MT 030 60 F PDF

Service and Replacement
TIGER TRACTOR
Parts Manual
MANUAL MT-030-60-F
Model Numbers:
TC-030-60
The Best Way

To Go
About Your
Business
®
by TAYLOR-DUNN
Shown with optional OPS
WARNING
READ THE OPERATOR’S MANUAL BEFORE OPERATING
THIS VEHICLE.
The operator’s manual contains important information
regarding the safe operation of this vehicle. Starting Serial Number: 210000
Ending Serial Number: See Introduction Chapter
C
My Vehicle information
Vehicle Serial Number: .
Engine Model Number: .
Engine Serial Number: .
Date Purchased: .
Date Delivered: .
Dealer Purchased From: .
Salesman Name: .
Your satisfaction is our #1 goal. If you have questions or concerns

with your vehicle, please contact your sales Representative or
Service Advisor at your local dealership.
Taylor-Dunn has a worldwide dealer and distribution network to
provide replacement parts and service for our vehicles.
Refer to our web site, www.taylor-dunn.com, for a dealer lookup
application.
Originally Published 7/30/2018

Revision C, 9/17/2018, contents subject to change without notice
Taylor-Dunn® Mfg.
2114 W. Ball Rd.
Anaheim, CA 92804
(800)-688-8680
(714) 956-4040
(FAX) (714) 956-0504
Visit our Web site: www.taylor-dunn.com

Taylor-Dunn Contact information
Service, Parts, Sales:
Taylor-Dunn has a network of dealers distributed around the globe to support
our vehicles. Information regarding vehicle sales, replacement parts, or service
should be obtained through your local dealer. A dealer locator can be found on
the Taylor-Dunn website at www.taylor-dunn.com.
If you do not have access to the internet, you can call the factory direct at:
01 (714) 956-4040
Feedback regarding this or any Taylor-Dunn vehicle manual can be sent to:
Taylor-Dunn Manufacturing
Attn: Tech Writer
2114 West Ball Road
Anaheim, CA 92804
The Taylor-Dunn® Corporation:
Leading Provider of Commercial & Industrial Vehicles since 1949
Taylor-Dunn Manufacturing:
From the day we shipped our first vehicle in 1949, we have pursued a singular goal: to build tough, rugged, dependable vehicles to help
our customers move personnel, equipment, and materials. It’s that simple. For over sixty years, our standard and custom vehicles - Burden
Carriers, Personnel Carriers, Stock Chasers, Electric Carts, Tow Tractors & more - have been the leading solution for customers in a
broad range of industrial, commercial, and ground-support markets.
Decades of experience are an invaluable asset, and it is an asset we cherish and protect. Our guiding principle is to provide application-
specific solutions, which are reliable, efficient, and economical.
Our domestic and international network of quality Taylor-Dunn Dealers and Parts & Service Support keeps our customers moving.
Tiger Tractor:
Tiger manufacturing has become a leading manufacturer of internal combustion engine industrial tractors and ground support equipment.
With tractor capacities ranging from 3,000 - 12,000 pounds drawbar pull, they are ideal for industrial applications as well as aircraft
ground support. As with all Taylor-Dunn vehicles; quality, service, support and reliability are built into all Tiger Tractor products.
Shown below is just a small sample of what Taylor-Dunn has to offer to keep your business moving:
Note: Each section title page contains Master Table of Contents
a section table of contents Introduction.......................................................7
Service/Maintenance Guidelines....................13
Special Tool List...............................................17
Preventative Maintenance...............................19
Lubrication........................................................23
Storing/Returning to Service...........................27
Front Axle..........................................................29
Drive Axle..........................................................35
Steering.............................................................45
Brakes...............................................................53
Engine................................................................61
Transmission....................................................63
Tires/Wheels.....................................................109
Battery...............................................................113
Suspension.......................................................117
Wiring and Hydraulic Diagrams......................121
Hardware Information......................................129
Replacement Parts...........................................135
Optional Equipment.........................................189
Introduction
Table of Contents
Introduction
About this manual............................................8
Who Should Read This Manual.......................8
Replacement Parts...........................................8
How To Use This Manual.................................8
Conventions.............................................................9
Signal Words and Their Definitions:.........................9
Responsibilities........................................................10
How to Identify Your Vehicle...........................11
Web Site Registration......................................11
WARNING
This section is one section of a complete service
manual. Before starting any procedure, read all
warnings and instructions that are located in the
Service Guidelines chapter.
Introduction
TC-030-60
ABOUT THIS MANUAL HOW TO USE THIS MANUAL
The purchase of this vehicle shows a belief in This manual is organized into three main sections:
high quality products manufactured in the USA.
Taylor-Dunn®, a leading manufacturer of electric burden
Introduction
and personnel carriers since 1949, wants to be sure This section describes how to use this service manual
this vehicle provides years of reliable service. Please and how to identify your vehicle.
continue to read this manual and enjoy this high quality
Taylor-Dunn® vehicle.
Maintenance, Service, and Repair
This section gives specific information on the servicing
This manual is to serve as a guide for the service,
of the vehicle and a schedule for maintenance checks.
repair, and operation of Taylor-Dunn® vehicles and is
not intended as a training guide. Taylor-Dunn® has made This manual is for mechanical repairs only and does
every effort to include as much information as possible not include electrical diagnosis procedures. Electrical
about the operation and maintenance of this vehicle. diagnosis procedures are included in a separate manual.
Before servicing, operating, training or performing Replacement Parts
maintenance on this or any other Taylor-Dunn® vehicle,
This section provides an illustrated view of various
read the appropriate Taylor-Dunn® manual.
assemblies. The illustrations are accompanied by tables
Each Taylor-Dunn® manual references the applicable identifying the parts.
models and serial numbers on the front cover.
Please, be aware of all cautions, warnings, instructions,
and notes contained in this manual.
WHO SHOULD READ THIS MANUAL

This manual is intended for use by anyone who is going
to operate, own, perform maintenance on, service, or
order parts for this Taylor-Dunn® vehicle. Each person
shall be familiar with the parts of this manual that apply
to their use of this vehicle.
REPLACEMENT PARTS
To maintain peak performance, only use original Taylor-
Dunn replacement parts intended for use on your vehicle.
Taylor-Dunn components are designed and tested for
use on specific Taylor-Dunn model vehicles. Only use
the correct Taylor-Dunn replacement components for
your Taylor-Dunn vehicle.
Electrical components not tested by Taylor-Dunn (or
intended for use on other Taylor-Dunn vehicles) may
have unanticipated interaction and/or interference with
the vehicles control system resulting in unsafe operation
or damage to the electrical system.
Mechanical components not tested by Taylor-Dunn (or
from other model Taylor-Dunn vehicles) may have an
undesirable affect on the operation of the vehicle, result
in additional frame stress, or stress other components
resulting in premature failure or an unsafe condition.
Due to the unknown properties of non-Taylor-Dunn tested
components or from components not originally equipped
on the vehicle, we cannot approve their use in a Taylor-
Dunn vehicle.
Page-8 MT-030-60-F
Introduction
TC-030-60
Conventions
Symbols and/or words used to define Dangers, Warnings, Cautions, and Notices are found throughout this manual.
The “Words” in this context will be referred to as “Signal words.” The words defined here as “signal words” may be
used elsewhere in the text of this document without being a signal word. When used as a signal word, the signal
word will be enclosed in a solid rectangle with white background (example below).
Signal Words and Their Definitions:
DANGER: This signal word will be accompanied by the safety alert symbol (see below). “DANGER” will indicate
a hazard that, if not avoided, WILL result in death or serious bodily injury to yourself, the operator or
passengers of the vehicle, or people in the immediate area of the vehicle.
WARNING: This signal word will be accompanied by the safety alert symbol (see below). “WARNING” will indicate
a hazard that, if not avoided, may result in death or serious bodily injury to yourself, the operator or
passengers of the vehicle, or people in the immediate area of the vehicle.
CAUTION: This signal word will be accompanied by the safety alert symbol (see below). “CAUTION” will indicate a
hazard that, if not avoided, may result in minor or moderate injury to yourself, the operator or passengers
of the vehicle, or people in the immediate area of the vehicle.
NOTICE: This signal word will not be accompanied by the safety alert symbol. “NOTICE” will indicate a condition
that if not avoided may result in property damage. “Property” is defined as the vehicle, components in
the vehicle and/or the surrounding area such as buildings, other vehicles, etc.
Safety Messages
Important information notifying you of any conditions that WARNING
may result in hazards to yourself, persons nearby, and/
or hazards to the vehicle will be presented in a text box This is an example of a safety alert message. This
with a black border and may include a signal word (see message will contain information about a hazard and/
above). To the right is an example of a safety message. or instructions on avoiding a hazard. The actual size
and location of this warning box may vary.
The safety message may include additional warning
icons representing the type of hazard. The following
is a list of these icons and what they represent. These
icons may also be included on the various warning and
information decals applied to the vehicle.
Some of the decals applied to the
vehicle will have icons representing their
function. The icons and their definitions
Safety alert symbol (see are listed below:
above).
Read the operators manual.
Represents a high voltage
hazard. Read the maintenance manual.
Represents an explosion
Keep arms and legs inside the
hazard.
vehicle.
Represents a corrosive Parking brake ON.

chemical hazard.
Parking brake OFF.
Represents a fire hazard.
Do not get wet.
Represents a poisonous
chemical hazard. Do not spray wash.
MT-030-60-F Page-9
Introduction
TC-030-60
Responsibilities
Of the Owner Of the Service Personnel
The owner of this or any Taylor-Dunn vehicle is The service personnel are responsible for the service
responsible for the overall maintenance and repairs and maintenance of the vehicle. At no time shall a
of the vehicle, as well as the training of operators. service person allow any untrained personnel to service
The owner is also responsible for operator training per or repair this or any Taylor-Dunn® vehicle. For the
the following federal regulations: purposes of training, a qualified service person may
• ANSI/ITSDF 56.8-2006 Personnel and Burden oversee the repairs or services being made to a vehicle
Carriers: Part II, Paragraph 6.2a. by an individual in training. At no time shall an untrained
• ANSI/ITSDF 56.9 – 2007 Safety Standard for individual be allowed to service or repair a vehicle without
Operator Controlled Industrial Tow Tractors: Part supervision. This manual is not a training guide.
II, paragraph 4.11. Personnel performing service and repair shall have
• Code of Federal Regulations (CFR) Title 29, knowledge of:
Subtitle B, Chapter Xvii OSHA, Part 1910.178 • Basic standard automotive repair procedures
Powered Industrial Trucks (2011): 1910.178, • Basic DC electrical theory
Section (l). • Use of digital and analog multi-meters
Per OSHA Regulation, 29 CFR 1910.178 Powered • Lead acid batteries
Industrial Truck Operator Training, the owner must Personnel performing maintenance shall have basic
keep a record of conducted training and maintenance knowledge of standard automotive maintenance
performed on the vehicle. procedures and lead acid batteries.
Of the Passengers
The passengers are responsible to remain fully
seated, keeping their hands, arms, and legs inside WARNING
the vehicle at all times. Each passenger shall be
fully aware of the vehicle’s operation. All forms of
The only personnel authorized to repair, modify, or
recklessness are Of the Operator
adjust any part of this or any Taylor-Dunn vehicle is
A vehicle shall not be operated until the operator has a factory authorized service technician. Repairs made
successfully completed an operator training course by unauthorized personnel may result in damage to
provided by the owner of the vehicle. the vehicles systems which could lead to an unsafe
condition resulting in severe bodily injury and/or
The operator is responsible to be sure that the vehicle property damage. Unauthorized repairs may also
is operated only on authorized roads, highways, and void the vehicles warranty.
installations.
The operator is responsible to confirm that all
passengers are properly seated and properly using
the available restraints. WARNING
The operator is responsible for the safe operation of
the vehicle, pre-operational and operational checks To maintain peak performance, always use original
on the vehicle, and the reporting of any problems to Taylor-Dunn replacement parts intended for use
service and repair personnel. on your vehicle. Taylor-Dunn components are
designed and tested for use on specific Taylor-Dunn
to be avoided. Do not engage in horseplay. model vehicles. Only use the correct Taylor-Dunn
replacement components for your Taylor-Dunn
vehicle.
Do not modify your vehicle:
Modifications to this vehicle may have an undesirable
affect on the operation of the vehicle, result in
additional frame stress, or stress other components
resulting in premature failure or an unsafe condition
and may lead to an accident resulting in serious injury
or death.
Page-10 MT-030-60-F
Introduction
TC-030-60
HOW TO IDENTIFY YOUR VEHICLE
This manual is valid only for the serial numbers listed on the front cover. If the ending serial number is blank, then
this manual was for current production vehicles when printed. If you did not receive this manual with the vehicle,
you should confirm this manual is valid for your serial number at the Taylor-Dunn web site.
The locations of the model and serial numbers are shown in the illustrations below:
WEB SITE REGISTRATION

Registering on the Taylor-Dunn web site will give you access to a wealth of information about your vehicle and the
entire Taylor-Dunn line of vehicles. Your contact information will remain confidential and will not be shared outside
of the Taylor-Dunn corporation.
Once registered on the Taylor-Dunn web site, you will have access to:
• Additional Taylor-Dunn product information.
• Worldwide Taylor-Dunn dealer contacts
• Vehicle Service, Maintenance, Operator, Troubleshooting, and Parts manuals.
• Replacement part number lookup utility
www.taylor-dunn.com
MT-030-60-F Page-11
Notes:
Introduction
TC-030-60
Page-12 MT-030-60-F
Service/Maintenance
Guidelines
Table of Contents
Service/Maintenance Guidelines
READ ME FIRST-Maintenance Guidelines and
General instructions..................................14
Vehicle Modifications.......................................15
Using Non-OEM Replacement Components:...........15
TC-030-60
READ ME FIRST-MAINTENANCE GUIDELINES AND GENERAL
INSTRUCTIONS
WARNING
Read and follow all of the guidelines listed below.
Failure to follow these guidelines may result in severe
bodily injury and/or property damage.
• Read the operator’s manual before operating this vehicle.

• Avoid fire hazards and have fire protection equipment present in the work area.
• Conduct vehicle performance checks in an authorized area where safe clearance exists.
• Ventilate the work area properly.
• Regularly inspect and maintain the following systems in a safe working condition: brakes, steering
mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and
safety devices.
• Inspect and maintain battery limit switches, protective devices, electrical conductors, and connections in
conformance with Taylor-Dunn’s® recommended procedures.
• Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts.
• Do not use an open flame to check level or leakage of battery electrolyte.
• Do not use open pans of fuel or flammable fluids for cleaning parts.
• Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle.
WARNING WARNING
The only personnel authorized to repair, modify, or The vehicle may operate at any time while performing
adjust any part of this or any Taylor-Dunn vehicle is control system test procedures.
a factory authorized service technician. Repairs made
by unauthorized personnel may result in damage to All tests must be performed with the drive wheels
or improper operation of the vehicles systems which off of the ground and the vehicle supported with
could lead to an unsafe condition resulting in severe jack stands.
bodily injury and/or property damage. Testing with drive wheels on the ground may result in
Unauthorized repairs may also void the vehicles vehicle movement causing severe bodily injury and/
warranty. or property damage.
WARNING WARNING
BEFORE STARTING ANY REPAIRS When lifting the vehicle, always use a hoist with
lifting strap, or a jack of adequate capacity. Use jack
• Turn the ignition switch OFF. stands to support the vehicle before starting any
repairs. Failure to use lifting and support devices of
• Place the transmission shift lever in Park or
rated load capacity may result in severe bodily injury.
Neutral.
• Set the park brake.
• Place blocks under the front or rear wheels to
WARNING
prevent vehicle movement. DO NOT remove or service any component in the
pressurized hydraulic system before confirming that
• If working on any electrical system component or all pressure has been relieved.
removing the dash then disconnect the negative
cable from the battery. Failure to confirm pressure has been relieved may
result in high pressure fluid jets escaping that may
penetrate skin causing severe personal injury.
WARNING
Periodic maintenance and service must be performed DANGER
on this vehicle. Failure to complete these scheduled Internal combustion engines give off various fumes
maintenance and service procedures can result in and gases while running, including carbon monoxide.
severe bodily injury and/or property damage. It is Do not start or run the engine in a closed or poorly
the owner and/or operators responsibility to ensure ventilated building where the exhaust gases can
that proper service and maintenance is performed on accumulate. Breathing these gases may result severe
the vehicle, described in this manual. personal injury or death.
Page 14 MT-030-60-F
TC-030-60
VEHICLE MODIFICATIONS Using Non-OEM Replacement Components:
Taylor-Dunn vehicles are designed and manufactured To maintain peak performance, always use original
in accordance with ANSI/ITSDF and OSHA regulations. Taylor-Dunn replacement parts intended for use on your
Per ANSI/ITSDF and OHSA, modifications to the vehicle vehicle.
must be approved by the manufacturer. Listed below are Taylor-Dunn components are designed and tested for
the specific regulations: use on specific Taylor-Dunn model vehicles. Only use
the correct Taylor-Dunn replacement components for
ANSI/ITSDF 56.8-2006 Personnel and your Taylor-Dunn vehicle.
Burden Carriers:
Electrical Components:
Paragraph 8.2q: Electrical components not tested by Taylor-Dunn (or intended
Modifications and additions which affect capacity and safe for use on other Taylor-Dunn vehicles) may have unanticipated
machine operation shall not be performed by the customer or interaction and/or interference with the vehicles control system
user without manufacture’s prior written authorization; where resulting in unsafe operation or damage to the electrical system.
authorized modifications have been made, the user shall ensure
that capacity, operation, warning, and maintenance instructions Mechanical Components:
plates, tags, or decals are changed accordingly. Mechanical components not tested by Taylor-Dunn (or from
other model Taylor-Dunn vehicles) may have an undesirable
Paragraph 8.2r: affect on the operation of the vehicle, result in additional frame
Care shall be taken to ensure that all replacement parts are stress, or stress other components resulting in premature failure
interchangeable with the original parts and of a quality at least or an unsafe condition.
equal to that provided in the original equipment. Due to the unknown properties of non-Taylor-Dunn tested
components or from components not originally equipped on the
ANSI/ITSDF 56.9 – 2007 Safety Standard for vehicle, we cannot approve their use in a Taylor-Dunn vehicle.
Operator Controlled Industrial Tow Tractors:
Paragraph 6.2.14:
Modifications and additions which affect capacity and safe tow
tractor operation shall not be performed without manufacture’s
prior written approval. Capacity, operation, and maintenance
instructions plates, tags, or decals are changed accordingly.
Code of Federal Regulations (CFR) Title 29,

Subtitle B, Chapter Xvii OSHA, Part 1910.178
Powered Industrial Trucks (2011)
1910.178(a)(4)
Modifications and additions which affect capacity and safe
operation shall not be performed by the customer or user without
manufacturers prior written approval. Capacity, operation, and
maintenance instruction plates, tags, or decals shall be changed
accordingly.
1910.178(q)(6)
Industrial trucks shall not be altered so that the relative positions
of the various parts are different from what they were when
originally received from the manufacturer, nor shall they be
altered either by the addition of extra parts not provided by
the manufacturer or by the elimination of any parts, except
as provided in paragraph (q)(12) of this section. Additional
counterweighting of fork trucks shall not be done unless
approved by the truck manufacturer.
MT-030-60-F Page 15
Notes:
TC-030-60
Page 16 MT-030-60-F
Special Tool List
TOOL LIST
The tools shown here are generic for servicing Tiger Tractors. Not all tools will be required
for servicing your vehicle.
Part Number Description

96-500-59 LPG fuel system test kit
62-027-53 Ford MSG423 and DSG425 engine test lead and
software.
62-027-52 GM 3.0 & 4.2 engine test lead and software.
77-200-00 Battery hydrometer
77-201-00 Battery filler
Tool List
Notes:
TC-030-60
Page 18 MT-030-60-F
Preventative Maintenance
Table of Contents
Preventative Maintenance
Daily Visual Inspection....................................20
Pre-Operation Inspection.................................20
Maintenance Schedule.....................................20
Maintenance Guidelines for Severe Duty
Applications..............................................................20
First 15 hours of Operation.......................................21
Every Week..............................................................21
Every Month or 150 hours........................................21
Every 3 Months or 500 hours...................................21
Every 6 Months or 1,000 hours)...............................21
Every Year or 2,000 hours.......................................21
Every 2 Years or 4,000 hours...................................21
WARNING
PM Schedule
TC-030-60
DAILY VISUAL INSPECTION PRE-OPERATION INSPECTION
WARNING WARNING
This section is one section of a complete service This section is one section of a complete service
manual. Before starting any procedure, read all manual. Before starting any procedure, read all
warnings and instructions that are located in the warnings and instructions that are located in the
Service Guidelines chapter. Service Guidelines chapter.
The following items shall be inspected once every day The following items shall be inspected every time before
before the vehicle is put into service: the vehicle is driven:
External frame damage (body). Rear and side view mirror adjustments.
Operation of all lights and warning alarms. Steering operation.
Proper operation of all instrument panel gauges Brake operation (service and park brake).
and warning lights. Tire pressure (visual inspection only).
Smooth and proper operation of seat belts (if Proper operation of trailer hitch.
equipped).
Engine oil level. MAINTENANCE SCHEDULE
Engine coolant level.
Fan belts. A PM Check List is available and was included on the
Air cleaner service indicator (optional). documentation CD that was provided with your vehicle.
Drain fuel system water separator (diesel engines). The document number is PM-0007.
Transmission oil level.
Maintenance Guidelines for Severe Duty
Hydraulic system fluid level.
Brake fluid level. Applications
Inspect for leaking fluids, grease, gasoline, or LPG This maintenance schedule is based on the average
fuel. typical application. If the vehicle is operated under
Tire tread or sidewall damage. “severe conditions”, service procedures shall be
Proper operation of transmission shift lever and conducted more frequently than specified. The frequency
starter interlocks. of service under severe conditions is determined by the
Proper operation of adjustable seat mechanisms use of the vehicle. The owner/operator must evaluate
(if equipped). the operating environment to determine the increase in
Smooth and proper operation of all controls such maintenance frequency.
as but not limited to: In addition, the entire vehicle shall be inspected monthly
Throttle pedal for signs of damage.
Brake pedal
Parking brake The following list is meant as a guide and is not all-
Steering inclusive of a “severe duty” application.
Horn • Operation in excess of 150 hours per month.
Etc. • Extreme temperature.
Proper operation of all locking mechanisms such • Bumpy, dusty, or ill maintained roads.
as but not limited to: • Excessively wet areas.
Hood latches • Corrosive or contaminated areas.
Cargo box’s • Frequent loading of the vehicle at/near capacity.
Cab doors
Etc.
Proper operation of all interlocking switches such
as but not limited to:
Ignition switch
Seat or foot interlock switch
Brake interlock switch.
Etc.
Page 20 MT-030-60-F
PM Schedule
TC-030-60
First 15 hours of Operation Every 6 Months or 1,000 hours)
Re-torque wheel nuts. All 3 month items plus the following:
Inspect all hardware for tightness. Inspect all hardware for tightness
Adjust front wheel bearings. Tighten all electrical connections.
Every Week Inspect wiring for cracks, fraying, wear.
Inspect engine cooling and/or heater hoses.
All daily items plus the following:
Inspect steering king pins.
Check all tires tread for debris.
Align the front end.
Every Month or 150 hours
Every Year or 2,000 hours
All weekly items plus the following:
Engine coolant level.
All 6 month items plus the following:
Inspect spark plugs.
Change drive axle oil (first 150 hours only, then
Inspect valve lash (Perkins engine)
1000 hours)
Change hydrostatic fluid and optional filter.
Clean radiator exterior.
Change fuel filters.
Inspect/Adjust front wheel bearings.
Change transmission fluid and filters.
Wash and clean battery terminals
Change rear axle oil.
Check battery fluid level.
Clean and repack front wheel bearings, change
Check all tires air pressure.
seals.
Adjust valve lash (Cummins engine) (first 150 hours
Test radiator cap.
then 2000 hours)
Flush and replace the brake fluid.
Every 3 Months or 500 hours Inspect brakes for wear.
All monthly items plus the following: Test battery and alternator.
Inspect/Adjust fan/accessory belts. Inspect all suspension bushings.
Inspect air filter, replace as required. Inspect the chassis for damage.
Inspect brake fluid level. Rotate tires.
Inspect power steering/hydraulic fluid levels.
Inspect transmission fluid level.
Lubricate chassis.
Every 2 Years or 4,000 hours
Change engine oil. All yearly items plus the following:
Adjust service and park brake. Change engine coolant.
Inspect wheel bearings Inspect/test fuel injectors.
Check interlocks for proper operation. Replace spark plugs and cables..
Re-torque the wheel nuts. Inspect/clean PCV valve.
Inspect and tighten all power electrical connections. Replace fan/accessory belts.
Inspect all hardware for tightness (first 500 hours Inspect water pump for leaks.
then every 1,000 hours). Inspect turbocharger.
Inspect engine mounts
Inspect parking brake.
MT-030-60-F Page 21
Notes:
PM Schedule
TC-030-60
Page 22 MT-030-60-F
Lubrication
Table of Contents
Lubrication
Lubrication and Fluids Chart...........................24
Hazardous Waste Disposal..............................24
Engine Oil.................................................................25
Transmission Fluid Specifications:...........................25
Coolant Specifications..............................................26
Lubrication
TC-030-60
LUBRICATION AND FLUIDS CHART
Assembly Component # Capacity Lubricant
Front Axle:
King Pin, Upper 2 - NLGI Grade 2 lithium multi-purpose grease
King Pin, Lower 2 - NLGI Grade 2 lithium multi-purpose grease
Ball Joint 4 - NLGI Grade 2 lithium multi-purpose grease
Wheel Bearing 4 - NLGI Grade 2 lithium high temp bearing grease
Drive Axle:
Differential gear box 1 8 pints 80W-90 API GL5 Hypoid gear oil
Planetary gear box 2 4 pints 80W-90 API GL5 Hypoid gear oil
Drive Shaft:
Universal joints 2 - NLGI Grade 2 lithium multi-purpose grease
Slip joint 1 - NLGI Grade 2 lithium multi-purpose grease
Brake Fluid:
Master Cylinder 1 DOT 3, Meets or exceeds SAE J1703
Linkages:
Brake pedal pivot 3 - Multi-purpose spray lubricant
Park brake handle 3 - Multi-purpose spray lubricant
Park brake cable 2 - Multi-purpose spray lubricant
Shift lever 3 - Multi-purpose spray lubricant
Power Steering:
Power Steering Pump 1 1/2 - 3/4 gal. Meets or exceeds Ford ESW-M2C128-C
HAZARDOUS WASTE DISPOSAL

This vehicle contains various components and/or fluids that may be classified as hazardous waste.
This includes but is not limited to Lead, Acid, Oil, Grease.
The brake linings originally installed by the factory do not contain asbestos. However, since it is possible that
asbestos brake linings were installed as replacement parts, brake linings should be handled as hazardous
waste.
The requirements for disposal of hazardous waste vary by location. Consult your local regulations regarding
the proper disposal of hazardous waste products.
Page 24 MT-030-60-F
Lubrication
TC-030-60
Engine Oil Transmission Fluid Specifications:
Taylor-Dunn does not recommend the use of oil additives.
The location of the engine oil dipstick will vary depending
NOTICE
Transmission fluid rises with temperature. Do not
on the engine installed in your vehicle.
fill beyond the “Cold Check” band on the dipstick
Before checking engine oil level: Turn engine off and wait when the transmission is below normal operating
10 minutes to allow oil to return to the oil pan. temperature.
Oil level should be between the ADD and FULL marks An overfilled transmission may overheat and/or leak
on the dipstick. fluid leading to transmission damage.
Only add oil if level is BELOW the add mark on the Ford C6
dipstick.
Meets or exceeds Ford specification ESW-M2C33-F
Only use oil displaying the appropriate American
Petroleum Institute (API) Symbol on the container. Allison AT545
Dextron® III (below -13ºF (-25ºC) require preheat
Oil type and capacities before operation)
Capacity Allison 2100RDS
Engine Type API (quart/liter)
Use only TES 295® fluids that are approved Allison
Perkins 1104 CH-4 11/10.4
approved.
Cummins B3.3 CH-4 8/7.5
DO NOT use fluids that do not specifically state
GM 3.0L SJ or SH 4.5/4.25 “Allison approved.” The fluid container should have
GM 4.3L SJ or SH 5/4.75 the Allison TES 295® approval number and/or the
Ford LRG/DSG/ SJ or SH 4.5/4.25 Allison approved logo (shown below).
MSG Refer to the Allison web site for a list of approved fluids:
Ford ESG SJ or SH 6/6 www.allisontransmission.com
Recommended Viscosity Temperatures below -22ºF (-30ºC) require preheat

before operation)
Engine Temp (°C) Temp (°F) Viscosity
Perkins -40 to 10 -40 to 50 0W20
-40 to 30 -40 to 86 0W30
-40 to 40 -40 to 104 0W40
-30 to 30 -22 to 86 5W30
-30 to 40 -22 to 104 5W40
-20 to 40 -4 to 104 10W30
-10 to 50 14 to 122 15W40
Cummins -40 to 20 -40 to 68 5W30
-25 o 20 -13 to 68 10W30
-10 to 50 14 to 122 15W40
All Temp’s 5W20
Ford LRG/ESG All Temp’s 5W30
Ford MSG.DSG All Temp’s 5W20
GM (KEM and -18 to 50 0 to 122 10W30
PSI) -25 to 0 -13 to 32 5W30
MT-030-60-F Page 25
Lubrication
TC-030-60
Coolant Specifications
WARNING
Antifreeze (coolant) contains mono ethylene glycol
and other constituents which are toxic if taken
internally and can be absorbed in toxic amounts
on repeated or prolonged skin contact. Persons
using antifreeze are recommended to adhere to the
following precautions:
• Antifreeze must never be taken internally. If
antifreeze is swallowed accidentally, medical
advice should be sought immediately.
• Precautions should be taken to avoid skin contact
with antifreeze. In the event of accidental spillage
onto the skin, antifreeze should be washed off as
soon as practicable. If clothing is splashed with
antifreeze, it should be removed and washed
before being worn again, to avoid prolonged skin
contact.
• For regular and frequent handling of antifreeze,
protective clothing (plastic or rubber gloves,
boots and impervious overalls or aprons) must
be used to minimize skin contact.
WARNING
DO NOT remove the radiator cap until the engine
has cooled. The cooling system in hot engines is
pressurized. Hot fluids and steam may be vented at
high rates causing severe burns and/or other severe
injuries.
NOTICE
Allow engine to cool before adding coolant. Adding
coolant to a hot engine may damage the engine do
to temperature differential.
Do not use hard water or water that has been
conditioned using salt or sea water.
Coolant specifications: 1:1 mix of water with coolant that Water Quality
meets ASTM D4985 specifications. Elements Maximum
Be sure to use good quality water. Excessive levels of Level
Calcium/Magnesium, chloride, or sulfur can lead to scaling C a l c i u m / M a g n e s i u m 170 ppm
problems or cooling system corrosion. carbonates(CaCO3 + MgCO3)
It is not necessary to remove the radiator cap to inspect the Chloride (Cl) 40 ppm
coolant level or add coolant to the system. Coolant level can Sulfur (SO4) 100 ppm
be inspected at the coolant recovery tank. Total solids 340 mg.L
There are two level lines on the coolant recovery tank. The Acidity pH of 5.5 to
coolant level should be at the upper line when the engine is 9.0
hot or the level should be at the lower line when the engine
is cool.
Page 26 MT-030-60-F
Storing/Returning to
Service
Table of Contents
Storing/Returning to Service
Storing and Returning to Service..................28
Chassis.....................................................................28
Engine......................................................................28
Transmission............................................................28
Battery......................................................................28
Returning to Service.................................................28
WARNING
Storing
TC-030-60
STORING AND RETURNING TO SERVICE
WARNING
Transmission
manual. Before starting any procedure, read all Short term (less than 1 year) : Check and fill
warnings and instructions that are located in the transmission fluid to proper level.
Long Term: Allison 2100RDS and AT545: Refer to
Allison service manual for additional long term storage
Information regarding service and preparation items for
procedures.
storing or returning to service can be found in the vehicle
service manual Battery
Preparation of storage or returning a vehicle to service
shall only be performed by qualified technician.
Clean the battery, then
fill and charge before
NOTICE
If your vehicle will not be operated for several weeks putting the vehicle Storing batteries that are
then use the following guidelines to ensure long life of in storage. Do not discharged or allowing
your vehicle. store batteries in a s t o r e d b a t t e r i e s t o
discharged condition. discharge while in storage
Chassis I f s t o r e d i n s u b - cause sulphation of the
Lube all grease fittings. freezing climate then battery plates. This will
result in reduced capacity
the battery should be
Clean, dry, and check all exposed electrical and premature failure of the
removed and stored batteries.
connections. in a temperature
Inflate the tires to proper pressure (if applicable). controlled environment.
For extended storage, the vehicle should be elevated If stored for a prolonged period, the battery should be
so that the tires are not touching the ground. charged as follows:
Engine
Storage Temperature Charging Interval
Thoroughly clean exterior of engine.
(F/C) (months)
Check and fill engine oil to proper level.
Check and fill cooling system to proper level. Over 60/15 1
If storage will be over one month:
Drain and refill engine oil with an oil preservative. Between 40/4 and 60/15 2
Remove the air intake and seal with waterproof
tape. Below 40/4 6
Disconnect the exhaust from the head pipe and seal
with waterproof tape. Returning to Service
If equipped with turbocharger, disconnect both
intake and exhaust from the turbo, spray with Check the battery state of charge and charge if
anti-corrosive spray approved for your engine required.
and seal with waterproof tape. Perform all applicable maintenance checks in the
If stored in a cold climate, remove alternator/ Maintenance Schedule.
accessory drive belts and stored in a temperature
Remove any blocks from the vehicle and/or place the
controlled environment.
vehicle down on to the ground.
Drain fuel system and refill with preservative fuel.
Seal the fuel tank vent with waterproof tape. Test drive before putting into normal service.
Drain and refill engine coolant.
Page 28 MT-030-60-F
Front Axle
Table of Contents
Front Axle
Inspect the Front Wheel Bearings and King
Pin...............................................................30 WARNING
Adjust Front Wheel Bearings
(new bearings)............................................30 This section is one section of a complete
service manual. Before starting any
Adjust Front Wheel Bearings
procedure, read all warnings and
(used bearings)..........................................31 instructions that are located in the
Align Front Wheels...........................................31 Service Guidelines chapter.
Front Hub, Steering Knuckle, King Pin..........32
Disassembly.............................................................32
Reassembly..............................................................32
Replace Front Wheel Bearings.......................33
Rebuild the Steering Cylinder.........................33
Replace Ball Joint............................................33
Replace the Steering Cylinder........................33
Hardware Torque..............................................33
Front Axle
TC-030-60
INSPECT THE FRONT WHEEL ADJUST FRONT WHEEL
BEARINGS AND KING PIN BEARINGS (NEW BEARINGS)
WARNING WARNING
DO NOT use this procedure to set used wheel bearings.

1: Raise the front of the Refer to Adjust Front Wheel Bearing for Used Bearings
vehicle and support adjustment procedure.
with jack stands.
Setting the proper wheel bearing preload is the
2: Grab the top and
combination of tightening the two wheel bearing nuts.
bottom of the tire/
wheel assembly. Feel Use tool #96-500-47 to adjust bearings.
for any movement or 1: Raise the front of the vehicle and support with
play while pulling and jack stands.
pushing on the top 2: Remove the hub cap cover bolts, hub cap, and
and bottom of the tire. gasket.
Any movement or play 3: Push on the inner brake pad to force the brake
is an indication of loose wheel bearings or king pistons into the brake caliper so that the brake
pin. pads are not contacting the rotor.
3: Spin the wheel and listen for any grinding noise. 4: Remove the outer bearing nut and keyed washer.
Any grinding noise may be an indication of worn 5: While rotating the hub, tighten the inner bearing
or damaged wheel bearings. nut to 30 foot pounds (40 Newton meters).
4: Lower the vehicle. 6: Loosen the nut and then while rotating the hub
5: Remove the blocks from behind the wheels and tighten the inner bearing nut to 10 foot pounds
test drive the vehicle. (13 Newton meters).
7: Install the keyed washer and outer bearing
nut then tighten the nut to torque listed in the
Hardware Torque table at the end of this section.
8: Bend the keyed washer up against a flat on the
outer nut.
9: Install the hub cap. Use a new gasket.
10: Lower the vehicle.
11: Remove the blocks from behind the wheels and
test drive the vehicle.
Page 30 MT-030-60-F
Front Axle
TC-030-60
ADJUST FRONT WHEEL ALIGN FRONT WHEELS
BEARINGS (USED BEARINGS)
WARNING
WARNING This section is one section of a complete service
This section is one section of a complete service warnings and instructions that are located in the
manual. Before starting any procedure, read all Service Guidelines chapter.
Alignment of the front wheels consists of setting the
DO NOT use this procedure to set new wheel bearings. Toe In only. Camber and Castor are fixed and cannot
Refer to Adjust Front Wheel Bearing for new bearing be adjusted.
adjustment procedure. The Toe In specification is 0 to +0.25 inch (6.3 mm)
Setting the proper wheel bearing preload is the
combination of tightening the two wheel bearing nuts. 1: After the toe is set, make sure ball joint hardware
Use tool #96-500-47 to adjust bearings. is tightened per torque listed in the Hardware
1: Raise the front of the vehicle and support with Torque table at the end of this section.
jack stands. 2: Lower the vehicle.
2: Remove the hub cap cover bolts, hub cap, and 3: Remove the blocks from behind the wheels and
gasket. test drive the vehicle.
3: Push on the inner brake pad to force the brake
pistons into the brake caliper so that the brake
pads are not contacting the rotor.
4: Remove the outer bearing nut and keyed washer.
5: While rotating the hub, tighten the inner bearing
nut to 30 foot pounds (40 Newton meters).
6: Loosen the nut and then while rotating the hub
hand tighten the inner nut until it is snug against
the bearing.
7: Now, rotate the nut counterclockwise 30 to 45
degrees. The tool is marked with notches at 30
and 45 degrees.
8: Install the keyed washer and outer bearing
nut then tighten the nut to torque listed in the
9: Bend the keyed washer up against a flat on the
outer nut.
10: Install the hub cap. Use a new gasket.
11: Lower the vehicle, remove the blocks from behind
the wheels and test drive the vehicle.
MT-030-60-F Page 31
Front Axle
TC-030-60
FRONT HUB, STEERING KNUCKLE, Reassembly

1: Thoroughly clean and inspect all parts.
KING PIN 2: If the hub seal was removed it must be replaced.
WARNING 3:
4:
Use a new hub cap gasket.
Pack the king pin thrust bearing and wheel
This section is one section of a complete service bearings with grease before reassembly.
manual. Before starting any procedure, read all 5: Always use new cotter pins.
Service Guidelines chapter. WARNING
Failure to correctly broach or ream bronze bushings
It is recommended that if a wearable component is may result in steering difficulty and loss of control
replaced on one side of a vehicle, the same components of the vehicle causing severe bodily injury and /or
should be replaced on the other side of the vehicle. property damage.
Disassembly 6: If installing new king pin bushings, make sure

1: Raise the front of the vehicle and support with the hole in the bushings lines up with the grease
jack stands. fittings in the steering knuckle. The new bushings
2: Remove the front wheels. must be reamed or broached to 1.1095 - 1.1105
3: If equipped with front brakes, remove the brake inches (28.181 - 28.207 mm)
caliper assembly. Refer to Brake section for 7: Reassemble in reverse order of disassembly.
instructions. 8: Tighten the ball joint nuts per torque listed in the
4: Remove the hub cap cover bolts (1), hub cap (3), Hardware Torque table at the end of this section.
and gasket (4). Note: The gasket will have to be 9: Tighten the steering arm nuts per torque listed
replaced. in the Hardware Torque table at the end of this
5: Remove the bearing adjustor nuts (7), washer section.
(5), keyed washer (6), and the outer bearing (8). 10: Refer to Adjust Front Wheel Bearings for wheel
6: Remove the hub assembly (9, 10, 11, 8, 12). bearing adjustment procedure.
7: If required, remove the rotor (not shown) by 11: Lubricate the king pin bushings after assembly is
pressing out the wheel studs. complete.
8: If required, remove the seal (12) and inner
bearing (8). Note: If the seal is removed, it must
be replaced.
9: Remove the ball joint(s) from the steering arm
(14). Note: The cotter pins (15) must be replaced.
10: Remove the steering arm nut (17) and remove
the steering arm from the steering knuckle (13).
Note: The cotter pin (19) must be replaced.
Note: The king pin cap (20c) is part of the king
pin kit and is not available as a separate
component. Do not remove the cap unless
the king pins are to be replaced.
11: Drill a 3/16 inch hole in the center of the
king pin cap (20c). Insert a #14 x 2 inch long
sheet metal screw into the hole and screw in
until the cap is removed.
12: Using a drift punch, tap out the tapered king
pin retaining pin (20h).
13: Using a soft metal or wooden rod, insert
the rod through the bottom of the steering
knuckle and tap out the king pin (20i) then
remove the steering knuckle from the axle.
14: Press the upper and lower king pin bushings
(20g, 20b) out of the steering knuckle.
Page 32 MT-030-60-F
Front Axle
TC-030-60
REPLACE FRONT WHEEL REBUILD THE STEERING
BEARINGS CYLINDER
WARNING Refer to Steering Component Service section

manual. Before starting any procedure, read all REPLACE BALL JOINT
Service Guidelines chapter. Refer to Steering Component Service section
It is recommended that if a wearable component is

replaced on one side of a vehicle, the same components REPLACE THE STEERING
should be replaced on the other side of the vehicle.
CYLINDER
This procedure assumes that the front hub has been
removed from the vehicle. Refer to the front hub Refer to Steering Component Service section
assembly removal instructions for details and warnings
regarding the removal and installation procedure.
1: Thoroughly clean all grease from the inside of the
hub.
2: Use a race puller or press to remove the inner
HARDWARE TORQUE
CAUTION If hardware is not listed here, refer to standard torque
Make sure the inner and outer bearing races are values in the appendix.
pressed properly into the hub. Improperly pressed Description Foot Pounds Newton Meters
races will result in premature failure of the bearings. Outer Wheel Bearing Nut 50 67
and outer races. Ball Joint Clamp 28-32 38-43
3: Install new races. Ball Joint Nuts 45-55 61-74
4: Pack inner bearing with appropriate grease and Hub Cap Bolts 20 27.1
install in the hub along with a new grease seal. Steering Arm Nuts Tighten to 160 Foot Pounds (217
5: Apply a thin film of grease to the seal lip. N-M) and then to next slot to insert
6: Slide the hub/bearing assembly onto the spindle cotter pin
being careful not to damage the seal lip.
7: Pack outer bearing with appropriate grease and
install in the hub.
8: Reassemble the hub to the steering knuckle
using the inner bearing nut only at this time.
9: Refer to Adjust Front Wheel Bearings (New
Bearings) for procedure to adjust the wheel
bearings.
CAUTION
New front wheel bearing adjustment must be
inspected after the first 24 hours of operation. This
includes new vehicle installations. Failure to inspect
the bearings after the break in period may result in
premature failure of the bearings.
MT-030-60-F Page 33
Front Axle
Notes:
TC-030-60
Page 34 MT-030-60-F
Drive Axle
Table of Contents
Drive Axle
Check Oil Level.................................................36
WARNING
TA-268......................................................................36 This section is one section of a complete
TA-267......................................................................36 service manual. Before starting any
Change Oil.........................................................36 procedure, read all warnings and instructions
TA-268......................................................................36 that are located in the Service Guidelines
TA-267......................................................................36 chapter.
Disassembly.....................................................37
Wheelend, Planetary - TA268 Drive Axle.................37
Main Housing Disassembly......................................38
Nose Reduction Box Disassembly - TA267..............39
Prepare Parts for Assembly............................39
Cleaning...................................................................39
Drying......................................................................39
Inspection.................................................................39
Assembly..........................................................40
Bevel Pinion and Cage Assembly............................40
Differential and Bevel Ring Gear Assembly.............40
Main Housing and Differential and Bevel Ring Gear Assembly...
40
Main Housing and Pinion Cage Assembly...............41
Nose Reduction Box Assembly - TA267...................41
Wheel End, TA-268..................................................42
Wheel End. TA-267..................................................44
Hardware Torque..............................................44
TA-267: Has has Primary Nose

Gear Reduction.
This section covers more than one type of

drive axle. Refer to these pictures for the
type of axle installed in your vehicle.
TA-268: Has Planetary Gear

Wheel End Reduction
Drive Axle
TC-030-60
CHECK OIL LEVEL CHANGE OIL
WARNING WARNING
TA-268 TA-268
1: Park the vehicle on a level surface. 1: Rotate the wheel hubs (see illustration) so that
2: Remove the oil level plug (A) on the axle housing. the fill/level/drain plugs are at the bottom of the
3: The oil level should be very close to the bottom of hub in the drain position.
the level plug hole. 2: Place an oil drain pan underneath the drive axle
4: Reinstall the plug. center section and both wheel hubs.
5: Rotate the wheel hub so that the fill/level/drain 3: Remove the drain plugs from the center section
plug is positioned as shown in the illustration and both wheel hubs.
below. 4: Remove the fill/level plug from the center section.
6: Remove the plug. 5: Allow all oil to drain from the 3 gear boxes.
7: The oil level should be very close to the bottom of 6: Install the drain plug on the center section only.
the plug hole. 7: Rotate both wheel hubs so that the fill/level/drain
8: Reinstall the plug. plugs are at the “level” position as shown in the
illustration.
TA-267 8: Fill all 3 gear cases with oil up to the bottom of
1: Park the vehicle on a level surface.
the level plug holes. Refer to Lubrication section
2: Remove the oil level plugs on the primary and
for oil specification.
secondary reduction gear boxes.
9: Install the 3 level plugs.
3: The oil level should be very close to the bottom of
the level plug hole. TA-267
4: Reinstall the plugs. 1: Place an oil drain pan underneath the drive axle
center section.
2: Remove the drain plugs on the primary gear
box and center section. The primary drain is
on the bottom of the box and not shown in the
illustration.
3: Remove the level plugs on the primary and
secondary reduction gear boxes.
4: Allow all oil to drain from the gear boxes and
reinstall the drain plugs.
5: Fill both gear cases with oil up to the bottom of
the level plug holes. Refer to Lubrication section
for oil specification.
Center Section 6: Install the level plugs.
TA-268 Wheel Hub

Shown in “Level” position
Page 36 MT-030-60-F
Drive Axle
TC-030-60
DISASSEMBLY
WARNING TA-267
Perform the following prior to disassembly.

1: Remove axle from vehicle if required.
2: Clean exterior axle surfaces. Steam clean or
pressure wash the complete axle assembly after TA-268
plugging all breathers and vents. Do not direct full
pressure at any seals (input shaft, wheel hubs or
brakes).
3: Drain oil from nose box, axle housing and wheel
ends.
Wheelend, Planetary - TA268 Drive Axle

1: Match mark the planetary spider and wheel hub 12: Remove the green return spring and black return
prior to disassembly to assure correct alignment spring from their anchor pins.
during reassembly. 13: Grasp the leading brake shoe assembly while
2: Remove 16 planetary spider to wheel hub cap removing the shoe retaining clip. Lift and rotate
screws and washers. the clip until it is disconnected.
3: Install three puller screws in tapped holes of 14: Remove the leading shoe, adjusting lever and
planetary spider. Remove planetary spider adjusting bolt.
assembly. 15: Grasp the trailing brake shoe assembly while
4: Remove snap ring and thrust washer from the removing the two retaining clips. Lift and rotate
ends of the three planetary pinion shafts. Remove the clips until disconnected.
the planetary pinions. 16: If complete wheel cylinder service is required,
5: Remove the planetary pinion shaft setscrews disconnect the hydraulic lines from the cylinder,
from the three pinion shafts. Press each pinion remove the wheel cylinder mounting cap screws
shaft in the direction of the spider mounting and wheel cylinder.
flange to remove.
6: Remove axle shaft retaining snap ring from the
axle shaft. Remove planetary sun gear and axle
shaft.
7: Support the wheel hub assembly, remove
planetary ring gear and wheel bearing adjusting
nut.
8: Remove the outer wheel bearing cone. Remove
the wheel hub and drum assembly. It may be
necessary to manually retract the brake shoes
to remove the hub and drum. If required, insert a
stiff wire through the adjustment slot in the brake
backing plate and push the stamped auto adjust
spring away from the star wheel while using an
adjustment tool to rotate the adjustment bolt star
wheel.
9: For wheel hub disassembly, remove the wheel
hub seal, inner bearing cone, inner bearing cup
and outer bearing cup.
10: If servicing the brakes, unscrew the cap screw
from the auto adjuster pivot.
11: Disconnect the short link and long link from the
auto adjuster pivot. Remove the two links.
MT-030-60-F Page 37
Drive Axle
TC-030-60
Main Housing Disassembly
Both axle ends, brakes, and nose reduction (if equipped) must be removed before proceeding with this section.
1: With nose box, wheel ends, axle shafts and brakes removed; insert a long bar or tube 1 to 1-1/2 inch (25.4
- 38 mm)diameter through the axle differential section and both axle housings. This will prevent dropping of
the differential and bevel ring gear assembly when the case halves are split.
2: Remove the eleven caps crews, washers and locknuts securing the two axle housing halves. Remove the
plain housing half.
3: Remove differential and bevel ring gear assembly. If bearing replacement is required, use a suitable bearing
puller to remove the housing half tapered bearing cups from the housing halves.
4: Match mark the plain differential case half and flanged differential case half to aid alignment at reassembly.
5: Remove the eight differential case cap screws and washers . Separate the plain differential case half from
the flanged differential case half.
6: Remove the two differential side gears, two side gear thrust washers, four differential pinions, four pinion
thrust washers and the differential spider.
7: If replacement of the bevel ring gear is required, remove the twelve cap screws, washers and locknuts
securing the bevel ring gear to the flanged differential case half. Press the bevel ring gear off of the flanged
differential case half using a suitable press.
8: Remove the bevel pinion and cage assembly and pinion cage gasket from the remaining housing half.
9: For bevel pinion gear or bearing replacement, place the bevel pinion and cage assembly in a suitable press
and press the bevel pinion from the pinion cage assembly. The outer bearing cone and pinion bearing
selective spacer will be pressed free along with the pinion cage assembly.
10: Remove the bevel pinion inner roller bearing snap ring. Press the bevel pinion inner roller bearing and inner
tapered bearing cone free from the bevel pinion utilizing a suitable press.
11: Press tapered bearing cups free from the pinion cage utilizing a suitable press.
Page 38 MT-030-60-F
Drive Axle
TC-030-60
Nose Reduction Box Disassembly - TA267 PREPARE PARTS FOR ASSEMBLY
1: Loosen input shaft nut, remove washer and input
flange from then input shaft.
2: Remove input shaft bearing cap screws, lock
WARNING
washers and bearing cap. This section is one section of a complete service
3: Remove snap ring from OD of input shaft manual. Before starting any procedure, read all
outboard bearing. warnings and instructions that are located in the
4: Remove the fifteen reduction box cover to case Service Guidelines chapter.
capscrews, lock washers and nuts. Remove
cover. Cleaning
5: Remove input shaft with outboard bearing • Parts with Rough Finishes — Clean parts with a
and inboard bearing. If bearing replacement is cleaning solvent and brush or hot tank the parts in
required, remove the outboard bearing snap ring a weak alkaline solution. Wash hot tanked parts
and press both bearings off of the input shaft with water to remove the alkaline solution.
6: Straighten the lock tabs on driven gear nut lock. • Parts with Machined or Ground Surfaces — Clean
Remove outer nut, lock and inner nut. parts with a cleaning solvent and brush. Remove
7: Remove driven gear using a gear puller and the remaining gasket material using a gasket scraper,
1/2-13 puller holes located in gear web section. taking care to not damage the machined surfaces.
8: Remove driven gear thrust washer. Do not clean ground or polished parts with water,
9: Remove the six reduction box case to axle steam, alkaline solution, or place in a hot tank.
locknuts and washers.
10: Remove reduction box case. Drying
• Dry all parts after washing using clean rags or
paper towels.
• Corrosion Prevention — Apply a light oil film to all
parts to be reused and reassembled.
Inspection
Inspect all parts carefully before the axle is
reassembled. Replace all damaged parts.
• All Seals/Gaskets — Replace only, do not reuse.
• All Bearings — Inspect all bearings, cups and
cones for pitting or damage. Replace as required.
• All Castings — Inspect for damage or cracking.
Replace as required. Do not weld.
• Drop/Reduction Gear set — Inspect both gears for
pitting or damage. Replace as required.
• Bevel Gear Set — Inspect pinion and ring gear for
pitting or damage. Replace only as a matched set.
• Differential Assembly — Inspect differential case
thrust washers and thrust washer surfaces for
wear or damage. Replace differential case and
thrust washers as matched sets only. Inspect
differential spider and pinion gears for wear or
damage. Replace only in matched sets. Inspect
differential side gears for wear or damage.
Replace only in matched sets.
• Planetary Wheel end — Inspect all gearing for
pitting or damage. Replace as required.
• Axle Shafts — Inspect both axle shafts for spline
wear and evidence of torsional cracking. Mount
shafts between centers and check for a maximum
of 0.010 inch (0.254 mm) shaft runout. Replace if
wear, cracks or excessive runout observed.
MT-030-60-F Page 39
Drive Axle
TC-030-60
ASSEMBLY
Differential and Bevel Ring Gear Assembly
WARNING 1: Press the bevel ring gear firmly against shoulder
of flanged differential case half. Install the twelve
This section is one section of a complete service capscrews, washers and locknuts securing the
manual. Before starting any procedure, read all bevel ring gear to the flanged differential case
warnings and instructions that are located in the half. Tighten the locknuts to the specified amount
Service Guidelines chapter. listed in the Hardware Torque Table at the end of
this section.
Bevel Pinion and Cage Assembly 2: Lubricate the differential pinion gears, pinion
1: Press inner roller bearing firmly against bevel thrust washers, side gears, side gear thrust
pinion shoulder and install inner roller bearing washers, spider, flanged differential case half and
snap ring. plain differential case half using gear lubricant.
2: Press inner tapered bearing cone firmly against 3: Assemble differential components into the
bevel pinion shoulder. flanged differential case half. Install plain
3: Press tapered bearing cups firmly against the differential case half, aligning with mark on
pinion cage shoulders. flanged differential case half. Install 4 differential
4: Lubricate bearing cups and cones with a light case cap screws and washers equally spaced.
machine oil. Loosely tighten the cap screws and check for free
5: Insert bevel pinion with inner tapered bearing rotation of the differential gearing. If rotation OK,
cone in pinion cage. install remaining cap screws and washers and
6: If assembling a TA268; skip to step #9. tighten all cap screws to the specified amount
7: If assembling a TA267; position selective spacer listed in the Hardware Torque Table at the end of
over bevel pinion stem. Press outer tapered this section.
bearing cone firmly against the selective spacer. 4: If differential tapered bearing cones are to be
Rotate pinion bearing cage several revolutions to replaced, press new bearings squarely against
assure good bearing cone to cup contact. differential case halves, seating fully.
8: While the bevel pinion and cage are still
Main Housing and Differential and Bevel
positioned in a hydraulic press, apply a 25,000
(11,339 kg) pound axial load to the bearings. Ring Gear Assembly
Wrap a string around the 4.23 inch (107.4 mm) 1: If the main housing half tapered bearing
outer diameter of the pinion cage. Apply a pound cups were removed from the housing halves,
scale to the string and observe the reading press new tapered bearing cups squarely into
required to rotate the bearing cage. A reading their bores, seating fully against the housing
of 2.5 to 7 pounds (1.1-3.1 kg) is required. If the shoulders.
reading is above 7 pounds (3.1 kg), disassemble 2: Lubricate the tapered bearing cups and cones
bevel pinion and cage and replace the selective and insert differential and bevel ring gear
spacer with a thicker selective spacer. If assembly into the pinion mount housing half(#).
the reading is below 2.5 pounds (1.1 kg), Install new housing half gasket on housing half
disassemble bevel pinion and cage and replace flange after applying sealant to both faces of the
the selective spacer with a thinner spacer. Repeat gasket.
this procedure until proper scale load is obtained. 3: Install plain housing half aligning with mating
(If alternate selective thickness spacers are not holes in the pinion mount housing half. Install
available, grind stock from the existing spacer to the eleven cap screws, lock washers and nuts.
increase preload or cut an additional shim from Torque to the specified amount listed in the
shim stock and add to the existing spacer to Hardware Torque Table at the end of this section.
reduce preload). This completes the bevel pinion 4: Check for free rotation of differential and bevel
cage assembly, skip to next section. ring gear. If binding observed, disassemble
9: If assembling a TA268; install the outer bearing housing halves, remove differential and ring gear
cone, bevel pinion thrust washer and bevel pinion and make certain that both differential tapered
inner nut. Tighten the nut to torque specified at bearing cones and cups are fully seated against
the end of this section. Check the bevel pinion their respective shoulders.
bearing rolling torque and tighten or loosen the
nut to achieve 5-15 inch pound rolling torque (56-
169 Ncm). Once rolling torque is correct, install
bevel pinion nut lock and bevel pinion outer nut.
Tighten the outer nut to torque specified at the
end of this section and bend lock tabs of nut lock
to secure both inner and outer nuts.
Page 40 MT-030-60-F
Drive Axle
TC-030-60
Main Housing and Pinion Cage Assembly Nose Reduction Box Assembly - TA267
1: If assembling a TA267; skip to step #5. 1: Press input shaft oil seal to bottom of bore in
2: If assembling a TA268; apply a light film of reduction box case.
sealing compound to both sides of the pinion 2: Apply a light film of sealing compound to both
cage gasket. Install the gasket and pinion cage sides of the pinion cage gasket. Install gasket on
assembly in main housing half bore. pinion cage.
3: Press bevel pinion oil seal to bottom of bore in 3: Mount reduction box case onto pinion cage.
bevel pinion oil seal cover. Apply a 1/8 inch (3.1 Install six locknuts and washers. Tighten locknuts
mm) diameter bead of silicone gasket compound to the specified amount listed in the Hardware
to the pinion cage/seal cover mounting surface. Torque Table at the end of this section.
Install the cover and seal on the pinion cage. 4: Install the driven gear thrust washer and driven
4: Install six pinion cage cap screws and washers. gear.
Tighten cap screws to the specified amount listed 5: Install driven gear inner nut and torque to the
in the Hardware Torque Table at the end of this specified amount listed in the Hardware Torque
section. This completes the main housing and Table at the end of this section. Install driven gear
pinion cage assembly, skip to next section. nut lock and outer driven gear nut. Torque outer
5: If assembling a TA267; apply silicone sealant nut to the specified amount listed in the Hardware
sealing compound to both sides of the pinion Torque Table at the end of this section and bend
cage gasket. Install the gasket and pinion cage tabs of nut lock over inner and outer nut.
assembly in main housing half bore. 6: Press new input shaft bearings and onto input
shaft. Remove the snap ring from OD of the
outboard input shaft bearing. Install the outboard
input shaft bearing to input shaft snap ring. Install
the input shaft and bearings into bore of the
reduction box case.
7: Apply silicone sealant to mounting face of
reduction box case. Install reduction box cover,
two reduction box dowels, fifteen reduction box
cap screws, fifteen lock washers, and fifteen nuts.
Torque nuts to the specified amount listed in the
Hardware Torque Table at the end of this section.
8: Install the outboard input shaft bearing OD snap
ring. Apply silicone sealant to mating face of input
shaft bearing cap and install cap on reduction box
cover. Install four cap screws and lock washers.
Torque to the specified amount listed in the
Hardware Torque Table at the end of this section.
9: Install input flange, washer, and nut on the input
shaft. Torque nut tothe specified amount listed
in the Hardware Torque Table at the end of this
section.
MT-030-60-F Page 41
Drive Axle
TC-030-60
Wheel End, TA-268
1: Before starting brake reassembly, apply a small 13: Thread the wheel bearing adjustment nut onto
quantity of Texaco Thermatex EP-2 grease to the the spindle. Tighten nut to 400 foot pounds
following brake components: (542 Nm). Rotate the wheel hub while rapping
• Adjustment bolt assembly the hub several times with a 10 pound (4.5 kg)
• Contact points of levers and shoes that ride dead blow mallet, Retighten the nut to 400 foot
against each other pounds (542 Nm), rotate the hub and rap the hub
• Push rod ends of the wheel cylinder again. Retighten, rotate and rap again. Loosen
• Anchor pins with mating holes and tighten cap the nut 1/4 of a turn and then retighten to torque
screws to the specified amount listed in the specified at the end of this section for final
Hardware Torque Table at the end of this section. adjustment.
2: If equipped, install parking brake lever on the 14: Install the planetary ring gear. Note that the pin
trailing shoe and the parking link on the leading from the wheel bearing adjustment nut must
shoe. engage the mating hole on the back side of the
3: Install the two anchor pins in the backing plate planetary ring gear. Index the planetary ring gear
holes. to mate with the pin.
4: Position the trailing shoe with the wheel cylinder 15: Install axle shaft, sun gear and sun gear retaining
push rod and anchor pin. Install anchor pin ring.
retainer clip by positioning it on the pin and 16: If the planetary spider was disassembled, install
rotating it until it sets flat on the shoe. the three planetary pinion shafts from the inside
5: If equipped, install the parking brake cable face of the planetary spider. Press the uncoated
through the backing plate and engage the end of each shaft into the respective spider bore
parking brake lever. until the standout of each shaft is 1.775 to 1.770
6: Install the stamped auto adjusting spring on the inches (4.509- 4.499 cm) from the machined
leading shoe. spider face to far end of the pinion shaft.
7: Assemble a star wheel adjustment bolt and shoe 17: If a new planetary pinion shaft was installed,
spring to the trailing shoe and leading shoe and carefully drill a 5/16 inch (7.9 mm) diameter hole,
as the leading shoe is positioned with the wheel 1/4 inch (6.35 mm) deep into the planetary pinion
cylinder push rod and anchor pin. Install anchor shaft by drilling through the 3/8-16 hole in the
pin retaining clip. planetary spider.
8: Install the green return spring onto the leading 18: Clear all chips from the drilled holes and install
shoe for the right hand brake and trailing shoe for planetary pinion shaft setscrews in, the three
the left hand brake. Install the black return spring tapped holes. Tighten the setscrews to the
onto the trailing shoe for the right hand brake and specified amount listed in the Hardware Torque
leading shoe for the left hand brake. Table at the end of this section.
9: Install the short auto adjustment wire to connect 19: Apply lubricant to the bores of planetary pinion
the adjuster pivot to the pin near the brake gears. Install the gears the planetary pinion
shoe anchor. Install the long auto adjust wire to shafts. Install the planetary pinion thrust washers
connect the adjuster pivot to the stamped auto and snap rings.
adjust spring. Tighten adjuster pivot bolt. 20: Apply a 1/8 inch (3.2 mm)bead of silicone sealant
10: Rotate the star wheel on the adjustment bolt to to the mounting face of the planetary spider. The
verify easy rotation with a ‘click’ in one direction bead should be continuous end encircle each of
and restricted rotation in the other direction. the 16 mounting holes. Install the planetary spider
11: If tapered bearing cups were removed from the assembly into the wheel hub. Install the sixteen
wheel hub press new inner cup and outer cup to cap screws and washers. Torque the cap screws
the bottom of their bores. Lubricate and install to the specified amount listed in the Hardware
inner bearing cone. Press wheel hub oil seal into Torque Table at the end of this section.
bore flush with wheel hub casting. 21: Reattach the brake lines to the wheel cylinders
12: Lubricate spindle seal journal and wheel hub and bleed the brake system.
seal lip. Install wheel hub and drum onto the 22: Adjust brakes by inserting an adjusting tool
spindle. Lubricate outer bearing cone and install through the forward slot in the brake backing
on spindle. Take care to not let the hub drop plates and engaging the star wheel of the
before the outer bearing cone is positioned on adjuster. Move the tool handle downward to
the spindle. expand the shoes until a resistance to hub/drum
rotation is felt. Adjust in the opposite direction
until the hub/drum just rotates freely.
Page 42 MT-030-60-F
Drive Axle
TC-030-60
MT-030-60-F Page 43
Drive Axle
TC-030-60
Wheel End. TA-267 14: Install the shoe retainer spring clip to the inboard
1: If inner bearing cup was removed from carrier shoe and lining. Insert the shoe and lining into the
and tube assembly, press new bearing cup to caliper with the spring clip positioned in the bore
bottom of bore in carrier and tube assembly. of the piston. Install the outboard shoe and lining
2: If tapered bearing cones were removed from the 15: Position the caliper assembly over the brake rotor
axle shafts, press new tapered bearing cones and in the slot of the brake reaction plate. Apply
onto shafts making certain that the shaft collar is lithium grease to the body of the brake slide pins
in place and that the bearing cones are seated and Loctite® 242 to the threaded area of the slide
against the collar. Install the axle shafts into the pins. Install the slide pins and tighten torque
carrier and tube assembly. specified at the end of this section.
3: Assemble axle shaft retainer spacer to end 16: Reconnect brake lines to calipers and depress
of carrier and tube assembly using three the vehicle brake pedal several times to seat the
equally spaced cap screws (do not assemble brake pads. Bleed the brake system and refill the
the retainer spacer shims that were removed master cylinder.
during disassembly). Lightly tighten the three 17: To prevent rattling of the outboard shoe, use a 12
cap screws until zero axial bearing clearance inch Channel lock type pliers to clinch the ears
is obtained. Using a feeler gauge, measure the of the outboard shoe and lining to the caliper
gap between retainer spacer and end of carrier housing.
and tube assembly. This measurement will be
used to select the correct shim pack using any
combination of 0.010 inch shims, 0.005 inch
shims, or 0.003 inch shim .
4: If a new axle shaft seal is required, press flush
with outer surface of the oil seal retainer.
5: Remove the retainer spacer and three cap
screws. Apply sealant to all faces of the shims
and assemble to carrier and tube assembly along
with the retainer spacer.
6: Apply sealant to both faces of retainer gasket and
position gasket in the retainer bore. Assemble the
seal retainer to carrier and tube assembly and
install 6 cap screws and lock washers. Tighten to
torque specified at the end of this section.
7: If brake disc was removed from brake disc hub
reinstall disc to hub and press eight wheel studs
to secure the disc to hub. HARDWARE TORQUE
8: Install O-ring into the internal groove in the
brake disc hub. Lubricate the O-ring and the If hardware is not listed here, refer to standard torque
seal journal of the brake disc hub. Install hub values in the appendix.
assembly onto the axle shaft. Description Foot Pounds Newton Meters
9: Install hub retaining washer and retaining nut Brake Slide Pins 35 49
Tighten nut to torque specified at the end of this Pinion Mount Housing cap screw/nut 65-85 88-115
section and install cotter pin. Differential Gearing cap screw 85-115 115-156
10: If service of the brake calipers was not required, Bevel Pinion inner and outer nuts 350 474
go to step 15. If the brake calipers were removed Reduction Box cap screw/nut 40-55 54-75
only for pad replacement go to 13.
Input Flange nut 200-275 271-373
11: Start caliper reassembly by dipping a new piston
Flanged Differential Case
seal in brake fluid. Assemble the seal into the cap screw/locknut 60-75 81-102
groove in the caliper housing bore.
Pinion Cage cap screw 130-165 176-224
12: Assemble the piston boot to the piston. Install
Planetary Spider Assembly cap screw 85-115 115-156
the piston in the caliper housing bore, pushing it
Hub Retaining nut 350 474
to the bottom of the bore. Seat the piston boot in
caliper housing boot bore. Outboard Input Shaft cap screw 35-50 49-68
13: Prior to pad reassembly, verify that the slide pin Axle Seal Retainer cap screw 35-50 49-68
inboard and outboard bushings arc in place in Planetary Pinion Shaft setscrews 30-35 41
the caliper housing. Lubricate the bushings and Anchor Pin cap screw 12-16 16.2-21.6
inboard sleeve with lithium grease. Install the Reduction Box Case locknut 110-145 149-196
inboard sleeve. Wheel bearing adjustment nut 100 136
Page 44 MT-030-60-F
Steering
Table of Contents
Steering
Hydraulic System-Operation...........................46
Steering System.......................................................46
Brake System...........................................................46
Hydraulic Flow Diagrams................................47
Steering Control Valve.....................................48
Remove....................................................................48
Install........................................................................48
Disassemble.............................................................48
Reassemble.............................................................49
Troubleshooting, Hydrostatic Steering..........50
Replace Ball Joint............................................51
Hydraulic Pressure...........................................51
Hydraulic Pump w/Reservoir....................................51
Hydraulic Pump with External Reservoir..................51
Wheel Alignment..............................................51
Hardware Torque..............................................51
WARNING
Steering
TC-030-60
HYDRAULIC SYSTEM-OPERATION
WARNING
Note: Hydrostatic steering is optional on some models.
This vehicle is equipped with hydrostatic steering. With hydrostatic

steering there is no mechanical linkage connecting the steering These illustrations are typical examples of
wheel to the front wheels. The steering action is performed by the steering valve and brake hydroboost.
hydraulic pressure. The hydraulic system is also shared by the The location of the components will vary
brake system. depending on the model vehicle.
The term “hydrostatic” refers to fluids at rest, typically under

pressure. Depending on the vehicle, the system is powered by a
hydraulic pump on the engine (internal combustion) or an electric
motor (electric vehicles). For vehicles with internal combustion
engines, the pump may be belt or gear driven depending on the
engine. The pressurized fluid from the pump is routed through the
brake hydroboost and then the steering valve (refer to illustration).
Depending on options ordered with your vehicle, there may be a
filter installed after the steering valve. The pressure in the hydraulic
system is controlled by a relief valve integral to the hydraulic pump
or an external valve. The pressure may be fixed or adjustable, refer
to sections later in this chapter for more information.
Steering System
The pressurized hydraulic fluid from the pump is routed through the
steering valve which is connected to the steering cylinder on the
front axle with two hydraulic hoses. The steering valve maintains
an equal (the static in hydrostatic) pressure on both sides of the
steering cylinder. As the steering wheel is turned, the steering
valve permits small amounts of hydraulic fluid to flow into one side
of the cylinder and out of the other causing the ram in the cylinder
to move left or right.
If the engine stops, the steering valve operates as a small pump
which allows steering control but with a significant increase of effort
required by the operator.
Brake System
The brake hydroboost is mounted to the brake master cylinder.
Utilizing the hydraulic pressure from the pump, the hydroboost
amplifies the pressure applied to the brake pedal by the operator
which significantly decreases the amount of effort required to apply
the brakes. Since the hydroboost uses the hydraulic pressure while
braking, it is not unusual for steering effort to increase during heavy
braking.
If the engine stops, there is a small reserve pressure stored in
an accumulator inside the hydroboost so that the vehicle can be
stopped safely. The amount of stored reserve pressure will allow
up to two power assisted stops. After the brake pedal has been
depressed two times, the effort required to apply the brakes will
increase significantly.
Page 46 MT-030-60-F
Steering
TC-030-60
HYDRAULIC FLOW DIAGRAMS
MT-030-60-F Page 47
Steering
TC-030-60
STEERING CONTROL VALVE Disassemble
Refer to exploded illustration later in this proce-
WARNING dure.
1: Remove the steering column assembly (32) from
the Steering Valve.
2: Clamp the Steering Valve as shown in a vise. use
Service Guidelines chapter. protective material such as leather on the vise
jaws. Do not over tighten the vise or the housing
may be damaged.
Remove 3: Remove the cap screws and end cap (2).
1: Remove the dash assembly. 4: Remove the seal (3) from the end cap.
2: Remove the steering wheel. 5: Remove the Gerotor (4).
3: Disconnect the horn switch wires from the 6: Remove the seal (3) from the Gerotor.
column. 7: Remove the drive spacer (5).
4: Remove the hydraulic hoses from the steering 8: Remove the drive (7).
valve body. Tie the hoses so that the ends of the 9: Remove the spacer plate (6).
hose remain above the level of the reservoir to 10: Remove the seal (3) from the housing.
prevent fluid from draining out. 11: Remove Steering Valve from the vice.
5: Remove the four bolts holding the steering valve 12: Remove the upper retaining ring (19).
assembly to the tilt bracket. 13: Place the assembly on the bench with the ports
6: Remove the valve assembly from the vehicle. facing up.
14: Rotate the spool and sleeve assembly (9) until
Install the centering pin (10) is horizontal then push
Instal the valve in reverse order of removal. spool and sleeve assembly just far enough to
Tighten mounting bolts to torque listed in the free the gland bushing (18) from the housing and
Hardware Torque table at the end of this section. remove the bushing.
15: Remove the quad seal (17) from the seal gland
Reconnect the battery, remove the blocks from
bushing.
behind the wheels and test drive the vehicle.
16: Carefully remove the dust seal (16) from the
The hydraulic system does not have to be bled. gland bushing.
To expel any air in the system, power up the 17: Remove the two bearing races and the thrust
pump and turn the steering wheel fully in both bearing (13, 14) from the spool/sleeve assembly.
directions. 18: While slowly rotating the spool/sleeve assembly,
carefully remove it through the back of the
housing. It should come out easily without forcing.
19: Remove the pin (10) from the spool/sleeve
assembly.
20: Push the spool out just far enough so that the
springs (11) clear the slot in the sleeve and
remove the springs.
21: While rotating the spool, Push it back through the
sleeve to remove it.
22: Remove the seal (15) from the housing.
23: Thread a 10-24 machine screw into the check
valve ball seat (23). Pull the screw with a pair of
pliers to remove the seat.
24: Remove the two seals from the seat.
25: Remove the check ball and retainer (21,22).
Page 48 MT-030-60-F
Steering
TC-030-60
Reassemble bushing. Smooth the seal into place with your
1: Thoroughly clean all components and air dry. finger. Do not use any seal that freely falls into
Read cleanliness caution at the beginning of this pocket of the bushing.
section. 16: Install the seal gland bushing assembly over the
2: Use new seals. Lightly lubricate all seals with spool end. Tap in place with a rubber hammer.
petroleum jelly prior to assembly. Bushing should be flush against the bearing race.
3: Install the check valve retainer (21). Make sure it 17: Install the retaining ring (19). Make sure it is
is straight in the bore. properly seated.
4: Install the check ball (22). 18: Clamp the Steering Valve as shown in a vise. Use
5: Install seals on the check ball seat (23). protective material such as leather on the vise
6: Carefully install the lubricated check ball seat/seal jaws. Do not over tighten the vise or the housing
assembly into the housing. Do not twist the seals. may be damaged.
Push down to the shoulder of the hole. 19: The spool /sleeve assembly should be flush with
7: Lubricate the spool with hydraulic fluid and the end.
assemble the spool and sleeve (9). Make sure 20: Install seal (3) in housing.
that the spring slots are at the same end. The 21: Install spacer plate (6).
spool should freely rotate in the sleeve. 22: Rotate the spool/sleeve assembly until the pin
8: Position the springs (11) on the bench so that is parallel with the port face and install the drive
extended edge is down and arched center section (7). Mark the end of the drive with a line that is
is together. parallel with the port face.
9: Compress the extended end of the centering 23: Install seal (3) on to the meter (4).
spring set and push into the spool. 24: With the seal side of the meter facing the spacer
10: Center the spring set in the parts so that they plate, align the star valleys of the meter to the line
push down evenly and flush with the upper on the drive. Do not allow the drive to rotate.
surface of the spool and sleeve. 25: Install the drive spacers.
11: Install the pin (10) into the spool/sleeve assembly. 26: Install seal in meter or end cap and install the end
It should be flush at both ends. cap. Cross tighten the bolts in two stages. First
12: Keeping the pin horizontal, install the spool/ to 120 inch pounds (14 Nm) then to final torque
sleeve assembly through the bottom of the listed in the Hardware Torque table at the end of
housing until it is flush with the bottom of the this section.
housing.
13: Install the seal, races, and thrust bearing into the
top of the housing.
14: Install dust seal (16) into the seal gland bushing
(18). Flat or smooth side must face down into the
bushing.
15: Install the quad ring seal (17) into the gland
MT-030-60-F Page 49
Steering
TC-030-60
TROUBLESHOOTING, HYDROSTATIC STEERING
The cause of most steering problems can be identified by the symptoms. The entire steering system must be analyzed
by a qualified technician before any components are removed. Use the following chart to identify probable cause
of steering problems.
Symptoms: Possible Cause: Repair Procedure:
Slow or difficult Steering. Worn or faulty pump. Inspect power steering pump for proper operation.
Loss of Power Assist. Faulty flow divider. Flow divider is in the brake Hydro-Boost assembly. If the
flow divider is not functioning correctly then replace the
HydroBoost.
Faulty relief valve. Replace the relief valve.
Faulty steering linkage. Inspect steering linkage and steering knuckles for binding.
Overloaded steer axle.
Wandering: Air in system. Locate cause of air bleed and repair. Add oil to reservoir.
Vehicle Will Not Hold a Straight Line. Steering control unit worn. Replace the control unit.
Faulty steering linkage. Inspect steering linkages for loose fittings.
Faulty steering cylinder. Inspect the steering cylinder.
Front end out of alignment. Realign front end.
Drifting: Steering control unit worn. Replace the control unit.
Vehicle Pulls to the Left or Right. Faulty steering linkage. Inspect steering linkages for loose fittings.
Front end out of alignment. Realign front end.
Slipping: Faulty steering control unit. Replace the control unit.
Slow Rotation of Steering Wheel Will Faulty steering cylinder. Inspect the steering cylinder internal seals.
Not Turn Vehicle.
Intermittent Hard Steering or Thermal shock Thermal shock can occur if the system is operated for an
Steering Wheel Locks Up. extended period without turning the steering wheel. In this
After lock, Steering Wheel May Spin situation, there may be an large temperature differential
Free With No Steering Action. between the fluid in the system and the fluid in the steering
control unit. If the steering wheel is turned quickly, the
steering may temporarily seize and could be followed with a
free wheeling steering wheel. Thermal shock could damage
the steering control unit.
Erratic Steering. Air is system. Locate cause of air bleed and repair. Add fluid to reservoir.
Faulty steering cylinder. Inspect and repair or replace cylinder.
Damage due to thermal shock. Replace control unit.
Sticking flow control spool. Replace flow control valve.
Soft or Spongy Steering. Air in system. Locate cause of air bleed and repair. Add fluid to reservoir.
Low fluid level Add fluid to reservoir.
Rotation of Steering Wheel Does Not Broken steering column Inspect the steering column assembly.
Turn Vehicle. No fluid in steering control unit. Start the steering pump. If this does not correct the problem
No Resistance in Steering. then inspect the steering pump for proper operation.
Faulty steering control unit. Replace the steering control unit.
Rotation of Steering Wheel does not Faulty steering cylinder. Inspect the steering cylinder internal seals.
Turn Vehicle.
Slight resistance Felt When Steering.
Excessive Free Play at Steering Wheel. Loose steering wheel. Inspect the steering wheel nut.
Faulty steering column Inspect the steering column assembly for loose or worn
components.
Excessive Free Play at Steered Wheels. Faulty steering linkage. Inspect the steering linkages for loose components.
Leaking cylinder seals. Inspect the steering cylinder internal seals.
Binding or Poor Centering of Faulty steering column. Inspect steering column components.
Steering Wheel. High back pressure in return line. Inspect fluid return line for obstructions.
Debris in the fluid. Flush the system and clean the steering control unit.
Steering Unit Locks Up. Debris in the fluid. Flush the system and clean the steering control unit.
Low pump pressure. Inspect the power steering pump for proper operation.
Damage due to thermal shock. Replace the steering control unit.
Worn or broken pin. Replace the steering control unit.
Steering Wheel Moves by Itself. Parts assembled incorrectly. Reassemble properly.
Improper timing in steering unit. Reassemble properly.
Hydraulic hoses not connected properly. Reconnect hoses properly.
Vehicle Steers in Wrong Direction. Hydraulic hoses not connected properly. Reconnect hoses properly.
Steering Wheel “Kicks Back” at Inlet check valve missing. Install the check valve.
Start of Steering.
Instability / Hoses Jump. Air in system. Locate cause of air bleed and repair. Add fluid to reservoir.
Page 50 MT-030-60-F
Steering
TC-030-60
REPLACE BALL JOINT WHEEL ALIGNMENT
WARNING Refer to Front Axle section


replaced on one side of a vehicle, the same components
should be replaced on the other side of the vehicle.
It is likely that the ball joint will be damaged when
removed from the steering arm. It is recommended that HARDWARE TORQUE
the ball joint should be replaced if removed.
If hardware is not listed here, refer to standard torque
This procedure assumes that the front axle has been values in the appendix.
removed from the vehicle. Refer to the component Description Foot Pounds Newton Meters
assembly removal instructions for details and warnings Steering wheel nut 35 47
regarding the removal and installation procedure. Steering Valve Mounting Bolts 16.7 22
1: Loosen the ball joint clamp or jam nut.
Steering Valve Cap Bolts (final) 19.6 27
2: Remove the cotter pin and discard.
See instructions for 1st stage torque
3: Remove the ball joint nut.
Ball Joint Clamps 28-32 38-43
4: Using a pickle fork, remove the ball joint from the
steering arm. Ball joint Nuts 45-55 61-74
5: Install a new ball joint in reverse order of removal.
6: Tighten the ball joint nut per torque listed in the
7: Install a new cotter pin.
8: Lubricate the ball joint with the appropriate
grease.
9: Realign the front wheels. Refer to procedure
“Align Front wheels.”
HYDRAULIC PRESSURE
Hydraulic Pump w/Reservoir
The hydraulic pressure for systems with a pump
and integral reservoir is fixed and cannot be ad-
justed.
Hydraulic Pump with External Reservoir
Systems with an external reservoir will have an
adjustable pressure relief valve. The relief valve
will be located on the output hose of the hydraulic
pump. The illustration shows the relief valve on a
typical Perkins engine installation. The location of
the valve may vary depending on how the vehicle
is configured.
The valve should only have to be adjusted one time
at installation.
Perkins Engine: 1,525 PSI (10,514 kPa)
Cummins Engine: N/A at time or printing.
MT-030-60-F Page 51
Notes:
Steering
TC-030-60
Page 52 MT-030-60-F
Brakes
Table of Contents
Brakes
Power Brakes-Operation.................................54
Master Cylinder................................................54
Bleed Brake System.........................................54
Front Brake.......................................................55
Service Limits:..........................................................55
Inspection.................................................................55
Replace Pads...........................................................55
Rebuild Caliper.........................................................55
Rear Brake - Axle TA267..................................56
Service Limits...........................................................56
Disassembly.............................................................56
Inspection.................................................................56
Assembly .................................................................56
Installation................................................................56
Adjust Parking Brake (drive shaft brake drum)
57
Primary Adjustment..................................................57
Secondary Adjustment.............................................57
Inspection.................................................................57
Adjust Parking Brake (drive shaft disc brake) 57
WARNING
Primary.....................................................................57 This section is one section of a complete service
Secondary................................................................57
Inspection.................................................................57
Mounting Procedure.................................................58
Adjustment Procedure..............................................58 Service Guidelines chapter.
Ball and Cam Replacement......................................58
Lining Replacement..................................................58
WARNING
Sleeve Seal Replacement........................................59
Hardware Torque..............................................60
Current Taylor-Dunn® brakes are asbestos free.
However, there is the possibility that the original
brakes were replaced with aftermarket parts
containing asbestos. Since this possibility exists,
all brake parts should be handled as if they contain
asbestos. Refer to Appendix for recommended
handling precautions.
WARNING
Hydraulic fluid and components must be kept clean.
Thoroughly clean exterior of any hydraulic component
before disconnecting hoses or fittings. Perform all
maintenance and repairs in a clean environment. Do
not use cloth or paper towels to clean components
due to possible contamination with lint or other
fiber. Failure to follow these guidelines will result in
premature failure of hydraulic system components.
Brakes
TC-030-60
POWER BRAKES-OPERATION BLEED BRAKE SYSTEM
The power brake system is powered by the hydraulic WARNING
pump on the engine or an electrically driven pump on
electric tractors. The hydraulic system is shared by the This section is one section of a complete service
hydrostatic steering. Refer to the steering section for a manual. Before starting any procedure, read all
description of the hydraulic system operation. warnings and instructions that are located in the
MASTER CYLINDER Note: Start this procedure at the wheel furthest

from the master cylinder, then work toward
There are no serviceable components in the hydroboost the wheel closest to the master cylinder.
or master cylinder. If there is a fault in the hydroboost The rear bleeder valves can be accessed
or master cylinder then the entire assembly must be through the center rear inspection cover.
replaced.
1: Thoroughly clean the area around the master
cylinder cap and remove the cap.
2: Add brake fluid from a new sealed container to
the master cylinder. Fill to 1/4” (6.35 mm) from
the top of the master cylinder chamber.
3: The master cylinder fluid level will drop as the
brakes are bled. Periodically check and fill the
master cylinder during this procedure. Do not
allow the fluid level in the master cylinder to drop
WARNING too low as this will allow air into the brake lines.
Current Taylor-Dunn® brakes are asbestos free. 4: Attach a clear hose to the bleeder valve on the
However, there is the possibility that the original brake cylinder that is to be bled. Route the hose
brakes were replaced with aftermarket parts into a clear container for waste brake fluid.
containing asbestos. Since this possibility exists, 5: Pump the brake pedal a few times and then press
all brake parts should be handled as if they contain and hold light pressure to the brake pedal.
asbestos. Refer to Appendix for recommended 6: Open the brake bleeder valve.
handling precautions. 7: Depress the foot pedal to the floor and then close
the bleeder valve. Do not release pressure on the
brake pedal until the bleeder valve is closed.
WARNING 8: Slowly release the foot pedal, allowing it to return

to its released position.
• Only use DOT 3 brake fluid from a new sealed Note: Check and fill the master cylinder frequently
container. during the bleeding process. Do not allow
the fluid level in the master cylinder to drop
• DOT 3 brake fluid is corrosive and will damage
paint finishes.
low enough to allow air to enter the brake
lines. If air enters the brake lines during the
• Dispose of brake fluid in accordance with local bleeding process, then you will have to start
state and federal regulations. again from the beginning.
• Read and follow all warnings on the brake fluid 9: Repeat the above steps until you are sure that
container.
all of the air is expelled from the brake line. Any
air bubbles that can be seen in the clear hose
attached to the bleeder is an indication that there
is still air in the brake lines.
10: Repeat this process with each of the other
wheels.
Note: When finished, top off the master cylinder
with fluid. See Check Master Cylinder Fluid
for information on filling the master cylinder.
Page 54 MT-030-60-F
Brakes
TC-030-60
FRONT BRAKE 11: Measure the thickness of the rotor. If the
thickness of the rotor is less than the service limit
WARNING then the rotor must be replaced. Refer to the front
axle section for information on removing/installing
This section is one section of a complete service the brake rotor.
manual. Before starting any procedure, read all 12: Reinstall the rotor and brake assembly. Tighten
warnings and instructions that are located in the the brake mounting bolts per torque listed in the
Service Guidelines chapter. Hardware Torque table at the end of this section.
13: Bleed the brake system.
Service Limits: 14: Lower the vehicle.
• Brake pad Thickness: 1/16 inches (1.58 mm). 15: Remove the blocks from behind the wheels and
• Rotor Thickness: 0.20 inches (5 mm). test drive the vehicle.
• Rotor runout: 0.005 inches (0.127 mm). Rebuild Caliper
Inspection There are no internally serviceable components in the
1: Raise the front of the vehicle and support with front brake calipers. If there is a problem with the caliper
jack stands. then it must be replaced as an assembly.
2: Remove the front wheels.
3: Measure the distance between the rotor and the
brake pad backing plate (all 4 pads, both ends of
each pad). If any one of the four brake pads are
equal to or less that the service limit then all four
pads should be replaced.
4: Measure the rotor thickness in three places. If the
rotor thickness is less than the service limit then
the rotor must be replaced.
5: Measure the rotor runout. If the runout exceeds
the service limit, then the rotor must be
resurfaced. After resurfacing the rotor, measure
the rotor thickness. If the rotor thickness is less
than the service limit, then the rotor must be
replaced.
6: Lower the vehicle.
Replace Pads
1: Raise the front of the vehicle and support with
jack stands.
2: Remove the wheels. Refer to procedure in “Tires
and Wheels” section.
3: Thoroughly clean the exterior of the brake caliper
assemblies.
4: Remove the safety wire from the two caliper
retaining bolts and discard.
5: Remove the two caliper bolts.
6: Slide the brake housing off of the mounting
bracket and remove the brake pads.
7: Thoroughly clean the sliding surfaces of the
bracket and housing.
8: Apply an anti-seize lubricant to the machined “V”
groove in the brake bracket. Be careful not to WARNING
apply too much lubricant. Current Taylor-Dunn® brakes are asbestos free.
9: Assemble the housing and new pads to the However, there is the possibility that the original
bracket and confirm that the housing slides freely brakes were replaced with aftermarket parts
with no binding. containing asbestos. Since this possibility exists,
10: Remove and resurface the rotor to remove all all brake parts should be handled as if they contain
asbestos. Refer to Appendix for recommended
grooves or run out. Refer to the front axle section
for information on removing the hub.
MT-030-60-F Page 55
Brakes
TC-030-60
REAR BRAKE - AXLE TA267
WARNING
Service Guidelines chapter. Inspection
The brake pads must be removed from the caliper for
Service Limits
inspection. Refer to the Brake Disassembly procedure
Brake pad Thickness: 1/16” (1.6 mm)
to remove the pads from the caliper.
Rotor Thickness: 0.826” (21 mm)
Rotor runout: 0.005 inches (0.127 mm). Measure the thickness of the brake linings. If the brake
lining is equal to or less than the service limit then the
linings should be replaced.
replaced on one side of a vehicle, the same components
should be replaced on the other side of the vehicle. Measure the rotor in a minimum of 3 places around the
rotor. If any measurement is less than the service limit,
Disassembly then the rotor must be replaced.
1: Remove pad pins.
2: Remove caliper from mounting fixture. Mount a dial indicator and measure the rotor runout on
3: Discard worn stator pads. the inside and outside surfaces. If the runout exceeds
4: Remove boot and piston from the housing at the the service limit, then the rotor must be machined. After
same time. Do so by holding the brake against machining, confirm that the rotor thickness is not less
a table surface with the piston facing down and than the service limit.
slowly applying air pressure to the inlet port. Assembly
Once the piston is out of the housing, tilt the
piston to one side and pry the boot out of the Important: there may be more parts in a service kit than
housing. Discard these pieces only if you are your brake requires. Check the parts list carefully for the
rebuilding. exact quantity.
5: Remove the square-ring from the cylinder of the Note: All parts must be thoroughly cleaned prior
housing. to assembly.
6: Inspect housing bore. It must be clean and rust 1: Insert rubber rings and sleeves.
free. If rust is present, use emery or crocus cloth 2: Lubricate sleeves with a high temperature grease
to remove. The square-ring seals against the before assembly.
piston surface. So small scratches and cavities in 3: Lubricate the cylinder of the housing, square-
the bore wall will not affect sealing performances. ring, the boot, and piston with brake fluid before
However, since the bore guides the piston reassembly.
movement, any cylinder wall imperfection, which 4: Install the square-ring in the groove in the
causes the piston to catch or wedge in the bore cylinder bore furthest from the opening.
must be taken care of. If the piston cannot be 5: Install a boot onto the piston. The small opening
properly guided in the bore, replace the brake of the boot is to be seated in the groove on the
7: Clean all ports and mounting surfaces. Wash front side of the piston. Pull the boot over the full
housing in a solvent to remove any dirt, loose length of the piston and extend the boot beyond
rust, and any petroleum products. the end of the piston about 1/4 inch (6.35 mm).
8: Inspect bushing in slide mount for signs of wear. Start the boot lip into the cylinder groove. Use a
Replace as necessary vice or shop press to slowly move the piston into
9: Inspect all other parts for unusual wear or rust. the cylinder until the piston bottoms out. Verify
Clean or replace as necessary. that the boot has properly seated in the cylinder
bore groove
Installation
1: Slide the brake over the rotor with one pad on
each side of rotor.
2: Align mounting sleeve holes in caliper with
mounting holes in mounting bracket.
3: Insert pad pins and torque to 30-40 ft. Lbs.
4: Attach brake line using M10 x 1.5 banjo port.
5: Bleed the brake system.
Page 56 MT-030-60-F
Brakes
TC-030-60
ADJUST PARKING BRAKE (DRIVE ADJUST PARKING BRAKE (DRIVE
SHAFT BRAKE DRUM) SHAFT DISC BRAKE)
WARNING Primary
1: Release the park brake and rotate the knob on
This section is one section of a complete service the end of the park brake handle until the parking
manual. Before starting any procedure, read all brake holds firm when applied.
warnings and instructions that are located in the 2: If the knob is fully tightened and the brake
Service Guidelines chapter. does not hold, go to the Secondary adjustment
Primary Adjustment procedure.
1: Release the park brake and rotate the knob on
the end of the park brake handle until the parking
Secondary
brake holds firm when applied. Perform the Primary adjustment procedure first before
2: If the knob is fully tightened and the brake performing this procedure.
does not hold, go to the Secondary adjustment 1: Fully loosen the adjustment knob on the end of
procedure. the park brake handle.
2: Loosen the jam nut on the clevis below the park
Secondary Adjustment brake handle.
Perform the Primary adjustment procedure first before 3: Tighten the brake cable to remove most slack in
performing this procedure. the brake system and then tighten the jam nut.
1: Release the park brake. 4: Perform the Primary adjustment procedure.
1: Fully loosen the adjustment knob on the end of 5: Release the park brake and test drive the vehicle.
the park brake handle.
2: Adjust the bellcrank link so that the bellcrank
Inspection
upper arm is 5 degrees past vertical pointing to Service Limits
the rear of the vehicle. • Brake pad Thickness: 0.090 inches (2.29 mm).
3: Adjust the brake cable to remove any remaining • Rotor Thickness: 0.400 inches (10.2 mm).
freeplay in the linkage. • Rotor runout: 0.010 inches 0.127 mm).
4: Adjust the primary adjustment until the parking 1: Measure the thickness of the brake linings. If the
brake holds firm when applied. brake lining is equal to or less than the service
5: Release the park brake and test drive the vehicle. limit then the linings should be replaced.
2: Measure the rotor in a minimum of 3 places
Inspection around the rotor. If any measurement is less than
Service Limits the service limit, then the rotor must be replaced.
• Brake Shoe Lining Thickness: 1/16 inch (1.6 mm). 3: Mount a dial indicator and measure the rotor
• Drum Inside Diameter: 9.030 inches 229.36 mm). runout on the inside and outside surfaces. If the
• Drum Runout: 0.010 inches (0.254 mm). runout exceeds the service limit, then the rotor
1: Measure the brake shoe lining at the thinnest must be machined. After machining, confirm that
point on the shoe. If this is 1/16-inch or less then the rotor thickness is not less than the service
the brake shoe must be replaced.. limit.
2: Measure the inside diameter of the brake drum
in 3-places. If the difference between any of the
measurements exceeds 0.010-inches then the
brake drum must be turned or replaced.
3: If the brake drum is grooved or worn beyond
the service limit then the brake drum must be
replaced
MT-030-60-F Page 57
Brakes
TC-030-60
Mounting Procedure Note: Prior to the installation of the cams (4),
it is recommended that “alpha 2000”
Refer to the illustration on the following pages for item
grease (anti-seize & lubricating compound)
numbers.
manufactured by chemtool, be applied to
1: Insert Mounting Bolts through Sleeves (9) and
ramp areas of the cams.Install new inner
thread Brake Mounting Locking Nuts as far as
Cam (4) on Adjusting Bolt (2), taking care to
possible on Mounting Bolts. This is not required if
orient protrusions into holes in Torque Plate
brake assembly comes with the sleeve/bolt sub-
(5).
assy (9). Position the brake over disc and align
with mounting holes in mounting bracket. 5: Install Ball/Retainer Assembly (8) onto Adjusting
2: Thread mounting bolts into mounting bracket, Bolt (2), orienting balls into pockets of inner Cam
adjusting nuts until a 0.020” - 0.060” gap exists (4). Install outer Cam (4) onto Adjusting Bolt
between the Sleeves (9) and the Locking Nuts. (2), orienting pockets onto Balls of Ball/Retainer
Tighten the Locking Nuts to 75 to 85 lb-ft of Assembly (8). Install Boot (3) over cam assembly.
torque against the bracket. 6: Install Lever (1), using protrusions on back of
3: Refer to Adjustment Procedure to set clearance outer Cam (4) and holes in Lever (1) to orient
of installed brake assembly. lever to proper operating position.
7: Install remaining washers and nuts (11,17,16,12
Adjustment Procedure & 13) and follow adjustment procedure in Section
Refer to the illustration on the following pages for item 4.
numbers. Note: MAKE SURE TO ORIENT COATED FACE
1: Loosen two Adjustment Nuts (12 & 13) (one full OF THRUST WASHER (11) TOWARD
nut and one jam nut except when using a 0.50 STAINLESS STEEL WASHER (17).
inch thick disc which requires two jam nuts).
2: Tighten inner Nut (12) until firm contact is made Lining Replacement
with the disc by the linings. Torque to 100 lbs Refer to the illustration on the following pages for item
in. Make certain Lever (1) is in proper operating numbers.
position for application. 1: Replace both linings when either has worn to
3: Back off inner Nut (12) 4 to 5 flats and check that 0.090 inch remaining.
disc is free to move. 2: Loosen two Adjustment Nuts (12 & 13) enough to
4: Tighten outer Nut (13) against inner Nut (12) to slide each Torque Plate (5 & 7) away from disc far
lock Adjustment Bolt (2) in place. Torque to 45 to enough to provide clearance to remove old carrier
55 lb-ft. & lining assemblies (6) and install new ones. (It
Ball and Cam Replacement may be necessary to remove one or both Nuts.)
3: Collapse Lining Retraction Spring (10) and
Refer to the illustration on the following pages for item remove from brake Head Assembly.
numbers. 4: Slide Torque Plates (5 & 7) away from disc, move
1: Remove both Adjustment Nuts (12 & 13), Thrust, Carrier & Lining Assemblies (6) out of pockets,
Stainless Steel and Hardened Washers (11, 17 & and remove from the Brake Head Assembly from
16), Lever (1), and Boot (3) from Adjustment Bolt the side.
(2). Note: Prior to the installation of the new linings,
2: Remove outer Cam (4) and Ball/Retainer it is recommended that a coating of “alpha
Assembly (8) from Adjustment Bolt (2). 2000” grease (anti-seize & lubricating
3: Use a screwdriver, or similar tool, to gently pry compound) manufactured by chemtool, be
inner Cam (4) protrusions on back of cam, loose applied to the interface of the sleeve (9) and
from Torque Plate (5), and remove from Adjusting the torque plates (5) & (7). After grease has
Bolt (2). Remove Seal (15) from Adjusting Bolt been applied, slide torque plates back and
(2). forth on sleeve as far as possible to insure
4: Install the new Seal (15) on the Adjusting Bolt (2), that the grease has been introduced into the
inserting through inner Cam (4) until Seal (15) bores of the torque plates. Install new Carrier
bottoms out on Torque plate (5). & Lining Assemblies (6) in each Torque Plate
(5 & 7).
5: Install Lining Retention Spring (10) into Brake
Head Assembly. Be sure spring’s “feet” are
positioned properly in holes in both Lining Carrier
Assemblies (6).
6: Adjust brake per Adustment Procedure on this
page.
Page 58 MT-030-60-F
Brakes
TC-030-60
Sleeve Seal Replacement
1: Loosen the two locking nuts on the mounting
bolts and remove the sleeve/bolt subassembly (9)
from the brake. Remove sleeve seals (14). WARNING
2: Insert new sleeve seals (14) between the Torque Current Taylor-Dunn® brakes are asbestos free.
Plates (5 & 7) and align with the sleeve bores. However, there is the possibility that the original
Note: Prior to the installation of the mounting bolt brakes were replaced with aftermarket parts
& sleeve assembly, it is recommended that containing asbestos. Since this possibility exists,
“alpha 2000” grease (anti-seize & lubricating all brake parts should be handled as if they contain
compound) manufactured by chemtool, be asbestos. Refer to Appendix for recommended
applied to the sleeves and the bores of the
torque plates.
3: Insert Sleeve/Bolt sub-assembly (9) through the
front torque plate (5), sleeve seal (14), and back
torque plate (7).
4: Mount brake per paragraph 3.2 and adjust per ITEM # DESCRIPTION QTY.
1 LEVER 1
Adjustment Procedure on the preceding page.
2 BOLT1/2-20X5.5 1
3 BOOT 1
4 CAM 2
5 TORQUE PLATE FRONT 1
6 LIMNG & CARRRIER ASSY 2
7 TORQUE PLATE REAR 1
8 BALL/RETAINER SUB ASSY 1
9 SLEEVE OR SLEEVE/BOLT SUB ASSY 2
10 SPRING FLAT 1
11 GARLOCK THRUST BEARING 1
12 1/2-2OHEXNUT 1
13 1/2-2OJAIVINUT 1
14 SEAL SLEEVE 2
15 IDSEAL 1
16 WASHER HARDENED 1
17 WASHER 1
MT-030-60-F Page 59
Brakes
TC-030-60
HARDWARE TORQUE
If hardware is not listed here, refer to standard torque
values in the appendix.
Description Foot Pounds Newton Meters
Brake Mounting Bolts 40 54
Notes:
Page 60 MT-030-60-F
Engine
Taylor-Dunn provides a vehicle operator’s manual with every vehicle.
Engine maintenance, repair, and diagnosis are covered in separate supplemental manuals. Each
engine will have its own manuals.
Some are available in electronic format (EF) and were included on the vehicle documentation
CD delivered with your vehicle. They can also be downloaded from our web site:
www.taylor-dunn.com
Manuals not available in electronic format can be ordered through your local Taylor-Dunn distributor.
A dealer lookup utility is available on our web site.
Following is the current list of available manuals:
Engine Type Manual Number EF

Service M7-001-58 Y
Operator M7-001-59 Y
Ford 2.3L DSG423
Parts M7-001-60 Y
Diagnosis M7-001-26 Y
Service M7-001-71 Y
Operator M7-001-70 Y
Ford 2.5L MSG425
Parts M7-001-76 Y
Diagnosis M7-001-26 Y
Service M7-001-32 Y
Operation/Maintenance M7-001-31 Y
PSI GM 3.0
Diagnostics M7-001-33 Y
Parts M7-001-34 Y
Service M7-001-52 N
Perkins 1104C
Operation/Maintenance M7-001-54-OTC N
Service M7-001-38 N
C u m m i n s 3 . 3 L Tu r b o
Operation/Maintenance M7-001-37 N
QSB3.3
Troubleshoot/Repair M7-001-45 N
Service M7-001-67 N
Cummins 3.3L NA Operation/Maintenance M7-001-68 N
Owner’s M7-001-66-OTC N
Service M7-001-48 N
Cummins 4.5L B4.5
Operation/Maintenance M7-001-49 N
Cummins parts manuals available online at the Cummins web site:

store.cummins.com/store/index.html
Notes:
Engine
TC-030-60
Page 62 MT-030-60-F
Transmission
Table of Contents
Transmission Repair................................................................85
DIAGNOSIS AND TESTING .............................64 Intermediate Band Adjustment.................................85
GENERAL INFORMATION ...............................64 Diagnosis and Testing.....................................86
Service...............................................................65 Adjustments......................................................86
Transmission Fluid Level..........................................65 Intermediate Band ...................................................86
Transmission Fluid Flow...........................................66 Fig. 3 Hydraulic Control System...............................87
Transmission Fluid Leakage.....................................66 Control Valve Assembly...................................88
Fluid Leakage in Converter area..............................67 Remove....................................................................88
Converter Leakage Check........................................68 Install........................................................................88
Control Pressure Test...............................................68
Engine Vacuum Pressure.........................................68
Intermediate Servo...........................................88
Remove....................................................................88
Vacuum Pump Method.............................................69
Install........................................................................88
Vacuum Diaphragm Test..........................................69
Governor Check.......................................................71 Governor...........................................................89
Shift Point Checks....................................................71 Remove....................................................................89
Air Pressure Checks.................................................72 Install........................................................................89
Diagnosis Guides.....................................................73 Disassembly and Assembly............................89
Removal and Installation.................................76 Transmission............................................................89
Vacuum Diaphragm..................................................76 Control Valve Body...................................................92
Fluid Drain and Refill................................................76 Intermediate Servo...................................................95
Fluid Cooler Lines....................................................76 Governor..................................................................95
Downshift and Manual Linkage................................95
Cleaning and Inspection..................................76
Parking Pawl Linkage...............................................97
Transmission............................................................76
Servo Apply Lever....................................................97
Control Valve Body...................................................77
Front Pump...............................................................97
Intermediate Servo...................................................77
Reverse High Clutch................................................98
Governor..................................................................77
Forward Clutch.........................................................99
Front Pump...............................................................77
Input Shell and Sun Gear.........................................102
Reverse High Clutch................................................78
Output Shaft Hub and Ring Gear.............................102
Forward Clutch.........................................................78
One Way Clutch.......................................................102
Direct Clutch Piston Check ball Leakage Procedure....................
Low Reverse Clutch Piston......................................103
78
Planetary One-Way Clutch.......................................78 Specifications...................................................106
Converter and Fluid Cooler......................................79
Converter End Play and One Way Clutch Check.....79
Stator to Impeller Interference Check.......................80
Stator to Turbine Interference Check.......................81
Pinion Carriers..........................................................81
Stator Support..........................................................82
Specifications...................................................83
WARNING
Transmission
TC-030-60
DIAGNOSIS AND TESTING
Troubleshooting the automatic transmission is simplified by using the proven methods of diagnosis. One of the
most important things to remember is that there is a definite procedure to follow. Do not try to short cut or take it for
WARNING
granted that someone else has done the critical checks or adjustments. The following procedures are recommended
for checking and/or verifying that the various components are adjusted and operating properly. If an Automatic
Transmission Tester is used, Rotunda model 014-00737 or equivalent, follow the manufacturers instructions.
GENERAL INFORMATION
All automatic transmissions are equipped with high temperature resistant seals. This includes those seals used on
the manual and kickdown levers, the O-rings and oil pan gasket. Under no conditions should older design seals be
used on the transmissions, except the regular service replacement oil pan gasket, which is of special leak prevention
design. This should still be used.
Page 64 MT-030-60-F
Transmission
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SERVICE
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Page 84 MT-030-60-F
Transmission
TC-030-60
REPAIR
Description
The C6 transmission is a three speed unit Capable of providing automatic upshifts and downshifts through the three
forward gear ratios. The transmission Is also capable of providing manual selection of first and second gears.
Fig. 1 shows the location of the converter, front pump, clutches, gear train and most of the Internal parts used in the
C6 transmission. The identification tag (Fig. 2), is attached to the intermediate servo lower front cover bolt. The first
line On the tag shows the transmission model prefix and suffix. A number appearing after the suffix indicates that
the internal parts in the transmission have been changed after initial production start-up. For example, a PGD-BN
model transmission that has been changed internally would read PGD-BN1. Both transmissions are basically the
same, but some service parts in the PGN-BN transmission are slightly different than the PGD-BN1 transmission.
Therefore, it is important that the codes on the transmission identification tag be checked when ordering parts or
making inquiries about the transmission.
The hydraulic control system schematic is shown in Fig. 3. The converter housing and the fixed splines which engage
the splined outside diameter of the low-reverse clutch steel plates, are both cast integrally into the case.
Only one (intermediate) band is used in the C6 transmission. This along with the forward clutch is used to obtain
intermediate gear.
MT-030-60-F Page 85
Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Notes:
Transmission
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Page 108 MT-030-60-F

Tires/Wheels
Table of Contents
Tires/Wheels
Tire Inflation......................................................110
Tire Inspection..................................................110
Tire/Wheel Assembly.......................................111
Remove/Install..........................................................111
Hardware Torque..............................................111
WARNING
Tires/Wheels
TC-030-60
TIRE INFLATION
WARNING
Refer to the vehicle specifications in the Operator section

for information on tire pressures.
Tire pressures must be checked when the tire is cold.
WARNING
NEVER exceed the maximum tire pressure as
indicated on the side wall of the tire.
Exceeding the maximum tire pressure may result in
explosive failure of the tire resulting in severe bodily
injury.
The illustration is an example of the side wall
information on a tire.
TIRE INSPECTION 4: Inspect the inner and outer side walls for cracks.
If any cracks are seen, then the tire should be
WARNING replaced. Refer to Replace the Tire section for
information regarding replacing the tire.
This section is one section of a complete service 5: Inspect the valve stem for cracks. If any cracks
manual. Before starting any procedure, read all are seen, then the valve stem should be
warnings and instructions that are located in the replaced. It is also recommended that the valve
Service Guidelines chapter. stem be replaced whenever the tire is replaced.
Note: Refer to Replace the Tire section for
1: Check the tire pressure. Refer to Tire Inflation information regarding replacing the valve
section for information on checking the tire stem.
pressure.
2: Inspect the tire tread depth. Minimum 6: Inspect the tread and side walls for debris in
recommended tread depth is 1/16-inch (1.6 the rubber that could lead to a puncture. If any
mm). There are a series of tread depth wear debris is found it should be removed and the tire
indicators around the circumference of the tire. inspected for a leak.
They will appear as 1/2-inch (6.3 mm) bands
across the tread as the tire approaches its wear
limit (see illustration below). Replace the tire if
any tread depth indicator can be seen or any part
of the tread depth is 1/16-inch or less. Refer to
Replace the Tire section for information regarding
replacing the tire.
3: Inspect for uneven tire wear on the front
tires. Uneven tire wear could be a result of
an improperly inflated tire or a misaligned or
damaged front end.
Note: Refer to Tire Inflation section or Steering
Component Service section for information
on proper tire inflation or front end wheel
alignment.
Page 110 MT-030-60-F

Tires/Wheels
TC-030-60
TIRE/WHEEL ASSEMBLY HARDWARE TORQUE
WARNING If hardware is not listed here, refer to standard torque
manual. Before starting any procedure, read all Wheel Nut, Front 90-110 122-149
warnings and instructions that are located in the Wheel Nut, Rear (M20 studs) 250-270 339-366
Service Guidelines chapter. Wheel Nut, Rear (9/16 studs) 110-120 149-163
Wheel Nut, Rear (1/2 studs) 100-110 135-149
WARNING
Vehicle may be equipped with poly filled tires. Poly
filled tires can weight up to 300 pounds (136 kg). If
vehicle is equipped with poly filled tires, a hydraulic
tire jack will be required to remove the tire/wheel
assembly. Failure to use a proper tire jack may result
in severe personal injury.
WARNING
Improper assembly or disassembly of a split rim
wheel can result if tire explosion causing severe
injury. Refer tire/wheel repair to a qualified tire
supplier.
Remove/Install
1: Raise the wheel to be replaced off of the ground
and support with jack stands.
2: Remove the wheel nuts and remove the wheel.
3: Install in reverse order.
4: Cross tighten the wheel nuts in two stages as
follows:
1st stage to approximately 20 foot pounds (27
Newton meters).
2nd stage to torque listed in the Hardware Torque
table at the end of this section.
5: Lower the wheel to the ground.
6: Remove the blocks from behind the wheels.
7: Release the parking brake and test drive the
vehicle.
WARNING
Wheel nuts must be re-torqued after 15 hours of
operation for new vehicles and whenever the wheel
has be removed. Failure to re-torque the wheel nuts
may result in wheel falling off the vehicle resulting
severe bodily injury and/or property damage.
MT-030-60-F Page 111

Notes:
Tires/Wheels
TC-030-60
Page 112 MT-030-60-F

Battery
Table of Contents
Battery
Cleaning............................................................114
Testing...............................................................114
Specific Gravity........................................................114
Watering............................................................115
Storing...............................................................115
Storage.....................................................................115
Returning to Service.................................................115
Remove/install..................................................116
Hardware Torque..............................................116
WARNING
WARNING
manual. Before starting any procedure, read all • Explosive mixtures of Hydrogen gas are present
warnings and instructions that are located in the within battery cells at all times. Do not work
Service Guidelines chapter. with or charge battery in an area where open
flames (including gas furnace or water heater
pilots), sparks, cigarettes, or any other sources
of combustion are present. Always provide ample
ventilation in rooms where batteries are being
charged. Failure to do so may result in severe
bodily injury and/or property damage.
• A battery is a live electrical source. It cannot be
disconnected or neutralized. Do not drop any
tool or conductive object onto the battery. A
conductive object that comes in contact with the
battery terminals will initiate a short circuit of the
battery. This could cause the battery to explode
resulting in severe bodily injury and/or property
damage.
• Battery electrolyte is poisonous and dangerous.
It contains sulfuric acid. Avoid contact with skin
eyes or clothing. Wear rubber gloves and safety
glasses while servicing batteries. DO NOT INGEST!
This may result in severe bodily injury.
Battery
TC-030-60
CLEANING TESTING
WARNING WARNING
WARNING Specific Gravity

Note: The battery must be fully charged before
Battery electrolyte will stain and corrode most
performing this test.
surfaces. Immediately and thoroughly clean any
surface outside of the battery that the battery This test should only be performed on non-maintenance
electrolyte comes in contact with. Failure to clean
free batteries. The caps on maintenance free batteries
may result in property damage.
should never be removed. Removing a cap on a
maintenance free battery will destroy the seals in the
1: Dry dirt can be readily blown off with low-pressure
battery and result in premature battery failure.
air or brushed off.
2: Wetness or wet dirt on the battery indicates The specific gravity of a cell is an indication of the actual
battery acid. Using a nonmetallic brush with state of charge of the cell. A fully charged cell should
flexible bristles, wash the battery off with a have a reading of 1275 to 1300 (see the illustration to
strong solution of baking soda and hot water (1 the right). A discharged cell will read 1100. Ideally, all
pound (0.45 kg) of soda to 1 gallon (3.78 liters) cells in a battery will have the same reading. Any cells
of water). Continue until all fizzing stops, which in a battery that vary by more than 25-points may be an
indicates that the acid has been neutralized. Then indication of a bad cell.
rinse thoroughly with clear water. DO NOT get Clean the battery. Refer to Cleaning section for
any of the solution into the battery cells. information on cleaning the battery.
3: Using a battery terminal cleaning brush along
with the same solution used in the previous step, Using part number 77-200-00 hydrometer, check and
clean the inside of each battery connector and record the specific gravity of each cell in the battery.
each battery post. If, after charging, none of the cells exceed a hydrometer
4: Reconnect the battery, remove the blocks from reading of 1250 then there may be a fault in the charging
the wheels and test drive. system. If the charging system checks OK then the
battery is no longer accepting a charge and should be
replaced.
The highest reading will be the cell that is accepting
the most charge. This reading will be used to gauge all
other cells.
Compare the specific gravity readings to the highest
reading, if the difference between any of the cells is more
than 25-points, then the battery should be replaced.
Page 114 MT-030-60-F

Battery
TC-030-60
WATERING STORING
WARNING WARNING
WARNING Storage
Thoroughly clean the battery and battery
Battery electrolyte will stain and corrode most compartment. Refer to Cleaning in this section
surfaces. Immediately and thoroughly clean any
for information regarding cleaning the battery.
surface outside of the battery that the battery
electrolyte comes in contact with. Failure to clean Check the electrolyte level and charge the battery.
may result in property damage. Refer to Watering in this section for information
regarding checking the electrolyte level.
Note: The battery should be fully charged before Store the vehicle or battery (if removed) in a cool,
performing this procedure. dry, well ventilated area.
If storing for more than one month, the battery
This procedure should only be performed on non- should be charged per the table below.
maintenance free batteries. The caps on maintenance
free batteries should never be removed. Removing a Temperature (ºF/ºC) Charging Interval
cap on a maintenance free battery will destroy the seals (months)
in the battery and result in premature battery failure.
Over 60/15.5 1
1: Clean the battery. Refer to Cleaning section for
information on cleaning the battery. Between 40/4.4 and 60/15.5 2
2: Check the electrolyte level in all battery cells. Below 40/4.4 6
If low, fill to the correct level with distilled water
using part number 77-201-00 battery filler, never
add additional battery electrolyte to the batteries.
Returning to Service
Thoroughly clean the battery and battery
3: Reconnect the battery, remove the blocks from
compartment. Refer to Cleaning in this section
the wheels and test drive.
for information regarding cleaning the battery.
Check the electrolyte level and charge the battery.
Refer to Watering in this section for information
regarding checking the electrolyte level.
Test the battery. Refer to Testing section for
information on testing the battery.
The battery is now ready to be put back into service.
MT-030-60-F Page 115

Battery
TC-030-60
REMOVE/INSTALL HARDWARE TORQUE
WARNING If hardware is not listed here, refer to standard torque
This section is one section of a complete service Note: Depending on options ordered with the
manual. Before starting any procedure, read all vehicle, the battery may have either a post
warnings and instructions that are located in the or stud terminal.
Service Guidelines chapter. Description Inch Pounds Newton Meters
Battery Terminal (clamp type) 48-60 5.4-6.7
WARNING Battery Terminal (stud type) 120-130 13.5-14.5
Always remove the negative cable from the battery

first (negative ground systems) and connect the
negative cable last.
1: Remove the negative cable from the battery .

2: Remove the positive cable from the battery.
3: Remove all battery hold downs and remove the
battery from the vehicle.
4: Inspect the battery compartment for corrosion.
If there is significant corrosion, then the battery
compartment should be cleaned and painted.
5: Install the battery
6: Connect the positive battery cable and torque the
battery terminal hardware per torque listed in the
7: Connect the negative battery cable and torque
the battery terminal hardware per torque listed
in the Hardware Torque table at the end of this
section.
Page 116 MT-030-60-F

Suspension
Table of Contents
Suspension
Front..................................................................118
Rear...................................................................118
Hardware Torque..............................................119
WARNING
Suspension
TC-030-60
FRONT
REAR
Page 118 MT-030-60-F

Suspension
TC-030-60
HARDWARE TORQUE
If hardware is not listed here, refer to standard torque values in the
appendix.
Front Spring Eye Bolts ** **
** - Tighten until the spring hangers or mounting brackets

are solid against the spring eye and then loosen the nut 1/4
turn. The spring hangers should be able to swing free with no
lateral movement of the spring.
NOTICE
DO NOT over torque the spring hanger or spring eye
hardware. Hardware that is too tight will inhibit the
spring movement resulting in premature failure of
the spring, spring hardware, or frame.
MT-030-60-F Page 119

Notes:
Suspension
TC-030-60
Page 120 MT-030-60-F

Wiring and Hydraulic
Diagrams
Table of Contents
Wiring and Hydraulic Diagrams
Wire Diagrams..................................................122
Hydraulic diagram with External Reservoir...123
Hydraulic Diagram with Integral Reservoir....124
Adjust Pressure, Cummins B3.3 Engine........125
Adjustment, Pump Max Pressure:............................125
B. Adjustment, Steering Max Pressure:....................125
Hardware Torque..............................................127
WARNING
Wiring/Hydraulics
TC-030-60
WIRE DIAGRAMS
WARNING
The wire diagrams are too large to be legible at this size.

Diagrams were included on the original Vehicle Documentation CD delivered with the vehicle.
The diagram numbers are listed below:
SCH-00036 Chassis
SCH-00054 Ford MSG Engine
SCH-00058 Ford MSG Engine Interface (Can Bus display)
SCH-00059 Ford MSG Engine Interface (Gauges)
SCH-00034 PSI GM 3.0L Engine
Page 122 MT-030-60-F

Wiring/Hydraulics
TC-030-60
HYDRAULIC DIAGRAM WITH EXTERNAL RESERVOIR
MT-030-60-F Page 123

Wiring/Hydraulics
TC-030-60
HYDRAULIC DIAGRAM WITH INTEGRAL RESERVOIR
Page 124 MT-030-60-F

Wiring/Hydraulics
TC-030-60
ADJUST PRESSURE, CUMMINS B3.3 ENGINE

WARNING
Notes: Hydraulic fluid will leak from hoses when disconnected.

This procedure requires two people.
The pump adjustment screw is facing down on the bottom of the pump.
Hydraulic system must be purged of all air before adjusting pressures.
Adjustment, Pump Max Pressure:

1: Remove outlet hose from the pump and connect a 2,000
PSI pressure gauge to the outlet. DO NOT reconnect the
hose to the pump.
2: Loosen the adjustment screw jam nut.
3: Start the engine.
4: Adjust pressure to 1,500 PSI MAX.
5: Stop engine, remove the gauge and reconnect hose to the
pump.
B. Adjustment, Steering Max Pressure:

1: Remove outlet hose from the regulator and
connect 1,000 PSI pressure gauge in the line
then reconnect the hose to the regulator.
2: Start the engine
3: Turn steering all the way to left or right and hold
against steering stop.
Note: Steering may be hard due to low pressure.
4: Adjust regulator to 600 PSI MAX.
5: Tighten the jam nut.
6: Turn engine off and remove the gauge.
7: Start engine again and inspect all fitting for leaks
MT-030-60-F Page 125

Wiring/Hydraulics
TC-030-60
Page 126 MT-030-60-F

Wiring/Hydraulics
TC-030-60
HARDWARE TORQUE
If hardware is not listed here, refer to standard torque values in the
appendix.
Brake Body Bolts 11 14.9
MT-030-60-F Page 127

Notes:
Wiring/Hydraulics
TC-030-60
Page 128 MT-030-60-F

Hardware Information
Table of Contents
Hardware Information
Torque Guidelines for Standard hardware.....130
Hardware Identification.............................................130
Hex Nuts...................................................................131
Hex Lock Nuts (stover).............................................131
Other Nuts................................................................131
Generic Torque Values.............................................132
Replacing Hardware.........................................134
WARNING
Hardware
TC-030-60
TORQUE GUIDELINES FOR STANDARD HARDWARE
Note: Torque values specified are for clean dry threads.
Note: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8
bolt, use grade 2 torque value.
Hardware Identification
Hex Head Bolts and Screws

The grade of SAE bolts and screws are identified by markings on the head
as illustrated to the right.
The grade of a metric hex head bolt or screw is cast directly on the head.
Below is an example of a 10.9. The location and style of the text will vary. SAE Grade 2 SAE Grade 5
SAE Grade 8 SAE Grade 9
Other types of bolts and screws
Truss Head, Grade 2 Carriage Bolt, Grade 2
Page 130 MT-030-60-F

Hardware
TC-030-60
Hex Nuts
Nuts with no markings are to be treated as S.A.E. Grade 2
S.A.E. Grade 5 S.A.E. Grade 8
5.8 8.8 10.9 12.9

Metric Nuts
Hex Lock Nuts (stover)

Lock nuts use a letter to indicate the grade of the nut. Grade A’ locknuts would be the equivelent of Grade
‘2’ hex nuts, Grade ‘B’ as Grade ‘5’ and Grade ‘C’ as Grade ‘8’.
NOTE: Nuts with no markings are to be treated as S.A.E. Grade A
S.A.E. Grade B S.A.E. Grade C
Grade L’9
Other Nuts
Other nuts used by Taylor-Dunn® should be treated as S.A.E. grade A
MT-030-60-F Page 131

Hardware
TC-030-60
Generic Torque Values
All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardness
specification. Reduce torque approximately 10-15% for lubricated threads.
Refer to the service section assembly procedure for critical torque values.
Imperial (inch), Foot Pounds Imperial (inch), Newton Meters

Grade, SAE Grade, SAE
Dia. Pitch 2 5 8 L9 Dia. Pitch 2 5 8 L9
#4 40 * * * * #4 40 * * * *
#6 32 * * * * #6 32 * * * *
#8 32 * * * * #8 32 * * * *
#10 32 * * * * #10 32 * * * *
#12 32 * * * * #12 32 * * * *
1/4 20 5.5 8.5 12.5 11 1/4 20 7.4 11.5 16.9 14.9
28 6.5 10.5 28 8.8 14.2
5/16 18 12.0 17.5 24.5 22 5/16 18 16.2 23.7 33.2 29.8
24 12.5 19.0 * * 24 16.9 25.8 * *
3/8 16 20 30 43 40 3/8 16 27.1 41 58 54
24 22.5 33 50 45 24 30.5 45 68 61
7/16 14 27 50 70 65 7/16 14 37 68 95 88
20 36 55 77 70 20 49 75 104 95
1/2 13 49 75 106 95 1/2 13 66 102 144 129
20 55 85 120 110 20 75 115 163 149
9/16 12 70 109 153 140 9/16 12 95 148 614 190
18 78 121 171 160 18 106 164 232 217
5/8 11 97 150 212 195 5/8 11 132 203 287 264
18 110 170 240 225 18 149 230 325 305
3/4 10 172 275 376 350 3/4 10 233 373 510 475
16 192 297 420 390 16 260 403 569 529
7/8 9 278 429 593 565 7/8 9 377 582 804 766
14 306 473 818 625 14 415 641 1109 847
1 8 416 644 909 850 1 8 564 873 1232 1152
14 466 721 1018 930 14 632 978 1380 1261
1-1/8 7 590 794 1287 1700 1-1/8 7 800 1076 1744 2304
12 662 891 1444 1850 12 897 1208 2364 2508
1-1/4 7 832 1120 1817 2950 1-1/4 7 1128 1518 2463 4000
12 922 1241 2012 3330 12 1250 1682 2727 4514
Conversion Formulas:
1: Foot Pounds = Newton Meters x 0.737562149
2: Newton meters = Foot Pounds x 1.355817948
Page 132 MT-030-60-F

Hardware
TC-030-60
All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess
specification. Reduce torque approximately 10-15% for lubricated threads.
Refer to the service section assembly procedure for critical torque values.
Metric, Newton Meters Metric, Foot Pounds

Grade, N-m Grade, N-m
Dia. Pitch 4.6 8.8 10.9 12.9 Dia. Pitch 4.6 8.8 10.9 12.9
3 0.50 0.51 * * * 3 0.50 0.38 * * *
4 0.70 0.95 3.1 * * 4 0.70 0.7 2.3 * *
5 0.80 2.28 6.1 * * 5 0.80 1.7 4.5 * *
6 1.00 3.92 10.4 15.5 * 6 1.00 2.9 7.7 11.4 *
8 1.00 * 27.0 * * 8 1.00 * 19.9 * *
1.25 9.48 25.0 37.0 * 1.25 7 18.4 27.3 *
10 1.00 * 57.0 * * 10 1.00 * 42 * *
1.25 * 54.0 * * 1.25 * 40 * *
1.50 19.1 51.0 75.0 * 1.50 14.1 38 55 *
12 1.25 * 96.0 * * 12 1.25 * 71 * *
1.50 * 92.0 * * 1.50 * 68 * *
1.75 32.6 87.0 160 * 1.75 24 64 118 *
14 1.50 * 150 * * 14 1.50 * 111 * *
2.00 51.9 140 205 * 2.00 38 103 151 *
16 1.50 * * * * 16 1.50 * * * *
2.00 79.9 215 310 * 2.00 60 158 229 *
18 1.50 * * * * 18 1.50 * * * *
2.00 * * * * 2.00 * * * *
2.50 110 300 * * 2.50 81 221 * *
20 1.50 * * * * 20 1.50 * * * *
2.00 * * * * 2.00 * * * *
2.50 156 430 * * 2.50 115 317 * *
22 1.50 * * * * 22 1.50 * * * *
2.00 * * * * 2.00 * * * *
2.50 211 580 * * 2.50 156 428 * *
24 2.00 * * * * 24 2.00 * * * *
3.00 270 740 * * 3.00 199 524 * *
27 3.00 * * * * 27 3.00 * * * *
3.00 398 * * * 3.00 293 * * *
30 2.00 * * * * 30 2.00 * * * *
3.50 540 * * * 3.50 398 * * *
Conversion Formulas:
1: Foot Pounds = Newton Meters x 0.737562149
2: Newton meters = Foot Pounds x 1.355817948
MT-030-60-F Page 133

Hardware
TC-030-60
REPLACING HARDWARE
WARNING
WARNING
Failure to follow the following guidelines may result in failure of the hardware resulting in severe bodily injury
or property damage:
• Many assemblies require specific torque settings for some hardware. Refer to the appropriate assembly
procedure for information regarding proper hardware torque.
• All hardware should be inspected for thread damage or corrosion prior to reassembly. If any evidence of
damage is found then the hardware should be replaced.
• Battery hardware should always be replaced when installing new batteries.
• Never reuse cotter pins or safety locking wire. Never use a wire, nail, or any other material to substitute
for a cotter pin.
• The locking force of a locknut is diminished when it is removed. Locknuts should be replaced whenever
removed.
• Some hardware may requires the use of a thread locking compound. Always thoroughly clean both male
and female threads when applying thread locking compounds.
Page 134 MT-030-60-F

Replacement Parts
TABLE OF CONTENTS
Replacement Parts Hitches..............................................................167
Ordering Parts for Your Vehicle......................136 Instrument Panel..............................................168
Taylor-Dunn Web Site Information..................136 Lights.................................................................169
Axle Assembly, Front.......................................138 Linkage, Cummins B3.3 Throttle.....................170
Axle Assembly, Rear........................................140 Steering Hydrostatic........................................171
Axle Assembly, Rear Primary Gears...............142 Steering, Hydrostatic, Mechanical..................177
Axle Assembly, Rear Axle & Hubs..................144 Steering, Manual...............................................178
Brakes, Pedal Linkage.....................................146 Suspension, Front............................................179
Brakes, Brake Lines.........................................148 Suspension/Axle Mount, Rear.........................180
Brakes, Front Axle............................................150 Transmission Assembly / Drive Shaft............181
Transmission: Ford C6 Cooling................................182
Brakes, Parking Brake.....................................151 Transmission: Ford C6 Intermediate Band...............183
Brakes, Rear Axle.............................................152 Transmission: Ford C6 Internal................................184
Decals................................................................153 Transmission: Ford C6 Housing...............................186
Electrical, Circuit Breaker Panel.....................154 Transmission: Ford C6 Linkage................................188
Transmission: Ford C6 Valve Body..........................189
Electrical, Miscellaneous.................................155
Transmission, Hydraulic Hoses.....................190
Engine, Cummins B3.3....................................156
Wheels and Tires..............................................191
Engine, GM 3.0 (PSI).........................................157
Engine, Cooling System PSI GM 3.0L.............158 Optional Equipment
Engine, Cooling System, Cummins B3.3.......159 Cab.....................................................................192
Engine, Intake, Air Cleaner..............................160 Cab Heater (TT-140-62)....................................192
Exhaust, PSI GM 3.0L.......................................162 Cab Doors.........................................................193
Exhaust, Cummins B3.3..................................162 Hitches..............................................................194
Frame and Body...............................................163 Remote Hitch Release (cab)............................194
Fuel System, Cummins B3.3...........................164 Lights.................................................................195
Fuel System, PSI GM 3.0L Gasoline...............165 Shift Inhibitor (Full Range Shifter)..................195
Heater (optional)...............................................166 Rear View Mirrors, Cab Door...........................195
Note: Your vehicle may have been ordered with

special order options. These options typically
start with the letter “K”. Refer to your vehicle
sales order for information.
Replacement part numbers for special order
options are not included in the standard manual.
Replacement Parts TC-030-60
ORDERING PARTS FOR YOUR VEHICLE
WARNING
The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is a factory
authorized service technician. Repairs made by unauthorized personnel may result in damage to the vehicles
systems which could lead to an unsafe condition resulting in severe bodily injury and/or property damage.
Unauthorized repairs may also void the vehicles warranty.
WARNING
To maintain peak performance, always use original Taylor-Dunn replacement parts intended for use on your
vehicle. Taylor-Dunn components are designed and tested for use on specific Taylor-Dunn model vehicles. Only
use the correct Taylor-Dunn replacement components for your Taylor-Dunn vehicle.
Do not modify your vehicle:
Modifications to this vehicle may have an undesirable affect on the operation of the vehicle, result in additional
frame stress, or stress other components resulting in premature failure or an unsafe condition and may lead
to an accident resulting in serious injury or death.
This section contains a comprehensive parts list that includes all of the typical replacement parts available as of the
published date of this manual. This parts list should be used as a guide only.
This parts list does not include special order options that may have been ordered for your vehicle. To identify special
order options, refer to the original vehicle sales order. Any special order options will have a ‘K’ letter prefix in the
option number. The vehicle option list is also available on the Taylor-Dunn web site. The serial number of the vehicle
is required to obtain the option list.
Only use original Taylor-Dunn parts purchased from an authorized Taylor-Dunn distributor. Refer to the Taylor-Dunn
web site to locate your local distributor or call the factory direct at (714) 956-4040 for referral to a local dealer.
When contacting your dealer, always include the serial number of the vehicle to ensure obtaining the correct
replacement parts. The Taylor-Dunn web site includes a parts lookup utility. By using this utility you can obtain the
most current parts list for your vehicle. The serial number of the vehicle is required to use the lookup utility.
TAYLOR-DUNN WEB SITE INFORMATION

Registering on the Taylor-Dunn web site will give you access to a wealth of information about your vehicle and the
entire Taylor-Dunn line of vehicles. Your contact information will remain confidential and will not be shared outside
of the Taylor-Dunn corporation.
Once registered on the Taylor-Dunn web site, you will have access to:
• Additional Taylor-Dunn product information.
• Worldwide Taylor-Dunn dealer contacts
• Vehicle Service, Maintenance, Operator, and Parts manuals.
• Replacement part number lookup utility
www.taylor-dunn.com
Manual # in footer
Page 136 MT-030-60-F
Manual # in footer
TC-030-60 Replacement Parts
My Vehicle information
Vehicle Serial Number: .
Engine Model Number: .
Engine Serial Number: .
Date Purchased: .
Date Delivered: .
Dealer Purchased From: .
Notes
Salesman Name: .
MT-030-60-F * Not available at time of printing Page 137

AXLE ASSEMBLY, FRONT
Page 138 MT-030-60-F

Axle Assembly, Front

Item No. Part No. Description Qty
1 88-401-46 Bolt 12
2 88-401-96 Washer 12
3 500845 Hub Cap 2
4 500844 Gasket 2
5 500841 Washer 2
6 500843 Washer 2
7 500842 Nut 4
8 500849 Bearing 4
9 500850 Race 4
10 500898 Wheel Stud (disc brake) 10
500861 Wheel Stud (no disc brake) 10
11 500846 Hub 2
12 500851 Seal 2
13 --- Steering Knuckles
501042 Manual and Hydrostatic steering, Right 1
501041 Manual and Hydrostatic steering, Left 1
20 500857 Kit, King Pin (left and right) 1
26 --- Axle Beams
14-900-14 Straight axle, Hydrostatic steering with brakes 1
14-900-14 Straight axle, Hydrostatic steering no brakes 1
14-900-15 Straight axle, Manual steering with brakes 1
14-900-15 Straight axle, Manual steering no brakes 1
- 500571 Grease Fitting, King Pin Bushing 4
- A10621 Shim, King Pin -

AXLE ASSEMBLY, REAR
Page 140 MT-030-60-F

Axle Assembly, Rear Secondary Gears
504595 Complete Axle Assembly 1
1 A11485 Ring and Pinion gear 1
2 TIG-2001-125 Differential gear 4
3 TIG-2001-121 Axle gear 2
4 TIG-2001-119 Thrust washer 2
5 TIG-2001-127 Flat washer 4
6 TIG-2001-123 Differential spider 1
7 TIG-2001-107 Bearing 2
8 TIG-2001-151 Bearing Race 2
9 CL-111437 Bearing 1
10 TIG-2001-199 Inner cone bearing 1
11 TIG-2001-201 CUP-BEARING HM803110 1
12 TIG-2001-195 Lock ring 1
13 N/A use gasket sealent only -
14 TIG-2001-193 Gasket 1
15 A11490 Differential flange (See #100) 1
16 A11491 Differential housing (See #100) 1
17 A11451 Bearing cage assembly 1
18 A11495 Housing 1
19 A11496 Housing 1
20 A11472 Shim pac 0
21 A11432 Roll pin 1
22 TIG-2001-263 Pin 1
23 TIG-2001-155 Thrust block 1
24 TIG-2001-271 Breather 1
25 - - -
26 60835 Plug, magnetic 1
27 TIG-2001-149 Nut 11
28 TIG-2001-147 Washer 11
29 - - -
30 - - -
31 TIG-2001-149 Nut (See #110) 12
32 A10174 (See #110) 12
33 A10174 Washer (See #110) 12
34 A11427 Cap screw (See #110) 12
35 RKW-P112 Plug 1
36 - -
37 88-4202-17 Cap screw 11
38 A10163 Washer (See #100) 8
39 A10162 Cap screw (See #100) 8
100 A11452 Differential housing assembly (15, 16, 38, 39) 1
110 TIG-2001-291 Hardware kit 1

AXLE ASSEMBLY, REAR PRIMARY GEARS
Page 142 MT-030-60-F

Axle Assembly, Rear Primary Gears
1 TIG-2001-281 Nut 1
2 TIG-2001-231 Washer 1
3 A11481 Nut 4
4 97-126-01 Washer 4
5 - - -
6 TIG-2001-233 Flange 1
7 A11467 Cap screw 4
8 TIG-2001-235 Seal 1
9 - - -
10 - - -
11 - - -
12 - - -
13 - - -
14 - - -
15 - - -
16 - - -
17 A11450 Stud, Case mounting 6
18 A11465 Nut 15
19 97-126-01 Washer 15
20 RKW-1229Y1507 Washer 6
21 TTI-401577 Nut 6
22 A11466 Plug 1
25 TIG-2001-245 PLUG-MAGNETIC 1250U125 1
26 A10642 Gear case assembly (Includes 27, 43) 1
27 - Cover, included with # 26 -
28 - - -
29 TIG-2001-329 Bearing cap 1
30 - - -
31 A11430 Snap ring 1
32 CL-231396 Bearing 1
33 TIG-2001-201 CUP-BEARING HM803110 1
35 RKW-1229G913 Washer 1
37 TIG-2001-323 Gear 1
38 TIG-2001-321 GEAR-INPUT,FIN. 3892X5172 1
39 A10189 Nut 1
40 TIG-2001-227 Locking washer 1
41 A10189 Nut 1
42 TIG-2001-223 Key 2
43 TIG-2001-263 Dowel 2
AXLE ASSEMBLY, REAR AXLE & HUBS
Page 144 MT-030-60-F

Axle Assembly, Rear Axles

1 TIG-2001-604OE Shaft assembly, right 1
TIG-2001-603OE Shaft assembly, left 1
2 A11462 Cotter 2
3 TIG-2001-189 Nut 2
4 TIG-2001-187 Washer 2
5 TIG-2001-608 O-Ring 2
6 TIG-2001-606 Hub 2
7 404217NS Brake rotor 2
8 TTI-500216 Wheel Stud 8
9 UN-34443 Shim, 0.003 5
TIG-2001-171 Shim, 0.005 (package of 10) 4
A11437 Shim, 0.010 (package of 5) 3
10 TIG-2001-173 Spacer 1
11 TIG-2001-175 Gasket 1
12 TIG-2001-167 Bearing race 1
14
15 TIG-2001-167 Bearing race 1
16 A11493 Collar 1
17 88-401-47 Cap screw 6
18 401602 Washer 6
19 TIG-2001-177 Seal 1

BRAKES, PEDAL LINKAGE
Brake Pedal Linkage

1 503249 Pivot, Push Rod 1
88-402-84 Jam Nut 1
2 - - -
3 88-402-85 Washer, Push Rod Pivot 2
500563 Cotter Pin 1
4 502855 Brake Pedal, includes bushings 1
5 500185 Bolt, Pedal Pivot 1
88-401-80 Nut 1
503191 Bushing 2
88-402-85 Washer, 1/2, Spacer 1
88-401-95 Washer, 3/8 1
6 505502 Hydroboost Assembly 1
7 88-401-48 Bolt 4
88-401-95 Washer 8
88-401-80 Nut 4
Page 146 MT-030-60-F


BRAKES, BRAKE LINES
Page 148 MT-030-60-F

Brake Lines
1 500591 Brake Line, Master Cylinder (front port) to Front T Fitting 1
2 503206 Brake Line, T to Left Front Brake Hose 1
3 500148A Brake Line, T to Rear Axle (rear calipers) 1
4 503207 Brake Line, Front Left Hose to Front Right Hose 1
5 500591 Brake Line, Master Cylinder (rear port) to T fitting 1
6 500147 Brake Line, T to Rear Axle (front calipers) 1
7 500146 Brake Line, Rear Axle Rear Calipers 1
8 500145 Brake Line, Rear Axle Front Calipers 1
9 504592 Brake Hose, Brake Line to Rear Axle Rear Calipers 1
10 504592 Brake Hose, Brake Line to Rear Axle Front Calipers 1
11 504590 Brake Hose, Rear Left Caliper 2
500576 Copper washer 2
12 504590 Brake Hose, Rear Right Caliper 2
500576 Copper washer 2
13 504592 Brake Hose, Front 2
14 502518 Brake Fitting, Front T 1
15 98-515-92 Brake Fitting, Rear T, W / Mounting bracket 2
16 99-525-25 Brake Fitting, Front Caliper 2
17A 500195 Brake Fitting, Master Cylinder 1
17B 502198 Brake Fitting, Master Cylinder 1
18 500159 Brake Fitting, Coupler, Rear Axle 2
19 500552 Brake Light Switch, Hydraulic 1
20 504084 Brake Fitting, Brake light Switch 1
21 502013 Brake Fitting, T 1
Not Shown 500243 Hose Clamp, Rear Axle Brake Lines 1
Note: Front brakes are optional, item #’s: 2, 4, 13, 14, 16, 21. For rear brake only, item 21 is replaced with 18.

BRAKES, FRONT AXLE
Front Brakes
1 500673 Caliper Assembly, Left 1
500673 Caliper Assembly, Right 1
2 500375 Mounting Bracket 2
3 500374 Rotor 2
4 88-402-07 Bolt, 7/16 Grade 8 4
88-402-28 Nut, Reversable Lock 4
5 88-401-77 Bolt, Caliper Mounting 4
6 88-401-96 Washer, Split Lock, Caliper Mounting 4
- 903641 Piston 4
- 41-348-62 Kit, Brake Pad, Includes 4 pads and safety wire -
- 505879 Safety Wire (for #5) Per Ft.
Page 150 MT-030-60-F

BRAKES, PARKING BRAKE

1 500543 Handle, Park Brake 1
2 506314 Cable, Park brake 1
3 500022-V6 Bracket, Handle Mounting 1
4 88-402-48 Bolt, Bracket to Frame, Front 2
88-402-67 Bolt, Bracket to Frame, Rear 2
88-402-85 Washer, Bracket to Frame 8
88-402-75 Nut, Bracket to Frame 4
5 500864 Spring, Return 1
6 41-386-03 Mount, Return Spring 1
7 96-772-00 Clevis Pin, Handle 1
500563 Cotter Pin 1
8 96-772-00 Clevis Pin, Caliper 1
500563 Cotter Pin 2
9 501277 U-bolt, Rear Cable Mount 1
10 501277 U-bolt, Front Cable Mount 1
11 41-386-00 Bracket, Rear Cable Mounting 1
88-402-75 Nut, Mounting 2
12 96-762-00 Clevis 1
13 88-119-80 Nut 1
14 88-400-02 Bolt, Handle Mounting 4
88-400-90 Washer 8
88-400-78 Nut 4
- 501273 Caliper Assembly 1
245437 Kit, Brake Pads
- 501272 Brake Rotor 1

BRAKES, REAR AXLE

- A15203 Caliper Assembly (universal Front or Rear) 4
- 41-490-43 Kit, Brake Pad Replacement 1
- - Includes pads, inner and outer clips for all 4 calipers -
- 41-490-44 Kit, Boot and Square Ring 4
- 41-490-45 Kit, Mounting (1 caliper) 4
- - Includes Slide Pins, Sleeves, and Rubber Rings (1 & 2) -
Page 152 MT-030-60-F

DECALS
1 500237 DECAL \ WARNING FAN 1
2 501040-7 Shift 1
3 - - -
4 94-301-41 DECAL, DOT 3 BRAKE FLUID 1
5 94-301-42 DECAL, ARMS/LEGS, 2 PASS 1 or 2
6 94-384-04 DECAL, TRAFFIC STDS NOTICE 1
7 94-384-19 DECAL, LEAVING VEHICLE (IC) 1
8 94-309-00 DECAL, PARK BRAKE WARNING 1
9 94-313-00 DECAL, BATTERY WARNING (GASES) 1
10 94-313-20IC DECAL, SAFETY WARNING, 5x6 IC 1
11 94-319-01 DECAL, BATTERY DISCONNECT, IC 2
12 94-384-26 DECAL, POWER STEERING FLUID 1
13 94-384-48 DECAL, WARNING PINCH/CRUSH 1
*14 94-373-75-xx DECAL, DIESEL EMISSIONS, xxxx 1
15 94-306-13 DECAL, UNLEADED FUEL 0 or 1
*: The”xx” denotes the ending 2 digits for the vehicle year of manufacture.
The “xxxx” denotes the year of manufacture.

ELECTRICAL, CIRCUIT BREAKER PANEL

500781 Circuit Breaker\10A 4
502533 Circuit Breaker Boot 1
500790 Buss Bar\3 Gang 1
500788 Bracket\4-Circuit Breaker 2
Page 154 MT-030-60-F

ELECTRICAL, MISCELLANEOUS

- 75-153-66 Harness, Main 1
- 500263 Ground Strap, Engine To Chassis 1
- 505326 CABLE, ALT CHG LEAD, CUMMINS 1
- 505333 Lead, Ignition, Cummins 1
- 500364 Boot\Insulating\Battery Cable 4
- 500586 Horn\ w/ Bracket 1
201040 Horn Button 1
500558-A Relay\Horn (4 Pin) 1
75-152-65 Harness, Adaptor, Horn > 1
- 500560 Hour Meter Switch 1
- 500759-0250 Wire Loom Nylon 1/4 Per Foot
- 500759-0350 Wire Loom\ 3/8” \ Nylon Per Foot
- 500759-0500 Wire Loom \ 1/2” \ Nylon Per Foot
- 500759-0750 Loom, Nylon 3/4” Per Foot
- 500759-1000 Loom, Nylon 1” Per Foot
- 502556A Boot\Top Post\Positive 1
- 504933 Battery/Group 24M 1
502556 Cable, Battery, 1G X 5’, POS 1
500098 Hold Down Bar, Battery 1
50-243-16 Rod All Thread Battery Hold Down 2
- 500532 Sending Unit\Oil Pressure 1
- 500548 Sending Unit\Temperature 1
- 500105-A Solenoid 1
- 502496 Relay\Accessory 1
- 501389 Cable Battery 2 GA48” Black T-Post 1
- 500283-1 CLAMP CBL 1/4 X 1/2 INSUL(#4) As Needed
- 500283-2 CLAMP CBL 3/8 X 1/2 INSUL As Needed
- 500283-3 CLAMP CBL 3/4 X 1/2 INSUL As Needed
- 500283-8 CLAMP CBL 1-1/8 X 1/2 INSUL As Needed
- 500283-10 CLAMP CBL 2 X 3/4 INSUL As Needed
- 500890 Battery disconnect switch Optional
94-376-00 Decal, Kill switch

ENGINE, CUMMINS B3.3

- 67-000-02 Engine Assembly 1
- 30-701-04 Bracket, Engine mount, Frame Right 1
- 30-701-05 Bracket, Engine mount, Frame Left 1
- 30-701-32 Bracket, Engine mounting (Right) 1
- 30-701-33 Bracket, Engine mounting (Left) 1
- 505801 Engine mount 2
75-000-00 Harness, Glow Plugs 1
- 67-500-88 Sender, Oil pressure 1
- 500548 Sender, Temperature 1
- 4-2775785 Cable, Throttle 1
- ** Hydraulic pump 1
- * Belt, Fan 1
- 67-501-33 Starter 1
- * Alternator 1
- 67-500-89 Oil filter 1
- * Fuel shut off valve 1
- 67-500-90 Fuel water/Separator 1
- * Fuel pump 1
- 67-500-84 Glow Plug 4
- 66-000-70 Heat Shield 1
- 30-701-28 Bracket, accelerator cable 1
- 30-701-31 Bracket, Cable return spring 1
- 505326 Cable, Alternator 1
**This engine will have one of two hydraulic pumps and also affects the hoses attached to the
pump. The pumps are not interchangeable unless the hoses are also changed. Identify the pump
on your engine using the pictures below.
99-508-05
Page 156 MT-030-60-F

ENGINE, GM 3.0 (PSI)
- 67-000-97 Engine Assembly, Gasoline 1
- 67-000-99 Engine Assembly, LPG 1
- 00-900-25 MOUNTING BRACKET, R, GM ENGINE 1
- 00-900-26 MOUNTING BRACKET, L, GM ENGINE 1
- 505499 FRAME MOUNT, EURO 2
- 4-2778901 MOUNT-ENGINE (65 DURO) 2
- 88-407-40 M16X2 X 40MM 10.9 FLGHCS 2
- 66-900-07 Mount, Steering Pump, Lower 1
- 66-900-20 Mount, Steering Pump, Upper 1
- 66-900-06 Mount, Steering Pump, Rear 1
- 66-900-08 Belt, Steering Pump 1
- 66-900-09 PULLEY, WATER PUMP, 2 GROOVES 1
- 505699 Heat Shield, Hose, 36 inches 1
4-2771715 Hydraulic Pump
A15570 THERMOSTAT 1
GM-10105135 GASKET, WATER OUTLET 1
GM-14096154 GASKET, VALVE COVER 1
GM-14096660 GASKET KIT, CYLINDER HEAD 1
GM-15544596 CAP, HEATER WATER OUTLET 1
GM-25366425 INJECTOR, MAIN PORT FUEL 4
GM-30100297 BELT, ALTERNATOR 1
GM-33500647 GASKET, INTAKE/EXHAUST 1
GM-88894247 PUMP KIT, WATER 1
GM-93419731 FLYWHEEL WITH RING GEAR 1
MC-G10006 FAN, PULLER, 18” 1
TTI-507117 STARTER 1
GM-33000264 BOLT, STARTER 3/8-16 x 4.5 2
500548 SENDING UNIT, TEMPERATURE 1
66-499-76 ECU 1
67-500-03 FILTER, OIL 1
67-500-04 FUEL PUMP 1
67-500-05 FILTER, FUEL 1
67-500-10 THROTTLE BODY 1
67-500-11 MODULE, THROTTLE 1
67-500-24 OXYGEN SENSOR 1
67-500-91 SPACER, FAN 1
67-500-92 SENSOR, TEMPERATURE (ECM) 1
67-500-93 GASKET, INTAKE TO EXHAUST 1
75-147-53 HARNESS, ENGINE 1

ENGINE, COOLING SYSTEM PSI GM 3.0L

1 500103-FX Radiator 1
2 500111-A Mount 4
88-401-31 Nut 8
88-401-40 Washer, Flat 8
88-401-41 Washer, Lock 8
3 500262 Cap 1
4 505700 Hose, Radiator Upper 1
5 504510 Hose, Radiator Lower 2
6 505734 Coupler, Lower Hose 1
7 506344 Clamp, Lower Radiator Hose 4
8 505996 Fan Shroud 1
88-400-01 Bolt 6
88-400-90 Washer 12
88-400-78 Nut 6
9 506338 Clamp, Upper Radiator Hose 2
Not Shown 500130 Tank, Coolant Recovery 1
- Includes Tank, Wire bracket, Hoses, clamps
01-900-60 Bracket, Coolant Recovery Tank 1
88-401-48 Bolt, bracket mounting 2
88-401-95 Washer 4
88-401-87 Nut 2

Page 158 MT-030-60-F

ENGINE, COOLING SYSTEM, CUMMINS B3.3

1 500103-V6 Radiator 1
500111-A Rubber Mount 4
66-000-25 Bracket, Radiator mounting, Left 1
66-000-26 Bracket, Radiator mounting, Right 1
2 500262 Cap, Radiator 1
3 500130 Coolant recovery kit 1
01-900-60 Mounting bracket 1
4 K1T-600-65 Fan Cover 1
5 K4N-HO-020 Hose 1
6 506344 Clamp 2
7 K4N-HO-019 Hose 1
8 506388 Clamp 2
9 See Heater Option -

ENGINE, INTAKE, AIR CLEANER
GM Gasoline Engine GM LPG Engine
18
19
Cummins B3.3
Page 160 MT-030-60-F

Engine, Air Cleaner
1 500805-7-A Air Filter Assembly 1
67-500-01 Filter element 1
2 504558 Mounting Bracket, Frame 1
3 88-401-02 Bolt 4
88-401-40 Washer 8
88-401-31 Nut 4
4 504274 Coupler, elbow, GM LPG 1
504274 Coupler, Elbow, Cummins B3.3 1
5 502131 Clamp 2
6 505962 Tube Intake, GM Engine 1
66-900-31 Tube, intake, GM LPG engine 1
K1T-600-66 Tube, Intake, Cummins B3.3 1
7 66-000-62 Coupler, GM engine, LPG 1
K4N-EL-001 Coupler, Elbow, Cummins Diesel B3.3 1
8 502522 Clamp, Hose, GM Engine (gasoline/LPG) 2
9 323-71 Hose, GM engine (gasoline) 18 inches
505857 Hose, GM LPG engine 1
10 500661 Clamp 2
11 500805-7-B Mounting Bracket, Clamp 1
88-401-02 Bolt 2
88-401-40 Washer 4
88-401-31 Nut 2
12 * Bolt 1
14 504943 Fitting, Hose adaptor 1
15 32619 Clamp 2
16 504275 Coupler, Flex, Cummins B3.3 1
17 502131 Clamp
18 66-000-33 Cover, Air Intake (includes clamp) 0 or 1
19 66-000-82 Filter Monitor 0 or 1

EXHAUST, PSI GM 3.0L
- 500250 Hanger, Exhaust 2
- 500555 Clamp, Muffler 2
- 503954 Wrap, Exhaust Pipe Per Foot
- 502522 Clamp, Hose 4
- 505872 Gasket, 2-Bolt 2
- 505888 Gasket, 3-Bolt 1
- 505958 Head Pipe Weldment 1
- 505980 Exhaust Pipe 1
- 66-400-16 Muffler / Catalytic Converter 1
EXHAUST, CUMMINS B3.3

- 500250 Hanger, Exhaust 2
- 500703-D MUFFLER 1
- 502200 TAIL PIPE 1
- 503954 MUFFLER WRAP 2” Per Foot
- K1T-600-59 EXHAUST HEADPIPE 1
Page 162 MT-030-60-F

FRAME AND BODY

- * Frame, standard
500033 Hood, Gasoline model 1
506333 Hood,LPG Model 1
500140 Hinge 1
500589 Handle, Hood 2
500574 Latch, Hood 2
500557 Bump Stop 2
500362 Gas Spring, Hood 2
500363 Ball Stud 4
500052-A Prop Rod, Hood 1
500051 Clip, Prop Rod 1
500054 Bracket, Prop Rod 1
504445 Cowling, Right 1
504446 Cowling, Left 1
K1T-100-24 Cowling, Left, Cummins B3.3 1
500364 Cowling Mounting Grommet 16
500220-R Cowling Mounting Receptacle 8
500220-WS Cowling Mounting Wing Stud 8
01-900-50 Transmission Cover 1
500298-A Boot, Parking Brake Handle 1
500624 Gasket, Left Rear Per Foot
500975 Gasket, Right Rear Per Foot
500539 Bracket, Shifter Mounting 1
500284-B Driver Seat 1
88-401-31 5/16 NC HEXNUT GR8 4
88-401-40 5/16 FLW THRU-HARD GR8 4
88-401-41 5/16 SPLKWASH GR8 4
500284-B Passenger Seat 1
88-401-31 5/16 NC HEXNUT GR8 4
88-401-40 5/16 FLW THRU-HARD GR8 4
88-401-41 5/16 SPLKWASH GR8 4
505303 HIP RESTRAINT, TC-30/60, Passenger 1
88-402-47 1/2 X 1 3/4 NC HEXHDSCR GR8 3
88-402-75 1/2 NC TOPLKNT GR9 3
88-402-85 1/2 FLW THRU-HARD GR8 6
00-900-13 HIP RESTRAINT, DRIVER,TC-30/60 1
88-402-47 1/2 X 1 3/4 NC HEXHDSCR GR8 3
88-402-75 1/2 NC TOPLKNT GR9 3
88-402-85 1/2 FLW THRU-HARD GR8 6
504438 Pocket, Fuel Filler 1
500581 COLLAR \ FUEL POCKET 1
00-900-10 Firewall, Gasoline model 1
00-900-15 Firewall, LPG model 1
504669 Hole Plug, 5/16 3
505313 Hole Plug, 3/8 4
500338 PLATE, COVER, FLYWHEEL HOUSING 1
500077 Plug, Defrost Vent 1
500370 Rubber Pad, Throttle Pedal, Cummins / Perkins Engine 1

FUEL SYSTEM, CUMMINS B3.3

1 500201 Fitting, Adaptor 1
2 503829 Fitting, Elbow 1
3 500547 Fuel level sender 1
4 99-803-02 Fuel line, Return 1
5 99-803-01 Fuel line, Pickup 1
6 504932 Fuel hose, Return 1
7 505601 Fuel hose, Pickup 1
- 500023 Fuel tank 1
- 504044 Cap, Fuel filler with screen 1
Page 164 MT-030-60-F

FUEL SYSTEM, PSI GM 3.0L GASOLINE

1 67-500-06 Pressure Regulator 1
2 98-545-00 Fuel Line Assembly, Secondary Filter to Regulator 1
3 505952 Fuel Line Assembly, Return to Tank 1
4 98-545-01 Fuel Line Assembly, Regulator to Engine 1
5 500023 Tank, Fuel (standard) 1
500024 Mount 1
500547 Fuel Level Sender 1
505461 Fuel Cap 1
500201 FTG, 5/16 INV FL - 1/4 MPT 1
504942 Barb Fitting, Hose 2
504087 Reducer 3/8 - 1/4 NPT 1
88-402-46 1/2 X 1 1/2 NC HEXHDSCR GR8 4
88-402-75 1/2 NC TOPLKNT GR9 4
88-402-85 1/2 FLW THRU-HARD GR8 8
- 67-500-05 Fuel Pump 1
- 98-545-02 Fuel Line Assembly, Tank to Pump, includes filter 1
05-211-05 Filter, Primary 1
- 505955 Fuel Line, Primary Filter to Pump 1
- 98-540-12 Fuel Line, Primary Filter to Secondary Filter 1 foot
- 504661 Clamp, Hose 8
- 67-500-05 Filter, Secondary 1
- 504085 BKT FUEL FILTER 1
66-410-50 Fuel pickup tube (in fuel tank) 1

HEATER (OPTIONAL)
Option Numbers: TL-140-02, TL-140-51, TN-140-02, TN-140-61

- 94209 Heater 1
- 32371 HOSE 5/8 GENL PRP 350 PSI RED 8
- 32619 Clamp, Hose #12 6
- 4-2774697 Switch-Rocker (Headlight) 2
- 500136 Fan, Cab Cooling 1
- 502028 Y Connector 5/8 Hose 2
- 94211 Valve 1
- 94442 Lens Insert, Defroster Fan, GR 1
- 94443 Lens Insert, Heater, Yellow 0 1
- 99-500-31 Elbow, 5/8 Hose X 3/8 MPT 2
- 99-525-54 Bushing, 3/4 X 3/8, Brass 2
- 4-2777647 Cable 1
Page 166 MT-030-60-F

HITCHES
Part No. Description Qty Part No. Description Qty

40233 Coupler 1 97-800-40 Coupler 1
40234 Coupler Pin 1 97-800-43 Coupler Pin 1
97-800-31 Pin Cable holder 1 97-800-31 Pin Cable holder 1
88-403-36 Bolt 4 97-305-03 Key Ring (chain) 2
88-403-70 Nut 4 30-550-01 Chain, up to s/n 184999 1 foot
88-403-81 Lock Washer 4 30-550-02 Chain, starting s/n 185000 1.4 feet
88-403-80 Flat Washer 4 88-403-35 Bolt 4
88-403-70 Nut 4
88-403-80 Flat Washer 4

INSTRUMENT PANEL

1 500128 Switch, Ignition (keykless) 0 or 1
2 500550 Switch, Headlight 1
3 500116 Gauge, Oil Pressure 1
4 See Lights Light, Check Engine 1
5 500545 Gauge, Coolant Temperature 1
6 502452 Gauge, Volts 1
7 500546 Gauge, Fuel 1
8 500537 Gauge, Hour Meter 1
- * Switch, Ignition (keyed) 0 or 1
- 500041-M Panel, Formed 1
- 88-401-47 Bolt, Panel Mounting 2
- 88-401-95 Washer, Panel Mounting 2
- 88-401-96 Lock Washer, Panel Mounting 2
97-211-30 U-nut 2
Page 168 MT-030-60-F

LIGHTS

1 505999 Headlight 2
2 503415 Taillight 2
3 506201 Backup Light 2
4 504420 Reflector, Front Round 2
5 502142 Reflector, Side, Red 2
6 502143 Reflector, Side, Amber 2
7 501332 Dash Light, Red (Lens Only)
502321 Bulb1
7 72-028-41 Dash Light, Amber (includes bulb)
72-079-00 Bulb1
8 502321 Bulb, Shift Light (optional) 1
- 502321 Bulb, Fuel Gauge 1
Note: Actual location of dash lights

may vary depending on the vehicle
configuration

LINKAGE, CUMMINS B3.3 THROTTLE

1 4-2385580 Ball Coupler 1
2 30-701-25 Arm, Throttle 1
3 85-209-09 Spring, Return 1
30-701-31 Bracket, Return Spring 1
4 4-2775785 Cable 1
5 4-2384914 Clamp 1
503931 Spacer, Throttle Cable 1
6 66-502-68-04 TPS 1
7 502474 Arm, Throttle Pedal 1
8 500370 Throttle Pedal 1
9 88-405-05 Bolt, Throttle Stop 1
88-401-95 Washer, Flat 2
88-401-80 Nut 1
32-000-05 Bushing 1
10 66-502-68-05 Rod end 1
11 66-502-68-06 Rod end (with spring) 1
Page 170 MT-030-60-F
STEERING HYDROSTATIC
Illustration not available
Common (All Engines)

- 201038 Steering Valve 1
61950 Support, Steering Valve 1
- 201039 Steering Wheel 1
- 45930 Column 1
- 504795 HYD RES MT TC-80/120 1
- 73399 End Assembly Rod (RH) 2
- 61621 TIE ROD CLAMP ASSY 1
- 504407 RESERVIOR, HYD, 1.5 QT 1
- 94082 Cap / Dipstick 1
- 31406 Hose Clamp 2
- 201030A Cylinder, Steering, Hydraulic 1
- 503739 HOSE, HYDROBOOST TO STR VLV 1
- 505485 Hose, Steering Valve to Cylinder, Right 1
- 505487 Hose, Steering Valve to Cylinder, Left 1
- - Fitting, Included with Hydroboost
- 99-528-00 FIlter (optional) 0 or 1

Page 172 MT-030-60-F

Cummins 3.3 with 99-508-05 Pump
1 99-508-05 Hydraulic Pump (see illustration)
99-530-69 Hose, Pressure to Brake Hydroboost 0 or 1
3 See Brake Pedal Brake Hydroboost 1
4 99-530-10 Hose, Pressure to Steering Valve 1
5 99-508-04 Hose, Pressure Relief 1
* Hose, Steering Valve to Filter (optional) 1
6 201038 Steering Control Valve 1
504125 Fitting, 90 Degree Swivel 2
504124 Fitting, Adapter 2
502134 Boot, Rubber 1
504577 Mounting Ring for Rubber Boot 1
503716 Mounting Bracket 1
7 99-530-71 Hose, Steering Valve “L” 1
8 99-530-72 Hose, Steering Valve “R” 1
9 See mechanical parts Steering Cylinder 1
10 201134 Filter Assembly (optional) 1
99-528-00 Replacement Cartridge 1
76744 Fitting, 90° 2
11 505986 Hose, Return Line Assembly 1
* Hose, Return Line Assembly, optional filter 0 or 1
- 504596 Hose clamp (Hydroboost & Pump return lines) 2
- 201037 Steering Column 1
12 99-597-61 Reservoir 0 or 1
13 99-530-93 Hose, Reservoir to Pump 0 or 1

Page 174 MT-030-60-F

Cummins 3.3 with 99-508-11 Pump

1 99-508-11 Hydraulic Pump (see illustration)
2 * Hose, Pressure to Brake Hydroboost 0 or 1
5 * Hose, Pressure Relief 1
* Hose, Steering Valve to Filter (optional) 1
76744 Fitting, 90° 2
11 505986 Hose, Return Line Assembly 1
* Hose, Return Line Assembly, optional filter 1
12 99-597-61 Reservoir 1
13 * Hose, Reservoir to Pump 1
14 * Hose 1

PSI GM 3.0L Engine

1 See Engine Hydraulic Pump
2 505639 Hose, Pressure to Brake Hydroboost 1
504777 Fitting, Pump outlet, PSI GM Engine 1
5 99-530-11 Hose, Steering Valve to Filter (optional) 1
76744 Fitting, 90° 2
11 505986 Hose, Return Line Assembly 0 or 1
99-530-12 Hose, Return Line Assembly, optional filter 0 or 1
Page 176 MT-030-60-F

STEERING, HYDROSTATIC, MECHANICAL

14 14-900-10 Steering Arm, Right 1
504381 Steering Arm, Left 1
15 500563 Cotter Pin 4
16 500838 Key 2
17 500837 Nut, Castle 2
18 - Nut, Castle, included w ball joint 4
19 88-527-16 Cotter Pin 2
20 - - -
21 86-510-00 Clamp, Ball Joint 2
22 500855 Ball Joint, Left Thread 1
500854 Ball Joint, Right Thread 1
23 14-000-01 Steering Cylinder 1
24 201032 Jam Nut 2
25 500854 Ball Joint, Right Thread 2
- 14-900-11 Tie Rod 1
- 201039 Steering Wheel 1
201283 Nut 1
- 88-128-13 Bolt, Steering Stop 2
- 500840 Nut, Steering Stop Bolt 2

STEERING, MANUAL

201039 Steering Wheel 1
201283 Nut 1
500102 Steering Gear 1
500010-B Bracket, Mounting 1
500095 Bracket, Upper shaft support 1
500071 U-bolt 1
503527 Pitman Arm 1
* Nut 1
* Washer 1
501255-1 Drag link (501255) 1
501242-A Rod End 2
- Castle Nut (included with rod end) 2
501242-C Jam nut 2
500848 Steering arm, Right 1
500847 Steering arm, Left 1
500837 Nut 2
500838 Key, 1/4 Square 2
88-527-16 Cotter pin 2
14-900-11 Tie rod 1
500855 Rod end (L) 1
500854 Rod end (R) 1
86-510-00 Clamp 2
- Castle Nut (included with rod end) 2
500563 Cotter pin 2
88-128-13 Stop, Knuckle 2
500840 Nut 2
Page 178 MT-030-60-F

SUSPENSION, FRONT

1 500582 Spring, Leaf 2
2 500583 Bushing, Spring Eye 4
3 500046 U-bolt 2
88-402-75 Nut, U-bolt 4
88-402-85 Washer 4
4 500045 Plate, U-bolt 2
5 88-402-94 Bolt, Spring Eye 4
88-403-10 Washer 8
88-403-05 Nut 4
6 88-402-52 Bolt 4
88-402-75 Nut 4
88-402-85 Washer 8

SUSPENSION/AXLE MOUNT, REAR

1 500061 Spring, Leaf 2
2 500561 Bushing, Spring Eye 4
3 500055 U-bolt,Driver side Inner (long) 1
500059 U-bolt, (short) 3
88-403-28 Nut 8
88-403-10 Washer 8
4 506319 Plate, U-bolt 2
5a 88-402-94 Bolt, Spring Eye, Front 2
5b 88-402-95 Bolt, Spring Eye, Rear 2
88-403-10 Washer 8
88-403-05 Nut 4
6 500012 Spring Mount, Right Rear 2
7 500008 Spring Mount, Left Rear 2
88-402-75 **Bolt, Spring Mount, Short 14
88-402-67 **Bolt, Spring Mount, Long 2
88-402-85 Washer, Spring Mount 8
88-402-75 Nut, Spring Mount 16
* - Two long bolts are installed in the front right spring mount, front holes only. Also hold park brake mount.
Page 180 MT-030-60-F

TRANSMISSION ASSEMBLY / DRIVE SHAFT

See bulletin BUL-10-02-001 Transmission Assembly 1
- 500011-V6 MOUNT BRKT TRANS F4.9 1
- 502246 TRANS MOUNT \ ISOLATOR 1
- 502324 DIPSTICK TUBE FORD C6 1
- 505733 BAR, TRANSMISSION SPACER, PSI GM Engine 1
- 502323 Dipstick 1
- 201134 Filter, External (optional) 1
- 99-528-00 Replacement Cartridge 1
- 76744 Fitting, 90 Degree 2
- 90536 Fitting, Adapter 2
- 503052 Shifter Assembly, Forward/Reverse 1
- 504092 Switch, Reverse/Neutral 1
- 66-501-09 Shift Rod 1
- 500529 Rod End 1
- 501245 Arm, Shifter 1
- 502737 Spacer, 1/2” 1
- 81-200-05 Drive shaft, PSI GM Engine (park brake on axle) 1
- 86-553-10 U-Joint, Front (park brake on axle) 1
- 86-553-11 U-Joint, Rear 1
502554 Drive Shaft, Cummins Engine (park brake on axle) 1
- 86-553-11 U-Joint, Rear 1
- * Drive Shaft, Ford MSG Engine (park brake on axle) 1
- * Drive Shaft, Ford MSG Engine (park brake on transmission) 1
- 505497 U-Joint, Front (park brake on transmission) 1
- 86-553-11 U-Joint, Rear 1
- 500810 FLEX PLATE 1
- 500811 RING/FLEX PLATE/USE W/500810 1
- 502427 BOLT/SPECIAL FLEXPLATE C6 6
- K1T-600-56 Adaptor, Fles Plate, Cummins B3.3 1
- K4N-SP-002 Spacer, Transmission, Cummins B3.3 1
- 502587 Kit, Shift Inhibitor Forward/Reverse (optional) 1
- - Kit includes: solenoid, pressure switch, relay, indicator light, decal
- 236440 Solenoid 1
- 501040-6A Light Assembly 1
- 502321 Bulb 1
- 274561 Pressure Switch 1
- 500656 Relay 1
- 75-153-64 Harness
- 501040-11 Fitting, pressure switch 1
- 01-900-61 Heat shield 1

Transmission: Ford C6 Cooling

1 K0T-600-33 Hose assembly 1
2 K0T-600-32 Hose assembly 1
3 503829 Fitting, 45 degree 2
4 500201 Fitting, 5/16 Inverted flare x 1/4 Pipe 0 or 2
500155 Fitting, 5/16 Inverted flare x 1/8 Pipe 0 or 2
Page 182 MT-030-60-F

Transmission: Ford C6 Intermediate Band

1 * Intermediate band servo piston spring 1
2 * Intermediate band servo cover piston seal 1
3 * Intermediate band servo piston and rod assembly 1
4 * Intermediate band Piston Seal 1
5 - - -
6 * Intermediate band servo cover gasket 1
7 * Intermediate band servo cover 1
8 * Bolt 4
9 * Intermediate band adjusting lever shaft 1
10 * RETAINER,BALL CHECK 1
11 * Intermediate band servo lever 1
12 * Intermediate band servo lever shaft retainer 1
13 * Nut 1
14 * Adjusting screw 1
15 * Intermediate band anchor strut 1
16 * Intermediate band 1
17 * Intermediate band strut 1

Transmission: Ford C6 Internal

1 * Input Shaft 1
2 * Stator Support (part of front pump) 1
3 * Thrust washer 1
4 * Intermediate Drum seal 1
5 * Intermediate drum 1
6 * Seal 1
7 * Direct drive clutch piston oil seal, outer 1
8 * Direct clutch piston 1
9 * Spring 1
10 * Reverse clutch external spline plate (steel) 1
11 * Reverse clutch internal spline plate (friction) 1
12 * Forward clutch internal spline plate (friction) 1
13 * Forward clutch external spline plate (steel) 1
14 * Direct clutch external spline plate (steel) 1
15 * Direct clutch internal spline plate (friction) 1
16 * Clutch piston spring retainer 1
17 * Direct drive clutch piston spring retainer ring 1
18 * Direct drive clutch pressure plate 1
19 * Retaining ring 1
20 * Intermediate drum thrust washer 1
21 * Forward clutch cylinder seal 2
22 * Forward clutch cylinder assembly 1
23 * Seal 1
24 * Forward clutch piston oil seal, outer 1
Page 184 MT-030-60-F

25 * Forward clutch piston 1
26 * Forward clutch piston 1
27 * Forward clutch piston disc spring 1
29 * Forward clutch pressure plate (front) 1
30 * Forward clutch pressure plate 1
31 * Snap ring 1
32 * Forward clutch hub thrust race 1
33 * Forward clutch hub thrust bearing assembly 1
34 * Forward clutch hub thrust race 1
36 * Forward ring gear hub 1
37 * Forward ring gear 1
38 * Planet carrier thrust washer 1
39 * Forward planet 1
40 * Front retainer 1
41 * Sun gear assembly 1
42 * Input shell 1
43 * Input shell thrust washer 1
44 * Rear retainer 1
45 * Output shaft thrust washer 1
46 * Output shaft park gear 1
47 * Oil distributor sleeve 1
48 * Oil distributor tube, inlet 1
49 * Snap ring 1
50 * Bolt 4
51 * Governor housing seal ring 3
52 * Governor body oil collector body 1
53 * Governor body assembly 1
54 * Bolt 4
55 * - -
56 * Output shaft 1
57 * - -
58 * - -
59 * Snap ring 1
60 * Thrust washer #7 1
61 * Planet carrier thrust washer 1
63 * Reverse planet 1
64 * Ring gear 1
65 * Output shaft hub 1
67 * Output shaft hub thrust bearing 1
68 * Snap ring 1
69 * Reverse clutch hub 1
70 * Snap ring 1
71 * One way clutch 1
72 * Inner race, One way clutch 1
73 * Snap ring 1
74 * Reverse clutch pressure plate 1
75 * Snap ring 1
76 * Spring retainer 1
77 * Spring 1
78 * Reverse piston 1
79 * Included w/#78 1
80 * Included w/#78 1
81 * Reverse clutch piston outer seal 1
82 * Reverse clutch piston inner seal 1
83 * Forward clutch hub thrust washer 1

Transmission: Ford C6 Housing

1 * Case 1
2 66-501-34 Housing Tailshaft 1
3 * Transmission oil pan 1
4 FD-C6AZ7A191B Oil pan gasket 1
5 67-500-12 Extension housing gasket 1
6 * Gasket, front pump 1
7 * - -
8 * Torque Converter 1
9 - - -
10 - - -
11 * Sealing ring 1
12 * Seal, front pump 1
13 * Bolt 5
14 * Bushing (included in #15) 1
Page 186 MT-030-60-F

15 * Stator support, front pump 1
16 * Housing, front pump 1
17 * Bolt
18 * Bolt 2
19 66-501-33 Spacer, End Yoke 1
20 45-000-06 Extension housing oil seal 1
21 * Bolt 4
22 * - -
23 * Bolt, part of valve body assembly 1
24 * Valve body separating plate (part of 129A) 1
25 - See valve body assembly -
29 See valve body assembly Oil pan screen gasket 1
30 See valve body assembly Oil screen 1
31 See valve body assembly Bolt -
32 * Bolt 17
33 * - -
34 * - -
35 * - -
36 * - -
37 97-202-01 Nut, Sealing 1
38 * Adjusting screw 1
39 * Plug 1
40 502323 Dip Stick 1
66-900-10 Dip Stick (yellow handle) 1
41 502324 Tube, Dip stick 1
42 505630 O-Ring, Dipstick tube 1
43 * - -
44 * - -
45 * - -
46 * - -
47 504093 Park/neutral position switch 1
48 * Bolt 1
49 * Manual control lever oil seal 1
50 * Intermediate band servo lever 1
51 * Ball, Intermediate band adjusting lever shaft 1
52 * Intermediate band adjusting lever shaft 1
53 * Bolt, part of valve body assembly 1
54 * Parking brake shaft plug 1
55 * Parking plate shaft 1
56 * Parking plate torsion spring 1
57 * Parking rod support plate 1
58 * Over running clutch to case bolt 5
59 * Nut 1
60 * Oil tube connector 2
61 * Throttle control valve diaphragm assembly 1
62 * Primary throttle valve 1
63 * Throttle control valve rod 1
64 * Vacuum diaphragm clip 1

Transmission: Ford C6 Linkage

1 * Output shaft park gear 1
2 * Bolt 1
3 * Parking pawl shaft 1
4 * Parking pawl return spring 1
5 * Parking brake pawl 1
6 * Output shaft thrust washer 1
7 * Park rod guide plate 1
8 * Parking rod support plate 1
9 * Parking plate torsion spring 1
10 * Parking plate shaft 1
11 * Parking brake shaft plug 1
12 See Housing Park/neutral position switch 1
13 * O-Ring 1
14 * Downshift control outer lever 1
15 * Washer 1
16 * Nut 1
17 * Downshift detent lever, inner 1
18 * Nut 1
19 * Manual valve detent lever, inner 1
20 * Manual control lever oil seal 1
21 * Manual control lever 1
22 * Grommet 1
23 * Clip 1
24 * Parking pawl actuating rod 1
Page 188 MT-030-60-F

Transmission: Ford C6 Valve Body

1 * Bolt 8
2 * Bolt 2
3 * Throttle pressure valve secondary spacer 1
4 * Gear selector valve rod 1
5 * Bolt 1
6 Order kit #17 Oil pan screen gasket 1
7 * Valve body separating plate (part of 129A) 1
8 * Valve body separating plate gasket 1
9 * Bolt
10 Order kit #17 Oil screen 1
11 * Bolt 2
12 * Sleeve 1
13 * Manual valve detent lever spring 1
14 * Pin 1
15 * Detent plug 1
16 * Bolt 1
17 MC-00002 Kit, Pan gasket, Screen gasket, and Screen

TRANSMISSION, HYDRAULIC HOSES
GM Engine
- 99-530-16 Hose assembly, Radiator to Filter (optional) 0 or 1
- 99-530-15 Hose Assembly, Filter to Transmisison (optional) 0 or 1
- 503709 Hose Assembly, Radiator to Transmission 0 or 1
- 503708 Hose Assembly, Transmission to Radiator 1
- 503829 Fitting, Radiator Transmission Cooler 2
Cummins B3.3 Engine

- K1T-600-01 Hose Assembly, Radiator to Transmission 1
- 66-502-01 Hose Assembly, Transmission to Radiator 1
- 503829 Fitting, Radiator Transmission Cooler 2
Page 190 MT-030-60-F

WHEELS AND TIRES

503343 Wheel Assembly, Front, 650 x 10 2
500164 Tire, 6.50 x 10, includes tube
500972 Wheel, 10 x 5.5
502758 Wheel Assembly, Rear 2
500257 Tire, LT225-75R16 LR-D (tubeless)
500684 Wheel, 16 x 6
500218 Valve Stem

Optional Equipment
This information is provided is to be used for identifying replacement components for OEM installed options only.
It is not intended to be used as a guide or instructions on how to install an option on a vehicle. If you wish to install
an option that was not installed by the factory, then contact your local Taylor-Dunn dealer for information on field
installation kits.
CAB
502644 Cab Assembly, Complete (includes all of listed parts)
500307-D CAB WLDMNT 78” TC-30/60 1
500315 CAB WINDOW \ SIDE REAR 2
500316-B CAB WINDSHIELD \ FRNT ROUNDED 1
500317-12 CAB \ INSULATION\ TOP REAR 2
500604 CAB STRIKER BOLT 2
500610 WIPER ARM 1
500611 CAB WIPER BLADE 1
500624 TRIM SEAL \ FRNT CAB & LOW > 5
500629 CAB SEAL, GASKET \ BOTTOM CAB 7 ft
500639 TOGGLE SWITCH - SPST 1
500665 DECAL, WIPER 1
502144 DOME LIGHT, METAL HOUSING 1
502584 CAB WINDOW/REAR/POST 2001 > 1
502627 BUSHING/WIRING THRU CAB 2
502640 INSULATION, REAR CAB 1
505450 NYLON INSULATION RETAINER, 2” 11
505648 CONNECTOR, WIPER MOTOR 1
505649 TERM, WIPER MOTOR 4
506277 CAB HARNESS, 2009+ 1
506332 WIPER MOTOR, 3” SHAFT 1
88-828-09 #10X3/4,HXWSHR HD,SELF DRL GR2 3
98-310-00 RUBBER WINDOW CHANNEL 35 ft
CAB HEATER (TT-140-62)
32371 HOSE 5/8 GENL PRP 350 PSI RED 8
4-2777647 CABLE ASSY-CHOKE (GTP) 1
500617 CAB HEATER VENT 1
500661 CLAMP, HOSE, #10 6
500663 DECAL, HEATER 1
500691 FTG, ADAPT BUSHING 1/2-3/8 NPT 1
502028 Y CONNECTOR 5/8 HOSE 2
502549 HEATER/DEFROSTER KIT 1
94211 WATER VALVE 5/8-5/8 HOSE 1
99-500-31 ELBOW, 5/8 HOSE X 3/8 MPT 1
K1T-600-69 Bracket, Heater Hoses, Cummins B3.3 1
Page 192 MT-030-60-F

CAB DOORS
502641 Door Assembly, Left
502642 Door Assembly, Right

The following are components for each door:
500303-11 COVER, DOOR, LATCH, LH 1
500304-11 COVER, DOOR, LATCH, RH 1
500303A-6 WEATHER STRIP, DOORS 12.5 ft
500306 HINGE, DOOR, CAB, SHORT 3
500310 WINDOW LT DOOR 1
500311 WINDOW RT DOOR > 1
500601 DOOR HANDLE W/GSKT\DRIVERS LH 1
500600 DOOR HANDLE W/GASKET \ PASS RH 1
500602 DOOR LATCH / LH > 1
500603 DOOR LATCH \ RH > 1
500605 DOOR LATCH LINK 1
500606 DOOR LATCH LINK CLIP 2
500607 BRKT DOOR LCH 2 ft
500630 DOOR STOP CHAIN 1
501324 TUBING \ 1” I.D. VINYL 0.84 ft
502634 TRIM SEAL/NEW STYLE 12/02 4 ft
502636 DOOR WELDMENT, LH > 1
502637 DOOR WELDMENT, RH 1
88-048-61 WASHER, #10 SAE 4
88-400-07 1/4 X 2 1/4 NC HEXHDSCR GR8 2
88-400-31 1/4 X 3/4 NC SS SCHSCR18-8 2
88-400-90 1/4 FLW THRU-HARD GR8 8
88-400-92 1/4 SPLKWASH GR8 2
88-401-01 5/16 X 1 NC HEXHDSCR GR8 7
88-401-03 5/16 X 1 1/2 NC HEXHDSCR GR8 9
88-401-30 5/16 NC TOPLKNT GR9 1
88-401-31 5/16 NC HEXNUT GR8 6
88-401-40 5/16 FLW THRU-HARD GR8 3
88-401-41 5/16 SPLKWASH GR8 7
88-737-15 RVT, 1/8 X 3/8 - 1/4 HD, BLACK 20
88-828-09 #10X3/4,HXWSHR HD,SELF DRL GR2 4
95-512-00 HANDLE,BLACK PLASTIC 1
98-310-00 RUBBER WINDOW CHANNEL 9 ft

HITCHES
97-814-00
97-800-53
505836
Note: Pictures or illustrations

are not to scale.
Remote Release, Cab
REMOTE HITCH RELEASE (CAB)

1 500232-C WIRE ROPE \ 1/8 VINYL COATED 2
503056 CLAMP, U-BOLT, 3/16 2
2 501131 ROD, REMOTE RELEASE 1
3 501132 PIVOT ARM, REMOTE RELEASE 1
4 501134 PIVOT BRKT, REMOTE RELEASE 1
5 88-401-47 3/8 X 1 1/4 NC HEXHDSCR GR8 4
88-401-96 3/8 SPLKWASH GR8 4
6 96-762-00 3/8 IN.CLEVIS CAST 2
7 96-772-00 PIN,CLEVIS,3/8 X 1 1/8 IN. GR2 2
88-401-92 3/8 NF HVYHEXJAMNUT 2
88-527-13 1/8 X 1-1/4 STEEL COTTER PIN 2
8 88-401-48 3/8 X 1 1/2 NC HEXHDSCR GR8 (handle and pivot) 2
88-401-80 3/8 NC TOPLKNT GR C 2
88-401-95 3/8 FLW THRU-HARD GR8 4
- 505873 PLT, REINFORCING, HITCH RELEASE (inside cab, rear) 1
- 501130 HANDLE, HITCH RELEASE 1
- 501133 BRACKET,HANDLE,REMOTE RELEASE 1
88-401-47 3/8 X 1 1/4 NC HEXHDSCR GR8 4
88-401-80 3/8 NC TOPLKNT GR C 4
88-401-95 3/8 FLW THRU-HARD GR8 4
- 500557 BUMPER, RUBBER (handle stop) 1
- 88-401-31 5/16 NC HEXNUT GR8 1
- 88-401-41 5/16 SPLKWASH GR8 1
Page 194 MT-030-60-F

LIGHTS
72-005-00 Work Lights (cab mounted) 2
500639 Switch 1
504025 Harness 1
72-072-00 Replacement Bulb
503555 Rotating Beacon
500650 Light, Front Turn Signal 2
504945 Turn Signal Switch (ending S/N 185731) 1
71-141-22 Turn Signal Switch (starting S/N 185732) 1
500636 Flasher, Turn Signal 1
REAR VIEW MIRRORS, CAB DOOR

- 500615 Mirror Assembly, Right 1
- 500616 Mirror Assembly, Left 1
- 88-400-03 1/4NC x 1-1/4 Hex Screw 4
- 88-400-04 1/4NC x 1-1/2 Hex Screw 4
- 88-400-78 1/4 Lock nut 8
- 88-400-90 1/4 Flat Washer 8
SHIFT INHIBITOR (FULL RANGE SHIFTER)

- * Shifter Assmebly 1
- Pressure Switch
- 500656 Relay 1
- 501040-1-B PIN, SHIFT INHIBITOR 1
- 501040-10 SET SCREW, SHIFT INHIBITOR 1
- 501040-11 FTG, BK PRESSURE SWITCH 1
- 501040-15 CIRCUIT BREAKER \ 6A \ PUSH TO RESET 1
- 501040-16 DECAL, PUSH TO RESET 1
- 501040-2 BRACKET, SHIFT INHIBITOR 1
- 501040-3 SOLENOID, SHIFT INHIBITOR 1
- 501040-5B HARNESS, SHIFT INHIBITOR 1

Notes:
Page 196 MT-030-60-F

WARNING
Operating, servicing and maintaining a passenger vehicle or off-
highway motor vehicle can expose you to chemicals including
engine exhaust, carbon monoxide, phthalates, and lead, which
are known to the State of California to cause cancer and birth
defects or other reproductive harm. To minimize exposure, avoid
breathing exhaust, do not idle the engine except as necessary,
service your vehicle in a well-ventilated area and wear gloves
or wash your hands frequently when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/
passenger-vehicle.
Taylor-Dunn® Manufacturing.
2114 West Ball Road.
Anaheim, CA 92804
(800)-688-8680
(714) 956-4040
FAX: (714) 956-0504
Visit our Website: www.taylor-dunn.com

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Service and Replacement

The Best Way

Shown with optional OPS

Engine Model Number: .

Engine Serial Number: .

Dealer Purchased From: .

Your satisfaction is our #1 goal. If you have questions or concerns

Originally Published 7/30/2018

Visit our Web site: www.taylor-dunn.com

WHO SHOULD READ THIS MANUAL

Represents a corrosive Parking brake ON.

WEB SITE REGISTRATION

• Read the operator’s manual before operating this vehicle.

Code of Federal Regulations (CFR) Title 29,

Part Number Description

Assembly Component # Capacity Lubricant

HAZARDOUS WASTE DISPOSAL

Recommended Viscosity Temperatures below -22ºF (-30ºC) require preheat

DO NOT use this procedure to set used wheel bearings.

FRONT HUB, STEERING KNUCKLE, Reassembly

Disassembly 6: If installing new king pin bushings, make sure

This section is one section of a complete service

It is recommended that if a wearable component is

TA-267: Has has Primary Nose

This section covers more than one type of

TA-268: Has Planetary Gear

TA-268 Wheel Hub

Perform the following prior to disassembly.

Wheelend, Planetary - TA268 Drive Axle

Note: Hydrostatic steering is optional on some models.

This vehicle is equipped with hydrostatic steering. With hydrostatic

The term “hydrostatic” refers to fluids at rest, typically under

This section is one section of a complete service

It is recommended that if a wearable component is

MASTER CYLINDER Note: Start this procedure at the wheel furthest

WARNING 8: Slowly release the foot pedal, allowing it to return

Engine Type Manual Number EF

Cummins parts manuals available online at the Cummins web site:

Page 100 MT-030-60-F

MT-030-60-F Page 101

Page 102 MT-030-60-F

MT-030-60-F Page 103

Page 104 MT-030-60-F

MT-030-60-F Page 105

Page 106 MT-030-60-F

MT-030-60-F Page 107

Page 108 MT-030-60-F

Refer to the vehicle specifications in the Operator section

Page 110 MT-030-60-F

MT-030-60-F Page 111

Page 112 MT-030-60-F

WARNING Specific Gravity

Page 114 MT-030-60-F

MT-030-60-F Page 115

WARNING Battery Terminal (stud type) 120-130 13.5-14.5

Always remove the negative cable from the battery

1: Remove the negative cable from the battery .

Page 116 MT-030-60-F

Page 118 MT-030-60-F

** - Tighten until the spring hangers or mounting brackets

MT-030-60-F Page 119

Page 120 MT-030-60-F

The wire diagrams are too large to be legible at this size.