D Inner Springs (3 used)
Remove range solenoid valves (A), valve spools (B), outer springs (C), and inner springs (D).
Shift Valve Springs Free Length 50 mm
(2 in.)
Test Length 32 mm at 16.7 N
(1.3 in. at 3.8 lb.-force)
Outer Springs Free Length 50 mm
(2 in.)
(1.3 in. at 6.7—8.2 lb.-force)

TRANSMISSION
[15] -
LEGEND:
A O-rings (9 used)
Lubricate O-rings (A) with clean hydraulic oil.
[16] -
LEGEND:
A Range Solenoid Valves (3 used)
B Valve Spools (3 used)
C Outer Springs (3 used)
D Inner Springs (3 used)
Install inner springs (D), outer springs (C), valve spools (B), and range solenoid valves (A).
Range Solenoid Valve Torque 35 N·m
(26 lb.-ft.)
Exploded View—Shift Control Housing

TRANSMISSION
LEGEND:
B Sensors (3 used)
C Shift Control Housing
D Packing
E Plugs (3 used)

TRANSMISSION

[1] -
LEGEND:
B Sensors (3 used)
Remove socket head screws (A) and sensors (B).
[2] - Inspect sensors and replace as necessary.
[3] -
LEGEND:
A Packing
Remove packing (A).
[4] - Inspect packing and replace as necessary.
[5] - Install packing.

TRANSMISSION
[6] -
LEGEND:
B Sensors (3 used)
Install sensors (B) and socket head screws (A). Tighten to specification.
(89 lb.-in.)

TRANSMISSION

[1] -
LEGEND:
[2] -
→NOTE:
Use 110 mm (4-5/16 in.) and 92 mm (3-5/8 in.) driver disks to install new bearing cups until
fully seated.
[3] -
LEGEND:
A Bearing Cup
[4] - Use 62 mm (2-7/16 in) driver disk to install new bearing cup until fully seated.

TRANSMISSION

[1] -
LEGEND:
Install JDG11241 Lift Fixture Tool (A) to input shaft, output shaft and lubrication tube.
[2] - Use overhead hoist to install gear assemblies and lubrication tube.
[3] - Remove JDG11241 Lift Fixture Tool.
[4] -
→NOTE:
Bearing cups are slip fit.
LEGEND:
Install bearing cups (A).

TRANSMISSION
[5] -
LEGEND:
A Bearing Support
C Lubrication Tube Cap Screw
Install bearing support (A).
[6] - Clean threads and apply Loctite™ 242 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (us)
to cap screws (B).
(235 lb.-ft.)
[8] - Clean threads and apply Loctite™ 242 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (us)
to lubrication tube cap screw (C).
[9] - Install lubrication tube cap screw (C) and tighten to specification.
(89 lb.-in.)

TRANSMISSION
[10] -
LEGEND:
B JDG11320 Output Shaft Adjusting Ring Tool
C JDG11190 MFWD Adjusting Ring Tool
[11] - Rotate each shaft several revolutions in each directions to seat bearings.
[13] - Using JDG11320 Output Shaft Adjusting Ring Tool (B) and JDG11190 MFWD Adjusting
Ring Tool (C), adjust end play to specification.
(0.0005—0.003 in.)

TRANSMISSION
[14] -
LEGEND:
A Retainers (2 used)
Clean threads and apply Loctite™ 242 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (us)
to cap screws (B).
[15] - Install retainers (A) and cap screws (B). Tighten to specification.
(180 lb.-in.)
[16] - Verify end play is within specification.

(0.0005—0.003 in.)

TRANSMISSION
Install Shift Forks

[1] -
LEGEND:
A Plugs (2 used)
B C-D Shift Rail Assembly
C E Shift Rail Assembly
D Shift Forks (2 used)
Install shift forks (D).
[2] - Install C-D shift rail assembly (B) and E shift rail assembly (C).
Number Name Use
• PM37477 (us)
to actuator plugs (A).
[4] - Install actuator plugs (A) and tighten to specification.
(96 lb.-ft.)

TRANSMISSION
[5] -
LEGEND:
A Plug
B A-B Shift Rail Assembly
C Shift Fork
Install shift fork (C) and A-B shift rail assembly (B).
Number Name Use
• PM37477 (us)
to actuator plug (A).
[7] - Install actuator plug (A) and tighten to specification.
(96 lb.-ft.)

TRANSMISSION
[8] -
LEGEND:
Number Name Use
• PM37477 (us)
to set screws (A).
[9] - Install set screws (A) and tighten to specification.
(30 lb.-ft.)

TRANSMISSION
Install MFWD Clutch
LEGEND:
B MFWD Baffle
[1] - Install MFWD baffle (B).

[2] - Clean threads and apply PM37477 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (us)
[3] - Install socket head screws (A) and tighten to specification.
(180 lb.-in.)

TRANSMISSION
[4] -
LEGEND:
A Thrust Washer
B Bearing Cone
Install bearing cone (B) and thrust washer (A).
[5] -
LEGEND:
A MFWD Clutch
Install MFWD clutch (A).

TRANSMISSION
[6] -
LEGEND:
A MFWD Shaft
Install MFWD shaft (A).
[7] -
LEGEND:
A O-ring
B Scavenge Screen
Install scavenge screen (B) and O-ring (A).

TRANSMISSION
[8] -
LEGEND:
B MFWD Cover
Number Name Use
• PM38657 (us)
[9] - Install MFWD cover (B).
Number Name Use
• PM37477 (us)
to cap screws (A).
(54 lb.-ft.)

TRANSMISSION
[12] -
LEGEND:
A Adjusting Ring
Install adjusting ring (A) using a brass drift.
[13] - Rotate shaft several revolutions in each direction to seat bearings.
[15] - Using a brass drift, adjust end play to specification.
(0.0005—0.003 in.)

TRANSMISSION
[16] -
LEGEND:
A Cap Screw
B Retainer
Clean threads and apply PM37477 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (us)
to cap screw (A).
[17] - Install retainer (B) and cap screw (A). Tighten to specification.
(180 lb.-in.)
[18] - Verify that end play is within specification.

(0.0005—0.003 in.)

TRANSMISSION
Install Rear Cover

[1] -
LEGEND:
A O-Ring
B Rear Cover
D Seals (2 used)
Replace O-ring (A).
Number Name Use
• PM38657 (us)
[3] - Install rear cover (B).
Number Name Use
• PM37477 (us)
to cap screws (C).
[5] - Install cap screws (C) and tighten to specification.
(54 lb.-ft.)

TRANSMISSION
[6] - Replace seals (D).

TRANSMISSION
Install Valve Assembly

[1] -
LEGEND:
B Valve Cover
C Packing
Install packing (C), valve cover (B), and cap screws (A) loosely
[2] -
LEGEND:
B Valve Manifold
C Gasket
Install gasket (C), range box valve manifold (B, and cap screws (A).
[3] - Tighten all cap screws to specification in a spiral pattern starting in the center of the
valve manifold.
Valve Manifold Cap Screws Torque 35 N·m
(26 lb.-ft.)

AUTOPOWR/IVT TRANSMISSION (g) by Belgreen
[4] - Tighten to specification in the same sequence after five minutes.
Install Sensors
[1] -
LEGEND:
Inspect range box speed sensors (A) and replace as needed.
[2] - Install range box speed sensors and tighten to specification.
(204 lb.-in.)

Section 51 - AUTOPOWR/IVT TRANSMISSION

Table of contents
Other Material ........................................................................................................................ 1
Specifications ......................................................................................................................... 3
Remove IVT Transmission ...................................................................................................... 4
Install IVT Transmission ....................................................................................................... 23
Group 05 - General Repair Procedures ................................................................................ 45
Other Material ...................................................................................................................... 45
General Repair Procedures—Transmission ........................................................................... 46
Hydrostatic Module Replacement ........................................................................................ 49
Group 20 - Transmission Repair ............................................................................................ 51
Other Material ...................................................................................................................... 54
Specifications ....................................................................................................................... 55
Separate Transmission Housings ......................................................................................... 60
Install Transmission Front Housing in Repair Stand ............................................................. 64
Install Transmission Rear Housing in Repair Stand .............................................................. 65
Disassemble IVT Transmission ............................................................................................. 67
Exploded View—Front Valve Housing ................................................................................... 93
Repair Front Valve Housing .................................................................................................. 95
Exploded View—Rear Valve Housing .................................................................................. 104
Repair Rear Valve Housing ................................................................................................. 106
Exploded View—Hydrostatic Gear Train ............................................................................. 114
Repair Hydrostatic Gear Train ............................................................................................ 116
Cross Sectional View—Synchronizer .................................................................................. 134
Repair Synchronizer ........................................................................................................... 136
Cross Sectional View—Mode 2/Mode 3 Clutch Assembly ................................................... 149
Repair Mode 3 Clutch Assembly ......................................................................................... 151
Cross Sectional View—MFWD Clutch .................................................................................. 160
Cross Sectional View—Park Brake ...................................................................................... 179
Repair Park Brake .............................................................................................................. 182
Repair Reverse Idler ........................................................................................................... 192
Cross Sectional View—Mode-1 Clutch ................................................................................ 196
Repair Mode-1 Clutch ......................................................................................................... 198
Cross Sectional View—SU Idler ........................................................................................... 205
Repair SU Idler ................................................................................................................... 207
Exploded View—Input Planetary ........................................................................................ 214
Cross Sectional View—Input Planetary ............................................................................... 215
Repair Input Planetary ....................................................................................................... 217
Repair Mode 2 Clutch ......................................................................................................... 227
Repair Mode 2 Shaft ........................................................................................................... 235

Repair Differential Drive Shaft ........................................................................................... 239

Repair Accumulator ............................................................................................................ 241
Group 30 - Assemble Transmission .................................................................................... 244
Other Material .................................................................................................................... 245
Specifications ..................................................................................................................... 246
Install Hydrostatic Module .................................................................................................. 248
Install Front Valve Housing ................................................................................................ 252
Install Bearing Cups in Rear Housing ................................................................................. 254
Install Output Shaft Assembly ............................................................................................ 256
Install Mode-1 Clutch Assembly ......................................................................................... 264
Install Mode 3 Clutch Assembly ......................................................................................... 266
Install Park Brake ............................................................................................................... 269
Install Reverse Shaft Assemblies ....................................................................................... 274
Install Synchronizer Assembly ............................................................................................ 276
Install MFWD Clutch Assembly ........................................................................................... 278
Install Bearing Support and Adjust Bearings ...................................................................... 279
Assemble Transmission Housings ...................................................................................... 295
Install Rear Valve Housing ................................................................................................. 300
Install Sensors .................................................................................................................... 302

Section 51 - AUTOPOWR/IVT TRANSMISSION Group 00: Component Removal and Installation

List of References
Other Material
Specifications
Remove IVT Transmission
Install IVT Transmission
→NOTE:

JDG19 Lifting Eyes
JDG909 Lifting Eyes

Other Material
Number Name Use
• PM38657 (us)
High Flex Form-In-Place Gasket Used to seal surfaces.
• TY9484 Loctite™ (canadian)

Specifications
Differential Case-to-Transmission Cap Screws Torque 500 N·m
(370 lb.-ft.)
Mid-Frame-to-Cross Member Cap Screws Torque 500 N·m
(370 lb.-ft.)
(370 lb.-ft.)
Drive Shaft-to-Engine Cap Screws Torque 125 N·m
(92 lb.-ft.)
Rear Hood Support Cap Screws Torque 320 N·m
(236 lb.-ft.)
Stabilizer Hitch Cap Screws Torque 430 N·m
(317 lb.-ft.)
(52 lb.-ft.)
Drawbar Front Support Bracket Cap Screws Torque 430 N·m
(317 lb.-ft.)
(75 lb.-ft.)
(92 lb.-ft.)
(94 lb.-ft.)
(54 lb.-ft.)
(54 lb.-ft.)
(443 lb.-ft.)
(54 lb.-ft.)
Radar Assembly Cap Screws Torque 70 N·m
(52 lb.-ft.)
Shield-to-Chassis Cap Screws Torque 73 N·m
(54 lb.-ft.)

Remove IVT Transmission

[1] - Open hood.
[2] - Depress latches and remove right and left-hand side shields.
[3] - Remove front weights or front hitch, if equipped. (See Remove and Install Front 3-Point
Relieve cab suspension pressure. (See Depressurize Cab Suspension System in Section
90, Group 35.)
Relieve TLS pressure. (See Relieve Pressure From Suspended MFWD Axle Hydraulic
System in Section 59, Group 20.)
[6] - With engine off, depress brake pedals ten times fully releasing between depressions.
[7] - Bleed air brake reservoirs. (See Bleed Air from Air Trailer Brake Reservoirs in Section 60,
Group 35.)
[8] -
→NOTE:
Pumping fuel out through fill tube with a transfer pump will aid in fuel
removal.

LEGEND:
A Drain Valve
C Shields (2 used)
[9] - Remove cap screws (B) and shields (C).

[10] -
LEGEND:
A Radar Connector
C Cap Screws (2 Used)

Loosen cap screws (B).
Remove cap screws (C) and lower radar assembly.

[11] -
LEGEND:
A Cap Screw
B Retainer
C Drawbar Pin
Remove cap screw (A), retainer (B), and drawbar pin (C).
[12] -
CAUTION:
Drawbar weighs over 28 kg (62 lbs.). Use proper lifting equipment to avoid
personal injury.
LEGEND:
A Drawbar
Remove drawbar (A).

[13] -
LEGEND:
B Drawbar Front Support
C Spacers (2 used)
Remove cap screws (A), drawbar front support (B), and spacers (C).

[14] -
LEGEND:
B Pins (2 used)
D Retainer
E Drawbar Pin
F Drawbar
H Stabilizer Hitch

b. Remove retainer cap screw (C), retainer (D), and drawbar pin (E).

[15] -
LEGEND:
Drain hydraulic oil by removing transmission drain plugs (A).
[16] -
→NOTE:
LEGEND:
C JDG2061 Front Adapter
D JDG11217P1 Long Nose Stand
Install JDG11217P3 Jack Screw (A), JDG11217P2 Rear Outrigger Support Stand (B), and
JDG2061 Front Adapter (C) to JDG11217P1 Long Nose Stand (D). DO NOT tighten cap screws.

[17] -
→NOTE:
LEGEND:
Attach JDG11217P2 Rear Outrigger Support Stand to the drawbar support using cap screws
(A).
[18] -
LEGEND:
Adjust JDG11217P3 Jack Screw (A) to drawbar support.
[19] - Position JDG2061 Front Adapter under the front half of the transmission.
[20] - Tighten cap screws on JDG11217P2 Rear Outrigger Support Stand and JDG2061 Front
Adapter.

[21] - Remove air intake. (See Remove and Install Intake Housing and Remove and Install
Aspirator Hose in Section 30, Group 15.)
[23] - Remove rear wheels. (See Operators Manual.)
[25] - Remove fuel tanks. (See Remove and Install Left-Hand Fuel Tank and Remove and
Install Right-Hand Fuel Tank in Section 30, Group 10.)
[26] -
LEGEND:
Remove cap screws (A) and left-hand fuel tank support (B).
[27] -
LEGEND:
Remove cap screws (A) and right-hand fuel tank support (B).

[28] -
LEGEND:
B Front Cab Support
Remove any wiring harness brackets and clamps attached to front cab support.
[29] - Remove cap screws (A) and front cab support (B).
[30] -
Air Compressor

LEGEND:
A Hose
B Lines (3 used)
D Lines (5 used)
F Hanger Bolt
Remove hose (A).

Remove lines (B).
Remove cap screws (C) and compressor.
Identify, label, and disconnect harness from air trailer brake assembly (G).
Disconnect lines (D).
Remove cap screws (E).
Loosen hanger bolt (F).
Lift air trailer brake assembly off hanger bolt and remove.

[31] -
LEGEND:
B Line
C Lines (2 used)
E Lines (2 used)
F Hoses (6 used)
For tractors equipped with mid-mount SCV, perform the following:
[32] -
Remove lines (C).

Disconnect hoses (F).

Remove line (B).

Disconnect lines (E).
CAUTION:
Remove cap screws (G) and mid-mount SCV/TLS™ support plate.
Remove front differential lock line (D).
[35] -

LEGEND:
B Bracket
Remove cap screws (A) from bracket (B).
Remove front brake valve. (See Remove and Install Front Brake Valve in Section 60,
Group 20.)
Remove hydraulic trailer brake valve. (See Remove and Install Hydraulic Trailer Brake
Remove ActiveCommand Steering (ACS™) valve. (See Remove and Install
Remove AutoTrac™ valve. (See Remove and Install AutoTrac™ Valve in Section 60,
Group 10.)

[37] - Remove pump drive housing. (See Remove and Install Pump Drive Housing Section 56,
Group 45.)
[38] - Identify, label, and disconnect remaining wiring harnesses and hydraulic lines.
[39] -
LEGEND:
A KJD10539 Support Stand Adapters (2 used)
B JT07211 Rear Differential Support Stands (2 used)
Attach JT07211 Rear Differential Support Stand (B) and KJD10539 Support Stand Adapter (A).

[40] -
LEGEND:
B Shields (2 used)
Remove caps screws with washers (A) and shields (B).
[41] -
LEGEND:
Remove drive shaft-to-engine cap screws (A).

[42] -
Illustrated with Front PTO
LEGEND:
A Front Support-to-Mid-Frame Cap Screws (12 used)
Remove mid-frame cap screws with washers (B).

[43] - Remove cap screws with washers (A).
[44] -
IMPORTANT:
When tractor is separated MFWD drive shaft remains with engine. Ensure
that drive shaft does not fall or catch while separating tractor.
Carefully roll JDG11217 Splitting Stand rearward.

[45] -
LEGEND:
Attach JDG909 Lifting Eyes (A) and JDG19 Lifting Eyes (B).
[46] - Attach to overhead hoist.

[47] -
LEGEND:
Remove cap screws with washers (A).
[48] - Remove transmission from rear differential.

Install IVT Transmission

[1] -
LEGEND:
Install JDG909 Lifting Eyes (A) and JDG19 Lifting Eyes (B).
Number Name Use
• PM38657 (us)
[3] -
→NOTE:
Fabricate guide pins (A) as needed by removing heads from M20 x 120 mm
cap screws.

LEGEND:
Use overhead hoist to install transmission to rear differential.
[4] -
LEGEND:
(370 lb.-ft.)

[5] -
LEGEND:
Lower transmission onto splitting stand and remove from overhead hoist.
[6] - Remove lifting eyes (A and B).
[7] -
Align mid-frame and front frame of tractor.If equipped with MFWD: install MFWD drive
shaft.

[8] -
Illustrated with Front PTO

LEGEND:

[9] - Install cap screws with washers (B) and tighten to specification.
Mid-Frame-to-Cross Member Cap Screws Torque 500 N·m
(370 lb.-ft.)
[10] - Tighten cap screws (A) to specification.

(370 lb.-ft.)
[11] -
IMPORTANT:
New torque value must be calculated for use with torque wrench adapters.
(See Use Torque Wrench Adapter in Section 10, Group 10).

LEGEND:
Tighten cap screws (A) to specification with JDG861 Torque Wrench Adapter .
Drive Shaft-to-Engine Cap Screws Torque 125 N·m
(92 lb.-ft.)

[12] -
LEGEND:
B Shields (2 used)
Install shields (B) and caps screws with washers (A). Tighten to specification.
Rear Hood Support Cap Screws Torque 320 N·m
(236 lb.-ft.)

[13] -
LEGEND:
A KJD10539 Support Stand Adapters (2 used)
B JT07211 Rear Differential Support Stands (2 used)
Remove JT07211 Rear Differential Support Stand (B) and KJD10539 Support Stand Adapter
(A).
[14] - Install pump drive housing. (See Remove and Install Pump Drive Housing Section 56,
Group 45.)
Install front brake valve. (See Remove and Install Front Brake Valve in Section 60,
Group 20.)
Install hydraulic trailer brake valve. (See Remove and Install Hydraulic Trailer Brake
Install ActiveCommand Steering (ACS™) valve. (See Remove and Install
Install AutoTrac™ valve. (See Remove and Install AutoTrac™ Valve in Section 60, Group
10.)
[16] -

Air Compressor
LEGEND:
A Hose
B Lines (3 used)

D Lines (5 used)
F Hanger Cap Screw
Install air trailer brake assembly (G) onto hanger cap screw (F).
Install cap screws (E).
Tighten cap screws (E and F) to specification.
(92 lb.-ft.)
Connect lines (D).

Connect harness to air trailer brake assembly.
Install compressor and cap screws (C).
(94 lb.-ft.)
Install lines (B).

Install hose (A).
[17] -

LEGEND:
B Bracket
Install bracket (B) and cap screws (A).
(54 lb.-ft.)

[19] -
CAUTION:
LEGEND:
B Line
C Lines (2 used)
E Lines (2 used)
F Hoses (6 used)
For tractors equipped with TLS™, perform the following:
Install mid-mount SCV/TLS™ support plate and cap screws (G).


(54 lb.-ft.)
Install line (B).

Connect lines (E).
Install lines (C).

Connect hoses (F).
Install line clamps (A).
Install front differential lock line (D).
[22] -
LEGEND:
B Line
Install line (B).

Route backup pump cables forward.
Install shield and cap screws (A).

[23] -
LEGEND:
B Front Cab Support
Attach wiring harness brackets and clamps to front cab support.
[24] - Install front cab support (B) and cap screws (A). Tighten cap screws to specification.
(443 lb.-ft.)
[25] - Install hydraulic lines and wiring harnesses.

[26] -
LEGEND:
Install left-hand fuel tank support (B) and cap screws (A). Tighten to specification.
(54 lb.-ft.)

[27] -
LEGEND:
Install right-hand fuel tank support (B) and cap screws (A). Tighten to specification.
(54 lb.-ft.)
[28] - Install fuel tanks. (See Remove and Install Left-Hand Fuel Tank and Remove and Install
[29] - Install wiring harness.
[30] - Install rear wheels. (See Operators Manual.)

[32] -
LEGEND:
Adjust JDG11217P3 Jack Screw (A) to the lowest position.
[33] -
→NOTE:
Splitting stand must be removed from right-hand side of tractor.
JDG11217P2 Rear Outrigger Support Stand is part of JDG11217 Splitting
Stand .
LEGEND:
Remove cap screws (A), JDG11217P2 Rear Outrigger Support Stand, and JDG2061 Front
Adapter from the drawbar support.

[34] -
LEGEND:
Install transmission drain plugs (A) and tighten to specification.
(75 lb.-ft.)
[35] -

LEGEND:
B Pins (2 used)
D Retainer
E Drawbar Pin
F Drawbar
H Stabilizer Hitch
a. Install stabilizer hitch (H) and cap screws with washers (G). Tighten to specification.
(317 lb.-ft.)
b. Install drawbar (F).

c. Install drawbar pin (E), retainer (D), and retainer cap screw (C). Tighten to specification.
(52 lb.-ft.)
d. Install pins (B) and cotter pins (A).

[36] -
LEGEND:
B Drawbar Front Support Bracket
C Spacers (2 used)
Install spacers (C), drawbar front support bracket (B), and cap screws (A). Tighten to
specification.
Drawbar Front Support Bracket Cap Screws Torque 430 N·m
(317 lb.-ft.)
[37] -
LEGEND:
A Drawbar
Install drawbar (A).

[38] -
LEGEND:
A Cap Screw
B Retainer
C Drawbar Pin
Install drawbar pin (C), retainer (B), and cap screw (A). Tighten cap screw to specification.
(52 lb.-ft.)

[39] -
LEGEND:
A Radar Connector
Install radar assembly and cap screws (C).

Tighten cap screws (B and C) to specification.
Radar Assembly Cap Screws Torque 70 N·m
(52 lb.-ft.)
Connect radar harness connector (A).

Section 51 - AUTOPOWR/IVT TRANSMISSION Group 05: General Repair Procedures
[40] -
LEGEND:
A Drain Valve
C Shields (2 used)
Close drain valve (A).
[41] - Install shields (C) and cap screws (B). Tighten to specification.
Shield-to-Chassis Cap Screws Torque 73 N·m
(54 lb.-ft.)
[42] - Install air intake. (See Remove and Install Intake Housing and Remove and Install
Aspirator Hose in Section 30, Group 15.)
[43] - Install exhaust pipe. (See Service Exhaust System in Section 30, Group 30.)
[45] - Install front weights or front hitch, if equipped. (See Remove and Install Front 3-Point



List of References
Other Material
General Repair Procedures—Transmission
Hydrostatic Module Replacement
→NOTE:

JDG766 Clip Removal Tool
Other Material
Number Name Use
• PM38657 (us)
• TY9484 (canadian) High Flex Form-In-Place Gasket Used to seal transmission housings.

General Repair Procedures—Transmission
→NOTE:

servicing the transmission.
Thoroughly clean the outside of the transmission to reduce the possibility of contamination.
Completely clean all components after any failure that generates contamination.
Lubricate each component part with clean hydraulic oil.
Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly
during assembly.
Use new O-rings, seals, and gaskets.
Cleaning and Inspection:
Transmission
Clean all parts with clean solvent and use moisture-free air to dry all parts and clean out
oil passages.
Hydraulic Valves
Valves in the front valve housing and front cover should not require service unless there
is a major transmission failure.
Removal, disassembly, cleaning, and inspection is recommended after a major failure.
Remove the valve bore plug retainer clips using JDG766 Clip Removal Tool . Do not pry
against the housing surfaces.
Thoroughly clean all metallic valve components in clean solvent and blow dry with
moisture-free compressed air. Check oil passages for obstructions. Flush any debris
from the oil passages with clean solvent.
Inspect valve bores for scoring or burrs. Inspect mating surfaces for burrs and scoring. If
necessary, use crocus cloth to polish valves. Avoid rounding the sharp edges of valves
with the crocus cloth.
Check valves for binding.
Inspect springs for distortion, wear, or damage.
Bearings
Clean bearings with clean solvent.

Dry the bearings thoroughly and lubricate with oil before inspection. Inspect bearings
for roughness of rotation, and excessive wear of rollers or balls.
Never dry bearings with compressed air. Spinning a bearing without lubrication can
damage the bearing.
Inspect thrust washers and thrust surfaces for distortion, roughness, scoring, or wear.
Springs
Inspect all springs for wear, damage, or distortion.
Shafts
Inspect the shaft bearing surfaces for wear or damage.

Check shaft splines.
Inspect bushings for scoring, burrs, roundness, sharp edges and evidence of
overheating. Remove scores with crocus cloth. Remove burrs and sharp edges with a
scraper or knife blade. Replace bushings if out-of-round, deeply scored, or excessively
worn.
Planetary Assemblies
The pins and shafts should be checked for loose fit and/or complete disengagement.
Inspect the pinion gears for damaged or excessively worn teeth.
Check for smooth rotation of the pinion gears.
Sealing Instructions:
IMPORTANT: DO NOT use TY16285 Cure Primer to clean the surfaces.

The primer action will cause the new sealer material to set up TOO
fast to allow adequate assembly time.
Scrape surfaces to remove old sealer material. Gel-type paint removers containing
ethylene chloride, rubbing alcohol, or hot soapy water can be used.
Clean surfaces to remove oil and grease residue.

Test for clean surface by applying a few drops of cool water to the surfaces. If water
puddles or forms beads, repeat the cleaning procedure.
Keep surfaces clean after they have been cleaned.
IMPORTANT: DO NOT use an excessive amount of sealant.
Apply aTHIN even layer of PM38657 Form-in-Place Gasket to one surface of the joint.
Number Name Use
⚬ PM38657 (us)
⚬ TY9484 (canadian) High Flex Form-In-Place Used to seal transmission
⚬ 17430 Loctite ™ Gasket housings.
(loctite)

Narrow overlap areas must be covered with sealant. Prevent sealant from entering any
of the oil passages. Be sure the sealant loops around the oil passages.
Work fast to prevent the sealant from drying before assembly is completed.
Make sure the sealed surfaces stay dry, clean, and oil free.
Allow 30 minutes minimum cure time at room temperature before filling with oil.
Clutch Disks
IMPORTANT: DO NOT use solvent to clean clutch disks.
Clean new clutch disks using a lint-free cloth.
New clutch disks should be soaked in hydraulic oil for 15 minutes before assembly.

Hydrostatic Module Replacement
Hydrostatic Charge and Servo Screens
Hydrostatic Control Solenoid Screen
Hydrostatic Cylinder Block Bores
LEGEND:

Section 51 - AUTOPOWR/IVT TRANSMISSION Group 20: Transmission Repair
A Hydrostatic Servo and Charge Screens

B Hydrostatic Control Solenoid Screen
C Hydrostatic Rotating Group Bore
Hydrostatic Module
In the event of a transmission or drive train failure and resulting contamination of the oil, it
mayNOT always be necessary to replace the hydrostatic module. Use the following
guidelines to determine if hydrostatic module requires replacement.
If possible, check the following conditions before tractor,

transmission, or drive train is disassembled:
CAUTION:
Some codes indicating transmission pressure sensor failures and

transmission filter restriction conditions MAY block several of the following
filter bypass ”Warning” and ”Stop Engine” codes from appearing.
Transmission or some type of drive train failure WITH:
”Warning” or ”Stop Engine” codes that indicate a transmission filter bypass condition.
(See Operation and Test Manual.)
20 percent or more contamination of either hydrostatic servo screen or hydrostatic
charge screen (A).
Contamination of hydrostatic control solenoid screen (B).
If any of the above conditions exist, be sure to check for the following conditions:
After transmission is disassembled, replace hydrostatic module if any

of the following conditions exist:
Contamination embedded in hydrostatic gear train bearings.

Either of the hydrostatic rotating groups cannot be turned.
Scoring visible from the back side of the rotating group cylinder bores (C).

Group 20 - Transmission Repair

List of References
Other Material
Specifications
Separate Transmission Housings
Install Transmission Front Housing in Repair Stand
Install Transmission Rear Housing in Repair Stand
Disassemble IVT Transmission
Exploded View—Front Valve Housing
Repair Front Valve Housing
Exploded View—Rear Valve Housing
Repair Rear Valve Housing
Exploded View—Hydrostatic Gear Train
Repair Hydrostatic Gear Train
Cross Sectional View—Synchronizer
Repair Synchronizer
Cross Sectional View—Mode 2/Mode 3 Clutch Assembly
Repair Mode 3 Clutch Assembly
Cross Sectional View—MFWD Clutch
Repair MFWD Clutch
Cross Sectional View—Park Brake
Repair Park Brake
Repair Reverse Idler

Cross Sectional View—Mode-1 Clutch
Repair Mode-1 Clutch
Cross Sectional View—SU Idler
Repair SU Idler
Exploded View—Input Planetary
Cross Sectional View—Input Planetary
Repair Input Planetary
Repair Mode 2 Clutch
Repair Mode 2 Shaft
Repair Differential Drive Shaft
Repair Accumulator

→NOTE:

D01045AA Disk Set
D01061AA Blind-Hole Puller Set
JDG19 Lifting Eyes
JDG909 Lifting Eyes
JDG933 Driver Disk 137 mm (5-3/8 in.)
JDG1255 Slinger-Seal Installer
JDG1405 Bearing Installer
JDG1860 Seal Installer
JDG8092 Driver Handle
JDG11187 Locking Nut Tool
JDG11191 Hydro Adjusting Ring Tool
JDG11196 472 mm DDS Spline Socket
JDG11211 Snap Ring Installer
JDG11212 MFWD Clutch Alignment Tool
JDG11215 Park Brake Alignment Tool
JDG11305 MFWD Output Shaft Seal Installer

JT05550 Lifting Eyebolts
Other Material
Number Name Use
• PM37477 (us)
• TY9473 Loctite™ Thread Lock and Sealer Used to retain cap screws and
(canadian) (Medium Strength) seal surfaces.
• 242 (loctite)

Specifications
Hydro Control Solenoid Valve Torque 35 N·m
(26 lb.-ft.)
System 1 Oil Pressure Sensor Plug Torque 35 N·m
(26 lb.-ft.)
System 1 Oil Pressure Sensor Torque 16 N·m
(142 lb.-in.)
Transmission Oil Boost Check Valve Spring Free Length 48 mm
(1.89 in.)
(1.39 in. at 10—12.36 lb.-force)
Transmission Oil Boost Check Valve Plug Torque 35 N·m
(26 lb.-ft.)
Transmission Oil Boost Solenoid Valve Spring Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)
Transmission Oil Boost Solenoid Valve Torque 35 N·m
(26 lb.-ft.)
Hydraulic Oil Cooler Control Solenoid Valve Spring Free Length 74.3 mm
(2.93 in.)
(2.48 in. at 56.65—69.24 lb.-force)
(2.36 in. at 79.58 lb.-force)
Hydraulic Oil Cooler Control Solenoid Valve Torque 35 N·m
(26 lb.-ft.)
(239 lb.-in.)
Pressure Regulating Valve Inner Spring Free Length 110 mm
(4.33 in.)
(3.21 in. at 32.7—37 lb.-force)
(4.33 in.)

(3.21 in. at 73.13—82 lb.-force)
(26 lb.-ft.)
Loop Flush Shut-Off Solenoid Valve Cap Screws Torque 10 N·m
(89 lb.-in.)
Loop Flush Relief Valve Spring Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)
Loop Flush Relief Valve Plug Torque 20 N·m
(177 lb.-in.)
Lube Relief Valve Spring Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)
Lube Relief Valve Plug Torque 35 N·m
(26 lb.-ft.)
Mode 1/3 Selector Solenoid Valve Spring Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)
Mode 1/3 Selector Solenoid Valve Torque 35 N·m
(26 lb.-ft.)
Mode 1/3 and Mode 2 Clutch Solenoid Valve Cap Screws Torque 20 N·m
(177 lb.-in.)
Clutch Enable Solenoid Valve Spring Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)
Clutch Enable Solenoid Valve Torque 35 N·m
(26 lb.-ft.)

(142 lb.-in.)
Park Brake Inlet Check Valve Spring Free Length 18.5 mm
(0.73 in.)
Park Brake Inlet Check Valve Plug Torque 20 N·m
(177 lb.-in.)
Park Brake Supply Solenoid Valve Cap Screws Torque 10 N·m
(89 lb.-in.)
Park Brake Sump Block Solenoid Valve Cap Screws Torque 10 N·m
(89 lb.-in.)
Park Brake Pressure Sensor Torque 16 N·m
(142 lb.-in.)
Forward and Reverse Synchronizer Solenoid Valve Springs Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)
Forward and Reverse Synchronizer Solenoid Valves Torque 35 N·m
(26 lb.-ft.)
MFWD Clutch Solenoid Valve Cap Screw Torque 10 N·m
(89 lb.-in.)
Sun 1 Input Shaft Bearing Support Cap Screws Torque 125 N·m
(92 lb.-ft.)
Hydro Bearing Support Cap Screws Torque 125 N·m
(92 lb.-ft.)
SU Idler Gear Bearing Support Cap Screws Torque 125 N·m
(92 lb.-ft.)
SU Idler Gear Bearing Support Retaining Clip Cap Screws Torque 20 N·m
(180 lb.-in.)
Sun 1 Input Shaft/Ring 1 Drive Gear Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)
Ring 1 Drive Adjusting Nut Retaining Clip Cap Screw Torque 20 N·m
(180 lb.-in.)
Synchronizer Spring Free Length 39.7 mm
(1.56 in.)

(1.26 in. at 32—40 lb.-force)
(0.87 in. at 74—91 lb.-force)
Shift Fork Spring Free Length 39.7 mm
(1.56 in.)
(1.26 in. at 32—40 lb.-force)
(0.87 in. at 74—91 lb.-force)
Synchronizer Shift Rail Nut Torque 90 N·m
(66 lb.-ft.)
Synchronizer Shift Fork Socket Head Screws Torque 37 N·m
(27 lb.-ft.)
MFWD Piston Socket Head Screws Torque 70 N·m
(52 lb.-ft)
Park Brake Piston Cap Screws Torque 70 N·m
(52 lb.-ft.)
Park Brake Clutch Cap Screws Torque 70 N·m
(52 lb.-ft.)
Reverse Idler Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)
SU Idler End Play 0.05—0.20 mm
(0.002—0.007 in.)
Input Planetary Pinion Gear Screws Torque 12 N·m
(106 lb.-in.)
Ring 2 Gear Cap Screws Torque 73 N·m
(54 lb.-ft.)
Accumulator Outer Spring Free Length 237.33 mm
(9.34 in.)
(8.07 in. at 295—395 lb.-force)
Test Length 170 mm at 2975— 3426 N
(6.69 in. at 669—770 lb.-force)
Accumulator Middle Spring Free Length 247.29 mm
(9.74 in.)
(8.07 in. at 152—194 lb.-force)
(6.69 in. at 292—339 lb.-force)

Accumulator Inner Spring Free Length 237.87 mm
(9.36 in.)
(8.07 in. at 72—100 lb.-force)
(6.69 in. at 163—194 lb.-force)
Accumulator Halves Torque 75 N·m
(55 lb.-ft.)

Separate Transmission Housings

[1] -
LEGEND:
A Rear Valve Housing
Remove rear valve housing (A).
[2] -
LEGEND:
A Jumper Tubes (4 used)
Remove jumper tubes (A).

[3] -
LEGEND:
B Flange
C Hydraulic Line
Remove cap screws (A), flange (B), and hydraulic line (C).
[4] -
LEGEND:
Install JDG909 Lifting Eyes (A) and attach to overhead hoist.

[5] -
LEGEND:
A Transmission Cap Screws (22 used)
Remove transmission cap screws (A).
[6] -
→NOTE:
Ensure input shaft and SU idler shaft (A) remain with front transmission
housing.
SU idler shaft may remain with rear housing when transmission housings
are separated. Reinstall SU idler shaft in front transmission housing as
illustrated.
Input shaft washer may become misplaced when front and rear
transmission halves are separated.

LEGEND:
A SU Idler Shaft
Raise hoist and separate transmission.

Install Transmission Front Housing in Repair Stand

[1] -
LEGEND:
B JDG11149P1 Lower Adapter
C JDG11149P2 Top Adapter
Remove transmission from tractor. (See Remove IVT Transmission in Group 00.)
[2] -
→NOTE:
JDG11149P1 Lower Adapter, JDG11149P2 Top Adapter, and JDG11149P5
Main Plate are part of JDG11149 IVT Transmission Mounting Fixture .

[3] - Use cap screws (A) to install JDG11149P1 Lower Adapter (B) and JDG11149P2 Top
[4] - Install JDG909 Lifting Eyes and attach to overhead hoist.
[5] -
Use overhead hoist to install front housing in JDG11149 IVT Transmission Mounting Fixture.

Install Transmission Rear Housing in Repair Stand

[1] -
LEGEND:
B JDG11149P3 Lower Adapter
C JDG11149P4 Top Adapter
Remove transmission from tractor. (See Remove Transmission in Group 00.)
[2] -
→NOTE:
JDG11149P3 Lower Adapter, JDG11149P4 Top Adapter, and JDG11149P5
Main Plate are part of JDG11149 IVT Transmission Mounting Fixture .

[3] - Use cap screws (A) to install JDG11149P3 Lower Adapter (B) and JDG11149P4 Top
[4] - Install JDG909 Lifting Eyes and attach to overhead hoist.

[5] -
Use overhead hoist to install rear housing in JDG11149 IVT Transmission Mounting Fixture.

Disassemble IVT Transmission

[1] - Install front and rear halves of transmission into repair stands. (See Install Transmission
Front Housing in Repair Stand and Install Transmission Rear Housing in Repair Stand in this
group.)
[2] -
LEGEND:
A Hub
Remove hub (A) from input shaft.
[3] -
LEGEND:
A Cap Scews (2 used)
B Retainer
Remove cap screws (A) and retainer (B).

[4] -
LEGEND:
A Input Shaft
Remove input shaft (A).
[5] -
LEGEND:
A SU Idler Shaft
Remove SU idler shaft (A).

[6] -
LEGEND:
A Planetary
Remove planetary (A).
[7] -
LEGEND:
A Ring 1 Gear
Remove ring 1 gear (A).

[8] -
LEGEND:
A Front Valve Housing
Remove front valve housing (A).
[9] -
LEGEND:
Remove jumper tubes (A).

[10] -
LEGEND:
A JDG19 Lift Eyes (2 used)
Install JDG19 Lifting Eyes (A) and attach to overhead hoist.
[11] -
LEGEND:
A Retaining Plugs (4 used)
Remove hydrostatic module retaining plugs (A).

[12] -
LEGEND:
A Hydrostatic Assembly
Remove hydrostatic assembly (A).
[13] -
LEGEND:
A Seal
B Snap Ring
C Bearing
[14] - Replace bearing (C).
[15] - Install snap ring and new seal.

[16] -
LEGEND:
A Slot
[17] -
LEGEND:
A Lock Nut
B Washer
Remove lock nut (A) and washer (B).

[18] -
LEGEND:
[19] -
IMPORTANT:
Bearing cup must be installed 3.5 mm below surface.
→NOTE:
Driver Disks are part of D01045AA Disk Set .

LEGEND:
A Bearing Cup
B Washer
C Bearing Cups
D Bearing Cup
E Bearing Cup
F Bushing
G Seal
H O-Ring
Replace bearing cup (A) and washer (B) using 89 mm (3.5 in.) driver disk.
[20] - Replace bearing cups (C) using 89 mm (3.5 in.) driver disk until fully seated against
housing.
[21] -
IMPORTANT:
Bearing cup must be install 3 mm below surface.
Replace bearing cup (D) using JDG933 Driver Disk 137 mm (5-3/8 in.) .
[22] -
IMPORTANT:
Bearing cup must be install 3 mm below surface.
Replace bearing cup (E) using 111 mm (4.375 in.) driver disk.
[23] - Inspect bushing (F), seal (G), and O-ring (H). Replace parts as necessary.
[24] -
IMPORTANT:
Insert pry bar through pump drive hole and hold reverse idler shaft
assembly in place when removing cover. Failure to so will disrupt
synchronizer.
→NOTE:
Pry bar and reverse idler illustrated with cover removed.

LEGEND:
B Cover
Install JDG19 Lifting Eyes (A) in jack screw holes and attach to overhead hoist.
[25] - Install pry bar through pump drive hold and hold reverse idler shaft assembly in place
when removing cover.
[26] - Remove cover (B) from rear housing.

[27] -
LEGEND:
B Baffle
Remove cap screws (A) and baffle (B).
[28] -
LEGEND:
A JT05550 Lifting Eyebolts
B MFWD Clutch
Install JT05550 Lifting Eyebolts (A).
[29] - Remove MFWD clutch (B).

[30] -
LEGEND:
A Synchronizer Gear
Remove synchronizer gear (A).
[31] -
LEGEND:
A Snap Ring
Depress shift rail to remove snap ring (A).

[32] -
LEGEND:
A Bearing Cone
B Synchronizer Assembly
C Reverse Input Gear
Remove bearing cone (A), synchronizer assembly (B), and reverse input gear (C).
[33] -
LEGEND:
A Idler Gear
Remove idler gear (A).

[34] -
LEGEND:
A Pump Drive Gear
B PTO Shaft
Remove pump drive gear (A) and PTO shaft (B).
[35] -
LEGEND:
A Reverse Idler
Remove reverse idler (A).

[36] -
LEGEND:
B Parking Brake
Remove cap screws (A) and parking brake (B).
[37] -
→NOTE:
Plug is installed to prevent trapped oil from spraying when park brake is
removed.
LEGEND:
A Plug
Thread in plug (A) loosely as shown.

[38] -
LEGEND:
[39] -
CAUTION:
Piston assembly weighs approximately 15 kg (35 lb.)
→NOTE:
Push piston assembly up from bottom side to aid in removal.
LEGEND:
A Piston Assembly

Remove piston assembly (A).

[40] -
LEGEND:
A Plug
Remove plug (A).
[41] -
LEGEND:
A Plug
B Scavenge Screen
Remove plug (A) and scavenge screen (B).

[42] -
LEGEND:
A Bearing Race
Remove bearing race (A).
[43] -
IMPORTANT:
Rotate transmission no further then horizontal position to ensure mode 3
clutch will not fall out when snap ring is removed.
LEGEND:
A Snap Ring
Remove snap ring (A) from mode 3 shaft.

[44] -
LEGEND:
A Cap Screw
B Retainer
C Accumulator
Remove cap screw (A), retainer (B), and accumulator (C).
[45] -
CAUTION:
Ring 2 gear weighs approximately 17 kg (37 lb).
LEGEND:
B Retainers (2 used)
C Ring 2 Gear
Remove cap screws (A), retainers (B) with wear pads and ring 2 gear (C).

[46] -
LEGEND:
A Mode 3 Clutch
B Mode 2 Clutch
Remove mode 3 clutch (A) and mode 2 clutch (B).
[47] -
LEGEND:
A Wear Pads (4 used)
Remove wear pads (A).

[48] -
LEGEND:
B Mode 1 Clutch Support
Remove cap screws (A) and mode 1 clutch support (B).
[49] -
LEGEND:
A Mode 1 Clutch
Remove mode 1 clutch (A).

[50] -
LEGEND:
B Mid Bearing Support
[51] -
→NOTE:
Thread two cap screws into threaded jack screw holes in mid bearing
support to aid in removal.
Remove mid bearing support (B).

[52] -
LEGEND:
A Mode 2 Output Shaft
Remove mode 2 output shaft (A).

[53] -
LEGEND:
A Differential Drive Shaft
Remove differential drive shaft (A).

[54] -
LEGEND:
A Mode 3 Gear
Remove mode 3 gear (A).

[55] -
LEGEND:
A Mode 1/3 Gear
Remove mode 1/3 gear (A).
[56] -
→NOTE:
Threaded eyebolt may be used to aid in removal of SU idler.

LEGEND:
B SU Idler Assembly
Remove cap screws (A) and SU idler assembly (B).
Exploded View—Front Valve Housing

LEGEND:
A Hydro Control Solenoid Valve
B System 1 Oil Pressure Sensor
C System 1 Inlet Screen
D Transmission Oil Boost Check Valve
E Transmission Oil Boost Solenoid Valve
F Hydraulic Oil Cooler Control Solenoid
G Transmission Oil Temperature Sensor
H Pressure Regulating Valve
I Loop Flush Shut-Off Solenoid
J Loop Flush Relief Valve
K Lube Relief Valve

Repair Front Valve Housing

[1] -
IMPORTANT:
Disassemble and assemble valve in a clean work area free of dust and dirt.
Absolute cleanliness is essential when working on hydraulic components.
Replace and lubricate all O-rings with clean hydraulic oil before installing
LEGEND:
A Hydro Control Solenoid Valve
Remove hydro control solenoid valve (A).
[3] - Install hydro control solenoid valve and tighten to specification.
Hydro Control Solenoid Valve Torque 35 N·m
(26 lb.-ft.)

[4] -
LEGEND:
A System 1 Oil Pressure Sensor
B System 1 Oil Pressure Sensor Plug
C System 1 Inlet Screen
D O-Rings (2 used)
Remove system 1 oil pressure sensor (A), system 1 oil pressure sensor plug (B), and system
1 inlet screen (C).
[6] - Lubricate O-rings (D).
[7] - Install system 1 inlet screen and system 1 oil pressure sensor plug. Tighten to
specification.
System 1 Oil Pressure Sensor Plug Torque 35 N·m
(26 lb.-ft.)
[8] - Install system 1 oil pressure sensor and tighten to specification.

System 1 Oil Pressure Sensor Torque 16 N·m
(142 lb.-in.)

[9] -
LEGEND:
A Transmission Oil Boost Check Valve Plug
B Transmission Oil Boost Check Valve Spring
C Transmission Oil Boost Check Valve
Remove transmission oil boost check valve plug (A), transmission oil boost check valve plug
spring (B), and transmission oil boost check valve (C).
Transmission Oil Boost Check Valve Spring Free Length 48 mm
(1.89 in.)
(1.39 in. at 10—12.36 lb.-force)
[11] - Install transmission oil boost check valve, transmission oil boost check valve spring,
and transmission oil boost check valve plug. Tighten to specification.
Transmission Oil Boost Check Valve Plug Torque 35 N·m
(26 lb.-ft.)

[12] -
LEGEND:
A Transmission Oil Boost Solenoid Valve
B Transmission Oil Boost Solenoid Valve Spool
C Transmission Oil Boost Solenoid Valve Spring
Remove transmission oil boost solenoid valve (A), transmission oil boost solenoid valve spool
(B), and transmission oil boost solenoid valve spring (C).
Transmission Oil Boost Solenoid Valve Spring Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)
[14] - Install transmission oil boost solenoid valve spring, transmission oil boost solenoid
valve spool, and transmission oil boost solenoid valve. Tighten to specification.
Transmission Oil Boost Solenoid Valve Torque 35 N·m
(26 lb.-ft.)

[15] -
LEGEND:
A Hydraulic Oil Cooler Control Solenoid Valve
B Hydraulic Oil Cooler Control Solenoid Valve Spool
C Hydraulic Oil Cooler Control Solenoid Valve
D Hydraulic Oil Cooler Control Solenoid Valve Spring
Remove hydraulic oil cooler control solenoid valve (A), hydraulic oil cooler control solenoid
valve spool (B), hydraulic oil cooler control solenoid valve (C), and hydraulic oil cooler control
solenoid valve spring (D).
Hydraulic Oil Cooler Control Solenoid Valve Spring Free Length 74.3 mm
(2.93 in.)
(2.48 in. at 56.65—69.24 lb.-force)
(2.36 in. at 79.58 lb.-force)
[17] - Install hydraulic oil cooler control solenoid spring, hydraulic oil cooler control solenoid
valve, hydraulic oil cooler control solenoid valve spool, and hydraulic oil cooler control
solenoid valve. Tighten to specification.
Hydraulic Oil Cooler Control Solenoid Valve Torque 35 N·m
(26 lb.-ft.)

[18] -
LEGEND:
A Transmission Oil Temperature Sensor
B O-Ring
Remove transmission oil temperature sensor (A).
[20] - Lubricate O-ring (B) and install sensor. Tighten to specification.
(239 lb.-in.)

[21] -
LEGEND:
A Pressure Regulating Valve Plug
B Pressure Regulating Valve
C Shims (2 used)
D Pressure Regulating Valve Inner Spring
E Pressure Regulating Valve Outer Spring
Remove pressure regulating valve plug (A), pressure regulating valve (B), shims (C), pressure
regulating valve inner spring (D), and pressure regulating valve outer spring (E).
Pressure Regulating Valve Inner Spring Free Length 110 mm
(4.33 in.)
(3.21 in. at 32.7—37 lb.-force)
(4.33 in.)
(3.21 in. at 73.13—82 lb.-force)
[23] - Install pressure regulating valve springs, shims, and pressure regulating valve.
[24] - Install pressure regulating valve plug and tighten to specification.
(26 lb.-ft.)

[25] -
LEGEND:
B Loop Flush Shut-Off Solenoid Valve
C Clamp
Remove cap screws (A), loop flush shut-off solenoid valve (B), and clamp (C).
[27] - Install clamp, loop flush shut-off solenoid valve, and cap screws. Tighten to
specification.
Loop Flush Shut-Off Solenoid Valve Cap Screws Torque 10 N·m
(89 lb.-in.)
[28] -
LEGEND:
A Loop Flush Relief Valve Plug
B Loop Flush Relief Valve Spring
C Loop Flush Relief Valve Ball
Remove loop flush relief valve plug (A), loop flush relief valve spring (B), and loop flush relief
valve ball (C).


Loop Flush Relief Valve Spring Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)
[30] - Install loop flush relief valve ball, loop flush relief valve spring, and loop flush relief
valve plug. Tighten to specification.
Loop Flush Relief Valve Plug Torque 20 N·m
(177 lb.-in.)
[31] -
LEGEND:
A Lube Relief Valve Plug
B Lube Relief Valve Spring
C Lube Relief Valve
Remove lube relief valve plug (A), lube relief valve spring (B), and lube relief valve (C).
Lube Relief Valve Spring Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)

[33] - Install lube relief valve, lube relief valve spring, and lube relief valve plug. Tighten to
specification.
Lube Relief Valve Plug Torque 35 N·m
(26 lb.-ft.)
Exploded View—Rear Valve Housing
LEGEND:
A Mode 1/3 Selector Solenoid
B Mode 1/3 Clutch Solenoid
C Mode 2 Clutch Solenoid
D Clutch Enable Solenoid Valve
E Clutch Enable Pressure Sensor
F Park Brake Supply Inlet Check Valve
G Park Brake Sump Block Solenoid
H Park Brake Supply Solenoid

I Park Brake Pressure Sensor

J Forward Synchronizer Solenoid
K Reverse Synchronizer Solenoid
L MFWD Clutch Solenoid

Repair Rear Valve Housing

[1] -
IMPORTANT:
Replace and lubricate all O-rings with clean hydraulic oil before installing
LEGEND:
A Mode 1/3 Selector Solenoid Valve
B Mode 1/3 Selector Solenoid Valve Spool
C Mode 1/3 Selector Solenoid Valve Spring
Remove mode 1/3 selector solenoid valve (A), mode 1/3 selector solenoid valve spool (B),
and mode 1/3 selector solenoid valve spring (C).
Mode 1/3 Selector Solenoid Valve Spring Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)
[3] - Install mode 1/3 selector solenoid valve spring, mode 1/3 selector solenoid valve spool,
and mode 1/3 selector solenoid valve. Tighten to specification.
Mode 1/3 Selector Solenoid Valve Torque 35 N·m
(26 lb.-ft.)

[4] -
LEGEND:
B Clamps (2 used)
C Mode 1/3 Clutch Solenoid Valve
D Mode 2 Clutch Solenoid Valve
Remove cap screws (A), clamps (B), mode 1/3 clutch solenoid valve (C), and mode 2 clutch
solenoid valve (D).
[6] - Install mode 2 clutch solenoid valve, mode 1/3 clutch solenoid valve, clamps, and cap
screws. Tighten to specification.
Mode 1/3 and Mode 2 Clutch Solenoid Valve Cap Screws Torque 20 N·m
(177 lb.-in.)

[7] -
LEGEND:
A Clutch Enable Solenoid Valve
B Clutch Enable Solenoid Valve Spool
C Clutch Enable Solenoid Valve Spring
Remove clutch enable solenoid valve (A), clutch enable solenoid valve spool (B), and clutch
enable solenoid valve spring (C).
Clutch Enable Solenoid Valve Spring Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)
[9] - Install clutch enable solenoid valve spring, clutch enable solenoid valve spool, and
clutch enable solenoid valve. Tighten to specification.
Clutch Enable Solenoid Valve Torque 35 N·m
(26 lb.-ft.)

[10] -
LEGEND:
A Clutch Enable Pressure Sensor
B O-Ring
Remove clutch enable pressure sensor (A).
[12] - Lubricate O-ring (B) and install clutch enable pressure sensor. Tighten to specification.
(142 lb.-in.)
[13] -
LEGEND:
A Park Brake Inlet Check Valve Plug
B O-Ring
C Park Brake Inlet Check Valve Spring
D Park Brake Inlet Check Valve Ball
Remove park brake inlet check valve plug (A) O-ring (B), park brake inlet check valve spring
(C), and park brake inlet check valve ball (D).


Park Brake Inlet Check Valve Spring Free Length 18.5 mm
(0.73 in.)
[15] - Install park brake inlet check valve ball, park brake inlet check valve spring, O-ring,
and park brake inlet check valve plug. Tighten to specification.
Park Brake Inlet Check Valve Plug Torque 20 N·m
(177 lb.-in.)
[16] -
LEGEND:
B Park Brake Supply Solenoid Valve
C Clamp
Remove cap screws (A), park brake supply solenoid valve (B), and clamp (C).
[18] - Install clamp, park brake supply solenoid valve, and cap screws. Tighten to
specification.
Park Brake Supply Solenoid Valve Cap Screws Torque 10 N·m
(89 lb.-in.)

[19] -
LEGEND:
A Cap Screw
B Clamp
C Park Brake Sump Block Solenoid Valve
Remove cap screw (A), clamp (B), and park brake sump block solenoid valve (C).
[21] - Install park brake sump block solenoid valve, clamp, and cap screw. Tighten to
specification.
Park Brake Sump Block Solenoid Valve Cap Screws Torque 10 N·m
(89 lb.-in.)
[22] -
LEGEND:
A Park Brake Pressure Sensor
B O-Ring
Remove park brake pressure sensor (A) with O-ring (B).

[24] - Install park brake pressure sensor and tighten to specification.

Park Brake Pressure Sensor Torque 16 N·m
(142 lb.-in.)
[25] -
LEGEND:
A Forward Synchronizer Solenoid Valve
B Forward Synchronizer Solenoid Valve Spool
C Forward Synchronizer Solenoid Valve Spring
D Reverse Synchronizer Solenoid Valve
E Reverse Synchronizer Solenoid Valve Spool
F Reverse Synchronizer Solenoid Valve Spring
Remove forward synchronizer solenoid valve (A), forward synchronizer solenoid valve spool
(B), and forward synchronizer solenoid valve spring (C), reverse synchronizer solenoid valve
(D), reverse synchronizer solenoid valve spool (E), reverse synchronizer solenoid valve spring
(F).
Forward and Reverse Synchronizer Solenoid Valve Springs Free Length 46.4 mm
(1.83 in.)
(1.50 in. at 31—41 lb.-force)
[27] - Install forward and reverse synchronizer solenoid valve springs, forward and reverse
synchronizer solenoid valve spools, and forward and reverse synchronizer solenoid valves.
Tighten to specification.
Forward and Reverse Synchronizer Solenoid Valves Torque 35 N·m
(26 lb.-ft.)

[28] -
LEGEND:
A Cap Screw
B Clamp
C MFWD Clutch Solenoid Valve
Remove cap screw (A), clamp (B), and MFWD clutch solenoid valve (C).
[30] - Install MFWD clutch solenoid valve, clamp, and cap screw. Tighten to specification.
MFWD Clutch Solenoid Valve Cap Screw Torque 10 N·m
(89 lb.-in.)

Exploded View—Hydrostatic Gear Train
LEGEND:
A Ring Unit
B First Sun Unit
C Second Sun Unit
D Bearing Support
E Cylindrical Roller Bearing
F Cylindrical Roller Bearing

G Bearing Support
H Cap Screws (7 used)
I Cap Screws (4 used)
J O-Rings (3 used)
K Sealing Ring
L Bearing Cup
M Bearing Cone
N Input Assembly
O Ring 1 Drive Gear
P Bearing Cone
Q Bearing Cup
R Adjusting Ring
S Retainer
T Cap Screw
U Snap Ring
V Thrust Washer
W Needle Bearing
X Spacer
Y Bearing Cup
Z Bearing Cone
AA First SU Idler Gear
BB Bearing Cone
CC Bearing Support
DD Bearing Cup
EE Adjusting Ring

Repair Hydrostatic Gear Train

[1] -
LEGEND:
B Bearing Support
C SU Idler Gear
Remove cap screws (A), bearing support (B), and SU idler gear (C).
[2] -
CAUTION:
Hydro bearing support weighs approximately 33 kg (73 lb.)

LEGEND:
B Hydro Bearing Support
Remove cap screws (A) and hydro bearing support (B).
[3] -
IMPORTANT:
Prevent damage to bearing support. Properly support bearing frame when
installing bearings and bearing cup.
→NOTE:
Ensure bearing cup is pressed to adjusting ring.
LEGEND:
A Bearing Cup
B 110 mm (4-5/16 in.) Driver Disk
Replace bearing cup (A).
[4] - Use 110 mm (4-5/16 in.) driver disk (B) and press to install bearing cup.

[5] -
LEGEND:
A Bearing Cones (2 used)
Replace bearing cones (A).
[6] - Press bearing cones until fully seated.
[7] -
LEGEND:
A Bearing Cup
[8] - Use 110 mm (4-5/16 in.) driver disk (B) to install bearing cup until fully seated.

[9] -
LEGEND:
A Bearings (2 used)
B Bearing Cup
C 86 mm (3-3/8 in.) Driver Disk
D 76 mm (3 in.) Driver Disk
E 127 mm (5 in.) Driver Disk
Replace bearings (A) and bearing cup (B).
[10] - Use 86 mm (3-3/8 in.) driver disk (C) and press to install bearing until fully seated.
[11] - Use 76 mm (3 in.) driver disk (D) and press to install bearing until fully seated.
[12] -
→NOTE:
Ensure bearing cup is pressed to adjusting ring.
Use 127 mm (5 in.) driver disk (E) and press to install bearing cup.

[13] -
LEGEND:
B Output Assembly
Remove seal rings (A) and output assembly (B).
[14] -
LEGEND:
A Gears (2 used)
B Bearing Races (2 used)
Remove gears (A) and bearing races (B).

[15] -
LEGEND:
A Sun 1 Input Shaft
B Gear
Remove sun 1 input shaft (A) and gear (B).
[16] -
LEGEND:
B Sun 1 Input Shaft Bearing Support
Remove cap screws (A) and sun 1 input shaft bearing support (B).

[17] -
No further disassembly of hydrostatic module is allowed.

IMPORTANT:
Before shipping hydrostatic module transfer the ”Hydrostatic Gear Train”
to the replacement module. (See Exploded View—Hydrostatic Gear Train in
this group.)
Return hydrostatic module core for remanufacture.

[18] -
LEGEND:
A Bearing Cup
[19] - Use 98 mm (3-7/8 in.) driver disk (B) and press to install bearing cup.
[20] -
LEGEND:
Remove bearing cones (A) from input shaft.
[21] - Use press and spacer to install bearing cones until fully seated.

[22] -
LEGEND:
A Snap Ring
B Washer
C Bearing
D Spacer
E Bearing Cone
Remove snap ring (A), washer (B), bearing (C), spacer (D), and bearing cone (E).
[23] -
LEGEND:
A Bearing Cup

[24] - Use 98 mm (3-7/8 in.) driver disk (B) and press to install bearing cup until fully seated.
[25] -
LEGEND:
A Spacer
B Bearing
C Washer
D Snap Ring
Install spacer (A), bearing (B), washer (C), and snap ring (D).
[26] -
LEGEND:
A Bearing Cone

[27] -
LEGEND:
B Sun 1 Input Shaft Bearing Support
Install sun 1 input shaft bearing support (B) and cap screws (A). Tighten to specification.
Sun 1 Input Shaft Bearing Support Cap Screws Torque 125 N·m
(92 lb.-ft.)

[28] -
LEGEND:
A Sun 1 Input Shaft
B Gear
Install sun 1 input shaft (A) and gear (B).
[29] -
LEGEND:
A Gears (2 used)
B Bearing Races (2 used)
Install gears (A) and bearing races (B).

[30] -
LEGEND:
B Ring 1 Drive Gear
Install ring 1 drive gear (B) and seal rings (A).
[31] -
LEGEND:
A O-Rings (3 used)
Install O-rings (A).

[32] -
LEGEND:
B Hydro Bearing Support
Install hydro bearing support (B) and cap screws (A). Tighten to specification.
Hydro Bearing Support Cap Screws Torque 125 N·m
(92 lb.-ft.)

[33] -
LEGEND:
B Bearing Support
C SU Idler Gear
Install SU idler gear (C), bearing support (B), and cap screws (A). Tighten to specification.
SU Idler Gear Bearing Support Cap Screws Torque 125 N·m
(92 lb.-ft.)
[34] -
LEGEND:
A JDG11191 Hydro Adjusting Ring Tool
B Adjusting Ring
Using JDG11191 Hydro Adjusting Ring Tool (A) adjust adjusting ring (B) until minimal amount
of end play can be measured.

[35] -
LEGEND:
A SU Idler Shaft
B JDG11196 472 mm DDS Spline Socket
Install SU idler shaft (A).
[36] - Using JDG11196 472 mm DDS Spline Socket (B) record initial rolling drag torque.
[37] - Using JDG11191 Hydro Adjusting Ring Tool tighten adjusting ring until initial rolling
drag torque is increased by 1.4—3.6 N·m (12—32 lb.-in.).

[38] -
LEGEND:
A Retaining Clip
B Cap Screw
Install retaining clip (A) and cap screw (B). Tighten to specification.
SU Idler Gear Bearing Support Retaining Clip Cap Screws Torque 20 N·m
(180 lb.-in.)
[39] -
→NOTE:
Ensure to rotate both shafts several times before checking end play.

LEGEND:
A JDG11191 Hydro Adjusting Ring Tool
Use JDG11191 Hydro Adjusting Ring Tool (A) to adjust end play.
Sun 1 Input Shaft/Ring 1 Drive Gear Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)

[40] -
LEGEND:
A Ring 1 Drive Adjusting Nut Retaining Clip
B Cap Screw
Install ring 1 drive adjusting nut retaining clip (A) and cap screw (B). Tighten to specification.
Ring 1 Drive Adjusting Nut Retaining Clip Cap Screw Torque 20 N·m
(180 lb.-in.)
Cross Sectional View—Synchronizer

LEGEND:
A Sleeve
B O-Ring
C Snap Ring
D Snap Ring
E Plate
F O-Ring
G Seal
H O-Ring
I Stop
J Compression Ring
K Piston
L O-Ring
M Seal
N Forward/Reverse Shift Bar
O Fork
P Cap Screw
Q Nut
R Bushing

Repair Synchronizer
[1] -
LEGEND:
A Snap Ring
B Piston Sleeve
C Spring Retainer
D Synchronizer Spring
Remove snap ring (A), piston sleeve (B), spring retainer (C), and synchronizer spring (D).
Synchronizer Spring Free Length 39.7 mm
(1.56 in.)
(1.26 in. at 32—40 lb.-force)
(0.87 in. at 74—91 lb.-force)
[3] - Lubricate O-ring and install spring, spring retainer, piston sleeve, and snap ring.

[4] -
LEGEND:
A Reverse Output Gear
B Reverse Input Gear
C Synchronizer
Remove reverse output gear (A), reverse input gear (B), and synchronizer (C).
[5] -
LEGEND:
A Synchronizer Shift Fork Socket Head Screws (2 used)
Remove synchronizer shift fork socket head screws (A).

[6] -
LEGEND:
A Shift Fork Assembly
Remove shift fork assembly (A).
[7] -
LEGEND:
A Reaction Plate
B Shift Fork Spring
C Spring Retainer
Remove reaction plate (A), shift fork spring (B), and spring retainer (C).


Shift Fork Spring Free Length 39.7 mm
(1.56 in.)
(1.26 in. at 32—40 lb.-force)
(0.87 in. at 74—91 lb.-force)
[9] -
LEGEND:
A Synchronizer Shift Rail Nut
B Shift Piston
Remove nut (A) and shift piston (B).
[10] -
LEGEND:
A Seal
B O-ring
Remove seal (A) and O-ring (B) from piston.

[11] -
LEGEND:
A O-ring
B JDG1860 Seal Installer
C Seal
Install NEW O-ring (A).
[12] - Position JDG1860 Seal Installer (B) and seal (C) on piston.
[13] -
LEGEND:
A JDG1860 Seal Installer with Driver
Use small ID of JDG1860 Seal Installer driver to push seal part way down installer.

[14] -
LEGEND:
A JDG1860 Seal Installer Driver
Invert driver (A) to finish installing seal to piston.
[15] -
LEGEND:
A Synchronizer Shift Rail Nut
B Shift Piston
Install shift piston and synchronizer shift rail nut. Tighten to specification.
Synchronizer Shift Rail Nut Torque 90 N·m
(66 lb.-ft.)

[16] -
LEGEND:
A Reaction Plate
B Shift Fork Spring
C Spring Retainer
Install spring retainer (C), shift fork spring (B), and reaction plate (A).
[17] -
→NOTE:
Ensure arrow (B) faces away from the reaction plate as shown.
LEGEND:
A Shift Fork Assembly
B Arrow

Install shift fork assembly (A).

[18] -
LEGEND:
A Synchronizer Shift Fork Socket Head Screws (2 used)
Install synchronizer shift fork socket head screws (A) and tighten to specification.
Synchronizer Shift Fork Socket Head Screws Torque 37 N·m
(27 lb.-ft.)
[19] -
LEGEND:
A Bearing Cone

[20] -
LEGEND:
A Bearing Cup
[21] -
LEGEND:
A Oil Dam Snap Ring
Remove oil dam snap ring (A).
[23] - Install oil dam snap ring.
[24] -
→NOTE:

LEGEND:
Use 98 mm (3-7/8 in.) driver disk (A) to install bearing cup until fully seated.
[25] -
LEGEND:
A Bearing Cone

[26] -
LEGEND:
A Bearing Cone
Replace bearing cone (A) using hydraulic press.
[27] -
LEGEND:
A Reverse Input Gear Sleeve
Remove reverse input gear sleeve (A).
[29] - Install reverse input gear sleeve.

[30] -
LEGEND:
A Cones (2 used)
B Collar
Remove cones (A) and collar (B).
[31] -
LEGEND:
A Springs (3 used)
B Balls (3 used)
C Cams (3 used)
Remove springs (A), balls (B), and cams (C).
[33] -
→NOTE:
A hose clamp can be used to help retain cams, balls, and springs.
Install springs, balls, and cams.

[34] -
→NOTE:
Press down evenly on hub and three cams.
Ensure correct placement of tabs (C) on collar slot (D).
LEGEND:
A Hub Assembly
B Collar
C Tab
D Collar Slot
Carefully install hub assembly (A) into collar (B).
[35] -
IMPORTANT:
Lugs (B) on cones must align with notches (C) in collar.
LEGEND:
A Cones (2 used)
B Lugs (3 used)
C Notches (3 used)
Install cones (A).

Cross Sectional View—Mode 2/Mode 3 Clutch

Assembly
LEGEND:
A Mode 2 Clutch Hub
B Seal
C Seal
D Piston
E Disk Spring
F Piston
G Snap Ring
H Clutch Plates (7 used)
I Clutch Disks (6 used)
J Clutch Cover
K Cap Screws (6 used)
L Thrust Washer
M Mode 3 Output Shaft
N Valve Seat
O Steel Ball
P Bearing Race
Q Seal
R Needle Bearing
S Snap Ring
T Piston
U Seal
V Disk Spring
W Retainer
X Snap Ring

Y Clutch Plates (9 used)

Z Clutch Disks (8 used)
AA Clutch Cover
BB Snap Ring
CC Spur Gear
DD Sealing Rings (2 used)
EE Ring Gear
FF Snap Ring

Repair Mode 3 Clutch Assembly

[1] -
IMPORTANT:
Only compress gear (B) far enough to remove snap ring.
LEGEND:
B Gear
C Snap Ring
Position clutch assembly in press.
[2] - Use JDG754 Spring Compressor (A) to remove snap ring (C).
[3] -
LEGEND:
A Sleeve
B Gear
Remove sleeve (A) and gear (B).

[4] -
LEGEND:
A Snap Ring
[5] -
LEGEND:
A Cover
B Disks (8 used)
C Plates (9 used)
Remove cover (A), disks (B), and plates (C).
[6] -
IMPORTANT:
Only compress sleeve (B) far enough to remove snap ring.

LEGEND:
A Snap Ring
B Sleeve
C JDG754 Spring Compressor
Use JDG754 Spring Compressor (C) to remove snap ring (A).
[7] -
LEGEND:
A Sleeve
B Springs (4 used)
C Piston
Remove sleeve (A), springs (B), and piston (C).
[8] -
→NOTE:

LEGEND:
A Snap Ring
B Bearing
Remove snap ring (A) and bearings (B).
[9] -
IMPORTANT:
Only press in bearing far enough to install snap ring.
Use a 62 mm (2-7/16 in.) driver disk (C) to install new bearing.

[10] - Install snap ring.

[11] -
LEGEND:
A Seal
Install new seal (A).
[12] -
LEGEND:
A Seal
Install new seal (A) on piston.

[13] -
LEGEND:
A Seals
B Piston
[14] -
IMPORTANT:
Ensure correct orientation of springs.
LEGEND:
A Springs (4 used)
Install springs (A) as illustrated.

[15] -
LEGEND:
A Snap Ring
B Sleeve
C JDG754 Spring Compressor
Install sleeve (B).
[16] -
IMPORTANT:
Only compress sleeve far enough to remove snap ring.
→NOTE:
Ensure correct orientation of snap ring (A).
Use JDG754 Spring Compressor (C) and hydraulic press to install snap ring.

[17] -
IMPORTANT:
→NOTE:
Ensure correct orientation of cover.
LEGEND:
A Cover
B Disks (8 used)
C Plates (9 used)
Install cover (A), disks (B), and plates (C).
[18] -
LEGEND:
A Snap Ring

[19] -
LEGEND:
A Sleeve
B Gear
Install gear (B) and sleeve (A).
[20] -
IMPORTANT:
Only compress gear (B) far enough to install snap ring.
→NOTE:
Ensure correct orientation of snap ring.

LEGEND:
B Gear
C Snap Ring
Use JDG754 Spring Compressor (A) and press to install snap ring (C).
Cross Sectional View—MFWD Clutch

LEGEND:
A Gear
B Bearing Cup
C Snap Ring
D MFWD Shaft
E O-Ring
F Disk Spring
G Pin
H Plate
I Piston
J Packing
K Packing
L Packing
M Cap Screw
N Output Hub
O Clutch Plates (11 used)
P Clutch Disks (10 used)
Q Bearing Cone
R Bearing Cup
S Seal Rings (2 used)
T Adjusting Ring

Repair MFWD Clutch

[1] - Position MFWD clutch in hydraulic press.
[2] - Remove seal rings (A).
[3] -
LEGEND:
B Snap Ring
Use press to compress piston assembly far enough to remove snap ring (B).
[4] - Release tension on MFWD clutch.
[5] -
→NOTE:

LEGEND:
Reposition MFWD clutch in hydraulic press with piston assembly facing down.
[6] - Use 98 mm (3-7/8 in.) driver disk (A) and press to remove piston assembly.
[7] -
LEGEND:
B Piston Assembly
Install JT05550 Lifting Eyebolts (A).

[8] - Lift piston assembly (B).

[9] -
LEGEND:
A Output Hub
Remove output hub (A).
[10] -
LEGEND:
A Clutch Plates (11 used)
B Clutch Disks (10 used)
Remove clutch plates (A) and disks (B).

[11] -
LEGEND:
Remove socket head screws (A).
[12] -
LEGEND:
A Seal
B Piston
Remove seal (A) with piston (B).

[13] -
LEGEND:
A Springs (3 used)
Remove springs (A).
[14] -
LEGEND:
A Plate
B Seals
Remove seals (B) with plate (A).

[15] -
LEGEND:
A Seal
Replace seal (A) on plate.
[16] -
LEGEND:
A Seal
Replace seal (A) on piston.

[17] -
LEGEND:
A Plate
B Seals (2 used)
Lubricate seals (B) with clean hydraulic oil and install plate (A).
[18] -
LEGEND:
A O-Rings (2 used)
Replace O-rings (A).
[19] -
IMPORTANT:

LEGEND:
A Springs (3 used)

[20] -
LEGEND:
A Seal
B Piston
Replace seal (A).
[21] - Lubricate seal with clean hydraulic oil and install piston (B).

[22] -
LEGEND:
Apply LOCTITE 242 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (us)
[23] - Install socket head screws and tighten to specification.
MFWD Piston Socket Head Screws Torque 70 N·m
(52 lb.-ft)

[24] -
LEGEND:
A Bearing Cup
[25] -
IMPORTANT:
Properly support housing when installing bearing cup.
LEGEND:
Use 124 mm (4-7/8 in.) driver disk (A) and press to install bearing cup.

[26] -
IMPORTANT:
Properly support housing when installing bearing cone.
LEGEND:
A Bearing Cone
B Spacer
Replace bearing cone (A).
[27] - Use press and spacer (B) to install bearing cone.
[28] -
IMPORTANT:
Properly support housing when removing shaft.

LEGEND:
A Punch
Use hydraulic press and punch (A) to remove shaft.
[29] -
LEGEND:
A Shaft
Use press to install shaft (A).
[30] -
→NOTE:
Ensure correct orientation of output hub. (See Cross Sectional View—MFWD
Clutch .)

LEGEND:
A Output Hub
Install output hub (A).
[31] -
IMPORTANT:
LEGEND:
A Clutch Plates (11 used)
Install clutch plates (A) and clutch disks (B).

[32] -
LEGEND:
A JDG11212 MFWD Clutch Alignment Tool
Use JDG11212 MFWD Clutch Alignment Tool (A) to align gear.
[33] -
LEGEND:
B Piston Assembly
Install piston assembly (B).
[34] - Remove JT05550 Lifting Eyebolts (A).

[35] -
LEGEND:
B Snap Ring
Use press to install snap ring (B).
[36] - Install seal rings (A).
[37] -
LEGEND:
A JDG11212 MFWD Clutch Alignment Tool
Remove JDG11212 MFWD Clutch Alignment Tool (A).

[38] -
LEGEND:
Use 98 mm (3-7/8 in.) driver disk (A) and press to push clutch assembly against snap ring.
Cross Sectional View—Park Brake

LEGEND:
A Plate
B Packing
C Piston
D Packing
E Disk Springs (3 used)
G Housing
H Clutch Plates (11 used)

I Clutch Disks (10 used)
J Cap Screws (10 used)
K Bearing Ball
L Bearing Cone
M Ring
N MFWD Output Shaft
O Bushing
P Tone Wheel

Repair Park Brake

[1] -
LEGEND:
[2] - Remove housing, brake disks, and brake plates.
[3] -
LEGEND:
B Piston Assembly
Gradually loosen cap screws (A).
[4] - Remove piston assembly (B).

[5] -
LEGEND:
A Springs (3 used)
Remove springs (A).
[6] -
LEGEND:
A Oil Seal
Remove oil seal (A).

[7] -
LEGEND:
A O-Ring
B Spring Radius Ring
Replace O-ring (A) and spring radius ring (B).
[8] -
LEGEND:
A Shaft
B Tone Wheel
Remove shaft (A) and tone wheel (B).

[9] -
LEGEND:
A Piston
Remove piston (A).
[10] -
LEGEND:
A Bearing Cone

[11] -
LEGEND:
A Bearing
Replace bearing (A).
[12] -
LEGEND:
A Seals (2 used)
Replace seals (A).

[13] -
LEGEND:
A Piston
Lubricate seals with clean hydraulic oil and install piston (A).
[14] -
IMPORTANT:

LEGEND:
A Springs (3 used)
[15] -
IMPORTANT:
Ensure correct orientation of tone wheel (B).
LEGEND:
A Shaft
B Tone Wheel
Install shaft (A) and tone wheel (B).

[16] -
LEGEND:
B Piston Assembly
Install piston assembly (B).
(52 lb.-ft.)
[18] -
IMPORTANT:
Brake plates and disks are a matched set. DO NOT mix plates and disks
with other brake sets.
→NOTE:
Ensure correct orientation of brake plates.

LEGEND:
A JDG11215 Park Brake Alignment Tool
C Brake Plates (11 used)
Use JDG11215 Park Brake Alignment Tool (A) to align brake disks (B) and plates (C).
[19] - Install housing.
[20] - Gradually tighten cap screws (D) to specification.
(52 lb.-ft.)

[21] - Remove JDG11215 Park Brake Alignment Tool (A).

[22] -
LEGEND:
A JDG11305 MFWD Output Shaft Seal Installer
B Oil Seal
Use JDG11305 MFWD Output Shaft Seal Installer (A) to install oil seal (B).

Repair Reverse Idler

[1] -
LEGEND:
A Spring Pin
[2] -
LEGEND:
A Nut
Remove nut (A).

[3] -
LEGEND:
A Shaft
Use hydraulic press and spacer to remove shaft (A).
[4] -
LEGEND:
A Bearing Cone

[5] -
LEGEND:
A Bearing Cups ( 2 used)
[6] -
→NOTE:
LEGEND:
Use 71 mm (2-13/16 in.) driver disk (A) to install bearing cups.
[7] -
IMPORTANT:
Ensure at least 0.2 mm end play exists after pressing.
→NOTE:
Ensure correct orientation of gear.

LEGEND:
A Gear
B Bearing Cone
Install gear (A).
[8] - Use press to install bearing cone (B).
[9] -
LEGEND:
A Nut
Install nut (A).

[10] -
Adjust end play.

Reverse Idler Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)
[11] -
→NOTE:
Tighten nut until slot in nut is aligned with hole in shaft.
LEGEND:
A Spring Pin
Install spring pin (A).
Cross Sectional View—Mode-1 Clutch

LEGEND:
A Mode-1 Clutch Hub
B Thrust Washer
C Mode-1 Clutch Drum
D Seal
E Piston
F Seal
G Disk Springs (5 used)
H Snap Ring
I O-Ring
J Clutch Plates (10 used)
K Clutch Disks (9 used)
L Clutch Cover
M Snap Ring
N Thrust Washer
O Sealing Rings (2 used)

Repair Mode-1 Clutch

[1] -
LEGEND:
A Clutch Hub
Remove clutch hub (A).
[2] -
LEGEND:
A Thrust Washer
Inspect thrust washer (A) and replace as necessary.

[3] -
LEGEND:
A Snap Ring
[4] -
LEGEND:
A Cover
B Disks (10 used)
C Plates (9 used)
Remove cover (A), disks (B), and plates (C).

[5] -
LEGEND:
B Snap Ring
Use JDG754 Spring Compressor (A) and press to remove snap ring (B).
[6] -
LEGEND:
A Springs (5 used)
B Piston
Remove springs (A) and piston (B).

[7] -
LEGEND:
A Seal
Install new seal (A) on piston.
[8] -
LEGEND:
A Seal
B O-Ring
Replace seal (A) and O-ring (B).

[9] -
LEGEND:
A Seals (2 used)
B Piston
[10] -
IMPORTANT:
Note correct orientation of springs.

LEGEND:
A Springs (5 used)
Install springs (A) as illustrated.
[11] -
→NOTE:
Ensure correct orientation of snap ring.
LEGEND:
A Snap Ring
Use JDG754 Spring Compressor and press to install snap ring (A).

[12] -
LEGEND:
A Clutch Hub
Install clutch hub (A).
[13] -
IMPORTANT:
→NOTE:
Ensure correct orientation of cover.
LEGEND:
A Plates (9 used)
B Disks (10 used)

C Cover
D Gear
Install plates (A), disks (B), and cover (C) on gear (D).
[14] -
LEGEND:
A Snap Ring
Cross Sectional View—SU Idler
LEGEND:
1 Sealing Ring
2 SU Idler Retaining Nut
3 Bearing Cone
4 Bearing Cup
5 Housing
6 Bearing Cup
7 Bearing Cone
8 Sealing Ring
9 SU Idler Shaft

Repair SU Idler
[1] -
LEGEND:
Remove sealing rings (A).
[2] -
→NOTE:
JDG11187P1 Locking Nut Tool and JDG11187P2 Locking Nut Tool are part of
JDG11187 Locking Nut Tool .
LEGEND:
A JDG11187P1 Locking Nut Tool
B JDG11187P2 Locking Nut Tool
Use JDG11187P2 Locking Nut Tool to hold the shaft while using JDG11187P1 Locking Nut Tool
to remove nut.

[3] -
LEGEND:
A SU Idler Shaft
Use hydraulic press to remove SU idler shaft (A).
[4] -
LEGEND:
A Bearing Cone

[5] -
LEGEND:
A Bearing Cup
[6] -
→NOTE:
LEGEND:
B Bearing Cup
Use 117 mm (4-5/8 in.) driver disk (A) to install bearing cup (B).

[7] -
LEGEND:
A Bearing Cup
[8] -
LEGEND:
Use 89 mm (3-1/2 in.) driver disk (A) to install bearing cup.

[9] -
LEGEND:
A Bearing Cone
Use hydraulic press and bearing separator to remove bearing cone (A).
[10] - Use press to install new bearing cone.
[11] -
LEGEND:
A Bearing Cone
Install shaft.
[12] -
IMPORTANT:
Ensure end play exists in excess of 0.2 mm to allow for bearing setting.
→NOTE:
JDG1255 Slinger-Seal Installer can be used to install bearing cone (A).
Use press to install bearing cone.

[13] -
LEGEND:
A SU Idler Retaining Nut
Install SU idler retaining nut (A).

[14] -
LEGEND:
A JDG11187P1 Locking Nut Tool
B JDG11187P2 Locking Nut Tool
Use JDG11187P1 Locking Nut Tool (A) and JDG11187P2 Locking Nut Tool (B) to adjust end
play.
SU Idler End Play 0.05—0.20 mm
(0.002—0.007 in.)

[15] -
LEGEND:
Replace sealing rings (A).
Exploded View—Input Planetary
LEGEND:
A Ring Gear
B Thrust Washer
C Planet Pinion Carrier
D Input Shaft
E Washer
F Thrust Washer
G First Sun Gear
H Pin
I Planet Pinion
J Needle Bearing
K Cylindrical Roller Bearing
L Spacer
M Shaft Retaining Pin
N Screw
O Bearing
P Snap Ring
Q Washer
R Seal Rings (2 used)
S Transmission Input Hub
T Cap
U Orifice
Cross Sectional View—Input Planetary
LEGEND:
A Ring Gear
B Thrust Washer
C Planet Pinion Carrier
D Input Shaft
E Washer
F Thrust Washer
G First Sun Gear
H Pin
I Planet Pinion
J Needle Bearing
K Cylindrical Roller Bearing
L Spacer
M Shaft Retaining Pin
N Screw
O Bearing
P Snap Ring
Q Washer
R Ring
S Transmission Input Hub
T Cap
U Orifice
V Sealing Rings (2 used)

Repair Input Planetary

[1] -
LEGEND:
A Screws (3 used)
Remove screws (A).
[2] -

LEGEND:
A Retaining Pin (3 used)
Install retaining pins (A) in pinion shafts.

[3] -
LEGEND:
A Shafts (3 used)
B Washers (3 used)
Remove shafts (A) washers (B).
[4] -
LEGEND:
A Retaining Pin
B Shaft
Remove retaining pin (A) from shaft (B).

[5] -
LEGEND:
A Planetary Pinions (3 used)
Remove planetary pinions (A).
[6] -
LEGEND:
A Needle Bearing
B Spacer
Remove needle bearing (A) and spacer (B).
[7] -
→NOTE:
Use D01061AA Blind-Hole Puller Set to aid in removal of bearing.

LEGEND:
A Bearing
Remove bearing (A).
[8] -
→NOTE:
LEGEND:
Use 62 mm (2-7/16 in.) driver disk (A) and hydraulic press to install bearing until fully seated.

[9] -
LEGEND:
A Needle Bearing
B Spacer
Install needle bearing (A) and spacer (B).
[10] -
LEGEND:
A Sun Gear
B Thrust Washers (2 used)
Remove sun gear (A) and thrust washers (B).
[12] - Install sun gear and thrust washers.

[13] -
IMPORTANT:
Sun gear and planet pinions MUST be timed. Match markings as illustrated
for each planet pinion.
LEGEND:
A Planetary Pinions (3 used)
Install planetary pinions (A).

[14] -
LEGEND:
A Retaining Pin
B Shaft
Install retaining pin (A) into shaft (B).
[15] -
LEGEND:
A Shafts (3 used)
B Washers (3 used)
Install shafts (A) from bottom of carrier until retaining pins align with carrier holes.
[16] - Install washers (B).

[17] -
LEGEND:
Install retaining pins (A).

[18] -
LEGEND:
A Input Planetary Pinion Gear Screws (3 used)
If reusing input planetary pinion gear screws (A), apply LOCTITE 242 Thread Lock and Sealer
(Medium Strength)
Number Name Use
• PM37477 (us)
and tighten to specification.
Input Planetary Pinion Gear Screws Torque 12 N·m
(106 lb.-in.)

Repair Mode 2 Clutch

[1] -
LEGEND:
A Thrust Washers (2 used)
Remove thrust washers (A).
[2] -
LEGEND:

[3] -
LEGEND:
A Cover
Remove cover (A), clutch plates (B), and clutch disks (C).
[4] -
LEGEND:
A JDG11211 Snap Ring Installer
B Snap Ring
Use JDG11211 Snap Ring Installer (A) and hydraulic press to remove snap ring (B).

[5] -
LEGEND:
A Mode 2 Clutch Hub
B Seals (2 used)
Remove mode 2 clutch hub (A) with seals (B).
[6] -
LEGEND:
A Piston
B Spring
Remove piston (A) and spring (B).

[7] -
LEGEND:
A Seal
Replace seal (A) on piston.
[8] -
LEGEND:
A Seal
B Seal
Replace seals (A and B) and lubricate with clean hydraulic oil.
[9] -
→NOTE:
Ensure correct orientation of spring.

LEGEND:
A Piston
B Spring
Install spring (B) and piston (A).

[10] -
LEGEND:
A Mode 2 Clutch Hub
B Seals (2 used)
Lubricate seals (B) with clean hydraulic oil and install mode 2 clutch hub (A).
[11] -
LEGEND:
A JDG11211 Snap Ring Installer
B Snap Ring
Use JDG11211 Snap Ring Installer (A) and hydraulic press to install snap ring (B).
[12] -
IMPORTANT:

LEGEND:
A Cover
Install cover (A), clutch plates (B), and clutch disks (C).
[13] -
LEGEND:
Ring 2 Gear Cap Screws Torque 73 N·m
(54 lb.-ft.)

[14] -
LEGEND:
Install thrust washers (A).

Repair Mode 2 Shaft

[1] -
LEGEND:
Remove seal rings (A).
[2] -
LEGEND:
A Clutch Seals (2 used)
Remove mode 2 clutch seals (A).
[3] -
→NOTE:

LEGEND:
A Bearing Cone
Use hydraulic press, bearing separator, and 89 mm (3-1/2 in.) driver disk to remove bearing
cone (A).
[4] - Use JDG1405 Bearing Installer to install bearing cone.
[5] -
LEGEND:
A Bearing Cone
Use hydraulic press, bearing separator, and 89 mm (3-1/2 in.) driver disk to remove bearing
cone (A).
[6] - Use spacer, hydraulic press, and 127 mm (5 in.) driver disk to install bearing cone.

[7] -
LEGEND:
A Snap Ring
[8] -
LEGEND:
A Thrust Washer
B Spacers (2 used)
C Needle Bearings (2 used)
Remove thrust washer (A), spacers (B), and needle bearings (C).
[10] - Install spacers, needle bearings, and thrust washer.

[11] -
LEGEND:
A Snap Ring
[12] -
LEGEND:
A Clutch Seals (2 used)
Install mode 2 clutch seals (A).

[13] -
LEGEND:
Install seal rings (A).
Repair Differential Drive Shaft

[1] -
LEGEND:
A Sealing Ring
B Bearing
C Differential Drive Shaft
Remove sealing ring (A) from differential drive shaft (C).
[2] - Replace bearing (B) using hydraulic press.
[3] - Install new sealing ring on differential drive shaft and lubricate with clean hydraulic oil.

Repair Accumulator
[1] -
LEGEND:
A Front Accumulator Housing
B Spring Plate
C Outer Spring
D Middle Spring
E Inner Spring
F Accumulator Pin
G Piston
H Rear Accumulator Housing
Slowly remove front accumulator housing (A).
[2] - Remove accumulator spring plate (B), outer spring (C), middle spring (D), inner spring
(E), accumulator pin (F), and piston (G) from rear accumulator housing (H).


Accumulator Outer Spring Free Length 237.33 mm
(9.34 in.)
(8.07 in. at 295—395 lb.-force)
(6.69 in. at 669—770 lb.-force)
Accumulator Middle Spring Free Length 247.29 mm
(9.74 in.)
(8.07 in. at 152—194 lb.-force)
(6.69 in. at 292—339 lb.-force)
Accumulator Inner Spring Free Length 237.87 mm
(9.36 in.)
(8.07 in. at 72—100 lb.-force)
(6.69 in. at 163—194 lb.-force)
[4] -
LEGEND:
A O-Ring
Lubricate O-ring (A) with clean hydraulic oil and install on rear accumulator housing.

Section 51 - AUTOPOWR/IVT TRANSMISSION Group 30: Assemble Transmission
[5] -
LEGEND:
A Front Accumulator Housing
B Spring Plate
C Outer Spring
D Middle Spring
E Inner Spring
F Accumulator Pin
G Piston
H Rear Accumulator Housing
Lightly lubricate piston (G) with clean hydraulic oil and install.
[6] - Install accumulator pin (F), inner spring (E), middle spring (D), outer spring (C),
accumulator spring plate (B), and front accumulator housing (A) in rear accumulator housing
(H).
[7] - Tighten accumulator halves to specification.
Accumulator Halves Torque 75 N·m
(55 lb.-ft.)

Group 30 - Assemble Transmission

List of References
Other Material
Specifications
Install Hydrostatic Module
Install Front Valve Housing
Install Bearing Cups in Rear Housing
Install Output Shaft Assembly
Install Mode-1 Clutch Assembly
Install Mode 3 Clutch Assembly
Install Park Brake
Install Reverse Shaft Assemblies
Install Synchronizer Assembly
Install MFWD Clutch Assembly
Install Bearing Support and Adjust Bearings
Assemble Transmission Housings
Install Rear Valve Housing
Install Sensors
→NOTE:


D01045AA Disk Set
JDG19 Lifting Eyes
JDG909 Lifting Eyes
JDG11188 Output Shaft Bearing Support Tool
JDG11189 Counter Shaft Bearing Support Tool
JDG11213 Input Shaft Turning Tool
Other Material
Number Name Use
• PM37477 (us)
Thread Lock and Sealer (Medium Used to retain cap screws
Strength) and seal surfaces.
• PM38657 (us)

Specifications
Hydrostatic Module Retaining Plugs Torque 420 N·m
(310 lb.-ft.)
Ring 1 Retainer Cap Screws Torque 125 N·m
(92 lb.-ft.)
Front Valve Housing Cap Screws Torque 15 N·m
(133 lb.-in.)
SU Idler Assembly Cap Screws Torque 125 N·m
(92 lb.-ft.)
Mode 2 Output Shaft Mid Bearing Support Cap Screws Torque 125 N·m
(92 lb.-ft.)
Mode 2 Output Shaft Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)
Mode 1 Clutch Retaining Ring Cap Screw Torque 25 N·m
(18 lb.-ft.)
Mode 1 Clutch Support Cap Screws Torque 125 N·m
(92 lb.-ft.)
(92 lb.-ft.)
Accumulator Cap Screw Torque 115 N·m
(85 lb.-ft.)
Park Brake Scavenge Screen Plug Torque 102 N·m
(75 lb.-ft)
(52 lb.-ft.)
(52 lb.-ft.)
MFWD Baffle Cap Screws Torque 10 N·m
(89 lb.-in.)
Rear Bearing Support Cap Screws Torque 125 N·m
(92 lb.-ft.)
Output Shaft Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)
MFWD Shaft Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)
Reverse Input Shaft Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)
MFWD Shaft Retaining Clip Cap Screw Torque 20 N·m

(180 lb.-in.)
MFWD Manifold Cap Screws Torque 125 N·m
(92 lb.-ft.)
Reverse Counter Shaft Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)
Reverse Counter Shaft Adjusting Ring Torque 25 N·m
(221 lb.-in.)
Reverse Counter Shaft Retaining Clip Cap Screw Torque 20 N·m
(180 lb.-in.)
Transmission Cap Screws Torque 500 N·m
(370 lb.-ft.)
Pipe Flange-to-Rear Housing Cap Screws Torque 70 N·m
(52 lb.-ft.)
Rear Valve Housing Cap Screws Torque 15 N·m
(133 lb.-in.)
Ring 2 Sensor Torque 10 N·m
(89 lb.-in.)
Forward/Reverse Position Sensor Cap Screws Torque 10 N·m
(89 lb.-in.)
Reverse Counter Shaft Sensor Cap Screw Torque 10 N·m
(89 lb.-in.)
Reverse Counter Shaft Sensor Torque 10 N·m
(89 lb.-in.)
MFWD Sensor Torque 10 N·m
(89 lb.-in.)

Install Hydrostatic Module

[1] -
LEGEND:
A Hydrostatic Module
Attach hydrostatic module (A) to an overhead hoist with two JDG19 Lifting Eyes .
[2] -
LEGEND:
A JDG19 Lift Eyes (2 used)
Attach overhead hoist to JDG19 Lift Eyes (A) and position hydrostatic module in front housing.

[3] -
LEGEND:
A Retaining Plugs (4 used)
Install hydrostatic module retaining plugs (A) and tighten to specification.
Hydrostatic Module Retaining Plugs Torque 420 N·m
(310 lb.-ft.)
[4] -
LEGEND:
A Ring 1 Gear
Install ring 1 gear (A).

[5] -
LEGEND:
A Planetary
Install planetary (A).
[6] -
LEGEND:
A SU Idler Shaft
Install SU idler shaft (A).

[7] -
LEGEND:
A Input Shaft
Install input shaft (A).
[8] -
LEGEND:
A Cap Scews (2 used)
B Retainer
Install retainer (B) and cap screws (A).
(92 lb.-ft.)

Install Front Valve Housing

[1] -
LEGEND:
Lubricate O-rings with clean hydraulic oil and install jumper tubes (A).
[2] -
LEGEND:
A Front Valve Housing
Install gasket and front valve housing (A).

[3] - Tighten cap screws to specification in a spiral pattern starting in the center of the valve
housing.
Front Valve Housing Cap Screws Torque 15 N·m
(133 lb.-in.)

Install Bearing Cups in Rear Housing

[1] -
LEGEND:
A Adjusting Ring
Loosely install adjusting ring (A).
[2] -
LEGEND:
A Oil Dam Plate
B Washer
C Adjusting Ring
Install oil dam plate (A) and washer (B), and adjusting ring (C).

[3] -
LEGEND:
A Bearing Cup
B Bearing
Install bearing cup (A) to washer.
[4] -
→NOTE:
Use 124 mm (4-7/8 in.) driver disk to install bearing (B) until fully seated.
[5] -
LEGEND:
A Bearing Cup
Use 89 mm (3-1/2 in.) driver disk to install bearing cup (A) until fully seated.

Install Output Shaft Assembly
LEGEND:
B SU Idler Assembly
[1] - Install SU idler assembly (B).

SU Idler Assembly Cap Screws Torque 125 N·m
(92 lb.-ft.)
[3] - Verify SU idler shaft end play. (See Repair SU Idler in Group 20.)

[4] -
LEGEND:
A Mode 1/3 Gear
Install mode 1/3 gear (A).

[5] -
LEGEND:
A Mode 3 Gear
Install mode 3 gear (A).

[6] -
LEGEND:
Install differential drive shaft (A).

[7] -
LEGEND:
A Mode 2 Output Shaft
Install mode 2 output shaft (A).
[8] -
→NOTE:
LEGEND:
A Bearing Cup
D Bearing Cup

Remove bearing cups (A and D).

[9] - Use 159 mm (6-1/4 in.) driver disk (B) and 117 mm (4-5/8 in.) driver disk (C) to install
new bearing cups (A and D).
[10] -
LEGEND:
B Mid Bearing Support
C Adjusting Ring
Install mid bearing support (B) with adjusting ring (C).
Mode 2 Output Shaft Mid Bearing Support Cap Screws Torque 125 N·m
(92 lb.-ft.)
[12] -
→NOTE:
Rotate shaft several times in each direction before checking end play of
shaft.

Install dial indicator as illustrated with pointer against mode 2 output shaft.
[13] - Apply upward pressure to shaft using prybar and record end play reading.
[14] -
LEGEND:
A Adjusting Ring
B JDG11191 Hydro Adjusting Ring Tool
Using JDG11191 Hydro Adjusting Ring Tool (B), adjust end play to specification.
Mode 2 Output Shaft Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)

[15] -
LEGEND:
A Retaining Clip
B Cap Screw
Apply LOCTITE 242 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (us)
to cap screw (B).
[16] - Install retaining clip (A) and cap screw (B). Tighten to specification.
Mode 1 Clutch Retaining Ring Cap Screw Torque 25 N·m
(18 lb.-ft.)

Install Mode-1 Clutch Assembly

[1] -
LEGEND:
A Mode 1 Clutch
Install mode 1 clutch (A).
[2] -
IMPORTANT:
Ensure drum is the correct height before proceeding.
Ensure height from the top of the transmission case to the top of mode 1 clutch is 67 mm
(2-5/8 in.).
[3] -
→NOTE:
LEGEND:
B Bearing
Use 94 mm (3-11/16 in.) driver disk (A) to install bearing (B) until fully seated.
[4] -
LEGEND:
A Snap Ring
[5] -
LEGEND:
B Mode 1 Clutch Support
Install mode 1 clutch support (B).
Mode 1 Clutch Support Cap Screws Torque 125 N·m
(92 lb.-ft.)

Install Mode 3 Clutch Assembly

[1] - Apply a coat of grease to inside of mode 2 shaft.
[2] -
LEGEND:
A Wear Pads (4 used)
Install wear pads (A).
[3] -
LEGEND:
A Mode 3 Clutch
B Mode 2 Clutch
Install mode 2 clutch (B) and mode 3 clutch (A).

[4] -
LEGEND:
C Ring 2 Gear
Install ring 2 gear (C) and retainers (B) with wear pads.
(92 lb.-ft.)
[6] -
IMPORTANT:
Rotate housing no further then horizontal position to install snap ring.
LEGEND:
A Snap Ring
[7] -
LEGEND:
A Cap Screw
B Retainer
C Accumulator
Install accumulator (C), retainer (B), and cap screw (A). Tighten to specification.
Accumulator Cap Screw Torque 115 N·m
(85 lb.-ft.)

Install Park Brake

[1] -
LEGEND:
A Bearing Race
Install bearing race (A).
[2] -
→NOTE:
Ensure scavenge screen tang is properly aligned.
LEGEND:
A Plug
B Scavenge Screen
Install scavenge screen (B).

[3] - Install plug (A) and tighten to specification.

Park Brake Scavenge Screen Plug Torque 102 N·m
(75 lb.-ft)
[4] -
LEGEND:
A Piston Assembly
B O-Ring
Install O-ring (B) and piston assembly (A).

[5] -
LEGEND:
A Park Brake Piston Cap Screws (6 used)
Install park brake piston cap screws (A) and tighten to specification.
(52 lb.-ft.)
[6] -
IMPORTANT:
Brake plates and disks are a matched set. DO NOT mix plates and disks
with other brake sets.
→NOTE:
Ensure correct orientation of brake plates.

LEGEND:
A JDG11215 Park Brake Alignment Tool
C Brake Plates (11 used)
Use JDG11215 Park Brake Alignment Tool (A) to align brake disks (B) and plates (C).
[7] - Install housing.
[8] - Gradually tighten cap screws (D).
(52 lb.-ft.)

[9] - Remove JDG11215 Park Brake Alignment Tool (A).

Install Reverse Shaft Assemblies

[1] -
LEGEND:
A Idler Gear
B Reverse Idler
Install idler gear (A) and reverse idler (B).
[2] -
LEGEND:
A PTO Shaft
Install PTO shaft (A).

[3] -
LEGEND:
A Pump Drive Gear
Install pump drive gear (A).

Install Synchronizer Assembly

[1] -
LEGEND:
A Bearing Cone
B Synchronizer Assembly
C Reverse Input Gear
Install reverse input gear (C), synchronizer assembly (B), and bearing cone (A).
[2] -
LEGEND:
A Snap Ring

[3] -
LEGEND:
A Reverse Output Gear
Install reverse output gear (A).

Install MFWD Clutch Assembly

[1] -
LEGEND:
B MFWD Clutch
Use JT05550 Lifting Eyebolts (A) and overhead hoist to install MFWD clutch (B).
[2] - Remove JT05550 Lifting Eyebolts.
[3] -
LEGEND:
B Baffle
Install MFWD baffle (B).
MFWD Baffle Cap Screws Torque 10 N·m
(89 lb.-in.)

Install Bearing Support and Adjust Bearings
LEGEND:
A O-rings (2 used)
B Seals (2 used)
[1] - Replace and lubricate O-rings (A) and seals (B).

[2] -
LEGEND:
B Rear Bearing Support
Use JDG19 Lifting Eyes (A) and overhead hoist to install rear bearing support (B).
[3] - Remove lifting eyes.

[4] -
LEGEND:
B Bearing Cone
C Washer
D Nut
Rear Bearing Support Cap Screws Torque 125 N·m
(92 lb.-ft.)
[5] - Install bearing cone (B), washer (C), and nut (D).
[6] - Reach through pump drive opening, hold pump drive gear, and hand tighten nut (D).
[7] - Loosen nut approximately three degrees.
[8] - Roll in bearings by rotating pump drive gear several revolutions in each direction.
[9] - Install dial indicator on pump drive shaft.
[10] -
→NOTE:
Pump drive assembly weighs 3 kg (7 lb.).

Use pry bar to pry up on pump drive gear and measure end play.
[11] -
IMPORTANT:
The rearmost bearing is a slip fit on gear, adjust nut by hand to accomplish
end play.
Adjust end play to specification.

Pump Drive Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)
[12] -
LEGEND:
A Slot
Once end play is obtained, stake nut by driving lock nut tab into slot (A).

[13] -
LEGEND:
[14] -
IMPORTANT:
Avoid damage to transmission. Pump off park brake until MFWD shaft
rotates freely. Do NOT exceed 2000 kPa (20 bar) (290 psi).
→NOTE:
Diagnostic receptacle coupler is threaded in side of transmission housing at
rear valve housing location.
LEGEND:
A Diagnostic receptacle Coupler
Install diagnostic receptacle coupler (A) and attach to hydraulically operated hand pump.
[15] - Operate hand pump to 1200 kPa (12 bar) (174 psi). Maintain pressure to prevent park
brake from dragging.

[16] -
LEGEND:
A Dial Indicator
B JT05550 Lifting Eyebolt
Roll in bearings by rotating MFWD shaft several times in each direction.
[17] - Install dial indicator (A) above sealing ring grooves on MFWD shaft.
[18] -
IMPORTANT:
Excessive force deflects housing several thousandths of an inch.
Do not to exceed a force equal to twice the mass of parts.
→NOTE:
MFWD shaft assembly weighs 51 kg. (112 lb.).
Pull up on shaft using JT05550 Lifting Eyebolts (B) and overhead hoist.
[19] - Record end play.
[20] -
→NOTE:
Each notch on retainer is equivalent to 0.063 mm (.0025 in.).

LEGEND:
A JDG11190 MFWD Adjusting Ring Tool
Use JDG11190 MFWD Adjusting Ring Tool (A) to adjust MFWD shaft end play to specification.
MFWD Shaft Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)
[21] - If end play is within spec, perform the following:
Tighten adjusting ring to align next available notch with retaining clip.
Repeat measurement.
[22] - If end play is too tight, perform the following:
Loosen adjusting ring.

Pry up on piston.
Tap down on housing to unseat bearing cup.
Reset end play.

[23] -
LEGEND:
A MFWD Shaft Retaining Clip
B Cap Screw
Install MFWD shaft retaining clip (A).
Number Name Use
• PM37477 (us)
to cap screw (B).
[25] - Install cap screw and tighten to specification.
MFWD Shaft Retaining Clip Cap Screw Torque 20 N·m
(180 lb.-in.)

[26] -
LEGEND:
A Output Shaft
B M24 Lifting Eyebolt
C Internal Threaded Adapter
Install M24 Lifting Eyebolt (B) and internal threaded adapter (C) into output shaft (A).

[27] -
LEGEND:
A Pry Bar
B Synchronizer
Install pry bar (A) through pump drive opening and engage synchronizer (B).
[28] - Roll in bearings by rotating output shaft several times in each direction.
[29] - Disengage synchronizer.
[30] - Install dial indicator on gear or bearing race.

[31] -
IMPORTANT:
→NOTE:
Output shaft assembly weighs 40 kg (88 lb.).
Pull up on shaft using M24 Lifting Eyebolt.

[32] - Record end play.
[33] -
IMPORTANT:
Do not use a punch and hammer. Impact can move bearing more than
intended.
→NOTE:
Each notch on retainer is equivalent to 0.054 mm (.0021 in.).
LEGEND:
A JDG11188 Output Shaft Bearing Support Tool
Use JDG11188 Output Shaft Bearing Support Tool (A) to adjust output shaft end play to
specification.
Output Shaft Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)

[34] -
LEGEND:
A Output Shaft Retainer
If end play is within spec, perform the following:
Tighten adjusting ring to align next available notch with output shaft retainer (A).
Repeat measurement.

Pry up on shaft.
Reset end play.

[36] -
LEGEND:
A MFWD Manifold
Install MFWD manifold (A) and cap screws (B). Tighten to specification.
MFWD Manifold Cap Screws Torque 125 N·m
(92 lb.-ft.)
[37] -
LEGEND:
A Reverse Counter Shaft Adjusting Ring
Install reverse counter shaft adjusting ring (A).

[38] -
LEGEND:
A Dial Indicator
B M24 Lifting Eyebolt
Install M24 Lifting Eyebolt (B) into reverse counter shaft.
[39] - Roll in bearings by rotating reverse counter shaft several times in each direction.
[40] - Install dial indicator (A).
[41] -
IMPORTANT:
→NOTE:
Reverse counter shaft assembly weighs 8 kg (18 lb.).
Pull up on shaft using M24 Lifting Eyebolt (B) and overhead hoist.
[42] -
→NOTE:
Each notch on the retainer is equivalent to 0.059 mm (.0023 in.).

LEGEND:
A JDG11189 Counter Shaft Bearing Support Tool
Use JDG11189 Counter Shaft Bearing Support Tool (A) to adjust end play to specification.
Reverse Counter Shaft Bearing End Play 0.05—0.20 mm
(0.002—0.007 in.)
[43] - If end play is within spec, perform the following:
Tighten adjusting ring to align next available notch with retaining clip.
Repeat measurement.

Pry up on shaft.
Reset end play.

[45] -
LEGEND:
A Oil Dam
B Oil Dam Retainer
C JDG11189 Counter Shaft Bearing Support Tool
Install oil dam (A).
[46] -
IMPORTANT:
Do not over tighten oil dam retainer. Excessive tightening moves first
retainer and reduces end play setting.
Install oil dam retainer (B) using JDG11189 Counter Shaft Bearing Support Tool (C). Tighten to
specification.
Reverse Counter Shaft Oil Dam Retainer Torque 10 N·m
(88 lb.-in.)

[47] -
LEGEND:
A Reverse Counter Shaft Retaining Clip
B Cap Screw
Install reverse counter shaft retaining clip (A).
Number Name Use
• PM37477 (us)
to cap screw (B).
[49] - Install cap screw and tighten to specification.
Reverse Counter Shaft Retaining Clip Cap Screw Torque 20 N·m
(180 lb.-in.)

Assemble Transmission Housings

[1] -
LEGEND:
Install JDG909 Lifting Eyes (A).
[2] -
IMPORTANT:
Do not apply PM38657 High Flex Form-In-Place Gasket to areas around lube
passages (B).
Front Transmission Housing

Rear Transmission Housing

LEGEND:
A PM38657 High Flex Form-In-Place Gasket Application Area
B PM38657 High Flex Form-In-Place Gasket NON-Application Area
C PM38657 High Flex Form-In-Place Gasket Application Area
D PM38657 High Flex Form-In-Place Gasket NON-Application Area
Clean sealing surfaces and apply PM38657 High Flex Form-In-Place Gasket in designated
areas (A) on front half of transmission surface only.
Number Name Use
• PM38657 (us)
[3] -
IMPORTANT:
Do not apply PM38657 High Flex Form-In-Place Gasket to areas around lube
passages (B).
Apply PM38657 High Flex Form-In-Place Gasket in designated areas (C) on rear half of
transmission surface only.

[4] -
IMPORTANT:
While installing front and rear housings together ensure mating edges are
parallel.
→NOTE:
When installing front and rear housings ensure all mating parts are
properly aligned using the following order of contact sequence:
SU idler shaft splines

Input shaft internal spline
Ring 2 to planetary assembly
Sun 2 to planetary assembly
Use a 2 1/2 inch socket on pump drive shaft nut as turning tool to aid in
uniting transmission halves.
Using overhead hoist install front and rear transmission housing together.

[5] -
LEGEND:
Transmission Cap Screws Torque 500 N·m
(370 lb.-ft.)
[6] - Remove lifting eyes.

[7] -
LEGEND:
B Flange
C Hydraulic Line
Install hydraulic line (C), flange (B), and cap screws (A). Tighten to specification.
Pipe Flange-to-Rear Housing Cap Screws Torque 70 N·m
(52 lb.-ft.)

Install Rear Valve Housing

[1] -
LEGEND:
Lubricate O-rings wth clean hydraulic oil and install jumper tubes (A).
[2] -
LEGEND:
A Rear Valve Housing
Install gasket and rear valve housing (A).

[3] - Tighten cap screws to specification in a spiral pattern starting in the center of the valve
housing.
Rear Valve Housing Cap Screws Torque 15 N·m
(133 lb.-in.)

Install Sensors
[1] -
LEGEND:
A Ring 2 Sensor
B Foward/Reverse Position Sensor
Install ring 2 sensor (A) and tighten to specification.
(89 lb.-in.)
[2] - Install forward/reverse position sensor (B) and cap screws (C). Tighten to specification
Forward/Reverse Position Sensor Cap Screws Torque 10 N·m
(89 lb.-in.)

[3] -
LEGEND:
A Ring 2 Sensor
B Reverse Counter Shaft Sensor
C Reverse Counter Shaft Sensor Cap Screw
D Reverse Counter Shaft Sensor
Install ring 2 sensor (A) and tighten to specification.
(89 lb.-in.)
[4] - Install reverse counter shaft sensor (B) and reverse counter shaft sensor cap screw (C).
Tighten to specification
Reverse Counter Shaft Sensor Cap Screw Torque 10 N·m
(89 lb.-in.)
[5] - Install reverse counter shaft sensor (D) and tighten to specification.
Reverse Counter Shaft Sensor Torque 10 N·m
(89 lb.-in.)

DRIVE SYSTEMS (g) by Belgreen
[6] -
LEGEND:
A MFWD Sensor
Install MFWD sensor (A) and tighten to specification.
MFWD Sensor Torque 10 N·m
(89 lb.-in.)

Section 56 - DRIVE SYSTEMS

Table of contents
Other Material ........................................................................................................................ 2
Specifications ......................................................................................................................... 4
Sealing Instructions ................................................................................................................ 4
Remove Front PTO Assembly ................................................................................................. 6
Install Front PTO Assembly ................................................................................................... 13
Remove Differential Case ..................................................................................................... 21
Install Differential Case ........................................................................................................ 29
Remove Final Drive .............................................................................................................. 37
Install Final Drive ................................................................................................................. 50
Group 10 - Rear Differential .................................................................................................. 57
Other Material ...................................................................................................................... 58
Specifications ....................................................................................................................... 59
General Repair Procedures—Rear Differential ..................................................................... 60
Remove Rear Differential ..................................................................................................... 62
Disassemble, Inspect, and Assemble Rear Differential ........................................................ 67
Remove Rear Differential Drive Shaft .................................................................................. 79
Determine Rear Differential Drive Shaft Cone Point Shim Pack ........................................... 86
Assemble and Install Rear Differential Drive Shaft ............................................................... 90
Install Rear Differential ........................................................................................................ 98
Side Quill Adjustment Information ..................................................................................... 103
Measure End Play and Adjust Rear Differential Preload ..................................................... 104
Adjust Rear Differential Backlash ....................................................................................... 107
Group 20 - Final Drive ........................................................................................................... 109
Other Material .................................................................................................................... 110
Specifications ..................................................................................................................... 111
General Repair Procedures—Final Drive ............................................................................ 112
Cross-Sectional View—100 mm Rear Axle Housing And Shaft ........................................... 113
Cross-Sectional View—100 mm Planet Pinion Carrier ........................................................ 114
Cross-Sectional View—110/120 mm Final Drive ................................................................. 116
Remove Planet Pinion Carrier—100 mm ............................................................................ 118
Remove Planet Pinion Carrier—110/120 mm ..................................................................... 121
Disassemble, Inspect, and Assemble Planet Pinion Carrier—100 mm ................................ 124
Disassemble, Inspect, and Assemble Planet Pinion Carrier—110/120 mm ......................... 129
Remove Axle Housing ........................................................................................................ 132
Disassemble and Assemble Axle Housing .......................................................................... 134
Disassemble, Inspect, and Assemble Axle Shaft ................................................................ 135
Install Axle Housing ............................................................................................................ 138
Install Planet Pinion Carrier And Check Rolling Drag Torque—100 mm ............................. 140
Install Planet Pinion Carrier And Check Rolling Drag Torque—110/120 mm ...................... 149

Group 30 - Rear PTO ............................................................................................................. 158

Specifications ..................................................................................................................... 160
Other Material .................................................................................................................... 160
General Repair Procedures—PTO ....................................................................................... 161
Cross-Sectional View—PTO Clutch ..................................................................................... 163
Remove And Disassemble PTO Clutch ............................................................................... 165
Assemble And Install PTO Clutch ........................................................................................ 173
Remove And Disassemble Output Shaft and PTO Shifter ................................................... 182
Remove And Disassemble Countershaft ............................................................................ 191
Disassemble and Assemble Shaft Position Rod .................................................................. 194
Cross-Sectional View—Two-Speed Shiftable PTO Countershaft .......................................... 195
Cross-Sectional View—Three-Speed Shiftable PTO Countershaft ....................................... 195
Assemble And Install Countershaft .................................................................................... 197
Cross-Sectional View—Single-Speed PTO Output Shaft ...................................................... 200
Cross-Sectional View—Two-Speed Shiftable PTO Output Shaft .......................................... 202
Cross-Sectional View—Three-Speed Shiftable PTO Output Shaft ....................................... 204
Exploded View—Shiftable PTO Shifter ................................................................................ 205
Exploded View—Power Assisted PTO Shifter ...................................................................... 205
Recondition Mechanical Shifter .......................................................................................... 208
Recondition Power Assisted PTO Shifter ............................................................................. 211
Assemble And Install Output Shaft and PTO Shifter ........................................................... 222
Replace PTO Output Shaft Oil Seal ..................................................................................... 234
Group 35 - Front PTO ............................................................................................................ 236
Other Material .................................................................................................................... 237
Specifications ..................................................................................................................... 237
General Repair Procedures—Front PTO .............................................................................. 238
Remove and Install Front PTO Oil Cooler ........................................................................... 240
Remove and Install Front PTO Pump .................................................................................. 243
Disassemble and Assemble Front PTO Gearcase Housing ................................................. 244
Disassemble Front PTO Clutch ........................................................................................... 248
Assemble Front PTO Clutch ................................................................................................ 251
Replace Front PTO Brake ................................................................................................... 254
Remove Front PTO input Shaft ........................................................................................... 256
Install Front PTO Input Shaft .............................................................................................. 261
Remove Front PTO Output Shaft ........................................................................................ 267
Install Front PTO Output Shaft ............................................................................................ 269
Remove and Install Modulating Valve ................................................................................ 272
Repair Pressure Regulating Valve ...................................................................................... 272
Repair Oil Cooler Bypass Valve .......................................................................................... 273
Repair Lube Relief Valve .................................................................................................... 274
Group 40 - Primary Brakes ................................................................................................... 275
Other Material .................................................................................................................... 275
Specifications ..................................................................................................................... 275
Remove and Install Brake Piston ........................................................................................ 276

Group 45 - Pump Drive Housing .......................................................................................... 282

Other Material .................................................................................................................... 282
Specifications ..................................................................................................................... 282
Remove and Install Pump Drive Housing ........................................................................... 283
Repair Pump Drive Housing ............................................................................................... 285

Section 56 - DRIVE SYSTEMS Group 00: Component Removal and Installation

List of References
Other Material
Specifications
Sealing Instructions
Remove Front PTO Assembly
Install Front PTO Assembly
Remove Differential Case
Install Differential Case
Remove Final Drive
Install Final Drive

→NOTE:

DFRW98—Rear Axle Guide Pin
DFRW236—Front PTO Support Bracket
JDG19 Lifting Eyes
JDG909 Lifting Eyes
JDG1494 Rear Axle Lifting Tool
JDG1707 Axle Lifting Bracket
JDG2042 Ring Adapter
JT05549 Lifting Eyebolt
JT07056 Service Jack
JT07336 Lift Sling

Other Material
Number Name Use
• PM38657 (us)
• PM38628 (canadian) Used to seal transmission
High Flex Form-In-Place Gasket
• 17430 LOCTITE ™ housings.
(loctite)
• PM37477 (us)
Thread Lock and Sealer (Medium
• PM38621 (canadian) Used to retain cap screw.
Strength)
• PM38654 (PM37479
and PM37421
[ Smaller Size ]
) (us) Thread Lock and Sealer Used to retain cap screws
• PM38624 (PM38623 (High Strength) and seal surfaces.
[ Smaller Size ]
) (canadian)

Specifications
Front PTO Mounting Cap Screws Torque 430 N·m
(317 lb.-ft.)
Front PTO Drive Coupler Cap Screws Torque 216 N·m
(159 lb.-ft.)
Auxiliary drive-to-Front support Cap Screws Torque 125 N·m
(92 lb.-ft.)
Drive Pulley-to-Shaft Mounting Cap Screws Torque 85 N·m
(63 lb.-ft.)
(370 lb.-ft.)
Shield Cap Screws Torque 73 N·m
(54 lb.-ft.)
Hydraulic Line Cap Screws Torque 33 N·m
(292 lb.-in.)
Pneumatic Trailer Brake Assembly Cap Screws Torque 125 N·m
(92 lb.-ft.)
Plugs Torque 102 N·m
(75 lb.-ft.)
100 mm Axle Final Drive Housing-to-Differential Case Cap Screws Torque Turn 200 N·m + 90°
148 lb.-ft. + 90°
110—120 mm Axle Final Drive Housing-to-Differential Case Cap Screws (A) Torque Turn 285 N·m + 90°
210 lb.-ft. + 90°
110—120 mm Axle Final Drive Housing-to-Differential Case Cap Screws Torque Turn 230 N·m + 90°
170 lb.-ft. + 90°
Mounting Bracket Nuts Torque 70 N·m
(52 lb.-ft.)
Cab Mount Cap Screws Torque 300 N·m

[ Zinc-Flake Coated ]
(221 lb.-ft.)
ActiveSeat™ Cap Screws Torque 15 N·m
(133 lb.-in.)
Suspended Cab Cap Screws Torque 220 N·m
(162 lb.-ft.)
Drain Plugs Torque 102 N·m
(75 lb.-ft.)

ethylene chloride can be used.

Test for clean surface by applying a few drops of cool water to the surfaces. If water
puddles or forms beads, repeat procedure.
Keep surfaces clean after cleaning.
Apply a thin even layer of PM38657 High Flex Form-In-Place Gasket to one surface of
the joint.
Number Name Use
⚬ PM38657 (us)
⚬ PM38628 (canadian) High Flex Form-In-Place Used to seal transmission
⚬ 17430 LOCTITE ™ Gasket housings.
(loctite)
of the oil passages. Ensure that sealant loops around the oil passages.
DO NOT allow oil to contact sealant after sealant is applied.

Remove Front PTO Assembly

[1] - Remove front hitch. (See Remove and Install Front 3-Point Hitch in Section 70, Group
35.)
[2] - Remove fan belt. (See Remove and Install Fan Belt in Section 30, Group 20.)
[3] -
LEGEND:
B Shield
Remove cap screws (A) and shield (B).
[4] -
→NOTE:
Drape fuel cooler assembly, engine control unit, and alternator over right
front tire.
Move fuel cooler assembly aside.

[5] - Remove cap screws (C) and move engine control unit aside.
[6] - Remove cap screws (D) and move alternator aside.
[7] - Remove cap screws (E) and auxiliary drive pulley.

[8] -
LEGEND:
Identify, label, and disconnect wiring harnesses.
[9] - Remove cap screws (A) and move front PTO filter housing aside.
[10] -
→NOTE:
Do not remove compressor from tractor. Hold compressor aside while
removing auxiliary drive housing.
Remove cap screws (B) and move air conditioning compressor aside.
[11] - Remove cap screws (C) to move front load center and ether aid, if equipped.
[12] -
CAUTION:
Auxiliary drive housing weighs approximately 100 kg (221 lb.).

LEGEND:
A Lifting Eye
C Auxiliary Drive Housing
Install JDG19 Lifting Eyes (A) and support with suitable lifting device.
[13] - Remove caps screws (B) and auxiliary drive housing (C).
[14] -
LEGEND:
A Drain Plug
Remove drain plug (A) and drain oil in suitable catch pan.

[15] -
LEGEND:
B Coupler
C Oil Filter Lines
D Oil Cooler Lines
Rotate coupler (B) using JDG820 Flywheel Rotation Tool and remove cap screws (A).
[16] - Disconnect oil filter lines (C).
[17] - Disconnect oil cooler lines (D).
[18] - Cap and plug lines and fittings to prevent contamination.
[19] -
LEGEND:
A harness Connectors (4 used)
Disconnect harness connectors (A) from gearcase.

[20] -
LEGEND:
A JT07211 Rear Differential Support Stand
B KJD10539 Support Stand Adapter
Raise front of tractor.
[21] - Attach JT07211 Rear Differential Support Stand (A) with KJD10539 Support Stand
Adapter (B) using M20 x 40 mm (10.9 grade) cap screws.
[22] -
CAUTION:
Front PTO Gearcase weighs approximately 181 kg (400 lb.).

LEGEND:
A JT05549 Lifting Eyebolt
Install JT05549 Lifting Eyebolt (A) and support with a suitable lifting device.
[23] -
LEGEND:
B Spacers (2 used)
Remove cap screws (A) and spacers (B).

[24] -
LEGEND:
A DFRW236 Front PTO Support Bracket
B JT07056 Service Jack
Attach DFRW236—Front PTO Support Bracket (A) to JT07056 Service Jack (B).
[25] -
LEGEND:
B Washers (2 used)
Carefully lower PTO gearcase until mounting holes can be accessed.
[26] - Attach DFRW236 Front PTO support bracket to lower mounting holes using M20 x 70
mm (10.9 grade) cap screws (A) and washers (B).
[27] - Remove lifting device and JT05549 Lifting Eyebolt from gearcase.
[28] - Lower PTO gearcase and remove from beneath tractor.

Install Front PTO Assembly

[1] - Install front PTO gearcase from beneath front support DFRW236—Front PTO Support
Bracket and JT07056 Service Jack .
[2] -
CAUTION:
Front PTO gearcase weighs approximately 181 kg (400 lb.).
LEGEND:
A JT05549 Lifting Eyebolt
Install JT05549 Lifting Eyebolt (A) and support with suitable lifting device.
[3] - Remove DFRW236—Front PTO Support Bracket.
[4] - Raise gearcase into position.

[5] -
LEGEND:
B Spacers (2 used)
Install cap screws (A) and spacers (B). Tighten to specification.
Front PTO Mounting Cap Screws Torque 430 N·m
(317 lb.-ft.)
[6] -

LEGEND:
Remove JT07211 Rear Differential Support Stand (A) and KJD10539 Support Stand Adapter
(B).

[7] -
LEGEND:
A Harness Connectors (4 used)
Connect wiring harness (A).
[8] -
LEGEND:
B Coupler
C Oil Filter Lines
D Oil Cooler Lines
Connect oil filter lines (C) and oil cooler hoses (D).

[9] - Clean threads and apply PM38654 Thread Lock and Sealer to cap screws (A).
Number Name Use
• PM38654 (PM37479 and
PM37421
[ Smaller Size ]
• PM38624 (PM38623 (High Strength) and seal surfaces.
[ Smaller Size ]
) (canadian)
[10] -
IMPORTANT:
Install all cap screws before tightening to ensure proper alignment.
Rotate coupler (B) using JDG820 Flywheel Rotation Tool and install cap screws.
Front PTO Drive Coupler Cap Screws Torque 216 N·m
(159 lb.-ft.)
[12] -
LEGEND:
A Lifting Eye
C Auxiliary Drive Housing
Install auxiliary drive housing (C) and cap screws (B).


Auxiliary drive-to-Front support Cap Screws Torque 125 N·m
(92 lb.-ft.)
[14] - Remove JDG19 Lifting Eyes (A) from auxiliary drive housing.
[15] -
LEGEND:
Install front load center and ether aid, if equipped, using cap screws (C).
[16] - Install wiring harnesses.
[17] - Install air conditioning compressor and cap screws (B).
[18] - Install front PTO filter housing and cap screws (A).

[19] -
LEGEND:
B Shield
Install drive pulley and cap screws (E). Tighten to specification.
Drive Pulley-to-Shaft Mounting Cap Screws Torque 85 N·m
(63 lb.-ft.)
[20] - Install alternator and cap screws (D).

[21] - Install engine control unit and cap screws (C).
[22] - Install fuel coolers, shield (B), and cap screws (A).
[23] - Install fan belt. (See Remove and Install Fan Belt in Section 30, Group 20.)
[24] - Install front hitch. (See Remove and Install Front 3-Point Hitch in Section 70, Group
35.)

[25] -
LEGEND:
A Check/Fill Plug
Fill gear case with Hy-Gard™ hydraulic oil until level with fill port (A).

Remove Differential Case

[1] -
AutoPowr™/IVT™ Transmission
AutoQuad™/PowrQuad™/CommandQuad™ Transmission
LEGEND:
A Plugs (3 used)
Drain hydraulic oil by removing plugs (A).
[2] -
→NOTE:
JDG11217P1 Long Nose Stand and JDG11217P2 Rear Outrigger Support
Stand are part of JDG11217 Splitting Stand .

LEGEND:
A JDG11217P2 Rear Outrigger Support Stand
B JDG11217P1 Long Nose Stand
Install JDG11217P2 Rear Outrigger Support Stand (A) to JDG11217P1 Long Nose Stand (B).
DO NOT tighten cap screws.
[3] -
→NOTE:
JDG11217 Splitting Stand must be brought in from right side of tractor.
LEGEND:
Attach JDG11217 Splitting Stand to the drawbar support using cap screws (A).
[4] - Tighten cap screws on JDG11217P2 Rear Outrigger Support Stand.
[5] - Remove rear wheels. (See Section 80, Group 20.)
[7] - Remove hitch frame. (See Remove and Install Rear Hitch Frame in Section 70, Group
00.)
[8] - Remove both final drives. (See Remove Final Drive in this section.)

[9] -
For tractors equipped with air trailer brakes perform the following steps:
Identify, label, and disconnect lines (A).
LEGEND:
A Lines (4 used)
C Hanger Bolt
D Pneumatic Trailer Brake Assembly
Remove cap screws (B) and loosen hanger bolt (C).
Remove pneumatic trailer brake assembly (D).

[10] -
LEGEND:
A Hydraulic Lines (2 used)
Remove hydraulic lines (A).
[11] -
LEGEND:
A Hydraulic Trailer Brake Valve
For tractors equipped with hydraulic trailer brakes: Remove hydraulic trailer brake
valve (A). (See Remove and Install Hydraulic Trailer Brake Valve in Section 60, Group 30.)

[12] -
LEGEND:
A Brake Control Manifold
For tractors equipped with secondary brakes or trailer brakes: Remove brake control
manifold (A). (See Remove and Install Brake Control Manifold in Section 60, Group 20.)
[13] -
LEGEND:
A Lines (4 used)
Identify, label, and disconnect remaining lines (A).

[14] -
LEGEND:
A Shields
Remove shields (A).
[15] -
IMPORTANT:
Ensure JDG2061 Front Adapter does NOT contact oil drain housing, oil drain
pipe, or fuel crossover hose.

LEGEND:
Position JDG2061 Front Adapter (A) underneath the transmission.

[16] -
LEGEND:
Remove cap screws with washers (A).
[17] -
Separate differential from transmission.

Install Differential Case

Number Name Use
• PM38657 (us)
[2] -
Unite differential and transmission.

[3] -
LEGEND:
(370 lb.-ft.)

[4] -
LEGEND:
Remove JDG2061 Front Adapter (A) from underneath the transmission.

[5] -
LEGEND:
A Shields
Install shields (A) and tighten cap screws to specification.
Shield Cap Screws Torque 73 N·m
(54 lb.-ft.)

[6] -
LEGEND:
A Lines (4 used)
Connect lines (A).
[7] -
LEGEND:
A Brake Control Manifold
For tractors equipped with secondary brakes or trailer brakes: Install brake control
manifold (A). (See Remove and Install Brake Control Manifold in Section 60, Group 20.)

[8] -
LEGEND:
A Hydraulic Trailer Brake Valve
For tractors equipped with hydraulic trailer brakes: Install hydraulic trailer brake valve
(A). (See Remove and Install Hydraulic Trailer Brake Valve in Section 60, Group 30.)
[9] -
LEGEND:
Install hydraulic lines (A) and tighten cap screws to specification.
Hydraulic Line Cap Screws Torque 33 N·m
(292 lb.-in.)
[10] -

LEGEND:
A Lines (4 used)
C Hanger Bolt
D Pneumatic Trailer Brake Assembly
For tractors equipped with air trailer brakes perform the following steps:
Install pneumatic trailer brake assembly (D).

Install cap screws (B) and hanger bolt (C). Tighten to specification.
Pneumatic Trailer Brake Assembly Cap Screws Torque 125 N·m
(92 lb.-ft.)
Connect lines (A).
[11] - Install both final drives. (See Install Final Drive in this section.)

[12] - Install hitch frame. (See Remove and Install Rear Hitch Frame in Section 70, Group
00.)
[14] - Install rear wheels. (See Section 80, Group 20.)
[15] -
→NOTE:
JDG11217 Splitting Stand must be removed from the right side of the
tractor.
LEGEND:
Remove cap screws (A) and JDG11217 Splitting Stand.

[16] -
LEGEND:
A Plugs (3 used)
Plugs Torque 102 N·m
(75 lb.-ft.)

Remove Final Drive

[1] -
LEGEND:
A Plugs (2 used)
For tractors equipped with cab suspension perform the following:
Depressurize cab suspension. (See Depressurize Cab Suspension System in Section 90,
Group 35.)
[2] - Drain final drives by removing plugs (A).

[3] -
LEGEND:
A Cap Screw
B Retainer
C Pin
Remove cap screw (A), retainer (B), and pin (C).

[4] -
LEGEND:
A Drawbar
Remove drawbar (A).
[5] -
LEGEND:
B Bracket
C Spacers (2 used)
Remove cap screws (A), bracket (B), and spacers (C).
[6] -
CAUTION:
Stabilizer weighs approximately 81 kg (179 lb.).

LEGEND:
A Cotter Pin (2 used)
B Pin (2 used)
D Retainer
E Pin
F Drawbar
H Stabilizer Hitch
For tractors equipped with stabilizers:

b. Remove cap screws (C), retainer (D), and pin (E).
[7] -
→NOTE:

LEGEND:
C JDG11217P1 Long Nose Stand
Install JDG11217P3 Jack Screw (A) and JDG11217P2 Rear Outrigger Support Stand (B) to
JDG11217P1 Long Nose Stand (C). DO NOT tighten cap screws.
[8] -
→NOTE:
LEGEND:
Attach JDG11217 Splitting Stand to the drawbar support using cap screws (A).

[9] -
LEGEND:
A Jack Screw
Adjust jack screw (A) to drawbar support.
[10] - Tighten cap screws on JDG11217.
[11] - Remove rear wheels. (See Section 80, Group 20.)
[12] -
LEGEND:
B JT07336 Lift Sling
[13] - Using an overhead hoist attach JT07336 Lift Sling (B) and raise slightly.

[14] -
LEGEND:
A Cap Screw
B Nut
C Ball Joint
D Cap Screw
E Panhard Rod
F Cap Screw
G Bushing
For tractors equipped with cab suspension, perform the following:
Remove cap screw (A).

Remove nut (B) and ball joint (C). (See Remove and Install Sensor Ball Joint Rod in
Remove cap screw (D) and panhard rod (E) from left side of cab.
Remove cap screw (F) and bushing (G).

[15] -
LEGEND:
For non-suspended cab mounts, perform the following:
Remove cab mount cap screws (A) from both sides of tractor.
Unwrap drain hoses from all corners of cab mounts.
[16] -
LEGEND:
A ActiveSeat™ Cap Screws (2 used)
For tractors equipped with ActiveSeat™, perform the following: Remove cap screws
(A).
[17] -
→NOTE:
Non-suspended cab mounts illustrated, procedure for suspended cab
mounts are similar.

Cab Mounts (Left Side)
Cab Mounts (Right Side)

LEGEND:
B Cab Mounts (2 used)
Remove cap screws (A) and cab mounts (B).
[18] -
LEGEND:
A Backup Pump
B Cables
a. Remove backup pump (A) and move cables (B) aside. (See Remove and Install Backup
Pump in Section 60, Group 10.)
b.
Identify, label, and disconnect lines (A).
c.
LEGEND:
A Nuts (2 used)
B Bracket
Remove nuts (A) and bracket (B).
[19] -
IMPORTANT:
For tractors equipped with a backup pump, note location of studded cap
screws (A) for reassembly.

LEGEND:
A Studded Cap Screws (2 used)
C JDG1494 Rear Axle Lifting Tool
D JDG2042 Ring Adapter
For 120 mm or 110 mm axles, perform the following:
a. Remove cap screws (B).

b. Install JDG1494 Rear Axle Lifting Tool (C) and JDG2042 Ring Adapter (D).
c. Attach JDG1494 Rear Axle Lifting Tool to hoist.
[20] -

LEGEND:
A JDG1707 Axle Lifting Bracket
B JDG1494 Rear Axle Lifting Tool
For 100 mm axles, perform the following:
a. Attach adapter JDG1707 Axle Lifting Bracket (A) to JDG1494 Rear Axle Lifting Tool (B)
with supplied hardware.
b.
LEGEND:
c. Install JDG1494 Rear Axle Lifting Tool and JDG2042 Ring Adapter.
d. Attach JDG1494 Rear Axle Lifting Tool to hoist.

[21] -
LEGEND:
For flanged axles: Install JDG909 Lifting Eyes (A) and attach to hoist.
[22] -
→NOTE:
DFRW98—Rear Axle Guide Pin can be used to aid removal of final drives.
FOR ALL AXLES: Remove two final drive-to-differential case cap screws across from each
other and install DFRW98—Rear Axle Guide Pins.
[23] - Remove remaining final drive-to-differential case cap screws.
[24] -
CAUTION:
Parts (A—C) can fall causing possible injury.
LEGEND:
A Ring Gear
B Sun Pinion Shaft

C Brake Backing Plate

Carefully move final drive away from differential case.

Install Final Drive
LEGEND:
[1] - Clean sealing surfaces and apply PM38657 Form-in-Place Gasket

Number Name Use
• PM38657 (us)
to differential case and outer ring gear surfaces only.
[2] -
IMPORTANT:
Final drive ring gear has an identification groove on its outer
circumference.
For 7200R, 7215R and 7230R, ring gear must be installed with
identification groove towards differential case.
For 7260R and 7280R, ring gear must be installed with identification
groove towards axle housing.
→NOTE:
DFRW98—Rear Axle Guide Pin can be used to aid installation of final drives.
Install ring gear on final drive assembly leaving a slight gap between final drive housing and
ring gear to prevent sealant from setting prior to tightening of cap screws.
[3] -
IMPORTANT:
Always useNEW cap screws and tighten cap screws to specification in a
diagonal method.
For tractors equipped with 100 mm axles, perform the following: Tighten cap screws
to specification.

100 mm Axle Final Drive Housing-to-Differential Case Cap Screws Torque Turn 200 N·m + 90°
148 lb.-ft. + 90°
[4] - For tractors equipped with 110 mm and 120 mm axles, perform the following:
Tighten cap screws (A) to specification.
110—120 mm Axle Final Drive Housing-to-Differential Case Cap Screws (A) Torque Turn 285 N·m + 90°
210 lb.-ft. + 90°
Tighten remaining cap screws to specification.

110—120 mm Axle Final Drive Housing-to-Differential Case Cap Screws Torque Turn 230 N·m + 90°
170 lb.-ft. + 90°
[5] -
LEGEND:
A Nuts (2 used)
B Bracket
For tractors equipped with a backup pump, perform the following steps:
a. Install bracket (B) and nuts (A). Tighten to specification.

Mounting Bracket Nuts Torque 70 N·m
(52 lb.-ft.)

b.
LEGEND:
A Lines
Connect lines (A).
c.
LEGEND:
A Backup Pump
B Cables
Install backup pump (A) and cables (B). (See Remove and Install Backup Pump in

[6] -
LEGEND:
B Washer
C Bushing
D Rebound Washer
E Mount
a. Install mounts using diagram for reference.

b. Apply PM37477 Thread Lock and Sealer to cab mount cap screws (A) and tighten to
specifications.
Number Name Use
⚬ PM37477 (us)
Thread Lock and Sealer (Medium Used to retain cap
⚬ PM38621 (canadian)
Strength) screw.
⚬ 242 Loctite™ (loctite)
(221 lb.-ft.)

[7] -
LEGEND:
A ActiveSeat™ Cap Screws (2 used)
For tractors equipped with ActiveSeat™, perform the following: Install cap screws
(A).
ActiveSeat™ Cap Screws Torque 15 N·m
(133 lb.-in.)

[8] -
LEGEND:
A Cap Screw
B Nut
C Ball Joint
D Cap Screw
E Panhard Rod
F Cap Screw
G Bushing
Route drain hoses down each corner of cab.

Install bushing (G) and cap screw (F). Tighten to specification.
(162 lb.-ft.)
Install cap screw (D) and panhard rod (E) on left side of cab.
Install nut (B) and ball joint (C).
Install cap screw (A).

Section 56 - DRIVE SYSTEMS Group 10: Rear Differential
[9] -
LEGEND:
A Plugs (2 used)
Drain Plugs Torque 102 N·m
(75 lb.-ft.)
[10] - Fill hydraulic system. (See Fill Hydraulic System in Section 70, Group 05.)
[11] - Calibrate cab suspension sensor. (See Operation and Test TM Section 245, Group
CSC.)

Group 10 - Rear Differential

List of References
Other Material
Specifications
General Repair Procedures—Rear Differential
Remove Rear Differential
Disassemble, Inspect, and Assemble Rear Differential
Remove Rear Differential Drive Shaft
Determine Rear Differential Drive Shaft Cone Point Shim Pack
Assemble and Install Rear Differential Drive Shaft
Install Rear Differential
Side Quill Adjustment Information
Measure End Play and Adjust Rear Differential Preload
Adjust Rear Differential Backlash

→NOTE:

D01045AA Disk Set
DFRW237—Differential Drive Shaft Removal Tool
JDG877 Sealing Ring Loading Tool Set
JDG878 Sealing Ring Resizing Tool
JDG880B Differential Bearing Quill Adjustment Tool
JDG932 Driver Disk (162 mm or 6-3/8 in.)
JDG11210 Retainer Tool
Other Material
Number Name Use
• PM37418 (us)
• PM38621 (canadian) Thread Lock and Sealer (Medium Strength) Retain cap screw.
• PM38655 (us)
• PM38625 (canadian) Flexible Form-in-Place Gasket Install oil seal.
Lubricate outer diameter of bearing
• RE23148 (us) AMBLYGON ™ Seal Grease
cups and oil seal lips.
• TY6341 (us) Multi-Purpose SD Polyurea Lubricate bearings and bushings

Specifications
7200R/7215R/7230R Differential Clutch Disk Thickness (new) 3.18 mm
(0.125 in.)
7260R/7280R Differential Clutch Disk Thickness (new) 3.20 mm
(0.126 in.)
Pinion Shaft-to-Pinion Hub Cap Screws Torque 70 N·m
(52 lb.-ft.)
Differential Housing Cover Cap Screws Torque 310 N·m
(228 lb.-ft.)
7260R/7280R Mid-Dam Deflector Depth Depth 11 mm
(0.43 in.)
Spiral Bevel Pinion Shaft Retaining Nut Torque 550 N·m
(406 lb.-ft.)
Spiral Bevel Pinion Shaft Assembly End Play 0.013—0.089 mm
(0.0005—0.0035 in.)
Oil Line Cap Screw Torque 35 N·m
(26 lb.-ft.)
7260R/7280R Differential Preload 0.05—0.13 mm
(0.002—0.005 in.)
7200R/7215R/7230R Differential Preload 0.025—0.076 mm
(0.001—0.003 in.)
Differential Backlash 0.15—0.35 mm
(0.006—0.013 in.)
Differential Side Quill Lock Plate Retaining Cap Screws Torque 25 N·m
(221 lb.-in.)

General Repair Procedures—Rear Differential
→NOTE:
Before beginning repair, review following guidelines. Guidelines are

provided to emphasize need for attention to detail and care when servicing
differential.
Identification:
7200R/7215R/7230R tractors are equipped with a 425 mm differential.

7260R/7280R tractors are equipped with a 472 mm differential.
Fasteners must be tightened to specified torque.

Lightly coat needle bearings and thrust washers with petroleum jelly during assembly.
Perform specified preload and backlash checks.
Differential ring gear and drive shaft are replaced as a matched set.
Inspection Before Disassembly:
Inspect pinion shaft and ring gear before removal as follows:

Wipe lubricant from internal working parts and visually inspect parts for wear and
damage.
Rotate gears to check for roughness.
Inspect pinion gear teeth for signs of scoring, abnormal wear or nicks.
IMPORTANT:
Heat bearing cones in a bearing heater. Use a thermometer and do not

exceed 150 °C (300 °F).
Bearings
damage bearing.
Clean bearings with clean solvent, dry thoroughly, and oil before inspection. Inspect
bearings for roughness of rotation and excessive wear of rollers.
Inspect bearing cups for excessive wear.

Bearing assemblies must turn without roughness.

Replaced both bearing cone and roller assembly if either cup or cone has excessive
wear.
Ensure that bearing cups and cones are fully seated during installation.
Shafts
Inspect shaft bearing surfaces for wear or damage.

Inspect shafts and replace if excessively worn or damaged.
Gears
Examine gear teeth for excessive wear. Replace as necessary.

Inspect pinion shafts for loose fit and complete disengagement.
Inspect pinion gears for damaged or excessively worn teeth.
Check for smooth rotation of pinion gears.
Differential Lock
IMPORTANT:
DO NOT use solvent to clean disks. Use a lint-free cloth. Soak new disks in
hydraulic oil for 15 minutes before assembly.
Inspect separator plate ears for excessive wear or damage. Check plates for flatness.
Inspect disk lugs and hub splines for excessive wear or damage. Inspect disks for worn
or scored surfaces.
→NOTE: If disk facing material chips, flakes, or scratches easily,
replace disks regardless of facing thickness.
Clean all oil passages.

Remove Rear Differential
LEGEND:
B Shield
C Pinion Shaft Retaining Cap Screw
IMPORTANT:
Thoroughly clean all parts and interior of differential case after removing
differential.
[1] - Remove differential case. (See Remove Differential Case in Group 00.)
[2] - Remove cap screws (A) and shield (B).
[3] - Remove one pinion shaft retaining cap screw (C).
[4] -
CAUTION:

LEGEND:
A JDG879-1 Bar
B Cap Screw and Washer
C JDG879-3 Handle Extension
Differential assembly and ring gear weigh approximately 60 kg (132 lb.).
Use caution when handling.

→NOTE:
JDG879-1 Bar and JDG879-3 are part of JDG879A Differential and Pinion
Lifting Fixture .
Install JDG879-1 Bar (A) using M10 x 120 mm cap screw and washer (B).
[5] - Attach JDG879-3 Handle Extension (C).
[6] - Support tool with a hoist and a person on handle extension.

[7] -
472 mm Differential Quill
425 mm Differential
LEGEND:
B Lock Plate (2 used)
C JDG880 Differential Bearing Quill Tool
D Differential Bearing Quills (2 used)
Remove cap screws (A) and lock plates (B) from both sides.

[8] -
→NOTE:
Remove right-hand quill first.
Remove differential bearing quills (D) using JDG880B Differential Bearing Quill Adjustment
Tool (C).
[9] - Remove differential from differential case.

Disassemble, Inspect, and Assemble Rear

Differential
LEGEND:
B Pry Slots

[2] - Inspect gear teeth on gearset.
[3] - Remove cover using pry slots (B).
[4] -
IMPORTANT:
Ring gear and pinion shaft are a matched set and cannot be replaced
individually.
Ensure number stamped on ring gear and end of pinion shaft are identical.
Adjust cone point when replacing ring gear and pinion shaft.
If necessary, remove ring gear from differential.

[5] - Heat new ring gear in a bearing heater. Use a thermometer and do not exceed 150 °C
(300 °F).
[6] -
IMPORTANT:
Ensure that ring gear is fully seated.
Install ring gear.

[7] -
CAUTION:
LEGEND:
A Piston
High-pressure air can cause piston to move suddenly with great force
causing serious injury.
Remove differential lock piston (A) from cover by applying air to lock piston inlet.
[8] -
LEGEND:
A Gear, Thrust Washer, Disk, and Separator Plates
Remove gear, thrust washer, disks, and separator plates (A).
[9] - Inspect clutch disks and replace as necessary.
7200R/7215R/7230R Differential Clutch Disk Thickness (new) 3.18 mm
(0.125 in.)
7260R/7280R Differential Clutch Disk Thickness (new) 3.20 mm
(0.126 in.)

[10] -
IMPORTANT:
LEGEND:
A Housing
B Cover
Ensure that cups are seated in bottom of bores.
Install new bearing cup in differential housing (A) using JDG933 Driver Disk 137 mm (5-3/8
in.) .
[11] - Install new bearing cup in differential housing cover (B) using JDG932 Driver Disk (162
mm or 6-3/8 in.) .

[12] -
IMPORTANT:
LEGEND:
B Sealing Rings (4 used)
C Packings (4 used)
Install new bearing cones (A) until fully seated against shoulders.
→NOTE:
Driver disk is part of the D01045AA Disk Set .
Install bearing cone on right quill using a 95 mm (3-3/4 in.) driver disk.
[13] - Heat bearing cone in a bearing heater and install onto left quill. Use a thermometer
and do not exceed 150 °C (300 °F).
[14] - Allow to cool and seat the cone using a brass drift. (See General Repair
Procedures—Rear Differential in this group.)
[15] - Remove sealing rings (B) and packings (C).

[16] -
LEGEND:
B Shaft Removal Cap Screw
[17] - Install a 19M7361 (12 x 50 mm) cap screw (B) into pinion shaft.
[18] - Use a slide hammer to pull pinion shafts from hub.
[19] - Leave shafts in pinion assemblies.
[20] -
LEGEND:
A Hub
Remove pinion hub (A).

[21] -
LEGEND:
A Shafts (3 used)
B Spherical Thrust Washer (3 used)
Push shafts (A) into pinion assemblies and remove spherical thrust washers (B), outer thrust
washers, needles, inner thrust washers, and pinions with shafts.
[22] -
LEGEND:
A Bevel Gear
B Thrust Washer
Remove bevel gear (A) and thrust washer (B).
[24] - Install bevel gear and thrust washer into housing.

[25] -
LEGEND:
A Spherical Thrust Washer (3 used)
B Tabs
C Needle Thrust Washer (6 used)
D Needle Bearings (54 used)
Coat spherical thrust washers (A) lightly with TY6341 Multi-Purpose Grease and install. Ensure
that tabs (B) are positioned in recess.
Number Name Use
[26] - Coat ID of pinions lightly with TY6341 Multi-Purpose Grease and install needle roller
bearings (D).
Number Name Use
[27] - Install needle thrust washers (C) on each side of needle bearings in pinions.

[28] -
IMPORTANT:
Needle thrust washer must be between needles and spherical thrust
washer, and needles and hub.
Install pinion shafts into pinion gears.

[29] -
LEGEND:
A Pinion Assembly
B Pinion Shaft
From inside, install pinion assemblies (A) into spherical thrust washer.
[30] - Push shafts (B) into housing.
[31] -
LEGEND:
Push shafts into hub and install cap screws (A).

(52 lb.-ft.)
[33] -
→NOTE:
Ensure to strike the shaft only.
Strike each shaft with a drift or socket.

(52 lb.-ft.)
[35] -
LEGEND:
A Differential Bevel Lock Gear
B Thrust Washer
C Disk (3 used)
D Housing
Install differential bevel lock gear (A) ensuring that thrust washer (B) is correctly positioned.
[36] - Install disks and separator plates alternately, starting with a disk (C) against housing
(D).

[37] -
LEGEND:
A Piston
Lightly lubricate seal lips with clean hydraulic oil and install piston (A) into differential cover.
[38] - Apply TY6341 Multi-Purpose Grease to retain piston in housing.
Number Name Use
[39] -
LEGEND:
Install differential cover and cap screws (A).
(228 lb.-ft.)
[41] - Ensure that differential assembly rotates freely.

[42] -
→NOTE:
LEGEND:
A JDG877-2 Mandrel
B Sealing Ring
C JDG877-1 Pusher
D JDG877-3 Spacer
E JDG878 Resizing Tool
Sealing ring tools are part of the JDG877 Sealing Ring Loading Tool Set .
7260R/7280R Differentials Perform the Following:
Install JDG877-2 Mandrel (A) onto quill.

Install a sealing ring (B) onto mandrel and fit bottom sealing ring onto quill using
JDG877-1 Pusher (C).
Install JDG877-3 Spacer (D) into JDG877-2 Mandrel and install mandrel onto quill.
Install a sealing ring onto mandrel and fit top sealing ring onto quill using JDG877-1
Pusher.
IMPORTANT: Leave resizing tool in position until just before installing
quill.
Remove sealing ring loading tool and install JDG878 Sealing Ring Resizing Tool (E).

[43] -
LEGEND:
A Packings (4 used)
7200R/7215R/7230R Differentials Perform the Following:
Install new packings (A).

Install new sealing rings (B).

Remove Rear Differential Drive Shaft

[1] - Remove rear differential. (See Remove Rear Differential in this group.)
[2] -
LEGEND:
A Cap Screw
B Oil Line
Remove cap screw (A) and oil line (B).
[3] -
LEGEND:
A Slots (2 used)
Remove retaining nut tab from slots (A).
[4] -
→NOTE:
JDG11210P1 Retainer Tool and JDG11210P2 Retainer Tool are part of
JDG11210 Retainer Tool .

7260R/7280R Differentials
For 7260R/7280R differentials: Use JDG11196 472 mm DDS Spline Socket (A) and
JDG11210P1 Retainer Tool (B) to remove retaining nut.
7200R/7215R/7230R Differential
LEGEND:
A JDG11196 472 mm DDS Spline Socket
B JDG11210P1 Retainer Tool
C JDG11195 425 mm DDS Spline Socket
D JDG11210P2 Retainer Tool
For 7200R/7215R/7230R differentials: Use JDG11195 425 mm DDS Spline Socket (C),
JDG11210P1 (B), and JDG11210P2 Retainer Tool (D) to remove retaining nut.
[5] - Discard retaining nut.
[6] -
→NOTE:
May need to gently strike DFRW237 plate to unseat bearing cone.

LEGEND:
A DFRW237—Differential Drive Shaft Removal Tool
C Nuts (2 used)
Use DFRW237—Differential Drive Shaft Removal Tool (A), cap screws (B), and nuts (C) to
separate rear differential drive shaft from the bearing cone.
[7] -
LEGEND:
A Bearing Cone

[8] -
LEGEND:
Remove rear differential drive shaft (A).
[9] -
LEGEND:
A Mid-Dam Deflector
For 7260R/7280R differentials: Remove mid-dam deflector (A).

[10] -
Front Bearing Cup
Rear Bearing Cup

LEGEND:
[11] -
IMPORTANT:
Amount and size of shims removed will vary, retain shim packs for
reassembly.

Cone Point Shim Pack
Differential Drive Shaft Shim Pack

LEGEND:
A Shim Pack
Remove shims (A).

[12] -
LEGEND:
A Head Dam Deflector
B Bearing Cone
Remove head dam deflector (A) and bearing cone (B).

Determine Rear Differential Drive Shaft Cone Point

Shim Pack
LEGEND:
A Rear Bearing Cone
IMPORTANT:
Use a thermometer and do not exceed 150 °C (300 °F).
[1] - Heat new bearing (A) in a bearing heater.

[2] - Install bearing until fully seated against shoulder of shaft.
[3] -
IMPORTANT:
Ensure bearing cone is fully seated against spiral bevel shaft shoulder.
Allow bearing to cool and seat bearing using a brass drift.

[4] -


LEGEND:
A Etched Number on Differential Case
B Etched Number on Spiral Bevel Pinion
C Bearing Height Measurement
Record etched number on differential case (A).
[5] -
→NOTE:
If there is no etched mounting distance number on spiral bevel pinion (B),
use appropriate formula with mounting distance constant.
Record etched number on spiral bevel pinion (B).

[6] - Position bearing cup onto rear bearing cone, hold tightly, and record bearing height
measurement (C).
[7] - Calculate shim pack using appropriate formula. ReferenceEXAMPLES below.
7200R, 7215R, 7230R
40K ECO/50K, PQ/AQ/CQ
Formula (A) - (B) - (C) = Total Shim Pack
260.267 mm Etched Number On Differential Case (A)
- 213.43 mm Etched Number On Spiral Bevel Pinion (B)
- 46.182 mm Bearing Height Measurement (C)
= 0.655 mm Total Shim Pack
40K ECO/50K, PQ/AQ/CQ
Formula (A) - 213 mm - (C) - 0.393 mm = Total Shim Pack
- 213 mm Shaft Mounting Distance Constant
- 0.393 mm Constant Dimension
40K/50K, IVT
30K/40K, PQ/AQ
Formula (A) - (B) - (C) - 0.063 mm = Total Shim Pack
- 213.48 mm Etched Number On Spiral Bevel Pinion (B)
40K/50K, IVT
30K/40K, PQ/AQ, 2WD

7260R, 7280R
40K/50K, IVT

Assemble and Install Rear Differential Drive Shaft

[1] -
IMPORTANT:
Arrow indicates front on differential case. Ensure correct orientation of
mid-dam deflector.
→NOTE:
LEGEND:
A Depth
For 7260R/7280R differentials: Use 100 mm (3-15/16 in.) driver disk to install mid-dam
deflector to specified depth (A).
Verify correct depth using depth micrometer.
7260R/7280R Mid-Dam Deflector Depth Depth 11 mm
(0.43 in.)
[2] - Apply RE23148 AMBLYGON ™ Grease to OD of bearing cups and inside diameter of
pinion end bearing bore in input quill.
[3] -
→NOTE:
Shims must always be measured individually due to slight variations in
thickness. Never measure an entire shim pack at once.

LEGEND:
A Shim Pack
Determine correct cone point shim pack thickness and install shim pack (A). (See Determine
Rear Differential Drive Shaft Cone Point Shim Pack in this group.)
[4] -
Rear Bearing Cup

LEGEND:
A Bearing Cup
For 7260R/7280R differentials: Use 170 mm (6-11/16 in.) driver disk to install rear bearing
cup (A) until fully seated.
For 7200R/7215R/7230R differentials: Use 133 mm (5-1/4 in.) driver disk to install rear
bearing cup (A) until fully seated.

[5] -
Front Bearing Cup

LEGEND:
A Bearing Cup
For 7260R/7280R differentials: Use 133 mm (5-1/4 in.) driver disk to install front bearing
cup (A) until fully seated.
For 7200R/7215R/7230R differentials: Use 102 mm (4 in.) driver disk to install front
bearing cup (A) until fully seated.
[6] -
LEGEND:
A Shim Pack
Install shim pack (A) that was previously removed.
[7] - Add 0.25 mm (0.010 in.) shims to shim pack to create intentional end play.

[8] -
LEGEND:
Install rear differential drive shaft (A).
[9] -
IMPORTANT:
Use a thermometer and do not exceed 150°C (300°F).
LEGEND:
A Bearing cone
Heat bearing cone in a bearing heater and install front bearing cone (A) on shaft against end
play shims.
[10] -
IMPORTANT:
Install NEW retaining nut during reassembly.
→NOTE:
JDG11210P1 Retainer Tool and JDG11210P2 Retainer Tool are part of
JDG11210 Retainer Tool .

7260R/7280R Differential
For 7260R/7280R differentials: Use JDG11196 472 mm DDS Spline Socket (A) and
JDG11210P1 Retainer Tool (B) to install new retaining nut.
7200R/7215R/7230R Differential
LEGEND:
A JDG11196 472 mm DDS Spline Socket
B JDG11210P1 Retainer Tool
C JDG11195 425 mm DDS Spline Socket
D JDG11210P2 Retainer Tool
For 7200R/7215R/7230R differentials: Use JDG11195 425 mm DDS Spline Socket (C),
JDG11210P1 (B), and JDG11210P2 Retainer Tool (D) to install new retaining nut.
[11] - Tighten retaining nut to specification.
(406 lb.-ft.)
[12] - Rotate drive shaft back and forth six times.

[13] - Retighten retaining nut to specification.

[14] -
LEGEND:
A Dial Indicator
Install a dial indicator (A) with pointer contacting end of drive shaft. Measure and record end
play.
[15] - Remove retaining nut.
[16] -
LEGEND:
A DFRW237—Differential Drive Shaft Removal Tool
C Nuts (2 used)
Use DFRW237—Differential Drive Shaft Removal Tool (A), cap screws (B), and nuts (C) to
separate rear differential drive shaft from the bearing cone.

[17] -
→NOTE:
Shims must always be measured individually due to slight variations in
thickness. Never measure an entire shim pack.
Subtract enough shims to provide correct final end play using end play measurement.
Spiral Bevel Pinion Shaft Assembly End Play 0.013—0.089 mm
(0.0005—0.0035 in.)
[18] - Install shim pack.

[19] -
IMPORTANT:
Use a thermometer and do not exceed 150°C (300°F).
Heat bearing cone in a bearing heater and install front bearing cone on shaft against shims.
[20] - Install retaining nut and tighten to specification.
(406 lb.-ft.)
[21] - Rotate drive shaft back and forth six times.

[22] - Retighten retaining nut to specification.
[23] - Verify final end play.
[24] -
LEGEND:
A Slots (2 used)
Stake retaining nut tab into slots (A).

[25] -
LEGEND:
A Head Dam Deflector
Use a brass drift to install head dam deflector (A) until fully seated.
[26] -
LEGEND:
A Cap Screw
B Line
Lubricate coupler and install oil line (B).
[27] - Install cap screw (A) and tighten to specification.
Oil Line Cap Screw Torque 35 N·m
(26 lb.-ft.)

Install Rear Differential
LEGEND:
A JDG879-1 Bar
C JDG879-3 Handle Extension

CAUTION:
Differential assembly and ring gear weigh approximately 60 kg (132 lb.).

Use caution when handling.
→NOTE:
JDG879-1 Bar and JDG879-3 are part of JDG879A Differential and Pinion
Lifting Fixture .
[1] - Install JDG879-1 Bar (A) using M10 x 120 mm cap screw and washer (B).
[2] - Attach JDG879-3 Handle Extension (C).
[3] - Support tool with a hoist and a person on handle extension.
[4] - Install differential into differential case.

[5] -
LEGEND:
B Packings (2 used)
C JDG880 Differential Bearing Quill Tool
D Notch
E Threaded Hole (6 used)
Lubricate left-hand quill sealing rings (A) and packings (B) with TY6341 Multi-Purpose Grease
and install.
Number Name Use
.
[6] - Using JDG880B Differential Bearing Quill Adjustment Tool (C), tighten until bottom
surface of notches (D) are flush with adjacent machined surface of differential case.
[7] - Rotate quill clockwise until closest notch to any threaded hole (E) is aligned.

[8] -
LEGEND:
A Resizing Tool
C Packing
D JDG880 Differential Bearing Quill Tool
E Notch
F Threaded Hole (6 used)
Remove resizing tool (A).

[9] - Lubricate right-hand quill sealing rings (B) and packing (C) with TY6341 Multi-Purpose
Grease and install.
Number Name Use
[10] - Using JDG880B Differential Bearing Quill Adjustment Tool (D), tighten quill leaving a
small amount of end play.
[11] - Rotate quill clockwise until closest notch (E) to any threaded hole (F) is aligned.
[12] -
LEGEND:
A Pinion Shaft Retaining Cap Screw
Remove differential lifting fixture tools.
[13] - Install pinion shaft retaining cap screw (A) and tighten to specification.
(52 lb.-ft.)
[14] -
→NOTE:
Ensure to strike the shaft only.
Strike pinion shaft with a drift or socket.

[15] - Tighten cap screw to specification.
(52 lb.-ft.)
[16] - Rotate differential a minimum of six revolutions to seat bearings.

Side Quill Adjustment Information
From aligned notch and hole (A), clockwise rotation provides the following adjustments:
From Notch: To Hole: Amount of Adjustment:
B 2 0.025 mm (0.001 in.)
C 3 0.05 mm (0.002 in.)
D 4 0.075 mm (0.003 in.)
E 5 0.10 mm (0.004 in.)
F 6 0.125 mm (0.005 in.)
G 1 0.15 mm (0.006 in.)

Measure End Play and Adjust Rear Differential

Preload
LEGEND:
A Dial Indicator
[1] - Install dial indicator inside differential case.

[2] - Measure end play by moving housing side-to-side with prybars.

[3] -
Calculate amount to tighten the quill to achieve the specified preload.

7260R/7280R Differential Preload 0.05—0.13 mm
(0.002—0.005 in.)
7200R/7215R/7230R Differential Preload 0.025—0.076 mm
(0.001—0.003 in.)
EXAMPLE
0.30 mm (0.012 in.) Measured End Play
+ 0.10 mm (0.004 in.) Desired Preload
_______________
= 0.40 mm (0.016 in.) Amount to Tighten Quill
[4] -
IMPORTANT:
Use side quill adjustment information to help determine amount of rotation
to obtain correct preload specification. (See Side Quill Adjustment
Information in this group.)
→NOTE:
In the example the desired preload is the mid-range of the 7260R/7280R
preload specification.
Rotate non-ring gear side bearing quill clockwise as follows to obtain correct preload.
a. From aligned notch and hole (A), rotate quill aligning notch (G) with cap screw hole (1).

This provides 0.15 mm (0.006 in.) adjustment of preload.

b. From aligned notch and hole (A), rotate quill aligning notch (G) with cap screw hole (1).
c. From aligned notch and hole (A), rotate quill aligning notch (E) with cap screw hole (5).
→NOTE:
Adding the three adjustments, a total of 0.40 mm (.016 in.) of
adjustment was made and provides preload of 0.10 mm (0.004 in.).
[5] - Backlash must be checked after carrier ring gear preload is established. (See Adjust
Rear Differential Backlash in this group.)

Adjust Rear Differential Backlash

[1] -
IMPORTANT:
Adjust backlash only after preload adjustment is completed.
LEGEND:
A Dial Indicator
Install a dial indicator (A) on case with pointer resting against a ring gear tooth at OD of gear.
[2] - Hold pinion shaft stationary and rotate ring gear, noting backlash.
[3] - Check backlash at three locations 120° apart.
[4] - Adjust backlash.
Differential Backlash 0.15—0.35 mm
(0.006—0.013 in.)
[5] -
IMPORTANT:
Rotate both quills the same amount to maintain correct preload.
Count number of notches and loosen opposite quill same number of notches when quill is
tightened.
[6] - If backlash is high, rotate left-hand quill counterclockwise and right-hand (gear side)
quill clockwise.
[7] - If backlash is low, rotate right-hand (gear side) quill counterclockwise and left-hand quill
clockwise.

Section 56 - DRIVE SYSTEMS Group 20: Final Drive
[8] -
LEGEND:
A Retaining Cap Screw
B Lock Plate
Install lock plates (B), retaining cap screws (A), and tighten to specification.
Differential Side Quill Lock Plate Retaining Cap Screws Torque 25 N·m
(221 lb.-in.)
[9] - Install final drives. (See Install Final Drive in Group 00.)
[10] - Install hitch frame. (See Remove and Install Rear Hitch Frame in Section 70, Group
00.)

Group 20 - Final Drive

List of References
Other Material
Specifications
General Repair Procedures—Final Drive
Cross-Sectional View—100 mm Rear Axle Housing And Shaft
Cross-Sectional View—100 mm Planet Pinion Carrier
Cross-Sectional View—110/120 mm Final Drive
Remove Planet Pinion Carrier—100 mm
Remove Planet Pinion Carrier—110/120 mm
Disassemble, Inspect, and Assemble Planet Pinion Carrier—100 mm
Disassemble, Inspect, and Assemble Planet Pinion Carrier—110/120 mm
Remove Axle Housing
Disassemble and Assemble Axle Housing
Disassemble, Inspect, and Assemble Axle Shaft
Install Axle Housing
Install Planet Pinion Carrier And Check Rolling Drag Torque—100 mm
Install Planet Pinion Carrier And Check Rolling Drag Torque—110/120 mm

→NOTE:

DF1057—Axle Adjusting Tool
DFRW30A—Axle Jacking Tool
DFRW94—Rear Axle Support Stand
JDG778A Rolling Drag Torque Tool
JDG867 Axle Seal Installer
JDG890A Planetary Carrier Lifting Tool
JDG931 178 mm (7 in.)
JDG1562B Axle Seal Installer
JDG1563 197 mm (7-3/4 in.)
JDG1573 120 mm Rear Axle Support Stand
JDG1662 Spacer Ring
JDG11221 100 mm Flanged Axle Seal Installer
JT01673 Bearing Cup Installer
JT05726 Wheel and Axle Lift
JT07219 Rear Axle Support Stand

Other Material
Number Name Use

• PM38652 (us)
• PM38626 (canadian) High-Temperature Retaining Compound Used to retain
• 620 LOCTITE ™ (Maximum Strength) parts.
(loctite)
Specifications
New Bearings and Cups Rolling Drag Torque 0.6—3 N·m
(5—27 lb.-in.)
Used Bearings and Cups Rolling Drag Torque 0.3—2 N·m
(3—18 lb.-in.)
Pinion Shaft Retaining Shoulder Bolt Nut Torque 18 N·m
(159 lb.-in.)
Carrier Retaining Cap Screw Torque Initial Torque 600 N·m
(442 lb.-ft.)
Carrier Retaining Cap Screw Final Torque 908 N·m
(670 lb.-ft.)

General Repair Procedures—Final Drive
→NOTE:
Before beginning the repair, review the following guidelines. Guidelines are
servicing the final drive.
Thoroughly clean the outside of the final drive before disassembly.
Handle parts carefully to prevent nicking or burring machined surfaces.

During assembly, lubricate each part with clean hydraulic oil.
Perform specified rolling drag torque check.
Inspect the planet pinion carrier and axle shaft before removal from the axle housing as
follows:
Wipe the lubricant from the internal working parts and visually inspect the parts
for excessive wear or damage.
Inspect the gears for roughness.
Inspect the pinion gear teeth for signs of scoring, abnormal wear, nicks, or chips.
Clean all parts with clean solvent and use moisture-free air for drying.
IMPORTANT:
Heat bearing cones in a bearing heater. Use a thermometer and do not

exceed 150 °C (300 °F).
Bearings
damage the bearing.
Clean the bearings with clean solvent, dry thoroughly, and oil before inspection. Inspect
bearings for roughness of rotation, and for excessive wear of rollers.
Inspect bearing cups for scoring, galling, or excessive wear. Pinion bearing cups must
be seated in the bore.

If inspection reveals either a worn bearing cup or a worn cone and roller assembly,
replace both parts.
Shafts
Do not use a torch to remove axle bearing cones. Heating of the shaft causes
premature axle failure.
Inspect the shaft bearing for wear or damage. If excessive wear or damage is found,
replace the shaft and inspect the related components.
Inspect shaft splines and replace if excessively worn or damaged.
Gears
Examine the gear teeth for scoring, chipping, or excessive wear.
Planetary Assemblies
Inspect the pinion gears for damaged or excessively worn teeth.

Check for smooth rotation of the pinion gears.
Cross-Sectional View—100 mm Rear Axle Housing

And Shaft

LEGEND:
A Planet Pinion Carrier
B Carrier Retaining Washer
C Shims
D Thrust Washer
E Retaining Cap Screw
F Bearing Cone
G Axle Housing
H Bearing Cup
I Bearing Cone
J Oil Seal
K Bearing Spacer
L Axle Shaft
M Bearing Cup
Cross-Sectional View—100 mm Planet Pinion Carrier

LEGEND:
A Planet Pinion Roller Bearings (6 used)
C Pinion Retaining Washers (3 used)
D Planet Pinions (3 used)
E Planet Pinion Roller Bearing Cups (6 used)
F Axle Shaft Retaining Washer
G Planet Pinion Carrier
Cross-Sectional View—110/120 mm Final Drive
LEGEND:
1 Thrust Washer (6 used)
2 Needle Rollers (204 used)
3 Final Drive Gear
4 Planet Pinion
5 Spacer
6 Shoulder Bolt (3 used)
7 Nut (3 used)
8 Planet Pinion Shaft (3 used)
9 Shims
10 Axle Shaft
11 Bearing Spacer
12 Oil Seal
13 Bearing Cone
14 Bearing Cup
15 Axle Housing
16 Bearing Cone
17 Bearing Cup
18 Thrust Washer
19 Cap Screw
20 Thick Washer
21 Carrier Retaining Washer

22 Lock Plate
23 Planet Pinion Carrier
24 O-Ring

Remove Planet Pinion Carrier—100 mm
CAUTION:
Wheel, tire, and axle housing assemblies are heavy. Use JT05726 Wheel
and Axle Lift to prevent the possibility of personal injury.
[1] - Remove final drive. (See Remove Final Drive in Group 00.)
[2] - Remove final drive ring gear.

[3] -
LEGEND:
A Adjusting Tool
B Support Stand
C Holding Screw
Install DF1057—Axle Adjusting Tool (A) to axle housing and lift final drive with hoist as shown.
[4] -
→NOTE:
DFRW94—Rear Axle Support Stand can be used in place of JT07219.
Install final drive assembly into the JT07219 Rear Axle Support Stand (B) that is bolted to the
floor.
[5] - Tighten holding screw (C) into keyway of axle.
[6] -
→NOTE:
Because of high torque of planet pinion retaining cap screws, leaving
carrier on axle prevents carrier from turning during cap screw loosening.

LEGEND:
A Lock Plate
B Locking Lugs
C Cap Plug
Loosen pinion retaining cap screws, if planet pinions need to be removed.
[7] - Remove cap plug (C), slightly loosen or tighten planet pinion carrier special cap screw,
and remove lock plate (A) from screw head and locking lugs (B).
[8] - Remove cap screw from carrier and carrier assembly.
[9] -
Inspect the condition of lock plate.

[10] - Replace if plate is bowed.

Remove Planet Pinion Carrier—110/120 mm

[1] -
→NOTE:
Refer to Final Drive—Cross-Sectional View during disassembly.
LEGEND:
A Support Stand
B Holding Screw
Remove final drive. (See Remove Final Drive in Group 00.)
[2] - Remove the final drive gear.
[3] - Install the final drive assembly into JT07219 Rear Axle Support Stand or JDG1573 120
mm Rear Axle Support Stand (A) that is bolted to the floor.
[4] - Tighten the holding screw (B) into the keyway of the axle.

[5] -
LEGEND:
A O-Ring
B Special Cap Screw
C Lock Plate
Remove the O-ring (A), slightly loosen or tighten the planet pinion carrier retaining washer-to-
axle special cap screw (B), and remove the lock plate (C) from the screw head.
[6] - Remove the cap screw from the carrier.
[7] -
LEGEND:
A Lifting Tool
Install the JDG890A Planetary Carrier Lifting Tool (A) and remove the carrier assembly.

[8] -
LEGEND:
A Thrust Washer
B Shims
C Thick Washer
Remove the carrier-to-bearing thrust washer (A).
[9] - Remove the shims (B) and the thick washer (C) from the end of the axle shaft.
[10] -
Inspect the condition of the lock plate.

[11] - Replace the plate, if plate is bowed.

Disassemble, Inspect, and Assemble Planet Pinion

Carrier—100 mm
→NOTE:
Refer to Cross-Sectional View—100 mm Planet Pinion Carrier during

disassembly and assembly.
[1] - Remove planet pinion retaining cap screw and special washer.
[2] - Remove planet pinion and top bearing cone from carrier pinion shaft using a puller with
a 56 mm (2-3/16 in.) driver disk.
[3] -
Remove bottom bearing cone from carrier pinion shaft using a knife-edge puller, puller tools,
and a 55 mm (2-3/16 in.) driver disk.

[4] -
LEGEND:
A Brass Drift
Remove one bearing cup from planet pinion using a brass drift (A).
[5] -
Remove remaining bearing cup using a JT01673 Bearing Cup Installer .

[6] -

LEGEND:
A Pinion Retaining Cap Screw
B Pinion Retaining Washer
C Outer Pinion Bearing Cone
D Outer Pinion Bearing Cup
E Planet Pinion
F Inner Pinion Bearing Cup
G Inner Pinion Bearing Cone
H Planet Pinion Carrier
I Carrier-to-Axle Shaft Retaining Washer
Inspect parts (A—I) and replace as necessary.
[7] - Install new bearing cups, small ID toward the inside shoulder, into the planet pinion.
Install against the shoulder using a JT01673 Bearing Cup Installer .
[8] - Heat bottom bearing cone and install onto carrier pinion shaft with large OD against the
carrier shoulder. Allow bearing cone to cool and seat bearing cone using a brass drift. (See
General Repair Procedures—Final Drive in this group.)
[9] - Install carrier-to-axle shaft retaining washer in center of carrier with the stepped side
facing the end of axle shaft.
[10] - Install planet pinion assemblies onto carrier pinion shafts.
[11] - Heat top bearing cone and install onto carrier pinion shaft leaving end play between
cup and cone. (See General Repair Procedures—Final Drive in this group.)

[12] -
IMPORTANT:
Thoroughly clean the oil from the internal and external threads. Use only
the specified retaining compound.
Clean the threads and apply a 12 mm (0.5 in.) long bead of PM38652 High-Temperature
Retaining Compound (Maximum Strength) to the cap screw, starting at the thread end.
Number Name Use
• PM38652 (us)
• PM38626 (canadian) High-Temperature Retaining Compound Used to retain
• 620 LOCTITE ™ (Maximum Strength) parts.
(loctite)
[13] - Clean threads and apply PM38652 High-Temperature Retaining Compound (Maximum
Strength) to carrier pinion shaft threads. Ensure that no retaining compound gets into the
bearings.
[14] - Apply oil to bearing cones.
[15] - Put washers over the bearing cones and start cap screws into carrier pinion shaft.
[16] - Tighten cap screws while rotating pinions until a slight drag occurs.
[17] -
LEGEND:
A Pinion Rotating Tool
Install the JDG778A Rolling Drag Torque Tool (A) and note drag torque while rotating the
pinion with the tool.

[18] - Tighten the cap screw until correct drag torque is obtained.
New Bearings and Cups Rolling Drag Torque 0.6—3 N·m
(5—27 lb.-in.)
Used Bearings and Cups Rolling Drag Torque 0.3—2 N·m
(3—18 lb.-in.)
[19] -
IMPORTANT:
Rotate the pinion a minimum of three revolutions after each cap screw
adjustment before checking the drag torque.
Install planet pinion carrier assembly and check rolling drag torque. (See Install Planet Pinion
Carrier And Check Rolling Drag Torque—100 mm in this group.)

Disassemble, Inspect, and Assemble Planet Pinion

Carrier—110/120 mm
[1] -
→NOTE:
Refer to Final Drive—Cross-Sectional View during disassembly and
assembly.
LEGEND:
A Nut
B Bolt
Remove the pinion shaft retaining shoulder bolt nut (A).
[2] - Remove the shoulder bolt (B).
[3] -

LEGEND:
A Pinion
B Thrust Washer
C Spacer
D Needle Rollers (68 used in each pinion)
E Pinion Shaft Retaining Shoulder Bolt
F Nut
G Pinion Shaft
Remove the shaft (G).
[4] - Remove the planet pinion assembly and planet pinion thrust washers (B) from the
carrier.
[5] - Remove the needle rollers (D) and spacer (C) from the pinions.
[6] - Remove the carrier retaining washer from the carrier.
[7] -
→NOTE:
Use a coating of grease to hold the rollers in the pinions during assembly.
Assemble in reverse order making sure to install the carrier retaining washer in the carrier
before installing the pinion assemblies.

[8] -
LEGEND:
A Nuts
B Bolts
Install the pinion shaft retaining shoulder bolts (B).
[9] - Tighten nuts (A).
Pinion Shaft Retaining Shoulder Bolt Nut Torque 18 N·m
(159 lb.-in.)

Remove Axle Housing
LEGEND:
A Jacking Tool
[1] - Remove ring gear.

[2] - Remove planet pinion carrier. (See Remove Planet Pinion Carrier—100 mm or Remove
Planet Pinion Carrier—110/120 mm in this Group.)
[3] -
→NOTE:
Use a disk between head of jack and axle shaft to avoid damage to end of
shaft.
Press axle shaft through inner bearing using a hydraulic jack and DFRW30A—Axle Jacking
Tool (A).
[4] - Remove hydraulic jack, disk, and jacking tool and remove bearing cone.
[5] - Remove the carrier-to-bearing thrust washer.
[6] - Remove axle housing from axle shaft using a hoist with a chain or strap around axle
housing. Ensure that housing is balanced on chain or strap.
[7] -
→NOTE:
Refer to Cross-Sectional View—100 mm Rear Axle Housing And Shaft or
Cross-Sectional View—110/120 mm Final Drive during disassembly and
assembly.

Inspect the ring gear.

Disassemble and Assemble Axle Housing

[1] -
→NOTE:
Refer to Final Drive—Cross-Sectional View during disassembly and
assembly.
Remove inner and outer bearing cups using puller tools.

[2] - Install outer bearing cup tight to bottom of bore using appropriate driver disk.
Outer Bearing Driver Disk
100 mm Axle .......... JT01673 Bearing Cup Installer
110 mm Axle .......... JDG931 178 mm (7 in.)
120 mm Axle .......... JDG1563 197 mm (7-3/4 in.)
[3] - Install inner bearing cup tight to bottom of bore using driver disk.
Inner Bearing Driver Disk
100 mm Axle .......... JT01673 Bearing Cup Installer
110 mm Axle .......... JDG932 Driver Disk (162 mm or 6-3/8 in.)
120 mm Axle .......... JDG932 Driver Disk (162 mm or 6-3/8 in.)

Disassemble, Inspect, and Assemble Axle Shaft
IMPORTANT:
DO NOT use a torch to remove axle bearing cones. Heating of the axle shaft
causes premature axle failure.
[1] - Remove parts from axle shaft using puller tools and a hydraulic jack.
[2] - Make sure knife-edge puller is hooked over outer bearing spacer.
[3] -
IMPORTANT:
Ensure correct orientation of axle seal.
Install spacer so chamfered edge faces flange.
→NOTE:
Place axle seal on flanged axle BEFORE pressing spacer and bearing onto
axle shaft.

LEGEND:
A Spacer
B Seal
For flanged axles, perform the following:
a. Remove old spacer (A) and seal (B).

b. Install seal loosely against flange.
c. Install spacer.

[4] -
CAUTION:
LEGEND:
A Axle Seal Spacer Large OD
Heat spacer in a bearing heater. Use a thermometer and do not exceed 240
°C (465 °F).
For all axles, perform the following:
a. Heat axle bearing spacer to 240 °C (465 °F).

b. Install spacer against shoulder on axle shaft with tapered ID of spacer facing toward
shoulder on axle.
c. Allow bearing cone to cool and reseat bearing and spacer against axle shoulder using a
brass drift.
d. Lightly oil bearing.

Install Axle Housing

[1] -
LEGEND:
A Screw
Lift axle housing vertically over axle shaft.
[2] - Carefully lower axle housing over shaft.
[3] - Tighten the holding screw (A) into the keyway of the axle shaft.
[4] - Turn axle housing three revolutions to seat outer bearing cone.
[5] -
IMPORTANT:
LEGEND:
A Bearing Cone
B Thrust Washer
DO NOT install the bearing cone all the way in place. This ensures end play.
Heat and install inner bearing cone (A). (See General Repair Procedures—Final Drive in this
group.)

[6] - Apply clean lubricating oil and install a new thrust washer (B) on top of bearing cone
when bearing cools.

Install Planet Pinion Carrier And Check Rolling Drag

Torque—100 mm
[1] -
LEGEND:
A Carrier Retaining Cap Screw
B Carrier Retainer Washer
Check axle housing on axle shaft to ensure that there is a measurable amount of end play.
[2] - Install carrier assembly onto axle shaft.
[3] -
IMPORTANT:
Use of a new carrier retaining cap screw is recommended.
→NOTE:
Lubricate inner and outer bearings with oil before tightening carrier
retaining cap screw.
Shims must not be installed between carrier retaining washer and axle
shaft.
Install carrier retaining cap screw (A) through carrier retainer washer (B).
[4] - Tighten cap screw into axle shaft by hand, ensure that retainer washer is correctly
positioned in carrier.

[5] -
LEGEND:
A DF1057 Axle Adjusting Tool
B Cap Screw
C Carrier Assembly
D Torque Wrench
Install DF1057—Axle Adjusting Tool (A) on axle flange.
[6] - Tighten carrier retaining cap screw (B) to specification.
(442 lb.-ft.)
[7] - Rotate axle housing by hand three full revolutions in both directions to seat bearing
rollers.

[8] - Loosen carrier retaining cap screw to zero torque.

[9] - Retighten carrier retaining cap screw (B) to specification.
(442 lb.-ft.)
[10] - Loosen carrier retaining cap screw to zero torque.

[11] - Check axle housing on axle shaft to ensure that there is no preload on bearings.
[12] - Install a non-click type torque wrench (D).
[13] - With retaining cap screws loose, rotate axle housing three times and record rolling
drag. This is the baseline rolling drag.
[14] - Remove carrier assembly (C) from axle.
[15] -
→NOTE:
Lead balls are available by ordering R72232.
Ensure that thrust washer (A) is still in position.
LEGEND:
A Thrust Washer
B Shims
C Thick Washer
Put two 8—10 mm (0.3—0.4 in.) diameter lead balls on end of axle shaft 180° apart. Use
grease to hold balls in position.
[16] - Install carrier assembly.
[17] - Install and tighten carrier retaining cap screw to 200 N·m (148 lb.-ft.).

[18] -
LEGEND:
B Torque Wrench
Rotate axle housing 3 times in both directions using DF1057 Axle Adjusting Tool (A) and a
non-click type torque wrench (B) to check rolling drag torque. Make note of rolling drag
torque. Rolling drag torque must increase 8—16 N·m (71—142 lb.-in.) over ”baseline” reading
for axles with used bearings or 16—28 N·m (142—248 lb.-in.) for axles with new bearings.
[19] - If reading is low, increase torque on carrier retaining cap screw in 68 N·m (50 lb.-ft.)
increments.
[20] - Rotate axle housing 3 times in both directions and check rolling drag torque. Continue
procedure until correct increase over baseline reading is obtained.

[21] -
LEGEND:
A Thrust Washer
B Shim Pack
C Thick Washer
Remove planetary assembly and measure individual thickness of flattened lead balls.
Average thickness of two lead balls equals thickness of shim pack required.
[22] -
→NOTE:
Thick washer is part of shim pack. Shims must always be measured
individually due to slight variations in thickness. Never measure an entire
pack.
Relieve bearing preload by lifting axle assembly and hitting inner end of axle shaft with a
heavy lead hammer.
[23] - Install shim pack (B) as previously determined. Install thick washer (C) next to end of
axle shaft. Be sure thrust washer (A) is correctly positioned.
[24] - Install planetary assembly and tighten carrier retaining cap screw to specification
using a torque multiplier wrench.
(670 lb.-ft.)

[25] -
LEGEND:
B Torque Wrench
Rotate axle housing 3 times in both directions using DF1057 Axle Adjusting Tool (A) and a
non-click type torque wrench (B) to check rolling drag torque. Make note of rolling drag
torque. Rolling drag torque must increase 8—16 N·m (71—142 lb.-in.) over ”baseline” reading
for axles with used bearings or 16—28 N·m (142—248 lb.-in.) for axles with new bearings.
[26] -
IMPORTANT:
Remove any preload on bearings before ADDING shims.
→NOTE:
Adding or removing a 0.13 mm (0.005 in.) shim changes rolling drag torque
by approximately 8 N·m (71 lb.-in.).
→NOTE:
Add shims if rolling drag torque is high or remove shims if rolling drag
torque is low.
Adjust shim pack thickness as required.

[27] -
LEGEND:
A Lock Plate
B Lock Plate Lugs
C Cap Plug
Replace lock plate (A) if necessary.
[28] - Install lock plate with lugs between lock lugs (B) on carrier. If plate lugs do not fit
between the lock lugs, tighten carrier retaining cap screw slightly (8° maximum).
[29] - Install cap plug (C) around cap screw head with lock plate installed.
[30] - Install final drive. (See Install Final Drive in Group 00.)
[31] -

LEGEND:
A Jackscrews (2 used)
For tractors with flanged axles, perform the following:
Ensure axle is in a horizontal position.

Apply clean hydraulic oil to OD and ID of seal surfaces, housing, and axle ring surfaces
before seal installation
Install JDG11221 100 mm Flanged Axle Seal Installer .
IMPORTANT: Ensure seal is flush with axle housing.
Thread jackscrews (A) against axle flange to push seal until flush with axle housing.
[32] -
IMPORTANT:
DO NOT disassemble seal. Disassembly damages seal.

Assembled 100 mm Axle Seal Installer
LEGEND:
A Seal Installer
For tractors with bar axles, perform the following: Tighten set screw to retain spacer
ring to installer.
[33] - Apply clean hydraulic oil to OD and ID of seal surfaces, housing, and axle ring surfaces
[34] - Install axle seal flush with axle housing using JDG867 Axle Seal Installer (A) and
JDG1662 Spacer Ring .

Install Planet Pinion Carrier And Check Rolling Drag

Torque—110/120 mm
[1] - Check axle housing on axle shaft to make sure that there is a measurable amount of
end play.
[2] - Install planetary assembly.
[3] -
IMPORTANT:
Use of a new carrier retaining cap screw is recommended.
→NOTE:
Lubricate inner and outer bearings with oil before tightening carrier
retaining cap screw.
Shims must not be installed between carrier retaining washer and axle
shaft.
Tighten special cap screw to 600 N·m (442 lb.-ft.).

[4] - Turn axle three revolutions in each direction to ensure that bearing cups and cones are
seated.
[5] - Loosen special cap screw to zero torque.
[6] - Retighten special cap screw to 600 N·m (442 lb.-ft.).
[7] - Loosen special cap screw to zero torque.

[8] - Check axle housing on axle shaft to make sure that there is no preload on bearings.
LEGEND:
A Adjusting Tool
Install DF1057—Axle Adjusting Tool (A).
[9] - Rotate axle three times and record rolling drag torque with the special cap screw loose,
using a non-click type torque wrench.
[10] - This is the “baseline” rolling drag torque.
[11] -
LEGEND:
A Thrust Washer
B Shims
C Thick Washer
Remove special cap screw and planetary assembly.

[12] -
→NOTE:
Lead balls are available by ordering R72232.
Ensure that thrust washer (A) is still in position.
Put two 8—10 mm (0.3—0.4 in.) diameter lead balls on end of axle shaft 180° apart. Use
grease to hold balls in position.
[13] -
LEGEND:
A Adjusting Tool
Install planetary assembly.
[14] - Install and tighten special cap screw to 270 N·m (200 lb.-ft.).
[15] - Rotate the carrier at least three times in both directions using DF1057 Axle Adjusting
Tool (A).
[16] - Use a non-click type torque wrench to check rolling drag torque.
[17] - Make note of the rolling drag torque.
[18] - The rolling drag torque must increase 12—20 N·m (9—15 lb.-ft.) over ”baseline”
reading.
[19] - If reading is low, increase torque on special cap screw in 68 N·m (50 lb.-ft.) steps.
[20] - Rotate the carrier at least three times in both directions and check rolling drag torque
each time. Continue procedure until correct increase in reading is obtained.

[21] -
LEGEND:
A Thrust Washer
B Shim Pack
C Thick Washer
Remove planetary assembly and measure the individual thickness of flattened lead balls.
Average thickness of the two lead balls equals thickness of shim pack required.
[22] -
→NOTE:
The thick washer is part of the shim pack. Shims must always be measured
individually due to slight variations in thickness. Never measure an entire
pack.
Relieve the bearing preload by lifting the axle assembly and hitting the inner end of the axle
shaft with a heavy lead hammer.
[23] - Install shim pack (B) as previously determined. Install the thick washer (C) next to end
of axle shaft. Be sure thrust washer (A) is correctly positioned.

[24] -
Install planetary assembly and tighten special cap screw.

(670 lb.-ft.)
[25] -
LEGEND:
A Adjusting Tool
Rotate axle housing three times using DF1057—Axle Adjusting Tool (A).
[26] - Use a non-click type torque wrench to check rolling drag torque wrench.
[27] - The rolling drag torque must increase 12—20 N·m (9—15 lb.-ft.) over “baseline”
reading for axles with used bearings or 25—40 N·m (18—30 lb.-ft..) for axles with new
bearings.

[28] -
IMPORTANT:
Remove any preload on bearings before adding shims.
→NOTE:
Adding or removing a 0.13 mm (0.005 in.) shim will change rolling drag
torque by approximately 8 N·m (6 lb.-ft.).
→NOTE:
Add shims if rolling drag torque is high or remove shims if rolling drag
torque is low.
Adjust shim pack thickness as required.

[29] -
LEGEND:
A O-ring
B Cap Screw
C Lock Plate
Install lock plate (C).
[30] - Slightly loosen or tighten the special cap screw (B) to hold the lock plate on the cap
screw.
[31] - Install the O-ring (A) over the cap screw head.
[32] - Install final drives. (See Install Final Drive in Group 00.)

[33] -
LEGEND:
A Jackscrews (2 used)
For tractors with flanged axles, perform the following:
Ensure that axle is in a horizontal position.

Apply clean hydraulic oil to OD and ID of seal surfaces, housing, and axle ring surfaces
Install JDG11222 120 mm Flanged Axle Seal Installer .
IMPORTANT: Ensure that seal is flush with axle housing.
Thread jackscrews (A) against axle flange to push seal until flush with axle housing.
[34] -
→NOTE:
Tools to install seal on bar axles:

JDG1662 Spacer Ring
JDG1562-1A and JDG1562-2 are part of JDG1562B Axle Seal Installer .

Section 56 - DRIVE SYSTEMS Group 30: Rear PTO
LEGEND:
A Seal Installer
For bar axles, perform the following: Install axle seal flush with axle housing using
appropriate seal installer (A):
Axle Diameter Installer Spacer Ring
110 mm Axle JDG868 JDG1662
120 mm Axle JDG1562-2 JDG1562-1A


Group 30 - Rear PTO

List of References
Specifications
Other Material
General Repair Procedures—PTO
Cross-Sectional View—PTO Clutch
Remove And Disassemble PTO Clutch
Assemble And Install PTO Clutch
Remove And Disassemble Output Shaft and PTO Shifter
Remove And Disassemble Countershaft
Disassemble and Assemble Shaft Position Rod
Cross-Sectional View—Two-Speed Shiftable PTO Countershaft
Cross-Sectional View—Three-Speed Shiftable PTO Countershaft
Assemble And Install Countershaft
Cross-Sectional View—Single-Speed PTO Output Shaft
Cross-Sectional View—Two-Speed Shiftable PTO Output Shaft
Cross-Sectional View—Three-Speed Shiftable PTO Output Shaft
Exploded View—Shiftable PTO Shifter
Exploded View—Power Assisted PTO Shifter
Recondition Mechanical Shifter
Recondition Power Assisted PTO Shifter
Assemble And Install Output Shaft and PTO Shifter
Replace PTO Output Shaft Oil Seal

→NOTE:

D01044AA Bushing, Bearing and Seal Driver Set
JDG19 Lifting Eyes
JDG11209 PTO Seal Installer
JDG11328 Seal Driver
JT01610 Seal Installer Disk

Specifications
Clutch Backing Plate Cap Screw Torque 36 N·m
(26 lb.-ft.)
Shaft Position Rod Torque 80 N·m
(59 lb.-ft.)
Front Bearing Support Cap Screw Torque 90 N·m
(66 lb.-ft.)
Witch End Out Sensor to Support Cap Screws Torque 15 N·m
(133 lb.-in.)
PTO Clutch Assembly End Play 0.015—0.2 mm
(0.0005—0.008 in.)
PTO Output Shaft End Play 0.015—0.2 mm
(0.0005—0.008 in.)
Nut to Shaft Position Rod Torque 2 N·m
(18 lb.-in.)
Bearing Quill Cap Screws Torque 58 N·m
(43 lb.-ft.)
Countershaft End Play 0.025—0.13 mm
(0.001—0.005 in.)
Shifter Support Cap Screws Torque 58 N·m
(43 lb.-ft.)
Shifter Fork-to-Special Pin Screw Torque 18 N·m
(159 lb.-in.)
Electromagnets-to-Shifter Fork Support Screws Torque 33 N·m
(292 lb.-in.)
Other Material
Number Name Use
• TY6341 (us) SD Polyurea Grease Used to lubricate PTO adapter.
Number Name Use
• PM37477 (PM37418
[ Smaller Size ]
) (us) Thread Lock and Sealer Used to retain cap screws and
• PM38621 (canadian) (Medium Strength) seal surfaces.

General Repair Procedures—PTO
→NOTE:
servicing the PTO.
Thoroughly clean the outside of PTO housing to reduce possible contamination.

Install the correct shim pack.
Perform specified end play checks.
Use new O-rings and seals.
Inspect the clutch, countershaft, and output shaft before removal as follows:
Wipe the lubricant from the internal working parts and visually inspect the parts
for wear and damage.
Rotate the gears to check for roughness.
Inspect the gear teeth for signs of scoring, abnormal wear, or nicks.
Bearings
damage the bearing.
Replace bearing cone and roller assembly if either the cup or cone has excessive wear.
Springs
Shafts


Inspect bushings for scoring, burrs, roughness, sharp edges, and evidence of
overheating. Remove scores with crocus cloth or knife. Replace bushings if out-of-
round, deeply scored, or excessively worn.
Gears
Examine the gear teeth for scoring, chipping, or excessive wear. Replace as necessary.
Clutch
IMPORTANT:
DO NOT use solvent to clean the disks. Use a lint-free cloth. Soak new disks
in hydraulic oil for 15 minutes before assembly.
Inspect the separator plate ears for excessive wear or damage. Check the plates for
flatness.
Inspect the disk lugs and hub splines for excessive wear or damage. Inspect the disks
for worn or scored surfaces.
→NOTE:
Replace disks if the disk facing material chips, flakes, or scratches easily.

Cross-Sectional View—PTO Clutch
LEGEND:
A Bearing Cone
B Bearing Cup
C Snap Ring
D Backing Plate with Gear
E Clutch Hub with Thrust Washers
F Disks (5 used)
[ 7260R/7280R use 6 Disks. ]
G Separator Plates (4 used)

[ 7260R/7280R use 5 Separator Plates. ]
H Clutch Return Plate
I Clutch Piston
J Clutch Drum
K Brake Plate
L Brake Piston
M Sealing Rings (2 used)
N Bearing Cup
O Bearing Cone
P Retaining Ring
Q Lube Cut-Off Valve
R PTO Housing
S Piston Seals (2 used)
T Bushing
U Piston Return Springs (7 used)
V Snap Ring
W Bearing Support

Remove And Disassemble PTO Clutch

[1] -
LEGEND:
A Rear Hitch Frame
Remove rear hitch frame (A). (See Remove and Install Rear Hitch Frame in Section 70, Group
00.)
[2] -
LEGEND:
B WEO Sensor

[3] - Remove WEO sensor (B).

[5] -
LEGEND:
A JDG19 (2 used)
B Chain
C Bearing Support
Install two JDG19 Lifting Eyes (A). Attach a chain and hoist to remove bearing support (C).
[6] -

LEGEND:
A Bearing Cup Retaining Snap Rings (2 used)
Remove retaining snap rings (A).
[7] - Remove bearing cups (B).

[8] -
→NOTE:
LEGEND:
A Shaft Position Rod
B Bearing
C Bearing-to-Gear Thrust Washers (2 used)
D Output Shaft Drive Gear
If bearing (B) is difficult to remove, loosen or remove shaft position rod (A).
Remove front bearing (B) using a knife-edge puller.

[9] - Remove bearing-to-gear thrust washers (C), and output shaft drive gear (D) from shaft.
[10] - Remove output shaft drive gear needle roller bearings, needle bearing spacer, and
needle bearing-to-shaft thrust washer.

[11] - For SHIFTABLE PTOs, perform the following steps: Remove shaft position rod
(A).
[12] -
LEGEND:
A PTO Clutch
B Rear Hitch Frame
Remove PTO clutch assembly (A) from rear hitch frame (B).
[13] -
→NOTE:
Refer to Cross-Sectional View—PTO Clutch during disassembly and
assembly.
Remove clutch backing plate with gear.

[14] -
→NOTE:
Driver disks handles are part of D01044AA Bushing, Bearing and Seal
Driver Set .
Remove front bearing cone using a press, a knife-edge puller, and a 55 mm (2-3/16 in.) driver
disk.

[15] -
IMPORTANT:
Tractor PTO clutches could have five clutch disks and four separator plates
or six clutch disks and five separator plates.
LEGEND:
A PTO Clutch Hub
B Disks (5 or 6 used)
C Separator Plates (4 or 5 used)
D Return Plate

[16] -
LEGEND:
A Bearing Cone
B Lube Cut off Valve
C Valve Retainer
Remove valve retainer (C) and lube cut off valve (B).
[17] -
LEGEND:
Inspect sealing rings (A).
[18] - Remove rear bearing cone using a press, knife-edge puller, and a 45 mm (1-3/4 in.)
driver disk.

[19] -
LEGEND:
A Snap Ring
Put clutch drum assembly in a press and install a JDG754 Spring Compressor .
[20] - Compress return springs and remove snap ring (A).
[21] - Remove return springs and clutch piston.
[22] -
LEGEND:
A Piston Seals
Replace piston seals (A).

Assemble And Install PTO Clutch
LEGEND:
A Bearing Cone
B Lube Cut off Valve
C Valve Retainer
[1] - Install rear bearing (A) on clutch drum against shoulder using a press and a 51 mm (2
in.) driver disk.
[2] - Install lube cut off valve (B) and valve retainer (C).
[3] -
LEGEND:
Install seal rings (A), ensure that ends are not in line.

[4] -
Install clutch piston.

[5] - Install return springs alternately, starting with OD against piston.
[6] -
Put clutch drum assembly in a press and install a JDG754 Spring Compressor .
[7] - Compress return springs and install snap ring.
[8] - Install bushing using JDG755 Bushing Installer .

[9] -
LEGEND:
A PTO Clutch Hub
B Disks (5 used)
[ 7260R/7280R use 6 Disks. ]

[ 7260R/7280R use 5 Separator Plates. ]
D Return Plate
Install PTO clutch hub (A).
[10] - Install clutch return plate (D).
[11] - Install separator plates (C) and disks (B) alternately starting with a disk against return
plate.
[12] -
Heat bearing cone and install on backing plate. Allow bearing cone to cool and seat bearing
against shoulder using a brass drift. (See General Repair Procedures—PTO in this group.)

[13] - Install clutch backing plate with gear and tighten cap screws to specification.
Clutch Backing Plate Cap Screw Torque 36 N·m
(26 lb.-ft.)
[14] -
LEGEND:
A PTO Brake Plate and Piston
B Rear Bearing Cup
Install rear bearing cup in housing using a 73 mm (2-7/8 in.) driver disk.
[15] - Lubricate piston with clean hydraulic oil and install PTO brake plate and piston (A).
[16] -
LEGEND:
A PTO Clutch Assembly
B Rear Hitch Frame
Install PTO clutch assembly (A) into rear hitch frame (B).

[17] -
LEGEND:
B Bearing
Install output shaft drive gear (D) over bearings and spacer.
[18] - Install output gear-to-front bearing thrust washers (C).
[19] - Install front bearing cone (B) onto shaft.

[20] - For SHIFTABLE PTOs, perform the following steps: Install shaft position rod (A)
(59 lb.-ft.)
.
[21] -
LEGEND:
A JDG19 (2 used)
B Chain
C Bearing Support
Install two JDG19 Lifting Eyes (A). Attach a chain and hoist to install bearing support (C).

[22] -
LEGEND:
B WEO Sensor
Install cap screws (C) and tighten to specification.
Front Bearing Support Cap Screw Torque 90 N·m
(66 lb.-ft.)
[23] - Install WEO sensor (B).

(133 lb.-in.)
[25] -
LEGEND:
A Bearing Cups
B Snap Rings
Install bearing cups (A) and thin snap rings (B).

[26] - Rotate output shaft several times in each direction to seat bearings.
[27] -
LEGEND:
A Clutch Assembly
B Output Shaft
Install a dial indicator with pointer resting on end of shafts (A and B).

[28] - Force shafts up and down using a prybar. Note end play readings.
[29] - Remove bearing retaining snap ring and measure thickness.
[30] -
→NOTE:
Snap rings are available in various sizes. (See PARTS CATALOG.)
Measure and install correct snap ring to provide end play.

(0.0005—0.008 in.)
(0.0005—0.008 in.)
[31] - Install Rear Hitch Frame. (See Remove and Install Rear Hitch Frame in Section 70,
Group 00.)

Remove And Disassemble Output Shaft and PTO

Shifter
LEGEND:
B WEO Sensor

[2] - Remove WEO sensor (B).

[4] -
LEGEND:
A JDG19 (2 used)
B Chain
C Bearing Support
Install two JDG19 Lifting Eyes (A). Attach a chain and hoist to remove bearing support (C).
[5] -

→NOTE:
LEGEND:
B Bearing
If bearing (B) is difficult to remove, loosen or remove shaft position rod (A).
Remove front bearing (B) using a knife-edge puller.

[6] - Remove bearing-to-gear thrust washers (C), and output shaft drive gear (D) from shaft.
[7] - Remove output shaft drive gear needle roller bearings, needle bearing spacer, and
[8] - For SHIFTABLE PTOs, perform the following steps: Remove shaft position rod (A).

[9] -
LEGEND:
A Roll Pin
B Shiftier Shaft
C O-ring
D Counter Shaft Gear Retaining Snap Ring
E Counter Shaft Gear
F Counter Shaft Bearing Support
Remove roll pin (A).
[10] - Pull shiftier shaft (B) out of housing and Remove O-ring (C).

[11] - Remove counter shaft gear retaining snap ring (D) and counter shaft gear (E).
[12] - Remove counter shaft bearing support (F).
[13] -
Shaft with Power Assisted PTO Shift
Shaft With Manual PTO Shift

LEGEND:
B Counter Shaft
C Output Shaft
D Power Assisted PTO Shifter
E Manual PTO Shifter
For THREE-SPEED SHIFTABLE PTO, perform the following steps: Remove cap screws
(A).
[14] - Tilt counter shaft (B) to left-hand side of hitch frame.
[15] - Remove output shaft (C) with ether power assisted PTO shifter (D) or manual PTO
shifter (E) out as one unit.

[16] -
LEGEND:
A Oil Seal
B Rear Bearing Cup
For All PTOs, perform the following steps:
→NOTE:
Refer to Cross-Sectional View—Single-Speed PTO Output Shaft , Cross-
Sectional View—Two-Speed Shiftable PTO Output Shaft , or Cross-Sectional
View—Three-Speed Shiftable PTO Output Shaft during disassembly and
assembly.
[17] - Remove rear oil seal (A). Do not install new seal until after output shaft is installed in
housing. (See Replace PTO Output Shaft Oil Seal in this group.)
[18] - Install new rear bearing cup (B) using JT01610 Seal Installer Disk .

[19] -
Two-Speed Shiftable PTO
Three-Speed Shiftable PTO

LEGEND:
A Sleeve Retaining Snap Ring
B Output Drive Sleeve
C Gear Retaining Snap Ring
D 540 Standard Output Gear
For SHIFTABLE PTOs, perform the following steps: Remove snap ring (A) and sleeve
(B).
[20] - Remove snap ring (C) and gear (D).

[21] -
LEGEND:
A Thrust Washer Retaining Snap Ring
B Thrust Washer
D 540 Economy Output Gear
E Shift Collar
For THREE-SPEED SHIFTABLE PTO, perform the following step: Remove parts (A—E).

[22] -
Two-Speed PTOs
Three-Speed PTO
LEGEND:
A Rear Bearing
B Magnetic Speed Pickup Disk
For ALL PTOs, perform the following steps: Remove rear bearing (A) and magnetic
speed pickup disk (B) using a press and a knife-edge puller.

Remove And Disassemble Countershaft
LEGEND:
A Countershaft Snap Ring
B Countershaft Drive Gear
C Quill Retaining Cap Screws (4 used)
D Bearing Quill
E Countershaft
→NOTE:
Single speed PTO does not have a countershaft.
[1] - For SHIFTABLE PTO, perform the following steps:

[2] - Remove snap ring (A) and countershaft drive gear (B).
[3] - Remove quill retaining cap screws (C) and countershaft bearing quill (D) and shims.
[4] - Remove countershaft (E).

[5] -
LEGEND:
A Bearing Cup
Remove countershaft bearing cup (A).

[6] -
LEGEND:
A Rear Bearing Cone
B Front Bearing Cone
C Snap Ring
D 540 rpm Drive Gear
Remove rear bearing cone (A).
[7] - Remove front bearing cone (B).
[8] - For THREE-SPEED SHIFTABLE PTO, perform the following step: Remove snap
ring (C) and gear (D).

[9] - For SHIFTABLE PTOs, perform the following steps:
LEGEND:
A Bearing Cup
Remove bearing cup (A) from quill using a press and a 73 mm (2-7/8 in.) driver disk.
[10] - Install new bearing cup using a 67 mm (2-5/8 in.) driver disk and a press.
Disassemble and Assemble Shaft Position Rod

[1] -
LEGEND:
A Nut
B Magnet
C Retainer
D Spring
E Shaft Position Rod
Remove nut (A) from shaft position rod (E).
[2] - Remove magnet (B) and retainer (C).
[3] - Remove spring (D).

[5] - Assemble in reverse order and tighten nut (A) to specification.

Nut to Shaft Position Rod Torque 2 N·m
(18 lb.-in.)
Cross-Sectional View—Two-Speed Shiftable PTO

Countershaft
LEGEND:
A Snap Ring
C Bearing Cone
D Bearing Cup
E Bearing Quill
F Shim Pack
G PTO Housing
H Bearing Cup
I Bearing Cone
J Countershaft

Cross-Sectional View—Three-Speed Shiftable PTO

Countershaft
LEGEND:
A Snap Ring
C Bearing Cone
D Bearing Cup
E Bearing Quill
F Shim Pack
G PTO Housing
H Bearing Cup
I Bearing Cone
J Countershaft
K Snap Ring
L 540 rpm Drive Gear

Assemble And Install Countershaft
LEGEND:
A Bearing Cup
→NOTE:
Single speed PTO does not have a countershaft.
[1] - Install new rear bearing cup (A) in the housing using a 74 mm (2-15/16 in.) driver disk.

[2] -
LEGEND:
A Rear Bearing Cone
B Front Bearing Cone
C Snap Ring
D 540 rpm Drive Gear
For THREE-SPEED SHIFTABLE PTO, perform the following step: Install gear (D) and
snap ring (C).
[3] - For ALL PTOs, perform the following steps: Install new rear bearing cone (A) on
the shaft using a press and a 45 mm (1-3/4 in.) driver disk.
[4] - Heat the front bearing cone (B) and install on the shaft. Allow the bearing cone to cool
and seat bearing against the shoulder using a brass drift. (See General Repair
Procedures—PTO in this group.)

[5] -
Install countershaft into housing.

[6] - Install same shim pack that was removed.
[7] - Install bearing quill. Tighten cap screws to specification.
Bearing Quill Cap Screws Torque 58 N·m
(43 lb.-ft.)
[8] - Rotate countershaft several times each direction to seat bearings.

[9] - Install a dial indicator with pointer resting on end of countershaft.
[10] - Force countershaft up and down using a prybar. Note end play reading.
[11] -
→NOTE:
Shims are available in various sizes. (See PARTS CATALOG). Measure shims
individually for accurate measurement.
Remove quill and add or subtract shims to provide end play.

Countershaft End Play 0.025—0.13 mm
(0.001—0.005 in.)

[12] -
LEGEND:
A Snap Ring
Install countershaft drive gear (B) and retaining snap ring (A).
Cross-Sectional View—Single-Speed PTO Output

Shaft

LEGEND:
A Bearing Support
B Snap Ring
C Bearing Cup
D Bearing Cone
E Thrust Washer
F 1000 Output Drive Gear
G Output Drive Shaft
H Magnetic Speed Pickup Disk
I Magnetic Speed Pickup Sensor
J Bearing Cone
K Bearing Cup
L PTO Housing
M Oil Seal

Cross-Sectional View—Two-Speed Shiftable PTO

Output Shaft
LEGEND:
A Bearing Support
B Snap Ring
C Bearing Cup
D Bearing Cone
E Thrust Washer
G Snap Ring
H Output Drive Sleeve
I Output Drive Collar
J 540 Output Drive Gear
K Output Drive Shaft
L Magnetic Speed Pickup Disk
M Bearing Cone
N Bearing Cup
O PTO Housing
P Oil Seal
Q Snap Ring
R Thrust Washer
S Needle Roller Bearings (2 used)

T Needle Bearing Spacer

U PTO Shaft Position Rod
V Shaft Position Rod Seal
W Reversible PTO Shaft

Cross-Sectional View—Three-Speed Shiftable PTO

Output Shaft
LEGEND:
A Bearing Support
B Snap Ring
C Bearing Cup
D Bearing Cone
E Thrust Washer
G Snap Ring
H Output Drive Sleeve
I Output Drive Collar
J 540 Output Drive Gear
K Output Drive Shaft
L Magnetic Speed Pickup Disk
M Bearing Cone
N Bearing Cup
O PTO Housing
P Oil Seal
Q 540 Output Gear
R Snap Ring
S Thrust Washer
T Snap Ring
U Needle Bearing-to-Shaft Thrust Washer
V Needle Roller Bearings (2 used)

W Needle Bearing Spacer
X PTO Shaft Position Rod
Y Shaft Position Rod Seal
Z Reversible PTO Shaft
Exploded View—Shiftable PTO Shifter
LEGEND:
A Shifter Cam Shaft
B O-Ring
C Shifter Cam-to-Cam Shaft Spring Pin
D Shifter Cam Shaft-to-Support Spring Pin
E Shifter Cam
F Shift Yoke Assembly
G Support
H Shift Rail
I Detent Spring
Exploded View—Power Assisted PTO Shifter

Exploded view, PTO shifter
LEGEND:
1 Screw
2 Shifter fork
3 Special pin
4 Screw
5 Pack of electromagnets
6 Spring pin
7 Clamp
8 Shifter fork
9 Screw
10 Washer
11 Snap ring
12 Washer
13 Spring

14 Guide sleeve
15 Screw
16 Snap ring
17 Support for shifter fork
18 Locking pin
19 Detent
20 Nut

Recondition Mechanical Shifter
LEGEND:
A Lower Shift Yoke Assembly
B O-ring
C Shift lever Shaft
D Shift Cam
E Shifter Support
F Upper Shift Yoke Assembly
[1] - Install lower shift yoke assembly (A).

[2] - Install O-ring (B) on shift lever shaft (B) insert shaft threw housing and shift cam (D).

[3] - Install support (E) ensuring that hollow dowel pins are installed in PTO housing and
tighten cap screws to specifications
Shifter Support Cap Screws Torque 58 N·m
(43 lb.-ft.)
[4] -

LEGEND:
A Shifter Cam
B Shift Yoke Assembly and Collar
C Spring Pins (2 used)
D Detent Spring
Install shift yoke assembly and collar (B) onto output shaft.
[5] -
IMPORTANT:
The lever on the cam shaft must point forward.
Push cam and shaft into support until and spring pin holes in support align with groove in
shaft.
[6] - Push cam (A) inward aligning detent spring (D) and yoke rollers in center of cam tracks.
[7] - Rotate shifter shaft so arm is forward and install spring pin (C).

Recondition Power Assisted PTO Shifter

Disassemble the Power Assisted PTO Shifter
[1] -
LEGEND:
A Screw
B Spring Pin
Remove screws (A).
[2] -
→NOTE:
LEGEND:
A Pack of Electromagnets
B Shift Unit
The pack of electromagnets is seated firmly on spring pins (B). Gently tap
with electromagnets a plastic-headed hammer to remove.
Remove pack of electromagnets (A) from shift unit (B).

[3] -
LEGEND:
A Screw
B Shifter Fork
Remove screw (A) and shifter fork (B).
[4] -
LEGEND:
A Locking Pin
Remove locking pin (A).

[5] -
LEGEND:
A Screw
B Shifter Fork
Remove screw (A) and shifter fork (B).
[6] -
LEGEND:
A Snap Rings
B Special Pin
Use a press to remove snap rings (A) and special pin (B).

[7] -
LEGEND:
A Pin
B Washers
C Spring
D Snap Ring
Disassemble special pin (A).
[8] - Inspect parts (A—D) and replace as necessary.
[9] -
Clean all components and assemble special pin.

Exploded View of Shift Mechanism
LEGEND:
1 Support for Shifter Fork
2 Guide Sleeve
3 Snap Ring
4 Special Pin
5 Washer
6 Snap Ring
7 Shifter Fork
8 Screw
9 Washer
10 Locking Pin
11 Shifter Fork
Assemble the Power Assisted PTO Shifter

[1] -
→NOTE:
LEGEND:
A Snap Ring
B Special Pin
C Snap Ring
D Guide Sleeve
When installing special pins, always use new snap rings.
Install snap rings (A).

[2] -
→NOTE:
Ensure that special pins are installed in correct position.
Install special pin (B) and snap rings (C).

[3] -
→NOTE:
Press new guide sleeves all the way into support for shifter fork.
Replace guide sleeves (D), if necessary.

[4] -
IMPORTANT:
LEGEND:
A Shifter Fork
B Long Protrusion on Shift Rod
C Weld
Install shifter fork with correct side up.
Install shifter fork (A) as shown, with the long protrusion (B) and weld (C) on the inside.

[5] -
LEGEND:
A Screw
B Shifter Fork
Apply PM37477 Thread Lock and Sealer (Medium Strength) to screw (A) on shifter fork (B),
Number Name Use
• PM37477 (PM37418
[ Smaller Size ]
(159 lb.-in.)
[6] -
LEGEND:
A Locking Pin
Install locking pin (A).

[7] -
IMPORTANT:
Install shifter fork with correct side up.
LEGEND:
A Screw
B Shifter Fork
Install shifter fork (B) and apply PM37477 Thread Lock and Sealer (Medium Strength) to
screw (A). Tighten to specification.
Number Name Use
• PM37477 (PM37418
[ Smaller Size ]
(159 lb.-in.)

[8] -
→NOTE:
LEGEND:
A Pack of Electromagnets
B Shift Unit
C Screw
D Spring Pin
Install electromagnets on shift unit by gently tapping with a plastic-headed
hammer until it bottoms.
Install pack of electromagnets (A) on shift unit (B).

[9] - Align threaded bores for screws (C) as well as bores for spring pins (D) are exactly
aligned.
[10] -
→NOTE:
LEGEND:
A Screws
B Spring Pin
Spring pins (B) must not stick out.

Apply PM37477 Thread Lock and Sealer (Medium Strength) and tighten screws (A) to
specification.
Number Name Use
• PM37477 (PM37418
[ Smaller Size ]
Electromagnets-to-Shifter Fork Support Screws Torque 33 N·m
(292 lb.-in.)

Assemble And Install Output Shaft and PTO Shifter
Two-Speed PTO
Three-Speed PTO
LEGEND:
A Rear Bearing Cone
B Magnetic Speed Pickup Disk
[1] - Install magnetic speed pickup disk (B) against shoulder using a brass drift.
[2] - Install disk with "This Side Up" toward rear of shaft.
[3] - Heat rear bearing cone (A) and install on shaft.
[4] - Allow bearing to cool and seat bearing against magnetic speed pickup disk using a
brass drift. (See General Repair Procedures—PTO in this group.)

[5] -
LEGEND:
A Thrust Washer Retaining Snap Ring
B Thrust Washer
D 540 Economy Output Gear
E Shift Collar
For THREE-SPEED SHIFTABLE PTO, perform the following steps: Install shift collar (E),
gear (D), and snap ring (C).
[6] - Install thrust washer (B) against snap ring (C) and install snap ring (A) into snap ring
groove against thrust washer (B).

[7] -
Two-Speed Shiftable PTO
Three-Speed Shiftable PTO

LEGEND:
A Sleeve Retaining Snap Ring
B Output Drive Sleeve
D 540 Standard Output Gear
For SHIFTABLE PTOs, perform the following steps: Install gear (D) and snap ring (C).
[8] - Install sleeve (B).
[9] - Install sleeve retaining snap ring (A).
[10] -

LEGEND:
A JDG11328 Seal Driver
B Seal
C Output Shaft
For TRACTORS WITH SHAFT POSITION SWITCHES, perform the following steps:
Install shaft position seal (B) with JDG11328 Seal Driver (A) into output shaft (C).
[11] -
→NOTE:
Tractors with single speed PTO have no shift linkage.
For SINGLE SPEED PTOs, perform the following step: Install output shaft into PTO
housing.

[12] -
Shaft with Power Assisted PTO Shift
Shaft With Manual PTO Shift

LEGEND:
B Counter Shaft
C Output Shaft
D Power Assisted PTO Shifter
E Manual PTO Shifter
For SHIFTABLE PTOs, perform the following steps: Tilt counter shaft (B) to left-hand
side of hitch frame.
[13] - Install output shaft (C) with ether power assisted PTO shifter (D) or manual PTO shifter
(E) in as one unit.
[14] - Install cap screws (A).
[15] -

LEGEND:
A Roll Pin
B Shifter Shaft
C O-ring
D Counter Shaft Gear Retaining Snap Ring
E Counter Shaft Gear
F Counter Shaft Bearing Support
Replace O-ring (C) on shifter shaft (B) install through housing.
[16] - Install roll pin (A).
[17] - Install counter shaft bearing support (F).

[18] - Install counter shaft gear (E) and counter shaft gear retaining snap ring (D).
[19] - For All PTOs, perform the following steps:
→NOTE:
Refer to Cross-Sectional View—Single-Speed PTO Output Shaft , Cross-
Sectional View—Two-Speed Shiftable PTO Output Shaft , or Cross-Sectional
View—Three-Speed Shiftable PTO Output Shaft during disassembly and
assembly.
[20] -
LEGEND:
A Thrust Washer
B Needle Roller Bearings
C Spacer
D Output Shaft
Install needle bearing-to-shaft thrust washer (A).
[21] - Install two needle roller bearings (B) with spacer (C) in between them on output shaft
(D).

[22] -
LEGEND:
B Bearing
Install output shaft drive gear (D) over needle roller bearings, needle bearing spacer, and
[23] - Install bearing-to-gear thrust washers (C).
[24] - Remove front bearing (B)

[25] - For All SHIFTABLE PTOs, perform the following steps: Install shaft position rod
(A) and tighten to specification.
(59 lb.-ft.)
[26] -
LEGEND:
A JDG19 (2 used)
B Chain
C Bearing Support
Remove two JDG19 Lifting Eyes (A). remove chain (B) and hoist from bearing support (C).

[27] -
LEGEND:
B WEO Sensor
Tighten front bearing support and tighten cap screws (C) to specification.
Front Bearing Support Cap Screws Torque 90 N·m
(66 lb.-ft.)
[28] - Install witch end out sensor (B).

[29] - Install cap screws (A). to specification.
(133 lb.-in.)
[30] -
LEGEND:
A Bearing
B Snap Rings
Install bearing cups (A) and thin snap rings (B).

[31] - Rotate output shaft several times in each direction to seat bearings.
[32] -
LEGEND:
A Clutch Assembly
B Output Shaft
Install a dial indicator with pointer resting on end of shafts (A and B).

[33] - Force shafts up and down using a prybar. Note end play readings.
[34] - Remove bearing retaining snap ring and measure thickness.
[35] -
→NOTE:
Snap rings are available in various sizes. (See PARTS CATALOG.)
Measure and install correct snap ring to provide end play.

(0.0005—0.008 in.)
(0.0005—0.008 in.)
[36] - Install rear hitch frame (A). (See Remove and Install Rear Hitch Frame in Section 70,
Group 00.)

Replace PTO Output Shaft Oil Seal
LEGEND:
A Seal
B JDG11209P1
C JDG11209P2
→NOTE:
JDG11209P1, JDG11209P2, and JDG11209P3 are part of JDG11209 PTO Seal

Installer .
[1] - For Single Speed PTO, perform the following:
Apply PM37477 Thread Lock and Sealer (Medium Strength) to outer edge of seal (A).
Number Name Use
⚬ PM37477 (us)
⚬ PM38621
Thread Lock and Sealer Used to retain cap screws
(canadian)
(Medium Strength) and seal surfaces.
⚬ 242 Loctite™
(loctite)
Install JDG11209P1 PTO Seal Driver Spud (B) over PTO shaft.
Install seal (A) using JDG11209P2 PTO Seal Installer (C).

Section 56 - DRIVE SYSTEMS Group 35: Front PTO
[2] -
LEGEND:
A Seal
B JDG11209P3
C JDG11209P2
For Reversible and Shiftable PTOs, perform the following:
[3] - Remove PTO output shaft retaining snap ring, shaft, and oil seal (A).
Apply PM37477 Thread Lock and Sealer (Medium Strength) to outer edge of seal (A).
Number Name Use
⚬ PM37477 (us)
⚬ PM38621
(canadian)
⚬ 242 Loctite™
(loctite)
Install JDG11209P3 PTO Seal Driver Spud (B) into PTO output shaft.
Install seal (A) using JDG11209P2 PTO Seal Installer (C).
Install PTO shaft and retaining snap ring.

Group 35 - Front PTO

List of References
Other Material
Specifications
General Repair Procedures—Front PTO
Remove and Install Front PTO Oil Cooler
Remove and Install Front PTO Pump
Disassemble and Assemble Front PTO Gearcase Housing
Disassemble Front PTO Clutch
Assemble Front PTO Clutch
Replace Front PTO Brake
Remove Front PTO input Shaft
Install Front PTO Input Shaft
Remove Front PTO Output Shaft
Install Front PTO Output Shaft
Remove and Install Modulating Valve
Repair Oil Cooler Bypass Valve
Repair Lube Relief Valve

→NOTE:

D01053AA Spanner Wrench
JDG19 Lifting Eyes
JDG11407 Spanner Socket
Other Material
Number Name Use
• PM37477 (PM37418
[ Smaller Size ]
) (us) Thread Lock and Sealer (Medium Used to retain cap screws
• PM38621 (canadian) Strength) and seal surfaces.
• PM38655 (us)
• PM38625 (canadian) Flexible Form-in-Place Gasket Used to seal surfaces.
Specifications
Oil Cooler Mounting Cap Screws Torque 35 N·m
(25 lb.-ft.)
Pump Housing Cap Screws Torque 37 N·m
27 lb.-ft.
Cover-to-Cover Cap Screws Torque 73 N·m
(54 lb.-ft.)
PTO Clutch Assembly Cover-to-Drum Cap Screws Torque 37 N·m
(27 lb.-ft.)
PTO Spool Valve Socket-Head Cap Screws Torque 3 N·m
(27 lb.-in.)
Modulating Valve Retainer Cap Screw Torque 40 N·m
(30 lb.-ft.)
(7.212 in.)

General Repair Procedures—Front PTO
→NOTE:
servicing the PTO.
Thoroughly clean the outside of PTO housing to reduce possible contamination.

Inspect the clutch, countershaft, and output shaft before removal as follows:
Wipe lubricant from internal working parts and visually inspect parts for wear and
damage.
Rotate gears to check for roughness.
Inspect gear teeth for signs of scoring, abnormal wear, or nicks.
Bearings
damage the bearing.
Replace both the bearing cone and roller assembly if either the cup or cone has
excessive wear.
Springs
Shafts


Inspect bushings for scoring, burrs, roughness, sharp edges, and evidence of
overheating. Remove scores with crocus cloth or knife. Replace bushings if out-of-
round, deeply scored, or excessively worn.
Gears
Examine the gear teeth for scoring, chipping, or excessive wear. Replace as necessary.
Clutch
IMPORTANT:
DO NOT use solvent to clean the disks. Use a lint-free cloth. Soak new disks
in hydraulic oil for 15 minutes before assembly.
Inspect the separator plate ears for excessive wear or damage. Check the plates for
flatness.
Inspect the disk lugs and hub splines for excessive wear or damage. Inspect the disks
for worn or scored surfaces.
→NOTE:
Replace disks if the disk facing material chips, flakes, or scratches easily.

Remove and Install Front PTO Oil Cooler

a. Remove fan drive. (See Remove and Install Electronic Fan Drive in Section 30, Group
20.)
b. Remove fan shroud. (See Remove and Install Fan Shroud in this group.)
c. Relieve hydraulic pressure in front axle oil lines. (See Relieve Pressure From Suspended
MFWD Axle Hydraulic System in Section 59, Group 20.)
d.
LEGEND:
A Oil Supply Line
B Harness
C Clamp
D Front SCV Hoses (4 used)
Remove oil supply line (A) and disconnect harness (B).
e. Remove clamp (C).
f. Disconnect front SCV hoses (D).

g.
LEGEND:
A Front PTO Oil Cooler Lines (2 used)
Disconnect oil cooler lines (A) and move aside.
h. Remove cap screws (B) and plate (C).
i.
LEGEND:
A Oil Cooler Adapters (2 used)
Remove oil cooler adapters (A) and cap screws (B).
j. Remove oil cooler.
k. Inspect parts and replace as necessary.

l. Install in reverse order.
(25 lb.-ft.)
[2] - For tractors not equipped with TLS™, perform the following:
a. Remove front PTO assembly. (See Remove Front PTO Assembly in this section.)
b.
LEGEND:
A Oil Cooler Adapters (2 used)
Remove oil cooler adapters (A).
c. Remove cap screws (B) and oil cooler.
d. Inspect parts, replace as necessary.
e. Install oil cooler using cap screws (B). Tighten to specification.
(25 lb.-ft.)
f. Install front PTO Assembly. (See Install Front PTO Assembly in this section.)

Remove and Install Front PTO Pump

[1] -
LEGEND:
A Pump-to-Housing Cap Screws (4 used)
B Pump
Remove pump-to-housing cap screws (A) and pump (B).
[2] -
LEGEND:
A O-Ring Seal
B Spline
C Seal Surface
Remove O-ring seal (A).
[3] - Inspect splines (B) and seal surface (C) on input shaft.
[4] - Install seal flush with outer face of pump housing.
[5] - Assemble pump in reverse order and tighten cap screws to specification.
Pump Housing Cap Screws Torque 37 N·m
27 lb.-ft.

Disassemble and Assemble Front PTO Gearcase

Housing
LEGEND:
A JDG19 Special Lifting Bracket (3 used)
B Chain (3 used)
C Cover
[1] - Remove front PTO. (See Remove Front PTO Assembly in Group 00.)
[2] - Attach JDG19 Lifting Eyes (A) and eyelet (B).
[3] - Remove cap screws and attach chain (C) as shown, and remove cover (D).
[4] -
→NOTE:
Counterclockwise front PTOs have two idler gears. Clockwise PTOs have
only one larger idler gear. Both are disassembled and assembled in the
same manner.

Counterclockwise Front PTO Shown

LEGEND:
A Input Shaft
B Idler Gears
C Output Drive Shaft
D Front PTO Clutch
Remove input shaft (A), idler gears (B) and output drive shaft (C).
[5] - Remove front PTO clutch (D).
[6] -
→NOTE:
Bearings and pins are slip fit in housings.
LEGEND:
C Idler Gear
D Retaining Pin
Replace bearing cones (A) as necessary.
[7] - Freeze bearing cups (B) and install in gear (C) until fully seated.

[8] - Inspect retaining pin (D) for damage and replace as necessary.
[9] -
LEGEND:
A O-Ring (2 used)
C Oil Sleeve
D O-Ring For Suction Galley
Replace O-rings (A and D) and oil sleeve (C).
[10] - Remove and install bearing cups (B) as necessary.
[11] -
→NOTE:
Counterclockwise front PTOs have two idler gears. Clockwise PTOs have
only one larger idler gear. Both are disassembled and assembled in the
same manner.

Counterclockwise Front PTO Shown

LEGEND:
A Input Shaft
B Idler Gears
C Output Drive Shaft
D Front PTO Clutch
Install input shaft (A) (See Assemble Front PTO input shaft in. this group.)
[12] - Install idler gears (B) and output drive shaft (C). (See Install Output Drive Shaft in this
group.)
[13] - Install front PTO clutch (D) (See Install Front PTO Clutch in this group.)
[14] - Apply a small bead of PM38655 Flexible Form-in-Place Gasket around mating surface
of housing.
Number Name Use
• PM38655 (us)
• PM38625 (canadian) Flexible Form-in-Place Gasket Used to seal surfaces.
[15] - Install cover (D) and tighten cap screws to specification.
Cover-to-Cover Cap Screws Torque 73 N·m
(54 lb.-ft.)
[16] - Install front PTO. (See Install Front PTO Assembly in Group 00.)

Disassemble Front PTO Clutch
LEGEND:
A Bearing
D Cover
[1] - Disassemble front PTO gearcase housing. (See Disassemble and Assemble Front PTO
Gearcase Housing in this section.)
[2] - Remove bearing (A) and PTO clutch.
[3] - Replace seal rings (B) as required.
[4] - Remove cap screws (C) and cover (D).

[5] -
LEGEND:
A Clutch Disks (5 used)
B Clutch Separator Plates (4 used)
C Backing Plate
D PTO Clutch Hub
Remove clutch disks (A), plates (B) and backing plate (C), from hub (D).
[6] -
LEGEND:
B Snap Ring
C Piston Return Springs (7 used)
Compress piston return springs using JDG754 Spring Compressor (A).
[7] - Remove snap ring (B) and return springs (C).

[8] -
LEGEND:
A Clutch Piston
B Inner Packing Ring
C Outer Packing Ring
Remove piston (A).
[9] - Replace packing rings (B—C) as necessary.
[10] - Replace parts as necessary and install in reverse order.

Assemble Front PTO Clutch
LEGEND:
A Clutch Piston
B Inner Packing Ring
C Outer Packing Ring
D Piston Return Springs (7 used)
E Return Spring Retaining Snap Ring
F JDG754 Spring Compressor
[1] - Install packing rings (B—C).

[2] - Install piston (A) in housing and alternately install seven return springs (D) starting with
OD against piston.
[3] - Compress springs using JDG754 Spring Compressor (F) and install snap ring (E).

[4] -
LEGEND:
A Thick Backing Plate
C Clutch Separator Plates (4 used)
Install thick backing plate (A) against piston.
[5] - Alternately install five disks (B) and four separator plates (C) starting with a disk against
backing plate.

[6] -
LEGEND:
A Cover
B Cover-to-Drum Cap Screws (6 used)
Install cover (A). Apply PM37477 Thread Lock and Sealer (Medium Strength)
Number Name Use
• PM37477 (PM37418
[ Smaller Size ]
to threads of cover-to-drum cap screws (B). Tighten screws to specification.
PTO Clutch Assembly Cover-to-Drum Cap Screws Torque 37 N·m
(27 lb.-ft.)

[7] -
LEGEND:
A Bearing
Install clutch on shaft and install bearing (A).
[8] - Assemble gearcase. (See Disassemble and Assemble Front PTO Gearcase Housing in
this group.)
Replace Front PTO Brake
LEGEND:
A PTO Brake Assemblies
[1] - Remove PTO clutch. (See Disassemble and Assemble Front PTO Gearcase Housing in
this group.)
[2] - Remove brake assemblies (A) and replace as necessary.

[3] - Install PTO clutch. (See Disassemble and Assemble Front PTO Gearcase Housing in this
group.)

Remove Front PTO input Shaft

[1] - Remove front PTO. (See Remove Front PTO Assembly in Group 00.)
[2] - Disassemble front PTO gearcase housing. (See Disassemble and Assemble Front PTO
Gearcase Housing in this Group.)
[3] -
LEGEND:
A Snap Ring
B Shift Fork
C Shaft
D O-Ring
E Keyway
Remove snap ring (A) from shaft (C).
[4] - Remove shaft (C) from shift fork (B) to remove keyway (E).
[5] - Replace O-ring (D) on shaft (C).
[6] -
LEGEND:
A Plug
B Spring
C Ball
Remove Plug (A).
[7] - Remove spring (B) and ball (C) from housing.

[8] -
LEGEND:
A Socket-Head Screws (3 used)
B Washers (3 used)
C Spool Valve
D Input Shaft
Remove socket-head screws (A) and washers (B).
[9] - Remove input shaft (D) with spool valve (C).

[10] -
LEGEND:
A Shift Fork
B Spool Valve
C Input Shaft
Remove shift fork (A) from input shaft (C).
[11] - Remove spool valve (B) from shift fork.
[12] -

LEGEND:
A Intput Shaft
B Front Bearing
C Gear
D Shift Collar
E Washer
F Seal Rings (2 used)
G Rear Bearing
Remove rear bearings (G) from input shaft (A) using a press.
[13] - Remove gear (C) and shift collar (D).
[14] - Remove sealing rings (F)
[15] - Turn shaft over and remove front bearing (B) and washer (E) using a press.

Install Front PTO Input Shaft

[1] -
LEGEND:
A Input Shaft
B Front Bearing
C Gear
D Shift Collar
E Washer
F Seal Rings (2 used)
G Rear Bearing
Turn shaft over and install washer (E) and bearing (G) using a press.
[2] - Install shift collar (D) and gear (C).
[3] - Install new sealing rings (F).

[4] - Install front bearings (B) on input shaft (A) using a press.
[5] -
LEGEND:
A Shift Fork
B Spool Valve
C Input Shaft
Install spool valve (B) on shift fork (A).
[6] - Install shift fork (A) on input shaft (C).

[7] -
LEGEND:
A Socket-Head Screws (3 used)
B Washers (3 used)
C Spool Valve
D Input Shaft
Install input shaft (D) with spool valve (C) and shift fork.
Number Name Use
• PM37477 (PM37418
[ Smaller Size ]
to socket-head screws (A) and Install washers (B) tighten to specifications.
PTO Spool Valve Socket-Head Cap Screws Torque 3 N·m
(27 lb.-in.)

[9] -
LEGEND:
A Plug
B Spring
C Ball
Install ball (C) and spring (B) in housing).
[10] - Install Plug (A).
[11] -

LEGEND:
A Snap Ring
B Shift Fork
C Shaft
D O-Ring
E Keyway
Replace O-ring (D) on shaft (C).

[12] - Install shaft (C) and keyway (E) in shift fork (B).
[13] - Install snap ring (A) on shaft (C).
[14] - Assemble front PTO gearcase housing. (See Disassemble and Assemble Front PTO
Gearcase Housing in this Group.)
[15] - Install front PTO pump. (See Remove and Install Front PTO Pump in this Group.)
[16] - Install front PTO. (See Install Front PTO Assembly in Group 00.)

Remove Front PTO Output Shaft

[1] -
LEGEND:
A Bearing
Disassemble PTO gearcase housing. (See Disassemble and Assemble Front PTO Gearcase
Housing in this group.)
[2] - Remove shaft and clutch assembly.
[3] - Remove bearing (A) and PTO clutch.
[4] -
LEGEND:
A Output Shaft Assembly
B Bearing
Remove output shaft assembly (A) from housing.

[5] - Remove bearing (B) from output shaft.

[6] -
LEGEND:
A Lock Ring
B Spanner Nut
Pry lock ring tab (A) from slot.
[7] - Remove spanner nut (B) using D01053AA Spanner Wrench .
[8] -
LEGEND:
A Bearings (2 used)
B Output Shaft
Remove bearings (A) and output shaft (B).

Install Front PTO Output Shaft

[1] -
LEGEND:
Install bearing cups (A) in output gear.
[2] -
LEGEND:
A Bearings (2 used)
B Output Shaft
Install bearings (A) and output gear on shaft (B).

[3] -
LEGEND:
A Lock Ring
B Spanner Nut
Install lock ring (A) and spanner nut (B).
[4] - Tighten spanner nut to specification using JDG11407 Spanner Socket .
Spanner Nut to Output Shaft Torque 375 N·m
(277 lb.-ft.)
[5] - Install JDG11407 Spanner Socket and a non-click type torque wrench onto spanner nut
(B).
[6] - Rotate shaft and record rolling drag torque.
Gear to Output Shaft Rolling Drag Torque 4—9 N·m
(35—80 lb.-in.)
IMPORTANT:
Increase or decrease torque on spanner nut to establish 4—9 N·m (35—80
lb.-in.) of rolling torque.
[7] - Tighten spanner nut to align next available lock ring tab
[8] - Bend tab (A) into slot (B).
[9] -
IMPORTANT:
Use a thermometer and do not exceed 150° C (300° F).

LEGEND:
A Output Shaft Assembly
B Bearing
Heat bearing (B) in a bearing heater.
[10] - Install bearing on output shaft assembly (A) and allow to cool. Ensure bearing is fully
seated.
[11] - Assemble Front PTO gearcase housing. (See Disassemble and Assemble Front PTO
Gearcase Housing in this group.)

Remove and Install Modulating Valve
LEGEND:
A Cap Screw
B Retainer
C Modulating Valve
[1] - Disconnect modulating valve harness.

[2] - Remove cap screw (A), retainer (B) and modulating valve (C).
[3] -
LEGEND:
A Solenoid Valve
B O-Ring Packings
Clean solenoid valve (A).
[4] - Replace O-ring packings (B). Install valve and tighten retainer cap screw (C) to
specification.
Modulating Valve Retainer Cap Screw Torque 40 N·m
(30 lb.-ft.)

LEGEND:
A Plug
B Shim Pack
C Spring
D Regulating Valve Assembly
[1] - Remove plug (A) and shim pack (B).

[2] - Remove spring (C) and pressure regulating valve (D).
(7.212 in.)
Repair Oil Cooler Bypass Valve
LEGEND:
A Plug
B Spring
C Oil Cooler Bypass Ball
[1] - Remove plug (A).

Section 56 - DRIVE SYSTEMS Group 40: Primary Brakes
[2] - Remove spring (B) and oil cooler bypass ball (C).
Repair Lube Relief Valve
LEGEND:
A Retaining Snap Ring
B Retaining Ring
C Adapter
D Spring
E Ball
[1] - Remove retaining snap ring (A), retaining ring (B), and adapter (C).
[2] - Remove Valve spring (D) and ball (E).

Group 40 - Primary Brakes

List of References
Other Material
Specifications
Remove and Install Brake Piston
→NOTE:

Other Material
Number Name Use
• TY6341 (us)
Multi-Purpose SD Polyurea Grease Used to lubricate oil seals.
Specifications
425 mm Differential Retractors Protrusion 11—13 mm
0.43—0.51 in.
0.51—0.59 in.

Remove and Install Brake Piston

[1] -
CAUTION:
Parts (A—C) can fall causing possible injury.
→NOTE:
If ring gear (A) and pinion shaft (B) remain after final drive is removed,
remove before proceeding.
LEGEND:
A Ring Gear
B Pinion Shaft
C Backing Plate
Remove final drive. (See Remove Final Drive in Group 00.)

[2] -
LEGEND:
A Piston Plate
B Brake Disk
C Backing Plate
Remove backing plate (C), brake disk (B), and brake piston plate (A).
[3] -
LEGEND:
A M10 Cap Screws (3 used)
B Brake Piston
Install M10 cap screws (A).
[4] - Remove brake piston (B) by prying against cap screws (A).

[5] -
LEGEND:
A Inner Oil Seal
B Outer Oil Seal
Remove oil seals (A and B).
[7] - Apply TY6341 Multi-Purpose SD Polyurea Grease
Number Name Use
• TY6341 (us)
Multi-Purpose SD Polyurea Grease Used to lubricate oil seals.
to oil seals and install.
[8] -
LEGEND:
A Retractors
For tractors equipped with retractors, perform the following steps:
a. Use press to remove retractors (A).

b. Inspect parts and replace as necessary.

IMPORTANT:
Ensure roll pins are started straight and splits are oriented to the
center as illustrated.
Use press to install retractors.
→NOTE:
Protrusion (A) is measured from top of retractor to machined surface
of back plate
LEGEND:
A Protrusion
Brake retractors must protrude to specification.
0.43—0.51 in.
0.51—0.59 in.

[9] -
LEGEND:
A DFRW30A—Axle Jacking Tool
B 51 mm (2 in.) Spacers (2 used)
C M16 Cap Screws (2 used)
Install primary brake piston into differential case using DFRW30A—Axle Jacking Tool (A), 51
mm (2 in.) spacers (B), and two M16 x 108 mm (4.25 in.) cap screws (C).
[10] -
LEGEND:
A Pinion Shaft
Install pinion shaft (A).

Section 56 - DRIVE SYSTEMS Group 45: Pump Drive Housing
[11] -
LEGEND:
A Piston Plate
B Brake Disk
C Backing Plate
Install brake piston plate (A), brake disk (B), and backing plate (C).
[12] - Install final drive. (See Install Final Drive in Group 00.)
[13] - Bleed brakes. (See Bleed Brakes in Section 60, Group 20.)
[14] -
IMPORTANT:
Retractors must be set.
For tractors equipped with retractors, perform the following steps:
a. Lock brake pedals together.

b. Slowly depress brake pedals fully three times.

Group 45 - Pump Drive Housing

List of References
Other Material
Specifications
Remove and Install Pump Drive Housing
Repair Pump Drive Housing
Other Material
Number Name Use
• PM38657 (us)
Specifications
Pump Drive Mounting Cap Screws Torque 128 N·m
(95 lb.-ft.)
Drive Gear Cap Screw Torque 15 N·m
(133 lb.-in.)

Remove and Install Pump Drive Housing
LEGEND:
A Backup Pump Line
B Lube Line
E Pump Drive Housing
[1] - Remove left rear wheel. (See Section 80, Group 20.)
[2] - drain hydraulic reservoir. (See Drain Hydraulic System in Section 70, Group 5.)
[3] - Remove air compressor if equipped. (See Remove and Install Air Compressor in Section
60, Group 35.)
[4] - Remove integrated hydraulic pump. (See Remove and Install Integrated Hydraulic Pump
in Section 70, Group 00.)
[5] - Remove transmission pump. (See Remove and Install Transmission Pump in Section 70,
Group 00.)
[6] - Remove scavenge and lube pump. (See Remove and Install Scavenge and Lube Pump in
[7] - If equipped with backup pump, remove line (A).
[8] - Disconnect line (B) and remove cap screws (C).
[9] -
CAUTION:
Pump drive housing weighs approximately 40 kg (88 lb.).
Support pump drive housing (E) and remove cap screws (D) evenly to avoid interference with
bearing cap.


[12] - Apply PM38657 High Flex Form in Place Gasket to sealing surface on pump drive
housing.
Number Name Use
• PM38657 (us)
Pump Drive Mounting Cap Screws Torque 128 N·m
(95 lb.-ft.)

Repair Pump Drive Housing

[1] -
LEGEND:
A Nut
B Cap Screw
C Pin
D Gear Assembly
Remove nut (A) and cap screw (B).
[2] - Remove pin (C) and gear assembly (D).

[3] -
LEGEND:
A Bearings Caps (2 used)
Remove bearing caps (A).
[4] -
IMPORTANT:
Note location of shafts. The shafts are pump-specific.
LEGEND:
A Main Hydraulic Pump Dive Shaft
B Scavenge Pump Dive Shaft
Identify and remove pump drive shafts (A) and (B).

[5] -
Cross sectional view. Not all lube passages are illustrated.

LEGEND:
A Lube Passages
Ensure all lube passages (A) are open.
[6] -
LEGEND:
A Bearings (4 used)
Replace bearings (A).

[7] -
LEGEND:
A Main Hydraulic Pump Dive Shaft
B Scavenge Pump Dive Shaft
Install shafts (A) and (B) into pump drive housing.
[8] -
LEGEND:
A O-ring
Replace O-rings (A).

[9] -
LEGEND:
A Bearing Caps (2 used)
B Nuts
Install bearings caps (A) and nuts (B).
[10] -
LEGEND:
A Bearings (2 used)
Replace bearings in gear (A).

[11] -
LEGEND:
A Gear assembly
B Pin
Install gear assembly (A) and pin (B).
[12] -
LEGEND:
A Cap Screw
B Nut
Install cap screw (A) and nut (B).
Drive Gear Cap Screw Torque 15 N·m
(133 lb.-in.)

1100 SERIES MFWD AXLE (g) by Belgreen
[14] -
For tractors without air compressor: Install plug (A).


Table of contents
Group 00 - Component Removal And Installation ................................................................ 1
Other Material ........................................................................................................................ 1
Specifications ......................................................................................................................... 1
Remove Non-Suspended MFWD Axle ..................................................................................... 3
Install Non-Suspended MFWD Axle ........................................................................................ 7
Group 05 - Final Drives ............................................................................................................. 9
Other Material ...................................................................................................................... 10
Specifications ....................................................................................................................... 12
General Repair Procedures—MFWD Axle ............................................................................. 13
Cross-Sectional View—Planetary Carrier and Wheel Hub ..................................................... 15
Remove, Recondition, and Install Planetary Carrier and Wheel Hub .................................... 17
Cross-Sectional View—Knuckle Spindle Assembly ............................................................... 33
Disassemble, Inspect, and Assemble Knuckle Spindle Assembly ......................................... 35
Replace Kingpin Bearings and Seals .................................................................................... 56
Determine Kingpin Shim Pack .............................................................................................. 58
Group 10 - Axle Housing ......................................................................................................... 60
Specifications ....................................................................................................................... 61
Install MFWD Axle Onto Rollover Stand ................................................................................ 62
Remove And Install Final Drive Assembly ............................................................................ 63
Remove Right-Hand Axle Housing ....................................................................................... 65
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack .................... 66
Adjust Backlash .................................................................................................................... 71
Backlash Shim Pack Example and Worksheet ...................................................................... 72
Install Left-Hand Axle Housing Bearing Cup and Shim Pack ................................................. 73
Disassemble Right-Hand Axle Housing and Determine Shim Pack ....................................... 74
Preload Shim Pack Example and Worksheet ........................................................................ 80
Install Right-Hand Axle Housing ........................................................................................... 82
Replace MFWD Pivot Bushing ............................................................................................... 84
Group 15 - Differential ............................................................................................................ 85
Specifications ....................................................................................................................... 85
Cross-Sectional View—Differential Housing—Limited Slip Differential (2.5 Ratio) ................ 86
Repair Differential Housing—Limited Slip Differential .......................................................... 89
Assemble Differential—Limited Slip Differential ................................................................... 93
Cross-Sectional View—Differential Drive Shaft And Input Quill .......................................... 102
Remove And Disassemble Differential Drive Shaft ............................................................. 104
Determine Differential Drive Shaft Cone Point Shim Pack .................................................. 109

Assemble and Install Differential Drive Shaft ..................................................................... 112

Section 57 - 1100 SERIES MFWD AXLE Group 00: Component Removal And Installation

List of References
Other Material
Specifications
Remove Non-Suspended MFWD Axle
Install Non-Suspended MFWD Axle
→NOTE:
For further information, see SERVICEGARD™ online tool catalog.
JDG909 Lifting Eyes
JT07336 Lift Sling
Other Material
Number Name Use
• PM38657 (us)
• PM38628 (canadian) High Flex Form-In-Place Gasket Used to seal contacting surfaces.

Specifications
MFWD Axle Pivot Pin Retainer Cap Screws Torque 500 N·m
(369 lb.-ft.)
Front Wheel-to-Hub Cap Screws Torque 600 N·m
(442 lb.-ft.)
Drive Shaft Cap Screw Torque 70 N·m
(52 lb.-ft.)
Test for clean surface by applying a few drops of cool water to surfaces. If water
joint.
Number Name Use
⚬ PM38657 (us)
High Flex Form-In-Place Used to seal contacting
Gasket surfaces.
⚬ 17430 Loctite™ (us)
oil passages. Ensure sealant loops around all oil passages.


[1] -
LEGEND:
[2] - Remove front weights or front hitch, if equipped.
[3] - Remove radar, if equipped. (See Replace Radar Sensor—IVT™ Transmissions or Replace
Radar Sensor—CommandQuad™, AutoQuad™, and PowrQuad™ Transmissions in Section 40,
Group 30.)
[4] - Disassemble yokes and remove MFWD drive shaft.
[5] - Raise front of tractor and install JT07211 Rear Differential Support Stand (A) with
KJD10539 Support Stand Adapter (B) using M20 x 40 mm (10.9 grade) cap screws to both
sides of tractor.
[6] - Remove front tires and fenders. (For further information, see Operator’s Manual.)

[7] -
LEGEND:
A Steering Cylinder Lines
B Wire Harness
Identify, label, and disconnect steering cylinder lines (A).
[8] - Remove wire harness (B) from axle (if equipped).

[9] -
Left-Hand Kingpin
Right-Hand Kingpin
LEGEND:
A JDG909 Lifting Eyes
Install JDG909 Lifting Eyes (A) onto kingpins.
[10] - Install nylon straps into lifting eyes.
[11] - Install JT07336 Lift Sling to overhead hoist and attach nylon straps.
[12] - Apply a slight amount of tension to straps.

[13] -
LEGEND:
A Axle Pivot Pin Retainer
B Pivot Pin
Remove axle pivot pin retainer (A) and pivot pin (B).
[14] - Lower and remove axle.


[1] -
LEGEND:
A Shims
B Shim
C Pivot Pin
Install axle making sure that axle is fully rearward.
[2] - Install pivot pin making sure that pin is fully rearward.
[3] - Add shims (A) until one shim (B) slides over front of pivot pin (C).
[4] -
→NOTE:
Install shim (B) to provide pivot pin end play.
Install shim (B) and retainer.

[5] - Tighten MFWD axle pivot pin retainer cap screws to specification.
(369 lb.-ft.)
[6] - Install front tires and fenders. (For further information, see Operator’s Manual.)
[7] - Tighten front wheel-to-hub cap screws to specification.
(442 lb.-ft.)
[8] - Connect steering lines.

[9] - Install wire harness onto axle.

Section 57 - 1100 SERIES MFWD AXLE Group 05: Final Drives
[10] - Install MFWD drive shaft and yokes. Tighten to specification.

Drive Shaft Cap Screw Torque 70 N·m
(52 lb.-ft.)
[11] - Install radar, if equipped. (See Replace Radar Sensor—IVT™ Transmissions or Replace
Group 30.)
[12] - Install front weights or front hitch, if equipped.
[13] - Remove cone stands.
[14] - Connect battery ground cable.


List of References
Other Material
Specifications
General Repair Procedures—MFWD Axle
Cross-Sectional View—Planetary Carrier And Wheel Hub
Remove, Recondition, and Install Planetary Carrier and Wheel Hub
Cross-Sectional View—Knuckle Spindle Assembly
Disassemble, Inspect, and Assemble Knuckle Spindle Assembly
Replace Kingpin Bearings and Seals
Determine Kingpin Shim Pack

→NOTE:
D01045AA Disk Set
DFRW4—Axle Wheel Hub Tool
JDG19 Lifting Eyes
JDG909 Lifting Eyes
JDG1123 Driver Disk
JDG1211 Bushing Installer Pilot
JDG1212 Bushing Remover
JDG1216 Ring Gear Holding Tool
JDG1218A Seal Installer
JDG1219B Seal Installer
JDG1220 Spacer Installer

Other Material
Number Name Use
• PM38657 (us)
Used to seal contacting
surfaces.
• PM37477 (us)
• PM38654 (us)
Thread Lock and Sealer Used to retain cap screws and
(High Strength) seal surfaces.

Specifications
Ring Gear Retainer Nut Initial Torque 126 N·m
(92 lb.-ft.)
Ring Gear Retainer Nut Final Torque 176 N·m
(130 lb.-ft.)
Retainer Lock Screw Torque 50 N·m
(37 lb.-ft.)
Planet Pinion Retaining Cap Screws Torque 310 N·m
(229 lb.-ft.)
Carrier-to-Wheel Hub Cap Screws Torque 126 N·m
(93 lb.-ft.)
Spacer with Bushing Distance Below Seal Surface 6—7 mm
(0.24—0.27 in.)
Upper Kingpin-to-Knuckle Housing Cap Screws Torque 545 N·m
(402 lb.-ft.)
Lower Kingpin-to-Knuckle Housing Cap Screws Torque 310 N·m
(228 lb.-ft.)


Before Beginning Repair:
Thoroughly clean outside of axlebefore disassembly , to reduce possibility of

contamination.
Removal, disassembly, cleaning, and inspection of parts is recommended after a major

failure.

Lightly coat needle bearings, thrust washers, and seals with petroleum jelly during
assembly.
Tighten fasteners to specified torque.
Seal Break-In:
IMPORTANT:
When U-Joint assembly inner and outer oil seals and knuckle spindle inner
oil seal are replaced, break-in new seals.
Seal Break-In Procedure:
Operate tractor for 10-15 minutes at a speed of less than 8 km/h (5 mph).
Check seal areas for signs of leakage before putting tractor in service.
Cleaning Parts:
Clean all parts and flush any debris from oil passages with clean solvent.
Use moisture-free air to dry parts (except bearings) and to clean out oil passages.
IMPORTANT:
DO NOT use solvent to clean clutch and brake disks; use a lint-free cloth.
Inspection:
Bearings and Bushings
Dry bearings thoroughly and lubricate with clean oil before inspection. Never dry

bearings with compressed air.

IMPORTANT: Spinning a bearing without lubrication can damage
bearing.
Inspect bearings for roughness of rotation, and excessive wear of rollers or balls.
Inspect bushings, removing scored surfaces with crocus cloth. Remove burrs and sharp
edges with a scraper or knife blade. Replace bushing if out-of-round, deeply scored, or
excessively worn.
Clutch-Brake Disks and Plates
Inspect clutch and brake disks and plates. Replace disks if facing material chips, flakes,
or scratches easily regardless of facing thickness. Soak new disks in clean hydraulic oil
for 15 minutes before assembling.
Inspect disk and plate teeth. Check for flatness.
Hubs, Gears, and Shafts
Inspect thrust washers and thrust surfaces.

Check hub thrust surfaces and splines for scoring.
Inspect shaft bearing surfaces and splines.
Check planetary pins and shafts for loose fit and/or complete disengagement.
Inspect gear and pinion teeth for damage or excessive wear.
Check for smooth rotation of gears and pinions.

Cross-Sectional View—Planetary Carrier and Wheel

Hub
LEGEND:
1 Bearing Cups
2 Bearing Cones
3 Snap Ring
4 Ring Gear Hub
5 Sun Pinion Gear

6 Thrust Washer
7 Pinion Shaft Assembly
8 Thrust Washer
9 Needle Roller
10 Bushing
11 Retainer
12 Planet Pinion
14 Retainer
15 Ring Gear
16 Cap Screws
17 O-ring
18 Wheel Hub
19 Oil Seal
20 Slinger
21 Excluder Seal
22 Ball Bearing
23 Spacer
24 Oil Seal
25 Snap Ring
26 Snap Ring

Remove, Recondition, and Install Planetary Carrier

and Wheel Hub
[1] -
→NOTE:
Refer to Planetary Carrier and Wheel Hub—Cross-Sectional View during
LEGEND:
A Wheel Hub Caps Screws
B Pry Slots
C JDG19 Lifting Eyes
Remove wheels and fenders. (For further information, see Operator’s Manual.)
[2] - Drain planetary carrier lube oil.
[3] -
CAUTION:
Carrier weighs over 36 kg (80 lb.). Use proper lifting equipment to prevent
possible personal injury.

[4] - Install JDG19 Lifting Eyes (C) to carrier with existing wheel hub cap screw and threaded
hole.

[5] - Remove carrier from wheel hub using pry slots (B).
[6] -
→NOTE:
Sun pinion gear can stay with wheel hub assembly.
LEGEND:
Remove sun pinion gear and thrust washer.
[7] - Make a mark on planet pinions, retainers, and carrier so parts are installed in their
original location.
[8] - Remove cap screws (A) and retainers (B).
[9] - Remove planet pinions, needle bearings, and thrust washers.
[10] -
→NOTE:
Remove needle bearing inner race using a puller and a 39 mm (1-9/16 in.) disk.
[11] -
→NOTE:
Sun pinion gear (A) can stay with planetary carrier or wheel hub assembly
during carrier removal.

LEGEND:
A Sun Pinion Gear
B Socket Head Screw
Remove sun pinion gear (A) and socket head screws (B).
[12] - Remove socket-head screw (B).

[13] -
LEGEND:
A Retainer Nut
B JDG1253 Spanner Socket
Remove retainer nut (A), using JDG1253 Spanner Socket (B).

[14] -
LEGEND:
A Alignment Marks
Make alignment marks (A) on ring gear hub and knuckle spindle spline.
[15] -
IMPORTANT:
Ensure ring gear hub outer bearing does not fall when hub is removed.
Remove ring gear hub.

[16] -
LEGEND:
A Planetary Ring Gear
B Outer Bearing
Inspect planetary ring gear (A), ring gear hub, and outer bearing (B).
[17] - Disassemble and replace parts as necessary.
[18] -
LEGEND:
A Bearing Cone
B Snap Ring
[19] - Make alignment identification marks on ring gear hub and ring gear.
[20] - Remove snap ring (B) and ring gear from hub.

[22] - Install ring gear and snap ring to hub in reverse order.
[23] -
LEGEND:
A DFRW4— Axle Wheel Hub Tool
Install DFRW4—Axle Wheel Hub Tool (A) to wheel hub.
[24] - Remove wheel hub from knuckle spindle housing.
[25] -
→NOTE:
Ensure not to damage wheel hub seal bore when removing seal.

LEGEND:
A Oil Seal
B Bearing
Remove oil seal (A) and bearing (B) from wheel hub.
[26] - Inspect bearing cups and replace as necessary.
[27] -
IMPORTANT:
Remove any roughness or excess sealant from seal bore using a fine emery
cloth.
[28] - Clean sealing and bearing surfaces of knuckle spindle housing.

[29] - Install bearing cups into wheel hub using JDG1123 Driver Disk .
[30] -
IMPORTANT:
Wheel hub bearing cone must be installed before hub seal is pressed into
hub.
LEGEND:
A Wheel Hub Bearing Cone

B Long Wiper Lip

Install wheel hub bearing cone (A).
[31] - Apply a thin coat of PM38657 High Flex Form-In-Place Gasket to wheel hub seal bore.
Number Name Use
• PM38657 (us)
[32] -
→NOTE:
Oil aids installation of wheel hub and adjustment of bearings.
Apply a coating of oil to rubber side of hub seal and wheel hub bearing cone (A).
[33] - Install seal onto JDG761 Seal Installer with long wiper lip (B) toward driver.
[34] -
IMPORTANT:
JDG761 seal installer must be used to install seal.
Install seal into wheel hub using JDG761 Seal Installer until tool is tight against hub.
[35] - Apply a thin coat of grease to wiper seal lip.
[36] -
LEGEND:
A JDG1216 Ring Gear Holding Tool
Install ring gear hub with outer bearing cone into wheel hub.
[37] - Hold wheel hub and ring gear together using JDG1216 Ring Gear Holding Tool (A).
[38] - Clean rust and dirt from knuckle housing seal surface using a scraper and emery cloth.

[39] -
→NOTE:
Ensure that wheel hub and ring gear are clamped together.
LEGEND:
A DFRW4— Axle Wheel Hub Tool
B Marks
[40] - Aligning marks (B) on knuckle spindle splines and ring gear hub, install wheel hub.
[41] - Remove DFRW4—Axle Wheel Hub Tool (A).
[42] - Apply oil to knuckle housing threads, ring gear hub retainer threads, and contacting
surface of retainer and ring gear hub.

[43] -
LEGEND:
A Ring Gear Retainer Nut
Install ring gear retainer and remove wheel hub and ring gear clamp.
[44] -
IMPORTANT:
Turning wheel hub before retainer is tightened could result in damage to
wheel hub seal.
Tighten ring gear retainer nut (A) to specification , using JDG1253 Spanner Socket
(B)without turning hub.
(92 lb.-ft.)
[45] - Tighten wheel hub retainer to specificationwhile rotating wheel hub continuously.
(130 lb.-ft.)
[46] - Recheck torque while rotating hub in opposite direction a minimum of six revolutions.

[47] -
LEGEND:
A Screw Hole
B O-ring
Turn retaining nut clockwise to align a notch with either screw hole (A). Then turn retainer
clockwise to line up opposite hole with notch.
[48] - Apply PM37477 Thread Lock and Sealer (Medium Strength) to threaded hole and install
retainer lock screw. Tighten to specification.
(37 lb.-ft.)
Number Name Use

• PM37477 (us)
[49] -
Replace O-ring (B) as necessary.

[50] -
IMPORTANT:
LEGEND:
A Inner Race
B Driver Disk
Install planet pinions in original position, as marked, unless pinions have
been replaced.
→NOTE:
Ensure carrier is supported on outer flange surface.
[51] - Install inner race (A) onto carrier using a press and a 57 mm (2-1/4 in.) driver disk (B)
until flush with top of post.
[52] -
LEGEND:
B Needle Bearings (3 used)
C Planet Pinions (3 used)
D Retainers (3 used)
Install thrust washers (A), planet pinions (C), and needle bearings (B).
[53] - Lubricate needle bearings and install retainers (D).
[54] -
LEGEND:
A Planet Pinion Retaining Cap Screws (3 used)
Degrease planet retaining cap screws and tapped holes in carrier.
[55] - Apply PM38654 Thread Lock and Sealer (High Strength) to threads of planet retaining
cap screws if reusing old screws.
Number Name Use
• PM38654 (us)
[56] -
IMPORTANT:
Planet pinions must not bind when turning.
Install and tighten planet pinion retaining cap screws (A) to specification.
(229 lb.-ft.)

[57] -
Clean old sealant from thrust washer and planetary carrier.

[58] - Apply PM37477 Thread Lock and Sealer (Medium Strength) to three spots on thrust
washer and install thrust washer onto planetary carrier.
Number Name Use
• PM37477 (us)
[59] - Install sun pinion gear into planet pinion carrier.

[60] -
LEGEND:
A Carrier-to-Wheel Hub Cap Screws (2 used)
Install carrier assembly to wheel hub.
[61] - Tighten carrier-to-wheel hub cap screws (A), to specification.
(93 lb.-ft.)
[62] - Install wheels and fenders. (For further information, see Operator’s Manual.)
[63] - Fill planetary carrier with oil.

LEGEND:
1 Axle Housing
2 U-Joint/Axle Shaft
3 Bushing
4 Axle Housing Spacer
5 Oil Seal
6 Bearing Cups (2 used)
7 Knuckle Spindle Housing
8 Grease Seals (2 used)
9 Shim Pack
11 Lower Kingpin
12 Bearing Cones (2 used)
13 Snap Ring
14 Spacer
15 Roller Ball Bearing
16 Snap Ring

17 Oil Seal
19 Upper Kingpin
20 Sensor
21 O-Ring
22 Adapter
23 Shaft
24 Seal
25 Plate

Disassemble, Inspect, and Assemble Knuckle

Spindle Assembly
[1] -
LEGEND:
A Wheel Hub Cap Screws (2 used)
B Pry Slots
[3] - Drain oil from differential case.
[4] -
CAUTION:
Remove wheel hub cap screws (A).

hole.

[7] -
→NOTE:
LEGEND:
A Sun Pinion Gear
B Socket Head Screw
Remove sun pinion gear (A).
[8] - Remove socket head screw (B).

[9] -
LEGEND:
A Retainer
Remove retainer (A), using JDG1253 Spanner Socket (B).

[10] -
LEGEND:
A Alignment Marks
[11] -
IMPORTANT:
Ensure ring gear hub outer bearing does not fall to floor when hub is
removed.

[12] -
LEGEND:
A DFRW4- Axle Wheel Hub Tool

[14] -
LEGEND:
A Connector Shield
B Harness
C Brake Hose
D Upper Kingpin
Remove connector shield (A).
[15] - Disconnect harness (B) from sensor.
[16] - Disconnect brake hose (C) if equipped.
[17] - Remove upper kingpin (D).
[18] -

LEGEND:
B Tie Rod
C Steering Cylinder
D Lower Kingpin
Install JDG909 Lifting Eyes (A) to knuckle spindle housing and attach to an overhead hoist.
[19] - Remove tie rod (B) from knuckle spindle housing.

[20] - Remove steering cylinder (C) from steering arm.

[21] - Remove lower kingpin (D) and shims.
[22] -
→NOTE:
Pry out on axle shaft to remove bellows seal from axle housing.
LEGEND:
A Axle Shaft
Remove knuckle spindle housing and axle shaft (A) from axle housing.

[23] -
LEGEND:
A Spacer
Inspect spacer (A) for looseness.

[24] -
LEGEND:
A Bushing
B Slide Hammer
Remove spacer with bushing (A) using a slide hammer (B) and three-jaw internal puller.
[25] -
LEGEND:
A Spacer with Bushing
B JDG1220 Spacer Installer
C JDG1211 Bushing Installer Pilot
D Seal Surface
Install spacer with bushing (A) using JDG1220 Spacer Installer (B) with JDG1211 Bushing
Installer Pilot (C).

[26] -
→NOTE:
JDG1220 Spacer Installer installs spacer to correct depth.
Spacer with bushing must be below seal surface (D).

(0.24—0.27 in.)
[27] -
LEGEND:
A Bushing
Inspect and replace bushing (A) as necessary.

[28] -
LEGEND:
A Bushing
B JDG1212 Bushing Remover
Remove bushing (A), using a slide hammer and JDG1212 Bushing Remover (B).
[29] -
→NOTE:
LEGEND:
A Bushing
B Spacer
C Driver Disk
D JDG1211 Bushing Installer Pilot
Install bushing (A) flush with spacer (B) using a 76 mm (3 in.) driver disk (C) and JDG1211

Bushing Installer Pilot (D).

[30] -
LEGEND:
A Snap Ring
B Spacer
Remove snap ring (A) and spacer (B) from axle.
[31] - Remove U-joint/axle shaft from knuckle spindle housing.

[32] -
LEGEND:
A Seal
Remove seal (A) from knuckle spindle housing, taking care not to scratch housing.

[33] -
LEGEND:
A Snap Ring
B Roller Bearing
Remove snap ring (A) and roller bearing (B) from knuckle spindle housing.
[34] - Remove any roughness from seal bore area with emery cloth.
[35] - Install roller bearing (B) tight against bottom of bore using an 89 mm (3-1/2 in.) driver
disk.

[37] -
→NOTE:
LEGEND:
A JDG537 Driver Handle
B Seal
C JDG1218A Seal Installer
D Counterbore Surface
JDG1218A Seal Installer MUST be used to install seal.
[38] - Apply a thin coat of PM38657 Form-in-Place Gasket to seal bore area.
Number Name Use
• PM38657 (us)
[39] -
IMPORTANT:
Seal (B) must be installed to a depth of 8.25—8.75 mm (0.325—0.344 in.)
from counterbore surface (D).
Install seal (B) in knuckle spindle housing until driver contacts housing using JDG1218A Seal
Installer (C) with JDG537 Driver Handle (A).

[40] -
LEGEND:
A Bellows Seal
B Slinger
C Excluder Seal
Remove bellows seal (A), slinger (B), and excluder seal (C) from U-joint/axle shaft as
necessary, taking care not to damage seal surfaces.

[41] -
LEGEND:
A Planetary Shaft Yoke
B Snap Rings (8 used)
C Caps With Needle Bearings (8 used)
D Center Section
E Crosses (2 used)
F Axle Shaft Yoke
Install planetary shaft yoke (A) or axle shaft yoke (F) in vise.
[42] - Remove snap rings (B).
[43] - Strike upper caps with needle bearings of crosses (E) until bottom cap can be
removed. Rotate shaft and remove other cap.
[44] - Assemble new joint by putting cross and U-joint into vise. Use two sockets, one on
each cap, and squeeze assembly together.
[45] - Install snap rings (B).

[46] -
LEGEND:
A Spring Lip
B Rubber Ribs
Clean axle housing seal bore with solvent and remove rough edges with emery cloth.
[47] - Fill area between spring lip (A) and beginning of rubber ribs (B) of bellows seal inside
diameter with grease.
[48] -
→NOTE:
Outside diameter of seal must be free of oil and grease before installation.
LEGEND:
A PM38657 High Flex Form-In-Place Gasket
B Bellows Seal
C JDG1219B Seal Installer
Apply PM38657 High Flex Form-In-Place Gasket
Number Name Use
• PM38657 (us)

(A) to shaft.
[49] - Install bellows seal (B) using JDG1219B Seal Installer (C).
[50] -
→NOTE:
JDG1255-1 and JDG1255-2 are part of JDG1255 Slinger-Seal Installer .
LEGEND:
A Slinger
B JDG1255-1 Slinger Seal Installer
C JDG1255-2 Collar
D Excluder Seal
Install slinger (A) into JDG1255-1 Slinger Seal Installer (B) with lip in tool and press onto shaft
until slinger contacts shoulder of shaft.
[51] - Clean dirt and grease from inside diameter of dust seal and outside diameter of
slinger.

[52] - Install JDG1255-2 Collar (C) into JDG1255-1 Slinger Seal Installer (B) and press
excluder seal (D) onto slinger.
[53] - Apply a heavy bead of grease to inside lip of dust seal.
[54] -
LEGEND:
A Spacer
B Snap Ring
Install axle shaft into knuckle spindle housing.
[55] - Install spacer (A) and snap ring (B) to axle shaft.


[1] -
LEGEND:
A Kingpin Bearing Cones (2 used)
Inspect and replace kingpin bearing cones (A) as necessary.
[2] -
→NOTE:
Install new cones using a 41mm (1-5/8 in.) driver disk.

[3] -
LEGEND:
A Kingpin Bearing Seals (2 used)
Inspect and remove kingpin bearing seals (A) as necessary.
[4] - Inspect and replace top and bottom bearing cups as necessary.

[5] -
→NOTE:
Install bearing cups before installing seals.
LEGEND:
A Seals (2 used)
Install bearing cups using a 72 mm (2-13/16 in.) driver disk.
[6] -
→NOTE:
Install seals (A) with lip of seal facing installer.
Install seals (A) using JDG770 Seal Installer (B).


[1] -
→NOTE:
Shim pack is only used on lower kingpin.
LEGEND:
B Upper Kingpin
C Shims
Install lower kingpin, without shims using cap screws (A) in diagonal holes. Leave cap screws
loose.
[2] - Install upper kingpin (B) and tighten to specification.
(402 lb.-ft.)
[3] - Tighten two diagonal cap screws (A) evenly to 25, then 50, then 70 N˙m.
[4] - Rotate knuckle housing to maximum front and rear angles to roll-in bearings. Retighten
cap screws to 70 N·m.
[5] - Measure gap (C) between kingpin and knuckle housing at two corners without cap
screws, using a feeler gauge.
[6] - Add readings and divide by two to obtain average. Average reading will be necessary
shim pack for correct bearing preload.
[7] - Remove lower kingpin.

Section 57 - 1100 SERIES MFWD AXLE Group 10: Axle Housing
[8] - Install shim pack, kingpin, and cap screws, then tighten to specification.
(228 lb.-ft.)


List of References
Specifications
Install MFWD Axle Onto Rollover Stand
Remove And Install Final Drive Assembly
Remove Right-Hand Axle Housing
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack
Adjust Backlash
Backlash Shim Pack Example and Worksheet
Install Left-Hand Axle Housing Bearing Cup and Shim Pack
Disassemble Right-Hand Axle Housing and Determine Shim Pack
Preload Shim Pack Example and Worksheet
Install Right-Hand Axle Housing
Replace MFWD Pivot Bushing
→NOTE:
DFRW132—Differential Side Bevel Gear End Play Tool
D01045AA Disk Set

D01290AA Push-Puller
D01301AA Internal Puller
JDG1217 Differential Housing Tool Set
JDG1222 Puller Jaws
JDG10227 Axle Mounting Bracket
Specifications
(402 lb.-ft.)
(228 lb.-ft.)
Tie Rod-to-Kingpin Retaining Nut Torque 195 N·m
(144 lb.-ft.)
JDG1217-2 Plate Cap Screw Torque 2.6 N·m
(24 lb.-in.)
Axle Housing Cap Screws Torque 350 N·m
(258 lb.-ft.)


[1] -
LEGEND:
A Drain Plugs (2 used)
Remove drain plugs (A) and drain oil from case.
[2] - Remove MFWD axle from tractor. (See Remove Non-Suspended MFWD Axle in
Group 00.)
[3] -
LEGEND:
A JDG10227 Axle Mounting Bracket
Install JDG10227 Axle Mounting Bracket (A) on D05223ST Engine Rollover Stand .
[4] - Install axle onto bracket using a hoist and straps.
[5] - Remove axle from rollover stand in reverse order.


[1] -
LEGEND:
A DFRW4 Axle Wheel Hub Tool
B Tie Rod
C Steering Cylinder
D Lower Kingpin and Shims
E Upper Kingpin
Drain differential.
[2] - Attach DFRW4—Axle Wheel Hub Tool (A) to wheel hub assembly and attach to an
overhead hoist.
[3] -
→NOTE:
Support wheel hub assembly on opposite end of axle when removing tie
rod.
Remove tie rod (B) and steering cylinder (C) from knuckle spindle housing.
[4] - Remove lower kingpin and shims (D).
[5] - Remove upper kingpin (E).
[6] - Pry out on axle shaft to remove bellows seal from axle housing and remove assembly
from axle.
[8] - Install original kingpin shim pack or determine new shim pack as necessary. (See
Determine Kingpin Shim Pack in Group 05.)
[9] - Tighten upper kingpins to specification.
(402 lb.-ft.)
[10] - Tighten lower kingpins to specification.

(228 lb.-ft.)
[11] - Tighten tie rod to specification.

(144 lb.-ft.)
[12] - Fill axle assembly with oil.


[1] -
LEGEND:
A Straps
B Axle housing Cap Screws (14 used)
Remove axle from tractor. (See Remove Non-Suspended MFWD Axle in Group 00.)
[2] - Install axle in axle rollover stand. (See Install MFWD Axle Onto Rollover Stand in this
group.)
[3] - Remove final drive assemblies. (See Remove And Install Final Drive Assembly in this
group.)
[4] - Rotate axle in stand so right-hand side of axle is up.
[5] - Attach straps (A) to axle housing.
[6] - Remove axle housing cap screws (B) and right-hand side axle assembly.

Disassemble Left-Hand Axle Housing and Determine

Bearing Cup Shim Pack
[1] -
LEGEND:
A DFRW132—Differential Side Bevel Gear End Play Tool
B Wing Nut
Install DFRW132—Differential Side Bevel Gear End Play Tool (A) to differential.
[2] - Tighten wing nut (B).
[3] - Remove differential from case using a hoist.
[4] -
→NOTE:
Recommended shop puller tools are:
4-1/2 in. Legs for Push-Puller

LEGEND:
A D01290AA Puller Jaws
B D01301AA Internal Puller
C Legs (2 used)
Install JDG1222 Puller Jaws (A) to D01301AA Internal Puller (B).

[5] -
→NOTE:
Ensure that jaws are positioned in puller slots in housing.
Remove bearing cup from differential case/axle housing using a D01290AA Push-Puller with
4-1/2 in. legs (C) and D01301AA Internal Puller with JDG1222 Puller Jaws.
[6] -
→NOTE:
JDG1217-4 is part of JDG1217 Differential Housing Tool Set .
LEGEND:
A Nominal Shim Pack
B Dummy Bearing Cup
Install nominal shim pack (A) of 2.75 mm (0.108 in.) and JDG1217-4 Dummy Bearing Cup (B).
[7] - Install dummy bearing cup tight against shims in bottom of bore.

[8] -
LEGEND:
Install differential using DFRW132—Differential Side Bevel Gear End Play Tool (A).
[9] -
LEGEND:
A Housing Bearing Cup
B JDG1217-3 Centering Ring
C JDG1217-2 Plate
D JDG1217-1 Bridge
F JDG1217-2 Plate Cap Screw
Install axle housing bearing cup (A) on differential housing bearing cone.
[10] -
→NOTE:
Use tools from JDG1217 Differential Housing Tool Set .

Install JDG1217-3 Centering Ring (B).

[11] - Install JDG1217-2 Plate (C) and JDG1217-1 Bridge (D).
[12] - Install and tighten cap screws (E).
[13] - Install JDG1217-2 Plate Cap Screw (F) and tighten to specification.
(24 lb.-in.)
[14] - Rotate housing six revolutions in each direction to roll-in housing bearings.
[15] - Retighten JDG1217-2 Plate Cap Screw (F) to specification.
[16] -

LEGEND:
A JDG1217-5 Indicator Post
B Indicator Post Magnetic Base
C Differential Housing Cover
D Indicator Post Arm
E Differential Case Axle Housing Flange
F Indicator Post Alignment Mark
Install JDG1217-5
[ Included in JDG1217 Differential Housing Tool Set ]
Indicator Post (A) with magnetic base (B) tight against differential housing cover (C) and
indicator post arm (D) at a right angle with base.
[17] - Position dial indicator on differential case axle housing flange (E) with pointer against
indicator post arm (D) resting on alignment mark (F).
Adjust Backlash
[1] -
→NOTE:
Refer to Backlash Shim Pack Example and Worksheet.
Hold yoke stationary, and move ring gear to measure backlash.

[2] - Measure backlash in three locations 120° apart.
[3] - Add three readings and divide by three to obtain average.
[4] - Subtract 0.25 mm (0.010 in.) from result of Step 3.
[5] - Multiply result of Step 4 by 1.333.
[6] - Subtract bearing growth factor 0.13 mm (0.005 in.) from result of Step 5.
[7] - Subtract result of Step 6 from nominal shim pack 2.75 mm (0.108 in.).
[8] - Result of Step 7 is necessary final shim pack to establish required backlash of
0.13—0.53 mm (0.005—0.021 in.).

→NOTE:
Use nominal shim pack and JDG1217-4 Dummy Bearing Cup
Step Number Example Value Measured Value
BACKLASH READINGS
3 Reading One 1.27 mm ___________
Reading Two + 1.42 mm + ___________
Reading Three + 1.40 mm + ___________
_________________ __________________
Total of Three Readings .......... = 4.09 mm = ___________
CALCULATE AVERAGE BACKLASH
4 Divide (Total Readings of Step 3) by 3 .......... ÷ 3 ÷ 3
= ___________ = ___________
= 1.36 mm = ___________
CALCULATE TARGET BACKLASH
5 Subtract Target Backlash From Step 4 .......... — 0.25 mm — 0.25 mm
_________________ __________________
= 1.11 mm = ___________
RELATION OF SHIMS TO BACKLASH
6 Multiply Step 5 by 1.170 .......... x 1.170 x 1.170
= 1.30 mm = ___________
CALCULATE FOR BEARING GROWTH FACTOR
7 Subtract Bearing Growth From Step 6 .......... — 0.13 mm — 0.13 mm
_________________ __________________
= 1.17 mm = ___________
NOMINAL SHIM PACK 2.75 mm 2.75 mm
8 Subtract Step 7 From Nominal Shim Pack .......... — 1.17 mm — ___________
_________________ __________________
FINAL BACKLASH SHIM PACK .......... = 1.58 mm = ___________

Install Left-Hand Axle Housing Bearing Cup and

Shim Pack
[1] -
IMPORTANT:
Correct backlash must exist before installing bearing cup. (See Adjust
Backlash in this group.)
LEGEND:
A Shim Pack
B Permanent Bearing Cup
Remove tools and differential housing.
[2] -
→NOTE:
Ensure permanent bearing cup is installed and NOT dummy cup.
Install previously calculated shim pack (A) under PERMANENT bearing cup (B).
[3] -
→NOTE:
Install PERMANENT bearing cup tight against shims in bottom of bore using a 111 mm (4-3/8
in.) driver disk.
[4] - Install differential housing using DFRW132—Differential Side Bevel Gear End Play Tool .
[5] - Recheck backlash and adjust as necessary.

Disassemble Right-Hand Axle Housing and

Determine Shim Pack
[1] -
→NOTE:
The recommended puller tools are:

LEGEND:
A JDG1222 Puller Jaws
C Legs (2 used)
Install JDG1222 Puller Jaws (A) to D01301AA internal puller (B).
[2] -
→NOTE:
Ensure jaws are positioned in puller slots of housing.
Remove bearing cup from axle housing using D01290AA Push-Puller with 11-3/4 in. legs (C).
[3] -
→NOTE:
Left-hand axle housing shim pack must be determined before right-hand
shim pack. (See Disassemble Left-Hand Axle Housing and Determine
Bearing Cup Shim Pack in this group.)

LEGEND:
A Axle Housing Bearing Cup
B JDG1217-3 Centering Ring
C JDG1217-2 Plate
D JDG1217-1 Bridge
[4] -
→NOTE:
Use tools from JDG1217 Differential Housing Tool Set .
Install JDG1217-3 Centering Ring (B).

[5] - Install JDG1217-2 Plate (C) and JDG1217-1 Bridge (D).
(24 lb.-in.)
[10] -

LEGEND:
A Bridge
B Differential Case Surface
Use steps from Preload Shim Pack Example and Worksheet to calculate shim pack.
a. Measure distance in four places from top of bridge (A) to differential case surface (B).
b. Add four readings and divide by four to obtain average.
c.
LEGEND:
A Bridge
B Bearing Cup
Using a depth micrometer measure distance in four places from top of bridge (A) to top
of bearing cup (B).
d. Add four readings and divide by four to obtain average.
e. Subtract result ofStep d from result ofStep b .

f.
LEGEND:
A JDG1217-1 Bridge
B Axle Housing Flange
C Bearing Cup Bore Surface
Put JDG1217-1 Bridge (A) on axle housing flange (B).
g. Measure distance in four places from top of tool (A) to bearing cup bore surface (C).
h. Add four readings and divide by four to obtain average.
i.
LEGEND:
A JDG1217-1 Bridge


C Calculated Shim Pack
D Bearing Cup
Measure distance in four places from top of JDG1217-1 bridge (A) to axle housing flange
(B).
j. Add four readings and divide by four to obtain average.
k. Subtract result ofStep j from result ofStep h .
l. Subtract result ofStep e from result ofStep k .
m. Result ofStep l is shim pack needed for required bearing preload.
[11] -
→NOTE:
Ensure bearing cup is tight against shims in bottom of bore after installing.
Install calculated shim pack (C) and bearing cup (D) using a 111 mm (4-3/8 in.) driver disk.


Step Example Value Measured Value
TOOL-TO-CASE READINGS
(a) Reading One 88.93 mm ___________
Reading Two + 88.87 mm + ___________
Reading Three + 88.95 mm + ___________
Reading Four + 88.85 mm + ___________
_________________ __________________
Total of Four Readings = 355.60 mm = ___________
AVERAGE TOOL-TO-CASE SURFACE READING
(b) Divide (Total Readings of Step a) by 4 = 88.90 mm = ___________
TOOL-TO-BEARING CUP READINGS
(c) Reading One 50.22 mm ___________
Reading Two + 50.11 mm + ___________
Reading Three + 50.24 mm + ___________
Reading Four + 50.09 mm + ___________
_________________ __________________
AVERAGE TOOL-TO-CUP READINGS
(d) Divide (Total Readings of Step c) by 4 = 50.17 mm = ___________
CUP-TO-CASE SURFACE
(e) Subtract Step d From Step b
Step b 88.90 mm ___________
Step d — 50.17 mm — ___________
_________________ __________________
= 38.73 mm = ___________
TOOL-TO-CUP BORE SURFACE READINGS
(g) Reading One 129.20 mm ___________
Reading Two + 129.70 mm + ___________
Reading Three + 129.25 mm + ___________
Reading Four + 129.75 mm + ___________
_________________ __________________
AVERAGE CUP BORE READINGS
(h) Divide (Total Readings of Step g) by 4 = 129.48 mm = ___________
TOOL-TO-AXLE SURFACE READINGS
(i) Reading One 88.93 mm ___________
Reading Two + 88.87 mm + ___________
Reading Three + 88.95 mm + ___________
Reading Four + 88.85 mm + ___________
_________________ __________________
AVERAGE AXLE SURFACE READING
(j) Divide (Total Readings of Step i) by 4 = 88.90 mm = ___________
(k) Subtract Step j From Step h
Step h 129.48 mm ___________
Step j — 88.90 mm — ___________
_________________ __________________
= 40.58 mm = ___________
(l) Subtract Step e From Step k
Step k 40.58 mm ___________
Step e — 38.73 mm — ___________
_________________ __________________
FINAL PRELOAD SHIM PACK = 1.85 mm = ___________


[1] -
LEGEND:
A O-ring
Install O-ring (A).
[2] -
LEGEND:
Install guide pins (A) in left-hand axle housing.

[3] -
LEGEND:
A Axle Housing
Install lifting strap on axle housing and attach to an overhead hoist.
[4] - Install axle housing (A) onto left-hand axle housing.
[5] - Remove guide pins (B).
[6] - Install and tighten axle housing cap screws (C) to specification.
(258 lb.-ft.)
[7] - Install final drive assemblies. (See Remove And Install Final Drive Assembly in this
group.)
[8] - Remove axle from stand.
[9] - Install axle on tractor. (See Install Non-Suspended MFWD Axle in Group 00.)

Section 57 - 1100 SERIES MFWD AXLE Group 15: Differential

[1] -
LEGEND:
A Bushing Split
B Chamfer Edge
C Pilot Disk
D Driver Disk
[2] - Remove bushing.
[3] -
IMPORTANT:
Install bushing with bushing split (A) at 12 o′clock position.
→NOTE:
Install front bushing using a 62 mm (2-7/16 in.) pilot disk (C) and a 64 mm (2-1/2 in.) driver
disk (D) until edge of bushing is flush with bottom edge of chamfer (B).
[4] - Repeat procedure for rear bushing.

Group 15 - Differential
List of References
Specifications
Cross-Sectional View—Differential Housing—Limited Slip Differential (2.5 Ratio)
Repair Differential Housing—Limited Slip Differential
Assemble Differential—Limited Slip Differential
Cross-Sectional View—Differential Drive Shaft And Input Quill
Remove And Disassemble Differential Drive Shaft
Determine Differential Drive Shaft Cone Point Shim Pack
Assemble And Install Differential Drive Shaft
→NOTE:
D01045AA Disk Set

Specifications
(184 lb.-ft.)
Bevel Side Gear Disk Pack End Play 0.10—0.50 mm
(0.003—0.020 in.)
Differential Drive Shaft End Play 0.025—0.08 mm
(0.001—0.003 in.)
Cross-Sectional View—Differential Housing—Limited

Slip Differential (2.5 Ratio)
LEGEND:
2 Differential Lower Half
3 Bevel Pinions (4 used)
4 Thrust Washers (4 used)
5 Short Pinion Shafts (2 used)
6 Pin
7 Spacers (2 used)
8 Disks with Facing (8 used)

9 Separator Plates (8 used)
11 Shim Pack
12 Housing Cover
13 Ring Gear
14 Bevel Gears (2 used)
15 Long Pinion Shaft

LEGEND:
2 Lower Differential Half
6 Pin
7 Spacers with Facing (2 used)


11 Shim Pack
12 Housing Cover
13 Ring Gear

Repair Differential Housing—Limited Slip

Differential
[1] -
LEGEND:
B Cover
C Ring Gear
Remove cap screws (A), cover (B), and ring gear (C).
[2] -
LEGEND:
A Disk Pack and Bevel Gear
Remove disk pack and bevel gear (A).

[4] -
LEGEND:
A Pins (2 used)
B Shafts (3 used)
C Bevel Gears (4 used)
Remove pins (A), shafts (B), bevel gears (C), and thrust washers.
[5] -
LEGEND:
B Bevel Side Gear and Disk Pack
Install DFRW132—Differential Side Bevel Gear End Play Tool (A) through bevel side gear.
[6] - Remove bevel side gear and disk pack (B).


[8] -
LEGEND:
A Separator Plate
B Shim Pack
Remove separator plate (A) and shim pack (B).
[10] -
→NOTE:
LEGEND:

A Tapered Roller Bearing Cone

B Driver Disk
Remove tapered roller bearing cone (A) from differential housing using a press, puller tools,
and a 58 mm (2-5/16 in.) driver disk (B).
[11] -
LEGEND:
A Tapered Roller Bearing
B Driver Disk
Remove tapered roller bearing (A) from cover using a press, puller tools, and a 58 mm
(2-5/16 in.) driver disk (B).


[1] -
IMPORTANT:
Coat parts individually with oil AFTER end play is correctly adjusted.
LEGEND:
A Separator Plate
Install one separator plate (A) into differential housing.
[2] -
LEGEND:
A Bevel Gear
B Spacer
D Disks (5 used)
For 4.0 ratio differentials: Install spacer (B), with lined side facing disk pack, onto bevel
gear (A).
[3] - Install separator plates (C) and disks (D).

[4] -
→NOTE:
There is no facing material on spacer for 2.5 ratio differentials.
LEGEND:
A Bevel Gear
B Spacer
C Disks (4 used)
D Separator Plates (3 used)
For 2.5 ratio differentials: Install spacer (B).
[5] - Install disks (C) and separator plates (D).
[6] -
LEGEND:
A Disk Pack
B DFRW132—Differential Side Bevel Gear End Play Tool
Install bevel side gear with disk pack (A) in differential housing using DFRW132—Differential
Side Bevel Gear End Play Tool (B).

[7] -
→NOTE:
Tabs (B) on thrust washer must line up with groove (C) in housing.
LEGEND:
A Conical Thrust Washers (4 used)
B Tabs
C Groove
Install conical thrust washers (A).
[8] -
→NOTE:
Ensure pin bore (D) is in vertical position when installing short pinion
shafts (C).

LEGEND:
A Bevel Pinions (4 used)
B Long Pinion Shaft
C Short Pinion Shafts (2 used)
D Pin Bore
Install bevel pinions (A), long pinion shaft (B), and short pinion shafts (C).

[9] -
LEGEND:
A Pinion Shaft Locking Pin (2 used)
Install pinion shaft locking pins (A).
[10] -
LEGEND:
A Separator Plate
Install one separator plate (A) in cover.

[11] -
LEGEND:
A Bevel Gear
B Spacer
D Disks (5 used)
gear (A).
[13] -
→NOTE:
LEGEND:
A Bevel Gear
B Spacer
C Disks (4 used)

[15] -
LEGEND:
A Bevel Gear with Disk Pack
B DFRW132—Differential Side Bevel Gear End Play Tool
Install bevel gear with disk pack (A) in cover using DFRW132—Differential Side Bevel Gear
End Play Tool (B).
[16] - Remove tool.
[17] -
LEGEND:
A DFRW132— Differential Side Bevel Gear End Play Tool
Install DFRW132— Differential Side Bevel Gear End Play Tool (A) through bevel gear pack and
cover from opposite end.

[18] -
LEGEND:
A Ring Gear
B Bevel Side Gear
[19] - Install cover with disk pack and bevel side gear (B) on differential housing.

[20] -
LEGEND:
A Differential Housing Cover Cap Screws (12 used)
B End Play Checking Locations
Install and tighten differential housing cover cap screws (A) to specification.
(184 lb.-ft.)
[21] - Check disk pack end play in four locations (B) with dial indicator and end play tool.
[22] - Select shims to provide correct end play.
(0.003—0.020 in.)
[23] - Disassemble differential, install calculated shim pack, and reassemble.

[24] - Recheck disk pack end play.

[25] -
Repeat checking procedure for opposite disk pack.

(0.003—0.020 in.)

[29] -
CAUTION:
Heat parts in a bearing heater. Use a thermometer and do not exceed 150
°C (300 °F). Plan a safe handling procedure to avoid burns.
LEGEND:
A Tapered Roller Bearing Cones (2 used)
Heat tapered roller bearing cones (A) and install on differential housing.

Cross-Sectional View—Differential Drive Shaft And

Input Quill
LEGEND:
1 Differential Drive Shaft
2 Load Ring
3 Bearing Cup
4 Bearing Cone
5 Oil Seal
6 Yoke
7 Lock Plate
8 Pinion Shaft Retaining Nut
9 Special Washer
10 O-Ring
11 Bearing Cone
12 Shim Pack
13 Bearing Cup
14 Differential Case


[1] -
LEGEND:
A Lock Plate Ears
Straighten special lock plate ears (A).
[2] -

LEGEND:
A Yoke
B Pinion Shaft Retaining Nut
C Lock Plate
D Washer
E O-ring
F Yoke
G Pinion Shaft
Retain yoke (A) and remove pinion shaft retaining nut (B) and lock plate (C).
[3] - Remove special washer (D) from pinion shaft (G).
[4] - Remove O-ring (E) and yoke (F).
[5] - Remove pinion shaft (G).
[6] -
LEGEND:
A Seal
B Bearing Cone
Remove seal (A) and bearing cone (B).

[7] -
Outer Bearing Cup
Inner Bearing cup

LEGEND:
A Outer Bearing Cup
B Inner Bearing Cup
Remove outer bearing cup (A) and inner bearing cup (B).

[8] -
LEGEND:
A Load Ring
Remove load ring (A).
[9] -
→NOTE:
LEGEND:
A Bearing Cone
B Driver Disk
Remove bearing cone (A) from bevel pinion drive shaft using a press, puller tool, and a 25
mm (1 in.) driver disk (B).

[10] -
LEGEND:
A Shim Pack
Remove shim pack (A).

Determine Differential Drive Shaft Cone Point Shim

Pack
LEGEND:
A Differential Case Dimension
B Differential Drive Shaft Dimension
[1] - Record dimension stamped on differential case (A).

[2] - Record dimension stamped on differential drive shaft (B).
[3] -
→NOTE:
Constant dimension includes nominal bearing width and bearing growth
allowance.

Calculate shim pack using theEXAMPLE listed below.
162.120 mm Differential Case Dimension (A)
- 131.050 mm Differential Drive Shaft Dimension (B)
_________
= 0.760 mm Correct Shim Pack Thickness
[4] -
LEGEND:
A Shim Pack
Install shim pack (A).
[5] -
CAUTION:
LEGEND:
A Drive Shaft Bearing
Heat bearing in a bearing heater. DO NOT exceed 150 °C (300 °F). Plan a
safe handling procedure to avoid burns.

Heat drive shaft bearing (A) and install until bearing bottoms against shim pack.

Assemble and Install Differential Drive Shaft

[1] -
→NOTE:
LEGEND:
A Inner Bearing Cup
B Outer Bearing Cup
Install inner bearing cup (A) into input quill using a 108 mm (4-1/4 in.) driver disk tight
against bottom of bore.
[2] - Install outer bearing cup (B) into input quill using an 81 mm (3-3/16 in.) driver disk tight
against bottom of bore.
[3] -
LEGEND:
A Load Ring
Install a new load ring (A).

[4] -
LEGEND:
A Bearing Cone
B Seal
[5] - Install seal (B) using JDG851 Seal Installer .
[6] -
LEGEND:
A Drive Shaft
Install drive shaft (A) into input quill.
[7] -
→NOTE:
Align slot in shaft (A) with one of relieved sides of yoke (B) to facilitate
bending lock plate.
Yoke must install on shaft splines freely.

LEGEND:
A Shaft
B Yoke
Align relieved sides of yoke (B) with slot in shaft (A) and install yoke onto drive shaft. Yoke
must install on shaft splines freely.
[8] -
LEGEND:
A O-ring
B Yoke
C Special Washer
D Lock Plate
E Retaining Nut
Install O-ring (A) in yoke (B).
[9] - Install special washer (C) with counterbore side toward input yoke with tab and slot
aligned.
[10] - Install lock plate (D) next to special washer with tab and slot aligned.

[11] - Install retaining nut (E).

[12] -
LEGEND:
A Dial Indicator
B Nut
Position dial indicator (A) with pointer resting on end cap screw.
[13] -
IMPORTANT:
Force pinion shaft fully inward and then fully outward when measuring end
play.
Measure shaft end play by forcing pinion shaft inward and outward.
[14] - Tighten nut (B) gradually, repeating measuring procedure until shaft end play is within
specification.
(0.001—0.003 in.)

1300 SERIES MFWD AXLE (g) by Belgreen
[15] -
LEGEND:
A Lock Plate
Bend outer diameter of lock plate(A) down against special washer and up against flat of nut.
[16] - Check ring gear backlash. (See Adjust Backlash in Group 10.)


Table of contents
Other Material ........................................................................................................................ 1
Specifications ......................................................................................................................... 1
Remove Non-Suspended MFWD Axle ..................................................................................... 3
Install Non-Suspended MFWD Axle ........................................................................................ 7
Group 05 - Final Drives ............................................................................................................. 9
Other Material ...................................................................................................................... 10
Specifications ....................................................................................................................... 11
General Repair Procedures—MFWD Axle ............................................................................. 12
Cross-Sectional View—Planetary Carrier and Wheel Hub ..................................................... 14
Remove, Recondition, and Install Planetary Carrier and Wheel Hub .................................... 16
Specifications ....................................................................................................................... 60
Install MFWD Axle Onto Rollover Stand ................................................................................ 61
Remove And Install Final Drive Assembly ............................................................................ 62
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack .................... 65
Adjust Backlash .................................................................................................................... 70
Backlash Shim Pack Example and Worksheet ...................................................................... 71
Install Left-Hand Axle Housing Bearing Cup and Shim Pack ................................................. 72
Disassemble Right-Hand Axle Housing and Determine Shim Pack ....................................... 73
Preload Shim Pack Example and Worksheet ........................................................................ 79
Install Right-Hand Axle Housing ........................................................................................... 81
Replace MFWD Pivot Bushing ............................................................................................... 83
Group 15 - Differential ............................................................................................................ 84
Specifications ....................................................................................................................... 84
Repair Differential Housing—Limited Slip Differential .......................................................... 88
Assemble Differential—Limited Slip Differential ................................................................... 92
Cross-Sectional View—Differential Drive Shaft And Input Quill .......................................... 101
Remove And Disassemble Differential Drive Shaft ............................................................. 103

Assemble And Install Differential Drive Shaft ..................................................................... 109


List of References
Other Material
Specifications
→NOTE:
JDG909 Lifting Eyes
JT07336 Lift Sling
Other Material
Number Name Use
• PM38657 (us)
• PM38628 (canadian) High Flex Form-In-Place Gasket Used to seal housings.

Specifications
(368 lb.-ft.)
(442 lb.-ft.)
(52 lb.-ft.)
joint.
Number Name Use
⚬ PM38657 (us)
⚬ PM38628 (canadian) High Flex Form-In-Place Gasket Used to seal housings.


[1] -
LEGEND:
[3] - Remove radar, if equipped. (See Replace Radar Sensor—IVT™ Transmissions or Replace
Group 30.)
[4] - Disassemble yokes and remove MFWD drive shaft.
sides of tractor.
[6] - Remove wheels and fenders. (For further information, see Operator’s Manual.)

[7] -
LEGEND:
A Steering Cylinder Lines
B Wire Harness
Identify, label, and disconnect steering cylinder lines (A).
[8] - Remove wire harness (B) from axle (if equipped).

[9] -
Left-Hand Kingpin
Right-Hand Kingpin
LEGEND:
Install JDG909 Lifting Eyes (A) onto kingpins.

[13] -
LEGEND:
A Axle Pivot Pin Retainer
B Pivot Pin
Remove retainer (A) and pivot pin (B).
[14] - Lower and remove axle.


[1] -
LEGEND:
A Shims
B Shim
C Pivot Pin
Install axle making sure that axle is fully rearward.
[2] - Install pivot pin.
[3] - Add shims (A) until one shim (B) slides over front of pivot pin (C).
[4] -
→NOTE:
Install shim (B) to provide pivot pin end play.
Install shim (B) and retainer.

[5] - Tighten pivot pin retainer cap screws to specification.
(368 lb.-ft.)
(442 lb.-ft.)
[8] - Connect steering lines.

[9] - Install wire harness onto axle.

[10] - Install MFWD drive shaft and yokes. Tighten to specification.

(52 lb.-ft.)
[11] - Install radar, if equipped. (See Replace Radar Sensor—IVT™ Transmissions or Replace
Group 30.)
[12] - Install front weights or front hitch, if equipped.
[13] - Remove cone stands.
[14] - Connect battery ground cable.


List of References
Other Material
Specifications
Cross-Sectional View—Planetary Carrier and Wheel Hub
Remove, Recondition, and Install Planetary Carrier and Wheel Hub

→NOTE:
D01045AA Disk Set
JDG19 Lifting Eyes
JDG909 Lifting Eyes
JDG1123 Driver Disk

Other Material
Number Name Use
• PM38657 (us)
Used to seal contacting
• PM38628 (canadian) High-Flex Form-In-Place Gasket
surfaces.
• PM37477 (us)
• PM38654 (us)
Specifications
(92 lb.-ft.)
(130 lb.-ft.)
(37 lb.-ft.)
(229 lb.-ft.)
(93 lb.-ft.)
(0.24—0.27 in.)
(402 lb.-ft.)


Before Beginning Repair:
Thoroughly clean outside of axlebefore disassembly , to reduce the possibility of

contamination.
Removal, disassembly, cleaning, and inspection of parts is recommended after a major

failure.

Lightly coat needle bearings, thrust washers, and seals with petroleum jelly during
assembly.
Tighten fasteners to the specified torque.
Seal Break-In:
IMPORTANT:
When U-Joint assembly inner and outer oil seals and knuckle spindle inner
oil seal are replaced, break-in new seals.
Seal Break-In Procedure:
Operate tractor for 10-15 minutes at a speed of less than 8 km/h (5 mph).
Check seal areas for signs of leakage before putting tractor in service.
Cleaning Parts:
Clean all parts and flush any debris from oil passages with clean solvent.
Use moisture-free air to dry parts (except bearings) and to clean out oil passages.
IMPORTANT:
DO NOT use solvent to clean clutch and brake disks; use a lint-free cloth.
Inspection:
Bearings and Bushings
Dry bearings thoroughly and lubricate with clean oil before inspection. Never dry

bearings with compressed air.

IMPORTANT: Spinning a bearing without lubrication can damage the
bearing.
Inspect bearings for roughness of rotation, and excessive wear of rollers or balls.
Inspect bushings, removing scored surfaces with crocus cloth. Remove burrs and sharp
edges with a scraper or knife blade. Replace bushing if out-of-round, deeply scored, or
excessively worn.
Clutch-Brake Disks and Plates
Inspect clutch and brake disks and plates. Replace disks if facing material chips, flakes,
or scratches easily regardless of facing thickness. Soak new disks in clean hydraulic oil
for 15 minutes before assembling.
Inspect disk and plate teeth. Check for flatness.
Hubs, Gears, and Shafts
Inspect thrust washers and thrust surfaces.

Check hub thrust surfaces and splines for scoring.
Inspect shaft bearing surfaces and splines.
Check planetary pins and shafts for loose fit and/or complete disengagement.
Inspect gear and pinion teeth for damage or excessive wear.
Check for smooth rotation of gears and pinions.


Hub
LEGEND:
1 Bearing Cups
2 Bearing Cones
3 Snap Ring
4 Ring Gear Hub
5 Sun Pinion Gear

6 Thrust Washer
8 Thrust Washer
9 Needle Roller
10 Bushing
11 Retainer
12 Planet Pinion
14 Retainer
15 Ring Gear
16 Cap Screws
17 O-Ring
18 Wheel Hub
19 Oil Seal
20 Slinger
21 Excluder Seal
22 Ball Bearing
23 Spacer
24 Oil Seal
25 Snap Ring
26 Snap Ring


and Wheel Hub
[1] -
→NOTE:
LEGEND:
B Pry Slots
C JDG19 Lift Eyes
[3] -
CAUTION:
Remove planetary carrier-to-wheel hub cap screws (A).

hole.

[6] -
→NOTE:
LEGEND:
[7] - Make a mark on planet pinions, retainers, and carrier so parts are installed in their
original location.
[10] -
→NOTE:
Remove needle bearing inner race using a puller and a 39 mm (1-9/16 in.) driver disk.
[11] -
→NOTE:

LEGEND:
A Sun Pinion Gear
B Socket Head Screw
Remove sun pinion gear (A) and socket head screw.

[12] -
LEGEND:
A Retainer Nut
Remove retainer nut (A), using JDG1253 Spanner Socket (B).

[13] -
LEGEND:
A Alignment Marks
[14] -
IMPORTANT:
Ensure ring gear hub outer bearing does not fall to floor when hub is
removed.

[15] -
LEGEND:
B Outer Bearing
[17] -
LEGEND:
A Bearing Cone
B Snap Ring
[18] - Make alignment marks on ring gear hub and ring gear.
[19] - Remove snap ring (B) and ring gear from hub.
[21] -
LEGEND:
A DFRW4—Axle Wheel Hub Tool
[23] -
→NOTE:
Take care not to damage wheel hub seal bore when removing seal.

LEGEND:
A Oil Seal
B Bearing
[24] - Inspect bearing cups and replace if necessary.
[25] -
IMPORTANT:
cloth.
Clean sealing and bearing surfaces of knuckle spindle housing.

[27] -
IMPORTANT:
hub.
LEGEND:

B Wiper Seal Lip

Number Name Use
• PM38657 (us)
• PM38628 (canadian) High-Flex Form-In-Place Gasket Used to seal contacting surfaces.
[29] -
→NOTE:
[30] - Install seal onto JDG761 Seal Installer with long wiper seal lip (B) toward driver.
[31] -
IMPORTANT:
JDG761 Seal Installer must be used to install seal.
Install seal into wheel hub until tool is tight against hub.
[33] -
LEGEND:

[36] -
LEGEND:
B Alignment Marks
[37] -
→NOTE:
Ensure wheel hub and ring gear stay clamped together.
Aligning alignment marks (B) on knuckle spindle splines and ring gear hub, install wheel hub.
[38] - Remove axle wheel hub tool.

[40] -
LEGEND:
[41] -
IMPORTANT:
wheel hub seal.
Tighten ring gear retainer nut (A) to specification using JDG1253 Spanner Socket (B)without
turning hub.
(92 lb.-ft.)
[42] - Tighten ring gear retainer nut to specificationwhile rotating wheel hub continuously.
(130 lb.-ft.)

[44] -
LEGEND:
A Screw Hole
B O-ring
[45] - Apply PM37477 Thread Lock and Sealer (Medium Strength) to threaded hole.
Number Name Use
• PM37477 (us)
[46] - Install retainer lock screw and tighten to specification.
(37 lb.-ft.)
[47] - Replace O-ring (B) as necessary.

[48] -
IMPORTANT:
been replaced.
→NOTE:
LEGEND:
A Inner Race
B Driver Disk
Install inner race (A) onto carrier using a press and a 57 mm (2-1/4 in.) driver disk (B) until
flush with top of post.
[49] -
LEGEND:
[51] -
LEGEND:
A Planet Retaining Cap Screws (3 used)
Degrease planet retaining cap screws and tapped holes in carrier
Number Name Use
• PM38654 (us)
[53] -
IMPORTANT:
Tighten planet pinion retaining cap screws (A) to specification.

(229 lb.-ft.)

[54] -

Number Name Use
• PM37477 (us)

[57] -
LEGEND:
[58] - Install carrier-to-wheel hub cap screws and tighten to specification.
(93 lb.-ft.)

LEGEND:
1 Axle Housing
3 Bushing
5 Oil Seal
9 Shim Pack
11 Lower Kingpin
13 Snap Ring
14 Spacer
16 Snap Ring

17 Oil Seal
19 Upper Kingpin
20 Sensor
21 O-Ring
22 Adapter
23 Shaft
24 Seal
25 Plate


Spindle Assembly
[1] -
→NOTE:
Refer to Planetary Carrier and Wheel Hub—Cross-Sectional View, and
Knuckle Spindle Assembly—Cross-Sectional View during disassembly and
assembly.
LEGEND:
B Pry Slots
[3] -
CAUTION:
Remove planetary carrier to wheel hub cap screws (A).

[4] - Install JDG19 Lifting Eyes (C) to carrier with existing cap screw and threaded hole.

[6] -
→NOTE:
Thrust washer (A) and sun pinion gear (B) may stay with planetary carrier
or wheel hub assembly during carrier removal.
LEGEND:
A Thrust Washer
B Sun Pinion Gear
C Socket Head Screw
Remove thrust washer (A) and sun pinion gear (B).
[7] - Remove socket head screw (C).

[8] -
LEGEND:
A Retainer
Remove retainer (A) using JDG1253 Spanner Socket (B).

[9] -
LEGEND:
A Alignment Marks
[10] -
IMPORTANT:

[11] -
LEGEND:
A DFRW4-Axle Wheel Hub Tool

[13] -
LEGEND:
A Snap Ring
B Steering Cylinder Pin
C Tie Rod End
D Sensor Connector
E Upper Kingpin
Drain oil from differential case.
[14] -
→NOTE:
Steering cylinder hoses do not need to be removed.
Remove snap ring (A) and steering cylinder pin (B). Move steering cylinder out of way.
[15] - Remove tie rod end (C) from steering arm.
[16] - Disconnect sensor connector (D).

[18] -
LEGEND:
B Lower Kingpin
[19] - Remove lower kingpin (B) and shims.
[20] -
→NOTE:

LEGEND:
A Axle Shaft
[21] -

LEGEND:
A Spacer

[22] -
LEGEND:
B Slide Hammer
[23] -
LEGEND:
D Seal Surface

[24] -
→NOTE:
JDG1220 Spacer Installer will install the spacer to the correct depth below
seal surface.
Install spacer with bushing to specification.

(0.24—0.27 in.)
[25] -
LEGEND:
A Bushing

[26] -
LEGEND:
A Bushing
Remove bushing (A) using a slide hammer and JDG1212 Bushing Remover (B).
[27] -
→NOTE:
LEGEND:
A Bushing
B Spacer
C Driver Disk


[28] -
LEGEND:
A Snap Ring
B Spacer

[30] -
LEGEND:
A Seal

[31] -
LEGEND:
A Snap Ring
B Roller Bearing
[32] - Remove any roughness form seal bore area with emery cloth.
disk.

[35] -
→NOTE:
LEGEND:
B Seal
JDG1218A Seal Installer (C) MUST be used to correctly install the seal.
Apply a thin coat of PM38657 Form-in-Place Gasket to seal bore area.

Number Name Use
• PM38657 (us)
[36] -
IMPORTANT:

[37] -
LEGEND:
A Bellows Seal
B Slinger
C Excluder Seal
necessary taking care not to damage seal surfaces.

[38] -
LEGEND:
D Center Section
E Crosses (2 used)
F Axle Shaft Yoke
[40] - Strike upper caps with needle bearings (C) of cross (E) until bottom cap can be

[43] -
LEGEND:
A Spring Lip
B Rubber Ribs
[45] -
→NOTE:
LEGEND:
B Bellows Seal
Number Name Use
• PM38657 (us)

(A) to shaft.
[47] -
→NOTE:
LEGEND:
A Slinger
B JDG1255-1 Slinger-Seal Installer
C JDG1255-2 Collar
D Excluder Seal
slinger.

[51] -
LEGEND:
A Spacer
B Snap Ring


[1] -
LEGEND:
Inspect and replace kingpin bearing cones (A) as necessary.
[2] -
→NOTE:
Install new bearing cones using a 41mm (1-5/8 in.) driver disk.
[3] -
LEGEND:
A Kingpin Bearing Seals (2 used)
Remove kingpin bearing seal (A).
[4] - Remove top and bottom bearing cups.
[5] - Inspect and replace as necessary.

[6] -
→NOTE:
Install bearing cups before installing seals.
Install seal with lip of seal facing installer.
LEGEND:
A Seals (2 used)
Install bearing cups using a 72 mm (2-13/16 in.) driver disk.
[7] - Install seals (A) using JDG770 Seal Installer (B).


[1] -
→NOTE:
LEGEND:
B Upper Kingpin
C Shims
Install lower kingpin, without shims using two cap screws (A) in diagonal holes. Leave cap
screws loose.
[2] - Install upper kingpin (B) and tighten kingpin-to-knuckle housing cap screws to
specification.
(402 lb.-ft.)
[3] - Tighten two diagonal cap screws (A) evenly to 25, then 50, then 70 N˙m.
[4] - Rotate knuckle housing to maximum front and rear angles to roll-in bearings. Retighten
cap screws to 70 N˙m.
[5] - Measure gap at shim (C) between kingpin and knuckle housing at two corners without
cap screws using a feeler gauge.
[6] - Add readings and divide by two to obtain average. Average reading will be the
necessary shim pack for correct bearing preload.
[7] - Remove lower kingpin.

[8] - Install shim pack, kingpin, and kingpin-to-knuckle housing cap screws. Tighten to
specification.
(402 lb.-ft.)


List of References
Specifications
Install and Remove MFWD Axle To Rollover Stand
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack
Adjust Backlash
Disassemble Right-Hand Axle Housing and Determine Shim Pack
→NOTE:
D01045AA Disk Set

JDG1222 Puller Jaws
Specifications
(402 lb.-ft.)
(144 lb.-ft.)
(24 lb.-in.)
(258 lb.-ft.)


[1] -
LEGEND:
Remove drain plugs (A) and drain oil from case.
[2] - Remove MFWD axle from tractor. (See Remove Non-Suspended MFWD Axle in
Group 00.)
[3] -
LEGEND:
Install JDG10227 Axle Mounting Bracket (A) on D05223ST Engine Rollover Stand .
[4] - Install axle onto bracket using a hoist and straps.
[5] - Remove axle from rollover stand in reverse order.


[1] -
LEGEND:
A DFRW4 Axle Wheel Hub Tool
B Tie Rod
C Steering Cylinder
E Upper Kingpin
overhead hoist.
[3] -
→NOTE:
rod.
from axle.
[9] - Tighten kingpin-to-knuckle housing cap screws to specification.
(402 lb.-ft.)
[10] - Tighten tie rod-to-kingpin retaining nut to specification.

(144 lb.-ft.)


[1] -
LEGEND:
A Straps
B Axle Housing Cap Screws (14 used)
[2] - Install axle in axle rollover stand. (See Install and Remove MFWD Axle To Rollover Stand
in this group.)
group.)
[5] - Attach straps (A) to axle housing.
[6] - Remove cap screws (B) and right-hand side axle assembly.


Bearing Cup Shim Pack
[1] -
LEGEND:
A DFWR132-Differential Side Bevel Gear End Play Tool
B Wing Nut
[4] -
→NOTE:
Recommended shop puller tools are:

LEGEND:
C Legs (2 used)
Install JDG1222 Puller Jaws (A) to D01301AA Internal Puller (B).

[5] -
→NOTE:
Ensure jaws are positioned in puller slots in housing.
Remove bearing cup from differential case/axle housing using a push-puller with 4-1/2 in.
legs (C) and internal puller with JDG1222 Puller Jaws.
[6] -
→NOTE:
LEGEND:
A Nominal Shim Pack
B JDG1217-4 Dummy Bearing Cup
[7] - Install dummy bearing cup tight against shims in bottom of bore.

[8] -
LEGEND:
A DFRW132-Differential Side Bevel Gear End Play Tool
[9] -
LEGEND:
B JDG11193P5 Centering Plate
C JDG1217-2 Plate
D JDG11193P8 Bridge

[10] -
→NOTE:
JDG1217-2 Plate is part of JDG1217 Differential Housing Tool Set .
JDG11193P5 Centering Plate and JDG11193P8 Bridge Tool are part of
JDG11193 Differential Housing Tool Set .
Install JDG11193P5 Centering Plate (B).

[11] - Install JDG1217-2 Plate (C) and JDG11193P8 Bridge (D).
(24 lb.-in.)
[15] - Retighten JDG1217-2 Plate Cap Screw to specification.
[16] -
→NOTE:
JDG1253-2 Indicator Post is part of JDG1252 Differential Housing Tool Set .

LEGEND:
B Indicator Post Magnetic Base
D Indicator Post Arm
F Indicator Post Alignment Mark
Install JDG1253-3 Indicator Post (A) with magnetic base (B) tight against housing cover (C)
and arm (D) at a right angle with base.
indicator post arm (D) resting on alignment mark (F).
Adjust Backlash
[1] -
→NOTE:
Hold yoke stationary, and move ring gear to measure backlash.

0.13—0.53 mm (0.005—0.021 in.).

→NOTE:
BACKLASH READINGS
3 Reading One 1.27 mm ___________
Reading Two + 1.42 mm + ___________
Reading Three + 1.40 mm + ___________
_________________ __________________
= ___________ = ___________
= 1.36 mm = ___________
_________________ __________________
= 1.11 mm = ___________
= 1.30 mm = ___________
_________________ __________________
= 1.17 mm = ___________
_________________ __________________


Shim Pack
[1] -
IMPORTANT:
LEGEND:
A Shim Pack
[2] -
→NOTE:
Ensure permanent bearing cup is installed and NOT the dummy cup.
[3] -
→NOTE:
Install cup in axle housing. Install cup tight against shims in bottom of bore using a 111 mm


Determine Shim Pack
[1] -
→NOTE:

LEGEND:
C Legs (2 used)
Install JDG1222 Puller Jaws (A) to Internal puller (B).
[2] -
→NOTE:
[3] -
→NOTE:
Bearing Cup Shim Pack in this group.)

LEGEND:
C JDG1217-2 Plate
D JDG11193P8 Bridge
[4] -
→NOTE:
JDG11193P8 Bridge Tool and JDG11193P5 Centering Plate are part of

(24 lb.-in.)
[8] - Rotate housing six revolutions in each direction to roll in housing bearings.
[10] -

LEGEND:
A Bridge
a. Measure distance in four places from top of bridge (A) to differential case surface (B).
c.
LEGEND:
A Bridge
B Bearing Cup
Using a depth micrometer, measure distance in four places from top of bridge (A) to top
of bearing cup (B).

f.
LEGEND:
A JDG11193P8 Bridge
Put JDG11193P8 Bridge (A) on axle housing flange (B).
g. Measure distance in four places from top of tool (A) to bearing cup bore surface (C).
i.
LEGEND:
A Bridge


C Calculated Shim Pack
D Bearing Cup
Measure distance in four places from top of bridge (A) to axle housing flange (B).
→NOTE:
Ensure bearing cup (D) is tight against shims in bottom of bore.
[11] - Install calculated shim pack (C) and bearing cup (D) using a 111 mm (4-3/8 in.) driver
disk.


(a) Reading One 88.93 mm ___________
Reading Two + 88.87 mm + ___________
Reading Three + 88.95 mm + ___________
Reading Four + 88.85 mm + ___________
_________________ __________________
(c) Reading One 50.22 mm ___________
Reading Two + 50.11 mm + ___________
Reading Three + 50.24 mm + ___________
Reading Four + 50.09 mm + ___________
_________________ __________________
CUP-TO-CASE SURFACE
Step b 88.90 mm ___________
Step d — 50.17 mm — ___________
_________________ __________________
= 38.73 mm = ___________
(g) Reading One 129.20 mm ___________
Reading Two + 129.70 mm + ___________
Reading Three + 129.25 mm + ___________
Reading Four + 129.75 mm + ___________
_________________ __________________
(i) Reading One 88.93 mm ___________
Reading Two + 88.87 mm + ___________
Reading Three + 88.95 mm + ___________
Reading Four + 88.85 mm + ___________
_________________ __________________
Step h 129.48 mm ___________
Step j — 88.90 mm — ___________
_________________ __________________
= 40.58 mm = ___________
Step k 40.58 mm ___________
Step e — 38.73 mm — ___________
_________________ __________________


[1] -
LEGEND:
A O-ring
Install O-ring (A).
[2] -
LEGEND:

[3] -
LEGEND:
A Axle Housing
C Axle Housing Cap Screws (14 used)
[6] - Install axle housing cap screws (C) and tighten to specification.
(258 lb.-ft.)
[7] - Install final drive assemblies. (See Remove And Install Final Drive Assembly in Group
00.)
[8] - Remove axle from stand. (See Install and Remove MFWD Axle To Rollover Stand in this
group.)


[1] -
LEGEND:
A Bushing Split
B Chamfer Edge
C Pilot Disk
D Driver Disk
[2] - Remove bushing.
[3] -
IMPORTANT:
Install bushing with bushing split (A) at 12 o′clock position.
→NOTE:
Install front bushing using a 62 mm (2 7/16 in.) pilot disk (C), and a 64 mm (2 1/2 in.) driver
disk (D), until edge of bushing is flush with bottom of chamfer edge (B).
[4] - Repeat procedure for rear bushing.

List of References
Specifications
Cross-Sectional View—Differential Drive Shaft And Input Quill
→NOTE:
For further information see SERVICEGARD™ online tool catalog.
D01045AA Disk Set
Specifications
(184 lb.-ft.)

(0.003—0.020 in.)
All Axles Constant Dimension 199.612 mm
(7.859 in.)
Yoke Retaining Cap Screw Torque 225 N·m
(166 lb.-ft.)
(0.001—0.003 in.)

LEGEND:
6 Pin
7 Spacers (2 used)

11 Shim Pack
12 Housing Cover
13 Ring Gear

LEGEND:
6 Pin

11 Shim Pack
12 Housing Cover
13 Ring Gear


Differential
[1] -
LEGEND:
A Differential Cap Screws (12 used)
B Cover
C Ring Gear
Remove cap screws (A), cover (B) and ring gear (C).
[2] -
LEGEND:
A Disk Pack
Remove disk pack (A) and bevel gear .

[3] -
LEGEND:
A Pins (2 used)
B Shafts (3 used)
[4] -
LEGEND:
B Disk Pack
[5] - Remove bevel side gear and disk pack (B).

[6] -
LEGEND:
A Separator Plate
B Shim Pack
[7] -
→NOTE:
LEGEND:
B Driver Disk

[8] -
LEGEND:
B Driver Disk


[1] -
IMPORTANT:
LEGEND:
A Separator Plate
[2] -
LEGEND:
A Bevel Gear
B Spacer
D Disks (5 used)
gear (A).

[4] -
→NOTE:
LEGEND:
A Bevel Gear
B Spacer
C Disks (4 used)
[6] -
LEGEND:
A Disk Pack
B DFRW132-Differential Side Bevel Gear End Play Tool

[7] -
→NOTE:
Tabs (B) on conical thrust washer must line up with groove (C) in housing.
LEGEND:
B Tabs
C Groove
[8] -
→NOTE:
shafts (C).

LEGEND:
B Long Pinion Shaft
D Pin Bore

[9] -
LEGEND:
A Pinion Shaft Locking Pins (2 used)
[10] -
LEGEND:
A Separator Plate

[11] -
LEGEND:
A Bevel Gear
B Spacer
D Disks (5 used)
gear (A).
[13] -
→NOTE:
LEGEND:
A Bevel Gear
B Spacer
C Disks (4 used)

[15] -
LEGEND:
A Disk Pack
End Play Tool (B).
[16] - Remove DFRW132--Differential Side Bevel Gear End Play Tool (B).
[17] -
LEGEND:
A DFRW132 Differential Housing Tool
Install DFRW132 Differential Housing Tool (A) through bevel gear pack and cover from
opposite end.

[18] -
LEGEND:
A Ring Gear
B Bevel Side Gear

[20] -
LEGEND:
(184 lb.-ft.)
[21] - Check disk pack end play in four locations (B) with dial indicator and end play tool.
(0.003—0.020 in.)


[25] -

(0.003—0.020 in.)

[29] -
CAUTION:
LEGEND:
A Tapered Roller Bearing Cones (2used)


Input Quill
LEGEND:
B Snap Ring
C Thrust Washer
D Bearing Cup
E Bearing Cone
F Oil Seal
G Yoke
H Yoke Retaining Cap Screw
I Special Washer
J Shim Pack
K O-ring
L Shim Pack
M Bearing Cone
N Bearing Cup
O Differential Case


[1] -

LEGEND:
A Yoke
B JDG924 Yoke Holding Tool
C Cap Screw
D Special Washer
E Shim Pack
F O-ring
G Pinion Shaft
Retain yoke (A) using JDG924 Yoke Holding Tool (B) and remove cap screw (C).
[2] - Remove special washer (D).
[3] - Remove shim pack (E), O-ring (F), and yoke (A).
[4] - Remove pinion shaft (G).
[5] -
LEGEND:
A Seal
B Bearing Cone

[6] -
LEGEND:
A Inner Bearing Cup
B Shim Pack
Remove inner bearing cup (A) and shim pack (B).
[7] -
LEGEND:
A Snap Ring
B Thrust Washer
Remove snap ring (A) and thrust washer (B).

[8] -
LEGEND:
A Outer Bearing Cup
Remove outer bearing cup (A).
[9] -
→NOTE:
LEGEND:
A Bearing Cone
B Driver Disk


Pack
[1] -
LEGEND:
A Dimension
Record metric dimension (A), stamped on differential case.
[2] -
→NOTE:
Constant dimension includes nominal bearing width, and bearing growth
allowance.
Subtract constant dimension from dimension stamped on differential case, to obtain correct
shim pack thickness.
(7.859 in.)
EXAMPLE
XXX.XX mm (X.XXX in.) Dimension on Differential Case
- 199.612 mm (7.859 in.) Constant Dimension
__________________
= XXX.XX mm (X.XXX in.) Correct Shim Pack Thickness

[3] -
CAUTION:
LEGEND:
Heat drive shaft bearing (A) and install until bearing bottoms against head of pinion shaft.


[1] -
LEGEND:
A Snap Ring
B Thrust Washer
Install thrust washer (B) and snap ring (A) into input quill.
[2] -
→NOTE:
LEGEND:
A Outer Bearing Cup
Install outer bearing cup (A) into input quill using an 81 mm (3-3/16 in.) driver disk.

[3] -
LEGEND:
A Inner Bearing Cup
B Shim Pack
Install previously calculated shim pack (B) into input quill
[4] - Install inner bearing cup (A) into input quill using a 108 mm (4-1/4 in.) driver disk until
tight against bottom of bore.
[5] -
LEGEND:
A Seal
B Bearing Cone
Install bearing cone (B).
[6] - Install seal (A) using JDG851 Seal Installer .
[7] -
→NOTE:
Yoke must install on shaft splines freely.


LEGEND:
A Yoke
B JDG924 Yoke Holding Tool
C Yoke Retaining Cap Screw
D Special Washer
E Shim Pack
F O-ring
G Pinion Shaft
Install drive shaft (G) into input quill.
[8] - Install JDG924 Yoke Holding Tool (B) to yoke (A).
[9] - Install yoke onto pinion shaft (G).
[10] - Install O-ring (F) and a known thickness shim pack (E).
[11] - Install special washer (D) and yoke retaining cap screw (C). Tighten to specification.
(166 lb.-ft.)
[12] -
LEGEND:
A Dial Indicator
B Retaining Nut
[13] -
IMPORTANT:
Force pinion shaft fully inward and then fully outward when measuring end
play.
Measure shaft end play by forcing pinion shaft inward and outward.

SUSPENDED MFWD AXLE (g) by Belgreen
[14] - Remove or install shims, repeating measuring procedure until shaft end play is within
specification.
(0.001—0.003 in.)
[15] - Retighten yoke retaining cap screw to specification.

(166 lb.-ft.)

Section 59 - SUSPENDED MFWD AXLE

Table of contents
Other Material ........................................................................................................................ 1
Specifications ......................................................................................................................... 1
Remove Suspended MFWD Axle ............................................................................................ 3
Install Suspended Axle ........................................................................................................... 9
Group 05 - Final Drives ........................................................................................................... 14
Other Material ...................................................................................................................... 15
Specifications ....................................................................................................................... 17
Cross-Sectional View—Planetary Carrier and Wheel Hub Without Brake ............................. 18
Cross-Sectional View—Planetary Carrier and Wheel Hub With Brake .................................. 20
Remove, Recondition, and Install Planetary Carrier and Wheel Hub Without Brake ............ 22
Remove, Recondition, and Install Planetary Carrier and Wheel Hub With Brake .................. 38
Other Material ...................................................................................................................... 92
Specifications ....................................................................................................................... 93
Install Suspended MFWD Axle Onto Repair Stand ................................................................ 94
Remove and Install Final Drive Assembly ............................................................................ 96
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack—Limited Slip
Differential .................................................................................................................... 99
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack—Locking
Differential .................................................................................................................. 105
Adjust Backlash .................................................................................................................. 111
Backlash Shim Pack Example and Worksheet .................................................................... 112
Install Left-Hand Axle Housing Bearing Cup and Shim Pack ............................................... 113
Disassemble Right-Hand Axle Housing and Determine Shim Pack—Limited Slip Differential
..................................................................................................................................... 114
Disassemble Right-Hand Axle Housing and Determine Shim Pack—Locking Differential
..................................................................................................................................... 120
Preload Shim Pack Example and Worksheet ...................................................................... 126
Install Right-Hand Axle Housing ......................................................................................... 128
Bearing Support Exploded View ......................................................................................... 129
Remove and Recondition Bearing Support ......................................................................... 132
Group 15 - Differential .......................................................................................................... 144


Specifications ..................................................................................................................... 145
Cross-Sectional View—Differential Housing—Limited Slip Differential (2.5 Ratio) .............. 145
Cross-Sectional View—Differential Housing—Limited Slip Differential (4.0 Ratio) .............. 146
Repair Differential Housing—Limited Slip Differential ........................................................ 148
Assemble Differential—Limited Slip Differential ................................................................. 152
Cross-Sectional View—Differential Housing—Heavy Duty With Hydraulic Differential Lock
..................................................................................................................................... 162
Repair Differential Housing—With Hydraulic Differential Lock ........................................... 163
Assemble Differential—With Hydraulic Differential Lock .................................................... 174
Cross-Sectional View—Differential Drive Shaft And Input Quill—Suspended MFWD Axle
..................................................................................................................................... 183
Remove and Disassemble Differential Drive Shaft ............................................................. 185
Assemble and Install Differential Drive Shaft ..................................................................... 192
Group 20 - Suspension Components .................................................................................. 197
Specifications ..................................................................................................................... 198
TLS™ Hydraulic Control Valve Block .................................................................................. 199
Relieve Pressure From Suspended MFWD Axle Hydraulic System ..................................... 201
Replace Suspended MFWD Axle Position Sensor ................................................................ 202
Cross-Sectional View—Suspended MFWD Axle Cylinder Piston Seals ................................ 202
Repair Suspended MFWD Axle Cylinder Seals .................................................................... 204
Check and Charge Accumulators ....................................................................................... 207

Section 59 - SUSPENDED MFWD AXLE Group 00: Component Removal And Installation

List of References
Other Material
Specifications
Remove Suspended MFWD Axle
Install Suspended Axle
→NOTE:
JDG909 Lifting Eyes
JT07336 Lift Sling
JDG1182 Puller Adapter
Other Material
Number Name Use
• PM38657 (us)
housings.

Specifications
Suspended Axle Bearing Support-to-Cross Member Cap Screw Torque 500 N·m
(369 lb.-ft.)
Cylinder Pin Retaining Cap Screw Torque 130 N·m
(95 lb.-ft.)
Panhard Link Pin Retaining Cap Screw Torque 130 N·m
(95 lb.-ft.)
Suspended Axle Rear Driveline U-Joint Cap Screw Torque 70 N·m
(51 lb.-ft.)
Front Wheel-to-Hub Cap Screw Torque 600 N·m
(442 lb.-ft.)
joint.
Number Name Use
⚬ PM38657 (us)
⚬ PM38628 (canadian) High Flex Form-In-Place Used to seal transmission
⚬ 17430 Loctite™ Gasket housings.
(loctite)

Remove Suspended MFWD Axle

[1] -
LEGEND:
sides of tractor.
[4] - Remove front tires and fenders. (For further information, see Operator’s Manual.)
[5] -
CAUTION:
High pressure can exist at any hydraulic connection. Avoid injury from
high-pressure leaks by relieving system pressure before disconnecting any
hydraulic lines, fittings, or connections.
Relieve hydraulic pressure from suspension system. (See Relieve Pressure From Suspended
MFWD Axle Hydraulic System in Group 20.)
[6] - Remove radar, if equipped. (See Replace Radar Sensor—IVT™ Transmissions in Section
40, Group 30.)

[7] -
LEGEND:
A Shield
B Rear Driveline
Remove shield (A).
[8] - Disconnect rear driveline (B) from front driveline.

[9] -
LEGEND:
A Lines
B Bearing Support Cap Screws (4 used)
Disconnect lines (A).
[10] - Cap and plug lines to prevent contamination.
[11] - Support rear of front driveline housing with a floor jack and remove bearing support
cap screws (B).
[12] - Lower floor jack and separate support from tractor.

[13] -
LEGEND:
A Connector Shield
B Wire Harness
Remove connector shield (A) and wiring harness (B).

[14] -
Left-Hand Kingpin
Right-Hand Kingpin
LEGEND:
Install JDG909 Lifting Eyes (A) on to kingpins.

[18] -
LEGEND:
A Pin Retaining Cap Screws and Washers (3 used)
B Retaining Pins (3 used)
C JDG1182 Puller Adapter
Remove pin retaining cap screws and washers (A).
[19] - Remove retaining pins (B) from lift cylinders and panhard link using JDG1182 Puller
Adapter (C) and slide hammer.
[20] - Lower and remove axle from tractor.

Install Suspended Axle

[1] -
LEGEND:
Install guide pins (A).
[2] -
IMPORTANT:
Ensure position sensor arm (A) is oriented as shown to avoid damaging
position sensor.
LEGEND:
A Position Sensor Arm
Install axle.

[3] -
LEGEND:
A Bearing Support Cap Screws (4 used)
Tighten bearing support cap screws (A) to specification.
Suspended Axle Bearing Support-to-Cross Member Cap Screw Torque 500 N·m
(369 lb.-ft.)

[4] -
LEGEND:
A Lines
Connect lines (A).

[5] -
LEGEND:
A Suspension Cylinders (2 used)
B Cylinder Retaining Pins (2 used)
C Washers (2 used)
D Cylinder Pin Retaining Cap Screws (2 used)
Install foam seals and suspension cylinders (A) onto both sides of axle.
[6] - Install retaining pins (B), washers (C), and cap screws (D).
[7] - Tighten cylinder pin retaining cap screws to specification.
Cylinder Pin Retaining Cap Screw Torque 130 N·m
(95 lb.-ft.)
[8] -
LEGEND:
A Panhard Link Retaining Pin
B Washer
C Panhard Link Retaining Cap Screw
Install retaining pin (A), washer (B), and cap screw (C).

Section 59 - SUSPENDED MFWD AXLE Group 05: Final Drives
[9] - Tighten panhard link pin retaining cap screw to specification.

Panhard Link Pin Retaining Cap Screw Torque 130 N·m
(95 lb.-ft.)
[10] -
LEGEND:
A Connector Shield
B Wire Harness
Install wire harness (B) and connector shield (A).
[11] - Connect rear driveline to front driveline.
[12] - Tighten rear driveline-to-U-joint clamp cap screws to specification.
Suspended Axle Rear Driveline U-Joint Cap Screw Torque 70 N·m
(51 lb.-ft.)
[13] - Install radar, if equipped. (See Replace Radar Sensor—IVT™ Transmissions in Section
40, Group 30.)
[14] - Install wheels and fenders. (For further information, see Operator′s Manual.)
(442 lb.-ft.)
[16] - Calibrate suspended MFWD axle system. (See Operation and Test TM—Section 245,
Group SFA.)
[17] - Bleed front brakes. (See Bleed MFWD Brakes in Section 60, Group 20.)


List of References
Other Material
Specifications
Cross-Sectional View—Planetary Carrier and Wheel Hub Without Brake
Cross-Sectional View—Planetary Carrier and Wheel Hub With Brake
Remove, Recondition, and Install Planetary Carrier and Wheel Hub Without Brake
Remove, Recondition, and Install Planetary Carrier and Wheel Hub With Brake

→NOTE:
D01045AA Disk Set
JDG19 Lifting Eyes
JDG909 Lifting Eyes
JDG983 Snap Ring Expander Tool
JDG1123 Driver Disk

Other Material
Number Name Use
• PM38657 (us)
housings.
• PM37477 (us)
• PM38654 (us)

Specifications
(92 lb.-ft.)
(130 lb.-ft.)
(37 lb.-ft.)
(229 lb.-ft.)
(93 lb.-ft.)
Brake Housing Socket Head Screws Torque 12 N·m
(106 lb.-in.)
Wheel Hub Retainer Initial Torque 126 N·m
(93 lb.-ft.)
Wheel Hub Retainer Final Torque 176 N·m
(130 lb.-ft.)
(0.24—0.27 in.)
(400 lb.-ft.)


Hub Without Brake
LEGEND:
3 Snap Ring
4 Ring Gear Hub
5 Sun Pinion Gear

6 Thrust Washer
8 Thrust Washer
10 Bushing
11 Retainer
12 Planet Pinions (3 used)
14 Retainer (3 used)
15 Ring Gear
17 O-ring
18 Wheel Hub
19 Oil Seal
20 Slinger
21 Excluder Seal
22 Ball Bearing
23 Spacer
24 Oil Seal
25 Snap Ring
26 Snap Ring


Hub With Brake
LEGEND:
1 Snap Ring
2 Snap Ring
3 Wheel Hub
4 Bearing Cup
5 Bearing Cone
6 Bearing Cup
7 Bearing Cone
9 Oil Seal
10 Snap Ring
11 Oil Seal
12 Spacer
13 Snap Ring
14 O-ring
15 O-ring
16 Inner Brake Piston Seal
17 O-ring
19 Brake Hub
20 Compression Springs (12 used)
21 Washers (12 used)
23 Retainer
24 Thrust Washer
25 Axle Shaft
26 Sun Pinion Gear
28 Inner Bearing Races (3 used)
30 Retainers (3 used)
32 Planet Pinions (3 used)
33 Ring Gear
34 Snap Ring
35 O-ring
36 Outer Brake Piston Seal
37 Brake Piston
38 Plates (2 used)
39 Brake Disks (2 used)
40 Backing Plate


and Wheel Hub Without Brake
[1] -
→NOTE:
LEGEND:
A Planetary Carrier-to-Wheel Hub Cap Screws (2 used)
B Pry Slots
[3] -
CAUTION:

hole.

[6] -
→NOTE:
LEGEND:
[7] - Make alignment marks on planet pinions, retainers, and carrier so parts are installed in
their original location.
[8] - Remove retaining cap screws (A) and retainers (B).
[10] -
→NOTE:
[11] -
→NOTE:

LEGEND:
A Sun Pinion Gear
B Socket Head Cap Screw
Remove sun pinion gear (A) and socket head cap screw (B).

[12] -
LEGEND:
Remove ring gear retainer nut (A), using JDG1253 Spanner Socket (B).

[13] -
LEGEND:
A Alignment Marks
[14] -
IMPORTANT:

[15] -
LEGEND:
B Outer Bearing
[17] -
LEGEND:
A Bearing Cone
B Snap Ring
[18] - Make alignment marks on ring gear hub and ring gear.
[19] - Remove snap ring (B) and ring gear.

[22] -
LEGEND:
[24] -
→NOTE:
Take care not to damage wheel hub seal bore when removing seal.

LEGEND:
A Oil Seal
B Bearing
[25] - Inspect bearing cups and remove if necessary.
[26] -
IMPORTANT:
cloth.
Clean sealing and bearing surfaces of knuckle spindle housing.

[28] -
IMPORTANT:
hub.
LEGEND:

B Wiper Seal Lip

Number Name Use
• PM38657 (us)
[30] -
→NOTE:
[32] -
IMPORTANT:
[34] -
LEGEND:

[37] -
LEGEND:
B Alignment Marks
[38] -
→NOTE:
Ensure wheel hub and ring gear stay clamped together.
Aligning alignment marks (B) on knuckle spindle splines and ring gear hub, install wheel hub.
[39] - Remove axle wheel hub tool.

[41] -
LEGEND:
[42] -
IMPORTANT:
wheel hub seal.
Tighten ring gear retainer nut (A) to specification using JDG1253 Spanner Socket (B)without
turning hub.
(92 lb.-ft.)
[43] - Tighten ring gear retainer nut to specificationwhile rotating wheel hub continuously.
(130 lb.-ft.)

[45] -
LEGEND:
A Screw Hole
B O-ring
Number Name Use
• PM37477 (us)
[47] - Install retainer lock screw and tighten to specification.
(37 lb.-ft.)
[48] - Replace O-ring (B) as necessary.

[49] -
IMPORTANT:
been replaced.
→NOTE:
LEGEND:
A Inner Race
B Driver Disk
Install inner race (A) flush with top of post using 57 mm (2-1/4 in.) driver disk (B).
[50] -
LEGEND:

[52] -
LEGEND:
Number Name Use
• PM38654 (us)
[54] -
IMPORTANT:
(229 lb.-ft.)

[55] -

Number Name Use
• PM37477 (us)

[58] -
LEGEND:
[59] - Install carrier-to-wheel hub cap screws (A) and tighten to specification.
(93 lb.-ft.)


and Wheel Hub With Brake
[1] -
→NOTE:
LEGEND:
A Planetary Carrier-to-Wheel Hub Cap Screws (2 used)
B Pry Slots
[3] -
CAUTION:
possible injury.

hole.

[6] -
→NOTE:
LEGEND:
[7] - Make alignment marks on planet pinions, retainers, and carrier so parts are installed in
their original location.
[10] -
→NOTE:

[11] -
IMPORTANT:
been replaced.
→NOTE:
Ensure that carrier is supported on outer flange surface.
LEGEND:
A Inner Race
B Driver Disk
Install inner race (A) flush with top of post using 57 mm (2-1/4 in.) driver disk (B).
[12] -

LEGEND:
E Planet Pinion Retaining Cap Screws (3 used)
Install parts (A—C).
[13] - Lube needle bearings and install retainer (D).

[14] -
LEGEND:
Number Name Use
• PM38654 (us)
[16] -
CAUTION:
Planet pinions cannot bind when turning.
(229 lb.-ft.)
[17] -
→NOTE:
Sun pinion thrust washer (A) can remain with planetary carrier during
removal.

LEGEND:
A Thrust Washer
B Sun Pinion Gear
C Socket Head Cap Screw
Remove thrust washer (A), sun pinion gear (B), and socket head cap screws (C).
[18] -
LEGEND:
A Snap Ring
B Ring Gear
Compress snap ring (A).
[19] - Remove ring gear (B) and snap ring.
[20] - Inspect ring gear and replace as necessary.

[21] -
LEGEND:
A JDG1253 Spanner Socket
Remove retainer using JDG1253 Spanner Socket (A).
[22] -

LEGEND:
A Alignment Marks
B Brake Assembly
C Pry Bar
Make alignment marks (A) on brake assembly and knuckle spindle.
[23] - Remove brake assembly (B) using pry bar (C).
[24] -

LEGEND:
A Bearing
B Snap Ring
C JDG983 Snap Ring Expander Tool
Remove bearing (A).
[25] - Remove snap ring (B) using JDG983 Snap Ring Expander Tool (C) with JDG983-2
Special Tips.

[26] -
LEGEND:
A Backing Plate
B Snap Ring
Remove backing plate (A).
[27] - Remove snap ring (B).

[28] -
LEGEND:
A Disks (7 used)
B Plates (6 used)
Remove disks (A) and plates (B).

[29] -
LEGEND:
A O-rings (2 used)
B Socket Head Cap Screws (12 used)
C Washers (12 used)
D Springs (12 used)
Turn assembly over and remove O-rings (A).
[30] - Remove socket head cap screws (B), washers (C), and springs (D).

[31] -
LEGEND:
A Brake Piston
B Housing
Remove brake piston (A) from housing (B).
[32] -
→NOTE:
Allow seals to reshape before installing into piston.

LEGEND:
A Inner Brake Seal and O-ring
B Outer Brake Seal and O-ring
Remove inner brake seal and O-ring (A) and outer seal and O-ring (B).
[34] -
LEGEND:
A Screw Holes
B Housing
Align screw holes (A) in brake piston with holes in housing (B).

[35] -
LEGEND:
A Brake Piston
B Housing
Press brake piston (A) into housing (B).

[36] -
LEGEND:
A Brake Housing Socket Head Screws (12 used)
Install springs, washers, and brake housing socket head screws (A) and tighten to
specification.
Brake Housing Socket Head Screws Torque 12 N·m
(106 lb.-in.)
[37] - Install remaining parts in reverse order.

[38] -
LEGEND:
A DFRW—Axle Wheel Hub Tool
[39] - Remove wheel hub from knuckle spindle.
[40] -
LEGEND:
A Oil Seal
B Bearing

[41] - Inspect bearing cups and remove if necessary.

IMPORTANT:
Remove any roughness or excess sealant in seal bore with emery cloth.
[42] -
LEGEND:
A JDG1123 Driver Disk
Install bearing cups into wheel hub using JDG1123 Driver Disk (A).
[43] -
IMPORTANT:
hub.
LEGEND:
B Wiper Seal Lip

Number Name Use
• PM38657 (us)
housings.
[45] -
→NOTE:
Apply a coating of oil to rubber inside diameter of hub seal and wheel hub bearing cone (A).
[47] -
→NOTE:
[49] - Clean sealing and bearing surfaces of knuckle spindle housing.
[50] - Clean rust and dirt from seal surface using a scraper and emery cloth.

[51] -
LEGEND:
[52] - Install wheel hub and remove tool.
[53] - Apply grease to O-rings.
[54] - Align alignment marks on brake assembly and knuckle spindle.
[55] - Install brake assembly.
[56] - Install snap ring and ring gear.
[57] - Apply oil to knuckle housing threads, retainer threads, and contacting surface of
retainer and brake housing.

[58] -
LEGEND:
Install wheel hub retainer.
[59] -
IMPORTANT:
Turning wheel hub before wheel hub retainer is tightened could result in
damage to wheel hub seal.
Tighten wheel hub retainer to initial specification, using JDG1253 Spanner Socket (A) without
turning hub.
Wheel Hub Retainer Initial Torque 126 N·m
(93 lb.-ft.)
[60] - Tighten wheel hub retainer to final specification while rotating wheel hub continuously.
Wheel Hub Retainer Final Torque 176 N·m
(130 lb.-ft.)

[62] -
LEGEND:
A Screw Holes
B O-ring
Turn wheel hub retainer clockwise to align a notch with either screw holes (A). Then turn
retainer clockwise to line up opposite hole with notch.
Number Name Use
• PM37477 (us)
[64] -
(37 lb.-ft.)
Install retainer lock screw and tighten to specification.

[65] - Replace O-ring (B).

[66] -
LEGEND:
[67] - Install carrier-to-wheel hub cap screws (A) and tighten to specification.
(93 lb.-ft.)
[70] - Bleed front brakes. (See Bleed MFWD Brakes in Section 60, Group 20.)

LEGEND:
1 Axle Housing
3 Bushing
5 Oil Seal
9 Shim Pack
11 Lower Kingpin
13 Snap Ring
14 Spacer
16 Snap Ring

17 Oil Seal
19 Upper Kingpin
20 Sensor
21 O-ring
22 Adapter
23 Shaft
24 Seal
25 Plate


Spindle Assembly
[1] -
→NOTE:
Refer to Planetary Carrier and Wheel Hub—Cross-Sectional View, and
Knuckle Spindle Assembly—Cross-Sectional View during disassembly and
assembly.
LEGEND:
B Pry Slots
[3] -
CAUTION:

[4] - Install JDG19 Lifting Eyes (C) to carrier with existing cap screw and threaded hole.

[6] -
→NOTE:
Thrust washer (A) and sun pinion gear (B) may stay with planetary carrier
or wheel hub assembly during carrier removal.
LEGEND:
A Thrust Washer
B Sun Pinion Gear
C Socket Head Screw
For axles without brakes perform the following: Remove thrust washer (A) and sun
pinion gear (B).
[7] - Remove socket head screw (C).

[8] -
LEGEND:
A Wheel Hub Retainer
Remove wheel hub retainer (A) using JDG1253 Spanner Socket (B).

[9] -
LEGEND:
A Alignment Marks
[10] -
IMPORTANT:

[11] -
→NOTE:
Thrust washer (A) can remain with planetary carrier during removal.
For axles with brakes perform the following:

LEGEND:
A Thrust Washer
B Sun Pinion Gear
Remove thrust washer (A) and sun pinion gear (B).
[12] - Remove socket head cap screw (C).
[13] -
LEGEND:
A Snap Ring
B Ring Gear
Compress snap ring (A).
[14] - Remove ring gear (B) and snap ring.

[15] - Inspect ring gear and replace as necessary.

[16] -
LEGEND:
Remove wheel hub retainer using JDG1253 Spanner Socket (A).
[17] -

LEGEND:
A Alignment Marks
B Brake Assembly
C Pry Bar
Make alignment marks (A) on brake assembly and knuckle spindle.
[18] - Remove brake assembly (B) using pry bar (C).
[19] - For all axles perform the following:

LEGEND:

[21] -
LEGEND:
A Connector Shield
B Wire Harness
C Brake Hose
D Upper Kingpin
Remove connector shield (A).
[22] - Disconnect wire harness (B) from sensor.
[23] - Disconnect brake hose (C) if equipped.
[24] - Remove upper kingpin (D).
[25] -

LEGEND:
B Tie Rod
C Steering Cylinder
D Lower Kingpin
[26] - Remove tie rod (B) from knuckle spindle housing.

[27] - Remove steering cylinder (C) from steering arm.

[28] - Remove lower kingpin (D) and shims.
[29] -
→NOTE:
LEGEND:
A Axle Shaft

[30] -
LEGEND:
A Spacer

[31] -
LEGEND:
B Slide Hammer
[32] -
LEGEND:
D Seal Surface

[33] -
→NOTE:
JDG1220 Spacer Installer will install the spacer to the correct depth below
seal surface (D).
Install spacer with bushing to specification.

(0.24—0.27 in.)
[34] -
LEGEND:
A Bushing

[35] -
LEGEND:
A Bushing
Remove bushing (A) using a slide hammer and JDG1212 Bushing Remover (B).
[36] -
→NOTE:
LEGEND:
A Bushing
B Spacer
C Driver Disk


[37] -
LEGEND:
A Snap Ring
B Spacer

[39] -
LEGEND:
A Seal

[40] -
LEGEND:
A Snap Ring
B Roller Bearing
[41] - Remove any roughness form seal bore area with emery cloth.
disk.
[44] -
→NOTE:
JDG1218A Seal Installer (C) MUST be used to correctly install the seal.

LEGEND:
B Seal
Apply a thin coat of PM38657 Form-in-Place Gasket to seal bore area.
Number Name Use
• PM38657 (us)
[45] -
IMPORTANT:

[46] -
LEGEND:
A Bellows Seal
B Slinger
C Excluder Seal
necessary taking care not to damage seal surfaces.

[47] -
LEGEND:
D Center Section
E Crosses (2 used)
F Axle Shaft Yoke
[49] - Strike upper caps with needle bearings (C) of cross (E) until bottom cap can be

[52] -
LEGEND:
A Spring Lip
B Rubber Ribs
[54] -
→NOTE:
LEGEND:
B Bellows Seal
Number Name Use
• PM38657 (us)

(A) to shaft.
[56] -
→NOTE:
LEGEND:
A Slinger
B JDG1255-1 Slinger-Seal Installer
C JDG1255-2 Collar
D Excluder Seal
slinger.

[60] -
LEGEND:
A Spacer
B Snap Ring


[1] -
LEGEND:
Inspect and replace bottom kingpin bearing cones (A) as necessary.
[2] -
IMPORTANT:
Top and bottom kingpin bearing cones have same inside diameter but
different outside diameter. Larger cone is installed on bottom kingpin.
→NOTE:
Driver disk are part of D01045AA Disk Set .
Install new kingpin bearing cones using a 44 mm (1-3/4 in.) driver disk.
[3] -
LEGEND:
A Kingpin Bearing Seal
Remove kingpin bearing seal (A).

[4] - Remove top and bottom bearing cups.

[5] - Inspect and replace as necessary.
[6] -
→NOTE:
Install bearing cup before installing seal.
LEGEND:
A Top Seal
Install top bearing cup using a 72 mm (2-13/16 in.) driver disk.
[7] - Install top seal (A) using JDG770 Seal Installer (B).
[8] - Install bottom bearing cup using a 76 mm (3 in.) driver disk.
[9] - Install bottom seal using JDG1254 Seal Installer .


[1] -
→NOTE:
LEGEND:
A Kingpin-to-Knuckle Housing Cap Screws (8 used)
B Upper Kingpin
C Gap
Install lower kingpin, without shims using two cap screws (A) in diagonal holes. Leave cap
screws loose.
[2] - Install upper kingpin and tighten kingpin-to-knuckle housing cap screws to specification.
(400 lb.-ft.)
[3] - Tighten two lower kingpin caps screws (A) alternately to 20 N·m (177 lb.-in.), then 60
N·m (44 lb.-ft.), then 100 N·m (73 lb.-ft.), and then 200 N·m (148 lb.-ft.).
[4] - Rotate knuckle housing to maximum front and rear angles to roll in bearings. Retighten
cap screws to 200 N·m (148 lb.-ft.).
[5] - Measure gap (C) between kingpin and knuckle housing at two corners without cap
screws, using a feeler gauge.
[6] - Add readings and divide by two to obtain average. Average reading is shim pack used
for correct bearing preload.

Section 59 - SUSPENDED MFWD AXLE Group 10: Axle Housing
[7] - Install shim pack, kingpin, and kingpin-to-knuckle housing cap screws. Tighten to
specification.
(400 lb.-ft.)


List of References
Other Material
Specifications
Install Suspended MFWD Axle Onto Repair Stand
Remove and Install Final Drive Assembly
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack—Limited Slip
Differential
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack—Locking
Differential
Adjust Backlash
Disassemble Right-Hand Axle Housing and Determine Shim Pack—Limited Slip Differential
Disassemble Right-Hand Axle Housing and Determine Shim Pack—Locking Differential
Bearing Support Exploded View
Remove and Recondition Bearing Support

→NOTE:
DFRW235—MFWD Input Shaft Holding Tool
D01045AA Disk Set
JDG1222 Puller Jaws
Other Material
Number Name Use
• TY6341 (us) Multi-Purpose SD Polyurea Used to lubricate bearings and
• CXTY6341 (canadian) Grease bushings.

Specifications
(402 lb.-ft.)
(144 lb.-ft.)
(24 lb.-in.)
Plate Preload Cap Screw Preload Torque 2.6 N·m
(24 lb.-in.)
(258 lb.-ft.)
Cover-to-Bearing Support Socket-Head Screw Torque 37 N·m
27 (lb.-ft.)
Bearing Quill-to-Driveline Housing Socket-Head Screw Torque 37 N·m
(27 lb.-ft.)
Yoke Cap Screw Torque 310 N·m
(229 lb.-ft.)
Driveline Housing-to-Axle Cap Screw Torque 340 N·m
(251 lb.-ft.)

Install Suspended MFWD Axle Onto Repair Stand

[1] -
LEGEND:
Remove drain plugs (A) and drain oil.
[2] - Remove axle from tractor. (See Remove Suspended MFWD Axle in Group 00.)
[3] -
LEGEND:
A Driveline Housing
Remove driveline housing (A) from axle.

[4] -
LEGEND:
Install JDG10227 Axle Mounting Bracket (A) onto D05223ST Engine Rollover Stand .
[5] - Install axle onto mounting bracket using a hoist and straps.
[6] - Remove axle from repair stand in reverse order.

Remove and Install Final Drive Assembly

[1] -
LEGEND:
A DFRW4-Axle Wheel Hub Tool
B Tie Rod
C Steering Cylinder
E Upper Kingpin
overhead hoist.
[3] -
→NOTE:
rod.
from axle.
[9] - Install and tighten kingpin-to-knuckle housing cap screws to specification.
(402 lb.-ft.)
[10] - Install and tighten tie rod-to-kingpin retaining nut to specification.

(144 lb.-ft.)


[1] -
LEGEND:
A Lifting Straps
Remove axle from tractor. (See Remove Suspended MFWD Axle in Group 00.)
[2] - Install axle in axle rollover stand. (See Install Suspended MFWD Axle Onto Repair Stand
in this group.)
group.)
[4] - Remove steering cylinders from axle.
[6] - Attach lifting straps (A) to axle housing.
[7] - Remove cap screws (B) and right-hand side axle assembly.


Bearing Cup Shim Pack—Limited Slip Differential
[1] -
LEGEND:
A DFRW132 Differential Side Bevel Gear End Play Tool
B Wing Nut
[3] - Remove differential from case using a suitable lifting device.
[4] -
→NOTE:
Recommended puller tools are:

LEGEND:
A JDG1222 Puller Jaws (2 used)
B Internal Puller
C Legs (2 used)
Install JDG1222 Puller Jaws (A) to an internal puller (B).

[5] -
→NOTE:
Remove bearing cup from left-hand axle housing using a push-puller with 4-1/2 in. legs (C)
and internal puller with JDG1222 Puller Jaws.
[6] -
→NOTE:
JDG1217-4 is part of JDG1217 Differential Housing Tool Set
LEGEND:
A Shim Pack
[7] - Install Dummy Bearing Cup tight against shims in bottom of bore.

[8] -
LEGEND:
[9] -
LEGEND:
C JDG1217-2 Plate
D JDG11193P8 Bridge

[10] -
→NOTE:
JDG11193P8 Bridge and JDG11193P5 Centering Plate are part of JDG11193
Differential Housing Tool Set .

(24 lb.-in.)
[16] -
→NOTE:
JDG1252-3 Indicator Post is part of JDG1252 Differential Housing Tool Set .

LEGEND:
B Magnetic Base
D Arm
F Alignment Mark
Install JDG1252-3 Indicator Post (A) with magnetic base (B) tight against differential housing
cover (C).
arm (D) resting on alignment mark (F).
[18] - Adjust backlash. (See Adjust Backlash in this group.)


Bearing Cup Shim Pack—Locking Differential
[1] -
LEGEND:
B Wing Nut
[4] -
→NOTE:

LEGEND:
B Internal Puller
C Legs (2 used)
Install JDG1222 Puller Jaws (A) to an internal puller (B).

[5] -
→NOTE:
Remove bearing cup from left-hand axle housing using a push-puller with 4-1/2 in. legs (C)
and internal puller with JDG1222 Puller Jaws.
[6] -
→NOTE:
LEGEND:
A Shim Pack
[7] - Install Dummy Bearing Cup tight against shims in bottom of bore.

[8] -
LEGEND:
[9] -
→NOTE:
JDG11193P1 and JDG11193P8 are part of JDG11193 Differential Housing
Tool Set .
Bearing cup has close tolerance fit with centering plate and must be
installed correctly to prevent binding.
LEGEND:
A Differential Bearing Cup
C JDG1769-3 Plate
D JDG11193P8 Bridge Tool

F Plate Preload Cap Screw
Install differential bearing cup (A) from right-hand axle housing onto bearing.
[10] - Install JDG11193P1 Differential Centering Plate (B) into differential case.
[11] - Install JDG1769-3 Plate (C) onto differential bearing cup (A).
[12] - Install JDG11193P8 Bridge Tool (D).
[14] -
→NOTE:
Ensure plate preload cap screw is centered on JDG1769-3 Plate.
Tighten plate preload cap screw (F) to specification.

Plate Preload Cap Screw Preload Torque 2.6 N·m
(24 lb.-in.)
[15] - Rotate differential six revolutions in each direction to roll in housing bearings and
retighten plate preload cap screw (F) to specification.
[16] -
→NOTE:
JDG1252-3 Indicator Post (A) is part of JDG1252 Differential Housing Tool
Set .

LEGEND:
B Magnetic Base
D Arm
F Alignment Mark
Install JDG1252-3 Indicator Post (A) with magnetic base (B) tight against differential housing
cover (C).
arm (D) resting on alignment mark (F).
[18] - Adjust backlash (See Adjust Backlash in this Group.)

Adjust Backlash
[1] -
→NOTE:
LEGEND:
A DFRW235—MFWD Input Shaft Holding Tool
B Spacers (2 used)
C Cap Screw
Install DFRW235—MFWD Input Shaft Holding Tool (A) and two 25 mm (1 in.) spacers (B).
[2] - Tighten cap screw (C) to hold yoke stationary, and move ring gear to measure backlash.
0.13—0.53 mm (0.005—0.021 in.).

→NOTE:
BACKLASH READINGS
3 Reading One 1.27 mm ___________
Reading Two + 1.42 mm + ___________
Reading Three + 1.40 mm + ___________
_________________ __________________
= ___________ = ___________
= 1.36 mm = ___________
_________________ __________________
= 1.11 mm = ___________
= 1.30 mm = ___________
_________________ __________________
= 1.17 mm = ___________
_________________ __________________


Shim Pack
[1] -
IMPORTANT:
LEGEND:
A Shim Pack
[2] -
→NOTE:
Ensure permanent bearing cup (B) is installed and NOT dummy cup.
[3] -
→NOTE:
Install permanent bearing cup (B) in axle housing tight against shim pack (A) in bottom of
bore using a 111 mm (4-3/8 in.) driver disk.


Determine Shim Pack—Limited Slip Differential
[1] -
→NOTE:

LEGEND:
C Legs (2 used)
Install JDG1222 Puller Jaws (A) to an D01301AA Internal Puller (B).
[2] -
→NOTE:
[3] -
→NOTE:
Bearing Cup Shim Pack—Limited Slip Differential in this group.)

LEGEND:
C JDG1217-2 Plate
D JDG11193P8 Bridge
[4] -
→NOTE:
JDG11193P8 Bridge Tool and JDG11193P5 Centering Plate are part of

(24 lb.-in.)
[10] -

LEGEND:
A Bridge
a. Measure distance in four places from top of JDG11193P8 Bridge (A) to differential case
surface (B).
c.
LEGEND:
A JDG11193P8 Bridge
B Axle Housing Bearing Cup
Using a depth micrometer, measure distance in four places from top of Bridge (A) to top
of axle housing bearing cup (B).

f.
LEGEND:
A JDG11193P8 Bridge
Put Bridge (A) on axle housing flange (B).
g. Measure distance in four places from top of Bridge (A) to bearing cup bore surface (C).
i.
LEGEND:
A JDG11193P8 Bridge


C Shim Pack
D Axle Housing Bearing Cup
Measure distance in four places from top of Bridge (A) to axle housing flange (B).
→NOTE:
Ensure bearing cup (D) is tight against shims in bottom of bore.
[11] - Install calculated shim pack (C) and axle housing bearing cup (D) using a 111 mm


Determine Shim Pack—Locking Differential
[1] -
→NOTE:

LEGEND:
B Internal Puller
C Legs (2 used)
Install JDG1222 Puller Jaws (A) to an D0130AA internal puller (B).
[2] -
→NOTE:
Ensure that jaws are positioned in puller slots of housing.
Remove differential bearing cup from axle housing using a push-puller with 11-3/4 in. legs
(C).
[3] -
→NOTE:
Bearing Cup Shim Pack—Locking Differential in this group.)

LEGEND:
A JDG11193P1 Differential Bearing Cup
C JDG1769-3 Plate
D JDG11193P8 Bridge
F Preload Cap Screw
Install differential bearing cup (A) from right-hand axle housing onto bearing.
[4] -
→NOTE:
JDG11193P1 and JDG11193P8 are part of JDG11193 Differential Housing
Tool Set .
→NOTE:
Install JDG11193P1 Differential Centering Plate (B) into differential case.

[5] - Install JDG1769-3 Plate (C) onto differential bearing cup.
[6] - Install JDG11193P8 Bridge (D).
[8] -
→NOTE:
Ensure preload cap screw is centered in JDG1769-3 Plate (C)
Tighten preload cap screw (F) to specification.

Preload Cap Screw Preload Torque 2.6 N·m
(24 lb.-in.)
[10] - Re-tighten preload cap screw (F) to specification.

[11] -
LEGEND:
A JDG11193P8 Bridge
a. Measure distance in four places from top of (A) to differential case surface (B).
c.
LEGEND:
A JDG11193P8 Bridge
B Differential Bearing Cup
Using a depth micrometer, measure distance in four places from top of Bridge (A) to top
of differential bearing cup (B).

f.
LEGEND:
A JDG11193P8 Bridge
Put Bridge (A) on axle housing flange (B).
g. Measure distance in four places from top of Bridge (A) to bearing cup bore surface (C).
i.
LEGEND:
A JDG11193P8 Bridge


C Shim Pack
D Axle Housing Bearing Cup
Measure distance in four places from top of bridge (A) to axle housing flange (B).
→NOTE:
Ensure axle housing bearing cup (D) is tight against shims in bottom of
bore.
[12] - Install calculated shim pack (C) and axle housing bearing cup (D) using a 111 mm


(a) Reading One 88.93 mm ___________
Reading Two + 88.87 mm + ___________
Reading Three + 88.95 mm + ___________
Reading Four + 88.85 mm + ___________
_________________ __________________
(c) Reading One 50.22 mm ___________
Reading Two + 50.11 mm + ___________
Reading Three + 50.24 mm + ___________
Reading Four + 50.09 mm + ___________
_________________ __________________
CUP-TO-CASE SURFACE
Step b 88.90 mm ___________
Step d — 50.17 mm — ___________
_________________ __________________
= 38.73 mm = ___________
(g) Reading One 129.20 mm ___________
Reading Two + 129.70 mm + ___________
Reading Three + 129.25 mm + ___________
Reading Four + 129.75 mm + ___________
_________________ __________________
(i) Reading One 88.93 mm ___________
Reading Two + 88.87 mm + ___________
Reading Three + 88.95 mm + ___________
Reading Four + 88.85 mm + ___________
_________________ __________________
Step h 129.48 mm ___________
Step j — 88.90 mm — ___________
_________________ __________________
= 40.58 mm = ___________
Step k 40.58 mm ___________
Step e — 38.73 mm — ___________
_________________ __________________


[1] -
LEGEND:
A O-ring
Install O-ring (A).
[2] -
LEGEND:

[3] -
LEGEND:
A Axle Housing
C Axle Housing Cap Screws (14 used)
[6] - Install axle housing cap screws (C) and tighten to specification.
(258 lb.-ft.)
[7] - Install final drive assemblies. (See Remove And Install Final Drive Assembly in this
group.)
[8] - Remove axle from stand. (See Install Suspended MFWD Axle Onto Repair Stand in this
group.)
[9] - Install axle on tractor. (See Install Suspended Axle in Group 00.)
Bearing Support Exploded View

LEGEND:
1 Cap Screw
2 Washer
3 Yoke
4 Seal
5 Seals (2 used)
6 Socket Head Cap Screws (16 used)
7 End Cover
8 O-ring
9 Snap Rings (2 used)
10 Ball Bearing
11 Bearing Quill
12 Lubrication Fitting
13 Bearing
14 Bearing Support
15 Driveline Housing

16 Driveline
17 O-ring

Remove and Recondition Bearing Support

[1] -
LEGEND:
A Driveline Housing
Remove axle from tractor (See Remove Suspended MFWD Axle in Group 00.)
[2] - Remove driveline housing (A) from axle.
[3] -
LEGEND:
A Yoke Cap Screw
B Washer
C Yoke
Remove yoke cap screw (A), washer (B), and yoke (C).
[4] -

LEGEND:
A Drive Shaft
B Seal
C Snap Ring
Remove drive shaft (A), seal (B), and snap ring (C).

[5] -
LEGEND:
A Ball Bearing
B Puller
Remove ball bearing (A) using puller (B).
[6] -
LEGEND:
A Snap Ring
C Bearing Quill
Remove rear snap ring (A).
[7] - Remove socket head cap screws (B) and bearing quill (C).

[8] -
LEGEND:
A Socket head Cap Screws (8 used)
B Cover
Remove socket head cap screws (A) and cover (B).
[9] -
→NOTE:

LEGEND:
A Seal
B Driver Disk
Remove seal (A).
[10] - Install new seal using a 117 mm (4-5/8 in.) driver disk (B).
[11] -
LEGEND:
A O-ring
Remove O-ring (A) from cover.
[12] - Coat new O-ring (A) with oil and install onto cover.
[13] -
LEGEND:
A Bearing support
B Spherical Bearing
C Driveline Housing
Remove bearing support (A) together with spherical bearing (B) from driveline housing (C).

[14] -
LEGEND:
A Spherical Bearing
B Bearing Support
Remove spherical bearing (A) from bearing support (B).

[15] -
LEGEND:
A Seal
B Driver Disk
Remove seal (A) from support.
[16] - Install new seal using a 117 mm (4-5/8 in.) driver disk (B).

[17] -
LEGEND:
A Spherical Bearing
Apply TY6341 Multi-Purpose SD Polyurea Grease to spherical bearing (A) and install.
Number Name Use
• TY6341 (us) Used to lubricate bearings and
Multi-Purpose SD Polyurea Grease
• CXTY6341 (canadian) bushings
[18] -
LEGEND:
A Cover
B Bearing Support
C Socket Head Cap Screws (8 used)
Install cover (A) on bearing support (B).
[19] - Install socket head cap screws (C) and tighten to specification in a crisscross pattern.
Cover-to-Bearing Support Socket-Head Screw Torque 37 N·m
(27 lb.-ft.)

[20] -
LEGEND:
A Bearing Support Assembly
B Driveline Housing
Slide bearing support assembly (A) onto driveline housing (B).
[21] -
LEGEND:
A Bearing Quill
Install bearing quill (A) into spherical bearing.
[22] - Install socket head cap screws (B) and tighten to specification in a crisscross pattern.
Bearing Quill-to-Driveline Housing Socket Head Screw Torque 37 N·m
(27 lb.-ft.)

[23] -
LEGEND:
A Snap Ring
Install snap ring (A) in rear groove.
[24] -
LEGEND:
A Ball Bearing
B Bearing Quill
C Driver Disk
Install ball bearing (A) into bearing quill (B) using a 76 mm (3 in.) driver disk (C).
[25] - Install front snap ring.

[26] -
LEGEND:
A Seal
Install seal (A) with letters facing inside quill using an 86 mm (3-3/8 in.) driver disk.
[27] - Install driveline.
[28] -
LEGEND:
A Yoke
B Washer
C Yoke Cap Screw
Install yoke (A), washer (B), and yoke cap screw (C).
[29] - Tighten yoke cap screw to specification.
Yoke Cap Screw Torque 310 N·m
(229 lb.-ft.)

Section 59 - SUSPENDED MFWD AXLE Group 15: Differential
[30] -
LEGEND:
A Driveline Housing
B Driveline Housing-to-Axle Cap Screws (13 used)
Install driveline housing (A) onto axle.
[31] - Install and tighten driveline housing-to-axle cap screws (B) to specification.
Driveline Housing-to-Axle Cap Screw Torque 340 N·m
(251 lb.-ft.)
[32] - Install axle onto tractor (See Install Suspended Axle in Group 00.)

List of References
Specifications
Cross-Sectional View—Differential Housing—Heavy Duty With Hydraulic Differential Lock
Repair Differential Housing—With Hydraulic Differential Lock
Assemble Differential—With Hydraulic Differential Lock
Cross-Sectional View—Differential Drive Shaft And Input Quill—Suspended MFWD Axle
Remove and Disassemble Differential Drive Shaft
→NOTE:
D01045AA Disk Set

Specifications
(184 lb.-ft.)
(0.003—0.020 in.)
Socket Head Cap Screws Torque 50 N·m
(37 lb.-ft.)
Bearing Quill-to-Housing Torque 250 N·m
(184 lb.-ft.)
(7.859 in.)
Differential Drive Shaft Cap Screw Torque 310 N·m
(229 lb.-ft.)
(0.001—0.003 in.)


LEGEND:
6 Pin
7 Spacers (2 used)
11 Shim Pack
12 Housing Cover
13 Ring Gear


LEGEND:
6 Pin
11 Shim Pack
12 Housing Cover
13 Ring Gear


Differential
[1] -
LEGEND:
A Differential Cap Screws (12 used)
B Cover
C Ring Gear
Remove cap screws (A), cover (B), and ring gear (C).
[2] -
LEGEND:
A Disk Pack
Remove disk pack (A) and bevel gear.

[3] -
LEGEND:
A Pins (2 used)
B Shafts (3 used)
[4] -
LEGEND:
B Bevel Side Gear
[5] - Remove bevel side gear (B) and disk pack.

[6] -
LEGEND:
A Separator Plate
B Shim Pack
[7] -
→NOTE:
LEGEND:
B Driver Disk

[8] -
LEGEND:
B Driver Disk


[1] -
IMPORTANT:
LEGEND:
A Separator Plate
[2] -
LEGEND:
A Bevel Gear
B Spacer
D Disks (5 used)
gear (A).

[4] -
→NOTE:
LEGEND:
A Bevel Gear
B Spacer
C Disks (4 used)
[6] -
LEGEND:
A Disk Pack

[7] -
→NOTE:
Tabs (B) on conical thrust washer must line up with groove (C) in housing.
LEGEND:
B Tabs
C Groove
[8] -
→NOTE:
shafts (C).

LEGEND:
B Long Pinion Shaft
D Pin Bore

[9] -
LEGEND:
[10] -
LEGEND:
A Separator Plate

[11] -
LEGEND:
A Bevel Gear
B Spacer
D Disks (5 used)
gear (A).
[13] -
→NOTE:
LEGEND:
A Bevel Gear
B Spacer
C Disks (4 used)

[15] -
LEGEND:
A Disk Pack
End Play Tool (B).
[16] - Remove DFRW132—Differential Side Bevel Gear End Play Tool (B).
[17] -
LEGEND:
Install DFRW132— Differential Side Bevel Gear End Play Tool (A) through bevel gear pack and
cover from opposite end.

[18] -
LEGEND:
A Ring Gear
B Bevel Side Gear

[20] -
LEGEND:
(184 lb.-ft.)
[21] - Check disk pack end play in four end play checking locations (B) with dial indicator and
end play tool.
(0.003—0.020 in.)


[25] -

(0.003—0.020 in.)

[29] -
CAUTION:
LEGEND:

Cross-Sectional View—Differential Housing—Heavy

Duty With Hydraulic Differential Lock
LEGEND:
2 Spacer
3 Socket Head Cap Screws (2 used)
4 Pins (2 used)
7 Spacer
8 Snap Ring
11 Spacer
12 Roller Bearing
14 Bearing Quill
15 Ring Gear

Repair Differential Housing—With Hydraulic

Differential Lock
[1] -
LEGEND:
A Roller Bearing
Remove roller bearing (A) from assembly.

[2] -
LEGEND:
B JDG986 Driver Disk (133 mm or 5-1/4 in.)
C Bearing Puller
D Bearing Quill-to-Housing Cap Screws (12 used)
Remove tapered roller bearing (A) using JDG986 Driver Disk (133 mm or 5-1/4 in.) (B) and
bearing puller (C).
[3] - Remove cap screws (D).

[4] -
LEGEND:
A Cover
Remove cover (A).
[5] -
LEGEND:
A Spacer
Remove spacer (A).

[6] -
LEGEND:
A Splined Disks (10 used)
Remove splined disks (A).
[7] -
LEGEND:
A Tanged Disks (10 used)
Remove tanged disks (A).

[8] -
LEGEND:
A Snap Ring
Remove snap ring (A) using snap ring pliers.
[9] -
LEGEND:
A Spacer
Remove spacer (A).

[10] -
LEGEND:
A Pins (2 used)
Remove pins (A).
[11] -
LEGEND:
A Bevel Gear
Remove bevel gear (A).

[12] -
LEGEND:
A Socket Head Cap Screws (2 used)
[13] -
LEGEND:
Remove retaining pins (A).

[14] -
LEGEND:
Remove retaining pins (A).
[15] -
LEGEND:
A Bevel Pinions and Thrust Washers (4 used)
Remove bevel pinions and thrust washers (A).

[16] -
LEGEND:
A Pin
Remove pin (A), bevel pinions, and thrust washers.
[17] -
LEGEND:
A Bevel Gear
Remove bevel gear (A).

[18] -
LEGEND:
A Spacer
B Lubrication Groove
Remove spacer (A) and inspect lubrication groove (B).
[19] -
→NOTE:
LEGEND:
B Driver Disk
C Bearing Puller
Remove tapered roller bearing (A) using 58 mm (2-5/16 in.) driver disk (B) and bearing puller
(C).

Assemble Differential—With Hydraulic Differential

Lock
[1] -
IMPORTANT:
Coat individual parts with oil only AFTER disk pack has been correctly
adjusted.
LEGEND:
A Spacer
B Lubrication Grooves
Install spacer (A) with lubrication grooves (B) into differential housing as shown.

[2] -
LEGEND:
A Bevel Gear
Install bevel gear (A).
[3] -
LEGEND:
A Pin
Install pin (A) in differential housing so that hole in center is perpendicular to housing.

[4] -
LEGEND:
B Bevel Pinions (2 used)
Install conical thrust washers (A) and bevel pinions (B) on both sides of housing.
[5] - Slide shaft through washers and pinions.
[6] -
→NOTE:
Tabs (B) on thrust washer must line up with groove (C) in housing.
LEGEND:
B Tab
C Groove

[7] -
LEGEND:
Install bevel pinion (A) into both sides of differential housing.
[8] -
→NOTE:
Install pinion shaft so that shaft bore is vertical to housing.
LEGEND:
A Pinion Shafts (2 used)
Install pinion shafts (A) through thrust washers and bevel pinions and into long shaft bore.

[9] -
LEGEND:
[10] -
LEGEND:
Install socket head cap screws (A). Tighten to specification.
Socket Head Cap Screws Torque 50 N·m
(37 lb.-ft.)

[11] -
LEGEND:
A Bevel Gear
Install bevel gear (A).
[12] -
LEGEND:
A Pins (2 used)
Install pins (A).
[13] -
→NOTE:
Ensure holes in spacer (A) are aligned with pins in housing.

LEGEND:
A Spacer
Install spacer (A).
[14] -
LEGEND:
A Snap Ring
Install snap ring (A) using snap ring pliers.

[15] -
LEGEND:
A Tanged Disks (11 used)
Install one tanged disk (A) metal side down into housing.
[16] -
LEGEND:
A Splined Disks (11 used)
Install one splined disk (A) metal side down into housing.
[17] - Repeat Steps 16 and 17 until 11 tanged disks and 11 splined disks are installed.

[18] -
LEGEND:
A Backing Plate
Install backing plate (A) in housing.
[19] -
LEGEND:
A Cover
Install cover (A) and bearing quill-to-housing cap screws. Tighten to specification.
Bearing Quill-to-Housing Cap Screws Torque 250 N·m
(184 lb.-ft.)

[20] -
CAUTION:
LEGEND:
[21] -
Install roller bearings.

Input Quill—Suspended MFWD Axle

LEGEND:
1 Bearing Cone
2 Bearing Cup
3 Shim Pack
4 Differential Case
5 Snap Ring
6 Spacer
7 O-ring
8 Special Washer
9 Cap Screw
10 O-ring
11 Drive Shaft
12 Coupler
13 Shim Pack
14 Oil Seal
15 Bearing Cone
16 Bearing Cup
17 Differential Drive Shaft

Remove and Disassemble Differential Drive Shaft

[1] -
LEGEND:
A Pipe Wrench
B Coupler
C Pinion Shaft Retaining Cap Screw
Install a large pipe wrench (A) to coupler (B) and loosen pinion shaft retaining cap screw (C).
[2] -
LEGEND:
A Pinion Shaft Retaining Cap Screw
B Special Washer
C Shim Pack
Remove cap screw (A), special washer (B), and shim pack (C).

[3] -
LEGEND:
A O-ring
B Coupler
Remove O-ring (A) and coupler (B) from shaft.
[4] - Remove shaft from input quill.
[5] -
LEGEND:
A Seal
B Bearing Cone

[6] -
LEGEND:
A Inner Bearing Cup
B Shim Pack
Remove inner bearing cup (A) and shim pack (B).

[7] -
LEGEND:
A Snap Ring
B Spacer
C Outer Bearing Cup
Remove snap ring (A) and spacer (B).
[8] - Remove outer bearing cup (C).
[9] -
→NOTE:

LEGEND:
A Bearing Cone
B Driver Disk


Pack
[1] -
LEGEND:
A Metric Dimension
Record metric dimension (A), stamped on differential case.
[2] -
→NOTE:
Constant dimension includes nominal bearing width and bearing growth
allowance.
Subtract constant dimension from dimension stamped on differential case to obtain correct
shim pack thickness.
(7.859 in.)
EXAMPLE
XXX.XX mm (X.XXX in.) Dimension on Differential Case
- 199.612 mm (7.859 in.) Constant Dimension
__________________
= XXX.XX mm (X.XXX in.) Correct Shim Pack Thickness

[3] -
CAUTION:
LEGEND:
Heat large drive shaft bearing (A) and install on shaft until bearing bottoms against gear.


[1] -
LEGEND:
A Shim Pack
B Inner Bearing Cup
Install previously calculated shim pack (A) into input quill.
[2] -
→NOTE:
Install inner bearing cup (B) tight against bottom of bore using a 120 mm (4-3/4 in.) driver
disk.

[3] -
LEGEND:
A Snap Ring
B Spacer
C Outer Bearing Cup
Install snap ring (A) into input quill.
[4] - Install spacer (B) and outer bearing cup (C) tight against snap ring using an 81 mm

[5] -
LEGEND:
A Seal
B Bearing Cone
Install bearing cone (B).
[6] - Install seal (A) using a 95 mm (3-3/4 in.) driver disk.
[7] -
LEGEND:
A Drive Shaft
Install drive shaft (A) into input quill.

[8] -
LEGEND:
A O-ring
B Coupler
Install coupler (B) and O-ring (A), making sure that O-ring is in coupler groove.
[9] -
LEGEND:
A Shim Pack
B Special Washer
C Differential Drive Shaft Cap Screw
Install shim pack (A), special washer (B), and differential drive shaft cap screw (C).
[10] - Install a large pipe wrench onto coupler and tighten cap screw to specification.
Differential Drive Shaft Cap Screw Torque 310 N·m
(229 lb.-ft.)
[11] - Rotate pinion shaft six turns in each direction to roll in bearings.

Section 59 - SUSPENDED MFWD AXLE Group 20: Suspension Components
[12] -
LEGEND:
A Dial Indicator
[13] -
IMPORTANT:
Force pinion shaft fully inward and then fully outward when measuring
differential drive shaft end play.
Measure differential drive shaft end play by forcing pinion shaft inward and outward.
[14] - Remove or install shims, repeating measuring procedure until differential drive shaft
end play is within specification.
(0.001—0.003 in.)

Group 20 - Suspension Components

List of References
Specifications
TLS™ Hydraulic Control Valve Block
Relieve Pressure From Suspended MFWD Axle Hydraulic System
Replace Suspended MFWD Axle Position Sensor
Cross-Sectional View—Suspended MFWD Axle Cylinder Piston Seals
Repair Suspended MFWD Axle Cylinder Seals
Check and Charge Accumulators
→NOTE:
JDG1227 Suspended Axle Cylinder Tool Set
JDG1272 Bushing-Seal Installer
JT03515 Accumulator Charging Set
JT05563 Nitrogen Charging Hose

Specifications
Lower Solenoid Valve Torque 27 N·m
(239 lb.-ft.)
Raise Solenoid Nut to Valve Torque 6 N·m
(53 lb.-in.)
Raise Solenoid Valve Torque 27 N·m
(239 lb.-ft.)
Lower Solenoid Nut to Valve Torque 6 N·m
(53 lb.-in.)
Spring Rate Increase Solenoid Valve Torque 27 N·m
(239 lb.-ft.)
Spring Rate Increase Solenoid Nut to Valve Torque 6 N·m
(53 lb.-in.)
Spring Rate Decrease Solenoid Valve Torque 27 N·m
(239 lb.-ft.)
Spring Rate Decrease Solenoid Nut to Valve Torque 6 N·m
(53 lb.-in.)
Pressure Relief Valve Torque 35 N·m
(26 lb.-ft.)
Spring Rate Pressure Sensor Torque 16 N·m
(142 lb.-in.)
Diagnostic Receptacle Torque 27 N·m
(239 lb.-ft.)
Lift Cylinder Supply Fitting (Head Side) Torque 100 N·m
(74 lb.-ft.)
Lift Cylinder Supply Fitting (Rod Side) Torque 100 N·m
(74 lb.-ft.)
Socket Head Cap Screw Torque 20—25 N·m
(177—221 lb.-in.)
Accumulator Mounting Bracket Cap Screws Torque 73 N·m
(54lb.-ft.)

TLS™ Hydraulic Control Valve Block
LEGEND:
A Supply Port Fitting (if equipped)
B Return Port Fitting (if equipped)
C Spring Rate Decrease Solenoid Valve
D Valve Housing
E Lift Cylinder Supply Fitting (Rod Side)
F Spring Rate Pressure Sensor
G Pressure Relief Valve
H Diagnostic Receptacle
I Lower Solenoid Valve
J Lift Cylinder Supply Fitting (Head Side)
K Mid Stack SCV Load Sense Fitting (if equipped)
L Load Sense Fitting
M Raise Solenoid Valve
N Spring Rate Increase Solenoid Valve
[1] -
→NOTE:
Raise solenoid valve (M) and lower solenoid valve (I).
Remove raise solenoid valves (M and I).

[2] - Replace O-rings and backup rings.

[3] - Install raise solenoid valve (M) and lower solenoid valve (I). Tighten to specifications.
Lower Solenoid Valve Torque 27 N·m
(239 lb.-ft.)
Raise Solenoid Nut to Valve Torque 6 N·m
(53 lb.-in.)
Raise Solenoid Valve Torque 27 N·m
(239 lb.-ft.)
Lower Solenoid Nut to Valve Torque 6 N·m
(53 lb.-in.)
[4] -
→NOTE:
Spring rate increase solenoid valve (N) and spring rate decrease solenoid
valve (C) are not serviceable.
Remove spring rate increases solenoid valve (N and C).

[5] - Replace O-rings and backup rings.
[6] - Install spring rate increase solenoid valve (N) and spring rate decrease solenoid valve
(C). Tighten to specification.
Spring Rate Increase Solenoid Valve Torque 27 N·m
(239 lb.-ft.)
Spring Rate Increase Solenoid Nut to Valve Torque 6 N·m
(53 lb.-in.)
Spring Rate Decrease Solenoid Valve Torque 27 N·m
(239 lb.-ft.)
Spring Rate Decrease Solenoid Nut to Valve Torque 6 N·m
(53 lb.-in.)
[7] - Pressure Relief Valve (G): Replace O-rings.

[8] - Install pressure relief valve (G) and tighten to specifications.
Pressure Relief Valve Torque 35 N·m
(26 lb.-ft.)
[9] - Spring Rate Pressure Sensor (F): Replace O-rings.

[10] - Install spring rate pressure sensor (F) and tighten to specifications.
Spring Rate Pressure Sensor Torque 16 N·m
(142 lb.-in.)
[11] - Diagnostic Receptacle (H): Replace O-rings.

[12] - Install diagnostic receptacle (H) and tighten to specifications.

Diagnostic Receptacle Torque 27 N·m
(239 lb.-ft.)
[13] - Lift Cylinder Supply Fittings (E and J): Replace O-rings.

[14] - Install head sides to cylinder and accumulator parts. Tighten to specifications.
Lift Cylinder Supply Fitting (Head Side) Torque 100 N·m
(74 lb.-ft.)
Lift Cylinder Supply Fitting (Rod Side) Torque 100 N·m
(74 lb.-ft.)
Relieve Pressure From Suspended MFWD Axle

Hydraulic System
[1] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve
system pressure before disconnecting or connecting hydraulic or other
lines. Tighten all connections before applying pressure.
→NOTE:
Bleed valves (A) are located on hydraulic control valve on right-hand side
of tractor under fuel tank.
LEGEND:
A Bleed Valves
Press in and rotate bleed valves (A) counterclockwise and release to relieve system pressure.
Allow tractor front frame to settle down on front axle stops.
[2] - Tighten bleed valves.
Replace Suspended MFWD Axle Position Sensor

[1] -
LEGEND:
A Harness Connector
B Nuts (2 used)
[3] - Remove position sensor assembly.
[5] - Calibrate suspended MFWD axle system. (See Operation and Test TM—Section 245,
Group SFA.)
Cross-Sectional View—Suspended MFWD Axle

Cylinder Piston Seals

LEGEND:
A Piston Seal Assembly
B O-rings (2 used)
C Piston Wear Rings (2 used)
D Piston
E Piston Rod

Repair Suspended MFWD Axle Cylinder Seals
→NOTE:
Piston is part of piston rod and cannot be separated from rod.
Refer to Cross-Sectional View—Suspended MFWD Axle Cylinder Piston Seals

during seal installation..
[1] -
LEGEND:
A O-rings (2 used)
B JDG1227-1 Seal Installer
C Sealing Ring Assembly
D JDG1227-2 Pusher
Inspect and replace seals as necessary.
[2] - Inspect piston seal grooves.
[3] - Inspect piston and piston rod outside diameter.
[4] - Remove nicks or grooves or replace piston rod as necessary.

[5] - Install O-rings (A) by stretching and pulling O-rings over the end of piston.
[6] -
→NOTE:
Warm sealing ring assembly and wear rings in hot water 90 °C (194 °F) for
5 minutes before installing.
JDG1227-1 and JDG1227-2 are part of JDG1227 Suspended Axle Cylinder
Tool Set .
Install JDG1227-1 Seal Installer (B) and push piston sealing ring assembly (C) into groove
using JDG1227-2 Pusher (D).
[7] - Remove installer and pusher.
[8] -
→NOTE:
JDG1227-4 is part of JDG1227 Suspended Axle Cylinder Tool Set .
LEGEND:
A Wear Rings (2 used)
B Sealing Ring Assembly
C JDG1227-4 Collet Guides (2 used)
D JDG1227-4 Collet Guide Clamp
Install wear rings(A) into grooves and apply a light coat of oil to wear rings and sealing ring
assembly (B).
[9] - Install JDG1227-4 Collet Guides (C) and Clamp (D) to resize sealing ring assembly and
hold wear rings in position.

Check and Charge Accumulators

[1] -
CAUTION:
system pressure before disconnecting or connecting hydraulic or other
lines. Tighten all connections before applying pressure.
IMPORTANT:
Hydraulic pressure must be relieved to obtain a correct pressure reading.
LEGEND:
A Connector
B Accumulator Mounting Bracket Cap Screws (4 Used)
Relieve hydraulic pressure from suspension system. (See Relieve Pressure From Suspended
MFWD Axle Hydraulic System in this group.)
[2] - For tractors without front hitch perform the following: Disconnect connector (A)
from dampening manifold solenoid.

[3] -
IMPORTANT:
Support accumulator bracket after lowering to avoid putting stress on
hoses.
Remove accumulator mounting bracket cap screws (B) and lower bracket.
[4] - For All tractors perform the following:
Without Front Hitch
With Front Hitch

LEGEND:
A Dust Cap
Remove dust cap (A).
[5] -
IMPORTANT:
Relieve initial breaking torque on socket head cap screw (A), without
loosening.

Without Front Hitch
With Front Hitch

LEGEND:
A Socket Head Cap Screw
Relieve initial breaking torque on socket head cap screw (A) using a 6 mm hex key wrench.
[6] -
→NOTE:
JT03515-2 Accumulator Adapter is part of JT03515 Accumulator Charging
Set .

LEGEND:
A O-ring
B JT03515-2 Accumulator Adapter
C Hex Stem
Remove O-ring (A) from JT03515-2 Accumulator Adapter (B), coat with grease, and install.
Push hex stem (C) into adapter.

[7] -
Without Front Hitch
With Front Hitch

LEGEND:
A JT03515-2 Accumulator Adapter
B Hex Stem
C Bleed-Off Screw
Install Accumulator Adapter (A) onto accumulator and hand tighten. Push hex stem (B) into
adapter and socket head cap screw while rotating stem slightly so stem fits into socket head
screw.
[8] -
→NOTE:
Ensure bleed-off screw (C) is tight and is not leaking.
Close bleed-off screw (C) and tighten Accumulator Adapter (A) to accumulator enough to
prevent gas leakage.

[9] -
→NOTE:
Without Front Hitch
With Front Hitch

LEGEND:
A Valve Stem Depressor
B JT03515-1 Accumulator Pressure Checking and Charging Adapter
C JT03515-2 Accumulator Adapter
D Bleed-Off Screw
Valve stem depressor (A) must be backed out. Minimum pressure range of
gauge must be twice pressure specification.
→NOTE:
JT03515-1 Accumulator Pressure Checking and Charging Adapter and
JT03515-2 Accumulator Adapter are part of JT03515 Accumulator Charging
Set .
Back out (counterclockwise) valve stem depressor (A) and install JT03515-1 Accumulator
Pressure Checking and Charging Adapter (B) to valve stem of JT03515-2 Accumulator Adapter
(C).
[10] - Install 20000 kPa (3000 psi) gauge.
[11] - Close bleed-off screw (D).
[12] - Turn in (clockwise) hex stem (A).
Without Front Hitch
With Front Hitch

LEGEND:
A Hex Stem
B Bleed-off Screw
[13] - Determine outer temperature of accumulator using a non-contact temperature

measuring gun.
[14] -
→NOTE:
Loosen hex stem only enough to get a pressure reading on gauge.

Loosen hex stem (A) approximately one turn to check accumulator pressure.
Accumulator Temperature/Pressure Table
Temperature ± 5 °C (9 °F) Pressure ± 70 kPa (0.7 bar) (10 psi)
0 C (32 °F) 3540 kPa (35.4 bar) (513 psi)
10 C (50 °F) 3670 kPa (36.7 bar) (532 psi)
20 C (68 °F) 3800 kPa (38.0 bar) (551 psi)
30 C (86 °F) 3930 kPa (39.3 bar) (570 psi)
40 C (104 °F) 4060 kPa (40.6 bar) (589 psi)
50 C (122 °F) 4190 kPa (41.9 bar) (608 psi)
IMPORTANT:
Varying accumulator charge levels from table decreases system
performance.
Pressure OK: Go to Step 19.

Pressure High: Open bleed-off screw (B) to obtain correct pressure. Go to step 19.
Pressure Low: Go to Step 15.
→NOTE:
If accumulator pressure is under 50% of a full charge, accumulator must be
replaced.
[15] -

CAUTION:
With Front Hitch

LEGEND:
C Valve Stem Depressor
Never charge an accumulator with OXYGEN. An explosion could result if oil
and oxygen mix under pressure. Use only NITROGEN.
→NOTE:
Purge hose before attaching. Charging hose can be attached directly to
JT03515-2 Accumulator Adapter (A), JT03515-1 Accumulator
Pressure Checking and Charging Adapter (B) is not available. Use a
nitrogen tank regulator gauge with 200 kPa (2 bar) (25 psi) or less
increments and a maximum range of 20000 kPa (200 bar) (3000 psi).
Back out (counterclockwise) valve stem depressor (C) completely on JT05563 Nitrogen

Charging Hose . Purge hose and attach to JT03515-1 Accumulator Pressure Checking and
Charging Adapter (B).
[16] -
LEGEND:
A Regulator Screw
B Shutoff Valve
Adjust nitrogen tank regulator screw (A) to obtain gauge reading of zero pressure. Open tank
shutoff valve (B) one turn. Turn in (clockwise) valve stem depressor on nitrogen charging
hose.
[17] - While reading gauge on pressure checking adapter, adjust nitrogen tank regulator
screw (A) to obtain pressure specification found in Step 14.
[18] - Allow gas pressure to stabilize 5 minutes.
[19] -
IMPORTANT:
To prevent breakage of hex stem, DO NOT use the hex stem to tighten the
accumulator Socket head screw to specified torque.
Without Front Hitch

With Front Hitch

LEGEND:
A Hose Valve Stem Depressor
B Valve Stem Depressor
C Hex Stem
Tighten hex stem (C).
[20] - Back out (counterclockwise) charging hose valve stem depressor (A) and valve stem
depressor (B).
[21] -
LEGEND:
A Tank Regulator Screw
B Shutoff Valve
Loosen nitrogen tank regulator screw (A) until screw turns freely. Close tank shutoff valve (B).

[22] -
Without Front Hitch
With Front Hitch

LEGEND:
A JT03515-2 Accumulator Adapter Bleed-off Screw
JT03515-1 Accumulator Pressure Checking and Charging Adapter Bleed-off
B
Screw
Open bleed-off screws (A and B) to relieve pressure from adapters.
[23] - Close bleed-off screws (A and B).

[24] -
Without Front Hitch
With Front Hitch

LEGEND:
A Nitrogen Charging Hose
B JT03515-1 Pressure checker Adapter
Remove nitrogen charging hose (A) from JT03515-1 Accumulator Pressure Checking and
Charging Adapter (B).
[25] - Remove JT03515-1 Accumulator Pressure Checking and Charging Adapter (B) from
JT03515-2 Accumulator Adapter (C).

[26] -
→NOTE:
Without Front Hitch
With Front Hitch

LEGEND:
A Bleed-Off Screw
There should not be any leakage of gas from accumulator after pressure
was relieved from adapter at Step 17.
Loosen bleed-off screw (A) and listen for sound of gas leakage.
[27] - Remove JT03515-2 Accumulator Adapter (B).

[28] -
Without Front Hitch
With Front Hitch

LEGEND:
Tighten accumulator socket head cap screw (A) to specification.
Accumulator Socket Head Cap Screw Torque 23 N·m
(204 lb.-in.)
[29] - Apply soap suds around accumulator socket head cap screw (A) and look for bubbles.
No Leakage: Go to Step 38.
Leakage: Do following steps:

[30] -
Without Front Hitch
With Front Hitch

LEGEND:

[31] -
Without Front Hitch
With Front Hitch

LEGEND:
B Hex Stem
C Bleed-Off Screw
Reinstall JT03515-2 Accumulator Adapter (A).
[32] - Loosen hex stem (B) and open bleed-off screw (C) to discharge accumulator.
[33] - Remove JT03515-2 Accumulator Adapter (A).

[34] -
Without Front Hitch
With Front Hitch

LEGEND:
B O-ring
Remove socket head cap screw (A) and inspect for nicks or burrs.
[35] - Remove and inspect O-ring (B).
[37] - Repeat accumulator charging procedure, Steps 6—29.

[38] -
Without Front Hitch
With Front Hitch

LEGEND:
A Hex Stem
Hold hex stem (A) in tightened position and remove JT03515-2 Accumulator Adapter (B) from
accumulator.

[39] -
Without Front Hitch
With Front Hitch

LEGEND:
A Dust Cap
Install dust cap (A).

STEERING AND BRAKES (g) by Belgreen
[40] -
LEGEND:
A Accumulator Mounting Bracket
B Connector
For tractors without front hitch perform the following: Install accumulator mounting
bracket (A).
[41] - Install and tighten accumulator mounting bracket cap screws to specification.
Accumulator Mounting Bracket Cap Screws Torque 73 N·m
(54 lb.-ft.)
[42] - Connect connector (B) to dampening manifold solenoid.

Section 60 - STEERING AND BRAKES

Table of contents
Group 05 - Steering Column .................................................................................................... 1
Specifications ......................................................................................................................... 1
Repair Steering Column ......................................................................................................... 2
Repair Steering Column with ActiveCommand Steering (ACS™) ......................................... 10
Group 10 - Steering Control Assembly ................................................................................. 18
Specifications ....................................................................................................................... 19
General Repair Procedures—Steering .................................................................................. 21
Remove and Install Steering Valve ...................................................................................... 22
Repair Steering Valve .......................................................................................................... 30
Remove and Install AutoTrac™ Valve .................................................................................. 40
Repair AutoTrac™ Valve ...................................................................................................... 42
Remove and Install ActiveCommand Steering (ACS™) Valve ............................................... 45
Repair ActiveCommand Steering (ACS™) Valve ................................................................... 47
Remove and Install ActiveCommand Steering (ACS™) Return Circuit Relief Valve .............. 53
Repair ActiveCommand Steering (ACS™) Return Circuit Relief Valve .................................. 54
Remove and Install Priority Valve Housing ........................................................................... 57
Remove and Install Backup Manifold ................................................................................... 60
Repair Backup Manifold ....................................................................................................... 62
Remove and Install Backup Pump ........................................................................................ 66
Bleed Steering System ......................................................................................................... 66
Group 15 - Steering Cylinders ............................................................................................... 68
Specifications ....................................................................................................................... 68
Remove and Install Steering Cylinder—MFWD ..................................................................... 69
Remove and Install Steering Cylinder—Two-Wheel Drive .................................................... 71
Repair Steering Cylinder ...................................................................................................... 72
Group 20 - Service Brakes ...................................................................................................... 74
Specifications ....................................................................................................................... 76
General Repair Procedures—Brake Valve ............................................................................ 79
Remove and Install Brake Rods ............................................................................................ 80
Remove and Install Brake Valve ........................................................................................... 84
Repair Brake Valve—Manual Backup ................................................................................... 87
Repair Brake Valve—Powered Backup ............................................................................... 103
Remove and Install Front Brake Valve ............................................................................... 114
Repair Front Brake Valve ................................................................................................... 115
Remove and Install Secondary Brake Valve ....................................................................... 117
Repair Secondary Brake Valve ........................................................................................... 119
Remove and Install Brake Control Manifold ....................................................................... 121
Remove and Install Lube Manifold ..................................................................................... 123
Remove and Install Park Brake Release Manifold .............................................................. 125
Repair Park Brake Release Manifold ................................................................................... 127
Manually Release Park Brake—IVT™ .................................................................................. 130

Manually Release Park Brake—CommandQuad™ .............................................................. 133

Bleed MFWD Brakes ........................................................................................................... 136
Bleed Brakes ...................................................................................................................... 138
Check Brakes ..................................................................................................................... 142
Group 30 - Hydraulic Trailer Brake ..................................................................................... 143
Specifications ..................................................................................................................... 143
Hydraulic Trailer Brake Component Location ..................................................................... 143
Remove and Install Hydraulic Trailer Brake Valve ............................................................. 144
Group 35 - Air Trailer Brake ................................................................................................. 145
Specifications ..................................................................................................................... 146
Air Trailer Brake System .................................................................................................... 146
Bleed Air from Air Trailer Brake Reservoirs ........................................................................ 147
Remove and Install Air Compressor ................................................................................... 149
Repair Air Compressor ....................................................................................................... 151
Remove and Install Air Trailer Brake Pre-Brake Valve ........................................................ 153
Repair Air Trailer Brake Pre-Brake Valve ............................................................................ 154
Remove and Install Air Trailer Brake Park Valve ................................................................ 156
Remove and Install Air Trailer Brake Valve ........................................................................ 157
Remove and Install Air Pressure Control Valve .................................................................. 159

Section 60 - STEERING AND BRAKES Group 05: Steering Column
Group 05 - Steering Column

List of References
Specifications
Repair Steering Column
Repair Steering Column with ActiveCommand Steering (ACS™)
Specifications
(25 lb.-ft.)

Repair Steering Column

[1] -
LEGEND:
A Emblem
B O-ring
C Nut
D Special Washers
E Knob
F Large Nut
G Retainer
H Snap Ring

[3] -
LEGEND:
A Tray
B Screws (2 used)
C Upper Cowl
E Clips (2 used)
F Module
[5] - Remove cowl (C) over module (F).

[6] -
LEGEND:
B Support Bracket
D Lower Cowl
E Ignition Switch Connector
F Ether Aid Switch Connector
G Module Harness Connector
H Lever Cover
[7] - Disconnect harness connectors from ignition switch (E) and ether aid switch (F).
[8] - Remove cap screws (C) and remove lower cowl (D).
[9] - Disconnect module harness connector (G).
[10] - Remove lever cover (H).

[11] -
LEGEND:
B Steering Module
C Guide
D Top Cover
E Harness
[12] - Remove steering module (B), guide (C), and top cover (D) noting how harness (E) is
routed.
[13] -
LEGEND:
A Cap Screw
B Lever Arm
C Spring
D Link
E Ratchet
F Set Screw
Remove cap screw (A) and lever arm assembly (B) noting how spring (C) is fastened to inside
of housing.
[14] - Remove link (D) and ratchet (E).
[15] - Remove set screw (F).

[16] -
LEGEND:
A Ratchet
Move column to a horizontal position.
[17] - Remove ratchet (A).
[18] -
LEGEND:
A Torsion Spring
C Pivot Pin
Move steering column to vertical position.
[19] - Remove torsion spring (A) from housing.
[20] - Remove cap screw and washer (B).
[21] - Slide housing off pivot pins (C).
[22] - Remove housing and shaft assembly.

[23] -
LEGEND:
A Bushings
B Ratchet
Inspect and replace bushings (A) and ratchet (B) as required.
[24] -
LEGEND:
A U-joint Cap Screw
[25] - Remove lower shaft and U-joint assembly.

[26] -
LEGEND:
A Retaining Ring
B Washer
C Inner Shaft
D Outer Shaft
E Snap Ring
F Shaft
Remove retaining ring (A) and washer (B).
[27] - Remove inner and outer steering shafts (C) and (D).
[28] - Remove snap ring (E) and shaft (F).
[29] -
IMPORTANT:
Upper steering column housing, bearing, and steering wheel position
sensor must be replaced as an assembly.
Assemble and install steering column.

[30] -
IMPORTANT:

Install covers.
(25 lb.-ft.)

Repair Steering Column with ActiveCommand

Steering (ACS™)
[1] -
LEGEND:
A Emblem
B O-ring
C Nut
D Special Washers
E Knob
F Large Nut
G Retainer
H Snap Ring

[3] -
LEGEND:
A Tray
B Screws (2 used)
C Upper Cowl
E Clips (2 used)
F Module
[5] - Remove cowl (C) over steering column module (F).

[6] -
LEGEND:
B Support Bracket
[8] -
LEGEND:
A Steering Wheel Module Connector
B Ether Aid Switch Connector
C Steering Column Module Connector
D Ignition Switch Connector
E Lower Cowl
Identify, label, and disconnect harness connectors (A—D).
[9] - Remove lower cowl (E).

[10] -
LEGEND:
B Lever Cover
C Steering Column Module
D Guide
E Top Cover
[11] - Remove lever cover (B).
[12] - Remove steering column module (C), guide (D), and top cover (E).

[13] -
LEGEND:
B Steering Wheel Module
Remove cap screws (A) and steering wheel module (B).
[14] -
LEGEND:
A Retaining Ring
B Washer
C Inner Shaft
D Outer Shaft
Remove retaining ring (A) and washer (B).
[15] - Remove inner and outer steering shafts (C) and (D).

[16] -
LEGEND:
A Cap Screw
B Lever Arm
C Spring
D Link
E Ratchet
F Set Screw
Remove cap screw (A) and lever arm assembly (B) noting how spring (C) is fastened to inside
of housing.
[17] - Remove link (D) and ratchet (E).
[18] - Remove set screw (F).
[19] -
LEGEND:
A Ratchet
Move column to a horizontal position.
[20] - Remove ratchet (A).

[21] -
LEGEND:
A Torsion Spring
C Housing
Move steering column to vertical position.
[22] - Remove torsion spring (A) from housing.
[23] - Remove cap screw and washer (B).
[24] - Slide housing (C) off pivot pins and remove.
[25] -
LEGEND:
A Ratchet
C Guide
D Bushing
Remove ratchet (A).
[26] - Remove cap screws (B) and guide (C).
[27] - Inspect bushing (D) and replace as necessary.

Section 60 - STEERING AND BRAKES Group 10: Steering Control Assembly
[28] -
IMPORTANT:
Steering wheel module is serviced as an assembly.
Assemble and install steering column in reverse order.

[29] -
IMPORTANT:
Install covers.
(25 lb.-ft.)

Group 10 - Steering Control Assembly

List of References
Specifications
General Repair Procedures—Steering
Remove and Install Steering Valve
Repair Steering Valve
Remove and Install AutoTrac™ Valve
Repair AutoTrac™ Valve
Remove and Install ActiveCommand Steering (ACS™) Valve
Repair ActiveCommand Steering (ACS™) Valve
Remove and Install ActiveCommand Steering (ACS™) Return Circuit Relief Valve
Repair ActiveCommand Steering (ACS™) Return Circuit Relief Valve
Remove and Install Priority Valve Housing
Remove and Install Backup Manifold
Repair Backup Manifold
Remove and Install Backup Pump
Bleed Steering System

Specifications
Steering Mounting Bracket-to-Valve Cap Screws Torque 25 N·m
(221 lb.-in.)
Steering Mounting Bracket-to-Cab Cap Screws Torque 55 N·m
(40 lb.-ft.)
End Cap-To-Valve Housing Cap Screws Torque (First Sequence) 18 N·m
(159 lb.-in.)
Torque (Final Sequence) 24 N·m
(212 lb.-in.)
AutoTrac™ Valve Mounting Cap Screws Torque 70 N·m
(52 lb.-ft.)
Steering Enable Spool Valve Spring Free Length 44.45 mm
(1.75 in.)
(1.48 in. at 16.95 lb.-force)
33.78 mm at 119.5 N
(1.33 in. at 26.86 lb.-force)
Steering Enable Solenoids Torque 52 N·m
(38 lb.-ft.)
Load Sense Blocking Valve Torque 40 N·m
(30 lb.-ft.)
ACS™ Valve Mounting Cap Screws Torque 70 N·m
(52 lb.-ft.)
Steering Shock Relief Valves Torque 40 N·m
(30 lb.-ft.)
Shuttle Valves Torque 40 N·m
(30 lb.-ft.)
Pressure Reducing Valve Torque 40 N·m
(30 lb.-ft.)
ACS Return Circuit Relief Valve Cap Screws Torque 35 N·m
(25 lb.-ft.)
ACS Return Circuit Relief Valve Torque 88 N·m
(65 lb.-ft.)
Priority Valve Mounting Cap Screws Torque 70 N·m
(52 lb.-ft.)
Backup Manifold Socket Head Cap Screws Torque 20 N·m
(177 lb.-in.)
Backup Manifold Sensors Torque 16 N·m

(142 lb.-in.)
Backup Manifold Check Valves Torque 54 N·m
(40 lb.-ft.)
Backup Manifold Pressure Reducing Valve Torque 34 N·m
(25 lb.-ft.)
Backup Pump Mounting Cap Screws Torque 70 N·m
(37 lb.-ft.)

General Repair Procedures—Steering
CAUTION:
High pressure can exist at any hydraulic connection.
IMPORTANT:
Absolute cleanliness is essential when working on the hydraulic system.

Contamination can result in serious damage or inadequate operation.
→NOTE:

servicing the steering system.
Repair:
Most steering components are serviced as kits.

O-rings, seals, and backup rings are included in the kits.
Replace all seals, O-rings, and backup rings.

Lubricate all internal parts with clean hydraulic oil during assembly.
Components must be tightened to the specified torque.
Clean parts with clean solvent. Use moisture-free compressed air to dry parts and to
clear oil passages of any contamination. DO NOT use shop towels to dry parts.
Valve components must not bind in housing bores.
Inspect springs for wear, damage, or distortion.

Remove and Install Steering Valve
LEGEND:
B Cab Riser Panel
C Air Conditioning Line (High Pressure)
D Air Conditioning Line (Low Pressure)
[1] - Remove cab riser panel (B) by removing cap screws (A) under floor mat.
90, Group 10.)
[3] - Disconnect and plug air conditioner lines. (C and D).
[4] - Remove intake system. (See Remove and Install Intake Housing in Section 30, Group
15.)
[5] - Remove aspirator hose. (See Remove and Install Aspirator Hose in Section 30, Group
15.)

[6] -
IVT™
CommandQuad™, AutoQuad™, and PowrQuad™

LEGEND:
B Load Sense Line
C Return Line
D Steering Supply Line
E Left Steering Line
F Right Steering Line
Disconnect load sense line (B).
[7] - Disconnect return line (C).
[8] - Identify, label, and disconnect steering lines (D—F).

[9] -
LEGEND:
Remove cap screws (A) and steering valve.
[10] -
LEGEND:
A Upper Coupling
B Coupling Isolator
C Lower Coupling
Remove coupling parts (A—C).

[11] -
LEGEND:
A Cap Screws and Washers (4 used)
B Mounting Bracket
C Isolators (4 used)
Remove cap screws and washers (A) and mounting bracket (B).
[12] - Remove and discard isolators (C).
[15] -
IMPORTANT:
Do not use oil or petroleum based lubricants to lubricate isolators.
Petroleum based lubricants causes rubber to expand and make installation
more difficult.
Lightly lubricate new isolators (C) with warm soapy water.

[16] - Press isolators into mounting bracket (B) by hand.
[17] -
IMPORTANT:
Allow isolators to dry before further installation.
Ensure that isolators are fully seated before mounting bracket is installed
on valve.
Install mounting bracket and cap screws and washers (A).

[18] -

LEGEND:
B Upper Coupling
C Coupling Isolator
D Lower Coupling
In the order shown, tighten cap screws (A) to specification.
Steering Mounting Bracket-to-Valve Cap Screws Torque 25 N·m
(221 lb.-in.)
[19] -
IMPORTANT:
Cap screws must be tightened a second time to ensure that uniform torque
is obtained.

Repeat tightening procedure in order shown.

[20] - Install coupling parts (B—C) as illustrated.
[21] -
→NOTE:
LEGEND:
A second person is required to turn steering wheel during installation of
steering valve.
Align steering valve coupler to steering column shaft.

[22] - Apply clean hydraulic oil to threads of cap screws (A), install, and tighten to
specification.
Steering Mounting Bracket-to-Cab Cap Screws Torque 55 N·m
(40 lb.-ft.)

[23] -
IVT™

LEGEND:
B Load Sense Line
C Return Line
Connect load sense line (B).
[24] - Connect return line (C).
[25] - Connect steering lines (D—F).

[26] -
LEGEND:
B Cab Riser Panel
Install air conditioner lines (C and D).
[27] - Install aspirator hose. (See Remove and Install Aspirator Hose in Section 30, Group
15.)
[28] - Install intake system. (See Remove and Install Intake Housing in Section 30, Group
15.)
[29] - Bleed system by turning steering wheel full left and full right five times.
[30] - Charge air conditioning system. (See Charge Air Conditioning System in Section 90,
Group 10.)
[31] - Install cab riser panel (B) and cap screws (A).
[32] - Bleed steering system. (See Bleed Steering System in this group.)

Repair Steering Valve

[1] -
IMPORTANT:
Disassemble and assemble steering valve in a clean work area free of dust
and dirt. Keep hands clean at all times during the assembly procedure.
→NOTE:
Only a seal repair kit is available for service.
LEGEND:
A Guide
C End Cap
Clean steering valve and surrounding area.
[2] - Place valve in vise with end cap pointing up.
[3] - Remove cap screws (B), noting the location of check ball guide (A) for assembly
procedure.
[4] - Remove end cap (C).

[5] -
CAUTION:
Violent steering wheel movement can occur if gerotor is not timed. Mark
end of drive shaft and gerotor gear for proper reassembly.
LEGEND:
A Gerotor Assembly
B Timing Line
Mark a timing line (B) across drive shaft and gerotor gear.
[6] - Remove gerotor assembly (A).
[7] -
LEGEND:
A Drive Shaft
B Spacer Plate
Remove drive shaft (A) and spacer plate (B).

[8] -
LEGEND:
A Check Ball Guide (2 used)
Remove check ball guides (A).

[9] -
LEGEND:
A Magnet
B Check Valve Bore (2 used)
C Steel Ball (2 used)
Using a magnet (A), remove one steel ball (C) from each check valve bore (B).
[10] -
IMPORTANT:
Rotate spool assembly to keep sleeve assembly from binding during
removal. Do not allow sleeve assembly to bind. Doing so could cause sleeve
damage and require replacement of entire steering valve.
LEGEND:
A Sleeve Assembly
Rotate and remove sleeve assembly (A) from housing in direction shown.

[11] -
LEGEND:
A Drive Pin
Watch for drive pin (A) as it will fall from sleeve assembly when sleeve assembly is
completely removed.
[12] -
LEGEND:
A Seal
Remove seal (A) from housing.
[13] - Inspect all parts for wear or damage. If wear or damage is evident on any metal parts,
replace complete steering valve.
[14] - Install new seal (A) flush with top of housing.

[15] -
LEGEND:
A Drive Pin
Position drive pin (A) in sleeve assembly.
[16] -
IMPORTANT:
Rotate spool assembly to keep sleeve assembly from binding during
installation. Do not allow sleeve assembly to bind. Doing so could cause
sleeve damage and require replacement of entire steering valve.
LEGEND:
A Sleeve Assembly
Apply clean hydraulic oil to sleeve assembly.
[17] - Push sleeve assembly (A) into housing while rotating sleeve assembly.

[18] -
LEGEND:
A Check Ball Guide (2 used)
B O-Ring
Install check balls and check ball guides (A) in housing.
[19] - Install new O-ring (B).
[20] -
IMPORTANT:
For correct operation, the drive shaft must be installed into gerotor star so
groove is in alignment with one of the roots of gerotor star teeth.
LEGEND:
A Gerotor Star
B Drive Shaft
Install gerotor star (A) on drive shaft so root of tooth is in alignment with groove in end of
drive shaft (B).

[21] -
LEGEND:
A Drive Shaft
B Spacer
C Slot
D O-Ring (2 used)
Install O-rings (D).
[22] - Install drive shaft (A) and spacer (B). Slot (C) must engage pin in spool and sleeve
assembly.
[23] -
LEGEND:
A Gerotor Ring
B Spacer
C O-Ring (2 used)
D End Cap
Install O-rings (C) on gerotor ring (A).
[24] - Install gerotor ring and spacer (B).

[25] -
LEGEND:
A Guide
C End Cap
Install end cover (C) and cap screws (B). Install guide (A) in previously marked hole.

[26] -
Tighten cap screws to specification using sequence shown.

End Cap-To-Valve Housing Cap Screws Torque (First Sequence) 18 N·m
(159 lb.-in.)
Torque (Final Sequence) 24 N·m
(212 lb.-in.)

Remove and Install AutoTrac™ Valve
LEGEND:
A AutoTrac™ Valve
B Hydraulic Lines (4 used)
C Hydraulic Lines (7 used)

IMPORTANT:
→NOTE:
Left rear wheel can be moved out or removed to gain access to AutoTrac™
valve.
Line and hose configurations vary depending on tractor options.
[1] - Remove left-hand fuel tank. (See Remove and Install Left-Hand Fuel Tank in Section 30,
Group 10.)
[2] - Identify, label, and disconnect wire harness from AutoTrac™ valve (A).
[3] - Remove hydraulic lines (B).
[4] - Disconnect hydraulic lines (C).
[5] - Remove cap screws (D) and AutoTrac™ valve.
[6] - Install in reverse order and tighten cap screws to specification.
AutoTrac™ Valve Mounting Cap Screws Torque 70 N·m
(52 lb.-ft.)

Repair AutoTrac™ Valve
LEGEND:
A Steering Solenoids (2 used)
B Steering Enable Solenoid
C O-Rings (3 used)
D Steering Enable Spool Valves

E Springs
IMPORTANT:
Steering solenoids (A) areNOT serviceable.DO NOT REMOVE.
[1] - Remove steering enable solenoid (B).

[2] - Remove steering enable spool valve (D) and spring (E).
(1.75 in.)
(1.48 in. at 16.95 lb.-force)
33.78 mm at 119.5 N
(1.33 in. at 26.86 lb.-force)
[4] - Lightly lubricate spool valve with clean hydraulic oil.

[5] - Install spring and spool valve.
[6] - Lightly lubricate new O-rings (C) with clean hydraulic oil and install solenoid.
(38 lb.-ft.)

[8] -
LEGEND:
A Load Sense Blocking Valve
B O-Rings (3 used)
C Backup Rings (4 used)
Remove load sense blocking valve (A).
[9] - Lightly lubricate new O-rings (B) and backup rings (C) with clean hydraulic oil and install
valves.
(30 lb.-ft.)

Remove and Install ActiveCommand Steering

(ACS™) Valve
LEGEND:
A ACS™ Valve

IMPORTANT:
→NOTE:
Left rear wheel can be moved out or removed to gain access to ACS™ valve.
[1] - Remove left-hand fuel tank. (See Remove and Install Left-Hand Fuel Tank in Section 30,
Group 10.)
[2] - Identify, label, and disconnect wire harness from ACS™ valve (A).
[3] - Remove hydraulic lines (B).
[5] - Remove cap screws (D) and ACS™ valve.
[6] - Install in reverse order and tighten cap screws (D) to specification.
ACS™ Valve Mounting Cap Screws Torque 70 N·m
(52 lb.-ft.)

Repair ActiveCommand Steering (ACS™) Valve
LEGEND:
A Steering Solenoids (4 used)
B Steering Control Spool Valve Position Sensors (4 used)
C Steering Enable Solenoids (2 used)
D O-Rings (3 used)

E Steering Enable Spool Valves (2 used)

F Springs (2 used)
IMPORTANT:
Steering solenoids (A) and steering control spool valve positions sensors
(B) areNOT serviceable.DO NOT REMOVE.
[1] - Remove steering enable solenoids (C).

[2] - Remove steering enable spool valves (E) and springs (F).
(1.75 in.)
(1.48 in. at 16.95 lb.-force)
33.78 mm at 119.5 N
(1.33 in. at 26.86 lb.-force)
[4] - Lightly lubricate spool valves with clean hydraulic oil.

[5] - Install springs and spool valves.
[6] - Lightly lubricate new O-rings (D) with clean hydraulic oil and install solenoids.
(38 lb.-ft.)

[8] -
LEGEND:
A Steering Shock Relief Valves (2 used)
B O-Rings (2 used)
D Jam Nut
Remove steering shock relief valves (A).
[9] -
IMPORTANT:
Steering shock relief valves are not adjustable. DO NOT loosen jam nut (D).
Lightly lubricate new O-rings (B) and backup rings (C) with clean hydraulic oil and install
valves.
Steering Shock Relief Valves Torque 40 N·m
(30 lb.-ft.)

[11] -
LEGEND:
A Shuttle Valves (2 used)
B O-Rings (3 used)
Remove shuttle valves (A).
[12] - Lightly lubricate new O-rings (B) and backup rings (C) with clean hydraulic oil and
install valves.
Shuttle Valves Torque 40 N·m
(30 lb.-ft.)

[14] -
LEGEND:
A Pressure Reducing Valve
B O-Rings (3 used)
D Jam Nut
Remove pressure reducing valve (A).
[15] -
IMPORTANT:
Pressure reducing valve is not adjustable. DO NOT loosen jam nut (D).
Lightly lubricate new O-rings (B) and backup rings (C) with clean hydraulic oil and install
valve.
Pressure Reducing Valve Torque 40 N·m
(30 lb.-ft.)

[17] -
LEGEND:
A Load Sense Blocking Valve
B O-Rings (3 used)
Remove load sense blocking valve (A).
[18] - Lightly lubricate new O-rings (B) and backup rings (C) with clean hydraulic oil and
install valves.
(30 lb.-ft.)

Remove and Install ActiveCommand Steering

(ACS™) Return Circuit Relief Valve
LEGEND:
C Return Circuit Relief Valve
CAUTION:
IMPORTANT:
[1] - Identify, label, and disconnect hydraulic lines (A).

[2] - Remove cap screws (B) and return circuit relief valve (C).
[3] - Inspect parts and replace as necessary. (See Repair ActiveCommand Steering (ACS™)
Return Circuit Relief Valve in this group.)
ACS Return Circuit Relief Valve Cap Screws Torque 35 N·m
(25 lb.-ft.)

Repair ActiveCommand Steering (ACS™) Return

Circuit Relief Valve

[1] -
LEGEND:
A Relief Valve
B O-Rings
Remove relief valve (A).

[3] - Lubricate O-rings (B) with clean hydraulic oil and install relief valve.
ACS Return Circuit Relief Valve Torque 88 N·m
(65 lb.-ft.)

Remove and Install Priority Valve Housing

LEGEND:
D Priority valve
E O-ring
IMPORTANT:
→NOTE:
Left rear wheel can be moved out or removed to gain access to priority
valve.
[1] - Remove backup manifold if equipped. (See Remove and Install Backup Manifold in this
group.)
[2] - Remove park brake release manifold if equipped.(See Remove and Install Park Brake
Release Manifold in Group 20.)
[3] - Remove hydraulic lines (A).
[4] - Disconnect hydraulic lines (B).
[5] - Remove cap screws (C) and priority valve (D).
[8] - Install new O-ring (E).


Priority Valve Mounting Cap Screws Torque 70 N·m
(52 lb.-ft.)

Remove and Install Backup Manifold
LEGEND:
D Backup Manifold
E O-rings (3 used)

CAUTION:
Depress pedals ten times, fully releasing between depressions.
→NOTE:
Move out or remove left rear wheel to gain access to backup manifold.
[1] - Identify, label, and disconnect wire harness.

[3] - Disconnect hydraulic lines (B).
[4] - Remove socket head cap screws (C) and backup manifold (D).
[5] - Inspect parts and replace as necessary. (See Repair Backup Manifold in this group.)
[6] - InstallNEW O-rings (E) and assemble in reverse order.
[7] - Tighten socket head cap screws to specification.
Backup Manifold Socket Head Cap Screws Torque 20 N·m
(177 lb.-in.)
[8] - Bleed brakes. (See Bleed Brakes in this group.)

Repair Backup Manifold
LEGEND:
A Backup Manifold Sensors (3 used)
[1] - Inspect and replace sensors (A) as necessary.

Backup Manifold Sensors Torque 16 N·m
(142 lb.-in.)
[3] -

LEGEND:
A Check Valves (4 used)
B O-Rings
Remove check valves (A).
[5] - Lubricate O-rings (B) with clean hydraulic oil and install check valves.
(40 lb.-ft.)

[7] -
LEGEND:
B O-Rings
Remove check valves (A).
[9] - Lubricate O-rings (B) with clean hydraulic oil and install check valves.
(40 lb.-ft.)

[11] -
LEGEND:
B O-Rings
[13] - Lubricate O-rings (B) with clean hydraulic oil and install pressure reducing valve.
Backup Manifold Pressure Reducing Valve Torque 34 N·m
(25 lb.-ft.)

Remove and Install Backup Pump
LEGEND:
A Positive Cable
B Ground Cable
E Backup Pump
[1] - Disconnect battery ground cable.

[2] - Disconnect positive cable (A) and ground cable (B).
[4] - Remove cap screws (D) and backup pump (E).
[5] - Inspect parts and repair as necessary.
[6] - Assemble in reverse order and tighten cap screws (C) to specification.
Backup Pump Mounting Cap Screws Torque 70 N·m
(37 lb.-ft.)

Section 60 - STEERING AND BRAKES Group 15: Steering Cylinders
Bleed Steering System

[1] - Check hydraulic oil level.
[2] - Place transmission in PARK.
[3] - Start engine and set speed to 1200 +/20 rpm.
[4] - Heat hydraulic oil to 20 °C (68 °F).
[5] - Cycle steering cylinders full left and full right six times.
[6] - Shut engine OFF.

Group 15 - Steering Cylinders

List of References
Specifications
Remove and Install Steering Cylinder—MFWD
Remove and Install Steering Cylinder—Two-Wheel Drive
Repair Steering Cylinder
Specifications
Steering Cylinder Piston-to-Rod Bolt Torque 230 N·m
(170 lb.-ft.)
Tie Rod End-to-Steering Arm Nut Torque 150 N·m
(110 lb.-ft.)
Axle-to-Knee Cap Screws Torque 610 N·m
(450 lb.-ft.)
Knee Clamp-to-Axle Cap Screws Torque 50 N·m
(36 lb.-ft.)
Steering Cylinder End Retaining Nut Torque 200 N·m
(148 lb.-ft.)

Remove and Install Steering Cylinder—MFWD

[1] -
LEGEND:
A Snap Rings (3 used)
B Pins (2 used)
C Seals (4 used)
D Steering Cylinder
Identify, label, and disconnect hydraulic lines.
[2] - Remove snap rings (A).
[3] - Remove pins (B).
[4] - Remove seals (C) and steering cylinder (D).
[6] - Install steering cylinder (D) and seals (C).
[7] - Drive pins (B) through bores once seals are aligned.
[8] - Install snap rings (A), and ensure pins (B) are securely fastened.
[9] - Connect hydraulic lines.

[10] - Start engine and turn steering wheel full left and full right several times to bleed
hydraulic system.

Remove and Install Steering Cylinder—Two-Wheel

Drive
[1] -
LEGEND:
A Tie Rod End Nut
B Steering Cylinder Hoses
C Knee Clamp and Cap Screws
D Axle-to-Knee Cap Screws
Remove front wheel.
[2] - Remove nut (A) and disconnect tie rod.
[3] - Disconnect steering cylinder hoses (B) and plug or cap hoses and cylinder ports.
[4] - Remove cap screws (C) and knee clamp.
[5] - Remove cap screws (D) and remove knee.
[6] -
→NOTE:
Remove cylinder end by loosening nut and striking casting with lead
hammer.

LEGEND:
A Steering Cylinder Nut
Remove nut (A) and remove cylinder.
[7] - Replace parts as necessary and assemble in reverse order.
Tie Rod End-to-Steering Arm Nut Torque 150 N·m
(110 lb-ft)
(450 lb-ft)
Knee Clamp-to-Axle Cap Screws Torque 50 N·m
(36 lb-ft)
Steering Cylinder End Retaining Nut Torque 200 N·m
(148 lb-ft)
[8] - Connect hydraulic lines.

[9] - Start engine and turn steering wheel full left and full right several times to bleed
hydraulic system.
Repair Steering Cylinder

Section 60 - STEERING AND BRAKES Group 20: Service Brakes
See Component Technical Manual for 100 series hydraulic cylinder repair.

Group 20 - Service Brakes

List of References
Specifications
General Repair Procedures—Brake Valve
Remove and Install Brake Rods
Remove and Install Brake Valve
Repair Brake Valve—Manual Backup
Repair Brake Valve—Powered Backup
Remove and Install Front Brake Valve
Repair Front Brake Valve
Remove and Install Secondary Brake Valve
Repair Secondary Brake Valve
Remove and Install Brake Control Manifold
Remove and Install Lube Manifold
Remove and Install Park Brake Release Manifold
Repair Park Brake Release Manifold
Manually Release Park Brake—IVT™
Manually Release Park Brake—CommandQuad™
Bleed MFWD Brakes
Bleed Brakes
Check Brakes

→NOTE:

DFRW178—Front Brake Bleed Wrench
DFRW213—Hydraulic Trailer Brake Test / Bleed Assembly
D01045AA Disk Set
JDG1666 Park Brake Release Hand Pump Kit
JT03474 Male-to-Male Quick Coupler
JT07045 Hydraulic Pressure Gauge
JT07115 Master Hydraulic Kit
JT07115SUP Supplemental Master Hydraulic Kit
JT07118 Two-Valve Manifold
JT07119 Test Hose
JT07134 Bleed Pipe

Specifications
Brake Pedal Mounting Cap Screw Torque 60 N·m
(44 lb.-ft.)
Brake Valve Mounting Bracket-to-Cab Cap Screws Torque 70 N·m
(52 lb.-ft.)
(22 lb.-ft.)
Inlet Valve Spring Free Length 15 mm
(0.6 in.)
(0.38 in. at 0.33—0.37 lb.-force)
Manual-Stage Dump Valve Spring Free Length 30 mm
(1.2 in.)
(0.46 in. at 4.1—4.7 lb.-force)
Inlet and Return Elbows Torque 52 N·m
(38 lb.-ft.)
Load-Sense Shut-Off Outer Spring (B) Free Length 18 mm
(0.7 in.)
(0.24 in. at 1.35—1.65 lb.-force)
Load-Sense Shut-Off Inner Spring (C) Free Length 31 mm
(1.2 in.)
(0.50 in. at 2.9—3.3 lb.-force)
Load-Sense Elbow Fitting Torque 40 N·m
(30 lb.-ft.)
Load-Sense Plug Torque 15 N·m
(132 lb.-in.)
Brake Function Connector Spring Free Length 15 mm
(0.6 in.)
(0.43 in. at 0.44—0.54 lb.-force)
Brake Function Elbow Fitting Torque 40 N·m
(30 lb.-ft.)
Brake Valve Springs Free Length 114 mm
(4.5 in.)

(2.26 in. at 50—56 lb.-force)
Makeup Check Valve Springs Free Length 23 mm
(0.9 in.)
(0.34 in. at 1.76—2.04 lb.-force)
Load-Sense Shuttle Spring Free Length 9 mm
(0.36 in.)
(0.19 in. at 0.23—0.43 lb.-force)
Load-Sense Shuttle Valve Inner Plug Torque 8 N·m
(72 lb.-in.)
Load-Sense Shuttle Valve Outer Plug Torque 40 N·m
(30 lb.-ft.)
Relief Valve Springs Free Length 29 mm
(1.1 in.)
(0.53 in. at 6—7.3 lb.-force)
Plunger Springs Free Length 24 mm
(0.9 in.)
(0.82 in. at 168—210 lb.-force)
Brake Valve End Cover Torque 28 N·m
(20 lb.-ft.)
Brake Valve Spring Plugs Torque 168 N·m
(124 lb.-ft.)
Brake Valve Mounting Bracket-to-Valve Cap Screws Torque 25 N·m
(18 lb.-ft.)
Inlet Check Spring Free Length 15 mm
(0.6 in.)
(0.375 in. at 0.33—0.37 lb.-force)
Brake Valve Springs Free Length 114.3 mm
(4.5 in.)
(3.45 in. at 23.7—26.3 lb.-force)
(2.26 in. at 50.3—55.7 lb.-force)
Inlet Fitting Torque 50 N·m
(37 lb.-ft.)

Front Brake Valve Cap Screws Torque 70 N·m
(52 lb.-ft.)
Front Brake Solenoid Screws Torque 4 N·m
(35 lb.-in.)
Front Brake Enable Solenoid Screws Torque 4 N·m
(35 lb.-in.)
Secondary Brake Valve Cap Screws Torque 70 N·m
(52 lb.-ft.)
Secondary Brake Solenoid Screws Torque 4 N·m
(35 lb.-in.)
Secondary Brake Enable Solenoid Screws Torque 4 N·m
(35 lb.-in.)
Brake Control Manifold Cap Screws Torque 35 N·m
(26 lb.-ft.)
Lube Manifold Cap Screws Torque 80 N·m
(60 lb.-ft.)
Park Brake Release Manifold Socket Head Cap Screws Torque 20 N·m
(177 lb.-in.)
Park Brake Release Check Valve Torque 54 N·m
(40 lb.-ft.)
Park Brake Release Pressure Reducing Valve Torque 34 N·m
(25 lb.-ft.)

General Repair Procedures—Brake Valve
CAUTION:
hydraulic lines, fittings or connections.
IMPORTANT:

→NOTE:

servicing the brake valve.
Repair:
Most brake valve components are serviced as kits.

O-rings, seals, and backup rings are included in the brake valve overhaul kit.
Left- and right-hand brake valve components are select fit and must be kept separate.
Replace all seals, O-rings, and backup rings.
Components must be tightened to the specified torque.
Clean parts with clean solvent. Use moisture-free compressed air to dry parts and to
clear oil passages of any contamination. DO NOT use shop towels to dry parts.
Valve components must not bind in housing bores.
System Startup:
Brake system must be bled. (See Bleed Brakes in this group.)

Remove and Install Brake Rods
LEGEND:
A Tray
B Screws (2 used)
C Upper Cowl
E Clips (2 used)
[1] - Remove tray (A) and screws (B) from upper cowl (C).
[2] - Pull upper cowl rearward off alignment pins (D) and clips (E).

[3] -
LEGEND:
B Bracket
D Lower Cowl
Disconnect harness connectors from ignition and ether aid switches.
[4] - Remove cap screws (A) and bracket (B).
[5] - Remove cap screws (C) and lower cowl (D).

[6] -
LEGEND:
A Brake Pedal Mounting Cap Screw
B Brake Pedals (2 used)
C Washers (2 used)
Remove brake pedal mounting cap screw (A).
[7] - Remove brake pedals (B) and washers (C).

[8] -
LEGEND:
A Retaining Rings (2 used)
B Pin
C Brake Rod
D Bearing
Remove retaining rings (A), pin (B), and brake rod (C).
[9] -
→NOTE:
Right-hand brake pedal uses two bearings.
Remove bearings using a 35 mm (1-3/8 in.) driver disk and handle.

[10] - Press new bearings into pedal using a 16 mm (5/8 in.) pilot with a 38 mm (1-1/2 in.)
driver disk.
[11] - Assemble brake rods and pedals in reverse order.
[12] - Tighten brake pedal mounting cap screw to specification.
Brake Pedal Mounting Cap Screw Torque 60 N·m
(44 lb.-ft.)
[13] - Depress brake pedal several times, fully releasing between depressions, to ensure
smooth pedal operation without binding.

Remove and Install Brake Valve
Brake Valve—Manual Backup
Brake Valve—Powered Backup

LEGEND:
A Cap Screw
B Return Line
C Brake Supply Line
D Load Sense Line
E Brake Function Lines (2 used)
F Mounting Cap Screws (2 used)
G Bracket Cap Screws (4 used)
CAUTION:
Depress pedals ten times, fully releasing between depressions.
[1] - Remove brake rods. (See Remove and Install Brake Rods in this group.)
[3] - Remove cap screw (A) and fuel line.
[4] - Identify, label, and disconnect lines (B—E).
[5] - Identify, label, and disconnect harness from brake valve.
[6] -
→NOTE:
Depending on tractor configurations, bracket cap screws (G) may need to
be loosened to allow brake valve to be removed.
Remove mounting cap screws (F) and brake valve.


[8] - Apply clean hydraulic oil to threads of cap screws (F), install, and tighten to
specification.
Brake Valve Mounting Bracket-to-Cab Cap Screws Torque 70 N·m
(52 lb.-ft.)
[9] - Tighten bracket cap screws (G) to specification.

(22 lb.-ft.)

[11] - Check brakes. (See Check Brakes in this group.)

Repair Brake Valve—Manual Backup

[1] -
LEGEND:
B Mounting Bracket
D Gasket
E Boot
F Brake Position Sensor
[2] - Remove isolators (C).
[3] - Remove gasket (D), boot (E), and position sensor (F).

[4] -
IMPORTANT:
LEGEND:
A Function Lines Capped
B Inlet Elbow
C Brake Plungers
Keep left- and right-hand brake valve components separate since parts are
select fit.
Cap two brake function lines (A).

[5] - Remove inlet elbow (B).
[6] -
→NOTE:
Valve chambers must be filled with oil to eject inlet valve.
Hold a rag over inlet port. Depress both brake plungers (C) to eject inlet valve.

[7] -
IMPORTANT:
LEGEND:
A Inlet Elbow
B Filter
C Filter Dome
D Inlet Valve
E O-ring
F Inlet Valve Ball
G Retainer
H Spring
Filter (B) must be installed with the dome (C) toward the inlet valve (D).
[8] - Inspect parts (A—H) and install new O-ring (E).

Inlet Valve Spring Free Length 15 mm
(0.6 in.)
(0.38 in. at 0.33—0.37 lb.-force)

[9] -
→NOTE:
LEGEND:
A Inlet Valve Port
B Return Port
C Manual-Stage Dump Valve
D Plug
E Spring
F Manual-Stage Dump Valve
G Manual-Stage Piston
H Backup Ring
I O-ring
Do not install valve parts if the manual-stage piston is removed.
Manual-stage piston can be accessed through inlet valve port (A) and
return port (B).

[10] - Remove, inspect, and install parts (D—G).

Manual-Stage Dump Valve Spring Free Length 30 mm
(1.2 in.)
(0.46 in. at 4.1—4.7 lb.-force)
[11] - Replace backup ring (H) and O-ring (I).

[12] - Install inlet valve parts in port (A).
[13] - Install inlet and return elbows. Tighten to specification.
Inlet and Return Elbows Torque 52 N·m
(38 lb.-ft.)

[14] -
→NOTE:
LEGEND:
A Plug
[ Plug design varies ]
B Load-Sense Shut-Off Spring (Outer)
C Load-Sense Shut-Off Spring (Inner)
D Ball
E Seat
F O-ring
G Load-Sense Shut-Off Valve
H Backup Ring
I O-ring
J Load-Sense Shut-Off Valve Port
K Load-Sense Port
L Hex Wrench
M Orifice
Load-sense shutoff valve can be accessed through load-sense port (K).

[15] - Remove and inspect parts (A—G).

Load-Sense Shut-Off Outer Spring (B) Free Length 18 mm
(0.7 in.)
(0.24 in. at 1.35—1.65 lb.-force)
Load-Sense Shut-Off Inner Spring (C) Free Length 31 mm
(1.2 in.)
(0.50 in. at 2.9—3.3 lb.-force)
[16] - Install new O-rings (F) and (I) and backup ring (H).
[17] - Remove orifice (M) from load-sense port (K) using an hex key wrench (L).
[18] - Inspect orifice for contamination, then install.
[19] - Position brake valve housing horizontally and install valve parts ensuring seat (E) is
correctly positioned.
[20] - Install load-sense elbow fitting at port (K).
[21] - Install load-sense plug (A). Tighten to specification.
Load-Sense Elbow Fitting Torque 40 N·m
(30 lb.-ft.)
Load-Sense Plug Torque 15 N·m
(132 lb.-in.)
[22] -
LEGEND:
A Elbow (Brake Function Connector)
B Spring
C Special Washer
D Orifice
Remove brake function elbow fitting (A).
[23] - Inspect spring (B), washer (C), and orifice (D).

Brake Function Connector Spring Free Length 15 mm
(0.6 in.)
(0.43 in. at 0.44—0.54 lb.-force)
[24] - Install parts with indented side of orifice toward the spring. Tighten to specification.
Brake Function Elbow Fitting Torque 40 N·m
(30 lb.-ft.)

[25] -
IMPORTANT:
LEGEND:
A Plug
B Brake Valve Spring
C Spring Guide
D Makeup Check Valve Spring
E Makeup Check Valve
F Pin
G O-ring
H Makeup Plug
I O-ring
J Ring Insert
K O-ring
Left- and right-hand brake valves MUST be reinstalled in original bores.
[26] - Remove makeup check valve parts (A—K) for both left- and right-hand brakes.


Brake Valve Springs Free Length 114 mm
(4.5 in.)
(2.26 in. at 50—56 lb.-force)
Makeup Check Valve Springs Free Length 23 mm
(0.9 in.)
(0.34 in. at 1.76—2.04 lb.-force)
[28] - Assemble in reverse order using a small amount of petroleum jelly to hold spring guide
(C) and pin (F).
[29] -
→NOTE:
Ball (C) shuttles inside of spring (D).
LEGEND:
A Outer Plug
B Inner Plug
C Ball
D Spring
Remove and inspect load-sense shuttle passage parts (A—D).
Load-Sense Shuttle Spring Free Length 9 mm
(0.36 in.)
(0.19 in. at 0.23—0.43 lb.-force)

[30] - Install shuttle passage parts using new O-rings on plugs (A and B). Tighten plugs to
specification.
Load-Sense Shuttle Valve Inner Plug Torque 8 N·m
(72 lb.-in.)
Load-Sense Shuttle Valve Outer Plug Torque 40 N·m
(30 lb.-ft.)
[31] -
LEGEND:
A Cover
B Wiper Rings
C Stroke Limiter Cover
Remove cover (A), wiper rings (B), and stroke limiter cover (C).
[32] -
IMPORTANT:

LEGEND:
A Spools
B O-rings
C Balls
D Relief Valve Springs
E Annular Rings
F Pistons
G Quad-Rings
H Plungers
I Plunger Springs
J Wiper Ring
All orifices must be clear of contamination. Left- and right-hand brake
valves MUST be reinstalled in original bores.
→NOTE:
Use brake valve springs from opposite end to aid removal of parts.
Remove and inspect parts (A—J).

Relief Valve Springs Free Length 29 mm
(1.1 in.)
(0.53 in. at 6—7.3 lb.-force)
(0.9 in.)
(0.82 in. at 168—210 lb.-force)
[33] - Install new quad rings (G).

[34] -
IMPORTANT:
Compress annular rings making sure that rings do not bind during
assembly.
→NOTE:
Use a small amount of petroleum jelly to hold balls (C) on spools (A) during
assembly.
Assemble parts horizontally as a sub-assembly to prevent balls (C) and springs (D) from
misaligning.
[35] - Install cover, wiper rings, and stroke limiter cover; then tighten cap screws to
specification.
Brake Valve End Cover Torque 28 N·m
(20 lb.-ft.)

[36] -
IMPORTANT:
LEGEND:
A Makeup Check Valve Assembly
B Spring Guide
Ensure that spring guides are correctly positioned during assembly.
→NOTE:
Put a small amount of petroleum jelly on the end of large brake valve
springs to hold the spring guides (B) in position during assembly.
Install makeup check valve assemblies (A) making sure spring guides (B) are correctly
positioned.
[37] - Install brake valve springs and tighten plugs to specification.
Brake Valve Spring Plugs Torque 168 N·m
(124 lb.-ft.)

[38] -
IMPORTANT:
LEGEND:
B Mounting Bracket
D Gasket
E Boot
more difficult.

[40] -
IMPORTANT:
To prevent brake rod from binding, ensure that boot (E) and gasket (D) are
properly aligned and seated.

Install brake position sensor (F), boot (E), and gasket (D).
[41] -
IMPORTANT:
on valve.

[42] -
LEGEND:
(18 lb.-ft.)
[43] -
IMPORTANT:
is obtained.

Repair Brake Valve—Powered Backup

[1] -
LEGEND:
B Mounting Bracket
D Gasket
E Boot
[2] - Remove isolators (C).
[3] - Remove gasket (D), boot (E), and position sensor (F).

[4] -
LEGEND:
A Brake Function Ports (2 used)
B Load-Sense Port
C Inlet Fitting
D Pistons (2 used)
Cap brake function ports (A) and load-sense port (B).
[5] - Remove inlet fitting (C).
[6] -
→NOTE:
Valve chambers must be filled with oil to eject valve.
Remove inlet valve by depressing pistons (D).

[7] - Pressure ejects inlet valve. Use a rag around inlet port to prevent losing parts.

[8] -
LEGEND:
A Inlet Fitting
B Inlet Screen
C Inlet Valve
D O-ring
E Inlet Valve Ball
F Retainer
G Spring
Remove parts (A—G).
Inlet Check Spring Free Length 15 mm
(0.6 in.)
(0.375 in. at 0.33—0.37 lb.-force)

[10] -
LEGEND:
A Plugs (2 used)
B Brake Valve Springs (2 used)
Remove plugs (A) and brake valve springs (B).
Brake Valve Springs Free Length 114.3 mm
(4.5 in.)
(3.45 in. at 23.7—26.3 lb.-force)
(2.26 in. at 50.3—55.7 lb.-force)

[12] -
IMPORTANT:
LEGEND:
A Screw
B Cover
C Wiper Rings (2 used)
D Stroke Limiter Cover
E Pistons (2 used)
Left and right brake valve components are select fit and must be kept
separate.
Remove screw (A) and cover (B).

[13] - Remove wiper rings (C), stroke limiter cover (D), and pistons (E).

[14] -
LEGEND:
A Spools (2 used)
B Plug
C O-ring
D Orifice
Remove spools (A).
[15] - Remove plug (B) and orifice (D).
[16] -
IMPORTANT:
Ensure that all orifices are clean and free of debris.
Inspect orifice for contamination, replace if necessary, and install.

[17] - Replace O-ring (C) and install plug.
[18] - Lightly lubricate spools with clean hydraulic oil.
[19] - Install spools into same bores in which they were removed.

[20] -
LEGEND:
A Plunger
B Plunger Spring
C Piston
D Wiper Ring
E Quad-Ring
Remove plungers (A) and plunger springs (B) from pistons (C).
(0.9 in.)
(0.82 in. at 168—210 lb.-force)
[22] - Install new wiper rings (D).

[23] - Install plunger springs and plungers into pistons.
[24] - Install new quad rings (E).

[25] -
LEGEND:
A Screw
B Cover
C Wiper Rings (2 used)
D Stroke Limiter Cover
E Pistons (2 used)
Install pistons (E), stroke limiter cover (D), and wiper rings (C).
[26] - Install cover (B) and screw (A).
[27] -
LEGEND:
A Plugs (2 used)
B Brake Valve Springs (2 used)
Install brake valve springs (B).
[28] - Install new O-rings on plugs (A) and install plugs.

[29] -
IMPORTANT:
LEGEND:
A Inlet Fitting
B Inlet Screen
C Inlet Valve
D O-ring
E Inlet Valve Ball
F Retainer
G Spring
Inlet screen (B) must be clean and free of debris.
Install new O-ring (D).

[30] - Install parts (A—G).
[31] - Tighten inlet fitting (A) to specification.
Inlet Fitting Torque 50 N·m
(37 lb.-ft.)

[32] -
IMPORTANT:
LEGEND:
B Mounting Bracket
D Gasket
E Boot
more difficult.

[34] -
IMPORTANT:
To prevent brake rod from binding, ensure that boot (E) and gasket (D) are
properly aligned and seated.

Install brake position sensor (F), boot (E), and gasket (D).
[35] -
IMPORTANT:
on valve.

[36] -
LEGEND:
(18 lb.-ft.)
[37] -
IMPORTANT:
is obtained.

Remove and Install Front Brake Valve
LEGEND:
C Accumulator and Bracket
→NOTE:
Left rear wheel can be moved out or removed to gain access to front brake
valve.
[1] - Identify, label, and disconnect harness from front brake valve.
[2] - Disconnect hydraulic lines (A).
[3] - Remove cap screws (B) and move accumulator and bracket (C) off to side.
[4] - Remove front brake valve.
[5] - Inspect parts and replace as necessary. (See Repair Front Brake Valve in this group.)
[7] - Tighten cap screws (B) to specification.
Front Brake Valve Cap Screws Torque 70 N·m
(52 lb.-ft.)
[8] - Bleed MFWD brakes. (See Bleed MFWD Brakes in this group.)

Repair Front Brake Valve
LEGEND:
A Screws (2 used)
B Front Brake Solenoid Valve
C Screws (2 used)
D Front Brake Enable Solenoid Valve
E O-rings (3 used)
F Backup Rings (2 used)
G O-rings (4 used)

IMPORTANT:
Absolute cleanliness is essential.
[1] - Remove screws (A) and solenoid (B).

[2] - Remove screws (C) and enable solenoid (D).
[3] - Replace O-rings (E) and backup rings (F).
[4] - Ensure that valve passages are clean and free of debris.
[5] - Lightly lubricate O-rings and backup rings with clean hydraulic oil and install solenoid.
[6] - Tighten screws (A) to specification.
Front Brake Solenoid Screws Torque 4 N·m
(35 lb.-in.)
[7] - Replace O-rings (G).

[9] - Lightly lubricate O-rings with clean hydraulic oil and install enable solenoid.
[10] - Tighten screws (C) to specification.
Front Brake Enable Solenoid Screws Torque 4 N·m
(35 lb.-in.)

Remove and Install Secondary Brake Valve
LEGEND:
A Supply Line
B Outlet Line
C Return Line
→NOTE:
Left rear wheel can be moved out or removed to gain access to secondary
brake valve.
[1] - Identify, label, and disconnect harness from secondary brake valve.
[2] - Remove supply line (A).
[3] - Disconnect outlet line (B) and return line (C).
[4] - Remove cap screws (D) and remove secondary brake valve.
[5] - Inspect parts and replace as necessary. (See Repair Secondary Brake Valve in this
group.)
[7] - Tighten cap screws (G) to specification.

Secondary Brake Valve Cap Screws Torque 70 N·m
(52 lb.-ft.)

Repair Secondary Brake Valve
LEGEND:
A Screws (2 used)
B Secondary Brake Solenoid Valve
C Screws (2 used)
D Secondary Brake Enable Solenoid Valve
E O-rings (3 used)
G O-rings (4 used)

IMPORTANT:

Secondary Brake Solenoid Screws Torque 4 N·m
(35 lb.-in.)

Secondary Brake Enable Solenoid Screws Torque 4 N·m
(35 lb.-in.)

Remove and Install Brake Control Manifold
LEGEND:
A Hydraulic Trailer Brake Pilot Line
B Left Brake Function Line
C Right Brake Function Line
D Air Trailer Brake Pilot Line
E Left Brake Valve Line
F Secondary Brake Pilot Line
G Right Brake Valve Line
I Brake Control Manifold
IMPORTANT:
→NOTE:

[2] - Identify, label, and disconnect harness from brake control manifold.
[3] - Remove hydraulic lines (A—C).
[4] - Disconnect hydraulic lines (D—G).
[5] - Remove cap screws (H) and brake control manifold (I).
Brake Control Manifold Cap Screws Torque 35 N·m
(26 lb.-ft.)
[9] - Bleed brakes. (See Bleed Brakes in Group 20.)

Remove and Install Lube Manifold
LEGEND:
A Front Brake Return Line
B Secondary Brake Return Line
C Lube Supply Line
D Power Distribution Lube Line
E PTO Lube Line
G Lube Manifold
H O-Rings (3 used)

IMPORTANT:
→NOTE:
[2] - Identify, label, and disconnect harness from lube manifold.
[3] - Remove hydraulic lines (A and B).
[4] - Disconnect hydraulic lines (C—E).
[5] - Remove cap screws (F) and lube manifold (G).
[7] - Install new O-rings (H) and assemble in reverse order.
Lube Manifold Cap Screws Torque 80 N·m
(60 lb.-ft.)

Remove and Install Park Brake Release Manifold
LEGEND:
C Park Brake Release Manifold
D O-ring
→NOTE:
Move out or remove left rear wheel to gain access to park brake release
manifold.

[2] - Remove socket head cap screws (B) and park brake release manifold (C).
[3] - Inspect parts and replace as necessary. (See Repair Park Brake Release Manifold in this
group.)
[4] - InstallNEW O-ring (D) and assemble in reverse order.
[5] - Tighten socket head cap screws to specification.
Park Brake Release Manifold Socket Head Cap Screws Torque 20 N·m
(177 lb.-in.)

Repair Park Brake Release Manifold
LEGEND:
A Check Valve)
B O-Rings
→NOTE:
Move out or remove left rear wheel to gain access to backup manifold.
[1] - Remove check valve (A).


[3] - Lubricate O-rings (B) with clean hydraulic oil and install check valve.
Park Brake Release Check Valve Torque 54 N·m
(40 lb.-ft.)
[5] -
LEGEND:
B O-Rings
[7] - Lubricate O-rings (B) with clean hydraulic oil and install pressure reducing valve.


Park Brake Release Pressure Reducing Valve Torque 34 N·m
(25 lb.-ft.)

Manually Release Park Brake—IVT™
LEGEND:
B Debris Shield
C Solenoids
D Cap
Before Towing

→NOTE:
Park brake must be released before tractor can be towed.
Use the following method to release park brake for towing tractor when
tractor does not move with direction/speed control lever in a position for
driving tractor. If this method does not release park brake with engine
running, there is a park brake solenoid or valve problem that must be
repaired before park brake can be released.
CAUTION:
Prevent possible injury;
Keep park brake engaged except when moving tractor.

Before performing park release procedure, chock tractor wheels to
prevent rolling.
Releasing park brake is only temporary. Perform release procedure
immediately before towing and reverse procedure when finished
towing.
IMPORTANT:
Drive train problems prevent tractor from moving, but engine can be
operated for power steering and brakes while being towed. Do not run
engine if any of the following listed conditions exist because further
damage occurs including contaminating transmission or hydraulic system.
Transmission is noisy
Transmission low-pressure warning light is on
Pressure is severely pulsating
Any fluid is leaking
Engine knocks
Fuel pump failure
[1] - Connect tow vehicle to vehicle being towed.

[2] - Remove cap screws (A) and debris shield (B).
[3] - Using JDG1666-3 Power Lead from JDG1666 Park Brake Release Hand Pump Kit , locate
and energize park brake and park sump solenoids (C) on transmission rear valve housing.
[4] - Remove cap (D) and install a DR fitting.

[5] -
IMPORTANT:
Avoid debris that can cause valve leakage and unexpected park brake
engagement. Use filters included in kit when adding oil to pump.
Connect hand pump from JDG1666 Park Brake Release Hand Pump Kit to DR.
[6] - Check hand pump reservoir oil level and add oil if necessary.
[7] - Close hand pump shutoff valve and open the reservoir bleed screw 1/4 turn from point
of O-ring contact.
[8] -
IMPORTANT:
Avoid possible damage to transmission. Do Not exceed 4000 kPa (40 bar)
(580 psi) to release park brake.
Operate hand pump to get 2000 kPa (20 bar) (290 psi). Maintain this pressure to prevent
park brake from dragging.
[9] -
→NOTE:
Disconnecting the power lead allows the park brake to engage, but oil does
not return to hand pump. Opening the hand pump shutoff valve first
returns oil to hand pump reservoir.
IMPORTANT:
If tractor movement must be stopped immediately, open hand pump
shutoff valve.
Slowly pull tractor approximately 7 m (21 ft.) and stop tow vehicle.
→NOTE:
Ensure tractor in tow rolls freely to a stop. If tractor stops quickly, park
brake is dragging. If park brake is dragging, recheck release procedure and
ensure PTI (IVT control unit) address 23 is greater than 1240 kPa (12.4 bar)
(179 psi).
[10] - After tractor has been moved to desired location, open the hand pump shutoff valve
and allow pressure to bleed down to zero.
[11] - Close shutoff valve and bleed screw.
[12] - Disconnect hand pump from DR.
[13] - Remove DR from tractor and install cap.
[14] - Install debris shield and cap screws.

Manually Release Park Brake—CommandQuad™
LEGEND:
A Solenoids
B Cap
Before Towing
→NOTE:
Park brake must be released before tractor can be towed.
Use the following method to release park brake for towing tractor when
tractor does not move with direction/speed control lever in a position for
driving tractor. If this method does not release park brake with engine
running, there is a park brake solenoid or valve problem that must be
repaired before park brake can be released.

CAUTION:
Prevent possible injury;
Keep park brake engaged except when moving tractor.

Before performing park release procedure, chock tractor wheels to
prevent rolling.
Releasing park brake is only temporary. Perform release procedure
immediately before towing and reverse procedure when finished
towing.
IMPORTANT:
Drive train problems prevent tractor from moving, but engine can be
operated for power steering and brakes while being towed. Do not run
engine if any of the following listed conditions exist because further
damage occurs including contaminating transmission or hydraulic system.
Transmission is noisy
Transmission low-pressure warning light is on
Pressure is severely pulsating
Any fluid is leaking
Engine knocks
Fuel pump failure
[1] - Connect tow vehicle to vehicle being towed.

[2] - Using JDG1666-3 Power Lead from JDG1666 Park Brake Release Hand Pump Kit , locate
and energize park brake and park sump solenoids (A) on range box valve manifold.
[3] - Remove cap (B) and install a DR fitting.
[4] -
IMPORTANT:
Avoid debris that can cause valve leakage and unexpected park brake
engagement. Use filters included in kit when adding oil to pump.
Connect hand pump from JDG1666 Park Brake Release Hand Pump Kit to DR.
[5] - Check hand pump reservoir oil level and add oil if necessary.
[6] - Close hand pump shutoff valve and open the reservoir bleed screw 1/4 turn from point
of O-ring contact.

[7] -
IMPORTANT:
Avoid possible damage to transmission. Do Not exceed 4000 kPa (40 bar)
(580 psi) to release park brake.
Operate hand pump to get 2000 kPa (20 bar) (290 psi). Maintain this pressure to prevent
park brake from dragging.
[8] -
→NOTE:
Disconnecting the power lead allows the park brake to engage, but oil does
not return to hand pump. Opening the hand pump shutoff valve first
returns oil to hand pump reservoir.
IMPORTANT:
If tractor movement must be stopped immediately, open hand pump
shutoff valve.
Slowly pull tractor approximately 7 m (21 ft.) and stop tow vehicle.
→NOTE:
Ensure tractor in tow rolls freely to a stop. If tractor stops quickly, park
brake is dragging. If park brake is dragging, recheck release procedure and
ensure PTQ (CommandQuad™ control unit) address 23 is greater than 1240
kPa (12.4 bar) (179 psi).
[9] - After tractor has been moved to desired location, open the hand pump shutoff valve
and allow pressure to bleed down to zero.
[10] - Close shutoff valve and bleed screw.
[11] - Disconnect hand pump from DR.
[12] - Remove DR from tractor and install cap.

Bleed MFWD Brakes

[1] -
→NOTE:
Front brake system uses John Deere HY-GARD™.
LEGEND:
A MFWD Hub
B MFWD Hub Drain Plug
Rotate right-hand MFWD hub plug (B) to 12 o′clock position.
[2] - Position a pan under hubs to catch oil that leaks during bleeding process.
[3] - Look into hub plug hole to locate brake bleed screw.
[4] -
→NOTE:
A second person is required to assist.
Start engine and have assisting person depress brake pedal.

[5] -
CAUTION:
Oil sprays toward hub plug hole while bleeding brakes.
→NOTE:
Push in on tool while bleeding. Oil bleeding from brake system pushes tool
out of position.
A standard 6 mm Allen (hex) wrench works.

Loosen brake bleed screw approximately 1.5 turns with DFRW178—Front Brake Bleed
Wrench .
[6] - Allow brake to bleed for approximately 5 seconds.
[7] - Close bleed screw.
[8] - Repeat steps 1-8 on opposite side of vehicle.
[9] - Rotate hub plug to nine o’clock position.
[10] - Check for proper hub oil level.
[11] - Install hub plugs.
[12] - Calibrate MFWD brakes. (See XMA address 21 for ACS MFWD front brakes or XMC
address 21 for AutoTrac MFWD front brakes.) Refer to Operation and Test Manual for proper
procedure.

Bleed Brakes
LEGEND:
A Right Service Brake Bleed DR
B Left Service Brake Bleed DR
C Return Oil Pressure DR—R Port
D Air Trailer Brake Bleed DRs (2 used)
E Hydraulic Trailer Brake Quick Coupler
F Hydraulic Trailer Brake Bleed Screw
G Oil Filler Tube
→NOTE:
JT07118, JT07119, and JT07134 are part of JT07115 Master Hydraulic Kit
and JT07115SUP Supplemental Master Hydraulic Kit .
[1] - Assemble JT07118 Two-Valve Manifold and three JT07119 Test Hose .
[2] - Connect two outer test hoses to service brake bleed DRs (A and B).
[3] - Connect hose from center port of manifold to DR on top of SCV stack marked “R” (C).
[4] - FOR TRACTORS EQUIPPED WITH HYDRAULIC TRAILER BRAKES:
Assemble JT07118 Two-Valve Manifold and two JT07119 Test Hose .

Connect left hose to DFRW213—Hydraulic Trailer Brake Test / Bleed Assembly .
Install DFRW213 — Hydraulic Trailer Brake Test / Bleed Assembly to hydraulic trailer
brake quick coupler (E).
Connect right hose to JT07134 Bleed Pipe .
Secure bleed pipe in oil filler tube (G).
Connect JT07045 Hydraulic Pressure Gauge to center port of two-valve manifold.
Break torque on bleed screw (F). Do not open bleed screw any further at this time.
Install piece of clear tubing, 5 mm (3/16 in.) ID X 1.5 m (60 in.) long to bleed screw
fitting.
Insert other end of clear tubing in oil fill tube (G).
[5] - IF EQUIPPED WITH AIR TRAILER BRAKES:
Assemble JT07118 Two-Valve Manifold and three JT07119 Test Hose .

Connect two outer test hoses to air brake bleed DRs (D).
Connect third hose to center port of two-valve manifold with JT03474 Male-to-Male
Quick Coupler and connect other end to JT07134 Bleed Pipe .
Secure bleed pipe in oil filler tube (G).

[8] - Start engine and set speed to 1200 +/- 20 rpm.
[9] - Heat hydraulic oil to 20 °C (68 °F).
[10] - Open all valves on manifolds.

[11] -
CAUTION:
Prevent personal injury. High-pressure oil escaping from bleed screw port
can penetrate the skin. To limit pressure at bleed screw port, apply only
light force to brake pedals while bleeding pilot circuit. DO NOT depress
brake pedals more than 12—18 mm (0.5—0.75 in.).
Open bleed screw (F) on hydraulic trailer brake valve 1/2 to one turn (if equipped).
[12] - FOR TRACTORS EQUIPPED WITH SECONDARY BRAKE:
Fully raise secondary brake switch for 30 seconds.

Lower secondary bake switch.
[13] - Engage right brake pedal.

[14] - Engage left brake pedal while releasing right pedal.
[15] - Repeat Steps 13 and 14 three times fully releasing between depressions.
[16] - Lock pedals together.
[17] - Depress pedals three times fully releasing between depressions.
[18] -
IMPORTANT:
To prevent damage to seat platform and other cab components, do not
install any type of brake pedal braces or depressors.
Depress pedals and hold for minimum of 2 minutes.

[19] -
IMPORTANT:
Maintain pressure on pedals until all test hoses have been disconnected or
isolated to prevent air from entering system.
Close bleed screw (F) on hydraulic trailer brake control valve.

[20] - Shut valves on air trailer brake bleed DRs (D).
[21] - Shut valves on rear service brake bleed DRs (A and B).

[22] - FOR TRACTORS EQUIPPED WITH HYDRAULIC TRAILER BRAKES:
Close right valve to oil fill tube (G). Leave left valve from coupler (E) open.
Apply increasing force to either brake pedal until pressure at trailer brake coupler peaks
at 14700—15300 kPa (147—153 bar; 2130—2220 psi). Hold for 5—10 seconds.
→NOTE:
At this time pressure relief valve in hydraulic trailer brake control valve is
open and bleeding pressure relief valve circuit.
[23] - Close all valves on all manifolds.

[24] - Release brake pedals.
[25] - Shut engine OFF.
[26] - Check brakes. (See Check Brakes in this group.)

Section 60 - STEERING AND BRAKES Group 30: Hydraulic Trailer Brake
Check Brakes
→NOTE:
Disconnect all implements or trailers from vehicle.
[1] - For All Tractors:
With engine at slow idle, depress brake pedal.

Ensure that pedal feels solid within 43 mm (1.75 in.) of travel.
Set engine to 1500 rpm.
Drive vehicle straight forward at 4 km/h (2.5 mph).
Depress LEFT brake pedal and verify that vehicle pulls left.
Depress RIGHT brake pedal and verify vehicle pulls right.
Drive vehicle straight forward at 8 km/h (5 mph).
Depress clutch and BOTH brake pedals to stop vehicle. Verify that front end does not
pull to either side.
Drive vehicle straight forward at 8 km/h (5 mph).
Depress clutch, shut engine OFF, and wait 2 seconds.
Depress brake pedal and verify vehicle stops.
Drive vehicle to a slopped location (loading dock ramp).
Depress clutch and BOTH brake pedals and verify brakes hold vehicle on incline.
[2] - For Tractors With Secondary Brake:
Drive vehicle to a slopped location (loading dock ramp).

Place shift lever intoPARK .
Engage and hold the secondary brake switch.
Place shift lever intoNEUTRAL and verify that secondary brake holds vehicle on incline.
Release the secondary brake switch.
Ensure that secondary brake is fully released and tractor rolls.

Section 60 - STEERING AND BRAKES Group 30: Hydraulic Trailer Brake
Group 30 - Hydraulic Trailer Brake

List of References
Specifications
Hydraulic Trailer Brake Component Location
Remove and Install Hydraulic Trailer Brake Valve
Specifications
Hydraulic Trailer Brake Valve Cap Screws Torque 35 N·m
(26 lb.-ft.)
Hydraulic Trailer Brake Component Location
LEGEND:
A Hydraulic Trailer Brake Control Valve
B Priority Oil from Priority Valve
C Load Sense Line to Priority Valve
D Return to Sump
E Trailer Brake Service Line to Quick Coupler
F Pilot Oil Signal Line from Brake Line tee′s
G Hydraulic Trailer Brake Bleed Diagnostics Receptacle

Section 60 - STEERING AND BRAKES Group 35: Air Trailer Brake
Remove and Install Hydraulic Trailer Brake Valve
LEGEND:
A Pressure Line
B Load Sense Line
C Pilot Oil Line
D Trailer Brake Service Line
E Return Line
IMPORTANT:
[2] - Identify, label, and disconnect hydraulic lines (A—E).
[3] - Remove cap screws (F) and hydraulic trailer brake valve.
[5] - Assemble in reverse order and tighten cap screws to specification.
Hydraulic Trailer Brake Valve Cap Screws Torque 35 N·m
(26 lb.-ft.)

Group 35 - Air Trailer Brake

List of References
Specifications
Air Trailer Brake System
Bleed Air from Air Trailer Brake Reservoirs
Remove and Install Air Compressor
Repair Air Compressor
Remove and Install Air Trailer Brake Pre-Brake Valve
Repair Air Trailer Brake Pre-Brake Valve
Remove and Install Air Trailer Brake Park Valve
Remove and Install Air Trailer Brake Valve
Remove and Install Air Pressure Control Valve

Specifications
(92 lb.-ft.)
Air Trailer Brake Pre-Brake Valve Cap Screws Torque 80 N·m
(60 lb.-ft.)
Pre-Brake Solenoid Screws Torque 4 N·m
(35 lb.-in.)
Pre-Brake Enable Solenoid Screws Torque 4 N·m
(35 lb.-in.)
Air Trailer Brake Park Valve Cap Screw Torque 25 N·m
(220 lb.-in.)
Air Pressure Control Valve Cap Screw Torque 25 N·m
(220 lb.-in.)
Flange-to-Sump Socket Head Cap Screws Torque 23 N·m
(203 lb.-in.)
Back Plate-to-Sump Socket Head Screws Torque 23 N·m
(203 lb.-in.)
Barrel-to-Sump Nuts Torque 23 N·m
(203 lb.-in.)
Head Cover-to-Barrel Cap Screws Torque 23 N·m
(203 lb.-in.)
Air Trailer Brake System

European and NA Trailer Air Brake Component Diagram
LEGEND:
A Air Supply Line from Compressor
B Control Valve
C Park Solenoid Valve
D Brake Manifold
E Brake Bleed Diagnostic Receptacle
F Air Shuttle Check Valve
G Supply Coupler (Red)
H Control Coupler (Yellow)
I Secondary Brake Pilot Line
J Secondary Brake Pressure Sensor
Bleed Air from Air Trailer Brake Reservoirs
LEGEND:
A Red Air Trailer Brake Coupler
With engine off, manually depress release valve inside red air trailer brake coupler (A).

Remove and Install Air Compressor
LEGEND:
A Air Lines (2 used)
B Hydraulic Line
E Air Compressor
F O-Ring
[1] - Bleed air from trailer brake system. (See Bleed Air from Air Trailer Brake Reservoirs in
this group.)
[2] - Disconnect air lines (A).
[3] - Remove hydraulic line (B).
[5] - Remove cap screws (D) and air compressor (E).
[7] - Install new O-ring (F).

[8] - Assemble in reverser order.

(92 lb.-ft.)

Repair Air Compressor

[1] -
LEGEND:
B Upper Head Gasket
C Lower Head Gasket
D Nuts (4 used)
E Barrel-to-Sump Seal
F Back Plate Seal
G Socket Head Screws (4 used)
H Flange-to-Sump Seal
I Socket Head Cap Screws (6 used)
Remove cap screws (A) with cover and upper head gasket (B) with head.
[2] - Remove lower head gasket (C), nuts (D), barrel, and barrel-to-sump seal (E).
[3] - Remove socket head screws (G), back plate, and back plate seal (F).
[4] - Remove socket head cap screws (I), flange, and flange-to-sump seal (H).

[6] - Assemble in reverse order and tighten the following to specification

Flange-to-Sump Socket Head Cap Screws Torque 23 N·m
(203 lb.-in.)
Back Plate-to-Sump Socket Head Screws Torque 23 N·m
(203 lb.-in.)
Barrel-to-Sump Nuts Torque 23 N·m
(203 lb.-in.)
Head Cover-to-Barrel Cap Screws Torque 23 N·m
(203 lb.-in.)

Remove and Install Air Trailer Brake Pre-Brake

Valve
LEGEND:
C Air Trailer Brake Pre-Brake Valve
CAUTION:
IMPORTANT:
[1] - Identify, label, and disconnect harness from air trailer brake pre-brake valve (C).
[3] - Remove cap screws (B) and remove valve.
[4] - Replace parts as necessary. (See Repair Air Trailer Brake Pre-Brake Valve in this group.)
[6] - Tighten cap screws (B) to specification.
Air Trailer Brake Pre-Brake Valve Cap Screws Torque 80 N·m
(60 lb.-ft.)

Repair Air Trailer Brake Pre-Brake Valve
LEGEND:
A Screws (2 used)
B Pre-Brake Solenoid Valve
C Screws (2 used)
D Pre-Brake Enable Solenoid Valve
E O-Rings (3 used)
G O-Rings (4 used)

IMPORTANT:

Pre-Brake Solenoid Screws Torque 4 N·m
(35 lb.-in.)

Pre-Brake Enable Solenoid Screws Torque 4 N·m
(35 lb.-in.)

Remove and Install Air Trailer Brake Park Valve
LEGEND:
B Cap Screw
C Air Trailer Brake Park Valve
[1] - Bleed air from air trailer brake reservoirs. (See Bleed Air from Air Trailer Brake
Reservoirs in this group.)
[2] - Identify, label, and disconnect harness from air trailer brake park valve (C).
[3] - Disconnect air lines (A).
[4] - Remove cap screw (B) and remove valve.
[6] - Assemble in reverse order and tighten to specification.
(220 lb.-in.)

Remove and Install Air Trailer Brake Valve
LEGEND:
B Hydraulic Line
C Hydraulic Line
D Air Lines (2 used)
F Air Trailer Brake Valve
CAUTION:
IMPORTANT:

[2] - Remove air lines (A).

[3] - Remove hydraulic line (B).
[4] - Disconnect hydraulic line (C).
[5] - Disconnect air lines (D).
[6] - Remove cap screws (E) and air trailer brake valve (F).
(220 lb.-in.)

HYDRAULICS (g) by Belgreen
Remove and Install Air Pressure Control Valve
LEGEND:
C Air Pressure Control Valve
[2] - Remove air lines (A).
[3] - Remove cap screws (B) and air pressure control valve (C).
Air Pressure Control Valve Cap Screw Torque 25 N·m
(220 lb.-in.)

Table of contents
Specifications ......................................................................................................................... 2
Remove and Install Filter Housing .......................................................................................... 4
Remove and Install Integrated Hydraulic Pump ..................................................................... 8
Remove and Install Transmission Pump ............................................................................... 12
Remove and Install Scavenge and Lube Pump .................................................................... 14
Remove and Install Mid-Stack Valve .................................................................................... 17
Remove and Install Hitch-SCV Valve Stack .......................................................................... 20
Remove and Install Rear Hitch Frame .................................................................................. 26
Remove and Install Front 3-Point Hitch ................................................................................ 35
Group 05 - General Repair Procedures ................................................................................ 43
Specifications ....................................................................................................................... 43
General Repair Procedures—Hydraulic Systems .................................................................. 44
Drain Hydraulic System ........................................................................................................ 45
Fill Hydraulic System ............................................................................................................ 48
Bleed Hydraulic System ....................................................................................................... 52
Group 15 - Integrated Hydraulic Pump ................................................................................ 54
Specifications ....................................................................................................................... 54
Other Material ...................................................................................................................... 54
Remove and Install Hydraulic Compensator Valve ............................................................... 55
Repair Hydraulic Compensator Valve ................................................................................... 58
Disassemble, Repair, and Assemble Integrated Hydraulic Pump ......................................... 60
Group 25 - Hitch Valve, Selective Control Valves and Couplers ...................................... 61
Specifications ....................................................................................................................... 63
Disassemble and Assemble Hitch-SCV Valve Stack ............................................................. 64
Disassemble and Assemble Hitch-SCV Valve Stack - 3D Animation ..................................... 72
Service Pressure Compensator ............................................................................................ 74
Service Pressure Compensator - 3D Animation .................................................................... 76
Service Pressure Compensating Check Valve ...................................................................... 77
Service Pressure Compensating Check Valve - 3D Animation .............................................. 81
Service Spool Centering Spring Assembly ............................................................................ 82
Service Spool Centering Spring Assembly - 3D Animation ................................................... 88
Test Surge Relief Valve ........................................................................................................ 90
Test Surge Relief Valve - 3D Animation ................................................................................ 91
Service Surge Relief Valve ................................................................................................... 92
Service Surge Relief Valve - 3D Animation ........................................................................... 94
Service Shuttle Valve ........................................................................................................... 95
Service Shuttle Valve - 3D Animation .................................................................................. 99
Remove and Install Coupler Housing ................................................................................. 100
Remove and Install Coupler Housing - 3D Animation ......................................................... 101

Repair Couplers .................................................................................................................. 103

Repair Couplers - 3D Animation ......................................................................................... 106
Group 30 - Rear Hitch ........................................................................................................... 107
Other Material .................................................................................................................... 108
Specifications ..................................................................................................................... 109
Remove and Install Rear Hitch Lift Cylinders ..................................................................... 110
Disassemble, Inspect, and Assemble Lift Cylinder ............................................................. 112
Replace Rockshaft Bushings .............................................................................................. 113
Repair Draft Sensing .......................................................................................................... 117
Group 35 - Front Hitch .......................................................................................................... 133
Specifications ..................................................................................................................... 133
Other Material .................................................................................................................... 133
Exploded View—Front Hitch ............................................................................................... 133
Remove and Install Front Hitch Lift Cylinders .................................................................... 136
Repair Front Hitch Lift Cylinder .......................................................................................... 139

Section 70 - HYDRAULICS Group 00: Component Removal and Installation

List of References
Specifications
Remove and Install Filter Housing
Remove and Install Integrated Hydraulic Pump
Remove and Install Transmission Pump
Remove and Install Scavenge and Lube Pump
Remove and Install Mid-Stack Valve
Remove and Install Hitch-SCV Valve Stack
Remove and Install Rear Hitch Frame
Remove and Install Front 3-Point Hitch
→NOTE:

D01045AA Disk Set
JDG909 Lifting Eyes

Specifications
Specificatio
Item Measurement
n
Hydraulic Filter Base Cap Screws Torque 50 N·m
(37 lb.-ft.)
Line Clamp Cap Screws Torque 50 N·m
(37 lb.-ft.)
Integrated Hydraulic Pump-to-Pump Drive Housing Cap Screws Torque 128 N·m
(94 lb.-ft.)
Priority Valve Cap Screws Torque 70 N·m
(52 lb.-ft.)
Transmission Pump-to-Pump Drive Housing Cap Screws Torque 128 N·m
(94 lb.-ft.)
Scavenge and Lube Pump-to-Pump Drive Housing Cap Screws Torque 128 N·m
(94 lb.-ft.)
Mid-Stack Mounting Cap Screws Torque 73 N·m
(54 lb.-ft.)
TLS Valve Mounting Cap Screws Torque 73 N·m
(54 lb.-ft.)
Valve Stack-to-Hitch Frame Retaining Nuts Torque 130 N·m
(96 lb.-ft.)
Hitch Frame-to-Differential Case Cap Screws Torque 500 N·m
(368 lb.-ft.)
Center Link Bracket-to-Hitch Frame Cap Screws Torque 430 N·m
(317 lb.-ft.)
Front Push Bar Cap Screws Torque 430 N·m
(320 lb.-ft.)
Rear Push Bar Cap Screws Torque 310 N·m
(228 lb.-ft.)
(54 lb.-ft.)
(54 lb.-ft.)
Draw Bar Pin Retainer Cap Screw Torque 70 N·m
(52 lb.-ft.)
Draw Bar Reinforcement Cap Screws Torque 430 N·m
(317 lb.-ft.)
Draft Cover Cap Screws Torque 70 N·m
(52 lb.-ft.)
Sway Block Cap Screws Torque 200 N·m

Specificatio
Item Measurement
n
(148 lb.-ft.)
PTO Shield Cap Screws Torque 70 N·m
(52 lb.-ft.)
Draw Bar Support Cap Screws Torque 430 N·m
(317 lb.-ft.)
(228 lb.-ft.)

Remove and Install Filter Housing

[1] -
→NOTE:
LEGEND:
A Hydraulic Filter
Drain hydraulic system. (See Drain Hydraulic System in Group 05.)
[2] - Remove hydraulic filter (A).

[3] -
LEGEND:
B Line
C Line
D Line
E Line
F Filter Base
G Spacer Plate
Disconnect lines (B—E).
[4] - Remove cap screws (A), filter base (F), and spacer plate (G).
[5] -
LEGEND:
A O-Rings (4 used)
Install new O-rings (A).

[6] -
LEGEND:
B Line
C Line
D Line
E Line
F Filter Base
G Spacer Plate
Install spacer plate (G), filter base (F), and cap screws (A). Tighten to specification.
Hydraulic Filter Base Cap Screws Torque 50 N·m
(37 lb.-ft.)
[7] - Install lines (B—E).

[8] -
LEGEND:
A Hydraulic Filter
Install hydraulic filter (A).
[9] - Fill hydraulic system. (See Fill Hydraulic System in Group 05.)

Remove and Install Integrated Hydraulic Pump
→NOTE:
LEGEND:
A Hydraulic Filter Housing
B Air Compressor
C Shield
D Lines (6 used)
F Priority Valve
[1] - Drain hydraulic system. (See Drain Hydraulic System in Group 05.)
[2] - Remove hydraulic filter housing (A). (See Remove and Install Filter Housing in this
group.)
[3] - Remove air compressor (B) if equipped. (See Remove and Install Air Compressor in
Section 60, Group 35).
[4] - Remove shield (C).
[5] - Identify, label, and disconnect lines (D).
[6] - Remove cap screws (E) priority valve (F).

[7] -
LEGEND:
A Line
C Integrated Hydraulic Pump
Remove line (A).
[8] - Remove cap screws (B) and integrated hydraulic pump (C).
[9] -
LEGEND:
A Port
B O-ring
Pre-fill pump crankcase with clean hydraulic oil at port (A).
[10] - Install new O-ring (B).

[11] -
LEGEND:
A Line
C Integrated Hydraulic Pump
Install integrated hydraulic pump (C) and cap screws (B). Tighten to specification.
Integrated Hydraulic Pump-to-Pump Drive Housing Cap Screws Torque 128 N·m
(94 lb.-ft.)
[12] - Install O-ring and line (A).

[13] -
LEGEND:
A Hydraulic Filter Housing
B Air Compressor
C Shield
D Lines (6 used)
F Priority Valve
Install new O-rings on priority valve (F).
[14] - Install priority valve and cap screws (E). Tighten to specification.
Priority Valve Cap Screws Torque 70 N·m
(52 lb.-ft.)
[15] - Install air compressor (B) if equipped. (See Remove and Install Air Compressor in
section 60, Group 35.)
[16] - Install hydraulic filter housing (A). (See Remove and Install Filter Housing in this
group.)
[17] - Install shield (C).
[18] - Install O-rings and lines (D).
[19] - Install NEW hydraulic filter.
[20] - Fill hydraulic system. (See Fill Hydraulic System in Group 05.)

Remove and Install Transmission Pump
→NOTE:
Procedure illustrated with IVT transmission. Procedures for PowrQuad™

and AutoQuad™ transmissions are similar.
Line and Hose configurations vary depending upon tractor options.
Transmission Pump for IVT™ Tractors Illustrated
LEGEND:
A Line
C Suction Line
D Pressure Line (1 used on PowrQuad™ and AutoQuad™)(2 used on IVT™)
[2] - Remove line (A), cap screws (B), and suction line (C).
[3] - Disconnect pressure lines (D).
[4] - Remove cap screws (E) and pump.

[5] -
LEGEND:
A O-ring
InstallNEW O-ring (A).
[6] -
Transmission Pump for IVT™ Tractors Illustrated

LEGEND:
A Line
C Suction Line
D Pressure Line (1 used on PowrQuad™ and AutoQuad™) (2 used on IVT™)
Install pump and caps screws (E). Tighten to specification.
Transmission Pump-to-Pump Drive Housing Cap Screws Torque 128 N·m
(94 lb.-ft.)
[7] - Install line (A).

[8] - Install O-rings, suction line (C), and cap screws (B).
[9] - Install O-rings and pressure lines (D).

Remove and Install Scavenge and Lube Pump
→NOTE:
Procedure illustrated with IVT™ transmission. Procedures for PowrQuad™

and AutoQuad™ transmissions are similar
LEGEND:
A Line
B Fitting
C Scavenge Pump Suction Line
D Lube Pump Suction Line
F Scavenge and Lube Pump
G O-rings (6 used)
[2] - Remove lines (A—D).
[3] - Remove cap screws (E).
[4] - Remove scavenge and lube pump (F).
[5] - Remove and replace O-rings (G).
[6] -
LEGEND:
A O-ring
InstallNEW O-ring (A).
[7] -

LEGEND:
A Line
B Line
C Scavenge Pump Suction Line
D Lube Pump Suction Line
F Scavenge and Lube Pump
G O-rings (6 used)
Install pump (F) and caps screws (A). Tighten to specification.
Scavenge and Lube Pump-to-Pump Drive Housing Cap Screws Torque 128 N·m
(94 lb.-ft.)
[8] - Install O-rings (G) and suction lines (C and D).

[9] - Install lines (A and B).

Remove and Install Mid-Stack Valve

[1] -
LEGEND:
A Cover
Remove cover (A).
[2] - Thoroughly clean area around mid-stack valve.
[3] -
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious
injury. Avoid the hazard by relieving pressure before disconnecting
hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from
high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the
skin must be surgically removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of injury should reference a
knowledgeable medical source. Such information is available from Deere &
Company Medical Department in Moline, Illinois, U.S.A.

LEGEND:
A Screws
B Shield
C SCV Drain Hose
D Return Line
E Pressure Line
F Connector
G Connector
H Load Sense Line
I Line
J Line
K Cap Screws (3 used)
L Cap Screws (2 used)
M Load Sense Line
Remove screws (A) and shield (B).
[4] - Remove SCV drain hose (C).
[5] - Disconnect pressure and return lines (D and E).
[6] - Disconnect connector (F).
[7] - Disconnect load sense line (H).
[8] - Remove cap screws (K) and mid-stack valve.
[9] - For tractors equipped with TLS™ perform the following: Disconnect
connector (G).
[10] - Remove lines (I and J).
[11] - Disconnect load sense line (M).
[12] - Remove cap screws (L) and remove mid-stack valve with TLS™ valve as an assembly.
(54 lb.-ft).
(54 lb.-ft).

Remove and Install Hitch-SCV Valve Stack

[1] -
CAUTION:
Valve stack is heavy. Use proper lifting equipment to prevent possible
personal injury.
IMPORTANT:
To prevent damage to SCV valve stack electrical connections clean valve
stack and surrounding area with compressed air. DO NOT use high pressure
water or steam over 75 bar (1000 PSI) and no closer than 200 mm (8 in.) to
clean valve stack.
→NOTE:
Line configurations vary depending on tractor options.
Fully lower 3-point hitch.

[2] -
LEGEND:
A Drain Hose
B Lift Cylinder Line
C Hitch Return Line
Remove drain hose (A).
[3] - Disconnect lift cylinder line (B).
[4] - Remove hitch return line (C).

[5] -
LEGEND:
A Load Sense Hose
B Load Sense Line
C Rear Retaining Nut
D Front Retaining Nut
Disconnect load sense hose (A) and load sense line (B).
[6] - Remove rear retaining nut (C) at lower rear corner of valve stack.
[7] - Remove front retaining nut (D).

[8] -
LEGEND:
A JDG1574 Lifting Bracket
Attach JDG1574 Lifting Bracket to valve stack with two M12 x 70 mm cap screws.
[9] - Use chain hoist and remove valve stack.
[10] -
LEGEND:
A O-Rings (2 used)
B O-Ring
Install new O-rings (A and B).
[11] - Install SCV stack.

[12] -
LEGEND:
A Load Sense Hose
B Load Sense Line
C Rear Retaining Nut
D Front Retaining Nut
Install front and rear retaining nuts (C and D). Tighten to specification.
Valve Stack-to-Hitch Frame Retaining Nuts Torque 130 N·m
(96 lb.-ft.)
[13] - Install load sense hose (A).

[14] - Install load sense line (B).

[15] -
LEGEND:
A Drain Hose
B Lift Cylinder Line
C Hitch Return Line
Install drain hose (A).
[16] - Connect lift cylinder line (B).
[17] - Install hitch return line (C).
[18] - Cycle 3-point hitch several times to remove air from hoses and lift cylinders.

Remove and Install Rear Hitch Frame

[1] -
→NOTE:
LEGEND:
A Quick Coupler
Remove hitch quick coupler (A), if equipped.
[2] -
LEGEND:
A Sway Limiters (2 used)
Disconnect sway limiters (A) from both lower draft links.

[3] -
LEGEND:
A Draw Bar Reinforcement
B Pin Retainer
D Draw Bar Pin
Remove draw bar reinforcement (A), if equipped.
[4] - Remove retainer cap screw (C), retainer (B), and draw bar pin (D).
[5] - Remove draw bar.
[6] -
LEGEND:
A Cover Cap Screws (10 used)
B Cover
C Draft Sensor Harness
Remove cover cap screws (A) and cover (B).
[7] - Disconnect draft sensor harness (C).

[8] -
LEGEND:
A Center Link
B Center Link Bracket
C SCV Valve Stack
Remove center link (A) and center link bracket (B).
[9] - Remove SCV Valve Stack (C). (See Remove and Install Hitch-SCV Valve Stack in this
group.)
[10] -
→NOTE:
Wiring harnesses stay with tractor when rear hitch frame is removed.
LEGEND:
A Implement Connector
B Seven-Terminal Outlet Socket
Disconnect wiring harnesses from rear of implement connector (A), and seven-terminal outlet
socket (B).
[11] -
LEGEND:
A Air Brake Couplers (2 used)
B Case Drain Fitting
C Brackets (3 used)
Disconnect lines from rear of air brake couplers (A).

Disconnect line from rear of case drain fitting (B).
[12] - Remove brackets (C).

[13] -
LEGEND:
A Hitch Position Sensor
Disconnect wiring harness from hitch position sensor (A).
[14] - Identify, label, and disconnect hydraulic lines (B).

[15] -
LEGEND:
A Left And Right Sway Blocks
Remove left and right side sway blocks (A).
[16] -
LEGEND:
B PTO shield
D Rear Draw Bar Support
Remove cap screws (A) and rear PTO shield (B).
[17] -
CAUTION:
Rear draw bar support weighs approximately 51 kg (113 lb.) use caution
when handling.
Remove caps screws (C) and rear draw bar support (D).

[18] -
CAUTION:
Rear Hitch Frame weighs approximately 771 kg (1700 lb.) use proper
lifting equipment.
LEGEND:
Attach JDG909 Lifting Eyes (A) to hitch frame casting positioned as illustrated, also attach
lifting strap around rock shaft housing.
[19] - Connect hitch frame to proper lifting device.

[21] -
Remove hitch frame.

[23] - Clean adjoining gasket surfaces.
[24] - Apply a small bead of PM38657 High Flex Form-In-Place Gasket around mating surface
of housing.
Number Name Use
• PM38657 (us)


Draw Bar Pin Retainer Cap Screw Torque 70 N·m
(52 lb.-ft.)
Draw Bar Reinforcement Cap Screws Torque 430 N·m
(317 lb.-ft.)
Draft Cover Cap Screws Torque 70 N·m
(52 lb.-ft.)
Sway Block Cap Screws Torque 200 N·m
(148 lb.-ft.)
PTO Shield Cap Screws Torque 70 N·m
(52 lb.-ft.)
Draw Bar Support Cap Screws Torque 430 N·m
(317 lb.-ft.)
Hitch Frame-to-Differential Case Cap Screws Torque 500 N·m
(368 lb.-ft.)
Center Link Bracket-to-Hitch Frame Cap Screws Torque 430 N·m
(317 lb.-ft.)

Remove and Install Front 3-Point Hitch

[1] - Lower front 3 point hitch.
[2] -
LEGEND:
A Pin
B Center link
Remove pin (A).
[3] - Remove center link (B).
[4] -

LEGEND:
A Retaining Clip
B Pin
C Nut
D Washer
E Pivot Pin
F Lift Arm
Remove retaining clip (A).
[5] - Remove pin (B).
[6] - Remove nut (C) and washer (D).
[7] -
CAUTION:
Lift arm weighs approximately 56 kg (112 lb.) use appropriate lifting
device.
Support lift arm (F) and remove pivot pin (E).

[8] -
→NOTE:
Pilot and driver disks are part of D01045AA Disk Set .
LEGEND:
A Bushings (2 used)
Inspect bushings (A) and replace as necessary.
[9] - Install bushings using 33 mm (1-5/16 in.) pilot disk and 38 mm (1-1/2 in.) driver disk.

[10] -
LEGEND:
B Lock Nuts (2 used)
C Lift Cylinder Pins (2 used)
D Front Hitch Draft Link
Remove cap screws (A) and nuts (B).
[11] -
CAUTION:
Front Hitch Draft Link weighs approximately 127 kg (279 lb.) use
appropriate lifting device.
Support front hitch draft link (D) and remove pins (C).

[12] -
LEGEND:
A Plug
B Retaining Pin
C Pivot Pin
D Bushings (2 used)
E Front Hitch Draft Link
Remove plug (A) and retaining pin (B).
[13] - Remove pivot pin (C).
[14] - Remove front hitch draft link (E).
[15] - Inspect bushings (D) and replace as necessary.
[16] - Install bushings using 68 mm (2-5/16 in.) pilot disk and 76 mm (2-1/2 in.) driver disk.

[17] -
LEGEND:
A Hydraulic Hoses (4 used)
C Cylinders (2 used)
D Pins (2 used)
Disconnect hydraulic hoses (A).
[19] - Support cylinders (C) and remove pins (D).
[20] -
CAUTION:
Push bar weighs approximately 326 kg (718 lb.) use appropriate lifting
device.

LEGEND:
A Push Bar
C Nuts (2 used)
D Washers (2 used)
E Rear Push Bar Support
Support push bar (A).
[22] - Loosen nuts (C) in both directions so washers (D) are loose.
[23] - Remove cap screws (F).
[24] - Lower push bar (A) to ground and remove.

Section 70 - HYDRAULICS Group 05: General Repair Procedures

Front Push Bar Cap Screws Torque 430 N·m
(320 lb.-ft.)
(228 lb.-ft.


List of References
Specifications
General Repair Procedures—Hydraulic Systems
Drain Hydraulic System
Fill Hydraulic System
Bleed Hydraulic System
Specifications
Drain Plug Torque 102 N·m
(75 lb.-ft.)

General Repair Procedures—Hydraulic Systems
IMPORTANT:

→NOTE:
Before beginning hydraulic system repair, review the following guidelines.

They are provided to emphasize the need for attention to detail and care
when servicing the hydraulic system.
Discard and replace shaft seals, O-rings, and gaskets.

Cleaning:
Clean all disassembled parts with clean solvent. Use moisture-free compressed air to
dry parts and to clear oil passages of any contamination. DO NOT use shop towels to
dry parts.
If a failure occurred causing contamination of transmission and hydraulic system,
cleanup procedures must be performed. Clean and flush differential housing and
transmission.
Inspection:
Inspect components for clear valve passages.

Valves must move smoothly in valve bores. Binding cannot be tolerated.
Inspect bearings for roughness of rotation, and excessive wear of rollers.
System Startup:
IMPORTANT:
Fill hydraulic system procedure MUST be followed BEFORE engine is started

if system has been drained. Failure to perform this procedure can damage
pump.
Fill hydraulic system. (See Fill Hydraulic System in this group.)

Drain Hydraulic System

[1] -
IVT/ Transmission
PowrQuad Transmission
LEGEND:
A Transmission Drain Plug
B Reservoir Drain Plug
C PTO Drain Plug
D Final Drive Drain Plugs (2 used)
Park tractor on level surface.
[2] - Lower hitch.
[3] - Let engine run at idle for 1—2 minutes, then stop the engine.
[4] - Move drawbar to the side so oil can drain.
[5] - Remove transmission drain plug (A), reservoir drain plug (B), and PTO drain plug (C),
and final drive drain plugs (D).

[6] -
Suction Screen Location IVT™/AutoPowr™ Transmission (Right Side of Transmission)
Suction Screen Location PowrQuad™ PLUS, AutoQuad™ PLUS, and CommandQuad™

Transmissions (Left Side of Transmission)
Transmission and Hydraulic Filter (Left Side of Tractor)

LEGEND:
A Suction Screen Tube or Cover
B Transmission and Hydraulic Oil Filter
Remove suction tube or suction screen cover (A).

[7] - Remove suction screen and wash carefully in cleaning solvent. Blow dry with
compressed air.
[8] - Install screen and oil line making sure that gasket and O-ring are correctly positioned.
[9] - Remove transmission and hydraulic oil filter (B).
[10] - Lubricate new filter seal with clean hydraulic oil.
[11] - Install filter until gasket contacts surface. Hand tighten additional 1/2 turn.
[12] - Install drain plugs after oil has drained and tighten to specification.
Drain Plug Torque 102 N·m
(75 lb.-ft.)

Fill Hydraulic System

[1] -
IMPORTANT:
When filling the tractor with oil. Use only ONE of the following procedures
“Adding Oil With Pump” or “Adding Oil Without Pump”.DO NOT PERFORM
BOTH PROCEDURES.
ADDING OIL WITHOUT PUMP
Open hydraulic oil transfer valve (C). Valve is located on left side of tractor in front of
draft linkage.
Rear of Tractor
Left Side of Tractor

LEGEND:
A Power Beyond Return Port
B Fill Tube
C Oil Transfer Valve
Remove fill tube (B) cap and pour 128 L (135 qt.) of hydraulic oil (see Fuel, Lubricants,
and Coolant Section) into fill tube.
Wait 15 minutes for oil to transfer to hydraulic reservoir.

Close oil transfer valve (C).

IMPORTANT: To prevent damage to tractor, oil must be visible in sight
glass when oil transfer valve is closed before starting tractor.
Observe oil level in sight glass. Oil will lower in sight glass when oil transfer valve is
closed.
If oil level is visible in sight glass, continue toStep 2 .If oil isNOT visible in sight glass,
open oil transfer valve and wait another 5 minutes. Repeat until oil is present in sight
glass.
IMPORTANT: Oil must be visible in sight glass before continuing to
Step 2.
ADDING OIL WITH PUMP
Remove cap from power beyond return port (A).

Install a hydraulic quick coupler and extension into power beyond return port (C).
Tighten to hand-tight.
Install a male ISO hose tip to a pump outlet hose.
Connect pump outlet hose to power beyond quick coupler.
Pump 38 L (40 qt.), of hydraulic oil into power beyond port or 50 L (53 qt.) if optional
hydraulic reservoir is installed.
IMPORTANT: To prevent damage to tractor, oil must be visible in sight
glass before starting tractor.
Remove pump outlet hose from power beyond quick coupler.

Remove male ISO hose tip from pump outlet hose.
Place pump outlet hose into fill tube (B).
Pump 90 L (95 qt.) of hydraulic oil into fill tube (B).
[2] -
IMPORTANT:
Oil transfer valve must be closed before continuing oil fill procedure.
Start and leave engine at slow idle for 5 minutes.

[3] - Check oil level in sight glass. With tractor idling,slowly add oil to tractor fill tube (B).
Observe oil level rising in sight glass. There is a slight delay between adding oil and the time
it shows up in oil level sight glass. Top up oil level according to oil level sight glass. (See
Operator’s Manual Specifications for hydraulic oil capacities.)

IVT™/AutoPowr™ Transmission

PowrQuad™ PLUS, AutoQuad™ PLUS, and CommandQuad Transmissions
LEGEND:
A Maximum Operating Level
B Normal Operating Range
C Add Level
When transmission and hydraulic oil level is at add level (C), add recommended amount for
specified transmission to reach top of the normal operating range (B):
IVT™ / AutoPowr™ Transmission Volume 13 L (14 qt.).

PowrQuad™ PLUS, AutoQuad™ PLUS, and CommandQuad™ Transmissions Volume 8 L
(8.5 qt.).
Road Transportation - In applications where tractor is used for mainly road transportation
and light hydraulic work, adjust oil level to normal operating range (B). A lower oil level may
allow tractor to operate more efficiently at transport speeds. Oil level above the maximum
operating level (A) can result in power loss and heat generation during transport.
For Side-Hill Applications or High Oil Volume Requirements - Oil level should be
slightly below or at maximum operating level (A).

Bleed Hydraulic System
→NOTE:
Hydraulic system must be bled after any hydraulic components, hydraulic

pumps, or valves have been replaced and before hitch is calibrated.
Run Engine speed at 1500 rpm. If using needle valve manifold, open both
valves two turns.
[1] -
LEGEND:
A Jumper Hose
Fully raise and lower hitch five times.
[2] - Install jumper hose in each SCV coupler and cycle each SCV for 15 seconds.
[3] - For tractors equipped with mid-stack SCV, perform the following:
Install jumper hose in each valve coupler and cycle each for 15 seconds.
[4] - Remove jumper hose.

Section 70 - HYDRAULICS Group 15: Integrated Hydraulic Pump
[5] - Stall each SCV individually and hold for 15 seconds beginning with:
a. Number VI SCV (if equipped).

b. Number V SCV (if equipped).
c. Number IV SCV (if equipped).
d. Number III SCV.
e. Number II SCV.
f. Ending with number I SCV.
[6] - For tractors equipped with mid-stack SCV, perform the following:
Stall each mid-stack valve for 15 seconds.
[7] - Bleed brakes (See Bleed Brakes in Section 60, Group 20.)

Group 15 - Integrated Hydraulic Pump

List of References
Specifications
Other Material
Remove and Install Hydraulic Compensator Valve
Repair Hydraulic Compensator Valve
Disassemble, Repair, and Assemble Integrated Hydraulic Pump
Specifications
Compensator Valve Socket Head Cap Screws Torque 15 N·m
(137 lb.-in.)
End Cover Socket Head Cap Screws Torque 205 N·m
(151 lb.-ft.)
Other Material
Number Name Use
• PM37477 (us)

Remove and Install Hydraulic Compensator Valve
CAUTION:
the pressure in the system before disconnecting or connecting hydraulic or
other lines. Tighten all connections before applying pressure.
IMPORTANT:
→NOTE:
Left rear wheel may be slid out or removed to access compensator valve.
[1] - Clean area around hydraulic pump and compensator valve (A).
[2] - Disconnect load sense hose (B).
[3] - Remove socket head cap screws (C) and compensator valve (A).
LEGEND:
A Hydraulic Compensator Valve
B Load Sense Hose

[1] -
LEGEND:
A Gasket
B Tabs
C Housing
Inspect parts and replace as necessary. (See Repair Hydraulic Compensator Valve in this
group.)
[2] -
→NOTE:
Seat gasket tabs (B) in housing (C) to aid installation.
Install compensator valve using anew gasket (A).

[3] - Tighten compensator valve socket head cap screws evenly to specification.
Compensator Valve Socket Head Cap Screws Torque 15 N·m
(137 lb.-in.)
[4] - Install load sense hose.

[5] -
IMPORTANT:
Compensator pressure must be adjusted on the tractor if compensator is
disassembled. (See Diagnostic Technical Manual—Section 270.)
→NOTE:
Compensator is preset at the factory and will not require adjustment after
installing on the tractor.
Check system pressure. (See Diagnostic Technical Manual—Section 270.)

Repair Hydraulic Compensator Valve
LEGEND:
A Housing
B O-Ring
C Plug
D Load Sense Valve
E Valve Seat
F Spring
G Adjusting Screw Dimensions (2 used)
H Plate
I O-Ring
J Backup Ring
K Ajusting Screws (2 used)
L O-Ring
M Fitting
N Lock Nuts (2 used)
O Fitting
P O-Ring
Q Plate
R Spring
S Plate
T Pressure Limiting Valve
U O-Ring
V Orifice
W Seals (2 used)
X Plugs (2 used)

IMPORTANT:
[1] - Measure and note dimension (G) at adjusting screw (K).

[2] - Disassemble compensator valve.
[3] - Clean parts and inspect for wear or damage.
[4] - Pressure limiting valve (T) and load sense valve (D) must not stick in the bores.
IMPORTANT:
If excessive wear, sticking valves, or damage is present, replace entire
compensator valve.
[1] - Coat parts with clean hydraulic oil.

[2] - To prevent valve seat misalignment, assemble with compensator housing in vertical
position.
[3] - Turn adjusting screw (K) until dimension (G), noted during disassembly, is achieved.
[4] - Install compensator. (See Remove and Install Hydraulic Compensator Valve in this
group).

Group 25: Hitch Valve, Selective Control Valves and
Couplers
Disassemble, Repair, and Assemble Integrated

Hydraulic Pump
[1] -
LEGEND:
A Socket Head Cover Cap Screws (4 used)
B O-ring
C Rings (2 used)
D Rotor
E Vanes (7 used)
Remove integrated hydraulic pump. (See Remove and Install Integrated Hydraulic Pump in
Group 00.)
[2] - Remove socket head cap screws (A) and cover.
[3] - Replace O-ring (B).
[4] - Inspect and replace parts (C—E) as necessary.
[5] - Install cover and socket head cap screws (A). Tighten to specification.
End Cover Socket Head Cap Screws Torque 205 N·m
(151 lb.-ft.)
[6] - Install integrated hydraulic pump. (See Remove and Install Integrated Hydraulic Pump in
Group 00.)

Couplers
Group 25 - Hitch Valve, Selective Control Valves and

Couplers
List of References
Specifications
Disassemble and Assemble Hitch-SCV Valve Stack
Disassemble and Assemble Hitch-SCV Valve Stack - 3D Animation
Service Pressure Compensator
Service Pressure Compensator - 3D Animation
Service Pressure Compensating Check Valve
Service Pressure Compensating Check Valve - 3D Animation
Service Spool Centering Spring Assembly
Service Spool Centering Spring Assembly - 3D Animation
Test Surge Relief Valve
Test Surge Relief Valve - 3D Animation
Service Surge Relief Valve
Service Surge Relief Valve - 3D Animation
Service Shuttle Valve
Service Shuttle Valve - 3D Animation
Remove and Install Coupler Housing
Remove and Install Coupler Housing - 3D Animation
Repair Couplers
Repair Couplers - 3D Animation

Couplers
→NOTE:

D01019AA Manually Operated Hydraulic Pump
JDG1579 Coupler Tool
JDG10664 Relief Valve Core Removal Tool
JDG10665 Spool Centering Spring Assembly Tool
JDG10666 Pressure Compensator Removal Brush
JDG10667 Shuttle Valve Removal Tool

Couplers
Specifications
Valve Stack-to-Tractor Mounting Cap Screws Torque 125 N·m
(91 lb.-ft)
Valve Stack Tie-Bolt Nuts Torque 26 N·m
(20 lb.-ft)
Pressure Compensator Plug Torque 68 N·m
(50 lb.-ft)
Pressure Compensating Check Valve Plugs Torque 65 N·m
(48 lb.-ft)
Valve Spool Centering Spring Assembly-to-Valve Spool Torque 19 N·m
(168 lb.-in)
Valve Spring Cover Screws Torque 5.5 N·m
(48 lb.-in)
Coupler Housing-to-Valve Housing Torque 22 N·m
(195 lb.-in.)
Surge Relief Valve Pressure 22800-23800 kPa
228—238 bar
(3307—3452 psi)
Surge Relief Valve Seat Torque 24 N·m
(212 lb.-in.)
Surge Relief Valve Cap Torque 54 N·m
(40 lb.-ft)

Couplers
Disassemble and Assemble Hitch-SCV Valve Stack
CAUTION:
Valve stack is heavy. Use proper lifting equipment to prevent possible

personal injury.
→NOTE:
Valve stack configurations vary.
[1] -
LEGEND:
A Tie Bolts (2 used)
B JDG1574 Lifting Bracket
Remove tie bolts (A).
[2] -
IMPORTANT:
Valve stack must be disassembled and assembled in vertical position to
prevent part damage and misalignment.
ALL valves should be reinstalled in the same position in valve stack as
removed from. If valve sections are not returned to their original positions
valve stack will require recalibration with latest version of software.
Carefully lower the valve stack in a vertical position to a clean work surface.
[3] - Remove JDG1574 Lifting Bracket (B).

Couplers
[4] -
IMPORTANT:
ALL valves should be reinstalled in the same position in valve stack as
removed. If valve sections are not returned to their original positions valve
stack will require recalibration with latest version of software.
LEGEND:
A Valve Stack Sections
Identify location of valve stack sections (A).
[5] -
→NOTE:
Some O-rings may stick to attaching surfaces when removing the individual
selective control valve sections.
Tie bolts may turn when removing the retaining nuts. Remove the tie bolt
with nut from the valve stack. Remove the nut and reinstall the tie bolt.

Couplers
LEGEND:
A Nuts and washers (3 used)
B Top Cover
Remove nuts and washers (A)and top cover (B).
[6] -
IMPORTANT:
LEGEND:
A Shims (3 used)
Shims (A) will need to be returned to same locations as removed from.
Note location of any shims (A) on valve stack tie bolts.

Couplers
[7] -
LEGEND:
A Tubes
Carefully remove valve stack sections individually from valve stack.
[8] - Remove tubes (A) from between valve stack sections.
[9] -
LEGEND:
A Machined Surfaces
Inspect housing machined surfaces (A) for rust or contamination. Use a 280 grit honing stone
or crocus cloth to remove only the high spots of rust.
IMPORTANT:
If this surface is cleaned with a honing stone, shims will need to be
installed on tie bolts between this surface and adjoining valve section.

Couplers

Couplers
[10] -
LEGEND:
A Check Valve
B Backup Rings (2 used)
C O-Rings (5 used)
Install check valve (A).
[11] - Install new backup rings (B) and O-rings (C) on each valve section.

Couplers
[12] -
IMPORTANT:
DO NOT intermix check valve (A) with other series valves. A wrong size
shuttle can cause a malfunction.
IMPORTANT:
Prevent valve malfunction and leaks, ensure all O-rings are completely
seated in grooves and no paint chips or other contaminates are on
adjoining surfaces.
Ensure check valves (A) remain in position during assembly.

[13] -
LEGEND:
A Jumper Tubes (2 used per Coupler Housing)
Install new O-ring on jumper tubes (A).
[14] - Install jumper tubes (A).

Couplers
[15] -
LEGEND:
A Tie Bolt Nuts (3 used)
B Top Cover
Install top cover (B), washers, and tie bolt nuts (A).
[16] -
IMPORTANT:
DO NOT overtighten tie bolt nuts. Overtightening will cause valves to
malfunction.

Couplers
Tighten nuts in sequence 1-3 to specification.

Valve Stack Tie-Bolt Nuts Torque 26 N·m
(20 lb.-ft.)
[17] -
IMPORTANT:
Valve stack must be recalibrated with latest version of software if a valve
section is replaced or if valve sections positions are changed in valve stack.
Calibrate valve stack sections. (See appropriate SCC or HCC configuration procedure in
Diagnostic Technical Manual, Section 245.)
Disassemble and Assemble Hitch-SCV Valve Stack -

3D Animation
RXVI00001.smg

Couplers
If you can`t open video, download and install CATIA Composer Player>

Couplers
Service Pressure Compensator

[1] -
CAUTION:
Use caution when removing plug, 300 N (70 lb.) force needed on back side
of plug.
Remove plug (A).

[2] -
→NOTE:
JDG10666 Pressure Compensator Removal Brush (C) may be used to remove
spool if needed.

Couplers
LEGEND:
A Spool
B Spring
C JDG10666 Pressure Compensator Removal Brush
Remove spool (A) and spring (B).
[3] - Check spool for damage and wear.
[4] - Lubricate spool and housing bore.
[5] -
LEGEND:
A Spring
B Spool
C O-ring
D Plug
Install spring (A) and spool (B).
[6] - Install O-ring (C) on plug (D).
[7] - Tighten plug (D) to specification.
Pressure Compensator Plug Torque 68 N·m
(50 lb-ft)

Couplers
Service Pressure Compensator - 3D Animation
RXVI00006.smg

Couplers
Service Pressure Compensating Check Valve

[1] -
→NOTE:
Valve section must be removed from valve stack to service both check
valves
LEGEND:
A Coupler Housing
Remove coupler housing (A). (See Remove and Install Coupler Housing in this group.)
[2] -
LEGEND:
A Plugs (2 used)
B Springs (2 used)
C Pilot Valves (2 used)
D Check Valves (2 used)
Remove plugs (A), springs (B), pilot valves (C), and check valves (D).

Couplers
[3] -
LEGEND:
A Check Valve Surface
B Valve Seat Surface
Inspect check valve surface (A) and valve seat surface (B) for damage, wear, or deterioration.
[4] -
LEGEND:
A Parts
Parts (A) are serviced as a kit.

Couplers
[5] -
LEGEND:
B Pilots (2 used)
Install check valves (A) and pilots (B).

Couplers
[6] -
LEGEND:
A 8.45—9.45 mm (0.3327—0.3720 in.)
B 18.24—19.04 mm (0.7181—0.749 in.)
Measure to verify dimensions (A and B).

Couplers
[7] -
LEGEND:
A Springs (2 used)
B O-rings (2 used)
C Plugs (2 used)
[8] - Install new O-rings (B) on plugs (C).
[9] - Install and tighten plugs to specification.
Pressure Compensating Check Valve Plugs Torque 65 N·m
(48 lb.-ft.)
[10] - Install coupler housing and return valve assembly to valve stack.
Service Pressure Compensating Check Valve - 3D

Animation
RXVI00010.smg

Couplers
Service Spool Centering Spring Assembly

Disassembly Spool Centering Spring Assembly
[1] -
CAUTION:
Use caution when removing spring cover. There is spring force behind
cover.
LEGEND:
A Screws (4 used)
B Spring Cover
C Spring
Remove screws (A) and spring cover (B).
[2] - Remove spring (C).

Couplers
[3] -
IMPORTANT:
Avoid damage to position sensor on opposite end of spool. Move valve
spool a MAXIMUM of 30 mm (1.18 in.).
LEGEND:
A 30 mm (1.18 in.)
Install JDG10665 Spool Centering Spring Assembly Tool on valve spool.

Couplers
[4] -
LEGEND:
A Screws (2 used)
Thread in screws (A) to capture spring and washer.
[5] -
Use an Allen wrench and a thin open-end wrench to remove centering spring assembly.

Couplers
[6] -
LEGEND:
A Alignment Pin
B Spring Compressor
Install alignment pin (A) and spring compressor (B).
[7] -
LEGEND:
A Screws (2 used)
Compress tool together and remove screws (A).

Couplers
[8] -
LEGEND:
A Washer
B Spring
C Sleeve
Relieve pressure to remove washer (A) and spring (B) from sleeve (C).
Assemble Spool Centering Spring Assembly
[1] - Assemble washer (A) and spring (B) on sleeve (C).

[2] -
LEGEND:
A Screws (2 used)
Compress tool together and thread in screws (A) to retain spring and washer.

Couplers
[3] -
LEGEND:
A Alignment Pin
B Spring Compressor
Remove spring compressor (B) and alignment pin (A).
[4] -
Install assembly to valve spool. Tighten to specification.

Valve Spool Centering Spring Assembly-to-Valve Spool Torque 19 N·m
(168 lb.-in.)

Couplers
[5] -
LEGEND:
A Screws (2 used)
Loosen screws (A) and remove tool.
[6] -
LEGEND:
A Screws (4 used)
B Cover
C Spring
D Seal
Install new seal (D) in cover (B).
[7] - Install spring (C), cover (B), and screws (A). Tighten to specification.
(48 lb-in)
Service Spool Centering Spring Assembly - 3D

Animation

Couplers
RXVI00004.smg

Couplers
Test Surge Relief Valve
CAUTION:
Ensure tractor engine is NOT running for this test.
→NOTE:
Surge relief valve may be tested on tractor.
Location of hitch valve on stack will vary on tractors.
Hitch valve may need to be removed from tractor if surge relief valve needs
adjustment.
[1] -
Connect D01019AA Manually Operated Hydraulic Pump to hitch valve port.

Couplers
[2] - Operate hand pump to check pressure.

Surge Relief Valve Pressure 22800-23800 kPa
228—238 bar
(3307—3452 psi)
[3] - Add or remove shims under surge relief valve spring cap as necessary or repair valve.
(See Service Surge Relief Valve in this group.)
Test Surge Relief Valve - 3D Animation
RXVI00002.smg

Couplers
Service Surge Relief Valve

[1] -
LEGEND:
A Cap
Remove cap (A).
[2] -
LEGEND:
A Shims (2 used)
B Spring
C Poppet
Remove shims (A), spring (B), and poppet (C).

Couplers
[3] -
LEGEND:
A JDG10664 Relief Valve Core Removal Tool
B Valve Seat
C O-ring
Use JDG10664 Relief Valve Core Removal Tool (A) to remove valve seat (B).
[4] - Inspect seat and poppet. Replace as necessary.
[5] - Install new O-ring (C) and seat. Tighten to specification.
Surge Relief Valve Seat Torque 24 N·m
(212 lb.-in.)

Couplers
[6] -
LEGEND:
A Poppet
B Spring
C Shims (2 used)
D O-ring
E Cap
Install poppet, (A) spring (B), and shims (C)
[7] - Install new O-ring (D) and cap (E). Tighten to specification.
Surge Relief Valve Cap Torque 54 N·m
(40 lb.-ft.)
Service Surge Relief Valve - 3D Animation
RXVI00003.smg

Couplers
Service Shuttle Valve

[1] -
CAUTION:
Use caution removing spring cover. There is spring force behind cover.
LEGEND:
A Screws (4 used)
B Spring Cover
C Spring
Remove screws (A) and spring cover (B).
[2] - Remove spring (C).

Couplers
[3] -
LEGEND:
A Plug
Remove plug (A).
[4] -
→NOTE:
JDG10667 Shuttle Valve Removal Tool (A) will need to reach completely to
stop (B) to remove shuttle valve. Replace valve section if valve tool does
not reach stop.

Couplers
LEGEND:
A JDG10677 Shuttle Valve Removal Tool
B Stop
C Shuttle Valve
Use JDG10667 Shuttle Valve Removal Tool (A) to remove shuttle valve (C).
[5] -
IMPORTANT:
Note location of shuttle valve short land (A) and long land (B). Incorrect
orientation will cause SCV to malfunction.
LEGEND:
A Shuttle Valve Short Land
B Shuttle Valve Long Land
C JDG10667 Shuttle Valve Removal Tool
D Stop
Clean and lubricate shuttle valve short land (A).

Couplers
[6] -
→NOTE:
JDG10667 Shuttle Valve Removal Tool (C) will need to reach completely to
stop (D) to install shuttle valve. Replace valve section if valve tool does not
reach stop.
Use opposite end of JDG10667 Shuttle Valve Removal Tool (C) to install shuttle valve.
[7] -
LEGEND:
A Plug
B Seal
Install new seal (B) on plug (A).
[8] - Install plug (A).
[9] -
LEGEND:
A Screws with washers (4 used)
B Spring Cover
C Spring
D Seal
Install new seal (D) in spring cover (B).

Couplers
[10] - Install spring (C), spring cover (B), and screws (A). Tighten to specification.
(48 lb.-in.)
Service Shuttle Valve - 3D Animation
RXVI00005.smg

Couplers
Remove and Install Coupler Housing

[1] -
IMPORTANT:
Valve section must be removed from valve stack before coupler housing
can be removed.
→NOTE:
Take note of orientation of coupler housing before removal.
LEGEND:
B Coupler Housing
Remove socket head screws (A) and coupler housing (B).

Couplers
[2] -
LEGEND:
A O-rings (2 used)
B Backup Rings (2 used)
Replace O-rings (A) and backup rings (B).
[3] -
LEGEND:
B Coupler Housing
Correctly position coupler housing (B) on valve housing.
[4] - Install and tighten socket head screws (A) to specification.
Coupler Housing-to-Valve Housing Torque 22 N·m
(195 lb.-in.)

Couplers
Remove and Install Coupler Housing - 3D Animation
RXVI00009.smg

Couplers
Repair Couplers
[1] -
LEGEND:
A Screws (4 used)
B Cover
Remove screws (A) and cover (B).
[2] -
LEGEND:
A Retaining Rings (2 used)
Remove outer retaining rings (A).
[3] -
→NOTE:
Coupler tool only locks detent balls in outward position. Handle (B) forces
coupler out of housing.
A 22 mm to 23 mm OD socket inserted in coupler may also be used to lock
detent balls.

Couplers
LEGEND:
A JDG1579 Coupler Tool
B Handle
Insert JDG1579 Coupler Tool (A) into coupler and move handle (B) down to remove coupler.
[4] -
→NOTE:
Couplers are serviced as an assembly.
Replace seals.
[5] -
LEGEND:
A Retaining Ring
Remove retaining ring (A) and handle.

Couplers
[6] -
LEGEND:
A Handle
B O-ring
Replace O-ring (B).
[7] - Install handle (A) and retaining ring.
[8] -
LEGEND:
A Seals
Install seals (A).
[9] - Install couplers and retaining rings.

Section 70 - HYDRAULICS Group 30: Rear Hitch
[10] -
LEGEND:
A Screws (4 used)
B Cover
Install cover (B) and screws (A).
Repair Couplers - 3D Animation
RXVI00008.smg

Group 30 - Rear Hitch

List of References
Other Material
Specifications
Remove and Install Rear Hitch Lift Cylinders
Disassemble, Inspect, and Assemble Lift Cylinder
Replace Rockshaft Bushings
Repair Draft Sensing
→NOTE:

JDG-PST Power Shift Transmission Repair Kit
D01045AA Disk Set

Other Material
Number Name Use
• PM38656 (us)
• RE62967 (us) Liquid Adhesive Gasket Used to seal cover.

Specifications
Cylinder Pin Cap Screws Torque 70 N·m
(52 lb.-ft.)
Rockshaft Bushing Bushing Depth 33 mm
(1.3 in.)
Rockshaft Seal Seal Depth 20 mm
(0.9 in.)
Draft Sensing Shaft Retaining Pin Plug Torque 650 N·m
(480 lb.-ft.)
Draft Sensing Shaft Cover Cap Screws Torque 70 N·m
(52 lb.-ft.)
Cylinder Pin Retainer Cap Screws Torque 70 N·m
(52 lb.-ft.)
Draft Shaft Cover Cap Screws Torque 70 N·m
(52 lb.-ft.)
(317 lb.-ft.)
(52 lb.-ft.)

Remove and Install Rear Hitch Lift Cylinders

[1] -
LEGEND:
A Hydraulic Hoses (2 used)
B Cylinder Pin Retainer Cap Screws (4 used)
Lower hitch to lowest position.
[2] -
CAUTION:
hydraulic lines, fittings, or connections.
Disconnect hydraulic hoses (A).

[3] - Cap and plug hoses and ports to prevent contamination.
[4] - Secure lift arm before removing cylinder.
[5] - Remove cap screws (B) from drive pins.

[6] -
CAUTION:
LEGEND:
A Pins (2 used)
Lift cylinders are heavy. Use proper lifting equipment to prevent injury.
→NOTE:
Slide hammer is part of D01210AA Slide Hammer Puller .
Remove pins (A) using a JDG11001 Puller Adapter and slide hammer.
[7] - Remove cylinder.
[8] -
LEGEND:
A O-Rings (2 used)
[9] -
→NOTE:
Lubricate pins with multi-purpose grease.

Install cylinder in reverse order.

[10] - Tighten cylinder pin retainer caps screws to specification.
Cylinder Pin Retainer Cap Screws Torque 70 N·m
(52 lb.-ft.)
[11] - InstallNEW O-rings and connect hydraulic hoses.
Disassemble, Inspect, and Assemble Lift Cylinder
See Component Technical Manual for repair information.

Replace Rockshaft Bushings

[1] -
→NOTE:
Rear wheels may need to be moved out on axles or removed to service
rockshaft, rockshaft bushings, and seals.
LEGEND:
A Potentiometer Linkage
B JDG983 Snap Ring Expander Tool
C Snap Ring
Lower hitch.
[2] - Disconnect potentiometer linkage (A).
[3] - Remove lift cylinders and lift links. (See Remove and Install Rear Hitch Lift Cylinders in
this group.)
[4] -
CAUTION:
Prevent possible personal injury. Wear eye protection and use a protective
blanket as a shield when removing snap ring.
→NOTE:
JDG983-2 Special Tips are part of JDG983 Snap Ring Expander Tool .
Remove snap ring (C) using JDG983 Snap Ring Expander Tool (B) and JDG983-2 Special Tips.
[5] - Scribe marks on lift arm and rockshaft to aid in reassembly.
[6] - Remove lift arms.

[7] -
LEGEND:
A Seal
B Bushing
C O-Ring
Slide rockshaft from housing far enough to replace bushing.
→NOTE:
Remove old bushing using a hack saw.
[8] - Remove seal (A), bushing (B), and O-ring (C).

[9] -
LEGEND:
A Bushing
B JDG1272 Bushing-Seal Installer
C JDG537 Handle
Installbushing (A) using bushing side of JDG1272 Bushing-Seal Installer (B) and JDG537
Driver Handle (C).
[10] - Drive bushing until driver contacts housing.

[11] -
LEGEND:
A O-Ring
Install O-ring (A).
[12] -
LEGEND:
A Seal
B JDG1272 Bushing-Seal Installer
C JDG537 Handle
Invert JDG1272 Bushing-Seal Installer (B) on JDG537 Handle (C).
IMPORTANT:
Seal is installed with lip of seal away from housing.
[13] - Install new seal (A) usingSEAL side of driver. Drive in seal until driver contacts
housing.
[14] - Repeat process on other side.
[15] - Install rockshaft, lift arms, and snap rings.
[16] - Install lift cylinders. (See Remove and Install Rear Hitch Lift Cylinders in this group.)

[17] -
LEGEND:
A Grease Fittings (2 used)
Lubricate both rockshaft bushing grease fittings.

Repair Draft Sensing

[1] -
LEGEND:
A Draft Link Retaining Ring
B Retainer
C Draft Link
Remove draft link retaining ring (A) and retainer (B).
[2] - Remove draft links (C) from draft sensing shaft.

[3] -
LEGEND:
B Pins (2 used)
D Retainer
E Drawbar Pin
G Stabilizer Hitch
Remove cotter pins (A) and pins (B).

Remove retainer cap screw (C), retainer (D), and drawbar pin (E).
Remove cap screws with washers (F) and stabilizer hitch (G).

[4] -
LEGEND:
A Cap Screw
B Retainer
C Drawbar Pin
For all other tractors, perform the following:
Remove cap screw (A), retainer (B), and drawbar pin (C).
[5] -
CAUTION:
Drawbar weighs approximately 28 kg (62 lbs.). Use proper lifting
equipment to avoid personal injury.
LEGEND:
A Drawbar
Remove drawbar (A).

[6] -
LEGEND:
A Cap Screws
B Harness Shield
C Cover Plate
Remove cap screws (A), harness shield (B), and cover plate (C).
[7] -
LEGEND:
A Sensing Strap
B Brackets (2 used)
C Draft Sensor and Retaining Bracket
Remove sensing strap (A) and brackets (B).
[8] - Remove draft sensor and retaining bracket (C).

[9] -
LEGEND:
A Retaining Pin
B Plug
Remove plug (B) and retaining pin (A).
[10] -
IMPORTANT:
Becareful not to damage draft sensing shaft during removal process.
LEGEND:
A Draft Sensing Shaft
B Seal
C Seal Retainer
Drive left-hand end of draft sensing shaft (A) to remove shaft, seal (B) and seal retainer (C).

[11] -
LEGEND:
A Outer Seal
B Retaining Ring
C Bearing
D Inner Seal
Remove outer seal (A), retaining ring (B), bearing (C) and inner seal (D).

[12] -
LEGEND:
A Top of Tractor
B Front of Tractor
C Bearing Seam
Position seam of bearing outer race toward front and top of tractor, as illustrated.
[13] -
→NOTE:
Coat all draft shaft seals with grease before installing into hitch frame.

LEGEND:
A Retaining Ring
B Spherical Bearing
C Inner Seal
Install inner seal (C).
[14] - Use JDG1198 Bearing Installer and JDG537 Driver Handle to install spherical bearing
(B) until it bottoms in bore.
[15] - Install retaining ring (A).
[16] -
→NOTE:
JTO1731 Collet is part of D01061AA Blind-Hole Puller Set .
LEGEND:
A Bushings (2 used)
B Sleeves (2 used)
Inspect bushings (A) and replace as necessary.
[17] - Remove bushings using JTO1731 Collet and a slide hammer.

[18] -
IMPORTANT:
Upper sleeve (A) must be installed in bore before installing bushing (B).
→NOTE:
Driver and pilot disks are part of D01045AA Disk Set .
LEGEND:
A Upper Sleeve
B Bushing
C Bushing Split
Install sleeve until fully seated into upper bore using a 41 mm (1-5/8 in.) driver and a 28 mm
(1-1/8 in.) pilot disk.
[19] - Position bushing split (C) as illustrated and install into sleeve using 41 mm (1-5/8 in.)
driver and 28 mm (1-1/8 in.) pilot disk.

[20] - Install bushing (B) into lower sleeve (C) using 41 mm (1-5/8 in.) driver and 27 mm
(1-1/16 in.) pilot disk.
LEGEND:
A Draft Sensing Shaft
B Bushing
C Lower Sleeve
[21] - Install draft sensing shaft (A).

[22] -
IMPORTANT:
Position bushing split 90° towards rear of tractor from upper bushing.
Install bushing and sleeve into lower bore using 41 mm (1-5/8 in.) driver and 27 mm (1-1/16
in.) pilot disk.
[23] - Drive lower sleeve-bushing assembly until shaft has minimum end play between upper
and lower bushings, this allows draft shaft pin installation.

[24] -
LEGEND:
A Draft Sensing Shaft Pin
B Plug
Install pin (A).
[25] - Clean threads and apply PM38656 Thread Lock and Sealer to plug (B).
Number Name Use
• PM38656 (us)
• 277 LOCTITE™ (loctite)
[26] - Install plug and tighten to specification.
Draft Sensing Shaft Retaining Pin Plug Torque 650 N·m
(480 lb.-ft.)

[27] -
LEGEND:
A Outer Seal
B Seal Retainer
C JDG652-1 Installer
Install outer seals (A).
[28] -
→NOTE:
JDG652-1 is part of JDG-PST Power Shift Transmission Repair Kit .
Install seal retainer (B) flush to 1 mm inside edge of shaft chamfer using JDG652-1.
[29] -
→NOTE:
LEGEND:
A Retaining Ring
B Retaining Collar
C Draft Link
Bevel on draft link retainer collar (B) must be positioned toward retainer
ring (A).

Install draft link (C), retaining collar (B), and retaining ring (A) on both sides of tractor.
[30] -
LEGEND:
A Draft Sensing Strap Brackets (2 used)
B Bottom Holes
C Sensor
D Draft Sensing Strap
Install draft sensing strap brackets (A). Install in bottom hole (B) first, pressing upward toward
top hole in shaft.
[31] - Install sensor (C) and bracket making sure protrusion on back side of sensor aligns
correctly with slot in shaft.
[32] -
IMPORTANT:
Ensure ends of draft sensing strap (D) are correctly and fully inserted into
brackets (A).
Install draft sensing strap (D).

[33] - Adjust draft sensing sensor. (See Adjust Draft Link Sensor in Section 40, Group 30.)

[34] - Apply RE62967 Liquid Gasket to inside surface of cover (C), ensuring that adhesive
encircles all holes on cover.
LEGEND:
B Harness Shield
C Cover
[35] - Install cover, harness shield (B), and cap screws (A). Tighten to specification.
Draft Shaft Cover Cap Screws Torque 70 N·m
(52 lb.-ft.)
Number Name Use

• RE62967 (us) Liquid Adhesive Gasket Used to seal cover.
[36] -

LEGEND:
B Pins (2 used)
D Retainer
E Drawbar Pin
G Stabilizer Hitch
Install stabilizer hitch (G) and cap screws with washers (F). Tighten to specification.
(317 lb.-ft.)
Install drawbar.
Install drawbar pin (E), retainer (D), and retainer cap screw (C). Tighten to specification.
(52 lb.-ft.)
Install pins (B) and cotter pins (A).

Section 70 - HYDRAULICS Group 35: Front Hitch
[37] -
LEGEND:
A Cap Screw
B Retainer
C Drawbar Pin
For all other tractors, perform the following:
Install drawbar pin (C), retainer (B), and cap screw (A). Tighten cap screw to
specification.
(52 lb.-ft.)

Group 35 - Front Hitch

List of References
Specifications
Other Material
Exploded View—Front Hitch
Remove and Install Front Hitch Lift Cylinders
Repair Front Hitch Lift Cylinder
Specifications
Top Cylinder Pin Cap Screw Torque 125 N·m
92 lb.-ft.
Other Material
Number Name Use
• PT569 (us)
Exploded View—Front Hitch

LEGEND:
A Main Frame
B Right-hand Lift Arm
C Left-hand Lift Arm
D Lift Arm Support
E Push Bar
F Rear Push Bar Support
G With Out Push Bar Support
H Lift Cylinders (2 used)

I Lift Arm Support Mounting Pin
J Lift Arm Support Bushing (2 used)
K Lift Arm Mounting Pin
L Lower Lift Cylinder Mounting Pin (2 used)
M Upper Lift Cylinder Mounting Pin (2 used)
N Lift Arm Position Pin (2 used)
O Center Link
P Center Link Pin
Q Retaining Clip (3 used)

Remove and Install Front Hitch Lift Cylinders

[1] - Lower front hitch completely.
[2] -
LEGEND:
A Hitch Position Sensor Linkage
B Draft Link
Disconnect hitch position sensor linkage (A) from draft link (B).
[3] -
CAUTION:
Front hitch weighs approximately 350 kg (772 lb.) use proper supporting
equipment.
Support front hitch draft link and lift arms with a floor jack.

[4] -
LEGEND:
B Lock Nuts (2 used)
C Lift Cylinder Pins (2 used)
Remove lock nuts (B) and socket head cap screws (A).
[5] - Remove lower lift cylinder pins (C).
[6] - Lower draft link and lift arms to the ground.

[7] -
LEGEND:
A Cylinder Hydraulic Hoses (4 used)
Identify, label, and disconnect cylinder hydraulic hoses (A).
[8] -
CAUTION:
Lift cylinders weigh approximately 16 kg (35 lb.) use caution when
handling.
LEGEND:
A Cap Screw
B Top Cylinder Pin
Support cylinder, remove cap screw (A), and top cylinder pin (B).

MISCELLANEOUS (g) by Belgreen
[9] -
LEGEND:
A Lift Cylinder
Remove lift cylinder (A).
[11] - Replace hydraulic hose O-rings, and assemble in reverse order.
Top Cylinder Pin Cap Screw Torque 125 N·m
92 lb.-ft.
Repair Front Hitch Lift Cylinder
See Component Technical Manual for repair information.

Section 80 - MISCELLANEOUS
Table of contents
Group 05 - Hood ......................................................................................................................... 1
Specifications ......................................................................................................................... 2
Position Hood Forward ........................................................................................................... 2
Remove and Install Hood ....................................................................................................... 4
Remove and Install Grille and Headlight Assembly ................................................................ 6
Adjusting Front Grille Lights ................................................................................................... 9
Aiming Head Lights .............................................................................................................. 11
Remove and Install Hood Side Panels .................................................................................. 12
Remove and Install Hood Screens ........................................................................................ 13
Remove and Install Hood Latch ............................................................................................ 15
Group 10 - Front Axle (Two-Wheel Drive) ............................................................................ 16
Essential, Recommended and Fabricated Tools ................................................................... 16
Specifications ....................................................................................................................... 17
Other Material ...................................................................................................................... 17
Remove Front Axle (Two-Wheel Drive) ................................................................................ 18
Install Front Axle (Two-Wheel Drive) .................................................................................... 20
Replace Knee Bushings ........................................................................................................ 21
Replace Wheel Bearings ...................................................................................................... 26
Group 20 - Rear Wheels .......................................................................................................... 28
Specifications ....................................................................................................................... 29
Wheel Tightening Stand ....................................................................................................... 29
Service Heavy-Duty Wheel Clamps ...................................................................................... 31
Installing Rear Drive Wheel to Cast Hub .............................................................................. 41
Installing Rear Steel Wheel to Hub ....................................................................................... 43
Adjusting and Tightening Rear Steel Wheels—Cast Hubs .................................................... 44
Adjusting and Tightening Rear Wheels—Heavy Duty Cast 10-Bolt Hubs ............................. 46
Adjusting and Tightening Wheels—Heavy-Duty 12-Bolt Hubs .............................................. 48
Group 25 - Wagon And Pick-Up Hitch ................................................................................... 51
Specifications ....................................................................................................................... 51
Repair Wagon Hitch ............................................................................................................. 51
Adjust Wagon Hitch Release ................................................................................................ 52
Repair Pick-Up Hitch ............................................................................................................. 53
Adjust Pick-Up Hitch ............................................................................................................. 55

Section 80 - MISCELLANEOUS Group 05: Hood
Group 05 - Hood
List of References
Specifications
Position Hood Forward
Remove and Install Hood
Remove and Install Grille and Headlight Assembly
Adjusting Front Grille Lights
Aiming Head Lights
Remove and Install Hood Side Panels
Remove and Install Hood Screens
Remove and Install Hood Latch

Specifications
Low Beam Screws Torque 2 N·m
(18 lb.-in.)
Headlight Screws Torque 2 N·m
(18 lb.-in.)
Grille-to-Hood Screws Torque 17 N·m
(150 lb.-in.)
Grille-to-Side Panel Screws Torque 17 N·m
(150 lb.-in.)
Hood Screws Torque 17 N·m
(150 lb.-in.)
Cooling Screen Screws Torque 5 N·m
(44 lb.-in.)
Rear Hood Screen Screws Torque 5 N·m
(44 lb.-in.)
Base Plate Cap Screws Torque 5 N·m
(44 lb.-in.)
Latch-to-Base Plate Cap Screws Torque 30 N·m
(22 lb.-ft.)
Position Hood Forward

LEGEND:
A Harness Connector
B Pin
[1] - Disconnect hood harness connector (A).

[2] - Remove pin (B) from rear hood linkage.
[3] - Lower front of hood as illustrated.

Remove and Install Hood
LEGEND:
A Harness Connector
B Rear Linkage Pin
C Front Linkage Pin
D Lifting Straps
[1] - Attach nylon straps (D) around rear hood support and through opening in hood.

[2] - Attach straps to overhead hoist as illustrated.

[3] - Disconnect harness (A).
[4] - Remove rear linkage pin (B).
[5] - Remove front linkage pin (C) and lift hood off tractor.

Remove and Install Grille and Headlight Assembly

[1] -
LEGEND:
A Grille-to-Side Panel Screws (6 used)
B Grille-to-Hood Screws (11 used)
Remove hood. (See Remove and Install Hood in this group.)
[2] - Remove screws (A and B).
[3] - Remove grille.

[4] -
LEGEND:
A Headlight Screws (5 used)
B Headlight Assembly
C Low Beam Screws (4 used)
D Low Beam Assembly
Remove screws (A) and headlight assembly (B).
[5] - Remove screws (C) and low beam assembly (D).
[7] - Assemble in reverse order and tighten screws to specification.
Low Beam Screws Torque 2 N·m
(18 lb.-in.)
Headlight Screws Torque 2 N·m
(18 lb.-in.)
Grille-to-Hood Screws Torque 17 N·m
(150 lb.-in.)
Grille-to-Side Panel Screws Torque 17 N·m
(150 lb.-in.)

[8] - Install hood. (See Remove and Install Hood in this group.)

Adjusting Front Grille Lights
LEGEND:
A High Beam Lowering Adjustment Screw
B High Beam Tilt Up And In Adjustment Screw
C High Beam Tilt Up And Out Adjustment Screw
D Center Spot Lowering Adjustment Screw
E Center Spot Tilt Up And In Adjustment Screw
F Center Spot Tilt Up And Out Adjustment Screw
G Low Beam Lowering Adjustment Screw
H Low Beam Tilt Up And In Adjustment Screw
I Low Beam Tilt Up And Out Adjustment Screw
→NOTE:
To adjust front grille lights, use the following steps as needed

[1] - Adjust High Beam Headlights:
To lower the high beam aim, turn high beam adjustment screw (A) counterclockwise.
To raise and tilt in high beam, turn high beam adjustment screw (B) counterclockwise.
To raise and tilt out high beam, turn high beam adjustment screw (C) counterclockwise.
[2] - Adjust Center Spot Light:
To lower center spot light, turn center spot adjustment screw (D) counterclockwise.
To raise and tilt in center spot beam, turn center spot beam adjustment screw (E)
counterclockwise.
To raise and tilt out center spot beam, turn center spot beam adjustment screw (F)
counterclockwise.
[3] - Adjust Low Beam Headlights:
To lower low beam headlights aim, turn low beam adjustment screw (G)
counterclockwise.
To raise and tilt in low beam headlights, turn low beam adjustment screw (H)
counterclockwise.
To raise and tilt out low beam headlights, turn low beam adjustment screw (I)
counterclockwise.

Aiming Head Lights
LEGEND:
A Low Beam Road Lights
B Distance, Center of Low Beam Road Lights To Ground
C Distance, 7.5 meters (25 ft)
D Horizontal Line on Wall
E Center of Low Beam Road Light
F Distance, 914 mm (36 in.)
Distance, 355 mm (14 in.) (Center of Low Beam Road Light Beam To Center
G
of High Beam).
H Road Lights High Beam Center
Distance, 787 mm (31 in.) (Road Light High Beam Center To Tractor Center
I
Line
Distance, 635 mm (25 in.) (Road Light High Beam Center To Front Inner
J
Flood Beam Center)
K Front Inner Hood Beam Center
[1] - Park tractor on a level surface with low beam road lights (A) 7.5 meters (25 ft) (C) from
a vertical wall. Turn on low beam road lights.
[2] - Measure the distance (B) from center of low beam road lights to the ground.
[3] - Mark a horizontal line on the wall at the same height as center of low beam road lights.
[4] - On the wall, mark each low beam road light beam center, then determine vertical
center line between low beam road light′s beam.
[5] - On the wall, mark vertical center line.
[6] - Distance between low beam road light′s beam center and center line should be 914 mm
(36 in.) ((F)).
[7] - Turn on high beam road lights.

[8] - Adjust high beam road lights so edge of bright area (H) isat least one tenth of distance
(B)above center of low beam road lights spot (E).
[9] - On the wall, mark each high beam road light beam center (H), then determine vertical
center line between high beam road light′s beam.
[10] - Distance between high beam road light′s beam center and center line should be 787
mm (31 in.) (I).
[11] - Make sure that front inner hood lights are programmed on, then turn on field lights.
[12] - Distance between high beam road light′s beam center (K) and inner hood light center
line should be 635 mm (25 in.) (J).
Remove and Install Hood Side Panels

[1] -
LEGEND:
A Hood Screws (12 used)
B Side Panel
Remove hood. (See Remove and Install Hood in this group.)
[2] - Remove grille. (See Remove and Install Grille and Headlight Assembly in this group.)
[3] - Support side panel (B) and remove hood screws (A).
[4] - Install in reverse order. Tighten hood screws to specification.
Hood Screws Torque 17 N·m
(150 lb.-in.)

Remove and Install Hood Screens
LEGEND:
A Screws (16 used)
B Cooling Screens (2 used)
C Screws (26 used)
D Rear Hood Screen
[1] - Remove hood. (See Remove and Install Hood in this group.)
[2] - Remove screws (A) and cooling screens (B).
[3] -
→NOTE:
Hood side panels must be removed to access the rear hood screen. (See
Remove and Install Hood Side Panels in this group.)
Remove screws (C) and rear hood screen (D).


Cooling Screen Screws Torque 5 N·m
(44 lb.-in.)
Rear Hood Screen Screws Torque 5 N·m
(44 lb.-in.)

Section 80 - MISCELLANEOUS Group 10: Front Axle (Two-Wheel Drive)
Remove and Install Hood Latch

[1] -
LEGEND:
A Rod
B Base Plate Cap Screws (4 used)
C Latch-to-Base Plate Socket Head Cap Screws (2 used)
D Spring
Open hood.
[2] - Disconnect rod (A).
[4] - Remove socket head cap screws (C) to remove latch from base plate.
[5] - Inspect spring (D) and replace as necessary.
Base Plate Cap Screws Torque 5 N·m
(44 lb.-in.)
Latch-to-Base Plate Socket Head Cap Screws Torque 30 N·m
(22 lb.-ft.)

Group 10 - Front Axle (Two-Wheel Drive)

List of References
Specifications
Other Material
Remove Front Axle (Two-Wheel Drive)
Install Front Axle (Two-Wheel Drive)
Replace Knee Bushings
Replace Wheel Bearings
→NOTE:

D01045AA Disk Set
JDG23 Lift Sling
JDG1076A Cone Stand and Adapter

Specifications
(317 lb-ft)
Front Pivot Pin Cap Screws Torque 310 N·m
(229 lb-ft)
(229 lb-ft)
Hub Retaining Nut Torque 48 N·m
(35 lb-ft)
Knee Clamp-to-Axle Cap Screw Torque 50 N·m
(36 lb-ft)
Steering Arm-to-Spindle Cap Screw Torque 620 N·m
(457 lb-ft)
Tie Rod End-to-Steering Arm Nuts Torque 150 N·m
(110 lb-ft)
Tie Rod End-to-Tube Cap Screw Torque 62 N·m
(46 lb-ft)
Tie Rod Clamp Cap Screws Torque 68 N·m
(50 lb-ft)
Wheel-to-Hub Cap Screws Torque 310 N·m
(229 lb-ft)
Steering Arm End Play 0.3—1.0 mm
(0.010—0.040 in.)
Front Axle Pivot Bushing Wear Tolerance 2.0 mm
(0.080 in.)
Front Wheel Toe-in Toe-in 0—3 mm
(0—0.125 in.)
(0—1/8 in.)
Other Material
Number Name Use

Remove Front Axle (Two-Wheel Drive)
LEGEND:
A JDG1076A Cone Stands and Adapters
[1] - Disconnect battery ground from rear of engine.

[2] - Raise tractor and install JDG1076A Cone Stand and Adapter (A) under front of
transmission.
[3] - Remove front wheels.
[4] -
LEGEND:
A Steering Hoses
Disconnect hoses (A) from steering cylinders. Plug or cap all openings in hoses and cylinders.

[5] -
LEGEND:
A JDG23 Lift Sling
B Cap Screws
C Pivot Pin Retainer
D Pivot Pin
Install lift straps(A) around outer portion of axle.
[6] - Attach straps to JDG23 Lift Sling and install lift sling on hoist.
[7] - Raise axle slightly to remove load on pivot pin.
[8] - Remove pivot pin retainer cap screws(B), pivot pin retainer(C), and shims.
[9] - Remove pivot pin(D) and carefully lower axle from tractor.

Install Front Axle (Two-Wheel Drive)
LEGEND:
A Retainer Cap Screws (2 used)
B Pivot Pin
[1] - Install front axle making sure axle is positioned fully rearward.
[2] - Add shims until pivot pin (B) is flush.
[3] - Install final shim and retainer.
Front Axle Clearance 0.2—0.7 mm
(0.01—0.03 in.)
[4] - Tighten pivot pin retainer cap screws (A) to specification.

Axle Pivot Pin Retainer Cap Screw Torque 310 N·m
(229 lb-ft)
[5] - Tighten wheel-to-hub cap screws to specification.

(229 lb-ft)
[6] - Adjust front wheel toe-in.

Front Wheel Toe-in Toe-in 0—3 mm
(0—0.125 in.)
(0—1/8 in.)

Replace Knee Bushings
LEGEND:
A Steering Arm Retaining Cap Screw
B Spindle
C Steering Arm
[1] - Raise and support front axle.

[2] - Remove hub cap, cotter pin, and retaining nut from spindle.
[3] -
IMPORTANT:
Use care in removing wheel and hub assembly from spindle. Bearing may
be damaged if it falls from hub.
Remove wheel and hub assembly.

[4] - Remove steering arm-to-spindle cap screw(A).
[5] -
IMPORTANT:
Support spindle(B) during removal. Spindle may be damaged if it falls to
the floor.
Strike steering arm(C) with lead hammer to loosen arm from spindle.
[6] - Remove spindle.
[7] - Remove knee bushing.

[8] -
LEGEND:
A Grease Hole
Align grease hole of new bushing with grease fitting in axle(A).
[9] - Install bushing flush with bottom of chamfer using a 50mm or 2in. pilot disk and
54mm or 2-1/8in. driver disk.

[10] -
LEGEND:
A Locator Pin
Install spindle in axle and align thrust washer with locator pin(A).
[11] - Install steering arm on spindle and tighten cap screw to specification.
Steering Arm-to-Spindle Cap Screw Torque 620 N·m
(457 lb-ft)

[12] -
LEGEND:
A Steering Arm Retaining Cap Screw
Attach dial indicator to front axle with contact point on steering arm-to-spindle cap
screw(A).
[13] - Adjust indicator to zero.
[14] - Move spindle up and down in knee to determine end play.
[15] - Check spindle for smooth turning.
[16] - Add or subtract washers to provide correct steering arm end play.
Steering End Play End Play 0.3—1.0 mm
(0.010—0.040 in.)
[17] - Lubricate bushings with TY6341 Multi-Purpose SD Polyurea Grease.

[18] - Pack hub bearings with TY6341 Multi-Purpose SD Polyurea Grease.
Number Name Use
[19] - Install wheel and hub assembly.

[20] - Tighten hub retaining nut to specification, then loosen nut until cotter pin can be
installed.
Hub Retaining Nut Torque 48 N·m
(35 lb-ft)
[21] - Install hub cap.

Replace Wheel Bearings
[1] - Support axle at knee.

[2] - Remove wheel assembly.
[3] - Remove hub cap, cotter pin, and retaining nut from spindle.
[4] -
IMPORTANT:
Use care in removing hub assembly from spindle. Bearing may be damaged
if it falls from hub.
Remove hub from spindle.

[5] - Clean and inspect bearing cones, cups, and seals for excessive wear and damage.
[6] - Remove bearing cups from hub.
[7] -
→NOTE:
Some drivers and driver handles are part of D01045AA Disk Set .
Press new bearing cups into hub using a 113mm or 4-7/16in. disk for the inner bearing cup
and a 75mm or 2-15/16in. disk for the outer bearing cup.
[8] - Pack bearings with TY6341 Multi-Purpose SD Polyurea Grease.
Number Name Use
[9] -
→NOTE:
D01045AA Disk Set may be used in place of 5-1/2in. driver disk.

Section 80 - MISCELLANEOUS Group 20: Rear Wheels
Press new oil seal cup into hub using a 113mm or 4-7/16in. pilot disk and a 140mm or
5-1/2in. driver disk.
[10] - Carefully drive a new oil seal onto spindle and fill lips with TY6341 Multi-Purpose SD
Polyurea.
[11] - Install wheel hub with bearings onto spindle.
[12] - Tighten hub retaining nut to specification, then loosen nut until cotter pin can be
installed.
Tighten Wheel Hub Retaining Nut Torque 48 N·m
(35 lb-ft)
[13] - Install hub cap.

[14] - Install wheel assembly and tighten cap screws.
Wheel-to-Wheel Hub Cap Screws Torque 310 N·m
(229 lb-ft)

Group 20 - Rear Wheels

List of References
Specifications
Wheel Tightening Stand
Service Heavy-Duty Wheel Clamps
Installing Rear Drive Wheel to Cast Hub
Installing Rear Steel Wheel to Hub
Adjusting and Tightening Rear Steel Wheels—Cast Hubs
Adjusting and Tightening Rear Wheels—Heavy Duty Cast 10-Bolt Hubs
Adjusting and Tightening Wheels—Heavy-Duty 12-Bolt Hubs
→NOTE:

DFRW219—Wheel Tightening Stand
JDG10741 Wheel Tightening Stand

Specifications
Socket Head Cap Screw Torque 50 N·m
(37 lb.-ft.)
Wheel Hub Cap Screws

Initial Sequence Torque 405 N·m
(300 lb.-ft.)

Final Sequence Torque 610 N·m
(450 lb.-ft.)
Wheel Bolts Torque 600 N·m
(445 lb.-ft.)
Wheel-to-Hub Bolts Torque 600 N·m
(445 lb.-ft.)
Wheel Hub Sleeve Bolts

Initial Torque 204 N·m
(150 lb.-ft.)
Secondary Torque 410 N·m
(300 lb.-ft.)
Final Torque 600 N·m
(445 lb.-ft.)

(300 lb.-ft.)
(450 lb.-ft.)
Wheel Bolts Initial Torque 405 N·m
300 lb.-ft.
Wheel Bolts Final Torque 610 N·m
450 lb.-ft.

LEGEND:
A Wheel Tightening Stand
B Torque Wrench
→NOTE:
Wheel tightening stand (A) may be fabricated. (See DFRW219—Wheel

Tightening Stand in Section 99, Group 10.)
[1] - JDG10741 Wheel Tightening Stand (A) may be used to aid in tightening wheel hardware.
[2] - It will support the torque wrench (B) when tightening cap screws at different heights.

Service Heavy-Duty Wheel Clamps

[1] -
→NOTE:
Wheel assembly is generally set for customer′s row-crop spacing. Return
assembly to that setting after service.
LEGEND:
A Snap Ring
B Sleeve Cap Screws
D Pinion
[2] - Loosen (without removing) sleeve cap screws (B) just enough to move wheel.
[3] -
IMPORTANT:
Do not loosen or remove socket head cap screw (C). Doing so could result
in wheel binding or wheel damage.
Turn pinion gear (D) to move wheel.

[4] -
IMPORTANT:
Wheel Handling Equipment

Avoid personal injury. Use suitable wheel handling equipment when
removing wheel assemblies.
→NOTE:
JT05726 Wheel and Axle Lift may be use to handle tractor wheels.
Remove wheel assembly from axle.

[5] -
LEGEND:
A Cap Screw
B Washers
Remove cap screws (A) and washers (B).
[6] - Remove socket head cap screw (C) and remove ring and clamps from other side of
wheel.

[7] -
IMPORTANT:
LEGEND:
A Clamp
B Spring Pin (4 used)
C Spring (4 used)
D Clamp
Do not remove rust preventive coating from clamps (A and D).
Clean dirt and contaminates from clamps (A and D), springs (C), and spring pins (B).
[8] - Check clamps, spring pins, and springs for wear and damage.

[9] -
LEGEND:
A Clamp Adjoining Surfaces
Clean dirt and contaminates from clamp adjoining surfaces (A) in wheel.

[10] -
Assemble clamps, spring pins, and springs as shown and install in wheel.
[11] -

LEGEND:
A Clamp Ring
B Keyway
Install clamp ring (A) making sure clamp key is properly seated in wheel keyway (B).
[12] -

LEGEND:
A Cap Screw
B Washers
Install socket head cap screw (C) and tighten to specification.
Socket Head Cap Screw Torque 50 N·m
(37 lb-ft)
[13] - Loosely install cap screws (A) and washers (B), then tighten to specification.

[14] -
Install wheel on axle and set to operator′s desired position.

[15] -
→NOTE:
Using a square to measure at four locations around the wheel may help set
wheel perpendicular to axle.
Tighten sleeve cap screw in numerical order, stamped on wheel (A), until cap screws
maintain initial torque.

Initial Sequence Torque 405 N·m
(300 lb-ft)
[16] - Tighten sleeve cap screw in numerical order until they maintain final torque.

Final Sequence Torque 610 N·m
(450 lb-ft)
[17] - Install snap ring at end of axle.

[18] - Drive tractor a minimum of 100 meters (100 yd) and tighten bolts in numerical order
until they maintain final torque.
→NOTE:
Advise customer to retighten cap screw after working3 HOURS, 10 HOURS,
andDAILY for first week of operation.

Installing Rear Drive Wheel to Cast Hub
Heavy Duty Cast 10-Bolt Hub Shown
LEGEND:
A Wheel Rim
B Tight Fit Hole
C Loose Fit Hole
[1] -
CAUTION:
Avoid the possibility of personal injury. Failure to follow torquing sequence
and procedure will result in damage to equipment and may result in
personal injury. Wheel bolts are critical and require repeated torquing.
→NOTE:
The wheel rim (A) has onetight fit hole smaller than the other holes.
Oneslot fit hole is 180° from the tight fit hole, for improved wheel
centering.
Install and hand tighten bolt in thetight fit hole (B).

[2] - Install and hand tighten bolt in theslot fit hole (C).
[3] - Install and hand tighten remaining bolts.
[4] - Tighten all bolts until bolts maintain torque according to specifications.
Wheel Bolts Torque 600 N·m
(445 lb.-ft.)
[5] - Drive tractor 100 m (110 yd.) and retighten bolts.

[6] - Tighten again at3 HOURS ,10 HOURS , andDAILY for the first week of operation and
then every 250 hours.
IMPORTANT:
Carefully follow procedure for retightening wheel bolts. Failure to do so
could lead to wheel hub damage.

Installing Rear Steel Wheel to Hub
Standard Hub Shown
LEGEND:
A Wheel to Hub Bolts
[1] -
CAUTION:
→NOTE:
Check the hole sizes on duals, the wheel rim (A) may have onetight fit hole
smaller than the other holes. Oneslot fit hole is 180° from the tight fit hole,
for improved wheel centering.
Install and hand tighten bolts (A).

[2] - Tighten all bolts until bolts maintain torque according to specifications.
Wheel-to-Hub Bolts Torque 600 N·m
(445 lb.-ft.)
[3] - Drive tractor 100 m (110 yd.) and retighten bolts.

[4] - Tighten again at3 HOURS ,10 HOURS , andDAILY for the first week of operation and
then every 250 hours.
IMPORTANT:
Carefully follow procedure for tightening wheel bolts. Failure to do so could
result in equipment damage.

Adjusting and Tightening Rear Steel Wheels—Cast

Hubs
LEGEND:
A Lower Hub Center Bolt
B Outer Hub Sleeve Bolts
C Inner Jack Screws
D Adjusting Screw
CAUTION:
Avoid personal injury. NEVER run the engine with transmission in gear and
rear wheels off the ground. MFWD wheels could pull rear wheels off
support. MFWD must be disengaged and transmission in NEUTRAL to
rotate axle.
[1] - Raise tractor on level ground and turn wheels so rack on axle is on top.
[2] - Loosen lower hub center bolt (A) against retaining nut and loosen outer hub sleeve bolts
(B).
→NOTE:
If sleeves are difficult to break loose, strike end of axle with a heavy
hammer and use penetrating oil.
[3] - Tighten inner jack screws (C) on upper and lower hub sleeves as necessary to loosen
sleeves.
[4] -
→NOTE:
Observe tread width limitations when adjusting rear wheels.
Turn adjusting screw (D) to slide wheel to desired position.

[5] - Loosen the jack screws (C) all the way against stop.
CAUTION:
[6] - Tighten hub sleeve bolts (B) to initial torque specifications beginning with center bolt in
lower sleeve, then tighten remaining bolts in diagonal method.
[7] - Tighten bolts to secondary torque specifications using same sequence.
[8] - Drive tractor a minimum of 100 m (110 yd.) and tighten bolts to final torque
specifications.

(150 lb.-ft.)
Secondary Torque 410 N·m
(300 lb.-ft.)
(445 lb.-ft.)
IMPORTANT:
Some sleeve bolts may loosen as sleeve is tightened. Repeat star shaped
torquing pattern until ALL sleeve bolts maintain proper torque. Failure to
follow procedure could result in damage to equipment and may result in
personal injury.
[9] - Retighten bolts after working3 HOURS ,10 HOURS , andDAILY during the first week of
operation and then every 250 hours.

Adjusting and Tightening Rear Wheels—Heavy Duty

Cast 10-Bolt Hubs
Heavy Duty Cast Drive Hub Shown
CAUTION:
Avoid personal injury. Never run the engine with transmission in gear and
rear wheels off the ground. MFWD wheels could pull rear wheels off
support. Disengage MFWD and put transmission in NEUTRAL to rotate axle.
Never operate tractor with a loose rim, wheel, or hub.
CAUTION:

[1] - Raise the tractor on level ground with rack upward on the axle.
[2] - Loosen (without removing) sleeve bolts (1—10) enough to move wheel.
[3] -
IMPORTANT:
Do not loosen or remove the two allen head screws. Doing so could result
in wheel jamming or damage.
Turn pinion gear (A) to move wheel to desired position.

[4] - Tighten sleeve bolts (1—10) in numerical order to initial torque specifications. Make
sure that wheel is perpendicular to axle.
[5] - Tighten sleeve bolts (1—10) in numerical order to final torque specifications.
[6] - Drive tractor a minimum of 100 m (110 yd.) and retighten bolts in numerical order to
final torque specifications.

(300 lb.-ft.)
(450 lb.-ft.)
[7] - Retighten bolts after working3 HOURS ,10 HOURS , andDAILY during the first week of
operation and then every 250 hours.
IMPORTANT:
Some sleeve bolts may loosen as sleeve is tightened. Repeat numerical
torquing pattern until ALL sleeve bolts maintain proper torque. Failure to
follow procedure could result in damage to equipment and may result in
personal injury.

Adjusting and Tightening Wheels—Heavy-Duty 12-

Bolt Hubs
12 Bolt Heavy-Duty Drive Wheel
CAUTION:
Avoid personal injury. Never run the engine with transmission in gear
when adjusting wheels. Wheels on the ground could pull supported wheels
off jackstands.
Never operate tractor with a loose rim, wheel, or hub.

IMPORTANT:
Tractors are equipped 12 bolt heavy-duty drive wheels and hubs. Numbers
indicating proper torquing sequences are cast into wheel hub.
Carefully follow procedure. Failure to do so could lead to sleeve or cast

wheel damage.
IMPORTANT:
Clean any paint, grease, film, rust or debris from axle shafts, cap screws,
and threads before positioning and installing wheel sleeves and cast
wheel.DO NOT apply any lubricant to cap screws, threads, wheel, or axle.
[1] - Raise the tractor on level ground and support tractor with jackstands.
[2] - Loosen (without removing) sleeve bolts (1—12) enough to move wheel.
IMPORTANT:
Do not loosen or remove the two allen head screws. Doing so could result
in wheel jamming or damage.
[3] -
CAUTION:
Use a hoist, wheel dolly, or proper lifting equipment to safely slide and
adjust wheels on axles and avoid possibility of personal injury.
Failure to follow torquing sequence and procedure will result in damage to
wheel sleeves and may result in personal injury. Wheel bolt torques are
critical and require repeated tightening.
Move wheel to desired position.

[4] - Tighten bolts (1—12) in numerical torque sequence until bolts maintain initial torque.
Make sure that wheel is perpendicular to axle.
Wheel Bolts Initial Torque 405 N·m
300 lb-ft
[5] - Tighten bolts (1—12) in numerical order until bolts maintain final torque.
Wheel Bolts Final Torque 610 N·m
450 lb-ft

Section 80 - MISCELLANEOUS Group 25: Wagon And Pick-Up Hitch
[6] -
IMPORTANT:
Some sleeve bolts may loosen as sleeve is tightened. Repeat star shaped
numbered sequence torquing pattern until ALL sleeve bolts maintain the
proper torque. Failure to follow procedure could result in damage to
equipment and may result in personal injury.
Drive tractor unloaded in a largefigure-8 pattern a minimum of four times and tighten bolts
in numerical order until bolts maintain final torque of 610 N·m (450 lb-ft).
[7] -
IMPORTANT:
Keep wheel sleeve cap screws tightened to specification. If tractor is
operated with loose wheel sleeves or under-torqued cap screws it may be
necessary to replace sleeves and cast wheels.
Torque bolts after working3 HOURS, 10 HOURS, andDAILY during the first week of
operation or until boltsdo not move when retorquing.

Group 25 - Wagon And Pick-Up Hitch

List of References
Specifications
Repair Wagon Hitch
Adjust Wagon Hitch Release
Repair Pick-Up Hitch
Adjust Pick-Up Hitch
Specifications
Pick-Up Upper Hitch Frame Cap Screws Final Torque 430 N·m
(170 lb-ft)
Repair Wagon Hitch
LEGEND:
A Cover
B Cable Lever
C Hitch Pin
D Bushing
E Snap Ring
F Hitch Coupling
G Housing
H Hitch Pin Control Lever
I Locking Latch
J Locking Pin
K Locking Pin Levers
L Cam
M Locking Pin Control Lever
N Cover
Adjust Wagon Hitch Release
LEGEND:
A Control Lever
B Adjusting Nuts
[1] - Close the wagon hitch and move control lever (A) to the latched position.
[2] - Adjust cable by turning hex nuts (B) until cable lever begins to move.

Repair Pick-Up Hitch
LEGEND:
A Cap Screws (10used)
B Washers (10used)
C Upper Frame
D Lower Frame
E Wear Plates
F Caps Screws (8used)
G Nuts (8used)
H Cap Screws (2used)
I Rubber Damper (2used)
J Retaining Pin
K Hydraulic Cylinder
L Guide
M Pins
N Locking Pin Mechanism

O Drawbar
[1] - Disassemble and repair as required.

[2] - Install upper frame(C) using cap screws(A) and washers(B); then tighten to
specificaton.
Upper Hitch Frame Cap Screw Final Torque 430 N·m
(170 lb-ft)
[3] - Lubricate parts as required.

Adjust Pick-Up Hitch
LEGEND:
A Lower Frame
B Lift Link Tubes
C Pins
D Cylinder Stop
[1] - Raise hitch. Do not use external raise/lower switch.

[2] - Press lower frame (A) using a jack until frame is against stop. Rubber damper must be
pressed together.
[3] - Turn lift link tubes (B) until pins (C) will freely move into position. Install washer and
cotter pin.
[4] -
CAUTION:
Avoid the possibility of personal injury. Check hitch function by opening
and closing hitch several times. Locking pin must be completely through
bore when hitch is closed.
Adjust cable by closing hitch and moving cab control lever to the detent position.

OPERATOR STATION (g) by Belgreen
[5] - Adjust cable until locking pin can easily extend and retract with control lever.
[6] - Adjust cylinder stop (D) until locking pin can easily extend and retract with control lever.


Table of contents
Other Material ........................................................................................................................ 1
Specifications ......................................................................................................................... 1
Remove Cab ........................................................................................................................... 3
Install Cab ............................................................................................................................ 15
Repair Cab ........................................................................................................................... 27
Remove Inner Roof ............................................................................................................... 28
Install Inner Roof .................................................................................................................. 42
Group 05 - Heating, Ventilating, and Air Conditioning (HVAC) ........................................ 55
Remove HVAC Module ......................................................................................................... 56
Install HVAC Module ............................................................................................................. 59
Remove and Install Heater Control Valve (Without ClimaTrak™) ......................................... 60
Leak Test Manual Heater Control Valve ............................................................................... 61
Remove and Install Heater Control Valve (With ClimaTrak™) .............................................. 62
Remove and Install Mode Control Cable .............................................................................. 64
Group 10 - Air Conditioning System ..................................................................................... 65
Other Material ...................................................................................................................... 66
Specifications ....................................................................................................................... 67
Hose and Tubing O-Ring Connection Torques ...................................................................... 68
Discharge Air Conditioning System ...................................................................................... 69
Flushing, Purging, and Evacuating Information .................................................................... 71
Purge Air Conditioning System ............................................................................................. 72
Evacuate Air Conditioning System ....................................................................................... 74
Charge Air Conditioning System .......................................................................................... 76
Refrigerant Oil Information .................................................................................................. 77
Check Compressor Oil Charge .............................................................................................. 78
Determine Correct Refrigerant Oil Charge ........................................................................... 79
Add Refrigerant Oil to System .............................................................................................. 81
Add Refrigerant Oil to Pressurized System ........................................................................... 82
Remove and Install Compressor ........................................................................................... 84
Replace Receiver-Dryer ....................................................................................................... 86
Remove and Install Expansion Valve ................................................................................... 88
Remove and Install Air Conditioning Condenser .................................................................. 89
Group 15 - Air Suspension Seat ............................................................................................ 90
Other Material ...................................................................................................................... 90
Specifications ....................................................................................................................... 90
Remove and Install Seat ...................................................................................................... 92
Repair Seat Air System ........................................................................................................ 94
Repair Seat Suspension ....................................................................................................... 97

Repair Seat Back ................................................................................................................ 107

Repair Seat Control Knobs ................................................................................................. 109
Group 16 - ComfortCommand™ Seat .................................................................................. 114
Specifications ..................................................................................................................... 114
Remove and Install Seat .................................................................................................... 115
Remove and Install Seat Top ............................................................................................. 117
Repair Seat Back ................................................................................................................ 121
Repair and Install Seat Control Knobs ................................................................................ 124
Group 20 - ActiveSeat™ ........................................................................................................ 127
Other Material .................................................................................................................... 128
Specifications ..................................................................................................................... 129
Purging Air from ActiveSeat™ System ............................................................................... 130
Remove and Install ActiveSeat™ ....................................................................................... 132
Remove and Install ActiveSeat™ Actuator ......................................................................... 135
Remove and Install ActiveSeat™ Actuator Hoses .............................................................. 138
Remove and Install ActiveSeat™ Control Valve Assembly ................................................. 141
ActiveSeat™ Hydraulic Control Valve Block ....................................................................... 144
Remove and Install ActiveSeat™ Accumulator .................................................................. 148
Checking and Charging Replacement Accumulators—ActiveSeat™ .................................. 150
Repair ActiveSeat™ Air System ......................................................................................... 164
Repair ActiveSeat™ Suspension ........................................................................................ 168
Repair ActiveSeat™ Back ................................................................................................... 178
Repair ActiveSeat™ Control Knobs .................................................................................... 180
Group 25 - Armrest ................................................................................................................ 185
Remove and Install Left Hand Armrest .............................................................................. 186
Group 30 - Cab Door and Windshield ................................................................................. 187
Specifications ..................................................................................................................... 187
Repair Cab Door Latch ....................................................................................................... 188
Cab Door Adjustment—Step 1 ............................................................................................ 193
Preparing Windshield Glass or Side Window For Replacement .......................................... 199
Group 35 - Cab Suspension .................................................................................................. 203
Specifications ..................................................................................................................... 203
Depressurize Cab Suspension System ............................................................................... 205
Remove and Install Cab Leveling Control Valve ................................................................. 206
Repair Cab Leveling Valve ................................................................................................. 208
Remove and Install Sensor Ball Joint Rod ........................................................................... 208
Adjust Sensor Rod .............................................................................................................. 209
Remove and Install Position Sensor ................................................................................... 210
Remove and Install Accumulator ....................................................................................... 211
Charging Accumulator ........................................................................................................ 212
Remove and Install Hydraulic Cylinders ............................................................................. 224

Remove and Install Panhard Rod ....................................................................................... 224

Bleeding Suspended Cab System ....................................................................................... 226

Section 90 - OPERATOR STATION Group 00: Component Removal and Installation

List of References
Other Material
Specifications
Remove Cab
Install Cab
Repair Cab
Remove Inner Roof
Install Inner Roof
→NOTE:

JDG19 Lifting Eyes
JT07336 Lift Sling
Other Material
Number Name Use
• PM37477 (us)
Strength) screw.

Specifications

(221 lb.-ft.)
(162 lb.-ft.)
Inner Roof Retaining Nuts Torque 40 N·m
(30 lb.-ft.)
Ground Wire Cap Screw Torque 70 N·m
(51 lb.-ft.)

Remove Cab
LEGEND:
B Cab Riser Panel
CAUTION:
Depress brake pedals ten times, fully releasing between depressions.
[1] - Lower 3-point hitch assembly.

Depressurize cab suspension. (See Depressurize Cab Suspension System in Group 35.)
[3] - Remove cab riser panel (B) by removing cap screws (A) under floor mat.
[4] - Discharge air conditioning system. (See Discharge Air Conditioning System in Group
10.)

[5] - Disconnect and plug air conditioner lines (C and D).

15.)
[7] - Remove aspirator hose. (See Remove and Install Aspirator Hose in Section 30, Group
15.)
[8] -
CAUTION:
LEGEND:
A Brake Valve
B Cap Screw and Fuel Hose
Exhaust System may be hot. Wait until exhaust is cool to the touch before
removing.
Remove exhaust system. (See Service Exhaust System in Section 30, Group 30.)
[9] - Remove cap screw and fuel hose (B) from brake valve (A).

[10] -
LEGEND:
A ACS™ Connector
B Load Sense Line
C Return Line
For tractors equipped with ACS™, perform the following:

Disconnect return line (C).
[11] -

IVT™

LEGEND:
B Load Sense Line
C Return Line
For tractors NOT equipped with ACS™, perform the following:

Disconnect return line (C).
Identify, label, and disconnect steering lines (D—F).
[12] -
CAUTION:

Engine Drain Valve—9.0 L
Engine Drain Plug—6.8L

LEGEND:
A Heater Hoses (2 used)
B Engine Drain Valve—9.0L
C Engine Drain Plug—6.8L
Coolant may be hot. Wait until radiator is cool to the touch before draining
coolant.
Open engine drain valve (B) or drain plug (C) and drain coolant into suitable container.
[13] - Remove heater hoses (A).
[14] -
LEGEND:
B Harness Connector
C Hose
Remove cap screws (A) and windshield washer reservoir.
[15] - Disconnect harness connector (B) and hose (C).
[16] -


LEGEND:
A Cover
C Cab Positive Cable
D Harness Connectors (10 used)
E Screws (8 used)
F Control Boxes (3 used)
G Fuel Tank Vent Hose
H Cab Wall Connectors (2 used)
I Harness Cover
Remove cap screws (B) and cover (A).
[17] - Remove cab positive cable (C).
[18] - Remove harness cover (I).
[19] - Remove harness connectors (D) and leave at rear hitch area.
[20] - Remove screws (E), control boxes (F), and leave at rear hitch area.
[21] - Remove fuel tank vent hose (G) and leave at rear hitch area.
[22] - Disconnect cab wall connectors (H).
[23] - Route harnesses to be raised with cab through rear window, or leave at rear hitch
area.

[24] -
LEGEND:
A Rear Brake Lines (2 used)
B Cap Screw and Bracket
Disconnect and plug rear brake lines (A).
[25] - Remove cap screw and bracket (B).
[26] -
LEGEND:
A Pressure Line
B Return Line
C Clamp
For tractors equipped with ActiveSeat™, perform the following:
IMPORTANT:
Air must be purged after seat hydraulic system has been opened for
service. (See Purging Air from ActiveSeat™ System in Group 20.)
Disconnect pressure line (A).

Slide clamp (C) back and remove return line (B).
Cap and plug all openings to prevent contamination.

[27] -
Park Lock and Range Cables

LEGEND:
A Park Lock Cable
B E Range Cable
C A and B Range Cable
D C and D Range Cable
For tractors equipped with PowrQuad™ or AutoQuad™, perform the following:
→NOTE:
Fuel tanks removed for illustration purposes.
Label and disconnect park lock cable (A).

Label and disconnect range cables (B—D).

[28] -
LEGEND:
A JDG19 Lift Brackets
[29] - Using an overhead hoist attach JT07336 Lift Sling (B) and raise slightly.
[30] -
LEGEND:
A Cap Screw
B Nut
C Ball Joint
D Cap Screw
E Panhard Rod
F Cap Screw
G Bushing
→NOTE:
Front cab mounts of suspended cab are serviced same as non-suspended
cab mounts.


Remove nut (B) and ball joint (C). (See Remove and Install Sensor Ball Joint Rod in
Group 35.)
Remove cap screw (D) and disconnect panhard rod (E) from left side of cab.
Remove cap screw (F) and bushing (G).
Carefully remove cab ensuring that all lines and harnesses are loose from bottom of
cab.
[31] -
LEGEND:
Remove cab mount cap screws (A) from both sides of tractor.
Carefully remove cab ensuring that all lines and harnesses are loose from bottom of
cab.

Install Cab
[1] -
LEGEND:
B Washer
C Bushing
D Rebound Washer
E Mount

Install mounts using diagram for reference.
→NOTE: All four cab mounts are installed the same.
Apply PM37477 Thread Lock and Sealer to cab mount cap screws (A) and tighten to
specification.
Number Name Use
⚬ PM37477 (us)
Strength) screw.

(221 lb.-ft.)

[2] -
LEGEND:
A Cap Screw
B Nut
C Ball Joint
D Cap Screw
E Panhard Rod
F Cap Screw
G Bushing
→NOTE:
Front cab mounts of suspended cab are serviced same as non-suspended
cab mounts.

Install bushing (G) and cap screw (F). Tighten to specification.
(162 lb.-ft.)
Install cap screw (D) and panhard rod (E) on left side of cab.
Install nut (B) and ball joint (C). (See Remove and Install Sensor Ball Joint Rod in Group
35.)
Install cap screw (A).

[3] -
LEGEND:
A JDG19 Lift Brackets
Remove JT07336 Lift Sling (B) and JDG19 Lifting Eyes (A).
[4] -
Park Lock and Range Cables

LEGEND:
A Park Lock Cable
B E Range Cable
C A and B Range Cable
D C and D Range Cable
For tractors equipped with PowrQuad™ or AutoQuad™, perform the following:
→NOTE:
Fuel tanks removed for illustration purposes.
Connect park lock cable (A).

Connect range cables (B—D).
[5] -
LEGEND:
A Pressure Line
B Return Line
C Clamp
For tractors equipped with ActiveSeat™, perform the following:
IMPORTANT:
Air must be purged after seat hydraulic system has been opened for
service.
Install lines (A and B).

Install clamp (C).
[6] -
LEGEND:
A Rear Brake Lines (2 used)
B Cap Screw and Bracket
Connect rear brake lines (A).

[7] - Install cap screw and bracket (B).

[8] -

LEGEND:
A Cover
C Cab Positive Cable
D Harness Connectors (10 used)
E Screws (8 used)
F Control Boxes (3 used)
G Fuel Tank Vent Hose
H Cab Wall Connectors (2 used)
I Harness Cover
Install cab wall connectors (H).
[9] - Install fuel tank vent hose (G).
[10] - Install control boxes (F) and screws (E).
[11] - Connect harness connectors (D).
[12] - Install harness cover (I).
[13] - Connect cab positive cable (C).
[14] - Install cover (A) and cap screws (B).

[15] -
LEGEND:
B Harness Connector
C Hose
Install harness connector (B) and hose (C).
[16] - Install washer reservoir and cap screws (A).

[17] -
LEGEND:
A Heater Hoses (2 used)
Install heater hoses (A).
[18] - Fill with coolant.

[19] -
LEGEND:
A ACS™ Connector
B Load Sense Line
C Return Line
For tractors equipped with ACS™, perform the following:
Connect harness connector (A).

Connect return line (C).
[20] -

IVT™

LEGEND:
B Load Sense Line
C Return Line
For tractors NOT equipped with ACS™, perform the following:

Connect return line (C).
Connect steering lines (D—F).

[21] -
LEGEND:
A Brake Valve
B Cap Screw and Fuel Hose
Install cap screw and fuel hose (B) on brake valve (A).

[22] -
LEGEND:
B Cab Riser Panel
Install air conditioner lines (C and D).
[23] - Install exhaust system. (See Service Exhaust System in Section 30, Group 30.)
[24] - Install aspirator hose. (See Remove and Install Aspirator Hose in Section 30, Group
15.)
[25] - Install intake system. (See Remove and Install Intake Housing in Section 30, Group
15.)
[26] - Charge air conditioning system. (See Charge Air Conditioning System in Group 10.)
[27] - Install cab riser panel (B) and cap screws (A).
[28] - Bleed brakes. (See Bleed Brakes in Section 60, Group 20.)
[29] - Purge air from ActiveSeat™. (See Purging Air from ActiveSeat™ System in Group 20.)
[30] - Calibrate cab suspension sensor. (See Operation and Test TM Section 245, Group
CSC.)

Repair Cab
CAUTION:
Make certain all parts are installed correctly to maintain rollover

protection (ROPS) if cab is loosened or removed for any reason. Tighten
mounting bolts to proper torque.
A tractor rollover creates a severe stress on the cab structure. If the

structural members have been bent, buckled, or stretched, reuse of a cab
is not recommended .
Do not weld, grind, drill, or cut on the cab structural members when
making a repair on the body frame. Doing so can weaken the members
sufficiently to limit the effectiveness in protecting the operator during a
rollover or upset.

Remove Inner Roof

[1] - Remove HVAC module. (See Remove HVAC Module in Section 90, Group 05.)
[2] - Remove beacon light, if equipped.
[3] -
LEGEND:
B Roof Handrail
C Fresh Air Filter Cover
Remove cap screws (A) from roof handrail (B).
[4] - Turn knob to remove cover (C) and fresh air filter.

[5] -
LEGEND:
A Harness
B Screws (9 Used)
C Seal
Remove seal (C).
[6] - Remove screws (B) from cover.
[7] - Disconnect blower motor harness (A).
[8] - Remove blower motor assembly from tractor.
[9] -

LEGEND:
A Connector
B Screw
C Mounting Screw (3 used)
D Shield
E Nut
F Wiper Motor
[10] - Remove screw (B) and ground wire.
[11] - Remove mounting screws (C) and pull wiper assembly through opening in headliner.
[12] - Remove shield (D), nut (E), and wiper motor (F).

[13] -
LEGEND:
A Bezel Assembly
B Connectors (2 used)
C Nut
D Antenna
Pull bezel assembly (A) towards center of cab.
[14] - Disconnect connectors to courtesy light, remote mirror switch, and rear wiper switch, if
equipped.
[15] - Remove bezel.
[16] - Disconnect radio connectors (B).
[17] - Remove nut (C).
[18] - Disconnect antenna (D).

[19] -
LEGEND:
A Radio Removal Tools
Install radio removal tools (A) into radio and pull out radio.
[20] -
LEGEND:
A Bezel Cover
B Mirror
C Sun Shade
E Coat Hook
F Resonator Port Bezels (2 used)
G Filter Cover
H Screws (4 used)
I Headliner
Remove cab post covers.

[21] -
→NOTE:
Bezel assembly is held in place with clips. Pull straight out on assembly
when removing.
Remove bezel assembly (A) and disconnect switches.

[22] - Remove mirror (B).
[23] - Remove sun shade (C).
[24] - Remove dome light assembly (D) and disconnect light.
[25] - Remove coat hook (E).
[26] - Remove resonator port bezels (F).
[27] - Remove filter cover (G).
[28] - Remove headliner-to-inner roof screws (H).
[29] - Remove headliner (I).
[30] -
Radio Speakers
LEGEND:
A Speakers (4 used)
B Screws (16 used)
Remove screws (B) and lower speakers from inner roof.
[31] - Disconnect cab harness connectors from speakers (A).

[32] -
LEGEND:
A Cable Retainers (2 used)
B Mode Control Cable
For tractors not equipped with Automatic Temperature Control (ATC), perform the
following:
Remove cable retainers (A) and mode control cable (B).
[33] -

LEGEND:
A Wiring Harness
B Blower Motor Speed Control
C Screws (4 used)
D Air Flow Mode Control Doors
E Screws (2 used)
F ATC Unit
G Drain Hoses (4 used)
H Ground Wire
For tractors equipped with ATC, perform the following:
Disconnect wiring harness (A) and remove blower motor speed control (B).
Remove screws (E) and ATC unit (F).
[34] - For all tractors, perform the following:
Remove screws (C) and air flow mode control doors (D).
Remove drain hoses (G) and ground wire (H).

[35] -
LEGEND:
A Cab Recirculation Filter
B Screws (4 used)
C Cover
Remove cab recirculation filter (A), screws (B), and cover (C).

[36] -
LEGEND:
A Boot
B Plugs (2 used)
C Clamp
D Wiring Harness Connector
Remove wiring harness from clips and route back through boot (A) into cab.
[37] - Remove plugs (B) and clamp (C).
[38] - Disconnect harness connector (D) and route wiring harness into cab.

[39] -
LEGEND:
A Wiring Harness Connectors (2 used)
B Roof Control Unit
Disconnect wiring harness connectors (A) and remove roof control unit (B).

[40] -
LEGEND:
A Screws (3 used)
B A/C Hoses
C Clamp
D Heater Hoses
Remove screws (A).
[41] - Route wiring harness and A/C hoses (B) to left front cab support.
[42] - Remove clamp (C) and route heater hoses (D) to right front cab support.

[43] -
LEGEND:
A Screws (24 used)
B Speaker Covers (4 used)
Remove screws (A) and speaker covers (B).
[44] -
CAUTION:
Inner roof weighs approximately 46 kg (101 lb.). Use caution when
handling.

LEGEND:
A Lifting Straps (2 used)
B Inner Roof
C Inner Roof Retaining Nuts (4 used)
Install lifting straps (A) through speaker holes and attach to overhead hoist.
[45] - Remove nuts (C) and inner roof (B).

Install Inner Roof

[1] -
CAUTION:
Inner roof weighs approximately 46 kg (101 lb.). Use caution when
handling.
LEGEND:
A Lifting Straps (2 used)
B Inner Roof
C Inner Roof Retaining Nuts (4 used)
Install lifting straps (A) through speaker holes and attach to overhead hoist.
[2] - Install inner roof (B) onto cab support.

[3] - Install nuts (C) and tighten to specification.

Inner Roof Retaining Nuts Torque 40 N·m
(30 lb.-ft.)
[4] - Remove lifting straps.

[5] -
LEGEND:
A Screws (24 used)
B Speaker Covers (4 used)
Install speaker covers (B) and screws (A).

[6] -
LEGEND:
A Screws (3 used)
B A/C Hoses
C Clamp
D Heater Hoses
Route heater hoses (D) to proper location and install clamp (C).
[7] - Route wiring harness and A/C hoses (B) to proper location and install screws (A).

[8] -
LEGEND:
A Wiring Harness Connectors (2 used)
B Roof Control Unit
Install roof control unit (B) and connect harness connectors (A) .

[9] -
LEGEND:
A Boot
B Plugs (2 used)
C Clamp
D Wiring Harness Connector
Route wiring harness from cab and connect harness connector (D).
[10] - Install clamp (C) and plugs (B).
[11] - Route wiring harness back through boot (A) from cab and install in clips.

[12] -
LEGEND:
A Cab Recirculation Filter
B Screws (4 used)
C Cover
Install cab recirculation filter (A), cover (C), and screws (B).
[13] -
LEGEND:
A Cable Retainers (2 used)
B Mode Control Cable
For tractors not equipped with Automatic Temperature Control (ATC), perform the
following:
Install mode control cable (B) and cable retainers (A).
[14] -

LEGEND:
A Wiring Harness
B Blower Motor Driver
C Screws (4 used)
D Air Flow Mode Control Doors
E Screws (2 used)
F ATC Unit
G Drain Hoses (4 used)
H Ground Wire
For tractors equipped with ATC, perform the following:

Install blower motor speed control (B) and connect wiring harness (A).
Install ATC unit (F) and screws (E).
[15] - For all tractors, perform the following:
Install air flow mode control doors (D) and cap screws (C).
Install drain hoses (G) and ground wire (H). Tighten to specification.
Ground Wire Cap Screw Torque 70 N·m
(51 lb.-ft.)
[16] -
Radio Speakers
LEGEND:
A Speakers (4 used)
B Screws (16 used)
Connect cab harness connectors to speakers (A).
[17] - Place speakers in inner roof and install screws (B).

[18] -
LEGEND:
A Bezel Cover
B Mirror
C Sun shade
E Coat Hook
F Resonator Port Bezels (2 used)
G Filter Cover
H Screws (4 used)
I Headliner
Install headliner (I).
[19] - Install headliner-to-inner roof screws (H).
[20] - Install filter cover (G).
[21] - Install resonator port bezels (F).
[22] - Install coat hook (E).
[23] - Install dome light assembly (D) and connect light.
[24] - Install sun shade (C).
[25] - Install mirror (B).
[26] -
→NOTE:
Bezel assembly is held in place with clips.
Connect switches and install bezel assembly (A).

[27] - Install cab post covers.
[28] - Install radio.

[29] -
LEGEND:
A Bezel Assembly
B Connectors (2 used)
C Nut
D Antenna
Hold bezel towards center of cab.
[30] - Connect connectors to courtesy light, remote mirror switch, and rear wiper switch if
equipped.
[31] - Connect antenna (D).
[32] - Install nut (C).
[33] - Connect radio connectors (B).
[34] - Install bezel assembly (A).
[35] -

LEGEND:
A Connector
B Screw
C Mounting Screws (3 used)
D Shield
E Nut
F Wiper Motor
Install wiper motor (F), nut (E), and shield (D).
[36] - Install wiper assembly through opening in headliner and mounting screws (C).
[37] - Connect connector (A).
[38] - Install ground wire and screw (B).

[39] -
LEGEND:
A Harness
B Screws (9 Used)
C Seal
Install blower motor assembly.
[40] - Install screws (B).
[41] - Connect blower motor harness (A).
[42] - Install seal (C).

Group 05: Heating, Ventilating, and Air Conditioning
(HVAC)
[43] -
LEGEND:
B Roof Railing
C Fresh Air Filter Cover
Install fresh air filter and cover (C).
[44] - Install roof railing (B) and cap screws (A).
[45] - Install HVAC module. (See Install HVAC Module in Section 90, Group 05.)
[46] - Install beacon light, if equipped.

(HVAC)
Group 05 - Heating, Ventilating, and Air

Conditioning (HVAC)
List of References
Remove HVAC Module
Install HVAC Module
Remove and Install Heater Control Valve (Without ClimaTrak™)
Leak Test Manual Heater Control Valve
Remove and Install Heater Control Valve (With ClimaTrak™)
Remove and Install Mode Control Cable

(HVAC)
Remove HVAC Module
LEGEND:
A Screws
B Green Roof
C Antenna Cable
[1] - For all tractors: Drain cooling system.

[2] - Discharge system. (See Discharge Air Conditioning System in Group 10.)
[3] - Remove all screws (A) from top of cab green roof (B).
[5] - Remove green roof.

(HVAC)
[6] -
LEGEND:
A Socket Head Cap Screw (12 Used)
B Blower Motor Connector
C Thermostat Probe
D Cover
E Expansion Valve
F Air Temperature Sensor
G Blower Speed Resistor
Remove socket head cap screw (A).
[7] - Disconnect blower motor connector (B).
[8] - Disconnect and remove thermostat probe (C).
[9] - Remove cover (D) with blower motor.
[10] - Disconnect expansion valve (E) then cap lines to prevent contamination.
[11] - Disconnect and identify air temperature sensor (F) and blower speed resistor
connector (G) for reassembly.

(HVAC)
[12] -
LEGEND:
A Heater Inlet Hose
B Heater Outlet Hose
C Socket Head Cap Screw (4 Used)
D HVAC Module
Clamp off heater inlet hose (A) and disconnect from module.
[13] - Clamp off heater outlet hose (B) and disconnect from module.
[14] - Disconnect evaporator temperature sensor and duct air temperature sensor.
[15] - Remove socket head cap screw (C).
[16] - Remove HVAC module (D) from roof.

(HVAC)
Install HVAC Module

[1] - Flush evaporator if module was air tested.
[2] - Add 60 mL (2 oz) of refrigerant oil to module before installation if evaporator was
completely flushed or replaced with a new evaporator, and if no system leaks found. If leaks
existed, check refrigerant oil charge. (See Determine Correct Refrigerant Oil Charge in Group
10.)
[3] - Inspect O-rings on high and low-pressure lines.
[4] -
→NOTE:
Be sure that cab harness is above heater blower motor when installing
HVAC module.
Install module at rear of cab.

[5] -
IMPORTANT:
Be sure blower outlet duct and fresh air duct are properly aligned.
Complete installation in reverse order of removal.

[6] -
IMPORTANT:
Replace foam seal each time the A/C compartment cover is removed.
DO NOT overtighten A/C compartment cover screws.
Make sure drain hose always slopes some amount toward ground.
[7] - Purge, evacuate, and charge system. (See Flushing, Purging, and Evacuating
Information in Group 10.)

(HVAC)
Remove and Install Heater Control Valve (Without

ClimaTrak™)
LEGEND:
A Valve Location
B Inlet Hose Clamp
C Heater Control Valve
D Outlet Hose Clamp
E Cable
[1] - Remove cab roof.

[2] - Locate heater control valve (A).
[3] - Drain or clamp off coolant lines.
[4] - Remove inlet hose clamp (B) and outlet hose clamp (D).
[5] - Disconnect hoses from heater control valve (C).
[6] - Disconnect temperature control cable (E).
[7] - Adjust temperature control cable so heater control valve is fully closed when
temperature control knob is in the coldest position.

(HVAC)
[8] - Wash compartment with clean water to remove spilled antifreeze.

IMPORTANT:
DO NOT overtighten roof screws.
Leak Test Manual Heater Control Valve
→NOTE:
LEGEND:
A Valve Inlet
B Valve Control Arm
C Valve Outlet
D Cable Support
Valve is not serviceable.
[1] - Connect water pressure hose to heater control valve inlet (A).
[2] - Move valve arm (B) to fully closed position. Arm should be against stop opposite of
cable support (D).
[3] - Check for leakage from valve outlet (C).
[4] - Replace if required.

(HVAC)
Remove and Install Heater Control Valve (With

ClimaTrak™)
LEGEND:
A Valve Location
B Inlet Hose Clamp
C Outlet Hose Clamp
D Connector
IMPORTANT:
Heater valve test must be performed before replacing valve. (See

Operation and Test Manual for Test Procedure.)
[1] - Remove cab roof.

[2] - Locate heater control valve (A).
[3] - Drain or clamp off coolant lines.
[4] - Remove inlet hose clamp (B) and outlet hose clamp (C).
[5] - Disconnect connector (D) from valve.

(HVAC)
[6] - Pull valve from hoses and replace as necessary.

[7] - Check for leakage from the valve outlet, replace as necessary.
[8] - Perform ClimaTrak™ (ATC) Calibration Procedure. (See Operation and Test Manual for
Calibration Procedure.)

Section 90 - OPERATOR STATION Group 10: Air Conditioning System
Remove and Install Mode Control Cable
LEGEND:
A Mode Control Knob
B Cable Retainers 2 Used
C Cable Adjuster
D Mode Doors
E Timing Marks
[1] - Remove head liner in cab.

[2] - Remove outer green roof.
[3] - Remove mode control knob (A) and cable retainers (B).
[4] - Remove cable from mode doors (D).
[5] - Inspect parts and replace as necessary. Assemble in reverse order.
[6] - Ensure timing marks (E) are across from each other.
[7] - Adjust cable adjuster (C) until mode doors open and close fully when mode control knob
is rotated.

Group 10 - Air Conditioning System

List of References
Other Material
Specifications
Hose and Tubing O-Ring Connection Torques
Discharge Air Conditioning System
Flushing, Purging, and Evacuating Information
Purge Air Conditioning System
Evacuate Air Conditioning System
Charge Air Conditioning System
Refrigerant Oil Information
Check Compressor Oil Charge
Determine Correct Refrigerant Oil Charge
Add Refrigerant Oil to System
Add Refrigerant Oil to Pressurized System
Remove and Install Compressor
Replace Receiver-Dryer
Remove and Install Expansion Valve

→NOTE:

JDG10555 Recovery/Recycling Station
JDG10974 Recovery/Recycling, and Charging Station
JT02098 Air Conditioning R-12/R134a Fitting Kit
JT02129 Air Conditioning Oil Injector
Other Material
Number Name Use
• R36757 (us) John Deere Cleaner Clean air filters
• TY16134 (us) R-134a Flushing Solvent Flush system
• TY15949 (12 oz) (us) R-134a Refrigerant Charge the system
• TY15950 (15 lb) (us) R-134a Refrigerant Charge the system
• TY15951 (30 lb) (us) R-134a Refrigerant Charge the system
• TY22101 (8.5 oz) (us) R-134a Compressor Oil Lubricate the system
• TY27507 (us) Fluorescent Dye Cleaner Remove TY27506 Dye from components

Specifications
Evacuating System Required Vacuum at Sea Level 94 kPa (0.9 bar)
(28.6 in. Hg)
R-134a Refrigerant Capacity 1.84 kg
(4.0 lb.)
System Oil Charge 245 mL
(8.3 fl oz.)
Refrigerant Oil Charge

System Capacity 245 mL
(8.3 oz.)
Evaporator Capacity 60 mL
(2 fl oz.)
Condenser Capacity 60 mL
(2 fl oz.)
Receiver-Dryer Capacity 15 mL
(0.5 fl oz.)
Compressor Capacity 60 mL
(2 fl oz.)
Total Hose Capacity 60 mL
(2 fl oz.)
Compressor Mounting Cap Screws Torque 35 N·m
(26 lb.-ft.)
Suction Line Clamp Torque 8 N·m
(71 lb.-in.)
Discharge Line Clamp Torque 8 N·m
(71 lb.-in.)

Hose and Tubing O-Ring Connection Torques

Metal Tube Outside Diameter Thread and Fitting Size Torque
N·m (lb.-ft.)
1/4 7/16 14-20 (10-15)
3/8 5/8 14-20 (10-15)
1/2 3/4 33-39 (24-29)
5/8 7/8 35-42 (26-31)
3/4 1-1/16 41-47 (30-35)

Discharge Air Conditioning System
LEGEND:
B Cab Riser Panel
C Discharge Fitting
D Suction Fitting
[1] - Operate air conditioning system for 10 minutes with engine at 2000 rpm if compressor
is operable.
[2] - Set temperature control for maximum cooling and blower switch at high. This allows
refrigerant oil to be circulated through system and indicates quantity of oil in compressor.
[3] - Stop engine and use the following procedure to discharge system:
[4] - Remove cab riser panel (B) by removing cap screws (A) under floormat.
[5] -
IMPORTANT:
Use only R-134a Refrigerant Recovery, Recycling, and Charging machines.
Do not mix R-134a equipment, refrigerant, and refrigerant oils with R-12
systems.
Connect gauges to JDG10974 Recovery/Recycling, and Charging Station .

[6] -
→NOTE:
JDG10555 Recovery/Recycling Station may be substituted for JT02050 and
Manifold Gauges.
→NOTE:
JDG10974 Recovery/Recycling Station can be used in Europe.
Connect low-pressure hose (blue) to suction fitting (D). Connect high-pressure hose (red) to
discharge fitting (C).
[7] - Follow the manufacturer′s instructions and discharge system. Cap the fittings to prevent
contamination.

Flushing, Purging, and Evacuating Information

Flushing:
Flushing the system or a component is a cleaning process using a liquid solvent to remove oil
and debris.
When to flush the air conditioning system:
The compressor has an internal failure

No oil remains in used compressor
Oil drained from compressor appears or smells overheated
System was contaminated with a mixture of refrigerant oils
System was left open to the atmosphere long enough for dirt, moisture, or debris to
enter the tubing or components
System has an internal blockage
The R-134a system requires a two-step process as follows:
Primary Flush:
IMPORTANT:
Use only fresh solvent for the primary flush.
Automotive parts cleaning solvents used according to applicable guidelines can be utilized for
a system primary flush.
IMPORTANT:
Do Not Use diesel fuel, gasoline, fuel oil, water, alcohol, or any cleaning
fluids formulated for dissolving oils, grease, and antifreeze.
Final Flush:
Use 2 L (1/2 gal.) TY16134 Flushing Solvent or equivalent.

Review applicable MSDS data for hazard identification rating.
Separate the air conditioning system into two circuits and follow the flushing procedure
listed in this group.
Recover all used solvents with appropriate flushing equipment.
Purge the air conditioning system with compressed air for the recommended amount of
time specified in the flushing procedure.

IMPORTANT:
Failure to use a recommended final flushing solvent after using a parts

cleaning solvent for the primary flush will cause the refrigerant oil to
become diluted and compressor life will be shortened.
→NOTE:
Failure to properly purge the system will dilute the solvent.
Use 0.5 L (0.5 qt.) of clean solvent for flushing a serviceable compressor that will be
reinstalled on a machine.
Purging:
Purging the system or a component is a cleaning process using a gas to force liquid from the
system. Purging alone will not remove refrigerant oil from the system.
When to purge an air conditioning system:
After flushing system with solvent, to prevent oil dilution

System was contaminated with nitrogen or two refrigerants
System was left open to the atmosphere and flushing could not be performed
Installation of new lines, condenser, or evaporator was required
Evacuating:
Evacuating the system is a process to remove air and moisture from the system, by creating
a vacuum.
Solvents
The following solvent is recommended for flushing air conditioning systems. Use only
solvents with an equivalent MSDS.
TY16134 A/C System Flushing Solvent
→NOTE:
New solvent used in parts cleaning tank can be used for the PRIMARY flush,
providing a FINAL flush with TY16134 Solvent is performed. Parts tank
solvents will not evaporate below 60 °C (140 °F). Therefore TY16134
Solvent must be used for the final flush, since the evaporation temperature
is much lower, and it is easily removed when evacuating the system.

Purge Air Conditioning System
IMPORTANT:
Air compressors used for purging systems require a water separator.

Purging without a separator adds moisture, creating hydrofluoric acid when
combined with refrigerant oil. Acid is corrosive to metal tubing.
[1] - Connect dry nitrogen hose to gauge manifold center hose.

[2] - Connect gauge manifold suction hose to compressor suction port and open valves.
[3] - Connect gauge manifold discharge hose to compressor discharge port, and open valve.
Disconnect discharge hose from gauge manifold to allow purging nitrogen to atmosphere.
[4] - Open nitrogen tank valve and adjust regulator to 275 kPa (2.75 bar) (40 psi). Purge
system for 2 minutes. Disconnect nitrogen supply.
[5] - Evacuate system. (See Evacuate Air Conditioning System in this group.)

Evacuate Air Conditioning System
LEGEND:
B Cab Riser Panel
C Discharge Fitting
D Suction Fitting
IMPORTANT:

Do not mix R-134a equipment, refrigerant, and refrigerant oils with R-12
systems.
[1] - Remove cab riser panel (B) by removing cap screws (A) under floormat.

[2] - Connect JDG10974 Recovery/Recycling, and Charging Station and Manifold Gauges.
→NOTE:
JDG10555 Recovery/Recycling Station can be substituted for JT02050 or
JT02045.
Pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level).
Deduct 1 in. Hg from 29.9 in. for each 300 m (1000 ft.) elevation above sea
level.
→NOTE:
[3] - Connect low-pressure hose (blue) to suction fitting (D) on compressor. Connect high-
pressure hose (red) to discharge fitting (C) on compressor.
[4] -
IMPORTANT:
A decrease in vacuum of 1 in. Hg or more in 5 minutes indicates an
excessive leak, or there is still liquid R-134a in system.
Follow manufacturer′s instructions and evacuate system.

Evacuating System Required Vacuum at Sea Level 94 kPa (0.9 bar)
(28.6 in. Hg)
a. Evacuate system for 15 minutes if ambient temperature is below 30 °C (85 °F), to

remove air, nitrogen, and moisture.
b. Evacuate system for 30—45 minutes if ambient temperature is above 30 °C (85 °F), to
remove air, nitrogen, and moisture.
c. Charge system. (See Charge Air Conditioning System in this group.)

Charge Air Conditioning System

[1] - Evacuate system. (See Evacuate Air Conditioning System in this group.)
[2] -
IMPORTANT:
Prevent compressor damage. DO NOT mix R-134a equipment, refrigerant,
and refrigerant oils with R-12 systems.
Connect JDG10974 Recovery/Recycling, and Charging Station to charge system.

→NOTE:
JDG10555 Recovery/Recycling Station can be substituted for JT02045.
→NOTE:
[3] - Connect low-pressure hose (blue) to suction fitting on compressor. Connect high-
pressure hose (red) to discharge fitting on compressor.
[4] -
IMPORTANT:
Do not run engine. System must hold a minimum vacuum of 28.6 in. Hg.
Deduct 1 in. Hg from 29.9 in. for each 300 m (1000 ft.) elevation above sea
level.
Charge the system.

[5] - Weigh refrigerant supply tank and invert so refrigerant enters system as a liquid.
[6] - Begin charging through discharge port first. When suction pressure nearly equals
discharge pressure, open suction valve.
[7] -
IMPORTANT:
Close discharge valve on gauge manifold before starting engine and
compressor, to prevent over pressurizing refrigerant container.
Continue charging system to capacity. Start engine to complete charging system if a heated
cylinder is not being used.
R-134a Refrigerant Capacity 1.84 kg
(4.0 lb.)

[8] - Close both gauge manifold valves and perform a system operational check as follows:
Engine at 2000 rpm Close door and all windows.

Compressor operating with temperature control at maximum cooling, and blower at
PURGE.
Check ambient air temperature, cab air duct temperature, suction, and discharge
pressures. Compare to the temperature-pressure chart and temperature drop
specifications in Operation and Test TM—Section 290, Group 15.
Refrigerant Oil Information
CAUTION:
New compressors are charged with a mixture of nitrogen, R-134a

refrigerant, and TY22101 (R-134a) Refrigerant Oil. Wear safety goggles
and discharge compressor slowly to avoid possible injury.
New compressors contains 230—255 mL (7.7—8.5 fl oz.) of new oil. The oil level visible
through the suction port is normally below the drive shaft. The amount of trapped oil is 81 mL
(2.7 fl oz.). Approximately 60 mL (2 fl oz.) will seep into the cylinders during shipping and
storage.
Typically 21 mL (0.7 fl oz.) of oil covers internal surfaces of the compressor exposed to
refrigerant gas and cannot be drained.
The oil level will be above the drive shaft when 255 mL (8.5 fl oz.) is put in a dry compressor.
The normal operating oil level of a used compressor is 30—45 mL (1.0—1.5 fl oz.) and cannot
be seen through the suction port.

Check Compressor Oil Charge

[1] - Remove compressor. (See Remove and Install Compressor in this group.)
[2] - Remove manifold caps and drain oil in clean container. Record amount.
[3] -
→NOTE:
Save oil if compressor is new.
If more than 6 mL (0.2 fl oz) of oil was drained and oil appears normal, or any other
components were replaced or flushed, check if the refrigerant oil charge is correct. (See
Determine Correct Refrigerant Oil Charge in this group.)
If less than 6 mL (0.2 fl oz) of oil was drained or oil appears very black, perform the following:
a. Flush with solvent to internally wash out oil if compressor is serviceable.

b. Remove and clean expansion valve, but do not disassemble valve.
c. Remove and discard receiver-dryer. (See Replace Receiver-Dryer in this group.)
d. Install a new receiver-dryer.
e. Flush complete system. (See Flushing, Purging, and Evacuating Information in this
group.)
f. Install required oil. (See Determine Correct Refrigerant Oil Charge in this group.)
g. Connect all components.
h. Purge, evacuate, and charge system. (See Purge Air Conditioning System , Evacuate Air
Conditioning System , and Charge Air Conditioning System in this group.)

Determine Correct Refrigerant Oil Charge
→NOTE:
Determine amount of system oil charge prior to installation of compressor.
Compressors are divided into three categories when determining correct oil charge.
New compressor
Used compressor, not flushed
Used compressor, flushed
[1] -
CAUTION:
Use extreme caution when handling refrigerant oil. Wear protective gloves
and goggles at all times. Wash immediately with soap and water if oil
comes in contact with skin.
DO NOT spill R-134a compressor oil on acrylic or ABS plastic. Oil will
deteriorate these materials rapidly.
Add correct amount of oil ifcomplete system was flushed :
New Compressor—contains correct amount of new oil, 245 mL (8.3 fl oz.)

Used Compressor—Drained, NOT Flushed—Add 230 mL (7.7 fl oz.) of new oilDrained,
Flushed—Add 245 mL (8.3 fl oz.) of new oil
System Oil Charge 245 mL
(8.3 fl oz.)
[2] - Add correct amount of oil for the compressorand each component if complete system
was NOT flushed:
New compressor contains 245 mL (8.3 fl oz.) of new oil. Connect battery to clutch coil
and rotate drive shaft to remove all oil. Return 45 mL (1.5 fl oz.) of oil to compressor.
Used Compressor
Drained, NOT Flushed—Add 45 mL (1.5 fl oz.) of new oil
Drained, Flushed—Add 60 mL (2 fl oz.) of new oil
Remove compressor to determine correct oil charge if any components listed below have
been removed, drained, and flushed.

IMPORTANT:
Use care adding oil. Too much oil in the system will reduce maximum
cooling capacity. Too little oil will result in poor lubrication of the
compressor, leading to early compressor failure.
→NOTE:
If complete system was purged with all components in place, amount of oil
lost is negligible.
Use following chart as a guide for adding oil:
Refrigerant Oil Charge

System Capacity 245 mL
(8.3 oz.)
Evaporator Capacity 60 mL
(2 fl oz.)
Condenser Capacity 60 mL
(2 fl oz.)
Receiver-Dryer Capacity 15 mL
(0.5 fl oz.)
Compressor Capacity 60 mL
(2 fl oz.)
Total Hose Capacity 60 mL
(2 fl oz.)
→NOTE:
Hoses =10 mL per m (0.1 fl oz. per ft.) Approximate total length equals 6 m
(20 ft.).
If any section of hose is removed and flushed or replaced, measure length of hose and use
the formula to determine correct amount of oil to be added.

IMPORTANT:
DO NOT leave the system or R-134a compressor oil containers open. Oil
easily absorbs moisture.
DO NOT spill R-134a compressor oil on acrylic or ABS plastic. Oil will
deteriorate these materials rapidly.
Identify R-134a oil containers and measures to eliminate accidental mixing

of different oils.
Add Refrigerant Oil to System

[1] - Add approximately 170 mL (5.6 fl oz.) of oil through compressor suction port and 85 mL
(2.9 fl oz.) into discharge port when system has been completely flushed.
[2] -
→NOTE:
If dye has been installed in the system, the receiver-dryer should be tagged
with a sticker from the correct kit.
IMPORTANT:
Use only TY22101 (R-134a) Refrigerant Oil.
→NOTE:
Some oil may have to be added through compressor line and fitting.
Install manifold to compressor, if removed, and tighten cap screws to specification.

Compressor-to-Manifold Cap Screws Torque 26 N·m
(19 lb.-ft.)

Add Refrigerant Oil to Pressurized System
LEGEND:
A Needle Valve
B JT02129 Air Conditioning Oil Injector
C Hose End
D Injector End
E Low-Pressure Valve
F High-Pressure Valve
G Low-Pressure Quick Connector
H High-Pressure Quick Connector
I Refrigerant Container
→NOTE:
JT02129 Air Conditioning Oil Injector is designed to add up to 60 mL (2 fl oz)

of refrigerant oil to a system that is already pressurized. A/C Oil Injector
can also add oil if the system has no pressure or is under a vacuum.
[1] - Close needle valve (A) on JT02129 Air Conditioning Oil Injector (B).
[2] - Add up to 60 mL (2 fl oz) of refrigerant oil into JT02129 Air Conditioning Oil Injector (B).
[3] - Connect hose end of injector to a (R134a) 360 mL (12 fl oz) refrigerant supply can.
[4] - Connect other end of injector (D) to the center hose of a gauge manifold set and bleed
air from hoses, if necessary.

[5] - Connect gauge manifold connector (G) to the suction, and gauge manifold connector (H)
to the discharge connector fittings on the compressor.
[6] - Operate engine at 1500 rpm and turn compressor switch on.
[7] - Open the suction side valve (E) on the gauge set and the valve on the refrigerant supply
can (I).
[8] - Hold injector upright with valve at the bottom.
[9] - Open valve on injector for five seconds to force oil into the system.
[10] -
→NOTE:
Suction pressure will increase when oil enters the compressor, and
decrease after oil has passed through the compressor.
Open injector valve for five seconds to ensure all oil has been forced into the system.
[11] - Repeat Steps 2—10 if additional oil is required.
[12] - Close gauge set and refrigerant supply valves. Slowly loosen the hoses to relieve the
pressure.
[13] - Remove injector and cap both ends.

Remove and Install Compressor
LEGEND:
B Auxiliary Drive Shield
C Harness Connector
D Discharge Line Clamp
E Suction Line Clamp
[1] - Discharge system. (See Discharge Air Conditioning System in this group.)
[2] - Open hood and remove front left side panel.
[3] - Remove cap screws (A) and auxiliary drive shield (B).
[4] - Remove belt from compressor pulley.
[5] - Disconnect harness connector (C).
[6] -
IMPORTANT:
Cap all lines and fittings to prevent contamination.
Disconnect line clamps (D and E).

[7] - Remove cap screws (F) and remove compressor.

[8] - Check refrigerant oil charge. (See Determine Correct Refrigerant Oil Charge in this
group.)
[9] - Flush complete system if compressor failed internally due to damaged parts or seizure.
(See Flushing, Purging, and Evacuating Information in this group.)
[10] -
IMPORTANT:
Not flushing complete system if compressor failed will cause repeat failures
of air conditioning system.
Add required oil. (See Determine Correct Refrigerant Oil Charge in this group.)
[11] - Install compressor. Tighten to specification.
Compressor Mounting Cap Screws Torque 35 N·m
(26 lb.-ft.)
[12] - Connect lines and clamps. Tighten to specification.

Suction Line Clamp Torque 8 N·m
(71 lb.-in.)
Discharge Line Clamp Torque 8 N·m
(71 lb.-in.)
[13] - Install auxiliary drive shields.

[14] - Purge, evacuate, and charge system. (See Purge Air Conditioning System , Evacuate
Air Conditioning System , and Charge Air Conditioning System in this group.)
IMPORTANT:
If new compressor clutch was installed, turn compressor on and off (engine
running) in one second intervals for 5 seconds (cycle five times in 5
seconds). This will burnish clutch and hub drive surfaces.

Replace Receiver-Dryer
LEGEND:
A Outlet Line
B Inlet Line
C Clamp
→NOTE:
The receiver-dryer is not serviceable. Install new receiver-dryer if

malfunction is suspected.
Receiver-dryer should be replaced if system was contaminated, flushed,

open to atmosphere for more than 24 hours, or if older than two years and
system was discharged.
[1] - Discharge system. (See Discharge Air Conditioning System in this group.)
[2] - Open hood.

[3] -
IMPORTANT:
Cap lines to prevent contamination.
Disconnect outlet line (A) from left side of tractor.

[4] - Disconnect inlet line (B) from right side of tractor.
[5] - Remove clamp (C).
[6] - Remove receiver-dryer.
[7] - Add 7.5 mL (0.25 oz.) of R-134a refrigerant oil to system if new receiver-dryer is
installed and no major leaks exist. If leaks exist, follow procedure for checking and adding
refrigerant oil. (See Determine Correct Refrigerant Oil Charge in this group.)
[8] - Install receiver-dryer and tighten connections.
[9] - Purge, evacuate, and charge system. (See Purge Air Conditioning System , Evacuate Air
Conditioning System , and Charge Air Conditioning System in this group.)

Remove and Install Expansion Valve
LEGEND:
A Screws
B Cab Roof
C Antenna Cable
[1] - For all tractors: Drain cooling system.

[2] - Discharge air conditioning system. (See Discharge Air Conditioning System in this
group.)
[3] - Remove all screws (A) from top of cab roof (B).
[5] - Remove cab roof (B).
[6] -
LEGEND:
A Front Retainer Plate
B Socket-Head Screws 3 used
C Rear Retainer Plate
D Expansion Valve
Remove socket-head cap screw (B) and front retainer plate (A).

Section 90 - OPERATOR STATION Group 15: Air Suspension Seat
[7] - Remove two socket-head cap screws (B) that go through expansion valve (D) and
remove rear retainer plate (C).
[8] - Disconnect expansion valve (D) then cap lines to prevent contamination.

Remove air conditioning condenser. (See Remove and Install Air Conditioning Condenser in

Group 15 - Air Suspension Seat

List of References
Other Material
Specifications
Remove and Install Seat
Repair Seat Air System
Repair Seat Suspension
Repair Seat Back
Repair Seat Control Knobs
→NOTE:

JDG1424 Support Block
Other Material
Number Name Use
• PM37477 (PM37418
[ Smaller Size ]

Specifications
Air Spring Cap Screw Torque 4 N·m
(35 lb-in.)

LEGEND:
A JDG1424 Support Block
IMPORTANT:
Seat can remain in cab for all repairs.
→NOTE:
Plastic rivets from boot will be ruined if removed and should not be reused.
→NOTE:
Seat must be in the UP position to remove cap screws (B).
[1] - Cut or pull rivets from bottom of seat boot using side cutting pliers.
[2] - Install JDG1424 Support Block (A) into lower rail and tighten set screw.
[3] - Lift front of boot and remove cap screws (B).

[4] - Remove right hand armrest from seat. (See Remove and Install CommandARM™
Assembly in Section 40, Group 35).
[5] - Remove left hand armrest from seat. (See Remove and Install Left Hand Armrest in
Group 25.)
[6] - Remove cap screws (B) and disconnect operator presence switch connector from rear of
seat cushion.
[7] -
CAUTION:
Approximate weight of seat is 65 kg (140 lb.). An additional person is
required to remove seat from cab.
→NOTE:
It may be necessary to disconnect gas operated cylinder from door to allow
clearance for seat removal.
Remove seat through cab door.


Repair Seat Air System

[1] -
→NOTE:
LEGEND:
It is not necessary to remove seat from cab to service air system.
Access Air System:
Move seat to full UP position.

IMPORTANT: Plastic rivets from boot will be ruined if removed and
should not be reused.
Cut or pull rivets from top of seat boot using side cutting pliers.
CAUTION:
Do not attempt to bleed air system without JDG1424 Support Block in
place. It prevents injury from the sudden collapse of the scissors
suspension.
Pull down boot and install JDG1424 Support Block (A) into lower rail and tighten set
screw.
Relieve pressure from air spring using height adjustment switch.

[2] -
CAUTION:
LEGEND:
A Air Spring
B Air Lines
C Cap Screw
D Screw
E T-Fitting
suspension.
Remove and Install Air Spring:
Remove air lines (B) from air spring (A) to bleed.

Remove T-fitting (E).
Remove cap screw (C).
Remove screw (D) from bottom of air spring by removing seat.
Inspect and replace air lines as necessary.
Install in reverse order using the following special instructions:
Clean and apply PM37477 Thread Lock and Sealer (Medium Strength) to threads of
screw (D) and tighten cap screw (C) to specification.
Number Name Use
⚬ PM37477 (PM37418
[ Smaller Size ]
⚬ PM38621 (canadian) (Medium Strength) and seal surfaces.
⚬ 242 LOCTITE ™
(loctite)
(35 lb.-in.)

Tighten screw (D) carefully, but do NOT overtighten.
[3] -
CAUTION:
LEGEND:
A Air Line
B Harness Connector
C Tie Bands
D Screws (2 used)
suspension.
Remove and Install Compressor:
Remove air line (A) from compressor valve.

Cut tie bands (C) and disconnect compressor harness connector (B) from seat harness.
Remove screws (D) and remove compressor.
Slide compressor up against cross-member before tightening screws.

Repair Seat Suspension
LEGEND:
→NOTE:
The following instructions are for repair of suspension assembly in order of

removal. Do ONLY the procedures that pertain to the seat failure. Complete
seat removal is not required or recommended.
[1] - Access Suspension Components:

IMPORTANT: Plastic rivets from boot will be ruined when removed and
screw.

[2] -
IMPORTANT:
LEGEND:
A Cable Nut
B Cable End
C Shock Absorber Clamp
D E-Clips
E Washer and Bushing (Top)
F Bushing (Bottom)
G Pin
Clamp (C) is set at factory and moving will cause shock absorber to be out
of adjustment.
Replace Ride Stabilizer Shock Absorber:
Pull down boot and install JDG1424 Support Block into lower rail and tighten set screw.
Loosen lower cable nut (A). Remove snap ring (B). Remove cable nut (A) and pull cable
from bracket.
Remove E-clips (D).
Note location of plastic washer and bushing (E); then remove top pin (G).
Note location of bushing (F). Remove shock absorber from scissor suspension.

[3] -
LEGEND:
Remove and Install Seat Top:
Remove right hand armrest assembly. (See Remove and Install CommandARM™
Assembly in Section 40, Group 35.)
Remove left hand armrest assembly. (See Remove and Install Left Hand Armrest in
Group 25.)
IMPORTANT: Note and mark where slide rails are positioned, mounting
will affect seat movement.
Remove Cap screws (A). Cap screws can be accessed by sliding seat fore and aft.

[4] -
LEGEND:
A Pins (2 used)
B E-Clips (2 used)
Replace Lateral Shock Absorber:
Remove seat top. (See Step 3.)

Remove E-clips (B) and pins (A).
[5] -
LEGEND:
A Lateral Shock
B Ride Stabilizer Cable
C Lateral Springs
D Fore-and-Aft Lockout Arm
E Roller Pins (2 used)
Remove and Install Lateral Frame:

Remove lateral shock absorber. (See Step 4.)
Disconnect ride stabilizer cable (B) from shock absorber.

Slide lateral frame from side-to-side to release and remove lateral springs (C).
Remove fore and aft lockout arm (D).
IMPORTANT: Use of heat is permissible to loosen retaining compound.
Use only a butane torch. DO NOT exceed 93 °C (200 °F). DO NOT use a
cutting torch.
Remove roller pins (E) from front of housing. Roller pins are installed using retaining
compound. Use heat to aid removal if necessary.
Slide housing sideways to align rear rollers with notches in frame. Pull up on front of
frame and push back to remove.
Clean all retaining compound from roller pins and threaded holes and apply new
PM37477 Thread Lock and Sealer (Medium Strength). Install roller pins (E) through
frame and into rollers. Ensure that rollers are properly aligned with roller pins.
Number Name Use
▪ PM37477
(PM37418
[ Smaller Size ]
▪ PM38621 (Medium Strength) and seal surfaces.
(canadian)
▪ 242 LOCTITE ™
(loctite)
Install tie band (F) to prevent ride stabilizer cable damage when seat is moved.
Tighten roller pins until resistance can be felt when sliding frame. Back off roller
pins just until frame moves easily.

[6] -
CAUTION:
LEGEND:
A Nut
B Shaft
C Plastic Bushing, Spring, Washer, Rubber Isolator
D Fore-and-Aft Lock Arm
E E-Clip
E-clip (A) and washer are under spring tension and can fly off causing
injury.
Replace Fore-and-Aft Shock Absorber:
Remove nut (A) from fore and aft shock absorber.

Using locking pliers, unscrew shaft (B) from shock.
Remove plastic bushing, spring, washer, and rubber isolator (C).
Remove fore and aft lockout arm (D) from seat frame.
Pull up on front of shock absorber while pushing back on frame to release support from
frame arm. Remove E-clip (E) from frame pin; then remove shock absorber.
Inspect all parts and replace as necessary.

[7] -
LEGEND:
A Fore-and-Aft Shock Absorber
B Fore-and-Aft Frame
C Scissors Suspension
Remove and Install Fore-and-Aft Frame:
Remove fore and aft shock absorber (A). (See Step 6.)
Push frame (B) to the rear; then lift to clear rear rollers of scissors suspension (C). Tip
frame up and pull forward to clear front rollers.

[8] -
LEGEND:
A Ride Stabilizer Shock Absorber
B Compressor
C Air Spring
D Bumper
E Lock Nut
F Shaft
Remove and Install Scissors Suspension:
Remove ride stabilizer shock absorber. (See Step 2.)

Remove compressor. (See Step 3 in Repair Seat Air System in this group.)
Remove air spring. (See Step 2 in Repair Seat Air System in this group.)
Remove four cap screws (E) and suspension frame from tractor. Remove lock nut (F)
and pull shaft (G) from seat frame.
Remove and install bumpers (D) as necessary. Apply PM37477 Thread Lock and Sealer
(Medium Strength) to threads of bumper before installing nuts.
Number Name Use
⚬ PM37477 (PM37418
[ Smaller Size ]
⚬ PM38621 (canadian) (Medium Strength) and seal surfaces.
⚬ 242 LOCTITE ™
(loctite)
[9] -

LEGEND:
B Bearing Retainer
C Ball Bearings (24 used)
D Seat Base Plate
E Screws (4 used)
F Screws (2 used)
Remove and Install Seat Swivel:
Remove right hand armrest assembly. (See Remove and Install CommandARM™

Remove left hand armrest assembly. (See Remove and Install Left Hand Armrest in
Group 25.)
Remove seat cushion by removing screws (F).
→NOTE: Top seat assembly rotates on bearings, care to remove top
seat assembly so bearings are not displaced
Remove cap screws (A) to remove top seat assembly. Center plate and washer for
swivel seat assembly on underside of seat top may drop out when cap screws are
removed.
Remove bearing retainer (B) and ball bearings (C).

→NOTE: Note mounting holes used, mounting will affect seat
movement.
Remove screws (E) and seat base plate (D).
Replace parts as necessary.


Repair Seat Back

[1] -
LEGEND:
A Seat Back
B Screws (4 used)
C Screws (2 used)
D Bracket Lock Nuts (2 used)
E Pivot Lock Nuts (2 used)
F Spring
G Cable
H Pin
I Lumbar Support
Remove and Install Seat Back:
Remove screws (B) from seat back (A).

If equipped with a heated seat, disconnect wire harness.
Remove seat back cushion.
Remove screws (C).
Disconnect cable (G) from lumbar support (I) to remove lumbar adjusting knob.

Remove pin (H) and remove lumbar support.

Remove bracket lock nuts (D).
Remove pivot lock nuts (E) and spring (F) to remove seat back.
CAUTION:
Carefully move seat back all the way forward to release tension on
spring before removing.

[2] -
LEGEND:
A Latch Assembly
B Lock Nut (2 used)
C Pivot Lock Nut
D Spring
E Knob
Repair Seat Back Adjuster:
Remove lock nut (B), pivot lock nut (C) and latch assembly (A).
Replace spring (D) and knob (E) as necessary.

Repair Seat Control Knobs

Upper Control Knobs:
[1] -
LEGEND:
A Nuts (2 used)

B Spring
C Slotted Hole
D Cap Screw
E Latch Arm
F E-Clip
G Pin
H Lever
I Detent Balls (2 used)
J Springs (2 used)
Loosen nuts (A) and disconnect spring (B).
[2] - Remove cable from slotted hole (C).
[3] - Remove cap screw (D) and latch arm (E).
[4] -
CAUTION:
Use caution removing E-clip (A). Spring force can cause clip and washer to
fly off causing injury.
Remove E-clip (F) and pin (G).

[5] -
CAUTION:
Use caution when removing lever. Force springs (H) can cause detent balls
(G) to fly out causing injury.
Remove lever (H), detent balls (I) and springs (J).

[7] - Apply grease to detent balls:
Number Name Use
• TY6341 (us) Multi-Purpose SD Polyurea Used to lubricate detent balls.
[9] - Adjust cable end by moving nuts until seat latch arm operates properly when lever is
functioned.
Lower Control Knobs:

[1] -
LEGEND:
A Plastic Rivets
B Rubber Seat Boot
C Screw
D Cover Plate
Remove plastic rivets (A) and push rubber seat boot down (B).
[2] - Remove screws (C) and cover plate (D).

[3] -
LEGEND:
A Retaining Clip
B Retaining Rod
Remove retaining ring (A) from knob retaining rod (B).
[4] -

Section 90 - OPERATOR STATION Group 16: ComfortCommand™ Seat
LEGEND:
A Damper Knob
B Lateral Isolator Knob
C Fore and Aft Isolator Knob
D Knob Retaining Rod
E Ball Bearing
F Compression Spring
G Retaining Ring
[5] - Apply grease to ball bearing (E):
Number Name Use
• TY6341 (us) Multi-Purpose SD Polyurea Used to lubricate ball bearing.

Group 16 - ComfortCommand™ Seat

List of References
Specifications
Remove and Install Seat Top
Repair Seat Back
Repair and Install Seat Control Knobs
Specifications
Backrest Cap Screws Torque 25 N·m
(18 lb.-ft.)

LEGEND:
A Cap Screw
B Nut
[1] - Install fully threaded cap screw (A) with nut (B) into lower rail at rear of suspension.
[2] - Disconnect seat harness.
[3] - Remove right hand armrest from seat. (See Remove and Install CommandARM™
Assembly in Section 40, Group 35).
[4] - Remove left hand armrest from seat. by removing armrest adjust handle.
[5] - Remove mounting cap screws (C).

[6] -
CAUTION:
→NOTE:
It may be necessary to disconnect gas operated cylinder from door to allow
clearance for seat removal.
Remove seat through entrance door.


Remove and Install Seat Top

[1] -
LEGEND:
A Screws (3 used)
B Seat Cushion
C Seat Switch Compensator
D Seat Cushion Angle Adjust Mount
E Seat Cushion Depth Adjust
F Seat Plate
G Guides (4 used)
Remove and Install Seat Top Assembly
Remove seat back from seat plate (F). (See Repair Seat Back in this group.)
Remove screws (A) and cushion (B).
Remove seat switch compensator (C).
Remove rivets from seat cushion angle adjust mount (D) and seat cushion depth adjust
(E).
Remove seat cushion depth adjust from guides (G).

[2] -
LEGEND:
A Nuts (4 used)
B Seat Plate
C Plate
E Side to Side Isolator
F Swivel
G Nuts (4 used)
Remove and Install Seat Assembly:
Remove nuts (A) and seat plate (B).

Remove plate (C) by removing cap screw (D) from side to side isolator (E).
Remove swivel (F) from side to side isolator by removing nuts (G)
[3] -

LEGEND:
A Swivel
C Right Hand Slide Rail
D Left Hand Slide Rail
F Seat Suspension
Remove and Install Seat Suspension Assembly:
Remove swivel (A) by removing cap screws (B) from right hand slide rail (C) and left
hand slide rail (D).
Remove cap screws (E) and right and left hand slide rails from seat suspension.

[4] -
LEGEND:
B Seat Belt Assembly
C Seat Plate
Remove and Install Seat Belt Assembly
Remove seat belt assembly (B) by removing cap screws (A) from seat plate (C).

Repair Seat Back

[1] -
LEGEND:
A Seat Back Cushion
B Screws (4 used)
C Armrest Adjust Handle
E Seat Back
F Spring
G Bushing
Remove and Install Seat Back:

Remove screws (B) and seat back cushion (A).

Remove bushing (G) and armrest adjust handle (C) from left hand armrest.
Remove bushing (G) and armrest adjust handle (C) from right hand armrest. If equipped
with CommandARM™ (See Remove and Install CommandARM™ Assembly in Section 40,
Group 35.)
CAUTION:
Carefully tilt seat back all the way forward to release tension from
spring before removing.Spring may jump when seat back tilt adjuster
is removed.
Remove cap screws (D), seat back (E), and spring (F).

Tighten cap screws (D) to specification:
Backrest Cap Screws Torque 25 N·m
(18 lb.-ft.)

[2] -
LEGEND:
A Backrest Extension
B Bushings (2 used)
C Seat Back
Remove and Install Backrest Extension
Extend backrest extension (A) out completely.

Remove bushings (B) from seat back (C).

Repair and Install Seat Control Knobs

[1] -
LEGEND:
A Rivet
B Spring
C Seat Back Tilt Adjuster
Repair Seat Back Tilt Adjuster
→NOTE:
Seat back tilt adjuster is located on the left rear of the operators seat.
Tilt seat back completely forward.
CAUTION:
Spring may jump when seat back tilt adjuster is removed.
Remove rivet (A) from seat back tilt adjuster (C).
Remove seat back adjuster and spring (B).


[2] -
LEGEND:
A Screw
B Adjuster Knob
C Carrier
D Rod
E Lumbar Bracket
Repair Lumbar Adjuster:
Remove screw (A) from adjuster knob (B).

Remove rivets that attach carrier (C) to seat back.
Disconnect rod (D) from carrier (C) and lumbar bracket (E).

Section 90 - OPERATOR STATION Group 20: ActiveSeat™
[3] -
LEGEND:
A Rivets
B Lumbar Plates (2 used)
C Foam Block
D Linkage
E Lumbar Bracket
Repair Lumbar Adjuster:
Remove rivets (A) from backrest.

Remove linkage (D), lumbar plates (B), lumbar bracket (E) and foam block (C).

Group 20 - ActiveSeat™
List of References
Other Material
Specifications
Purging Air from ActiveSeat™ System
Remove and Install ActiveSeat™
Remove and Install ActiveSeat™ Actuator
Remove and Install ActiveSeat™ Actuator Hoses
Remove and Install ActiveSeat™ Control Valve Assembly
ActiveSeat™ Hydraulic Control Valve Block
Remove and Install ActiveSeat™ Accumulator
Checking and Charging Replacement Accumulators—ActiveSeat™
Repair ActiveSeat™ Air System
Repair ActiveSeat™ Suspension
Repair ActiveSeat™ Back
Repair ActiveSeat™ Control Knobs
→NOTE:

DFRW148—ActiveSeat™ Control Valve Holding Tool

Other Material
Number Name Use
• PM37477 (us)

Specifications
Rod Cap Screw Torque 61 N·m
(45 lb.-ft.)
Mounting Cap Screws Torque 55 N·m
(40 lb.-ft.)
Screws to Valve Block Torque 5.6 N·m
(50 lb.-in.)
Filter Torque 24 N·m
(212 lb.-in.)
Check Valve Torque 24 N·m
(212 lb.-in.)
Proportional Pressure Reducing Valve Torque 24 N·m
(212 lb.-in.)
Accumulator Torque 13 N·m
(115 lb.-in.)
Replacement Accumulator 160 mL (10 cu. in.) Charge Pressure 1400—1600 kPa at 20 °C
(14—16 bar at 20 °C)
(203—232 psi at 68 °F)
Accumulator Socket Head Screw Torque 20—25 N·m
(177—221 lb.-in.)
Accumulator Socket Head Cap Screw Torque 20—25 N·m
(177—221 lb.-in.)
(35 lb.-in.)

Purging Air from ActiveSeat™ System
IMPORTANT:
Air must be purged from ActiveSeat™ hydraulics any time system is opened
for service.
→NOTE:
The tractor must be running, stationary, and seat firmness switch in

CENTER position.
[1] -
Left-Hand Armrest
LEGEND:
A ActiveSeat™ Firmness Control Switch
B ActiveSeat™ Height Control Switch
Position firmness switch (A) inCENTER position.
→NOTE:
Switch must be in CENTER position to start test or test deactivates.
[2] - Lower seat to lowest position using height control switch (B).
[3] - Access ASU address 071.
[4] - Cycle warning light switchonce .
→NOTE:
Test must be started within 1 minute after cycling warning light switch or
test deactivates.

[5] - Raise seat by putting seat firmness switch in (+) position. When seat reaches upper
stop you will hear a ”squeal”. Leave in (+) for 2 minutes to purge air.
→NOTE:
If seat firmness switch is left in (+) or (-) position for 4 minutes, test
deactivates.
[6] - Lower seat by putting seat firmness switch in (-) position. When seat reaches lower stop
you will hear a ”squeal”. Leave in (-) for 2 minutes to purge air.
→NOTE:
If seat firmness switch is left in (+) or (-) position for 4 minutes, test
deactivates.
[7] - Cycle warning light switchonce to end the test mode.

[8] - Test cycle can be repeated several times to purge air from system.

Remove and Install ActiveSeat™

LEGEND:
A Rivets
C JDG1424 Seat Support Block
D Rod End Hose
E Cap End Hose
F CommandARM™
G Harness Connector
→NOTE:
Plastic rivets from boot are ruined when removed and should not be
reused.
Seat must be in the UP position to remove cap screws (B).
[1] - Move seat to full UP position.

[2] - Remove rivets from top of seat boot using a pair of side cutters to cut or pull out rivets
(A).
[3] - Pull down boot and install JDG1424 Support Block (C) in track of seat and tighten
setscrew.
[4] - Remove cap screws (B) from inside of seat frame.
[5] - Disconnect hydraulic hoses (D and E) from actuator. Cap and plug to prevent
contamination.
[6] - Remove right-hand armrest assembly. (See Remove and Install CommandARM™
[7] - Disconnect harness connector (G).
[8] - Remove rear cap screws (H).
[9] -
CAUTION:
→NOTE:
Remove entrance door gas cylinder and hold door open as far as possible to
allow clearance for seat removal.
Remove seat through entrance door.


[11] -
IMPORTANT:
Air must be purged from ActiveSeat™ hydraulics any time system is opened
for service.
Purge air from system. (See Purging Air from ActiveSeat™ System in this group.)

Remove and Install ActiveSeat™ Actuator
Actuator
Mounting Screws
LEGEND:
B Hoses
C E-Clip
D Actuator
E Rod Cap Screw
IMPORTANT:
Seat can remain in cab for all repairs.

[1] - Move seat to full UP position.

[2] -
→NOTE:
reused.
Remove rivets from top of seat boot using a pair of side cutters to cut or pull out rivets.
[3] - Pull down boot and install JDG1424 Support Block (A) into either lower rail and tighten
setscrew.
[4] - Disconnect and cap actuator hoses (B) to prevent contamination.
[5] - Remove rod cap screw (E) at rod end of actuator.
CAUTION:
Use caution removing E-clip (C). Spring force can cause clip and washer to
[6] - Remove E-clip (C) and remove actuator (D).

[8] -
→NOTE:
Hoses (B) must be connected and positioned on actuator as shown.
Tighten rod cap screw (E) at rod end of actuator.

Rod Cap Screw Torque 61 N·m
(45 lb.-ft.)
[9] -
IMPORTANT:
Move seat through its full range of motion to make sure that there is no
interference between hoses and suspension components.

Hose Clearance
LEGEND:
A Hoses
B Compressor Mounting Screws
C Seat Base
Observe that hoses (A) do not interfere with compressor mounting screws (B) or seat base
(C), when seat is moved through its full range of motion.
[10] -
→NOTE:
Purging Air from ActiveSeat™ system must be performed if system has
been opened.

Remove and Install ActiveSeat™ Actuator Hoses

[1] -
→NOTE:
reused.
Cut or pull rivets from bottom of seat boot using side cutting pliers.
[2] -

LEGEND:
A Rod End Hose
B Cap End Hose
D Valve Access Plate
F Valve Mounting Plate
G Grommets (3 used)
I DFRW148 Tool
Remove cap screws (C) and remove valve access plate (D).
[3] - Remove cap screws (E) from valve mounting plate (F).
[4] - Remove cap screws (H) and install DFRW148—ActiveSeat™ Control Valve Holding Tool
(I) through valve mounting plate (F) into control valve.
[5] - Inspect grommets (G) and replace as necessary.
[6] - Disconnect hydraulic hoses (A) and (B) from control valve.
[7] - Disconnect hydraulic hoses (A) and (B) from actuator. Plug and cap hose ends and valve
openings to prevent system contamination.
→NOTE:
Hoses (A) and (B) must be connected and positioned on actuator and valve
as shown.

[10] - Install DFRW148—ActiveSeat™ Control Valve Holding Tool (I) through valve mounting
plate (F) and valve.
[11] - Lift tool, align two mounting screws (H), and tighten.
[12] - Remove tool (I) and install remaining cap screw (H).
[13] - Align valve mounting plate (F) and install screws (E).
[14] - Install valve access plate (D) and screws (C).
[15] - Install hose grommet under seat.
[16] -
IMPORTANT:
Move seat through its full range of motion to make sure that there is no
interference between hoses and suspension components.
Hose Clearance
LEGEND:
A Hoses
B Compressor Mounting Screws
C Seat Base
Lower seat and observe that hoses (A) do not interfere with compressor mounting screws (B)
or seat base (C), when the seat is moved through its full range of motion.
[17] -
→NOTE:
Air must be purged from ActiveSeat ™ hydraulic system any time it is
opened.

Remove and Install ActiveSeat™ Control Valve

Assembly
Hoses and Harness
LEGEND:
A Hydraulic Hose (2 used)
B Harness Connectors
IMPORTANT:
If control valve components have been repaired or replaced, calibration of

seat is necessary
[1] - Remove control valve mounting plate (See Remove and Install ActiveSeat™ Actuator
Hoses in this group.)
[2] - Disconnect harness connectors (B) from valve.
[3] - Disconnect hoses (A) from valve. Plug and cap hose ends and valve openings to prevent
system contamination.
[5] - Replace grommets if damaged.

[6] -
Floor Plate Opening on Larger Production Tractors

LEGEND:
A DFRW148 Tool
B Plate
C Valve
D Cap Screw (3 used)
E Cap Screw (9 used)
Install DFRW148—ActiveSeat™ Control Valve Holding Tool (A) through mounting plate (B) and
valve (C).
[7] - Lift tool, align two mounting screws (D) and tighten.
[8] - Remove tool (A); then install and tighten remaining cap screw to specification.
Mounting Cap Screws Torque 55 N·m
(40 lb.-ft.)
[9] - Align floor plate and install screws (E).

[10] - Install hose grommet.
[11] -
IMPORTANT:
Air must be purged from ActiveSeat™ hydraulic system any time it is
opened.

[12] - Calibrate seat. (See Operation and Test Manual for Calibration Procedure.)

ActiveSeat™ Hydraulic Control Valve Block
LEGEND:
A Accumulator
B Adapter Fitting
C Block
D Check Valve
E Filter
F Fitting, Actuator Rod End
G Fitting, Actuator Cap End
H Test Port
I Inlet Fitting
J Outlet Fitting
K Proportional Pressure Reducing Valve
L Solenoid Coil
M Washer
N Nut
O Control Valve
P Screws (4 used)

[1] -
Control Valve
LEGEND:
A Control Valve
B O-rings (4 used)
C Spring Pin
Control valve (A) is not serviceable.
[2] - Remove and replace O-rings (B).
[3] - Use spring pin (C) to align valve.
[4] - Tighten screws to valve block.
Screws to Valve Block Torque 5.6 N·m
(50 lb.-in.)

[5] -
Filter
Check Valve
LEGEND:
A O-rings
B Backup Rings
C O-rings
Remove backup rings (B), O-rings (A), and replace as necessary.
[6] - Remove and replace O-rings (C) as necessary.
[7] - Install valve and filter and tighten.
Filter Torque 24 N·m
(212 lb.-in.)
Check Valve Torque 24 N·m
(212 lb.-in.)

[8] -
LEGEND:
A O-ring
B O-ring
C O-ring
Proportional Pressure Reducing Valve: Remove and replace O-rings (A—C) as necessary.
[9] - Install valve and tighten.
Proportional Pressure Reducing Valve Torque 24 N·m
(212 lb.-in.)

Remove and Install ActiveSeat™ Accumulator
Cover Plate
LEGEND:
A Accumulator
B O-rings
C Screws (4 used)
D Cover
→NOTE:
Accumulator can be removed without removing control valve.

[1] - Remove screws (C) and remove cover (D).

[2] - Unscrew accumulator (A) from control valve.
[3] - Remove and replace O-rings (B) as necessary.
[4] - Install accumulator (A) and fitting and tighten.
Accumulator Torque 13 N·m
(115 lb.-in.)

Checking and Charging Replacement

Accumulators—ActiveSeat™
LEGEND:
A Dust Cap

IMPORTANT:
Accumulators from factory are not chargeable; they can only be replaced.
→NOTE:
Replacement accumulator is shipped with oil in gas side of accumulator; do

not drain oil from accumulator. Replacement accumulators can be charged.
[1] - Remove accumulator from control valve. (See Remove and Install ActiveSeat™
Accumulator in this group.)
[2] -
IMPORTANT:
Relieve initial breaking torque on socket head cap screw (B), without
loosening.
Remove accumulator dust cap (A). Relieve initial breaking torque on socket head cap screw
(B) using a 6 mm hex key wrench.
[3] -
→NOTE:
JT03515-2 is part of JT03515 Accumulator Charging Set
LEGEND:
A O-ring
B Adapter
C Hex Stem
Remove O-ring (A) from JT03515-2 Accumulator Adapter
[ For European Tractors, use FKM10474 ]
(B), coat with grease, and install. Push hex stem (C) into adapter.

[4] -
LEGEND:
A Adapter
B Hex Stem
C Bleed-Off Screw
Assemble adapter (A) onto accumulator and hand tighten. Push hex stem (B) into adapter
and socket head cap screw while rotating the stem slightly so the stem fits into the screw.
[5] -
→NOTE:
Make sure bleed-off screw (C) is tight and is not leaking.
JT03515-1 and JT03515-2 are part of JT03515 Accumulator Charging Set
Close bleed-off screw (C) and tighten adapter (A) to accumulator enough to prevent gas
leakage.

[6] -
→NOTE:
LEGEND:
D Bleed-Off Screw
Valve stem depressor (A) must be completely backed out. Minimum
pressure range of gauge should be approximately twice the accumulator
pressure specification.
Back out (counterclockwise) valve stem depressor (A) and install JT03515-1 Accumulator
Pressure Checking and Charging Adapter (B) to valve stem of accumulator adapter (C).
Install 7000 kPa (70 bar) (1000 psi) gauge to check accumulator.
[8] - Turn in (clockwise) valve stem depressor (A).

[9] -
LEGEND:
A Hex Stem
B Bleed Screw
Determine outer temperature of accumulator.
[10] -
→NOTE:
Loosen the hex stem only enough to get a pressure reading on the gauge.
Replacement Accumulator 160 mL (10 cu. in.) Charge Pressure 1400—1600 kPa at 20 °C
(14—16 bar at 20 °C)
(203—232 psi at 68 °F)
Pressure OK: Go to Step 14

Pressure High: Open bleed off screw (B) to obtain correct pressure. Go to step 14.
Pressure Low: Go to Step 11

[11] -
CAUTION:
LEGEND:
A Accumulator Adapter
B Pressure Adapter
Never charge an accumulator with OXYGEN. An explosion could result if oil
and oxygen mix under pressure. Use only NITROGEN.
→NOTE:
Purge hose before attaching. The charging hose can be attached directly to
the accumulator adapter (A) if a pressure checker adapter (B) is not
available. Use a nitrogen tank regulator gauge with 200 kPa (2 bar) (25 psi)
or less increments and a maximum range of 20 000 kPa (200 bar) (3000
psi).
Charging Hose . Purge hose and attach to pressure checker adapter (B).

[12] -
LEGEND:
A Regulator Screw
B Shut-Off Valve
Adjust nitrogen tank regulator screw (A) to obtain gauge reading of zero pressure. Open tank
shutoff valve (B) one turn. Turn in (clockwise) valve stem depressor on nitrogen charging
hose.
screw (A) to obtain pressure specification found in Step 10.
Wait 5 minutes for gas pressure to stabilize.

[14] -
IMPORTANT:
LEGEND:
B Adapter Valve Stem Depressor
C Hex Stem
accumulator socket head cap screw to the specified torque.
Tighten accumulator adapter hex stem (C).

[15] - Back out (counterclockwise) charging hose valve stem depressor (A) and pressure
checker adapter valve stem depressor (B).

[16] -
LEGEND:
B Shut-Off Valve
Loosen nitrogen tank regulator screw (A) until screw turns freely. Close tank shutoff valve (B).
[17] -
LEGEND:
A Accumulator Adapter Bleed-off Screw
B Pressure Checker Adapter Bleed-off Screw
Open pressure checker adapter bleed-off screw (B) and accumulator adapter bleed-off screw
(A) to relieve pressure from adapters.
[18] - Close bleed-off screws (A) and (B).

[19] -
LEGEND:
B Pressure Checker Adapter
C Accumulator Adapter
Remove charging hose (A) from pressure checker adapter.
[20] - Remove pressure checker adapter (B) from accumulator adapter (C).

[21] -
→NOTE:
LEGEND:
A Accumulator Adapter Bleed-Off Screw
B Hex Stem
There should not be any leakage of gas from accumulator after pressure
was relieved from adapter at Step 17.
Loosen accumulator adapter bleed-off screw (A) and listen for sound of gas leakage.
Remove accumulator adapter (C).
[22] -
LEGEND:
A Socket Head Screw
B O-ring Washer
Tighten socket head screw (A) to specification.
Accumulator Socket Head Screw Torque 20—25 N·m
(177—221 lb.-in.)

Apply soap suds around socket head screw (A) and look for bubbles from around (B).
No Leakage: Go to Step 26
Leakage: Do following steps:
[23] -
LEGEND:
B Hex Stem
Install accumulator adapter (C).
Loosen hex stem (B) and open bleed-off screw (A) to discharge accumulator.
Remove accumulator adapter (C).

[24] -
LEGEND:
B O-ring Washer
Remove and inspect O-ring washer (B).
Replace parts as required.
Repeat accumulator charging procedure, Steps 3—22.
[25] -
LEGEND:
A Hex Stem
B Accumulator Adapter
Hold hex stem (A) in the tightened position and remove accumulator adapter (B) from
accumulator.

[26] -
LEGEND:
B O-ring Washer
C Dust Cap
Tighten socket head cap screw (A).
Accumulator Socket Head Cap Screw Torque 20—25 N·m
(177—221 lb.-in.)
Replace dust cap O-ring washer (B) as necessary and install dust cap (C).
Install accumulator to control valve. (See Remove and Install ActiveSeat™ Accumulator in
this group.)

Repair ActiveSeat™ Air System
→NOTE:
LEGEND:
It is not necessary to remove seat from cab to service air system.
[1] - Access Air System:

IMPORTANT: Plastic rivets from boot are ruined when removed and
CAUTION:
suspension.
screw.
Relieve pressure from air spring using height adjustment switch.

[2] -
CAUTION:
LEGEND:
A Air Spring
B Air Lines
C Cap Screw
D Screw
E T-Fitting
suspension.
Remove and Install Air Spring:
Remove air lines (B) from air spring (A) to bleed.

Remove T-fitting (E).
Remove cap screw (C).
Remove screw (D) from bottom of air spring by removing seat from mounting plate.
Inspect and replace air lines as necessary.
Tighten cap screw (C) to specification.
(35 lb.-in.)
Clean and apply PM37477 Thread Lock and Sealer (Medium Strength) to threads
of screw(D). Carefully tighten screw , but do NOT overtighten.
Number Name Use
▪ PM37477 (us)
▪ PM38621
(canadian)
▪ 242 Loctite™ (us)
▪ (loctite)

[3] -
CAUTION:
LEGEND:
A Air Line
B Harness Connector
C Tie Bands
D Screws (2 used)
suspension.
Remove and Install Compressor:
Remove air line (A) from compressor valve.

Cut tie bands (C) and disconnect compressor harness connector (B) from seat harness.
Remove screws (D) and remove compressor.
Slide compressor up against cross-member before tightening screws.

[4] -
LEGEND:
A Fitting
B Clamps (2 used)
C Air Reservoir
Remove and Install Air Reservoir:
Bleed air from seat suspension. (See step 2.)

Disconnect air fitting (A) from air reservoir.
Remove clamps (B).
Pull up on air reservoir (C) to remove from suspension.

Repair ActiveSeat™ Suspension
LEGEND:
→NOTE:
The following instructions are for repair of suspension assembly in order of

removal. Do ONLY the procedures that pertain to the seat failure. Complete
seat removal is not required or recommended.
[1] - Access Suspension Components:

IMPORTANT: Plastic rivets from boot are ruined when removed and
screw.

[2] -
LEGEND:
Remove and Install Seat Top:
Remove right-hand armrest assembly. (See Remove and Install CommandARM™

Remove left-hand armrest assembly. (See Remove and Install Left Hand Armrest in
Group 25.)
IMPORTANT: Note and mark where slide rails are positioned, mounting
affects seat movement.
Remove cap screws (A). Cap screws are accessed by sliding seat fore and aft.

[3] -
LEGEND:
A Pins (2 used)
B E-Clips (2 used)
Replace Lateral Shock:

Remove E-clips (B) and pins (A).
[4] -
LEGEND:
A Lateral Shock
B Accelerometer Connector
C Lateral Springs
D Fore-and-Aft Lockout Arm
E Roller Pins (2 used)
F Tie Band
Remove and Install Lateral Frame:


Remove lateral shock absorber. (See Step 3.)
Disconnect accelerometer connector (B).
IMPORTANT: Tie bands holding harnesses must be replaced and
positioned properly or damage to harness occurs.
Note location and remove tie band (F).
Slide lateral frame from side-to-side to release and remove springs (C).
Remove fore and aft lockout arm (D).
IMPORTANT: Use of heat is permissible to loosen retaining compound.
Use only a butane torch. DO NOT exceed 93 °C (200 °F). DO NOT use a
cutting torch.
Remove roller pins (E) from front of housing. Roller pins are installed using retaining
compound. Use heat to aid removal if necessary.
Slide housing sideways to align rear rollers with notches in frame. Pull up on front of
frame and push back to remove.
Assemble in reverse order using the following special instructions:
Clean all retaining compound from roller pins and threaded holes and apply new
PM37477 Thread Lock and Sealer (Medium Strength).
Number Name Use
▪ PM37477 (us)
▪ PM38621
(canadian)
▪ 242 Loctite™
(us)
Install roller pins through frame and into rollers. Ensure that rollers are properly
aligned with roller pins.
Install tie band to prevent harness damage when seat is moved.
Tighten roller pins until resistance can be felt when sliding frame. Loosen
approximately 1/4 of a turn or until rollers move freely.

[5] -
LEGEND:
A Nut
B Shaft
C Bushing, Spring, Washer, and Isolator
D Fore-and-Aft Lock Arm
E E-Clip
Replace Fore-and-Aft Shock Absorber:
Remove nut (A) from fore and aft shock absorber.

Using locking pliers, loosen and remove shaft (B).
Remove bushing, spring, washer, and isolator (C).
Remove fore and aft lockout arm (D) from seat frame.
Pull up on front of shock absorber while pushing back on frame to release support from
frame arm.
Remove E-clip (E) from frame pin and remove shock absorber.
Inspect parts and replace as necessary

[6] -
LEGEND:
A Fore-and-Aft Shock
B Fore-and-Aft Frame
C Scissors Suspension
D Connector
E Tie Band
Remove and Install Fore-and-Aft Frame:
Remove fore and aft shock absorber (A). (See Step 5.)
Note location and remove tie band (E).
Disconnect connector (D).

Push frame (B) to the rear and lift to clear rear rollers of scissors suspension (C). Tip
frame up and pull forward to clear front rollers.
Install tie band (E) to prevent harness damage when seat is moved.
[7] -

LEGEND:
A Actuator Cylinder
B Compressor
C Air Spring
D Bumpers (2 used)
F Lock Nut
G Shaft
H Tie Bands
I Seat Position Sensor
Remove and Install Scissors Suspension:
Remove actuator cylinder (A). (See Remove and Install ActiveSeat™ Actuator in this
group.)
Remove compressor (B). (See Repair ActiveSeat™ Air System , Step 3.)
Remove air spring (C). (See Repair ActiveSeat™ Air System , Step 2.)
IMPORTANT: Seat position sensor is damaged when moved past its
range of motion and must be removed before scissors suspension is
removed.
Remove seat position sensor (I).

Note location and remove tie bands (H).
Remove cap screws (E) and frame from tractor.

Remove lock nut (F) and pull shaft (G) from seat frame.
Remove bumpers (D) and remove scissor suspension.
Apply PM37477 Thread Lock and Sealer (Medium Strength) to threads of bumper
before installing nuts.
Number Name Use
▪ PM37477 (us)
▪ PM38621
(canadian) Thread Lock and Sealer Used to retain cap screws
▪ 242 Loctite™ (Medium Strength) and seal surfaces.
(us)
▪ (loctite)
Clean all retaining compound from seat position sensor cap screws and apply new
PM37477 Thread Lock and Sealer (Medium Strength).
Number Name Use
▪ PM37477 (us)
▪ PM38621
(canadian) Thread Lock and Sealer Used to retain cap screws
▪ 242 Loctite™ (Medium Strength) and seal surfaces.
(us)
▪ (loctite)
Install seat position sensor to scissors suspension.
Install all tie bands to prevent harness damage when seat is moved.
Calibrate seat position sensor. (See Operation and Test TM Section 245, Group
ASU.)
[8] -

LEGEND:
B Bearing Retainer
C Ball Bearings (24 used)
D Seat Base Plate
E Screws (4 used)
F Screws (2 used)
Remove and Install Seat Swivel:
Remove right-hand armrest assembly. (See Remove and Install CommandARM™

Assembly Section 40, Group 35.)
Remove left-hand armrest assembly. (See Remove and Install Left Hand Armrest in
Group 25.)
Remove seat cushion by removing screws (F).
→NOTE: Top seat assembly rotates on bearings, care to remove top
seat assembly so bearings are not displaced
Remove cap screws (A) to remove top seat assembly. Center plate and washer for
swivel seat assembly on underside of seat top may drop out when cap screws are
removed.
Remove bearing retainer (B) and ball bearings (C).

→NOTE: Note mounting holes used, mounting affects seat movement.
Remove screws (E) and seat base plate (D).


Repair ActiveSeat™ Back
LEGEND:
A Seat Back
B Screws (4 used)
C Screws (2 used)
D Lock Nuts (2 used)
E Pivot Lock Nuts (2 used)
F Spring
G Cable
H Pin
I Lumbar Support

[1] - Remove and Install Seat Back:
Remove screws (B) from seat back (A).

If equipped with a heated seat, disconnect wire harness.
Remove seat back cushion.
Remove screws (C).
Disconnect cable (G) from lumbar support (I) to remove lumbar adjusting knob.
Remove pin (H) and lumbar support.
Remove lock nuts (D).
CAUTION:
Carefully move seat back all the way forward to release tension on
spring before removing.
Remove pivot lock nuts (E) and spring (F) to remove seat back.
[2] -
LEGEND:
A Latch Assembly
B Lock Nut (2 used)
C Pivot Lock Nut
D Spring
E Knob
Remove and Install Back Seat Adjust:
Remove lock nut (B), pivot lock nut (C), and latch assembly (A).
Remove spring (D) and knob (E).

Repair ActiveSeat™ Control Knobs

Upper Control Knobs:
[1] -
LEGEND:
A Nuts (2 used)

B Spring
C Slotted Hole
D Cap Screw
E Latch Arm
F E-Clip
G Pin
H Lever
I Detent Balls (2 used)
J Springs (2 used)
Loosen nuts (A) and disconnect spring (B).
[2] - Remove cable from slotted hole (C).
[3] - Remove cap screw (D) and latch arm (E).
[4] -
CAUTION:
Use caution removing E-clip (A). Spring force can cause clip and washer to
Remove E-clip (F) and pin (G).

[5] -
CAUTION:
Use caution when removing lever. Force springs (H) can cause detent balls
(G) to fly out causing injury.
Remove lever (H), detent balls (I), and springs (J).

[7] - Apply grease to detent balls.
Number Name Use
• TY6341 (us) Multi-Purpose SD Polyurea Used to lubricate detent balls.
[9] - Adjust cable end by moving nuts until seat latch arm operates properly when lever is
functioned.
Lower Control Knobs:

IMPORTANT:
LEGEND:
A Rivets
B Rubber Seat Boot
C Screws (2 used)
D Cover Plate
reused.
[1] - Cut or pull rivets (A) from top of seat boot using side cutting pliers.
[2] - Push rubber seat boot (B) down.

[3] - Remove screws (C) and cover plate (D).
[4] -
LEGEND:
A Retaining Clip
B Retaining Rod
Remove retaining ring (A) from retaining rod (B).
[5] -

Section 90 - OPERATOR STATION Group 25: Armrest
ActiveSeat™
ActiveSeat™ Blank Knob

LEGEND:
A Blank Knob
B Lateral Isolator Knob
C Fore and Aft Isolator Knob
D Retaining Ring
E Knob Retaining Rod
F Ball Bearing
G Compression Spring
H Dowel Pin
[6] - Apply grease to ball bearing (E).
Number Name Use
• TY6341 (us) Multi-Purpose SD Polyurea Used to lubricate bearings and bushings.

Section 90 - OPERATOR STATION Group 25: Armrest
Group 25 - Armrest
List of References
Remove and Install Left Hand Armrest

Section 90 - OPERATOR STATION Group 30: Cab Door and Windshield
Remove and Install Left Hand Armrest
Left Hand Tip-Up Armrest (ActiveSeat™)
Left Hand Tip-Up Armrest (Non-ActiveSeat™)
LEGEND:
A Armrest
[1] - Identify, label, and disconnect wiring harness from armrest (A).
[2] - Remove cap screws (B) and remove armrest.
[3] - Recondition armrest, (See Replace Seat Raise/Lower Switch , Replace Seat Firmness
Switch—ActiveSeat™ , and Replace Heated Seat Switch in Section 40, Group 25.)

Group 30 - Cab Door and Windshield

List of References
Specifications
Repair Cab Door Latch
Cab Door Adjustment—Step 1
Preparing Windshield Glass or Side Window For Replacement
Specifications
Latch Retaining Cap Screw Torque 15 N·m
(132 lb-in.)
Outer Handle Nut Torque 35 N·m
(26 lb-ft)
Outer Handle Cap Screw Torque 10 N·m
(96 lb-in.)
Door Latch Striker Torque 50 N·m
(37 lb-ft)

Repair Cab Door Latch
Latch Cover
Cab Door Latch assembly
LEGEND:
A Screws (3 used)
B Nut
C Cap Screw

[1] - Remove and Install Outside Release Handle:
a. Remove screws (A) and latch cover.

b. Remove nut (B), cap screw (C), and outside handle.
c. Inspect parts and replace as necessary.
d. Install outside handle and tighten cap screw and nut to specification.
Outer Handle Nut Torque 35 N·m
(26 lb-ft)
Outer Handle Cap Screw Torque 10 N·m
(96 lb-in.)
e. Adjust cab door. (See Cab Door Adjustment in this group.)

[2] -
Inner Release Handle

LEGEND:
A Inner Release Handle
B Adjusting Rod
C Cap Screw and Nut
D Clip
Remove and Install Inner Release Handle:
a. Remove clip (D) and adjusting rod (B), being careful not to drop washer.
b. Remove cap screw and nut (C) and pull inner handle (A).
c. Install washer on to release adjusting rod and install cap screws with head as shown in
picture.
d. Install in reverse order, and tighten cap screw.
e. Adjust cab door. (See Cab Door Adjustment in this group.)
[3] -

Latch Assembly
LEGEND:
A Latch Arm
B Latch Assembly Retaining Cap Screws (2 used)
C Clip
D Adjustment Rod Nut and Washer
E Latch Assembly
Remove and Install Latch Assembly:
a. Remove clip (C) from latch arm (A) and remove adjustment rod nut and washer (D).
b. Remove cap screws and nuts (B) and remove latch assembly (E).
c. Slide latch release adjusting rod from inner release handle and remove latch assembly.
d. Install washer on release adjusting rod and install latch cap screws with head toward
rear of tractor.
e. Tighten to specification.
Latch Retaining Cap Screw Torque 15 N·m
(132 lb-in.)
f. Adjust cab door. (See Cab Door Adjustment in this group.)
[4] -

Door Latch Adjustment

LEGEND:
A Nut
B Button
C Latch Travel Dimension
Adjust Door Handle Button:
a. Close latch jaws to fully latched position.

b. Adjust nut (A) so button (B) travels 5—7 mm (0.196—0.275 in.) (C) to unlatch latch
jaws.

Adjust Cab Door Bottom Edge
LEGEND:
A Seal
B Lower Cab Frame
IMPORTANT:
Four-step door adjustment procedure MUST be followed in sequence.
→NOTE:
To adjust door make sure latch is not engaged.
[1] - Visually verify that door is not sagging and measure from bottom edge of door seal (A)
to top of lower cab frame (B). Distance must be within specification.
Door Seal-to-top of lower cab frame Distance 6—12 mm
(0.25—0.50 in.)
[2] - Measure door gap at lower corner farthest away from door hinges.
[3] - If measurement is incorrect or door is sagging, loosen door hinge cap screws.
[4] - Slide a large piece of cardboard between open door and opening of cab.
[5] - Slowly close door using cardboard as an assistant to obtain measurement specified in
Step 1.

[6] - Tighten cap screws to specification and recheck measurement.

Cab Door Hinge Cap Screws Torque 35 N·m
(26 lb-ft)
Adjust Cab Door Striker
LEGEND:
A Striker
B Washers
C Latch Jaws
[1] - Add or subtract washers (B) until striker (A) is centered in latch jaws (C).
[2] - Tighten striker to specification.
Door Latch Striker Torque 50 N·m
(37 lb-ft)

Door Striker
Latch Assembly

LEGEND:
B Latch Assembly
C Striker
D Striker Center Line
E Jaw Top Lobe
F Latch Jaw
G Striker Plate Cap Screws (2 used)
[1] - Loosen cap screws (G).

[2] - Center striker (C) with top lobe (E) of latch jaw (F).
[3] - With latch jaw in open position, carefully close door against striker.
[4] -
→NOTE:
The striker center line (D) is when the striker is aligned in the center of the
latch jaw.
If striker cannot be centered, loosen cap screws (A) and adjust latch assembly (B).

Measure distance
Top View
LEGEND:
A Latch Level
B Corner Post
C Door Glass
D Ruler
E Gap Measurement

[1] -
→NOTE:
Gap between glass and corner post will depend on door seal thickness.
Adjust striker to get minimum seal compression without leak or whistle.
Latch will become more difficult to open as seal compression increases.
Insert thin ruler (D) at latch level (A).

[2] - Measure gap (E) from contacting surface of cab corner post (B) to outside surface of
glass (C).
[3] - Compare gap measurement to specification.
Corner Post to Door Glass. Distance 23 — 27 mm (0.90 — 1.06 in.)
[4] - Move striker to adjust gap measurement, as necessary.

[5] -
→NOTE:
If gap measurement is excessive, a whistling sound may develop when
blower speed turned to HIGH.
Start engine and turn blower speed to HIGH.

[6] - Check for air leaks.
[7] - Readjust striker, as necessary.
[8] - Tighten striker to specification.
Striker Torque 50 N·m
(37 lb-ft)
[9] - Confirm striker is still centered in latch (See Cab Door Adjustment—Step 3 in this
group.)

Preparing Windshield Glass or Side Window For

Replacement
LEGEND:
A Heat Shield
C Cab Riser Panels

IMPORTANT:
Windshield Glass or Side Window need to be installed by Auto Glass

Specialist.
→NOTE:
The following steps are to provide clearance to installing windshield.
[1] - Position hood forward. (See Position Hood Forward in Section 80, Group 05.)
15.)
[3] - Remove exhaust system. (See Service Exhaust System in Section 30, Group 30.)
[4] - Remove cab riser panels (C) by removing cap screws (D) under floormat.
[5] - Remove heat shield cap screws (B) and remove heat shield (A).
[6] -
LEGEND:
E Lights
F Handrails
G Corner Post Covers
H Wiper Arm
Remove mirrors and beacon light bracket if equipped.
[7] - Remove front wiper arm (H).

[8] - Remove lights (E) and handrails (F).

[9] - Remove corner post covers (G).
[10] -
IMPORTANT:
Ensure that glue surface is clear of any left over glass pieces.
LEGEND:
A Adhesive Surface
Clean adhesive surface (A).
[11] -
→NOTE:
Three people are required to install front windshield.
Install new glass from left-hand side and keep glass below cab roof line.

Section 90 - OPERATOR STATION Group 35: Cab Suspension
[12] -
IMPORTANT:
LEGEND:
A Adhesive Surface
C Bracket
Ensure that glue surface is clear of any left over glass pieces and adhesive.
Take care not to remove paint from glue surface.
Remove tool box if equipped.

[13] - If equipped remove cap screws (B) and bracket (C).
[14] - Clean adhesive surface (A).
[15] -
→NOTE:
Two people required to install side window.
Install side window.


Group 35 - Cab Suspension

List of References
Specifications
Depressurize Cab Suspension System
Remove and Install Cab Leveling Control Valve
Repair Cab Leveling Valve
Remove and Install Sensor Ball Joint Rod
Adjust Sensor Rod
Remove and Install Position Sensor
Remove and Install Accumulator
Charging Accumulator
Remove and Install Hydraulic Cylinders
Remove and Install Panhard Rod
Bleeding Suspended Cab System
Specifications
Raise and Lower Valve Spools Torque 35 N·m
(310 lb.-in.)
Solenoid Nuts Torque 6 N·m
(53 lb.-in.)
Position Sensor Ball Joint Rod Adjusting dimension 74.5 mm
(2.93 in.)
Replacement Accumulator Charge Pressure 5000 +/- 200 kPa at 20 °C
(50 +/- 2 bar at 20 °C)
(725 +/- 29 psi at 68 °F)
Accumulator Socket Head Screw Torque 41 +/- 1N·m
(363 +/- 9 lb.-in.)

(2.93 in.)
Hydraulic Cylinder Bleed Screws Torque 8 +/- 1 N·m
(71 +/- 8 lb.-in.)

Depressurize Cab Suspension System
CAUTION:
Do not restart the engine until all service is completed. The suspension
system refills when the engine is restarted.
→NOTE:
This procedure relieves oil pressure within the system to allow disassembly
of components.
[1] - Heat the hydraulic oil if oil temperature is below 20 °C (68 °F).
[3] - Turn key switch to RUN position (engine OFF).
[4] - Access CSC Address 22 in technician mode (See Access Control Unit Addresses in
Operation and Test TM Section 245, Group 05.)
The display shows the cab position as a percentage of full stroke.

The valve remains open for an additional 180 seconds after reaching the end stop. This
period ensures that system has fully depressurized.
When time period has elapsed, END is displayed.
[5] - Once ENTER is pressed, the suspension valve opens and lowers the cab to the end stop.
If ERR is displayed, the service code follows, and then END. Perform diagnosis for the
service code before continuing.
[6] - Press ENTER again.

[7] - The display returns to CSC.
[8] - Press the BACK button to return to the diagnostic list.
[9] - Turn key switch OFF.

Remove and Install Cab Leveling Control Valve
LEGEND:
A Cab Leveling Control Valve
B Return to Sump Line
C Cylinder Extend Lines (2 used)
D Cylinder Retract Lines (2 used)
E Supply Oil Line
F Load Sense Line
[1] - Identify, label, and disconnect harness from cab leveling control valve (A).
[2] - Disconnect lines (B—F)
[3] -
LEGEND:
A Cab Leveling Control Valve and Bracket
Remove cap screws (B) and cab leveling control valve and bracket (A).

[4] -
LEGEND:
A Cab Leveling Control Valve
B Mounting Bracket
Remove cap screws (C) and mounting bracket (B) from cab leveling control valve (A).

Repair Cab Leveling Valve
→NOTE:
Note orientation of solenoids (B) for reassembly.
LEGEND:
A Nuts (2 used)
B Solenoids (2 used)
C Raise Valve Spool
D Lower Valve Spool
[1] - Remove nuts (A) and solenoids.

[2] - Remove raise valve spool (C).
[3] - Remove lower valve spool (D).
[5] - Lubricate O-rings and backup rings with clean hydraulic oil.
Raise and Lower Valve Spools Torque 35 N·m
(310 lb.-in.)
Solenoid Nuts Torque 6 N·m
(53 lb.-in.)
Remove and Install Sensor Ball Joint Rod

[1] -
CAUTION:
The operator′s cab must be secured in such a way that no parts of the body
are at risk from pinching.
LEGEND:
A Nuts (2 used)
B Ball Joint Rod
C Sensor Arm
D Cab Mount Bracket
Remove nuts (A) and ball joint rod (B).
[3] -
IMPORTANT:
After removing ball joint rod, ensure to calibrate cab suspension sensor.
(See Operation and Test TM Section 245, Group CSC.)
Adjust Sensor Rod

[1] -
Remove sensor ball joint rod. (See Remove and Install Sensor Ball Joint Rod in this group.)
[2] - Measure dimension (A) between the two ends.
(2.93 in.)
[3] -
IMPORTANT:
After adjusting or replacing the sensor rod, be sure to calibrate the cab
suspension. (See Operation and Test TM Section 245, Group CSC.)
Install sensor ball joint rod.
Remove and Install Position Sensor
LEGEND:
A Cap screws (2 used)
B Position sensor

IMPORTANT:
After replacing sensor, ensure to calibrate cab suspension sensor. (See

Operation and Test TM Section 245, Group CSC.)
[1] - Identify, label, and disconnect harness from position sensor (B).
[2] - Remove screws (A) and position sensor.
Remove and Install Accumulator
LEGEND:
A Removal Point
B Accumulator
[1] -
→NOTE:
The following applies to all cab suspension accumulators.
Relieve pressure from hydraulic system (See Depressurize Cab Suspension System in this
group.)
[2] - Using a wrench, remove accumulator (B) at removal point (A).

Charging Accumulator
IMPORTANT:
Accumulators must be replaced every ten years.

LEGEND:
A Dust Cap
→NOTE:
Replacement accumulator is shipped with oil in gas side of accumulator; do

not drain oil from accumulator. Replacement accumulators can be charged.
[1] - Relieve pressure from cab suspension system. (See Depressurize Cab Suspension
System in this group.)
[2] - Remove accumulator from hydraulic cylinder. (See Remove and Install Accumulator in
this group.)
[3] - Remove accumulator dust cap (A).
[4] -
IMPORTANT:
Relieve initial breaking torque on socket head cap screw (B), without
loosening.
Relieve initial breaking torque on socket head cap screw (B).

[5] -
→NOTE:
LEGEND:
A O-ring
B Adapter
C Hex Stem
JT03515-2 is part of JT03515 Accumulator Charging Set
Remove O-ring (A) from JT03515-2

[ Accumulator Adapter For European Tractors, use FKM10474 ]

(B), coat with grease, and reinstall.

[6] - Push hex stem (C) into adapter.
[7] -
LEGEND:
A Adapter
B Hex Stem
C Bleed-Off Screw
Assemble adapter (A) onto accumulator and hand tighten.
[8] - Push hex stem (B) into adapter and socket head cap screw while rotating the stem
slightly so the stem slides into the screw.
[9] -
→NOTE:
Ensure bleed-off screw (C) is tight and is not leaking.
JT03515-1 and JT03515-2 are part of JT03515 Accumulator Charging Set
Close bleed-off screw (C) and tighten adapter (A) onto accumulator enough to prevent gas
leakage.

[10] -
→NOTE:
LEGEND:
D Bleed-Off Screw
Back out valve stem depressor (A) completely. Minimum pressure range of
gauge must be twice the accumulator pressure specification.
Back out (counterclockwise) valve stem depressor (A).

[11] - Install JT03515-1 Accumulator Pressure Checking and Charging Adapter (B) to valve
stem of JT03515-2 accumulator adapter (C).
[12] - Install 10000 kPa (100 bar) (1450 psi) gauge to check accumulator.
[14] - Turn in (clockwise) valve stem depressor (A).
LEGEND:
A Hex Stem
B Bleed-Off Screw

[15] - Determine outer temperature of accumulator.

[16] -
→NOTE:
Loosen the hex stem only enough to get a pressure reading on the gauge.
Replacement Accumulator Charge Pressure 5000 +/- 200 kPa at 20 °C
(50 +/- 2 bar at 20 °C)
(725 +/- 29 psi at 68 °F)
[17] - Open bleed-off screw (B) to obtain correct pressure.

[18] -
CAUTION:
LEGEND:
A Accumulator Adapter
B Pressure Adapter
Never charge an accumulator with OXYGEN. If oil and oxygen mix under
pressure an explosion could result. Use only NITROGEN.
→NOTE:
Purge hose before attaching. If pressure checker adapter (B) is not
available the charging hose can be attached directly to the accumulator
adapter (A).
Use a nitrogen tank regulator gauge with 200 kPa (2 bar) (25 psi) or less
increments and a maximum range of 20 000 kPa (200 bar) (3000 psi).
Charging Hose .

[19] - Purge hose and attach to pressure checker adapter (B).

[20] -
LEGEND:
A Regulator Screw
B Shut-Off Valve
Adjust nitrogen tank regulator screw (A) to obtain gauge reading of zero pressure.
[21] - Open tank shutoff valve (B) one turn and turn in (clockwise) valve stem depressor on
nitrogen charging hose.
screw (A) to obtain pressure specification.
[23] - Wait 5 minutes for gas pressure to stabilize.
[24] -

IMPORTANT:
LEGEND:
B Adapter Valve Stem Depressor
C Hex Stem
accumulator socket head cap screw to the specified torque.
Tighten accumulator adapter hex stem (C).

[25] - Back out (counterclockwise) charging hose valve stem depressor (A) and pressure
checker adapter valve stem depressor (B).

[26] -
LEGEND:
B Shut-Off Valve
Loosen nitrogen tank regulator screw (A) until screw turns freely.
[27] - Close tank shutoff valve (B).
[28] -
LEGEND:
A Accumulator Adapter Bleed-off Screw
B Pressure Checker Adapter Bleed-off Screw
Open pressure checker adapter bleed-off screw (B) and accumulator adapter bleed-off screw
(A) to relieve pressure from adapters.

[29] - Close bleed-off screws.

[30] -
LEGEND:
B Pressure Checker Adapter
Remove nitrogen charging hose (A) from pressure checker adapter.
[31] - Remove pressure checker adapter (B) from accumulator adapter (C).
[32] -
LEGEND:
Loosen accumulator adapter bleed-off screw (A) and listen for sound of gas leakage.
[33] - Remove accumulator adapter (B).

[34] -
LEGEND:
A Socket Head Screw
B O-ring Washer
(363 +/- 9 lb.-in.)
[35] - Apply soap water mix around socket head screw (A) and look for bubbles from around
O-ring washer (B).
[36] - Relieve initial breaking torque on socket head screw using a 6 mm hex key wrench.
[37] -
LEGEND:
B Hex Stem
Install accumulator adapter (C).
[38] - Loosen hex stem (B) and open accumulator adapter bleed-off screw (A) to discharge
accumulator.

[39] - Remove accumulator adapter (C).

[40] -
LEGEND:
B O-ring Washer
[41] - Remove and inspect O-ring washer (B).
[43] -
LEGEND:
A Hex Stem
Hold hex stem (A) in the tightened position and remove accumulator adapter (B) from
accumulator.

[44] -
LEGEND:
B O-ring Washer
(363 +/- 9 lb.-in.)
[45] - Replace dust cap O-ring washer (B) as necessary and install dust cap.
[46] - Install accumulator onto hydraulic cylinder. (See Remove and Install Accumulator in
this group.)
[47] - Bleed system. (See Bleeding Suspended Cab System in this group.)

Remove and Install Hydraulic Cylinders
LEGEND:
A Hoses (4 used)
C Hydraulic Cylinders (2 used)
[1] -
IMPORTANT:
After replacing hydraulic cylinders, ensure to calibrate cab suspension.
CAUTION:
Hydraulic cylinders are heavy, use caution when handling.
Relieve pressure from hydraulic system. (See Depressurize Cab Suspension System in this
group.)
[2] - Locate and find wiring harness connector on right-hand cylinder and disconnect.
[3] - Disconnect hoses (A).
[4] - Remove cap screws (B) and hydraulic cylinders (C).
[7] - Bleed cab suspension hydraulic system. (See Bleeding Suspended Cab System in this
group.)
[8] - Calibrate cab suspension system. (See Operation and Test TM Section 245, Group CSC).
Remove and Install Panhard Rod

LEGEND:
A Nuts (2 used)
B Cap Screw
C Bolt
D Panhard Rod
[1] - Remove nuts (A).

[2] - Remove cap screw (B), bolt (C), and panhard rod (D).

Bleeding Suspended Cab System
LEGEND:
A Bleed Screws (4 used)
[1] -
→NOTE:
This procedure fills the cab suspension hydraulic cylinders and lines with
oil and purges air from the system.
[2] - Heat the hydraulic oil if oil temperature is below 20 °C (68 °F).
[4] - Attach four bleed hoses to the bleed screw (A) nipples at top and bottom of suspension
cylinders.
[5] - Insert other ends of hoses into hydraulic oil fill tube.
[6] - Open the bleed screws at the TOP of both suspension cylinders. The bottom bleed
screws must remain closed.
[7] - Start engine and set speed at 1200 rpm.
[8] - Access CSC Address 21 in technician mode. (See Access Control Unit Addresses in
Operation and Test TM Section 245, Group 05.)
[9] - Once ENTER is pressed the system begins to fill.
[10] - Watch for a steady stream of oil flowing into the bleed hoses.

DEALER TOOLS (g) by Belgreen
[11] - If one hose flows before the other, close that bleed screw until both top hoses flow oil
then reopen the screw.
[12] - While both TOP bleed screws are open, open the two BOTTOM bleed screws.
[13] - Close both TOP bleed screws.
[14] -
CAUTION:
Cab starts moving suddenly after all bleed screws are closed.
If one hose flows before the other, close that bleed screw until both bottom hoses flow oil
then close both bleed screws.
[15] - Tighten bleed screws to specification:
Hydraulic Cylinder Bleed Screws Torque 8 +/- 1 N·m
(71 +/- 8 lb.-in.)
[16] - With all bleed screws closed, the cab begins to raise until it reaches mid-stroke and
stops. Display shows END.
[17] - Press ENTER again.
If ERR is displayed, the service code follows, and then END. Perform diagnosis for all
service codes before continuing.
[18] - The display returns to CSC.

[19] - Press the BACK button to return to the diagnostic list.
[20] - Turn key switch OFF.
→NOTE:
Bleeding sequence terminates when cab reaches middle of stroke or after 5
minutes of attempted bleed.

Section 99 - DEALER TOOLS

Table of contents
Group 05 - Dealer Fabricated Tools ........................................................................................ 1
DF1057—Axle Adjusting Tool ................................................................................................. 2
DFRW4—Axle Wheel Hub Tool ............................................................................................... 4
DFRW30A—Axle Jacking Tool ................................................................................................. 4
DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses ............................. 6
DFRW94—Rear Axle Support Stand ....................................................................................... 8
DFRW98—Rear Axle Guide Pin ............................................................................................... 9
DFRW132—Differential Side Bevel Gear End Play Tool ........................................................ 10
DFRW148—ActiveSeat™ Control Valve Holding Tool ........................................................... 11
DFRW178—Front Brake Bleed Wrench ................................................................................. 12
DFRW213—Hydraulic Trailer Brake Test / Bleed Assembly .................................................. 13
DFRW219—Wheel Tightening Stand .................................................................................... 14
DFRW235—MFWD Input Shaft Holding Tool ......................................................................... 15
DFRW236—Front PTO Support Bracket ................................................................................ 15
DFRW237—Differential Drive Shaft Removal Tool ............................................................... 16
Group 10 - Essential And Recommended Tools .................................................................. 18
D01019AA Manually Operated Hydraulic Pump ................................................................... 24
D01044AA Bushing, Bearing and Seal Driver Set ................................................................. 25
D01045AA Disk Set .............................................................................................................. 25
D01048AA 17-1/2 Ton Hydraulic Puller Set .......................................................................... 26
D01053AA Spanner Wrench ................................................................................................. 26
D01061AA Blind-Hole Puller Set ........................................................................................... 27
D01173AA 17-1/2 Ton Mechanical Puller Set ....................................................................... 27
D01210AA Slide Hammer Puller ........................................................................................... 28
D01290AA Push-Puller ......................................................................................................... 28
D01300AA Slide Hammer Puller ........................................................................................... 29
D01301AA Internal Puller ..................................................................................................... 29
D05104ST Radiator Pressure Tester .................................................................................... 29
D05117ST Spanner Wrench ................................................................................................. 30
D05223ST Engine Rollover Stand ......................................................................................... 30
D05361ST Rubber Stopper and Leak Detector Kit ............................................................... 30
JDG19 Lifting Eyes ................................................................................................................ 31
JDG23 Lift Sling .................................................................................................................... 31
JDG135 Driver Disk (140 mm or 5-1/2 in.) ............................................................................ 31
JDG141 Extraction Tool ........................................................................................................ 32
JDG155 Electrical Repair Tool Kit ......................................................................................... 32
JDG359 DEUTSCH Electrical Repair Tool Kit ......................................................................... 33
JDG537 Driver Handle .......................................................................................................... 33
JDG707 Crimping Tool .......................................................................................................... 34
JDG708 AMP Crimping Tool .................................................................................................. 34
JDG754 Spring Compressor .................................................................................................. 35
JDG755 Bushing Installer ...................................................................................................... 35
JDG761 Seal Installer ........................................................................................................... 35
JDG765 Bushing Installer ...................................................................................................... 35

JDG766 Clip Removal Tool .................................................................................................... 36

JDG772 Input Planetary Installation Tool .............................................................................. 36
JDG778A Rolling Drag Torque Tool ....................................................................................... 37
JDG783 Weather Pack Crimping Tool ................................................................................... 37
JDG820 Flywheel Rotation Tool ............................................................................................ 37
JDG861 Torque Wrench Adapter .......................................................................................... 38
JDG865 Crimping Tool .......................................................................................................... 38
JDG867 Axle Seal Installer .................................................................................................... 39
JDG868 Axle Seal Installer .................................................................................................... 39
JDG877 Sealing Ring Loading Tool Set ................................................................................. 39
JDG878 Sealing Ring Resizing Tool ...................................................................................... 40
JDG879A Differential and Pinion Lifting Fixture .................................................................... 40
JDG880B Differential Bearing Quill Adjustment Tool ............................................................ 40
JDG890A Planetary Carrier Lifting Tool ................................................................................. 41
JDG909 Lifting Eyes .............................................................................................................. 41
JDG931 178 mm (7 in.) ........................................................................................................ 41
JDG933 Driver Disk 137 mm (5-3/8 in.) ................................................................................ 42
JDG948 Terminal Extractor Tool ........................................................................................... 42
JDG983 Snap Ring Expander Tool ........................................................................................ 42
JDG1076A Cone Stand and Adapter ..................................................................................... 43
JDG1123 Driver Disk ............................................................................................................ 44
JDG1182 Puller Adapter ........................................................................................................ 44
JDG1198 Bearing Installer .................................................................................................... 44
JDG1211 Bushing Installer Pilot ............................................................................................ 45
JDG1212 Bushing Remover .................................................................................................. 45
JDG1216 Ring Gear Holding Tool .......................................................................................... 45
JDG1217 Differential Housing Tool Set ................................................................................. 45
JDG1218A Seal Installer ....................................................................................................... 46
JDG1219B Seal Installer ....................................................................................................... 46
JDG1220 Spacer Installer ..................................................................................................... 46
JDG1222 Puller Jaws ............................................................................................................. 47
JDG1227 Suspended Axle Cylinder Tool Set ......................................................................... 47
JDG1253 Spanner Socket ..................................................................................................... 48
JDG1254 Seal Installer ......................................................................................................... 48
JDG1255 Slinger-Seal Installer ............................................................................................. 48
JDG1272 Bushing-Seal Installer ............................................................................................ 49
JDG1405 Bearing Installer .................................................................................................... 49
JDG1413 Bearing Cone Installer ........................................................................................... 50
JDG1424 Support Block ........................................................................................................ 50
JDG1494 Rear Axle Lifting Tool ............................................................................................ 50
JDG1562B Axle Seal Installer ................................................................................................ 51
JDG1563 197 mm (7-3/4 in.) ................................................................................................ 51
JDG1573 120 mm Rear Axle Support Stand ......................................................................... 51
JDG1574 Lifting Bracket ....................................................................................................... 52

JDG1579 Coupler Tool .......................................................................................................... 52

JDG1662 Spacer Ring ........................................................................................................... 53
JDG1666 Park Brake Release Hand Pump Kit ....................................................................... 53
JDG1707 Axle Lifting Bracket ............................................................................................... 54
JDG1727 Terminal Crimping Tool ......................................................................................... 54
JDG1744 Master Repair Kit ................................................................................................... 55
JDG1885 STC Tools ............................................................................................................... 56
JDG2042 Ring Adapter ......................................................................................................... 57
JDG2046 Starter Wrench ...................................................................................................... 57
JDG2061 Front Adapter ........................................................................................................ 58
JDG8092 Driver Handle ........................................................................................................ 58
JDG10145 Terminal Crimping Tool ....................................................................................... 59
JDG10146 Extraction Tool .................................................................................................... 59
JDG10227 Axle Mounting Bracket ........................................................................................ 60
JDG10353 DEUTSCH Crimp and Extractor Tool Set .............................................................. 61
JDG10539 Radiator Pressure Tester Adapter ....................................................................... 61
JDG10555 Recovery/Recycling Station ................................................................................. 62
JDG10664 Relief Valve Core Removal Tool .......................................................................... 62
JDG10665 Spool Centering Spring Assembly Tool ................................................................ 63
JDG10666 Pressure Compensator Removal Brush ............................................................... 63
JDG10667 Shuttle Valve Removal Tool ................................................................................ 64
JDG10741 Wheel Tightening Stand ...................................................................................... 65
JDG10927 Terminal Extraction Tool ..................................................................................... 65
JDG10974 Recovery/Recycling, and Charging Station .......................................................... 66
JDG11001 Puller Adapter ...................................................................................................... 66
JDG11016 Die Assembly ....................................................................................................... 67
JDG11017 Crimping Tool ...................................................................................................... 67
JDG11019 Extraction Tool .................................................................................................... 68
JDG11149 IVT Transmission Mounting Fixture ..................................................................... 68
JDG11187 Locking Nut Tool .................................................................................................. 68
JDG11188 Output Shaft Bearing Support Tool ..................................................................... 69
JDG11189 Counter Shaft Bearing Support Tool .................................................................... 69
JDG11190 MFWD Adjusting Ring Tool .................................................................................. 69
JDG11191 Hydro Adjusting Ring Tool ................................................................................... 70
JDG11193 Differential Housing Tool Set ............................................................................... 70
JDG11195 425 mm DDS Spline Socket ................................................................................. 70
JDG11196 472 mm DDS Spline Socket ................................................................................. 71
JDG11209 PTO Seal Installer ................................................................................................ 71
JDG11210 Retainer Tool ....................................................................................................... 72
JDG11211 Snap Ring Installer .............................................................................................. 72
JDG11212 MFWD Clutch Alignment Tool .............................................................................. 73
JDG11213 Input Shaft Turning Tool ...................................................................................... 73
JDG11215 Park Brake Alignment Tool .................................................................................. 73
JDG11217 Splitting Stand ..................................................................................................... 73
JDG11219 Park Brake Installation Tool ................................................................................. 74
JDG11221 100 mm Flanged Axle Seal Installer .................................................................... 74
JDG11222 120 mm Flanged Axle Seal Installer .................................................................... 74

JDG11228 Die Set ................................................................................................................. 75

JDG11229 Die Set ................................................................................................................. 75
JDG11230 Die Set ................................................................................................................. 76
JDG11240 Mounting Fixture ................................................................................................. 76
JDG11241 Lift Fixture Tool ................................................................................................... 76
JDG11244 Radiator Pressure Tester Adapter ....................................................................... 77
JDG11252 Front Lifting Bracket ............................................................................................ 77
JDG11258 Rear Lifting Bracket ............................................................................................. 78
JDG11260 Lifting Bracket ..................................................................................................... 79
JDG11305 MFWD Output Shaft Seal Installer ....................................................................... 79
JDG11320 Output Shaft Adjusting Ring Tool ........................................................................ 79
JDG11328 Seal Driver .......................................................................................................... 80
JDG11407 Spanner Socket ................................................................................................... 80
JDG-PST Power Shift Transmission Repair Kit ....................................................................... 80
JT01610 Seal Installer Disk ................................................................................................... 81
JT01673 Bearing Cup Installer .............................................................................................. 81
JT02098 Air Conditioning R-12/R134a Fitting Kit .................................................................. 82
JT02129 Air Conditioning Oil Injector .................................................................................... 82
JT03474 Male-to-Male Quick Coupler ................................................................................... 82
JT03515 Accumulator Charging Set ...................................................................................... 83
JT05412 Universal Pressure Test Kit ..................................................................................... 83
JT05549 Lifting Eyebolt ........................................................................................................ 83
JT05550 Lifting Eyebolts ....................................................................................................... 84
JT05563 Nitrogen Charging Hose ......................................................................................... 84
JT05726 Wheel and Axle Lift ................................................................................................ 84
JT07045 Hydraulic Pressure Gauge ...................................................................................... 85
JT07056 Service Jack ............................................................................................................ 85
JT07115 Master Hydraulic Kit ............................................................................................... 86
JT07115SUP Supplemental Master Hydraulic Kit .................................................................. 86
JT07118 Two-Valve Manifold ................................................................................................ 87
JT07119 Test Hose ............................................................................................................... 87
JT07134 Bleed Pipe .............................................................................................................. 88
JT07195B Technician’s Electrical Repair Kit ......................................................................... 88
JT07211 Rear Differential Support Stand ............................................................................. 89
JT07219 Rear Axle Support Stand ........................................................................................ 89
JT07336 Lift Sling ................................................................................................................. 90
KJD10539 Support Stand Adapter ........................................................................................ 90

Section 99 - DEALER TOOLS Group 05: Dealer Fabricated Tools
Group 05 - Dealer Fabricated Tools

List of References
This list contains dealer fabricated tools used in TM110119.
DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses
DFRW213—Hydraulic Trailer Brake Test / Bleed Assembly

LEGEND:
A 660 mm (26 in.)
B 225 mm (8.87 in.)
C 1/2 in. Drilled Hole (2 Places)
D Welded Nut (Centered)
E 300 mm (11.8 in.)
F 274 mm (10.8 in.)
G 251 mm (9.9 in.)
H 224 mm (8.8 in.)
I 25 mm (1 in.)
J 0.25 x 1 x 1.38 in. Each Chain Link
K 3/4 in. Drilled Hole (8 Places)
L 0.19 x 2 x 2 in. Tube
M 25 mm (1 in.)
N 25 mm (1 in.)
O 11/16 in. Drilled Hole
P 105 mm (4.1 in.)

Q 51 mm (2 in.)
R 308 mm (12.1 in.)
S 356 mm (14 in.)
T 425 mm (16.7 in.)
U 25 mm (1 in.)
V 3/4 in. Drilled Hole (2 Places)
W 25 mm (1 in.)
X 89 mm (3.5 in.)
Material Required:
1—2 x 2 in. Steel Tube

1—2 x 1.2 in. Flat Steel
Use an odd number of links in the section of chain.
Tool is used to remove axle shaft and adjust axle bearings.

LEGEND:
A 305 mm (12 in.)
B 216 mm (8.5 in.)
C 127 mm (5 in.)
D 64 mm (2.5 in.)
E 35 mm (1.4 in.)
F Used for Planet Pinion Cover
G Used for Final Drive and Knuckle Assembly
H Used for Differential Carrier Assembly
I 51 x 305 x 13 mm (2 x 12 x 0.5 in.) Steel
J 76 x 76 x 13 mm (3 x 3 x 0.5 in.) Steel
K 76 x 76 x 13 mm (3 x 3 x 0.5 in.) Steel
L 57 mm (2.25 in.)
M Drill 25 mm (1 in.)
N Size to Accommodate Shackle Chosen, 13 mm (0.5 in.) Minimum (3 Holes)
Material Required:
(2) 76 x 76 x 13 mm (3 x 3 x 0.5 in.) Steel Plates

(1) 51 x 305 x 13 mm (2 x 12 x 0.5 in.) Steel Plate
Tool is used to remove and install wheel hub to knuckle spindle.

Material Required:
102 x 51 x 559 mm (4 x 2 x 22 in.) Steel Tubing
The axle jacking tool is made from specified tubing with (2) 9/16 x 14 in. steel threaded rods.
Use (4) 9/16 in. nuts and (2) 9/16 in. flat washers on the rods.
Tool is used to remove axle housing from axle shaft and installing primary brake piston.

DFRW63 - DFRW64 - DFRW65 - DFRW66 -

DFRW81—Tap-Out Harnesses
LEGEND:
A DFRW63 Tap-Out Harness
B DFRW64 Tap-Out Harness DFRW65 Tap-Out Harness
C DFRW66 Tap-Out Harness DFRW81 Tap-Out Harness
→NOTE:
Alphanumeric keys are for reference during harness fabrication procedure.
A 35-Pin CPC ™ bulkhead connector (R77456— Amp No. 206151-1) can be

substituted for A3, B3, and C3 WEATHER PACK ™ connectors, with the
appropriate terminals (R77464 Pin), for use with JT02016 Combine
Receptacle Kit.
DFRW63—Tap-Out Harness (A)
A1=R78055 4-Way WEATHER PACK ™ Shroud with four R78061 Pin Terminals
A2=RE12333 4-Way WEATHER PACK ™ Tower (with seal) with four R78060 Sleeve Terminals

A3=RE12333 4-Way WEATHER PACK ™ Tower (with seal) with four R78061 Pin Terminals
Also required:
Twelve R78063 Seals

Four 200 mm (8 in.) lengths of wire (14 gauge) of different colors
Four 150 mm (6 in.) lengths of wire (14 gauge) to match colors of 200 mm (8 in.) wires
Four AR67855 Wire Tap Connectors
DFRW64—Tap-Out Harness (B)
B1=R78054 3-Way WEATHER PACK ™ Shroud with three R78060 Sleeve Terminals
B2 and B3=RE12364 3-Way WEATHER PACK ™ Tower (with seal) with three R78061 Pin
Terminals
Also required:
Nine R78063 Seals

Three 200 mm (8 in.) lengths of wire (14 gauge) of different colors
Three 150 mm (6 in.) lengths of wire (14 gauge) to match colors of 200 mm (8 in.) wires
Three AR67855 Wire Tap Connectors
DFRW65—Tap-Out Harness (B)
B1=R78054 3-Way WEATHER PACK ™ Shroud with three R78061 Pin Terminals
B2=RE12364 3-Way WEATHER PACK ™ Tower (with seal) with three R78060 Sleeve Terminals
B3=RE12364 3-Way WEATHER PACK ™ Tower (with seal) with three R78061 Pin Terminals
Also required:
Three 200 mm (8 in.) lengths of wire (14 gauge) of different colors

Three 150 mm (6 in.) lengths of wire (14 gauge) to match colors of 200 mm (8 in.) wires
Three AR67855 Wire Tap Connectors
DFRW66—Tap-Out Harness (C)
C1=R78053 2-Way WEATHER PACK ™ Shroud with two R78061 Pin Terminals
C2=RE12331 2-Way WEATHER PACK ™ Tower (with seal) with two R78060 Sleeve Terminals
C3=RE12331 2-Way WEATHER PACK ™ Tower (with seal) with two R78061 Pin Terminals
Also required:
Two 200 mm (8 in.) lengths of wire (14 gauge) of different colors

Two 150 mm (6 in.) lengths of wire (14 gauge) to match colors of 200 mm (8 in.) wires

Two AR67855 Wire Tap Connectors
DFRW81—Tap-Out Harness (C)
A1=R78053 2-Way WEATHER PACK ™ Shroud with two R78060 Sleeve Terminals
A2=RE12363 2-Way WEATHER PACK ™ Tower (with seal) with two R78061 Pin Terminals
A3=RE12363 2-Way WEATHER PACK ™ Tower (with seal) with two R78061 Pin Terminals
Also required:
Six R78063 Seals

Two 200 mm (8 in.) lengths of wire (14 gauge) of different colors
Two 150 mm (6 in.) lengths of wire (14 gauge) to match colors of 200 mm (8 in.) wires
Two AR67855 Wire Tap Connectors
→NOTE:
Tool may be purchased From SERVICEGARD. Order JDG7219
Material Required:

13 x 381 x 858 mm (1/2 x 15 x 33-3/4 in.) Steel Plate

686 x 127 mm ID (27 x 5 in. ID) Steel Tubing
3/4 in. Cap Screw
Fabricate tool as illustrated.
Tool is used to support final drive during disassembly and assembly.
Material Required:
19M8021 Cap Screw
Remove cap screw head and cut slot in end.
Tool is used to install final drives.

DFRW132—Differential Side Bevel Gear End Play

Tool
LEGEND:
A Steel Plate
B Wood
C 152 mm (6 in.)
D 152 mm (6 in.)
E 16 mm (0.63 in.)
F 20 mm (0.75 in.)
G Nut and Bolt
H 6 mm (1/4 in.) Drilled Hole (3 Required)
I 203 mm (8 in.)
J 16 mm (0.63 in.)
K 6 mm (0.25 in.) Radius
L 32 mm (1.25 in.)
M 38 mm (1.5 in.)
N 13 mm (0.50 in.)
Material Required:
(1) 20 x 458 x 3 mm Steel Plate (0.75 x 18 x 0.125 in.)

(1) 20 x 20 x 152 mm Piece of Wood (0.75 x 0.75 x 6 in.)
(3) 6 x 50 mm (1/4 x 2 in.) Bolts
(3) Retaining Nuts
Two jaws are required.

Fabricate jaws as illustrated.
Grind a 6 mm (0.25 in.) radius on each corner (K) of jaws.
Assemble and install bolts and nuts as illustrated.
Tool is used to remove and install differential housing assembly to differential case and check
side bevel gear end play.
LEGEND:
A 19M7348 Cap Screw (10 mm x 150 mm)
B 3/8 in. Bar Stock (4 in. Long)
Material Required:
3/8 in. Bar Stock
19M7348 Cap Screw (10 mm x 150 mm)
Weld bar (B) to cap screw (A) as illustrated.
Tool is used to retain valve and align floor plate during valve removal and installation.

Materials
(1) 6 mm ”T” handle hex (allen) wrench with a minimum total length of 12,7 cm (5 in.).
(1) #2 rubber stopper with hole through center. Part of D05361ST Rubber Stopper and
Leak Detector Kit .
Assembly of Front Brake Bleed Tool
1. Install #2 rubber stopper on ”T” handle wrench with smaller end of stopper toward
handle of wrench.
2. Position the plug approximately 6,4 cm (2.5 in.) from end of wrench.
Use of Front Brake Bleed Tool
1. Insert wrench into brake bleed screw opening in front hub.

2. Position small end of rubber stopper flush with hub.
3. Follow brake bleed procedure.
→NOTE:
Avoid plugging hub opening tightly with rubber stopper. Air being
displaced during bleeding procedure must be allowed to vent.

DFRW213—Hydraulic Trailer Brake Test / Bleed

Assembly
LEGEND:
A Hydraulic Quick Connect Female Coupler
B Rubber Packing
C Straight Fitting (-8 (m) ORFS x M18 x 1.5 (m))
D Diagnostic Receptacle (13/16-16 (f) ORFS)
Materials:
(1) AR52361 — Hydraulic Quick Connect Female Coupler

(1) L34382 — Rubber Packing
(1) 38H5003 — Straight Fitting (-8 (m) ORFS x M18 x 1.5 (m))
(1) RE43774 — Diagnostic Receptacle (13/16-16 (f) ORFS)
→NOTE:
The following European fittings can also be used:
(1) AR52361 — Hydraulic Quick Connect Female Coupler

(1) FKM10302 — Connector
Assemble:
1. Install rubber packing (B) into hydraulic quick connect female coupler (A).
2. Assemble fittings as shown in diagram.
Use:
Used to test and bleed hydraulic trailer brakes at coupler.
LEGEND:
A 460 mm (18 in.) Minimum
B 460 mm (18 in.) Minimum
C 1400 mm (55 in.) Approximate
D 30 mm (2.25 in.) Approximate
Fabricate from 50 mm (2 in.) square steel tubing.

Attach 15 (5/8 in.) diameter hooks as illustrated.
Optional wheels contact floor when stand is tipped to move around shop area.
Used to aid in tightening wheel hardware.
LEGEND:
A 20 mm Hole
B 14 mm Hole
C M12 Nut
D M12 X 64 mm Cap Screw
Fabricate from angle iron 40 mm X 40 mm, 4 mm thick, approximately 305 mm long (1.5 in.
X 1.5 in., 0.25 in. thick, approximately 12 in. long).
Drill two 20 mm holes (A).
Drill 14 mm hole (B).
Weld M12 nut (C) centered on hole.
Insert M12 X 64 mm cap screw (D).

Material Required:
255 x 220.4 x 12.75 mm (10 x 8.687 x .5 in.) Steel Plate
Cut steel plate to size and drill holes as illustrated.
Tool is used to support front PTO housing while removing.

Section 99 - DEALER TOOLS Group 10: Essential And Recommended Tools
Material Required:
6.35 mm (1/4 in.) Steel Tubing 152.4 x 51 x 914.4 mm (6 x 2 x 36 in.)
Cut tubing to length and drill holes as illustrated.
Tool is used to separate the differential drive shaft from the bearing cone in the differential
case.

Group 10 - Essential And Recommended Tools

List of References
This list contains essential and recommended tools used in TM110119.
D01045AA Disk Set
D05117ST Spanner Wrench
JDG19 Lifting Eyes
JDG23 Lift Sling

JDG909 Lifting Eyes
JDG931 178 mm (7 in.)

JDG1123 Driver Disk
JDG1222 Puller Jaws

JDG1563 197 mm (7-3/4 in.)
JDG1662 Spacer Ring
JDG1885 STC Tools


JDG11228 Die Set
JDG11229 Die Set
JDG11230 Die Set

JT07119 Test Hose
JT07134 Bleed Pipe
JT07336 Lift Sling

Manually operated hydraulic pump
D01019AA

Used to pressurize hydraulic components.

Bushing, Bearing and Seal Driver Set
D01044AA
Used to install bushing, bearings, bearing cups and seals.
D01045AA Disk Set

Disk Set
D01045AA Set

Used to install bearing cups.

Hydraulic Puller Set
D01048AA
Used to remove bearings.

Spanner Wrench

D01053AA
Used to repair FPTO.

Blind-Hole Puller Set
D01061AA
[ Recommended Tool ]
Used to remove bearings and bushings from blind holes.

Mechanical Puller Set
D01173AA

Used to remove bearings.

Slide hammer puller
D01210AA
Used to remove bearings and gears.
Push-Puller
D01290AA
[ RECOMMENDED TOOL ]

Used to remove bearings and bearing cups.

Slide hammer puller
D01300AA
Used to remove bearings and gears.

Internal Puller
D01301AA
Used to remove bearings and bearing cups.


Radiator Pressure Tester
D05104ST
Used to pressure test radiator and radiator cap.
D05117ST Spanner Wrench

Spanner Wrench
D05117ST
Used to repair hydraulic cylinders.

Engine Repair Stand
D05223ST
Used to hold components during repair.


Rubber Stopper and Leak Detector Kit
D05361ST
Use to check hydraulic system connections.
JDG19 Lifting Eyes

Lifting Eyes
JDG19
Used to remove and install components.
JDG23 Lift Sling

Lift Sling
JDG23
Used to remove and install engines and components.


Driver Disk (140 mm or 5-1/2 in.)
JDG135
Used to install input housing oil baffle.

Extraction Tool
JDG141
Used to remove CPC ™ blade type connectors. Included in JDG155 Electrical Repair Tool Kit
and JT07195B Technician’s Electrical Repair Kit .

Electrical Repair Tool Kit
JDG155

LEGEND:
Kit includes:
• JDG107 Holding Plate
• JDG139 Contact Insertion Tool
• JDG140 Contact Extraction Tool
• JDG144 Crimping Pliers
• JDG145 Electrician′s Pliers
• JDG146 Carry Case
Used to repair electrical connectors.

DEUTSCH Electrical Repair Tool Kit
JDG359
Used to repair DEUTSCH electrical connectors.
[ Includes JDG360 Crimping Tool, JDG361, JDG362, and JDG363 extractors. ]

Driver Handle
JDG537

Used with bushing and seal installers.

Crimping Tool
JDG707
Used to crimp contacts to wires.

AMP Crimping Tool
JDG708

Used to crimp wire terminal ends for injection pump connector.

Spring Compressor
JDG754
Used to compress clutch piston return springs.

Bushing Installer
JDG755
Used to install bushings.

Seal Installer
JDG761
Used to install MFWD wheel hub seal.


Bushing Installer
JDG765
[ Used in conjunction with JDG537 Driver Handle ]
Used to install rockshaft bushings.

Clip Removal Tool
JDG766
Used to remove transmission valve bore plugs.

Seal Installer
JDG770
Used to install upper kingpin seal.


Input Planetary Installation Tool
JDG772
Used to assemble the planetary housing.

Rolling Drag Torque Tool
[ JDG778A Sub for JDG778 ]
Used to check rolling drag torque of final drive pinions.

Weather Pack Crimping Tool
JDG783

Flywheel Rotation Tool

JDG820
Used to rotate engine flywheel.

Transmission Shaft Universal Seal Installer
JDG851
Used to install shaft seal.

Torsional Damper Wrench
JDG861
Used to tighten torsional damper screw.

Crimping Tool
JDG865


Axle Seal Installer
JDG867
Used to install outer axle oil seal (100 mm axles).

Axle Seal Installer
JDG868
Used to install outer axle oil seal (110 mm axles).

Sealing Ring Mandrel
JDG877

Used to install differential lock sealing rings onto quill.

Sealing Ring Resizing Tool
JDG878
Used to compress differential lock sealing rings on quill.

Differential and Pinion Lifting Fixture
JDG879A
Used to remove and install differential housing and input quill assembly and other
components.

Differential Bearing Quill Adjustment Tool
JDG880B

Used to remove and install differential housing bearing quills.

Planetary Carrier Lifting Tool
JDG890A
Used to remove and install planetary carrier assembly.
JDG909 Lifting Eyes

Lifting Eyes
JDG909
JDG931 178 mm (7 in.)

Driver Disk (178 mm or 7 in.)
JDG931

Used to install bearing cup into axle housing.

JDG932
Used to install input shaft inner bearing cup into input housing.

JDG933
Used to install differential housing bearing cup.

Snap Ring Expander Tool

JDG983
Used to remove and install heavy duty snap rings.

JDG986
Used to install differential housing bearing cup.

Cone Stand and Adapter
JDG1076A
[ Replaces JDG1076 ]

Used to support tractors implements for service and repair.
JDG1123 Driver Disk

Driver Disk
JDG1123
Used to install bearing in wheel hub.

Reducing Adapter
JDG1182
Used to remove lift cylinder retaining pin.

Bearing Installer
[ JDG1198 RECOMMENDED TOOL ]
Used to install spherical bearing.


Bushing Installer Pilot
JDG1211
Used to install bushing.

Bushing Remover
JDG1212
Used to remove bushing from spacer.

Ring Gear Holding Tool
JDG1216
Used to clamp wheel hub and ring gear together.

Differential Housing Tool Set
JDG1217
Used to Adjust backlash and differential housing bearing preload on MFWD axles.

Seal Installer
JDG1218A
Used to install knuckle spindle housing seal.

Seal Installer
JDG1219B
Used to install bellows seal on drive shaft.

Spacer Installer
JDG1220

Used to install axle housing spacer.
JDG1222 Puller Jaws

Puller Jaw
JDG1222
Used to remove bearings, bearing cups and gears.

Suspended Axle Cylinder Tool Set
JDG1227
Used to install seal kit and assemble piston into cylinder.

JDG1252

Used to adjust differential preload and backlash.

Spanner Socket
JDG1253
Used to remove and install wheel hub retainer.

Seal Installer
JDG1254
Used to install lower kingpin seal.

Slinger-Seal Installer
JDG1255

Used to install oil slinger and excluder seal on to axle shaft.

Bushing-Seal Installer
JDG1272
Used to install rockshaft bushings and seals.

Seal Installer
JDG1356
Used to install MFWD wheel hub seal.

Bearing Installer
JDG1405

Used to remove brake housing from wheel hub.

Bearing Cone Installer
JDG1413
Used to install bearing cone to input pinion shaft.

Support Block
JDG1424
Used to support seat during suspension repair.

Rear Axle Lifting Tool
JDG1494

Used to remove and install 120 mm axle final drives.

Axle Seal Installer
JDG1562B
Used to install outer axle seal (120 mm axles).
JDG1563 197 mm (7-3/4 in.)

Driver Disk 197 mm (7-3/4 in.)
JDG1563
Used to install 120 mm axle outer bearing cup.

Rear Axle Support Stand

JDG1573
Used to support 120 mm final drive during disassembly and assembly.

Lifting Bracket
JDG1574
[ Recommended Tool—May be fabricated —See Section 99 (DFRW150) ]
Used to remove and install Hitch-SCV stack.

Coupler Tool

JDG1579
Used to remove SCV couplers.
JDG1662 Spacer Ring

Axle Outer Seal Installer
JDG1662
Used to install RE168641 replacement outer axle oil seal (100 mm and 110 mm axles).

Park Brake Release Hand Pump Kit
JDG1666

Used to release park brake.

Axle Lifting Bracket
JDG1707
Used with JT07218 to remove and install 7020 series 92 mm and 100 mm axle final drives.

Crimping Tool
JDG1727

Used to crimp terminals to wires

Master Repair Kit
JDG1744
Used to repair CINCH ™ wire connectors.
[ Includes JDG1725 Terminal Removal Tool, JDG1727 Crimping Tool, JDG1866 Crimper Jaw Set, JDG1868 Terminal Extraction Tool, and JDG1869
Secondary Lock Tool. ]

JDG1769


Seal Installer
JDG1860
Used to install packing on C1-C2 shift piston.
JDG1885 STC Tools

Snap to Connect Release Tools
JDG1885

Used to disconnect Snap-to-Connect lines and hoses.

Ring Adapter
JDG2042
Used with JT07218 Rear Axle Lifting Tool to remove and install rear final drives.

Starter Wrench
JDG2046

Used to remove and install engine starter.

Front Adapters
[ JDG2061 Used with JT07122 ]
Used to remove and install drive train.

Driver Handle
JD8092

Used with bushing and seal installers.

Crimping Tool
JDG10145

Terminal Extraction Tool
JDG10146

Used to extract terminals from connector.

Crimping Tool
JDG10198
Used to crimp terminals to wires.

Axle Mounting Bracket
JDG10277

Used to mount axle onto D05223ST Engine Rollover Stand.

DEUTSCH Crimp and Extractor Tool Set
JDG10353
Used to repair DEUTSCH™ implement connector.

Radiator Pressure Tester Adapter
JD10539


Recovery/Recycling, and Charging Station
JDG10555
Used to servicing air conditioning system using R134a refrigerant.

Shuttle Valve Removal Tool
JDG10664

Used to repair hydraulic valves.

Spool Centering Spring Assembly Tool
JDG10665


Pressure Compensator Removal Brush
JDG10666

Shuttle Valve Removal Tool
JDG10667


JDG10741
Used to aid in tightening wheel hardware.

Terminal Extraction Tool
JDG10927

Used to extract terminals from BRXSCV connector.

Recovery/Recycling, and Charging Station
JDG10974
Used to service air conditioning system using R134a refrigerant.

Reducing Adapter

JDG11001
Used to remove lift cylinder retaining pin.

Die Assembly
JDG11016

Crimping Tool
JDG11017


Extraction Tool
JDG11019
Used to extract terminals from connector.

IVT Transmission Mounting Fixture
JDG11149
Used to hold range box on rollover stand.


Locking Nut Tool
JDG11187
Used to tighten locking nut on SU Idler.

Output Shaft Bearing Support Tool
JDG11188
Used to remove and install output shaft quill.

Counter Shaft Bearing Support Tool
JDG11189
Used to remove and install counter shaft quill.

MFWD Adjusting Ring Tool
JDG11190

Used to remove and install MFWD quill.

Hydro Adjusting Ring Tool
JDG11191
Used to remove and install hydrostatic module quill.

JDG11193

425 mm DDS Spline Socket
JDG11195

Used to remove and install 425 mm DDS shaft.

472 mm DDS Spline Socket
JDG11196
Used to remove and install 472 mm DDS shaft.

PTO Seal Installer
JDG11209

Used to install PTO output shaft oil seal.

Retainer Tool
JDG11210
Used to remove and install DDS shaft.

Snap Ring Installer
JDG11211

Used to remove and install snap ring on mode 2 clutch.

MFWD Clutch Alignment Tool
JDG11212
Used to align gear in MFWD clutch assembly.

Input Shaft Turning Tool
JDG11213
Used to turn input shaft on IVT transmission.

Park Brake Alignment Tool
JDG11215
Used to align brake plates and disks.

Splitting Stand

JDG11217
Used to remove and install drive train, final drives, and front axles.

Park Brake Installation Tool
JDG11219
Used to remove and install parking brake.

100 mm Flanged Axle Seal Installer
JDG11221
Used to install flange axle seals.

120 mm Flanged Axle Seal Installer

JDG11222
Used to install flange axle seals.
JDG11228 Die Set

Die Set
JDG11228
JDG11229 Die Set

Die Set
JDG11229

JDG11230 Die Set

Die Set
JDG11230

Mounting Fixture
JDG11240
Used to hold range box on rollover stand.


Lift Fixture Tool
JDG11241
Used to remove and install input and output shafts.

Radiator Pressure Tester Adapter
JDG11244

Front Lifting Bracket
JDG11252

Used to remove engine.

Crimping Tool
JDG11255

Rear Lifting Bracket
JDG11258


Lifting Bracket
JDG11260

MFWD Output Shaft Seal Installer
JDG11305
Used to intal seal on IVT MFWD shaft.

Output Shaft Adjusting Ring Tool
JDG11320

Used to remove and install output shaft quill.

Seal Driver
Used to install seals in PTO output shafts.

Spanner Socket
JDG11407
Used to remove and install FPTO spanner nut.


Power Shift Transmission Repair Kit
JDG-PST
Used to repair power shift transmissions and other components.

Seal Installer Disk
JT01610
Used to install output shaft rear bearing cup.

Bearing Cup Installer
JT01673

Used to install outer bearing cup against bottom shoulder.

Air Conditioning R-12/R134a Fitting Kit
JT02098
Used connect flushing, purging, and pressure equipment.

Air Conditioning Oil Injector
JT02129
Used to add refrigerant oil to A/C system.

Male-to-Male Quick Coupler
[ JT03474 RECOMMENDED TOOL ]

Used to test hydraulic systems.

Accumulator Charging Set
[ JT03515 For European Tractors, substitute FKM10474 ]
Used to test and charge accumulators.

Universal Pressure Test Kit
Used to test hydraulic systems.


Lifting Eyebolt (M10)
JT05549
[ Recommended Tool ]

Metric Lifting Eyebolts
JT05550

Nitrogen Charging Hose
Used to charge accumulators.


Wheel and Axle Lift
JT05726
Used to remove and install wheels and axles.

Service Jack
JT07056

[ Sub to JT07056A. ]

Master Hydraulic Kit
JT07115
Used to check hydraulic systems and functions.

Supplemental Master Hydraulic Kit
JT07115SUP

Used to check hydraulic systems and functions.

Two-Valve Manifold
JT07118
[ JT07118 is part of JT07115 Master Hydraulic Kit ]
Used to bleed brakes.
JT07119 Test Hose

Test Hose
JT07119

JT07134 Bleed Pipe

Bleed Pipe
JT07134

Technician’s Electrical Repair Kit
JT07195B

LEGEND:
Kit includes:
• JDG361 Yellow Extractor/Insertion Tool
• JDG362 Blue Extractor/Insertion Tool
• JDG364 Weatherpack Extractor Tool
• JDG785 Blue Extractor/Insertion Tool
Used to repair wire connectors.

Rear Differential Support Stand
JT07211
Used to support tractor during final drive removal.

Rear Axle Support Stand
JT07219
[ RECOMMENDED TOOL—May be fabricated—See Section 99, Group 05 (DFRW94) ]
Used to support 100 and 110 mm final drives during disassembly and assembly.
JT07336 Lift Sling

Lift Sling
JT07336
Used to remove and install engines and components.

Adapter for support stand JT07211 to support the main frame

JD 7200R Series Repair Manual PDF

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John Deere Agriculture

7200R, 7215R, 7230R, 7260R and 7280R

REPAIR TECHNICAL MANUAL

TM110119, May 2013

<- Go to Global Table of contents TM110119-REPAIR TECHNICAL MANUAL

Section 58 - 1300 SERIES MFWD AXLE

<- Go to Global Table of contents TM110119-REPAIR TECHNICAL MANUAL

<- Go to Global Table of contents TM110119-REPAIR TECHNICAL MANUAL

Dealer Predelivery Information Form

<- Go to Global Table of contents TM110119-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

<- Go to Global Table of contents TM110119-REPAIR TECHNICAL MANUAL

Group 10 - General Information ............................................................................................ 36

<- Go to Global Table of contents TM110119-REPAIR TECHNICAL MANUAL

Follow recommended precautions and safe operating practices.

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol.

Follow Safety Instructions

Wear Protective Clothing

<- Go to Section TOC Section 10 page 2 TM110119-REPAIR TECHNICAL MANUAL

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Service Machines Safely

<- Go to Section TOC Section 10 page 3 TM110119-REPAIR TECHNICAL MANUAL

Stay Clear of Rotating Drivelines

Entanglement in rotating driveline can cause serious injury or death.

<- Go to Section TOC Section 10 page 4 TM110119-REPAIR TECHNICAL MANUAL

Handle Fluids Safely—Avoid Fires

Make sure machine is clean of trash, grease, and debris.

Prevent Battery Explosions

<- Go to Section TOC Section 10 page 5 TM110119-REPAIR TECHNICAL MANUAL

Prepare for Emergencies

Be prepared if a ﬁre starts.

Keep a ﬁrst aid kit and ﬁre extinguisher handy.

Remove Paint Before Welding or Heating

<- Go to Section TOC Section 10 page 6 TM110119-REPAIR TECHNICAL MANUAL

Avoid potentially toxic fumes and dust.

Remove paint before heating:

Dispose of paint and solvent properly.

Avoid Heating Near Pressurized Fluid Lines

<- Go to Section TOC Section 10 page 7 TM110119-REPAIR TECHNICAL MANUAL

Handle Starting Fluid Safely

Starting ﬂuid is highly ﬂammable.

Do not incinerate or puncture a starting ﬂuid container.

Avoid Hot Exhaust

<- Go to Section TOC Section 10 page 8 TM110119-REPAIR TECHNICAL MANUAL

<- Go to Section TOC Section 10 page 9 TM110119-REPAIR TECHNICAL MANUAL

Clean Exhaust Filter Safely

<- Go to Section TOC Section 10 page 10 TM110119-REPAIR TECHNICAL MANUAL

<- Go to Section TOC Section 10 page 11 TM110119-REPAIR TECHNICAL MANUAL

people and anything that can melt, burn, or explode.

Avoid contact with these components until cooled to safe temperatures.

If service procedure requires engine to be running:

Only engage power-driven parts required by service procedure

Keep hands, feet, and clothing away from power-driven parts.

<- Go to Section TOC Section 10 page 12 TM110119-REPAIR TECHNICAL MANUAL

Prevent Acid Burns

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

<- Go to Section TOC Section 10 page 13 TM110119-REPAIR TECHNICAL MANUAL

1. Flush your skin with water.

1. Do not induce vomiting.

<- Go to Section TOC Section 10 page 14 TM110119-REPAIR TECHNICAL MANUAL