MR 34 Orig

MODEL MR
MID-RANGE TOW TRACTOR
OPERATION, MAINTENANCE
& PARTS MANUAL
ORIGINALLY ISSUED MARCH 2012
Introduction MR: Mid-Range Tow Tractor
NOTE: The information contained in this publication is intended exclusively

for the use of TUG and its customers. Disclosure to non-TUG customers
Note may result in legal action by TUG.
NOTE: The information contained in this document is intended to be

accurate and up to date at the time of original issue. TUG reserves the right
Note
to update the information in this document, without warning, as deemed
prudent or necessary by TUG.
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MR: Mid-Range Tow Tractor Introduction
RECORD OF REVISIONS
Property of:
Company:
Address:
City: State: Zip Code:
REVISION DATA
Check each revision received, and insert the revised and supplementary pages in your manual. Tug
Technologies Corporation assumes no liability for personal injury or equipment failure due to any operation
performed without heed to manual revisions.
Date of original publication: March 2012
Revision Number Date Brief Description
10
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LIST OF EFFECTIVE PAGES
Chapter-Section Page Revision Chapter-Section Page Revision

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INTRO- 2 Orig NTRO- 38 Orig
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INTRO- 4 Orig SAFETY- 1 Orig
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MANUAL TABLE OF CONTENTS
Front Matter
Record of Revisions ........................................................................................................... INTRO-iii
List of Effective Pages ........................................................................................................ INTRO-iv
Manual Table of Contents ................................................................................................. INTRO-xiii
Copyright Notice .............................................................................................................. INTRO-xxx
Introduction ...................................................................................................................... INTRO-xxx
Unit Identification ............................................................................................................. INTRO-xxx
Technical Assistance ...................................................................................................... INTRO-xxxi
Warranty Policy Statement ............................................................................................ INTRO-xxxii
How to Use This Manual ............................................................................................... INTRO-xxxiv
SAFETY ............................................................................................................................... SAFETY-i

A. Discussion ..................................................................................................... SAFETY-i
B. Operator Responsibilities .............................................................................. SAFETY-i
D. Mechanic Responsibilities ........................................................................... SAFETY-iii
Chapter 1: General Information and Operating Instructions

SECTION 1: DESCRIPTION ...................................................................................................... 1-1-1
A. Introduction ........................................................................................................... 1-1-1
B. Braking System .................................................................................................... 1-1-2
1. Service Brakes .......................................................................................... 1-1-2
2. Parking Brake ........................................................................................... 1-1-2
C. Chassis ................................................................................................................. 1-1-2
D. Coolant and Lubrication System ........................................................................... 1-1-2
E. Electrical System .................................................................................................. 1-1-2
1. Alternator .................................................................................................. 1-1-3
2. Starter ....................................................................................................... 1-1-3
3. Vehicle Electrical Center Panel Assembly. ............................................... 1-1-3
F. Engine .................................................................................................................. 1-1-3
G. Drive Shaft ............................................................................................................ 1-1-3
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H. Air Intake System ................................................................................................. 1-1-4

1. Air Filter Assembly .................................................................................... 1-1-4
2. Air Filter Service Indicator ......................................................................... 1-1-4
I. Exhaust System .................................................................................................... 1-1-4
J. Fuel System .......................................................................................................... 1-1-4
K. Ignition .................................................................................................................. 1-1-4
L. Lights and Accessories ......................................................................................... 1-1-4
M. Seating ................................................................................................................. 1-1-5
N. Hitches .................................................................................................................. 1-1-5
O. Steering ................................................................................................................ 1-1-5
P. Suspension, Front ................................................................................................ 1-1-5
Q. Suspension, Rear ................................................................................................. 1-1-6
R. Tires and Wheels .................................................................................................. 1-1-6
S. Towing Capability .................................................................................................. 1-1-6
T. Trailer Breakaway Cable Attachment ................................................................... 1-1-6
U. Transmission ........................................................................................................ 1-1-6
V. Turning Radius ..................................................................................................... 1-1-6
SECTION 2: OPERATION .......................................................................................................... 1-2-1

A. Principles of Operation ......................................................................................... 1-2-1
B. Operating Indicators and Controls ........................................................................ 1-2-1
1. Dash Panel for MR with Deutz Tier 2 Engine ........................................... 1-2-1
2. Dash Panel for MR with Deutz Tier 4 Engine ........................................... 1-2-4
3. Dash Panel for MR with Kubota Engine ................................................ 1-2-11
4. Wiper Control Switches .......................................................................... 1-2-15
5. Turn Signal Lever.................................................................................... 1-2-15
6. Cab Dome Light Switch .......................................................................... 1-2-15
7. E-Stop Button Switch .............................................................................. 1-2-15
8. Battery Disconnect Switch (Optinal) ....................................................... 1-2-16
C. Operator's Compartment .................................................................................... 1-2-16
D. Preparation for Use ............................................................................................ 1-2-17
1. Fuel System ............................................................................................ 1-2-17
2. Battery .................................................................................................... 1-2-17
3. Brake System ......................................................................................... 1-2-17
4. Engine and Transmission ....................................................................... 1-2-17
5. Drive Axle and Reduction Gear Box ....................................................... 1-2-18
6. Tire Inflation ............................................................................................ 1-2-19
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7. Power Steering Reservoir ....................................................................... 1-2-19

E. Standard Operating Procedures ......................................................................... 1-2-19
1. Normal Starting ....................................................................................... 1-2-19
2. Cold Weather Starting ............................................................................. 1-2-19
3. Driving Instructions ................................................................................. 1-2-20
4. Towing Instructions ................................................................................. 1-2-20
SECTION 3: SPECIFICATIONS ................................................................................................. 1-3-1

A. General ................................................................................................................. 1-3-1
B. Engine .................................................................................................................. 1-3-1
1. Deutz (Tier 2) Diesel ................................................................................. 1-3-1
2. Deutz (Tier 4i Diesel ................................................................................. 1-3-1
3. Kubota Diesel .......................................................................................... 1-3-2
C. Transmission ........................................................................................................ 1-3-2
1. Ford C6 Automatic Transmission .............................................................. 1-3-2
2. Ford 4R75 Automatic Transmission .......................................................... 1-3-2
D. Drive Axle ............................................................................................................. 1-3-2

E. Steering ................................................................................................................ 1-3-2
F. Front Axle ............................................................................................................. 1-3-3
G. Wheels .................................................................................................................. 1-3-3
1. Front Wheels ............................................................................................ 1-3-3
2. Rear Wheels ............................................................................................. 1-3-3
H. Brakes .................................................................................................................. 1-3-3
I. Electrical System .................................................................................................. 1-3-3
J. Towing Capability .................................................................................................. 1-3-4
K. Turning Radius ..................................................................................................... 1-3-4
SECTION 4: SHIPPING .............................................................................................................. 1-4-1

A. Preparation ........................................................................................................... 1-4-1
1. Battery ...................................................................................................... 1-4-1
2. Fuel Tank .................................................................................................. 1-4-1
SECTION 5: STORAGE ............................................................................................................. 1-5-1

A. One Month to Six Months ..................................................................................... 1-5-1
1. Engine ....................................................................................................... 1-5-1
2. Tire ............................................................................................................ 1-5-2
3. Battery ...................................................................................................... 1-5-2
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4. Lubrication ................................................................................................ 1-5-2

5. Fluid Levels ............................................................................................... 1-5-2
B. Extended Period (More than Six Months) ............................................................. 1-5-2
1. Transmission ............................................................................................ 1-5-2
2. Drive Axle and Reduction Gear Box. ........................................................ 1-5-2
3. Battery ...................................................................................................... 1-5-3
Chapter 2: Maintenance
SECTION 1: SERVICING ........................................................................................................... 2-1-1

A. Preparation for Use .............................................................................................. 2-1-1
1. Fuel System .............................................................................................. 2-1-1
2. Battery ...................................................................................................... 2-1-1
3. Brake System ........................................................................................... 2-1-1
4. Engine and Transmission ......................................................................... 2-1-2
5. Drive Axle and Reduction Gear Box ......................................................... 2-1-2
6. Tire Inflation .............................................................................................. 2-1-2
7. Power Steering Reservoir ......................................................................... 2-1-2
B. Periodic Maintenance Schedule ........................................................................... 2-1-2
1. Daily .......................................................................................................... 2-1-2
2. Initial 200 Hour Maintenance .................................................................... 2-1-3
3. Every 6 Months ......................................................................................... 2-1-6
4. Yearly ........................................................................................................ 2-1-7
5. Every Two Years ....................................................................................... 2-1-8
C. Lubrication Schematic ........................................................................................ 2-1-10
D. Standard Jacking Procedure .............................................................................. 2-1-11
E. Alternator Belt Adjustment .................................................................................. 2-1-11
F. Headlight Adjustment .......................................................................................... 2-1-12
G. Brake Bleeding Procedure .................................................................................. 2-1-12
H. Stopping Distance Test ....................................................................................... 2-1-13
I. Hydraulic Flushing Procedure ............................................................................ 2-1-13
SECTION 2: TROUBLESHOOTING ........................................................................................... 2-2-1

A. General ................................................................................................................. 2-2-1
B. Steering ................................................................................................................ 2-2-4
C. Brake System ....................................................................................................... 2-2-6
D. Electrical ............................................................................................................... 2-2-8
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E. Electrical Schematics ......................................................................................... 2-2-11

F. Hydraulic Schematic ........................................................................................... 2-2-27
SECTION 3: REMOVAL/INSTALLATION................................................................................... 2-3-1

A. Cab ....................................................................................................................... 2-3-1
1. Removal .................................................................................................... 2-3-1
2. Installation ................................................................................................. 2-3-2
3. Doors ........................................................................................................ 2-3-2
(a) Removal ........................................................................................ 2-3-2
(b) Installation ..................................................................................... 2-3-3
(c) Adjustment .................................................................................... 2-3-3
4. Door Check Strap ..................................................................................... 2-3-3
(a) Removal ........................................................................................ 2-3-3
(b) Installation ..................................................................................... 2-3-3
5. Cab Heater ............................................................................................... 2-3-4
(a) Removal ........................................................................................ 2-3-4
(b) Installation ..................................................................................... 2-3-4
6. Window, Door ........................................................................................... 2-3-5
(a) Removal ........................................................................................ 2-3-5
(b) Installation ..................................................................................... 2-3-5
7. Front Windshield ....................................................................................... 2-3-5
(a) Removal ........................................................................................ 2-3-5
(b) Installation ..................................................................................... 2-3-6
8. Rear Windshield ....................................................................................... 2-3-6
(a) Removal ........................................................................................ 2-3-6
(b) Installation ..................................................................................... 2-3-6
9. Windows, Rear Side ................................................................................. 2-3-7
(a) Removal ........................................................................................ 2-3-7
(b) Installation ..................................................................................... 2-3-7
10. Rear View Mirror ....................................................................................... 2-3-8
(a) Removal ........................................................................................ 2-3-8
(b) Installation ..................................................................................... 2-3-8
11. Mirrors ....................................................................................................... 2-3-8
(a) Removal ........................................................................................ 2-3-8
(b) Installation ..................................................................................... 2-3-8
12. Mirror Mounting Brackets .......................................................................... 2-3-9
(a) Removal ........................................................................................ 2-3-9
(b) Installation ..................................................................................... 2-3-9
13. Wiper Motor, Front .................................................................................... 2-3-9
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(a) Removal ........................................................................................ 2-3-9

(b) Installation ................................................................................... 2-3-10
14. Wiper Motor, Rear ................................................................................... 2-3-11
(a) Removal ...................................................................................... 2-3-11
(b) Installation ................................................................................... 2-3-11
15. Windshield Wiper Switch (Front and Rear) ............................................. 2-3-12
(a) Removal ...................................................................................... 2-3-12
(b) Installation ................................................................................... 2-3-13
B. Hood Panel ......................................................................................................... 2-3-13
1. Removal .................................................................................................. 2-3-13
2. Installation ............................................................................................... 2-3-14
C. Pintle Hitches ...................................................................................................... 2-3-14
1. Removal .................................................................................................. 2-3-14
2. Installation ............................................................................................... 2-3-14
D. Seats .................................................................................................................. 2-3-14
1. Removal .................................................................................................. 2-3-14
2. Installation ............................................................................................... 2-3-15
3. Seatbelt, Retractable .............................................................................. 2-3-15
(a) Removal ...................................................................................... 2-3-15
(b) Installation ................................................................................... 2-3-15
E. Battery ................................................................................................................ 2-3-15
1. Removal .................................................................................................. 2-3-15
2. Installation ............................................................................................... 2-3-16
F. Dash Panel Assembly ......................................................................................... 2-3-16
1. Dash Illumination Lights .......................................................................... 2-3-16
(a) Removal ...................................................................................... 2-3-16
(b) Installation ................................................................................... 2-3-17
(c) Dash Illumination Light Bulb Replacement ................................. 2-3-17
2. Gauges ................................................................................................... 2-3-17
(a) Removal ...................................................................................... 2-3-17
(b) Installation ................................................................................... 2-3-18
(c) Gauge Bulb Replacement ........................................................... 2-3-19
3. Headlight Switch or Hitch Light Switch ................................................... 2-3-19
(a) Removal ...................................................................................... 2-3-19
(b) Installation ................................................................................... 2-3-20
4. Heater Switch ......................................................................................... 2-3-20
(a) Removal ...................................................................................... 2-3-20
(b) Installation ................................................................................... 2-3-21
5. Ignition Switch ......................................................................................... 2-3-21
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(a) Removal ...................................................................................... 2-3-21

(b) Installation ................................................................................... 2-3-22
6. Warning Light Assembly ......................................................................... 2-3-22
(a) Removal ...................................................................................... 2-3-22
(b) Installation ................................................................................... 2-3-23
7. Light Lenses ........................................................................................... 2-3-23
(a) Removal ...................................................................................... 2-3-23
(b) Installation ................................................................................... 2-3-24
8. Bulb, Warning Light ................................................................................ 2-3-25
(a) Removal ...................................................................................... 2-3-25
(b) Installation ................................................................................... 2-3-25
9. Turn Signal Flasher Unit ......................................................................... 2-3-26
(a) Removal ...................................................................................... 2-3-26
(b) Installation ................................................................................... 2-3-26
G. Exterior Lamp Assemblies .................................................................................. 2-3-27
1. Headlight Assembly ................................................................................ 2-3-27
(a) Removal ...................................................................................... 2-3-27
(b) Installation ................................................................................... 2-3-27
(c) Headlight Bulb Replacement ...................................................... 2-3-27
2. Turn Signal Light Assembly, Front .......................................................... 2-3-28
(a) Removal ...................................................................................... 2-3-28
(b) Installation ................................................................................... 2-3-28
3. Brake/Turn/Stop/ Light Assembly ............................................................ 2-3-29
(a) Removal ...................................................................................... 2-3-29
(b) Installation ................................................................................... 2-3-29
4. Back Up Light Assembly ......................................................................... 2-3-29
(a) Removal ...................................................................................... 2-3-29
(b) Installation ................................................................................... 2-3-29
5. Hitch Light Assembly .............................................................................. 2-3-30
(a) Removal ...................................................................................... 2-3-30
(b) Installation ................................................................................... 2-3-30
H. Dome Light Lamp Housing Assembly ................................................................. 2-3-30
1. Removal .................................................................................................. 2-3-30
2. Installation ............................................................................................... 2-3-31
3. Dome Light Bulb Replacement ............................................................... 2-3-31
I. Emergency Stop Switch ...................................................................................... 2-3-31
1. Removal .................................................................................................. 2-3-31
2. Installation ............................................................................................... 2-3-31
J. Vehicle Electric Center Panel Assembly ............................................................. 2-3-32
1. Vehicle Electric Center (VEC), Deutz Tier 2 and Kubota ........................ 2-3-32
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(a) Removal ...................................................................................... 2-3-32

(b) Installation ................................................................................... 2-3-32
2. Fuses (F1-F8) ......................................................................................... 2-3-33
(a) Removal ...................................................................................... 2-3-33
(b) Installation ................................................................................... 2-3-33
3. Relays (R1-R8) ....................................................................................... 2-3-33
(a) Removal ...................................................................................... 2-3-33
(b) Installation ................................................................................... 2-3-33
4. TUG Electric Center (TEC), Deutz Tier 4i ............................................... 2-3-34
(a) Removal ...................................................................................... 2-3-34
(b) Installation ................................................................................... 2-3-34
5. Fuses (F1-F12) ....................................................................................... 2-3-34
(a) Removal ...................................................................................... 2-3-34
(b) Installation ................................................................................... 2-3-34
6. Relays (K5-K8) ....................................................................................... 2-3-35
(a) Removal ...................................................................................... 2-3-35
(b) Installation ................................................................................... 2-3-35
7. Power Block ............................................................................................ 2-3-35
(a) Removal ...................................................................................... 2-3-35
(b) Installation ................................................................................... 2-3-36
8. Starter Relay ........................................................................................... 2-3-36
(a) Removal ...................................................................................... 2-3-36
(b) Installation ................................................................................... 2-3-36
9. Circuit Breaker, 60 Amp .......................................................................... 2-3-36
(a) Removal ...................................................................................... 2-3-36
(b) Installation ................................................................................... 2-3-37
10. Starter-Lockout Relay ............................................................................. 2-3-37
(a) Removal ...................................................................................... 2-3-37
(b) Installation ................................................................................... 2-3-37
11. Transmission Lockout Relay ................................................................... 2-3-38
(a) Removal ...................................................................................... 2-3-38
(b) Installation ................................................................................... 2-3-38
12. Glow Plug Relay ..................................................................................... 2-3-38
(a) Removal ...................................................................................... 2-3-38
(b) Installation ................................................................................... 2-3-38
13. Glow Plug Relay Socket ......................................................................... 2-3-39
(a) Removal ...................................................................................... 2-3-39
(b) Installation ................................................................................... 2-3-39
14. Main Power Solenoid .............................................................................. 2-3-40
(a) Removal ...................................................................................... 2-3-40
(b) Installation ................................................................................... 2-3-40
15. Mini Fuse, 20 Amp (VEC panel only) ...................................................... 2-3-40
(a) Removal ...................................................................................... 2-3-40
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(b) Installation ................................................................................... 2-3-41

(a) Removal ...................................................................................... 2-3-41
(b) Installation ................................................................................... 2-3-41
K. Starter ................................................................................................................. 2-3-41
1. Deutz Removal ....................................................................................... 2-3-41
2. Deutz Installation .................................................................................... 2-3-42
3. Kubota Removal ..................................................................................... 2-3-42
4. Kubota Installation .................................................................................. 2-3-43
L. Low Oil Pressure and High Oil Temperature Alarms ......................................... 2-3-43
1. Removal .................................................................................................. 2-3-43
2. Installation ............................................................................................... 2-3-43
M. Horn Assembly ................................................................................................... 2-3-44
1. Removal .................................................................................................. 2-3-44
2. Installation ............................................................................................... 2-3-44
N Fuel System ........................................................................................................ 2-3-45
1. Fuel Tank Transition Hose ...................................................................... 2-3-45
(a) Removal ...................................................................................... 2-3-45
(b) Installation ................................................................................... 2-3-45
2. Fuel Drain Petcock ................................................................................. 2-3-45
(a) Removal ...................................................................................... 2-3-45
(b) Installation ................................................................................... 2-3-46
3. Fuel Pump (Deutz only) .......................................................................... 2-3-46
(a) Removal ...................................................................................... 2-3-46
(b) Installation ................................................................................... 2-3-47
4. Fuel Filter Head (Deutz only) ................................................................. 2-3-47
(a) Removal ...................................................................................... 2-3-47
(b) Installation ................................................................................... 2-3-48
5. Fuel Filter Element (Deutz only) ............................................................. 2-3-48
(a) Removal ...................................................................................... 2-3-48
(b) Installation ................................................................................... 2-3-48
6. Fuel Level Sending Unit .......................................................................... 2-3-49
(a) Removal ...................................................................................... 2-3-49
(b) Installation ................................................................................... 2-3-49
7. Fuel Lines ............................................................................................... 2-3-49
(a) Removal ...................................................................................... 2-3-49
(b) Installation ................................................................................... 2-3-50
8. Fuel Hoses .............................................................................................. 2-3-50
(a) Removal ...................................................................................... 2-3-50
(b) Installation ................................................................................... 2-3-51
9. Fuel Tank ................................................................................................ 2-3-51
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(a) Removal ...................................................................................... 2-3-51

(b) Installation ................................................................................... 2-3-52
O. Accelerator and Modulator Assembly (Deutz Tier 2 and Kubota) ....................... 2-3-53
1. Accelerator Pedal ................................................................................... 2-3-53
(a) Removal ...................................................................................... 2-3-53
(b) Installation ................................................................................... 2-3-54
2. Accelerator Pedal Lever ......................................................................... 2-3-54
(a) Removal ...................................................................................... 2-3-54
(b) Installation ................................................................................... 2-3-54
3. Modulator Cable ..................................................................................... 2-3-54
(a) Removal ...................................................................................... 2-3-54
(b) Installation ................................................................................... 2-3-55
4. Throttle Cable ......................................................................................... 2-3-55
(a) Removal ...................................................................................... 2-3-55
(b) Installation ................................................................................... 2-3-56
P. Accelerator Pedal ( Deutz Tier 4i) ....................................................................... 2-3-56
1. Removal .................................................................................................. 2-3-56
2. Installation ............................................................................................... 2-3-56
Q. Air Intake Assembly ............................................................................................ 2-3-57
1. Air Filter Assembly .................................................................................. 2-3-57
(a) Removal ...................................................................................... 2-3-57
(b) Installation ................................................................................... 2-3-57
2. Air Filter Mounting Band ......................................................................... 2-3-57
(a) Removal ...................................................................................... 2-3-57
(b) Installation ................................................................................... 2-3-57
3. Air Filter Element .................................................................................... 2-3-58
(a) Removal ...................................................................................... 2-3-58
(b) Installation ................................................................................... 2-3-58
4. Hump Hose ............................................................................................. 2-3-58
(a) Removal ...................................................................................... 2-3-58
(b) Installation ................................................................................... 2-3-58
5. Filter to Turbo Transition Tube ................................................................ 2-3-59
(a) Removal ...................................................................................... 2-3-59
(b) Installation ................................................................................... 2-3-59
6. Rubber Reducer Hose ............................................................................ 2-3-59
(a) Removal ...................................................................................... 2-3-59
(b) Installation ................................................................................... 2-3-59
R. Oil Cooler Assembly ........................................................................................... 2-3-60
1. Transmission Fluid Cooler ...................................................................... 2-3-60
(a) Removal ...................................................................................... 2-3-60
(b) Installation ................................................................................... 2-3-60
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2. Oil Cooler (Deutz) ................................................................................... 2-3-61

(a) Removal ...................................................................................... 2-3-61
(b) Installation ................................................................................... 2-3-62
3. Radiator (Kubota) ................................................................................... 2-3-63
(a) Removal ...................................................................................... 2-3-63
(b) Installation ................................................................................... 2-3-63
S. Exhaust System .................................................................................................. 2-3-64
1. Header Pipe ............................................................................................ 2-3-64
(a) Removal ...................................................................................... 2-3-64
(b) Installation ................................................................................... 2-3-64
2. Muffler ..................................................................................................... 2-3-65
(a) Removal ...................................................................................... 2-3-65
(b) Installation ................................................................................... 2-3-65
3. Spark Arrestor ......................................................................................... 2-3-65
(a) Removal ...................................................................................... 2-3-65
(b) Installation ................................................................................... 2-3-66
4. Tail Pipe .................................................................................................. 2-3-66
(a) Removal ...................................................................................... 2-3-66
(b) Installation ................................................................................... 2-3-66
T. Engine and Engine Components ........................................................................ 2-3-67
1. Deutz Tier 2Quick Engine Change (QEC) .............................................. 2-3-67
(a) Removal ...................................................................................... 2-3-67
(b) Installation ................................................................................... 2-3-70
2. Deutz Tier 4i Quick Engine Change (QEC) ........................................... 2-3-74
(a) Removal ...................................................................................... 2-3-74
(b) Installation ................................................................................... 2-3-78
3. Kubota Quick Engine Change (QEC) ..................................................... 2-3-81
(a) Removal ...................................................................................... 2-3-81
(b) Installation ................................................................................... 2-3-85
4. Engine Mounts ........................................................................................ 2-3-89
(a) Removal ...................................................................................... 2-3-89
(b) Installation ................................................................................... 2-3-90
5. Fan .......................................................................................................... 2-3-90
(a) Removal ...................................................................................... 2-3-90
(b) Installation ................................................................................... 2-3-90
6. Flexplate ................................................................................................. 2-3-91
(a) Removal ...................................................................................... 2-3-91
(b) Installation ................................................................................... 2-3-91
7. Glow Plug ............................................................................................... 2-3-91
(a) Removal ...................................................................................... 2-3-91
(b) Installation ................................................................................... 2-3-91
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8. Oil Filter Element .................................................................................... 2-3-92

(a) Removal ...................................................................................... 2-3-92
(b) Installation ................................................................................... 2-3-92
9. Oil Pan .................................................................................................... 2-3-92
(a) Removal ...................................................................................... 2-3-92
(b) Installation ................................................................................... 2-3-93
10. Oil Pressure Sender ............................................................................... 2-3-93
(a) Removal ...................................................................................... 2-3-93
(b) Installation ................................................................................... 2-3-94
11. Oil Temperature Sender (Deutz) ............................................................. 2-3-94
(a) Removal ...................................................................................... 2-3-94
(b) Installation ................................................................................... 2-3-94
12. Coolant Temperature Sender (Kubota) ................................................... 2-3-94
(a) Removal ...................................................................................... 2-3-94
(b) Installation ................................................................................... 2-3-94
13. Thermostat .............................................................................................. 2-3-94
(a) Removal ...................................................................................... 2-3-94
(b) Installation ................................................................................... 2-3-95
U. Transmission Assembly ...................................................................................... 2-3-95
1. Filter Screen ........................................................................................... 2-3-95
(a) Removal ...................................................................................... 2-3-95
(b) Installation ................................................................................... 2-3-95
2. Shifter Assembly ..................................................................................... 2-3-96
(a) Removal ...................................................................................... 2-3-96
(b) Installation ................................................................................... 2-3-97
(c) Bulb Replacement ....................................................................... 2-3-97
3. Shifter Cable ........................................................................................... 2-3-98
(a) Removal ...................................................................................... 2-3-98
(b) Installation ................................................................................... 2-3-99
4. Transmission C6 ................................................................................... 2-3-100
(a) Removal .................................................................................... 2-3-100
(b) Installation ................................................................................. 2-3-102
5. Transmission 4R75 ............................................................................... 2-3-103
(a) Removal .................................................................................... 2-3-103
(b) Installation ................................................................................. 2-3-105
6. Transmission Band Adjustment C6 ....................................................... 2-3-106
(a) Removal .................................................................................... 2-3-106
(b) Installation ................................................................................. 2-3-106
7. Neutral Safety Switch C6 ...................................................................... 2-3-107
(a) Removal .................................................................................... 2-3-107
(b) Installation ................................................................................. 2-3-107
V. Front Axle, Suspension, and Wheels ................................................................ 2-3-108
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1. Axle Assembly ...................................................................................... 2-3-108

(a) Removal .................................................................................... 2-3-108
(b) Installation ................................................................................. 2-3-109
2. Front Wheel Assembly .......................................................................... 2-3-109
(a) Removal .................................................................................... 2-3-109
(b) Installation ................................................................................. 2-3-110
3. Brake Rotor and Hub Assembly ............................................................ 2-3-110
(a) Removal .................................................................................... 2-3-110
(b) Installation .................................................................................. 2-3-111
W. Drive Shaft, Drive Axle and Wheels .................................................................. 2-3-112
1. Drive Shaft ............................................................................................ 2-3-112
(a) Removal .................................................................................... 2-3-112
(b) Installation ................................................................................. 2-3-112
2. Drive Axle .............................................................................................. 2-3-113
(a) Removal .................................................................................... 2-3-113
(b) Installation ................................................................................. 2-3-114
3. Rear Wheel Assembly .......................................................................... 2-3-116
(a) Removal .................................................................................... 2-3-116
(b) Installation ................................................................................. 2-3-116
4. Shock Absorber .................................................................................... 2-3-116
(a) Removal .................................................................................... 2-3-116
(b) Installation ................................................................................. 2-3-117
X. Brake System ................................................................................................... 2-3-118
1. Brake Pedal .......................................................................................... 2-3-118
(a) Removal .................................................................................... 2-3-118
(b) Installation ................................................................................. 2-3-118
2. Front Brake Calipers and Brake Pads .................................................. 2-3-119
(a) Removal .................................................................................... 2-3-119
(b) Installation ................................................................................. 2-3-119
3. Brake Line System ................................................................................ 2-3-120
(a) Brake Hose (15-inch) Removal/Installation ............................... 2-3-120
(b) Left Rear Axle Brake Line Removal/Installation ........................ 2-3-121
(c) Right Rear Axle Brake Line Removal/Installation ..................... 2-3-121
(d) Brake Proportioning Line Removal/Installation ......................... 2-3-122
(e) Brake Line (H-Valve to Rear Proportioning Valve)
Removal/Installation .................................................................. 2-3-123
(f) Brake Lines (Master Cylinder to H-Valve)
(g) Brake Line (H-Valve to Brake Light Switch)
(h) Brake Line (Brake Light Switch to Front Tee)
CD387 INTRO-xxv
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(i) Brake Hose Removal/Installation .............................................. 2-3-125

(j) Brake Line (Front Tee to Left Caliper) Removal/Installation ...... 2-3-126
(k) Brake Line (Front Tee to Right Caliper) Removal/Installation ... 2-3-127
(l) H-Valve Removal/Installation .................................................... 2-3-128
(m) Regulating Rear Brake Valve Removal/Installation................... 2-3-128
(n) Brake Pressure Switch Removal/Installation ............................ 2-3-129
4. Hydro Boost Assembly .......................................................................... 2-3-129
(a) Removal .................................................................................... 2-3-129
(b) Installation ................................................................................. 2-3-130
Y. Parking Brake Assembly ................................................................................... 2-3-131
1. Park Brake Lever .................................................................................. 2-3-131
(a) Removal .................................................................................... 2-3-131
(b) Installation ................................................................................. 2-3-131
(c) Adjustment ................................................................................ 2-3-132
2. Parking Brake Shoes and Drum ........................................................... 2-3-132
(a) Removal .................................................................................... 2-3-132
(b) Installation ................................................................................. 2-3-133
Z. Hydraulic Power Steering System .................................................................... 2-3-134
1. Hydraulic Pump .................................................................................... 2-3-134
(a) Removal .................................................................................... 2-3-134
(b) Installation ................................................................................. 2-3-134
2. Hydraulic Reservoir .............................................................................. 2-3-135
(a) Removal .................................................................................... 2-3-135
(b) Installation ................................................................................. 2-3-135
3. Hydraulic Shut Off Valve ....................................................................... 2-3-136
(a) Removal .................................................................................... 2-3-136
(b) Installation ................................................................................. 2-3-136
4. Steer Valve Assembly ........................................................................... 2-3-136
(a) Removal .................................................................................... 2-3-136
(b) Installation ................................................................................. 2-3-137
5. Steering Cylinder .................................................................................. 2-3-137
(a) Removal .................................................................................... 2-3-137
(b) Installation ................................................................................. 2-3-138
6. Steering Wheel ..................................................................................... 2-3-139
(a) Removal .................................................................................... 2-3-139
(b) Installation ................................................................................. 2-3-139
7. Steering Column ................................................................................... 2-3-140
(a) Removal .................................................................................... 2-3-140
(b) Installation ................................................................................. 2-3-141
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Chapter 3: Overhaul
SECTION 1: RECOMMENDED OVERHAUL PERIODS ............................................................ 3-1-1
A. General ................................................................................................................. 3-1-1
B. Engine .................................................................................................................. 3-1-1
C. Transmission ........................................................................................................ 3-1-1
D. Front (Steer) Axle .................................................................................................. 3-1-1
SECTION 2: FRONT (STEER) AXLE ......................................................................................... 3-2-1

A. Axle Assembly ...................................................................................................... 3-2-1
1. Inspection ................................................................................................. 3-2-1
2. Removal .................................................................................................... 3-2-1
3. Installation ................................................................................................. 3-2-2
B. King Pin and Knuckles .......................................................................................... 3-2-3
1. Removal .................................................................................................... 3-2-3
2. Installation ................................................................................................. 3-2-4
C. Front Wheel Bearings ........................................................................................... 3-2-5
1. Removal .................................................................................................... 3-2-5
2. Installation ................................................................................................. 3-2-5
D. Front Leaf Springs and Shackles .......................................................................... 3-2-6
1. Removal .................................................................................................... 3-2-6
2. Installation ................................................................................................. 3-2-7
E. Tie Rod End .......................................................................................................... 3-2-8
1. Removal .................................................................................................... 3-2-8
2. Installation ................................................................................................. 3-2-8
F. Front Wheel Alignment ......................................................................................... 3-2-9
Chapter 4: Illustrated Parts List

A. Introduction ........................................................................................................... 4-1-1
B. Using the Illustrated Parts List .............................................................................. 4-1-2
1. Figure and Index Number ......................................................................... 4-1-2
2. Part Numbers ............................................................................................ 4-1-3
3. Description and Quantity .......................................................................... 4-1-3
4. Effectivity .................................................................................................. 4-1-4
C. Ordering Spare Parts ............................................................................................ 4-1-4
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SECTION 2: ILLUSTRATED PARTS LIST ................................................................................ 4-2-1

A. Introduction ........................................................................................................... 4-2-1
Figure 2-1. Frame Weldment (w/ Hitch, Light, and Back-up Alarm Options) ....... 4-2-2
Figure 2-2. Access Panels (Deutz Tier 2, Kubota) ............................................... 4-2-4
Figure 2-3. Access Panels (Deutz Tier 4i) ........................................................... 4-2-6
Figure 2-4. Hood Assembly ................................................................................. 4-2-8
Figure 2-5. Cab Mounting .................................................................................. 4-2-10
Figure 2-6. Cab Insulation ................................................................................. 4-2-12
Figure 2-7. Cab Mirrors ..................................................................................... 4-2-14
Figure 2-8. Cab Door Installation ....................................................................... 4-2-16
Figure 2-9. Driver (L/H) Door Assembly ............................................................ 4-2-18
Figure 2-10. Window, Driver (L/H) Door Assembly ........................................... 4-2-20
Figure 2-11. Passenger (R/H) Door Assembly .................................................. 4-2-22
Figure 2-12. Window, Passenger (R/H) Door Assembly .................................... 4-2-24
Figure 2-13. Cab Windows ................................................................................ 4-2-26
Figure 2-14. Front Windshield Wipers ............................................................... 4-2-28
Figure 2-15. Rear Windshield Wipers ................................................................ 4-2-30
Figure 2-16. Exterior Lamp Assemblies ............................................................. 4-2-32
Figure 2-17. Dome Light ..................................................................................... 4-2-34
Figure 2-18. Emergency Stop (E-Stop) Switch Assembly .................................. 4-2-36
Figure 2-19. Lower Dash Access Panel ............................................................ 4-2-38
Figure 2-20. Seat Installation ............................................................................. 4-2-40
Figure 2-21. Cab Heater Installation (Deutz) ..................................................... 4-2-42
Figure 2-22. Cab Heater Installation (Kubota) ................................................... 4-2-44
Figure 2-23. Dash Assembly w/ Harness (Deutz Tier 2) .................................... 4-2-46
Figure 2-24. Dash Assembly w/ Harness (Deutz Tier 4i) ................................... 4-2-48
Figure 2-25. Dash Assembly w/ Harness (Kubota) ............................................ 4-2-50
Figure 2-26. Console Assembly (CE option) ..................................................... 4-2-52
Figure 2-27. Alarm Assembly ............................................................................. 4-2-54
Figure 2-28. Brake Pedal Assembly .................................................................. 4-2-56
Figure 2-29 Steering Column Assembly ............................................................ 4-2-58
Figure 2-30. Hydraulic Steering System (Deutz) ............................................... 4-2-60
Figure 2-31. Hydraulic Steering System (Kubota) ............................................. 4-2-64
Figure 2-32. Front Suspension .......................................................................... 4-2-68
Figure 2-33. Front (Steer) Axle Assembly .......................................................... 4-2-70
Figure 2-34. Hub and Rotor Assembly .............................................................. 4-2-72
Figure 2-35. Brake Calipers Assembly ............................................................. 4-2-74
Figure 2-36. Rear Suspension Assembly ......................................................... 4-2-76
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Figure 2-37. Drain Plugs. Rear ( Drive ) Axle .................................................... 4-2-78

Figure 2-38. Gear Set and Differential. Rear Axle ............................................ 4-2-80
Figure 2-39. Planetary Wheel End Drive. Rear Axle ......................................... 4-2-82
Figure 2-40. Wet Brakes System. Rear Axle ..................................................... 4-2-84
Figure 2-41. Drop Box Drain Plugs. Rear Axle ................................................. 4-2-86
Figure 2-42. Front Wheel Assembly ................................................................ 4-2-88
Figure 2-43. Rear Wheel Assembly ................................................................... 4-2-89
Figure 2-44. Accelerator Deutz 4i ...................................................................... 4-2-90
Figure 2-45. Accelerator and Modulator Cables ( Deutz Tier 2 ) ....................... 4-2-92
Figure 2-46. Accelerator and Modulator Cables ( Kubota ) ............................... 4-2-94
Figure 2-47. Engine and Transmission Installation ( Deutz Tier2 ) .................... 4-2-96
Figure 2-48. Engine Installation ( Deutz Tier 4i ) ............................................... 4-2-97
Figure 2-49. Engine Installation ( Kubota ) ........................................................ 4-2-98
Figure 2-50. Engine Assembly ( Deutz Tier2 ) ................................................. 4-2-100
Figure 2-51. Front Engine Covers (Deutz Tier 2) ............................................ 4-2-104
Figure 2-52. Alternator Assembly (Deutz Tier 2) ............................................. 4-2-106
Figure 2-53. Starter Assembly (Deutz Tier 2) .................................................. 4-2-108
Figure 2-54. Timing Belt and PTO Assemblies (Deutz) ................................. 4-2-110
Figure 2-55. Hydraulic Pump PTO Drive Assembly (Deutz) ............................ 4-2-112
Figure 2-56. Oil Pan Installation (Deutz) ........................................................ 4-2-113
Figure 2-57. Engine Assembly ( Deutz Tier 4i ) ............................................... 4-2-114
Figure 2-58. Front Engine Covers (Deutz Tier 4i) ............................................ 4-2-118
Figure 2-59. Alternator Assembly (Deutz Tier 4i) ............................................ 4-2-120
Figure 2-60. Starter Assembly (Deutz Tier 4i) .................................................. 4-2-122
Figure 2-61. Engine Assembly. Front View ( Kubota ) .................................... 4-2-124
Figure 2-62. Engine Assembly. Rear View ( Kubota ) ...................................... 4-2-126
Figure 2-63. Heater Assembly ( Kubota ) ........................................................ 4-2-130
Figure 2-64. Air Intake Assembly ( Deutz ) ...................................................... 4-2-132
Figure 2-65. Air Intake Assembly, (Kubota MR-8 ) .......................................... 4-2-134
Figure 2-66. Air Intake Assembly, (Kubota V3600-T, MR10) .......................... 4-2-136
Figure 2-67. Fuel System (Deutz) ................................................................... 4-2-138
Figure 2-68 Fuel System ( Kubota ) ................................................................ 4-2-140
Figure 2-69. Exhaust System ( Deutz ) ........................................................... 4-2-142
Figure 2-70. Exhaust Assembly ( Kubota MR8 ) .............................................. 4-2-144
Figure 2-71. Exhaust System (Kubota MR10) ................................................. 4-2-146
Figure 2-72. Cooling System ( Deutz Tier 2 ) ................................................... 4-2-148
Figure 2-73. Cooling System ( Deutz Tier 4i ) .................................................. 4-2-150
CD387 INTRO-xxix
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Figure 2-74. Oil Cooling System (Kubota) ....................................................... 4-2-152

Figure 2-75. Engine and Transmission Deutz Tier 2 and C6) .......................... 4-2-154
Figure 2-76 Engine and Transmission ( Kubota and C6 ) .............................. 4-2-156
Figure 2-77. Transmission Oil Pan Assembly ( C6 ) ....................................... 4-2-157
Figure 2-78 Transmission Filter Screen and Valve Body ( C6 ) ...................... 4-2-158
Figure 2-79. Transmission Band Adjustment (C6) ........................................... 4-2-160
Figure 2-80. Shifter Assembly ( C6 ) .............................................................. 4-2-162
Figure 2-81 Shifter Linkage ( C6 ) ................................................................... 4-2-164
Figure 2-82. Park Brake Lever Installation ( C6 ) ............................................ 4-2-166
Figure 2-83. Transmission Park Brake Assembly ( C6 ) ................................ 4-2-168
Figure 2-84. Engine and Tramsmission Assembly ( Deutz Tier 4i and
4R75 Transmission ) ................................................................. 4-2--170
Figure 2-85. Transmission ( 4R75 ) Assembly ................................................. 4-2-172
Figure 2-86. Transmission Sensors Installation ( 4R75 ) ................................. 4-2-174
Figure 2-87. Transmission Oil Pan Installation (4R75) .................................... 4-2-176
Figure 2-88. Shifter Assembly (4R75 Transmission) ....................................... 4-2-178
Figure 2-89. Park Brake Assembly (4R75 Transmission) ................................ 4-2-180
Figure 2-90. Drive Shaft Assembly (C6) .......................................................... 4-2-182
Figure 2-91. Drive Shaft Assembly ( 4R75 Transmission ) ............................... 4-2-184
Figure 2-92. Deutz Tier 4i ECU and 4R75 TCU Installation ............................ 4-2-186
Figure 2-93. VEC Panel Assembly ( Deutz Tier 2 ) .......................................... 4-2-188
Figure 2-94 TEC Panel Assembly ( Deutz Tier 4i ) ........................................... 4-2-190
Figure 2-95. Brake Line System ...................................................................... 4-2-192
Figure 2-96. Hydroboost Installation ................................................................ 4-2-194
Figure 2-97. Battery Assembly ........................................................................ 4-2-196
Figure 2-98. Battery Assembly with Heater Option .......................................... 4-2-198
Figure 2-99. Battery Assembly ( CE Option ) .................................................. 4-2-200
Figure 2-100. Heater Junction Box ( Optional ) ............................................... 4-2-202
Figure 2-101. Horn Installation ........................................................................ 4-2-204
SECTION 3: NUMERICAL INDEX .............................................................................................. 4-3-1
SECTION 4: ALPHABETICAL INDEX ....................................................................................... 4-4-1
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Chapter 5: Appendices
SECTION 1: PERIODIC MAINTENANCE CHECKLIST ............................................................. 5-1-1
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS ................................................ 5-2-1

A. Description ............................................................................................................ 5-2-1
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COPYRIGHT NOTICE
This manual is copyrighted as an unpublished work.
This manual contains the confidential and proprietary information of TUG Technologies Corporation.
Neither this document, nor any information contained herein, may be reproduced or redistributed in any form
whatsoever without the express, written consent of an authorized agent of TUG Technologies Corporation.
Any attempt by any person other than an authorized agent of TUG Technologies Corporation to alter the
contents of this manual in any way shall be construed as copyright infringement, punishable by all applicable
laws.
All vendor literature contained in this manual is the copyrighted property of the respective vendors, protected
by the same laws governing this operation and maintenance manual.
© Copyright 2007 by TUG Technologies Corporation. All rights reserved.
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INTRODUCTION
The information and instructions in this handbook are intended to acquaint the operator with the important
operating features of the TUG model MR Mid-Range Tow Tractor. The various controls, gauges, switches,
and operating features are explained and illustrated throughout this handbook. Personnel responsible for
operation of the vehicle should read this manual carefully to become familiar with vehicle operation.
UNIT IDENTIFICATION
To aid the technician in repair or service work on this unit, a TUG identification plate is located on the
operator's compartment of the unit.
TUG TECHNOLOGIES CORPORATION

1995 DUNCAN DRIVE
KENNESAW, GEORGIA 30144
PH: 770 422−7230
MODEL:
SERIAL NO:
DRAWBAR CAP.: LBS.
MANUFACTURE DATE
The serial number identification of each unit will appear on the nameplate along with the date of manufacture.
The mailing address of TUG is also located on the data plate next to the TUG logo. This necessary
information will ensure the customer a fast and accurate response to any parts and/or service request.
Please verify the serial number on the identification nameplate of the unit and enter your unit serial number
here:
If applicable, enter your company identification number
here:
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TECHNICAL ASSISTANCE
Direct any questions concerning the operation of the MR Mid-Range Tow Tractor to:
TUG Technologies Corporation

P.O.Box
Kennesaw, GA 30156
Domestic: 1-800-989-8499
International: (770) 422-8021
Fax: (770) 422-8730
All information in this manual is based on the latest production information available at the time of
publication. Direct any questions concerning the contents or format of this manual to:
TUG Technologies Corporation

Attn: TUG Shop
P.O.Box 3028
Kennesaw, GA 30156
Domestic: 1-800-989-8499
Fax: (770) 422-8730
Email: TugShop@tugtech..com
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AIRCRAFT GROUND SUPPORT EQUIPMENT

WARRANTY POLICY STATEMENT
This Policy Statement sets forth the terms of the warranty provided by TUG Technologies Corp. with respect to ground power units, air start units, tow tractors,
cargo tractors and other equipment sold for use in the commercial aviation industry (“Aircraft Ground Support Equipment”).
STATEMENT OF WARRANTY AGAINST DEFECTS
Subject to the limitations and exclusions set forth below, TUG Technologies Corp. will repair or replace any defective or malfunctioning part of the Aircraft
Ground Support equipment for a period of twenty-four (24) months from the date first placed in service, or twenty-eight (28) months from date of shipment, or
the first 2,000 hours of operation, whichever expires first. Each piece of Aircraft Ground Support Equipment shall be presumed to have been placed in service
on the date of the TUG Technologies Corp. start-up report or, if there is no such report, on the date of shipment by TUG Technologies Corp. to the first retail
purchaser (“Buyer”).
WARRANTY AGAINST PATENT INFRINGEMENT
TUG Technologies Corp. warrants that none of the Aircraft Ground Support Equipment, the use thereof within the United States, or the applications, processes
or designs employed in the manufacture thereof infringes on the valid claim of any U.S. letter patent, patent application, copyright, trade secret or any other
property right of any third party. In the event of a breach or alleged breach of this warranty TUG Technologies Corp. shall, at its own expense, defend any suit
or proceeding brought against Buyer and shall fully protect and indemnify Buyer against any liability, cost, recovery or other expense in or resulting from such
suit or claim of infringement. Buyer shall give prompt notice in writing of any notice of claim of such suit and Buyer agrees to cooperate with TUG Technolo-
gies Corp. to enable it to make such defense. If in any such proceeding, the Aircraft Ground Support Equipment or any part thereof is held to constitute an
infringement and the full or partial use of the Aircraft Ground Support Equipment is enjoined, TUG Technologies Corp. shall, at no cost to Buyer, (i) obtain for
Buyer a license to use the Aircraft Ground Support Equipment or (ii) modify the Aircraft Ground Support Equipment so as to avoid the infringement without
degradation in performance. If TUG Technologies Corp. cannot obtain such a license, or the Aircraft Ground Support Equipment cannot be so modified, or if as
a result of any suit or infringement or alleged infringement, TUG Technologies Corp. may elect not to deliver, or may be prevented from delivering, the Aircraft
Ground Support Equipment or any part or component thereof, TUG Technologies Corp. shall, as Buyer’s exclusive remedy, promptly refund to Buyer all money
paid by Buyer for the Aircraft Ground Support Equipment.
EXCLUSIONS OF LIABILITY
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TUG TECHNOLOGIES CORP.’S LIABILITY UNDER THE FOREGOING
WARRANTY SHALL BE LIMITED TO THE COSTS OF REPAIR OR REPLACEMENT BY TUG TECHNOLOGIES CORP. OF ANY DEFECTIVE PART
OR WORKMANSHIP. TUG TECHNOLOGIES CORP. SHALL NOT HAVE ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES,
INCLUDING LOSS OF USE AND LOST PROFITS, IN CONNECTION WITH THE PURCHASE, SALES, SHIPMENT, SERVICE, REPAIR OR OPERATION
ARISING FROM THE FAILURE OF ANY AIRCRAFT GROUND SUPPORT EQUIPMENT OR A COMPONENT THEREOF, OR A BREACH OF ANY
WARRANTY. IN NO EVENT SHALL TUG TECHNOLOGIES CORP.’S LIABILITY TO ANY PERSON EXCEED THE PURCHASE PRICE OF THE TUG
TECHNOLOGIES CORP. AIRCRAFT GROUND SUPPORT EQUIPMENT.
TUG Technologies Corp. will, at its sole option, repair or replace any component, part or parts, if found on examination by TUG Technologies Corp. to be
defective and if the necessary return charges are prepaid by the Buyer. This applies to TUG Technologies Corp. manufactured components. Purchased compo-
nents will be handled based on their individual warranties.
Certain Aircraft Ground Support Equipment are installed on trucks or trailers supplied by TUG Technologies Corp. but manufactured by others. In addition,
most Aircraft Ground Support Equipment includes tires that are covered by the warranty issued by the original manufacturer. The warranty of TUG Technolo-
gies Corp. does not cover any failure of the chassis, drive train, cab or other part of the truck or trailer on which Aircraft Ground Support Equipment is installed
other than tow tractors or cargo tractors manufactured by TUG Technologies Corp.. Tires are specifically excluded from any warranty by TUG Technologies
Corp. and are covered only by the warranty, if any, extended by the original manufacturer.
TUG Technologies Corp. has not authorized any person to assume or create any different warranty, written or oral, express or implied, or any other liability on
behalf of TUG Technologies Corp. with respect to the Aircraft Ground Support Equipment.
TUG Technologies Corp. reserves the right to make changes in design and changes or improvements upon its products without any obligation upon itself to
install the same upon its products theretofore manufactured.
The foregoing warranty gives Buyer specific legal rights that may vary from state to state. Some states do not permit the limitation of incidental or consequential
damages or limitation of remedies under warranties. The above limitations apply only to the extent permitted by applicable law.
BUYER’S RESPONSIBILITY
TUG Technologies Corp. provides Buyer with a copy of the relevant operator manuals containing vital information relating to the proper use and maintenance
of the Aircraft Ground Support Equipment. Additional copies of operator manuals are available from TUG Technologies Corp. at a small charge. Any repairs
arising from failure to maintain the Aircraft Ground Support Equipment in accordance with the operator manuals, from operation of the Aircraft Ground
Support Equipment in a manner not recommended by the operator manual, or from the use of fuels, lubricants or coolants not meeting the specifications set
forth in the operator manuals, are for the account of Buyer.
Many factors affect the performance and reliability of the Aircraft Ground Support Equipment. Specific output ratings and operating parameters have been
established by TUG Technologies Corp.. Operation outside of the recommended parameters can adversely affect the service life of the Aircraft Ground Support
Equipment.
Buyer shall be responsible for all repairs arising from operation of Aircraft Ground Support Equipment above its output ratings, outside its recommended
operating parameters or misuse, accident, foreign object damage or damage caused by a third party.
The Aircraft Ground Support Equipment will require repairs and adjustments over time. The repairs should be performed only by TUG Technologies Corp.
authorized mechanics and with equipment and parts meeting the TUG Technologies Corp. specifications set forth in the operating manuals. Moreover, certain
items installed on the Aircraft Ground Support Equipment, such as belts and filters, wear out over a period of time and must be periodically replaced. Buyer
shall be responsible for any filters, belts, hoses or other normal maintenance items. Buyer shall be responsible for any repairs arising from alterations to the
Aircraft Ground Support Equipment, repairs performed by a person other than authorized representatives of TUG Technologies Corp. or the use of maintenance
items or parts not meeting the TUG Technologies Corp. specifications set forth in the operator manuals. The cost of routine or required maintenance and service
is the responsibility of the Buyer. The Buyer is required to keep documented evidence of when and by whom maintenance and service are performed.
CD387 INTRO-xxxv
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IN THE EVENT OF A FAILURE

1. Unless there is a threat to life or property, Buyer shall immediately cease using any Aircraft Ground Support Equipment that exhibits any fuel or oil leak,
vibration, unusual noise, high temperature, low oil pressure, black or white smoke, excessive fuel or oil consumption, or any other abnormal condition.
2. Do not disassemble or otherwise attempt to repair the Aircraft Ground Support Equipment. Contact TUG Technologies Corp. for the name and address of
the nearest facility authorized to repair Aircraft Ground Support Equipment. Have available all serial numbers, model numbers, date of purchase and other
information that will assist TUG Technologies Corp. to identify the equipment.
3. TUG Technologies Corp.’s Warranty Department will troubleshoot the problem and direct the Buyer to the nearest authorized repair facility, or dispatch a
field service representative to the location of the Aircraft Ground Support Equipment or provide buyer with replacement parts to be installed by Buyer.
Buyer will be asked for a purchase order or other commitment to pay any expenses that are not covered by the applicable warranty.
4. TUG Technologies Corp. will repair warranted failures during normal business hours using new or remanufactured parts at the option of TUG Technologies
Corp. Warranty Department. Buyer must pay for any repairs or charges not covered by the applicable warranty at the time services are rendered unless other
arrangements are made in advance.
5. TUG Technologies Corp. will invoice Buyer for all warranty replacement parts that are shipped for Buyer installation. Buyer shall be entitled to full credit
against the cost of such part, other than transportation charges, upon the return of the failed parts and determination by TUG Technologies Corp.’s Warranty
Department that such failure was covered by warranty. Such invoice shall be payable in full unless the failed part is returned within ten (10) days after
invoice date.
IF YOU HAVE A QUESTION
If you have any questions regarding the applicable warranty on your Aircraft Ground Support Equipment, contact:
TUG Technologies Corp.

P.O.Box 3028
Kennesaw, GA 30156
Domestic: 1-800-989-8499
Fax: (770) 422-8730
E-mail: TugShop@tugtech.com
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HOW TO USE THIS MANUAL

Important Notice: TUG recommends that the vehicle operator thoroughly study the contents of this handbook
before attempting to operate the vehicle.
This handbook is divided into five chapters. Refer to the Table of Contents at the front of this manual and each
chapter for details of chapter content.
Page numbering system uses a three-part page number. The first number represents the chapter in which the
page appears, the second number indicates the section within that chapter, while the third number is the page
number within that section.
Warnings, Cautions, and Notes are used throughout this handbook. Look for the following symbols, which
point out items of importance to the safety of the individual and protection of equipment.
SAFETY NOTES THAT MUST BE FOLLOWED TO AVOID SERIOUS

INJURY TO PERSONNEL OR EVEN DEATH.
SAFETY NOTES THAT NEED TO BE FOLLOWED TO PREVENT

DAMAGE TO EQUIPMENT.
Note Relevant information for the reader, that is not hazard-related.
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MR: Mid-Range Tow Tractor Safety
SAFETY
A. DISCUSSION
Operator and mechanic safety is so important at TUG that the initial design and build of every product
undergoes a thorough review of all the components to produce the safest equipment available today.
To reinforce this action, a separate chapter of this manual has been devoted to safety and must be read
by every operator and mechanic that may be involved with this equipment.
The safety chapter covers the following:
A. Discussion
B. Operator Responsibilities
C. Mechanic Responsibilities
It is strongly recommended that this chapter be reproduced and bound to your operator’s book along
with your station safety rules.
The Tug Model MR has been designed and built with operator and mechanic safety in mind from the
beginning. With these design features and precautions combined with common sense, the MR Mid-
Range Tow Tractor is the safest tow tractor available today.
B. OPERATOR RESPONSIBILITIES
1. Always follow Station Safety Rules. Obtain a written list before operating this tractor if one
is not already posted.
2. Before using this tractor, always check it for proper operation and condition of lights, brakes,
park brake, steering, horn and tires.
3. Do not operate a tractor with defective brakes, steering, tires, horn, parking brake or lights.
Refer to the maintenance section of the operation and service manual.
4. Always keep hands and feet away from rotating parts and tires. Wear secured clothing.
5. Always wear suitable footwear when operating this equipment, and avoid loose-fitting
clothing that might get caught in moving parts.
6. Always bring unit to a complete stop before dismounting or shifting from forward to reverse
or reverse to forward.
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Safety MR: Mid-Range Tow Tractor
7. Do not shift transmission into gear with engine above idle speed. Keep foot off accelerator
when shifting.
8. Always check that path is clear prior to backing:
(a) Check local station rules and sound horn, if permitted, prior to backing.
(b) If sounding the horn is not permitted, follow applicable safety rules for other
personnel prior to moving.
9. Always be sure load is secured before moving.
10. Always use safety chains between wagons to control uncoupled wagons from accidental hitch
releases.
11. Always use particular caution when in congested areas and around blind corners and rows of
carts. Be alert for other equipment and personnel.
12. Never operate at speeds inconsistent with operating conditions. Always limit speed to ensure
adequate time for braking in an emergency.
13. Do not use tractor to push other equipment. Use proper towing equipment.
14. Do not allow tractor to be pushed by other equipment. Use proper towing equipment.
15. Do not tamper with the engine speed governor.
16. Do not tow objects from any point on the tractor other than the hitch provided. Towing from a
point above the rear axle center line could cause the tractor to roll over backwards.
17. Do not disconnect or otherwise disable Ryder Safe Seat system if so equipped.
18. Do not remove radiator cap when the engine is hot, as serious burns may result. Allow
radiator to cool before removing cap.
19. Always be sure the load is contained within the bulkheads of the wagons. Without
bulkheads, a sudden stop could cause the load to shift onto the tractor.
20. Never refuel unit when the engine is running.
21. Do not fill the fuel cell above the bottom of filler screen. Do not overfill. Clean off any
spilled oil or fuel.
22. Do not smoke while refueling.
SAFETY-ii CD387
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23. Do not store, spill or use fuel near an open flame.
24. Do not check engine oil while engine is running.
25. Do not use the battery in this unit to start other vehicles.
26. Do not drive up or down hills with slopes greater than 15 degrees, or drive across any slope.
27. Always leave room when stopping or starting on hills to allow for slight roll downhill.
28. Never engage in “horseplay” with the tractor
29. Always exercise common sense, stay alert and keep aware of what is happening around the
tractor at all times.
C. MECHANIC RESPONSIBILITIES
This chapter must be read and thoroughly understood prior to performing any maintenance on this
equipment.
WARNING: FAILURE TO COMPLY WITH THE FOLLOWING SAFETY

PRECAUTIONS CAN RESULT IN SERIOUS INJURY OR DEATH AS
WELL AS EQUIPMENT DAMAGE.
1. Always follow Station Safety Rules. If a written list of the safety rules is not posted at the
station, obtain one prior to operating this tractor.
2. Always review the “Operator Responsibilities” section of this chapter prior to operating this
equipment.
3. Always keep hands and feet away from rotating parts and tires. Wear secured clothing.
4. Always wear suitable footwear when operating or servicing this equipment and avoid loose
fitting clothing that might get caught in moving parts.
5. Do not use the tractor to push other equipment. Use the proper towing equipment.
6. Do not allow the tractor to be pushed by other equipment. Use the proper towing equipment.
7. Always stop the engine when adjusting fan and alternator belts.
8. Always keep hands clear of the cooling fan.
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9. Do not remove radiator cap when the engine is hot, as serious burns may result. Allow
radiator to cool before removing cap.
10. Do not check engine oil while the engine is running.
11. Always disconnect the battery negative cable when working on the engine or under the hood.
12. If electrolyte is spilled, always wash hands or clothing immediately.
13. Do not touch hot engine, exhaust or hydraulic components as serious burns may result.
14. Do not smoke near the battery. Fumes from charging electrolyte are explosive. Always keep
the battery away from sparks, flame and smoking materials.
15. Always remove metal bracelets, watch bands, etc. prior to installing, removing or servicing
the battery.
16. Do not short the battery terminals.
17. When connecting battery, the positive terminal must always be connected first to prevent
sparks from accidental grounding.
18. Do not substitute throttle return springs with lighter or other springs.
19. Check brakes and fill master cylinder with DOT 3 brake fluid.
20. Check steering for excessive backlash.
21. Check all lights.
22. Check horn operation.
23. Check neutral start only switch for proper adjustment and operation.
24. Do not disconnect or otherwise disable the Ryder Safe Seat system if so equipped.
25. Check tire and wheel condition along with proper inflation pressures. Unless beads are seated
when mounting tires, over-inflation can result in explosion.
26. Ensure all lug nuts are torqued to proper value.
27. Always use proper lifting equipment to safely remove and replace heavy components.
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28. When working underneath the tractor, be sure it is supported properly on secure jack stands.
Do not rely on hydraulic jacks to support the tractor.
29. If the tractor is on a hydraulic or air operated lift, always be sure the safety support or lock is
in position prior to working under the tractor.
30. Always use a proper transmission jack and secure the transmission when removing or
replacing it.
31. Always jack the drive wheels off the floor when troubleshooting the drive system.
32. Never refuel the unit while the engine is running.
33. Do not fill the fuel cell above the bottom of filler screen. Do not overfill. Clean off any
spilled oil or fuel.
34. Do not smoke while refueling.
35. Do not store, spill or use fuel near an open flame.
36. Do not use the battery in this unit to start other vehicles.
37. Do not attempt to install or adjust control cables with the engine running.
38. Always replace a control cable that exhibits any gradual or sudden increase in no-load friction
or resistance, or decrease in usable stroke, or that has moisture inside, or has been frozen.
39. Do not use heat to attempt to dry or thaw a control cable.
40. Do not remove the seats from a control cable or attempt to lubricate it. Any control cable that
exhibits possible lubrication problems should be replaced.
41. Do not attempt to repair or modify a control cable. Any damaged control cable should be
replaced immediately.
42. Always avoid exposing control cables to fuels, oils, chemicals, paint, water or dirt as damage
may result.
43. Always adjust each control cable so that the utilized stroke of the cable is centered within the
cable’s available stroke.
44. Always deflate a tire and wheel assembly prior to removing it for servicing or dismounting.
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45. Do not use wheels or wheel components that are cracked, bent, pitted or corroded. Ensure all
wheel components are of the same type and size, and that wheel size and tire size match.
Inspect all components carefully prior to use.
46. Do not attempt to seat a tire bead or side or lock ring by using inflation pressure or any
flammable or explosive substance such as starting fluid or ether. Never inflate a tire beyond
40 psi to seat tire beads.
47. Do not hammer, pry or weld on or near an inflated or partially inflated wheel and tire
assembly.
48. Do not rework, weld, heat or braze any wheel parts for any reason.
49. Always use a safety cage or other restraining device and a clip-on air chuck with a remote
valve and pressure gauge when inflating a tire. Insure the tire and wheel assembly is properly
assembled prior to inflating it. Visually inspect it for proper seating of beads and side or lock
rings prior to removing it from the cage.
50. Do not add air to a tire that has been in service with less than 80% recommended pressure
without first fully deflating, removing, disassembling and inspecting the tire assembly for
damage.
51. Immediately replace any parts that show wear or deterioration.
52. Check the condition and tightness of all fasteners. Always use Grade 8 heat treated bolts
throughout the unit. Grade 8 heat treated bolts can be identified by six lines on the bolt head.
53. Always keep good maintenance records.
54. Never engage in “horseplay” with the tractor.
55. Always exercise good common sense, stay alert and be aware of what is happening around
the tractor at all times. Take nothing for granted when the safety of the tractor or the operator
is at stake. Remember, the operator is depending on you to provide him with a safe tractor.
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Chapter 1
MR: Mid-Range Tow Tractor Table of Contents
TABLE OF CONTENTS
A. Introduction ........................................................................................................... 1-1-1
B. Braking System .................................................................................................... 1-1-2
1. Service Brakes .......................................................................................... 1-1-2
2. Parking Brake ........................................................................................... 1-1-2
C. Chassis ................................................................................................................. 1-1-2
D. Coolant and Lubrication System ........................................................................... 1-1-2
E. Electrical System .................................................................................................. 1-1-2
1. Alternator .................................................................................................. 1-1-3
2. Starter ....................................................................................................... 1-1-3
3. Vehicle Electrical Center Panel Assembly. ............................................... 1-1-3
F. Engine .................................................................................................................. 1-1-3
G. Drive Shaft ............................................................................................................ 1-1-3
H. Air Intake System ................................................................................................. 1-1-4
1. Air Filter Assembly .................................................................................... 1-1-4
2. Air Filter Service Indicator ......................................................................... 1-1-4
I. Exhaust System .................................................................................................... 1-1-4
J. Fuel System .......................................................................................................... 1-1-4
K. Ignition .................................................................................................................. 1-1-4
L. Lights and Accessories ......................................................................................... 1-1-4
M. Seating ................................................................................................................. 1-1-5
N. Hitches .................................................................................................................. 1-1-5
O. Steering ................................................................................................................ 1-1-5
P. Suspension, Front ................................................................................................ 1-1-5
Q. Suspension, Rear ................................................................................................. 1-1-6
R. Tires and Wheels .................................................................................................. 1-1-6
S. Towing Capability .................................................................................................. 1-1-6
T. Transmission ........................................................................................................ 1-1-6
U. Turning Radius ..................................................................................................... 1-1-6
SECTION 2: OPERATION .......................................................................................................... 1-2-1
A. Principles of Operation ......................................................................................... 1-2-1
B. Operating Indicators and Controls ........................................................................ 1-2-1
1. Dash panel for MR with Deutz Tier 2 engine ............................................ 1-2-1
2. The dash panel for MR with Deutz Tier 4i engine ..................................... 1-2-4
3. The dash panel for MR with Kubota engine. ........................................... 1-2-11
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Chapter 1
Table of Contents MR: Mid-Range Tow Tractor
4. Wiper Control Switches ......................................................................... 1-2-15

5. Turn Signal Lever.................................................................................... 1-2-15
6. Cab Dome Light Switch .......................................................................... 1-2-15
7. E-Stop Button Switch. ............................................................................. 1-2-15
8. Battery Disconnect Switch (Optional). .................................................... 1-2-16
C. Operator's Compartment .................................................................................... 1-2-16
D. Preparation for Use ............................................................................................ 1-2-17
1. Fuel System ............................................................................................ 1-2-17
2. Battery .................................................................................................... 1-2-17
3. Brake System ......................................................................................... 1-2-17
4. Engine and Transmission ....................................................................... 1-2-17
5. Drive Axle and Reduction Gear Box ....................................................... 1-2-18
6. Tire Inflation ............................................................................................ 1-2-19
7. Power Steering Reservoir ....................................................................... 1-2-19
E. Standard Operating Procedures ......................................................................... 1-2-19
1. Normal Starting ....................................................................................... 1-2-19
2. Cold Weather Starting ............................................................................. 1-2-19
3. Driving Instructions ................................................................................. 1-2-20
4. Towing Instructions ................................................................................. 1-2-20
SECTION 3: SPECIFICATIONS ................................................................................................. 1-3-1
A. General ................................................................................................................. 1-3-1
B. Engine .................................................................................................................. 1-3-1
1. Deutz (Tier 2) Diesel ................................................................................. 1-3-1
2. Deutz (Tier 4i) Diesel ................................................................................ 1-3-1
3. Kubota Diesel ........................................................................................... 1-3-2
C. Transmission ........................................................................................................ 1-3-2
1. Ford C-6 automatic transmission. ............................................................. 1-3-2
2. Ford 4R75 automatic transmission. .......................................................... 1-3-2
D. Drive Axle ............................................................................................................. 1-3-2
E. Steering ................................................................................................................ 1-3-2
F. Front Axle ............................................................................................................. 1-3-3
G. Wheels .................................................................................................................. 1-3-3
1. Front Wheels ............................................................................................ 1-3-3
2. Rear Wheels ............................................................................................. 1-3-3
H. Brakes .................................................................................................................. 1-3-3
I. Electrical System .................................................................................................. 1-3-3
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Chapter 1
J. Towing Capability .................................................................................................. 1-3-4

K. Turning Radius ..................................................................................................... 1-3-4
SECTION 4: SHIPPING .............................................................................................................. 1-4-1
A. Preparation ........................................................................................................... 1-4-1
1. Battery ...................................................................................................... 1-4-1
2. Fuel Tank .................................................................................................. 1-4-1
SECTION 5: STORAGE ............................................................................................................. 1-5-1
A. One Month to Six Months ..................................................................................... 1-5-1
1. Engine ....................................................................................................... 1-5-1
2. Tire ............................................................................................................ 1-5-2
3. Battery ...................................................................................................... 1-5-2
4. Lubrication ................................................................................................ 1-5-2
5. Fluid Levels ............................................................................................... 1-5-2
B. Extended Period (More than Six Months) ............................................................. 1-5-2
1. Transmission ............................................................................................ 1-5-2
2. Drive Axle and Reduction Gear Box. ........................................................ 1-5-2
3. Battery ...................................................................................................... 1-5-3
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Chapter 1
1-TOC-iv CD387
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Chapter 1
MR: Mid-Range Tow Tractor Section 1
SECTION 1: DESCRIPTION
A. INTRODUCTION
The TUG Model MR mid-range tow tractor (Figure 1-1) is a four-wheeled, rear wheel drive, diesel
engine driven unit designed for towing aircraft and support equipment. The drive system consists of a
four-cylinder diesel engine, automatic transmission and a rear drive planetary reduction axle. Front
wheel steering is power assisted and has a 50-degree turning angle. Each front wheel is equipped
with hydraulically assisted disc brakes and each rear wheel is equipped with integrated hydraulic wet
disc brakes with six discs per side.
Figure 1-1. TUG Model MR
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Chapter 1
Section 1 MR: Mid-Range Tow Tractor
B. BRAKING SYSTEM
There is a split hydraulic braking system and mechanical parking brake utilized on the TUG Model
MR. The hydraulic brakes incorporated into the drive axle and hydraulic disc brakes incorporated on
the front wheels. The hydraulic braking system uses a dual line master cylinder to supply hydraulic
pressure for both the front and rear brakes.
1. Service Brakes
Service brakes are axle-integrated hydraulic wet disc brakes, with six (6) discs per side, on the
rear, and single-piston, floating caliper Delco brakes on the front axle. The brakes are
actuated through a hydraulically boosted, split master cylinder to maximize brake force and
minimize operator effort. The brake pedal is cantilevered to allow the driver to apply only 60
lbs. of force to achieve maximum braking at the tires.
2. Parking Brake
The mechanical parking brake operates by a linkage attached to the parking brake lever and a
drum located at the rear of the transmission.
C. CHASSIS
The chassis incorporates a welded construction and steel unibody frame, providing a structurally
sound platform for mounting the engine and other major components. The rear bumper and rear sides
provide the wheel loading to optimize tractive effort.
D. COOLANT AND LUBRICATION SYSTEM
Engine lube oil is circulated through a fluid to air heat exchanger, which provides engine cooling at an
optimum operating temperature. An oil filter is mounted on the right hand side of the engine. All the
oil discharged by the oil pump passes through the full flow filter before reentering the engine and
coolant system. The filter has an integral relief valve, which permits oil to bypass the filter if the
element becomes clogged.
E. ELECTRICAL SYSTEM
The TUG Model MR utilizes a 12-volt automotive type, negative ground, electrical system. The
system includes a 95 Amp alternator, 800cca sealed battery, ignition switch, head lights, turn signals,
tail lights, backup lights, horn button, ignition equipment, various gauges and all other circuits, front
and rear wiper motors, heater blower motor and interior cab light, emergency stop switch, hitch light,
and vehicle electrical center:
- (VEC) panel assembly with various relays and circuit fuses for MR-24 (Deutz Tier2) and MR-36
(Kubota)
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Chapter 1
- (TEC) panel assembly with various relays and circuit fuses for MR-34 (Deutz Tier 4i).
MR-10-34 (Deutz Tier 4i) is equipped with an updated version of plug and play electric
system.
1. Alternator
Electrical power is supplied by the alternator, which is mounted on the engine and is driven
by a belt operating from the engine drive pulley. The alternator contains an internal voltage
regulator and collectively provides:
- Deutz engine (Tier 2 and Tier 4i) - 95 Amps of DC power to vehicle and to provide charging
of the battery.
- Kubota - 90 Amps of DC power to vehicle and to provide charging of the battery.
2. Starter
The engine is started with a starter. The starter system draws upwards of 250 Amps when in
operation. The transmission is equipped with a pressure sensor to detect when the engine is
running. When the engine is running the pressure sensor will activate a cutout circuit on the
starter, preventing it and the ring gear from being damaged by their operating while the
engine is running.
3. Vehicle Electrical Center Panel Assembly.

The Vehicle Electrical Center Panel Assembly is located on the engine compartment firewall
and consists of:
- the vehicle electrical center (VEC) for MR-24 (Deutz Tier 2) and MR-36 (Kubota)
- TUG electric center (TEC) for MR-34 (Deutz Tier 4i)
- control relays
- solenoid
- fuses\ (Deutz Tier 2, Kubota).
F. ENGINE
The TUG Model MR is powered by a four cylinder, turbo-charged, diesel engine. The Deutz
BF4M2011 is an EPA Tier 2 certified diesel engine with 88 horsepower (at 2800 rpm) and 199 ft-lbs
at peak torque (1600 rpm). The Kubota V3600T provides 84.5 horsepower (at 2600 rpm ) and 218.3
ft-lbs at peak torque (1600 rpm). The Kubota V3600 porvides 66.8 horsepower (at 2600 rpm ) and
162 ft-lbs at peak torque (1600 rpm). All engines are certified to operate on VV-F-800 compatible
diesel fuel, as well as JP-5 and JP-8 aviation fuels. Use of JP-5 and JP-8 does not require the use of a
lubricity filter or fuel additives.
G. DRIVE SHAFT
The drive shaft is an automotive type shaft with double universal joints and a spline coupling.
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H. AIR INTAKE SYSTEM
The TUG Model MR is equipped with an air intake system that supplies clean air to the engine. It
utilizes an air filter, air filter service indicator, and intake hoses to route incoming air to the engine.
1. Air Filter Assembly

The TUG Model MR utilizes an air filter assembly that has a built-in tangential pre-cleaner
ahead of the air filter element. The air filter element can be replaced in a short time without
the use of any tools.
2. Air Filter Service Indicator

The TUG Model MR incorporates an air filter service indicator located on the outlet of the air
filter assembly. When the restriction limit of the air filter element is reached and service is
required, the air filter service indicator shows red through the full-view window. After the
filter has been serviced, the air filter service indicator must be reset by depressing the rubber
button on top; the indicator will show green through the full-view window.
I. EXHAUST SYSTEM
The TUG Model MR is equipped with an SAE ARP1247 compliant, flame/spark arrestor and muffler
in its exhaust system for preventing accidental emission of fire or sparks.
J. FUEL SYSTEM
The TUG Model MR has a stainless steel fuel tank located between the inner and outer frame rails on
the passenger’s side of the vehicle. The filler neck is 3 inches in diameter (internal) to allow filling
from aircraft fuel trucks. The rigid lines for the TUG Model MR’s fuel system are made from
stainless steel.
K. IGNITION
The engine in the TUG Model MR is activated through a 3-position keyless ignition switch located on
the operator’s console.
L. LIGHTS AND ACCESSORIES
1. The TUG Model MR uses two incandescent, sealed beam headlights. LED Lights are
optional.
2. The two tail/turning/brake lights are red LEDs and the two back up lights are white LEDs. A
lever on the steering column activates the directional turn signals.
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Chapter 1
3. The back up lights automatically turn on when the gear shifter is in the reverse position. The
TUG Model MR is also equipped with a hitch light on the rear bumper for operating in low
light conditions.
M. SEATING
The TUG Model MR is a two-passenger vehicle with the driver’s seat located on the left side of the
centerline and a passenger seat to the right; both seats are equipped with adjustable slides. Hip guards
are provided with all tractors. When cab is removed, hip guards must be relocated next to seats from
their storage location by the rear window. Seat belts are furnished for occupant safety.
N. HITCHES
The TUG Model MR has several different hitch options availble to both the front and rear bumpers (
Chapter 4, Section 2, Figure 1).
O. STEERING
1. A hydraulic steering system is used on the TUG Model MR. The TUG Model MR is
configured for left-hand drive (steering wheel and driver’s controls aligned to the left side of
the passenger compartment).
2. This system employs a 4-gpm flow-control vane pump, a hydrostatic, power assisted steer
valve, a hydro boost hydraulic brake booster, a 1,000 psi relief valve, reservoir and a shut-off
valve. When actuated the hydrostatic steer valve supplies pressurized hydraulic fluid to a
power steering cylinder that will steer the front wheels of the TUG Model MR. The shut-off
valve is used to prevent loss of hydraulic fluid from the reservoir when making any repairs to
the hydraulic steering system. The reservoir has a 6.8 quart capacity.
3. Refer to Chapter 2, Section 2 for the hydraulic schematic.
P. SUSPENSION, FRONT
The steering axle is a welded steel tube construction mounted to the chassis by two semi-elliptic,
mutli-leaf spring assemblies. Turning movement from the steering wheel is transmitted to the axle via
a steering valve connected to a steering cylinder through hydraulic hoses. This provides a high angle
lock with minimum amount of steering effort. A PTO driven pump supplies hydraulic pressure.
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Q. SUSPENSION, REAR
The rear suspension consists of a drive axle mounted to a trailing arm cradle, which is mounted to the
chassis at the front pivots. It is also supported at the rear with coil springs and gas charged shock
absorbers. The rear suspension utilizes limiting chains, which prevent the shock absorbers from
supporting the load of the rear suspension when the tractor is lifted off the ground.
R. TIRES AND WHEELS
1. The TUG Model MR uses 185Rx14 tires on the front steer axle, and 8.75x16.5 dual tire, rear
wheels. These are tubeless pneumatic tires mounted on one piece rims.
2. The tires are inflated to 90 psi in the front and 75 psi in the rear. For units equipped mankang
or federal front tires pressure - 75 psi. The rear wheel wells are designed to provide at least 2-
inches of clearance around the tires in all positions to allow for snow chains.
Solid front and rear tires are optional.
S. TOWING CAPABILITY
1. The TUG Model MR is a two-wheel drive, diesel powered type vehicle with a gross vehicle
weight of 10,000 lbs (MR-8) or 12,500 lbs (MR-10). In order to optimize the tractive effort
in this two-wheel configuration 83% of the vehicles weight is on the rear drive wheels of the
TUG Model MR.
2. The vehicle is capable of towing 100,000 lb in the forward and 80,000 lb in the reverse
direction.
T. TRANSMISSION
The TUG Model MR-24 (Deutz Tier2) and MR-36 (Kubota) utilizes a Ford C-6 automatic
transmission. The transmission has three (3) speeds in the forward direction and one speed in reverse.
The MR-34 (Deutz Tier 4i) is equipped with a Ford 4R75 electronic transmission. This transmission
has 3 forward gears and 1 reverse gear .
U. TURNING RADIUS
The turning radius of the TUG Model MR is 160-inches in a right hand turn and 155-inches in a left
hand turn. These turning radii are measured at the outer most edge of the frame.
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SECTION 2: OPERATION
A. PRINCIPLES OF OPERATION
The TUG Model MR is powered by an internal combustion 4-cylinder, oil or water-cooled diesel
engine and has an operating temperature range from -20 °F to 123 °F. Power is transmitted to the rear
wheels through a transmission, drive shaft, differential assembly, reduction gears and drive axle
assembly. Standard disc brakes are provided on the front wheels and hydraulic wet brakes are
provided on the rear wheels and are actuated by a foot pedal.
1. Steering is accomplished at the front wheels through a hydraulic power steering box and
sealed ball jointed linkage.
2. The vehicle employs a 12-volt, 800cca battery consisting of spiral cell technology to supply
power for the lights, starter motor, ignition, and instrumentation.
3. The unit’s frame is a welded steel unit. An adjustable driver’s seat is located on the left side
of the vehicle. A second adjustable seat is located on the right side for a passenger.
4. The vehicle is geared to travel at a maximum speed of 15 mph forward and 7 mph in reverse
with no towing load.
B. OPERATING INDICATORS AND CONTROLS
The operating controls are mounted throughout the cab, but mainly on the dash panel.
1. Dash panel for MR with Deutz Tier 2 engine

The dash panel for MR with Deutz Tier 2 engine (Figure 2-1) consists of a fuel level gauge,
oil temperature gauge, oil pressure gauge, hour meter, volt meter, head light switch, hitch
light switch, heater switch, ignition switch, and a cluster of warning/indicator lights
consisting of; brake warning light, headlights indicator light, coolant temperature warning
light, battery warning light, low oil pressure warning light, and engine glow plug indicator
light.
a. Fuel Level Gauge

The fuel level gauge (Figure 2-1) indicates the amount of fuel in the fuel tank. A
sending unit is installed in the tank and is electrically connected to the gauge. The
gauge is marked empty (E), ½, and full (F) to indicate the relative quantity of fuel in
the tank.
b. Oil Temperature Gauge

The oil temperature gauge for units, equipped with Deutz engines (Figure 2-1)
indicates the temperature of engine cooling oil system and has an indicating range
from 120 thru 300 °F.
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OIL TEMPERATURE GAUGE

FUEL LEVEL GAUGE OIL PRESSURE GAUGE
DASH ILLUMINATION
LIGHT
DASH ILLUMINATION
LIGHT
OIL OIL
FUEL PRESS
TEMP
HOURS
ELECTRONIC VOLTS
HOUR METER VOLTMETER

HEAD HITCH
LIGHT LIGHT HEATER RUN
HI OFF START
ON
OFF
OFF
LO
HEAD LIGHT SWITCH IGNITION SWITCH

HITCH LIGHT SWITCH
HEATER SWITCH
HIGH OIL TEMP WARNING
LIGHT
BRAKE WARNING
LIGHT OIL PRESSURE WARNING
LIGHT
HEADLIGHTS
INDICATOR
LIGHT COLD START WAIT
INDICATOR LIGHT
BATTERY WARNING LIGHT
Figure 2-1. Instrument Panel. Deutz Tier 2
c. Oil Pressure Gauge

The oil pressure gauge (Figure 2-1) indicates the oil pressure in engine only and has
an indicating range from 0 to 100 psi, the gauge does not indicate the amount of
engine oil.
d. Hour Meter Gauge

The hour meter gauge (Figure 2-1) indicates the total operating hours accumulated on
the vehicle.
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e. Voltmeter Gauge
The voltmeter gauge (Figure 2-1) indicates the state of charge of the battery.
f. Head Light Switch

The headlight switch is a two position (ON/OFF) toggle type switch (Figure 2-1),
which controls the two sealed beam headlights and the two LED tail lights.
g. Hitch Light Switch

The hitch light switch is a two position (ON/OFF) toggle type switch (Figure 2-1)
that turns the hitch light on and off.
h. Heater Switch
The heater switch is a three position (HI/OFF/LO) toggle type switch (Figure 2-1)
that controls the speed of the cab heater.
i. Ignition Switch
The ignition switch is a three position keyless switch (Figure 2-1) located on the
dash panel with conventional markings of OFF, RUN, and START and
incorporates an anti-restart function. Two safe-start relays prevent accidental
engagement of starter while engine is running.
j. Brake Warning Light

When the brake warning light is illuminated (Figure 2-1) it indicates there is a brake
fluid leak.
k. Head Light Indicator

When the head light indicator is illuminated (Figure 2-1) it indicates the headlights
are on.
l. Oil Temperature Warning Light
(1) When the oil/coolant temperature warning light is illuminated (Figure 2-1) it
indicates that the engine is over heating. It works in conjunction with the oil/
coolant temperature switch.
(2) When the oil/coolant temperature increases, the switch activates, sending a
signal to the oil/coolant temperature warning light and an audible alarm on
the driver’s console.
m. Battery Warning Light

When the battery warning light is illuminated (Figure 2-1) it indicates that the battery
is either disconnected from its circuit, not charging, or is below 11.8 volts.
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Chapter 1
n.. Oil Pressure Warning Light
(1) When the oil pressure warning light is illuminated (Figure 2-1) it indicates
that the engine oil pressure is too low for safe operations. A pressure switch
is mounted to the engine for detecting low oil pressure conditions.
(2) When the oil pressure drops below 6 psi the switch activates, sending a signal
to the warning light and an audible alarm on the driver’s console.
o. Engine Cold Start Wait Indicator Light

When the engine cold start wait indicator light is illuminated (Figure 2-1) it indicates
that the glow plug is operating. The engine will not start until the light goes out.
2. The dash panel for MR with Deutz Tier 4i engine

The dash panel for MR with Deutz Tier 4i engine (Figure 2-2) consists of a fuel level gauge,
Murphy Power View gauge( displays engine rpm, oil pressure, coolant temperature, battery
voltage, transmission oil temperature, engine hours, current gear and a variety of other engine
parameyers, that are user selectable), head light switch, hitch light switch, heater switch,
ignition switch, and a cluster of warning/indicator lights consisting of; brake warning light,
headlights indicator light, coolant temperature warning light, battery warning light, low oil
pressure warning light, and engine glow plug indicator light.
a. Fuel Level Gauge.
the tank.
b. Murphy Power View Gauge.
(1). The Murphy Power View Gauge uses J1939 CAN Bus technology to receive
messages from the engine and transmision electronic control units and
displays selected parameter information to the operator.
(a). Engine speed is shown in revolutions per minute (rpm) and has an indicating
range while the engine is running from 900 rpm to 2600 rpm.
(b). Oil pressure indicated the oil pressure in the engine only and has an
indicating range from 0 to 100 psi. The display does not indicate the amount
of engine oil.
(c). Coolant temperature indicates the temperature of engine coolant in the

cooling
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Chapter 1
(d). Battery voltage is displayed and indicated the state of charge of the battery.
Normal operating voltage range is between 24 and 32 V.
FUEL LEVEL GAUGE

DASH ILLUMINATION
LIGHT
GAUGE MURPHY POWER
VIEW
DASH ILLUMINATION
LIGHT
HEAD LIGHT IGNITION SWITCH

SWITCH
HEATER SWITCH
HITCH LIGHT HIGH OIL TEMP WARNING

SWITCH LIGHT
BRAKE WARNING
LIGHT OIL PRESSURE
WARNING LIGHT
HEADLIGHTS
INDICATOR
INDICATOR LIGHT
Figure 2-2. Instrument Panel. Deutz Tier 4i
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Chapter 1
(e). Transmission oil temperature displays the temperature of oil inside

the transmission.
(f). Engine hours displays the total operating hours accumulated

on the vehicle.
(g). Current gear displays the selected gear by the automatic

transmission.
(2). The MR10-34T tractor uses a Murphy PV101C digital display to

communicate engine and transmission on to the operator.
(a) Bottons ( See Figure 2-3):

There are four buttons along the bottom of the display. They
are used to navigate from the gauge display screens to menu
settings.
Figure 2-3. Murphy Power View Gauge Bottons
Menu Key
This button enters or exits menu screens.
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Chapter 1
Left Arrow Key (Scroll Up)

This button scrolls the screen and moves the parameter
selection to the left orupward.
Right Arrow Key (Scroll Down)

This buttons scrolls the screen and moves the parameter
selection to the right or downward.
Enter Key
This button selects a menu or parameter or hide/view
and active fault code.
(b) Gauge Display Screens

Turing the Stop, Run, Start Switch (SRS) to the RUN position,
power will be applied to the Power View Gauge and the
following parameters displayed to the operator.
Figure 2-4. Murphy Gauge Display Screen
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Chapter 1
RPM (See Fgure 2-4)

This parameter displays the engine Revolutions per Minute.
Typically the rpm range will vary between 800 and 2,600 rpm.
Oil Pressure (See Fgure 2-4)

This parameter displays the engine oil pressure in Pounds per Square
Inch. Under normal operating conditions the gauge will read between
30 and 90 psi.
Coolant Temperature (See Fgure 2-4)

This parameter displays the engine coolant temperature in degrees
Fahrenheit.
Typically under normal operating conditions the engine temperature

will be between 185 and 200 degrees Fahrenheit.
Battery Voltage (See Fgure 2-4)

This parameters displays the 12 volt system voltage in volts.
Typically in normal operating conditions the voltage will range

between 12 and 14 volts.
Transmission Oil Temperature (See Fgure 2-5)

This indicates the transmission oil temperature in degrees Fahrenheit.
Typically in normal operating conditions the transmission oil
temperature will vary between 150 and 170 degrees Fahrenheit.
Current Gear
This indicates the transmission gear selected and in use.
N, 1F, 2F, 3F, and 1R
Engine Hours
This indicates the number of hours the engine has been operating.
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Chapter 1
Figure 2-5. Murphy Gauge Display Screen
(b) Warning Messages
An amber LED warning lamp illuminates on the left side of the Power View display
when a engine or transmission warning fault code is present. The red LED warning
lamp illuminates on the right side of the display when an derate/shutdown fault code
is present.
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Chapter 1
c. Head Light Switch
The headlight switch is a two position (ON/OFF) toggle type switch (Figure
2-2), which controls the two sealed beam headlights and the two LED tail
lights.
d. Hitch Light Switch
The hitch light switch is a two position (ON/OFF) toggle type switch (Figure
2-2) that turns the hitch light on and off.
e. Heater Switch
The heater switch is a three position (HI/OFF/LO) toggle type switch (Figure
2-2) that controls the speed of the cab heater.
f. Ignition Switch
The ignition switch is a three position keyless switch (Figure 2-2) located on
dash with conventional markings of OFF, RUN, and START and incorporates an
anti-restart function. Two safe-start relays prevent accidental engagement of starter
while engine is running.
g. Brake Warning Light
When the brake warning light is illuminated (Figure 2-2) it indicates there is
a brake fluid leak.
h. Head Light Indicator

When the head light indicator is illuminated (Figure 2-2) it indicates the
headlights are on.
i. Oil Temperature Warning Light
(1) When the oil/coolant temperature warning light is illuminated

(Figure 2-2) it indicates that the engine is over heating.
(2) When the oil temperature increases to a high level, the engine ECU
will send a signal to the oil temperature warning light and an audible
alarm on the driver console.
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Chapter 1
j. Battery Warning Light
k. Oil Pressure Warning Light
that the engine oil pressure is too low for safe operations.
(2) When the oil pressure drops below 6 psi the engine ECU sends a signal
l. Engine Cold Start Wait Indicator Light
that the glow plug is operating. The operator should not start the engine until the
light goes out.
3. The dash panel for MR with Kubota engine.

The dash panel for MR with Kubota engine (Figure 2-6) consists of a fuel level gauge, water
temperature gauge, oil pressure gauge, hour meter, volt meter, head light switch, hitch light
switch, heater switch, ignition switch, and a cluster of warning/indicator lights consisting of;
brake warning light, headlights indicator light, coolant temperature warning light, battery
warning light, low oil pressure warning light, engine glow plug indicator light, and air filter
warning light (optional).
a. Fuel Level Gauge.
the tank.
b. Water Temperature Gauge
The water temperature gauge for units, equipped with Kubota engines (Figure 2-6)
indicates the temperature of engine cooling water system and has an indicating range
from 100 thru 250 °F.
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Chapter 1
c. Oil Pressure Gauge
The oil pressure gauge (Figure 2-6) indicates the oil pressure in engine only
and has an indicating range from 0 to 80 psi, the gauge does not indicate the
amount of engine oil.
DASH ILLUMINATION
OIL PRESSURE GAUGE LIGHT
WATER TEMPERATURE
GAUGE
VOLTMETER
FUEL LEVEL
GAUGE
DASH IGNITION
ILLUMINATION SWITCH
LIGHT
AIR FILTER
WARNING LIGHT
HOUR METER
HEATER
SWITCH
HITCH LIGHT
HEAD LIGHT SWITCH
SWITCH
HIGH WATER TEMP

WARNING LIGHT
BRAKE WARNING
LIGHT OIL PRESSURE
WARNING LIGHT
HEADLIGHTS
INDICATOR
INDICATOR LIGHT
Figure 2-6. Instrument Panel. Kubota
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Chapter 1
d. Hour Meter Gauge
The hour meter gauge (Figure 2-6) indicates the total operating hours accumulated on
the vehicle.
e. Volt Meter Gauge
The voltmeter gauge (Figure 2-6) indicates the state of charge of the battery.
f. Head Light Switch
The headlight switch is a two position (ON/OFF) toggle type switch (Figure 2-6),
which controls the two sealed beam headlights and the two LED tail lights.
g. Hitch Light Switch
The hitch light switch is a two position (ON/OFF) toggle type switch (Figure 2-6)
that turns the hitch light on and off.
h. Heater Switch.
The heater switch is a three position (HI/OFF/LO) toggle type switch
(Figure 2-6) that controls the speed of the cab heater.
i. Ignition Switch
The ignition switch is a three position keyless switch (Figure 2-6) located on the
dash with conventional markings of OFF, RUN, and START and
incorporates an anti-restart function. Two safe-start relays prevent accidental
engagement of starter while engine is running.
j. Brake Warning Light
When the brake warning light is illuminated (Figure 2-6) it indicates there is a brake
fluid leak.
k. Head Light Indicator
When the head light indicator is illuminated (Figure 2-6) it indicates the headlights
are on.
l. Water Temperature Warning Light
(1) When the water temperature warning light is illuminated (Figure 2-6) it
indicates that the engine is over heating. It works in conjunction with the
water temperature switch.
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Chapter 1
(2) When the oil temperature increases, the switch activates, sending a
signal to the oil temperature warning light and an audible alarm on
the driver’s console.
m. Battery Warning Light
n. Oil Pressure Warning Light
that the engine oil pressure is too low for safe operations. A pressure switch
is mounted to the engine for detecting low oil pressure conditions.
(2) When the oil pressure drops below 6 psi the switch activates, sending a signal
o. Engine Cold Start Wait Indicator Light
that the glow plug is operating. The operator should not start engine until the
light goes out.
p. Air Filter Warning Light (Optional)
The red light is illuminated (Figure 2-3) when air filter reaches maximum restriction
level.
Figure 2-7. Wiper Control Switches
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Chapter 1
4. Wiper Control Switches
(a) The front windshield wiper switch (Figure 2-7) is a 3-position type switch indicating
“OFF”, “LOW”, and “HIGH” that controls the motion of the front windshield wipers
and is mounted to the cab above the windshield.
(b) The rear windshield wiper switch (Figure 2-7) is a 2-position type switch that
controls the motion of the rear windshield wipers and is mounted to the cab above the
windshield.
5. Turn Signal Lever
(a) The turn signal lever is used when making right or left turns, operator selects left or
right accordingly.
(b) Turn indicators are mounted on the steering column.
6. Cab Dome Light Switch

The cab light dome switch is a 2 position (ON/OFF) push-button switch, located on the dome
light itself and operates the interior cab light.
7. E-Stop Button Switch.
The emergency stop botton is located on the left side of the engine cowling adjacent to
driver’s door. (See Figure 2-8). For units with CE option, emergency stop botton is located on
the right side of operator's console (See Figure 2-9). Switch must be reset to restart engine by
pulling and twisting the botton in the counter-clockwise direction.
E-STOP
BUTTON
Figure 2-8. E-Stop Botton
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Chapter 1
8. Battery Disconnect Switch (Optional).
The battery disconnect switch is located on the right side of operator's console (See Figure
2-9). This switch is used to disconnect positive power from the battery.
E-STOP BOTTOM
(CE OPTION)
BATTERY DISCONNECT
SWITCH
Figure 2-9. E-Stop Botton

C. OPERATOR'S COMPARTMENT
The operator’s compartment of the TUG Model MR is inside of a removable weatherproof cab
(optional). The cab is fully enclosed and is bolted to the frame to allow easy removal during warm
weather operations. A side view mirror is located on each of the cab doors. The cab is equipped with
front and rear windshields and two side door windows to provide maximum visibility in all directions.
All windows consist of tampered safety glass and are mounted to the cab in rubber seals for
weatherproofing. The front and rear windshields are equipped with wipers and are powered by small
electric motors. All mechanical and electrical components in the operator’s compartment (gauges,
switches, lights, levers, connectors and wire harnesses) are weatherproof and designed for outdoor
use.
A cab heater is installed on the firewall of the MR for providing heating for the operator’s
compartment. Fans in the cab heater circulate the warm air in the cab and provide front window
defrosting. The cab heater has a 6,000 BTU/hour heating capacity. A weatherproof switch on the
driver’s console activates the heater. A shut-off valve is located under the hood to keep coolant from
circulating through the cab heater during warm weather.
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Chapter 1
D. PREPARATION FOR USE
1. Fuel System
(a) Check all fuel line connections to make sure they are properly connected, from fuel
tank to fuel pump to fuel injectors.
(b) Make certain fuel tank drain valve is closed.
WARNING: Never fill the fuel tank while engine is running. Ensure
cleanliness and do not spill fuel.
(c) Fill fuel tank with diesel fuel, JP5, JP8, VV-F-800, ULSD.
Kubota V3600 (MR8) and Deutz Tier 4i (MR10) are only emmissions compliant
when running on ULSD.
2. Battery
(a) Check battery condition.
(b) If battery cables are disconnected, reconnect by attaching positive cable first.
3. Brake System
(a) Check hydro boost fluid level.
(b) If low, check for leaks in brake system.
(c) If applicable service hydro boost with brake fluid, DOT 3.
4. Engine and Transmission
(a) Check engine oil level, if applicable service engine with oil.
(b) Check transmission fluid level.
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NOTE: This check is performed to determine if there is fluid in the

Note transmission. If any fluid shows on the dipstick, do not add transmission
fluid until it is checked with the engine running, after the engine has reached
normal operating temperature.
(c) Check transmission-cooling lines for proper connections.
5. Drive Axle and Reduction Gear Box
(a) Check oil level in the drive axle and reduction gearbox, service with oil as needed.
NOTE: When checking the axle oil level at the planetary wheel end, it is
Note normal for the oil level to be ¼ -inch below the check port when the port is at
the 3 and 9 o’clock position (see Figure 2-5).
1/4"
Figure 2-5. Axle Oil Level at Planetary Wheel End
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Chapter 1
6. Tire Inflation
Check air pressure in tires, service with air as needed.

(See specifications in Chapter 1, Section 1, Paragraph R)
7. Power Steering Reservoir

Check level at reservoir, if applicable service with Dexron III transmission fluid.
E. STANDARD OPERATING PROCEDURES
1. Normal Starting
(a) Ensure parking brake is set.
(b) Ensure transmission shifter is in “PARK” position.
CAUTION: Do not operate starter longer than 20 seconds. If engine does

not start, wait 1 minute between attempted starts.
(c) Turn and hold ignition switch to “START”, when engine starts release switch to
“RUN” position.
(d) Observe gauges and warning lights for normal indications, any abnormalities shut the
tractor down.
2. Cold Weather Starting
(a) Ensure parking brake is set.
(b) Ensure transmission shifter is in “PARK” position.
(c) Glow plug operation - Turn ignition switch to run, allow glow plug light to illuminate
and turn off prior to attempting to start.
CAUTION: Do not operate starter longer than 20 seconds. If engine does

not start, wait 1 minute between attempted starts.
(d) Turn and hold ignition switch to “START”, when engine starts release switch to
“RUN” position.
(e) Observe gauges and warning lights for normal indications, if there is any
abnormalities shut the tractor down.
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Chapter 1
system and has an indicating range from 120 to 300°F.

3. Driving Instructions
(a) Ensure shift lever is in the “PARK” position.
(b) Ensure parking brake is set.
(c) Apply foot brake.
(d) Turn starter switch and engage starter.
(e) Release the parking brake.
(f) Move the transmission shift lever into the required position, i.e., forward or reverse.
(g) Release foot brake.
(h) Gently press the accelerator pedal, until the desired speed is achieved.
(i) To slow the tractor, slowly release the accelerator pedal and apply the service foot
brake.
(j) Each time you park, apply parking brake, return transmission shift lever to park and
turn starter switch to the “OFF” position.
4. Towing Instructions
a. Ensure the towing load is within the rated towing capacity of the tow tractor.
b. Ensure the hitch is properly latched.
c. Start as slowly as possible.
d. Travel at a speed consistent with road and load conditions.
e. Always be alert.
f. Do not carry unauthorized passengers.
WARNING: Match driving speeds to loads being towed and weatherwet or

conditions. Slow down when towing heavy loads and when road surface is
icy, especially on grades.
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SECTION 3: SPECIFICATIONS
A. GENERAL
1. Fuel Capacity .................................................................................................... 18.4 gal (69.7 L)

2. Fuel Type .......................................... ULSD. VV-F-800 Diesel Fuel or JP5 / JP8 Aviation fuels
3. Gross Weight ............................................................................................. 12,500 lbs (5,670 kg)
4. Weight with Cab ........................................................................................ 12,900 lbs (5,851 kg)
4. Ground Clearance ............................................................................................. 5.75 in (146mm)
5. Height (without Cab) ........................................................................................ 60 in (1524 mm)
6. Height (with Cab) ............................................................................................. 82 in (2083 mm)
7. Length (without Hitches) ................................................................................ 116 in (2946 mm)
8. Speed Forward (Maximum) ...................................................................... 15 mph (24 km/hour)
9. Speed Reverse (Maximum) ......................................................................... 7 mph (11 km/hour)
10. Towing Capacity .................................................................................. 100,000 lbs (45359.7 kg)
11. Turning Radius ............................................................................................ 12.9 ft (3931.9 mm)
12. Wheel Base ....................................................................................................... 69 in (1752 mm)
13. Width ................................................................................................................ 72 in (1829 mm)
B. ENGINE
1. Deutz (Tier 2) Diesel
(a) Type ................................................................................. Deutz Diesel, Turbo Charged

(b) Displacement .................................................................................................... 3.11 liter
(c) Fluid Dry Capacity (Total Volume) ..................................................... 15.8 qt (14.95 L)
(d) Fluid Wet Capacity (Oil Change Volume) .................................................. 8 qt (7.57 L)
(e) Fluid Type.......................................................................................................... 15W-40
(f) Number of Cylinders .................................................................................................... 4
(g) Weight (Approximate with Accessories), dry..................................545 lbs (247.21 kg)
2. Deutz (Tier 4i) Diesel
(a) Type ................................................................................. Deutz Diesel, Turbo Charged

(b) Displacement ................................................................................................... 3.62 liter
(c) Fluid Dry Capacity (Total Volume) ..................................................... 15.8 qt (14.95 L)
(d) Fluid Wet Capacity (Oil Change Volume) .................................................. 8 q (7.57 L)t
(e) Fluid Type.......................................................................................................... 15W-40
(f) Number of Cylinders .................................................................................................... 4
(g) Weight (Approximate with Accessories), dry..................................594 lbs (269.44 kg)
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3. Kubota Diesel
(a) Type ............................................................................... Kubota Diesel, Turbo Charged

(b) Displacement ..................................................................................................... 3.6 liter
(c) Oil Capacity ....................................................................................... 13.96 qt (13.21 L)
(d) Fluid Type.......................................................................................................... 15W-40
(e) Number of Cylinders .................................................................................................... 4
(f) Weight (Approximate with Accessories) ......................................... 606 lbs (274.88 kg)
C. TRANSMISSION
1. Ford C-6 automatic transmission.

The transmission has three (3) speeds in the forward direction and one speed in reverse.
a. Type .............................................................................................................................. Ford C-6

b. Fluid Capacity .................................................................................................. 13.2 qt (12.49 L)
c. Fluid Type .............................................................................................................. DEXRON III
2. Ford 4R75 automatic transmission.

The transmission has three (3) speeds in the forward direction and one speed in reverse.
a. Type ............................................................................................................................ Ford 4R75

b. Fluid Capacity ...................................................................................................... 6.6 qt (6.25 L)
c. Fluid Type ............................................................................................................... MERCON V
D. DRIVE AXLE
1. Type .................................................... AMS International 1151002 Series Planetary Reduction

2. Fluid Capacity
(a) Axle ................................................................................................................... 11 liters
(b) Drop Box .......................................................................................................... 2.5 liters
3. Fluid Type .................................................................................. Oil, Gear, SAE 80-90LS (GL5)
E. STEERING
1. Type .......................................................................................................................... Hydrostatic

2. Valve ................................................................................................................ Eaton Char-Lynn
3. Pump ............................................................................... Vickers 4 gpm flow-control vane type
4. Fluid Type .............................................................................................................. DEXRON III
5. Fluid Capacity ...................................................................................................... 6.8 qt (6.43 L)
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F. FRONT AXLE
1. Type ............................................................................................................. Brierton Dead Steer

2. Control .......................................................................Axle Mounted Steer Cylinder w/ Tie-Rod
3. End Type .................................................................................. Fabricated Knuckle w/ King Pin
G. WHEELS
1. Front Wheels
A. 185R x 14 (FEDERAL or NANKANG)
1. Inflation Pressure ........................................................................... 75 psi (5.1 atm)

2. Load Range .......................................................................... 3000 lbs (1360.79 kg)
3. Number of Studs .................................................................................................... 5
4. Tire Size ...................................................................................................... 185R14
B. TUG TUFF
1. Inflation Pressure ......................................................................... 90 psi (6.12 atm)

2. Load Range .............................................................................. 2390 lbs (1084 kg)
3. Number of Studs ................................................................................................... 5
4. Tire Size ..................................................................................................... 185R14
2. Rear Wheels
(a) Inflation Pressure ................................................................................... 75 psi (5.1 atm)
(b) Load Range ................................................................................... 3538 lbs (1604.8 kg)
(c) Number of Studs ........................................................................................................... 8
(d) Tire Size........................................................................................................ 8.75 x 16.5
H. BRAKES
1. Fluid Capacity ......................................................................................................... 32 oz (0.95)

2. Fluid Type ......................................................................................................................... DOT 3
3. Front Type ............................................................................................................................ Disc
4. Rear Type ..................................................................................................... Hydraulic Wet Disc
I. ELECTRICAL SYSTEM
1. Alternator ............................................................................................. Bosch, 95 Amps (Deutz)

90 Amps (Kubota)
2. Battery Type ......................................................................................... 12 volt, negative ground
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J. TOWING CAPABILITY
1. The vehicle is a two-wheel drive, diesel powered type vehicle with a gross vehicle weight of
12,500 lbs. In order to optimize the tractive effort in this two-wheel configuration 83% of the
vehicles weight is on the rear drive wheels of the TUG Model MR.
2. The TUG Model MR is capable of towing 100,000 lb in forward and 80,000 lb in reverse
direction.
K. TURNING RADIUS
The turning radius of the TUG Model MR is 160-inches in a right hand turn and 155-inches in a left
hand turn. These turning radii (Figure 3-1) are measured at the outer most edge of the frame.
Figure 3-1. Left and Right Turning Radius
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SECTION 4: SHIPPING
A. PREPARATION
WARNING: Extreme hazard exists when refueling and de-fueling the

tractor. No smoking. No open flames. No electrical device operations.
1. Battery
Disconnect battery terminals (negative terminal first) from battery posts and leave battery in
battery tray.
2. Fuel Tank
CAUTION: Dispose of fuel oil in accordance with local environmental

regulations.
Drain the fuel tank:
(a) Disconnect fuel line at lowest readily accessible connection and drain fuel from fuel
line.
(b) Reconnect fuel lines.
(c) Leave fuel cap on tank, but loosened.
(d) Make certain fuel tank drain valve is closed.
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SECTION 5: STORAGE
A. ONE MONTH TO SIX MONTHS
1. Engine
WARNING: Clean engine only when the engine switch is off.
(a) Clean engine using pressure washer equipment.
(b) Run engine until warm, and then turn off.
CAUTION: Dispose of oil in accordance with local environmental

regulations.
(c) Drain engine oil and fill with anti-corrosion oil.

regulations.
(d) Ensure fuel tank is full.
(e) Drain five gallons of fuel from the fuel tank.
(f) Add approximately two gallons of anti-corrosion oil.
(g) Top off the fuel tank with diesel fuel.
(h) Start engine. Allow engine to run approximately for 10 minutes.
(i) Switch off engine.
(j) Turn engine over manually several times to preserve cylinders and combustion
chamber.
(k) Loosen alternator mounting hex head bolt on the alternator-mounting bracket and the
mounting flange head bolt on the front end of the alternator.
(l) Spray grooves on alternator belt pulleys with anti-corrosion oil.
(m) Seal intake ports and exhaust ports.
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2. Tire
Raise the tractor in accordance with standard jacking procedure (Chapter 2, Section 1) to
prevent tire contact with the ground and reduce tire pressure to 15 psi..
3. Battery
Disconnect battery terminals, negative terminal first.
4. Lubrication
Ensure all lube points are lubricated with specified grease, oil, etc. in accordance with
lubrication procedures located in Chapter 2, Section 1..
5. Fluid Levels
Check all fluid levels and fill as required. Lubrication specifications are located in Chapter 2,
Section 1.
B. EXTENDED PERIOD (MORE THAN SIX MONTHS)
Perform all procedures identified under one to six month storage (paragraph A), plus the following for
extended storage.
1. Transmission
CAUTION: Dispose of Dexron III and MERCON V in accordance with

local environmental regulations.
Drain transmission fluid Dexron III or MERCON V and refill with new fluid.
CAUTION: Prolonged storage may be detrimental to seals in the drive axle

and reduction gearbox.
2. Drive Axle and Reduction Gear Box.

regulations.
(a) Drain drive axle and reduction gearbox by removing drain plug located on the
underside of the differential carrier housing.
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(b) Reinstall plug after draining the drive axle. Reduction gearbox is internally separated
and should be drained independently.
(c) Attach a CAUTION tag on steering wheel stating, “Oil has been removed from axle
and reduction gear box.”
3. Battery
(a) Remove battery and store separately.
NOTE: A recommended storeroom temperature of 32 °F should be

Note maintained. If the battery is stored in the open, it must be covered for
protection against dirt and moisture.
(b) Store battery in a cool dry place and it must not be exposed to direct sunlight.
(c) A slow charge should be given to the battery every month.
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1-5-4 CD387
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Chapter 2
TABLE OF CONTENTS
SECTION 1: SERVICING ........................................................................................................... 2-1-1
A. Preparation for Use .............................................................................................. 2-1-1
1. Fuel System .............................................................................................. 2-1-1
2. Battery ...................................................................................................... 2-1-1
3. Brake System ........................................................................................... 2-1-1
4. Engine and Transmission ......................................................................... 2-1-2
5. Drive Axle and Reduction Gear Box ......................................................... 2-1-2
6. Tire Inflation .............................................................................................. 2-1-2
7. Power Steering Reservoir ......................................................................... 2-1-2
B. Periodic Maintenance Schedule ........................................................................... 2-1-2
1. Daily .......................................................................................................... 2-1-2
2. Initial 200 Hour Maintenance .................................................................... 2-1-3
3. Every 6 Months ......................................................................................... 2-1-6
4. Yearly ........................................................................................................ 2-1-7
5. Every Two Years ....................................................................................... 2-1-8
C. Lubrication Schematic ........................................................................................ 2-1-10
D. Standard Jacking Procedure .............................................................................. 2-1-11
E. Alternator Belt Adjustment .................................................................................. 2-1-11
F. Headlight Adjustment .......................................................................................... 2-1-12
G. Brake Bleeding Procedure .................................................................................. 2-1-12
H. Stopping Distance Test ....................................................................................... 2-1-13
I. Hydraulic Flushing Procedure ............................................................................ 2-1-13
SECTION 2: TROUBLESHOOTING ........................................................................................... 2-2-1
A. General ................................................................................................................. 2-2-1
B. Steering ................................................................................................................ 2-2-4
C. Brake System ....................................................................................................... 2-2-6
D. Electrical ............................................................................................................... 2-2-8
E. Electrical Schematics ......................................................................................... 2-2-11
F. Hydraulic Schematic ........................................................................................... 2-2-27
SECTION 3: REMOVAL/INSTALLATION................................................................................... 2-3-1
A. Cab ....................................................................................................................... 2-3-1
1. Removal .................................................................................................... 2-3-1
2. Installation ................................................................................................. 2-3-2
3. Doors ........................................................................................................ 2-3-2
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(a) Removal ........................................................................................ 2-3-2

(b) Installation ..................................................................................... 2-3-3
(c) Adjustment .................................................................................... 2-3-3
4. Door Check Strap ..................................................................................... 2-3-3
(a) Removal ........................................................................................ 2-3-3
(b) Installation ..................................................................................... 2-3-3
5. Cab Heater ............................................................................................... 2-3-4
(a) Removal ........................................................................................ 2-3-4
(b) Installation ..................................................................................... 2-3-4
6. Window, Door ........................................................................................... 2-3-5
(a) Removal ........................................................................................ 2-3-5
(b) Installation ..................................................................................... 2-3-5
7. Front Windshield ....................................................................................... 2-3-5
(a) Removal ........................................................................................ 2-3-5
(b) Installation ..................................................................................... 2-3-6
8. Rear Windshield ....................................................................................... 2-3-6
(a) Removal ........................................................................................ 2-3-6
(b) Installation ..................................................................................... 2-3-6
9. Windows, Rear Side ................................................................................. 2-3-7
(a) Removal ........................................................................................ 2-3-7
(b) Installation ..................................................................................... 2-3-7
10. Rear View Mirror ....................................................................................... 2-3-8
(a) Removal ........................................................................................ 2-3-8
(b) Installation ..................................................................................... 2-3-8
11. Mirrors ....................................................................................................... 2-3-8
(a) Removal ........................................................................................ 2-3-8
(b) Installation ..................................................................................... 2-3-8
12. Mirror Mounting Brackets .......................................................................... 2-3-9
(a) Removal ........................................................................................ 2-3-9
(b) Installation ..................................................................................... 2-3-9
13. Wiper Motor, Front .................................................................................... 2-3-9
(a) Removal ........................................................................................ 2-3-9
(b) Installation ................................................................................... 2-3-10
14. Wiper Motor, Rear ................................................................................... 2-3-11
(a) Removal ...................................................................................... 2-3-11
(b) Installation ................................................................................... 2-3-11
15. Windshield Wiper Switch (Front and Rear) ............................................. 2-3-12
(a) Removal ...................................................................................... 2-3-12
(b) Installation ................................................................................... 2-3-13
B. Hood Panel ......................................................................................................... 2-3-13
1. Removal .................................................................................................. 2-3-13
2. Installation ............................................................................................... 2-3-14
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C. Pintle Hitches ...................................................................................................... 2-3-14

1. Removal .................................................................................................. 2-3-14
2. Installation ............................................................................................... 2-3-14
D. Seats .................................................................................................................. 2-3-14
1. Removal .................................................................................................. 2-3-14
2. Installation ............................................................................................... 2-3-15
3. Seatbelt, Retractable .............................................................................. 2-3-15
(a) Removal ...................................................................................... 2-3-15
(b) Installation ................................................................................... 2-3-15
E. Battery ................................................................................................................ 2-3-15
1. Removal .................................................................................................. 2-3-15
2. Installation ............................................................................................... 2-3-16
F. Dash Panel Assembly ......................................................................................... 2-3-16
1. Dash Illumination Lights .......................................................................... 2-3-16
(a) Removal ...................................................................................... 2-3-16
(b) Installation ................................................................................... 2-3-17
(c) Dash Illumination Light Bulb Replacement ................................. 2-3-17
2. Gauges ................................................................................................... 2-3-17
(a) Removal ...................................................................................... 2-3-17
(b) Installation ................................................................................... 2-3-18
(c) Gauge Bulb Replacement ........................................................... 2-3-19
3. Headlight Switch or Hitch Light Switch ................................................... 2-3-19
(a) Removal ...................................................................................... 2-3-19
(b) Installation ................................................................................... 2-3-20
4. Heater Switch ......................................................................................... 2-3-20
(a) Removal ...................................................................................... 2-3-20
(b) Installation ................................................................................... 2-3-21
5. Ignition Switch ......................................................................................... 2-3-21
(a) Removal ...................................................................................... 2-3-21
(b) Installation ................................................................................... 2-3-22
6. Warning Light Assembly ......................................................................... 2-3-22
(a) Removal ...................................................................................... 2-3-22
(b) Installation ................................................................................... 2-3-23
7. Light Lenses ........................................................................................... 2-3-23
(a) Removal ...................................................................................... 2-3-23
(b) Installation ................................................................................... 2-3-24
8. Bulb, Warning Light ................................................................................ 2-3-25
(a) Removal ...................................................................................... 2-3-25
(b) Installation ................................................................................... 2-3-25
9. Turn Signal Flasher Unit ......................................................................... 2-3-26
(a) Removal ...................................................................................... 2-3-26
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(b) Installation ................................................................................... 2-3-26

G. Exterior Lamp Assemblies .................................................................................. 2-3-27
1. Headlight Assembly ................................................................................ 2-3-27
(a) Removal ...................................................................................... 2-3-27
(b) Installation ................................................................................... 2-3-27
(c) Headlight Bulb Replacement ...................................................... 2-3-27
2. Turn Signal Light Assembly, Front .......................................................... 2-3-28
(a) Removal ...................................................................................... 2-3-28
(b) Installation ................................................................................... 2-3-28
3. Brake/Turn/Stop/ Light Assembly ............................................................ 2-3-29
(a) Removal ...................................................................................... 2-3-29
(b) Installation ................................................................................... 2-3-29
4. Back Up Light Assembly ......................................................................... 2-3-29
(a) Removal ...................................................................................... 2-3-29
(b) Installation ................................................................................... 2-3-29
5. Hitch Light Assembly .............................................................................. 2-3-30
(a) Removal ...................................................................................... 2-3-30
(b) Installation ................................................................................... 2-3-30
H. Dome Light Lamp Housing Assembly ................................................................. 2-3-30
1. Removal .................................................................................................. 2-3-30
2. Installation ............................................................................................... 2-3-31
3. Dome Light Bulb Replacement ............................................................... 2-3-31
I. Emergency Stop Switch ...................................................................................... 2-3-31
1. Removal .................................................................................................. 2-3-31
2. Installation ............................................................................................... 2-3-31
J. Electric Center Panel Assembly ......................................................................... 2-3-32
1. Vehicle Electric Center (VEC), Deutz Tier 2 and Kubota. ....................... 2-3-32
(a) Removal ...................................................................................... 2-3-32
(b) Installation ................................................................................... 2-3-32
2. Fuses (F1-F8) ......................................................................................... 2-3-33
(a) Removal ...................................................................................... 2-3-33
(b) Installation ................................................................................... 2-3-33
3. Relays (R1-R8) ....................................................................................... 2-3-33
(a) Removal ...................................................................................... 2-3-33
(b) Installation ................................................................................... 2-3-33
4. TUG Electric Center (TEC), Deutz Tier 4i ............................................... 2-3-34
(a) Removal ...................................................................................... 2-3-34
(b) Installation ................................................................................... 2-3-34
5. Fuses (F1-F12) ....................................................................................... 2-3-34
(a) Removal ...................................................................................... 2-3-34
(b) Installation ................................................................................... 2-3-34
6. Relays (K5-K8) ....................................................................................... 2-3-35
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(a) Removal ...................................................................................... 2-3-35

(b) Installation ................................................................................... 2-3-35
7. Power Block ............................................................................................ 2-3-35
(a) Removal ...................................................................................... 2-3-35
(b) Installation ................................................................................... 2-3-36
8. Starter Relay ........................................................................................... 2-3-36
(a) Removal ...................................................................................... 2-3-36
(b) Installation ................................................................................... 2-3-36
9. Circuit Breaker, 60 Amp .......................................................................... 2-3-36
(a) Removal ...................................................................................... 2-3-36
(b) Installation ................................................................................... 2-3-37
10. Starter-Lockout Relay ............................................................................. 2-3-37
(a) Removal ...................................................................................... 2-3-37
(b) Installation ................................................................................... 2-3-37
11. Transmission Lockout Relay ................................................................... 2-3-38
(a) Removal ...................................................................................... 2-3-38
(b) Installation ................................................................................... 2-3-38
12. Glow Plug Relay ..................................................................................... 2-3-38
(a) Removal ...................................................................................... 2-3-38
(b) Installation ................................................................................... 2-3-38
13. Glow Plug Relay Socket ......................................................................... 2-3-39
(a) Removal ...................................................................................... 2-3-39
(b) Installation ................................................................................... 2-3-39
14. Main Power Solenoid .............................................................................. 2-3-40
(a) Removal ...................................................................................... 2-3-40
(b) Installation ................................................................................... 2-3-40
(a) Removal ...................................................................................... 2-3-40
(b) Installation ................................................................................... 2-3-41
(a) Removal ...................................................................................... 2-3-41
(b) Installation ................................................................................... 2-3-41
K. Starter ................................................................................................................. 2-3-41
1. Deutz, Removal ...................................................................................... 2-3-41
2. Deutz Installation .................................................................................... 2-3-42
3. Kubota Removal ..................................................................................... 2-3-42
4. Kubota Installation .................................................................................. 2-3-43
L. Low Oil Pressure and High Oil Temperature Alarms .......................................... 2-3-43
1. Removal .................................................................................................. 2-3-43
2. Installation ............................................................................................... 2-3-43
M. Horn Assembly ................................................................................................... 2-3-44
1. Removal .................................................................................................. 2-3-44
2. Installation ............................................................................................... 2-3-44
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Chapter 2
N. Fuel System ........................................................................................................ 2-3-45

1. Fuel Tank Transition Hose ...................................................................... 2-3-45
(a) Removal ...................................................................................... 2-3-45
(b) Installation ................................................................................... 2-3-45
2. Fuel Drain Petcock ................................................................................. 2-3-45
(a) Removal ...................................................................................... 2-3-45
(b) Installation ................................................................................... 2-3-46
3. Fuel Pump (Deutz only) .......................................................................... 2-3-46
(a) Removal ...................................................................................... 2-3-46
(b) Installation ................................................................................... 2-3-47
4. Fuel Filter Head (Deutz only) ................................................................. 2-3-47
(a) Removal ...................................................................................... 2-3-47
(b) Installation ................................................................................... 2-3-48
5. Fuel Filter Element (Deutz only) ............................................................. 2-3-48
(a) Removal ...................................................................................... 2-3-48
(b) Installation ................................................................................... 2-3-48
6. Fuel Level Sending Unit .......................................................................... 2-3-49
(a) Removal ...................................................................................... 2-3-49
(b) Installation ................................................................................... 2-3-49
7. Fuel Lines ............................................................................................... 2-3-49
(a) Removal ...................................................................................... 2-3-49
(b) Installation ................................................................................... 2-3-50
8. Fuel Hoses .............................................................................................. 2-3-50
(a) Removal ...................................................................................... 2-3-50
(b) Installation ................................................................................... 2-3-51
9. Fuel Tank ................................................................................................ 2-3-51
(a) Removal ...................................................................................... 2-3-51
(b) Installation ................................................................................... 2-3-52
O. Accelerator and Modulator Assembly (DEUTZ TIER 2 AND KUBOTA) .............. 2-3-53
1. Accelerator Pedal ................................................................................... 2-3-53
(a) Removal ...................................................................................... 2-3-53
(b) Installation ................................................................................... 2-3-54
2. Accelerator Pedal Lever ......................................................................... 2-3-54
(a) Removal ...................................................................................... 2-3-54
(b) Installation ................................................................................... 2-3-54
3. Modulator Cable ..................................................................................... 2-3-54
(a) Removal ...................................................................................... 2-3-54
(b) Installation ................................................................................... 2-3-55
4. Throttle Cable ......................................................................................... 2-3-55
(a) Removal ...................................................................................... 2-3-55
(b) Installation ................................................................................... 2-3-56
P. Accelerator pedal (DEUTZ TIER 4i) ................................................................... 2-3-56
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Chapter 2
(a) Removal ...................................................................................... 2-3-56

(b) Installation ................................................................................... 2-3-56
Q. AIR INTAKE ASSEMBLY .................................................................................... 2-3-57
1. Air Filter Assembly .................................................................................. 2-3-57
(a) Removal ...................................................................................... 2-3-57
(b) Installation ................................................................................... 2-3-57
2. Air Filter Mounting Band ......................................................................... 2-3-57
(a) Removal ...................................................................................... 2-3-57
(b) Installation ................................................................................... 2-3-57
3. Air Filter Element .................................................................................... 2-3-58
(a) Removal ...................................................................................... 2-3-58
(b) Installation ................................................................................... 2-3-58
4. Hump Hose ............................................................................................. 2-3-58
(a) Removal ...................................................................................... 2-3-58
(b) Installation ................................................................................... 2-3-58
5. Filter to Turbo Transition Tube ................................................................ 2-3-59
(a) Removal ...................................................................................... 2-3-59
(b) Installation ................................................................................... 2-3-59
6. Rubber Reducer Hose ............................................................................ 2-3-59
(a) Removal ...................................................................................... 2-3-59
(b) Installation ................................................................................... 2-3-59
R. Cooling Assembly ............................................................................................... 2-3-60
1. Transmission Fluid Cooler ...................................................................... 2-3-60
(a) Removal ...................................................................................... 2-3-60
(b) Installation ................................................................................... 2-3-60
2. Oil Cooler (Deutz) ................................................................................... 2-3-61
(a) Removal ...................................................................................... 2-3-61
(b) Installation ................................................................................... 2-3-62
3. Radiator (Kubota) ................................................................................... 2-3-63
(a) Removal ...................................................................................... 2-3-63
(b) Installation ................................................................................... 2-3-63
S. Exhaust System .................................................................................................. 2-3-64
1. Header Pipe ............................................................................................ 2-3-64
(a) Removal ...................................................................................... 2-3-64
(b) Installation ................................................................................... 2-3-64
2. Muffler ..................................................................................................... 2-3-65
(a) Removal ...................................................................................... 2-3-65
(b) Installation ................................................................................... 2-3-65
3. Spark Arrestor ......................................................................................... 2-3-65
(a) Removal ...................................................................................... 2-3-65
(b) Installation ................................................................................... 2-3-66
4. Tail Pipe .................................................................................................. 2-3-66
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Chapter 2
(a) Removal ...................................................................................... 2-3-66

(b) Installation ................................................................................... 2-3-66
T. Engine and Engine Components ........................................................................ 2-3-67
1. Deutz Tier 2 Quick Engine Change (QEC) ............................................. 2-3-67
(a) Removal ...................................................................................... 2-3-67
(b) Installation ................................................................................... 2-3-70
2. Deutz Tier 4i Quick Engine Change (QEC) ............................................ 2-3-74
(a) Removal ...................................................................................... 2-3-74
(b) Installation ................................................................................... 2-3-78
3. Kubota Quick Engine Change (QEC) ..................................................... 2-3-81
(a) Removal ...................................................................................... 2-3-81
(b) Installation ................................................................................... 2-3-85
4. Engine Mounts ........................................................................................ 2-3-89
(a) Removal ...................................................................................... 2-3-89
(b) Installation ................................................................................... 2-3-90
5. Fan .......................................................................................................... 2-3-90
(a) Removal ...................................................................................... 2-3-90
(b) Installation ................................................................................... 2-3-90
6. Flexplate ................................................................................................. 2-3-91
(a) Removal ...................................................................................... 2-3-91
(b) Installation ................................................................................... 2-3-91
7. Glow Plug ............................................................................................... 2-3-91
(a) Removal ...................................................................................... 2-3-91
(b) Installation ................................................................................... 2-3-91
8. Oil Filter Element .................................................................................... 2-3-92
(a) Removal ...................................................................................... 2-3-92
(b) Installation ................................................................................... 2-3-92
9. Oil Pan .................................................................................................... 2-3-92
(a) Removal ...................................................................................... 2-3-92
(b) Installation ................................................................................... 2-3-93
10. Oil Pressure Sender ............................................................................... 2-3-93
(a) Removal ...................................................................................... 2-3-93
(b) Installation ................................................................................... 2-3-93
11. Oil Temperature Sender (Deutz) ............................................................. 2-3-94
(a) Removal ...................................................................................... 2-3-94
(b) Installation ................................................................................... 2-3-94
12. Coolant Temperature Sender (Kubota) ................................................... 2-3-94
(a) Removal ...................................................................................... 2-3-94
(b) Installation ................................................................................... 2-3-94
13. Thermostat .............................................................................................. 2-3-94
(a) Removal ...................................................................................... 2-3-94
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(b) Installation ................................................................................... 2-3-95

U. Transmission Assembly ...................................................................................... 2-3-95
1. Filter Screen ........................................................................................... 2-3-95
(a) Removal ...................................................................................... 2-3-95
(b) Installation ................................................................................... 2-3-95
2. Shifter Assembly ..................................................................................... 2-3-96
(a) Removal ...................................................................................... 2-3-96
(b) Installation ................................................................................... 2-3-97
(c) Bulb Replacement ....................................................................... 2-3-97
3. Shifter Cable ........................................................................................... 2-3-98
(a) Removal ...................................................................................... 2-3-98
(b) Installation ................................................................................... 2-3-99
4. Transmission C6. .................................................................................. 2-3-100
(a) Removal .................................................................................... 2-3-100
(b) Installation ................................................................................. 2-3-102
5. Transmission 4R75. .............................................................................. 2-3-103
(a) Removal .................................................................................... 2-3-103
(b) Installation ................................................................................. 2-3-105
6. Transmission Band Adjustment C6. ...................................................... 2-3-106
(a) Removal .................................................................................... 2-3-106
(b) Installation ................................................................................. 2-3-106
7. Neutral Safety Switch C6. ..................................................................... 2-3-107
(a) Removal .................................................................................... 2-3-107
(b) Installation ................................................................................. 2-3-107
V. Front Axle, Suspension, and Wheels ................................................................ 2-3-108
1. Axle Assembly ...................................................................................... 2-3-108
(a) Removal .................................................................................... 2-3-108
(b) Installation ................................................................................. 2-3-109
2. Front Wheel Assembly .......................................................................... 2-3-109
(a) Removal .................................................................................... 2-3-109
(b) Installation ................................................................................. 2-3-110
3. Brake Rotor and Hub Assembly ............................................................ 2-3-110
(a) Removal .................................................................................... 2-3-110
(b) Installation .................................................................................. 2-3-111
W. Drive Shaft, Drive Axle and Wheels .................................................................. 2-3-112
1. Drive Shaft ............................................................................................ 2-3-112
(a) Removal .................................................................................... 2-3-112
(b) Installation ................................................................................. 2-3-112
2. Drive Axle .............................................................................................. 2-3-113
(a) Removal .................................................................................... 2-3-113
(b) Installation ................................................................................. 2-3-114
3. Rear Wheel Assembly .......................................................................... 2-3-116
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(a) Removal .................................................................................... 2-3-116

(b) Installation ................................................................................. 2-3-116
4. Shock Absorber .................................................................................... 2-3-116
(a) Removal .................................................................................... 2-3-116
(b) Installation ................................................................................. 2-3-117
X. Brake System ................................................................................................... 2-3-118
1. Brake Pedal .......................................................................................... 2-3-118
(a) Removal .................................................................................... 2-3-118
(b) Installation ................................................................................. 2-3-118
2. Front Brake Calipers and Brake Pads .................................................. 2-3-119
(a) Removal .................................................................................... 2-3-119
(b) Installation ................................................................................. 2-3-119
3. Brake Line System ................................................................................ 2-3-120
(a) Brake Hose (15-inch) Removal/Installation ............................... 2-3-120
(b) Left Rear Axle Brake Line Removal/Installation ........................ 2-3-121
(c) Right Rear Axle Brake Line Removal/Installation ..................... 2-3-121
(d) Brake Proportioning Line Removal/Installation ......................... 2-3-122
(e) Brake Line (H-Valve to Rear Proportioning Valve) .................................
(f) Brake Lines (Master Cylinder to H-Valve) ..............................................
(g) Brake Line (H-Valve to Brake Light Switch) ...........................................
(h) Brake Line (Brake Light Switch to Front Tee) ........................................
Removal/Installation ................................................................. 2-3-124
(i) Brake Hose Removal/Installation .............................................. 2-3-125
(j) Brake Line (Front Tee to Left Caliper) Removal/Installation ...... 2-3-126
(k) Brake Line (Front Tee to Right Caliper) Removal/Installation ... 2-3-127
(l) H-Valve Removal/Installation .................................................... 2-3-128
(m) Regulating Rear Brake Valve Removal/Installation................... 2-3-128
(n) Brake Pressure Switch Removal/Installation ............................ 2-3-129
4. Hydro Boost Assembly .......................................................................... 2-3-129
(a) Removal .................................................................................... 2-3-129
(b) Installation ................................................................................. 2-3-130
Y. Parking Brake Assembly ................................................................................... 2-3-131
1. Park Brake Lever .................................................................................. 2-3-131
(a) Removal .................................................................................... 2-3-131
(b) Installation ................................................................................. 2-3-131
(c) Adjustment ................................................................................ 2-3-132
2. Parking Brake Shoes and Drum ........................................................... 2-3-132
(a) Removal .................................................................................... 2-3-132
(b) Installation ................................................................................. 2-3-133
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Z. Hydraulic Power Steering System .................................................................... 2-3-134

1. Hydraulic Pump .................................................................................... 2-3-134
(a) Removal .................................................................................... 2-3-134
(b) Installation ................................................................................. 2-3-134
2. Hydraulic Reservoir .............................................................................. 2-3-135
(a) Removal .................................................................................... 2-3-135
(b) Installation ................................................................................. 2-3-135
3. Hydraulic Shut Off Valve ....................................................................... 2-3-136
(a) Removal .................................................................................... 2-3-136
(b) Installation ................................................................................. 2-3-136
4. Steer Valve Assembly ........................................................................... 2-3-136
(a) Removal .................................................................................... 2-3-136
(b) Installation ................................................................................. 2-3-137
5. Steering Cylinder .................................................................................. 2-3-137
(a) Removal .................................................................................... 2-3-137
(b) Installation ................................................................................. 2-3-138
6. Steering Wheel ..................................................................................... 2-3-139
(a) Removal .................................................................................... 2-3-139
(b) Installation ................................................................................. 2-3-139
7. Steering Column ................................................................................... 2-3-140
(a) Removal .................................................................................... 2-3-140
(b) Installation ................................................................................. 2-3-141
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Chapter 2
SECTION 1: SERVICING
A. PREPARATION FOR USE
1. Fuel System
(a) Check all fuel line connections to make sure they are properly connected, from fuel
tank to fuel pump to fuel injectors.
(b) Make certain fuel tank drain valve is closed.
WARNING: NEVER FILL THE FUEL TANK WHILE ENGINE IS

RUNNING. ENSURE CLEANLINESS AND DO NOT SPILL FUEL.
(c) Fill fuel tank with diesel fuel, JP5, JP8, VV-F-800,or ULSD.
2. Battery
(a) Check battery condition.
(b) If battery cables are disconnected, reconnect by attaching positive cable first.
3. Brake System
(a) Check hydro boost fluid level.
(b) If low, check for leaks in brake system.
(c) If applicable service hydro boost with brake fluid, DOT 3.
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4. Engine and Transmission
(a) Check engine oil level, if applicable service engine with oil.
(b) Check transmission fluid level.
NOTE: This check is performed to determine if there is fluid in the

transmission. If any fluid shows on the dipstick, do not add transmission
Note
fluid until it is checked with the engine running, after the engine has reached
normal operating temperature.
(c) Check transmission-cooling lines for proper connections.
5. Drive Axle and Reduction Gear Box
(a) Check oil level in the drive axle and reduction gearbox, service with oil as needed.
NOTE: When checking the axle oil level at the planetary wheel end, it is
Note normal for the oil level to be ¼ -inch below the check port when the port is at
the 3 and 9 o’clock position (see Figure 2-3).
6. Tire Inflation
Check air pressure in tires (See Cahpter 1, Section 1 or Section 3), service with air as needed.
7. Power Steering Reservoir

Check level at reservoir, if applicable service with Dexron III.
B. PERIODIC MAINTENANCE SCHEDULE
1. Daily
(a) Check fuel level, add fuel as needed.
(b) Check engine oil level.
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Chapter 2
(c) Visually inspect unit and surrounding area for any of the following fluid leaks:
(1) Brake Fluid
(2) Fuel
(3) Power Steering Fluid
(4) Transmission Fluid
(5) Engine Oil
(6) Drive Axle and Reduction Gear Box Oil
(d) Check seat belt buckle and restraining device for proper operation.
2. Initial 200 Hour Maintenance
(a) Change engine oil and oil filter element.
Note NOTE: Oil must be at operating temperature before draining.
NOTE: For initial engine break-in period, the engine oil and oil filter
Note element must be changed at 200 hours of operation and then every six
months thereafter.
(1) Allow engine to warm up; oil temperature should be approximately 176 °F.
(2) Switch engine off.
WARNING: JACKING UNIT AND INSTALLATION OF JACK STANDS

MUST BE PERFORMED ON A HARD, FLAT, LEVEL SURFACE.
ASSISTANT(S) ACTING AS SAFETY OBSERVER IS A REQUIREMENT
TO ENSURE PROPER INSTALLATION. ADDITIONALLY, STABILITY
CHECK MUST BE PERFORMED PRIOR TO WORKING UNDERNEATH
THE CHASSIS, OTHERWISE SERIOUS INJURIES MAY OCCUR.
(3) Raise and support tractor on jack stands in accordance with standard jacking
procedure (see Standard Jacking Procedure, later this section).
(4) Locate engine oil drain valve on the right side of the oil pan.
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Chapter 2
(5) Locate cab heat exchanger shut-off valve; open valve if not already open.
WARNING: ENGINE OIL IS HOT. SERIOUS BURNS WILL RESULT

WITHOUT PROPER PRECAUTIONS BEING TAKEN WHEN DRAINING
ENGINE OIL.
CAUTION: DISPOSE OF FILTER AND OIL IN ACCORDANCE WITH

LOCAL ENVIRONMENTAL REGULATIONS.
(6) Place drain pan under engine and drain oil by opening the engine oil drain
valve.
(7) Close engine oil drain valve.
(8) Locate the engine oil filter element at the right rear of the engine.
(9) Remove the oil filter element using filter element wrench to loosen and spin
off. Catch any escaping oil. Discard oil filter element.
(10) Clean any dirt from filter head sealing surface by wiping with a lint-free
cloth.
(11) Apply a light film of oil to the rubber gasket of new oil filter element.
(12) Spin on new oil filter element by hand until gasket makes contact with
sealing surface. Tighten an additional quarter-turn using filter element
wrench.
(13) Locate engine oil fill cap on valve cover. Remove cap and add oil, 8 quarts
total.
(14) Check oil level.
(i) Remove oil dipstick.
(ii) Wipe dipstick with lint-free, clean cloth.
(iii) Insert dipstick until it stops and remove again.
(iv) Check oil level, and if necessary, top off to “MAX” mark on dipstick.
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Chapter 2
(15) Reinstall oil fill cap.
NOTE: If additional work is to be done which requires tractor to be raised,

Note it may be left on jack stands.
(16) Remove tractor from jack stands in accordance with standard jacking
(b) Change rear drive axle oil.
NOTE: For initial break-in period, the rear drive axle oil must be changed at
Note 200 hours of operation and then every year thereafter.
(2) Place a drain pan under the rear drive axle.
(3) Locate and remove drain plugs and sealing washers in the bottom of rear
drive axle housing and the gear reduction drop box. Discard sealing washers.
CAUTION: DISPOSE OF OIL IN ACCORDANCE WITH LOCAL

ENVIRONMENTAL REGULATIONS.
(4) Drain gear oil. Reinstall drive axle drain plugs and new sealing washers.
Torque drain plugs to 22 ft-lbs.
(5) Place drain pan under one of the planetary wheel ends.
(6) Locate and remove planetary oil drain plug and sealing washers. Discard
sealing washers.
(7) Drain oil from planetary by rotating it so that the drain plug hole is in the 6
o’clock position.
(8) Once oil has been drained, rotate the planetary so that the drain plug hole is
in the horizontal position (9 or 3 o’clock).
(9) Repeat steps (5) thru (8) for the other planetary wheel.
(10) Fill each planetary wheel end with 0.53 quarts of gear oil and reinstall
planetary oil drain plugs and new sealing washers. Torque planetary oil drain
plugs to 22 ft-lbs.
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Chapter 2
(11) Remove drive axle access panel to gain access to top of axle and gear
reduction drop box. Discard lock washers.
(12) Remove oil fill plug and sealing washer from the top of the gear reduction
drop box. Remove the rear axle oil fill plug and sealing washer from the top
of the rear drive axle. Discard sealing washers.
(13) Fill the drop box with 2.64 quarts of gear oil and reinstall drop box oil fill
plug and new sealing washer. Torque drop box oil fill plug to 22 ft-lbs.
(14) Fill the rear drive axle with 10.57 quarts of gear oil and reinstall rear axle oil
fill plug and new sealing washer. Torque rear axle oil fill plug to 22 ft-lbs.
NOTE: If additional work is to be done which required tractor to be raised,

3. Every 6 Months
(a) Change engine oil and oil filter element.
NOTE: For initial engine break-in period, the engine oil and oil filter
Note element must be changed at 200 hours of operation and then every six
months thereafter.
(b) Change air filter element.
(1) Locate the air filter at the front of the engine compartment.
(2) Check air filter service indicator. If other than green indication (normal),
replace air filter.
(3) Undo the three (3) latches that secure the air filter cap to the filter housing
and remove the air filter cap. Dispose of any dirt and debris that may be
present within the housing.
(4) Firmly grasp the air filter element with a slight twisting motion, pull the air
filter element out of the housing. Discard air filter element.
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Chapter 2
(5) Install new air filter element into the housing. Insert “open” end of filter
first, making sure the filter is fully seated inside.
(6) Reinstall air filter cap. Secure to filter housing by engaging the three (3)
latches.
(7) Reset air filter service indicator by depressing rubber button on air filter
service indicator.
(c) Inspect front and rear tires for wear and damage. Replace as required.
NOTE: For proper air pressure for both front and rear tires see Chapter 1,
Note
Section 1 or Section 3).
(d) Check front and rear tires for proper air pressure. Service with air as required.
(e) Check free play of front wheel bearings. Replace or repack front wheel bearings, as
required.
4. Yearly
(a) Change rear drive axle oil.
Note NOTE: For initial break-in period, the rear drive axle oil must be changed at
200 hours of operation and then every year thereafter.
(b) Inspect all brake system hoses for cracks and visible wear, replace as required.
(c) Change fuel filter/water separator element.
(1) Locate fuel filter/water separator element just behind the right hand engine
mount.
CAUTION: DISPOSE OF FILTER AND ANY FUEL OIL IN

ACCORDANCE WITH LOCAL ENVIRONMENTAL REGULATIONS.
(2) Unscrew fuel filter/water separator element from fuel filter head. Discard
fuel filter element.
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Chapter 2
(3) Fill new fuel filter/water separator element with fuel to within ½ inch of top.
Lightly coat the element sealing ring with fuel.
(4) Screw new fuel filter/water separator element onto fuel filter head until
sealing surface touches. Hand tighten an additional ¾ to 1 full turn.
5. Every Two Years
(a) Lubricate chassis.
(2) Wipe clean all lubrication points with rag prior to application of lubricant.
(3) Lubricate the following chassis components.
(i) Steering Cylinder Rod Ends (2)

(ii) King Pins/Knuckles (4)
(iii) Tie Rod Ends (2)
(iv) Front Suspension Shackles (2)
(v) Brake Pedal Pivot (1)
(b) Lubricate Driveshaft U-Joints as follows:
(i) Drive Shaft Front and Rear U-joints (2)

(ii) Drive Shaft Spline Slider (1)
(1) Remove drive axle access panel, located in operator’s compartment between
the seats towards the rear. Discard lock washers.
(2) Working through the drive axle access opening, lubricate the driveshaft rear
U-joint with lithium based grease.
(3) Working from below the tractor, lubricate the driveshaft front U-joint with
lithium based grease.
(4) Reinstall drive axle access panel using new lock washers.
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Chapter 2
(5) Wipe clean of excess lubricant upon completion.
NOTE: If additional work is to be done which required tractor to be raised,

(c) Check emergency stop switch.
CAUTION: ENSURE PARKING BRAKE IS SET BEFORE STARTING

ENGINE.
(1) Place tractor in park with parking brake set. Start engine and let idle.
(2) From outside the vehicle, depress the emergency stop switch located in front
of the operator’s compartment on the engine cowl section.
(3) If tractor shuts down, no further action is required. Circuit is functioning

correctly. Reset emergency stop switch.
(4) If tractor continues to run, replace emergency stop switch.
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Chapter 2
C. LUBRICATION SCHEMATIC
1 1
2 2
3
3
6
7
Item No. of Fittings Description

1 2 Steering Cylinder Rod Ends
2 4 King Pins
3 2 Tie Rod Ends
4 2 Front Suspension Shackles
5 1 Brake Pedal Pivot
6 2 Drive Shaft Front And Rear -U-Joints
7 1 Drive Shaft Spline Slider
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D. STANDARD JACKING PROCEDURE
CAUTION: RAISE FRONT OF TRACTOR FIRST.
1. Chock rear tires and engage parking brake.
2. Position floor jack under the center of the front bumper and raise tractor.
3. Place jack stands under the front bumper and lower tractor onto jack stands.
4. Position floor jack under the center of the rear bumper and raise tractor.
5. Place jack stands under rear bumper and lower tractor onto jack stands.
CAUTION: LOWER REAR OF TRACTOR FIRST.
6. Position floor jack under the center of the rear bumper and raise tractor off jack stands.
7. Remove jack stands from under the rear bumper and lower tractor to the ground.
CAUTION: ENSURE PARKING BRAKE IS ENGAGED.
8. Position floor jack under the center of the front bumper and raise tractor off jack stands.
9. Remove jack stands from under the front bumper and lower tractor to the ground.
E. ALTERNATOR BELT ADJUSTMENT
1. Loosen flange head bolt and hex head bolts.
2. Adjust the belt tension so that there is ¼ -inch to 3/8 -inch total deflection.
3. Tighten flange head bolts and hex head bolt.
4. Start engine and allow to run for 15 minutes.
5. Turn off engine and recheck belt tension. Readjust if necessary.
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F. HEADLIGHT ADJUSTMENT
1. Loosen nut on the horizontal flange bolt.
2. Aim headlight in desired direction.
3. Tighten nut.
G. BRAKE BLEEDING PROCEDURE
NOTE: Manual bleeding requires two (2) personnel; one to pump the brake
Note
pedal and another to open/close the bleeder valves.
1. With tractor on level ground, chock tires and apply park brake.
2. Fill master cylinder to within ¼ -inch of the top with DOT 3 brake fluid and install cap.
CAUTION: DISPOSE OF BRAKE FLUID IN ACCORDANCE WITH

3. Place a brake fluid catch pan under the brake bleeder valve that is being serviced.
4. Remove the rear axle access panel.
5. Through the rear axle access panel, locate the right drive axle bleeder valve and remove
rubber cap from right drive axle bleeder valve.
6. Slowly pump the brake pedal three (3) times. On the 4th stroke depress only ¾ of full stroke
and hold.
7. Crack the bleeder valve from bleeder valve adapter just enough for air to escape.
Note NOTE: To ensure that air is not drawn into the system, the bleeder valve
must be closed at the end of the 4th stroke, before the brake pedal is
released.
8. Close bleeder valve and release the brake pedal .
9. Repeat steps 6 thru 8 until all air is purged from the brake lines.
10. Refill the hydro boost with DOT 3 brake fluid and move to the next bleeder valve until all
have been serviced.
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Chapter 2
11. Proceed to the left drive axle bleeder valve. Repeat steps 3 and 6 thru10.
12. Proceed to the right front brake caliper bleeder valve. Repeat steps 3 and 6 thru10.
13. Proceed to the left front brake caliper bleeder valve. Repeat steps 3 and 6 thru10.
14. Reinstall rear axle access panel. Secure with hex head bolts, new lock washers and flat
washers.
H. STOPPING DISTANCE TEST
CAUTION: ENSURE AREA IS CLEAR OF ALL PERSONNEL AND

EQUIPMENT.
1. Find a level, clear area with enough space for the tractor to reach full speed and safely come
to a complete stop.
2. Identify a starting point at which to start applying the brakes.
3. While traveling, without a towed load, at full speed, depress the brake pedal using a
maximum force of 100 lbs when the front wheels of the tractor reach the previously identified
starting point.
4. Measure the distance from the previously identified starting point to the center of the front
wheels. The unit should come to a complete stop within 21 feet.
5. If tractor fails to stop within 21 feet, inspect the brake system.
I. HYDRAULIC FLUSHING PROCEDURE
1. Raise and support tractor on jack stands in accordance with standard jacking procedure (this
section).
2. Close hydraulic shutoff valve.
3. Disconnect supply tank to pump hose from pump inlet elbow and place free end in drain pan.
CAUTION: DISPOSE OF DEXRON III IN ACCORDANCE WITH LOCAL

4. Open hydraulic shutoff valve and drain fluid from hydraulic reservoir.
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Chapter 2
5. Reconnect supply tank to pump hose to pump inlet elbow.
6. Remove hex head bolts and hydraulic tank lid from hydraulic reservoir.
7. Remove magnetic drain plug from hydraulic reservoir and clean off debris with lint-free rag.
8. Clean any remaining debris from inside of hydraulic reservoir.
9. Reinstall magnetic drain plug.

10. Disconnect booster to reservoir hose and hose clamp from barb and drain into drain pan.
11. Disconnect hose, steer valve “T” to tank return from hydraulic reservoir and drain into drain
pan.
12. Disconnect barb from hydraulic reservoir.
13. Insert ¼ -inch NPT plugs into open ports in hydraulic reservoir.

14. Place free ends of hose, booster to reservoir and steer valve “T” to tank return into drain pan.
15. Refill hydraulic reservoir with Dexron III fluid.
CAUTION: DO NOT LET THE HYDRAULIC RESERVOIR EMPTY

COMPLETELY OF FLUID WHILE FLUSHING SYSTEM OR
HYDRAULIC PUMP MAY BE DAMAGED. PROCEDURE REQUIRES
TWO PERSONNEL, ONE TO REFILL FLUID AND ONE TO TURN ON/
OFF ENGINE AND OPERATE THE STEERING AND BRAKES.
Note NOTE: Retain at least three (3) gallons of Dexron III fluid in position to
rapidly fill hydraulic reservoir.
16. Turn on engine and run for 30 seconds, do not depress the accelerator. While engine is
running continuously pour Dexron III fluid into hydraulic reservoir to prevent system from
running dry.
17. While engine is running rotate steering wheel lock to lock and pump break pedal.
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Chapter 2
18. Turn off engine.
19. Remove plugs from hydraulic reservoir.
20. Install barb, hose clamp and booster to reservoir hose in to hydraulic reservoir port.
21. Install steer valve “T” to tank return hose into hydraulic reservoir port.
22. Refill hydraulic reservoir with Dexron III fluid.
23. Reinstall hydraulic tank lid and hex head bolts onto hydraulic reservoir.
24. Remove tractor from jack stands in accordance with standard jacking procedure (this section).
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Chapter 2
2-1-16 CD387
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Chapter 2
SECTION 2: TROUBLESHOOTING
A. GENERAL
Trouble Probable Cause Remedy
1. Tractor will not (a) Low or no fuel. (a) Check fuel level. Add fuel.
start.
(b) Low voltage or defective battery. (b) Recharge or replace battery.
(c) Blown fuse(s). (c) Replace fuse(s).
(d) Faulty ignition switch. (d) Replace ignition switch.
(e) Fuel pump failed. (e) Replace fuel pump.
(f) Defective starter relay. (f) Replace starter relay.
(g) Neutral safety switch out of (g) Adjust neutral safety switch.
adjustment.
(h) Defective neutral safety switch. (h) Replace neutral safety switch.
(i) Defective oil pressure switch (i) Replace oil pressure switch
(j) Starter motor failed. (j) Replace starter motor.
(k) Timing belt failed. (k) Replace timing belt or if

engine damaged internally due
to failure, replace engine.
(l) Fuel filter clogged. (l) Replace fuel filter(s).
2. Engine will not (a) Glow plug relay inoperative. (a) Replace glow plug relay.
start below
60°F.
(b) Glow plug inoperative. (b) Replace glow plug.
(c) Defective circuit. (c) Perform electrical diagnosis.
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Chapter 2
3. Loss of power / (a) Brakes binding. (a) Inspect all brake system
reduction in pulling components. Replace as
power. required.
(b) Automatic transmission fluid (b) Check transmission fluid level.

level incorrect.
(c) Fuel injection system out of (c) Inspect fuel injection pump.
adjustment or excessively Replace as required.
worn.
(d) Air intake restricted. (d) Check air filter service

indicator. Inspect for damage.
Replace filter cartridge or
damaged component.
(e) Exhaust system restricted. (e) Check for crushed tail pipe,
clogged muffler/spark arrestor.
Replace as required.
(f) Fuel line leak. (f) Inspect for leaks. Replace line.
(g) U–joint failed on drive shaft. (g) Replace drive shaft or U-joints.
(h) Transmission failed. (h) Replace transmission.
(i) Transmission oil filter (i) Replace transmission oil filter.

clogged. Check and refill transmission
fluid to proper level.
(j) Transmission bands slipping. (j) Adjust bands.
(k) Transmission slips. (k) Replace transmission.
(l) Turbocharger failed. (l) Replace turbocharger.
(m) Low or uneven cylinder (m) Perform compression check,

compression pressures. perform QEC if required.
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Chapter 2
4. Unable to maintain (a) Cooling hose deteriorated. (a) Replace hose.

engine-operating
temperature.
(b) Thermostat fails to close. (b) Replace engine oil thermostat.
(c) Oil cooler clogged. (c) Replace oil cooler.
5. Vehicle rides (a) Front suspension component (a) Check front suspension for
rough. failed. failures. Replace failed
component. Lubricate new
components as needed.
(b) Low tire pressure, flat tire, (b) Check tire pressure, tire and
damaged tire(s)/rim(s). rim condition for damage.
Add air to tires or replace
tire(s)/rim(s) as needed.
(c) Rear suspension component (c) Check rear suspension for

failed. failures. Replace failed
component. Lubricate new
components as needed.
6. Drive axle noise. (a) Lack of or improper (a) Lubricate as required.

lubrication.
(b) Wet disk brake noise. (b) Add friction modifier to axle
oil.
(c) Internal axle failure. (c) Replace axle.
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Chapter 2
B. STEERING
1. Vehicle will not (a) Worn U-joint. (a) Remove/replace U-joint/ drive
steer or steering shaft.
very difficult.
(b) Low hydraulic fluid. (b) Check for proper fluid level.
(c) Hydraulic pump failed. (c) Replace hydraulic pump.
(d) Steering valve failed. (d) Replace steering valve. Add

oil to hydraulics system as
needed.
(e) Hydraulic pump belt drive (e) Replace PTO drive belt.
fails.
(f) Kingpin corroded or seized. (f) Lube king pin, as required

replace kingpin.
2. Steering wanders or (a) Lack of lubrication or oil in (a) Lubricate or add oil as
weaves. steering system. required.
(b) Low tire pressure. (b) Check for proper tire pressure.
(c) Worn or damaged rod end(s). (c) Replace rod end(s).
(d) Worn or damaged king pin (d) Replace front axle.

bushing(s).
(e) Incorrect toe–in or loose rod (e) Adjust toe-in and rod ends.
end(s).
(f) Defective or loose steering (f) Replace or adjust mountings or

cylinder mountings. tighten bolts.
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Chapter 2
3. Vehicle pulls to one (a) Front brake dragging. (a) Inspect front calipers for
side. seized piston or caliper pins.
Repair or replace as required.
(a) Worn or defective wheel (a) Adjust or replace bearings.

bearings.
(b) Steering cylinder seal failed. (b) Replace steering cylinder.
(c) Low tire pressure. (c) Adjust air pressure.
(d) Front wheels not aligned (d) Re-align front end.

properly.
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Chapter 2
C. BRAKE SYSTEM
1. Excessive stopping (a) Excessive wear or glazing on (a) Replace front brake pads.
distance. front brake pads.
(b) Excessive wear on brake (b) Replace rear axle.

system.
(c) Fluid level low. (c) Service as required.
(d) Insufficient hydraulic (d) Inspect hydraulic system for

pressure. failures. Replace faulty
component (pump or hydro
boost).
(e) Defective proportioning (e) Replace proportioning valve.

valve.
(f) Leak or air in brake lines. (f) Check for and repair leak.
Bleed brakes.
2. Front brakes drag (a) Worn front brake pads and/or (a) Replace pads or rotor as
or uneven pull. rotor. needed.
(b) Seized caliper slide pins. (b) Replace brake caliper.
(c) Seized caliper pistons. (c) Replace brake caliper.
(d) Brake flex line collapsed (d) Replace brake flex line.
internally.
3. Rear brakes drag or (a) Worn or damaged wet disc (a) Replace rear axle.
uneven pull. brake component.
(b) Brake flex line collapsed (b) Replace brake flex line.
internally.
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Chapter 2
4. Brake pedal spongy (a) Insufficient fluid in hydro (a) Check brake system for leaks
or excessive travel. boost. and refill the hydro boost.
(b) Air trapped in system. (b) Bleed brakes and refill brake
system.
(c) Excessive front brake pad (c) Replace brake pads.

wear.
(d) Partial brake system failure. (d) Inspect brake system; hoses,
lines, fittings, calipers, etc.
Replace as required.
(e) Hydro boost mounting bolts (e) Tighten mounting bolts.

loose.
(f) Hydro boost defective. (f) Replace hydro boost.
5. Hard pedal. (a) High pressure to hydro boost. (a) Inspect hydraulic system.
Replace failed component as
required.
(b) Seized caliper pistons. (b) Replace brake caliper.
(c) Insufficient hydraulic (c) Inspect hydraulic system for

pressure. failures. Replace faulty
component (pump or hydro
boost).
(d) Defective brake lines. (d) Replace as required.
6. Tractor moves (a) Park brake pads worn. (a) Adjust or replace park brake
when parking brake shoes and/or drum.
is engaged.
(b) Park brake linkage out of (b) Adjust as necessary.
adjustment.
(c) Park brake linkage broken. (c) Replace failed park brake
linkage component.
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Chapter 2
D. ELECTRICAL
1. Alternator (a) Loose or defective mounting and (a) Adjust or replace mounting,
noisy. pulleys or belt. pulley or belt.
(b) Worn bearings. (b) Replace alternator.
2. Alternator (a) Short in battery. (a) Replace battery.

output
consistently
(b) Loose or defective wiring (b) Repair and/or tighten wiring or
high.
between battery and alternator. replace alternator.
3. Battery will not (a) Shorted cell in battery. (a) Replace battery.
stay charged.
(b) Alternator drive belt loose. (b) Tighten alternator belt.
(c) Defective alternator output. (c) Replace alternator and/or belts.
(d) Breaks in wiring. (d) Repair and/or replace as

necessary.
4. Gauge or (a) Blown fuse(s). (a) Replace fuse(s).

warning light
not functioning.
(b) Warning light bulb defective. (b) Replace light bulb.
(c) Defective relay. (c) Replace relay.
(d) Loose or defective wiring and/or (d) Repair wiring and/or ground
ground connections. connections as required.
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Chapter 2
5. Exterior (a) Blown fuse(s). (a) Replace fuse(s).

Lighting: Poor,
intermittent or
(b) Bulb defective. (b) Replace bulb.
no
lights(headlight
, taillight, (c) Defective head light switch. (c) Replace defective switch.
stoplight,
reverse light &
(d) Defective headlight relay. (d) Replace headlight relay.
hitch light).
(e) Loose or defective wiring and/or (e) Repair wiring and/or ground
(f) Defective 3 terminal led flasher. (f) Replace 3 terminal led flasher.
6. Interior (a) Blown fuse(s). (a) Replace fuse(s).

Lighting: Poor,
intermittent or
(b) Light defective. (b) Replace light.
no lights.(dash
light or dome
light). (c) Defective switch. (c) Replace switch.
(d) Loose or defective wiring and/or (d) Repair wiring and/or ground
(e) Defective switch. (e) Replace dome light.
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Chapter 2
7. Wiper motor works (a) Blown fuse(s). (a) Replace fuse(s).

intermittently, or
won’t work.
(b) Loose or defective wiring (b) Repair wiring connections as
connections. required.
(c) Loose or defective wiper (c) Replace or tighten wiper

switch connections. switch and/or connections.
(d) Loose or defective wiper (d) Replace or tighten wiper

linkage or wiper linkage clip. linkage or wiper linkage clip.
(e) Windshield wiper blade(s) (e) Replace windshield wiper

worn. blade(s).
(f) Seized wiper motor. (f) Replace wiper motor.
(g) Blown fuse(s). (g) Replace fuse(s).
8. Horn works (a) Defective relay. (a) Replace relay.

intermittently or no
sound.
(b) Defective horn. (b) Replace horn.
(c) Defective horn button. (c) Replace horn button.
(d) Loose or defective wiring and (d) Repair wiring and/or ground
(e) Shorted wire between horn (e) Repair wire.

button and relay.
9. Horn sounds (a) Stuck horn button. (a) Repair button.

continuously.
(b) Defective relay. (b) Replace relay.
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Chapter 2
E. ELECTRICAL SCHEMATICS Figure 2-1. MR10 -24 (Deutz Tier 2) Electrical System Schematic
CD387 2-2-11
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Chapter 2
Figure 2-2. MR10 -34 (Deutz Tier 4i) Electrical System Schematic
2-2-12 CD387
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Chapter 2
Figure 2-3. MR36 (Kubota) Electrical System Schematic
CD387 2-2-13
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Chapter 2
Figure 2-4. Vehicle Electric Center (VEC) Configuration, Deutz Tier 2 and Kubota
2-2-14 CD387
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Chapter 2
Figure 2-5. Vehicle Electric Center (VEC) Wiring (Deutz Tier 2 and Kubota)
CD387 2-2-15
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Chapter 2
Figure 2-6. MR10 -34 (Deutz Tier 4i) TUG Eelctric Center
2-2-16 CD387
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Chapter 2
Figure 2-7. Instrument Panel, Front View (MR10-24T)
CD387 2-2-17
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Chapter 2
Figure 2-8. Instrument Panel, Rear View (MR10-24T)
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Chapter 2
Figure 2-9. Instrument Panel, Front View (MR10-36T)
DATE:
BUILD SPEC.
DWG SIZE:
DRAWN BY:
NO. OF SHEET (s) DRAWING NUMBER: REV.
CD387 2-2-19
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Chapter 2
Figure 2-10. Vehicle Electrical Center (VEC) Fuse Panel (MR10-24T)
2-2-20 CD387
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Chapter 2
DATE:
BUILD SPEC.
DWG SIZE:
DRAWN BY: PROPRIETARY AND CONFIDENTIAL. USE OF THIS DRAWING WITHOUT WRITTEN
PERMISSION IS PROHIBITED.
CAGE CODE NO. OF SHEET (s) DRAWING NO: REV.
Figure 2-11 TUG Electric Center (TEC) Fuse Panel (MR10-34)
CD387 2-2-21
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Chapter 2
2-2-22 CD387
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Chapter 2
Figure 2-12. Neutral Safety/Reverse Switch Wiring (MR10-24T and MR-36)
CD387 2-2-23
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Chapter 2
Figure 2-13 Emergency Stop Switch Wiring
2-2-24 CD387
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Chapter 2
Figure 2-14. Turn Signal Switch Wiring
CD387 2-2-25
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Chapter 2
Figure 2-15. Schematic Block Heater Option
2-2-26 CD387
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Chapter 2
F. HYDRAULIC SCHEMATIC
CD387 2-2-27
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Chapter 2
2-2-28 CD387
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Chapter 2
SECTION 3: REMOVAL/INSTALLATION
A. CAB
CAUTION: DISCONNECT THE BATTERY TO PREVENT SHORTING

OF THE ELECTRICAL SYSTEM.
Note NOTE: Tractor can be safely operated with either the cab or doors removed.
Note NOTE: The cab assembly generally may be repaired without removal.
1. Removal
(a) Ensure the ignition switch is in the off position.
(b) Disconnect the cab harness electrical connector, located on the left side of the dash
housing, going into the cab.
(c) To remove cab, begin by removing the hex head bolts, flat washers, lock washers and
lock nuts. The bolts are located as follows:
(1) Hex head bolts, flat washers, and lock nuts are located below the windshield.
Discard lock nuts.
(2) Hex head bolts, flat washers, and lock washers are located under the side rear
windows. Discard lock washers.
(3) Hex head bolts, flat washers, and lock washers are located under the rear
window. Discard lock washers.
(d) Loosen seat belt mounting bracket bolts and rotate seat belt brackets with seat belt
180 degrees.
(e) Attach hoist to lifting chains.
(f) In the cab, the lifting eyes are in the down position, loosen hex head bolts, rotate
lifting eyes up and tighten bolts. Attach lifting chains to cab lifting eyes located at the
four corners of the cab. Tighten lifting eyes.
CD387 2-3-1
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Chapter 2
WARNING: A MINIMUM OF 2 PEOPLE SHOULD BE USED WHEN

REMOVING CAB FROM TRACTOR FRAME. CAB WEIGHS
APPROXIMATELY 540 LB.
(g) Slowly lift cab off of tractor frame with hoist.
2. Installation
(a) Attach hoist to lifting chains.
(b) Attach lifting chains to cab lifting eyes located at the four corners of the cab.
(c) Slowly lift cab and position over tractor frame with hoist.
(d) Slowly lower cab onto tractor frame making sure cab is properly aligned.
(e) Install hex head bolts, flat washers, new lock washers, and new lock nuts.
(f) Secure cab to tractor frame by tightening the cab mounting bolts located below the
windshield, the rear side windows, and below the rear window.
(g) Secure lifting eyes in the down position by tightening bolts.
(h) Reconnect cab harness electrical connector.
3. Doors
(a) Removal
(1) Open door and remove check strap pin from check strap mount to disengage
check strap.
WARNING: USE CAUTION WHEN REMOVING DOORS. EACH DOOR

WEIGHS APPROXIMATELY 50 LBS.
(2) With door open, lift door straight up about 4 inches until door mounted hinge
halves are clear of lower cab mounted hinge halves.
(3) Remove door assembly
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Chapter 2
(b) Installation
(1) Install the door assembly by aligning the door mounted hinge halves with the
lower cab mounted hinge halves.
(2) Install check strap pin through check strap mount and check strap.
(3) Close door or to check door alignment. Adjust if necessary. See below for
adjustment procedure.
(c) Adjustment
The adjustment of the cab door assembly is accomplished by loosening the button
head socket screws on the hinges. Hold the door in desired position and secure by
tightening the button head socket screws.
4. Door Check Strap
(a) Removal
(1) Open door and remove check strap pin from check strap mount to disengage
check strap.
(2) Remove check-mounting brackets by removing the button head socket

screws.
(3) Remove failed check strap and discard.
(b) Installation
(1) Place check-mounting brackets over new check strap.
(2) Position mounting brackets and check strap at mounting point on door.
(3) Insert button head socket screws though check mounting brackets and tighten
securely. The check strap should be sandwiched in between.
CD387 2-3-3
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Chapter 2
5. Cab Heater
(a) Removal
(1) Disconnect negative battery cable.
WARNING: ALLOW AMPLE TIME FOR ENGINE OIL TO COOL.
(2) Ensure heater valve is in closed position.
(3) Remove hose clamps, behind battery and under engine cowl, and remove
heater hoses from cab heater tubes. Plug hoses to prevent oil spillage. Plug
heater core inlet and outlet tubes to prevent spillage. Inspect cab heater hoses
for signs of wear/damage.
(4) From operator’s compartment, disconnect cab electrical heater connector

from right side of dash housing.
(5) Remove hex head bolts, lock washers, and flat washers. Discard lock
washers.
(6) Remove cab heater from unit.
(b) Installation
(1) Position cab heater on firewall and secure with flat washers, new lock
washers and bolts.
(2) Remove plugs on cab heater inlet and outlet tubes if equipped and reinstall or
replace cab heater hoses and hose clamps.
(3) From operator’s compartment, connect cab electrical heater connector at right
side of dash housing.
(4) Ensure heater valve is in open position.
(5) Connect the negative battery cable.
(6) Start unit and let run for 30 seconds to allow oil to circulate through the cab
heater.
(7) Shut unit down and check engine oil level; add oil as required to reach full
mark on dipstick.
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Chapter 2
6. Window, Door
(a) Removal
WARNING: WEAR SAFETY GLOVES IF GLASS IS CRACKED OR

BROKEN TO PREVENT INJURY.
(1) Remove window mounting rubber insert from outside of the window.
(2) From the inside of the door, push window outward to remove.
(3) Using isopropyl alcohol, clean window-mounting rubber of any debris.

Inspect window-mounting rubber for damage, replace as necessary.
(b) Installation
(1) If necessary, install new window mounting rubber into door. Trim any excess
if required.
(2) Insert new window by pushing inward against window.
(3) Begin installing the window mounting rubber insert on opposite side of the
start/end point of the window mounting rubber. Use rubber gasket lubricant
when installing insert into mounting rubber.
(4) Install window mounting rubber insert, using installation tool, from outside
of the window into the recess in the window mounting rubber. Trim any
excess if required.
7. Front Windshield
(a) Removal

(1) Remove window mounting rubber insert from outside of the windshield.
(2) Flip up wiper arms and temporarily secure with zip-ties.
(3) From the inside of the cab, push windshield outward to remove.
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Chapter 2
(4) Using Isopropyl Alcohol clean window mounting rubber of any debris.
(b) Installation
(1) If necessary, install new window mounting rubber into cab. Trim any excess
if required.
(2) Insert new windshield by pushing inward against window.
of the windshield into the recess in the window mounting rubber. Trim any
excess if required.
8. Rear Windshield
(a) Removal

(1) Remove window mounting rubber insert from outside of the rear windshield.
(2) Flip up wiper arm and temporarily secure with zip-ties.
(3) From the inside of the cab, push rear windshield outward to remove.
(4) Using isopropyl alcohol clean window mounting rubber of any debris.
(b) Installation
(1) If necessary, install new window-mounting rubber into cab. Trim any excess
if required.
(2) Insert new rear windshield by pushing inward against window.
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Chapter 2
of the windshield into the recess in the window mounting rubber. Trim any
excess if required.
9. Windows, Rear Side
(a) Removal

(1) Remove window-mounting rubber insert from outside of the rear side
window.
(2) From the inside of the cab, push rear side window outward to remove.
(3) Using isopropyl alcohol clean window mounting rubber of any debris.
(b) Installation
(1) If necessary, install new window mounting rubber into cab. Trim any excess
if required.
(2) Insert new rear side window by pushing inward against window.
of the window into the recess in the window mounting rubber. Trim any
excess if required.
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Chapter 2
10. Rear View Mirror
(a) Removal
Pull mirror up and off of rear view mirror mounting kit on windshield.
(b) Installation
Note NOTE: If installing mirror because of windshield replacement, it is

necessary to adhere a new rear mount to the inside of the windshield.
(1) Mark location for new rear view mirror mounting kit on the outside of the
windshield. It should be centered and approximately 3 inches below the top
of the windshield.
(2) Properly clean inside location with isopropyl alcohol.
(3) Secure mirror-mounting kit to windshield with adhesive. Use tape to

temporarily hold mirror-mounting kit until adhesive fully cures per
instructions in mirror mounting kit.
(4) Once adhesive has fully cured, install rear view mirror by sliding base over
mirror-mounting kit until it locks into position.
11. Mirrors
(a) Removal
(1) Locate mirror on cab.
(2) Remove hex nut, lock washer, hex head bolt, and flat washer from mirror
mounting bracket. Discard lock washer.
(3) Remove and discard mirror.
(b) Installation
(1) Position mirror on mirror mounting bracket and secure with hex head bolt,
flat washer, new lock washer, and hex nut.
(2) Sit in operator’s seat and visually check mirror alignment. Reposition mirrors
as required for best visibility.
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Chapter 2
12. Mirror Mounting Brackets
(a) Removal
(1) Remove mirror in accordance with procedure.
(2) Remove mirror mounting bracket by removing screws, lock washers and
nylon lock nuts. Discard lock washers and nylon lock nuts.
(b) Installation
(1) Attach mirror mounting bracket with screws, new lock washers and new
nylon lock nuts.
(2) Install mirror in accordance with procedure.
13. Wiper Motor, Front
(a) Removal
(1) Disconnect negative battery cable by loosening nut.
WARNING: THE FOLLOWING PROCEDURE REQUIRES TWO

PERSONS TO PREVENT INJURY. CAB OVERHEAD WIPER COVER IS
AWKWARD FOR ONE PERSON TO HANDLE.
(2) Remove front wiper cover mounting hardware screws and star washer.
(3) Temporarily hang the wiper cover from the front mounting points with wire
or plastic wire ties.
(4) Disconnect wiper motor wiring harness from cab wiring harness.
(5) Disconnect wiper linkage by removing clip and washer from pin.
(6) Remove driver side wiper arm by removing nuts and washers.
(7) Remove wiper arm connector, rubber boot, wiper pivot shaft nut, washer, and
rubber washer.
(8) Remove wiper adapter and gasket by removing screws.
(9) Remove bracket with wiper motor attached.
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Chapter 2
Note NOTE: The position of the wiper drive arm must be marked on the bracket
prior to removal. Failure to do so will result in improperly “parked” wipers.
(10) Locate wiper drive arm and remove flange nut.
(11) Remove flange bolts from wiper motor bracket and wiper motor.
(12) Remove and discard failed front wiper motor.
(b) Installation
(1) Install and align new front wiper motor on to wiper motor bracket.
(2) Secure wiper motor using flange bolts.
(3) Temporarily reconnect negative battery cable and wiper motor to cab harness.
Turn ignition to “on” position. Turn on wipers then turn off to establish
proper orientation. Then, turn ignition to “off” position and disconnect
negative battery cable.
Note NOTE: Position wiper drive arm so that it lines up with mark made prior to
removal.
(4) Attach wiper drive arm to wiper motor by installing and tightening flange
nut.
(5) Attach wiper motor bracket with wiper motor, wiper adapter and gasket with
screws.
(6) Connect wiper linkage by installing clip and washer on to pin.
(7) Install rubber washer, washer, wiper pivot shaft nut, rubber boot, and wiper
arm connector on to wiper pivot shaft.
(8) Install driver side wiper arm. Secure with nuts, and washers,.
(9) Install front wiper cover using mounting hardware screws and star washer.
(10) Connect negative battery cable by tightening nut.
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Chapter 2
14. Wiper Motor, Rear
(a) Removal
(2) Remove rear wiper cover by removing screws flat washers and lock nuts.
(3) Disconnect wiper motor wiring harness from cab wiring harness.
(4) Remove rear wiper arm by removing nuts and washers.
(5) Remove wiper arm connector, rubber boot, wiper pivot shaft nut, washer, and
rubber washer.
(6) Remove wiper adapter and gasket by removing screws.
(7) Remove bracket with wiper motor attached.
Note NOTE: The position of the wiper drive arm must be marked on the bracket
prior to removal. Failure to do so will result in improperly “parked” wipers.
(8) Locate wiper drive arm and remove flange nut.
(9) Remove flange bolts from wiper motor bracket and wiper motor.
(10) Remove and discard failed wiper motor.
(b) Installation
(1) Install and align new wiper motor onto wiper motor bracket.
(2) Secure wiper motor using flange bolts.
(3) Temporarily reconnect negative battery cable and wiper motor to cab harness.
Turn ignition to “on” position. Turn on wipers then turn off to establish
proper orientation. Then, turn ignition to “off” position and disconnect
negative battery cable.
NOTE: Position wiper drive arm so that it lines up with mark made prior to
Note removal.
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Chapter 2
(4) Attach wiper drive arm to wiper motor by installing and tightening flange
nut.
(5) Attach wiper motor bracket with wiper motor, wiper adapter and gasket with
screws.
(6) Install rubber washer, washer, wiper pivot shaft nut, rubber boot, and wiper
arm connector on to wiper pivot shaft.
(7) Install rear wiper arm. Secure with nuts and washers.
(8) Install rear wiper cover using screws, lock nuts and flat washers.
15. Windshield Wiper Switch (Front and Rear)
(a) Removal

(2) Remove front wiper cover by removing screws and star washer.
(3) Temporarily hang the wiper cover from the front mounting points with wire
or plastic wire ties.
CAUTION: ENSURE WIRES ARE CLEARLY MARKED TO AVOID

IMPROPER CONNECTION WHEN WIRES ARE RECONNECTED.
FAILURE TO PROPERLY CONNECT WIRING COULD RESULT IN
SERIOUS DAMAGE TO SYSTEM COMPONENTS.
(4) Tag and remove wires from applicable windshield wiper switch.
(5) Loosen set screw and remove windshield wiper switch knob.
(6) Remove nuts from switch.
(7) Remove and discard failed switch from front wiper cover.
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Chapter 2
(b) Installation
(1) Install windshield wiper switch into front wiper cover.
(2) Secure switch with nut.
(3) Connect wire leads to switch.
(4) Install windshield wiper switch knob and tighten set screw.

(5) Install front wiper cover with screws and star washer.
(6) Ensure wires do not interfere with wiper mechanics and operation.
B. HOOD PANEL
1. Removal
WARNING: THE HOOD IS VERY HEAVY AND MUST BE PROPERLY

SUPPORTED DURING REMOVAL. USE HOIST AND SLING TO
SUPPORT HOOD DURING REMOVAL.
(a) Disconnect hood latches.
(b) Open hood to vertical position.
(c) Using a choker hitch, wrap-lifting sling around hood hoist end through opening.
Attach open end to hoist to support during removal.
(d) Remove gas hood spring clips from hood strut ball studs and remove gas hood spring
from hood hinge arm.
(e) Remove hood hex head bolt, flat washers, and lock nuts so that hinges separate.
Carefully remove hood. Discard lock nuts.
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Chapter 2
2. Installation
(a) Position hood portion of the hood hinge arm with the firewall portion and install the
hinge hex head bolts, flat washers, and new lock nuts. Torque hex head bolts to 80 ft-
lbs.
(b) Attach the gas hood spring to the hood hinge ball studs.
(c) Install the gas hood spring clips.
C. PINTLE HITCHES
1. Removal
(a) Front pintle: Remove hex head bolts and lock washers. Discard lock washers.
(b) Rear pintle: Remove hex head bolts, flat washers, and lock nuts. Discard lock nuts.
(c) Remove pintle hitch.
2. Installation
Position front or rear pintle hitch into position and secure with hex head bolts, new lock
washers and flat washers and new lock nuts. Torque hex head bolts to 280 ft-lbs.
D. SEATS
1. Removal
(a) Remove rear axle access panel, remove hex head bolts, lock washers, and flat
washers. Discard lock washers.
Note NOTE: Two lock nuts are accessed through the rear axle access hatch, and
two lock nuts are accessed from the wheel well.
(b) Locate and remove flange nuts. Discard flange nuts.
(c) Lift seat straight up and remove seat.
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Chapter 2
2. Installation
(a) Position seat onto base plate, secure with new flange nuts.
(b) Install rear axle access panel with hex head bolts, new lock washers and flat washers.
3. Seatbelt, Retractable
(a) Removal
(1) Remove hex head bolt, flat washers, and lock nut. Discard lock nut.
(2) Remove retractable seat belt.
(3) If applicable, remove seat belt brackets, by removing hex head bolts, lock
washers and flat washers. Discard lock washers.
(b) Installation
(1) If applicable, install seat belt bracket, secure with hex head bolts, new lock
washers and flat washers.
(2) Align retractable seat belts to seat belt brackets, install hex head bolts, flat
washers and new lock nuts.
E. BATTERY
1. Removal
(a) Access engine compartment by unlatching left and right hood latches, lift hood and
install hood prop rod.
(b) Loosen nut and remove negative battery cable from battery negative terminal.
(c) Loosen nut and remove positive battery cable from battery positive terminal.
(d) Remove flange nuts and flat washers holding battery hold down bracket in place.
Remove hold down clips from threaded rods welded to battery tray and battery hold
down bracket. Remove battery from battery tray.
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Chapter 2
2. Installation
(a) Install battery on to battery tray; ensure battery posts are facing away from engine.
(b) Install battery hold down bracket over threaded rods welded to battery tray. Install
hold down clips on threaded rod. Install flat washers and new flange nuts on threaded
rods and tighten evenly until battery is secure.
CAUTION: ENSURE CABLE INSTALLATIONS TO THE BATTERY ARE

CORRECT TO PREVENT DAMAGE TO THE ELECTRICAL SYSTEM.
(c) Attach red positive battery cable to positive post on battery. Tighten battery terminal
nut.
(d) Attach black negative battery cable to negative post on battery. Tighten battery
terminal nut.
(e) Remove and secure prop rod.
(f) Close hood and secure with hood latches.
F. DASH PANEL ASSEMBLY
1. Dash Illumination Lights
(a) Removal
Note NOTE: Use caution while pulling dash panel from console. Do not pull on
wiring. Some wire ties may need to be removed in order to provide enough
slack.
(2) Remove dash panel pan head screws. Slowly pull dash panel away from dash
console.
(3) Tag and mark wiring then remove wiring from light base terminals.
(4) Locate dash light and remove nut and washer.
(5) Pull dash light out of dash panel.
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Chapter 2
(b) Installation
(1) Position dash light into dash panel.
(2) Install washer and nut on to dash light.
(3) Attach wiring to terminals.
(4) Reinstall any removed wire ties.
(5) Gently push dash panel into dash console and secure with pan head screws.
(c) Dash Illumination Light Bulb Replacement
(1) Remove dash light cover by rotating counterclockwise.
(2) Remove dash light bulb by pressing in on bulb and rotating ¼ turn
counterclockwise. Discard dash light bulb.
(3) Install new dash light bulb by pressing in and rotating ¼ turn clockwise.
(4) Install dash light cover by rotating clockwise.
2. Gauges
NOTE: The fuel level gauge, hour meter gauge, oil pressure gauge, oil
Note temperature gauge, and volt meter gauge are all similar in removal and
installation procedures and have been grouped together for simplicity.
(a) Removal
slack.
(2) Remove lower dash closeout plate by removing hex head bolts, lock washers
and flat washers. Discard lock washers.
(3) Locate faulty gauge.
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Chapter 2
(4) Remove light socket by pulling out from rear of gauge.

(5) Tag and remove wiring leads by carefully pulling them off each terminal
post.
(6) Unscrew gauge-retaining collar by turning in a counter clockwise direction.
(7) Remove gauge by pulling from front of dash panel. Discard faulty gauge.
(b) Installation
(1) Position new gauge in dash panel and install gauge retaining collar by
rotating it in a clockwise direction until it seats against the dash panel.
(2) Attach wiring leads. When applicable use the following:
(i) Voltmeter gauge, connect pink wire “4” to positive terminal. Install
black wire “G1” to negative terminal.
(ii) Oil temperature gauge, connect wire “24” to terminal “G”. Connect
wire “G1” to negative terminal. Connect wire “4” wire to positive
terminal.
(iii) Oil pressure gauge, connect brown wire “25” to terminal “G”.
Connect black wire “G1” to negative terminal. Connect pink wire “4”
wire to positive terminal.
(iv) Hour meter gauge, connect wire “G2” to negative terminal. Connect
wire “41” to positive terminal.
(v) Fuel level gauge, connect wire “23” to terminal “G”. Connect wire
“G2” to negative terminal. Connect wire “4” wire to positive
terminal.
(3) Install light socket into lamp opening of gauge.
(5) Install lower dash closeout plate and secure with hex head bolts, new lock
washers, and flat washers.
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Chapter 2
(c) Gauge Bulb Replacement
(3) Locate faulty back gauge light bulb, volt meter gauge, oil temperature gauge,
oil pressure gauge, hour meter gauge, and fuel level gauge.
(4) Remove light socket by pulling out from rear of gauge.
(5) Remove back gauge light bulb and discard.
(6) Insert new back gauge light bulb into light socket.
(7) Insert light socket into the back of the applicable gauge.
3. Headlight Switch or Hitch Light Switch
(a) Removal
NOTE: Use caution while pulling dash panel from console. Do not pull on
Note wiring. Some wire ties may need to be removed in order to provide enough
slack.
(3) Locate head light switch on dash panel.
(4) Remove retainer nut, and washer from head light switch.
(5) Remove head light switch with tanged washer from dash panel.
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Chapter 2
CAUTION: ENSURE THAT WIRES ARE CLEARLY MARKED TO

AVOID IMPROPER CONNECTION WHEN WIRES ARE
RECONNECTED. FAILURE TO PROPERLY CONNECT WIRING
COULD RESULT IN SERIOUS DAMAGE TO SYSTEM COMPONENTS.
(6) Tag and remove wire leads from switch.
(b) Installation
(1) Connect wire leads to head light switch.
(2) Place tanged washer on to head light switch.
(3) From the back of the dash panel, install head light switch, position toggle
with the “ON” position of the switch pointing upward and secure with nut
and washer.
4. Heater Switch
(a) Removal
slack.
(3) Locate heater switch on dash panel.
(4) Remove retainer nut, and washer from heater switch.
(5) Remove heater switch with tanged washer from dash panel.
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Chapter 2

(6) Tag and remove wire leads from switch.
(b) Installation
(1) Connect wire leads to heater switch.
(2) Place tanged washer on to heater switch.
(3) From the back of the dash panel, install heater switch, position toggle with
the “HIGH” position of the switch pointing upward and secure with nut and
washer.
5. Ignition Switch
(a) Removal
Note
slack.
(3) Loosen and remove knurled nut from ignition switch.
(4) Remove failed ignition switch from dash panel.
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Chapter 2

(5) Tag and remove leads from ignition switch.
(6) Discard failed ignition switch.
(b) Installation
(1) Connect wire leads to new ignition switch.
(2) Install jam nut on to ignition switch, run jam nut to base of ignition switch.
(3) From the back of the dash panel, install ignition switch.
(4) Position lever to the “OFF” position and secure with knurled nut
6. Warning Light Assembly
(a) Removal
slack.
(3) Carefully, push warning light assembly up from bottom and out of dash
panel.
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Chapter 2

(4) Tag and remove bulb holders from the associated warning light fixtures.
(5) Compress molded clips on mounting frame and push warning light assembly
out from dash panel.
(6) Remove warning light assembly.
(b) Installation
(1) Position warning light assembly into dash panel and force press warning light
assembly into dash, ensure molded clips of mounting frame seat themselves
behind the dash panel.
(2) Attach bulb holders to their associated warning light fixtures.
7. Light Lenses
Note NOTE: The lenses for battery warning light, brake warning light, engine
glow plug light, head light indicator light, high oil temperature warning
light, and oil pressure warning light, are all similar in removal and
installation procedures and have been grouped together for simplicity.
(a) Removal
slack.
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Chapter 2
panel.
(4) Remove faulty light holder and discard.
(5) Locate faulty lens: battery warning light, brake warning light, engine glow
plug light, head light indicator light, high oil temperature warning light, and
oil pressure warning light.

(6) To which ever is applicable, tag and remove bulb holder from applicable
defective light holder.
(7) Press applicable light lens: oil pressure warning light, engine glow plug light,
battery warning light, head light indicator light, brake warning light, high oil
temperature light outward to remove.
(8) Remove applicable lens: oil pressure warning light, engine glow plug light,
battery warning light, head light indicator light, brake warning light, high oil
temperature light, and discard.
(b) Installation
(1) Insert top edge of new applicable lens: battery warning light, brake warning
light, engine glow plug indicator light, head light indicator light, high oil
temperature warning light, and oil pressure warning light into warning light
assembly.
(2) Using thumb, press lower end of lens until it snaps into place.
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Chapter 2
8. Bulb, Warning Light
(a) Removal
slack.
panel.
(4) Locate failed warning light/indicator light: battery warning light, brake
warning light, engine glow plug indicator light, head light indicator light,
high oil temperature warning light, and oil pressure warning light.
(5) Remove bulb holder from applicable defective lens housing.
(6) Pull defective warning light bulb outward from bulb holder. Discard failed
warning light bulb.
(b) Installation
(1) Press new warning light bulb into bulb holder until bulb locks into place.
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Chapter 2
9. Turn Signal Flasher Unit
(a) Removal
slack.
(3) Locate flasher assembly on right side of dash opening.
(4) Remove push on terminals from flasher base. Discard failed turn signal
flasher.
(5) Remove the black (with red end) ground wire by removing screw, attached to
the low-pressure engine alarm.
(b) Installation
(1) Install brown wire “5B” to terminal “X” of the LED flasher.
(2) Install yellow wire “84” to terminal “L” of the LED flasher.
(3) Attach black ground wire to the negative terminal of the low-pressure engine
alarm with screw.
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Chapter 2
G. EXTERIOR LAMP ASSEMBLIES
1. Headlight Assembly
(a) Removal
(2) Locate defective headlight assembly and unplug connector from headlight
harness.
(3) Remove bolt, nut and lock washer that secure the light assembly to the frame.
Discard lock washers.
(4) Remove and discard failed headlight lamp assembly.
(b) Installation
(1) Install the new headlight assembly to the frame rail with bolt, new lock
washer and nut.
(2) Connect headlight wiring connector to headlight harness.
(c) Headlight Bulb Replacement
(2) Locate defective headlight bulb and unplug connector from headlight
harness.
(3) Remove locking wedge from connector.
(4) Remove headlight wires with terminal pins from connector.
(5) Remove failed headlight bulb from headlight assembly and discard.
(6) Insert wires of headlight bulb through opening in headlight assembly.
(7) Push new headlight bulb into headlight assembly until it bottoms out.
(8) Install and properly crimp new terminal pins onto headlight bulb wires.
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Chapter 2
(9) Install headlight bulb wires with terminal pins into connector. Ensure wires
are installed into proper socket of connector.
(10) Insert locking wedge into connector to secure headlight bulb wires.
(11) Connect headlight wiring connector to headlight harness.
2. Turn Signal Light Assembly, Front
(a) Removal
(2) Remove electrical connector from rear of turn signal light assembly.
(3) Remove turn signal light from mounting base by gently prying on the lamp
retaining tabs on the turn signal light assembly base.
(4) Remove and discard failed turn signal light assembly.
(5) If replacing turn signal light assembly bracket, remove screws, flat washers,
and nylon lock nuts. Discard nylon lock nuts.
(6) Remove and discard failed turn signal light assembly bracket.
(b) Installation
(1) Position new turn signal light assembly bracket and install screws, flat
washers and new nylon lock nuts.
(2) Install new turn signal lamp into base by snapping it into place.
(3) Connect electrical connector to turn signal light assembly.
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Chapter 2
3. Brake/Turn/Stop/ Light Assembly
(a) Removal
(2) Remove light assembly by pressing assembly inward and out of rubber
grommet.
(3) Disconnect electrical connector from light assembly. Discard failed light
assembly.
(b) Installation
(1) Connect electrical connector to new light assembly.
(2) Install new light assembly by pressing light forward into rubber grommet
ensure “TOP MARKING” is pointing upward.
Note NOTE: The rear light bulb is not replaceable. The entire back up light
assembly must be replaced. Refer to procedures for backup light assembly
below.
4. Back Up Light Assembly
(a) Removal
(2) Remove back-up light assembly by pressing light assembly inward and out of
rubber grommet.
(3) Disconnect wire plug from back-up light assembly. Discard failed light
assembly.
(b) Installation
(1) Connect electrical connector to new back-up light assembly.
(2) Install back-up light assembly by pressing light forward into rubber grommet;
ensure “TOP MARKING” is pointing upward.
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Chapter 2
5. Hitch Light Assembly
(a) Removal
(2) Remove hitch light assembly by pressing light assembly, from the outside,
out of rubber grommet.
(3) Rotate hitch light so that it may be pulled through the rubber grommet.
(4) Remove electrical connector from hitch light assembly. Discard failed light
assembly.
(b) Installation
(1) Attach electrical connector to new hitch light assembly.
(2) Install new hitch light assembly by pressing light, from outside, into rubber
grommet ensure “TOP MARKING” is pointing upward.
Note NOTE: The hitch light bulb is not replaceable. The entire hitch light
assembly must be replaced.
H. DOME LIGHT LAMP HOUSING ASSEMBLY
1. Removal
(a) Disconnect negative battery cable by loosening nut.
(b) Remove dome light screws from outer edge of dome light lens.
(c) Remove mounting screws from dome light base.
(d) Cut dome light wire and splice from main dome light supply wire.
(e) Remove and discard failed dome light.
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Chapter 2
2. Installation
(a) Splice new dome light wire to dome light supply wire.
(b) Attach dome light base with screws.
(c) Install dome light lens with screws.
(d) Connect negative battery cable by tightening nut.
3. Dome Light Bulb Replacement
(a) Remove dome light screws from outer edge of dome light.
(b) Remove dome light bulb from socket and discard.
(c) Install new dome light bulb into light socket.
(d) Attach dome light with screws.
I. EMERGENCY STOP SWITCH
1. Removal
(b) Locate emergency stop switch.
(c) Disconnect emergency stop switch electrical connector.
(d) Remove emergency stop switch mounting screws, lock washers and flat washers.
(e) Remove emergency stop switch from engine cowling. Discard failed emergency stop
switch.
2. Installation
(a) Position new emergency stop switch into engine cowling.
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Chapter 2
(b) Install emergency stop switch and secure with screws, new lock washers and flat
washers.
(c) Connect emergency stop switch electrical connector.
J. ELECTRIC CENTER PANEL ASSEMBLY
1. Vehicle Electric Center (VEC), Deutz Tier 2 and Kubota.
(a) Removal

(2) Tag and remove electrical plugs from VEC by pressing locking tabs down
and slowly pulling electrical plugs out of VEC receptacles.
(3) Remove bolts lock washers and flat washers from VEC. Discard lock
washers.
(4) Remove VEC.
(b) Installation
(1) Install VEC and secure with bolts new lock washers and flat washers.
Note NOTE: Connectors are polarized and will only mate in one direction.
(2) Attach electrical plugs and ensure locking tabs engage.
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Chapter 2
2. Fuses (F1-F8)
(a) Removal
(2) Release lower lid clips on VEC by pulling outward and lifting up cover.
(3) Remove and discard defective fuse, by pulling fuse outward away from VEC.
(b) Installation
(1) Install new fuse by pressing it into the fuse socket on VEC.
(2) Install VEC cover and press into place.
3. Relays (R1-R8)
(a) Removal
(2) Release VEC lower lid clips by pulling outward and lifting up cover.
(3) Insert small flat tip screwdriver under defective relay (R1-R8), and lift
upwards while wiggling back and forth until it releases.
(4) Remove and discard failed relay (R1-R8).
(b) Installation
(1) Install new relay (R1-R8) into VEC. Press firmly into place.
(2) Install VEC cover and press in place.
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Chapter 2
4. TUG Electric Center (TEC), Deutz Tier 4i
(a) Removal

(2) Tag and remove leads from transmission lockout relay.
(3) Remove hex head bolt and lock washer from transmission lockout relay.
Discard lock washer.
(4) Remove TEC with brackets.
(b) Installation
(1) Install TEC with brackets and secure with phillips screws, new lock washers
and flat washers.
Note NOTE: Connectors are polarized and will only mate in one direction.
(2) Attach electrical plugs and ensure locking tabs engage.
5. Fuses (F1-F12)
(a) Removal
(2) Release lower lid clips on TEC by pulling outward and lifting up cover.
(3) Remove and discard defective fuse, by pulling fuse outward away from TEC.
(b) Installation
(1) Install TEC with brackets and secure with phillips screws, new lock washers
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Chapter 2
(2) Install TEC cover and press into place.
6. Relays (K5-K8)
(a) Removal
(2) Release VEC lower lid clips by pulling outward and lifting up cover.
(3) Insert small flat tip screwdriver under defective relay (K5-K8), and lift
upwards while wiggling back and forth until it releases.
(4) Remove and discard failed relay (K5-K8).
(b) Installation
(1) Install new relay (K5-K8) into TEC. Press firmly into place.
(2) Install TEC cover and press in place.
7. Power Block
(a) Removal

(2) Locate power block on TEC mounting plate, tag and remove leads by
removing nut and lock washer.
(3) Remove screws and lock washers from power block. Discard lock washers.
(4) Remove and discard failed power block.
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Chapter 2
(b) Installation
(1) Position new power block and install screws and new lock washers.
(2) Install electrical leads onto power block and tighten nut to ensure good
connection.
8. Starter Relay
(a) Removal

(2) Tag and remove leads from starter relay.
(3) Remove hex head bolts, lock washers and flat washers from starter relay.
(4) Remove and discard failed starter relay.
(b) Installation
1) Install new starter relay to the TEC panel assembly and secure with hex head
bolt, new lock washer and flat washer.
(2) Connect starter cable to the main terminal, and solenoid wires to solenoid
terminals.
9. Circuit Breaker, 60 Amp
(a) Removal
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Chapter 2

(2) Tag and remove leads from circuit breaker.
(3) Remove screws and lock washers from circuit breaker. Discard lock washers.
(4) Remove and discard failed failed circuit breaker.
(b) Installation
(1) Install new circuit breaker to the VEC/TEC mounting plate and secure with
phillips screws and new lock washers.
(2) Connect electrical leads to the terminals.
10. Starter-Lockout Relay
(a) Removal

(2) Tag and remove leads from starter lockout relay.
(3) Remove hex head bolts and lock washers from starter lockout relay. Discard
lock washers.
(4) Remove and discard failed starter lockout relay.
(b) Installation
(1) Install new starter lockout relay to the VEC/TEC mounting plate and secure
with hex head bolts and new lock washers.
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Chapter 2
11. Transmission Lockout Relay
(a) Removal

(2) Tag and remove leads from transmission lockout relay
(3) Remove hex head bolts and lock washers from transmission lockout relay.
(4) Remove and discard failed transmission lockout relay.
(b) Installation
(1) Install new transmission lockout relay to the VEC/TEC mounting plate and
secure with hex head bolts and new lock washers.

lockout relay.
12. Glow Plug Relay
(a) Removal
(2) Carefully pull glow plug relay from relay socket.
(3) Remove and discard failed glow plug relay.
(b) Installation
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Chapter 2
(1) Carefully press glow plug relay into relay socket.
13. Glow Plug Relay Socket
(a) Removal
(2) Remove glow plug relay in accordance with procedure.

(3) Tag and remove leads from glow plug relay socket.
(4) Remove screw, lock washer and flat washer from glow plug relay socket.
(5) Remove and discard failed glow plug relay socket.
(b) Installation
(1) Install new glow plug relay socket to the VEC panel assembly and secure
with screw, new lock washer and flat washer.
(3) Install glow plug relay in accordance with procedure.
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Chapter 2
14. Main Power Solenoid
(a) Removal

(2) Tag and remove leads from main power solenoid.
(3) Remove hex head bolts and lock washers from main power solenoid. Discard
lock washers.
(4) Remove and discard failed main power solenoid.
(b) Installation
(1) Install new main power solenoid to the VEC/TEC panel assembly and secure
with hex head bolts and new lock washers.
15. Mini Fuse, 20 Amp (VEC panel only)
(a) Removal
(2) Remove fuse cover from VEC.
(3) Locate mini 20 amp fuse inside VEC.
(4) Open cap cover locate inline mini 20 amp fuse.
(5) Pull fuse out of receptacle. Discard failed fuse.
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Chapter 2
(b) Installation
(1) Install mini 20 amp fuse by pushing fuse into receptacle. Reinstall VEC
cover.
(2) For inline mini 20 amp fuse position cap cover on to base and snap in to
position to lock in place.
16. Mini Fuse, 25 Amp (VEC panel only)
(a) Removal
(2) Remove cover from VEC.
(3) Locate mini 25 amp fuse inside VEC.
(4) Open cap cover and locate inline mini 25 amp fuse.
(5) Pull fuse out of receptacle. Discard failed fuse.
(b) Installation
(1) Install new mini 25 amp fuse by pushing fuse into receptacle. Reinstall VEC
cover.
(2) For inline mini 25 amp fuse position cap cover on to base and snap in to
position to lock in place.
K. STARTER
1. Deutz, Removal
(b) Locate and remove the turbo oil drain line by removing bolt and turbo oil drain line
retainer.
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(c) Carefully remove turbo oil drain line from bottom of turbo charger by sliding it off
the turbo fitting. Remove and discard O-rings.
(d) Remove common positive battery cable, main positive battery cable and disconnect
green “6B” wire from starter.
(e) Disconnect header pipe from the turbo assembly by removing bolts. Remove turbo to
header pipe gasket.
(f) Remove the starter mounting flange bolts.
(g) Remove starter.
2. Deutz Installation
Note
NOTE: When installing starter, the solenoid should be at the 6:00 position.
(a) Position starter on to engine.
(b) Install starter mounting flange bolts.
(c) Install common positive battery cable, main positive battery cable and green “6B”
wire on to starter.
(d) Inspect turbo to header pipe gasket and install/replace with new as required. Connect
header pipe to turbo assembly by tightening bolts.
(e) Install new O-rings and on to turbo oil drain line.
(f) Install turbo oil drain line into bottom of turbo charger.
(g) Align lower end of turbo oil drain line with port in engine block.
(h) Install and secure bolt with turbo oil drain line retainer.
(i) Connect negative battery cable by tightening nut.
3. Kubota Removal
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Chapter 2
(b) Remove common positive battery cable, main positive battery cable and disconnect
green "6B" wire from starter.
(c) Remove the starter mounting flange bolts.
(d) Remove starter.
4. Kubota Installation
Note
NOTE: When installing starter, the solenoid should be at the 6:00 position.
(a) Position starter on to engine.
(b) Install starter mounting flange bolts.
(c) Install common positive battery cable, main positive battery cable and green “6B”
wire on to starter.
L. LOW OIL PRESSURE AND HIGH OIL TEMPERATURE ALARMS
1. Removal
(b) Remove lower dash closeout plate by removing hex head bolts, lock washers and flat
(c) Locate failed low oil pressure and high oil temperature alarms to the right of the
brake pedal inside the dash housing.
(d) Remove alarm nut from failed low oil pressure or high oil temperature alarm.
(e) Remove wiring from failed low oil pressure or high oil temperature alarm by
removing screw. Discard failed low oil pressure or high oil temperature alarm.
2. Installation
(a) Connect wiring to low oil pressure or high oil temperature alarm by installing and
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Chapter 2
tightening screw.
(b) Insert low oil pressure or high oil temperature alarm through hole in alarm mounting
plate located inside the dash housing.
(c) Secure low oil pressure or high oil temperature alarm by installing alarm nut. Tighten
alarm nut by hand.
(d) Install lower dash closeout plate and secure with hex head bolts, new lock washers,
and flat washers.
(e) Connect negative battery cable by tightening nut.
M. HORN ASSEMBLY
1. Removal
(a) Access engine compartment by unlatching left and right hood latches, lift hood and
install hood prop rod.
(b) Locate horn in engine compartment.
(c) Disconnect chassis harness by pulling wire connectors off horn terminals.
(d) Remove horn assembly by removing hex head bolt, lock washer, and flat washer.
(e) Remove and discard failed horn assembly.
2. Installation
(a) Attach horn to bracket with lock nut.
(b) Attach L-bracket to bracket with hex head bolt, star washer, and lock nut.
(c) Install horn assembly onto frame by attaching L-bracket with hex head bolt, new lock
washer, and flat washer.
(d) Connect chassis harness to horn by pushing connectors onto horn terminals.
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Chapter 2
N. FUEL SYSTEM
1. Fuel Tank Transition Hose
(a) Removal
(1) Locate fuel tank transition hose.
(2) Remove fuel filler hose clamps upper and lower.
(3) Rotate hose to break loose.
CAUTION: DISPOSE OF FUEL OIL IN ACCORDANCE WITH LOCAL

(4) Slide hose down as far as possible.
(5) Pull on upper end towards front of tractor to remove.
(6) Inspect fuel tank transition hose and replace as required.
(b) Installation
(1) Lightly lubricate ends of fuel tank transition hose with diesel fuel.
(2) Insert one end over the fuel tank neck, loosely install the fuel filler hose
clamps upper and lower at this time.
(3) Once installed on fuel tank, slide fuel filler hose clamp up and over the filler
neck on the frame.
(4) Tighten upper and lower fuel filler hose clamps to 40 in.-lbs. of torque.
2. Fuel Drain Petcock
(a) Removal
(1) Locate fuel drain petcock.

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Chapter 2
(2) Open fuel drain petcock to drain fuel into fuel container.
(3) Unscrew fuel drain petcock from fuel tank.
(4) Inspect fuel drain petcock and replace as required.
(b) Installation
(1) Apply thread sealant to fuel drain petcock threads.
(2) Install new fuel drain petcock into fuel tank.
(3) Add fuel to fuel tank and check for leaks.
3. Fuel Pump (Deutz only)
(a) Removal
(1) Locate fuel pump and loosen hose clamps.

(2) Remove fuel hoses and cap off.
(3) Remove fuel pump mounting bolts and flat washers.
(4) Remove fuel pump and fuel pump O-ring seal. Discard O-ring seal.
(5) Inspect fuel pump and replace as required.
Fuel Pump
Camshaft
Fuel Pump
Eccentric at BDC
Figure 3-1. Fuel Pump Eccentric BDC
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Chapter 2
(b) Installation
(1) Position new fuel pump O-ring seal on fuel pump.
(2) Set camshaft eccentric of fuel pump to BDC (bottom dead center). With the
fuel pump removed, locate fuel pump eccentric on camshaft. Rotate
crankshaft counterclockwise, which will turn the cam as well, since they are
connected via the timing belt. The cam will need to be rotated so that the
short side of the eccentric is seen (Figure 3-1).
(3) Position fuel pump onto engine.
(4) Install bolts and flat washers following an alternating pattern as far as they
will go by hand.
(5) Tighten bolts to 16 ft-lbs of torque.
(6) Connect fuel hoses to fuel pump.
(7) Tighten hose clamps.
(8) Return tractor to readiness condition.
4. Fuel Filter Head (Deutz only)
(a) Removal
(1) Locate fuel filter head.

Note
NOTE: Hose clamps may fall free when loosened.
(2) Loosen hose clamps and remove hoses and cap off.
(3) Remove and discard fuel filter element in accordance with procedure.
(4) Remove hex head bolts, flat washers and lock nuts from fuel filter head.
Discard lock nuts.
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(5) Remove fuel filter head.
(b) Installation
(1) Position fuel filter head on to frame.
(2) Insert hex head bolts with flat washers through fuel filter head and frame.
(3) Install new lock nuts on wheel well side.
(4) Install new fuel filter element in accordance with procedure.
(5) Connect fuel hoses to fuel filter head.
5. Fuel Filter Element (Deutz only)
(a) Removal
(1) Access engine compartment by unlatching left and right hood latches, lift
hood and install hood prop rod.
(2) Locate fuel filter element.

(3) Unscrew fuel filter element from fuel filter head.
(b) Installation
(1) Fill fuel filter element with fuel to within ½ -inch of top. Lightly coat the
fuel filter element sealing surface with diesel fuel.
(2) Screw new fuel filter element onto fuel filter head cover until fuel filter
element sealing surface touches. Hand-tighten an additional ¾ to 1 full turn.
(3) Remove and secure prop rod.
(4) Close hood and secure with hood latches.
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Chapter 2
6. Fuel Level Sending Unit
(a) Removal
(1) Remove fuel tank in accordance with procedure.
(2) Locate fuel level sending unit.

FAILURE TO TAG LEADS COULD RESULT IN SERIOUS DAMAGE TO
SYSTEM COMPONENTS.
(3) Remove screws, flat washers, and lock washers. Discard lock washers.
(4) Remove fuel level sending unit and gasket from fuel tank.
(5) Inspect fuel level sending unit and gasket; replace as required.
(b) Installation
(1) Install fuel tank sender harness onto new fuel level sending unit.
(2) Position gasket on fuel level sending unit so that all holes are aligned.
(3) Install fuel level sending unit and gasket on to the fuel tank.
(4) Install flat washers, new lock washers and screws.
(5) Tighten screws alternately as far as they will go by hand.
(6) Tighten screws in a criss-cross pattern to 30 in-lbs of torque.
(7) Install fuel tank in accordance with procedure.
7. Fuel Lines
(a) Removal

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(1) Open fuel drain petcock to drain fuel tank into fuel container.
(2) Close fuel drain petcock.

Note
NOTE: Hose clamp may fall free when fuel lines are separated.
(3) Locate rigid fuel line, loosen hose clamp, separate hose from line by carefully
pulling and twisting apart.
(4) Remove p-clamps from the frame studs by removing flange nuts. Discard
flange nuts. Remove p-clamps from fuel line and retain for use.
(5) Loosen compression fitting nut and remove fuel line. Discard failed fuel line,
compression fitting nut and compression fitting ferrule.
(b) Installation
(1) Route and position fuel line with compression fitting nut and compression
fitting ferrule.
(2) Apply loctite to threads of new compression fitting. Align compression fitting
nut to connector and tighten nut compression fitting.
(3) Install p-clamps on the fuel line, then install p-clamps on the frame studs and
secure by new flange nuts.
(4) Align straight end of fuel line to fuel hose by carefully pushing/pressing fuel
line into fuel hose.
(5) Install hose clamp on to fuel hose.
(6) Service fuel tank with recommended diesel fuel and check for leaks.
8. Fuel Hoses
(a) Removal

Note
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Chapter 2
NOTE: Hose clamp may fall free when fuel lines are separated.
(1) Locate applicable fuel hose, loosen hose clamps and position it out of the
way.
(2) Remove applicable fuel hose and annotate the length of hose:
(i) Loosen and remove hose clamps from fuel hose.
(ii) Separate fuel hose from its connections by carefully pulling and
twisting hose off.
(3) Remove hose clamps and retain for installation.
(b) Installation
(1) Cut hose to annotated length, route and position fuel hose.
(2) Install applicable fuel hose by carefully pushing and twisting hose onto its
connections.
(3) Install hose clamps, tighten to secure hose.
(4) Check for leaks.
9. Fuel Tank
(a) Removal
procedure (Chapter 2, Section 1).

(3) Drain fuel into fuel container by opening fuel drain petcock.
(4) Remove front axle in accordance with procedure.
(5) Remove wheel well closeout panel by removing hex head bolts, lock
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washers, flat washers, and lock nuts. Discard lock nuts and lock washers.
(6) Disconnect electrical connector of fuel tank sender harness from main wiring
harness.
(7) Disconnect rigid fuel lines from fuel tank in accordance with fuel line
removal procedure.
(8) Remove compression fitting connectors and fuel tank petcock.
(9) Remove hex head bolts, flat washers, and lock nuts. Discard lock nuts.
(10) Loosen fuel filler hose clamps.
(11) Slide fuel tank transition hose down onto tank neck so that it is clear of the
filler neck welded to the tractor frame.
(12) Tag and remove wiring leads from fuel tank sender harness.
(13) Remove fuel tank and isolators from tractor.
(14) Remove fuel level sending unit and gasket by removing screws, lock
washers, and flat washers. Discard lock washers.
(15) Remove fuel tank isolator angles from fuel tank. Remove any double sided
tape that may be present.
(16) Remove fuel level sending unit in accordance with procedure.
(17) Inspect fuel tank and replace as required.
(b) Installation
(1) Attach tank isolator angles to fuel tank with double sided tape.
(2) Position fuel level sending unit and gasket onto fuel tank. Secure with
screws, new lock washers, and flat washers.
(3) Attach wiring leads of fuel tank sender harness.
(4) Position fuel tank within tractor frame rails.
(5) Install fuel tank transition hose on to filler neck welded to tractor frame.
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(6) Tighten fuel filler hose clamps.
(7) Install fuel tank isolators, hex head bolts, flat washers, and new lock nuts.
(8) Apply loctite to threads of compression fitting connectors and fuel tank
petcock.
(9) Install compression fitting connectors and fuel tank petcock into tank ports.
Ensure fuel tank petcock is in closed position.
(10) Reconnect rigid fuel lines at fuel tank by tightening compression fitting nuts
on to compression fitting connector.
(11) Reconnect fuel level sending unit wire harness electrical connector to main
wiring harness.
(12) Fill fuel tank with fuel and check for leaks.
(13) Reinstall wheel well closeout panel. Secure with hex head bolts, new lock
washers, flat washers, and new lock nuts.
(14) Reinstall front steer axle in accordance with procedure.
(16) Connect negative battery cable.
O. ACCELERATOR AND MODULATOR ASSEMBLY (DEUTZ TIER 2 AND KUBOTA)
1. Accelerator Pedal
(a) Removal
(1) Locate accelerator pedal and remove ball joint cable end from throttle cable
stud on accelerator pedal lever.
(2) Remove accelerator pedal mounting bolts, lock washers and flat washers
from pedal mount and remove accelerator pedal from unit. Discard lock
washers.
(3) Remove accelerator pedal lever from accelerator pedal by removing lock nuts
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Chapter 2
and flat washer. Discard lock nuts.
(b) Installation
(1) Attach accelerator pedal lever to bottom side of accelerator pedal with flat
(2) Position accelerator pedal on unit and secure with accelerator mounting bolts,
new lock washers and flat washers to pedal mount on chassis.
(3) Attach ball joint cable end onto throttle cable stud at end of accelerator pedal
lever.
2. Accelerator Pedal Lever
(a) Removal
(1) Locate accelerator pedal and accelerator pedal lever.
(2) Remove and discard nylon lock nut from throttle cable stud.
(3) Remove and discard lock nuts and flat washers which secure the accelerator
pedal lever to the accelerator pedal.
(4) Remove accelerator pedal lever.
(b) Installation
(1) Secure accelerator pedal lever to accelerator pedal using new lock nuts and
flat washers.
(2) Install accelerator pedal lever and attach throttle cable stud and secure with
new nylon lock nut.
3. Modulator Cable
(a) Removal
(1) Locate modulator cable. At engine throttle lever remove end ball joint cable
from throttle cable stud.
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Chapter 2
(2) Remove ball joint cable end from modulator cable and retain.
(3) Locate accelerator and modulator cable mount, loosen cable jam nuts to
remove modulator cable from accelerator and modulator cable mount.

(4) Locate modulator cable clamp at rear of transmission. Remove modulator

cable clamp bolt, modulator cable clamp and retain.
(5) Disconnect (pull out) modulator from rear of transmission; plug the opening
to prevent fluid loss.
(6) Remove p-clamp by removing flange nut from the stud on the frame. Discard
flange nut.
(7) Remove modulator cable. Retain p-clamp if modulator cable is failed.
(b) Installation
(1) Position end of modulator into rear of transmission and attach modulator
cable clamp, secure with modulator cable clamp bolt.
(2) Reinstall ball joint cable end onto modulator cable.
(3) Position modulator cable, attach ball joint cable end to throttle cable stud
located on engine throttle lever.
(4) Affix cable to accelerator and modulator cable mount, tighten cable jam nuts.
Adjust as required.
(5) Position p-clamp on the modulator cable and install p-clamp and new flange
nut on the frame stud and tighten.
4. Throttle Cable
(a) Removal
(1) Locate throttle cable. At engine throttle lever remove ball joint cable end
from throttle cable stud.
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Chapter 2
(2) Remove ball joint cable end from throttle cable and retain.
(3) Locate accelerator and modulator cable mount, loosen cable jam nuts to
remove throttle cable from accelerator and modulator cable mount.
(4) At accelerator pedal lever, remove cable end from throttle cable.
(5) Remove throttle cable.
(b) Installation
(1) Reinstall cable end, to throttle cable and position throttle cable on accelerator
pedal lever.
(2) Affix throttle cable to accelerator and modulator cable mount, tighten throttle
cable jam nuts. Adjust as required.
(3) Reinstall cable end on other end of throttle cable.
(4) If required, readjust cable at accelerator and modulator cable mounts.
P. ACCELERATOR PEDAL (DEUTZ TIER 4I)
(a) Removal
(2) Locate accelerator pedal.
(3) Disconnect Plug P29 accelerator pedal harness from engine harness.
(4) Remove 4 flange bolts, holding accelerator pedal to the floor panel.
(5) Remove the pedal
(b) Installation
(1) Install accelerator pedal to the floor plate, using 4 flange bolts.
(2) Connect accelarator harness to the engine harness plug P29.
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Q. AIR INTAKE ASSEMBLY
1. Air Filter Assembly
(a) Removal
(1) Locate air filter assembly in engine compartment.

Note
NOTE: Bolt and nut are spring loaded.
(2) Slowly loosen air filter mounting band by loosening spring loaded mounting
bolt and mounting band nut.
(3) Loosen hose clamp, pull air filter assembly away from hump hose.
(4) Slide air filter assembly through air filter mounting band.
(5) Remove air filter assembly.
(b) Installation
(1) Slide air filter assembly through air filter mounting band.
(2) Insert air filter assembly into hump hose and tighten hose clamp.
(3) Tighten air filter mounting band by securing spring loaded mounting bolt and
mounting band nut.
2. Air Filter Mounting Band
(a) Removal
(1) Remove air filter assembly in accordance with procedure.
(2) Remove hex head bolts, flat washers and flange nut.
(3) Remove air filter mounting band.
(b) Installation
(1) Align air filter mounting band to tractor frame, install bolts, flat washers and
flange nuts.
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Chapter 2
(2) Install air filter assembly in accordance with procedure.
3. Air Filter Element
(a) Removal
(1) Locate air filter assembly in engine compartment.
(2) Locate air intake end cap and release spring retaining latches.
(3) Remove air intake end cap.
(4) Remove and discard air filter element from air filter housing.
(b) Installation
(1) Ensure air filter housing is free of dirt and debris.
(2) Install new air filter element into air filter housing.
(3) Attach air intake end cap and secure with spring retaining latches.
4. Hump Hose
(a) Removal
(1) Locate hump hose in air intake assembly at the front of the engine
compartment.
(2) Loosen hose clamps to remove hump hose.
(3) Remove hump hose from filter to turbo transition tube and air filter assembly.
(b) Installation
(1) Install hose clamps on hump hose.
(2) Position and align hump hose to filter to turbo transition tube and air filter
assembly.
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5. Filter to Turbo Transition Tube
(a) Removal
(1) Locate filter to turbo transition tube in air intake assembly at the front of the
engine compartment.
(2) Loosen hose clamps to remove filter to turbo transition tube.
(3) Remove filter to turbo transition tube from hump hose and rubber reducer
hose.
(b) Installation
(1) Install hose clamps on filter to turbo transition tube.
(2) Position and align filter to turbo transition tube to hump hose and rubber
reducer hose.
6. Rubber Reducer Hose
(a) Removal
(1) Locate rubber reducer hose in air intake assembly at the front of the engine
compartment.
(2) Loosen hose clamps to remove rubber reducer hose.
(3) Remove rubber reducer hose from filter and turbo transition tube.
(b) Installation
(1) Install hose clamps on rubber reduced hose.
(2) Position and align rubber reducer hose to filter to turbo transition tube.
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Chapter 2
R. COOLING ASSEMBLY
1. Transmission Fluid Cooler
(a) Removal
WARNING: USE EXTREME CARE WHEN LOOSENING

TRANSMISSION FLUID COOLER LINES. A SUDDEN RELEASE OF
PRESSURE CAN CAUSE SERIOUS INJURY TO PERSONNEL. LOOSEN
LINE SLOWLY AND ALLOW PRESSURE TO ESCAPE.
WARNING: ALLOW AMPLE TIME FOR ENGINE TO COOL.
(1) Remove air intake assembly in accordance with procedure.
(2) Remove flange nuts, flat washers and isolators, attaching top of the oil
coolers.
(3) Remove flange nuts, flat washers and isolators, located on the bottom of the
lower oil cooler mount bracket.
(4) Move oil cooler all the way to the left.
(5) Locate transmission fluid cooler.
(6) Disconnect transmission cooler supply line hose and transmission cooler
return line hose by removing hose clamps and install hose caps.
(7) Remove upper fluid cooler mount by removing lock nuts and flat washers.
Discard lock nuts.
(6) Remove transmission fluid cooler after moving cooler all the way to the
right.
(b) Installation
(1) Position transmission fluid cooler on to lower fluid cooler mount.
Note NOTE: Do not tighten nuts at this time.
(2) Install upper fluid cooler mount and install new lock nuts and flat washers,
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adjust upper fluid cooler mount so that it just comes in contact with the
transmission fluid cooler.
(3) Tighten new lock nuts and flat washers.
(4) Attach transmission cooler supply line hose to lower transmission fluid
cooler port by hose clamp.
(5) Attach transmission cooler return line hose to upper transmission fluid cooler
port by hose clamp.
(6) Install oil cooler assembly in accordance with procedure.
(7) Install air intake assembly in accordance with procedure.
(8) Refill transmission with Dexron III transmission fluid as required.
(9) Run engine and check for leaks. While engine is running and transmission is
up to operating temperature, add transmission fluid as required to reach full
mark on the dipstick.
2. Oil Cooler (Deutz)
(a) Removal
WARNING: USE EXTREME CARE WHEN LOOSENING OIL COOLER

LINES. A SUDDEN RELEASE OF PRESSURE CAN CAUSE SERIOUS
INJURY TO PERSONNEL. LOOSEN LINE SLOWLY AND ALLOW
PRESSURE TO ESCAPE.
(2) Locate oil cooler.
(3) Disconnect oil line cooler hoses at engine and install hose caps.
(4) Remove flange nuts, flat washers and isolators, attaching top of the oil
cooler.
(5) Remove flange nuts, flat washers and isolators located on the bottom of the
lower oil cooler mount bracket.
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(6) Move oil cooler all the way to the left
(7) Remove transmission cooler in accordance with procedure.
(8) Remove oil cooler from engine compartment.

(9) If installing a new oil cooler, remove fittings from oil cooler for reuse on
new oil cooler. Drain oil from oil cooler.
(b) Installation
(1) If fittings were removed, install fittings into upper and lower cooler ports.
(2) Lower oil cooler into position between the engine and front bumper.
(3) Move oil cooler all the way to the left.
(4) Install transmission cooler in accordance with procedure.
(5) Align two holes in bottom of oil cooler with isolator attached to lower oil
cooler mounting bracket.
(6) Attach upper flange of oil cooler to isolators install flange nuts and flat
washers.
(7) Attach oil cooler hose to fittings in upper oil cooler port and oil cooler hose
to fitting in lower oil cooler port.
(9) Refill engine oil with engine oil as required.
(10) Run engine and check for leaks. Add oil as required to reach full mark on the
dipstick.
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3. Radiator (Kubota)
(a) Removal
WARNING: USE EXTREME CARE WHEN LOOSENING RADIATOR

LINES. A SUDDEN RELEASE OF PRESSURE CAN CAUSE SERIOUS
INJURY TO PERSONNEL. LOOSEN LINE SLOWLY AND ALLOW
PRESSURE TO ESCAPE.
(2) Locate radiator.
(3) Open drain valve on the lower part of radiator and drain coolant from
radiator.
(4) Disconnect two upper hoses and one lower hose from radiator and install
hose caps.
(5) Remove flange nuts, flat washers and isilators, attaching top of the oil cooler
to the radiator mounts.
(6) Remove flange nuts, flat washers and isolators, located on the bottom of the
radiator mounts.
(7) Move radiator all the way to the back.
(8) Remove transmission cooler in accordance with procedure.
(9) Remove radiator.

(b) Installation
(1) Lower radiator into position between the engine and front bumper.
(2) Move oil cooler all the way to the back.
(3) Install transmission cooler in accordance with procedure.
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(4) Align two holes in bottom of radiator with isolator attached to bottom of
radiator mounts.
(5) Attach upper flange of radiator to isolators install flange nuts and flat washers
to the top of radiator mounts.
(6) Attach radiator hoses to the two upper radiator ports and radiator lower
radiator hose to lower radiator port.
(9) Refill engine with engine coolant as required.
(10) Run engine and check for leaks. Add coolant as required to reach full mark
on the dipstick.
S. EXHAUST SYSTEM
1. Header Pipe
(a) Removal
WARNING: ALLOW AMPLE TIME FOR ENGINE AND EXHAUST

COMPONENTS TO COOL.
(2) Locate header pipe and remove hex head bolts. Remove gasket from turbo
assembly.
(3) Locate pipe hanger, remove hex head bolt, flat washers and lock nut. Discard
lock nut.
(4) At muffler band clamp, remove flange bolts and flange nuts.
(5) Remove header pipe.
(b) Installation
(1) Inspect header pipe gasket, replace as required.
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(2) Position header pipe.
(3) Position header pipe gasket and install bolts into turbo assembly.
(4) Align header pipe to muffler and attach band clamp, install flange bolts, and
flange nuts.
(5) Attach pipe hanger, install hex head bolt, flat washers and new lock nut.
2. Muffler
(a) Removal

COMPONENTS TO COOL.
(1) Locate muffler, remove band clamp by removing flange bolt, and flange nut.
(2) Locate spark arrestor, remove exhaust clamp by removing flange nuts.
(3) Locate muffler hangers and remove hex head bolts, flat washers and lock
nuts. Discard lock nuts.
(4) Remove muffler.
(b) Installation
(1) Align and install muffler to header pipe and spark arrestor.
(2) Install exhaust clamp and tighten flange nuts.
(3) Install band clamp and install flange bolt and flange nut.
(4) Locate muffler hangers and install hex head bolts, flat washers and new lock
nuts.
3. Spark Arrestor
(a) Removal

COMPONENTS TO COOL.
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(1) Locate spark arrestor, remove band clamp by removing flange bolts and
flange nuts.
(2) Locate muffler, remove exhaust clamp by removing flange nuts.
(3) Remove spark arrestor.
(4) Remove sediment from spark arrestor by removing plug located in the front
of the spark arrestor and dumping sediment into trash can.
(b) Installation
(1) Align and install spark arrestor to muffler.
(2) Install exhaust clamp and tighten flange nuts.
(3) Install band clamp, secure with flange bolts and flange nuts.
4. Tail Pipe
(a) Removal

COMPONENTS TO COOL.
(1) Locate tail pipe, remove band clamp by removing flange bolts, and flange
nuts.
(2) Locate tail pipe hangers and remove hex head bolts, flat washers and lock
(3) Remove tail pipe.
(b) Installation
(1) Align and install tail pipe to spark arrestor.
(2) Install band clamp, secure with flange bolt and flange nut.
(3) Locate tail pipe hanger and install hex head bolt, washer and new lock nut.
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T. ENGINE AND ENGINE COMPONENTS
1. Deutz Tier 2 Quick Engine Change (QEC)
(a) Removal

COMPONENTS TO COOL.
(2) Raise and support tractor on jack stands. Perform in accordance with standard
jacking procedure (Chapter 2, Section 1).
(3) Remove hood assembly in accordance with procedure.

(4) Drain engine oil from engine into 10 gallon container.

(6) Remove lower oil cooler hose from oil cooler and drain oil from oil cooler
and hose.
(7) Remove oil cooler and oil cooler hose from unit in accordance with
procedure.
(8) Disconnect throttle cable and transmission modulator cable from engine
throttle lever.
(9) Remove accelerator and modulator cable mount with throttle cable and
modulator attached from right side engine motor mount by removing hex
head bolts, lock washers and flat washers. Discard lock washers.
(10) Remove exhaust system header pipe in accordance with procedure.
(11) Disconnect drive shaft at transmission output flange in accordance with

procedure.
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Chapter 2
(12) Remove side transmission closeout panels and top transmission closeout
panel from inside the operators’ compartment.
(13) Remove park brake lever from transmission in accordance with procedure.
(14) Disconnect engine wiring harness from main harness at firewall by

unplugging electrical connectors. Tie main harness back to prevent snagging
on engine.
(15) Disconnect positive main battery cable.
(16) Disconnect transmission pressure interlock switch and braided ground cable.
(17) Disconnect neutral safety switch in accordance with neutral safety switch
removal procedure.

(18) Disconnect fuel hoses in accordance with fuel hose removal procedure.
(19) Disconnect shifter cable and cable mounting bracket from transmission in
accordance with shifter removal procedure.

(20) Disconnect transmission cooling hoses from the rigid transmission cooler
supply and return lines located on the frame rail.
(21) Remove transmission modulator cable from transmission end only in

accordance with procedure.

(22) Set hydraulic shut off ball valve to the closed position. Remove all hydraulic
hoses from hydraulic pump located on the engine in accordance with
hydraulic pump removal procedure. Capture Dexron III in drip pan.
(23) Remove hex head engine mounting bolts, motor mount safety washers, flat
washers and lock nuts that pass through the engine mounts and the rubber
isolator mounts on the unit frame. Discard lock nuts.
(24) Remove the transmission isolator top lock nuts and flat washers from the
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Chapter 2
bottom of the transmission crossmember. Remove exhaust header pipe hanger

from transmission crossmember by removing hex head bolt, flat washers and
lock nut. Discard lock nuts.
CAUTION: DO NOT ATTEMPT TO LIFT ENGINE/TRANSMISSION

OUT OF TRACTOR AT THIS TIME.
(25) Using hoist, load leveling device, and lifting chains prepare to remove engine
by attaching chains at the front engine lifting bracket and rear engine lifting
bracket.
(26) Remove transmission crossmember mounting hardware: hex head bolts, flat
washers, and lock nuts. Discard lock nuts.
WARNING: EXERCISE CARE; ENGINE AND TRANSMISSION WEIGH

APPROXIMATELY 850-1000 LBS.
CAUTION: BEFORE LIFTING ENGINE VERIFY ALL WIRING HAS

BEEN DISCONNECTED. WHILE LIFTING, ENSURE NO WIRES OR
HOSES ARE SNAGGED ON ENGINE/TRANSMISSION.
WARNING: GUIDE ENGINE AND TRANSMISSION DURING THE

REMOVAL PROCESS TO PREVENT DAMAGE TO ENGINE,
TRANSMISSION, HYDRO-BOOST ASSEMBLY AND INJURY TO
PERSONNEL.
(27) Adjust load-leveling device to raise the front of the engine. Raise engine/
transmission assembly out of tractor. Adjustment of the load-leveling device
will be required to further raise the front of the engine. The engine/
transmission assembly will need to be positioned at a downward angle,
around 30 degrees, to allow removal as an assembly. Continue to raise
engine/transmission with hoist until clear of the unit.
(28) Remove the following hang items from the discrepant engine and retain for
installation on replacement engine:
(i) Right side engine motor mount with hex head bolts, lock washer, flat
washer. Discard lock washers.
(ii) Left side engine motor mount with hex head bolt, lock washer, flat
(iii) Engine throttle lever with bolts, nut, lock washer. Discard lock
washer.
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Chapter 2
(iv) Throttle return spring.
(v) Front and rear engine lifting brackets with bolts, lock washers, and
flat washers. Discard lock washers.
(vi) Adapters.
(vii) Hydraulic pump in accordance with removal procedure.
(viii) Engine wire harness.
(29) As required, separate engine from transmission by removing transmission

hex head mounting bolts and lock washers, flat washers and brackets. Discard
lock washers.
Note NOTE: Flywheel may fall free when flywheel bolts and flywheel
reinforcement plate is removed.
(i) Locate flexplate and remove top lock nuts and flat washers. Discard
lock nuts.
(ii) Locate plate-flex plate reinforcement; remove flexplate bolts.
(iii) Remove plate-flexplate reinforcement and retain.
(iv) Remove flexplate and retain.
(v) Locate C6 to 2011 adaptor, remove screw and flat washers. Retain
screws and flat washers.
(vi) Remove C6 to 2011 adaptor and retain.
(vii) Locate drive adaptor with hardware; remove bolts that attach drive
adaptor to crankshaft. Retain bolts.
(viii) Remove drive adaptor and retain.
(b) Installation
(1) Prior to installation inspect/examine the following items for wear or damage,
replace as required.
(i) Oil cooler hoses.
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Chapter 2
(ii) Air cleaner hoses.
(iii) Transmission lines.
(iv) Fuel lines in accordance with procedure.
(v) Exhaust pipe gasket.
(vi) Rubber engine mounts.
(2) Install the following hang items:
(i) Right side engine motor mount with hex head bolt new lock washer,
and flat washer.
(ii) Left side engine motor mount with hex head bolt, new lock washer,
flat washer.
(iii) Engine throttle lever with hex head bolts, nuts, new lock washers.
(v) Front engine lifting bracket with socket head bolt and new lock
washer, hex head bolt with flat washer and new lock washer.
(vi) Rear engine lifting bracket with hex head bolts, flat washer and new
lock washers.
(vii) Adapters.
(viii) Hydraulic pump in accordance with installation procedure.
(ix) Engine wire harness.
(3) Install drive adaptor to crankshaft with bolts.
(4) Tighten drive adaptor bolts to 70 ft-lbs of torque.
(5) Install C6 to 2011 adaptor on engine and secure with low head socket cap
(6) Install flexplate on to drive adaptor.
(7) Position flexplate reinforcement plate on flexplate.
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Chapter 2
(8) Install and tighten flexplate bolts to 60 ft-lbs of torque.
(9) Using visual placement, rotate torque converter until mounting holes will line
up approximately with holes in flexplate. Position transmission in place
behind engine, leaving an inch or so gap between torque converter and flex
plate.
(10) From the bottom, loosely thread new lock nuts with flat washers onto torque
converter studs that pass through holes in the flexplate, rotate flexplate/torque
converter to allow access to all four mounting locations.
(11) Slide transmission into final place, making sure that engine mounting holes
and transmission housing holes align properly.
(12) Position brackets on transmission.
(13) Thread transmission housing bolts with new lock washers and flat washers
(for brackets installation only) into place tightening transmission housing
bolts to just hand tight, skipping two bolts in alternating pattern until all bolts
are snug.
(14) Using the same pattern as mentioned above, tighten transmission housing
bolts to 45 ft-lbs of torque.
(15) Tighten first new top lock nut on torque converter. Rotate 180 degrees,
tighten second nut. Rotate 90 degrees; tighten third new top lock nut. Rotate
180 degrees; tighten forth new top lock nut. Using the identical pattern,
torque all nuts to 30 ft-lbs of torque.
(16) Reinstall flexplate closeout; secure with bolts new lock washers and flat
washers.
(17) Using hoist, load leveling device, and lifting chains prepare to install engine
by attaching chains at the front and rear engine lifting brackets.
CAUTION: GUIDE ENGINE AND TRANSMISSION DURING THE

INSTALLATION PROCESS TO PREVENT DAMAGE TO ENGINE,
TRANSMISSION, HYDRO BOOST ASSEMBLY AND INJURY TO
PERSONNEL.
(18) Install engine and transmission into tractor.
(19) Reinstall transmission crossmember and secure with hex head bolts flat
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Chapter 2
(20) Install new transmission isolator lock nuts and washers from the bottom of
the transmission crossmember.
(21) Reinstall engine mounting bolts, motor mount safety washers, washers and
new lock nuts that pass through the engine mounts and the rubber isolator
mounts on the unit frame.
(22) Install transmission modulator cable to transmission end only in accordance

with modulator cable installation procedure.
(23) Reconnect transmission cooling hoses to the rigid transmission cooler supply
and return lines located on the frame rail.
(24) Reconnect shifter cable and cable mounting bracket to transmission in

accordance with shifter installation procedure.
(25) Reconnect fuel hoses in accordance with fuel hose installation procedure.
(26) Reconnect transmission pressure starter interlock switch, braided ground

cable and neutral safety switch in accordance with neutral safety switch
installation procedure.
(27) Connect positive battery cable.
(28) Reconnect engine wiring harness to main harness at firewall by plugging in

electrical connectors.
(29) Reinstall all hydraulic hoses to hydraulic pump located on the engine and set
hydraulic shut off ball valve to the open position in accordance with
hydraulic pump installation procedure.
(30) Reinstall park brake lever to transmission in accordance with park brake lever
(31) Reconnect drive shaft at transmission output flange in accordance with drive
shaft installation procedure.
(32) Reinstall exhaust system header pipe in accordance with procedure.
(33) Reinstall accelerator and modulator cable mount to right side engine mount
with cables attached. Secure with hex head bolts, new lock washers, and flat
washers.
(34) Reconnect throttle cable and transmission modulator cable to throttle cable
studs on engine throttle lever.
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Chapter 2
(35) Reinstall oil cooler and oil cooler hoses and in accordance with procedure.
(36) Reinstall air cleaner assembly in accordance with procedure.
(37) Reinstall hood assembly in accordance with procedure.
(39) Install side transmission closeout panels and top transmission closeout panel
inside the operators’ compartment.
(40) Remove jack stands and lower tractor in accordance with standard jacking
(41) Check and add fluids as appropriate:
(i) Engine oil.
(ii) Transmission fluid.
(iii) Fuel.
(42) Adjust park brake in accordance with procedure (Chapter 2, Section 1).
(43) Start tractor, check for leaks and normal operating conditions.
2. Deutz Tier 4i Quick Engine Change (QEC)
(a) Removal

COMPONENTS TO COOL.

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Chapter 2
(4) Drain engine oil from engine into 10 gallon container.

(6) Remove lower oil cooler hose from oil cooler and drain oil from oil cooler
and hose.
(7) Remove oil cooler and oil cooler hose from unit in accordance with
procedure.
(8) Disconnect accelerator harness plug P29 from engine harness.

procedure.
(12) Remove park brake cable from transmission by removing cotter and clevis
pin from the park brake drum yoke. Discard cotter pin.

on engine.
removal procedure.

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Chapter 2
CAUTION: DISPOSE OF MERCON V IN ACCORDANCE WITH LOCAL



bracket.



PERSONNEL.
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Chapter 2
(iii) Engine throttle lever with bolts, nut, lock washer. Discard lock
washer.
(iv) Adapters.
(v) Hydraulic pump in accordance with removal procedure.
(vi) Engine wire harness.

lock washers.
NOTE: Flywheel may fall free when flywheel bolts and flywheel
Note
lock nuts.
(v) Locate 4R75 to flywheel adaptor, remove screw and flat washers.
Retain screws and flat washers.
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Chapter 2
(vi) Remove 4R75 to flywheel adaptor and retain.
(b) Installation
(i) Oil cooler hoses.
and flat washer.
flat washer.
(iii) Adapters.
(iv) Hydraulic pump in accordance with installation procedure.
(v) Engine wire harness.
(5) Install 4R75 to flywheel adaptor on engine and secure with low head socket
cap screws and flat washers.
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Chapter 2
plate.
are snug.
washers.

PERSONNEL.
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Chapter 2
(23) Reconnect shifter cable to transmission in accordance with shifter installation

procedure.


29) Reconnect park brake cable to transmission using clevis and new cotter pin.
(32) Reconnect accelerator harness plug P29 with engine harness.
(33) Reinstall oil cooler and oil cooler hoses and in accordance with procedure.
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Chapter 2
(i) Engine oil.
(iii) Fuel.
3. Kubota Quick Engine Change (QEC)
(a) Removal

COMPONENTS TO COOL.

(4) Drain engine coolant engine into 10 gallon container.
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Chapter 2

(6) Open drain valve on the bottom of radiator and drain coolant from radiator.
(7) Disconnect coolant hoses and overflow bottle tube from engine.
(8) Remove radiator and radiator hoses from unit in accordance with procedure.
(9) Disconnect throttle cable and transmission modulator cable from engine
throttle lever.
(10) Remove accelerator and modulator cables from cable mount bracket

procedure.
14) Remove park brake lever from transmission in accordance with procedure.

on engine.
removal procedure.


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Chapter 2
(22) Remove transmission modulator cable from transmission end only in



bracket.



PERSONNEL.
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Chapter 2
(iii) Engine accelerator arm with modulator slide stud and joint bolt.
(v) Throttle return spring bracket
(vi) Cable mount bracket
(vii) Radiator filler neck mount with radiator filler neck, bolts and lock
(viii) Adapters.
(ix) Hydraulic pump in accordance with removal procedure.
(x) Engine wire harness.

lock washers.
Note NOTE: Flywheel may fall free when flywheel bolts and flywheel
lock nuts.
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Chapter 2
(v) Locate C6 to flywheel adaptor, remove screw and flat washers.

Retain screws and flat washers.
(vi) Remove C6 to flywheel adaptor and retain.
(b) Installation
(i) Radiator hoses and overflow bottle tube.
and flat washer.
flat washer.
(iii) Engine accelerator arm with modulator slide stud and joint bolt.
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Chapter 2
(v) Throttle return spring bracket
(vi) Cable mount bracket.
(vii) Radiator filler neck mount with radiator filler neck, bolts and lock
(viii) Adapters.
(ix) Hydraulic pump in accordance with installation procedure.
(x) Engine wire harness.
(5) Install C6 to flywheel adaptor on engine and secure with low head socket cap
plate.
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Chapter 2
are snug.
washers.

PERSONNEL.
(22) Install transmission modulator cable to transmission end only in accordance

with modulator cable installation procedure.
(24) Reconnect shifter cable and cable mounting bracket to transmission in
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Chapter 2
accordance with shifter installation procedure.


(30) Reinstall park brake lever to transmission in accordance with park brake lever
(33) Reinstall accelerator and modulator cables on cable mount bracket.
(34) Reconnect throttle cable and transmission modulator cable to throttle cable
studs on engine throttle lever.
(35) Reinstall radiator and radiator hoses and in accordance with procedure.
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Chapter 2
(i) Coolant.
(iii) Fuel.
4. Engine Mounts
(a) Removal

COMPONENTS TO COOL.
(3) Attach lifting chain to hoist and front engine lifting bracket located on front
of engine cylinder head.
(4) Locate left and right motor mount, remove bolts, flat washers, safety washers,
and lock nuts. Discard lock nuts.
(5) Locate transmission isolator mount. Remove lock nuts and flat washers.
Discard lock nuts.
NOTE: The engine will need to be raised about 3 inches to gain access to the
rubber engine mounts.
Note
(6) Slowly raise front of engine with hoist in order to gain access to the rubber
engine mounts.
(7) Locate rubber engine mount, remove bolts, lock washers and flat washers.
(8) Remove rubber engine mount.
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Chapter 2
(b) Installation
(1) Position rubber engine mounts; install hex head bolts, new lock washers and
flat washers.
(2) Lower engine so that engine brackets just make contact with the rubber
engine mounts so that the mounting holes can be aligned for hex head bolts.
(3) Install hex head bolts, flat washers, safety washers, and new lock nuts.
Tighten hex head bolts and new lock nuts to 60 ft-lbs of torque.
5. Fan
(a) Removal

COMPONENTS TO COOL.
CAUTION: CARE MUST BE TAKEN DURING THE REMOVAL OF THE

FAN NOT TO CAUSE DAMAGE TO THE OIL COOLER.
(2) Locate fan and remove bolts and fan washers.
NOTE: Hidden fan washer may fall free from fan.

Note
(3) Remove fan from fan spacer hub.
(b) Installation
(1) Position fan washers on to front and rear of fan position one bolt through fan
and fan washers and align them onto the fan spacer hub.
(2) Install bolts.
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Chapter 2
6. Flexplate
(a) Removal
(1) Remove engine in accordance with procedure.
(2) Separate engine from transmission in accordance with procedure.
(3) Locate flexplate and flexplate reinforcement plate, remove bolts.
(4) Remove flexplate and flexplate reinforcement plate.
(b) Installation
(1) Align flexplate reinforcement plate on flexplate.
(2) Position flexplate reinforcement plate and flexplate on to drive adaptor,

install flexplate bolts.
(3) Install transmission and engine in accordance with procedure.
7. Glow Plug
(a) Removal

COMPONENTS TO COOL.
(2) Locate glow plug in engine intake manifold.
(3) Disconnect glow plug wire.
(4) Remove and discard failed glow plug and glow plug sealing washer.
(b) Installation
(1) Install new glow plug and new glow plug sealing washer into mounting hole
in intake manifold.
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Chapter 2
(2) Torque glow plug to 44 ft-lbs of torque.
(3) Connect glow plug wire.
8. Oil Filter Element
(a) Removal

COMPONENTS TO COOL.
Note NOTE: Ensure rubber seal need not remain on oil filter head.
(1) Locate oil filter element, unscrew to remove.
(2) Remove oil filter element by turning counter clockwise.
(3) Remove oil filter element. Discard oil filter element.
(b) Installation
(1) Wipe sealing surface clean using a lint-free cloth and apply a light film of oil
to the new oil filter element’s rubber seal.
(2) Position oil filter element to oil filter head, screw hand tight to install.
(3) Refill engine with engine oil as required.
9. Oil Pan
(a) Removal

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Chapter 2
(2) Drain oil from engine into drain pan.
(3) Locate oil pan, remove bolts.
(4) Remove oil pan.
(b) Installation
(1) Completely clean old RTV from the sealing surface of the oil pan and engine.
(2) Apply RTV compound to edge of oil pan forming a sealing gasket.
(3) Position oil pan and install bolts.
(4) Ensure engine oil drain valve is secure.
(5) Service with engine oil.
(6) Check for leaks.
(7) Lower tractor in accordance with standard jacking procedure (Chapter 2,

Section 1).
10. Oil Pressure Sender
(a) Removal
(2) Tag and disconnect wire from the oil pressure sending unit terminal. Unscrew
the oil pressure sending unit from its mounting.
(b) Installation
(1) Apply loctite to housing screw threads and install oil pressure sending unit by
screwing into its mounting hole on the engine housing and connect the wire
to the oil pressure sending unit terminal.
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Chapter 2
11. Oil Temperature Sender (Deutz)
(a) Removal
(2) Disconnect wire from temperature sender terminal and unscrew the
temperature sender from its mounting (tag and remove lead from unit).
(b) Installation
(1) Apply thread sealer to housing screw threads and install temperature sender
by screwing into its mounting hole on the engine housing and connect the
wire to the temperature sender terminal.
12. Coolant Temperature Sender (Kubota)
(a) Removal
(2) Disconnect wire from temperature sender terminal and unscrew the
temperature sender from its mounting (tag and remove lead from unit).
(b) Installation
(1) Apply thread sealer to housing screw threads and install temperature sender
by screwing into its mounting hole on the engine housing and connect the
wire to the temperature sender terminal.
13. Thermostat
(a) Removal
(2) Clean area around plug on engine with a shop rag.
(3) Remove plug and seal O-ring. Discard O-ring.
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Chapter 2
(4) Carefully remove thermostat and compression spring.
(b) Installation
Note NOTE: Ensure O-ring sealing surface is free from dirt and debris.
(1) Install thermostat and compression spring.
(2) Install new O-ring on to plug.
(3) Install plug, tighten plug to 56 ft-lbs of torque.
U. TRANSMISSION ASSEMBLY
1. Filter Screen
(a) Removal
(1) Raise and support the tractor on jack stands in accordance with standard

(2) Place drain pan under transmission and loosen transmission oil pan bolts,
drain oil from transmission.
(3) Remove oil pan bolts, transmission oil pan and oil pan gasket. Discard oil
pan gasket.
(4) Remove screws that attach the transmission filter screen to the lower valve
body assembly.
(5) Remove and discard transmission filter screen and transmission filter screen
gasket.
(b) Installation
(1) Install new transmission filter screen and new transmission filter screen
gasket, secure with screws.
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Chapter 2
CAUTION: USE CARE WHEN CLEANING, AS NOT TO NICK OR

GOUGE THE SEALING/MOUNTING SURFACE.
(2) Clean transmission oil pan and transmission oil pan gasket surfaces
thoroughly.
(3) Install transmission oil pan and oil pan gasket, secure with oil pan bolts to the
transmission case. Tighten oil pan bolts to 10 ft-lbs of torque.
procedure (Chapter 2, Section 1). Service transmission to the correct fluid
level with Dexron III transmission fluid (C6) or MERCON V (4R75).
(5) Return tractor to readiness condition.
2. Shifter Assembly
(a) Removal
(1) Locate shifter.
(2) Remove hex head bolts, lock washers and flat washers from shifter mount.
(3) Carefully raise the shifter from shifter mount to gain access to the cable
clamp anchor.
(4) Disconnect cable clamp anchor holding shifter cable in place below the
shifter by removing hex head bolts and lock nuts.
(5) Move shifter handle forward or backward until cable ball joint is in the
lowest accessible position and mark the hole location of the ball joint.
(6) Disconnect cable ball joint from shifter by removing cotter pin and pulling
ball joint free of the shifter.
(7) Remove light socket and shifter illumination bulb by pulling light socket out
of receptacle.
(8) Remove and discard failed shifter.
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Chapter 2
(b) Installation
(1) Ensure parking brake is set.
(2) Position the shifter just above the mounting point on the seat plate so that
“PARK” indicator is in the forward-most position. Slide shifter into position.
(3) Insert light socket with shifter illumination bulb into light socket receptacle
on base of shifter.
NOTE: If shifter is new, locate comparable cable mounting hole from the
Note removal procedures above.
(4) Move shifter handle forward or backwards until marked hole location for
cable ball joint is visible and accessible.
(5) Attach cable end ball joint to shifter through marked hole, entering from the
right side and secure with cotter pin.
(6) Install cable clamp anchor holding shifter cable in place below the shifter and
secure with hex head bolts and lock nuts.
(7) Slide shifter into shifter mount aligning the mounting holes and secure with
hex head bolts, new lock washer and flat washer.
(8) Start engine and test all shifter positions to ensure that shifting motion is
smooth and that forward and reverse engage properly. If they do not, the
cable must be adjusted up or down at the cable bracket anchor point below
the shifter.
(9) Check that the shifter handle lands at the correct markers on the shifter base
when gears are engaged. If not, move the cable attachment ball joint over in
one direction or the other.
(c) Bulb Replacement
(1) Locate shifter.
(3) Carefully raise the shifter from shifter mount to gain access to the light
socket.
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Chapter 2
(4) Remove light socket and shifter illumination bulb by pulling light socket out
of receptacle.
(5) Remove shifter illumination bulb from light socket by holding the socket
with one hand and pulling on the shifter illumination bulb with the other.
Discard failed shifter illumination bulb.
(6) Install new shifter illumination bulb into light socket.
(7) Insert light socket with shifter illumination bulb into light socket receptacle
on base of shifter.
hex head bolts, new lock washers and flat washers.
3. Shifter Cable
(a) Removal
WARNING: ENSURE TRACTOR IS POSITIONED SECURELY ON JACK

STANDS. TRACTOR COULD FALL, CAUSING SERIOUS BODILY
INJURY OR DEATH.
(2) Locate shifter.
(4) Carefully raise the shifter from shifter mount to gain access to the cable
bracket anchor.
(5) Disconnect cable bracket anchor holding shifter cable in place below the
shifter by removing hex head bolts and lock nuts. Discard lock nuts.
(6) Move shifter handle forward or backward until cable ball joint is in the
lowest accessible position and mark the hole location of the ball joint.
(7) Disconnect cable ball joint from shifter by removing cotter pin attached to the
cable ball joint and pulling ball joint free of the shifter. Discard cotter pin.
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Chapter 2
(8) Remove light socket and bulb by pulling light socket out of receptacle.
(9) Remove shifter and retain.
(10) Locate shifter cable attached to the transmission gear selector lever.
(11) Release shifter cable from U-bolt and cable clamp shim by removing nuts
and flat washers. Retain U-bolt, cable clamp shim, nuts and flat washers for
installation of new cable.
(12) Disconnect shifter cable from transmission gear selector lever by removing
cotter pin from pivot and pulling pivot free. Discard cotter pin.
(13) Remove and discard failed shifter cable.
(b) Installation
(1) Feed one end of shifter cable through the shifter mount from the cab area to
beneath the tractor in the transmission area.
(2) Attach shifter cable to transmission gear selector lever by placing pivot
through selector lever and secure with new cotter pin.
(3) Place shifter cable between cable clamp shim and U-bolt and secure U-bolt to
mounting bracket with nuts and flat washers.
(4) Position the shifter just above the mounting point on the seat plate so that
“PARK” indicator is in the forward-most position. Slide shifter into position.
Note NOTE: If shifter is new, locate comparable cable mounting hole from the
removal procedures above.
(5) Move shifter handle forward or backwards until marked hole location for
cable ball joint is visible and accessible.
(6) From underneath tractor, access transmission and move shifter lever on
transmission to center or neutral position. To locate neutral position rotate
shifter lever on transmission clockwise until it can no longer rotate, this is the
park position. Then slowly rotate shifter lever counter-clockwise two
positions. It will now be in the neutral position.
(7) Mount cable ball joint into marked hole, entering from the right side. Attach
new cotter pin on to ball joint.
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Chapter 2
(8) Install cable bracket anchor holding shifter cable in place below the shifter
and secure with hex head bolts and new lock nuts.
(9) Insert light socket with bulb into light socket receptacle on base of shifter.
hex head bolts, new lock washers and flat washers.
(11) Start engine and test all shifter positions to ensure that shifting motion is
smooth and that forward and reverse engage properly. If they do not, the
cable must be adjusted up or down at the cable clamp anchor point below the
shifter.
(12) Check that the shifter handle lands at the correct markers on the shifter base
when gears are engaged. If not, move the cable attachment ball joint over in
one direction or the other.
4. Transmission C6.
(a) Removal
(1) Chock wheels, place shifter into “NEUTRAL” position and disengage
parking brake.

INJURY OR DEATH.
(4) Remove parking brake lever in accordance with procedure .
(5) Disconnect shifter cable from transmission shift lever in accordance with
shifter cable removal procedure.

(6) Disconnect modulator cable from transmission in accordance with modulator

cable removal procedure.
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Chapter 2
(7) Remove transmission oil cooler hoses in accordance with rubber reducer hose
removal procedure.
(8) Remove drive shaft assembly in accordance with procedure.
(9) Disconnect neutral safety switch and transmission pressure switch electrical
connections from main wiring harness.

(10) Drain the transmission fluid from the transmission into a drain pan by
loosening the transmission oil pan bolts and breaking the transmission oil pan
loose by tapping on one corner of the transmission oil pan.
(11) Position transmission jack under transmission to support weight of

transmission.
WARNING: ENSURE TRANSMISSION IS POSITIONED SECURELY ON

TRANSMISSION JACK. TRANSMISSION COULD FALL, CAUSING
SERIOUS BODILY INJURY.
(12) Remove lock nuts and flat washers from transmission isolator studs, under
the transmission crossmember. Discard lock nuts.
(13) Remove hex head bolts, flat washers and lock nuts from transmission
crossmember. Discard lock nuts.
(14) Remove the transmission crossmember and retain for reinstallation.
(15) Gain access to torque converter by removing flexplate closeout from bottom
front of transmission housing. Remove hex head bolts, lock washers and flat
(16) Access torque converter. Remove one of four lock nuts and one of four flat
washers attaching torque converter to the flexplate. Rotate torque converter
until next lock nut and next flat washer is accessible, remove lock nut. Repeat
procedure to remove remaining lock nuts. Discard lock nuts.
(17) Remove hex head bolts and lock washers that attach the transmission to the
engine. Discard lock washers.
(18) Slide transmission back away from engine, lower transmission jack and
remove from tractor.
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(b) Installation
(1) Jack transmission into place.
behind engine, leaving an inch or so gap between torque converter and
flexplate.
(4) From beneath the tractor, loosely new thread lock nuts with flat washers onto
torque converter studs that pass through holes in the flexplate, rotate
flexplate/torque converter to allow access to all four mounting locations.
(5) Reinstall transmission crossmember and secure with hex head bolts, flat
(6) Thread transmission housing bolts with new lock washers into place. On
transmission housing, begin tightening bolt to just hand tight, skipping two
bolts in alternating pattern until all bolts are snug. Using the same pattern,
tighten transmission housing bolts to 45 ft-lbs of torque.
(7) Attach transmission mount isolator to transmission crossmember, secure with

lock nuts and flat washers.
(8) Remove transmission jack from beneath the tractor.
(9) Tighten first lock nut on torque converter. Rotate 180 degrees, tighten second
lock nut. Rotate 90 degrees, tighten third lock nut. Rotate 180 degrees,
tighten forth lock nut. Using the identical pattern, torque all lock nuts to 30
ft-lbs of torque.
(10) Install flex plate closeout, bolts, flat washers, and new lock washers.
(11) Install drive shaft assembly in accordance with procedure.
(12) Install parking brake mechanism in accordance with park brake installation
procedure.
(13) Reconnect shifter cable to transmission shift lever with accordance with
shifter cable installation procedure.
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(14) Reconnect modulator cable to transmission in accordance with modulator

cable installation procedure.
(15) Attach transmission oil cooler hoses in accordance with rubber reducer hose
(16) Reconnect neutral safety switch and transmission pressure switch electrical
connectors to main wiring harness.
(18) Service transmission to the correct fluid level with Dexron III transmission
fluid.
(19) Remove tractor from jack stands and return tractor to readiness condition.
Perform in accordance with standard jacking procedure (Chapter 2, Section
1).
5. Transmission 4R75.
(a) Removal
(1) Chock wheels, place shifter into “NEUTRAL” position and disengage
parking brake.

INJURY OR DEATH.
(4) Disconnect parking brake cable by pulling cotter pin, then clevis pin from
parking brake yoke at transmission. Discard cotter pin.
(5) Disconnect shifter cable from transmission shift lever in accordance with
shifter cable removal procedure.

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(6) Remove transmission oil cooler hoses in accordance with rubber reducer hose
removal procedure.
(7) Remove drive shaft assembly in accordance with procedure.
(8) Disconnect neutral safety switch and transmission pressure switch electrical
connections from main wiring harness.
CAUTION: DISPOSE OF MERCON V IN ACCORDANCE WITH LOCAL

(9) Drain the transmission fluid from the transmission into a drain pan by
loosening the transmission oil pan bolts and breaking the transmission oil pan
loose by tapping on one corner of the transmission oil pan.
(10) Position transmission jack under transmission to support weight of

transmission.
WARNING: ENSURE TRANSMISSION IS POSITIONED SECURELY ON

TRANSMISSION JACK. TRANSMISSION COULD FALL, CAUSING
SERIOUS BODILY INJURY.
(11) Remove lock nuts and flat washers from transmission isolator studs, under
the transmission crossmember. Discard lock nuts.
(12) Remove hex head bolts, flat washers and lock nuts from transmission
crossmember. Discard lock nuts.
(13) Remove the transmission crossmember and retain for reinstallation.
(14) Gain access to torque converter by removing flexplate closeout from bottom
front of transmission housing. Remove hex head bolts, lock washers and flat
(15) Access torque converter. Remove one of four lock nuts and one of four flat
washers attaching torque converter to the flexplate. Rotate torque converter
until next lock nut and next flat washer is accessible, remove lock nut. Repeat
procedure to remove remaining lock nuts. Discard lock nuts.
(16) Remove hex head bolts and lock washers that attach the transmission to the
engine. Discard lock washers.
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(17) Slide transmission back away from engine, lower transmission jack and
remove from tractor.
(b) Installation
(1) Jack transmission into place.
(2) Using visual placement, rotate torque converter until mounting holes will
line up approximately with holes in flexplate. Position transmission in place
behind engine, leaving an inch or so gap between torque converter and
flexplate.
(4) From beneath the tractor, loosely new thread lock nuts with flat washers onto
torque converter studs that pass through holes in the flexplate, rotate
flexplate/torque converter to allow access to all four mounting locations.
(5) Reinstall transmission crossmember and secure with hex head bolts, flat
(6) Thread transmission housing bolts with new lock washers into place. On
transmission housing, begin tightening bolt to just hand tight, skipping two
bolts in alternating pattern until all bolts are snug. Using the same pattern,
tighten transmission housing bolts to 45 ft-lbs of torque.
(7) Attach transmission mount isolator to transmission crossmember, secure with

lock nuts and flat washers.
(8) Remove transmission jack from beneath the tractor.
(9) Tighten first lock nut on torque converter. Rotate 180 degrees, tighten second
lock nut. Rotate 90 degrees, tighten third lock nut. Rotate 180 degrees,
tighten forth lock nut. Using the identical pattern, torque all lock nuts to 30
ft-lbs of torque.
(10) Install flex plate closeout, bolts, flat washers, and new lock washers.
(11) Install drive shaft assembly in accordance with procedure.
(12) Reconnect parking brake cable to cam and lever assembly by clevis and new
cotter pins.
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(13) Reconnect shifter cable to transmission shift lever with accordance with
shifter cable installation procedure.
(14) Attach transmission oil cooler hoses in accordance with rubber reducer hose
(15) Reconnect neutral safety switch and transmission pressure switch electrical
connectors to main wiring harness.
(17) Service transmission to the correct fluid level with Dexron III transmission
fluid.
1).
6. Transmission Band Adjustment C6.
(a) Removal

INJURY OR DEATH.
(2) Clean all debris from the band adjustor.
(3) Remove band adjustor nut.
(b) Installation
(1) Install band adjustor nut and tighten the band adjustor to 10 ft-lbs of torque.
(2) Back off the band adjustor exactly 1 ½ turns.
(3) Hold the band adjustor from turning and tighten the band adjustor nut to 40
ft-lbs of torque.
1).
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7. Neutral Safety Switch C6.
(a) Removal

INJURY OR DEATH.
(2) Disconnect negative battery cable
(3) Place shifter on "N" posityion.
(4) Locate safety switch on transmission
(5) Disconnect neutral safety switch electrical connector from main harness.
(6) Remove transmission gearshift lever by removing hex head bolts and lock
(7) Remove lock nut and lock washer, remove hex head bolts, lock washers and
flat washers. Discard lock washers
(8) Remove neuteral switch
(b) Installation
(1) Insert paper clip end into the small hole on the face of neutral sefety switch.
(2) Turn central part of switch either direction, while publishing on paper clip,
unit it passes completely through the neutral safety switch.
(3) While paper clip is still inserted, insral neutral safety switch on to
transmission. Secure with flat washers, new lock washers and hex head bolts.
(4) Remove paper clip.
(5) Reconnect neutral safety switch electrical connector with transmission

pressure switch wire to main harness.
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(6) Install new lock nut and new lock washer. Install transmission gear select
lever and secure by hex head bolt, new lock nut, hex head bolt and new lock
nut.
(8) Test operation of neutral safety switch.
(9) With shifter in park or neutral position, start engine.
V. FRONT AXLE, SUSPENSION, AND WHEELS
1. Axle Assembly
(a) Removal
(2) Remove front wheel assemblies in accordance with procedure.

(3) Disconnect front disc brake hoses from calipers in accordance with caliper
assembly removal procedure.
(4) Using a floor jack, support the front steer axle. Entering from either wheel
well, place floor jack at center of front steer axle and jack up until floor jack
is supporting only the weight of the front steer axle.
(5) Close hydraulic shutoff valve on bottom of the hydraulic reservoir.

(6) Disconnect the hydraulic hoses from the steering cylinder and cap off in
accordance with steering cylinder removal procedure.
(7) Remove axle U-bolts by removing lock nuts, flat washers, and spring clamp
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plates. Discard U-bolts and lock nuts.
(8) Slowly lower the front steer axle to the floor and roll jack out from tractor
until front steer axle clears tractor frame.
(9) Remove steering cylinder in accordance with procedure and retain.
(b) Installation
NOTE: Tie rod should be on the rearward side of axle assembly.

Note
(1) Center and balance front steer axle on floor jack in front of elevated tractor.
(2) Roll front steer axle assembly into place under front of tractor and slowly
raise front steer axle into position.
NOTE: Plates on top of axle must align to center of spring.

Note
(3) Install new axle u-bolts securing with spring clamp plate on top of leaf spring
and flat washers. Thread new lock nuts in place. Tighten lock nuts gradually
in a diagonal pattern until snug.
(4) Torque lock nuts to 50 ft.-lb of torque.
(5) Attach front brake hoses to calipers and tighten brake hose bolts securely in
accordance with caliper assembly installation procedure.
(6) Install steer cylinder in accordance with procedure.
(7) Attach front wheels in accordance with procedure.
2. Front Wheel Assembly
(a) Removal
CAUTION: DO NOT REMOVE HUB NUT. HUB NUT IS REMOVED FOR

AXLE OR BRAKE REPAIR ONLY.
(2) Remove lug nuts.

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(3) Remove tire and wheel front assembly.
(b) Installation
(1) Position tire and wheel front assembly on to hub.
(2) Install lug nuts and tighten to 125 ft-lbs of torque in a criss-cross pattern.
3. Brake Rotor and Hub Assembly
(a) Removal
(3) Start with the driver’s side front brake rotor. Remove the brake calipers in
accordance with front brake calipers removal procedure.
(4) Remove the grease cap from wheel hub.
(5) Remove the cotter pin from the spindle nut, remove spindle nut and tongued
spindle washer. Discard cotter pin.
CAUTION: THE HUB AND ROTOR ASSEMBLY IS HEAVY. TAKE CARE

TO AVOID DROPPING AS IT MAY CAUSE DAMAGE TO ASSOCIATED
COMPONENTS.
(6) Carefully slide the hub and rotor sub assembly off knuckle weldment and
spindle.
(7) Remove the wheel studs by pressing them out with hydraulic press.
(8) Separate brake rotor and hub.
NOTE: Brake rotor thickness shall not be less than 0.885 -inch.
Note
(9) Inspect rotor to determine if machining is required. Use a micrometer to
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measure the thickness of the brake rotor. If brake rotor thickness is less than
0.885 -inch, discard brake rotor.
(10) Inspect bearings and bearing races; replace as required.
(b) Installation
NOTE: If brake rotor has be machined to re-establish a smooth surface

ensure brake rotor thickness is not less than 0.885 -inch using a micrometer.
Note
(1) Install wheel studs by pressing them into brake rotor with hydraulic press.
(2) Install hub on to brake rotor.
(3) Using lithium based grease pack/repack inner wheel bearing and align it into
the hub.
(4) Set hub and rotor sub-assembly on to the spindle.
(5) Using lithium grease pack/repack outer wheel bearing and align it into the
hub and rotor sub-assembly.
(6) Install tongued spindle washer and spindle nut.
(7) Slowly rotate hub and rotor assembly tighten spindle nut to 15 ft-lbs of
torque to seat the bearings. Loosen the spindle nut ¼ turn.
(8) Install new cotter pin, if required, tighten the spindle nut slightly to align
castle and spindle hole.
(9) Install grease cap.
(10) Install the brake calipers in accordance with procedure.
(11) Install the front wheel assemblies in accordance with procedure.
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W. DRIVE SHAFT, DRIVE AXLE AND WHEELS
1. Drive Shaft
(a) Removal
NOTE: Once supported on jack stands, disengage parking brake.

Note
(2) Remove drive axle access panel to gain access to the drive shaft saddle bolts
by removing hex head bolts, lock washers and flat washers. Discard lock
washers.
(3) From underneath the unit, remove drive shaft saddle bolts, lock washers and
U-joint cap from transmission output flange. Discard lock washer.
WARNING: SUPPORT WEIGHT OF DRIVE SHAFT WITH A FLOOR

JACK. FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR
DAMAGE TO THE EQUIPMENT.
(4) Remove drive shaft rear section mounting hex head bolts and lock nuts
attaching drive shaft flange yoke end to the reduction gear drop box input.
Discard lock nuts.
(5) Remove drive shaft.
(b) Installation
(1) Position rear section of drive shaft flange to the reduction gear drop box input
and install new hex head bolts and new lock nuts to attach the drive shaft;
torque hex head bolts to 60 ft-lbs.
(2) Position front U-joint into transmission output flange.
(3) Install U-joint cap on to transmission output flange, install drive shaft saddle
bolts and new lock washers torque to 25 ft-lbs.
(4) Lubricate drive shaft in accordance with lubrication procedures (Chapter 2,

Section 1).
(5) Install drive axle access panel with hex head bolts, new lock washers and flat
washers.
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2. Drive Axle
(a) Removal
(1) Raise the tractor in accordance with standard jacking procedure (Chapter 2,
Section 1).
(2) Remove rear wheels in accordance with procedure.
(3) Disconnect and remove the drive shaft from the reduction gearbox in

(4) Disconnect brake hose from tee at the center of the axle and drain brake fluid
from brake hose into drain pan. Cap brake hose.
(5) Plug tee.
(6) Support rear axle cradle with a floor jack.
NOTE: It is not necessary to remove the lower limiting chain hex head
mounting bolts.
Note
(7) Locate spring mount and remove upper cradle limiting chains with upper
chain brackets, remove hex head bolts, flat washers, and lock nuts. Discard
lock nuts.
(8) Remove shock absorbers, upper mounting hardware, and lower mounting hex
head bolts, flat washers and lock nuts. Discard lock nut.
(9) Remove forward cradle pivot bolts, flat washers, and lock nuts. Discard lock
nuts.
(10) Lower rear axle cradle by lowering the jack so that the cradle assembly can
be rolled out from under the tractor frame. Remove coil springs from rear
axle cradle.

(11) Remove brake lines from fittings. Drain brake fluid from lines into drain pan.
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(12) Remove hex head bolt and lock washer. Discard lock washer.
(13) Remove bracket with tee and brake lines still attached.
(14) Remove brake line fittings and adapters from drive axle and retain.
CAUTION: AXLE MOUNT PLATE MAY FALL FREE WHEN AXLE

MOUNTING HEX HEAD BOLTS ARE REMOVED.
(15) Remove axle mounting hex head bolts flat washers lock nuts and axle mount
plates. Discard lock nuts.
(16) Using hoist, remove the rear axle from the rear axle cradle.
(b) Installation
(1) If required, raise and support tractor on jack stands in accordance with
standard jacking procedure (Chapter 2, Section 1).
(2) Using hoist, position drive axle on to the rear axle cradle.
(3) Position drive axle mount plates on drive axle.
NOTE: Do not fully tighten axle mounting hex head bolts at this time.
Note
(4) Install axle mounting hex head bolts, flat washers, new lock nuts and axle
mount plates.
(5) Install brake lines fittings and adapters onto drive axle. Port must face toward
the rear.
(6) Install brake lines with tee and bracket. Secure with hex head bolt and new
lock washer.
(7) Connect brake lines to brake fittings.
(8) Install shock absorbers onto the rear axle cradle. Secure with hex head bolts,
flat washers, and new lock nuts.
(9) Place coil springs over shock absorbers so that they rest on the rear axle
cradle within the spring cups welded to the rear axle cradle.
(10) Position rear axle cradle and drive axle under tractor.
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(11) Lift rear axle cradle into position using a floor jack.
NOTE: Attention to alignment is required.

Note
NOTE: Ensure shock absorbers and coil springs are aligned with mounting
points in upper mounts.
Note
(12) Position rear axle cradle and align cradle pivot tube to front frame mounts
and rear axle cradle just below shock absorbers.
(13) Lube cradle pivot bolts with anti-seize loctite silver grade, prior to
installation.
(14) Install cradle pivot bolts, washers and new lock nuts. Tighten lock nut so that
it just makes contact with frame mount. Bolt should still turn relatively easy.
(15) Install limiting chains with upper chain brackets to upper spring mounts and
install hex head bolts flat washers and new lock nuts.
(16) Install brake hose to tee at the center of the axle.
(17) Lower jack and move clear of vehicle.
CAUTION: USE A CRISS-CROSS PATTERN WHEN TIGHTENING

MOUNTING HARDWARE TO PREVENT OVER-TIGHTENING ONE
SIDE OF MOUNT PLATE.
(18) Tighten axle mounting hex head bolts and new lock nuts at the axle mount
plates to 300 ft-lbs of torque.
(19) Install drive shaft in accordance with procedure.
CAUTION: IT IS IMPERATIVE THAT THE DRIVE AXLE OIL BE

CHANGED WHEN THE FIRST 200 HOURS OF OPERATION IS
REACHED. AXLE DAMAGE WILL OCCUR IF THIS INITIAL DRIVE
AXLE OIL CHANGE IS NOT PERFORMED.
(20) Fill drive axle with oil in accordance with drive axle oil change procedure
(Chapter 2, Section 1).
(21) Service the brake system master cylinder and bleed the brake system in
accordance with brake bleeding procedure (Chapter 2, Section 1).
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NOTE: Ensure parking brake is disengaged.

Note
(22) If installing new axle, the brakes must be “broken in” prior to operation. With
tractor supported on jack stands, start engine and place shifter in drive
position. Allow drive axle to turn for at least 15 minutes to fully saturate
internal brake discs.
(23) Install rear wheel assemblies in accordance with procedure.
(24) Remove jack stands and lower tractor to ground, in accordance with standard
3. Rear Wheel Assembly
(a) Removal
(2) Disconnect tire valve 90 degree extension and tire valve 7 -inch extension
from inner dual wheel.
(3) Remove lug nuts.
(4) Remove outer dual wheel and tire assemblies, if required, remove inner dual
wheel and tire assembly.
(b) Installation
(1) If applicable, install inner dual wheel assembly, position outer wheel
assembly on to rear hub.
(2) Install lug nuts and tighten to 225 ft-lbs of torque.
(3) Install tire valve 90 degree extension and tire valve 7 -inch extension.
4. Shock Absorber
(a) Removal
(1) Raise the tractor in accordance with standard jacking procedure (Chapter 2,
Section 1).
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(2) Disconnect and remove the drive shaft from the drop box in accordance with
drive shaft removal procedure.
(3) Disconnect brake hose from tee at the center of the axle and drain brake hose
into drain pan.
(4) Cap hose and plug tee.
(6) Locate rear upper spring mount, and remove upper cradle limiting chains
with upper chain brackets, by removing hex head bolts, flat washers, and lock
nut. Do not remove lower attaching points. Discard lock nut.
(7) Remove shock absorber, lower mounting hex head bolt, flat washers, and
lock nut. Discard lock nut.
(8) Lower rear axle cradle by allowing it to pivot about the cradle pivot bolts.
The rear coil springs will be loose.
(9) Locate upper shock mounting hardware on the rear upper spring mounts;
remove nut, bushing washer, and rubber bushing from upper shock mounting
points.
(10) Remove shock absorbers and coil springs.
(b) Installation
(1) Install one rubber bushing and bushing washer on the upper mounting point
of each shock absorber.
(2) Insert the upper mounting point of the shock absorbers through the mounting
hole in the center of the upper spring mounts. Position a rubber bushing and a
bushing washer over each shock absorber upper mounting point. Secure with
nut.
(3) Align lower shock mounts so that the hole centers are in line with each other.
Position coil springs on rear axle cradle.
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(5) Raise rear axle cradle assembly into position using jack. The shock absorbers
must be inside the coil springs prior to positioning rear axle cradle. Raise
cradle until the lower shock absorber mounting holes line up with the
mounting points on the rear axle cradle.
(6) Install shock absorber, lower mounting hex head bolt, flat washer, and new
lock nut.
(7) Secure cradle limiting chains with upper chain brackets to upper rear spring
mounts. Locate cradle limiting chains with upper chain brackets, install hex
head bolt, flat washer, and new lock nut at upper spring mounts.
(8) Install brake hose to tee at the center of the axle.
(9) Install drive shaft in accordance with procedure.
(10) Bleed the brake system in accordance with brake bleeding procedure
(11) Lower tractor to ground in accordance with standard jacking procedure

X. BRAKE SYSTEM
1. Brake Pedal
(a) Removal
(1) Remove and discard cotter pin from brake pedal clevis pin and remove brake
pedal clevis pin from yoke. Discard cotter pin.
(2) Remove brake pedal hex head bolt, flat washers, and lock nut from brake
pedal and dash housing. Discard lock nut.
(3) Remove springs from brake pedal and remove brake pedal.
(b) Installation
NOTE: Do not over tighten lock nut and hex head bolt.
Note
(1) Place brake pedal in installed position within dash housing and insert brake
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pedal hex head bolt and flat washer from right side. Secure with flat washer
and new lock nut. Do not over tighten hex head bolt. Torque hex head bolt to
40 ft-lbs. Check for free pedal movement.
(2) Align yoke with hole in brake pedal and insert brake pedal clevis pin. Secure
with new cotter pin.
(3) Install springs onto brake pedal.
2. Front Brake Calipers and Brake Pads
(a) Removal

(3) Place drain pan under brake caliper and remove brake hose, brake hose bolt
and brake hose washers. Discard brake hose washers.
NOTE: Support the weight of the caliper, caliper weight may damage brake
Note hose.
(4) Remove caliper mounting pins, retainer bolt sleeves from caliper and remove
caliper from front axle.
(5) Remove and discard front caliper pad set from both sides of caliper.
(6) Place a block of wood across the caliper piston using a C-clamp; press the
caliper piston back to its original position.
(b) Installation
(1) Place a new front caliper pad set on to caliper and install caliper on to rotor.
(2) Clean and lubricate caliper mounting pins with brake grease.
(3) Reinstall caliper mounting pins, retainer bolt sleeves and o-rings to caliper.
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(4) Tighten caliper-mounting pins to 40-45 ft-lbs of torque.
(5) Install brake hose, brake hose bolt and new brake hose washers.
(7) Install front wheels in accordance with procedure.
(8) Remove jack stand and lower tractor in accordance with standard jacking
3. Brake Line System
(a) Brake Hose (15-inch) Removal/Installation

(3) Place drain pan under tee and remove 15 -inch brake hose by unscrewing
male end from tee and cap off.
(4) Remove female end of 15 -inch brake hose by removing clip, unscrewing 15
-inch brake hose from proportioning valve to rear brake line and pulling
female end through hole of bracket welded to tractor frame. Cap off
proportioning valve to rear brake line.
(5) Discard failed 15 -inch brake hose.
(6) Attach new 15 -inch brake hose by feeding female end through hole of
bracket welded to tractor frame. Secure female end to line, brake
proportioning valve to rear.
(7) Fasten clip over female end of 15 -inch brake hose.
(8) Screw male end of 15 -inch brake hose into tee.
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(10) Install rear wheels in accordance with procedure.
(b) Left Rear Axle Brake Line Removal/Installation

(3) Place drain pan under axle to catch any brake fluid. At the top of the axle,
remove left rear axle brake line by unscrewing from tee and cap off tee.
(4) At the bottom of the axle, remove left rear axle brake line by unscrewing
from brake fitting and cap off brake fitting.
(5) Discard failed left rear axle brake line.
(6) Install the bottom of the left rear axle brake line by inserting into brake
fitting.
(7) Install the top of the left rear axle brake line by inserting into tee.
(9) Install rear wheels in accordance with procedure.
(c) Right Rear Axle Brake Line Removal/Installation
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(3) Place drain pan under axle to catch any brake fluid. At the top of the axle,
remove right rear axle brake line by unscrewing from tee. Cap off tee.
(4) At the bottom of the axle, remove right rear axle brake line by unscrewing
from brake fitting and cap off brake fitting.
(5) Discard failed right rear axle brake line.
(6) Install the bottom of the right rear axle brake line by inserting into brake
fitting.
(7) Install the top of the right rear axle brake line by inserting into tee.
(9) Install rear wheels accordance with procedure.
(d) Brake Proportioning Line Removal/Installation
(2) Locate proportioning valve to rear brake line.
(3) Remove flange nuts to remove P-clamps. Discard flange nuts.

(4) Place drain pan under brake line connection to catch any brake fluid. Detach
proportioning valve to rear brake line from 15 -inch brake hose at rear of
tractor.
(5) At the front of proportioning valve to rear brake line, remove rear brake
regulating valve and cap off.
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(6) Discard failed brake proportioning valve to rear line.
(7) Connect new proportioning valve to rear brake line to rear brake regulating
valve.
(8) At rear of tractor, connect proportioning valve to rear brake line by feeding
through bracket welded to frame and securing into 15 -inch brake hose.
(9) Secure proportioning valve to rear brake line flange nuts and P-clamps.
(e) Brake Line (H-Valve to Rear Proportioning Valve)

Removal/Installation
(1) Locate brake line next to the hydro boost assembly.

(2) Place drain pan under brake line connection to catch any brake fluid. Remove
brake line from rear brake regulating valve and cap off rear brake regulating
valve.
(3) Remove brake line from brake warning adapter and cap off brake warning
adapter.
(4) Discard failed brake line.
(5) Connect brake line to brake warning adapter.
(6) Connect brake line to rear brake regulating valve.
(f) Brake Lines (Master Cylinder to H-Valve)

(1) Locate brake lines connected to the hydro boost assembly.
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(2) Disconnect brake line from brake master cylinder adapter or brake adapter
and cap off brake master cylinder adapter or brake adapter.
(3) Disconnect brake line from adapter or brake warning adapter and cap off
adapter or brake warning adapter.
(5) Connect brake line to adapter or brake warning adapter.
(6) Connect brake line to brake master cylinder adapter or brake adapter.
(g) Brake Line (H-Valve to Brake Light Switch)


(1) Place drain pan under brake line connection to catch any brake fluid. Locate
and remove brake line from brake adapter located on the hydraulic brake
warning valve. Cap off brake adapter to minimize brake fluid loss.
(2) Remove brake line opposite end, from tee, attached to brake pressure switch
and cap off tee.
(4) Attach brake line to tee, attached to brake pressure switch.
(5) Attach brake line to brake adapter located on the hydraulic brake warning
valve.
(h) Brake Line (Brake Light Switch to Front Tee)

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(2) Locate brake line.
(3) Remove P-clamp by removing flange nut.

(4) Remove brake line from tee at brake pressure switch and cap off tee.
(5) Remove brake line from tee and cap off tee.
(7) Attach brake line to tee, attached to brake pressure switch.
(8) Attach brake line to tee.
(9) Install P-clamp and secure with flange nut.
(i) Brake Hose Removal/Installation
(2) Locate brake hose.
(3) Remove clip.

(4) Place drain pan under brake line connection to catch any brake fluid.
Unscrew brake hose from brake line or brake line front tee to left caliper and
pull female end through bracket welded to tractor frame. Cap off brake line
or brake line front tee to left caliper.
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Chapter 2
(5) Remove brake hose bolt and brake hose washers from front left brake caliper
or front right brake caliper thus, detaching banjo fitted end of brake hose.
Discard brake hose washers.
(6) Discard failed brake hose.
(7) Attach banjo fitted end of brake hose to the front left brake caliper or the
front right brake caliper securing with brake hose bolt and new brake hose
washers.
8) Install female end of brake hose through bracket welded to tractor frame and
connect it to brake line or brake line front tee to left caliper.
(9) Install clip.
(j) Brake Line (Front Tee to Left Caliper) Removal/Installation
(2) Locate brake line front tee to left caliper.
(3) Remove clip.

(4) Place drain pan under brake line connection to catch any brake fluid. Remove
brake line front tee to left caliper from tee and cap off tee.
(5) Unscrew brake line front tee to left caliper from brake hose. Cap off brake
hose.
(6) Discard failed brake line front tee to left caliper.
(7) Attach brake line front tee to left caliper to tee.
(8) Attach brake line front tee to left caliper to brake hose.
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Chapter 2
(9) Install clip.
(k) Brake Line (Front Tee to Right Caliper) Removal/Installation
(2) Locate front tee to right caliper brake line.
(3) Remove clip.
(4) Remove P-clamps by flange nuts. Discard flange nuts.

(5) Place drain pan under brake line connection to catch any brake fluid.
Disconnect front tee to right caliper brake line from tee and cap off tee.
(6) Unscrew front tee to right caliper brake line from brake hose.
(7) Discard failed brake line, front tee to right caliper.
(8) Connect front tee to right caliper brake line to brake hose.
(9) Connect front tee to right caliper brake line to tee.
(10) Install P-clamps by attaching new flange nuts.
(11) Install clip.
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Chapter 2
(l) H-Valve Removal/Installation

(1) Place drain pan under hydraulic brake warning valve connections to catch
any brake fluid. Locate hydraulic brake warning valve. Disconnect hydraulic
brake warning valve from harness. Remove hydraulic brake warning valve
from adapter, adapters, and adapter. Cap off adapter, adapters and adapter to
minimize brake fluid loss.
(2) Remove brake pressure switch valve plug and retain.
(3) Discard failed hydraulic brake warning valve.
(4) Install brake pressure switch valve plug in new hydraulic brake warning
valve.
(5) Attach adapter, adapters and adapter with corresponding brake lines, to
hydraulic brake warning valve.
(6) Reconnect harness to hydraulic brake warning valve.
(m) Regulating Rear Brake Valve Removal/Installation

(1) Place drain pan under regulating rear brake valve connections to catch any
brake fluid. Locate and remove regulating rear brake valve from brake lines.
Cap off brake lines to minimize brake fluid loss.
(2) Discard failed regulating rear brake valve.
(3) Attach brake line to new regulating rear brake valve.
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Chapter 2
(n) Brake Pressure Switch Removal/Installation

(1) Place drain pan under brake pressure switch to catch any brake fluid. Locate
and unscrew brake pressure switch from brake pressure switch tee. Plug off
brake pressure switch tee to minimize brake fluid loss.
(2) Discard failed brake pressure switch.
(3) Screw in new brake pressure switch in to brake pressure switch tee.
4. Hydro Boost Assembly
(a) Removal
(1) Locate hydraulic shut off valve and place flow lever into the closed position.
(2) Disconnect brake pedal yoke from brake pedal by removing cotter pin and
clevis pin. Discard cotter pin.
(3) Remove brake pedal yoke and jam nut from hydro boost assembly.
(4) Remove brake lines, master cylinder to H-valve from brake master cylinder
adapter and adapter, install plugs on removed lines to prevent fluid
contamination.
(5) Remove hydro boost assembly by removing hex head bolts, lock nuts, and
flat washers. Discard lock nuts.

(6) Remove hydro boost assembly reservoir cover with gasket; pour out brake
fluid into drain pan.
(7) Remove hydraulic hoses, and from hydro boost assembly.
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Chapter 2
(8) Remove hydro boost assembly from tractor.
(9) If hydro-boost assembly is discarded remove adapters for future installation.
(b) Installation
(1) Prior to installing the hydro boost assembly, bleed the hydro boost assembly
as follows:
(i) Insert adapters to the outlet ports of the hydro boost assembly.
(ii) Support the hydro boost assembly in a vise and loosely install 3/16 -
inch inverted flare plugs in the adapters.
(iii) Fill the hydro boost assembly reservoir with DOT 3 brake fluid and
depress the cylinder push rod several times until all bubbles cease to
appear in the fluid.
(iv) Tighten the 3/16-inch inverted flare plugs and attempt to depress the
push rod. The push rod travel should be greatly restricted after all air
is expelled.
(2) Install hydro boost assembly reservoir cover with gasket.
(3) Install jam nut and brake pedal yoke on to push rod of hydro boost assembly.
Distance between the push rod end and jam nut must be 1½ -inch.
(4) Install the hydro boost assembly to the mounting bracket welded to the frame
with hex head bolts, flat washers, and new lock nuts.
(5) Reconnect hydraulic hoses.
(6) Connect brake pedal yoke to brake pedal by installing clevis pin. Secure
clevis pin with new cotter pin.
(7) Remove the output port 3/16-inch inverted flare plugs and install the master
cylinder to H-valve brake lines and master cylinder adapters.
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Chapter 2
Y. PARKING BRAKE ASSEMBLY
1. Park Brake Lever
(a) Removal
(1) Disengage park brake lever assembly.
(2) Remove the top transmission closeout panel and passenger side transmission
closeout panel.
(3) Disconnect hand brake lever by removing cotter pin and clevis pin from
clevis at the bellcrank. Discard cotter pin.
(4) Remove hex head bolts, flat washers, bushings, lock washers, and flat
washers at the base of the hand brake lever. Discard lock washers.
(5) Lift out the hand brake lever and brake rod with yoke and clevis. If replacing
lever with new one, remove brake rod with yoke and clevis by removing the
cotter pin and clevis pin from yoke. Discard cotter pin.
(b) Installation
(1) If installing new hand brake lever, install brake rod with yoke and clevis by
inserting new cotter pin and clevis pin at yoke.
NOTE: Use middle slot in the front side of the hand brake lever when
Note
mounting the hand brake lever to the bracket.
(2) Install hex head bolts, flat washers, bushings, new lock washers, and flat
washers at the base of the hand brake lever. Do not tighten hex head bolts at
this time.
(3) Connect hand brake lever by inserting new cotter pin and clevis pin at clevis
at the bellcrank.
(4) Tighten hex head bolts to secure hand brake lever. Torque hex head bolts to
35 ft-lbs.
(5) Install the top and passenger side transmission closeout panels.
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Chapter 2
(6) Test park brake for correct tightness when hand brake lever is engaged.
CAUTION: ENSURE AREA IS CLEAR OF ALL PERSONNEL AND

EQUIPMENT.
(7) Engage park brake by pulling up on hand brake lever, foot off accelerator,
engine at idle. Move shift selector to “REVERSE” position. If tractor does
not move, tractor has passed park brake test. If the parking brake is adjusted
too tightly brake drag will occur. Ensure parking brake does not drag while
traveling in either direction.
(c) Adjustment
Turn knob on hand brake lever clockwise to increase or counter clockwise to decrease
the hold on the brakes.
2. Parking Brake Shoes and Drum
(a) Removal
(2) Remove the top and side transmission closeout panels.
(3) Disengage parking brake by releasing the hand brake lever.
(4) Disconnect the driveshaft from the transmission output flange by removing
drive shaft saddle bolts, lock washers, and U-joint caps. Discard lock
washers.
(5) Remove tail shaft nut and discard.
(6) Remove park brake drum and output flange from transmission.
(7) Remove the two top brake shoe springs and the bottom brake shoe spring and
retain.
(8) Remove and discard worn park brake shoes from the brake shoe plate.
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Chapter 2
(b) Installation
(1) Position new park brake shoes on brake shoe plate.
(2) Install bottom brake shoe spring and top brake shoes springs.
(3) Install output flange with park brake drum attached on to transmission.
(4) Secure output flange to transmission with new tail shaft nut.
(5) Reconnect the driveshaft to the transmission output flange. Secure with U-
joint caps, new lock washers, and drive shaft saddle bolts.
(6) Check operation of park brake by engaging hand brake lever. If hand brake
lever will not fully engage, adjust hand brake lever.
(8) Install the top and side transmission closeout panels.
(9) Test parking brake for correct tightness when hand brake lever is engaged.
CAUTION: ENSURE AREA IS LEVEL AND CLEAR OF ALL

PERSONNEL AND EQUIPMENT.
(10) Engage park brake by pulling up on hand brake lever, foot off accelerator,
engine at idle. Move shift selector to “REVERSE” position. If tractor does
not move, tractor has passed park brake test. If the parking brake is adjusted
too tightly brake drag will occur. Ensure parking brake does not drag while
traveling in either direction.
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Chapter 2
Z. HYDRAULIC POWER STEERING SYSTEM
1. Hydraulic Pump
(a) Removal
(1) Locate hydraulic pump.
(2) Set hydraulic shut off valve to the “CLOSED” position.

(3) Remove hoses at the pump: brake booster to pump, supply tank to pump and
pump to tank and install hose plugs. Drain fluid from hydraulic pump into
drain pan.
CAUTION: HYDRAULIC PUMP WILL FALL FREE WHEN HEX HEAD

BOLTS ARE REMOVED. PREVENT HYDRAULIC PUMP FROM
FALLING BY SECURELY GRABBING HOLD OF VALVE.
(4) Remove hex head bolts, lock washers, and flat washers from hydraulic pump.
(5) Remove hydraulic pump from engine. Make sure that hydraulic pump
coupler and O-ring stay in place.
(6) Remove straight fitting, and pump inlet elbow and pump outlet elbow from
hydraulic pump.
(b) Installation
(1) Install fitting, and elbow in the hydraulic pump in accordance with Figure
30 (Deutz) and Figure 31 (Kubota) , Chapter 4, Section 2.
(2) Position hydraulic pump on to engine and install hex head bolts, new lock
washers and flat washers.
(3) Install hoses: brake booster to pump, supply tank to pump, and pump to tank.
(4) Set hydraulic shut off valve to the “OPEN” position.
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Chapter 2
(5) If hydraulic system has become contaminated due to pump failure, or

contamination caused pump failure, flush the system in accordance with
hydraulic flushing procedure (Chapter 2, Section 1).
(6) Service hydraulic reservoir with Dexron III fluid as required.
2. Hydraulic Reservoir
(a) Removal

(1) Remove magnetic drain plug to drain hydraulic reservoir into drain pan.
(2) Remove hoses: supply tank to pump, pump to tank, brake booster to
reservoir and steer valve “T” to tank.Install hose plugs.
(3) Remove hex head bolts, lock washers, flat washers and lock nuts. Discard
lock washers and lock nuts.
(4) Remove fittings and barb.
(5) Remove close nipple, hydraulic shut off valve and fitting as an assembly.
(b) Installation
(1) Install close nipple, hydraulic shut off valve and fitting as an assembly into
hydraulic reservoir.
(2) Install fittings and barb.
(3) Install hydraulic reservoir using hex head bolts, new lock washers, flat
(4) Install magnetic drain plug in hydraulic reservoir.
(5) Reconnect hoses: supply tank to pump, pump to tank, booster to reservoir and
steer valve “T” to hydraulic reservoir.
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Chapter 2
3. Hydraulic Shut Off Valve
(a) Removal

(1) Remove magnetic drain plug to drain hydraulic reservoir into drain pan, then
reinstall magnetic drain plug.
(2) Locate hydraulic shut off valve.
(3) Remove supply tank to pump hose and install hose plug.
(4) Remove fitting from hydraulic shut off valve.
(5) Remove hydraulic shut off valve from close nipple on bottom of hydraulic
reservoir.
(b) Installation
(1) Install hydraulic shut off valve onto close nipple.
(2) Install fitting onto hydraulic shut off valve.
(3) Install supply tank to pump hose.
4. Steer Valve Assembly
(a) Removal
(1) Locate hydraulic shut off valve, place flow lever into the “CLOSED”
position.
(2) Locate steer valve.

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Chapter 2
(3) Remove hoses: steer valve “R” to steering cylinder, steer valve “L” to steer
cylinder, steer valve “P” to booster, and steer valve “T” to tank from steer
valve.Install plugs into open hoses ends.
(4) Drain fluid from steer valve assembly into drain pan.
CAUTION: STEER VALVE WILL FALL FREE WHEN HEX HEAD

BOLTS ARE REMOVED. PREVENT STEER VALVE FROM FALLING
BY SECURELY GRABBING HOLD OF VALVE.
(5) Locate steer valve mount; remove hex head bolts, lock washers, and flat
(6) Remove O-ring fittings, and bosses from steer valve, retain fittings for
installation.
(b) Installation
(1) Install O-ring fittings and bosses into steer valve.
(2) Locate steer valve mount, align steer valve and steering column to mounting
holes in steer valve mount and install hex head bolts, new lock washers, and
flat washers.
(3) Remove hose plugs and install steer valve “R” to steer cylinder hose, steer
valve “L” to steering cylinder hose, steer valve “P” to booster hose, and steer
valve “T” to tank hose to steer valve.
(4) Locate hydraulic shut off valve, place flow lever into the “OPEN” position.
5. Steering Cylinder
(a) Removal
(1) Raise and support the tractor on jack stands. Perform procedure in
accordance with standard jacking procedure (Chapter 2, Section 1).
(3) Rotate steering wheel hard to the left to expose steering cylinder.
(4) Set hydraulic shut off valve to the “CLOSED” position.
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Chapter 2

(5) Disconnect steer valve “R” to steer cylinder hose and steer valve “L” to steer
cylinder hose from fittings, drain fluid from hoses into drain pan and cap off.
(6) Remove cotter pins and castellated nuts from R/H tie rod ends. Discard cotter
pins.
Note NOTE: Use the rod puller to disengage the rod end from the steer cylinder
mounting brackets on the front steer axle and L/H knuckle.
(7) Remove steering cylinder by removing rod ends from their mounts on the
front steer axle.
(8) Remove R/H tie rod ends with jam nuts and fittings from steering cylinder.
(b) Installation
(1) Install R/H tie rod ends with jam nuts into steering cylinder. Position steering
cylinder so that it is at half stroke (approx. 3 inches). Tighten jam nuts finger
tight.
(2) Install fittings.
(3) Install the R/H tie rod end that is in the fixed end of the steer cylinder into the
steer cylinder mounting bracket on the front steer axle.
(4) Pivot the L/H knuckle as needed to align L/H knuckle mounting hole with R/
H tie rod end in the free end of steering cylinder. Thread castellated nut on
securely.
(5) Tighten first castellated nut until tapered shaft of R/H tie rod end is fully
seated. Tighten an additional ¼ to ½ turn, align hole with castellated slot for
new cotter pin. Install new cotter pin.
(6) Tighten second castellated nut until tapered shaft of R/H tie rod end is fully
seated. Tighten an additional ¼ to ½ turn, align hole with castellated slot for
new cotter pin. Install new cotter pin.
(7) Reinstall steer valve “R” to steering cylinder hose and steer valve “L” to
steering cylinder hose and open shut off valve.
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Chapter 2
(8) Install front wheel assemblies in accordance with procedure.
(9) Remove jack stand and lower tractor. Perform in accordance with standard
6. Steering Wheel
(a) Removal
(1) Locate horn button assembly in center of steering wheel.
(2) Insert a small screwdriver to the edge of the horn button assembly and pry
upward, forcing horn assembly to pop out of center of steering wheel.

FAILURE TO TAG LEADS COULD RESULT IN DAMAGE TO SYSTEM
COMPONENTS.
(6) Connect wiring.
(7) Place hydraulic shut off valve flow lever to the “OPEN” position.
(3) Tag and remove wiring leads from horn button assembly.
(4) Remove steering column nut from steering column.
(5) With a wheel puller remove steering wheel.
(b) Installation
(1) Position steering wheel on to steering column.
(2) Install steering column nut and tighten to 25 ft-lbs of torque.
(3) Connect wiring leads to horn button assembly.
(4) Position horn button assembly into center of steering wheel and press into
place.
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Chapter 2
7. Steering Column
(a) Removal
(1) Locate steering column.

FAILURE TO TAG LEADS COULD RESULT IN DAMAGE TO SYSTEM
COMPONENTS.
(2) Tag and remove wiring from steer column.
(3) Locate hydraulic shut off valve, place flow lever to the “CLOSED” position.
(4) Locate steer valve.
CAUTION: STEER VALVE WILL FALL FREE WHEN HEX HEAD

BOLTS ARE REMOVED. PREVENT STEER VALVE FROM FALLING
BY SECURELY GRABBING HOLD OF VALVE.
(5) Locate steer valve mount, remove hex head bolts, lock washers, and flat
(6) Remove steering wheel in accordance with procedure.
(7) Remove turn signal control with ground turn signal switch wire.
(8) Locate upper steer clamp and rubber steering column isolator, remove hex
head bolts, flat washers and lock nuts. Discard lock nuts.
(9) Remove upper steer clamp and rubber steering column isolator, retain for
installation.
(10) Remove steering column.
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Chapter 2
(b) Installation
(1) Position steering column through dash.
(2) Attach steering column and steer valve to steer valve mount and secure with
hex head bolts new lock washers, and flat washers.
(3) Install upper steer clamp and rubber steering column isolator secure with hex
head bolts, flat washers and new lock nuts.
(4) Install turn signal control with ground turn signal switch wire.
(5) Install steering wheel in accordance with procedure.
(6) Connect wiring.
(7) Place hydraulic shut off valve flow lever to the “OPEN” position.
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Chapter 2
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Chapter 3
TABLE OF CONTENTS
SECTION 1: RECOMMENDED OVERHAUL PERIODS ............................................................ 3-1-1
A. General ................................................................................................................. 3-1-1
B. Engine .................................................................................................................. 3-1-1
C. Transmission ........................................................................................................ 3-1-1
D. Front (Steer) Axle .................................................................................................. 3-1-1
SECTION 2: FRONT (STEER) AXLE ......................................................................................... 3-2-1
A. Axle Assembly ...................................................................................................... 3-2-1
1. Inspection ................................................................................................. 3-2-1
2. Removal .................................................................................................... 3-2-1
3. Installation ................................................................................................. 3-2-2
B. King Pin and Knuckles .......................................................................................... 3-2-3
1. Removal .................................................................................................... 3-2-3
2. Installation ................................................................................................. 3-2-4
C. Front Wheel Bearings ........................................................................................... 3-2-5
1. Removal .................................................................................................... 3-2-5
2. Installation ................................................................................................. 3-2-5
D. Front Leaf Springs and Shackles .......................................................................... 3-2-6
1. Removal .................................................................................................... 3-2-6
2. Installation ................................................................................................. 3-2-7
E. Tie Rod End .......................................................................................................... 3-2-8
1. Removal .................................................................................................... 3-2-8
2. Installation ................................................................................................. 3-2-8
F. Front Wheel Alignment ......................................................................................... 3-2-9
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Chapter 3
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Chapter 3
SECTION 1: RECOMMENDED OVERHAUL PERIODS
A. GENERAL
The following overhaul periods are approximate and can vary greatly due to different
operating conditions. Units operating in extreme conditions such as high or low
temperatures, long periods of sustained operation, continued operation in sand or dust or
continued exposure to sea air or moisture require careful, regular inspections. Overhaul
periods may be adjusted with time and experience in operating this tractor. If an overhaul of
a component or system is anticipated or required, the procedures that cover that component
or system should be read and fully understood prior to attempting any part of the overhaul.
B. ENGINE
Overhaul when oil consumption exceeds 1 qt per 50 hours of operation or 5000 hours on the
engine hour meter. Engine workshop manuals are available by request.
C. TRANSMISSION
Overhaul when the engine hour meter exceeds 5000 hours. Transmission workshop
manuals are available by request.
D. FRONT (STEER) AXLE
If vehicle has been properly lubricated and maintained and has not experienced damage to
the steering system, the steering components will provide many hours of service without an
overhaul. Overhaul the steer axle when excessive play in axle components cannot be
corrected by replacing the individual components.
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Chapter 3
3-1-2 CD387
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Chapter 3
SECTION 2: FRONT (STEER) AXLE
A. AXLE ASSEMBLY
1. Inspection
(a) Raise and support tractor on jack stands in accordance with standard jacking
(b) Inspect front wheel bearings. To check wheel bearing play, rock the wheel at
12 and 6 o’clock position. If there is movement, the wheel bearing should be
serviced. To check wheel bearing noise, spin the wheel by hand and let it
rotate freely after spinning. Check for wheel bearing noise. If the wheel
bearing remains noisy after proper adjustment, replace the wheel bearing.
(c) Remove front wheel assemblies in accordance with procedure.
(d) Visually inspect front steer axle for any signs if damage. The following items
should be inspected to ensure axle performance: tie rod tube assembly, right
hand tie rod end, left hand tie rod end, steer cylinder right hand tie rod ends.
Replace any damaged components.
(e) Visually inspect thrust bearings for signs of lubricant leakage or damage.
Excessive vertical slop will be present in the knuckle if the thrust bearing is
severely worn. The thrust bearing is a permanently sealed and lubed bearing
and should be replaced if damaged or worn.
(f) Check for excessive play or binding where the knuckles interface with the
king pins. Worn king pin bushings will cause excessive play. A corroded or
seized king pin, or lack of lubrication will cause binding.
(g) Attach front wheels in accordance with procedure.
(h) Remove jack stands and lower tractor in accordance with standard jacking
2. Removal
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Chapter 3
(b) Remove front wheel assemblies in accordance with procedure.

(c) Disconnect front disc brake hoses from calipers in accordance with
procedure.
(d) Using a floor jack, support the front steer axle. Entering from either wheel
well, place floor jack at center of front steer axle and jack up until floor jack is
supporting only the weight of the front steer axle.
(e) Close hydraulic shutoff valve on bottom of the hydraulic reservoir.

(f) Disconnect the hydraulic hoses from the steering cylinder and cap off in
accordance with steer cylinder removal procedure.
(g) Remove axle U-bolts by removing lock nuts, flat washers, and spring clamp
plates. Discard U-bolts and lock nuts.
(h) Slowly lower the front steer axle to the floor and roll jack out from tractor until
front steer axle clears tractor frame.
(i) Remove steering cylinder in accordance with procedure and retain.
3. Installation
Note NOTE: Tie rod should be on the rearward side of axle assembly.
(a) Center and balance front steer axle on floor jack in front of elevated tractor.
(b) Roll front steer axle assembly into place under front of tractor and slowly raise
front steer axle into position.
Note NOTE : Plates on top of axle must align to center of spring.
(c) Install new axle u-bolts securing with spring clamp plate on top of leaf spring
and flat washers. Thread new lock nuts in place. Tighten lock nuts gradually
in a diagonal pattern until snug.
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Chapter 3
(d) Torque lock nuts to 50 ft.-lb of torque.
(e) Attach front brake hoses to calipers and tighten brake hose bolts securely in
accordance with caliper assembly installation procedure.
(f) Install steer cylinder in accordance with procedure.
(g) Attach front wheels in accordance with procedure.
(h) Remove jack stands and lower tractor in accordance with standard jacking
B. KING PIN AND KNUCKLES
1. Removal
(b) Remove front wheels in accordance with procedure.
(c) Disconnect the R/H tie rod end and L/H tie rod end from the R/H knuckle
weldment and L/H knuckle weldment by removing cotter pins and and castle
nuts. Discard cotter pins.
(d) Disconnect steer cylinder L/H tie rod end (driver’s side only) from the L/H
knuckle weldment by removing cotter pin and castle nut. Discard cotter pin.
(e) Remove the calipers in accordance with procedure.
(f) Remove hub and rotor assembly in accordance with procedure.
Note NOTE: Support knuckle weldment so that it does not fall free when
king pin is being removed.
(g) Remove top and bottom king pin caps by removing screws and lock washers.
(h) Remove and inspect king pin gasket, replace as necessary.
(i) Loosen screw by loosening jam nut.
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Chapter 3
(j) Pull king pin up and out the top or push the king pin down and out the bottom
of the knuckle weldment, and remove knuckle weldment. Remove and retain
thrust bearing and king pin shim.
2. Installation
(a) Position new knuckle weldment and thrust bearing and king pin shim on front
steer axle weldment at king pin journal.
NOTE: Flat spot on king pin must line up with screw in order to keep
Note king pin from rotating once fully installed.
(b) Lightly lube king pin with lithium based grease and insert through the top of
the knuckle front steer axle weldment, thrust bearing and king pin shim.
(c) Tighten screw and jam nut.
(d) Install bottom king pin cap with king pin gasket and secure with screws and
new lock washers.
(e) Install upper king pin cap with king pin gasket and secure with screws and
new lock washers.
(f) Install R/H tie rod end and L/H tie rod end to the R/H knuckle weldment and L/
H knuckle weldment using the castellated nuts and and new cotter pins.
(g) Install steer cylinder R/H tie rod end (driver’s side only) to the L/H knuckle
weldment. Secure with castellated nut and new cotter pin.
(h) Lube all points on front steer axle with lithium based grease (see Lubrication
Schematic, Chapter 2, Section 1).
(i) Install wheel in accordance with procedure and check and adjust wheel
alignment in accordance with procedure.
(j) Remove jack stands and lower tractor in accordance with standard jacking
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Chapter 3
C. FRONT WHEEL BEARINGS
1. Removal
(b) Remove front wheel assemblies in accordance with procedure.
(c) Remove the brake calipers in accordance with procedure.
(d) Remove the grease cap from wheel hub.
(e) Remove the cotter pin from the spindle nut, remove spindle nut and tongued
spindle washer. Discard cotter pin.
CAUTION: THE HUB AND ROTOR ASSEMBLY IS HEAVY, AVOID

DROPPING, MAY CAUSE DAMAGE TO ASSOCIATED COMPONENTS.
(f) Carefully slide the hub and rotor sub assembly off knuckle weldment spindle.
(g) Remove grease seal from hub and discard.
(h) Remove outer wheel bearing and race from hub.
(i) Remove inner wheel bearing and race from hub.
2. Installation
(a) Install inner bearing race and outer bearing race by pressing them into hub.
(b) Using lithium based grease pack inner wheel bearing and align it into the hub.
(c) Install new inner bearing grease seal into hub.
(d) Set hub and rotor sub-assembly onto the spindle.
(e) Using lithium based grease pack/repack inner wheel bearing and align it into
the hub.
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Chapter 3
(f) Set hub and rotor sub-assembly onto the spindle.
(g) Using lithium grease pack/repack outer wheel bearing and align it into the hub
and rotor sub-assembly.
(h) Install tongued spindle washer and spindle nut.
(i) Slowly rotate hub and rotor assembly tighten spindle nut to 15 ft-lbs of torque
to seat the bearings. Loosen the spindle nut ¼ turn.
(j) Install new cotter pin. If required, tighten the spindle nut slightly to align castle
and spindle hole.
(k) Install grease cap.
(l) Install the brake calipers in accordance with procedure.
(m) Install the front tires in accordance with procedure.
(n) Remove jack stands and lower tractor in accordance with standard jacking
D. FRONT LEAF SPRINGS AND SHACKLES
1. Removal
(b) Remove the front tires in accordance with procedure.
(c) Remove the front axle in accordance with procedure.
(d) Locate leaf spring mounts and remove hex head bolts, flat washers and lock
nuts from leaf springs allowing the front of the spring to rotate down and away
from the tractor. Discard lock nuts.
CAUTION: LEAF SPRING IS HEAVY AND MAY CAUSE INJURY TO

PERSONNEL. SUPPORT THE WEIGHT OF THE APPLICABLE LEAF
SPRING SO THAT IT DOES NOT FALL FREE WHEN LAST HEX HEAD
BOLT IS REMOVED.
3-2-6 CD387
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Chapter 3
(e) Remove hex head bolts, flat washers and lock nuts from leaf spring shackle
at the rear leaf spring hanger cross member. Discard lock nut.
(f) Remove leaf spring from the tractor with the shackle attached.
(g) Remove hex head bolts, flat washers, and lock nuts from shackles releasing
the leaf springs. Discard lock nut.
(h) Inspect shackle bushings and shackles for wear. The shackle bushings and/
or shackle should be replaced if the bushing has been deformed (egg
shaped) or the inside diameter exceeds 0.68-inches.
(i) If replacing shackle bushings, press out worn bushings with a hydraulic press
utilizing a properly sized arbor.
2. Installation
(a) If required, install new bushings into shackles with a hydraulic press utilizing a
properly sized arbor.
(b) Install shackles to the rear eye of the leaf springs using the hex head bolts,
flat washers and new lock nuts.
(c) Install shackles to the rear leaf spring cross member, install hex head bolts,
flat washers and new lock nuts.
(d) Install the front eye of the leaf springs to the spring mounts using hex head
bolts, flat washers and new lock nuts.
(e) Install the front steer axle in accordance with procedure.
(f) Install the front wheels in accordance with procedure.
CD387 3-2-7
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Chapter 3
(g) Remove jack stands and lower tractor in accordance with standard jacking
E. TIE ROD END
1. Removal
(b) Locate faulty tie rod end.
(c) Remove cotter pin and castellated nut from tie rod end. Discard cotter pin.
(d) Remove tie rod tube assembly with tie rod ends from front steer axle
weldment.
(e) Loosen jam nut on tie rod end.
(f) Remove and discard faulty tie rod end from tie rod tube assembly.
2. Installation
(a) Install tie rod end to tie rod tube, do not tighten jam nut at this time.
(b) Position wheels so they are aligned in the forward direction and parallel to
each other.
(c) Position tie rod tube assembly into left and right knuckle weldments, adjust tie
rod end and tighten jam nuts.
(d). Install castellated nut and new cotter pin.
(e) Lube tie rod end with lithium based grease.
(f) Perform front wheel alignment in accordance with procedure.
3-2-8 CD387
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Chapter 3
F. FRONT WHEEL ALIGNMENT
Note
NOTE: Front wheel alignment should only be checked or adjusted if
any steering component is replaced. Toe-in adjustment is the only
alignment required. Do not use front wheel alignment to correct for
bent or damaged components.
1. To adjust toe-in, position the tractor on a flat, smooth surface at least twenty feet in
length.
2. With the steering centered, run the tractor slowly in an absolute straight line without
touching the steering wheel.
3. Use the parking brake to stop the tractor at the end of the run.
4. Measure the tire centerline distance between the two front wheels, first at the 3
o’clock position and then at the 9 o’clock position. The difference between these two
measurements is the total toe.
Note
NOTE: The back (9 o’clock) measurement should be 1/16 -inch more
than the front 3 o’clock measurement. The wheels should be 1/16-
inch pigeon-toed.
5. Loosen jam nuts so that there is at least ¼-inch between the jam nut and the tie rod
tube.
6. Turn tie rod tube clockwise or counterclockwise until proper toe alignment is
achieved.
7. Tighten jam nuts and check toe-in alignment. Re-adjust if necessary.
CD387 3-2-9
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Chapter 3
3-2-10 CD387
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Chapter 4
TABLE OF CONTENTS
A. Introduction ........................................................................................................... 4-1-1
B. Using the Illustrated Parts List .............................................................................. 4-1-2
1. Figure and Index Number ......................................................................... 4-1-2
2. Part Number ............................................................................................. 4-1-3
3. Description and Quantity .......................................................................... 4-1-3
4. Effectivity .................................................................................................. 4-1-4
C. Ordering Spare Parts ............................................................................................ 4-1-4
SECTION 2: ILLUSTRATED PARTS LIST ................................................................................ 4-2-1
A. Introduction ........................................................................................................... 4-2-1
Figure 2-1. Frame Weldment (w/ Hitch, Light, and Back-up Alarm Options) ....... 4-2-2
Figure 2-2. Access Panels, Deutz Tier2, Kubota ................................................. 4-2-4
Figure 2-3. Access Panels, Deutz Tier4i .............................................................. 4-2-6
Figure 2-4. Hood Assembly ................................................................................. 4-2-8
Figure 2-5. Cab Mounting .................................................................................. 4-2-10
Figure 2-6. Cab Insulation ................................................................................. 4-2-12
Figure 2-7. Cab Mirrors ..................................................................................... 4-2-14
Figure 2-8. Cab Door Installation ....................................................................... 4-2-16
Figure 2-9. Driver (L/H) Door Assembly ............................................................ 4-2-18
Figure 2-10. Window, Driver (L/H) Door Assembly ............................................. 4-2-20
Figure 2-11. Passenger (R/H) Door Assembly .................................................. 4-2-22
Figure 2-12. Window, Passenger (R/H) Door Assembly .................................... 4-2-24
Figure 2-13. Cab Windows ................................................................................ 4-2-26
Figure 2-14. Front Windshield Wipers ............................................................... 4-2-28
Figure 2-15. Rear Windshield Wipers ................................................................ 4-2-30
Figure 2-16. Exterior Lamp Assemblies ............................................................. 4-2-32
Figure 2-17. Dome Light .................................................................................... 4-2-34
Figure 2-18. Emergency Stop Switch Assembly ................................................ 4-2-36
Figure 2-19. Lower Dash Access Panel ............................................................ 4-2-38
Figure 2-20. Seat Installation ............................................................................. 4-2-40
Figure 2-21. Cab Heater Installation (Deutz) ..................................................... 4-2-42
Figure 2-22 Cab Heater Installation (Kubota) .................................................... 4-2-44
Figure 2-23. Dash Assembly w/ Harness (Deutz Tier 2) .................................... 4-2-46
Figure 2-24. Dash Assembly w/ Harness ((Deutz Tier 4i ................................... 4-2-48
Figure 2-25. Dash Assembly w/ Harness ( Kubota ) .......................................... 4-2-50
Figure 2-26. Console Assembly ( CE Option ) ................................................... 4-2-52
Figure 2-27. Alarm Assembly ............................................................................. 4-2-54
CD387 4-TOC-i
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Chapter 4
Figure 2-28. Brake Pedal Assembly .................................................................. 4-2-56

Figure 2-29. Steering Column Assembly ........................................................... 4-2-58
Figure 2-30. Hydraulic Steering System ( Deutz ) ............................................. 4-2-60
Figure 2-31. Hydraulic Steering System ( Kubota ) ........................................... 4-2-64
Figure 2-32. Front Suspension .......................................................................... 4-2-68
Figure 2-33. Front ( Steer ) Axle Assembly ........................................................ 4-2-70
Figure 2-34. Hub and Rotor Assembly ............................................................. 4-2-72
Figure 2-35. Brake Calipers Assembly ............................................................. 4-2-74
Figure 2-36. Rear Suspension Assembly ......................................................... 4-2-76
Figure 2-37. Drain Plugs. Rear ( Drive ) Axle .................................................... 4-2-78
Figure 2-38. Gear Set and Differential. Rear Axle ............................................ 4-2-80
Figure 2-39. Planetary Wheel End Drive. Rear Axle ......................................... 4-2-82
Figure 2-40. Wet Brakes System. Rear Axle ..................................................... 4-2-84
Figure 2-41. Drop Box Drain Plugs. Rear Axle .................................................. 4-2-86
Figure 2-42. Front Wheel Assembly .................................................................. 4-2-88
Figure 2-43. Rear Wheel Assembly ................................................................... 4-2-89
Figure 2-44. Accelerator Deutz 4i ...................................................................... 4-2-90
Figure 2-45. Accelerator and Modulator Cables ( Deutz Tier 2 ) ....................... 4-2-92
Figure 2-46. Accelerator and Modulator Cables ( Kubota ) ............................... 4-2-94
Figure 2-47. Engine and Transmission Installation ( Deutz Tier2 ) .................... 4-2-96
Figure 2-48. Engine Installation ( Deutz Tier 4i ) ............................................... 4-2-97
Figure 2-49. Engine Installation ( Kubota ) ........................................................ 4-2-98
Figure 2-50. Engine Assembly ( Deutz Tier2 ) ................................................. 4-2-100
Figure 2-51. Front Engine Covers ( Deutz 2 ) ................................................. 4-2-104
Figure 2-52. AlternatorAssembly ( Deutz Tier 2 ) ............................................ 4-2-106
Figure 2-53 Starter Assembly ( Deutz Tier 2 ) ................................................. 4-2-108
Figure 2-54. Timing Belt and PTO Assemblies, Deutz ................................... 4-2-110
Figure 2-55. Hydraulic Pump PTO Drive Assembly, Deutz .............................. 4-2-112
Figure 2-56. Oil Pan Installation, Deutz ........................................................... 4-2-113
Figure 2-57. Engine Assembly ( Deutz Tier 4i ) ............................................... 4-2-114
Figure 2-57. Engine Assembly (Deutz Tier 4i) (cont'd) ................................... 4-2-116
Figure 2-58. Engine Front Cover ( Deutz Tier 4i ) ........................................... 4-2-118
Figure 2-59. Alternator Assembly ( Deutz Tier 4i ) .......................................... 4-2-120
Figure 2-60. Starter Installation ( Deutz Tier 4i ) ............................................. 4-2-122
Figure 2-61. Engine Assembly. Front View ( Kubota ) ..................................... 4-2-124
Figure 2-62. Engine Assembly. Rear View ( Kubota ) ...................................... 4-2-126
Figure 2-62. Engine Assembly. Rear View ( Kubota) (cont'd) .......................... 4-2-128
Figure 2-63. Heater Assembly ( Kubota ) ........................................................ 4-2-130
Figure 2-64. Air Intake Assembly ( Deutz ) ...................................................... 4-2-132
4-TOC-ii CD387
Orig
Chapter 4
Figure 2-65. Air Intake Assembly, Kubota ( MR-8 ) .......................................... 4-2-134

Figure 2-66. Air Intake Assembly, Kubota V3600-T ( MR-10 ) ......................... 4-2-136
Figure 2-67. Fuel System ( Deutz ) ................................................................. 4-2-138
Figure 2-68 Fuel System ( Kubota ) ................................................................ 4-2-140
Figure 2-69. Exhaust System ( Deutz ) ........................................................... 4-2-142
Figure 2-70. Exhaust Assembly ( Kubota MR8 ) .............................................. 4-2-144
Figure 2-71 Exhaust Assembly ( Kubota MR10 ) ............................................ 4-2-146
Figure 2-72. Cooling System ( Deutz Tier2 ) .................................................... 4-2-148
Figure 2-73. Cooling System ( Deutz Tier 4i ) .................................................. 4-2-150
Figure 2-74. Oil Cooling System ( Kubota ) ..................................................... 4-2-152
Figure 2-75. Engine and Transmission ( Deutz Tier 2 and C6 ) ..................... 4-2-154
Figure 2-76 Engine and Transmission ( Kubota and C6 ) .............................. 4-2-156
Figure 2-77. Transmission Oil Pan Assembly ( C6 ) ....................................... 4-2-157
Figure 2-78 Transmission Filter Screen and Valve Body ( C6 ) ...................... 4-2-158
Figure 2-79. Transmission Band Adjustment ( C6 ) ........................................ 4-2-160
Figure 2-80. Shifter Assembly ( C6 ) .............................................................. 4-2-162
Figure 2-81 Shifter Linkage ( C6 ) ................................................................... 4-2-164
Figure 2-82. Park Brake Lever Installation ( C6 ) ............................................ 4-2-166
Figure 2-83. Transmission Park Brake Assembly ( C6 ) ................................ 4-2-168
Figure 2-84. Engine and Tramsmission Assembly ( Deutz Tier 4i and 4R75 Trans-
mission ) ........................................................................................................... 4-2-170
Figure 2-85. Transmission ( 4R75 ) Assembly ................................................. 4-2-172
Figure 2-86. Transmission Sensors Installation ( 4R75 ) ................................. 4-2-174
Figure 2-87 Transmission Oil Pan Installation ( 4R75 ) ................................... 4-2-176
Figure 2-88. Shifter Assembly ( 4R75 Transmission ) ..................................... 4-2-178
Figure 2-89. Park Brake Assembly ( 4R75 Transmission ) .............................. 4-2-180
Figure 2-90. Drive Shaft Assembly ( C6 ) ......................................................... 4-2-182
Figure 2-91. Drive Shaft Assembly ( 4R75 Transmission ) ............................... 4-2-184
Figure 2-92. Deutz Tier 4i ECU and 4R75 TCU Installation ............................ 4-2-186
Figure 2-93. VEC Panel Assembly ( Deutz Tier 2 ) .......................................... 4-2-188
Figure 2-94 TEC Panel Assembly ( Deutz Tier 4i ) ........................................... 4-2-190
Figure 2-95. Brake Line System ...................................................................... 4-2-192
Figure 2-96. Hydroboost Installation ................................................................ 4-2-194
Figure 2-97. Battery Assembly ........................................................................ 4-2-196
Figure 2-98. Battery Assembly with Heater Option .......................................... 4-2-198
Figure 2-99. Battery Assembly ( CE Option ) .................................................. 4-2-200
Figure 2-100. Heater Junction Box ( Optional ) ............................................... 4-2-202
Figure 2-100. Horn Installation ........................................................................ 4-2-204
SECTION 3: NUMERICAL INDEX .............................................................................................. 4-3-1
SECTION 4: ALPHABETICAL INDEX ....................................................................................... 4-4-1
CD387 4-TOC-iii
Orig
Chapter 4
4-TOC-iv CD387
Orig
Chapter 4
SECTION 1: DESCRIPTION
A. INTRODUCTION
The Illustrated Parts List (IPL) contained in this manual furnishes spare parts and replacement parts
information as well as general part and assembly information necessary for maintenance of the TUG
Model MR Mid-Range Tow Tractor
CD387 4-1-1
Orig
Chapter 4
B. USING THE ILLUSTRATED PARTS LIST
The Illustrated Parts List (IPL) provides an illustrated breakdown of components and systems which
comprise the MR Mid-Range Tow Tractor. Each IPL consists of a figure illustrating a group of
related parts and a corresponding list identifying the parts by part number(s) and description. The
quantity given in the list is for the particular assembly shown in the illustration and is not necessarily
the quantity for the entire unit.
1. Figure and Index Number

The figure and index number refers to the figure on which the part is depicted. The index
number refers to the individual part shown on the illustration. See the following example for
further explanation of the Figure and Index Number.
Refers to the figure number, and the Fig & Tug Part
Description
item's number on that figure. Ind Number
46-1 TM1-1-9693 Engine, Deutz F4M2011 Tier II
Figure and index number blank: ENG-M1A-24 Engine, Deutz FM2011, without
This item is one of possibly many 46-2 TM1-ND-5046 Adapter (Oil Sensor Metric to E
items designated by a single 46-3 TM1-ND-5047 Reducer, Oil Sensor (Deutz)
Figure and Index Number. The first 46-4 T6-1001-133 Sender, Oil Pressure (Bore & Ta
item in such a group is assigned a 46-5 MD-P21-105 Isolator, Trasmission, Mount C6
number; the rest of these items are 46-6 T6-1008-111 Transmission, C6, 3 Speed
listed directly below. These items 46- T6-1001-101TP Parts, Transmission
are generally similar in function, but 46-7 02-02-140239 Fitting, 90°
have different applicabilities or 46-8 ------ Pump, Oil (Included with Engine
effectivities. 46-9 TM1-2-9739 Bracket, Exhaust at Engine
46-10 999-0230A Adapter, Drive
No Index Number: This item is 46-11 TPG-D5TZ-6375A Flywheel Assembly, C6
related to the components or 46-12 660-2-2320 Closeout, Flywheel - Diesel (De
system in the illustration, but is 46-13 ½-13 x 1 Bolt, Hex Head Ø ½-13 x 1" Lon
not actually shown. In certain 46-14 T6-7016-105 Cable, Ground, Braided 12EE
cases, such items are shown in 46-15 ------ Arm, Shift (Part of Transmission
other figures in section 4-2. 46-16 ------ Dipstick Assembly, Transmissio
NOTE: Sample tables in this section are intended to illustrate table structure
Note and format, and should not be used for reference of actual data. Refer to
applicable figure for specific required part information.
4-1-2 CD387
Orig
Chapter 4
2. Part Number
Parts are identified by part numbers assigned by TUG or, in the case of fasteners and related
materials, by industry standard specification. In a few instances, TUG part numbers are not
available. See the following illustration for further explanation of Part Numbers.
Part number assigned by

TUG.
Fig & Tug Part

Description
Ind Number
46-1 TM1-1-9693 Engine, Deutz F4M2011 Tier II

ENG-M1A-24 Engine, Deutz FM2011, without
46-2 TM1-ND-5046 Adapter (Oil Sensor Metric to E
46-3 TM1-ND-5047 Reducer, Oil Sensor (Deutz)
46-4 T6-1001-133 Sender, Oil Pressure (Bore & Ta
46-5 MD-P21-105 Isolator, Trasmission, Mount C6
46-6 T6-1008-111 Transmission, C6, 3 Speed
46- T6-1001-101TP Parts, Transmission
46-7 02-02-140239 Fitting, 90°
46-8 ------ Pump, Oil (Included with Engine
46-9 TM1-2-9739 Bracket, Exhaust at Engine
46-10 999-0230A Adapter, Drive
46-11 TPG-D5TZ-6375A Flywheel Assembly, C6
46-12 660-2-2320 Closeout, Flywheel - Diesel (De
46-13 ½-13 x 1 Bolt, Hex Head Ø ½-13 x 1" Lon
46-14 T6-7016-105 Cable, Ground, Braided 12EE
46-15 ------ Arm, Shift (Part of Transmission
46-16 ------ Dipstick Assembly, Transmissio
No TUG part number indicates that TUG has not assigned a

part number to the part. It may also indicate that the part is not
supplied separately from another part to which it is related.
3. Description and Quantity

A description and quantity is provided for each part listed in the IPL. The quantity given for
subassemblies and subparts is the number of subassemblies/parts contained in the component
or system depicted by the associated illustration, not necessarily the entire vehicle.
CD387 4-1-3
Orig
Chapter 4
4. Effectivity
The effectivity of each item in the parts list is given in part or in whole in the “Effective”
column of the IPL. Information concerning the effectivity of a particular part may also be
found in the description column, the figure title or in notes located at the bottom of the IPL
page. Effectivity is usually (but not always) associated with the serial number.
C. ORDERING SPARE PARTS
To ensure that proper spares and replacement parts are obtained, it is recommended that all major
components be procured directly from TUG. Use of parts not manufactured or supplied by TUG may
void the warranty on the vehicle. When replacing structural fasteners, use Grade 8 or higher material.
Spare parts can be ordered directly from TUG by telephoning TUG SHOP at
1-800-989-8499 (toll free in U.S. and Canada) or 770-422-8021 (outside U.S. or Canada). Ask for
TUG SHOP when calling. FAX messages can be sent to 770-422-8730 (U.S.).
When ordering parts, please be prepared with TUG part numbers, part description, figure and index
number and the revision of the IPL page (located in the footer of each page, directly under each page
number).
TUG SHOP business hours are from 8:00 a.m. until 5:00 p.m. Eastern time, Monday through Friday.
Answering machines are ready to receive calls after regular business hours. All calls received after
hours will be returned during the next regular business day.
4-1-4 CD387
Orig
Chapter 4
SECTION 2: ILLUSTRATED PARTS LIST
A. INTRODUCTION
The following illustrations and corresponding tables comprise the Illustrated Parts List (IPL) for the
MR Mid-Range Tow Tractor. Refer to Section 1 of this Chapter for instructions on using the IPL to
identify spare parts and replacement parts information. The IPL can also be used to obtain general part
and assembly information necessary for maintenance of the vehicle.
CD387 4-2-1
Orig
Chapter 4
12
13
10 11
14
26
16
15
17
23 18
19
9
20 1
25
8
21
2
22
3
4
24
5
7
6
Figure 2-1. Frame Weldment (w/ Hitch, Light, and Back-up Alarm Options)
4-2-2 CD387
Orig
Chapter 4
Table 2-1. Frame Weldment (w/ Hitch, Light, and Back-up Alarm Options)
Fig & Tug Part

Description Qty Effective
Ind Number
1-1 MR-1270K Frame Weldment Kit, MR10-36T 1 22 To 92

MR-1272K Frame, Weldment Kit MR8-36 1 "
MR-1271K Frame, Weldment Kit MR10-24T 1 1 To 92
MR-1309 Frame, Weldment MR10-34T 1 60 To 92
MR-1327 Frame Weldment Kit, MR10-36T 1 93 & Up
MR-1328 Frame, Weldment Kit MR10-24T 1 "
MR-1329 Frame, Weldment MR10-34T 1 "
1-2 MT-4-1175 Hitch Assembly, "E" (Opt.) 1 As Req'd
1-3 T6-4025-103 Pintle Hitch, Holland 400CA - Opt 1 "
1-4 ¾-10 x 2½ Bolt, Hex Head Ø ¾-10 x 2½" Long-Opt 4 "
1-5 ¾ Washer, Lock ¾" ID - Opt 4 "
1-6 T6-4025-108 Hitch, Pintle W/Push Botton - Opt 1 "
1-7 MR-1105 Ring, Lashing 4 1 & Up
1-8 ¾-10 Nut, Top Lock Hex ¾-10 4 "
1-9 ¾ Washer, Flat ¾" ID 4 "
1-10 ¾-10 x 5 Bolt, Hex Head Ø ¾-10 x 5" Long 4 "
1-11 660-2-1632B Post, Light, 42" (Opt.) 1 As Req'd
1-12 T6-9011-391 Light, Rotating Amber (Opt.) 1 "
T6-1300-223 Light, Flashing Amber (Opt.) 1 "
1-13 T6-1300-181 Alarm, Back-Up - 12VDC (Opt.) 1 "
1-14 MT-4-1177 Enclosure, Extention - Opt 1 "
1-15 MT-4-1176 Extension, Hitch 1 1 & Up
1-16 T6-4025-103 Pintle Hitch, Holland 400CA 1 "
1-17 MR-1283 Ring, Lifting - Opt 4 "
1-18 MR-1284 Plate, Rear Lifting Ring - Opt 2 As Req'd
1-19 MR-1285 Gusset, Rear Lifting Ring - Opt 4 "
1-20 MR-1110 Decal, Tire Pressure 75PSI 2 1 & Up
1-21 T-G1 Sticker, Diesel Only 1 "
1-22 T-A56 Decal, Ultra Low Sulfur Diesel 1 "
1-23 MT-4-1175 Hitch Assembly, "E" (Opt.) 1 As Req'd
1-24 MR-1326 Decal, Tire Pressure 90PSI 2 1 & Up
1-25 MR-1331 Ballast, Right, Rear Cast 1 93 & Up
1-26 MR-1330 Ballast, Left, Rear Cast 1 "
CD387 4-2-3
Orig
Chapter 4
11
9 10
6
4 7
5
2 28
3 25
1
24
23
26
8 27
13
21
20
19
15
12
22 13
17
16 18
14
15
12
14
Figure 2-2. Access Panels, Deutz Tier2, Kubota
4-2-4 CD387
Orig
Chapter 4
Table 2-2. AccessPanels, Deutz Tier2, Kubota
Fig & Tug Part

Ind Number
2-1 MR-1271K Frame Weldment Kit, MR10-24T 1 1 & Up

MR-1270K Frame Weldment Kit, MR10-36T 1 22 & Up
MR-1272K Frame Weldment Kit, MR8-36 1 "
2-2 MR-1103 Panel, Rear Axle Access (Wldmt) 1 1 & Up
2-3 ¼-28 Nutsert, Flange Ribbed ¼-28 4 "
2-4 ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 4 "
2-5 ¼ Washer, Lock ¼" ID 4 "
2-6 ¼ Washer, Flat ¼" ID 4 "
2-7 MR-1248 Panel, Top Transmission Closeout 1 "
2-12 MR-1244 Panel, Wheel Well Closeout 2 "
2-13 ¼-20 Nut-U ¼-20 UNC 4 "
2-14 ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 4 "
2-15 ¼-20 x 1½ Bolt, Hex Head Ø ¼-20 x 1½" Long 4 "
2-17 ¼-20 Nut, Top Lock Hex ¼-20 4 "
2-19 MR-1249 Panel, Side Transmission Closeout 2 "
2-23 MR-1157 Plate, Connector Mounting 1 "
2-24 10 Washer, Flat #10 4 "
2-25 10-32 Nut, Nylock #10-32 4 "
2-26 10-32 x 1 Screw, Phillips Pan Head Ø #10-32 x 1" Long 4 "
2-27 MR-1142 Elbow, Connector 2 "
2-28 MR-1086 Mat, Park Brake Boot 1 "
CD387 4-2-5
Orig
Chapter 4
31
9 11
10
6 7
30
4 29
5
32
28
2
33
3 25
1
24
23
26
8 27
13
21
20
19
15
12
22 13
17
16 18
14
15
12
14
Figure 2-3. Access Panels, Deutz Tier4i
4-2-6 CD387
Orig
Chapter 4
Table 2-3. Access Panels Deutz 4i
Fig & Tug Part

Ind Number
3-1 MR-1309 Frame, Weldment, MR10-34T 1 60 & Up

3-2 MR-1103 Panel, Rear Axle Access (Wldmt) 1 1 & Up
3-7 MR-1311 Panel, Top Transmission Closeout 1 60 & Up
3-8 ¼-28 Nutsert, Flange Ribbed ¼-28 19 1 & Up
3-13 ¼-20 Nut-U ¼-20 UNC 4 "
3-17 ¼-20 Nut, Top Lock Hex ¼-20 4 "
3-19 MR-1249 Panel, Side Transmission Closeout 2 "
3-23 MR-1157 Plate, Connector Mounting 1 "
3-24 10 Washer, Flat #10 4 "
3-25 10-32 Nut, Nylock #10-32 4 "
3-27 MR-1142 Elbow, Connector 2 "
3-28 TY-38 Decal, Hood Latch 1 "
3-29 T-430 Caution, Operators Shall Be… 1 "
3-30 1028 Warning, Avoid Injury 1 "
3-31 ML-26 Caution, Tractor To Come To… 1 "
3-32 MX4-10206 Decal, Vehicle Operation 1 "
3-33 MR-1086 Mat, Park Brake Boot 1 "
CD387 4-2-7
Orig
Chapter 4
21 19
4
9 17 20
22
11 18
6 12 14
5 13 2 25 26
9 16
15 4 31
13
22 3
14 11
8
9 30
17 7
10
4 10 29
7 6
52 23 24 38
8 5 36
51 32
50 7
53 27 32 45
37
24
32
31
27 28
40
42
44 47
46
29
1 35
25
37
26 53 45
40 41
23 42 46
30 47
26 39 28 34
49
43
48 29
35
54
33
41
35
42
44
36
40
Figure 2-4. Hood Assembly
4-2-8 CD387
Orig
Chapter 4
Table 2-4. Hood Assembly
Fig & Tug Part Fig & Tug Part

Description Qty Effective Description Qty Effective
Ind Number Ind Number
4-1 MR-1271K Frame Weldment Kit, MR10-24T 1 1 & Up 4-28 MR-1171 Arm, Hood Hinge 2 1 & Up
MR-1270K Frame Weldment Kit, MR10-36T 1 22 & Up 4-29 MD-CB1-127 Bushing, Hood 4 "
MR-1272K Frame Weldment Kit, MR8-36 1 " 4-30 ½-13 x 2½ Bolt, Hex Head Ø ½-13 x 2½" Long 2 "
MR-1309 Frame, Weldment, MR-34T 1 60 & Up 4-31 ½ Washer, Flat ½" ID 4 "
4-2 MR-1245 Hood 1 1 & Up 4-32 ½-13 Nut, Top Lock Hex ½-13 2 "
4-3 T6-4005-109 Handle, Hood 2 " 4-33 MT-1-1273 Spring, Gas Hood 2 "
4-4 ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 4 " 4-34 ------ End, Rod, Gas Hood Spring 4 "
4-5 ¼-20 Washer, Flat ¼" ID 4 " 4-35 MT-1-1277 Stud, 13mm Ball (1" Long Threaded) 2 "
4-6 ¼-20 Nut, Top Lock Hex ¼-20 4 " 4-36 MR-1194 Clip, Gas Hood Spring 4 "
4-7 T6-4006-111R Latch, Rubber Hood w/Hook 2 " 4-37 5/16-18 Nut, Top Lock Hex 5/16-18 2 "
4-8 10-32 x ¾ Screw, Phillips Pan Head Ø #10-32 x ¾" Long 8 " 4-38 5/16 Washer, Flat 5/16" ID 4 "
4-9 10-32 Nut, Nylock #10-32 4 " 4-39 MR-1175 Bracket, Hood Strut Ball Stud 2 "
4-10 660-4-0600-5 Bumper, Rubber Hood 2 " 4-40 MT-1-1349 Stud, 13mm Ball (0.63" Long Threaded) 2 "
4-11 8-32 Nut, Nylock #8-32 2 " 4-41 5/16-18 Nut, Top Lock Hex 5/16-18 2 "
4-12 MR-1246 Cowling 1 " 4-42 5/16 Washer, Flat 5/16" ID 4 "
4-13 MR-1172 Bracket, Firewall Cowl 2 " 4-43 10-32 x 1 Screw, Phillips Pan Head Ø #10-32 x 1" Long 4 "
4-14 ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 8 " 4-44 10-32 Nut, Nylock #10-32 4 "
4-15 ¼ Washer, Flat ¼" ID 8 " 4-45 5/16-18 x 1¼ Bolt, Hex Head Ø 5/16-18 x 1¼" Long 4 "
4-16 ¼ Washer, Lock ¼" ID 4 " 4-46 5/16 Washer, Flat 5/16" ID 8 "
4-17 ¼-20 Nut, Top Lock Hex ¼-20 4 " 4-47 5/16-18 Nut, Top Lock Hex 5/16-18 4 "
4-18 MR-1250 Guard, E-Stop 1 " 4-48 MR-1173 Bracket, Prop Rod Retainer 1 "
4-19 ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 2 " 4-49 T6-4005-121 Clip, Hood Rod 1 "
4-20 ¼ Washer, Flat ¼" ID 2 " 4-50 MR-1251 Rod, Hood Prop 1 "
4-21 ¼-20 Nut, Top Lock Hex ¼-20 2 " 4-51 MR-1193 End, Hood Prop Rod 1 "
4-22 12902092 Weather Stripping (Trim-Lock, 90°) 2 " 4-52 A9002 Clip, Prop Rod End Retainer 1 "
4-23 MR-1170 Base, Hood Hinge (Passenger Side) 1 " 4-53 A9008 Stud, 10mm Ball 1 "
4-24 MT-2-1092 Base, Hood Hinge (Driver Side) 1 " 4-54 ¼-20 Nut, Top Lock Hex ¼-20 1 "
4-25 3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long 6 "
4-26 3/8 Washer, Flat 3/8" ID 12 "
4-27 3/8-16 Nut, Top Lock Hex 3/8-16 6 "
CD387 4-2-9
Orig
Chapter 4
2
3
4
2
4
5
8
12 7
11 9
4
6
10
Figure 2-5. Cab Mounting
4-2-10 CD387
Orig
Chapter 4
Table 2-5. Cab Mounting
Fig & Tug Part

Ind Number
5-1 CMR-1001 Cab Weldment 1 1 & Up
5-3 3/8 Washer, Lock 3/8" ID 4 "
5-4 3/8 Washer, Flat 3/8" ID 8 "
5-5 7/16 Washer, Flat 7/16" ID 6 "
5-6 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
5-7 MR-1274-1 Grip Paper, Driver Step 1 "
5-8 ¾-10 x 1½ Bolt, Hex Head Ø ¾-10 x 1½" Long 4 "
5-9 HRN-MR-0009 Harness, Cab 1 "
5-10 MR-1274-2 Grip Paper, Passenger Step 1 "
5-11 MR-1274-4 Grip Paper, Passenger Floor 1 "
5-12 MR-1274-3 Grip Paper, Driver Floor 1 "
5- MR-1274 Grip Paper Kit (Includes items 7, 10-12) 1 "
CD387 4-2-11
Orig
Chapter 4
1
7
6
4
2
5
3
4
Figure 2-6. Cab Insulation
4-2-12 CD387
Orig
Chapter 4
Table 2-6. Cab Insulation
Fig & Tug Part

Ind Number
6-2 MR-1280 Plate, Data - Cab Assembly- Opt 1 As Req-ed
6-3 MR-1046 Seal, Bulb, Firewall 1 1 & Up
6-4 CMA-504 Strip, Seal (30.5' Long) 4 "
6- CMR-1018 Insulation Kit, Cab & Doors 1 "
6-5 ------ Insulation, Foam - Cab Rear (Part of CMR-1018) 2 "
6-6 ------ Insulation, Foam - Cab Side (Part of CMR-1018) 1 "
6-7 ------ Liner, Head 5' (Part of CMR-1018) 1 "
CD387 4-2-13
Orig
Chapter 4
13
12
11
14
7 1
8
5 2
2
7
10
6
9 3
8
2 4
2 6
10
3
9
4
Figure 2-7. Cab Mirrors
4-2-14 CD387
Orig
Chapter 4
Table 2-7. Cab Mirrors
Fig & Tug Part

Ind Number
7-1 CMR-1001 Cab, Weldment 1 As Req'd
7-2 T6-9011-383 Bracket, Mirror Mounting 4 "
7-3 #10-32 x ½ Screw, Phillips Pan Head Ø 10-32 x ½" Long 8 "
7-4 #10-32 Washer, Lock #10-32 8 "
7-5 #10-32 Nut, Nylock #10-32 8 "
7-6 M3-ND-5011 Mirror, 5" Convex 2 "
7-9 ¼-20 Nut, Top Lock Hex ¼-20 2 "
7-11 T6-9011-569 Bracket, Light on Rear Cab - Opt 1 "
7-12 T6-9003-171 Grommet, Windshield - Opt 1 "
7-13 T6-9011-391 Light, Rotating Amber - Opt 1 "
T6-1300-223 Light, Flashing Amber -Opt 1 "
7-14 MR-1258 Eye, Lifting 4 "
CD387 4-2-15
Orig
Chapter 4
11 15
10
25 3
18 22
17
19
14 2 5
16
1
4
12 13 16 17 22
15 4
18
11 3
10 24 25
6 14 23
13 19 5
12 20
21
21
7 19
24
8
23
9 7
20
Figure 2-8. Cab Door Installation
4-2-16 CD387
Orig
Chapter 4
Table 2-8. Cab Door Installation
Fig & Tug Part

Ind Number

8-2 CMR-1032 Door Assembly - L/H 1 "
8-3 CMR-1010 Hinge, Driver Door 2 "
8-5 ¼-20 x 1 Screw, Button Head Socket Ø ¼-20 x 1" Long 8 "
8-6 CMR-1033 Door Assembly - R/H 1 "
8-7 CMR-1011 Hinge, Passenger Door 2 "
8-10 CMR-1024 Plate, Striker Mount 2 "
8-11 CMR-1023 Plate, Striker Bolt Mount 2 "
8-12 CMR-1005 Bolt, Striker 2 "
8-13 10-32 x ¾ Screw, Phillips Pan Head Type F Ø 10-32 x ¾" Long 4 "
8-14 M12 Washer, Flat M12 4 "
8-15 CMR-1020 Plate, Striker Access 2 "
8-19 CMR-1013 Strap, Check 2 "
8-20 CMR-1022 Mount, Check Strap 2 "
8-21 MR-1262 Pin, Check Strap 2 "
8-22 CMR-1014 Bracket, Check Strap Mounting 4 "
CD387 4-2-17
Orig
Chapter 4
5
6
8
3 9
2
7
10
19 1
4
17
6
19 16 8
20 18 9
7
24
10
23
21 17 11
22 19 16 19 25
20 21
13
12
15 14
Figure 2-9. Driver (L/H) Door Assembly
4-2-18 CD387
Orig
Chapter 4
Table 2-9. Driver (L/H) Door Assembly
Fig & Tug Part

Ind Number
9-1 CMR-1002 Door Weldment Kit, Driver (L/H Door) 1 As Req'd
9-2 CMA-504 Strip, Seal, Door 14 "
9-3 CMR-1029 Window, Driver Side Door 1 "
9-4 MR-1014 Handle, Black Grab 1 "
9-5 T6-9003-165 Gasket, Glass Window Ref. "
9-6 CMR-1017 Handle Assembly, Driver Inner Door 1 "
9-7 ------ Base, Driver Door Paddle 1 "
9-8 ------ Handle, Driver Door Paddle 1 "
9-9 ¼-20 x ¾ Screw, Phillips Pan Head Ø ¼-20 x ¾" Long 2 "
9-10 10-32 x ¾ Screw, Phillips Pan Head Ø 10-32 x ¾" Long 2 "
9-11 ------ Insulation, Foam - Driver Door* 1 "
9-12 CMR-1021 Plate, Door Cover 1 "
9-16 CMR-1025 Rod, Driver Door Latch to Ext. Handle 1 "
9-17 CMR-1006 Latch, Driver Door 1 "
9-18 ¼-20 Nut, Top Lock Hex ¼-20 4 "
9-19 CMR-1015 Clip, Rod 2 "
9-20 CMR-1016 Clip, Rod 1 "
9-21 CMR-1009 Handle, Driver Door Paddle 1 "
9-22 10-32 x 1 Screw, Button Head Socket Ø 10-32 x 1" Long 4 "
9-23 ¼-20 x 1¼ Bolt, Hex Head Ø ¼-20 x 1¼" Long 4 "
9-25 CMR-1026 Rod, Driver Door Latch to Int. Handle 1 "
CD387 4-2-19
Orig
Chapter 4
17
1
2
3
5 6
16 15
14 13
12
7 8
11 10 9
Figure 2-10. Window, Driver (L/H) Door Assembly
4-2-20 CD387
Orig
Chapter 4
Table 2-10. Window, Driver /H) Door Assembly
Fig & Tug Part

Ind Number
10-1 CMR-1029-17 Latch, Slider 2 1&Up
10-2 CMR-1029-16 Screw, Phillips Pan Head, 6x1.00 4 "
10-3 CMR-1029-1 Frame, Window 1 "
10-4 CMR-1029-4 Vent Assembly 1 "
10-5 CMR-1029-5 Latch, Vent 1 "
10-6 CMR-1029-6 Screw, Phillips Pan Head, 8x .625 2 "
10-7 CMR-1029-8 Filler, Channel 4.8' "
10-8 CMR-1029-7 Seal, Bulb 3.2' "
10-9 CMR-1029-9 Million Assembly 1 "
10-11 CMR-1029-10 Plate, Splice 1 "
10-12 CMR-1029-12 Seal, Max 5' "
10-13 CMR-1029-3 Slider, Front Assembly 1 "
10-14 CMR-1029-13 Strip, Weather 7.7' "
10-15 CMR-1029-14 Plate, Strike 1 "
10-16 CMR-1029-15 Rivet, Zipriv, 0.125 3 "
10-17 CMR-1029-2 Slider, Rear, Assembly 1 "
CD387 4-2-21
Orig
Chapter 4
6 4
8
9
7
3
2
1
10
6 20
18 19
8 18 5
9 19
17
7
22 24
10
23
11
16 17 20
13
15 21
21 19
14 12 25 25 19
Figure 2-11. Passenger (R/H) Door Assembly
4-2-22 CD387
Orig
Chapter 4
Table 2-11. Passenger (R/H) Door Assembly
Fig & Tug Part

Ind Number
11-1 CMR-1003 Door Weldment Kit, Pass. (R/H Door) 1 As Req'd

11-2 CMA-504 Strip, Seal - Door 14 "
11-3 CMR-1030 Window, Passenger Side Door 1 "
11-4 T6-9003-165 Gasket, Glass Window Ref. "
11-5 MR-1014 Handle, Black Grab 1 "
11-6 CMR-1019 Handle Assembly, Pass. Inner Door 1 "
11-7 ------ Base, Driver Door Paddle 1 "
11-8 ------ Handle, Driver Door Paddle 1 "
11-10 10-32 x ¾ Screw, Phillips Pan Head Ø 10-32 x ¾" Long 2 "
11-11 ------ Insulation, Foam - Passenger Door* 1 "
11-12 CMR-1021 Plate, Door Cover 1 "
11-16 CMR-1026 Rod, Pass. Door Latch to Int. Handle 1 "
11-17 CMR-1008 Latch, Passenger Door 1 "
11-18 CMR-1025 Rod, Pass. Door Latch to Ext. Handle 1 "
11-19 CMR-1015 Clip, Rod 1 "
11-20 CMR-1016 Clip, Rod 2 "
11-21 CMR-1007 Handle, Passenger Door Paddle 1 "
11-22 ¼-20 Nut, Top Lock Hex ¼-20 4 "
11-25 10-32 x 1 Screw, Button Head Socket Ø 10-32 x 1" Long 4 "
CD387 4-2-23
Orig
Chapter 4
17
2
3
6 5
15 16
13 14
12
8 7
10 11
9
Figure 2-12. Window, Passenger (R/H) Door Assembly
4-2-24 CD387
Orig
Chapter 4
Table 2-12. Window, Passenger (R/H) Door Assembly
Fig & Tug Part

Ind Number
12-1 CMR-1029-17 Latch, Slider 2 1&Up
12-2 CMR-1029-16 Screw, Phillips Pan Head, 6x1.00 4 "
12-3 CMR-1030-1 Frame, Window 1 "
12-4 CMR-1030-4 Vent Assembly 1 "
12-5 CMR-1029-5 Latch, Vent 1 "
12-7 CMR-1029-8 Filler, Channel 4.8' "
12-8 CMR-1029-7 Seal, Bulb 3.2' "
12-9 CMR-1029-9 Million Assembly 1 "
12-11 CMR-1029-10 Plate, Splice 1 "
12-12 CMR-1029-12 Seal, Max 5' "
12-13 CMR-1030-3 Slider, Front Assembly 1 "
12-14 CMR-1029-13 Strip, Weather 7.7' "
12-15 CMR-1029-14 Plate, Strike 1 "
12-16 CMR-1029-15 Rivet, Zipriv, 0.125 3 "
12-17 CMR-1030-2 Slider, Rear, Assembly 1 "
CD387 4-2-25
Orig
Chapter 4
TYPICAL WINDOW MOUNTING
2
5
4
2
6
8 3
7 1
Figure 2-13. Cab Windows
4-2-26 CD387
Orig
Chapter 4
Table 2-13. Cab Windows
Fig & Tug Part

Ind Number
13-1 CMR-1031 Windows, Rear Side 2 1 & Up
13-2 T6-9003-165 Gasket, Glass Window (by the foot) 28' "
13-3 CMR-1028 Windshield, Rear 1 "
13-4 T6-9011-105 Fan, Cab - Opt. 2 As Req'd
49.32 13-5 5/16 x 1 Screw, Self Tapping Ø 5/16 x 1" Long 6 "
13-6 CMR-1027 Windshield 1 1 & Up
13-7 920408C1 Mirror, Rear View 1 "
13-8 A13850 Bracket, Mirror Mounting 1 "
R1.29
6 WINDSHIELD
24.15
(23.55)
19.60
4X R2.66
1
51.32
2X R2.66
2.82
3 REAR WINDOW
25.50
4X R2.66
CD387 4-2-27
Orig
Chapter 4
19 39
7 11
20 6 10
5 REF 9 REF
21
22 40
8 12
23
24 43
34 27
25 18 5 2
38 26
4 4
42 41 37
3 3
36 9
44 13 35
34 28
18
36 REF 29
45 33
44
30
45
1 37
14
38
32 31
15
17 16 13
Figure 2-14. Front Windshield Wipers
4-2-28 CD387
Orig
Chapter 4
Table 2-14. Front Windshield Wipers

14-1 CMR-1001 Cab Weldment 1 1 & Up 14-23 ------ Connector, Wiper Arm 1 1 & Up
14-2 MR-1256 Cover, Front Wiper 1 " 14-24 ------ Washer, Star 1 "
14-3 ¼-20 x ¾ Screw, Phillips Pan Head Ø ¼-20 x ¾" Long 3 " 14-25 ------ Nut, Wiper Arm 1 "
14-4 ¼ Washer, Star ¼" ID 3 " 14-26 ------ Pin, Wiper Pivot Shaft 1 "
14-5 MR-1252 Switch, Rear Windshield Wiper 1 " 14-27 ¼-28 Nut, Hex ¼-28 1 "
14-6 ------ Nut 2 " 14-28 10-32 x 3/8 Screw, Slotted Round Head Ø #10-32 x 3/8" Long 4 "
14-7 ------ Knob 1 " 14-29 10 Washer, Star #10 4 "
14-8 ------ Screw 1 " 14-30 ------ Linkage, Wiper Motor to Wiper Arm 1 "
14-9 MR-1252 Switch, Front Windshield Wiper 1 " 14-31 ------ Washer 1 "
14-10 ------ Nut 2 " 14-32 MR-1255 Clip, Wiper Linkage 1 "
14-11 ------ Knob 1 " 14-33 MT-1-2061 Pin, Wiper Pivot Shaft 1 "
14-12 ------ Screw 1 " 14-34 ¼ Washer, Star ¼" ID 2 "
14-13 HRN-MR-0009 Harness, Cab 1 " 14-35 ¼-28 Nut, Hex ¼-28 1 "
14-14 MR-1268 Motor, Wiper Front 1 " 14-36 MR-1254 Linkage, Wiper Arm to Wiper 1 "
14-15 M6-1.0 x 12 Bolt, Flange Head Ø M6-1.0 x 12mm Long 3 " 14-37 MR-1255 Clip, Wiper Linkage 2 "
14-16 ------ Arm, Drive 1 " 14-38 ------ Washer 2 "
14-17 M8-1.25 Nut, Flange M8-1.25 1 " 14-39 TM1-1-6529 Adapter, Pantograph Wiper, Dual 2 "
14-18 MR-1259 Shaft, Wiper Pivot 2 " 14-40 ------ Gasket, Pantograph Arm 1 "
14-19 ------ Washer, Rubber 1 " 14-41 ------ Washer 1 "
14-20 ------ Washer 1 " 14-42 ------ Nut, Pantograph Arm 1 "
14-21 ------ Nut, Wiper Pivot Shaft 1 " 14-43 10-32 x ¾ Screw, Phillips Pan Head Type F Ø 10-32 x ¾" Long 2 "
14-22 ------ Boot, Rubber 1 " 14-44 MR-1261 Arm, Wiper Drive 2 "
14-45 MR-1253 Blade, Wiper - Front, 16" 2 "
NOTE: P/N MR-1268, Front Wiper Motor includes items 15-18, 28-29 and 30-35.
CD387 4-2-29
Orig
Chapter 4
20
21
10
19
2
5
4
25 3
11
12
13
14 18 22
15
26
16 29 6
17 23
7
8
27 32
28 24 9
1
30
31
Figure 2-15. Rear Windshield Wipers
4-2-30 CD387
Orig
Chapter 4
Table 2-15. Rear Windshield Wipers
Fig & Tug Part

Ind Number

15-2 MR-1257 Cover, Rear Wiper 1 "
15-5 ¼-20 Nut, Top Lock Hex ¼-20 2 "
15-6 MR-1269 Motor, Wiper Rear 1 "
15-7 M6-1.0 x 12 Bolt, Flange Ø M6-1.0 x 12mm Long 3 "
15-8 ------ Arm, Drive 1 "
15-9 M8-1.25 Nut, Flange M8-1.25 1 "
15-10 MR-1259 Shaft, Wiper Pivot 2 "
15-11 ------ Washer, Rubber 1 "
15-12 ------ Washer 1 "
15-13 ------ Nut, Wiper Pivot Shaft 1 "
15-14 ------ Boot, Rubber 1 "
15-15 ------ Connector, Wiper Arm 1 "
15-16 ------ Washer, Star 1 "
15-17 ------ Nut, Wiper Arm 1 "
15-18 ------ Pin, Wiper Pivot Shaft 1 "
15-19 ¼-28 Nut, Hex ¼-28 1 "
15-20 10-32 x 3/8 Screw, Slotted Round Head Ø #10-32 x 3/8" Long 2 "
15-21 10 Washer, Star #10 3 "
15-22 ------ Linkage, Wiper Motor to Wiper Arm 1 "
15-23 ------ Washer, Flat 2 "
15-24 MR-1255 Clip, Wiper Linkage 2 "
15-25 TM1-1-6529 Adapter, Pantograph Wiper 1 "
15-26 ------ Gasket, Pantograph Adapter 1 "
15-27 ------ Washer 1 "
15-28 ------ Nut, Pantograph Arm 1 "
15-29 10-32 x ¾ Screw, Phillips Pan Head Type F Ø 10-32 x ¾" Long 2 "
15-30 MR-1261 Arm, Wiper Drive 1 "
15-31 MR-1253 Blade, Wiper Rear 2 "
15-32 HRN-MR-0009 Harness, Cab 1 "
NOTE: 1. P/N MR-1269, Rear Wiper Motor includes items 7-9, and 22-24.
2. P/N MR-1259, Shaft, Rear Pivot includes itens 11-18
CD387 4-2-31
Orig
Chapter 4
1 2
32 2 11 3
5 12 1
1
13
9 11
10 20
5 12
8
1 13
4 9
10
20
8
14 32 4
19 6
7
6
18 1
7
15 16 33
20
17
Front View 30
29
29
30
32
28
27
27
27
31
28 26 25
23
24
22 21 Rear View
Figure 2-16. Exterior Lamp Assemblies
4-2-32 CD387
Orig
Chapter 4
Table 2-16. Exterior Lamp Assemblies
Fig & Tug Part

Ind Number
16-1 MR-1149 Headlight Assembly w/Connector 2 1 & Up

16-2 MR-1149-1 Headlight Assembly 2 "
16-3 MR-1149-2 Bulb, Headlight 1 "
16-4 ------ Bracket, Headlight 1 "
16-5 3/8-16 x 1 Bolt, Carriage Ø 3/8-16 x 1" Long 1 "
16-6 3/8 Washer, Lock 3/8" ID 1 "
16-7 3/8-16 Nut, Top Lock Hex 3/8-16 1 "
16-8 5/16-18 x 2¼ Bolt, Flange Hex Head Ø 5/16-18 x 2¼" Long 1 "
16-9 5/16 Washer, Lock - External Tooth 5/16" ID 2 "
16-10 5/16-18 Nut, Flange Lock Hex 5/16-18 1 "
16-11 660-2-3444 Terminal, Deutsch Pin 2 "
16-12 RM4242 Connector, 2 Pin 1 "
16-13 MR-1143 Wedge, Locking 2 Pin 1 "
16-14 660-2-3174 Light Assembly, Turn Signal 2 "
16-15 ------ Lamp, Turn Signal (Part of 660-2-3174) 1 "
16-16 ------ Bracket, Turn Signal Lamp (Part of 660-2-3174) 1 "
16-18 10 Washer, Flat #10 4 "
16-19 10-32 Nut, Top Lock Hex #10-32 4 "
16-20 HRN-MR-0004 Harness, Headlight 1 "
16-21 TM1-1-9647 Light, Brake/Turn Red LED 2 "
16-22 ------ Grommet, Rubber 1 "
16-23 MR-1150 Light, Back Up LED 2 "
16-24 ------ Grommet 1 "
16-25 MR-1154 Light, Hitch 1 "
16-26 ------ Grommet 1 "
16-27 HRN-MR36-113 Harness, LED Tail Light 1 "
16-28 MR-1281 Socket, Ordinance Trailer - Opt. 1 As Req-ed
16-29 ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long - Opt 2 "
16-30 ¼ Washer, Lock ¼" ID - Opt 2 "
16-31 HRN-MR-0005 Harness, Hitch Light (MR10-24T, MR10-36T) 1 1 & Up
MR-1230 Harness, Hitch Light (MR8-36) 1 "
16-32 MR-1096 Closeout Headlight 2 "
16-33 MR-1075 Plate, Light Socket Cover 1 "
CD387 4-2-33
Orig
Chapter 4
4
5
3
6
1
2
Figure 2-17. Dome Light
4-2-34 CD387
Orig
Chapter 4
Table 2-17. Dome Light
Fig & Tug Part

Ind Number
17-1 G1-20429 Light, Dome, Chrome 12V 1 1 & Up
17-2 ------ Lens, Dome Light (Part of G1-20429) 1 "
17-3 ------ Base, Dome Light (Part of G1-20429) 1 "
17-4 ------ Bulb, Dome Light (Part of G1-20429) 1 "
17-5 8-32 x ¾ Screw, Phillips Pan Head Ø #8-32 UNF x ¾" Long 3 "
17-6 8-32 x ¼ Screw, Oval Head Ø #8-32 x ¼" Long 3 "
CD387 4-2-35
Orig
Chapter 4
1 7
9
10 8
2 4
3 5 6
11
DETAIL A
Figure 2-18. Emergency Stop Switch Assembly
4-2-36 CD387
Orig
Chapter 4
Table 2-18. Emergency Stop Switch Assembly
Fig & Tug Part

Ind Number
18-1 MR-1246 Cowling 1 1 & Up
18-2 MR-1155-1 E-Stop Assembly 1 "
HRN-MR-0010 Harness, E-Stop Assembly 1 "
18-3 MR-1100 Relief, Strain - ½ NPT, 0.17-0.45 Cable 1 "
18-4 M4-0.7 x 35 Screw, Phillips Pan Head Ø M4-0.7 x 35mm Long 2 "
18-6 M4 Washer, Lock M4 2 "
18-7 MR-1250 Guard, E-Stop 1 "
18-10 ¼-20 Nut, Top Lock Hex ¼-20 2 "
CD387 4-2-37
Orig
Chapter 4
5
3
2
1
4
Figure 2-19. Lower Dash Access Panel
4-2-38 CD387
Orig
Chapter 4
Table 2-19. Lower Dash Access Panel
Fig & Tug Part

Ind Number
19-1 MR-1247 Plate, Dash Closeout 1 1 & Up

CD387 4-2-39
Orig
Chapter 4
11
12
13
1
14 15
17 used without
15 3 CAB
stored with 18
CAB in place
8
17
9
18
10
7
2
used without
3 15 CAB
16
4 5 6
Figure 2-20. Seat Installation
4-2-40 CD387
Orig
Chapter 4
Table 2-20. Seat Installation
Tug Part
Fig & Ind Description Qty Effective
Number
20-1 660-2-3290 Seat, Sears, Vinyl Coldform with Logo 2 1 & Up
T6-9011-227 Seat, Vinyl Grammer GS12 - Opt 2 As Req'd
20-2 5/16-18 Nut, Flangelock Hex 5/16-18 4 1 & Up
20-3 T6-9011-103 Belt, Seat - Retractable 2 "
20-5 3/8 Washer, Flat 3/8" ID 8 "
20-6 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
20-7 MR-1116 Bracket, Seat Belt 4 "
20-8 3/8-16 x 1 Bolt, Hex Head Ø 3/8-16 x 1" Long 4 "
20-9 3/8 Washer, Lock 3/8" ID 4 "
20-10 3/8 Washer, Flat 3/8" ID 4 "
20-11 MR-1103 Panel, Rear Axle Access 1 "
20-15 MR-1115 Guard, Hip - Opt 2 "
20-17 3/8 Washer, Lock 3/8" ID 4 "
20-18 3/8 Washer, Flat 3/8" ID 4 "
CD387 4-2-41
Orig
Chapter 4
6
2 1
11
10 4
8
9 8 3
13 7 5
14 17
20
15
21
16
22
18 11
19
12
Figure 2-21. Cab Heater Installation (Deutz)
4-2-42 CD387
Orig
Chapter 4
Table 2-21. Cab Heater Installation (Deutz)
Fig & Tug Part

Ind Number
21-1 CMR-1001 Cab Weldment 1 As Req-ed

21-2 MR-1263 Heater, Cab 1
21-3 ------ Connector, Electric Heater 1 "
21-7 MR-1266-1 Hose, Heater - Black Ø 5/8" x 7" Long 1 "
21-8 ------ Clamp, Hose IDEAL 5010 2 "
21-9 T6-4800-126 Fitting, 90, ½" NPT to 5/8" Barb 1 "
21-10 MR-1266-3 Hose, Heater - Black Ø 5/8" x 40" Long (Heater to Engine) 1 "
21-11 ------ Clamp, Hose IDEAL 5010 2 "
21-13 TM1-ND-5253 Valve, Ball Deutz Heater 1 "
21-14 MR-1265 Bracket, ½" Ball Valve Mounting 1 "
21-17 ¼-20 Nut, Top Lock Hex ¼-20 2 "
21-18 TM1-1-8308 Barb, Hose 5/8" ID 1 "
21-19 MR-1266-2 Hose, Heater - Black Ø 5/8" x 17" Long (Engine to Valve) 1 "
21-20 ------ Clamp, Hose IDEAL 5010 2 "
21-22 TM1-ND-5255 Adapter, 18mm to ½" Female NPT 2 "
21- MR-1266 Hose Kit, Heater - 5/8" Black Ref. "
CD387 4-2-43
Orig
Chapter 4
13
12
1
15
11
14
10
9
2 7
8
6
5
3
4
Figure 2-22 Cab Heater Installation (Kubota)
4-2-44 CD387
Orig
Chapter 4
Table 2-22. Cab Heater Installation (Kubota)
Fig & Tug Part

Ind Number
22-1 EH-2802 Pad, Heater, 250 Watts, 120 Volts 1 As Req'd
22-2 MR-1060 Duct, Fresh Air Heater -Opt 1 "
22-3 ------- Clamp, Hose, IDEAL, 7/8"-2¾" ID, 5036-Opt 2 "
22-4 660-4-3530 Hose, 2"ID x 2.5L Rubber - Opt 1 "
22-5 MR-1069 Pipe, Fresh Air Heater - Opt 1 "
22-6 MR-1061 Intake, Fresh Air Heater 1 "
22-7 MR-1266-2 Hose, Heater, Black 17" 1 "
22-8 MR-1068 Hose, Heater, Thermostat 1 "
22-9 MT-1-1257 Hose, Heater 5/8" ID - 28473 1 "
22-10 TM1-1-8308 Barb, 5/8" Hose 1 "
22-11 MR-1265 Bracket, 1/2" Ball Valve MNTG 1 "
22-12 TM1-ND-5253 Valve, Ball Deutz Heater 1 "
22-13 T6-4800-126 Fitting, 90 1 "
22-14 ------- Clamp, Hose, 5010 6 "
22-15 MR-1271-19 Plate, Battery Support (Part of Frame) 1 "
CD387 4-2-45
Orig
Chapter 4
26
11
39 27
17
12 16 14
18
26 26
15
7 22
25
8 21
24
3 23
1 20 23 24 25
13
5 6 19
6 20
5
3 28
9 29
10
2 36 31
38
37 35 30
32
34 33
Figure 2-23. Dash Assembly w/ Harness (Deutz Tier2)

4-2-46 CD369
Orig
Chapter 4
Table 2-23. Dash Assembly w/ Harness (Deutz Tier2)
Tug Part
Number
23-1 MR-1158 Panel, Dash 1 1 & Up

23-3 MR-1152 Switch, 2 Position Toggle 2 "
23-4 ------ Washer, Tanged 1 "
23-5 ------ Washer 1 "
23-6 ------ Nut 1 "
23-9 ------ Washer 1 "
23-10 ------ Nut 1 "
23-11* T6-9011-702 Switch, Ignition, Waterproof 1 "
23-12 ------ Nut, Jam 1 "
23-13 ------ Nut, Knurled 1 "
23-14 014050 Light, Dash 2 "
23-15 ------ Cover, Dash Light 1 "
23-16 ------ Washer 1 "
23-17 ------ Nut 1 "
23-18 014050-1 Bulb, Dash Light (GE2660 12V 2W) 2 "
23-19 MR-1147 Gauge, Hour Meter 1 "
23-20 MR-1144 Gauge, Fuel Level 1 "
23-21 MR-1145-1 Bulb, Back Gauge Light Ref. "
23-22 ------ Socket, Light Ref. "
23-23 MR-1148 Gauge, Voltmeter 1 "
23-24 MR-1146 Gauge, Oil Temperature 1 "
23-25 MR-1145 Gauge, Oil Pressure 1 "
23-26 ------ Collar, Retaining - Gauge 5 "
23-27 HRN-MR-0003 Harness, Dash Panel 1 "
23-28 MR-1151 Light Assembly, Warning 1 "
23-29 595502 Frame, 3 Position Mounting 1 "
23-30 511502 Holder, 2 Position, Lamp 3 "
23-31 G1-30148-4 Lens, Oil Pressure Light 1 "
23-32 596120 Lens, Engine Glow Plug Light 1 "
23-33 G1-30148-6 Lens, Battery Warning Light 1 "
23-34 G1-30148-5 Lens, Headlight Indicator Light 1 "
23-35 G1-31008-3 Lens, Brake Warning Light 1 "
23-36 59L.159 Lens, High Oil Temp Warning Light 1 "
23-37 MR-1151-8 Light, Rear Hitch 6 "
23-38 MR-1151-9 Holder, Bulb 6 "
23-39 660-1-2896 Flasher, 3 Terminal LED 1 "
* For replacing order SB MR-002K with new ignition switch.
CD387 4-2-47
Orig
Chapter 4
13
12
10
23
11
6
10
5
9
8
3 6
5
1
4
3
7
2 15
16 14
17 18 22
21
19 20
Figure 2-24. Dash Assembly w/ Harness (Deutz Tier4i)
4-2-48 CD387
Orig
Chapter 4
Table 2-24. Dash Assembly w/ Harness (Deutz Tier2)
Tug Part
Number
24-1 MR-1316 Panel, Dash 1 60 & Up
24-3 MR-1152 Switch, 2 Position, 1 Pole, Toggle, Head Light 1 "
24-4 MR-1152 Switch, 2 Position, 1 Pole, Toggle, Hitch Light 1 "
24-5 MR-1153 Switch, 3 Position Toggle, Heater 1 "
T6-9011-701 Switch, Ignition, Keyed, Waterproof - Opt. 1 As Req'd
24-7 MR-1151 Light Assembly, Warning 1 60 & Up
24-8 AS-10273 Gauge, Murphy Power View 1 "
24-10 014050 Light, Dash 2 "
24-12 660-1-2896 Flasher, Solid State 1 "
24-13 HRN-MR34-113 Harness, Instrument Panel 1 "
24-17 G1-30148-3 Lamp & Socket, 12V 6 "
24-18 130-0094-000 Lens, Brake Warning Light 1 "
24-23 12960001 Decal, Seat Belt 1 "
CD387 4-2-49
Orig
Chapter 4
26
11
41 27
17
12 16 14
18
26 26
15
7 22
25
8 21
24
3 23
1 20 23 24 25
13
5 6 40
6 20
5
3 28
9 19 39
29
10 31
2 36
38
37 35 30
32
34 33
Figure 2-25. Dash Assembly w/ Harness (Kubota)
4-2-50 CD369
Orig
Chapter 4
Table 2-25. Dash Assembly w/ Harness ( Kubota )

Tug Part
Number
25-1 MR-1158 Panel, Dash 1 22 & Up

25-5 ------ Washer 1 "
25-6 ------ Nut 1 "
25-9 ------ Washer 1 "
25-10 ------ Nut 1 "
T6-9011-701 Switch, Ignition, Keyed, Waterproof - Opt. 1 As Req'd
25-12 ------ Nut, Jam 1 22 & Up
25-13 ------ Nut, Knurled 1 "
25-14 014050 Light, Dash 2 "
25-15 ------ Cover, Dash Light 1 "
25-16 ------ Washer 1 "
25-17 ------ Nut 1 "
25-19 MR-1147 Gauge, Hour Meter 1 "
25-21 MR-1145-1 Bulb, Back Gauge Light Ref. "
25-22 ------ Socket, Light Ref. "
25-23 MR-1148 Gauge, Voltmeter 1 "
25-24 MR-1039 Gauge, Water Temperature 1 "
25-25 MR-1048 Gauge, Oil Pressure, 80psi 1 "
25-26 ------ Collar, Retaining - Gauge 5 "
25-27 HRN-MR-0003 Harness, Dash Panel 1 "
25-28 MR-1151 Light Assembly, Warning 1 "
25-35 G1-31008-3 Lens, Brake Warning Light 1 "
25-37 MR-1151-8 Light, Rear Hitch 6 "
25-38 MR-1151-9 Holder, Bulb 6 "
25-39 T6-7010-120 Light, Red Warning - Flat Head (Opt.) 1 As Req'd
25-40 TA-59 Decal, Check Air Filter - Opt. 1 "
25-41 660-1-2896 Flasher, 3 Terminal LED 1 22 & Up
CD387 4-2-51
Orig
Chapter 4
1
2
3
4 5
Figure 2-26. Console Assembly ( CE Option )
4-2-52 CD387
Orig
Chapter 4
Table 2-26. Console Assembly ( CE Option )
Fig & Tug Part

Ind Number
26-1 MR-1104 Housing, Dash (Weldment) 1 1 & Up
26-2 T-Y11 Decal, Dash Mounted E-Stop - CE Opt. 1 As Req'd
26-3 660-1-3440 Button, Locking, Red - CE Opt. 1 "
26-4 660-1-3439 Block, Contact - NC (Stop) - CE Opt. 1 "
26-5 T6-7016-123 Switch, Battery Disconnect - CE Opt. 1 "
26-6 TA-50 Decal, OFF/ON - CE Opt. 1 "
CD387 4-2-53
Orig
Chapter 4
5
8
7
9
3
6
4
Figure 2-27. Alarm Assembly
4-2-54 CD387
Orig
Chapter 4
Table 2-27. Alarm Assembly
Fig & Tug Part

Ind Number
27-1 MR-1160 Plate, Alarm Mounting 1 1 & Up

27-2 10-32 Nut, Top Lock Hex #10-32 4 "
27-3 10 Washer, Flat #10 8 "
27-5 77971 Alarm, Low Oil Press and High Oil 2 "
27-6 ------ Nut, Alarm 2 "
27-7 ------ Wire, Ground Black Flasher 1 "
27-8 ------ Wire, Ground Black Dasher G3 1 "
27-9 6-32 Screw Ø #6-32 4 "
CD387 4-2-55
Orig
Chapter 4
8 10 7 4
9
6
11
5
12
Figure 2-28. Brake Pedal Assembly
4-2-56 CD387
Orig
Chapter 4
Table 2-28. Brake Pedal Assembly
Fig & Tug Part

Ind Number
28-1 MR-1180 Pedal, Brake (Weldment) 1 1 & Up

28-2 ¼-28 Fitting, Grease ¼-28 1 "
28-3 T6-4900-211 Spring, Throttle, Return 2 "
28-4 MR-1104 Housing, Dash (Weldment) 1 "
28-5 ½ Washer, Flat ¼" ID 2 "
28-6 ½-13 x 4½ Bolt, Hex Head Ø ½-13 x 4½" Long 1 "
28-7 ½-13 Nut, Top Lock Hex ½-13 1 "
28-8 MR-1127 Yoke 1 "
28-9 T6-4900-202 Hydro-Boost Assembly 1 "
28-10 1/8 x 1½ Pin, Cotter Ø 1/8 x 1½" Long 1 "
28-11 ½-20 Nut, Jam ½-20 1 "
28-12 MR-1196 Pin, Clevis - Brake Pedal 1 "
CD387 4-2-57
Orig
Chapter 4
24
22
5
23
6
3REF
8
11
7
10
9
16
18
17
14
12
13
15
3
21
20
19
Figure 2-29. Steering Column Assembly
4-2-58 CD387
Orig
Chapter 4
Table 2-29. Steering Column Assembly.
Fig & Tug Part

Ind Number
29-1 M3-1-1059 Button Assembly, Horn - Two Wire 1 1 & Up

29-2 M3-1-8020 Wheel, Steering 14" 1 "
29-3 TM1-1-8334 Column, Steering 1 "
29-4 X4015-101 Nut, Steering Column 1 1 & Up
29-5 T6-7007-101 Control, Turn Signal w/Harness 1 "
29-6 MR-1236 Wire, Ground - Turn Signal Switch 1 "
29-7 T6-5005-105 Clamp, Upper Steer 1 "
29-8 T6-9011-459 Isolator, Rubber - Steering Column 1 "
29-10 3/8 Washer, Flat 3/8" ID 4 "
29-11 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
29-12 MR-1247 Plate, Dash Closeout 1 "
29-17 HRN-MR-0003 Harness, Dash Panel ( Deutz, Tier 2, Kubota) 1 "
HRN-MR34-113 Harness, Instrument Panel, Deuz 4i 1 60 & Up
29-18 HRN-MR-0009 Harness, Cab 1 1 & Up
29-19 660-2-3444 Terminal, Deutsch Pin 4 "
29-20 RM4242 Connector, 2 Pin 4 "
29-21 MR-1143 Wedge, Locking 2 Pin 4 "
29-22 ------ Terminal, Nylon, Female Blade, Guick Slide, 14-16GA 2 "
29-23 ------ Tubing, Heatshrink 2 "
29-24 ------ Wire, Stranded 16 AWG 2 "
CD387 4-2-59
Orig
Chapter 4
1
4
2
21 10
13
6
14
7 3
8
9
10
11
59
60
12
63
16 66
61 6
15 65
62 51 11 18 28
61 12 20
17 19
49 50 29
55
13 14 20
48 56
54 22
53 26
22
24
33
35
32 23
47 21
58 46 25 34
52 41 27
57 39 28 29
37
45
44
40 33
42
38
36
43 31 30
Figure 2-30. Hydraulic Steering System ( Deutz )
4-2-60 CD387
Orig
Chapter 4
Table 2-30. Hydraulic Steering System ( Deutz )
Fig & Tug Part

Ind Number

30-2 M3-1-8020 Wheel, Steering 14" 1 "
30-4 X4015-101 Nut, Steering Column 1 "
30-5 MR-1271-49 Mount, Steer Valve (Welded), Tier 2 1 "
MR-1272-1 Mount, Steer Valve ( Welded ), Tier 4i 1 60 & Up
30-6 MR-1136 Valve, Steer 1 1 & Up
30-7 3/8-16 x 1¾ Bolt, Hex Head Ø 3/8-16 x 1¾" Long 4 "
30-8 3/8 Washer, Lock 3/8" ID 4 "
30-9 3/8 Washer, Flat 3/8" ID 4 "
30-10 660-6801-06-06 Elbow, Male O-Ring Boss to Male JIC-90° 6MJ-6MB90 1 "
30-11 06-06-070120 Fitting, Male O-Ring Boss to Male JIC, 6MJ-6MB 1 "
30-12 TM1-ND-5266 Elbow, Male O-Ring Boss to Male JIC-45° 6MJ-6MB45 2 "
30-13 MR-1220 Hose, Steer Valve "R" to Steer Cylinder 1 "
30-14 MR-1223 Hose, Steer Valve "L" to Steer Cylinder 1 "
30-15 5/8 Clamp, P - 5/8" 6 "
30-16 ¼-20 Nut, Flangelock Hex ¼-20 2 "
30-19 ¼-20 Nut, Top Lock Hex ¼-20 1 "
30-20 MR-1218 Hose, Steer Valve "P" to Booster 1 "
30-21 MR-1219 Hose, Steer Valve "T" to Tank Return 1 "
30-22 660-2501-06-06 Elbow, 90°, Male 6MJ-6MP90 2 "
30-23 MR-1135 Cylinder, Steering 1 "
30-24 T6-3001-60017 End, Tie Rod - R/H 2 "
30-25 T6-3001-601-4 Fitting, Grease Zerk 2 "
30-26 ¾-16 Nut, Jam ¾-16 UNF 2 "
30-27 MR-1128 Axle, Front Steer 1 "
30-28 ½-13 Nut, Slotted Hex ½-13 2 "
30-31 MR-1221 Hose, Pump to Brake Booster 1 "
30-32 MR-1224 Hose, Booster to Reservoir 1 "
30-33 ------ Clamp, Hose IDEAL 6203 2 "
CD387 4-2-61
Orig
Chapter 4
1
4
2
21 10
13
6
14
7 3
8
9
10
11
59
60
12
63
16 66
61 6
15 65
62 51 11 18 28
61 12 20
17 19
49 50 29
55
13 14 20
48 56
54 22
53 26
22
24
33
35
32 23
47 21
58 46 25 34
52 41 27
57 39 28 29
37
45
44
40 33
42
38
36
43 31 30
Figure 2-30. Hydraulic Steering System ( Deutz ) (cont'd)
4-2-62 CD387
Orig
Chapter 4
Table 2-30. Hydraulic Steering System ( Deutz ) (cont'd)
Fig & Tug Part

Ind Number
30-34 1½ Clamp, P - 1½" 2 1 & Up

30-36 MR-1199 Elbow, Pump Outlet 1 "
30-37 MR-1131 Pump, Steering W/Relief 1 "
30-38 TM1-ND-6509 Elbow, Pump Inlet 12MJ-16MB 1 "
30-39 78897 Adapter, Connector, Male, 6MJ x 8MP 1 "
30-40 MR-1225 Hose, Supply Tank to Pump 1 "
30-41 MR-1222 Hose, Pump to Tank 1 "
30-42 M10-1.5 x 30 Bolt, Hex Head Ø M10-1.5 x 30mm Long 2 "
30-45 MR-1203 Fitting, 12MJ x 12MP 1 "
30-46 MR-1137 Valve, Ball ¾" NPT, Hydraulic Shut-Off 1 "
30-47 MR-1204 Nipple, ¾" NPT Close 1 "
30-48 MR-1138 Reservoir, Hydraulic 1 "
30-49 MR-1138-4 Lid, Hydraulic Tank 1 "
30-50 MR-1138-8 Gasket, Hydraulic Tank Lid 1 "
30-51 ¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 6 "
30-52 TM1-ND-8016 Plug, ¼" NPT Magnetic Drain 1 "
30-53 04-06-070102 Fitting, 6MJ x 4MP 1 "
30-54 MR-1202 Barb, ¼" NPT to 3/8" Hose 1 "
30-56 3/8 Washer, Lock 3/8" ID 2 "
30-57 3/8 Washer, Flat 3/8" ID 6 "
30-58 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
30-59 660-4-0013-11 Cap, Filler 1 "
30-60 TM1-2-8008 Dipstick, Hydraulic Reservoir Cap 1 "
30-61 ------ Gasket, Vescor Breather Cap 2 "
30-62 ------ Strainer, Vescor Breather Cap 1 "
30-63 10-32 x ½ Screw, Self-Tapping Ø 10-32 x ½" Long 6 "
30-64 MR-1134 Plug, Hydraulic Pump 1 "
30-65 ------ Wire, Safety 2 "
30-66 MR-1098 Wrap, Heat 1 "
CD387 4-2-63
Orig
Chapter 4
1
4
21 10
2 13
6
14
7
8
9
60 10
11
63
61 59
12
62 16 65
6
61 15 64
11 18 28
51 12 20
17 19
49 50 29
55
13 14 20
48 56
54 22
53 26
22
24
33
35
32 23
47 21
58 46 25 34
52 41 27
57 28 29
38
45
39
40 31 33
37 44
43
42
30
36
Figure 2-31. Hydraulic Steering System ( Kubota )
4-2-64 CD387
Orig
Chapter 4
Table 2-31. Hydraulic Steering System ( Kubota )
Fig & Tug Part

Ind Number

31-2 M3-1-8020 Wheel, Steering 14" 1 "
31-4 X4015-101 Nut, Steering Column 1 "
31-5 MR-1272-1 Mount, Steel Valve (Welded) - MR8-36 1 22 & Up
31-6 MR-1136 Valve, Steer 1 1 & Up
31-8 3/8 Washer, Lock 3/8" ID 4 "
31-9 3/8 Washer, Flat 3/8" ID 4 "
31-10 660-6801-06-06 Elbow, Male O-Ring Boss to Male JIC-90° 6MJ-6MB90 1 "
31-11 06-06-070120 Fitting, Male O-Ring Boss to Male JIC, 6MJ-6MB 1 "
31-12 TM1-ND-5266 Elbow, Male O-Ring Boss to Male JIC-45° 6MJ-6MB45 2 "
31-13 MR-1220 Hose, Steer Valve "R" to Steer Cylinder 1 "
31-14 MR-1099 Hose, Steer Valve "L" to Steer Cylinder 1 22 & Up
31-15 5/8 Clamp, P - 5/8" 6 1 & Up
31-19 ¼-20 Nut, Top Lock Hex ¼-20 1 "
31-21 MR-1219 Hose, Steer Valve "T" to Tank Return 1 "
31-22 660-2501-06-06 Elbow, 90°, Male 6MJ-6MP90 2 "
31-24 T6-3001-60017 End, Tie Rod - R/H 2 "
31-25 T6-3001-601-4 Fitting, Grease Zerk 2 "
31-26 ¾-16 Nut, Jam ¾-16 UNF 2 "
31-27 MR-1128 Axle, Front Steer 1 "
31-28 ½-13 Nut, Slotted Hex ½-13 2 "
31-31 MR-1095 Hose, Pump to Brake Booster 1 22 & Up
MR-1058 Hose, Pump to Brake Booster (CE Opt.) 1 As Req'd
31-32 MR-1224 Hose, Booster to Reservoir 1 1 & Up
CD387 4-2-65
Orig
Chapter 4
1
4
21 10
2 13
6
14
7
8
9
60 10
11
63
61 59
12
62 16 65
6
61 15 64
11 18 28
51 12 20
17 19
49 50 29
55
13 14 20
48 56
54 22
53 26
22
24
33
35
32 23
47 21
58 46 25 34
52 41 27
57 28 29
38
45
39
40 31 33
37 44
43
42
30
36
Figure 2-31. Hydraulic Steering System ( Kubota) (Cont'd)
4-2-66 CD387
Orig
Chapter 4
Table 2-31. Hydraulic Steering System ( Kubota ) (Cont'd)
Fig & Tug Part

Ind Number
31-33 ------ Clamp, Hose IDEAL 6203 2 1 & Up

31-34 1½ Clamp, P - 1½" 2 "
31-36 660-2501-06-08 Elbow, Male 2501-06-08 1 22 & Up
31-37 MT-1-1330 Pump, Steering, w/Relief 1 "
31-38 TM1-ND-8003 Elbow, Pump Outlet 1 "
31-39 660-1-2447 Fitting, Hyd. Pump Inlet 12MJ-16MB 1 "
31-40 MR-1044 Hose, Reservoir to Pump 1 "
31-41 MR-1037 Hose, Pump to Reservoir 1 "
31-45 MR-1203 Fitting, 12MJ x 12MP 1 "
31-46 MR-1137 Valve, Ball ¾" NPT, Hydraulic Shut-Off 1 "
31-47 MR-1204 Nipple, ¾" NPT Close 1 "
31-48 MR-1022 Reservoir, Hydraulic 1 "
31-49 MR-1138-4 Lid, Hydraulic Tank 1 "
31-50 MR-1138-8 Gasket, Hydraulic Tank Lid 1 "
31-52 TM1-ND-8016 Plug, ¼" NPT Magnetic Drain 1 "
31-53 04-06-070102 Fitting, 6MJ x 4MP 1 "
31-54 MR-1202 Barb, ¼" NPT to 3/8" Hose 1 "
31-56 3/8 Washer, Lock 3/8" ID 2 "
31-57 3/8 Washer, Flat 3/8" ID 6 "
31-58 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
31-59 660-4-0013-11 Cap, Filler 1 "
31-60 TM1-2-8008 Dipstick, Hydraulic Reservoir Cap 1 "
31-61 ------ Gasket, Vescor Breather Cap 2 "
31-62 ------ Strainer, Vescor Breather Cap 1 "
31-63 10-32 x ½ Screw, Self-Tapping Ø 10-32 x ½" Long 6 "
31-64 ------ Wire, Safety 2 "
31-65 MR-1098 Wrap, Heat 1 "
CD387 4-2-67
Orig
Chapter 4
13 15 14 12
14 10
15
11 7
5
4
2
6 7
10 17
11
16
8
15
14
1 12 14 8
Figure 2-32. Front Suspension
4-2-68 CD387
Orig
Chapter 4
Table 2-32. Front Suspension
Tug Part
Number
32-1 MR-1128 Axle, Front Steer 1 1 & Up
32-2 T6-3002-202 Plate, Spring Clamp - Brierton 2 "
32-3 T6-3002-201 U-Bolt, Brierton Axle 4 "
32-4 ½ Washer, Flat ½" ID 8 "
32-5 ½-20 Nut, Top Lock Hex ½-20 8 "
32-6 MR-1130 Spring, Leaf - Heavy Duty 2 "
32-7 MH-1-806 Bushing, Leaf Spring (Included w/ Leaf Spring) 4 "
32-8 MR-1271-9 Mount, Leaf Spring (Welded) Ref. "
32-9 MR-1129 Shackle 2 "
32-10 MR-1128-1 Bushing, Front Shackle 4 "
32-11 MR-1128-2 Fitting, Grease 2 "
32-12 5/8-11 x 4½ Bolt, Hex Head Ø 5/8-11 x 4½" Long 4 "
32-14 5/8 Washer, Flat 5/8" ID 12 "
32-15 5/8-11 Nut, Top Lock Hex 5/8-11 6 "
32-16 MR-1128-9 Caliper, Front Brake, RH 1 "
32-17 MR-1128-10 Caliper, Front Brake, LH 1 "
CD387 4-2-69
Orig
Chapter 4
25
9
10
19 31
26 11
27 4
22 5
32
35
20 34
14 2
21 1 3
2 28
12
3 29
6 33
13
23 30
8
24
7 33
16
15 31
18 17
Figure 2-33. Front ( Steer ) Axle Assembly
4-2-70 CD387
Orig
Chapter 4
Table 2-33. Front ( Steer ) Axle Assembly
Fig & Tug Part

Ind Number
33- MR-1128 Axle, Front Steer 1 1 & Up
33-1 MR-1128-7 Axle Weldment, Front Steer 1
33-2 TM1-ND-8079-8 Nut, Jam 3/8-24 2 "
33-3 TM1-ND-8079-9 Screw, Cup Point Socket Set Ø 3/8-24 x ¾" Long 2 "
33-4 ½-13 x 2 Bolt, Hex Head Ø ½-13 x 2" Long 2 "
33-5 TM1-ND-8090 Nut, Top Lock Hex ½-13 2 "
33-6 MR-1128-3 Knuckle Weldment - R/H 1 "
33-7 TM1-ND-8097 Bushing, 1.235" OD x 1.1" ID (STL BCK Bronze) 2 "
33-8 T6-3001-601-4 Fitting, Grease 2 "
33-9 MR-1128-4 Knuckle Weldment - L/H 1 "
33-10 TM1-ND-8097 Bushing, 1.235" OD x 1.1" ID (STL BCK Bronze) 2 "
33-11 T6-3001-601-4 Fitting, Grease 2 "
33-12 T6-3001-60007 Pin, King 2 "
33-13 440E-46006 Bearing, Thrust - Timken T113 2 "
33-14 TM1-ND-8093 Shim, King Pin 2 "
33-15 T6-3001-60005 Cap, King Pin 4 "
33-16 TM1-ND-8099 Gasket, King Pin, Cover 4 "
33-17 T6-3001-60006 Screw, Button Head Socket Cap Ø #10-24 x 5/8" Long 8 "
33-18 10 Washer, Lock #10 8 "
33-19 MR-1128-6 Tube Assembly, Tie Rod 1 "
33-20 T6-3001-60017 End, Tie Rod - R/H 1 "
33-22 ¾-16 Nut, Top Lock Hex ¾-16 1 "
33-23 ½-13 Nut, Slotted Hex ½-13 1 "
33-25 T6-3001-60013 End, Tie Rod - L/H 1 "
33-27 ¾-16 Nut, Left Hand Jam ¾-16 1 "
33-28 ½-13 Nut, Slotted Hex ½-13 1 "
33-31 T6-3001-60017 End, Tie Rod - R/H 2 "
33-33 ¾-16 Nut, Top Lock Hex ¾-16 2 "
33-34 ½-13 Nut, Slotted Hex ½-13 2 "
CD387 4-2-71
Orig
Chapter 4
9
12
11
10 17 19
4
3 18 20
2
6 1
5
8
7
14
16
1
13 15
Figure 2-34. Hub and Rotor Assembly
4-2-72 CD387
Orig
Chapter 4
Table 2-34. Hub and Rotor Assembly
Fig & Tug Part

Ind Number
34-1 T6-3001-60025 Hub Assembly 1 1 & Up

34-2 MX4-10067-7 Hub 1 "
34-3 MR-1128-11 Rotor, 10.75"Dia. 1 "
34-4 T6-3001-60020 Stud, Wheel 5 "
34-5 T6-3003-105 Nut, Chamfer Lug, ½-20 x 60° 5 "
34-6 TM1-ND-9011 Bearing and Race - Outer Wheel 1 "
34-7 SP000029-1-13 Cone, Outer 1 "
34-8 SP000029-1-12 Cap, Outer 1 "
34-9 TM1-ND-9003 Bearing and Race - Inner Wheel 1 "
34-10 SP000029-1-11 Cup, Inner 1 "
34-11 SP000029-1-10 Cone, Inner 1 "
34-12 TM1-ND-9002 Seal, Inner 1 "
34-13 T6-3001-60031 Cap, Grease 1 "
34-14 T6-3001-60028 Washer, Tongue Spindle 1 "
34-15 MR-1128-5 Nut, 1-14, Spindle, 12-Slotted 1 "
34-16 3/16 x 2 Pin, Cotter Ø 3/16 x 2" Long 1 "
34-17 MR-1128-3 Knuckle Weldment - R/H 1 "
34-18 ------ Spindle Ref. "
34-19 MR-1128-4 Knuckle Weldment - L/H 1 "
34-20 ------ Spindle Ref. "
CD387 4-2-73
Orig
Chapter 4
5
4
3
8
7
1 2 9
5
4
3
10
Figure 2-35. Brake Calipers Assembly
4-2-74 CD387
Orig
Chapter 4
Table 2-35. Brake Calipers Assembly
Fig & Tug Part

Ind Number
35-1 MR-1128-10 Caliper, Front Brake, RH 1 1 & Up

35-2 MR-1128-9 Caliper, Front Brake, LH 1 "
35-3 ------ O-Ring 4 "
35-4 ------ Sleeve, Retainer Bolt 4 "
35-5 TM1-ND-8077B Bolt, Caliper Mounting 4 "
35-6 TM1-ND-8076 Pad Set, Front Caliper 1 "
35-7 T6-8013-165 Valve, Bleeder - Front Caliper 2 "
35-8 MR-1215 Hose, Brake 2 "
35-9 T6-8013-145 Bolt, Brake Hose 2 "
35-10 T6-8013-147 Washer, Brake Hose 4 "
CD387 4-2-75
Orig
Chapter 4
12 26 22
16
26
24 17 22
24
15 25
27 27
30 32 x4 18 26
31 24
35 3 x4 17
29
23 11
33
28 25
34 4 24
14 24
2 24 27
14
23
39
1 13
38
37
1
36
Detail 'A'
19
20
6
20
7 21 19
x4
25
10
26
9 x4
4
8
5
Figure 2-36. Rear Suspension Assembly
4-2-76 CD387
Orig
Chapter 4
Table 2-36. Rear Suspension Assembly

Fig & Tug Part
Ind Number
36-1 MT-4-1247 Axle, Rear Drive 1 1 & Up

36-2 MT-1-1215 Plate, Rear Axle Mount 2 "
36-3 MR-1186 Bolt, Hex Head Ø ¾-10 x 10" Long 8 "
36-4 MR-1188 Washer, Flat ¾" ID 16 "
36-5 MR-1187 Nut, Top Lock ¾-10 8 "
36-6 MT-4-1052 Cradle, Rear Axle (Wldmt) 1 "
36-7 TM1-1-3506 Bushing, Rear Cradle 4 "
36-8 MR-1133 Bolt, Cradle Pivot 2 "
36-9 1 Washer, Flat 1" ID 4 "
36-10 1-8 Nut, Nylon Insert Lock 1-8 2 "
36-11 ------ Mount, Spring, Rear - Driver Side (Part of Frame) 1 "
36-12 ------ Mount, Spring, Rear - Pass. Side (Part of Frame) 1 "
36-13 MT-1-1065 Spring, Rear Coil 2 "
36-14 MT-2-1056 Shock Absorber, Rear 2 "
36-15 P1135 Hardware Kit, Shock (Comes with Shock) 2 "
36-16 ------ Nut 2 "
36-17 ------ Washer, Bushing 4 "
36-18 ------ Bushing, Rubber 4 "
36-20 ½ Washer, Flat, ½" ID 4 "
36-21 ½-13 Nut, Top Lock Hex ½-13 2 "
36-22 MR-1177 Bracket, Upper Chain 2 "
36-23 MR-1132 Chain, Cradle Limiting 2 "
36-25 3/8 Washer, Flat 3/8" ID 8 "
36-26 3/8-16 Nut, Top Lock Hex 3/8-16 6 "
36-27 5/16 Washer, Flat 5/16" ID 8 "
36-28 T6-6011-111 Tee, Brake Line 2 "
36-29 MR-1182 Bracket, Rear - Brake Line Angle 1 "
36-35 MH-ND-543 Hose, Brake (19") 1 "
36-36 MR-1213 Line, Brake (Left Rear Drive Axle) 1 "
36-37 MR-1214 Line, Brake (Right Rear Drive Axle) 1 "
36-38 660-ND-1372 Fitting, Brake, 3/16 Inv. Flare to 1/8 NPT 2 "
36-39 MT-1-1338 Adapter, 14mm - Rear Brake 2 "
36-40 MR-1179 Box, Drop 1 "
CD387 4-2-77
Orig
Chapter 4
8 1
3 7 2
4 7
5
4
9 4
6
9
4
3
4
4 6
4 3
6
Figure 2-37. Drain Plugs. Rear ( Drive ) Axle
4-2-78 CD387
Orig
Chapter 4
Table 2-37. Drain Plugs. Rear ( Drive ) Axle.
Tug Part
Number
37-1 MT-4-1248-11 Plug, M18-1.5 - Drop Box 1 1 & Up

37-2 MT-4-1248-17 Washer, Sealing 18 x 24 x 1.5mm 1 "
37-3 MT-4-1247-62 Plug, M24-1.5 - Rear Axle 3 "
37-4 MT-4-1247-106 Washer, Sealing 24 x 30 x 1mm 8 "
37-5 MT-4-1247-65 Plug, Breather M24-1.5 - Drive Axle 1 "
37-6 MT-4-1247-105 Plug, Magnetic M24-1.5 - Drive Axle 4 "
37-7 MT-4-1247-27 Valve, Bleeder - Drive Axle 2 "
37-8 MT-4-1247-80 Adapter, Bleeder Valve 2 "
37-9 MT-4-1247 Axle, Rear Drive, W/O Drop Box 1 "
37-10 MR-1179 Box, Drop 1 "
CD387 4-2-79
Orig
Chapter 4
Figure 2-38. Gear Set and Differential. Rear Axle
4-2-80 CD387
Orig
Chapter 4
Table 2-38. Gear Set and Differential. Rear Axle.
Tug Part
Number
38-1 MT-4-1247-31 Nut, Pinon 1 1 & Up

38-2 MT-4-1247-43 Seal, Ring On Pinion, Outer 1 "
38-3 MT-4-1247-45 Seal, Ring On Pinion, Inside 1 "
38-4 MT-4-1247-24 Spacer, Preload 1 "
38-5 MT-4-1247-93 Shim 2 "
38-6 MT-4-1247-94 Shim 2 "
38-7 MT-4-1247-95 Shim 2 "
38-8 MT-4-1247-40 Bearing, Taper Roller 1 "
38-9 MT-4-1247-66 Nut, Adjusting 2 "
38-10 MT-4-1247-88 Shim 2 "
38-12 MT-4-1247-2 Gear, Bevel Set 1 "
38-13 MT-4-1247-90 Shim 2 "
38-14 MT-4-1247-91 Shim 2 "
38-15 MT-4-1247-92 Shim 2 "
38-17 MT-4-1247-71 Bolt, Differential Housing 12 "
38-18 MT-4-1247-82 Washer, Conic 12 "
38-19 MT-4-1247-10 Gear, Side 2 "
38-20 MT-4-1247-9 Washer, Satellite Brass 4 "
38-21 MT-4-1247-11 Gear, Satellite 4 "
38-22 MT-4-1247-19 Pin, Differential, Short 2 "
38-23 MT-4-1247-18 Pin, Differential, Long 1 "
38-24 MT-4-1247-16 Pin, Blocker 1 "
38-25 MT-4-1247-86 Pin, Elastic 2 "
38-26 MT-4-1247-8 Spacer, Side Gear 2 "
38-27 MT-4-1247-35 Housing, Differential 1 "
38-28 MT-4-1247-26 Cover, Differential 1 "
38-29 MT-4-1247-1 Differential Complete 1 "
CD387 4-2-81
Orig
Chapter 4
Figure 2-39. Planetary Wheel End Drive. Rear Axle
4-2-82 CD387
Orig
Chapter 4
Table 2-39. Planetary Wheel End Drive. Rear Axle.
Tug Part
Number
39-1 MT-4-1247-78 Bolt, Planetary Cover 4 1 & Up

39-2 MT-4-1247-66 Carrier, Planetary 2 "
39-3 MT-4-1247-36 Gear, Anulus 59T 2 "
39-4 MT-4-1247-79 Bolt, Anulus Carrier 24 "
39-5 MT-4-1247-7 Carrier, Anulus 59T 2 "
39-6 MT-4-1247-55 Ring, Snap 2 "
39-8 MT-4-1247-47 O-Ring, Planetary Cover 2 "
39-9 MT-4-1247-34 Hub 2 "
39-11 MT-4-1247-44 Seal, Cassette Ring On Planetary 2 "
39-12 MT-4-1247-32 Support, wheel Spindle/Hub 2 "
39-13 MT-4-1247-73 Bolt, Planetary Wheel End Drive 32 "
39-14 MT-4-1247-52 Ring, Snap 2 "
39-15 MT-4-1247-39 Bearing, Spheric Radial 2 "
39-16 MT-4-1247-50 Ring, Snap 2 "
39-17 MT-4-1247-13 Gear, Sun 13T 2 "
39-18 MT-4-1247-22 Pin Of Planetary Satellite 6 "
39-19 MT-4-1247-42 Bearing, Needle For Satellite 6 "
39-20 MT-4-1247-12 Planetary 22T 6 "
39-21 MT-4-1247-51 Ring, Snap 6 "
39-22 MT-4-1247-68 Nut, Lug 16 "
39-23 MT-4-1247-59 Stud, Wheel 16 "
CD387 4-2-83
Orig
Chapter 4
Figure 2-40. Wet Brakes System. Rear Axle
4-2-84 CD387
Orig
Chapter 4
Table 2-40. Wet Brakes System. Rear Axle.
Tug Part
Number
40-1 MT-4-1247-63 Plug 2 1 & Up
40-2 MT-4-1247-85 Washer, Copper 2 "
40-3 MT-4-1247-75 Bolt, Allen Head - Brake Cover Long 12 "
40-4 MT-4-1247-76 Bolt, Allen Head - Brake Cover Short 4 "
40-5 MT-4-1247-5 Cover, Brake 2 "
40-6 MT-4-1247-66 Nut, Adjusting 2 "
40-7 MT-4-1247-14 Washer, Conical 2 "
40-8 MT-4-1247-57 Spring, Reaction 2 "
40-9 MT-4-1247-60 Ball, Steel 4 "
40-10 MT-4-1247-23 Spacer 2 "
40-11 MT-4-1247-29 Lever, Brake 2 "
40-12 MT-4-1247-53 Ring, Snap 2 "
40-13 MT-4-1247-56 Gum Diagram For Brake 2 "
40-14 MT-4-1247-60 Ball, Steel 4 "
40-15 MT-4-1247-15 Piston, Service Brake 2 "
40-16 MT-4-1247-87 Ring, Guide, Service Brake Piston (PTEE) 2 "
40-17 MT-4-1247-49 O-Ring, Service Brake Piston (EPDM) 2 "
40-18 MT-4-1247-48 O-Ring, Bushing (EPDM) 2 "
40-19 MT-4-1247-74 Bolt, Service Brake Bushing 4 "
40-20 MT-4-1247-30 Bushing, Service Brake 2 "
40-21 MT-4-1247-25 Spacer Foe Service Brake 2 "
40-22 MT-4-1247-17 Shaft, Actuator 2 "
40-23 MT-4-1247-20 Pin Actuator/Actuator Shaft 2 "
40-24 MT-4-1247-54 Ring, Snap For Pin/Actuator Shaft 2 "
40-25 MT-4-1247-99 Actuator, Ball Ramp Brake 2 "
40-26 MT-4-1247-97 Disc, Counter 8 "
40-27 MT-4-1247-98 Disc, Friction 12 "
40-28 MT-4-1247-21 Pin, Brake 6 "
40-29 MT-4-1247-102 Brake Complete Assembly 1 "
40-30 MT-4-1247-100 Clip, Circle For Diagram (Not Shown) 2 "
CD387 4-2-85
Orig
Chapter 4
8 7
9
5
6
3
2
Figure 2-41. Drop Box Drain Plugs. Rear Axle
4-2-86 CD387
Orig
Chapter 4
Table 2-41. Drop Box Drain Plugs. Rear Axle.
Fig & Tug Part

Ind Number
41-1 MR-1179 Box, Drop 1 1 & Up
41-2 MT-4-1248-18 Ring, Copper 1 "
41-3 MT-4-1248-13 Plug, Oil Drain Magnetic 1 "
41-4 MT-4-1248-15 Bolt 16 "
41-5 MT-4-1248-16 Ring, Copper 2 "
41-6 MT-4-1248-12 Plug, Inspection 2 "
41-7 MT-4-1248-14 Plug, Vent 1 "
41-8 MT-4-1248-11 Plug, Oil Filling 1 "
41-9 MT-4-1248-17 Ring, Copper 1 "
CD387 4-2-87
Orig
Chapter 4
2
3
5
6
Figure 2-42. Front Wheel Assembly
Table 2-42. Front Wheel Assembly

Fig & Tug Part
Ind Number
42-1 MR-1324 Tire/Wheel Assembly - Front, Tug Tuff 2 1 & Up

MR-1092 Tire/Wheel Assembly - Front, Solid - Opt. 2 As Req'd Up to 92
42-2 MR-1324-1 Tire, Front 185-14 10pr Tug Tuff 2 1 & Up
MR-1092-1 Tire, Front, Solid - Opt 2 As Req'd Up to 92
42-3 MR-1102-2 Wheel, Front 185R14LT 2 1 & Up
MR-1092-2 Wheel, Front - Solid Tire - Opt 2 As Req'd Up to 92
42-4 MR-1102-3 Valve, Front Tire 2 1 & Up
42-5 MR-1102-4 Cap, Front Tire Valve 2 "
42-6 440E-46009 Nut, Wheel, Hex, ½-20 10 "
42-7 MT-4-2211 Lug Wrench Set, 17, 19, 21, 22 mm-Service Item 1 "
4-2-88 CD387
Orig
Chapter 4
4
1
9
8
10
7
5
6
Figure 2-43. Rear Wheel Assembly

Table 2-43. Rear Wheel Assembly
Fig & Tug Part
Ind Number
43-1 MT-1-2157 Tire/Wheel Assembly, Rear Dual - MR10 4 1 & Up

MR-1106 Tire/Wheel Assembly, Rear - MR8 2 "
MR-1093 Tire/Wheel Assembly, Rear Solid- MR10 - Opt. 4 As Req'd Up to 92
MR-1093 Tire/Wheel Assembly, Rear Solid-MR8 - Opt. 2 "
43-2 T6-2400-170 Tire, Rear 8.75 x 16.5 - MR10 4 1 & Up
T6-2400-170 Tire, Rear 8.75 x 16.5 - MR8 2 "
MR-1093-1 Tire, Rear, Solid - MR10 - Opt. 4 As Req'd Up to 92
MR-1093-1 Tire, Rear, Solid - MR8 - Opt. 2 "
43-3 MT-1-1048 Wheel, Dual 6.75 x 16.5 4 1 & Up
MR-1106-1 Wheel, MR8, Rear 2 "
MR-1093-2 Wheel, Rear, Solid - MR8 - Opt. 2 As Req'd Up to 92
MR-1093-2 Wheel, Rear, Solid - Opt. 4 "
43-4 MT-1-2157-1 Valve, Tire - Rear Dual 2 1 & Up
43-5 MR-1162 Extension, Tire Valve 90° - MR10 2 "
43-6 MT-1-2157-2 Cap, Tire Valve, Rear - MR10 2 "
43-7 MT-1-1358 Extension, Tire Valve 7" - MR10 2 "
43-8 MR-1161 Extension, Tire Valve 135° MR10 2 "
43-9 MT-1-2157-3 Nut, Lug, Rear 16 "
43-10 MT-4-2212 Lug Wrench Set, 24, 27, 30, 33 mm-Service Item 1 "
CD387 4-2-89
Orig
Chapter 4
Figure 2-44. Accelerator Deutz 4i
Table 2-44. Accelerator Deutz 4i
Fig & Tug Part

Ind Number
44-1 G1-30101-6 Pedal, Accelerator 1 60 & Up
44-2 ¼-20 x ¾ Screw Ø ¼-20 x ¾" Long 4 "
4-2-90 CD387
Orig
Chapter 4
CD387 4-2-91
Orig
Chapter 4
17
16
18 DETAIL 'A'
15
31
14
19
28
20
13 SEE DETAIL 'A'
20 19 25
24
32
11
25 29
23 30
22 26
21 21 11
12
33
9
6 DETAIL 'B'
11 7
10 27
13 1
8 5
3 2
4 SEE DETAIL 'B'
Figure 2-45. Accelerator and Modulator Cables (Deutz Tier2)
4-2-92 CD387
Orig
Chapter 4
Table 2-45. Accelerator and Modulator Cables (Deutz Tier2)
Tug Part
Number
45-1 T6-1009-103 Pedal, Accelerator 1 1 & Up

45-5 MT-2-1311 Lever, Accelerator Pedal 1 "
45-6 ¼-20 Nut, Top Lock Hex ¼-20 2 "
45-8 T6-1009-109 Stud, Throttle Cable 1 "
45-9 10-32 Nut, Nylock #10-32 1 "
45-10 MI-1-322 Cable, Throttle 1 "
45-11 ------ Nut, Jam (Part of Throttle Cable) 4 "
45-12 MR-1271-44 Anchor, Accelerator Cable (Wldmt, Part of Frame) Ref. "
45-13 660-4-0745-12 Joint, Ball 2 "
45-14 MR-1119 Lever, Engine Throttle 1 "
45-16 M6-1.0 Nut, M6-1.0 1 "
45-20 10-32 Nut, Nylock #10-32 2 "
45-21 MR-1120 Mount, Accelerator and Modulator Cable 1 "
45-25 MR-1094 Spring, Throttle Return 1 "
45-26 T6-4900-222 Cable, Modulator 60" Push Type 1 "
45-27 ------ Modulator (part of Modulator Cable) 1 "
45-28 ------ Nut, Jam (part of Modulator Cable) 2 "
45-29 D3AZ-7F006B Clamp, Modulator Cable (Part of Transmission) 1 "
45-30 5/16-18 x 17/32 Screw, Flange Head, 5/16-18x17/32 Long (Part of Transmission) 1 "
45-31 660-4-0745-12 Joint, Ball 1 "
45-32 3/8 Clamp, P - 3/8" 1 "
CD387 4-2-93
Orig
Chapter 4
17 16
18 15
19 14
13
20
12
11
21
6 10
5 7
4
9
3 8
2
1
Figure 2-46. Accelerator and Modulator Cables (Kubota)
4-2-94 CD387
Orig
Chapter 4
Table 2-46. Accelerator and Modulator Cables (Kubota)
Fig & Tug Part

Ind Number
46-1 ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 2 22 & Up

46-4 T6-1009-103 Pedal, Accelerator 1 "
46-6 ¼-20 Nut, Top Lock Hex ¼-20 2 "
46-7 10-32 Nut, Nylock #10-32 1 "
46-8 MR-1091 Lever, Accelerator Pedal 1 "
46-10 MR-1271-44 Anchor, Accelerator Cable (Wldmt) Ref. "
46-11 MR-1097 Cable, Throttle, Stranded Wire 1 "
46-12 T6-4900-222 Cable, Modulator 60" Push Type 1 "
46-13 660-4-0745-12 Joint, Ball 1 "
46-14 MR-1067 Slide, Modulator MR-36 1 "
46-15 MR-1059 Stud, Modulator Slide 1 "
46-16 T6-4900-174 Bracket, Throttle Return Spring 1 "
46-17 T6-4900-211 Spring, Throttle Return 1 "
46-18 MR-1015 Arm, Accelerator 1 "
46-19 MR-1019 Bracket, Cable Mount 1 "
46-20 D3AZ-7F006B Clip, Modulator Retainer (Part of Transmission) 1 "
46-21 5/16-18 x 17/32 Screw, Flange, 5/16-18x17/32"Long (Part of 1 "
Transmission)
CD387 4-2-95
Orig
Chapter 4
38 Table 2-47. Engine and Transmission Mounts (Deutz Tier 2)

39
Fig & Tug Part
34 7 5 4 Description Qty Effective
3 Ind Number
36 1 8 47-1 ENG-MR24-DEUTZ Engine, Deutz BF4M2011 1 1 & Up

47-2 MR-1163 Mount, Motor - Right Side Engine 1 "
35 37 2 47-3 M14-2.0 x 50 Bolt, Socket Head Cap Screw Ø M14-2.0 x 50mm Long 2 "
19 47-4 M14 Washer, Lock M14 2 "
15 20 47-6 MR-1118 Washer, Motor Mount Safety 1 "
16 21 47-8 ½ Washer, Flat, ½" ID 2 "
47-9 ½-13 Nut, Top Lock Hex ½-13 1 "
18 47-10 MR-1164 Mount, Motor - Left Side Engine 1 "
10
6 33 47-11 M14-2.0 x 50 Bolt, Socket Head Cap Screw Ø M14-2.0 x 50mm Long 3 "
12 37 47-13 M14 Washer, Flat M14 3 "
8 47-14 MR-1118 Washer, Motor Mount Safety 1 "
11 35 47-15 ½-13 x 3½ Bolt, Hex Head Ø ½-13 x 3½" Long 1 "
47-16 ½ Washer, Flat, ½" ID 2 "
47-17 ½-13 Nut, Top Lock Hex ½-13 1 "
19 9 47-18 TM1-ND-5004 Mount, Rubber, Engine 2 "
47-19 3/8-16 x ¾ Bolt, Hex Head Ø 3/8-16 x ¾" Long 4 "
20 47-20 3/8 Washer, Lock 3/8" ID 4 "
47-21 3/8 Washer, Flat 3/8" ID 4 "
21 36 47-22 MR-1183 Crossmember, Transmission 1 "
13 26 23 47-24 3/8 Washer, Flat 3/8" ID 8 "
18 27 24 47-25 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
47-26 T6-1008-111 Transmission, C-6, 3-Speed 1 "
14 30 22
47-27 MD-P21-105 Isolator, C-6 Transmission Mount 1 "
16 23 29 47-29 ½ Washer, Lock ½" ID 2 "
24 47-30 ½ Washer, Flat ½" ID 2 "
47-31 7/16 Washer, Flat 7/16" ID 2 "
17 24 47-32 7/16-14 Nut, Top Lock Hex 7/16-14 2 "
47-33 MR-1185 Bracket, Rear Engine Lift 1 "
23 31 25 47-34 MR-1184 Bracket, Front Engine Lift 1 "

24 32 47-37 M8 Washer, Flat M8 3 "
47-38 M12-1.75 x 40 Bolt, Socket Head Ø M12-1.75 x 40mm Long 1 "
28 47-39 M12 Washer, Lock M12 1 "
25 25
24
Figure 2-47. Engine and Transmission Mounts (Deutz Tier2)
4-2-96 CD387
Orig
Chapter 4
4 6 Table 2-48. Engine Installation (Deutz Tier 4i)

3 5 Fig & Tug Part
1 7 Ind Number
48-1 ENG-MR34-DEUTZ Engine, Deutz TD2011 L040 (MR-34T) 1 60 & Up

2 8 48-2 MR-1301 Mount, Motor - Right Side Engine 1 "
48-3 ½ Washer, Flat, ½" ID 4 "
9 48-4 ½-13 x 3½ Bolt, Hex Head Ø ½-13 x 3½" Long 2 "
10 48-5 M14 Washer, Flat M14 6 "
48-9 3/8 Washer, Lock 3/8" ID 4 "
3 12 48-10 3/8 Washer, Flat 3/8" ID 4 "
48-11 TM1-ND-5004 Mount, Rubber, Engine 2 "
13 48-12 MR-1271-51 Mount, Motor, Right Frame (Part of Frame) 1 "
28 48-13 MR-1118 Washer, Motor Mount Safety 1 "
3 48-14 ½-13 Nut, Top Lock Hex ½-13 1 "
27 15 48-15 MR-1300 Transmission, 4R75 W/Park Brake 1 "
8 14 48-16 Isolator, Transmission ( Part of Transmission) 1 "

48-17 ½ Washer, Lock ½" ID 2 "
9 48-19 ½ Washer, Flat ½" ID 2 "
10 48-21 3/8 Washer, Flat 3/8" ID 8 "
48-22 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
26 11 48-23 7/16 Washer, Flat 7/16" ID 2 "
48-24 7/16-14 Nut, Top Lock Hex 7/16-14 2 "
16 19 20 48-25 MR-1303 Crossmember, Transmission 1 "
13 48-26 MR-1271-50 Mount, Motor, Left Frame (Part of Frame) 1 "
29 17 48-28 MR-1164 Mount, Motor - Left Side Engine 1
48-29 MR-1126 Closeout Flywheel, Deutz 1 "
14 18
25
20 23
21 22
24
Figure 2-48. Engine Installation (Deutz Tier 4i)
CD387 4-2-97
Orig
Chapter 4
12
4
6
7
5
10
Figure 2-49. Engine Installation (Kubota)
4-2-98 CD387
Orig
Chapter 4
Table 2-49. Engine Installation (Kubota)
Fig & Tug Part

Ind Number
49-1 ENG-MR10-36T Engine, Kubota, V3600-T (MR10) 1 22 & Up

ENG-MA-36 Engine, Kubota (MR8) 2 "
49-2 ½-13 x 3½ Bolt, Hex Head, ½-13 x 3½"Long 2 "
49-3 ½ Washer, Flat, ½"ID 4 "
49-4 MR-1026 Mount, Engine Half RH 1 "
49-5 3/8-16x1¼ Bolt, Hex Head, 3/8-16x1¼ 4 "
49-6 3/8 Washer, Lock, 3/8"ID 4 "
49-7 MR-1040 Isolator, Rubber Engine 2 "
49-8 MR-1027 Mount, Frame, Half 2 "
49-9 TM1-1-5005 Washer, Stop Engine Mount 2 "
49-10 ½-13 Nut, Lock, ½ID-13 2 "
49-11 T6-4400-103 Adapter, Kubota SAE 4 to C6 1 "
49-12 MR-1025 Mount, Engine Half LH 1 "
CD387 4-2-99
Orig
Chapter 4
58
52
57
21 42
56 51 40 REF
22 20 46
45
22
21 53 47
49
54
48 41
32 55
33 78 77
34 39
19
15
18 40
36
50 44
17
37
18 31
1
16 59 38
6 35
30 26 43
61
72 74 27
78 24
78 60 23
13 4 72
14 28
12 7 5 73
64 24
2 25
11 8 3
63 70 75
9 Left Side View 29
62 71
65
10 68
76 67 Right Side View
66
75REF
62 69
Figure 2-50 Engine Assembly (Deutz Tier 2)
4-2-100 CD387
Orig
Chapter 4
Table 2-50. Engine Assembly (Deutz Tier2)

50-1 ENG-MR24-DEUTZ Engine, Deutz BF4M2011 1 1 & Up 50-35 ENG-MR24-DEUTZ-8 Tube, Dip Stick 1 1 & Up
50-2 TP-10389 Seal, Rear Crankshaft 1 " 50-36 ENG-MR24-DEUTZ-9 Dip Stick, Engine Oil level 1 "
50-3 DEU4272425 Flywheel 1 " 50-37 ------ O-Seal 1 "
50-4 DEU2109988 Bolt, Flywheel 8 " 50-38 TP-10408 Cap, Oil 2 "
50-5 TM1-ND-5301 Starter 1 " 50-39 ENG-MR24-DEUTZ-10 Sender, Temperature 1 "
50-6 TP-10390 Cover, Front, Hydraulic Pump 1 " 50-40 DEU4270206 Cover, Valve (Cylinder Head) 1 "
50-7 TP-10391 Line, Turbo Oil Drain 1 " 50-41 ENG-MR24-DEUTZ-11 Gasket, Valve Cover 1 "
50-8 TP-10404 Seal, O-Ring, Lower Turbo Oil Drain 1 " 50-42 TP-10411 Bolt, Valve Cover 10 "
50-9 ENG-MR24-DEUTZ-1 Retainer, Turbo Oil Drain Line 1 " 50-43 ENG-MR24-DEUTZ-12 Plug, Glow 1 "
50-10 TP-10394 Bolt, Turbo Oil Drain Line Retainer 1 " 50-44 ENG-MR24-DEUTZ-13 Washer, Sealing, Glow Plug 1 "
50-11 ENG-MR24-DEUTZ-2 Seal, O-Ring, Upper Turbo Oil Drain 1 " 50-45 ENG-MR24-DEUTZ-14 Injector, Fuel with Nozzle 4 "
50-12 TP-10396 Nipple, Screw In 1 " 50-46 TP-10417 Nozzle, Fuel Injector 4 "
50-13 TP-10397 Ring, Sealing 1 " 50-47 TP-10418 Ring, Sealing, Fuel Injector 4 "
50-14 TP-10398 Turbo Assembly 1 " 50-48 TP-10419 Claw, Fuel Injector Retainer 4 "
50-15 TM1-ND-5021 Gasket, Turbo 1 " 50-49 TP-10420 Bolt, Fuel Injection Retainer 4 "
50-16 M8-1.25 Nut, M8-1.25 3 " 50-50 TP-10421 Line, Fuel Return 1 "
50-17 TP-10399 Sleeve, Rubber 1 " 50-51 TP-10422 Ring, Sealing 8 "
50-18 TP-10400 Clamp, Spring Band 2 " 50-52 TP-10403 Bolt, Banjo 4 "
50-19 TP-10401 Pipe, Crankcase Breather 1 " 50-53 ENG-MR24-DEUTZ-15 Pump, Fuel Injection, Class A 4 See Note
50-20 ENG-MR24-DEUTZ-3 Line, Turbo Oil Feed 1 " ENG-MR24-DEUTZ-16 Pump, Fuel Injection, Class B 4 "
50-21 TP-10403 Bolt, Banjo 2 " ENG-MR24-DEUTZ-17 Pump, Fuel Injection, Class C 4 "
50-22 TP-10404 Ring, Sealing 4 " ENG-MR24-DEUTZ-18 Pump, Fuel Injection, Class D 4 "
50-23 ENG-MR34-DEUTZ-4 Fan, Cooling TD-2011 1 "
50-24 TP-10405 Washer, Fan 2 " NOTE: There are four (4) different classes of fuel injection pumps available that can be used on the MR.
50-25 M8-1.25 x 40 Bolt, Hex Head Ø M8-1.25 x 40mm Long 4 " They are: Class A, Class B, Class C and Class D. An identification tag is located on the side of
50-26 ENG-MR34-DEUTZ-2 Alternator, TD2011 1 " the fuel injection pump which calls out the class of that pump. Typically, all four of the fuel
50-27 TP-10511 Belt, Alternator, TD2011 1 " injection pumps on the MR engine are the same class but, there can be cases where multiple
50-28 TP-10459 Pan, Oil 1 " classes are used on the same engine. When one or more fuel injection pump is
50-29 M8-1.25 x 16 Bolt, Socket Head Cap Ø M8-1.25 x 16mm Long 20 " removed/replaced, it must be replaced with the same class pump.
50-30 TM1-ND-5040 Element, Oil Filter 1 "
50-31 ENG-MR24-DEUTZ-4 Thermostat, Engine 1 "
50-32 ENG-MR24-DEUTZ-5 Spring, Thermostat Compression 1 "
50-33 ENG-MR24-DEUTZ-6 Seal, O-Ring 1 "
50-34 ENG-MR24-DEUTZ-7 Plug, Thermostat 1 "
CD387 4-2-101
Orig
Chapter 4
58
52
57
21 42
56 51 40 REF
22 20 46
45
22
21 53 47
49
54 48 41
32 55
33 78 77
34 39
19
15
18 40
36
50 44
17
37
18 31
1
16 59 38
6 35
30 26 43
61
72 74 27
78 24
78 60 23
13 4 72
14 28
12 7 5 73
64 24
2 25
11 8 3
63 70 75
9 Left Side View 29
62 71
65
10 68
76 67 Right Side View
66
75REF
62 69
Figure 2-50 Engine Assembly (Deutz Tier 2) (cont'd)
4-2-102 CD387
Orig
Chapter 4
Table 2-50 Engine Assembly (Deutz Tier2)(cont'd)
Fig & Tug Part

Ind Number
50-54 TP-10427 Gasket, 0.35mm Compensating Ref. As Req'd

TP-10428 Gasket, 0.40mm Compensating Ref. "
50-55 TP-10446 Tappet, Roller 4 1 & Up
50-57 M8-1.25 Nut, M8-1.25 8 "
50-58 ENG-MR24-DEUTZ-19 Line, Injection Pump to Injector 4 "
50-59 TP-10452 Line, Fuel Supply 1 "
50-60 TP-10422 Ring, Sealing 8 "
50-61 TP-10403 Bolt, Banjo 4 "
50-62 TP-10456 Pump, Fuel Supply 1 "
50-63 TM1-1-9693-4 Seal, Fuel Pump O-Ring 1 "
50-65 M8-1.25 x 20 Bolt, Socket Head Cap Ø M8-1.25 x 20mm Long 2 "
50-66 ENG-MR24-DEUTZ-20 Solenoid, Fuel Shut Off 1 "
50-67 TM1-ND-8104 O-Ring, Fuel Shut Off Solenoid 1 "
50-68 TM1-ND-8103 Spring, Tension 1 "
50-70 MR-1282 Valve, Engine Oil Drain 1 "
50-71 ------ Seal, Engine Oil Drain Valve 1 "
50-72 TP-10414 Plug, Screw 2 "
50-73 ENG-MR24-DEUTZ-21 Sender, Oil Pressure 1 "
50-75 ENG-MR24-DEUTZ-22 Solenoid, Excess Fuel 1 "
50-76 ENG-MR24-DEUTZ-23 O-Ring, Excess Fuel Solenoid 1 "
50-77 TP-10454 Plug, Screw 1 "
CD387 4-2-103
Orig
Chapter 4
Table 2-51. Front Engine Covers (Deutz Tier2)
Fig & Tug Part

Ind Number
51-1 ENG-MR24-DEUTZ-24 Cover, Front, Oil Pump 1 1 & Up

51-2 TP-10469 Screw, Tamper Proof Ø M6-1.0 x 30mm Long 1 "
51-4 TP-10471 Cover, Front, Cam Shaft 1 "
51-5 ------ Rubber Ref. "
51-6 ------ Trim Lock Ref. "
5 51-8 TP-10390 Cover, Front, Hydraulic Pump 1 "
4 51-9 M6-1.0 x 25 Bolt, Hex Head Ø M6-1.0 x 25mm Long 5 "
6 51-10 TP-10475 Shield, Crankshaft 1 "
1 8
3
2
10
Figure 2-51. Front Engine Covers (Deutz Tier2)
4-2-104 CD387
Orig
Chapter 4
CD387 4-2-105
Orig
Chapter 4
#8 Wire
3
18
4
Positive Battery- 19
Alternator Cable 20
21
14 22
12
14 5 1
16
15
13
10
10
8 6
11
7
17
Figure 2-52. AlternatorAssembly ( Deutz Tier 2 )
4-2-106 CD387
Orig
Chapter 4
Table 2-52. Alternator Assembly ( Deutz Tier 2 )
Fig & Tug Part

Ind Number
52-1 ENG-MR34-DEUTZ-2 Alternator 1 1 & Up

52-2 TP-10476 Regulator, Voltage 1 "
52-3 M6 Washer, Star M6 1 "
52-4 M6-1.0 Nut, M6-1.0 1 "
52-5 TP-10517 Fan, Alternator 1 "
52-6 TP-10477 Pulley, Alternator 1 "
52-7 TP-10478 Washer, Plain, Alternator 1 "
52-8 TP-10479 Nut, Pulley, Alternator 1 "
52-9 TP-10480 Bracket, Cast Alternator Ref. "
52-11 M8-1.25 x 75 Bolt, Flange Head Ø M8-1.25 x 75mm Long 1 "
52-12 TP-10483 Bracket, Mounting, Alternator Ref. "
52-13 M10-1.5 x 25 Bolt, Flange Head Ø M8-1.25 x 25mm Long Ref. "
52-16 M8-1.25 Nut, M8-1.25 2 "
52-17 DEU1179565 Belt, Alternator 1 "
52-18 HRN-MR24-0001 Harness, Engine (See Note) 1 "
52-20 M6-1.0 Nut, M6-1.0 1 "
52-22 M8-1.25 Nut, M8-1.25 2 "
NOTE: Includes both positive battery alternator cable and #8 wire.
CD387 4-2-107
Orig
Chapter 4
11
13
12
10 9 2
5 1
4
8 7
Figure 2-53 Starter Assembly ( Deutz Tier 2 )
4-2-108 CD387
Orig
Chapter 4
Table 2-53 Starter Assembly ( Deutz Tier 2 )
Fig & Tug Part

Ind Number
53-1 ENG-MR24-DEUTZ Engine, Deutz BF4M2011 1 1 & Up

53-2 TM1-ND-5301 Starter 1 "
53-3 M10-1.5 x 25 Bolt, Flange Head Ø M10-1.5 x 25mm Long (Grade 2 "
10.9)
53-4 ENG-MR24-DEUTZ-25 Line, Turbo Oil Drain 1 "
53-5 ENG-MR24-DEUTZ-2 Seal, O-Ring, Upper Turbo Oil Drain 1 "
53-6 TP-10404 Seal, O-Ring, Lower Turbo Oil Drain 1 "
53-7 ENG-MR24-DEUTZ-1 Retainer, Turbo Oil Drain Line 1 "
53-8 TP-10394 Bolt, Turbo Oil Drain Line Retainer 1 "
53-9 MR-1234 Cable, Positive Common Battery 1 "
53-10 MR-1231 Cable, Positive Main Battery 1 "
53-11 ------ Wire 6B Ref. "
53-13 M10-1.5 Nut, Jam M10-1.5 1 "
CD387 4-2-109
Orig
Chapter 4
4 5
1 6
16
7 7
8
19
17 18
PTO DRIVE ASSEMBLY

15
20
TIMING BELT ASSEMBLY
14
9
13
10
11
12
Figure 2-54. Timing Belt and PTO Assemblies, Deutz
4-2-110 CD387
Orig
Chapter 4
Table 2-54. Timing Belt and PTO Assemblies, Deutz
Fig & Tug Part

Ind Number

ENG-MR34-DEUTZ Engine, Deutz TD2011 L040 (MR-34T) 1 60 & Up
54-2 DEU1179565 Belt, Alternator 1 1 & Up
54-3 TP-10487 Pulley, V-Groove 1 "
54-4 TP-10489 Hub, Fan Spacer 1 "
54-5 TP-10490 Bolt, Flange Head Ø M10-1.5 x 40mm Long 4 "
54-6 ENG-MR34-DEUTZ-4 Fan, Cooling, TD2011 1 "
54-7 TP-10405 Washer, Fan 2 "
54-8 TP-10488 Bolt, Hex Head Ø M8-1.25 x 40mm Long 4 "
54-9 TP-10491 Sprocket, Hydraulic Pump Drive 1 "
54-10 TP-10492 Adapter 1 "
54-11 TP-10475 Shield, Crankshaft 1 "
54-12 TP-10493 Bolt, Crankshaft 1 "
54-13 TP-10494 Belt Kit, PTO Drive w/Tensioner Pulley 1 "
54-14 ------ Pulley, Tensioner 1 "
54-15 TP-10390 Cover, Front, Hydraulic Pump 1 "
54-16 TP-10495 Sprocket, Camshaft 1 "
54-17 TP-10496 Pump, Engine Oil 1 "
54-18 TP-10497 Sprocket, Camshaft Drive 1 "
54-19 TP-10498 Belt Kit, Timing w/Tensioner Pulley 1 "
54-20 ------ Pulley, Tensioner 1 "
CD387 4-2-111
Orig
Chapter 4
1
6
5
4
7
8
3 2
Figure 2-55. Hydraulic Pump PTO Drive Assembly, Deutz
Table 2-55. Hydraulic Pump PTO Drive Assembly, Deutz
Fig & Tug Part

Ind Number
55-1 TP-10502 Bracket, Hydraulic Pump 1 1 & Up

55-2 TP-10503 Bolt, Torx Head Ø M10-1.5 x 90mm Long 2 "
55-3 TP-10504 Bolt, Torx Head Ø M10-1.5 x 75mm Long 1 "
55-4 TP-10506 O-Ring 1 "
55-5 660-1-2347 Coupler, Hydraulic Pump 1 "
55-6 TP-10494 Belt Kit, PTO Drive w/Tensioner Pulley 1 "
55-7 ------ Pulley Tensioner 1 "
55-8 ------ Bolt, Mounting 1 "
4-2-112 CD387
Orig
Chapter 4
Table 2-56. Oil Pan Installation. Deutz
Fig & Tug Part

1 Ind Number

ENG-MR34-DEUTZ Engine, Deutz TD2011 L040 (MR-34T) 1 "
56-2 TP-10459 Pan, Oil 1 "
56-4 MR-1282 Valve, Engine Oil Drain 1 "
56-5 TP-10458 Seal, Engine Oil Drain Valve 1 "
5
3
Figure 2-56. Oil Pan Installation, Deutz
CD387 4-2-113
Orig
Chapter 4
50
44
49
21 33
48 43 38 30 REF
20 37
22
41 39
22
21 45
40
46
32
47 36
35 34
52
19
15
18 31
42 30
17
51
18 29
1 53
16 28
56
6
57 27
2 55
59 58 26
3
35 24
35 54 23
13 75 59
14 60
12 7 5 24
73REF 73
4 70 25
11 8
61 63
9 Left Side View 74 66 69 Right Side View
10 67 68 71
62 72
64
65
Figure 2-57. Engine Assembly (Deutz Tier 4i)
4-2-114 CD387
Orig
Chapter 4
Table 2-57. Engine Assembly (Deutz Tier4i)

57-1 ENG-MR34-DEUTZ Engine, Deutz TD2011 L040 1 60 & Up 57-41 TP-10420 Bolt, Fuel Injection Retainer 4 60 & Up
57-2 TP-10389 Seal, Rear Crankshaft 1 " 57-42 TP-10421 Line, Fuel Return 1 "
57-3 DEU4272425 Flywheel 1 " 57-43 TP-10422 Ring, Sealing 8 "
57-4 DEU2109988 Bolt, Flywheel 8 " 57-44 TP-10403 Bolt, Banjo 4 "
57-5 ENG-MR34-DEUTZ-1 Starter, TD2011 1 " 57-45 TP-10423 Pump, Fuel Injection, Class A 4 See Note
57-6 TP-10390 Cover, Front, Hydraulic Pump 1 " TP-10424 Pump, Fuel Injection, Class B 4 "
57-7 TP-10391 Line, Turbo Oil Drain 1 " TP-10425 Pump, Fuel Injection, Class C 4 "
57-8 TP-10392 Seal, O-Ring, Lower Turbo Oil Drain 1 " TP-10426 Pump, Fuel Injection, Class D 4 "
57-9 TP-10393 Retainer, Turbo Oil Drain Line 1 " 57-46 TP-10427 Gasket, 0.35mm Compensating Ref. As Req'd
57-10 TP-10394 Bolt, Turbo Oil Drain Line Retainer 1 " TP-10428 Gasket, 0.40mm Compensating Ref. "
57-11 TP-10395 Seal, O-Ring, Upper Turbo Oil Drain 1 " TP-10429 Gasket, 0.45mm Compensating Ref. "
57-12 TP-10396 Nipple, Screw In 1 " TP-10430 Gasket, 0.50mm Compensating Ref. "
57-13 TP-10397 Ring, Sealing 1 " TP-10431 Gasket, 0.55mm Compensating Ref. "
57-14 TP-10398 Turbo Assembly 1 " TP-10432 Gasket, 0.60mm Compensating Ref. "
57-15 TM1-ND-5021 Gasket, Turbo 1 " TP-10433 Gasket, 0.65mm Compensating Ref. "
57-16 M8-1.25 Nut, M8-1.25 3 " TP-10434 Gasket, 0.70mm Compensating Ref. "
57-17 TP-10399 Sleeve, Rubber 1 " TP-10435 Gasket, 0.75mm Compensating Ref. "
57-18 TP-10400 Clamp, Spring Band 2 " TP-10436 Gasket, 0.80mm Compensating Ref. "
57-19 TP-10401 Pipe, Crankcase Breather 1 " TP-10437 Gasket, 0.85mm Compensating Ref. "
57-20 TP-10402 Line, Turbo Oil Feed 1 " TP-10438 Gasket, 0.90mm Compensating Ref. "
57-21 TP-10403 Bolt, Banjo 2 " TP-10439 Gasket, 0.95mm Compensating Ref. "
57-22 TP-10404 Ring, Sealing 4 " TP-10440 Gasket, 1.00mm Compensating Ref. "
57-23 ENG-MR34-DEUTZ-4 Fan, Cooling, TD2011 1 " TP-10441 Gasket, 1.05mm Compensating Ref. "
57-24 TP-10405 Washer, Fan 2 " TP-10442 Gasket, 1.10mm Compensating Ref. "
57-25 TP-10488 Bolt, Hex Head Ø M8-1.25 x 40mm Long 4 " TP-10443 Gasket, 1.15mm Compensating Ref. "
57-26 TP-10511 Belt, Alternator, TD2011 1 " TP-10444 Gasket, 1.20mm Compensating Ref. "
57-27 TP-10406 Dip Stick, Engine Oil Level 1 " TP-10445 Gasket, 1.30mm Compensating Ref. "
57-28 ENG-MR34-DEUTZ-2 Alternator, TD2011 1 " 57-47 TP-10446 Tappet, Roller 4 60 & Up
57-29 TP-10407 Plug, Glow 1 " 57-48 TP-10447 Washer, Flat M8 8 "
57-30 TP-10408 Cap, Oil 2 " 57-49 TP-10448 Nut, M8-1.25 8 "
57-31 TP-10409 Cover, Valve 1 " 57-50 TP-10449 Line, Injection Pump to Injector 4 "
57-32 TP-10410 Gasket, Valve Cover 1 " 57-51 TP-10450 Thermostat, Engine 1 "
57-33 TP-10411 Bolt, Valve Cover 10 " 57-52 TP-10451 Plug, Thermostat 1 "
57-34 TP-10412 Sender, Temperature 1 "
57-35 TP-10413 Ring, Sealing 3 " NOTE: There are four (4) different classes of fuel injection pumps available that can be used on the MR.
57-36 TP-10414 Plug, Screw 1 " They are: Class A, Class B, Class C and Class D. An identification tag is located on the side of
57-37 TP-10415 Injector, Fuel with Nozzle 4 " the fuel injection pump which calls out the class of that pump. Typically, all four of the fuel
57-38 TP-10417 Nozzle, Fuel Injector 4 " injection pumps on the MR engine are the same class but, there can be cases where multiple
57-39 TP-10418 Ring, Sealing, Fuel Injector 4 " classes are used on the same engine. When one or more fuel injection pump is
57-40 TP-10419 Claw, Fuel Injector Retainer 4 " removed/replaced, it must be replaced with the same class pump.
CD387 4-2-115
Orig
Chapter 4
50
44
49
21 33
48 43 38 30 REF
20 37
22
41 39
22
21 45
40
46
32
47 36
35 34
52
19
15
18 31
42 30
17
51
18 29
1 53
16 28
56
6
57 27
2 55
59 58 26
3
35 24
35 54 23
13 75 59
14 60
12 7 5 24
73REF 73
4 70 25
11 8
61 63
9 Left Side View 74 66 69 Right Side View
10 67 68 71
62 72
64
65
Figure 2-57. Engine Assembly (Deutz Tier 4i) (cont'd)
4-2-116 CD387
Orig
Chapter 4
Table 2-57. Engine Assembly (Deutz Tier4i)(cont'd)
Fig & Tug Part

Ind Number
57-53 TP-10452 Line, Fuel Supply 1 60 & Up

57-55 TP-10403 Bolt, Banjo 4 "
57-56 TP-10453 Sensor, Temperature, Glow Plug 1 "
57-57 TM1-ND-5040 Element, Oil Filter 1 "
57-59 TP-10454 Plug, Screw 2 "
57-60 TP-10102 Sensor, Speed 1 "
57-61 TP-10455 Sender, Oil Pressure 1 "
57-62 TP-10456 Pump, Fuel Supply 1 "
57-63 TM1-1-9693-4 Seal, Fuel Pump O-Ring 1 "
57-65 39587 Bolt, M81.25 x 20mmSocket Head Cap Fuel Pump 2 "
57-66 TP-10457 Plug, Engine Oil Drain 1 "
57-67 TP-10458 Seal, Engine Oil Drain 1 "
57-68 TP-10507 Bolt, Socket Head Cap Oil Pan 26 "
57-69 TP-10459 Pan, Oil 1 "
57-70 TP-10460 O-Ring Seal 1 "
57-71 TP-10461 Solenoid, Fuel Shut Off 1 "
57-72 TP-10462 Bolt, Hex Head Solenoid 2 "
57-73 TP-10463 Line, Pivot, Fuel 1 "
57-74 TM1-1-9693-6 Screw, Hollow 4 "
57-75 TM1-1-9693-7 Ring, Sealing 8 "
CD387 4-2-117
Orig
Chapter 4
Table 2-58. Engine Front Covers. Deutz Tier4i
Fig & Tug Part

Ind Number
58-1 TP-10468 Cover, Front, Oil Pump 1 60 & Up
58-2 TP-10469 Screw, Tamper Proof Ø M6-1.0 x 30mm Long 1 "
58-4 TP-10471 Cover, Front, Cam Shaft 1 "
58-5 TP-10472 Rubber 1 "
58-6 ------ Trim Lock Ref. "
58-8 TP-10390 Cover, Front, Hydraulic Pump 1 "
5 58-9 TP-10474 Bolt, Hex Head Ø M6-1.0 x 25mm Long 5 "
4 58-10 TP-10475 Shield, Crankshaft 1 "
6
7
1 8
3
2
10
Figure 2-58. Engine Front Covers. Deutz Tier 4i
4-2-118 CD387
Orig
Chapter 4
CD387 4-2-119
Orig
Chapter 4
24
3
18
4
19
25 20
21
14 22
12
14 5 1
16
15 9
13
10
8 23
10
6
11
7
17
Figure 2-59. Alternator Assembly ( Deutz Tier 4i )
4-2-120 CD387
Orig
Chapter 4
Table 2-59. Alternator Assembly ( Deutz Tier 4i )
Fig & Tug Part

Ind Number
59-1 ENG-MR34-DEUTZ-2 Alternator, TD2011 1 60 & Up

59-2 TP-10476 Regulator, Voltage 1 "
59-4 M6-1.0 Nut, M6-1.0 1 "
59-5 TP-10517 Fan, Alternator, TD2011 1 "
59-6 TP-10477 Pulley, Alternator 1 "
59-7 TP-10478 Washer, Plain, Alternator 1 "
59-8 TP-10479 Nut, Pulley, Alternator 1 "
59-9 TP-10480 Bracket, Cast Alternator 1 "
59-10 TP-10481 Bolt, Hex Head, Bracket Cast 3 "
59-11 TP-10482 Bolt, Flange Head Bracket Cast 1 "
59-12 TP-10483 Bracket, Mounting, Alternator 1 "
59-13 TP-10505 Bolt, Flange Head, Mounting 1 "
59-15 TP-10484 Bolt, Hex Head Mounting Bracket 1 "
59-16 M8-1.25 Nut, M8-1.25 2 "
59-17 TP-10511 Belt, Alternator, TD2011 1 "
59-18 HRN-MR34-111 Harness, Engine 41 Deutz 1 "
59-20 M6-1.0 Nut, M6-1.0 1 "
59-22 M8-1.25 Nut, M8-1.25 2 "
59-23 TP-10485 Ring, Supporting 1 "
59-24 HRN-MR34-111-3 Wire #8, Part of Harness 1 "
59-25 HRN-MR34-111-2 Cable, Positive, Alternator To Power Stud 1 "
CD387 4-2-121
Orig
Chapter 4
11
13
12
10 9 2
5 1
4
8 7
Figure 2-60. Starter Installation ( Deutz Tier 4i )
4-2-122 CD387
Orig
Chapter 4
Table 2-60. Starter Installation ( Deutz Tier 4i )
Fig & Tug Part

Ind Number
60-1 ENG-MR34-DEUTZ Engine, Deutz TD2011 L040 1 60 & Up
60-2 ENG-MR34-DEUTZ01 Starter, TD2011 1 "
60-3 TP-10505 Bolt, Flange Head, Mounting 2 "
60-4 TP-10391 Line, Turbo Oil Drain 1 "
60-5 TP-10395 Seal, O-Ring, Upper Turbo Oil Drain 1 "
60-6 TP-10400 Seal, O-Ring, Lower Turbo Oil Drain 1 "
60-7 TP-10393 Retainer, Turbo Oil Drain Line 1 "
60-8 TP-10394 Bolt, Turbo Oil Drain Line Retainer 1 "
60-9 MR-1234 Cable, Positive Common Battery 1 "
60-11 ------ Wire 6B (part of Engine Harness) 1 "
60-13 M10-1.5 Nut, Jam M10-1.5 1 "
CD387 4-2-123
Orig
Chapter 4
3
1
21
2 4
35
5
34 33 32
6 7 8
31
30 29 28 9
27 10
26
11
25
12
24
23 13
22 14
15 37
19
21 16
20
17 36
18
Figure 2-61. Engine Assembly. Front View ( Kubota )
4-2-124 CD387
Orig
Chapter 4
Table 2-61 Engine Assembly. Front View ( Kubota )
Fig & Tug Part

Ind Number
61-1 ENG-MA-36 Engine, Kubota (MR8) 1 22 & Up

ENG-MR10-36T Engine, Kubota, V3600-T (MR10) 1 "
61-2 ENG-MA-36-25 Valve, Breather 1 "
61-3 ENG-MA-36-56 Gauge, Oil (Dip Stick) 1 "
61-4 ENG-MA-36-57 Guide, Oil Gauge Assembly 1 "
61-5 ENG-MA-36-31 Gasket, Head Cover 1 "
61-6 ENG-MA-36-64 Manifold, Exhaust (MR8) 1 "
ENG-MR10-36T-4 Manifold, Exhaust (MR10, w/Kubota V3600-T) 1 "
61-7 ENG-MA-36-28 Gasket, Exhaust Manifold 1 "
61-8 ENG-MR10-36T-5 Turbocharger Assembly (MR10) 1 "
61-9 ENG-MA-36-6 Gasket 1 "
61-10 ENG-MA-36-60 Starter Assembly 1 "
61-11 MR-1038 Sender, Water Temperature 1 "
61-12 MD-HO9-123 Fitting, 8MP-6FP-Bush 1 "
61-13 ENG-MA-36-1 O-Ring, Oil Gauge Guide 1 "
61-14 T6-1300-165 Alarmstat, Kysor Water, 210 1 "
61-15 ENG-MA-36-22 Alternator Assembly 1 "
61-16 660-4-3630 Fitting, 2MBSPT-2FP 1 "
61-17 MR-1201 Fitting, 2MPX2FP-90 DEG 1 "
61-18 MR-1047 Sender, Oil Pressure 1 "
61-19 ENG-MA-36-18 Belt, V- 1 "
61-20 ------ Wire, 10 Gauge, Ground 1 "
61-21 HRN-MR36-111 Harness, Engine, MR Kubota 1 "
61-23 ------ Wire, 10 Gauge, Starter (to Stud) 1 "
61-24 M8-1.25 x 50 Bolt, Hex Head Ø M8-1.25 x 50 mm Long 4 "
61-26 MR-1065 Fan, Multi-wing, 8-Blade 1 "
61-27 ENG-MA-36-36 Pulley Fan Drive 1 "
ENG-MR-10-36T-1 Pulley, Fan (MR10, w/Kubota V3600-T) 1 "
61-28 ENG-MA-36-58 Pump Assembly, Water 1 "
61-29 ENG-MA-36-4 O-Ring, Water Pump 1 "
61-30 ENG-MA-36-45 Gasket, Water Pump 1 "
61-31 ENG-MA-36-59 Pipe, Water Return 1 "
61-32 ENG-MA-36-48 Thermostat Assembly 1 "
61-33 ENG-MA-36-55 Cover, Thermostat 1 "
61-34 ENG-MA-36-51 Gasket, Thermostat Cover 1 "
61-35 ------ Cable, Alternator to Stud (Part of Engine Harness) 1 "
61-36 EH-2802 Pad, Heater, 250 Watts, 120 Volts - Opt 1 "
EH-3202 Pad Heater, 250 Watts, 220V - Opt
61-37 T6-4900-152 Plug, Alternator, -D25 1 22 & Up
CD387 4-2-125
Orig
Chapter 4
13 14 15
12 16
17
11
5
10
18
9 8 19
7 20
21
5
22 23 24 25
4
6
3
2 26 27
1 28
29
31 30
56 55
32 33
54 34
27
35
36
37 38
39 28
46 40 41 42 43
53 47 48 44
52 45
49
51 50
Figure 2-62. Engine Assembly. Rear View ( Kubota )
4-2-126 CD387
Orig
Chapter 4
Table 2-62. Engine Assembly. Rear View ( Kubota )
Fig & Tug Part

Ind Number

62-2 ENG-MA-36-26 Tube, Breather 1 "
62-3 RM4003 Wire, 6 Gauge (Glow Plug to Glow Plug Switch) 1 "
62-4 ENG-MA-36-13 Plug, Glow 4 "
62-5 5000113 Clamp, Hose, 056 2 1/8-4" 2 "
62-6 ENG-MA-36-38 Pipe Assembly, Overflow 1 "
62-7 T6-4400-117 Hose, Upper Radiator 1 "
62-8 ------ Plug, Oil Filler 1 "
62-9 ENG-MA-36-5 O-Ring, Oil Filler Plug 1 "
62-10 ------ Valve, Bleeder 1 "
62-13 ------ Washer, Flat 4 "
62-14 ------ Bolt, Hex Head 4 "
62-15 MD-HO4-107 Cap, Radiator 1 "
62-16 T6-4700-469 Tubing, Clear 5/16" OD 1 "
62-17 MR-1055 Hose, Radiator to Filler Cap 1 "
62-18 MR-1020 Neck, Remote Radiator Fill 1 "
62-20 10mm Washer, Lock M10 1 "
62-21 MR-1021 Mount, Radiator Filler Neck 1 "
62-22 ENG-MA-36-36 Pipe Assembly, Overflow 2 "
62-23 ------ Holder Assembly, Nozzle 4 "
62-24 ------ Gasket 4 "
62-25 ENG-MA-36-19 Seal, Heat 4 "
62-26 MR-1066 Spacer, Fan 1 "
62-27 TM1-1-6521 Fitting, 5/8 Barb x 3/8 Male 2 "
62-28 ------ Clamp, Hose 2 "
62-29 MR-1015 Arm, Accelerator 1 "
62-30 MR-1068 Hose, Heater, Thermostat (Heater Outlet) 1 "
CD387 4-2-127
Orig
Chapter 4
13 14 15
12 16
17
11
5
10
18
9 8 19
7 20
21
5
22 23 24 25
4
6
3
2 26 27
1 28
29
31 30
56 55
32 33
54 34
27
35
36
37 38
39 28
46 40 41 42 43
53 47 48 44
52 45
49
51 50
Figure 2-62. Engine Assembly. Rear View ( Kubota) (cont'd)
4-2-128 CD387
Orig
Chapter 4
Table 2-62. Engine Assembly. Rear View ( Kubota) (cont'd)
Fig & Tug Part

Ind Number
62-31 ENG-MA-36-42 Solenoid, Stop (Fuel) 1 22 & Up

62-32 T6-4400-122 Connector, Fuel Solenoid 1 "
62-33 T6-4900-174 Bracket, Throttle Return Spring 1 "
62-34 T6-4900-211 Spring, Throttle Return 1 "
62-35 MR-1059 Stud, Modulator Slide 1 "
62-36 660-4-0745-12 Joint, Ball 1 "
62-37 ENG-MR10-36T-2 Plate, Fuel Pump Block Off 1 "
62-38 ENG-MA-36-11 Gasket, Fuel Pump 1 "
62-39 MR-1019 Bracket, Cable Mount 1 "
62-40 ENG-MA-36-39 Filter, Fuel 1 "
62-41 ENG-MA-36-14 Gasket 1 "
62-42 ENG-MA-36-16 Element, Fuel Filter 1 "
62-43 MT-1-1257 Hose, Heater 5/8" ID - 28473 (Heater Inlet) 1 "
62-44 ------ Clamp, Hose 1 "
62-45 T6-4400-118 Hose, Lower Radiator 1 "
62-46 ENG-MA-36-61 Cartridge, Oil Filter 1 "
62-47 ENG-MA-36-10 Plug, Drain 2 "
62-48 ENG-MA-36-12 Gasket, Drain Plug 2 "
62-49 ------ Clamp, Hose 1 "
62-50 ------ Hose, 5/16" ID 1 "
62-51 ------ Hose, 5/16" ID 1 "
62-52 660-4-3624 Adapter, Barb 5/16 to 3/16 1 "
62-53 T6-4400-134 Heater, Block 110V - Opt. 1 As Req'd
62-54 ------ Hose, 3/16" ID x 3" Long 1 22 & Up
62-55 ENG-MA-36-15 Bolt, Joint 1 "
62-56 ENG-MA-36-17 Gasket 1 "
CD387 4-2-129
Orig
Chapter 4
1
3
12
2
7
8
9
11 4
10
Figure 2-63. Heater Assembly ( Kubota )
4-2-130 CD387
Orig
Chapter 4
Table 2-63. Heater Assembly ( Kubota )
Fig & Tug Part

Ind Number
63-2 TM1-1-6521 Fitting, 5/8 Barb x 3/8 Male 2 "
63-3 ------- Clamp, Hose IDEAL 5010 6 As Req'd
63-4 MR-1068 Hose, Heater, Thermostat 1 "
63-5 MT-1-1257 Hose, Heater 5/8" ID - 28473 1 "
63-6 T6-4800-126 Fitting, 90° 1 "
63-7 TM1-ND-5253 Valve, Ball 1 "
63-8 MR-1265 Bracket, Mounting - ½" Ball Valve 1 "
63-9 TM1-1-8308 Barb, 5/8" Hose 1 "
63-10 MR-1266-2 Hose, Heater, Black 17" 1 "
63-11 T6-4400-134 Heater, Block, 110V 1 "
63-12 EH-2802 Pad, Heater, 250 Watts, 120 Volts 1 "
CD387 4-2-131
Orig
Chapter 4
21
22 1
20 4
5 11
10
7
6 12
14
9
16
15 8 13
17 2
18 3
19
1
Figure 2-64. Air Intake Assembly ( Deutz )
4-2-132 CD387
Orig
Chapter 4
Table 2-64. Air Intake Assembly ( Deutz )
Tug Part
Number
64-1 T6-1001-602 Air Filter Assembly 1 1 & Up

64-2 ------ Cap, End 1 "
64-3 ------ Cap, Rubber 1 "
64-4 ------ Housing, Air Filter 1 "
64-5 T6-1001-602F Element, Air Filter 1 "
64-6 ------ Clamp, Hose IDEAL 5056 1 "
64-7 T6-1001-603 Band, Air Filter Mounting 1 "
64-8 ------ Bolt, Mounting Spring Loaded 1 "
64-9 ------ Bolt, Mounting Band 1 "
64-10 ------ Mount, Air Filter Bracket - Wldmt (Part of Frame) 1 "
64-11 5/16-18 Nut, Flangelock Hex 5/16-18 2 "
64-12 5/16 Washer, Flat 5/16" ID 4 "
64-14 TM1-ND-5006 Hose, Air Cleaner Hump - Deutz 1 "
64-15 MR-1237 Tube, Transition (Filter to Turbo) 1 "
64-16 ------ Clamp, Hose IDEAL 5056 1 "
64-17 TP-10499 Clamp, Hose 1 "
64-18 TP-10500 Hose, Rubber, Reducer (Air Cleaner to Turbo) 1 "
64-19 TP-10501 Clamp, Hose IDEAL 5032 1 "
64-20 MR-1201 Elbow, 90°, 2MPx2FP-90 Deg 1 "
64-21 T6-1211-117 Indicator, Service - Air Filter 1 "
64-22 ------ Adapter, Straight 1 "
CD387 4-2-133
Orig
Chapter 4
6
13
1 5 7
2 3
4 4
12
9 8
4
10
11
Figure 2-65. Air Intake Assembly, Kubota ( MR-8 )
4-2-134 CD387
Orig
Chapter 4
Table 2-65. Air Intake Assembly, Kubota ( MR-8 )
Fig & Tug Part

Ind Number
65-1 T6-1206-103 Bands, Air Filter 2 22 & Up
65-2 MR-1016 Cleaner, Air 1 "
65-3 MR-1016-1 Filter, Primary Replacement 1 "
65-4 ------ Clamp, Hose, 3" 3 "
65-5 TM1-ND-5001 Elbow, Air Cleaner Hose - Deutz 1 "
65-6 ------ Clamp, Hose, 2.5" 2 "
65-7 MR-1051 Pipe Weldment, Air Cleaner to Intake 1 "
65-8 MR-1018 Elbow, Rubber COBRA 1 "
65-9 MR-1036 Mount, Air Cleaner 1 "
65-10 TM1-1-8150 Hose, Air Cleaner Intake Reducer 1 "
65-11 MR-1056 Pipe Weldment, Fresh Air Inlet 1 "
CD387 4-2-135
Orig
Chapter 4
1 5
7
2 3
4
8
10
11
12
13
14
15
Figure 2-66. Air Intake Assembly, Kubota V3600-T ( MR-10 )
4-2-136 CD387
Orig
Chapter 4
Table 2-66. Air Intake Assembly (Kubota MR10)
Fig & Tug Part

Ind Number
66-1 T6-1206-103 Bands, Air Filter 2 22 & Up
66-2 MR-1016 Cleaner, Air 1 "
66-3 MR-1016-1 Filter, Primary Replacement 1 "
66-4 ------ Clamp, Hose, 3" 3 "
66-5 TM1-1-9737 Connector, Hose 1.75" Dia 1 "
66-6 ------ Clamp, Hose, 2" 2 "
66-7 MR-1024 Pipe, Air Cleaner to Turbo 1 "
66-8 MR-1018 Elbow, Rubber COBRA 1 "
66-9 MR-1036 Mount, Air Cleaner 1 "
66-10 MR-1279 Minder, Filter, 12V - Opt. 1 As Req'd
66-11 TM1-1-8150 Hose, Air Cleaner Intake Reducer 1 22 & Up
66-12 ------ Clamp, Hose, 2.5" 1 "
66-13 MR-1056 Pipe Weldment, Fresh Air Inlet 1 "
CD387 4-2-137
Orig
Chapter 4
34 A 28
26
31
27 B
30 20
20 A
32 52 51
33 29 48
3REF 23
46
37 24 20
7 35
8
36 25 22
9 47
21 B
16 20 45
19 50
15
Typical Fuel
Tractor Frame
13 49
14
Line Connection 5 18
4 16
17
11 38 41 15
10
5 14
4
12 11
1 43
3
12
6 44
1
39 2
42
40
Figure 2-67. Fuel System (Deutz)
4-2-138 CD387
Orig
Chapter 4
Table 2-67. Fuel System (Deutz)
Tug Part Fig & Tug Part

Fig & Ind Description Qty Effective Description Qty Effective
Number Ind Number
67-1 MR-1139 Tank, Fuel (Wldmt) 1 1 & Up 67-27 TM1-1-9693-4 Seal, Fuel Pump O-Ring 1 1 & Up
67-2 T6-6010-111 Valve, Fuel Drain 1 " 67-28 M8 Washer, Flat M8 1 "
67-3 MR-1206 Line, Fuel (Tank to Pump) 1 " 67-29 39587 Bolt, Socket Head Cap Ø M8-1.25 x 20mm Long 1 "
67-4 5/16 Clamp, P - 5/16" 4 " 67-30 TP-10464 Head, Fuel Filter 2 "
67-5 ¼-20 Nut, Flangelock Hex ¼-20 2 " 67-31 MR-1168 Spacer, Fuel Filter 2 "
67-6 MR-1200 Fitting, ¼" NPT to 5/16" Compression 2 " 67-32 5/16 Washer, Flat 5/16" ID 1 "
67-7 MR-1200-2 Nut, 5/16" Compression Fitting 1 " 67-33 5/16-18 x 2 Bolt, Hex Head Ø 5/16-18 x 2" Long 2 "
67-8 MR-1200-3 Ferrule, 5/16" Compression Fitting 1 " 67-34 5/16-18 Nut, Top Lock Hex 5/16-18 2 "
67-9 MR-1200-1 Connector, 5/16" Compress Fitting 1 " 67-35 ENG-MR34-DEUTZ-7 Element, Fuel Filter 1 "
67-10 MR-1207 Line, Fuel Return 1 " 67-36 T6-9011-631 Hose Ø 5/16 x 20" Long, Low Pressure Fuel 1 "
67-11 MX4H-50024 Sending Unit, Fuel Level 1 " 67-37 T6-9011-631 Hose Ø 5/16 x 16½" Long, Low Pressure Fuel 1 "
67-12 TM1-ND-1006 Gasket, Fuel Sender 1 " 67-38 MR-1174 Isolator, Fuel Tank 2 "
67-13 HRN-MR-0006 Harness, Fuel Tank Sender 11 " 67-39 5/16 Washer, Flat 5/16" ID 2 "
67-14 10 Washer, Flat #10 5 " 67-40 5/16-18 x 1 Bolt, Hex Head Ø 5/16-18 x 1" Long 2 "
67-15 10 Washer, Lock #10 5 " 67-41 5/16-18 Nut, Top Lock Hex 5/16-18 2 "
67-16 10-32 x 1 Screw, Phillips Pan Head Ø #10-32 x 1" Long 5 " 67-42 MR-1176 Angle, Fuel Tank Isolator 2 "
67-17 MR-1209 Clamp, Hose - Fuel Filler 2 " 67-43 MR-1191 Tape, Double Sided AR "
67-18 MR-1208 Hose, Fuel Tank Transition 1 " 67-44 MR-1191 Tape, Double Sided (10") AR "
67-19 5000186 Cap, 3" Diesel Fuel 1 " 67-45 MR-1244 Panel, Wheel Well Closeout 1 "
67-20 ------ Clamp, Hose IDEAL 5010 10 " 67-46 MR-1189 Nut, U ¼-20 2 "
67-21 T6-9011-631 Hose Ø 5/16 x 20" Long 1 " 67-47 ¼ Washer, Flat ¼" ID 6 "
67-22 1¼ Clamp, P - 1¼" 1 " 67-48 ¼ Washer, Lock ¼" ID 2 "
67-23 ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 1 " 67-49 ¼-20 x 1½ Bolt, Hex Head Ø ¼-20 x 1½" Long 2 "
67-24 ¼ Washer, Lock ¼" ID 1 " 67-50 ¼-20 Nut, Top Lock Hex ¼-20 2 "
67-25 ¼ Washer, Flat ¼" ID 1 " 67-51 ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 2 "
67-26 TP-10456 Pump, Fuel 1 " 67-52 T6-9011-631 Hose Ø 5/16 x 20" Long, Low Pressure Fuel 1 "
CD387 4-2-139
Orig
Chapter 4
25
24 40
20 17
23
4 REF 39
22 18
7 21 19
8 26
20 5 19
3 17
38
11 16 41
15
Tractor Frame
27 37
Typical Fuel 10
14 28
Line Connection
9 16
13 29
12 30 36 15
6 14
5 1
13
4 31
12
3
32
1
34
33
35 2
Figure 2-68. Fuel System (Kubota)
4-2-140 CD387
Orig
Chapter 4
Table 2-68 Fuel System ( Kubota )
Fig & Tug Part

Ind Number
68-1 MR-1139 Tank, Fuel (Wldmt) 1 22 & Up

68-2 T6-6010-111 Valve, Fuel Drain 1 "
68-3 MR-1200 Fitting, ¼" NPT to 5/16" Compression 2 "
68-4 MR-1043 Line, Fuel Tank to Pump 1 "
68-5 5/16 Clamp, P - 5/16" 3 "
68-7 ------ Nut, 5/16" Compression Fitting 1 "
68-8 ------ Ferrule, 5/16" Compression Fitting 1 "
68-9 MR-1207 Line, Fuel Return 1 "
68-10 T6-9011-631 Hose Ø 5/16" Low Pressure Fuel/Oil, 4" Long 1 "
68-11 T6-4400-137 Pump, Fuel 1 "
68-12 TM1-ND-1006 Gasket, Fuel Sender 1 "
68-13 MX4H-50024 Sending Unit, Fuel Level 1 "
68-14 10 Washer, Flat #10 5 "
68-15 10 Washer, Lock #10 5 "
68-20 ------ Clamp, Hose IDEAL 5010 8 "
68-23 660-4-3624 Adapter, Barb 5/16 To 3/16 1 "
68-24 ------ Hose Ø 3/16" Low Pressure Fuel/Oil, 3" Long 1 "
68-25 ENG-MA-36-39 Filter, Fuel 1 "
68-26 5000186 Cap, 3" Diesel Fuel 1 "
68-27 HRN-MR-0006 Harness, Fuel Tank Sender 1 "
68-28 MR-1208 Hose, Fuel Tank Transition 1 "
68-29 MR-1209 Clamp, Hose - Fuel Filler 2 "
68-30 MR-1174 Isolator, Fuel Tank 2 "
68-31 MR-1191 Tape, Double Sided AR "
68-32 MR-1191 Tape, Double Sided (10") AR "
68-33 MR-1176 Angle, Fuel Tank Isolator 2 "
68-34 5/16 Washer, Flat 5/16" ID 2 "
68-36 5/16-18 Nut, Top Lock Hex 5/16-18 2 "
68-39 MR-1189 Nut, U ¼-20 2 "
68-41 ¼-20 Nut, Top Lock Hex ¼-20 2 "
CD387 4-2-141
Orig
Chapter 4
28
26
27
25
23
22
21
19
16
24
15
18
15 20 12
16
17 11
4 14
13
9
6
3
7
1 2
5 8
10
Figure 2-69. Exhaust System ( Deutz )
4-2-142 CD387
Orig
Chapter 4
Table 2-69 Exhaust System ( Deutz )
Fig & Tug Part

Ind Number
69-1 TP-10398 Turbo Assembly 1 1 & Up

69-2 MR-1238 Pipe, Header w/Flex 1 "
69-3 TP-10466 Gasket, Turbo to Header Pipe 1 "
69-5 MR-1243 Hanger, Exhaust Header (Wldmt) 1 "
69-7 3/8 Washer, Flat 3/8" ID 2 "
69-8 3/8-16 Nut, Top Lock Hex 3/8-16 1 "
69-9 2000059 Clamp, Exhaust 1 "
69-10 ------ Nut, Flange (Part of 2000059) 2 "
69-11 MR-1242 Clamp, Band 1 "
69-12 ------ Bolt, Flange (Part of MR-1242) 2 "
69-13 ------ Nut, Flange (Part of MR-1242) 2 "
69-14 MR-1240 Muffler 1 "
69-16 3/8 Washer, Flat 3/8" ID 4 "
69-17 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
69-18 MR-1242 Clamp, Band 1 "
69-21 MR-1241 Arrestor, Spark 1 "
69-22 MR-1242 Clamp, Band 1 "
69-25 MR-1239 Pipe, Tail 1 "
69-27 3/8 Washer, Flat 3/8" ID 2 "
69-28 3/8-16 Nut, Top Lock Hex 3/8-16 1 "
CD387 4-2-143
Orig
Chapter 4
6
4
3
5
2
Figure 2-70. Exhaust Assembly ( Kubota MR8 )
4-2-144 CD387
Orig
Chapter 4
Table 2-70. Exhaust Assembly ( Kubota MR8 )
Fig & Tug Part

Ind Number
70-1 ENG-MA-36-64 Manifold, Exhaust (MR8-36) 1 22 & Up

70-3 M10-1.5 Nut, Hex M10-1.5 4 "
70-4 MR-1052 Pipe, Header, Non-Turbo 1 "
70-5 T6-1005-119 Clamp, 2" Exhaust 2 "
70-6 MR-1054 Muffler & Spark Arrestor Assembly 1 "
70-7 MR-1053 Pipe, Tail, Non-Turbo 1 "
CD387 4-2-145
Orig
Chapter 4
12
10 9
3 11
4
1
7
5
8
Figure 2-71 Exhaust Assembly ( Kubota MR10 )
4-2-146 CD387
Orig
Chapter 4
Table 2-71. Exhaust System ( Kubota MR10 )
Fig & Tug Part

Ind Number
71-1 MR-1041 Pipe, Header V3600T 1 22 & Up

71-4 2000059 Clamp, 3" Heavy Duty 1 "
71-5 MR-1243 Hanger, Exhaust Header (Wldmt) 1 "
71-7 3/8 Washer, Flat 3/8" ID 2 "
71-8 3/8-16 Nut, Top Lock Hex 3/8-16 1 "
71-9 MR-1242 Clamp, Band 3 "
71-10 MR-1240 Muffler 1 "
71-11 MR-1241 Arrestor, Spark 1 "
71-12 MR-1239 Pipe, Tail 1 "
CD387 4-2-147
Orig
Chapter 4
27 26
30 Ref
5 7 15
18 6
9 29 Ref
25
8
10
16
3 17
4 26
14 13
1 27 28
Detail 'A'
2 11
27 13
21 26 14
22 24 23 11 Ref
See Detail 'B'
25 27
20 12
26 23
29 13
27
30
12 Ref
See Detail 'A' 19
Detail 'B'
Figure 2-72 Cooling System ( Deutz Tier 2 )
4-2-148 CD387
Orig
Chapter 4
Table 2-72. Cooling System ( Deutz Tier 2 )
Fig & Tug Part

Ind Number
72-1 660-4-3574 Cooler, Transmission Fluid 1 1 & Up

72-2 TM1-2-1089 Mount, Fluid Cooler Lower Ref. "
72-3 T6-9011-633 Mount, Fluid Cooler Upper 1 "
72-4 ¼-20 Nut, Top Lock Hex ¼-20 2 "
72-6 T6-9011-631 Hose Ø 5/16 x 21" Long 1 "
72-7 ------ Clamp, Hose IDEAL 5010 1 "
72-8 5/8 Clamp, P - 5/8" 1 "
72-10 ------ Clamp, Hose IDEAL 5010 1 "
72-11 MR-1227 Line, Transmission Cooler Supply 1 "
72-12 MR-1228 Line, Transmission Cooler Return 1 "
72-13 3/8 Clamp, P - 3/8" 5 "
72-15 T6-9011-631 Hose Ø 5/16 x 21" Long 1 "
72-16 ------ Clamp, Hose IDEAL 5010 1 "
72-17 5/8 Clamp, P - 5/8" 1 "
72-18 ------ Clamp, Hose IDEAL 5010 1 "
72-19 T6-9003-527 Hose, Cooling Transmission 2 "
72-20 MR-1165 Bracket, Lower Oil Cooler Mount 1 "
72-22 5/16 Washer, Flat 5/16" ID 4 "
72-24 0990 0244 Cooler, Oil 1 "
72-25 660-1-2412 Isolator 5 "
72-26 5/16 Washer, Flat 5/16" ID 10 "
72-28 660-1-2308 Fitting, Straight - Oil Cooler Hose 2 "
72-29 TM1-1-5009 Hose, Oil Cooler 21" 1 "
CD387 4-2-149
Orig
Chapter 4
30 Ref
23 22 29 Ref
6 9 7
7 15
25 8
7
16
4
14 19
10 Detail 'A'
22 12 Ref
1 13
23
2
17 11 Ref
3 11
23 26 13 18
5 21 22 14
22 24 23 27
See Detail 'B' Detail 'B'
25
20 12
22 23
23 13
See Detail 'A'
Figure 2-73 Cooling System ( Deutz Tier 4i )
4-2-150 CD387
Orig
Chapter 4
Table 2-73. Cooling System ( Deutz Tier 4i )
Fig & Tug Part

Ind Number

73-4 TM1-4-9858 Spacer, Threaded, Transmission Cooler (Part Of Frame) 4 "
73-5 ¼-20 x 1 Bolt, Hex Head, ¼" -20 x 1" Long 4 "
73-6 T6-9011-631 Hose Ø 5/16 x 21" Long 1 "
73-7 ------ Clamp, Hose IDEAL 5010 4 "
73-8 5/8 Clamp, P - 5/8" 2 "
73-10 660-1-2308 Fitting, Straight - Oil Cooler Hose 2 "
73-13 3/8 Clamp, P - 3/8" 5 "
73-15 T6-9011-631 Hose Ø 5/16 x 21" Long 1 "
73-16 TM1-ND-5049 Fitting, Oil Cooler 90JIC 1 "
73-17 TM1-ND-5260 Fitting, Oil Cooler, 45 1 "
73-18 T6-9003-527 Hose, Transmission Line 90 Degr. 1 "
73-20 MR-1165 Bracket, Lower Oil Cooler Mount 1 "
73-22 5/16 Washer, Flat 5/16" ID 14 "
73-24 TP-10465 Cooler, Oil, BF4M1011F 1 "
73-25 660-1-2412 Damper, Vibration - Oil Cooler 5 "
CD387 4-2-151
Orig
Chapter 4
6
4 7
5
8
9
10
3 16
11
2 12 17
13
1 14
11 18
15 19
11
11
21 23
20
11
22
27
11
23
24
26
25
Figure 2-74. Oil Cooling System ( Kubota )
4-2-152 CD387
Orig
Chapter 4
Table 2-74. Cooling System ( Kubota )
Tug Part
Number
74-2 ¼-20 Nut, Top Lock Hex ¼-20 2 "
74-4 MR-1167 Mount, Fluid Cooler Upper 1 "
74-5 ------ Clamp, Hose IDEAL 5010 7 "
74-6 MR-1226-1 Hose, Cooling Ø 5/16" x 24" Long (to Supply) 1 "
74-7 MR-1226-2 Hose, Cooling Ø 5/16" x 20" Long (to Return) 1 "
74-8 MR-1063 Radiator, Aluminum 1 "
74-9 660-1-2412 Damper, Vibration - Oil Cooler 4 "
74-10 5/16 Washer, Flat 5/16" ID 8 "
74-11 ------ Clamp, Hose 2" 7 "
74-13 MR-1029 Mount, Radiator, R/H 1 "
74-14 MR-1055 Hose, Radiator to Filler Cap 1 "
74-15 MR-1023 Shroud, Fan 1 "
74-18 MD-HO4-107 Cap, Radiator 1 "
74-19 MR-1020 Neck, Remote Radiator Fill 1 "
74-20 T6-4700-469 Tube, Clear, Overflow Bottle (to Neck) 1 "
74-21 T6-4400-117 Hose, Upper Radiator 1 "
74-22 T6-4400-118 Hose, Lower Radiator 1 "
74-24 MR-1045 Bracket, Overflow Bottle Mount 1 "
74-25 T6-4700-469 Tube, Clear, Overflow Bottle 1 "
74-26 T6-4700-432 Bottle, Overflow 1 "
74-27 MR-1028 Mount, Radiator, L/H 1 "
74- MR-1226 Hose Kit, Cooling (Includes items 6, 7) Ref. "
CD387 4-2-153
Orig
Chapter 4
14 13
1
2
17
3
9 12 18
4 16
5 20
21
6
7 15 19
29
21
8
30
31
32 22 27
19
23
25
24 25 23 28 26 11 10
Figure 2-75. Engine and Transmission ( Deutz Tier 2 and C6 )
4-2-154 CD387
Orig
Chapter 4
Table 2-75. Engine and Transmission Installation ( Deutz Tier2 and C6 )
Fig & Tug Part

Ind Number

75-2* 999-0230A Adapter, Drive 1 "
75-3* ------ Bolt, Drive Adapter 3 "
75-4* 999-02-3013 Housing, Adapter 1 "
75-5 660-4-3625 Washer, Flat (C6 to 2011 Adapter) 9 "
75-6 M10-1.5 x 25 Screw, Low Head Socket Ø M10-1.5 x 25mm Long 9 "
75-7 TPG-D5TZ-6375A Flywheel Assembly, C-6 1 "
75-8 TPG-C20Z-6A366A Reinforcement, Plate - Flywheel 1 "
75-9 TPG-378171-S100 Bolt, Hex 6 "
75-10 T6-1008-111 Transmission, C-6 - 3 Speed 1 "
75-11 T6-1008-111-4 Arm, Shift 1 "
75-12 T6-9003-601 Converter, Torque, C6 1 "
75-13 5/16 Washer, Flat 5/16" ID 4 "
75-14 3/8-24 Nut, Top Lock Hex 3/8-24 4 "
75-15 TPG-EOTZ-7A228A Tube, Oil Level 1 "
75-16 TPG-E7TZ-7A020D Dip Stick Assembly, Transmission 1 "
75-17 T6-1008-111-3 Seal, O-Ring 9/19 x .103" 1 "
75-18 T6-6011-113 Bracket, Transmission Line 2 "
75-20 7/16 Washer, Flat 7/16" ID 2 "
75-21 7/16 Washer, Lock 7/16" ID 6 "
75-22 MR-1233 Cable, Braided Ground 1 "
75-24 3/8 Washer, Flat 3/8" ID 1 "
75-25 3/8 Washer, Lock 3/8" ID 3 "
75-26 MR-1205 Elbow, 90° 1 "
75-27 TM1-ND-5043 Switch, Pressure Starter Interlock 1 "
75-28 MR-1122-1 Wire, Transmission Pressure Switch 1 "
75-29 MR-1126 Closeout, Flex Plate 1 "
75-30 ½ Washer, Flat ½" ID 2 "
75-31 ½ Washer, Lock ½" ID 2 "
75-32 ½-13 x 1 Bolt, Hex Head Ø ½-13 x 1" Long 2 "
* Part of TM1-1-5070 Adapter Assembly, C6 to Deutz
CD387 4-2-155
Orig
Chapter 4
5
3
4
6
2
Fig & Tug Part
Ind Number
8
76-1 ENG-MR10-36T Engine, Kubota, V3600-T (MR10) 1 22 & Up
ENG-MA-36 Engine, Kubota (MR8) 2 "
9 76-2 T6-4400-103 Adapter, Kubota SAE 4 to C6 1 "
76-3 M12-1.75 x 30 Bolt, Socket Head Ø M12-1.75 x 30mm Long 6 "
76-4 660-4-3625 Washer, Trans. Adapter 10 "
76-5 T6-1208-105 Pin, Dowel 2 "
76-6 TPG-D5TZ-6375A Flywheel (comes w/Transmission) 1 "
7 76-7 M10-1.5 x 25 Bolt, Socket Head Ø M10-1.5 x 25mm Long 10 "
76-8 TPG-C20Z-6A366A Reinforcement, Plate-Flywheel 1 "
76-9 TPG-378171-S100 Bolt, Hex Ø 7/16-20 x 0.80" Long 6 "
Figure 2-76. Engine and Transmission ( Kubota and C6 ) Table 2-76. Engine and Transmission Installation ( Kubota and C6 )
4-2-156 CD387
Orig
Chapter 4
Figure 2-77. Transmission Oil Pan Assembly ( C6 )
Table 2-77. Transmission Oil Pan Assembly ( C6 )
Fig & Tug Part

Ind Number
77-1 T6-1008-111 Transmission, C-6 - 3 Speed 1 1 & Up
77-2 C6AZ-7A191B Gasket, Transmission Oil Pan 1 "
77-3 E5TZ-7A194D Pan, Oil C6 Transmission 1 "
77-4 5/16-18 x 17/32" Bolt, Transmission Oil Pan, 5/16-18 x 17/32" Long 17 "
CD387 4-2-157
Orig
Chapter 4
1
2
4 3
8 9
9 10
Figure 2-78 Transmission Filter Screen and Valve Body ( C6 )
4-2-158 CD387
Orig
Chapter 4
Table 2-78. Transmission Filter Screen and Valve Body ( C6 )
Fig & Tug Part

Ind Number
78-1 T6-1008-111-5 Rod, Gear Selector Valve 1 1 & Up
78-2 T6-1008-111-9 Retainer, Throttle Pressure 1 "
78-3 T6-1008-111-10 Screen, Main Control Pump Inlet 1 "
78-4 T6-1008-123 Valve Body Assembly, 3 Speed 1 "
78-6 T6-1008-111-6 Gasket, Transmission Filter Screen 1 "
78-7 D5AZ-7A098B Screen, Transmission Filter 1 "
78-9 10-24 x 1¼ Bolt, Oil Screen Ø #10-24 x 1¼" Long 8 "
78-10 10-24 x 1 5/8 Bolt, Oil Screen Ø #10-24 x 1 5/8" Long 1 "
CD387 4-2-159
Orig
Chapter 4
1 2
Figure 2-79. Transmission Band Adjustment ( C6 )
4-2-160 CD387
Orig
Chapter 4
Table 2-79. Transmission Band Adjustment ( C6 )
Fig & Tug Part

Ind Number
79-1 T6-1008-111-7 Screw, Reverse Band Adjusting 1 1 & Up
79-2 T6-1008-111 Transmission, C-6 - 3 Speed 1 "
79-3 T6-1008-111-8 Nut, Band Adjustor 1 "
CD387 4-2-161
Orig
Chapter 4
6 9
12
13
10
11
8 14
7
3
5
16
4
15 2 17
Figure 2-80. Shifter Assembly ( C6 )
4-2-162 CD387
Orig
Chapter 4
Table 2-80. Shifter Assembly( C6 )
Tug Part
Number
80-1 TM1-1-8182 Cable, Shifter, 58" 1 1 & Up

80-2 TM1-2-9555 Mount, Shifter 1 "
80-6 MR-1124 Shifter 1 "
80-7* ------ Socket, Light 1 "
80-8 MR-1124-1 Bulb, Shifter Illumination 1 "
80-9* ------ Joint, Ball 1 "
80-10 3/32 x ½ Pin, Cotter Ø 3/32 x ½" Long 1 "
80-11* ------ Anchor, Bracket Cable 1 "
80-12* ------ Anchor, Cable Clamp 1 "
80-14 ¼-20 Nut, Top Lock Hex ¼-20 4 "
* Part of MR-1124 Shifter
CD387 4-2-163
Orig
Chapter 4
9
3
5 14
2 13
6 10
18 8 11
12
15
16
23
1
4 17
20
7
21
22
19 9
Figure 2-81 Shifter Linkage ( C6 )
4-2-164 CD387
Orig
Chapter 4
Table 2-81. Shifter Linkage ( C6 )
Tug Part
Number
81-1 T6-1008-111-4 Lever, Shift, Transmission 1 1 & Up

81-2 MR-1122 Switch, Neutral Safety 1 "
81-3 MR-1122-1 Wire, Transmission Pressure Switch 1 "
81-5 ¼-20 Nut, Top Lock Hex ¼-20 1 "
81-9 TM1-1-8154 Connection Kit, Transmission 1 "
81-10* ------ Bracket, Mounting 1 "
81-11* ------ Shim, Clamp, Cable 1 "
81-12* ------ U-Bolt #10-32 1 "
81-13* 10 Washer, Flat #10 2 "
81-14* 10-32 Nut, Nylock #10-32 2 "
81-15 5/16-18 x 17/32 Bolt, Transmission Oil Pan, 5/16-18 x 17/32" Long 17 "
81-16 MR-1178 Lever, Transmission Gear Select 1 "
81-18 5/16-18 Nut, Top Lock Hex 5/16-18 1 "
81-19 3/8-24 x 5/8 Bolt, Hex Head Ø 3/8-24 x 5/8" Long 1 "
81-20 3/8-24 Nut, Top Lock Hex 3/8-24 1 "
81-21* ------ Pivot 1 "
81-23 TM1-1-8182 Cable, Shifter, 58" 1 "
* Part of TM1-1-8154 Kit, Transmission Connection
CD387 4-2-165
Orig
Chapter 4
2 4
9
3
8
21
10 23
11
24
17 18
20
12 13
22 22
21
14
7
5 6 12
15
16
19 22
Figure 2-82. Park Brake Lever Installation ( C6 )
4-2-166 CD387
Orig
Chapter 4
Table 2-82. Park Brake Lever Installation ( C6 )

Tug Part
Number
82-1 T6-8005-101 Lever, Hand Brake 1 1 & Up

82-2 T6-8005-103 Bushing, Hand Brake 2 "
82-3 TM1-4-5037 Bracket, Park Brake (Wldmt) 1 "
82-6 ½-20 Nut, Nylock ½-20 1 "
82-7 3/8 Washer, Lock 3/8" ID 4 "
82-8 3/8 x 1½ Washer, Fender 3/8 x 1½" 2 "
82-9 3/8 x 2 Washer, Fender 3/8 x 2" 4 "
82-10 MD-CB1-129 Yoke 1 "
82-11 3/8-24 x 2½ Rod, All-Threaded Ø 3/8-24 x 2½" Long 1 "
82-12 TPG-C1TT-2857L Clevis 2 "
82-13 TPG-D3TZ-2A663D Bellcrank 1 "
82-14 TPG-D3TZ-2857A Clevis, Parking Brake 1 "
82-15 TPG-385555-S2 Spacer 1 "
82-16 TPG-385554-S2 Stud Ø 9/16-18 x 2.28" Long 1 "
82-17 9/16 Washer, Flat 9/16" ID 1 "
82-18 TPG-386034-S100 Nut, Slotted 9/16-18 1 "
82-19 TPG-B9TZ-2A710D Cam and Lever Assembly 1 "
82-20 3/8 x 1¼ Pin, Clevis Ø 3/8 x 1¼" Long 1 "
82-21 1/8 x ¾ Pin, Cotter Ø 1/8 x ¾" Long 4 "
82-22 5/16 x 1 Pin, Clevis Ø 5/16 x 1" Long 3 "
82-24 3/8-24 Nut, Jam 3/8-24 1 "
CD387 4-2-167
Orig
Chapter 4
22
28 25 29
13 33
27 36
21
31
20 30
38
18
17 37 35
32
34
26 24 31
19 23 36
14
11 8
15
7
3
14
12
10
9 4
16
5 2
6
Figure 2-83. Transmission Park Brake Assembly ( C6 )
4-2-168 CD387
Orig
Chapter 4
2-83. Transmission Park Brake Assembly ( C6 )
Fig & Tug Part

Ind Number
83-1 MR-1123 Shaft, Drive C6 to AMS 1 1 & Up

83-2 TPG-C6TZ-4A254B Saddle, U-Joint 2 "
83-3 TPG-D3TZ-7089B Flange, Output 1 "
83-4 TPG-D3TZ-2614A Drum, Park Brake 1 "
83-5 TPG-382884-S Bolt, Drive Shaft Saddle - Socket Head Ø 5/16-24 x 1" Long 4 "
83-6 5/16 Washer, Lock 5/16" ID 4 "
83-7 TPG-371887-S2 Nut, Nylock Jam 1" - Tail Shaft 1 "
83-8 TPG-385524-S2 Bolt Ø ½-13 x 1½" Long 4 "
83-9 ½-13 Nut, Top Lock Hex ½-13 4 "
83-10 T6-8005-135 Plate, Brake Shoes 1 "
83-11 TPG-D6TZ-2A703A Shield, Park Brake 1 "
83-12 TPG-58675-S2 Bolt, Hex Head Ø ½-13 x 1½" Long 4 "
83-13 ½-13 Nut, Top Lock Hex ½-13 4 "
83-14 T6-8005-143 Shoes, Park Brake 1 "
83-15 T6-8005-147 Spring, Brake Shoes, Top 2 "
83-16 T6-8005-149 Spring, Brake Shoes, Bottom 1 "
83-17 D0TZ-7A011A Seal, Transmission 1 "
83-18 E1ZZ-7065A Bearing, Tail Shaft 1 "
83-19 D5TZ-7070A Ring, Bearing Retainer 1 "
83-20 TPG-D1TZ-17285A Spacer, Speedo, Gear 1 "
83-21 T6-8005-129 Housing, Flange 1 "
83-22 D2AZ-7086A Gasket, Flange Housing 1 "
83-23 ½-20 Nut, Hex ½-20 3 "
83-24 ½ Washer, Lock - External Tooth ½" ID 3 "
83-25 ½-20 Nut, Nylock ½-20 1 "
83-26 TPG-D3TA-2A701AA Pipe, Parking Brake 1 "
83-27 TPG-C8HZ-7A002A Plug, Speedometer Gear Input 1 "
83-28 TPG-B9TZ-2A710D Cam and Lever Assembly 1 "
83-29 TPG-385554-S2 Stud Ø 9/16-18 x 2.28" Long 1 "
83-30 TPG-D3TZ-2A663D Bellcrank 1 "
83-31 TPG-C1TT-2857L Clevis 2 "
83-32 TPG-D3TZ-2857A Clevis, Parking Brake 1 "
83-33 TPG-385555-S2 Spacer 1 "
83-34 9/16 Washer, Flat 9/16" ID 1 "
83-35 TPG-386034-S100 Nut, Slotted 9/16-18 1 "
83-36 5/16 x 1 Pin, Clevis Ø 5/16 x 1" Long 3 "
83-37 1/8 x ¾ Pin, Cotter Ø 1/8 x ¾" Long 3 "
CD387 4-2-169
Orig
Chapter 4
2
3
11
4
5
6 7
8
9
10
12
Figure 2-84. Engine and Tramsmission Assembly (Deutz Tier 4i and 4R75 Transmission)
4-2-170 CD387
Orig
Chapter 4
Table 2-84. Engine and Transmission Assembly ( Deutz Tier 4i and 4R75 Transmission )
Fig & Tug Part

Ind Number
84-1 ENG-MR34-DEUTZ Engine, Deutz TD2011 L040 1 60 & Up

84-2 ENG-MR34-DEUTZ-10 Adapter,Flywheel To Flexplate 1 "
84-3 14mm-2.0 x 35mm Bolt, Drive Adapter, Allen Head M14-2.0x35 3 "
84-4 ENG-MR34-DEUTZ-8 Adapter, Transmission to Housing 1 "
84-5 M10 Washer, Flat (C6 to 2011 Adapter) 9 "
84-6 M10-1.5 x 25 Screw, Low Head Socket Ø M10-1.5 x 25mm Long 9 "
84-7 3/8-24 Nut, Top Lock Hex 3/8-24 4 "
84-8 ENG-MR34-DEUTZ-9 Flexplate 1 "
84-9 5/8 Washer, Flat 3/8" ID 4 "
84-10 TPG-C20Z-6A366A Reinforcement, Plate - Flywheel 1 "
84-11 TPG-378171-S100 Bolt, Hex 6 "
84-12 MR-1300 Transmission, 4R75 W/Park Brake 1 "
CD387 4-2-171
Orig
Chapter 4
15
16
17
18
12
11
8
7
9
10 9 8 6
5
3 2 1
13 4
14
Figure 2-85. Transmission ( 4R75 ) Assembly
4-2-172 CD387
Orig
Chapter 4
Table 2-85. Transmission ( 4R74 ) Assembly
Fig & Tug Part

Ind Number
85-1 MR-1300 Transmission,4R75 W/Park Brake 1 60 & Up

85-2 MR-1312 Mount, Park Brake Cable At Transmission 1 "
85-3 ½ Washer, Lock, ½ 1 "
85-4 ½-13 x 1¾ Bolt, Hex Head, ½-13 x 1¾ 1 "
85-5 MR-1310 Washer, Shift Plate 4R75 1 "
85-6 MR-1306 Plate, Shifter, 4R75 9 "
85-7 TM1-4-9843 Elbow, 90° 1 "
85-9 3/8 Washer, Lock 3/8" ID 3 "
85-10 3/8 Washer, Flat 3/8" ID 1 "
85-11 MR-1233 Cable, Braided Ground 1 "
85-12 TM1-ND-5043 Switch, Pressure Starter Interlock 1 "
85-13 MR-1300-2 Harness, 4R75 Tramsmission 1 "
85-14 HRN-MR34-114 Harness, 4F75 Transm Start/Back 1 "
85-15 MR-1323 Dipstick 4R75 1 "
85-16 TPG-EOTZ-7A228-A Tube, Transmission Dip Stick C6 1 "
85-17 MR-1300-11 Breather, Assembly, Transmission 1 "
85-18 MR-1300-5 Converter Assembly 1 "
CD387 4-2-173
Orig
Chapter 4
4 3
Figure 2-86. Transmission Sensors Installation ( 4R75 )
4-2-174 CD387
Orig
Chapter 4
Table 2-86. Transmission Sensors Installation ( 4R75 )
Fig & Tug Part

Ind Number
86-1 MR-1300 Transmission, 4R75 W/Park Brake 1 60 & Up
86-2 MR-1300-7 Sensor, Transm. Output Shaft Speed 1 "
86-3 MR-1300-8 Sensor, Transm. Range 1 "
86-4 MR-1300-6 Sensor, Transm.Turbine Shaft Speed 1 "
CD387 4-2-175
Orig
Chapter 4
1
2
Figure 2-87 Transmission Oil Pan Installation ( 4R75 )
4-2-176 CD387
Orig
Chapter 4
Table 2-87. Transmission Oil Pan Installation ( 4R75 )
Fig & Tug Part

Ind Number
87-1 MR-1300-12 Filter & Seal Assy 1 60 & Up
87-2 MR-1300-9 Gasket, Transmission Pan 1 "
87-3 MR-1300-10 Pan, Transmission 1 "
CD387 4-2-177
Orig
Chapter 4
3
14 5
1 4
13
5 4
12
6 3
15 8
7
11 10 9
Figure 2-88. Shifter Assembly ( 4R75 Transmission )
4-2-178 CD387
Orig
Chapter 4
Table 2-88. Shiter Assembly ( 4R75 Transmission )
Fig & Tug Part

Ind Number
88-2 T6-1002-151 Shifter, Morse 1 "
88-6 TM1-2-9555 Mount, Shifter 1 "
88-7 TM1-1-8182 Cable, Shifter, 58" 1 "
88-8 ¼-20 Nut, Lock, ¼"ID-20 2 "
88-9 MR-1318 Mount, Shifter Cable, 4R75 1 "
88-10 T6-1002-155 Clamp, Cable 1 "
88-12 T6-1004-119 Swivel, Shift Cable 1 "
88-13 MR-1306 Plate, Shifter, 4R75 1 "
88-15 MR-1310 Washer, Shifter Plate, 4R75, ¼-½ 1 "
CD387 4-2-179
Orig
Chapter 4
2 2
3 8
4 3
4
5 9
7
6 10
7 11
12
14 4
13
15 27
16
17
19
18 20
13 21
22
26
23
16
24
25
Figure 2-89. Park Brake Assembly ( 4R75 Transmission )
4-2-180 CD387
Orig
Chapter 4
Table 2-89. Park Brake Assembly ( 4R75 Transmission )
Fig & Tug Part

Ind Number
89-1 MR-1271-3 Housing, MR 8/10 Transmission (Part of Frame) 1 60 & Up

89-2 ¼-20 X 1" Bolt, Phillips, Ø¼-10 x 1" 8 "
89-3 ¼-20 x ¾ Bolt, Phillips, Ø¼-20 x ¾ 4 "
89-4 ¼ Washer, Flat, ¼ID 4 "
89-5 MR-1076 Mount, Park Brake Transm Housing 2 "
89-6 MR-1078 Bracket, LH Parking BRK Handle 1 "
89-7 ¼-20 Nut, Lock, ¼-20 8 "
89-8 ¼-20 Nut, Flange, ¼-20 4 "
89-9 MR-1313 Mount, Park BrakeCable At Handle 1 "
89-10 3/8-16 x 2 Bolt, Hex Head, Ø3/8-16 x 2" 2 "
89-11 3/8 Washer, Lock, 3/8"ID 2 "
89-12 3/8 Washer, Flat, 3/8"ID 4 "
89-13 T6-1002-155 Clamp, Cable 2 "
89-14 3/8-16 Nut, Lock, 3/8"ID-16 2 "
89-15 T6-8005-101 Lever, Hand Brake 1 "
89-16 T6-8005-103 Bushing, Hand Brake 2 "
89-17 1/8 x 1½ Pin, Cotter, 1/8 x 1½ 2 "
89-18 3/8 x 1 1/8 Pin, Clevis, Ø3/8 x 1 1/8" Long 2 "
89-19 MR-1307 Yoke, Park Brake Handle, 4R75 1 "
89-20 TM1-1-8182 Cable, Shifter (Parking Brake), 58" 1 "
89-21 ¼-20 X 1" Bolt, Hex Head, Ø¼-20 x 1" 4 "
89-22 MR-1300 Transmission, 4R75 W/Park Brake 1 "
89-23 3/32 x 1½ Pin, Citter, Ø3/32 x 1½"Long 1 "
89-24 5/16 x 1 Pin, Clevis Ø5/16 x 1"Long 1 "
89-25 MR-1308 Yoke, Park Brake Drum 1 "
89-26 MR-1312 Mount, Park Brake Cable At Transmission 1 "
89-27 MR-1077 Bracket, RH Parking Brake Handle 1 "
CD387 4-2-181
Orig
Chapter 4
17 16
15
14
8
4
5
1
2 9 11
10
6 12
7
3
13
Figure 2-90. Drive Shaft Assembly ( C6 )
4-2-182 CD387
Orig
Chapter 4
Table 2-90. Drive Shaft Assembly ( C6 )
Fig & Tug Part

Ind Number
90-1 MR-1123 Shaft, Drive C6 to AMS 1 1 & Up

90-2 ------ U-Joint 2 "
90-3 TPG-C6TZ-4A254B Saddle, U-Joint 2 "
90-4 7/16-14 Nut, Top Lock Hex 7/16-14 4 "
90-6 TPG-382884-S Bolt, Drive Shaft Saddle - Socket Head Ø 5/16-24 x 1" 4 "
Long
90-7 5/16 Washer, Lock 5/16" ID 4 "
90-8 MR-1179 Box, Drop 1 "
90-12 MT-4-1247 Axle, Rear Drive 1 "
90-13 TPG-D3TZ-7089B Flange, Output 1 "
90-14 MR-1103 Panel, Rear Axle Access (Wldmt) 1 "
CD387 4-2-183
Orig
Chapter 4
14 13
12
11
6
5
3 10
2 7 9
8
1 4
Figure 2-91. Drive Shaft Assembly ( 4R75 Transmission )
4-2-184 CD387
Orig
Chapter 4
Table 2-91. Drive Shaft Assembly ( 4R75 Transmission )
Fig & Tug Part

Ind Number

91-2 MR-1315 Drive Shaft, 4R75 1 "
91-3 ½-13 Nut, Flange, ½"ID-13 4 "
91-5 7/16-14 Nut, Top Lock Hex 7/16-14 4 "
91-6 MR-1179 Box, Drop 1 "
91-8 MT-4-1247 Axle, Rear Drive, W/Out Drop Box 1 "
91-11 MR-1103 Panel, Rear Axle Access - WLDM 1 "
91-12 ¼ Washer, Flat, ¼"ID 4 "
91-13 ¼ Washer, Lock, ¼"ID 4 "
91-14 ¼-20 x ¾ Bolt, Hex Head Ø¼-20 x ¾"Long 4 "
CD387 4-2-185
Orig
Chapter 4
10 5
1 12
2
9
3
4
To Front Right
Bottom of Engine
11
Figure 2-92. Deutz Tier 4i ECU and 4R75 TCU Installation
4-2-186 CD387
Orig
Chapter 4
Table 2-91. Deutz Tier 4i ECU and 4R75 TCU Installation
Fig & Tug Part

Ind Number
92-1 MR-1300-1 Controller, TCU 2200, 4R75 Transmission 1 60 & Up
92-2 MR-1300-2 Harness, 4R75 Tramsmission 1 "
92-3 MR-1300-4 Fuse, 10AMP 1 "
92-4 MR-1300-3 Fuse, 3 AMP 1 "
92-5 HRN-MR34-115 Harness, 4R75 Trans Power 1 "
92-6 TP-10513 ECU, TD2011 1 "
92-7 HRN-MR34-111-3 Harness, Deutz Engine 1 "
92-8 TP-10486 Cable, Interconnect. 1 "
92-9 G35-30050 Bracket, Diag. Port Relocation 1 "
92-10 G1-30148-7 Plug, Engine Diagnostic (Comes w/Engine) 1 "
92-11 MR-1319 Cover ECM 1 "
MR-1314 Cover ECM W/Cab - Opt 1 As Req-ed
92-12 MR-1321 Cable, Diagnostic & Software (Service Item) 1 60 & Up
CD387 4-2-187
Orig
Chapter 4
2
20 3 19
21
2928 23
25 22 18
3231 30 24
5 13
26 27 12
1 14
48 49 50 51 11 13 5 REF
6
34 33 6
39
7 15
10
42 8
9 16
4140 17
52
4
18
43
353637
44 46 45 53
38 47
Figure 2-93 VEC Panel Assembly (Deutz Tier 2)
4-2-188 CD387
Orig
Chapter 4
Table 2-93. VEC Panel Assembly (Deutz Tier 2 )

93- MR-1273 Panel Assembly, VEC Ref. 1 & Up 93-29 ¼ Washer, Lock ¼" ID 1 1 & Up
93-1 MR-1159 Panel, VEC Mounting 1 " 93-30 G8JN-1C6T-F-R-DC12 Relay (Trans. Lockout) (Part of HRN-MR-0007) 1 "
93-2 ¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 4 " 93-31 ¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 1 "
93-3 ¼ Washer, Lock ¼" ID 4 " 93-32 ¼ Washer, Lock ¼" ID 1 "
93-4 ¼ Washer, Flat ¼" ID 2 " 93-33 TM1-ND-5011 Relay, Glow Plug 1 1 to 54
93-5 660-4-3085 Vehicle Electric Center (VEC) 1 " TP-10416 Relay, Glow Plug, TD2011 1 54 & Up
93-6 660-4-3085-1 Relay (Spare) 3 " 93-34 MR-1198 Socket, Glow Plug Relay 1 1 to 54
93-7 660-4-3085-1 Relay (Master Charge & Wait Light) 1 " ENG-MR34-DEUTZ-8 Socket, Glow Plug Relay 1 54 & Up
93-8 660-4-3085-1 Relay (Low Oil Warning Light) 1 " 93-35 10-32 x ½ Screw, Phillips Pan Head Ø #10-32 x ½" Long 1 1 & Up
93-9 660-4-3085-1 Relay (Hitch Light) 1 " 93-36 10 Washer, Lock #10 1 "
93-10 660-4-3085-1 Relay (Tractor Horn) 1 " 93-37 10 Washer, Flat #10 1 "
93-11 660-4-3085-1 Relay (Dash Lights, Headlights, Shifter Light, Brake Light) 1 " 93-38 HRN-MR-0008 Harness, Glow Plug Relay 1 "
93-12 660-4-3085-3 Fuse, 20 Amp Mini 1 " 93-39 JB3816-2 Stud, Junction Block 1 "
93-13 660-4-3085-2 Fuse, 15 Amp Mini 5 " 93-40 8-32 x ½ Screw, Phillips Pan Head Ø #8-32 x ½" Long 2 "
93-14 660-4-3085-4 Fuse, 25 Amp Mini 2 " 93-41 8 Washer, Lock #8 2 "
93-15 ¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 4 " 93-42 HRN-MR24-0001 Harness, Engine MR Deutz 1 "
93-16 ¼ Washer, Lock ¼" ID 4 " HRN-MR36-111 Harness, Engine MR Kubota 1 22 & Up
93-17 ¼ Washer, Flat ¼" ID 4 " 93-43 MR-1234 Cable, Positive Common Battery 1 1 & Up
93-18 HRM-MR-0002 Harness, VEC 1 " 93-44 MR-1235 Cable, Positive, Master Solenoid 1 "
93-19 TM1-ND-5010 Breaker, Circuit 60 Amp, Deutz 1 " 93-45 MR-1156 Solenoid, Main Power 1 "
93-20 ¼ Washer, Lock ¼" ID 2 " 93-46 ¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 2 "
93-21 ¼-20 x ½ Screw, Phillips Pan Head Ø ¼-20 x ½" Long 2 " 93-47 ¼ Washer, Lock ¼" ID 2 "
93-22 660-2-3084 Relay, Starter 1 " 93-48 5/8 Clamp, P - 5/8" 3 "
93-23 ¼ Washer, Flat ¼" ID 2 " 93-49 ¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 3 "
93-24 ¼ Washer, Lock ¼" ID 2 " 93-50 ¼ Washer, Lock ¼" ID 3 "
93-25 ¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 2 " 93-51 660-4-3085-4 Fuse, 25 Amp Mini 1 "
93-26 HRN-MR-0007 Harness, Trans. Starter Interlock 1 " 93-52 660-4-3085-3 Fuse, 20 Amp Mini 1 "
93-27 G8JN-1C6T-F-R-DC12 Relay (Starter Lockout) (Part of HRN-MR-0007) 1 " 93-53 HRN-MR-0001 Harness, Main Chassis 1 "
CD387 4-2-189
Orig
Chapter 4
1 3 12
2 4 11
33 31
5 13
26
34 6 7 14
25
8 24
33 15
36 9 23
22
38 10 16
17
36 37
18
19
20
21
29
28
27
35 11
9
34 31
33 39
30
32
Figure 2-94 TEC Panel Assembly (Deutz Tier 4i)
4-2-190 CD387
Orig
Chapter 4
Table 2-94.. TEC Panel Assembly (Deutz Tier 4i)
Tug Part
Number
94-1 MR-1317 Plate, TEC Mounting 1 60 & Up

94-2 660-2-3084 Relay, Starter 1 "
94-3 HRN-MR-0008-2 Jumper, Harness, Glow Plug Relay 1 "
94-5 TM1-ND-5010 Breaker, Circuit 60 Amp, Deutz 1 "
94-6 8-32 x ½ Screw, Phillips Pan Head Ø #8-32 x ½" Long 2 "
94-7 660-1-3252 Block, Power 1 "
94-8 8 Washer, Lock #8 2 "
94-9 HRN-MR-0008-1 Harness, Glow Plug Relay 1 "
94-10 MT-4-2173-7 Bracket, Elec Fuse/Relay Panel 2 "
94-11 MR-1320 Panel, Fuse/Relay Assy 1 "
94-12 RM4294 Fuse, F1, Manual Reset, Mini 25 AMP, Ignition Switch Power 1 "
94-13 RM4294 Fuse, F4, Manual Reset, Mini 25 AMP, Horn/Reverce Lights 1 "
94-14 RM4292 Fuse, F7, Manual Reset, Mini 15 AMP, Rear Wiper 1 "
94-15 RM4292 Fuse, F10, Manual Reset, Mini 15 AMP, Cab Heater 1 "
94-16 RM4293 Fuse, F8, Manual Reset, Mini 20 AMP, Dash Power 1 "
94-17 RM4292 Fuse, F11, Manual Reset, Mini 15 AMP, Front Wiper 1 "
94-18 RM4292 Fuse, F9, Manual Reset, Mini 15 AMP, Fan, Dome Lights 1 "
94-19 RM4291 Relay, K6, 12 Volt, Horn Power 1 "
94-20 RM4291 Relay, K8, 12 Volt, Dash, Head & Tail Light, Shifter 1 "
94-21 RM4291 Relay, K7,12 Volt, Hitch Light 1 "
94-22 RM4291 Relay, K5,12 Volt, Engine ECM 1 "
94-23 RM4294 Fuse, F6, Manual Reset, Mini 25 AMP, Head & Tail Lights, Dash 1 "
94-24 RM4292 Fuse, F3, Manual Reset, Mini 15 AMP, Ignition 1 "
94-25 RM4292 Fuse, F5, Manual Reset, Mini 15 AMP, Hitch, Turn Lights 1 "
94-26 RM4294 Fuse, F2, Manual Reset, Mini 25 AMP, ECM Power 1 "
94-27 MR-1235 Cable, Positive, Master Solenoid 1 "
94-28 TP-10416 Socket, Glow Plug Relay 1 "
94-29 TP-10514 Relay, Glow Plug, Timer, TD2011, Tier 4i 1 "
94-30 HRN-MR34-115 Harness, 4R75 Trans. Power, Battery Cable 1 "
94-31 MR-1156 Solenoid, Main Power 1 "
94-35 HRN-MR34-115 Harness, 4R75 Trans. Power, Ignition Cable 1 "
94-36 HRN-MR-0007 Harness, Transmission Starter Interlock 1 "
94-37 TP-10508 Relay (Trans. Lockout) (Part of HRN-MR-0007) 1 "
94-38 TP-10508 Relay (Starter Lockout) (Part of HRN-MR-0007) 1 "
94-39 HRN-MR34-112 Harness, Main, MR34 1 "
CD387 4-2-191
Orig
Chapter 4
12 6
11 8
42 9
10 13
40
7
34 41 46
4
Detail 'A' 1
5
21 18
42 41 40 43 44 24 25 26 37
23 19
36 3
22 14
36 37 2
Detail 'A'
15
18 33 18
38 20 45
37 29 19
34 37
18
27 16 17
37 35
28 47 45
40
32 30 20 16 17
41
43
31
39 44
Figure 2-95. Brake Assembly
4-2-192 CD387
Orig
Chapter 4
Table 2-95. Brake Assembly
Tug Part Fig & Tug Part

Fig & Ind Description Qty Effective Description Qty Effective
Number Ind Number
95-1 MT-4-1247 Axle, Rear Drive AMS W/O Drop Box 1 1 & Up 95-25 MR-1211 Line, Brake (H-Valve to Rear Proportioning Valve) 1 1 & Up
95-2 MR-1213 Line, Brake (Left Rear Drive Axle) 1 " 95-26 MT-3-1392 Valve, Regulating - Rear Brake 1 "
95-3 MR-1214 Line, Brake (Right Rear Drive Axle) 1 " 95-27 MR-1278 Line, Brake (H-Valve to Brake Light Switch) 1 "
95-4 MT-1-1338 Adapter, 14mm - Rear Brake 2 " 95-28 MJ-ND-8010 Tee, Brake Pressure Switch 1 "
95-5 660-ND-1372 Fitting, Brake, 3/16 Inv. Flare to 1/8 NPT 2 " 95-29 660-1-3086 Switch, Brake Pressure 1 "
95-6 T6-6011-111 Tee, Brake Line 1 " 95-30 MR-1212 Line, Brake (Front Tee to Left Caliper) 1 "
95-7 MR-1182 Bracket, Rear - Brake Line Angle 1 " 95-31 T6-6011-111 Tee, Brake Line 1 "
95-8 ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 1 " 95-32 ¼-20 Nut, Flangelock Hex ¼-20 1 "
95-9 ¼ Washer, Flat ¼" ID 1 " 95-33 MR-1210 Line, Brake (Proportioning Valve to Rear Brake Hose) 1 "
95-10 ¼-20 Nut, Flangelock Hex ¼-20 1 " 95-34 MR-1276 Line, Brake (Front Tee to Right Caliper) 1 "
95-11 M16 Washer, Lock M16 1 " 95-35 MR-1275 Line, Brake (Brake Light Switch to Front Tee) 1 "
95-12 M16-2.0 x 25 Bolt, Hex Head Ø M16-2.0 x 25mm Long 1 " 95-36 ¼ Clamp, P - ¼" 9 "
95-13 MH-ND-543 Hose, Brake (19") 1 " 95-37 ¼-20 Nut, Flangelock Hex ¼-20 9 "
95-14 ------ Angle, Brake Line Mount (Wldmt) (Part of Frame) 1 " 95-38 TM1-ND-8077-RH Caliper, Front Right Brake 1 "
95-15 MD-CB21-121 Clip 1 " 95-39 TM1-ND-8077-LH Caliper, Front Left Brake 1 "
95-16 TM1-1-9787 Valve, Hydraulic Brake Warning 1 " 95-40 MR-1215 Hose, Brake 2 "
95-17 T6-600-114 Adapter, Brake 1 " 95-41 ------ Angle, Brake Line Mount (Wldmt) (Part of Frame) 2 "
95-18 T6-8011-107 Adapter, Brake Warning 2 " 95-42 MD-CB21-121 Clip 2 "
95-19 TM1-1-9791 Plug, Brake Pressure Switch Valve 1 " 95-43 T6-8013-147 Washer, Brake Hose 4 "
95-20 660-ND-1397 Adapter, Brake 1 " 95-44 T6-8013-145 Bolt, Brake Hose 2 "
95-21 T6-4900-202 Hydro-Boost Assembly 1 " 95-45 HRN-MR-0001 Harness, Main Chassis, Deutz Tier 2 & Kubota 1 "
95-22 T6-600-112 Adapter, Brake Master Cylinder 1 " HRN-MR34-112 Harness, Main, MR34 1 60 & Up
95-23 660-ND-1397 Adapter, Brake 1 " 95-46 MR-1179 Box, Drop 1 1 & Up
95-24 MR-1277 Line, Brake (Master Cylinder to H-Valve) 1 " 95-47 MR-1217 Line, Brake (Master Cylinder to H-Valve) 1 "
CD387 4-2-193
Orig
Chapter 4
Cover
Gasket Push Rod 2

3
24 26
27
5
Reservoir
1 6
DETAIL A
23 25
8
22
7 4
15 5 23
13 12
17
21
20
10 19 1.5
11 9 28
16
18 14
3REF
DETAIL B
Figure 2-96. Hydroboost Installation
4-2-194 CD387
Orig
Chapter 4
Table 2-96. Hydro-Boost Assembly
Tug Part
Number
96-1 T6-4900-202 Hydro-Boost Assembly 1 1 & Up

96-2 MR-1127 Yoke 1 "
96-3 ½-20 Nut, Jam ½-20 1 "
96-5 3/8 Washer, Flat 3/8" ID 8 "
96-6 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
96-7 T6-600-112 Adapter, Brake Master Cylinder 1 "
96-8 660-ND-1397 Adapter, Brake 1 "
96-9 MR-1217 Line, Brake (Master Cylinder to H-Valve) 1 "
96-10 TM1-1-9787 Valve, Hydraulic Brake Warning 1 "
96-11 T6-600-114 Adapter, Brake 2 "
96-12 T6-8011-107 Adapter, Brake Warning 2 "
96-13 660-ND-1397 Adapter, Brake 1 "
96-14 TM1-1-9791 Plug, Brake Pressure Switch Valve 1 "
96-15 MR-1278 Line, Brake (H-Valve to Brake Light Switch) 1 "
96-16 MJ-ND-8010 Tee, Brake Pressure Switch 1 "
96-17 660-1-3086 Switch, Brake Pressure 1 "
96-18 MR-1275 Line, Brake (Brake Light Switch to Front Tee) 1 "
96-19 MR-1211 Line, Brake (H-Valve to Rear Proportioning Valve) 1 "
96-20 MT-3-1392 Valve, Regulating - Rear Brake 1 "
96-21 MR-1210 Line, Brake (Proportioning Valve to Rear Brake Hose) 1 "
96-22 ¼ Clamp, P - ¼" 1 "
96-24 MR-1221 Hose, Pump to Brake Booster 1 "
96-26 MR-1224 Hose, Booster to Reservoir 1 "
96-27 ------ Clamp, Hose IDEAL 6203 1 "
96-28 MR-1277 Line, Brake (Master Cylinder to H-Valve) 1 "
CD387 4-2-195
Orig
Chapter 4
9 10
8 8
7 14 12
13
To Starter 11
To Engine
Black Ground
6
5
2
3
4
Figure 2-97. Battery Assembly
4-2-196 CD387
Orig
Chapter 4
Table 2-97. Battery Assembly
Tug Part
Number
97-1 MR-1166 Tray, Battery 1 1 & Up

97-2 ¼-20 x 1 Screw, Countersunk Head Ø ¼-20 x 1" Long 2 "
97-4 ¼-20 Nut, Top Lock Hex ¼-20 2 "
97-5 MR-1192 Isolator, Rubber - Battery 1 "
97-6 3000087 Battery, 12V, Optima 1 "
97-7 T6-9011-101B Tee, Battery Hold Down 1 "
97-8* ------ Clips, Hold Down 2 "
97-9 5/16 Washer, Flat 5/16" ID 2 "
97-11 MR-1232 Cable, Negative Main Battery 2 "
97-12** ------ Nut 1 "
97-14*** ------ Nut 1 "
* Part of T6-9011-101B Battery Hold Down Tee

** Part of MR-1232 Cable, Negative Main Battery
*** Part of MR-1231 Cable, Positive Main Battery
CD387 4-2-197
Orig
Chapter 4
9
8
7 10
8
12
14
13
To Starter 11
To Engine
Black Ground
6
3
4
Figure 2-98. Battery Assembly with Heater Option
4-2-198 CD387
Orig
Chapter 4
Table 2-98 Battery Assembly with Heater Option
Fig & Tug Part

Ind Number
98-4 ¼-20 Nut, Top Lock Hex ¼-20 2 "
98-5 660-1-3460 Heater, Battery Box - Opt. 1 As Req'd
G35-10034 Heater, Battery 240V, 200 Watt - Opt. 1 "
98-6 3000087 Battery, 12V, Optima 1 1 & Up
98-8 MR-1088 Bracket Battery Hold Down - Opt. 2 As Req'd
98-9 5/16 Washer, Flat 5/16" ID 2 1 & Up
98-12* ------ Nut 2 "
98-14 MR-1089 Box Assembly, Junction Heater - Opt. 1 As Req'd
* Part of MR-1231 Cable Positive Main Battery and MR-1232 Cable Negative Main Battery
CD387 4-2-199
Orig
Chapter 4
10
18 19 9
8
8
7
To Starter
14
17 16
12
13
11
To Engine
6
15 Black Ground
5
2
3
4
Figure 2-99. Battery Assembly ( CE Option )
4-2-200 CD387
Orig
Chapter 4
Table 2-99. Battery Assembly ( CE Option )
Fig & Tug Part

Ind Number

99-4 ¼-20 Nut, Top Lock Hex ¼-20 2 "
99-5 MR-1192 Isolator, Rubber - Battery 1 "
99-6 3000087 Battery, 12V, Optima 1 "
99-8 ------ Clips, Hold Down 2 "
99-9 5/16 Washer, Flat 5/16" ID 2 "
99-12 ------ Nut 1 "
99-13 MR-1070 Cable, Positive Main Battery to Fuse - CE Opt. 1 As Req'd
99-14 ------ Nut 1 1 & Up
99-15 T6-4900-157 Holder, Fuse 250A - CE Opt. 1 As Req'd
99-16 MR-1071 Cable, Positive (Fuse to Battery Disconnect Switch) - CE 1 "
Opt.
99-17 T6-4900-156 Fuse, 250A - CE Opt. 1 "
99-18 T6-7016-123 Switch, Battery Disconnect - CE Opt 1 "
99-19 MR-1072 Cable, Battery Disconnect Switch to Starter -CE Opt 1 "
Part of MR-1232 Cable, Negative Main Battery and CE Positive Main Battery Cable
CD387 4-2-201
Orig
Chapter 4
3
11 6
4
5
10
7
9 8
Figure 2-100. Heater Junction Box ( Optional )
4-2-202 CD387
Orig
Chapter 4
Table 2-100. Heater Junction Box ( Optional )
Tug Part
Number
MR-1089 Box, Junction, Assy 1 As Req'd
100-1 MR-1089-3 Feet, Mounting Box, Kit 1 "
100-2 MR-1089-1 Box, Junction, Heater 1 "
100-3 MR-1089-2 Panel, Heater Junction Box 1 "
100-4 MR-1089-4 Board, Terminal, 30 AMP, 4 Point 1 "
100-5 #8 Washer, Lock, #8 4 "
100-6 660-1-2252 Nut, Conduit - ½ NPT 3 "
100-7 8-16 x 0.31 Screw, Tapping, Pan Head, 8-16 x 0.31 4 "
100-8 8-16 x 0.63 Screw, Pan Head, 8-16 x 0.31 2 "
100-9 660-ND-2215 Relief, Strain 3/8 x ½ NPT 3 "
100-10 BLE-1-1502 Ring, Sealing ½ NPT 3 "
100-11 660-2-3463 Plug, 110V Hubbell 1 "
660-2-3464 Plug, 220V Hubbell 1 "
CD387 4-2-203
Orig
Chapter 4
8
9
1
5 10
3
2
4
7
1
11
Figure 2-100. Horn Installation
4-2-204 CD387
Orig
Chapter 4
Table 2-100. Horn Installation
Tug Part
Number
101-1 T6-7013-207 Horn Assembly 1 1 & Up

101-2* ------ Horn with Terminal Applications 1 "
101-3* ------ Bracket 1 "
101-4* ------ Bracket, L- 1 "
101-5* ------ Nut, Lock M8 2 "
101-6* ------ Washer, Star 1 "
101-7* ------ Bolt, Hex Head M8 1 "
101-10 ¼ Washer, Flat ¼" ID 1 "
101-11 HRN-MR-0001 Harness, Main Chassis 1 "
* Part of T6-7013-207 Horn Assembly
CD387 4-2-205
Orig
Chapter 4
4-2-206 CD387
Orig
Chapter 4
SECTION 3: NUMERICAL INDEX
Tug Part Number Description Fig & Ind#
------ Adapter, Straight 64-22

------ Anchor, Bracket Cable 80-11
------ Anchor, Cable Clamp 80-12
------ Angle, Brake Line Mount (Wldmt) (Part of Frame) 95-14
------ Arm, Drive 14-16
------ Arm, Drive 15-8
------ Base, Dome Light (Part of G1-20429) 17-3
------ Base, Driver Door Paddle 9-7
------ Bolt, Drive Adapter 75-3
------ Bolt, Flange (Part of MR-1242) 69-12
------ Bolt, Hex Head 62-14
------ Bolt, Hex Head M8 101-7
------ Bolt, Mounting 55-8
------ Bolt, Mounting Band 64-9
------ Bolt, Mounting Spring Loaded 64-8
------ Boot, Rubber 14-22
------ Bracket 101-3
------ Bracket, Headlight 16-4
------ Bracket, L- 101-4
------ Bracket, Mounting 81-10
------ Bracket, Turn Signal Lamp (Part of 660-2-3174) 16-16
------ Bulb, Dome Light (Part of G1-20429) 17-4
------ Bushing, Rubber 36-18
------ Cable, Alternator to Stud 61-35
------ Cable, Positive (Fuse to Battery Disconnect Switch) - CE Opt. 99-16
------ Cable, Positive Main Battery to Fuse - CE Opt. 99-13
------ Cap, End 64-2
------ Cap, Rubber 64-3
------ Clamp, Hose 62-28
------ Clamp, Hose 62-44
------ Clamp, Hose 62-49
------ Clamp, Hose 2" 74-11
------ Clamp, Hose IDEAL 5010 21-8
CD369 4-3-1
Rev 1
Chapter 4

------- Clamp, Hose IDEAL 5010 63-3
------ Clamp, Hose, 2" 66-6
------ Clamp, Hose, 2.5" 65-6
------ Clamp, Hose, 2.5" 66-12
------ Clamp, Hose, 3" 65-4
------ Clamp, Hose, 3" 66-4
------- Clamp, Hose, 5010 22-14
------- Clamp, Hose, IDEAL, 7/8"-2¾" ID, 5036-Opt 22-3
------ Clips, Hold Down 97-8
------ Collar, Retaining - Gauge 23-26
------ Connector, Electric Heater 21-3
------ Connector, Wiper Arm 14-23
------ Cover, Dash Light 23-15
------ End, Rod, Gas Hood Spring 4-34
------ Ferrule, 5/16" Compression Fitting 68-8
------ Gasket 62-24
------ Gasket, Pantograph Adapter 15-26
------ Gasket, Pantograph Arm 14-40
------ Gasket, Vescor Breather Cap 30-61
------ Grommet 16-26
------ Grommet 16-24
------ Grommet, Rubber 16-22
------ Handle, Driver Door Paddle 9-8
------ Holder Assembly, Nozzle 62-23
4-3-2 CD387
Orig
Chapter 4
------ Horn with Terminal Applications 101-2

------ Hose Ø 3/16" Low Pressure Fuel/Oil, 3" Long 68-24
------ Hose, 3/16" ID x 3" Long 62-54
------ Hose, 5/16" ID 62-50
------ Hose, 5/16" ID 62-51
------ Housing, Air Filter 64-4
------ Insulation, Foam - Cab Rear (Part of CMR-1018) 6-5
------ Insulation, Foam - Cab Side (Part of CMR-1018) 6-6
------ Insulation, Foam - Driver Door* 9-11
------ Insulation, Foam - Passenger Door* 11-11
------ Isolator, Transmission ( Part of Transmission) 48-16
------ Joint, Ball 80-9
------ Knob 14-7
------ Knob 14-11
------ Lamp, Turn Signal (Part of 660-2-3174) 16-15
------ Lens, Dome Light (Part of G1-20429) 17-2
------ Liner, Head 5' (Part of CMR-1018) 6-7
------ Linkage, Wiper Motor to Wiper Arm 14-30
------ Modulator (part of Modulator Cable) 45-27
------ Mount, Air Filter Bracket - Wldmt (Part of Frame) 64-10
------ Mount, Spring, Rear - Driver Side (Part of Frame) 36-11
------ Mount, Spring, Rear - Pass. Side (Part of Frame) 36-12
------ Nut 14-6
------ Nut 14-10
------ Nut 23-6
------ Nut 23-10
------ Nut 23-17
------ Nut 25-6
------ Nut 25-10
------ Nut 25-17
------ Nut 36-16
------ Nut 97-12
------ Nut 97-14
------ Nut 98-13
------ Nut 99-12
------ Nut 99-14
------ Nut, 5/16" Compression Fitting 68-7
------ Nut, Alarm 27-6
------ Nut, Flange (Part of 2000059) 69-10
------ Nut, Flange (Part of MR-1242) 69-13
CD387 4-3-3
Orig
Chapter 4
------ Nut, Jam 23-12

------ Nut, Jam 25-12
------ Nut, Jam (part of Modulator Cable) 45-28
------ Nut, Jam (Part of Throttle Cable) 45-11
------ Nut, Knurled 23-13
------ Nut, Lock M8 101-5
------ Nut, Pantograph Arm 14-42
------ Nut, Wiper Arm 14-25
------ Nut, Wiper Pivot Shaft 14-21
------ O-Ring 35-3
------ O-Seal 50-37
------ Pin, Wiper Pivot Shaft 14-26
------ Pivot 81-21
------ Plug, Oil Filler 62-8
------ Pulley Tensioner 55-7
------ Pulley, Tensioner 54-14
------ Rubber 51-5
------ Screw 14-8
------ Screw 14-12
------ Seal, Engine Oil Drain Valve 50-71
------ Shim, Clamp, Cable 81-11
------ Sleeve, Retainer Bolt 35-4
------ Socket, Light 23-22
------ Spindle 34-18
------ Spindle 34-20
------ Strainer, Vescor Breather Cap 30-62
------ Terminal, Nylon, Female Blade, Guick Slide, 14-16GA 29-22
------ Trim Lock 51-6
------ Trim Lock 58-6
------ Tubing, Heatshrink 29-23
------ U-Bolt #10-32 81-12
------ U-Joint 90-2
------ Valve, Bleeder 62-10
------ Washer 14-20
------ Washer 14-31
4-3-4 CD387
Orig
Chapter 4
------ Washer 14-38

------ Washer 14-41
------ Washer 15-12
------ Washer 15-27
------ Washer 23-16
------ Washer 25-16
------ Washer 23-5
------ Washer 23-9
------ Washer 25-5
------ Washer 25-9
------ Washer, Bushing 36-17
------ Washer, Flat 62-13
------ Washer, Rubber 14-19
------ Washer, Star 15-16
------ Washer, Tanged 23-4
------ Wire 6B 53-11
------ Wire 6B (part of Engine Harness) 60-11
------ Wire, 10 Gauge, Ground 61-20
------ Wire, 10 Gauge, Starter (to Stud) 61-23
------ Wire, Ground Black Dasher G3 27-8
------ Wire, Ground Black Flasher 27-7
------ Wire, Safety 30-65
------ Wire, Stranded 16 AWG 29-24
014050 Light, Dash 23-14
014050 Light, Dash 24-10
014050 Light, Dash 25-14
014050-1 Bulb, Dash Light (GE2660 12V 2W) 23-18
04-06-070102 Fitting, 6MJ x 4MP 30-53
04-06-070102 Fitting, 6MJ x 4MP 31-54
06-06-070120 Fitting, Male O-Ring Boss to Male JIC, 6MJ-6MB 30-11
0990 0244 Cooler, Oil 72-24
¼ Washer, Lock ¼" ID 2-5
¼ Washer, Flat ¼" ID 2-6
CD387 4-3-5
Orig
Chapter 4

¼ Washer, Star ¼" ID 14-4
¼ Washer, Lock ¼" ID - Opt 16-30
4-3-6 CD387
Orig
Chapter 4

¼ Washer, Flat, ¼ID 89-4
¼ Washer, Flat, ¼"ID 91-12
¼ Washer, Lock, ¼"ID 91-13
CD387 4-3-7
Orig
Chapter 4

¼ Clamp, P - ¼" 95-36
¼ Clamp, P - ¼" 96-22
¼-20 Nut-U ¼-20 UNC 2-13
¼-20 Nut, Top Lock Hex ¼-20 2-17
¼-20 Nut-U ¼-20 UNC 3-13
¼-20 Washer, Flat ¼" ID 4-5
¼-20 Nut, Top Lock Hex ¼-20 11-22
¼-20 Nut, Top Lock Hex ¼-20 18-10
¼-20 Nut, Top Lock Hex ¼-20 21-17
¼-20 Nut, Flangelock Hex ¼-20 30-16
¼-20 Nut, Top Lock Hex ¼-20 30-19
¼-20 Nut, Top Lock Hex ¼-20 31-19
¼-20 Nut, Top Lock Hex ¼-20 67-50
¼-20 Nut, Top Lock Hex ¼-20 68-41
4-3-8 CD387
Orig
Chapter 4

¼-20 Nut, Top Lock Hex ¼-20 80-14
¼-20 Nut, Lock, ¼"ID-20 88-8
¼-20 Nut, Lock, ¼-20 89-7
¼-20 Nut, Flange, ¼-20 89-8
¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 30-51
¼-20 x ½ Screw, Phillips Pan Head Ø ¼-20 x ½" Long 93-21
¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 2-4
¼-20 x ¾ Screw, Phillips Pan Head Ø ¼-20 x ¾" Long 9-9
CD387 4-3-9
Orig
Chapter 4

¼-20 x ¾ Screw Ø ¼-20 x ¾" Long 44-2
¼-20 x ¾ Bolt, Phillips, Ø¼-20 x ¾ 89-3
¼-20 x ¾ Bolt, Hex Head Ø¼-20 x ¾"Long 91-14
¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 2-14
¼-20 x 1 Screw, Button Head Socket Ø ¼-20 x 1" Long 8-5
¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long - Opt 16-29
¼-20 x 1 Bolt, Hex Head, ¼" -20 x 1" Long 73-5
¼-20 x 1 Screw, Countersunk Head Ø ¼-20 x 1" Long 97-2
¼-20 X 1" Bolt, Phillips, Ø¼-10 x 1" 89-2
¼-20 X 1" Bolt, Hex Head, Ø¼-20 x 1" 89-21
4-3-10 CD387
Orig
Chapter 4
¼-20 x 1¼ Bolt, Hex Head Ø ¼-20 x 1¼" Long 9-23

¼-20 x 1½ Bolt, Hex Head Ø ¼-20 x 1½" Long 2-15
¼-28 Nutsert, Flange Ribbed ¼-28 2-3
¼-28 Nut, Hex ¼-28 14-27
¼-28 Nut, Hex ¼-28 14-35
¼-28 Nut, Hex ¼-28 15-19
¼-28 Fitting, Grease ¼-28 28-2
½ Washer, Flat ½" ID 4-31
½ Washer, Flat ¼" ID 28-5
½ Washer, Flat, ½" ID 36-20
½ Washer, Lock ½" ID 47-29
½ Washer, Flat, ½"ID 49-3
½ Washer, Lock - External Tooth ½" ID 83-24
½ Washer, Lock, ½ 85-3
½-13 Nut, Top Lock Hex ½-13 4-32
½-13 Nut, Slotted Hex ½-13 30-28
½-13 Nut, Top Lock Hex ½-13 36-21
½-13 Nut, Top Lock Hex ½-13 47-17
CD387 4-3-11
Orig
Chapter 4
½-13 Nut, Top Lock Hex ½-13 48-14

½-13 Nut, Lock, ½ID-13 49-10
½-13 Nut, Top Lock Hex ½-13 83-13
½-13 Nut, Flange, ½"ID-13 91-3
½-13 x 1 Bolt, Hex Head Ø ½-13 x 1" Long 75-32
½-13 x 1½ Bolt, Hex Head Ø ½-13 x 1½" Long 47-28
½-13 x 1¾ Bolt, Hex Head, ½-13 x 1¾ 85-4
½-13 x 3½ Bolt, Hex Head, ½-13 x 3½"Long 49-2
½-20 Nut, Jam ½-20 28-11
½-20 Nut, Nylock ½-20 82-6
½-20 Nut, Hex ½-20 83-23
½-20 Nut, Nylock ½-20 83-25
½-20 Nut, Jam ½-20 96-3
¾ Washer, Lock ¾" ID - Opt 1-5
¾ Washer, Flat ¾" ID 1-9
¾-10 Nut, Top Lock Hex ¾-10 1-8
¾-10 x 1½ Bolt, Hex Head Ø ¾-10 x 1½" Long 5-8
¾-10 x 2½ Bolt, Hex Head Ø ¾-10 x 2½" Long-Opt 1-4
¾-10 x 5 Bolt, Hex Head Ø ¾-10 x 5" Long 1-10
¾-16 Nut, Jam ¾-16 UNF 30-26
¾-16 Nut, Jam ¾-16 UNF 31-26
¾-16 Nut, Top Lock Hex ¾-16 33-22
¾-16 Nut, Left Hand Jam ¾-16 33-27
¾-16 Nut, Top Lock Hex ¾-16 33-33
1/8 x ¾ Pin, Cotter Ø 1/8 x ¾" Long 82-21
1/8 x 1½ Pin, Cotter Ø 1/8 x 1½" Long 28-10
4-3-12 CD387
Orig
Chapter 4
1/8 x 1½ Pin, Cotter, 1/8 x 1½ 89-17

3/32 x ½ Pin, Cotter Ø 3/32 x ½" Long 80-10
3/32 x 1½ Pin, Cotter, Ø3/32 x 1½"Long 89-23
3/16 x 2 Pin, Cotter Ø 3/16 x 2" Long 34-16
3/8 Washer, Lock 3/8" ID 5-3
3/8 Washer, Flat 3/8" ID 5-4
3/8 Clamp, P - 3/8" 45-32
3/8 Washer, Lock, 3/8"ID 49-6
3/8 Clamp, P - 3/8" 72-13
3/8 Clamp, P - 3/8" 73-13
3/8 Washer, Flat, 3/8"ID 89-12
CD387 4-3-13
Orig
Chapter 4

3/8 x 1 1/8 Pin, Clevis, Ø3/8 x 1 1/8" Long 89-18
3/8 x 1¼ Pin, Clevis Ø 3/8 x 1¼" Long 82-20
3/8 x 1½ Washer, Fender 3/8 x 1½" 82-8
3/8 x 2 Washer, Fender 3/8 x 2" 82-9
3/8-16 Nut, Top Lock Hex 3/8-16 4-27
3/8-16 Nut, Top Lock Hex 3/8-16 5-6
3/8-16 Nut, Top Lock Hex 3/8-16 16-7
3/8-16 Nut, Top Lock Hex 3/8-16 20-6
3/8-16 Nut, Top Lock Hex 3/8-16 29-11
3/8-16 Nut, Top Lock Hex 3/8-16 30-58
3/8-16 Nut, Top Lock Hex 3/8-16 31-59
3/8-16 Nut, Top Lock Hex 3/8-16 36-26
3/8-16 Nut, Top Lock Hex 3/8-16 47-25
3/8-16 Nut, Top Lock Hex 3/8-16 48-22
3/8-16 Nut, Top Lock Hex 3/8-16 69-8
3/8-16 Nut, Top Lock Hex 3/8-16 69-17
3/8-16 Nut, Top Lock Hex 3/8-16 69-28
3/8-16 Nut, Top Lock Hex 3/8-16 71-8
3/8-16 Nut, Lock, 3/8"ID-16 89-14
3/8-16 Nut, Top Lock Hex 3/8-16 96-6
3/8-16 x ¾ Bolt, Hex Head Ø 3/8-16 x ¾" Long 47-19
3/8-16 x 1 Bolt, Carriage Ø 3/8-16 x 1" Long 16-5
3/8-16 x 1 Bolt, Hex Head Ø 3/8-16 x 1" Long 30-55
3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long 4-25
3/8-16 x 1½ Bolt, Hex Head Ø 3/8-16 x 1½" Long 47-23
3/8-16 x 1¾ Bolt, Hex Head Ø 3/8-16 x 1¾" Long 30-7
4-3-14 CD387
Orig
Chapter 4

3/8-16 x 2 Bolt, Hex Head, Ø3/8-16 x 2" 89-10
3/8-16x1¼ Bolt, Hex Head, 3/8-16x1¼ 49-5
3/8-24 Nut, Top Lock Hex 3/8-24 75-14
3/8-24 Nut, Top Lock Hex 3/8-24 81-20
3/8-24 Nut, Jam 3/8-24 82-24
3/8-24 Nut, Top Lock Hex 3/8-24 84-7
3/8-24 x 2½ Rod, All-Threaded Ø 3/8-24 x 2½" Long 82-11
3/8-24 x 5/8 Bolt, Hex Head Ø 3/8-24 x 5/8" Long 81-19
5/16 Washer, Flat 5/16" ID 4-38
5/16 Washer, Flat 5/16" ID 4-42
5/16 Washer, Flat 5/16" ID 4-46
5/16 Washer, Lock - External Tooth 5/16" ID 16-9
5/16 Washer, Flat 5/16" ID 36-27
5/16 Washer, Flat 5/16" ID 64-12
5/16 Clamp, P - 5/16" 67-4
5/16 Washer, Flat 5/16" ID 67-32
5/16 Washer, Flat 5/16" ID 67-39
5/16 Clamp, P - 5/16" 68-5
5/16 Washer, Flat 5/16" ID 68-34
5/16 Washer, Flat 5/16" ID 72-22
5/16 Washer, Flat 5/16" ID 72-26
5/16 Washer, Flat 5/16" ID 73-22
5/16 Washer, Flat 5/16" ID 74-10
5/16 Washer, Flat 5/16" ID 75-13
5/16 Washer, Lock 5/16" ID 83-6
5/16 Washer, Lock 5/16" ID 90-7
5/16 Washer, Flat 5/16" ID 97-9
5/16 Washer, Flat 5/16" ID 98-10
5/16 Washer, Flat 5/16" ID 99-9
5/16 x 1 Screw, Self Tapping Ø 5/16 x 1" Long 13-5
5/16 x 1 Pin, Clevis Ø 5/16 x 1" Long 82-22
5/16 x 1 Pin, Clevis Ø5/16 x 1"Long 89-24
5/16-18 Nut, Top Lock Hex 5/16-18 4-37
5/16-18 Nut, Top Lock Hex 5/16-18 4-41
5/16-18 Nut, Top Lock Hex 5/16-18 4-47
5/16-18 Nut, Flangelock Hex 5/16-18 20-2
5/16-18 Nut, Top Lock Hex 5/16-18 67-34
CD387 4-3-15
Orig
Chapter 4
5/16-18 Nut, Top Lock Hex 5/16-18 67-41

5/16-18 Nut, Top Lock Hex 5/16-18 68-36
5/16-18 Nut, Top Lock Hex 5/16-18 81-18
5/16-18 Nut, Flange Lock Hex 5/16-18 16-10
5/16-18 x 17/32 Screw, Flange Head, 5/16-18x17/32 Long (Part of Transmission) 45-30
5/16-18 x 17/32 Screw, Flange, 5/16-18x17/32"Long (Part of Transmission) 46-21

5/16-18 x 17/32 Bolt, Transmission Oil Pan, 5/16-18 x 17/32" Long 81-15
5/16-18 x 17/32" Bolt, Transmission Oil Pan, 5/16-18 x 17/32" Long 77-4
5/16-18 x 2¼ Bolt, Flange Hex Head Ø 5/16-18 x 2¼" Long 16-8
5/8 Clamp, P - 5/8" 30-15
5/8 Clamp, P - 5/8" 31-15
5/8 Clamp, P - 5/8" 72-8
5/8 Clamp, P - 5/8" 72-17
5/8 Clamp, P - 5/8" 73-8
5/8 Clamp, P - 5/8" 93-48
5/8-11 Nut, Top Lock Hex 5/8-11 32-15
6-32 Screw Ø #6-32 27-9
7/16 Washer, Flat 7/16" ID 47-31
7/16 Washer, Flat 7/16" ID 48-23
7/16 Washer, Flat 7/16" ID 75-20
7/16 Washer, Lock 7/16" ID 75-21
7/16-14 Nut, Top Lock Hex 7/16-14 47-32
7/16-14 Nut, Top Lock Hex 7/16-14 48-24
4-3-16 CD387
Orig
Chapter 4
7/16-14 Nut, Top Lock Hex 7/16-14 90-4

7/16-14 Nut, Top Lock Hex 7/16-14 91-5
8-32 Nut, Nylock #8-32 4-11
8-32 x ¼ Screw, Oval Head Ø #8-32 x ¼" Long 17-6
8-32 x ½ Screw, Phillips Pan Head Ø #8-32 x ½" Long 93-40
8-32 x ¾ Screw, Phillips Pan Head Ø #8-32 UNF x ¾" Long 17-5
8-16 x 0.31 Screw, Pan Head Tapping Ø 8-16 x 0.31" Long 100-7
9/16 Washer, Flat 9/16" ID 82-17
9/16 Washer, Flat 9/16" ID 83-34
#10-32 Washer, Lock #10-32 7-4
#10-32 Nut, Nylock #10-32 7-5
#10-32 x ½ Screw, Phillips Pan Head Ø 10-32 x ½" Long 7-3
10-32 Nut, Nylock #10-32 2-25
10-32 Nut, Nylock #10-32 3-25
10-32 Nut, Nylock #10-32 4-9
10-32 Nut, Nylock #10-32 4-44
10-32 Nut, Top Lock Hex #10-32 16-19
10-32 Nut, Top Lock Hex #10-32 27-2
10-32 Nut, Nylock #10-32 45-9
10-32 Nut, Nylock #10-32 45-20
10-32 Nut, Nylock #10-32 46-7
10-32 Nut, Nylock #10-32 81-14
10-32 x 3/8 Screw, Slotted Round Head Ø #10-32 x 3/8" Long 14-28
10-32 x ½ Screw, Self-Tapping Ø 10-32 x ½" Long 30-63
10-32 x ¾ Screw, Phillips Pan Head Ø #10-32 x ¾" Long 4-8
10-32 x ¾ Screw, Phillips Pan Head Type F Ø 10-32 x ¾" Long 8-13
10-32 x ¾ Screw, Phillips Pan Head Ø 10-32 x ¾" Long 9-10
10-32 x 1 Screw, Phillips Pan Head Ø #10-32 x 1" Long 2-26
10-32 x 1 Screw, Button Head Socket Ø 10-32 x 1" Long 9-22
CD387 4-3-17
Orig
Chapter 4

10-24 x 1 5/8 Bolt, Oil Screen Ø #10-24 x 1 5/8" Long 78-10
10-24 x 1¼ Bolt, Oil Screen Ø #10-24 x 1¼" Long 78-9
1 Washer, Flat 1" ID 36-9
1-8 Nut, Nylon Insert Lock 1-8 36-10
1¼ Clamp, P - 1¼" 67-22
1½ Clamp, P - 1½" 30-34
1½ Clamp, P - 1½" 31-35
8 Washer, Lock #8 93-41
10 Washer, Flat #10 2-24
10 Washer, Star #10 14-29
10mm Washer, Lock M10 62-20
14mm-2.0 x 35mm Bolt, Drive Adapter, Allen Head M14-2.0x35 84-3
1028 Warning, Avoid Injury 3-30
59L.159 Lens, High Oil Temp Warning Light 23-36
130-0094-000 Lens, Brake Warning Light 24-18
440E-46006 Bearing, Thrust - Timken T113 33-13
440E-46009 Nut, Wheel, Hex, ½-20 42-6
660-1-2308 Fitting, Straight - Oil Cooler Hose 72-28
660-1-2347 Coupler, Hydraulic Pump 55-5
660-1-2412 Isolator 72-25
660-1-2412 Damper, Vibration - Oil Cooler 73-25
4-3-18 CD387
Orig
Chapter 4
660-1-2447 Fitting, Hyd. Pump Inlet 12MJ-16MB 31-40

660-1-2896 Flasher, 3 Terminal LED 23-39
660-1-2896 Flasher, Solid State 24-12
660-1-3086 Switch, Brake Pressure 95-29
660-1-3252 Block, Power 94-7
660-1-3439 Block, Contact - NC (Stop) - CE Opt. 26-4
660-1-3440 Button, Locking, Red - CE Opt. 26-3
660-1-3460 Heater, Battery Box - Opt. 98-5
660-2-1632B Post, Light, 42" (Opt.) 1-11
660-2-3084 Relay, Starter 93-22
660-2-3084 Relay, Starter 94-2
660-2-3174 Light Assembly, Turn Signal 16-14
660-2-3290 Seat, Sears, Vinyl Coldform with Logo 20-1
660-2-3444 Terminal, Deutsch Pin 16-11
660-2-3463 Plug, 110V Hubbell 100-11
660-2-3464 Plug, 220V Hubbell 100-11
660-2501-06-06 Elbow, 90°, Male 6MJ-6MP90 30-22
660-2501-06-06 Elbow, 90°, Male 6MJ-6MP90 31-22
660-2501-06-08 Elbow, Male 2501-06-08 31-37
660-4-0013-11 Cap, Filler 30-59
660-4-0013-11 Cap, Filler 31-60
660-4-0600-5 Bumper, Rubber Hood 4-10
660-4-0745-12 Joint, Ball 45-13
660-4-0745-12 Joint, Ball 45-31
660-4-0745-12 Joint, Ball 46-13
660-4-0745-12 Joint, Ball 62-36
660-4-3085 Vehicle Electric Center (VEC) 93-5
660-4-3085-1 Relay (Spare) 93-6
660-4-3085-1 Relay (Master Charge & Wait Light) 93-7
660-4-3085-1 Relay (Low Oil Warning Light) 93-8
660-4-3085-1 Relay (Hitch Light) 93-9
660-4-3085-1 Relay (Tractor Horn) 93-10
660-4-3085-1 Relay (Dash Lights, Headlights, Shifter Light, Brake Light) 93-11
660-4-3085-2 Fuse, 15 Amp Mini 93-13
660-4-3085-3 Fuse, 20 Amp Mini 93-12
660-4-3085-3 Fuse, 20 Amp Mini 93-52
660-4-3085-4 Fuse, 25 Amp Mini 93-14
660-4-3085-4 Fuse, 25 Amp Mini 93-51
660-4-3530 Hose, 2"ID x 2.5L Rubber - Opt 22-4
660-4-3574 Cooler, Transmission Fluid 72-1
CD387 4-3-19
Orig
Chapter 4

660-4-3624 Adapter, Barb 5/16 to 3/16 62-52
660-4-3624 Adapter, Barb 5/16 To 3/16 68-23
660-4-3625 Washer, Flat (C6 to 2011 Adapter) 75-5
660-4-3625 Washer, Trans. Adapter 76-4
660-4-3630 Fitting, 2MBSPT-2FP 61-16
660-6801-06-06 Elbow, Male O-Ring Boss to Male JIC-90° 6MJ-6MB90 30-10
660-ND-1372 Fitting, Brake, 3/16 Inv. Flare to 1/8 NPT 36-38
660-ND-1397 Adapter, Brake 95-20
660-ND-2215 Relief, Strain 3/8 x ½ NPT 100-9
12902092 Weather Stripping (Trim-Lock, 90°) 4-22
12960001 Decal, Seat Belt 24-23
2000059 Clamp, Exhaust 69-9
2000059 Clamp, 3" Heavy Duty 71-4
3000087 Battery, 12V, Optima 97-6
39587 Bolt, M81.25 x 20mmSocket Head Cap Fuel Pump 57-65
39587 Bolt, Socket Head Cap Ø M8-1.25 x 20mm Long 67-29
5000113 Clamp, Hose, 056 2 1/8-4" 62-5
5000186 Cap, 3" Diesel Fuel 67-19
5000186 Cap, 3" Diesel Fuel 68-26
511502 Holder, 2 Position, Lamp 23-30
595502 Frame, 3 Position Mounting 23-29
596120 Lens, Engine Glow Plug Light 23-32
77971 Alarm, Low Oil Press and High Oil 27-5
78897 Adapter, Connector, Male, 6MJ x 8MP 30-39
920408C1 Mirror, Rear View 13-7
999-02-3013 Housing, Adapter 75-4
999-0230A Adapter, Drive 75-2
A13850 Bracket, Mirror Mounting 13-8
A9002 Clip, Prop Rod End Retainer 4-52
A9008 Stud, 10mm Ball 4-53
4-3-20 CD387
Orig
Chapter 4
AS-10273 Gauge, Murphy Power View 24-8

BLE-1-1502 Ring, Sealing ½ NPT 100-10
C6AZ-7A191B Gasket, Transmission Oil Pan 77-2
CMA-504 Strip, Seal (30.5' Long) 6-4
CMA-504 Strip, Seal, Door 9-2
CMA-504 Strip, Seal - Door 11-2
CMR-1001 Cab Weldment 5-1
CMR-1001 Cab, Weldment 7-1
CMR-1002 Door Weldment Kit, Driver (L/H Door) 9-1
CMR-1003 Door Weldment Kit, Pass. (R/H Door) 11-1
CMR-1005 Bolt, Striker 8-12
CMR-1006 Latch, Driver Door 9-17
CMR-1007 Handle, Passenger Door Paddle 11-21
CMR-1008 Latch, Passenger Door 11-17
CMR-1009 Handle, Driver Door Paddle 9-21
CMR-1010 Hinge, Driver Door 8-3
CMR-1011 Hinge, Passenger Door 8-7
CMR-1013 Strap, Check 8-19
CMR-1014 Bracket, Check Strap Mounting 8-22
CMR-1015 Clip, Rod 9-19
CMR-1017 Handle Assembly, Driver Inner Door 9-6
CMR-1018 Insulation Kit, Cab & Doors 6-
CMR-1019 Handle Assembly, Pass. Inner Door 11-6
CMR-1020 Plate, Striker Access 8-15
CMR-1021 Plate, Door Cover 9-12
CMR-1022 Mount, Check Strap 8-20
CMR-1023 Plate, Striker Bolt Mount 8-11
CMR-1024 Plate, Striker Mount 8-10
CMR-1025 Rod, Driver Door Latch to Ext. Handle 9-16
CMR-1025 Rod, Pass. Door Latch to Ext. Handle 11-18
CMR-1026 Rod, Driver Door Latch to Int. Handle 9-25
CMR-1026 Rod, Pass. Door Latch to Int. Handle 11-16
CMR-1027 Windshield 13-6
CMR-1028 Windshield, Rear 13-3
CMR-1029 Window, Driver Side Door 9-3
CD387 4-3-21
Orig
Chapter 4
CMR-1029-1 Frame, Window 10-3

CMR-1029-2 Slider, Rear, Assembly 10-17
CMR-1029-3 Slider, Front Assembly 10-13
CMR-1029-4 Vent Assembly 10-4
CMR-1029-5 Latch, Vent 10-5
CMR-1029-6 Screw, Phillips Pan Head, 8x .625 10-6
CMR-1029-7 Seal, Bulb 10-8
CMR-1029-8 Filler, Channel 10-7
CMR-1029-9 Million Assembly 10-9
CMR-1029-10 Plate, Splice 10-11
CMR-1029-12 Seal, Max 10-12
CMR-1029-12 Seal, Max 12-12
CMR-1029-13 Strip, Weather 10-14
CMR-1029-14 Plate, Strike 10-15
CMR-1029-15 Rivet, Zipriv, 0.125 10-16
CMR-1029-15 Rivet, Zipriv, 0.125 12-16
CMR-1029-16 Screw, Phillips Pan Head, 6x1.00 10-2
CMR-1029-17 Latch, Slider 10-1
CMR-1030 Window, Passenger Side Door 11-3
CMR-1031 Windows, Rear Side 13-1
CMR-1032 Door Assembly - L/H 8-2
CMR-1033 Door Assembly - R/H 8-6
D0TZ-7A011A Seal, Transmission 83-17
D2AZ-7086A Gasket, Flange Housing 83-22
D3AZ-7F006B Clamp, Modulator Cable (Part of Transmission) 45-29
D3AZ-7F006B Clip, Modulator Retainer (Part of Transmission) 46-20
D5AZ-7A098B Screen, Transmission Filter 78-7
D5TZ-7070A Ring, Bearing Retainer 83-19
4-3-22 CD387
Orig
Chapter 4
DEU1179565 Belt, Alternator 52-17

DEU2109988 Bolt, Flywheel 50-4
DEU4270206 Cover, Valve (Cylinder Head) 50-40
DEU4272425 Flywheel 50-3
E1ZZ-7065A Bearing, Tail Shaft 83-18
E5TZ-7A194D Pan, Oil C6 Transmission 77-3
EH-2802 Pad, Heater, 250 Watts, 120 Volts 22-1
EH-2802 Pad, Heater, 250 Watts, 120 Volts - Opt 61-36
EH-3202 Pad Heater, 250 Watts, 220V - Opt 61-36
ENG-MA-36 Engine, Kubota (MR8) 49-1
ENG-MA-36-1 O-Ring, Oil Gauge Guide 61-13
ENG-MA-36-4 O-Ring, Water Pump 61-29
ENG-MA-36-5 O-Ring, Oil Filler Plug 62-9
ENG-MA-36-6 Gasket 61-9
ENG-MA-36-10 Plug, Drain 62-47
ENG-MA-36-11 Gasket, Fuel Pump 62-38
ENG-MA-36-12 Gasket, Drain Plug 62-48
ENG-MA-36-13 Plug, Glow 62-4
ENG-MA-36-15 Bolt, Joint 62-55
ENG-MA-36-16 Element, Fuel Filter 62-42
ENG-MA-36-18 Belt, V- 61-19
ENG-MA-36-19 Seal, Heat 62-25
ENG-MA-36-22 Alternator Assembly 61-15
ENG-MA-36-25 Valve, Breather 61-2
ENG-MA-36-26 Tube, Breather 62-2
ENG-MA-36-28 Gasket, Exhaust Manifold 61-7
ENG-MA-36-31 Gasket, Head Cover 61-5
ENG-MA-36-36 Pulley Fan Drive 61-27
ENG-MA-36-36 Pipe Assembly, Overflow 62-22
ENG-MA-36-39 Filter, Fuel 62-40
ENG-MA-36-42 Solenoid, Stop (Fuel) 62-31
ENG-MA-36-45 Gasket, Water Pump 61-30
CD387 4-3-23
Orig
Chapter 4
ENG-MA-36-48 Thermostat Assembly 61-32

ENG-MA-36-51 Gasket, Thermostat Cover 61-34
ENG-MA-36-55 Cover, Thermostat 61-33
ENG-MA-36-56 Gauge, Oil (Dip Stick) 61-3
ENG-MA-36-57 Guide, Oil Gauge Assembly 61-4
ENG-MA-36-58 Pump Assembly, Water 61-28
ENG-MA-36-59 Pipe, Water Return 61-31
ENG-MA-36-60 Starter Assembly 61-10
ENG-MA-36-61 Cartridge, Oil Filter 62-46
ENG-MA-36-64 Manifold, Exhaust (MR8) 61-6
ENG-MA-36-64 Manifold, Exhaust (MR8-36) 70-1
ENG-MR10-36T Engine, Kubota, V3600-T (MR10) 49-1
ENG-MR-10-36T-1 Pulley, Fan (MR10, w/Kubota V3600-T) 61-27
ENG-MR10-36T-2 Plate, Fuel Pump Block Off 62-37
ENG-MR10-36T-4 Manifold, Exhaust (MR10, w/Kubota V3600-T) 61-6
ENG-MR10-36T-5 Turbocharger Assembly (MR10) 61-8
ENG-MR24-DEUTZ Engine, Deutz BF4M2011 47-1
ENG-MR24-DEUTZ-1 Retainer, Turbo Oil Drain Line 50-9
ENG-MR24-DEUTZ-2 Seal, O-Ring, Upper Turbo Oil Drain 50-11
ENG-MR24-DEUTZ-3 Line, Turbo Oil Feed 50-20
ENG-MR24-DEUTZ-4 Thermostat, Engine 50-31
ENG-MR24-DEUTZ-5 Spring, Thermostat Compression 50-32
ENG-MR24-DEUTZ-6 Seal, O-Ring 50-33
ENG-MR24-DEUTZ-7 Plug, Thermostat 50-34
ENG-MR24-DEUTZ-8 Tube, Dip Stick 50-35
ENG-MR24-DEUTZ-9 Dip Stick, Engine Oil level 50-36
ENG-MR24-DEUTZ-10 Sender, Temperature 50-39
ENG-MR24-DEUTZ-11 Gasket, Valve Cover 50-41
ENG-MR24-DEUTZ-12 Plug, Glow 50-43
ENG-MR24-DEUTZ-13 Washer, Sealing, Glow Plug 50-44
ENG-MR24-DEUTZ-14 Injector, Fuel with Nozzle 50-45
ENG-MR24-DEUTZ-15 Pump, Fuel Injection, Class A 50-53
ENG-MR24-DEUTZ-16 Pump, Fuel Injection, Class B 50-53
4-3-24 CD387
Orig
Chapter 4
ENG-MR24-DEUTZ-17 Pump, Fuel Injection, Class C 50-53

ENG-MR24-DEUTZ-18 Pump, Fuel Injection, Class D 50-53
ENG-MR24-DEUTZ-19 Line, Injection Pump to Injector 50-58
ENG-MR24-DEUTZ-20 Solenoid, Fuel Shut Off 50-66
ENG-MR24-DEUTZ-21 Sender, Oil Pressure 50-73
ENG-MR24-DEUTZ-22 Solenoid, Excess Fuel 50-75
ENG-MR24-DEUTZ-23 O-Ring, Excess Fuel Solenoid 50-76
ENG-MR24-DEUTZ-24 Cover, Front, Oil Pump 51-1
ENG-MR24-DEUTZ-25 Line, Turbo Oil Drain 53-4
ENG-MR34-DEUTZ Engine, Deutz TD2011 L040 (MR-34T) 48-1
ENG-MR34-DEUTZ Engine, Deutz TD2011 L040 57-1
ENG-MR34-DEUTZ-1 Starter, TD2011 57-5
ENG-MR34-DEUTZ-2 Alternator, TD2011 50-26
ENG-MR34-DEUTZ-2 Alternator 52-1
ENG-MR34-DEUTZ-4 Fan 50-23
ENG-MR34-DEUTZ-4 Fan, Cooling, TD2011 54-6
ENG-MR34-DEUTZ-5 ECU, TD2011 92-6
ENG-MR34-DEUTZ-6 Relay, Glow Plug, TD2011 93-33
ENG-MR34-DEUTZ-7 Element, Fuel Filter 67-35
ENG-MR34-DEUTZ-8 Adapter, Transmission to Housing 84-4
ENG-MR34-DEUTZ-9 Flexplate 84-8
ENG-MR34-DEUTZ-10 Adapter,Flywheel To Flexplate 84-2
G1-20429 Light, Dome, Chrome 12V 17-1
G1-30101-6 Pedal, Accelerator 44-1
G1-30148-3 Lamp & Socket, 12V 24-17
G1-30148-4 Lens, Oil Pressure Light 23-31
G1-30148-5 Lens, Headlight Indicator Light 23-34
G1-30148-6 Lens, Battery Warning Light 23-33
G1-30148-7 Plug, Engine Diagnostic (Comes w/Engine) 92-10
G1-31008-3 Lens, Brake Warning Light 23-35
CD387 4-3-25
Orig
Chapter 4

G35-10034 Heater, Battery 240V, 200 Watt - Opt. 98-6
G35-30050 Bracket, Diag. Port Relocation 92-9
G8JN-1C6T-F-R-DC12 Relay (Starter Lockout) (Part of HRN-MR-0007) 93-27
G8JN-1C6T-F-R-DC12 Relay (Trans. Lockout) (Part of HRN-MR-0007) 93-30
HRM-MR-0002 Harness, VEC 93-18
HRN-MR-0001 Harness, Main Chassis 93-53
HRN-MR-0001 Harness, Main Chassis, Deutz Tier 2 & Kubota 95-45
HRN-MR-0003 Harness, Dash Panel 23-27
HRN-MR-0003 Harness, Dash Panel, Deutz, Tier 2 29-17
HRN-MR-0004 Harness, Headlight 16-20
HRN-MR-0005 Harness, Hitch Light (MR10-24T, MR10-36T) 16-31
HRN-MR-0006 Harness, Fuel Tank Sender 67-13
HRN-MR-0007 Harness, Trans. Starter Interlock 93-26
HRN-MR-0007 Harness, Transmission Starter Interlock 94-36
HRN-MR-0008 Harness, Glow Plug Relay 93-38
HRN-MR-0008-1 Harness, Glow Plug Relay 94-9
HRN-MR-0008-2 Jumper, Harness, Glow Plug Relay 94-3
HRN-MR-0009 Harness, Cab 5-9
HRN-MR-0010 Harness, E-Stop Assembly 18-2
HRN-MR24-0001 Harness, Engine (See Note) 52-18
HRN-MR24-0001 Harness, Engine MR Deutz 93-42
HRN-MR34-111 Harness, Engine 41 Deutz 59-18
HRN-MR34-111-2 Cable, Positive, Alternator To Power Stud 59-25
HRN-MR34-111-3 Wire #8, Part of Harness 59-24
HRN-MR34-111-3 Harness, Deutz Engine 92-7
HRN-MR34-112 Harness, Main, MR34 94-39
HRN-MR34-113 Harness, Instrument Panel 24-13
HRN-MR34-113 Harness, Instrument Panel, Deuz 4i 29-17
HRN-MR34-114 Harness, 4F75 Transm Start/Back 85-14
HRN-MR34-115 Harness, 4R75 Trans Power 92-5
HRN-MR34-115 Harness, 4R75 Trans. Power, Battery Cable 94-30
HRN-MR34-115 Harness, 4R75 Trans. Power, Ignition Cable 94-35
HRN-MR36-111 Harness, Engine, MR Kubota 61-21
HRN-MR36-111 Harness, Engine MR Kubota 93-43
HRN-MR36-113 Harness, LED Tail Light 16-27
JB3816-2 Stud, Junction Block 93-39
4-3-26 CD387
Orig
Chapter 4
M10 Washer, Lock M10 30-43

M10 Washer, Flat M10 30-44
M10 Washer, Flat (C6 to 2011 Adapter) 84-5
M10-1.5 Nut, Jam M10-1.5 53-13
M10-1.5 Nut, Jam M10-1.5 60-13
M10-1.5 Nut, Hex M10-1.5 70-3
M10-1.5 x 20 Bolt, Hex Head Ø M10-1.5 x 20mm Long 62-19
M10-1.5 x 25 Bolt, Flange Head Ø M8-1.25 x 25mm Long 52-13
M10-1.5 x 25 Bolt, Flange Head Ø M10-1.5 x 25mm Long (Grade 10.9) 53-3
M10-1.5 x 25 Screw, Low Head Socket Ø M10-1.5 x 25mm Long 75-6
M10-1.5 x 25 Bolt, Socket Head Ø M10-1.5 x 25mm Long 76-7
M14-2.0 x 40 Bolt, Socket Head Cap Screw Ø M14-2.0 x 40mm Long 48-27
CD387 4-3-27
Orig
Chapter 4

M3-1-1059 Button Assembly, Horn - Two Wire 29-1
M3-1-8020 Wheel, Steering 14" 29-2
M3-ND-5011 Mirror, 5" Convex 7-6
M4-0.7 x 35 Screw, Phillips Pan Head Ø M4-0.7 x 35mm Long 18-4
M6 Washer, Star M6 52-3
M6-1.0 Nut, M6-1.0 45-16
M6-1.0 Nut, M6-1.0 52-4
M6-1.0 Nut, M6-1.0 52-20
M6-1.0 Nut, M6-1.0 59-4
M6-1.0 Nut, M6-1.0 59-20
M6-1.0 x 12 Bolt, Flange Ø M6-1.0 x 12mm Long 15-7
4-3-28 CD387
Orig
Chapter 4
M8-1.25 Nut, Flange M8-1.25 14-17

M8-1.25 Nut, Flange M8-1.25 15-9
M8-1.25 Nut, M8-1.25 50-16
M8-1.25 Nut, M8-1.25 50-57
M8-1.25 Nut, M8-1.25 52-22
M8-1.25 Nut, M8-1.25 57-16
M8-1.25 Nut, M8-1.25 59-22
M8-1.25 Nut, M8-1.25 52-16
M8-1.25 Nut, M8-1.25 59-16
M8-1.25 x 16 Bolt, Socket Head Cap Ø M8-1.25 x 16mm Long 50-29
M8-1.25 x 50 Bolt, Hex Head Ø M8-1.25 x 50 mm Long 61-24
MD-CB1-127 Bushing, Hood 4-29
MD-CB1-129 Yoke 82-10
MD-CB21-121 Clip 95-15
MD-CB21-121 Clip 95-42
MD-HO4-107 Cap, Radiator 62-15
MD-HO9-123 Fitting, 8MP-6FP-Bush 61-12
MD-P21-105 Isolator, C-6 Transmission Mount 47-27
MH-1-806 Bushing, Leaf Spring (Included w/ Leaf Spring) 32-7
MH-ND-543 Hose, Brake (19") 36-35
MH-ND-543 Hose, Brake (19") 95-13
MI-1-322 Cable, Throttle 45-10
MJ-ND-8010 Tee, Brake Pressure Switch 95-28
ML-26 Caution, Tractor To Come To… 3-31
MR-1014 Handle, Black Grab 9-4
MR-1015 Arm, Accelerator 46-18
MR-1016 Cleaner, Air 65-2
MR-1016-1 Filter, Primary Replacement 65-3
MR-1018 Elbow, Rubber COBRA 65-8
CD387 4-3-29
Orig
Chapter 4

MR-1019 Bracket, Cable Mount 46-19
MR-1020 Neck, Remote Radiator Fill 62-18
MR-1021 Mount, Radiator Filler Neck 62-21
MR-1022 Reservoir, Hydraulic 31-49
MR-1023 Shroud, Fan 74-15
MR-1024 Pipe, Air Cleaner to Turbo 66-7
MR-1025 Mount, Engine Half LH 49-12
MR-1026 Mount, Engine Half RH 49-4
MR-1027 Mount, Frame, Half 49-8
MR-1028 Mount, Radiator, L/H 74-27
MR-1029 Mount, Radiator, R/H 74-13
MR-1036 Mount, Air Cleaner 65-9
MR-1037 Hose, Pump to Reservoir 31-42
MR-1038 Sender, Water Temperature 61-11
MR-1039 Gauge, Water Temperature 25-24
MR-1040 Isolator, Rubber Engine 49-7
MR-1041 Pipe, Header V3600T 71-1
MR-1043 Line, Fuel Tank to Pump 68-4
MR-1044 Hose, Reservoir to Pump 31-41
MR-1045 Bracket, Overflow Bottle Mount 74-24
MR-1046 Seal, Bulb, Firewall 6-3
MR-1047 Sender, Oil Pressure 61-18
MR-1048 Gauge, Oil Pressure, 80psi 25-25
MR-1051 Pipe Weldment, Air Cleaner to Intake 65-7
MR-1052 Pipe, Header, Non-Turbo 70-4
MR-1053 Pipe, Tail, Non-Turbo 70-7
MR-1054 Muffler & Spark Arrestor Assembly 70-6
MR-1055 Hose, Radiator to Filler Cap 62-17
MR-1056 Pipe Weldment, Fresh Air Inlet 65-11
MR-1058 Hose, Pump to Brake Booster (CE Opt.) 31-32
MR-1059 Stud, Modulator Slide 46-15
MR-1060 Duct, Fresh Air Heater -Opt 22-2
MR-1061 Intake, Fresh Air Heater 22-6
MR-1062 Column, Tilt Steering, CharLynn (Opt.) 29-3
MR-1063 Radiator, Aluminum 74-8
MR-1065 Fan, Multi-wing, 8-Blade 61-26
MR-1066 Spacer, Fan 62-26
4-3-30 CD387
Orig
Chapter 4
MR-1067 Slide, Modulator MR-36 46-14

MR-1068 Hose, Heater, Thermostat 22-8
MR-1068 Hose, Heater, Thermostat (Heater Outlet) 62-30
MR-1069 Pipe, Fresh Air Heater - Opt 22-5
MR-1072 Cable, Battery Disconnect Switch to Starter -CE Opt 99-19
MR-1075 Plate, Light Socket Cover 16-33
MR-1076 Mount, Park Brake Transm Housing 89-5
MR-1077 Bracket, RH Parking Brake Handle 89-27
MR-1078 Bracket, LH Parking BRK Handle 89-6
MR-1086 Mat, Park Brake Boot 2-28
MR-1088 Bracket Battery Hold Down - Opt. 98-9
MR-1089 Box Assembly, Junction Heater - Opt. 98-15
MR-1089 Box, Junction, Assembly 100-
MR-1089-1 Box, Junction, Heater 100-2
MR-1089-2 Panel, Heater Junction Box 100-3
MR-1089-3 Feet, Mounting Box Kit 100-1
MR-1089-4 Board, Terminal, 30 AMP, 4 Point 100-4
MR-1091 Lever, Accelerator Pedal 46-8
MR-1092 Tire/Wheel Assembly - Front, Solid - Opt. 42-1
MR-1092-1 Tire, Front, Solid 42-2
MR-1092-2 Wheel, Front - Solid Tire 42-3
MR-1093 Tire/Wheel Assembly, Rear Solid - Opt. 43-3
MR-1093-1 Tire, Rear, Solid - Opt. 43-5
MR-1093-2 Wheel, Rear, Solid - Opt. 43-8
MR-1094 Spring, Throttle Return 45-25
MR-1095 Hose, Pump to Brake Booster 31-31
MR-1096 Closeout Headlight 16-32
MR-1097 Cable, Throttle, Stranded Wire 46-11
MR-1098 Wrap, Heat 30-66
MR-1099 Hose, Steer Valve "L" to Steer Cylinder 31-14
MR-1100 Relief, Strain - ½ NPT, 0.17-0.45 Cable 18-3
MR-1102-2 Wheel, Front 185R14LT 42-3
MR-1102-3 Valve, Front Tire 42-4
MR-1102-4 Cap, Front Tire Valve 42-5
MR-1103 Panel, Rear Axle Access (Wldmt) 2-2
MR-1103 Panel, Rear Axle Access 20-11
MR-1103 Panel, Rear Axle Access - WLDM 91-11
MR-1104 Housing, Dash (Weldment) 26-1
CD387 4-3-31
Orig
Chapter 4
MR-1105 Ring, Lashing 1-7

MR-1106 Tire/Wheel Assembly, Rear - MR8 43-2
MR-1106-1 Wheel, MR8, Rear 43-7
MR-1110 Decal, Tire Pressure 75PSI 1-20
MR-1115 Guard, Hip - Opt 20-15
MR-1116 Bracket, Seat Belt 20-7
MR-1118 Washer, Motor Mount Safety 47-6
MR-1119 Lever, Engine Throttle 45-14
MR-1120 Mount, Accelerator and Modulator Cable 45-21
MR-1122 Switch, Neutral Safety 81-2
MR-1122-1 Wire, Transmission Pressure Switch 75-28
MR-1123 Shaft, Drive C6 to AMS 83-1
MR-1124 Shifter 80-6
MR-1124-1 Bulb, Shifter Illumination 80-8
MR-1126 Closeout Flywheel, Deutz 48-29
MR-1126 Closeout, Flex Plate 75-29
MR-1127 Yoke 28-8
MR-1127 Yoke 96-2
MR-1128 Axle, Front Steer 30-27
MR-1128 Axle, Front Steer 33-
MR-1128-1 Bushing, Front Shackle 32-10
MR-1128-2 Fitting, Grease 32-11
MR-1128-3 Knuckle Weldment - R/H 33-6
MR-1128-4 Knuckle Weldment - L/H 33-9
MR-1128-5 Nut, 1-14, Spindle, 12-Slotted 34-15
MR-1128-6 Tube Assembly, Tie Rod 33-19
MR-1128-7 Axle Weldment, Front Steer 33-1
MR-1128-9 Caliper, Front Brake, RH 32-16
MR-1128-9 Caliper, Front Brake, LH 35-2
MR-1128-11 Rotor, 10.75"Dia. 34-3
4-3-32 CD387
Orig
Chapter 4
MR-1129 Shackle 32-9

MR-1130 Spring, Leaf - Heavy Duty 32-6
MR-1131 Pump, Steering W/Relief 30-37
MR-1132 Chain, Cradle Limiting 36-23
MR-1133 Bolt, Cradle Pivot 36-8
MR-1134 Plug, Hydraulic Pump 30-64
MR-1135 Cylinder, Steering 30-23
MR-1136 Valve, Steer 30-6
MR-1137 Valve, Ball ¾" NPT, Hydraulic Shut-Off 30-46
MR-1138-4 Lid, Hydraulic Tank 30-49
MR-1138-8 Gasket, Hydraulic Tank Lid 30-50
MR-1139 Tank, Fuel (Wldmt) 67-1
MR-1142 Elbow, Connector 2-27
MR-1143 Wedge, Locking 2 Pin 16-13
MR-1144 Gauge, Fuel Level 23-20
MR-1145 Gauge, Oil Pressure 23-25
MR-1145-1 Bulb, Back Gauge Light 23-21
MR-1146 Gauge, Oil Temperature 23-24
MR-1147 Gauge, Hour Meter 23-19
MR-1148 Gauge, Voltmeter 23-23
MR-1149 Headlight Assembly w/Connector 16-1
MR-1149-1 Headlight Assembly 16-2
MR-1149-2 Bulb, Headlight 16-3
MR-1150 Light, Back Up LED 16-23
MR-1151 Light Assembly, Warning 23-28
MR-1151-8 Light, Rear Hitch 23-37
CD387 4-3-33
Orig
Chapter 4
MR-1151-9 Holder, Bulb 23-38

MR-1152 Switch, 2 Position Toggle 23-3
MR-1152 Switch, 2 Position, 1 Pole, Toggle, Head Light 24-3
MR-1152 Switch, 2 Position, 1 Pole, Toggle, Hitch Light 24-4
MR-1153 Switch, 3 Position Toggle, Heater 24-5
MR-1154 Light, Hitch 16-25
MR-1155-1 E-Stop Assembly 18-2
MR-1156 Solenoid, Main Power 93-46
MR-1157 Plate, Connector Mounting 2-23
MR-1158 Panel, Dash 23-1
MR-1159 Panel, VEC Mounting 93-1
MR-1160 Plate, Alarm Mounting 27-1
MR-1161 Extension, Tire Valve 135° 43-13
MR-1163 Mount, Motor - Right Side Engine 47-2
MR-1164 Mount, Motor - Left Side Engine 47-10
MR-1165 Bracket, Lower Oil Cooler Mount 72-20
MR-1166 Tray, Battery 97-1
MR-1167 Mount, Fluid Cooler Upper 74-4
MR-1168 Spacer, Fuel Filter 67-31
MR-1170 Base, Hood Hinge (Passenger Side) 4-23
MR-1171 Arm, Hood Hinge 4-28
MR-1172 Bracket, Firewall Cowl 4-13
MR-1173 Bracket, Prop Rod Retainer 4-48
MR-1174 Isolator, Fuel Tank 67-38
MR-1175 Bracket, Hood Strut Ball Stud 4-39
MR-1176 Angle, Fuel Tank Isolator 67-42
MR-1177 Bracket, Upper Chain 36-22
MR-1178 Lever, Transmission Gear Select 81-16
MR-1179 Box, Drop 36-40
MR-1179 Box, Drop 37-10
MR-1179 Box, Drop 41-1
4-3-34 CD387
Orig
Chapter 4

MR-1179 Box, Drop 95-46
MR-1180 Pedal, Brake (Weldment) 28-1
MR-1182 Bracket, Rear - Brake Line Angle 36-29
MR-1183 Crossmember, Transmission 47-22
MR-1184 Bracket, Front Engine Lift 47-34
MR-1185 Bracket, Rear Engine Lift 47-33
MR-1186 Bolt, Hex Head Ø ¾-10 x 10" Long 36-3
MR-1187 Nut, Top Lock Hex ¾-10 36-5
MR-1188 Washer, Flat ¾" ID 36-4
MR-1189 Nut, U ¼-20 67-46
MR-1189 Nut, U ¼-20 68-39
MR-1191 Tape, Double Sided 67-43
MR-1191 Tape, Double Sided (10") 67-44
MR-1192 Isolator, Rubber - Battery 97-5
MR-1193 End, Hood Prop Rod 4-51
MR-1194 Clip, Gas Hood Spring 4-36
MR-1196 Pin, Clevis - Brake Pedal 28-12
MR-1198 Socket, Glow Plug Relay 93-34
MR-1199 Elbow, Pump Outlet 30-36
MR-1200 Fitting, ¼" NPT to 5/16" Compression 67-6
MR-1200-1 Connector, 5/16" Compress Fitting 67-9
MR-1200-2 Nut, 5/16" Compression Fitting 67-7
MR-1200-3 Ferrule, 5/16" Compression Fitting 67-8
MR-1201 Fitting, 2MPX2FP-90 DEG 61-17
MR-1201 Elbow, 90°, 2MPx2FP-90 Deg 64-20
MR-1202 Barb, ¼" NPT to 3/8" Hose 30-54
MR-1203 Fitting, 12MJ x 12MP 30-45
MR-1204 Nipple, ¾" NPT Close 30-47
MR-1205 Elbow, 90° 75-26
MR-1206 Line, Fuel (Tank to Pump) 67-3
MR-1207 Line, Fuel Return 67-10
MR-1208 Hose, Fuel Tank Transition 67-18
CD387 4-3-35
Orig
Chapter 4
MR-1209 Clamp, Hose - Fuel Filler 67-17

MR-1210 Line, Brake (Proportioning Valve to Rear Brake Hose) 95-33
MR-1211 Line, Brake (H-Valve to Rear Proportioning Valve) 95-25
MR-1212 Line, Brake (Front Tee to Left Caliper) 95-30
MR-1213 Line, Brake (Left Rear Drive Axle) 36-36
MR-1214 Line, Brake (Right Rear Drive Axle) 36-37
MR-1215 Hose, Brake 35-8
MR-1217 Line, Brake (Master Cylinder to H-Valve) 95-47
MR-1218 Hose, Steer Valve "P" to Booster 30-20
MR-1219 Hose, Steer Valve "T" to Tank Return 30-21
MR-1220 Hose, Steer Valve "R" to Steer Cylinder 30-13
MR-1222 Hose, Pump to Tank 30-41
MR-1224 Hose, Booster to Reservoir 30-32
MR-1225 Hose, Supply Tank to Pump 30-40
MR-1226 Hose Kit, Cooling (Includes items 6, 7) 74-
MR-1226-1 Hose, Cooling Ø 5/16" x 24" Long (to Supply) 74-6
MR-1226-2 Hose, Cooling Ø 5/16" x 20" Long (to Return) 74-7
MR-1227 Line, Transmission Cooler Supply 72-11
MR-1228 Line, Transmission Cooler Return 72-12
MR-1230 Harness, Hitch Light (MR8-36) 16-31
MR-1231 Cable, Positive Main Battery 53-10
4-3-36 CD387
Orig
Chapter 4

MR-1232 Cable, Negative Main Battery 97-11
MR-1233 Cable, Braided Ground 75-22
MR-1234 Cable, Positive Common Battery 53-9
MR-1235 Cable, Positive, Master Solenoid 93-45
MR-1236 Wire, Ground - Turn Signal Switch 29-6
MR-1237 Tube, Transition (Filter to Turbo) 64-15
MR-1238 Pipe, Header w/Flex 69-2
MR-1239 Pipe, Tail 69-25
MR-1240 Muffler 69-14
MR-1241 Arrestor, Spark 69-21
MR-1242 Clamp, Band 69-11
MR-1243 Hanger, Exhaust Header (Wldmt) 69-5
MR-1244 Panel, Wheel Well Closeout 2-12
MR-1245 Hood 4-2
MR-1246 Cowling 4-12
MR-1247 Plate, Dash Closeout 19-1
MR-1248 Panel, Top Transmission Closeout 2-7
MR-1249 Panel, Side Transmission Closeout 2-19
MR-1250 Guard, E-Stop 4-18
MR-1251 Rod, Hood Prop 4-50
MR-1252 Switch, Rear Windshield Wiper 14-5
MR-1252 Switch, Front Windshield Wiper 14-9
CD387 4-3-37
Orig
Chapter 4
MR-1253 Blade, Wiper - Front, 16" 14-45

MR-1253 Blade, Wiper Rear 15-31
MR-1254 Linkage, Wiper Arm to Wiper 14-36
MR-1255 Clip, Wiper Linkage 14-32
MR-1256 Cover, Front Wiper 14-2
MR-1257 Cover, Rear Wiper 15-2
MR-1258 Eye, Lifting 7-14
MR-1259 Shaft, Wiper Pivot 14-18
MR-1261 Arm, Wiper Drive 14-44
MR-1262 Pin, Check Strap 8-21
MR-1263 Heater, Cab 21-2
MR-1265 Bracket, ½" Ball Valve Mounting 21-14
MR-1265 Bracket, 1/2" Ball Valve MNTG 22-11
MR-1265 Bracket, Mounting - ½" Ball Valve 63-8
MR-1266 Hose Kit, Heater - 5/8" Black 21-
MR-1266-1 Hose, Heater - Black Ø 5/8" x 7" Long 21-7
MR-1266-2 Hose, Heater - Black Ø 5/8" x 17" Long (Engine to Valve) 21-19
MR-1266-2 Hose, Heater, Black 17" 22-7
MR-1266-3 Hose, Heater - Black Ø 5/8" x 40" Long (Heater to Engine) 21-10
MR-1268 Motor, Wiper Front 14-14
MR-1269 Motor, Wiper Rear 15-6
MR-1270K Frame Weldment Kit, MR10-36T 1-1
MR-1271-3 Housing, MR 8/10 Transmission (Part of Frame) 89-1
MR-1271-9 Mount, Leaf Spring (Welded) 32-8
MR-1271-19 Plate, Battery Support (Part of Frame) 22-15
MR-1271-44 Anchor, Accelerator Cable (Wldmt, Part of Frame) 45-12
MR-1271-44 Anchor, Accelerator Cable (Wldmt) 46-10
MR-1271-49 Mount, Steer Valve (Welded), Tier 2 30-5
MR-1271-50 Mount, Motor, Left Frame (Part of Frame) 48-26
MR-1271-51 Mount, Motor, Right Frame (Part of Frame) 48-12
MR-1271K Frame, Weldment Kit MR10-24T 1-1
MR-1272-1 Mount, Steer Valve ( Welded ), Tier 4i 30-5
MR-1272-1 Mount, Steel Valve (Welded) - MR8-36 31-5
MR-1272K Frame, Weldment Kit MR8-36 1-1
MR-1272K Frame Weldment Kit, MR8-36 2-1
4-3-38 CD387
Orig
Chapter 4
MR-1272K Frame Weldment Kit, MR8-36 4-1

MR-1273 Panel Assembly, VEC 93-
MR-1274 Grip Paper Kit (Includes items 7, 10-12) 5-
MR-1274-1 Grip Paper, Driver Step 5-7
MR-1274-2 Grip Paper, Passenger Step 5-10
MR-1274-3 Grip Paper, Driver Floor 5-12
MR-1274-4 Grip Paper, Passenger Floor 5-11
MR-1275 Line, Brake (Brake Light Switch to Front Tee) 95-35
MR-1276 Line, Brake (Front Tee to Right Caliper) 95-34
MR-1278 Line, Brake (H-Valve to Brake Light Switch) 95-27
MR-1279 Minder, Filter, 12V - Opt. 66-10
MR-1280 Plate, Data - Cab Assembly- Opt 6-2
MR-1281 Socket, Ordinance Trailer - Opt. 16-28
MR-1282 Valve, Engine Oil Drain 50-70
MR-1283 Ring, Lifting - Opt 1-17
MR-1284 Plate, Rear Lifting Ring - Opt 1-18
MR-1285 Gusset, Rear Lifting Ring - Opt 1-19
MR-1300 Transmission, 4R75 W/Park Brake 48-15
MR-1300 Transmission,4R75 W/Park Brake 85-1
MR-1300-1 Controller, TCU 2200, 4R75 Transmission 92-1
MR-1300-2 Harness, 4R75 Tramsmission 85-13
MR-1300-3 Fuse, 3 AMP 92-4
MR-1300-4 Fuse, 10AMP 92-3
MR-1300-5 Converter Assembly 85-18
MR-1300-6 Sensor, Transm.Turbine Shaft Speed 86-4
MR-1300-7 Sensor, Transm. Output Shaft Speed 86-2
MR-1300-8 Sensor, Transm. Range 86-3
MR-1300-9 Gasket, Transmission Pan 87-2
MR-1300-10 Pan, Transmission 87-3
MR-1300-11 Breather, Assembly, Transmission 85-17
MR-1300-12 Filter & Seal Assy 87-1
MR-1306 Plate, Shifter, 4R75 85-6
CD387 4-3-39
Orig
Chapter 4

MR-1307 Yoke, Park Brake Handle, 4R75 89-19
MR-1308 Yoke, Park Brake Drum 89-25
MR-1309 Frame, Weldment MR10-34T 1-1
MR-1309 Frame, Weldment, MR10-34T 3-1
MR-1309 Frame, Weldment, MR-34T 4-1
MR-1310 Washer, Shift Plate 4R75 85-5
MR-1310 Washer, Shifter Plate, 4R75, ¼ - ½ 88-15
MR-1312 Mount, Park Brake Cable At Transmission 85-2
MR-1313 Mount, Park BrakeCable At Handle 89-9
MR-1314 Cover ECM W/Cab - Opt 92-11
MR-1315 Drive Shaft, 4R75 91-2
MR-1317 Plate, TEC Mounting 94-1
MR-1318 Mount, Shifter Cable, 4R75 88-9
MR-1319 Cover ECM 92-11
MR-1320 Panel, Fuse/Relay Assy 94-11
MR-1321 Cable, Diagnostic & Software (Service Item) 92-12
MR-1323 Dipstick 4R75 85-15
MR-1324 Tire/Wheel Assembly - Front, Tug Tuff 42-1
MR-1327 Frame Weldment Kit, MR10-36T 1-1
MR-1328 Frame, Weldment Kit MR10-24T 1-1
MR-1330 Ballast, Left, Rear Cast 1-26
MR-1331 Ballast, Right, Rear Cast 1-25
MR-1324-1 Tire, Front 185-14 10pr Tug Tuff 42-2
MT-1-1048 Wheel, Dual 6.75 x 16.5 43-6
MT-1-1065 Spring, Rear Coil 36-13
MT-1-1215 Plate, Rear Axle Mount 36-2
MT-1-1257 Hose, Heater 5/8" ID - 28473 22-9
MT-1-1257 Hose, Heater 5/8" ID - 28473 (Heater Inlet) 62-43
MT-1-1257 Hose, Heater 5/8" ID - 28473 63-5
MT-1-1273 Spring, Gas Hood 4-33
MT-1-1277 Stud, 13mm Ball (1" Long Threaded) 4-35
MT-1-1330 Pump, Steering, w/Relief 31-38
MT-1-1338 Adapter, 14mm - Rear Brake 36-39
MT-1-1349 Stud, 13mm Ball (0.63" Long Threaded) 4-40
MT-1-1358 Extension, Tire Valve 7" 43-12
MT-1-2061 Pin, Wiper Pivot Shaft 14-33
MT-1-2157 Tire/Wheel Assembly, Rear Dual 43-1
MT-1-2157-1 Valve, Tire - Rear Dual 43-9
4-3-40 CD387
Orig
Chapter 4
MT-1-2157-2 Cap, Tire Valve, Rear 43-11

MT-1-2157-3 Nut, Lug, Rear 43-14
MT-2-1056 Shock Absorber, Rear 36-14
MT-2-1092 Base, Hood Hinge (Driver Side) 4-24
MT-2-1311 Lever, Accelerator Pedal 45-5
MT-3-1392 Valve, Regulating - Rear Brake 95-26
MT-4-1052 Cradle, Rear Axle (Wldmt) 36-6
MT-4-1175 Hitch Assembly, "E" (Opt.) 1-2
MT-4-1176 Extension, Hitch - Opt 1-15
MT-4-1177 Enclosure, Extention - Opt 1-14
MT-4-1247 Axle, Rear Drive 36-1
MT-4-1247 Axle, Rear Drive, W/O Drop Box 37-9
MT-4-1247 Axle, Rear Drive, W/Out Drop Box 91-8
MT-4-1247 Axle, Rear Drive AMS W/O Drop Box 95-1
MT-4-1247-1 Differential Complete 38-29
MT-4-1247-2 Gear, Bevel Set 38-12
MT-4-1247-5 Cover, Brake 40-5
MT-4-1247-7 Carrier, Anulus 59T 39-5
MT-4-1247-8 Spacer, Side Gear 38-26
MT-4-1247-9 Washer, Satellite Brass 38-20
MT-4-1247-10 Gear, Side 38-19
MT-4-1247-11 Gear, Satellite 38-21
MT-4-1247-12 Planetary 22T 39-20
MT-4-1247-13 Gear, Sun 13T 39-17
MT-4-1247-14 Washer, Conical 40-7
MT-4-1247-15 Piston, Service Brake 40-15
MT-4-1247-16 Pin, Blocker 38-24
MT-4-1247-17 Shaft, Actuator 40-22
MT-4-1247-18 Pin, Differential, Long 38-23
MT-4-1247-19 Pin, Differential, Short 38-22
MT-4-1247-20 Pin Actuator/Actuator Shaft 40-23
MT-4-1247-21 Pin, Brake 40-28
MT-4-1247-22 Pin Of Planetary Satellite 39-18
MT-4-1247-23 Spacer 40-10
MT-4-1247-24 Spacer, Preload 38-4
MT-4-1247-25 Spacer Foe Service Brake 40-21
MT-4-1247-26 Cover, Differential 38-28
MT-4-1247-27 Valve, Bleeder - Drive Axle 37-7
MT-4-1247-29 Lever, Brake 40-11
MT-4-1247-30 Bushing, Service Brake 40-20
MT-4-1247-31 Nut, Pinon 38-1
MT-4-1247-32 Support, wheel Spindle/Hub 39-12
CD387 4-3-41
Orig
Chapter 4
MT-4-1247-34 Hub 39-9

MT-4-1247-35 Housing, Differential 38-27
MT-4-1247-36 Gear, Anulus 59T 39-3
MT-4-1247-37 Bearing, Taper Roller 38-11
MT-4-1247-39 Bearing, Spheric Radial 39-15
MT-4-1247-42 Bearing, Needle For Satellite 39-19
MT-4-1247-43 Seal, Ring On Pinion, Outer 38-2
MT-4-1247-44 Seal, Cassette Ring On Planetary 39-11
MT-4-1247-45 Seal, Ring On Pinion, Inside 38-3
MT-4-1247-47 O-Ring, Planetary Cover 39-8
MT-4-1247-48 O-Ring, Bushing (EPDM) 40-18
MT-4-1247-49 O-Ring, Service Brake Piston (EPDM) 40-17
MT-4-1247-50 Ring, Snap 39-16
MT-4-1247-51 Ring, Snap 39-21
MT-4-1247-52 Ring, Snap 39-14
MT-4-1247-53 Ring, Snap 40-12
MT-4-1247-54 Ring, Snap For Pin/Actuator Shaft 40-24
MT-4-1247-55 Ring, Snap 39-6
MT-4-1247-56 Gum Diagram For Brake 40-13
MT-4-1247-57 Spring, Reaction 40-8
MT-4-1247-59 Stud, Wheel 39-23
MT-4-1247-60 Ball, Steel 40-9
MT-4-1247-60 Ball, Steel 40-14
MT-4-1247-62 Plug, M24-1.5 - Rear Axle 37-3
MT-4-1247-63 Plug 40-1
MT-4-1247-65 Plug, Breather M24-1.5 - Drive Axle 37-5
MT-4-1247-66 Nut, Adjusting 38-9
MT-4-1247-66 Carrier, Planetary 39-2
MT-4-1247-68 Nut, Lug 39-22
MT-4-1247-71 Bolt, Differential Housing 38-17
MT-4-1247-73 Bolt, Planetary Wheel End Drive 39-13
MT-4-1247-74 Bolt, Service Brake Bushing 40-19
MT-4-1247-75 Bolt, Allen Head - Brake Cover Long 40-3
MT-4-1247-76 Bolt, Allen Head - Brake Cover Short 40-4
MT-4-1247-78 Bolt, Planetary Cover 39-1
MT-4-1247-79 Bolt, Anulus Carrier 39-4
MT-4-1247-80 Adapter, Bleeder Valve 37-8
MT-4-1247-82 Washer, Conic 38-18
MT-4-1247-85 Washer, Copper 40-2
4-3-42 CD387
Orig
Chapter 4
MT-4-1247-86 Pin, Elastic 38-25

MT-4-1247-87 Ring, Guide, Service Brake Piston (PTEE) 40-16
MT-4-1247-88 Shim 38-10
MT-4-1247-90 Shim 38-13
MT-4-1247-91 Shim 38-14
MT-4-1247-92 Shim 38-15
MT-4-1247-93 Shim 38-5
MT-4-1247-94 Shim 38-6
MT-4-1247-95 Shim 38-7
MT-4-1247-97 Disc, Counter 40-26
MT-4-1247-98 Disc, Friction 40-27
MT-4-1247-99 Actuator, Ball Ramp Brake 40-25
MT-4-1247-100 Clip, Circle For Diagram (Not Shown) 40-30
MT-4-1247-102 Brake Complete Assembly 40-29
MT-4-1247-105 Plug, Magnetic M24-1.5 - Drive Axle 37-6
MT-4-1247-106 Washer, Sealing 24 x 30 x 1mm 37-4
MT-4-1248-11 Plug, M18-1.5 - Drop Box 37-1
MT-4-1248-11 Plug, Oil Filling 41-8
MT-4-1248-12 Plug, Inspection 41-6
MT-4-1248-13 Plug, Oil Drain Magnetic 41-3
MT-4-1248-14 Plug, Vent 41-7
MT-4-1248-15 Bolt 41-4
MT-4-1248-16 Ring, Copper 41-5
MT-4-1248-17 Washer, Sealing 18 x 24 x 1.5mm 37-2
MT-4-2173-7 Bracket, Elec Fuse/Relay Panel 94-10
MT-4-2211 Lug Wrench Set, 17, 19, 21, 22 mm-Service Item 42-7
MX4-10067-7 Hub 34-2
MX4-10206 Decal, Vehicle Operation 3-32
MX4H-50024 Sending Unit, Fuel Level 67-11
P1135 Hardware Kit, Shock (Comes with Shock) 36-15
RM4003 Wire, 6 Gauge (Glow Plug to Glow Plug Switch) 62-3
RM4242 Connector, 2 Pin 16-12
RM4291 Relay, K6, 12 Volt, Horn Power 94-19
RM4291 Relay, K8, 12 Volt, Dash, Head & Tail Light, Shifter 94-20
RM4291 Relay, K7,12 Volt, Hitch Light 94-21
RM4291 Relay, K5,12 Volt, Engine ECM 94-22
RM4292 Fuse, F7, Manual Reset, Mini 15 AMP, Rear Wiper 94-14
RM4292 Fuse, F10, Manual Reset, Mini 15 AMP, Cab Heater 94-15
RM4292 Fuse, F11, Manual Reset, Mini 15 AMP, Front Wiper 94-17
RM4292 Fuse, F9, Manual Reset, Mini 15 AMP, Fan, Dome Lights 94-18
CD387 4-3-43
Orig
Chapter 4
RM4292 Fuse, F3, Manual Reset, Mini 15 AMP, Ignition 94-24

RM4292 Fuse, F5, Manual Reset, Mini 15 AMP, Hitch, Turn Lights 94-25
RM4293 Fuse, F8, Manual Reset, Mini 20 AMP, Dash Power 94-16
RM4294 Fuse, F1, Manual Reset, Mini 25 AMP, Ignition Switch Power 94-12
RM4294 Fuse, F4, Manual Reset, Mini 25 AMP, Horn/Reverce Lights 94-13
RM4294 Fuse, F6, Manual Reset, Mini 25 AMP, Head & Tail Lights, Dash 94-23
RM4294 Fuse, F2, Manual Reset, Mini 25 AMP, ECM Power 94-26
SP000029-1-10 Cone, Inner 34-11
SP000029-1-11 Cup, Inner 34-10
SP000029-1-12 Cap, Outer 34-8
SP000029-1-13 Cone, Outer 34-7
T-430 Caution, Operators Shall Be… 3-29
T6-1001-602 Air Filter Assembly 64-1
T6-1001-602F Element, Air Filter 64-5
T6-1001-603 Band, Air Filter Mounting 64-7
T6-1002-151 Shifter, Morse 88-2
T6-1002-155 Clamp, Cable 88-10
T6-1002-155 Clamp, Cable 89-13
T6-1004-119 Swivel, Shift Cable 88-12
T6-1005-119 Clamp, 2" Exhaust 70-5
T6-1008-111 Transmission, C-6, 3-Speed 47-26
T6-1008-111 Transmission, C-6 - 3 Speed 75-10
T6-1008-111-3 Seal, O-Ring 9/19 x .103" 75-17
T6-1008-111-4 Arm, Shift 75-11
T6-1008-111-4 Lever, Shift, Transmission 81-1
T6-1008-111-5 Rod, Gear Selector Valve 78-1
T6-1008-111-6 Gasket, Transmission Filter Screen 78-6
T6-1008-111-7 Screw, Reverse Band Adjusting 79-1
T6-1008-111-8 Nut, Band Adjustor 79-3
T6-1008-111-9 Retainer, Throttle Pressure 78-2
T6-1008-111-10 Screen, Main Control Pump Inlet 78-3
T6-1008-123 Valve Body Assembly, 3 Speed 78-4
T6-1009-103 Pedal, Accelerator 45-1
T6-1009-109 Stud, Throttle Cable 45-8
T6-1206-103 Bands, Air Filter 65-1
T6-1208-105 Pin, Dowel 76-5
T6-1211-117 Indicator, Service - Air Filter 64-21
4-3-44 CD387
Orig
Chapter 4
T6-1300-165 Alarmstat, Kysor Water, 210 61-14

T6-1300-181 Alarm, Back-Up - 12VDC (Opt.) 1-13
T6-1300-223 Light, Flashing Amber (Opt.) 1-12
T6-1300-223 Light, Flashing Amber -Opt 7-13
T6-2400-170 Tire, Rear 8.75 x 16.5 43-4
T6-3001-60005 Cap, King Pin 33-15
T6-3001-60006 Screw, Button Head Socket Cap Ø #10-24 x 5/8" Long 33-17
T6-3001-60007 Pin, King 33-12
T6-3001-60013 End, Tie Rod - L/H 33-25
T6-3001-60017 End, Tie Rod - R/H 30-24
T6-3001-60017 End, Tie Rod - R/H 31-24
T6-3001-60017 End, Tie Rod - R/H 33-20
T6-3001-60017 End, Tie Rod - R/H 33-31
T6-3001-60020 Stud, Wheel 34-4
T6-3001-60025 Hub Assembly 34-1
T6-3001-60028 Washer, Tongue Spindle 34-14
T6-3001-60031 Cap, Grease 34-13
T6-3001-601-4 Fitting, Grease Zerk 30-25
T6-3001-601-4 Fitting, Grease 33-8
T6-3002-201 U-Bolt, Brierton Axle 32-3
T6-3002-202 Plate, Spring Clamp - Brierton 32-2
T6-3003-105 Nut, Chamfer Lug, ½-20 x 60° 34-5
T6-4005-109 Handle, Hood 4-3
T6-4005-121 Clip, Hood Rod 4-49
T6-4006-111R Latch, Rubber Hood w/Hook 4-7
T6-4025-103 Pintle Hitch, Holland 400CA - Opt 1-3
T6-4025-108 Hitch, Pintle W/Push Botton - Opt 1-6
T6-4400-103 Adapter, Kubota SAE 4 to C6 49-11
T6-4400-117 Hose, Upper Radiator 62-7
T6-4400-118 Hose, Lower Radiator 62-45
T6-4400-122 Connector, Fuel Solenoid 62-32
T6-4400-134 Heater, Block 110V - Opt. 62-53
T6-4400-134 Heater, Block, 110V 63-11
T6-4400-137 Pump, Fuel 68-11
T6-4700-432 Bottle, Overflow 74-26
T6-4700-469 Tubing, Clear 5/16" OD 62-16
T6-4700-469 Tube, Clear, Overflow Bottle (to Neck) 74-20
T6-4700-469 Tube, Clear, Overflow Bottle 74-25
CD387 4-3-45
Orig
Chapter 4
T6-4800-126 Fitting, 90, ½" NPT to 5/8" Barb 21-9

T6-4800-126 Fitting, 90 22-13
T6-4800-126 Fitting, 90° 63-6
T6-4900-152 Plug, Alternator, -D25 61-37
T6-4900-156 Fuse, 250A - CE Opt. 99-17
T6-4900-157 Holder, Fuse 250A - CE Opt. 99-15
T6-4900-174 Bracket, Throttle Return Spring 46-16
T6-4900-202 Hydro-Boost Assembly 28-9
T6-4900-211 Spring, Throttle, Return 28-3
T6-4900-211 Spring, Throttle Return 46-17
T6-4900-222 Cable, Modulator 60" Push Type 45-26
T6-5005-105 Clamp, Upper Steer 29-7
T6-600-112 Adapter, Brake Master Cylinder 95-22
T6-600-114 Adapter, Brake 95-17
T6-6010-111 Valve, Fuel Drain 67-2
T6-6011-111 Tee, Brake Line 36-28
T6-6011-111 Tee, Brake Line 95-6
T6-6011-111 Tee, Brake Line 95-31
T6-6011-113 Bracket, Transmission Line 75-18
T6-7007-101 Control, Turn Signal w/Harness 29-5
T6-7010-120 Light, Red Warning - Flat Head (Opt.) 25-39
T6-7013-207 Horn Assembly 101-1
T6-7016-123 Switch, Battery Disconnect - CE Opt. 26-5
T6-7016-123 Switch, Battery Disconnect - CE Opt 99-18
T6-8005-101 Lever, Hand Brake 82-1
T6-8005-103 Bushing, Hand Brake 82-2
T6-8005-129 Housing, Flange 83-21
T6-8005-135 Plate, Brake Shoes 83-10
T6-8005-143 Shoes, Park Brake 83-14
4-3-46 CD387
Orig
Chapter 4
T6-8005-147 Spring, Brake Shoes, Top 83-15

T6-8005-149 Spring, Brake Shoes, Bottom 83-16
T6-8011-107 Adapter, Brake Warning 95-18
T6-8013-145 Bolt, Brake Hose 35-9
T6-8013-147 Washer, Brake Hose 35-10
T6-8013-165 Valve, Bleeder - Front Caliper 35-7
T6-9003-165 Gasket, Glass Window 9-5
T6-9003-165 Gasket, Glass Window (by the foot) 13-2
T6-9003-171 Grommet, Windshield - Opt 7-12
T6-9003-527 Hose, Cooling Transmission 72-19
T6-9003-527 Hose, Transmission Line 90 Degr. 73-18
T6-9003-601 Converter, Torque, C6 75-12
T6-9011-101B Tee, Battery Hold Down 97-7
T6-9011-103 Belt, Seat - Retractable 20-3
T6-9011-105 Fan, Cab - Opt. 13-4
T6-9011-227 Seat, Vinyl Grammer GS12 - Opt 20-1
T6-9011-383 Bracket, Mirror Mounting 7-2
T6-9011-391 Light, Rotating Amber (Opt.) 1-12
T6-9011-391 Light, Rotating Amber - Opt 7-13
T6-9011-459 Isolator, Rubber - Steering Column 29-8
T6-9011-569 Bracket, Light on Rear Cab - Opt 7-11
T6-9011-631 Hose Ø 5/16 x 20" Long 67-21
T6-9011-631 Hose Ø 5/16 x 20" Long, Low Pressure Fuel 67-36
T6-9011-631 Hose Ø 5/16 x 16½" Long, Low Pressure Fuel 67-37
T6-9011-631 Hose Ø 5/16" Low Pressure Fuel/Oil, 4" Long 68-10
T6-9011-631 Hose Ø 5/16 x 21" Long 72-6
T6-9011-631 Hose Ø 5/16 x 21" Long 72-15
T6-9011-631 Hose Ø 5/16 x 21" Long 73-6
T6-9011-631 Hose Ø 5/16 x 21" Long 73-15
T6-9011-633 Mount, Fluid Cooler Upper 72-3
T6-9011-701 Switch, Ignition, Keyed, Waterproof - Opt. 24-6
T6-9011-702 Switch, Ignition, Waterproof 23-11
CD387 4-3-47
Orig
Chapter 4

TA-50 Decal, OFF/ON - CE Opt. 26-6
T-A56 Decal, Ultra Low Sulfur Diesel 1-22
TA-59 Decal, Check Air Filter - Opt. 25-40
T-G1 Sticker, Deisel Only 1-21
TM1-1-3506 Bushing, Rear Cradle 36-7
TM1-1-5005 Washer, Stop Engine Mount 49-9
TM1-1-5008 Hose, Oil Cooler 41" 72-30
TM1-1-6521 Fitting, 5/8 Barb x 3/8 Male 62-27
TM1-1-6529 Adapter, Pantograph Wiper, Dual 14-39
TM1-1-6529 Adapter, Pantograph Wiper 15-25
TM1-1-8150 Hose, Air Cleaner Intake Reducer 65-10
TM1-1-8154 Connection Kit, Transmission 81-9
TM1-1-8182 Cable, Shifter, 58" 80-1
TM1-1-8182 Cable, Shifter, 58" 81-23
TM1-1-8182 Cable, Shifter (Parking Brake), 58" 89-20
TM1-1-8308 Barb, Hose 5/8" ID 21-18
TM1-1-8308 Barb, 5/8" Hose 22-10
TM1-1-8308 Barb, 5/8" Hose 63-9
TM1-1-8334 Column, Steering 29-3
TM1-1-9647 Light, Brake/Turn Red LED 16-21
TM1-1-9693-4 Seal, Fuel Pump O-Ring 50-63
TM1-1-9693-6 Screw, Hollow 57-74
TM1-1-9693-7 Ring, Sealing 57-75
TM1-1-9737 Connector, Hose 1.75" Dia 66-5
TM1-1-9787 Valve, Hydraulic Brake Warning 95-16
TM1-1-9791 Plug, Brake Pressure Switch Valve 95-19
TM1-2-1089 Mount, Fluid Cooler Lower 72-2
TM1-2-8008 Dipstick, Hydraulic Reservoir Cap 30-60
TM1-2-9555 Mount, Shifter 80-2
4-3-48 CD387
Orig
Chapter 4
TM1-4-5037 Bracket, Park Brake (Wldmt) 82-3

TM1-4-9843 Elbow, 90° 85-7
TM1-4-9858 Spacer, Threaded, Transmission Cooler (Part Of Frame) 73-4
TM1-ND-1006 Gasket, Fuel Sender 67-12
TM1-ND-5001 Elbow, Air Cleaner Hose - Deutz 65-5
TM1-ND-5004 Mount, Rubber, Engine 47-18
TM1-ND-5006 Hose, Air Cleaner Hump - Deutz 64-14
TM1-ND-5010 Breaker, Circuit 60 Amp, Deutz 93-19
TM1-ND-5011 Relay, Glow Plug 93-33
TM1-ND-5021 Gasket, Turbo 50-15
TM1-ND-5040 Element, Oil Filter 50-30
TM1-ND-5043 Switch, Pressure Starter Interlock 75-27
TM1-ND-5049 Fitting, Oil Cooler 90JIC 73-16
TM1-ND-5253 Valve, Ball Deutz Heater 21-13
TM1-ND-5253 Valve, Ball 63-7
TM1-ND-5255 Adapter, 18mm to ½" Female NPT 21-22
TM1-ND-5260 Fitting, Oil Cooler, 45 73-17
TM1-ND-5266 Elbow, Male O-Ring Boss to Male JIC-45° 6MJ-6MB45 30-12
TM1-ND-5301 Starter 50-5
TM1-ND-6509 Elbow, Pump Inlet 12MJ-16MB 30-38
TM1-ND-8003 Elbow, Pump Outlet 31-39
TM1-ND-8016 Plug, ¼" NPT Magnetic Drain 30-52
TM1-ND-8076 Pad Set, Front Caliper 35-6
TM1-ND-8077B Bolt, Caliper Mounting 35-5
TM1-ND-8077-LH Caliper, Front Left Brake 95-39
TM1-ND-8077-RH Caliper, Front Right Brake 95-38
TM1-ND-8079-8 Nut, Jam 3/8-24 33-2
TM1-ND-8079-9 Screw, Cup Point Socket Set Ø 3/8-24 x ¾" Long 33-3
TM1-ND-8090 Nut, Top Lock Hex ½-13 33-5
TM1-ND-8093 Shim, King Pin 33-14
TM1-ND-8097 Bushing, 1.235" OD x 1.1" ID (STL BCK Bronze) 33-7
CD387 4-3-49
Orig
Chapter 4
TM1-ND-8099 Gasket, King Pin, Cover 33-16

TM1-ND-8103 Spring, Tension 50-68
TM1-ND-8104 O-Ring, Fuel Shut Off Solenoid 50-67
TM1-ND-9002 Seal, Inner 34-12
TM1-ND-9003 Bearing and Race - Inner Wheel 34-9
TM1-ND-9011 Bearing and Race - Outer Wheel 34-6
TP-10102 Sensor, Speed 57-60
TP-10389 Seal, Rear Crankshaft 50-2
TP-10390 Cover, Front, Hydraulic Pump 50-6
TP-10391 Line, Turbo Oil Drain 50-7
TP-10392 Seal, O-Ring, Lower Turbo Oil Drain 57-8
TP-10393 Retainer, Turbo Oil Drain Line 57-9
TP-10394 Bolt, Turbo Oil Drain Line Retainer 50-10
TP-10395 Seal, O-Ring, Upper Turbo Oil Drain 57-11
TP-10396 Nipple, Screw In 50-12
TP-10397 Ring, Sealing 50-13
TP-10398 Turbo Assembly 50-14
TP-10399 Sleeve, Rubber 50-17
TP-10400 Clamp, Spring Band 50-18
TP-10401 Pipe, Crankcase Breather 50-19
TP-10402 Line, Turbo Oil Feed 57-20
TP-10403 Bolt, Banjo 50-21
4-3-50 CD387
Orig
Chapter 4

TP-10405 Washer, Fan 50-24
TP-10406 Dip Stick, Engine Oil Level 57-27
TP-10407 Plug, Glow 57-29
TP-10408 Cap, Oil 50-38
TP-10408 Cap, Oil 57-30
TP-10409 Cover, Valve 57-31
TP-10410 Gasket, Valve Cover 57-32
TP-10411 Bolt, Valve Cover 50-42
TP-10412 Sender, Temperature 57-34
TP-10414 Plug, Screw 50-72
TP-10414 Socket, Glow Plug Relay 93-34
TP-10415 Injector, Fuel with Nozzle 57-37
TP-10417 Nozzle, Fuel Injector 50-46
TP-10418 Ring, Sealing, Fuel Injector 50-47
TP-10419 Claw, Fuel Injector Retainer 50-48
TP-10420 Bolt, Fuel Injection Retainer 50-49
TP-10421 Line, Fuel Return 50-50
TP-10423 Pump, Fuel Injection, Class A 57-45
TP-10424 Pump, Fuel Injection, Class B 57-45
TP-10425 Pump, Fuel Injection, Class C 57-45
TP-10426 Pump, Fuel Injection, Class D 57-45
CD387 4-3-51
Orig
Chapter 4
TP-10427 Gasket, 0.35mm Compensating 50-54

TP-10446 Tappet, Roller 50-55
TP-10447 Washer, Flat M8 57-48
TP-10448 Nut, M8-1.25 57-49
TP-10449 Line, Injection Pump to Injector 57-50
TP-10450 Thermostat, Engine 57-51
4-3-52 CD387
Orig
Chapter 4
TP-10451 Plug, Thermostat 57-52

TP-10452 Line, Fuel Supply 50-59
TP-10453 Sensor, Temperature, Glow Plug 57-56
TP-10455 Sender, Oil Pressure 57-61
TP-10456 Pump, Fuel Supply 50-62
TP-10456 Pump, Fuel 67-26
TP-10457 Plug, Engine Oil Drain 57-66
TP-10458 Seal, Engine Oil Drain Valve 56-5
TP-10458 Seal, Engine Oil Drain 57-67
TP-10459 Pan, Oil 50-28
TP-10459 Pan, Oil 56-2
TP-10459 Pan, Oil 57-69
TP-10460 O-Ring Seal 57-70
TP-10461 Solenoid, Fuel Shut Off 57-71
TP-10462 Bolt, Hex Head Solenoid 57-72
TP-10463 Line, Pivot, Fuel 57-73
TP-10464 Head, Fuel Filter 67-30
TP-10465 Cooler, Oil, BF4M1011F 73-24
TP-10466 Gasket, Turbo to Header Pipe 69-3
TP-10468 Cover, Front, Oil Pump 58-1
TP-10469 Screw, Tamper Proof Ø M6-1.0 x 30mm Long 51-2
TP-10470 Bolt, Hex Head Ø M6-1.0 x 70mm Long 58-3
TP-10471 Cover, Front, Cam Shaft 51-4
TP-10472 Rubber 58-5
TP-10475 Shield, Crankshaft 51-10
TP-10476 Regulator, Voltage 52-2
TP-10477 Pulley, Alternator 52-6
TP-10478 Washer, Plain, Alternator 52-7
TP-10479 Nut, Pulley, Alternator 52-8
TP-10480 Bracket, Cast Alternator 52-9
CD387 4-3-53
Orig
Chapter 4

TP-10481 Bolt, Hex Head, Bracket Cast 59-10
TP-10482 Bolt, Flange Head Bracket Cast 59-11
TP-10483 Bracket, Mounting, Alternator 52-12
TP-10484 Bolt, Hex Head Mounting Bracket 59-15
TP-10485 Ring, Supporting 59-23
TP-10486 Cable, Interconnect. 92-8
TP-10487 Pulley, V-Groove 54-3
TP-10489 Hub, Fan Spacer 54-4
TP-10490 Bolt, Flange Head Ø M10-1.5 x 40mm Long 54-5
TP-10491 Sprocket, Hydraulic Pump Drive 54-9
TP-10492 Adapter 54-10
TP-10493 Bolt, Crankshaft 54-12
TP-10494 Belt Kit, PTO Drive w/Tensioner Pulley 54-13
TP-10495 Sprocket, Camshaft 54-16
TP-10496 Pump, Engine Oil 54-17
TP-10497 Sprocket, Camshaft Drive 54-18
TP-10498 Belt Kit, Timing w/Tensioner Pulley 54-19
TP-10499 Clamp, Hose 64-17
TP-10500 Hose, Rubber, Reducer (Air Cleaner to Turbo) 64-18
TP-10501 Clamp, Hose IDEAL 5032 64-19
TP-10502 Bracket, Hydraulic Pump 55-1
TP-10503 Bolt, Torx Head Ø M10-1.5 x 90mm Long 55-2
TP-10505 Bolt, Flange Head, Mounting 59-13
TP-10506 O-Ring 55-4
TP-10507 Bolt, Socket Head Cap Oil Pan 57-68
TP-10508 Relay (Trans. Lockout) (Part of HRN-MR-0007) 94-37
TP-10508 Relay (Starter Lockout) (Part of HRN-MR-0007) 94-38
TP-10511 Belt, Alternator, TD2011 50-27
TP-10514 Relay, Glow Plug, Timer, TD2011, Tier 4i 94-29
TP-10517 Fan, Alternator 52-5
TP-10517 Fan, Alternator, TD2011 59-5
TPG-371887-S2 Nut, Nylock Jam 1" - Tail Shaft 83-7
TPG-378171-S100 Bolt, Hex 75-9
TPG-378171-S100 Bolt, Hex Ø 7/16-20 x 0.80" Long 76-9
4-3-54 CD387
Orig
Chapter 4
TPG-378171-S100 Bolt, Hex 84-11

TPG-382884-S Bolt, Drive Shaft Saddle - Socket Head Ø 5/16-24 x 1" Long 83-5
TPG-385524-S2 Bolt Ø ½-13 x 1½" Long 83-8
TPG-385554-S2 Stud Ø 9/16-18 x 2.28" Long 82-16
TPG-385554-S2 Stud Ø 9/16-18 x 2.28" Long 83-29
TPG-385555-S2 Spacer 82-15
TPG-385555-S2 Spacer 83-33
TPG-386034-S100 Nut, Slotted 9/16-18 82-18
TPG-386034-S100 Nut, Slotted 9/16-18 83-35
TPG-58675-S2 Bolt, Hex Head Ø ½-13 x 1½" Long 83-12
TPG-B9TZ-2A710D Cam and Lever Assembly 82-19
TPG-C1TT-2857L Clevis 82-12
TPG-C20Z-6A366A Reinforcement, Plate - Flywheel 75-8
TPG-C20Z-6A366A Reinforcement, Plate-Flywheel 76-8
TPG-C6TZ-4A254B Saddle, U-Joint 83-2
TPG-C8HZ-7A002A Plug, Speedometer Gear Input 83-27
TPG-D1TZ-17285A Spacer, Speedo, Gear 83-20
TPG-D3TA-2A701AA Pipe, Parking Brake 83-26
TPG-D3TZ-2614A Drum, Park Brake 83-4
TPG-D3TZ-2857A Clevis, Parking Brake 82-14
TPG-D3TZ-2A663D Bellcrank 82-13
TPG-D3TZ-7089B Flange, Output 83-3
TPG-D5TZ-6375A Flywheel Assembly, C-6 75-7
TPG-D5TZ-6375A Flywheel (comes w/Transmission) 76-6
TPG-D6TZ-2A703A Shield, Park Brake 83-11
TPG-E7TZ-7A020D Dip Stick Assembly, Transmission 75-16
TPG-EOTZ-7A228A Tube, Oil Level 75-15
TPG-EOTZ-7A228-A Tube, Transmission Dip Stick C6 85-16
T-Y11 Decal, Dash Mounted E-Stop - CE Opt. 26-2
TY-38 Decal, Hood Latch 3-28
X4015-101 Nut, Steering Column 29-4
CD387 4-3-55
Orig
Chapter 4
4-3-56 CD369
Rev 1
Chapter 4
SECTION 4: ALPHABETICAL INDEX
MT-4-1247-99 Actuator, Ball Ramp Brake 40-25

TP-10492 Adapter 54-10
660-4-3624 Adapter, Barb 5/16 to 3/16 62-52
660-4-3624 Adapter, Barb 5/16 To 3/16 68-23
MT-4-1247-80 Adapter, Bleeder Valve 37-8
78897 Adapter, Connector, Male, 6MJ x 8MP 30-39
999-0230A Adapter, Drive 75-2
TM1-1-6529 Adapter, Pantograph Wiper 15-25
TM1-1-6529 Adapter, Pantograph Wiper, Dual 14-39
------ Adapter, Straight 64-22
ENG-MR34-DEUTZ-8 Adapter, Transmission to Housing 84-4
ENG-MR34-DEUTZ-10 Adapter,Flywheel To Flexplate 84-2
T6-1001-602 Air Filter Assembly 64-1
T6-1300-181 Alarm, Back-Up - 12VDC (Opt.) 1-13
77971 Alarm, Low Oil Press and High Oil 27-5
T6-1300-165 Alarmstat, Kysor Water, 210 61-14
ENG-MR34-DEUTZ-2 Alternator 52-1
ENG-MA-36-22 Alternator Assembly 61-15
MR-1271-44 Anchor, Accelerator Cable (Wldmt) 46-10
MR-1271-44 Anchor, Accelerator Cable (Wldmt, Part of Frame) 45-12
------ Anchor, Bracket Cable 80-11
CD369 4-4-1
Rev 1
Chapter 4
------ Anchor, Cable Clamp 80-12

------ Arm, Drive 14-16
------ Arm, Drive 15-8
MR-1171 Arm, Hood Hinge 4-28
T6-1008-111-4 Arm, Shift 75-11
MR-1128-7 Axle Weldment, Front Steer 33-1
MR-1128 Axle, Front Steer 33-
MT-4-1247 Axle, Rear Drive AMS W/O Drop Box 95-1
MT-4-1247 Axle, Rear Drive, W/O Drop Box 37-9
MT-4-1247 Axle, Rear Drive, W/Out Drop Box 91-8
MT-4-1247-60 Ball, Steel 40-9
MT-4-1247-60 Ball, Steel 40-14
MR-1330 Ballast, Left, Rear Cast 1-26
MR-1331 Ballast, Right, Rear Cast 1-25
T6-1001-603 Band, Air Filter Mounting 64-7
TM1-1-8308 Barb, 5/8" Hose 22-10
TM1-1-8308 Barb, 5/8" Hose 63-9
TM1-1-8308 Barb, Hose 5/8" ID 21-18
------ Base, Dome Light (Part of G1-20429) 17-3
MT-2-1092 Base, Hood Hinge (Driver Side) 4-24
MR-1170 Base, Hood Hinge (Passenger Side) 4-23
4-4-2 CD387
Orig
Chapter 4
TM1-ND-9003 Bearing and Race - Inner Wheel 34-9

TM1-ND-9011 Bearing and Race - Outer Wheel 34-6
MT-4-1247-42 Bearing, Needle For Satellite 39-19
MT-4-1247-39 Bearing, Spheric Radial 39-15
E1ZZ-7065A Bearing, Tail Shaft 83-18
440E-46006 Bearing, Thrust - Timken T113 33-13
TP-10498 Belt Kit, Timing w/Tensioner Pulley 54-19
T6-9011-103 Belt, Seat - Retractable 20-3
ENG-MA-36-18 Belt, V- 61-19
MR-1253 Blade, Wiper - Front, 16" 14-45
MR-1253 Blade, Wiper Rear 15-31
660-1-3439 Block, Contact - NC (Stop) - CE Opt. 26-4
660-1-3252 Block, Power 94-7
MR-1089-4 Board, Terminal, 30 AMP, 4 Point 100-4
MT-4-1248-15 Bolt 41-4
TPG-385524-S2 Bolt Ø ½-13 x 1½" Long 83-8
MT-4-1247-75 Bolt, Allen Head - Brake Cover Long 40-3
MT-4-1247-76 Bolt, Allen Head - Brake Cover Short 40-4
MT-4-1247-79 Bolt, Anulus Carrier 39-4
TM1-ND-8077B Bolt, Caliper Mounting 35-5
3/8-16 x 1 Bolt, Carriage Ø 3/8-16 x 1" Long 16-5
CD387 4-4-3
Orig
Chapter 4
MR-1133 Bolt, Cradle Pivot 36-8

TP-10493 Bolt, Crankshaft 54-12
MT-4-1247-71 Bolt, Differential Housing 38-17
------ Bolt, Drive Adapter 75-3
14mm-2.0 x 35mm Bolt, Drive Adapter, Allen Head M14-2.0x35 84-3

TP-10482 Bolt, Flange Head Bracket Cast 59-11
M10-1.5 x 25 Bolt, Flange Head Ø M10-1.5 x 25mm Long (Grade 10.9) 53-3
TP-10490 Bolt, Flange Head Ø M10-1.5 x 40mm Long 54-5
5/16-18 x 2¼ Bolt, Flange Hex Head Ø 5/16-18 x 2¼" Long 16-8
M6-1.0 x 12 Bolt, Flange Ø M6-1.0 x 12mm Long 15-7
TPG-378171-S100 Bolt, Hex 75-9
TPG-378171-S100 Bolt, Hex 84-11
------ Bolt, Hex Head 62-14
------ Bolt, Hex Head M8 101-7
TP-10484 Bolt, Hex Head Mounting Bracket 59-15
4-4-4 CD387
Orig
Chapter 4

¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long - Opt 16-29
CD387 4-4-5
Orig
Chapter 4

TPG-58675-S2 Bolt, Hex Head Ø ½-13 x 1½" Long 83-12
MR-1186 Bolt, Hex Head Ø ¾-10 x 10" Long 36-3
¾-10 x 1½ Bolt, Hex Head Ø ¾-10 x 1½" Long 5-8
¾-10 x 2½ Bolt, Hex Head Ø ¾-10 x 2½" Long-Opt 1-4
¾-10 x 5 Bolt, Hex Head Ø ¾-10 x 5" Long 1-10
3/8-24 x 5/8 Bolt, Hex Head Ø 3/8-24 x 5/8" Long 81-19
4-4-6 CD387
Orig
Chapter 4

M8-1.25 x 50 Bolt, Hex Head Ø M8-1.25 x 50 mm Long 61-24
¼-20 x ¾ Bolt, Hex Head Ø¼-20 x ¾"Long 91-14
TP-10462 Bolt, Hex Head Solenoid 57-72
¼-20 x 1 Bolt, Hex Head, ¼" -20 x 1" Long 73-5
½-13 x 1¾ Bolt, Hex Head, ½-13 x 1¾ 85-4
CD387 4-4-7
Orig
Chapter 4
½-13 x 3½ Bolt, Hex Head, ½-13 x 3½"Long 49-2

3/8-16x1¼ Bolt, Hex Head, 3/8-16x1¼ 49-5
TP-10481 Bolt, Hex Head, Bracket Cast 59-10
¼-20 X 1" Bolt, Hex Head, Ø¼-20 x 1" 89-21
3/8-16 x 2 Bolt, Hex Head, Ø3/8-16 x 2" 89-10
TPG-378171-S100 Bolt, Hex Ø 7/16-20 x 0.80" Long 76-9
ENG-MA-36-15 Bolt, Joint 62-55
39587 Bolt, M81.25 x 20mmSocket Head Cap Fuel Pump 57-65
------ Bolt, Mounting 55-8
------ Bolt, Mounting Band 64-9
------ Bolt, Mounting Spring Loaded 64-8
10-24 x 1 5/8 Bolt, Oil Screen Ø #10-24 x 1 5/8" Long 78-10
10-24 x 1¼ Bolt, Oil Screen Ø #10-24 x 1¼" Long 78-9
¼-20 X 1" Bolt, Phillips, Ø¼-10 x 1" 89-2
¼-20 x ¾ Bolt, Phillips, Ø¼-20 x ¾ 89-3
MT-4-1247-78 Bolt, Planetary Cover 39-1
MT-4-1247-73 Bolt, Planetary Wheel End Drive 39-13
MT-4-1247-74 Bolt, Service Brake Bushing 40-19
39587 Bolt, Socket Head Cap Ø M8-1.25 x 20mm Long 67-29
TP-10507 Bolt, Socket Head Cap Oil Pan 57-68
CMR-1005 Bolt, Striker 8-12
5/16-18 x 17/32" Bolt, Transmission Oil Pan, 5/16-18 x 17/32" Long 77-4
5/16-18 x 17/32 Bolt, Transmission Oil Pan, 5/16-18 x 17/32" Long 81-15
T6-4700-432 Bottle, Overflow 74-26
MR-1089 Box Assembly, Junction Heater - Opt. 98-15
4-4-8 CD387
Orig
Chapter 4
MR-1179 Box, Drop 36-40

MR-1179 Box, Drop 37-10
MR-1179 Box, Drop 95-46
MR-1089 Box, Junction, Assembly 100-
MR-1089-1 Box, Junction, Heater 100-2
------ Bracket 101-3
MR-1088 Bracket Battery Hold Down - Opt. 98-9
MR-1265 Bracket, ½" Ball Valve Mounting 21-14
MR-1265 Bracket, 1/2" Ball Valve MNTG 22-11
CMR-1014 Bracket, Check Strap Mounting 8-22
G35-30050 Bracket, Diag. Port Relocation 92-9
MT-4-2173-7 Bracket, Elec Fuse/Relay Panel 94-10
MR-1172 Bracket, Firewall Cowl 4-13
MR-1184 Bracket, Front Engine Lift 47-34
------ Bracket, Headlight 16-4
MR-1175 Bracket, Hood Strut Ball Stud 4-39
TP-10502 Bracket, Hydraulic Pump 55-1
------ Bracket, L- 101-4
MR-1078 Bracket, LH Parking BRK Handle 89-6
T6-9011-569 Bracket, Light on Rear Cab - Opt 7-11
T6-9011-383 Bracket, Mirror Mounting 7-2
A13850 Bracket, Mirror Mounting 13-8
------ Bracket, Mounting 81-10
MR-1265 Bracket, Mounting - ½" Ball Valve 63-8
MR-1045 Bracket, Overflow Bottle Mount 74-24
TM1-4-5037 Bracket, Park Brake (Wldmt) 82-3
MR-1173 Bracket, Prop Rod Retainer 4-48
MR-1185 Bracket, Rear Engine Lift 47-33
MR-1077 Bracket, RH Parking Brake Handle 89-27
MR-1116 Bracket, Seat Belt 20-7
CD387 4-4-9
Orig
Chapter 4

T6-6011-113 Bracket, Transmission Line 75-18
------ Bracket, Turn Signal Lamp (Part of 660-2-3174) 16-16
MR-1177 Bracket, Upper Chain 36-22
MT-4-1247-102 Brake Complete Assembly 40-29
MR-1300-11 Breather, Assembly, Transmission 85-17
------ Bulb, Dome Light (Part of G1-20429) 17-4
MR-1149-2 Bulb, Headlight 16-3
MR-1124-1 Bulb, Shifter Illumination 80-8
660-4-0600-5 Bumper, Rubber Hood 4-10
MR-1128-1 Bushing, Front Shackle 32-10
MD-CB1-127 Bushing, Hood 4-29
MH-1-806 Bushing, Leaf Spring (Included w/ Leaf Spring) 32-7
TM1-1-3506 Bushing, Rear Cradle 36-7
------ Bushing, Rubber 36-18
MT-4-1247-30 Bushing, Service Brake 40-20
660-1-3440 Button, Locking, Red - CE Opt. 26-3
CMR-1001 Cab, Weldment 7-1
------ Cable, Alternator to Stud 61-35
MR-1072 Cable, Battery Disconnect Switch to Starter -CE Opt 99-19
MR-1321 Cable, Diagnostic & Software (Service Item) 92-12
TP-10486 Cable, Interconnect. 92-8
4-4-10 CD387
Orig
Chapter 4

------ Cable, Positive (Fuse to Battery Disconnect Switch) - CE Opt. 99-16

------ Cable, Positive Main Battery to Fuse - CE Opt. 99-13
HRN-MR34-111-2 Cable, Positive, Alternator To Power Stud 59-25
TM1-1-8182 Cable, Shifter (Parking Brake), 58" 89-20
TM1-1-8182 Cable, Shifter, 58" 81-23
MI-1-322 Cable, Throttle 45-10
MR-1097 Cable, Throttle, Stranded Wire 46-11
TM1-ND-8077-LH Caliper, Front Left Brake 95-39
TM1-ND-8077-RH Caliper, Front Right Brake 95-38
5000186 Cap, 3" Diesel Fuel 67-19
5000186 Cap, 3" Diesel Fuel 68-26
------ Cap, End 64-2
660-4-0013-11 Cap, Filler 30-59
660-4-0013-11 Cap, Filler 31-60
MR-1102-4 Cap, Front Tire Valve 42-5
T6-3001-60031 Cap, Grease 34-13
T6-3001-60005 Cap, King Pin 33-15
TP-10408 Cap, Oil 50-38
TP-10408 Cap, Oil 57-30
SP000029-1-12 Cap, Outer 34-8
CD387 4-4-11
Orig
Chapter 4

------ Cap, Rubber 64-3
MT-1-2157-2 Cap, Tire Valve, Rear 43-11
MT-4-1247-7 Carrier, Anulus 59T 39-5
MT-4-1247-66 Carrier, Planetary 39-2
ENG-MA-36-61 Cartridge, Oil Filter 62-46
T-430 Caution, Operators Shall Be… 3-29
ML-26 Caution, Tractor To Come To… 3-31
MR-1132 Chain, Cradle Limiting 36-23
T6-1005-119 Clamp, 2" Exhaust 70-5
2000059 Clamp, 3" Heavy Duty 71-4
T6-1002-155 Clamp, Cable 88-10
T6-1002-155 Clamp, Cable 89-13
2000059 Clamp, Exhaust 69-9
------ Clamp, Hose 62-28
------ Clamp, Hose 62-44
------ Clamp, Hose 62-49
TP-10499 Clamp, Hose 64-17
------ Clamp, Hose 2" 74-11
------- Clamp, Hose IDEAL 5010 63-3
TP-10501 Clamp, Hose IDEAL 5032 64-19
4-4-12 CD387
Orig
Chapter 4

5000113 Clamp, Hose, 056 2 1/8-4" 62-5
------ Clamp, Hose, 2" 66-6
------ Clamp, Hose, 2.5" 65-6
------ Clamp, Hose, 2.5" 66-12
------ Clamp, Hose, 3" 65-4
------ Clamp, Hose, 3" 66-4
------- Clamp, Hose, 5010 22-14
------- Clamp, Hose, IDEAL, 7/8"-2¾" ID, 5036-Opt 22-3
D3AZ-7F006B Clamp, Modulator Cable (Part of Transmission) 45-29
¼ Clamp, P - ¼" 95-36
¼ Clamp, P - ¼" 96-22
1¼ Clamp, P - 1¼" 67-22
1½ Clamp, P - 1½" 30-34
1½ Clamp, P - 1½" 31-35
3/8 Clamp, P - 3/8" 45-32
3/8 Clamp, P - 3/8" 72-13
3/8 Clamp, P - 3/8" 73-13
5/16 Clamp, P - 5/16" 67-4
5/16 Clamp, P - 5/16" 68-5
5/8 Clamp, P - 5/8" 30-15
5/8 Clamp, P - 5/8" 31-15
5/8 Clamp, P - 5/8" 72-8
5/8 Clamp, P - 5/8" 72-17
5/8 Clamp, P - 5/8" 73-8
5/8 Clamp, P - 5/8" 93-48
T6-5005-105 Clamp, Upper Steer 29-7
MD-CB21-121 Clip 95-15
MD-CB21-121 Clip 95-42
MT-4-1247-100 Clip, Circle For Diagram (Not Shown) 40-30
MR-1194 Clip, Gas Hood Spring 4-36
T6-4005-121 Clip, Hood Rod 4-49
D3AZ-7F006B Clip, Modulator Retainer (Part of Transmission) 46-20
A9002 Clip, Prop Rod End Retainer 4-52
CD387 4-4-13
Orig
Chapter 4

MR-1126 Closeout Flywheel, Deutz 48-29
MR-1096 Closeout Headlight 16-32
MR-1126 Closeout, Flex Plate 75-29
MR-1062 Column, Tilt Steering, CharLynn (Opt.) 29-3
SP000029-1-10 Cone, Inner 34-11
SP000029-1-13 Cone, Outer 34-7
TM1-1-8154 Connection Kit, Transmission 81-9
MR-1200-1 Connector, 5/16" Compress Fitting 67-9
------ Connector, Electric Heater 21-3
T6-4400-122 Connector, Fuel Solenoid 62-32
TM1-1-9737 Connector, Hose 1.75" Dia 66-5
T6-7007-101 Control, Turn Signal w/Harness 29-5
MR-1300-1 Controller, TCU 2200, 4R75 Transmission 92-1
MR-1300-5 Converter Assembly 85-18
T6-9003-601 Converter, Torque, C6 75-12
0990 0244 Cooler, Oil 72-24
TP-10465 Cooler, Oil, BF4M1011F 73-24
660-1-2347 Coupler, Hydraulic Pump 55-5
MR-1319 Cover ECM 92-11
MR-1314 Cover ECM W/Cab - Opt 92-11
MT-4-1247-5 Cover, Brake 40-5
4-4-14 CD387
Orig
Chapter 4

MT-4-1247-26 Cover, Differential 38-28
MR-1256 Cover, Front Wiper 14-2
ENG-MR24-DEUTZ-24 Cover, Front, Oil Pump 51-1
TP-10468 Cover, Front, Oil Pump 58-1
MR-1257 Cover, Rear Wiper 15-2
ENG-MA-36-55 Cover, Thermostat 61-33
TP-10409 Cover, Valve 57-31
DEU4270206 Cover, Valve (Cylinder Head) 50-40
MT-4-1052 Cradle, Rear Axle (Wldmt) 36-6
SP000029-1-11 Cup, Inner 34-10
TA-59 Decal, Check Air Filter - Opt. 25-40
T-Y11 Decal, Dash Mounted E-Stop - CE Opt. 26-2
TY-38 Decal, Hood Latch 3-28
TA-50 Decal, OFF/ON - CE Opt. 26-6
12960001 Decal, Seat Belt 24-23
T-A56 Decal, Ultra Low Sulfur Diesel 1-22
MX4-10206 Decal, Vehicle Operation 3-32
MT-4-1247-1 Differential Complete 38-29
TPG-E7TZ-7A020D Dip Stick Assembly, Transmission 75-16
ENG-MR24-DEUTZ-9 Dip Stick, Engine Oil level 50-36
TP-10406 Dip Stick, Engine Oil Level 57-27
MR-1323 Dipstick 4R75 85-15
MT-4-1247-97 Disc, Counter 40-26
CD387 4-4-15
Orig
Chapter 4
MT-4-1247-98 Disc, Friction 40-27

CMR-1032 Door Assembly - L/H 8-2
CMR-1033 Door Assembly - R/H 8-6
CMR-1002 Door Weldment Kit, Driver (L/H Door) 9-1
CMR-1003 Door Weldment Kit, Pass. (R/H Door) 11-1
MR-1315 Drive Shaft, 4R75 91-2
TPG-D3TZ-2614A Drum, Park Brake 83-4
MR-1060 Duct, Fresh Air Heater -Opt 22-2
ENG-MR34-DEUTZ-5 ECU, TD2011 92-6
TM1-ND-5001 Elbow, Air Cleaner Hose - Deutz 65-5
MR-1205 Elbow, 90° 75-26
TM1-4-9843 Elbow, 90° 85-7
MR-1201 Elbow, 90°, 2MPx2FP-90 Deg 64-20
660-2501-06-06 Elbow, 90°, Male 6MJ-6MP90 30-22
660-2501-06-06 Elbow, 90°, Male 6MJ-6MP90 31-22
660-2501-06-08 Elbow, Male 2501-06-08 31-37
TM1-ND-6509 Elbow, Pump Inlet 12MJ-16MB 30-38
MR-1199 Elbow, Pump Outlet 30-36
TM1-ND-8003 Elbow, Pump Outlet 31-39
T6-1001-602F Element, Air Filter 64-5
ENG-MA-36-16 Element, Fuel Filter 62-42
ENG-MR34-DEUTZ-7 Element, Fuel Filter 67-35
MT-4-1177 Enclosure, Extention - Opt 1-14
MR-1193 End, Hood Prop Rod 4-51
------ End, Rod, Gas Hood Spring 4-34
T6-3001-60013 End, Tie Rod - L/H 33-25
T6-3001-60017 End, Tie Rod - R/H 30-24
T6-3001-60017 End, Tie Rod - R/H 31-24
T6-3001-60017 End, Tie Rod - R/H 33-20
T6-3001-60017 End, Tie Rod - R/H 33-31
4-4-16 CD387
Orig
Chapter 4

MR-1155-1 E-Stop Assembly 18-2
MT-4-1176 Extension, Hitch - Opt 1-15
MT-1-1358 Extension, Tire Valve 7" 43-12
MR-1258 Eye, Lifting 7-14
ENG-MR34-DEUTZ-4 Fan 50-23
TP-10517 Fan, Alternator 52-5
TP-10517 Fan, Alternator, TD2011 59-5
T6-9011-105 Fan, Cab - Opt. 13-4
MR-1065 Fan, Multi-wing, 8-Blade 61-26
MR-1089-3 Feet, Mounting Box Kit 100-1
MR-1200-3 Ferrule, 5/16" Compression Fitting 67-8
------ Ferrule, 5/16" Compression Fitting 68-8
MR-1300-12 Filter & Seal Assy 87-1
CD387 4-4-17
Orig
Chapter 4

660-4-3630 Fitting, 2MBSPT-2FP 61-16
MR-1201 Fitting, 2MPX2FP-90 DEG 61-17
04-06-070102 Fitting, 6MJ x 4MP 30-53
04-06-070102 Fitting, 6MJ x 4MP 31-54
MD-HO9-123 Fitting, 8MP-6FP-Bush 61-12
T6-4800-126 Fitting, 90 22-13
T6-4800-126 Fitting, 90° 63-6
¼-28 Fitting, Grease ¼-28 28-2
660-1-2447 Fitting, Hyd. Pump Inlet 12MJ-16MB 31-40
TM1-ND-5049 Fitting, Oil Cooler 90JIC 73-16
TM1-ND-5260 Fitting, Oil Cooler, 45 73-17
660-1-2896 Flasher, Solid State 24-12
ENG-MR34-DEUTZ-9 Flexplate 84-8
TPG-D5TZ-6375A Flywheel (comes w/Transmission) 76-6
TPG-D5TZ-6375A Flywheel Assembly, C-6 75-7
4-4-18 CD387
Orig
Chapter 4

MR-1272K Frame, Weldment Kit MR8-36 1-1
MR-1272K Frame, Weldment Kit, MR8-36 2-1
MR-1272K Frame, Weldment Kit, MR8-36 4-1
MR-1271K Frame, Weldment Kit MR10-24T 1-1
MR-1328 Frame, Weldment Kit MR10-24T 1-1
MR-1271K Frame, Weldment Kit, MR10-24T 2-1
MR-1309 Frame, Weldment, MR-34T 4-1
MR-1327 Frame, Weldment Kit, MR10-36T 1-1
MR-1300-4 Fuse, 10AMP 92-3
660-4-3085-2 Fuse, 15 Amp Mini 93-13
660-4-3085-3 Fuse, 20 Amp Mini 93-12
660-4-3085-3 Fuse, 20 Amp Mini 93-52
660-4-3085-4 Fuse, 25 Amp Mini 93-14
660-4-3085-4 Fuse, 25 Amp Mini 93-51
T6-4900-156 Fuse, 250A - CE Opt. 99-17
MR-1300-3 Fuse, 3 AMP 92-4
RM4294 Fuse, F1, Manual Reset, Mini 25 AMP, Ignition Switch Power 94-12
RM4292 Fuse, F10, Manual Reset, Mini 15 AMP, Cab Heater 94-15
RM4292 Fuse, F11, Manual Reset, Mini 15 AMP, Front Wiper 94-17
RM4294 Fuse, F2, Manual Reset, Mini 25 AMP, ECM Power 94-26
RM4292 Fuse, F3, Manual Reset, Mini 15 AMP, Ignition 94-24
RM4294 Fuse, F4, Manual Reset, Mini 25 AMP, Horn/Reverce Lights 94-13
RM4292 Fuse, F5, Manual Reset, Mini 15 AMP, Hitch, Turn Lights 94-25
RM4294 Fuse, F6, Manual Reset, Mini 25 AMP, Head & Tail Lights, Dash 94-23
RM4292 Fuse, F7, Manual Reset, Mini 15 AMP, Rear Wiper 94-14
RM4293 Fuse, F8, Manual Reset, Mini 20 AMP, Dash Power 94-16
RM4292 Fuse, F9, Manual Reset, Mini 15 AMP, Fan, Dome Lights 94-18
------ Gasket 62-24
MR-1300-9 Gasket, Transmission Pan 87-2
CD387 4-4-19
Orig
Chapter 4

ENG-MA-36-12 Gasket, Drain Plug 62-48
ENG-MA-36-28 Gasket, Exhaust Manifold 61-7
D2AZ-7086A Gasket, Flange Housing 83-22
ENG-MA-36-11 Gasket, Fuel Pump 62-38
4-4-20 CD387
Orig
Chapter 4
T6-9003-165 Gasket, Glass Window (by the foot) 13-2

ENG-MA-36-31 Gasket, Head Cover 61-5
TM1-ND-8099 Gasket, King Pin, Cover 33-16
------ Gasket, Pantograph Adapter 15-26
------ Gasket, Pantograph Arm 14-40
ENG-MA-36-51 Gasket, Thermostat Cover 61-34
T6-1008-111-6 Gasket, Transmission Filter Screen 78-6
C6AZ-7A191B Gasket, Transmission Oil Pan 77-2
TP-10466 Gasket, Turbo to Header Pipe 69-3
ENG-MR24-DEUTZ-11 Gasket, Valve Cover 50-41
TP-10410 Gasket, Valve Cover 57-32
ENG-MA-36-45 Gasket, Water Pump 61-30
AS-10273 Gauge, Murphy Power View 24-8
ENG-MA-36-56 Gauge, Oil (Dip Stick) 61-3
MR-1145 Gauge, Oil Pressure 23-25
MR-1048 Gauge, Oil Pressure, 80psi 25-25
MR-1146 Gauge, Oil Temperature 23-24
MR-1039 Gauge, Water Temperature 25-24
MT-4-1247-36 Gear, Anulus 59T 39-3
MT-4-1247-2 Gear, Bevel Set 38-12
MT-4-1247-11 Gear, Satellite 38-21
MT-4-1247-10 Gear, Side 38-19
MT-4-1247-13 Gear, Sun 13T 39-17
MR-1274 Grip Paper Kit (Includes items 7, 10-12) 5-
MR-1274-3 Grip Paper, Driver Floor 5-12
MR-1274-1 Grip Paper, Driver Step 5-7
MR-1274-4 Grip Paper, Passenger Floor 5-11
MR-1274-2 Grip Paper, Passenger Step 5-10
CD387 4-4-21
Orig
Chapter 4
------ Grommet 16-26

------ Grommet 16-24
------ Grommet, Rubber 16-22
T6-9003-171 Grommet, Windshield - Opt 7-12
MR-1115 Guard, Hip - Opt 20-15
ENG-MA-36-57 Guide, Oil Gauge Assembly 61-4
MT-4-1247-56 Gum Diagram For Brake 40-13
MR-1285 Gusset, Rear Lifting Ring - Opt 1-19
CMR-1017 Handle Assembly, Driver Inner Door 9-6
CMR-1019 Handle Assembly, Pass. Inner Door 11-6
CMR-1009 Handle, Driver Door Paddle 9-21
T6-4005-109 Handle, Hood 4-3
CMR-1007 Handle, Passenger Door Paddle 11-21
P1135 Hardware Kit, Shock (Comes with Shock) 36-15
HRN-MR34-114 Harness, 4F75 Transm Start/Back 85-14
HRN-MR34-115 Harness, 4R75 Trans Power 92-5
HRN-MR34-115 Harness, 4R75 Trans. Power, Battery Cable 94-30
HRN-MR34-115 Harness, 4R75 Trans. Power, Ignition Cable 94-35
HRN-MR-0003 Harness, Dash Panel, Deutz, Tier 2 29-17
HRN-MR34-111-3 Harness, Deutz Engine 92-7
HRN-MR24-0001 Harness, Engine (See Note) 52-18
HRN-MR34-111 Harness, Engine 41 Deutz 59-18
HRN-MR24-0001 Harness, Engine MR Deutz 93-42
HRN-MR36-111 Harness, Engine MR Kubota 93-43
HRN-MR36-111 Harness, Engine, MR Kubota 61-21
HRN-MR-0010 Harness, E-Stop Assembly 18-2
4-4-22 CD387
Orig
Chapter 4
HRN-MR-0008 Harness, Glow Plug Relay 93-38

HRN-MR-0008-1 Harness, Glow Plug Relay 94-9
HRN-MR-0004 Harness, Headlight 16-20
HRN-MR-0005 Harness, Hitch Light (MR10-24T, MR10-36T) 16-31
MR-1230 Harness, Hitch Light (MR8-36) 16-31
HRN-MR34-113 Harness, Instrument Panel 24-13
HRN-MR34-113 Harness, Instrument Panel, Deuz 4i 29-17
HRN-MR36-113 Harness, LED Tail Light 16-27
HRN-MR-0001 Harness, Main Chassis, Deutz Tier 2 & Kubota 95-45
HRN-MR-0007 Harness, Trans. Starter Interlock 93-26
HRN-MR-0007 Harness, Transmission Starter Interlock 94-36
HRM-MR-0002 Harness, VEC 93-18
TP-10464 Head, Fuel Filter 67-30
MR-1149-1 Headlight Assembly 16-2
MR-1149 Headlight Assembly w/Connector 16-1
G35-10034 Heater, Battery 240V, 200 Watt - Opt. 98-6
660-1-3460 Heater, Battery Box - Opt. 98-5
T6-4400-134 Heater, Block 110V - Opt. 62-53
T6-4400-134 Heater, Block, 110V 63-11
CMR-1010 Hinge, Driver Door 8-3
CMR-1011 Hinge, Passenger Door 8-7
T6-4025-108 Hitch, Pintle W/Push Botton - Opt 1-6
------ Holder Assembly, Nozzle 62-23
T6-4900-157 Holder, Fuse 250A - CE Opt. 99-15
MR-1245 Hood 4-2
T6-7013-207 Horn Assembly 101-1
------ Horn with Terminal Applications 101-2
MR-1226 Hose Kit, Cooling (Includes items 6, 7) 74-
MR-1266 Hose Kit, Heater - 5/8" Black 21-
------ Hose Ø 3/16" Low Pressure Fuel/Oil, 3" Long 68-24
CD387 4-4-23
Orig
Chapter 4
T6-9011-631 Hose Ø 5/16 x 16½" Long, Low Pressure Fuel 67-37

T6-9011-631 Hose Ø 5/16 x 20" Long 67-21
T6-9011-631 Hose Ø 5/16 x 21" Long 72-6
T6-9011-631 Hose Ø 5/16 x 21" Long 72-15
T6-9011-631 Hose Ø 5/16 x 21" Long 73-6
T6-9011-631 Hose Ø 5/16 x 21" Long 73-15
660-4-3530 Hose, 2"ID x 2.5L Rubber - Opt 22-4
------ Hose, 3/16" ID x 3" Long 62-54
------ Hose, 5/16" ID 62-50
------ Hose, 5/16" ID 62-51
TM1-ND-5006 Hose, Air Cleaner Hump - Deutz 64-14
MH-ND-543 Hose, Brake (19") 36-35
MH-ND-543 Hose, Brake (19") 95-13
MR-1226-2 Hose, Cooling Ø 5/16" x 20" Long (to Return) 74-7
MR-1226-1 Hose, Cooling Ø 5/16" x 24" Long (to Supply) 74-6
MR-1266-2 Hose, Heater - Black Ø 5/8" x 17" Long (Engine to Valve) 21-19
MR-1266-3 Hose, Heater - Black Ø 5/8" x 40" Long (Heater to Engine) 21-10
MR-1266-1 Hose, Heater - Black Ø 5/8" x 7" Long 21-7
MT-1-1257 Hose, Heater 5/8" ID - 28473 22-9
MT-1-1257 Hose, Heater 5/8" ID - 28473 63-5
MT-1-1257 Hose, Heater 5/8" ID - 28473 (Heater Inlet) 62-43
MR-1068 Hose, Heater, Thermostat (Heater Outlet) 62-30
4-4-24 CD387
Orig
Chapter 4

MR-1058 Hose, Pump to Brake Booster (CE Opt.) 31-32
MR-1037 Hose, Pump to Reservoir 31-42
MR-1222 Hose, Pump to Tank 30-41
MR-1044 Hose, Reservoir to Pump 31-41
TP-10500 Hose, Rubber, Reducer (Air Cleaner to Turbo) 64-18
MR-1225 Hose, Supply Tank to Pump 30-40
T6-9003-527 Hose, Transmission Line 90 Degr. 73-18
999-02-3013 Housing, Adapter 75-4
------ Housing, Air Filter 64-4
MT-4-1247-35 Housing, Differential 38-27
T6-8005-129 Housing, Flange 83-21
MR-1271-3 Housing, MR 8/10 Transmission (Part of Frame) 89-1
MX4-10067-7 Hub 34-2
MT-4-1247-34 Hub 39-9
T6-3001-60025 Hub Assembly 34-1
TP-10489 Hub, Fan Spacer 54-4
CD387 4-4-25
Orig
Chapter 4
T6-1211-117 Indicator, Service - Air Filter 64-21

ENG-MR24-DEUTZ-14 Injector, Fuel with Nozzle 50-45
TP-10415 Injector, Fuel with Nozzle 57-37
CMR-1018 Insulation Kit, Cab & Doors 6-
------ Insulation, Foam - Cab Rear (Part of CMR-1018) 6-5
------ Insulation, Foam - Cab Side (Part of CMR-1018) 6-6
------ Insulation, Foam - Driver Door* 9-11
------ Insulation, Foam - Passenger Door* 11-11
MR-1061 Intake, Fresh Air Heater 22-6
660-1-2412 Isolator 72-25
MD-P21-105 Isolator, C-6 Transmission Mount 47-27
T6-9011-459 Isolator, Rubber - Steering Column 29-8
MR-1040 Isolator, Rubber Engine 49-7
------ Isolator, Transmission ( Part of Transmission) 48-16
660-4-0745-12 Joint, Ball 45-13
660-4-0745-12 Joint, Ball 45-31
660-4-0745-12 Joint, Ball 46-13
660-4-0745-12 Joint, Ball 62-36
------ Joint, Ball 80-9
HRN-MR-0008-2 Jumper, Harness, Glow Plug Relay 94-3
------ Knob 14-7
------ Knob 14-11
G1-30148-3 Lamp & Socket, 12V 24-17
------ Lamp, Turn Signal (Part of 660-2-3174) 16-15
CMR-1006 Latch, Driver Door 9-17
CMR-1008 Latch, Passenger Door 11-17
T6-4006-111R Latch, Rubber Hood w/Hook 4-7
130-0094-000 Lens, Brake Warning Light 24-18
4-4-26 CD387
Orig
Chapter 4

------ Lens, Dome Light (Part of G1-20429) 17-2
MT-2-1311 Lever, Accelerator Pedal 45-5
MR-1091 Lever, Accelerator Pedal 46-8
MT-4-1247-29 Lever, Brake 40-11
MR-1119 Lever, Engine Throttle 45-14
T6-1008-111-4 Lever, Shift, Transmission 81-1
MR-1178 Lever, Transmission Gear Select 81-16
660-2-3174 Light Assembly, Turn Signal 16-14
MR-1150 Light, Back Up LED 16-23
TM1-1-9647 Light, Brake/Turn Red LED 16-21
014050 Light, Dash 23-14
014050 Light, Dash 24-10
014050 Light, Dash 25-14
G1-20429 Light, Dome, Chrome 12V 17-1
T6-1300-223 Light, Flashing Amber (Opt.) 1-12
T6-1300-223 Light, Flashing Amber -Opt 7-13
MR-1154 Light, Hitch 16-25
T6-7010-120 Light, Red Warning - Flat Head (Opt.) 25-39
T6-9011-391 Light, Rotating Amber - Opt 7-13
T6-9011-391 Light, Rotating Amber (Opt.) 1-12
MR-1212 Line, Brake (Front Tee to Left Caliper) 95-30
CD387 4-4-27
Orig
Chapter 4
MR-1276 Line, Brake (Front Tee to Right Caliper) 95-34

MR-1206 Line, Fuel (Tank to Pump) 67-3
MR-1043 Line, Fuel Tank to Pump 68-4
ENG-MR24-DEUTZ-19 Line, Injection Pump to Injector 50-58
TP-10449 Line, Injection Pump to Injector 57-50
TP-10463 Line, Pivot, Fuel 57-73
ENG-MR24-DEUTZ-25 Line, Turbo Oil Drain 53-4
ENG-MR24-DEUTZ-3 Line, Turbo Oil Feed 50-20
TP-10402 Line, Turbo Oil Feed 57-20
------ Liner, Head 5' (Part of CMR-1018) 6-7
MR-1254 Linkage, Wiper Arm to Wiper 14-36
ENG-MR10-36T-4 Manifold, Exhaust (MR10, w/Kubota V3600-T) 61-6
4-4-28 CD387
Orig
Chapter 4
ENG-MA-36-64 Manifold, Exhaust (MR8) 61-6

ENG-MA-36-64 Manifold, Exhaust (MR8-36) 70-1
MR-1279 Minder, Filter, 12V - Opt. 66-10
M3-ND-5011 Mirror, 5" Convex 7-6
920408C1 Mirror, Rear View 13-7
------ Modulator (part of Modulator Cable) 45-27
MR-1268 Motor, Wiper Front 14-14
MR-1269 Motor, Wiper Rear 15-6
MR-1120 Mount, Accelerator and Modulator Cable 45-21
------ Mount, Air Filter Bracket - Wldmt (Part of Frame) 64-10
CMR-1022 Mount, Check Strap 8-20
MR-1025 Mount, Engine Half LH 49-12
MR-1026 Mount, Engine Half RH 49-4
TM1-2-1089 Mount, Fluid Cooler Lower 72-2
T6-9011-633 Mount, Fluid Cooler Upper 72-3
MR-1167 Mount, Fluid Cooler Upper 74-4
MR-1027 Mount, Frame, Half 49-8
MR-1271-9 Mount, Leaf Spring (Welded) 32-8
MR-1271-50 Mount, Motor, Left Frame (Part of Frame) 48-26
MR-1271-51 Mount, Motor, Right Frame (Part of Frame) 48-12
MR-1076 Mount, Park Brake Transm Housing 89-5
MR-1313 Mount, Park BrakeCable At Handle 89-9
MR-1021 Mount, Radiator Filler Neck 62-21
MR-1028 Mount, Radiator, L/H 74-27
MR-1029 Mount, Radiator, R/H 74-13
MR-1318 Mount, Shifter Cable, 4R75 88-9
------ Mount, Spring, Rear - Driver Side (Part of Frame) 36-11
------ Mount, Spring, Rear - Pass. Side (Part of Frame) 36-12
MR-1272-1 Mount, Steel Valve (Welded) - MR8-36 31-5
CD387 4-4-29
Orig
Chapter 4
MR-1272-1 Mount, Steer Valve ( Welded ), Tier 4i 30-5

MR-1271-49 Mount, Steer Valve (Welded), Tier 2 30-5
MR-1054 Muffler & Spark Arrestor Assembly 70-6
------ Nut 14-6
------ Nut 14-10
------ Nut 23-6
------ Nut 23-10
------ Nut 23-17
------ Nut 25-6
------ Nut 25-10
------ Nut 25-17
------ Nut 36-16
------ Nut 97-12
------ Nut 97-14
------ Nut 98-13
------ Nut 99-12
------ Nut 99-14
MR-1128-5 Nut, 1-14, Spindle, 12-Slotted 34-15
MR-1200-2 Nut, 5/16" Compression Fitting 67-7
------ Nut, 5/16" Compression Fitting 68-7
------ Nut, Alarm 27-6
T6-1008-111-8 Nut, Band Adjustor 79-3
T6-3003-105 Nut, Chamfer Lug, ½-20 x 60° 34-5
660-1-2252 Nut, Conduit - ½ NPT 100-6
------ Nut, Flange (Part of 2000059) 69-10
5/16-18 Nut, Flange Lock Hex 5/16-18 16-10
M8-1.25 Nut, Flange M8-1.25 14-17
M8-1.25 Nut, Flange M8-1.25 15-9
¼-20 Nut, Flange, ¼-20 89-8
4-4-30 CD387
Orig
Chapter 4
½-13 Nut, Flange, ½"ID-13 91-3

¼-28 Nut, Hex ¼-28 14-27
¼-28 Nut, Hex ¼-28 14-35
¼-28 Nut, Hex ¼-28 15-19
½-20 Nut, Hex ½-20 83-23
M10-1.5 Nut, Hex M10-1.5 70-3
------ Nut, Jam 23-12
------ Nut, Jam 25-12
------ Nut, Jam (part of Modulator Cable) 45-28
------ Nut, Jam (Part of Throttle Cable) 45-11
½-20 Nut, Jam ½-20 28-11
½-20 Nut, Jam ½-20 96-3
¾-16 Nut, Jam ¾-16 UNF 30-26
¾-16 Nut, Jam ¾-16 UNF 31-26
TM1-ND-8079-8 Nut, Jam 3/8-24 33-2
3/8-24 Nut, Jam 3/8-24 82-24
M10-1.5 Nut, Jam M10-1.5 53-13
M10-1.5 Nut, Jam M10-1.5 60-13
CD387 4-4-31
Orig
Chapter 4

¾-16 Nut, Left Hand Jam ¾-16 33-27
------ Nut, Lock M8 101-5
¼-20 Nut, Lock, ¼"ID-20 88-8
¼-20 Nut, Lock, ¼-20 89-7
½-13 Nut, Lock, ½ID-13 49-10
3/8-16 Nut, Lock, 3/8"ID-16 89-14
MT-4-1247-68 Nut, Lug 39-22
MT-1-2157-3 Nut, Lug, Rear 43-14
M6-1.0 Nut, M6-1.0 45-16
M6-1.0 Nut, M6-1.0 52-4
M6-1.0 Nut, M6-1.0 52-20
M6-1.0 Nut, M6-1.0 59-4
M6-1.0 Nut, M6-1.0 59-20
M8-1.25 Nut, M8-1.25 50-16
M8-1.25 Nut, M8-1.25 50-57
M8-1.25 Nut, M8-1.25 52-16
M8-1.25 Nut, M8-1.25 52-22
M8-1.25 Nut, M8-1.25 57-16
TP-10448 Nut, M8-1.25 57-49
M8-1.25 Nut, M8-1.25 59-16
M8-1.25 Nut, M8-1.25 59-22
10-32 Nut, Nylock #10-32 2-25
10-32 Nut, Nylock #10-32 3-25
10-32 Nut, Nylock #10-32 4-9
10-32 Nut, Nylock #10-32 4-44
#10-32 Nut, Nylock #10-32 7-5
10-32 Nut, Nylock #10-32 45-9
10-32 Nut, Nylock #10-32 45-20
10-32 Nut, Nylock #10-32 46-7
10-32 Nut, Nylock #10-32 81-14
8-32 Nut, Nylock #8-32 4-11
½-20 Nut, Nylock ½-20 82-6
½-20 Nut, Nylock ½-20 83-25
TPG-371887-S2 Nut, Nylock Jam 1" - Tail Shaft 83-7
1-8 Nut, Nylon Insert Lock 1-8 36-10
MT-4-1247-31 Nut, Pinon 38-1
TPG-386034-S100 Nut, Slotted 9/16-18 82-18
TPG-386034-S100 Nut, Slotted 9/16-18 83-35
4-4-32 CD387
Orig
Chapter 4

5/16-18 Nut, Top Lock Hex 5/16-18 4-37
10-32 Nut, Top Lock Hex #10-32 16-19
10-32 Nut, Top Lock Hex #10-32 27-2
¼-20 Nut, Top Lock Hex ¼-20 11-22
¼-20 Nut, Top Lock Hex ¼-20 18-10
¼-20 Nut, Top Lock Hex ¼-20 21-17
¼-20 Nut, Top Lock Hex ¼-20 30-19
¼-20 Nut, Top Lock Hex ¼-20 31-19
¼-20 Nut, Top Lock Hex ¼-20 67-50
¼-20 Nut, Top Lock Hex ¼-20 68-41
¼-20 Nut, Top Lock Hex ¼-20 80-14
TM1-ND-8090 Nut, Top Lock Hex ½-13 33-5
½-13 Nut, Top Lock Hex ½-13 36-21
½-13 Nut, Top Lock Hex ½-13 47-17
½-13 Nut, Top Lock Hex ½-13 48-14
½-13 Nut, Top Lock Hex ½-13 83-13
CD387 4-4-33
Orig
Chapter 4

MR-1187 Nut, Top Lock Hex ¾-10 36-5
¾-10 Nut, Top Lock Hex ¾-10 1-8
¾-16 Nut, Top Lock Hex ¾-16 33-22
¾-16 Nut, Top Lock Hex ¾-16 33-33
3/8-16 Nut, Top Lock Hex 3/8-16 4-27
3/8-16 Nut, Top Lock Hex 3/8-16 5-6
3/8-16 Nut, Top Lock Hex 3/8-16 16-7
3/8-16 Nut, Top Lock Hex 3/8-16 20-6
3/8-16 Nut, Top Lock Hex 3/8-16 29-11
3/8-16 Nut, Top Lock Hex 3/8-16 30-58
3/8-16 Nut, Top Lock Hex 3/8-16 31-59
3/8-16 Nut, Top Lock Hex 3/8-16 36-26
3/8-16 Nut, Top Lock Hex 3/8-16 47-25
3/8-16 Nut, Top Lock Hex 3/8-16 48-22
3/8-16 Nut, Top Lock Hex 3/8-16 69-8
3/8-16 Nut, Top Lock Hex 3/8-16 69-17
3/8-16 Nut, Top Lock Hex 3/8-16 69-28
3/8-16 Nut, Top Lock Hex 3/8-16 71-8
3/8-16 Nut, Top Lock Hex 3/8-16 96-6
3/8-24 Nut, Top Lock Hex 3/8-24 75-14
3/8-24 Nut, Top Lock Hex 3/8-24 81-20
3/8-24 Nut, Top Lock Hex 3/8-24 84-7
5/16-18 Nut, Top Lock Hex 5/16-18 67-34
5/16-18 Nut, Top Lock Hex 5/16-18 67-41
5/16-18 Nut, Top Lock Hex 5/16-18 68-36
5/16-18 Nut, Top Lock Hex 5/16-18 81-18
5/16-18 Nut, Top Lock Hex 5/16-18 4-41
5/16-18 Nut, Top Lock Hex 5/16-18 4-47
5/8-11 Nut, Top Lock Hex 5/8-11 32-15
7/16-14 Nut, Top Lock Hex 7/16-14 47-32
7/16-14 Nut, Top Lock Hex 7/16-14 48-24
7/16-14 Nut, Top Lock Hex 7/16-14 90-4
7/16-14 Nut, Top Lock Hex 7/16-14 91-5
MR-1189 Nut, U ¼-20 67-46
MR-1189 Nut, U ¼-20 68-39
440E-46009 Nut, Wheel, Hex, ½-20 42-6
4-4-34 CD387
Orig
Chapter 4

¼-20 Nut-U ¼-20 UNC 2-13
¼-20 Nut-U ¼-20 UNC 3-13
------ O-Ring 35-3
TP-10506 O-Ring 55-4
TP-10460 O-Ring Seal 57-70
MT-4-1247-48 O-Ring, Bushing (EPDM) 40-18
ENG-MR24-DEUTZ-23 O-Ring, Excess Fuel Solenoid 50-76
TM1-ND-8104 O-Ring, Fuel Shut Off Solenoid 50-67
ENG-MA-36-5 O-Ring, Oil Filler Plug 62-9
ENG-MA-36-1 O-Ring, Oil Gauge Guide 61-13
MT-4-1247-47 O-Ring, Planetary Cover 39-8
MT-4-1247-49 O-Ring, Service Brake Piston (EPDM) 40-17
ENG-MA-36-4 O-Ring, Water Pump 61-29
------ O-Seal 50-37
EH-3202 Pad Heater, 250 Watts, 220V - Opt 61-36
TM1-ND-8076 Pad Set, Front Caliper 35-6
EH-2802 Pad, Heater, 250 Watts, 120 Volts - Opt 61-36
TP-10459 Pan, Oil 50-28
TP-10459 Pan, Oil 56-2
TP-10459 Pan, Oil 57-69
E5TZ-7A194D Pan, Oil C6 Transmission 77-3
MR-1300-10 Pan, Transmission 87-3
MR-1273 Panel Assembly, VEC 93-
MR-1320 Panel, Fuse/Relay Assy 94-11
MR-1089-2 Panel, Heater Junction Box 100-3
MR-1103 Panel, Rear Axle Access 20-11
MR-1103 Panel, Rear Axle Access - WLDM 91-11
MR-1159 Panel, VEC Mounting 93-1
CD387 4-4-35
Orig
Chapter 4

G1-30101-6 Pedal, Accelerator 44-1
MR-1180 Pedal, Brake (Weldment) 28-1
MT-4-1247-20 Pin Actuator/Actuator Shaft 40-23
MT-4-1247-22 Pin Of Planetary Satellite 39-18
MT-4-1247-16 Pin, Blocker 38-24
MT-4-1247-21 Pin, Brake 40-28
MR-1262 Pin, Check Strap 8-21
MR-1196 Pin, Clevis - Brake Pedal 28-12
3/8 x 1¼ Pin, Clevis Ø 3/8 x 1¼" Long 82-20
5/16 x 1 Pin, Clevis Ø5/16 x 1"Long 89-24
3/8 x 1 1/8 Pin, Clevis, Ø3/8 x 1 1/8" Long 89-18
3/16 x 2 Pin, Cotter Ø 3/16 x 2" Long 34-16
3/32 x 1½ Pin, Cotter, Ø3/32 x 1½"Long 89-23
1/8 x 1½ Pin, Cotter, 1/8 x 1½ 89-17
MT-4-1247-18 Pin, Differential, Long 38-23
MT-4-1247-19 Pin, Differential, Short 38-22
T6-1208-105 Pin, Dowel 76-5
MT-4-1247-86 Pin, Elastic 38-25
T6-3001-60007 Pin, King 33-12
MT-1-2061 Pin, Wiper Pivot Shaft 14-33
4-4-36 CD387
Orig
Chapter 4

MR-1051 Pipe Weldment, Air Cleaner to Intake 65-7
MR-1024 Pipe, Air Cleaner to Turbo 66-7
MR-1069 Pipe, Fresh Air Heater - Opt 22-5
MR-1041 Pipe, Header V3600T 71-1
MR-1238 Pipe, Header w/Flex 69-2
MR-1052 Pipe, Header, Non-Turbo 70-4
TPG-D3TA-2A701AA Pipe, Parking Brake 83-26
MR-1053 Pipe, Tail, Non-Turbo 70-7
ENG-MA-36-59 Pipe, Water Return 61-31
MT-4-1247-15 Piston, Service Brake 40-15
------ Pivot 81-21
MT-4-1247-12 Planetary 22T 39-20
MR-1160 Plate, Alarm Mounting 27-1
MR-1271-19 Plate, Battery Support (Part of Frame) 22-15
T6-8005-135 Plate, Brake Shoes 83-10
MR-1280 Plate, Data - Cab Assembly- Opt 6-2
ENG-MR10-36T-2 Plate, Fuel Pump Block Off 62-37
MR-1075 Plate, Light Socket Cover 16-33
MT-1-1215 Plate, Rear Axle Mount 36-2
MR-1284 Plate, Rear Lifting Ring - Opt 1-18
T6-3002-202 Plate, Spring Clamp - Brierton 32-2
CMR-1020 Plate, Striker Access 8-15
CD387 4-4-37
Orig
Chapter 4
CMR-1023 Plate, Striker Bolt Mount 8-11

CMR-1024 Plate, Striker Mount 8-10
MR-1317 Plate, TEC Mounting 94-1
MT-4-1247-63 Plug 40-1
660-2-3463 Plug, 110V Hubbell 100-11
660-2-3464 Plug, 220V Hubbell 100-11
T6-4900-152 Plug, Alternator, -D25 61-37
MT-4-1247-65 Plug, Breather M24-1.5 - Drive Axle 37-5
ENG-MA-36-10 Plug, Drain 62-47
G1-30148-7 Plug, Engine Diagnostic (Comes w/Engine) 92-10
TP-10457 Plug, Engine Oil Drain 57-66
ENG-MR24-DEUTZ-12 Plug, Glow 50-43
TP-10407 Plug, Glow 57-29
ENG-MA-36-13 Plug, Glow 62-4
MR-1134 Plug, Hydraulic Pump 30-64
MT-4-1248-12 Plug, Inspection 41-6
MT-4-1248-11 Plug, M18-1.5 - Drop Box 37-1
MT-4-1247-62 Plug, M24-1.5 - Rear Axle 37-3
MT-4-1247-105 Plug, Magnetic M24-1.5 - Drive Axle 37-6
MT-4-1248-13 Plug, Oil Drain Magnetic 41-3
------ Plug, Oil Filler 62-8
MT-4-1248-11 Plug, Oil Filling 41-8
TPG-C8HZ-7A002A Plug, Speedometer Gear Input 83-27
ENG-MR24-DEUTZ-7 Plug, Thermostat 50-34
TP-10451 Plug, Thermostat 57-52
MT-4-1248-14 Plug, Vent 41-7
660-2-1632B Post, Light, 42" (Opt.) 1-11
ENG-MA-36-36 Pulley Fan Drive 61-27
------ Pulley Tensioner 55-7
ENG-MR-10-36T-1 Pulley, Fan (MR10, w/Kubota V3600-T) 61-27
TP-10487 Pulley, V-Groove 54-3
ENG-MA-36-58 Pump Assembly, Water 61-28
4-4-38 CD387
Orig
Chapter 4
TP-10496 Pump, Engine Oil 54-17

TP-10456 Pump, Fuel 67-26
T6-4400-137 Pump, Fuel 68-11
ENG-MR24-DEUTZ-15 Pump, Fuel Injection, Class A 50-53
TP-10423 Pump, Fuel Injection, Class A 57-45
ENG-MR24-DEUTZ-16 Pump, Fuel Injection, Class B 50-53
TP-10424 Pump, Fuel Injection, Class B 57-45
ENG-MR24-DEUTZ-17 Pump, Fuel Injection, Class C 50-53
TP-10425 Pump, Fuel Injection, Class C 57-45
ENG-MR24-DEUTZ-18 Pump, Fuel Injection, Class D 50-53
TP-10426 Pump, Fuel Injection, Class D 57-45
MR-1131 Pump, Steering W/Relief 30-37
MT-1-1330 Pump, Steering, w/Relief 31-38
MR-1063 Radiator, Aluminum 74-8
TPG-C20Z-6A366A Reinforcement, Plate-Flywheel 76-8
660-4-3085-1 Relay (Dash Lights, Headlights, Shifter Light, Brake Light) 93-11
660-4-3085-1 Relay (Hitch Light) 93-9
660-4-3085-1 Relay (Low Oil Warning Light) 93-8
660-4-3085-1 Relay (Master Charge & Wait Light) 93-7
660-4-3085-1 Relay (Spare) 93-6
G8JN-1C6T-F-R-DC12 Relay (Starter Lockout) (Part of HRN-MR-0007) 93-27
TP-10508 Relay (Starter Lockout) (Part of HRN-MR-0007) 94-38
660-4-3085-1 Relay (Tractor Horn) 93-10
G8JN-1C6T-F-R-DC12 Relay (Trans. Lockout) (Part of HRN-MR-0007) 93-30
TP-10508 Relay (Trans. Lockout) (Part of HRN-MR-0007) 94-37
TM1-ND-5011 Relay, Glow Plug 93-33
ENG-MR34-DEUTZ-6 Relay, Glow Plug, TD2011 93-33
TP-10514 Relay, Glow Plug, Timer, TD2011, Tier 4i 94-29
RM4291 Relay, K5,12 Volt, Engine ECM 94-22
RM4291 Relay, K6, 12 Volt, Horn Power 94-19
RM4291 Relay, K7,12 Volt, Hitch Light 94-21
RM4291 Relay, K8, 12 Volt, Dash, Head & Tail Light, Shifter 94-20
660-2-3084 Relay, Starter 93-22
660-2-3084 Relay, Starter 94-2
MR-1100 Relief, Strain - ½ NPT, 0.17-0.45 Cable 18-3
660-ND-2215 Relief, Strain 3/8 x ½ NPT 100-9
CD387 4-4-39
Orig
Chapter 4
T6-1008-111-9 Retainer, Throttle Pressure 78-2

D5TZ-7070A Ring, Bearing Retainer 83-19
MT-4-1247-87 Ring, Guide, Service Brake Piston (PTEE) 40-16
MR-1105 Ring, Lashing 1-7
MR-1283 Ring, Lifting - Opt 1-17
TM1-1-9693-7 Ring, Sealing 57-75
BLE-1-1502 Ring, Sealing ½ NPT 100-10
MT-4-1247-55 Ring, Snap 39-6
MT-4-1247-52 Ring, Snap 39-14
MT-4-1247-50 Ring, Snap 39-16
MT-4-1247-51 Ring, Snap 39-21
MT-4-1247-53 Ring, Snap 40-12
MT-4-1247-54 Ring, Snap For Pin/Actuator Shaft 40-24
TP-10485 Ring, Supporting 59-23
CMR-1029-15 Rivet, Zipriv, 0.125 10-16
CMR-1029-15 Rivet, Zipriv, 0.125 12-16
3/8-24 x 2½ Rod, All-Threaded Ø 3/8-24 x 2½" Long 82-11
CMR-1025 Rod, Driver Door Latch to Ext. Handle 9-16
CMR-1026 Rod, Driver Door Latch to Int. Handle 9-25
T6-1008-111-5 Rod, Gear Selector Valve 78-1
MR-1251 Rod, Hood Prop 4-50
CMR-1025 Rod, Pass. Door Latch to Ext. Handle 11-18
CMR-1026 Rod, Pass. Door Latch to Int. Handle 11-16
MR-1128-11 Rotor, 10.75"Dia. 34-3
------ Rubber 51-5
4-4-40 CD387
Orig
Chapter 4
TP-10472 Rubber 58-5

T6-1008-111-10 Screen, Main Control Pump Inlet 78-3
D5AZ-7A098B Screen, Transmission Filter 78-7
------ Screw 14-8
------ Screw 14-12
6-32 Screw Ø #6-32 27-9
¼-20 x ¾ Screw Ø ¼-20 x ¾" Long 44-2
T6-3001-60006 Screw, Button Head Socket Cap Ø #10-24 x 5/8" Long 33-17
TM1-ND-8079-9 Screw, Cup Point Socket Set Ø 3/8-24 x ¾" Long 33-3
5/16-18 x 17/32 Screw, Flange Head, 5/16-18x17/32 Long (Part of Transmission) 45-30
5/16-18 x 17/32 Screw, Flange, 5/16-18x17/32"Long (Part of Transmission) 46-21
TM1-1-9693-6 Screw, Hollow 57-74
8-32 x ¼ Screw, Oval Head Ø #8-32 x ¼" Long 17-6
10-32 x ¾ Screw, Phillips Pan Head Ø #10-32 x ¾" Long 4-8
8-32 x ¾ Screw, Phillips Pan Head Ø #8-32 UNF x ¾" Long 17-5
¼-20 x ½ Screw, Phillips Pan Head Ø ¼-20 x ½" Long 93-21
CD387 4-4-41
Orig
Chapter 4

#10-32 x ½ Screw, Phillips Pan Head Ø 10-32 x ½" Long 7-3
M4-0.7 x 35 Screw, Phillips Pan Head Ø M4-0.7 x 35mm Long 18-4
T6-1008-111-7 Screw, Reverse Band Adjusting 79-1
5/16 x 1 Screw, Self Tapping Ø 5/16 x 1" Long 13-5
MR-1046 Seal, Bulb, Firewall 6-3
MT-4-1247-44 Seal, Cassette Ring On Planetary 39-11
TP-10458 Seal, Engine Oil Drain 57-67
------ Seal, Engine Oil Drain Valve 50-71
TP-10458 Seal, Engine Oil Drain Valve 56-5
ENG-MA-36-19 Seal, Heat 62-25
TM1-ND-9002 Seal, Inner 34-12
CMR-1029-12 Seal, Max 10-12
CMR-1029-12 Seal, Max 12-12
ENG-MR24-DEUTZ-6 Seal, O-Ring 50-33
T6-1008-111-3 Seal, O-Ring 9/19 x .103" 75-17
4-4-42 CD387
Orig
Chapter 4

MT-4-1247-45 Seal, Ring On Pinion, Inside 38-3
MT-4-1247-43 Seal, Ring On Pinion, Outer 38-2
D0TZ-7A011A Seal, Transmission 83-17
660-2-3290 Seat, Sears, Vinyl Coldform with Logo 20-1
T6-9011-227 Seat, Vinyl Grammer GS12 - Opt 20-1
ENG-MR24-DEUTZ-21 Sender, Oil Pressure 50-73
TP-10455 Sender, Oil Pressure 57-61
MR-1047 Sender, Oil Pressure 61-18
ENG-MR24-DEUTZ-10 Sender, Temperature 50-39
TP-10412 Sender, Temperature 57-34
MR-1038 Sender, Water Temperature 61-11
TP-10102 Sensor, Speed 57-60
TP-10453 Sensor, Temperature, Glow Plug 57-56
MR-1300-7 Sensor, Transm. Output Shaft Speed 86-2
MR-1300-8 Sensor, Transm. Range 86-3
MR-1300-6 Sensor, Transm.Turbine Shaft Speed 86-4
MR-1129 Shackle 32-9
MT-4-1247-17 Shaft, Actuator 40-22
TPG-D6TZ-2A703A Shield, Park Brake 83-11
MR-1124 Shifter 80-6
T6-1002-151 Shifter, Morse 88-2
MT-4-1247-93 Shim 38-5
MT-4-1247-94 Shim 38-6
MT-4-1247-95 Shim 38-7
MT-4-1247-88 Shim 38-10
MT-4-1247-90 Shim 38-13
CD387 4-4-43
Orig
Chapter 4
MT-4-1247-91 Shim 38-14

MT-4-1247-92 Shim 38-15
------ Shim, Clamp, Cable 81-11
TM1-ND-8093 Shim, King Pin 33-14
MT-2-1056 Shock Absorber, Rear 36-14
T6-8005-143 Shoes, Park Brake 83-14
MR-1023 Shroud, Fan 74-15
------ Sleeve, Retainer Bolt 35-4
MR-1067 Slide, Modulator MR-36 46-14
MR-1198 Socket, Glow Plug Relay 93-34
MR-1281 Socket, Ordinance Trailer - Opt. 16-28
ENG-MR24-DEUTZ-22 Solenoid, Excess Fuel 50-75
ENG-MR24-DEUTZ-20 Solenoid, Fuel Shut Off 50-66
TP-10461 Solenoid, Fuel Shut Off 57-71
ENG-MA-36-42 Solenoid, Stop (Fuel) 62-31
MT-4-1247-23 Spacer 40-10
TPG-385555-S2 Spacer 82-15
TPG-385555-S2 Spacer 83-33
MT-4-1247-25 Spacer Foe Service Brake 40-21
MR-1066 Spacer, Fan 62-26
MR-1168 Spacer, Fuel Filter 67-31
MT-4-1247-24 Spacer, Preload 38-4
MT-4-1247-8 Spacer, Side Gear 38-26
TPG-D1TZ-17285A Spacer, Speedo, Gear 83-20
TM1-4-9858 Spacer, Threaded, Transmission Cooler (Part Of Frame) 73-4
------ Spindle 34-18
------ Spindle 34-20
T6-8005-149 Spring, Brake Shoes, Bottom 83-16
T6-8005-147 Spring, Brake Shoes, Top 83-15
MT-1-1273 Spring, Gas Hood 4-33
MR-1130 Spring, Leaf - Heavy Duty 32-6
4-4-44 CD387
Orig
Chapter 4
MT-4-1247-57 Spring, Reaction 40-8

MT-1-1065 Spring, Rear Coil 36-13
TM1-ND-8103 Spring, Tension 50-68
ENG-MR24-DEUTZ-5 Spring, Thermostat Compression 50-32
MR-1094 Spring, Throttle Return 45-25
T6-4900-211 Spring, Throttle, Return 28-3
TP-10495 Sprocket, Camshaft 54-16
TP-10497 Sprocket, Camshaft Drive 54-18
TP-10491 Sprocket, Hydraulic Pump Drive 54-9
ENG-MA-36-60 Starter Assembly 61-10
T-G1 Sticker, Deisel Only 1-21
CMR-1013 Strap, Check 8-19
CMA-504 Strip, Seal - Door 11-2
CMA-504 Strip, Seal (30.5' Long) 6-4
CMA-504 Strip, Seal, Door 9-2
TPG-385554-S2 Stud Ø 9/16-18 x 2.28" Long 82-16
TPG-385554-S2 Stud Ø 9/16-18 x 2.28" Long 83-29
A9008 Stud, 10mm Ball 4-53
MT-1-1349 Stud, 13mm Ball (0.63" Long Threaded) 4-40
MT-1-1277 Stud, 13mm Ball (1" Long Threaded) 4-35
JB3816-2 Stud, Junction Block 93-39
T6-3001-60020 Stud, Wheel 34-4
MT-4-1247-59 Stud, Wheel 39-23
MT-4-1247-32 Support, wheel Spindle/Hub 39-12
T6-7016-123 Switch, Battery Disconnect - CE Opt 99-18
MR-1152 Switch, 2 Position, 1 Pole, Toggle, Head Light 24-3
MR-1152 Switch, 2 Position, 1 Pole, Toggle, Hitch Light 24-4
CD387 4-4-45
Orig
Chapter 4

MR-1153 Switch, 3 Position Toggle, Heater 24-5
T6-7016-123 Switch, Battery Disconnect - CE Opt. 26-5
MR-1252 Switch, Front Windshield Wiper 14-9
MR-1122 Switch, Neutral Safety 81-2
MR-1252 Switch, Rear Windshield Wiper 14-5
T6-1004-119 Swivel, Shift Cable 88-12
T6-6011-111 Tee, Brake Line 36-28
T6-6011-111 Tee, Brake Line 95-6
T6-6011-111 Tee, Brake Line 95-31
------ Terminal, Nylon, Female Blade, Guick Slide, 14-16GA 29-22
ENG-MA-36-48 Thermostat Assembly 61-32
ENG-MR24-DEUTZ-4 Thermostat, Engine 50-31
TP-10450 Thermostat, Engine 57-51
MR-1324-1 Tire, Front 185-14 10pr Tug Tuff 42-2
MR-1092-1 Tire, Front, Solid 42-2
T6-2400-170 Tire, Rear 8.75 x 16.5 43-4
MR-1093-1 Tire, Rear, Solid - Opt. 43-5
4-4-46 CD387
Orig
Chapter 4
MR-1092 Tire/Wheel Assembly - Front, Solid - Opt. 42-1

MR-1324 Tire/Wheel Assembly - Front, Tug Tuff 42-1
MR-1106 Tire/Wheel Assembly, Rear - MR8 43-2
MT-1-2157 Tire/Wheel Assembly, Rear Dual 43-1
MR-1093 Tire/Wheel Assembly, Rear Solid - Opt. 43-3
T6-1008-111 Transmission, C-6, 3-Speed 47-26
MR-1300 Transmission,4R75 W/Park Brake 85-1
------ Trim Lock 51-6
------ Trim Lock 58-6
MR-1128-6 Tube Assembly, Tie Rod 33-19
ENG-MA-36-26 Tube, Breather 62-2
T6-4700-469 Tube, Clear, Overflow Bottle 74-25
T6-4700-469 Tube, Clear, Overflow Bottle (to Neck) 74-20
ENG-MR24-DEUTZ-8 Tube, Dip Stick 50-35
TPG-EOTZ-7A228A Tube, Oil Level 75-15
MR-1237 Tube, Transition (Filter to Turbo) 64-15
TPG-EOTZ-7A228-A Tube, Transmission Dip Stick C6 85-16
T6-4700-469 Tubing, Clear 5/16" OD 62-16
------ Tubing, Heatshrink 29-23
ENG-MR10-36T-5 Turbocharger Assembly (MR10) 61-8
------ U-Bolt #10-32 81-12
T6-3002-201 U-Bolt, Brierton Axle 32-3
------ U-Joint 90-2
T6-1008-123 Valve Body Assembly, 3 Speed 78-4
TM1-ND-5253 Valve, Ball 63-7
CD387 4-4-47
Orig
Chapter 4
------ Valve, Bleeder 62-10

MT-4-1247-27 Valve, Bleeder - Drive Axle 37-7
T6-8013-165 Valve, Bleeder - Front Caliper 35-7
ENG-MA-36-25 Valve, Breather 61-2
MR-1102-3 Valve, Front Tire 42-4
MT-1-2157-1 Valve, Tire - Rear Dual 43-9
660-4-3085 Vehicle Electric Center (VEC) 93-5
1028 Warning, Avoid Injury 3-30
------ Washer 14-20
------ Washer 14-31
------ Washer 14-38
------ Washer 14-41
------ Washer 15-12
------ Washer 15-27
------ Washer 23-16
------ Washer 25-16
------ Washer 23-5
------ Washer 23-9
------ Washer 25-5
------ Washer 25-9
------ Washer, Bushing 36-17
MT-4-1247-82 Washer, Conic 38-18
MT-4-1247-14 Washer, Conical 40-7
MT-4-1247-85 Washer, Copper 40-2
3/8 x 1½ Washer, Fender 3/8 x 1½" 82-8
3/8 x 2 Washer, Fender 3/8 x 2" 82-9
4-4-48 CD387
Orig
Chapter 4

660-4-3625 Washer, Flat (C6 to 2011 Adapter) 75-5
M10 Washer, Flat (C6 to 2011 Adapter) 84-5
¼-20 Washer, Flat ¼" ID 4-5
½ Washer, Flat ¼" ID 28-5
CD387 4-4-49
Orig
Chapter 4

¾ Washer, Flat ¾" ID 1-9
MR-1188 Washer, Flat ¾" ID 36-4
1 Washer, Flat 1" ID 36-9
4-4-50 CD387
Orig
Chapter 4

5/16 Washer, Flat 5/16" ID 4-38
5/16 Washer, Flat 5/16" ID 4-42
5/16 Washer, Flat 5/16" ID 4-46
5/16 Washer, Flat 5/16" ID 36-27
5/16 Washer, Flat 5/16" ID 64-12
5/16 Washer, Flat 5/16" ID 67-32
5/16 Washer, Flat 5/16" ID 67-39
5/16 Washer, Flat 5/16" ID 68-34
5/16 Washer, Flat 5/16" ID 72-22
5/16 Washer, Flat 5/16" ID 72-26
5/16 Washer, Flat 5/16" ID 73-22
5/16 Washer, Flat 5/16" ID 74-10
5/16 Washer, Flat 5/16" ID 75-13
5/16 Washer, Flat 5/16" ID 97-9
5/16 Washer, Flat 5/16" ID 98-10
5/16 Washer, Flat 5/16" ID 99-9
7/16 Washer, Flat 7/16" ID 47-31
7/16 Washer, Flat 7/16" ID 48-23
7/16 Washer, Flat 7/16" ID 75-20
9/16 Washer, Flat 9/16" ID 82-17
9/16 Washer, Flat 9/16" ID 83-34
CD387 4-4-51
Orig
Chapter 4

TP-10447 Washer, Flat M8 57-48
¼ Washer, Flat, ¼"ID 91-12
¼ Washer, Flat, ¼ID 89-4
½ Washer, Flat, ½"ID 49-3
3/8 Washer, Flat, 3/8"ID 89-12
½ Washer, Lock - External Tooth ½" ID 83-24
5/16 Washer, Lock - External Tooth 5/16" ID 16-9
#10-32 Washer, Lock #10-32 7-4
4-4-52 CD387
Orig
Chapter 4

¼ Washer, Lock ¼" ID - Opt 16-30
¾ Washer, Lock ¾" ID - Opt 1-5
5/16 Washer, Lock 5/16" ID 83-6
5/16 Washer, Lock 5/16" ID 90-7
7/16 Washer, Lock 7/16" ID 75-21
CD387 4-4-53
Orig
Chapter 4

10mm Washer, Lock M10 62-20
¼ Washer, Lock, ¼"ID 91-13
½ Washer, Lock, ½ 85-3
MT-4-1247-9 Washer, Satellite Brass 38-20
MT-4-1248-17 Washer, Sealing 18 x 24 x 1.5mm 37-2
MT-4-1247-106 Washer, Sealing 24 x 30 x 1mm 37-4
ENG-MR24-DEUTZ-13 Washer, Sealing, Glow Plug 50-44
MR-1310 Washer, Shift Plate 4R75 85-5
MR-1310 Washer, Shifter Plate, 4R75, ¼ - ½ 88-15
4-4-54 CD387
Orig
Chapter 4

TM1-1-5005 Washer, Stop Engine Mount 49-9
T6-3001-60028 Washer, Tongue Spindle 34-14
660-4-3625 Washer, Trans. Adapter 76-4
12902092 Weather Stripping (Trim-Lock, 90°) 4-22
MT-1-1048 Wheel, Dual 6.75 x 16.5 43-6
MR-1092-2 Wheel, Front - Solid Tire 42-3
MR-1102-2 Wheel, Front 185R14LT 42-3
MR-1106-1 Wheel, MR8, Rear 43-7
MR-1093-2 Wheel, Rear, Solid - Opt. 43-8
CMR-1029 Window, Driver Side Door 9-3
CMR-1030 Window, Passenger Side Door 11-3
CMR-1031 Windows, Rear Side 13-1
CMR-1027 Windshield 13-6
CMR-1028 Windshield, Rear 13-3
HRN-MR34-111-3 Wire #8, Part of Harness 59-24
------ Wire 6B 53-11
------ Wire 6B (part of Engine Harness) 60-11
------ Wire, 10 Gauge, Ground 61-20
------ Wire, 10 Gauge, Starter (to Stud) 61-23
RM4003 Wire, 6 Gauge (Glow Plug to Glow Plug Switch) 62-3
MR-1236 Wire, Ground - Turn Signal Switch 29-6
------ Wire, Ground Black Dasher G3 27-8
------ Wire, Ground Black Flasher 27-7
------ Wire, Stranded 16 AWG 29-24
CD387 4-4-55
Orig
Chapter 4
MR-1127 Yoke 28-8

MD-CB1-129 Yoke 82-10
MR-1127 Yoke 96-2
MR-1308 Yoke, Park Brake Drum 89-25
MR-1307 Yoke, Park Brake Handle, 4R75 89-19
4-4-56 CD387
Orig
Chapter 5
TABLE OF CONTENTS
SECTION 1: PERIODIC MAINTENANCE CHECKLIST ............................................................. 5-1-1
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS ................................................ 5-2-1
A. Description ............................................................................................................ 5-2-1
CD369 5-TOC-i
Orig
Chapter 5
5-TOC-ii CD369
Orig
Chapter 5
SECTION 1: PERIODIC MAINTENANCE CHECKLIST
TUG Model MR Tow Tractor
Serial Number: Date Manufactured:

Date: ID Number:
Special 6 Every
Service Requirement in Hours Daily Yearly
200 Hr Month 2 Years
Check for Working Controls
Check Fuel Level
Check Engine Oil Level
Inspect Unit/Surrounding Area for Fluid Leaks
Check Seat Belt Operation
Change Engine Oil and Oil Filter Element
Change Rear Drive Axle Oil
Change Air Filter Element
Check Tire Pressure and Condition
Check Free Play of Front Wheel Bearings
Inspect Brake System
Change Fuel Filter/Water Separator Element
Lubricate Chassis
Lubricate Driveshaft U-Joints
Check Emergency Stop Switch
CD387 5-1-1
Orig
Chapter 5
5-1-2 CD387
Orig
Chapter 5
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS
A. DESCRIPTION
The following pages/booklets contain additional information relevant to the operation and service of the
MR: Mid-Range Tow Tractor.
CD387 5-2-1
Orig
Chapter 5
5-2-2 CD387
Orig
OBJ_DOKU-15294-001.fm Seite 1 Donnerstag, 28. Februar 2008 9:58 09
Operation Manual
D/TD/TCD 2011
Notes
Notes gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
z This engine is defined exclusively for purpose
engine and guarantee perfect operation.
according to the scope of delivery and built by
the equipment manufacturer (use for the intend- Non-compliance results in the expiry of the war-
ed purpose). Any other use above and beyond ranty!
this will be considered as misuse. The manufac- Maintenance/cleaning work on the engine may
turer will not accept any liability for damages re- only be carried out when the engine is not run-
sulting from this. The user bears the sole risk. ning and has cooled down.
z Use for the intended purpose also includes ob- When doing this, make sure that the electrical
servance of the operating, maintenance and re- system is switched off (remove ignition key).
pair conditions specified by the manufacturer. The specifications for accident prevention with
The engine should only be operated, serviced electrical systems (e.g. VDE-0100/-0101/-0104/-
and repaired by personnel trained in its use and 0105 Electrical protective measures against dan-
the hazards involved. gerous contact voltages) must be observed.
The pertinent rules for the prevention of acci- Cover all electrical components tightly when
dents and other generally recognised safety and cleaning with liquids.
industrial medicine rules must be observed. z Do not work on the fuel system while the engine
z When the engine is running there is a danger of is running - Danger to life!
injury caused by: Wait for the pressure to drop after the engine has
– rotating and hot components come to a standstill (in engines with DEUTZ
– on motors with external ignition (high electri- Common Rail about 5 minutes, otherwise
cal voltage). Contact must be avoided! 1 minute) because the system is under high
z Unauthorised engine modifications will invalidate pressure - Danger to life!
any liability claims against the manufacturer for During the first trial run do not stand in the dan-
resultant damage. ger area of the engine.
z Equally, manipulations to the injection and con- Danger due to high pressure in case of leaks -
trol system can affect the engine's performance Danger to life!
and the exhaust characteristics. Adherence to – In case of leaks immediately contact work-
legislation on pollution can no longer be guaran- shop.
teed under such conditions. – When working on the fuel system, make sure
z Do not change the cooling air feed area to the that the engine is not started inadvertently
blower of fan. An unobstructed cooling air supply during repairs - Danger to life!
must be guaranteed.
The manufacturer will accept no liability for dam-
age resulting from this.
z When carrying out maintenance work on the en-
2 © 2008
Foreword
Dear customer, Engine serial number
Congratulations on the purchase of your DEUTZ en- Please enter the engine serial number here. This will
gine. simplify the handling of customer service, repair and
DEUTZ air/liquid-cooled engines are developed for a spare parts queries.
broad spectrum of applications. Consequently, a
wide range of variants is offered to meet the require-
ments of specific cases.
The engine is equipped accordingly for the particular Notes
installation situation, i.e. not all the components de- We reserve the right to make technical changes to
scribed in the operating manual are installed in your the descriptions and data in this operating manual in
engine. the interest of further development of the engines.
We have endeavoured to highlight any differences This document may only be reprinted and repro-
so that you will be able to locate the operating and duced, even in part, with our express permission.
maintenance instructions applicable to your engine
more quickly and easily.
Please make sure that this operating manual is avail-
able to everyone involved in the operation, mainte-
nance and repair of the engine and that they have
understood the contents.
If you have any queries, please contact us, we'll be
happy to advise you.
Sincerely,
DEUTZ AG
© 2008 3
Contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Suction system . . . . . . . . . . . . . . . . 47
Foreword. . . . . . . . . . . . . . . . . . . . . 3 Belt drives . . . . . . . . . . . . . . . . . . 49
1 General. . . . . . . . . . . . . . . . . . . . 5 Setting work . . . . . . . . . . . . . . . . . 51
2 Engine description . . . . . . . . . . . . . 7 Electrical system . . . . . . . . . . . . . . . 53
Type . . . . . . . . . . . . . . . . . . . . . 7 7 Faults. . . . . . . . . . . . . . . . . . . . . 55
Engine illustrations . . . . . . . . . . . . . . 9 Fault table . . . . . . . . . . . . . . . . . . 55
Lubricating oil schematic . . . . . . . . . . . 13 Engine management . . . . . . . . . . . . . 60
Fuel schematic . . . . . . . . . . . . . . . . 18 8 Transport and storage . . . . . . . . . . . 62
Coolant schematic . . . . . . . . . . . . . . 19 Transport . . . . . . . . . . . . . . . . . . . 62
Exhaust gas recirculation . . . . . . . . . . . 21 Protecting the engine against corrosion . . . 63
Electrics/Electronics . . . . . . . . . . . . . 23 9 Technical data . . . . . . . . . . . . . . . . 65
3 Operation . . . . . . . . . . . . . . . . . . 24 Engine and setting data . . . . . . . . . . . 65
Ambient conditions . . . . . . . . . . . . . . 24 Tools . . . . . . . . . . . . . . . . . . . . . 70
Initial commissioning . . . . . . . . . . . . . 25
Start procedure . . . . . . . . . . . . . . . . 27
Operation monitoring . . . . . . . . . . . . . 28
Stop procedure . . . . . . . . . . . . . . . . 30
4 Operating media. . . . . . . . . . . . . . . 31
Lubricating oil . . . . . . . . . . . . . . . . . 31
Fuel . . . . . . . . . . . . . . . . . . . . . . 33
Coolant . . . . . . . . . . . . . . . . . . . . 34
5 Maintenance . . . . . . . . . . . . . . . . . 35
Maintenance schedule . . . . . . . . . . . . 35
6 Care and maintenance work . . . . . . . . 38
Lubricating oil system. . . . . . . . . . . . . 38
Fuel system. . . . . . . . . . . . . . . . . . 40
Cooling system . . . . . . . . . . . . . . . . 44
Engine cleaning. . . . . . . . . . . . . . . . 46
4 © 2008
General
DEUTZ diesel engines
DEUTZ diesel engines are the product of years of re-
velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
search and development. Profound know-how com-
cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
bined with high quality requirements are the
functioning and high reliability. tact to your nearest local service partner.
guarantee for the production of engines with a long
life, high reliability levels and low fuel consumption. DEUTZ Xchange components
Obviously the high requirements for the protection of
the environment are also met. DEUTZ replacement parts are a low-cost alternative.
Of course, the quality standards here are just as high California
Safety precautions when the engine is running as for new parts. DEUTZ replacement parts are Proposition 65 Warning
equal to the original DEUTZ parts in function and re- Diesel engines and some of its constituents are
Maintenance work or repairs may only be performed liability. known to the State of California to cause cancer,
on the shut-down engine. Make sure that the engine birth defects and other reproductive harm.
cannot be started inadvertently - Danger of acci- Asbestos
dent! Masthead
The gaskets used in this engine contain no asbestos.
After repair work: Check that all guards have been DEUTZ AG
Please use the appropriate original DEUTZ parts for
replaced and that all tools have been removed from maintenance and repair work. Ottostraße 1
the engine.
51149 Köln
Observe industrial safety regulations when running Service
Germany
the engine in an enclosed space or underground. We want to preserve the high performance of our en-
gines, and with it the confidence and satisfaction of Phone: +49 (0) 221-822-0
When working on the running engine, work clothing
must be close fitting. our customers. We are therefore represented world- Fax: +49 (0) 221-822-5850
wide by a network of service branches. www.deutz.com
Never fill the fuel tank while the engine is running.
The DEUTZ name does not merely stand for engines E-Mail: info@deutz.com
Service and Maintenance that are the products of extensive development
Service and maintenance are also decisive for work, DEUTZ also stands for complete service pack-
whether the engine satisfactorily meets the set de- ages that ensure optimum operation of our engines,
mands. Recommended service intervals must there- and for customer services operations that you can
fore be observed and service and maintenance work count on.
must be carried out conscientiously. Please contact your DEUTZ-partner in case of mal-
Special care should be taken under abnormally de- functions and sare parts inquiries. Our specially
manding operating conditions. trained personnel will ensure fast, professional re-
pairs using original DEUTZ spare parts in case of
Original DEUTZ parts damage.
Original DEUTZ parts are subject to the same strict The DEUTZ home page gives you a continuously up-
quality demands as the DEUTZ engines. Further de- to-date overview of the service partners in your vicin-
© 2008 5
General
1 Danger
This symbol is used for all safety instruc-

tions which, if not observed, present a di-
rect danger to life and limb for the person
involved. Observe these carefully. The at-
tention of operating personnel should be
drawn to these safety instructions. Further-
more, the legislation for "general regula-
tions for safety and the prevention of
accidents" must be observed.
Caution
This symbol indicates a danger to the part

and engine. The relevant instructions must
be observed, failure to do so can lead to de-
struction of the part and the engine.
Notes
This symbol accompanies notes of a gen-

eral kind.
6 © 2008
Type Engine description

Engine type designation
C
2
This manual covers the following engine types
A B
D 2011 L02 i D 2011 L02 o D 2011 L04 w
D 2011 L03 i D 2011 L03 o TD 2011 L04 w
D 2011 L04 i D 2011 L04 o TCD 2011 L04 w Mot.-Typ Mot.-Nr.
TD 2011 L04 i TD 2011 L04 o
TCD
T Exhaust gas turbocharger R
DEUTZ AG
C Charge air cooler MADE IN GERMANY
D Diesel
2011 Rating plate Location of the rating plate

2011 Series The type (A), engine number (B) and performance The rating plate (C) is fixed to the cylinder head cov-
data are stamped on the rating plate. er or the crankcase.
L02/L03/L04 The engine type and number must be stated when
L in series purchasing spare parts.
02 No. of cylinders
03 No. of cylinders
04 No. of cylinders
i/o/w
i oil-cooled (integrated cooler)
o oil-cooled
w water-cooled
© 2008 7
Engine description Type
2 left
D
XXXXXXX
right
1
Engine serial number Cylinder numbering Volume blocking

The engine number (D) is stamped onto the crank- Cylinder arrangement Unauthorised settings on the regulator will exclude
case (arrow) and onto the rating plate. The cylinders are counted consecutively starting the manufacturer from all liability for resulting dam-
from flywheel (1). age. The blocking screws are adequately protected
against this:
Direction of rotation
z With locking varnish in version: torque adjust-
Looking onto the flywheel. ment
rotating to the left: counter-clockwise. z With protective plastic capsule in version: with-
Engine sides out torque adjustment.
Looking onto the flywheel.
8 © 2008
Engine illustrations Engine description

D 2011 L03 i
View from right (example)
2
18 1 Cooling fan (with integrated generator)
2 Tension pulley
3 Toothed belt cover
17 4 V-belt (fan)
5 Stop lever
16 6 Speed adjusting lever
7 Lubricating oil drain plug
15 8 Lubricating oil sump
9 Lubricating oil dipstick
14 10 Connection possibility for cab heating
11 Exchangeable fuel filter
?
1 12 Lube oil replacement filter
13 13 Fuel supply pump with integrated screen filter
14 Lubricating oil filling
12 ?
2 15 Removable air guidance cowling (access to fuel
injectors)
?
3 16 Lube oil cooler
11 17 Cylinder head cover
18 Air intake pipe
?
4
10
?
5
9
8 ?
6
© 2008 9
Engine description Engine illustrations
2 D 2011 L03 i
View from left (example)
1 Fuel return to fuel tank
2 Flywheel
3 Starter
4 Exhaust manifold line
5 Air intake pipe
4
1
10 © 2008
Engine illustrations Engine description
21 1
TCD 2011 L04 w
View from right (example)
2
1 Crankcase breather
20 2 2 Coolant outlet to the cooler
3 Coolant pump
19 4 Generator
5 V-belts
3 6 Toothed belt cover
18
7 Lubricating oil filling
8 Lubricating oil sump
9 Lubricating oil pump
17 10 Lubricating oil drain plug
11 Speed adjusting lever
16 12 Lubricating oil dipstick
13 Fuel supply pump with integrated screen filter
15 Lube oil replacement filter
16 Stop lever
15 17 Lube oil cooler
18 Coolant inlet
14 4 19 Injection pump
20 Coolant return to thermostat
13 21 Cylinder head cover
5
12 6
11
10 8 7
9
© 2008 11
Engine description Engine illustrations
2 TCD 2011 L04 w

View from left (example)
2 Connections charge air cooler
3 Flywheel
8 4 Starter
5 Coolant inlet
1 6 Turbocharger
7 7 Exhaust manifold line
8 Charge air line
4 3
12 © 2008
Lubricating oil schematic Engine description

TD 2011 L04 i
(example)
2
Toil > 95°C
9
Toil < 95°C 3 Pressure limiting valve
4 Cylinder (lubricating oil-cooled)
5 The lubricating oil is used first to cool the engine.
Toil < 63°C 5 Cylinder head
15 4 6 Lubricating oil return from the cylinders
7 Lubricating oil collection pipe to the thermostat
Toil > 63°C 8 Thermostat
(engine cold) lubricating oil flow directly to the lu-
bricating oil filter
14 7 6 11 16 (engine warm) lubricating oil flow through the lu-
bricating oil cooler
9 Lube oil cooler
2 10 Lubricating oil filter
11 Main lube oil channel
3 12 Turbocharger
13 Pressure holding valve
1 bar
14 Connection possibility for cab heating
10 7 bar The standard pressure holding valve must be re-
placed by a combination for this. Retrofitting only
by authorised qualified personnel.
1,7 bar 3 bar 15 Lubricating oil filter console with integrated
switching valve for controlling the hydraulic tap-
pet. When the engine is cold, lubricating
oil is fed to the hydraulic tappet.
0,3 bar
13 12 To achieve early adjustment of the fuel injection
1 in a cold start, the hydraulic tappets under the
fuel injectors are supplied with lubricating oil.
16 Hydraulic tappets
© 2008 13
Engine description Lubricating oil schematic
2 10
D 2011 L04 i
Exhaust gas recirculation
(example)
Toil> 95°C
11 8
Toil < 95°C 3 Pressure limiting valve
4 Cylinder (lubricating oil-cooled)
5 The lubricating oil is used first to cool the engine.
5 Cylinder head
16
4 6 Cooling valve housing (exhaust gas recircula-
Toil < 63°C
tion)
7 Lubricating oil return from the cylinders
Toil > 63°C 8 Rocker arm
9 Lubricating oil collection pipe to the thermostat
9 7 17 13 10 Thermostat
(engine cold) lubricating oil flow directly to the lu-
2
15 bricating oil filter
(engine warm) lubricating oil flow through the lu-
3 bricating oil cooler
11 Lube oil cooler
12
1 bar
12 Lubricating oil filter
7 bar
1,7 bar
14 14 Pressure holding valve
3 bar 15 Connection possibility for cab heating
0,3 bar
The standard pressure holding valve must be re-
placed by a combination for this. Retrofitting only
1 by authorised qualified personnel.
16 Lubricating oil filter console with integrated
Pö 12/2004 pet. When the engine is cold, lubricating
oil is fed to the hydraulic tappet.
To achieve early adjustment of the fuel injection
in a cold start, the hydraulic tappets under the
14 © 2008

2
© 2008 15
Engine description Lubricating oil schematic
2 10
TD 2011 L04 w
(example)
12 3 Pressure limiting valve
4 Lube oil cooler
Toil < 63°C 5 Lubricating oil filter
7 Lubricating oil pipe to the turbocharger
Toil > 63°C
8 Turbocharger
4 6 13 9 Lubricating oil return line from the exhaust turbo-
charger
10 Rocker arm
2 12 Lubricating oil filter console with integrated
5 pet. When the engine is cold, lubricating
3 oil is fed to the hydraulic tappet.
7 in a cold start, the hydraulic tappets under the
7 bar
11 13 Hydraulic tappets
8
3 bar
9 1
16 © 2008

D 2011 w
Exhaust gas recirculation
2
7 8 (example)
10 2 Lubricating oil pump
3 Pressure limiting valve
Toil <63°C
4 Lube oil cooler
5 Lubricating oil filter
6 Cooling valve housing (exhaust gas recircula-
Toil > 63°C
tion)
4 6 11 7 Main lube oil channel
8 Rocker arm
2 switching valve for controlling the hydraulic tap-
5 pet. When the engine is cold, lubricating
7 bar in a cold start, the hydraulic tappets under the
9 fuel injectors are supplied with lubricating oil.
3 bar
© 2008 17
Engine description Fuel schematic
2 Fuel schematic (example)

1 Fuel line from tank to fuel pump
9 2 Fuel supply pump with integrated screen filter
3 Fuel pipe from the supply pump to the fuel
change filter
5 Fuel pipe from the filter to the fuel injector
6 Fuel pipe to fuel injector
8 7 Injection pump
8 Injection line to injection valve
9 Injection valve
10 Return collection pipe
11 switching valve for controlling the hydraulic tap-
pet. When the engine is cold, lubricating
10 To achieve early adjustment of the fuel injection
in a cold start, the hydraulic tappets under the
6
5
12
2
1
4 3
18 © 2008
Coolant schematic Engine description

2
1
5
6
7
10
8 3
© 2008 19
Engine description Coolant schematic
2 Coolant schematic (example)

D/TD/TCD 2011 w
1 Cooler
2 Coolant inlet
3 Coolant pump
4 Coolant supply for engine cooling
5 Cylinder pipe/head cooling
7 Thermostat
(engine cold) coolant directly for engine cooling
(engine warm) coolant flow through the cooler
8 Coolant partial flow to the lubricating oil cooler

9 Lube oil cooler
20 © 2008
Exhaust gas recirculation Engine description

External exhaust gas recirculation
D 2011 L04 i D 2011 L04 o D 2011 L04 w
2
(example)
1 Exhaust gas partial flow
(not connected)
7 2 Exhaust gas partial flow
(connected)
8 3 Valve housing
4 Actuator
(electrically actuated)
5
3 5 Distributor pipe
6 Electrical connection
7 Switch
The switch is connected internally with the con-
6 trol linkage. The voltage to the actuator is inter-
rupted at load peaks.
8 Fuel filter console
The switch housing is designed to be safe from ma-
4 nipulation.
Only have work performed on the components by
authorised qualified personnel.
1 2 3
© 2008 21
Engine description Exhaust gas recirculation
2 Internal exhaust gas recirculation

Engines with turbocharger
TD/TCD 2011
1 Additional cams for exhaust gas recirculation
Inlet valve opens briefly during the outlet cycle
and emits an exhaust gas partial flow to the suc-
tion system.
This partial volume is sucked back in in the next
suction cycle.
2 Outlet valve
1 3 Inlet valve
2 3
[mm]
[°]
22 © 2008
Electrics/Electronics Engine description

Information about the engine electronics
This engine can be equipped optionally with an elec-
It is strictly prohibited:
a) to make changes or connections to the
Supply voltage
DEUTZ diesel engines must be operated with a 12 V
2
tronic DEUTZ control unit. wiring of the electrical control devices and or 24 V supply. An adequate charging condition of
the data transmission cable (CAN lines). the battery must be ensured. Interruption of the pow-
The equipping of the respective system depends on
b) to switch control units. er supply when the engine is running can lead to
the desired scope of function and the planned type of
Diagnostic and maintenance work may damage to the electrics/electronics. Failure of the
engine application.
only be carried out by authorised personnel supply voltage leads to engine standstill.
The resultant wiring with pin assignment can be seen using equipment approved by DEUTZ.
in the appropriate wiring diagram. Voltages above 32 Volt will destroy the control unit.
Installation instructions
The installation regulations of the DEUTZ AG must Diagnostics
also be taken into account. The control units are calibrated to the respective en-
gine and identified by the engine number. Every en- DEUTZ control units are equipped with self-diagno-
Precautions gine may only be operated with the appropriate sis. Active and passive error entries are saved in the
control unit. error memory. Active errors are displayed by error
The connections of the control units are lamp/diagnostic lamp (60). The active errors can
Setpoint transmitters (pedal value transmitters) nec- be called by blink codes or by the DEUTZ diagnostic
only dust and water proof when the mating
essary for vehicle operation must be connected to program SERDIA. Passive errors must be deleted by
plugs are plugged (protection class IP69K)!
the vehicle side cable harness and calibrated with SERDIA.
The control units must be protected against
the DEUTZ diagnostic program SERDIA (SERvice
spray water and moisture until plugging in z with error lamp (optional).
DIAgnosis). Wiring and cable assignment of the ve-
the mating plugs!
hicle side cable harness must be taken from the con- z via diagnostic socket (SERDIA).
Reverse polarity can lead to failure of the
nection diagram of the DEUTZ installation
control unit.
consulting.
To avoid damaging the control units, all the
connections on the control unit must be dis-
connected before electric welding work.
Interventions in the electrical system con-
trary to the DEUTZ regulations or by un-
qualified personnel can permamently
damage the engine electronics and have
serious consequences which are not cov-
ered by the manufacturer's guarantee.
© 2008 23
Operation Ambient conditions
3 Cold start aid

z Depending on the type of engine, glow plugs,
heating plugs, heating flange, flame glow system
can be used as cold starting aids.(27)
Coolant
D/TD/TCD 2011 w
0 °C
z Observe the mixing ratio anti-freeze/cooling wa-
ter. (34)
High ambient temperatures, high altitude
This engine can be equipped optionally

with an electronic DEUTZ control unit.
Under the operating conditions listed be-
low, the amount of fuel is reduced automat-
Low ambient temperatures
ically, controlled by the electronic control
Lubricating oil unit.
z Select the lubricating oil viscosity according to Under the following application and operating condi-
the ambient temperature. tions, the amount of fuel must be reduced.
z If cold starting occurs frequently cut the lube oil
z above 1000 m altitude
changing interval by half.
z above 30 °C ambient temperature
Fuel
Reason: Air density decreases as altitude or ambient
z Use winter fuel below 0 °C (33). temperature increase. This reduces the amount of
Battery oxygen in the engine intake air and the fuel-air mix-
ture would be too rich if the injected amount of fuel
z A good charging condition of the battery (53) were not reduced.
is the prerequisite for starting the engine.
z The results would be:
z Heating up the battery to approx. 20°C improves
the starting behaviour of the engine. (Remove – black smoke in the exhaust
and store the battery in a warm room). – high engine temperature
– reduction in engine performance
– possible impairment of starting behaviour
Consult your equipment supplier or DEUTZ partner if
you have any other questions.
24 © 2008
Initial commissioning Operation

Preparations for initial commissioning
3
(Maintenance schedule E 10)
z Remove engine corrosion protection
OIL
z Remove any transport devices.
z Check the battery and cable connections and
mount if necessary.
z Check belt tension (49).
z Have the engine monitor or warning system
checked by authorised personnel.
z Check the engine mounting.
z Check that all hose unions and clips fit properly.
The following additional work must be carried
out on generally overhauled engines:
z Check the fuel pre-filter and main filter and Fill with engine lube oil Pour in fuel
change if necessary.
z Check the intake air cleaner (if available, main- Low lubricating oil level and overfilling lead Only re-fuel when the engine is not running.
tain according to maintenance indicator). to engine damage. Ensure cleanliness.
z Drain lubricating oil and condensation water from Do not spill fuel.
the charge air cooler. Additional venting of the fuel system by a 5
z Fill with engine lube oil. The engines are generally supplied without minute trial run at idle speed or on low load
lubricating oil filling. is absolutely essential.
D/TD/TCD 2011 w
Select lubricating oil quality and viscosity
z Fill the coolant system (65). before filling. z The fuel low pressure system must be vented be-
Order DEUTZ lubricating oils from your fore the first start-up after filling with the manualy
DEUTZ partner supply pump.
z Fill the engine with lubricating oil via the lubricat- Only use clean commercially available brand diesel
ing oil filler neck. fuel. Observe fuel quality (33).
z Observe the lubricating oil filling level (65). Use summer or winter-grade fuel, depending on the
ambient temperature.
© 2008 25
Operation Initial commissioning
3 3 2
z Close compensation tank with valve.
z Start the engine and run up until the thermostat
Trial run
opens (line (2) heats up). Additional venting of the fuel system by a 5
z Engine operation with open thermostat 2 - 3 min- minute trial run at idle speed or on low load
utes. is absolutely essential.
z Check the coolant level and top up coolant if nec-
Carry out a brief trial run up to operating temperature
essary.
(approx. 90 °C) after preparations.
1 Danger of scalding from hot coolant! Do not load the engine if possible.
Cooling system under pressure! Only open
z Work with the engine not running:
the cap when cool!
– Check engine for tightness.
Observe safety regulations and national
specifications when handling cooling me- – Check lubricating oil level, if necessary top
dia. up.
– Check the coolant level and top up coolant if
z If required, repeat procedure with engine start. necessary.
Filling the coolant system z Fill up coolant to the MAX mark on the compen- z Work during the trial run:
sation tank and close the cooling system cap. – Check engine for tightness.
D/TD/TCD 2011 w z Switch on any available heating and set to the
highest level so that the heating circuit is filled
The coolant must have a prescribed con-
and vented.
centration of cooling system corrosion pro-
tection agent! z Observe the filling volume of the cooling system
Never operate the engine without coolant, (65).
even for a short time!
Order coolant corrosion protection agent

from your DEUTZ partner.
z Connect coolant outlet (2) and coolant inlet (1) to

the cooling system. Connect the feed line of the
compensation tank to the coolant pump or to the
coolant inlet line (3).
z Connect ventilation line from the engine and, if
necessary, from the cooler to the compensation
tank.
z Fill cooling system via the compensation tank.
26 © 2008
Start procedure Operation

Starting
3
Before starting, make sure that nobody is
standing in the immediate vicinity of the en- A
gine or work machine.
After repair work: Check that all guards
have been replaced and that all tools have
been removed from the engine.
When starting with the flame glow plug/ B
glow plug/heating flange system do not use
any other starting aid (e.g. injection with
start pilot). Risk of accident!
C
If the engine fails to fire and the error lamp
lights, the EMR2 has activated the start
© 25745-0
lock to protect the engine.
The start lock is released by switching off Without cold start aid Glow plugs with cold start aid
the system with the ignition key for about 30 z Insert key. z Insert key.
seconds. z Turn key to the right. – Position 0 = no operating voltage.
Do not actuate the starter for more than – Position 1 = operating voltage.
20 seconds. If the engine does not start up, z Turn key to the right.
– Pilot lamps (1) and (2) light up.
wait for one minute and then repeat the – Position 1 = operating voltage.
starting process. z Push the key in and turn further clockwise
– Pilot lamps (A), (B) and (C) light up.
If the engine does not start up after two at- against spring pressure.
– Level 2 = no function. – Preheat until the glow display goes out; an
tempts, determine the cause as per fault ta- error has occurred if the preheating indicator
ble (55). – Level 3 = start.
flashes; e.g. the preheating relay is stuck,
Do not run up the engine immediately to z release the key as soon as the engine starts up. which can discharge the battery completely
high idling speed / full load operation from – The pilot lamps will go out. when at a standstill.
cold. – Engine is ready for operation.
z Push the key in and turn further clockwise
Disconnect the engine by uncoupling de- against spring pressure.
vices to be driven where possible. – Level 2 = start.
z release the key as soon as the engine starts up.
– The pilot lamps will go out.
© 2008 27
Operation Operation monitoring
3 Operation monitoring by EMR2

Optional
The EMR2 system monitors the engine condition as
well as the engine electronics and displays these to
the driver/operator with the error lamp:
z Function test
– Ignition on, error lamp lights up for approx. 2
seconds and then goes out.
z The lamp does not light
– After the lamp test an extinguished lamp indi-
cates an error-free and trouble-free operat-
ing state within the scope of the control
possibility.
z Steady light Display instrument
– If a lamp lights steadily a monitored measur-
ing variable (e.g. coolant temperature, lubri- Possible displays:
cating oil pressure) has left the permissible z Colour scale
value range. – Display of operating state by coloured areas:
– green = normal operating state
z Flashing
– red = critical operatng state
– Serious error in the system.
Take suitable action.
z Measured value scale
– Actual value can be read off directly. The
nominal value should be taken from the
Technical Data (65).
28 © 2008
Operation monitoring Operation

Instruments and symbols
3
Instruments/symbols Designation Possible display: Measure
Lubricating oil pressure dis- Lubricating oil pressure below minimum Switch off engine
play
Lubricating oil pressure dis- Lubricating oil pressure in the red area Switch off engine
play
D/TD/TCD 2011 w Coolant temperature too high Switch off engine

Coolant temperature
Lubricating oil pressure pilot If the pilot lamp lights up after starting the engine or Switch off engine
lamp while the engine is running, the lubricating oil pres-
sure is too low
Lube oil level If the pilot lamp lights up after starting the engine or Fill up lube oil
while the engine is running, the lubricating oil level is
too low
D/TD/TCD 2011 w If the control lamp lights up after the engine starts or Shut down the engine, allow to cool and top up cool-
Coolant level while the engine is running, the coolant level is too ant
low
Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
123
Horn With acoustic signal See fault table (55).
© 2008 29
Operation Stop procedure
3 Electrical shutdown (optional)

z Move the key to position 0.
Control lamps A+B+C go out.
A A = charge pilot light
B = lube oil pressure pilot light
C = pilot light for pre-heating system
P = gear position: park
B 0 = gear position: switch off engine
1 = gear position: pre-heat engine
2 = gear position: start engine
Shutting off
Avoid switching off from full load (coking/

blockage of the remaining lubricating oil in
the turbocharger bearing housing). The lu-
bricating oil supply of the turbocharger is
then no longer guaranteed! This shortens
the life of the turbocharger.
Run the engine in low idling speed for ap-
proximately one minute after relieving the
load.
The control unit remains active for about
another 40 seconds to save the system
data (lag) and then switches off automati-
cally.
30 © 2008
Lubricating oil Operating media

General
Modern diesel engines place very high demands on
perature and oxidation stability as well as a relatively
low cold viscosity. Since some processes relevant to
the engines in this operating manual:
4
the definition of the lube oil change intervals are not Recommended quality class
the lubricating oil to be used. The specific engine
essentially dependent on the lube oil quality (such as DEUTZ Others
performances which have increased constantly over
the incorporation of soot and other contaminations),
the last few years lead to an increased thermal load DQC II - 05 ACEA E3-96/E5-02;
the lube oil change interval when using synthetic
on the lubricating oil. The lubricating oil is also more API CH-4/CG-4; DHD-1
lube oils may not be increased in relation to the spec-
exposed to contamination due to reduced oil com- DQC III - 05 ACEA E4-99/E6-04
ifications of the lube oil change intervals.
sumption and longer oil change intervals. For this
reason it is necessary to observe the requirements Biodegradable lubricating oils may be used in DQC IV - 05 Please contact your DEUTZ partner
and recommendations described in this operating DEUTZ engines if they meet the requirements of this
manual in order not to shorten the life of the engine. operating manual. DEUTZ lubricating oils DQC II-05
Lubricating oils always consist of a base oil and an TLS - 15W40 D
Quality
additive package. The most important tasks of a lu- Container Order number:
bricating oil (e.g. wear protection, corrosion protec- Lubricating oils are classified by DEUTZ according
to their efficiency and quality class (DQC: DEUTZ 5 litre container 0101 6331
tion, neutralisation of acids from combustion
products, prevention of coke and soot deposits on Quality Class). It basically applies that: with increas- 20 litre container 0101 6332
the engine parts) are assumed by the additives. The ing quality class (DQC I, II, III, IV) the lubricating oils 209 litre barrel 0101 6333
properties of the base oil are also decisive for the are more efficient and higher quality. The appended
quality of the product, e.g. with regard to thermal quality class designation (- 02 / - 05) indicates in
DEUTZ lubricating oils DQC III-05
load capacity. which year the classification was made.
TLX - 10W40 FE
In principle, all engine oils of the same specification Lubricating oils according to other comparable spec-
Container Order number:
can be mixed. However, mixing of engine oils should ifications can be used as long as they meet DEUTZ
requirements. In regions in which none of these 5 litre container 0101 6335
be avoided because the worst properties of the mix-
ture are always dominant. qualities are available, please contact your responsi- 20 litre container 0101 6336
ble DEUTZ partner.
The lubricating oil quality has a considerable influ- 209 litre barrel 0101 6337
ence on the life, performance and thus also on the or see www.deutz.com >> SERVICE >> Operating
costs-effectiveness of the engine. It basically applies Media and Diagnosis >> Deutz Quality Class >> DEUTZ lubricating oils DQC IV-05 synthetic
that: The better the lubricating oil quality, the better DQC Release List (current edition)
Container Order number:
these properties.
Minimum quality class 20 litre container 0101 7849
The lubricating oil viscosity describes the flow be-
haviour of the lubricating oil depending on the tem- DEUTZ Others 209 litre barrel 0101 7850
perature. The lubricating oil viscosity has no DQC I - 02 ACEA E2-96; API CF/CF-4
Lubricating oil change intervals
influence and effect on the lubricating oil quality. If the engine is operated with these lubricating oils,
the lub ricating oil change interval must be halved. z The intervals depend on:
Synthetic lubricating oils are used increasingly
and have advantages. These oils have a better tem- – lubricating oil quality
The following lubricating oils are recommended for
© 2008 31
Operating media Lubricating oil
4 – sulphur content in the fuel

– type of application of engine
Viscosity
The ambient temperature at the installation site or in
°C
z The lubricating oil change interval must be the application area of the engine is decisive for 45
halved if at least one of the following conditions choosing the right viscosity class. Too high a viscos-
applies: ity can lead to starting difficulties, too low a viscosity 40
– Constant ambient temperature below -10 °C can endanger the lubrication effect and cause a high
(14 °F) or lube oil temperature below 60 °C lubricating oil consumption. At ambient temperatures 35
(84 °F). below -40 °C, the lubricating oil must be pre-heated
– Sulphur content in the diesel fuel of 0.5-1 %. (e.g. by storing the vehicle or the machine in a hall). 30
In case of fuels containing more than 1% sul- The viscosity is classified according to SAE. Multi- 25
phur, contact your corresponding DEUTZ purpose lubricating oils should be used basically.
partner. Single-purpose lubricating oils can also be used in 20
SAE 20W-50
SAE 10W-30
SAE 10W-40
SAE 15W-40
– operation with bio-diesel fuel enclosed, heated spaces at temperatures >5 ° C.
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
z If the lubricating oil change intervals are not Depending on the ambient temperature we recom-
15
reached within a year, the oil should be changed mend the following common viscosity classes:
at least once a year. 10
The prescribed lubricating oil quality must 5
be observed when selecting the viscosity
class! 0
-5
-10
-15
-20
-25
-30
-35
-40
32 © 2008
Fuel Operating media

Permissible fuels
The following fuel specifications / standards are ap-
Winter operation with diesel fuel
4
proved: Only carry out mixing in the tank. Fill with
the appropriate amount of paraffin first,
z Diesel fuels then add the diesel fuel. Normal and high
– EN 590 grade fuels may not be mixed.
– ASTM D 975 1-D
– ASTM D 975 2-D At low ambient temperatures paraffin discharges can
lead to blockages in the fuel system and cause oper-
– NATO F-54
ating faults. Below 0 °C ambient temperature use
– JIS K2204 Grade 1 winter diesel (down to -20 °C) (filling stations provide
– JIS K2204 Grade 2 this in good time before the cold season starts).
z Below -20 °C paraffin should be added. The rel-
Use commercially available fuels with a sulphur con-
evant percentages are given in the adjacent dia-
tent below 0.5 %. The lubricating oil change intervals
gram.
must be halved at a higher sulphur content.
z Special diesel fuels can be used for arctic cli-
If other fuels are used which do not meet the require- mates to -44 °C. I Summer-grade diesel fuel
ments of the operating manual, the warranty will be II Winter-grade diesel fuel
voided. If it is necessary to use Summer diesel fuel below
0 °C, up to 30 % petroleum can be added according A Outdoor temperature
The certification measurements for compliance with
to the diagram opposite. B Percentage of paraffin to be added
the legal emission values are made with the test fu-
els specified in the laws. These correspond to the Usually a sufficient cold resistance can be achieved
diesel fuels in accordance with EN 590 and by adding a flow improver. Ask your DEUTZ partner.
ASTM D 975 described in the operation manual. No
emission values are guaranteed with the other fuels
described in this operation manual.
© 2008 33
Operating media Coolant
4 General z Total hardness too high:

Mixing with softened water (pH neutralized con-
ed to the materials in our engines. Order from your
DEUTZ partner.
Never operate the engine without coolant, densate or water softened by ion exchanger). Please contact your DEUTZ partner if the DEUTZ
even for a short time! z Total hardness or carbonate hardness too cooling system corrosion protection agent is not
low: available.
D/TD/TCD 2011 w Mixing with harder water (harder water is usually The cooling system must be monitored regularly.
available in the form of drinking water). This also includes checking the coolant system cor-
In liquid-cooled engines, the coolant must be condi-
tioned and monitored, otherwise the engine could be z Chlorides and/or sulphates too high: rosion protection agent concentration in addition to
damaged by: Mixing with softened water (pH neutralized con- checking the coolant level.
densate or water softened by ion exchanger).
z corrosion The cooling system corrosion protection agent con-
z cavitation Cooling system corrosion protection agent centration can be checked with conventional test in-
z freezing struments (e.g. refractometer).
Health damaging nitrous amines form
Water quality Cooling sys- Water percent- Cold protec-
when nitrite-based cooling system corro-
tem corrosion age tion up to
The right water quality is important for conditioning sion protection agents are mixed with
protection
the coolant. Clear, clean water within the following amine-based agents!
agent percent-
analysis values should always be used: age
Cooling system corrosion protection agents
Analysis values min max ASTM must be disposed of in an environmentally min. 35 % 65 % -22 °C
ph value 6,5 8,5 D 1293 friendly way. 40 % 60 % -28 °C
Chlorine (Cl) [mg/l] - 100 D 512 The conditioning of the coolant for liquid-cooled max. 45 % 55 % -35 °C
D 4327 DEUTZ compact engines is performed by mixing an At temperatures below -35 °C, please contact your
Sulphate (SO4) [mg/l] - 100 D 516 anti-freeze with corrosion protection inhibitors based responsible DEUTZ partner.
on ethylene glycol into the water.
Total hardness [mmol/l] 0,53 2,1 D 1126 It is possible to use other cooling system corrosion
(CaCO3) [mg/l] 53 213 DEUTZ cooling system corrosion protection protection agents (e.g. chemical corrosion protection
[°dGH] 3,0 12,0 - agent agents) in exceptional cases. Consult your DEUTZ
partner.
Specifications of the water quality are made by the Container Order number:
local water board. 5 litre container 0101 1490
The water must be conditioned if it deviates from the 20 litre container 0116 4160
analysis values. 210 litre barrel 1221 1500
z pH value too low:
This cooling system corrosion protection agent is
Addition of diluted sodium or potassium lye.
free from nitrite, amine and phosphate and is adapt-
Small trial mixtures are advisable.
34 © 2008
Maintenance schedule Maintenance

Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
5
Standard maintenance schedule
D/TD/TCD 2011
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E10 Initial commissioning Authorised specialists When commissioning new or overhauled engines
E20 Daily inspection Operator 1x daily or every 10 operating hours in continuous operation
E30 Maintenance Qualified personnel D: 1.000 1) / TD/TCD: 500 1)
E40 Extended maintenance I 1000
2)
E50 Extended maintenance II Authorised specialists 3.000 / 5.000 3) / 6.000 4)
EPA-certified engines
The EPA (Environmental Protection Agency) is a US Government organisation for the protection of the environment and human health.
Deviations from the standard maintenacne schedule for engines subject to EPA certification
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E60 Intermediate overhaul Authorised specialists 3.000
Observations
1)
The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (31).
Toothed belt change intervals recommended Engine application example:
values in op. h
2)
3,000 or max. 5 years Agricultural machinery; skid steer loader; wheel loader; high speed; impact load; extreme ambient tempera-
drilling machines; trench differs; joint cutters; excavators ture; high dust load
etc.
3)
5,000 or max. 5 years compressors; rollers; stackers; welding units; wheel medium to high variable speed; high ambient temper-
loaders small dumpers; skid steer loaders, etc. ature medium dust load
4)
6,000 or max. 5 years Electrical units 1500/1800 rpm; pump units with low low speed; medium ambient temperature low dust
speed; lifting platforms; cooling aggregates etc. load
© 2008 35
Maintenance Maintenance schedule
5 Maintenance measures
Stage Activity Measure Page

E10 The measures are listed in chapter 3. 25
E20 Check Lubricating oil level (if necessary top up) 38
D/TD/TCD 2011 w 26
Coolant level (top up if necessary)
Engine tightness (visual inspection for leaks)
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 48
E30 Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application 31/38
type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.
Lubricating oil filter/insert (every time the lubricating oil is changed) 39
Check TD/TCD: 51
Single checking and setting of the valve clearance if necessary at the first lubricating oil change
E40 Check Heating plugs
D/TD/TCD 2011 w 44
Coolant (additive concentration)
Battery and cable connectors 53
V-belts (retension or renew if necessary) 49
Engine mounting (tighten, replace if damaged when necessary)
Fastenings, hose unions / clips (renew if damaged)
Settings Valve clearance 51
Replace By-pass lubricating oil filter
Fuel filter cartridge 42
Clean Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary) 41/43
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 48
E50 Replace Toothed belt 35
E60 Replace Injection valve
Clean Charge air cooler entry area (drain lube oil/condensate)
Turbocharger compressor outlet
36 © 2008
Maintenance schedule Maintenance

Stage
Every 2
Activity
Replace
Measure
V-belts
Page
49
5
years Heating plugs
D/TD/TCD 2011 w 34 44
Coolant
Maintenance work outside the DEUTZ maintenance and service schedules
*If the water level warning system (lamp/siren) responds, the fuel pre-filter must be emptied immediately.
Maintenance profile
A self-adhesive maintenance diagram is delivered with every engine. It should be stuck in a well visible location on the engine or equipment.
Order number: 0312 3538
© 2008 37
Care and maintenance work Lubricating oil system
6 Regulations for working on the lubricating oil

system OIL ?
z The oil level must always be between the MIN
and MAX marks! Top up to the MAX mark if nec-
essary.
Do not work when the engine is running!
Smoking and naked lights prohibited! Changing the lubricating oil
Be careful of hot lubricating oil. Danger of
scalding!
OIL z Warm up the engine (lubricating oil temperature
> 80 °C).
+80°C
+176°F z Ensure that the engine or vehicle is in a level po-
Pay attention to utmost cleanliness when sition.
working on the lubricating oil system. Clean z Switch off the engine.
the area around the components con- z Place a collecting receptacle underneath the
cerned carefully. Blow damp parts dry with
compressed air.
Observe the safety regulations and nation-
! lube oil drain screw.
z Unscrew the lube oil drain screw, drain oil.
al specifications for handling lube oils. z Fit a new sealing ring to the lube oil drain screw,
Dispose of leaking lubricating oil and filter insert and tighten. (tightening torque 100 Nm).
elements properly. Do not allow used oil to Checking the lubricating oil level z Pour in lube oil.
seep away into the ground. – Quality/viscosity data.
Perform a trial run after all work. Pay atten- Low lubricating oil level and overfilling lead – Filling volume (65).
tion to tightness and lubricating oil pressure to engine damage. z Warm up the engine (lubricating oil temperature
and then check the engine oil level. The lubricating oil level may only be > 80 °C).
In case of fuels containing more than 1% checked with the engine in a horizontal po- z Ensure that the engine or vehicle is in a level po-
sulphur, contact your corresponding sition and switched off. sition.
DEUTZ partner. If the engine is warm, switch off the engine z Check lubricating oil level, if necessary top up.
and check the lubricating oil level after 5
minutes. If the engine is cold you can check
it immediately.
Be careful of hot lubricating oil. Danger of

scalding!
z Pull out the lubricating oil dipstick and wipe off

with a lint-free, clean cloth.
z Insert the lubricating oil dipstick as far as it will
go.
z Extract the lubricating oil dipstick and read off the
oil level.
38 © 2008
Lubricating oil system Care and maintenance work

6
Change lubricating oil filter z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- z Screw on new filter by hand until the gasket is in
filled. There is a danger of dirt contamina- place and then tighten with a torque of 15-17 Nm.
tion! z Fasten clamps of the twist protection (optional).
z Remove clamps when twist protection mounted
(optional).
z Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
z Collect draining lubricating oil
z Clean the sealing surface of the filter support
© 2008 39
Care and maintenance work Fuel system
6 Specifications when working on the fuel system Clean and dry the engine and engine com-
partment thoroughly before beginning
Engine must be switched off! work.
Smoking and naked lights prohibited! Areas of the engine compartment from
No injection/high pressure pipes may be which dirt could be loosened must be cov-
disconnected while the engine is running. ered with a fresh, clean foil.
Caution when handling hot fuel! Work on the fuel system may only be car-
Pay attention to utmost cleanliness when ried out in an absolutely clean environment.
refuelling and working on the fuel system. Contamination of the air such as dirt, dust,
Clean the respective affected parts careful- moisture etc. must be avoided.
ly. Blow damp areas dry with compressed
air.
Observe the safety regulations and nation-
al specifications for handling fuels.
Dispose of leaking fuel and filter elements
properly. Do not allow fuel to seep away
into the ground.
After all work on the fuel system, the sys-
tem should be vented, a trial run performed
and the tightness checked.
It will be necessary to vent the fuel system
when commissioning for the first time, after
maintenance work or if the tank has been
run dry.
Additional venting of the fuel system by a 5

minute trial run at idle speed or on low load
is absolutely essential.
Pay attention to utmost cleanliness due to
the high production accuracy of the system!
The fuel system must be tight and closed.
Make a visual inspection for leaks/damage
in the system.
40 © 2008
Fuel system Care and maintenance work

Vent the fuel system
z Pump in the direction of the arrow (3) until a
6
5 strong resistance is felt and pressure has built
up.
z The return line (5) must be filled.
4 ?
6
z Start the engine and run in idle or on low load. Air
is pressed through the return pipe 5) to the tank.
3 ?7
1
Fuel supply pump, sieve filter cartridge clean/
change
z Close fuel shutoff tap (with high-level tank) (sup-
ply (7)).
z Remove connection (4) to the fuel filter.
z Catch any escaping fuel.
z Loosen screw (1).
z Remove fuel screen (screw (1), cover and fuell
screen form one unit).
z Take the sealing ring (2) and clean it, renew
when damaged.
z Clean cover-fuel screen with fuel, renew de-
pending on the condition.
z Put the sealing ring (2) in position.
z Mount the cover-fuel filter with screw (1).
z Reinstall connection (4) to the fuel filter.
z Open fuel shutoff tap supply (7), start engine and
run in idle or on low load.
z Check for leaks after starting the engine.
© 2008 41
Care and maintenance work Fuel system
Change the fuel filter cartridge z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- z Screw on new filter by hand until the gasket is in
filled. There is a danger of dirt contamina- place and then tighten with a torque of 10-12 Nm.
tion! z Fasten clamps of the twist protection (optional).
z Remove clamps when twist protection mounted z Vent the fuel system.
(optional).
z Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
z Catch any escaping fuel.
z Clean the sealing surface of the filter support
42 © 2008
Fuel system Care and maintenance work

with fuel.
z Assembly in clockwise direction.
bubbles.
z Catch any escaping fuel. 6
7 z Open the fuel shutoff tap and vent the system, z Tighten the venting screw (7).
see venting the fuel system.
Vent the fuel system
5 1 z Start engine.
z Check for leaks after starting the engine. z Bring engine control to stop position.
z Position fuel collecting vessel below the con-
6 2 Change the fuel pre-filter insert stant-pressure valve in the crankcase/filter hous-
z Shut off the fuel supply to the engine (with high- ing.
4 3
level tank). z Open constant-pressure valve in the crankcase/
fuel stopcock in the filter housing.
z Place a vessel under the drain plug.
z Open the drain tap (4) and drain off the liquid. z Turn over the engine with starter (max. 20 Sec.)
z Unscrew the filter insert (2) together with the wa- until bubble-free fuel emerges at the constant-
ter collection vessel (3). pressure valve in the crankcase/filter housing.
z Unscrew the water collection vessel (3) from the z Screw in ventilation screws (tightening torque
Clean/change/vent the fuel pre-filter filter insert (2). 25-5 Nm) and constant-pressure valve.
– The special tool can be ordered under part z Bring engine control to the start position and
1 Fuel pre-filter holder
number 8192 (70). start.
2 Fuel filter insert
z Check for leaks after starting the engine.
3 Water collection vessel z Clean the water collection vessel (3) and all the
4 Water drain tap existing sealing surfaces (6) with a brush and
5 Fuel pump diesel fuel.
6 Sealing surface z Oil the gaskets and sealing surfaces (6) of the
7 Venting screw new DEUTZ original filter insert (2) lightly or wet
with diesel fuel.
z Shut off the fuel supply to the engine (with high- z Screw the water collection vessel (3) to the filter
level tank). insert (2).
z Place a vessel under the drain plug. z Screw a new filter insert (2) with water collection
z Open the drain tap (4) and drain off the liquid. vessel (3) onto the filter carrier 1) (tightening
z Unscrew the filter insert (2) together with the wa- torque 17-18 Nm)
ter collection vessel (3). z Open the fuel supply to the engine.
z Empty emulsion in the water collection vessel (3) z Vent the fuel system.
and clean the vessel.
z Mount the filter insert (2) and water collection Vent the fuel pre-filter.
vessel (3). Wet the sealing surfaces (6) of the fil- z Loosen the venting screw (7) slightly.
ter insert (2) and the water collection vessel (3) z Operate the pump until fuel emerges without
© 2008 43
Care and maintenance work Cooling system
6 Specifications when working on the cooling sys-

tem
D/TD/TCD 2011 w
Danger of scalding from hot coolant!

the cap when cool!
The coolant must have a prescribed con-
centration of cooling system corrosion pro- 1
tection agent!
Observe safety regulations and national
specifications when handling cooling me-
dia.
Observe the manufacturer's specifications
for an external cooler.
Dispose of leaking liquids properly and do
not allow them to seep into the ground. Check coolant additive concentration Emptying the cooling system
Order coolant corrosion protection agent D/TD/TCD 2011 w D/TD/TCD 2011 w
from your DEUTZ partner.
z Open the cooling system cap (1) carefully. z Open cooler locking cap carefully.
Never operate the engine without coolant,
even for a short time! z Check the coolant aditive concentration in the z Place a collection tray underneath the coolant
cooler/compensation tank (2) with a convention- connection (1).
Checking the coolant level with an external cool- al antifreeze measuring device (1) (e.g. hydrom- z Drain coolant.
er eter, refractormeter). z Reconnect and tighten the coolant connection
D/TD/TCD 2011 w z Necessary coolant additive concentration Cool- (1).
ant mixing ratio (34). z If the locking screw is not accessible, the drain-
z Fill in new coolant and vent the system according
You can order the appropriate test instrument from age can be carried out at the engine oil cooler
to the specifications of the cooling system manu-
your DEUTZ partner under order number 1824. (coolant duct).
facturer.
z Close cooler locking cap.
z Open the cooling system cap (1) carefully.
z The coolant level must always be between the
MIN and MAX marks of the compensation tank!
Fill up to the MAX mark if necessary.
44 © 2008
Cooling system Care and maintenance work

tion tank if necessary.
6
Fill and ventilate cooling system
Danger of scalding from hot coolant!

the cap when cool!
D/TD/TCD 2011 w
z Open the cooling system cap (1) carefully.
z Loosen the cooler venting screw if necessary.
z Fill coolant up to the max. mark or filling limit.
z Switch on any available heating and set to the
highest level so that the heating circuit is filled
and vented.
z Close the cooler venting screw.
z Close cooler locking cap.
z Run engine up to operating temperature (open-
ing temperature of the thermostat).
z Switch off the engine.
z Check coolant level in cooled engine and top up
to the MAX mark or filling level on the compensa-
© 2008 45
Care and maintenance work Engine cleaning
6 Cleaning work Cleaning with cold cleaner

z Spray the engine with cold cleaner and leave it
For all cleaning work, make sure that no for about 10 minutes to take effect.
parts are damaged (e.g. bent cooler mesh).
z Spray the engine clean with a high pressure wa-
Cover electrical/electronic parts and con-
ter jet.
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do z Warm up the engine so that the water residues
not aim the water/steam jet directly at them. evaporate.
Allow engine to warm up. Cleaning with a high pressure cleaner
Only carry out cleaning work on the engine z Clean the engine with a steam jet (maximum
when it is not running! spray pressure 60 bar, maximum steam temper-
Remove the engine cover and cooling air ature 90 °C, distance at least 1m).
cover if available and remount after clean- z Warm up the engine so that the water residues
ing. evaporate.
z Always clean the cooler and cooling fins from the
General exhaust air side to the fresh air side.
The following causes of soiling make it necessary to
clean the engine:
z High dust content in the air.
z Chaff and chopped straw in the area of the en-
gine.
z Coolant leaks
z Lubricating oil leakage
z Fuel leaks
Because of the different application conditions,
cleaning depends on the degree of dirt contamina-
tion.
Cleaning with compressed air
z Blow dirt off or out. Always blow out the cooler
and cooling fins from the exhaust air side to the
fresh air side.
46 © 2008
Suction system Care and maintenance work

Regulations for working on the intake system
1 5 2
Renewing the safety cartridge of the dry air filter
6
Do not work when the engine is running! Never clean the safety cartridge (4).
z Renew safety cartridge (4) according to the inter-

Pay attention to utmost cleanliness when
val in the maintenance schedule
working on the intake system, close intake
openings if necessary. z To do this:
Dispose of old filter elements properly. – Unscrew hexagon nut (5), pull out safety car-
tridge (4).
4 3 – Insert new safety cartridge, screw on hexag-
onal nut.
z Insert filter element (3), mount hood (2) and fix
with clamping yoke (1).
Maintaining the dry air filter
Do not clean the filter element (3) with pet-

rol or hot liquids!
Renew damaged filter elements.
z Maintain the filter element (3) according to the in-
terval in the maintenance schedule
z Lift up the clamping yoke (1).
z Remove the filter hood (2) and pull out the filter
element (3).
z Filter element (3):
– blow out with dry compressed air (max. 5
bar) from the inside to the outside if soiling is
only slight,
– renew if heavily soiled.
© 2008 47
Care and maintenance work Suction system
Maintenance indicators for dry air filter Clean the dust discharge valve of the dry air filter Emptying the cyclone precleaner
z The dry air filter is maintained according to a z Empty the dust discharge valve (1) by pressing
Never fill the dust container (3) with lubri-
maintenance switch or maintenance indicator. together the discharge slit.
cating oil!
z Maintenance is necessary when: z Remove any caked dust by pressing together the
– the yellow warning light of the maintenance upper section of the valve.
switch lights up when the engine is running. z Clean the discharge slit. z Loosen wing nut (1) and lift off housing cover (2).
– the red field (1) of the maintenance indica- z Remove the dust container (3) from the base (4)
tor is fully visible. and empty it. Clean the container using a brush
z After carrying out maintenance work, reset the and clean diesel fuel. Then dry.
signal by pressing the button on the mainte- z Place the dust container (3) on the base (4) and
nance indicator. The maintenance indicator is tighten the housing cover (2) with wing nut (1).
now ready for operation again.
48 © 2008
Belt drives Care and maintenance work
4
6
2
Checking the belt drive Checking the belt tension Tighten the generator V-belts
z Lower indicator arm (1) into the measuring de- z Loosen the screw (1), (2) and (3) slightly.
Only carry out work on the belt drive with
vice. z Push the generator (4) outwards in the direction
the engine at a standstill!
Always change both belts in sets in case of z Place guide (3) between two belt pulleys on the of the arrow until you get the correct V-belt ten-
wear on the double belts or damage to one V-belt (2). The stop have to be at the side. sion.
V-belt. z Press the button (4) at right angles to the V-belt z Retighten the screw (1), (2) and (3).
After repair work: Check that all guards (2) evenly until you hear or feel the spring snap
in. Renew the V-belts
have been replaced and that all tools have
been removed from the engine. z Lift the measuring device carefully without alter- z Loosen the screw (1), (2) and (3) slightly.
ing the position of the indicator arm (1). z Swing the generator (4) in in the opposite direc-
z Check the whole belt drive visually for damage. z Read the measured value at the point of inter- tion to the arrow.
z Renew damaged parts. section (arrow), scale (5) and indicator arm (1). z Remove the V-belt (5) and fit a new V-belt.
z Remount protective devices if necessary. z If necessary, re-tension belt and measure again. z Push the generator (4) outwards in the direction
z Pay attention to correct fit of new belts, check the of the arrow until you get the correct V-belt ten-
tension after running for 15 minutes. Tools
sion.
Belt tension measuring device (order number: z Retighten the screw (1), (2) and (3).
8115) can be obtained from your DEUTZ partner.
© 2008 49
OBJ_DOKU-15294-001.fm Seite 50 Freitag, 7. März 2008 11:47 11
Care and maintenance work Belt drives
6 z Retighten the screws (1) and (2).

z Checking the belt tension (65).
1 2
3 4
Tighten belt
z Loosen screws (1) and (2) and (3).
z Plug socket wrench insert of the torque wrench
ino the opening (4) of the tensioning pulley (3).
z Move the tensioning pulley (3) with the torque
wrench in the direction of the arrow (A) until the
correct belt tension is reached.
z Retighten the screws (1) and (2).
z Checking the belt tension (65).
Change the belt
z Loosen screws (1) and (2) and (3).
z Move the tensioning pulley (3) in the direction of
the arrow (B).
z Remove belt and fit new one.
z Plug socket wrench insert of the torque wrench
ino the opening (4) of the tensioning pulley (3).
z Move the tensioning pulley (3) with the torque
wrench in the direction of the arrow (A) until the
correct belt tension is reached.
50 © 2008
Setting work Care and maintenance work

Valve clearance setting schematic
Engines with turbocharger
6
TD/TCD 2011
This engine is equipped with an internal ex-

haust feedback system.
The inlet valve opens briefly in the out
stroke.
Do not confuse this with the valve over-
lap!
Valve overlap Settings

Cylinders Cylinders
1 4
Check valve clearance, adjust if necessary 3 2
z Let the engine cool down for at least 30 minutes z Engage hexagon socket head wrench (7) and in- 4 1
before setting the valve clearance: Lubricating oil sert and loosen the lock nut (4). 2 3
temperature below 80 °C. z Adjust the valve clearance setting screw (5) with
z Remove the cylinder head hood. the hexagon socket head wrench (7) so that the
z Place turning gear over fastening screws of the correct valve clerarance (1) is reached after
belt pulleys. tightening the lock nut (4).
z Turn the crankcase until reaching valve overlap. z Perform the setting procedure on every cylinder.
Outlet valve is not yet closed, inlet valve be- z Reinstall cylinder head cover, with new gasket.
gins to open.
The cylinders to be set can be seen in the
setting schematic.
z Check the valve clearance (1) between the rock-
er arm lugs (2) and the valve (3) with a feeler
gauge (6).
z The feeler gauge (6) must slide in with little re-
sistance.
z For permissible valve clearance, see (65)
z Adjust valve clearance if necessary:
© 2008 51
Care and maintenance work Setting work
6 Valve clearance setting schematic
1 Suction motor
D 2011
z Crankshaft position 1
Turn crankshaft until both vaalves overlap on the
1 2 1 2 3 1 2 3 4 cylinder.
Outlet valve is not yet closed, inlet valve begins
to open.
Setblack marked valves.
Mark the respective rocker arm with chalk to
check the setting you have made.
z Crankshaft position 2
Turn the crankshaft one turn (360 °).
Setblack marked valves.
2
1 2 1 2 3 1 2 3 4
52 © 2008
Electrical system Care and maintenance work

Regulations for working on the electrical system Danger of explosion! The gases emitted by
the battery are explosive!
6
Do not touch the voltage conducting parts, Fire, sparks, smoking and naked lights are
faulty warning lamps should be immediate- prohibited!
ly replaced. Danger of acid burns! Wear protective
gloves and glasses! Avoid contact with skin
Pay attention to correct polarity of the con- and clothing!
nections. Danger of short circuit! Do not rest tools on
Cover electrical/electronic parts and con- the battery!
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do Checking the voltage
not aim the water/steam jet directly at them. z Check the battery voltage with a conventional
Allow engine to warm up. voltmeter. The voltage indicates the charging
Touching a lead against the frame to check state. It should be between 12 and 14.4 Volt de-
whether it is live must not, under any cir- pending per battery.
cumstances, be carried out.
For electrical welding work, the ground ter- Check acid level Check acid density
minal of the welding gear must be clamped z Unscrew caps.
z Unscrew caps.
directly to the part being welded. z Measure the electrolyte density of individual cells
z Note the manufacturer’s specifications concern-
Three-phase current generator: Never dis- with a commercial hydrometer. Hydrometer
ing the liquid level.
connect the cables between battery, gener- reading indicates battery’s state of charge. The
ator and regulator while the engine is The liquid should normally be 10-15 mm above
the top edge of the plate or reach up to any avail- acid temperature when measuring should be 20
running. °C if possible.
able control device.
Battery z Only use distilled water to top up the battery. z Check the acid level before recharging.
z Screw in caps. z Screw in caps.
Electronically stored data could be lost if Acid density [kg/ l] Charge Measure
the battery is disconnected. status
Keep battery clean and dry. Normal Tropical
Make sure the battery is fitted correctly and 1,28 1,23 good none
securely. 1,20 1,12 half charge
Dispose of old batteries in an environmen-
tally friendly way. 1,12 1,08 empty charge
Removing the battery
z Always disconnect the minus pole first when re-
moving the battery. Otherwise there is a danger
© 2008 53
Care and maintenance work Electrical system
6 of short-circuit!
z Remove the fastenings and take out the battery.
Charging the battery
z Unscrew caps.
z Charge the battery with a conventional battery
charger. Observe the manufacturer specifica-
tions!
z Screw in caps.
Installing the battery
z Insert new or charged battery and attach the fas-
tenings.
z Clean the terminals and battery poles with fine
emery paper.
z Connect the plus pole first and then the minus
pole. Otherwise there is a danger of short-circuit!
Make sure the terminals have good contact.
Tighten clamp bolts hand-tight.
z Grease the assembled terminals with an acid-
free, acid-resistant grease.
54 © 2008
Fault table Faults

Faults and remedies
7
Faults Causes Measures
Engine does not start or is difficult to Not disconnected (if possible) Check coupling
start Below starting limit temperature Check
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Fuel quality does not comply with operating manual Change the fuel
Battery defective or discharged Check battery
Cable connection to starter loose or oxidized Check cable connections
Starter defective or pinion does not engage Check starter
Stop magnet defective (release circuit) Check lifting magnet
Engine stop lever still in stop position Check/replace
Stop magnet defective (release circuit) Check/replace
Incorrect valve clearance Check valve clearance and set if necessary
Injection valve defective Check fuel injector / change if necessary
Air filter clogged / turbocharger defective Check/replace
Air in fuel system Vent fuel system
Compression pressure too low Check compression pressure
Exhaust gas backpressure too high Check
Injection line leaks Check injection line
Engine does not start and diagnostic Engine electronics prevents starting Check error according to error code and
lamp flashes eliminate error if necessary
© 2008 55
Faults Fault table
7 Faults
Engine starts, but runs irregularly or
Causes
Belt/V-rib belt (fuel pump in belt drive)
Measures
Check whether torn or loose
fails Incorrect valve clearance Check valve clearance and set if necessary
Compression pressure too low Check compression pressure
Glow plugs defective Change
Air in fuel system Vent
Fuel filter contaminated Clean
Speed changes are possible and diag- Engine electronics has detected a system error and activates an equivalent speed Check error according to error code and
nostic lamp lights up eliminate error if necessary
56 © 2008
OBJ_DOKU-15294-001.fm Seite 57 Donnerstag, 10. Juli 2008 8:48 08
Fault table Faults

Faults
Engine becomes excessively hot.
Causes
Vent line blocked
Measures
Clean
7
Temperature warning system acti- Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
vates
Lubricating oil cooler fins soiled Clean
Lube oil filter contaminated on the air or lube oil side Change
Lube oil level too high Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil
Stop magnet defective (release circuit) Check lifting magnet
Coolant heat exchanger soiled Clean
Defective cooling water pump (torn or loose V-belt) Check whether torn or loose
Low coolant Fill up
Resistance in cooling system is too high / flow volume too low Check the cooling system
Cooling fan or exhaust thermostat defective, V-belt torn or loose Check/replace/tension
Heat short-circuit in the cooling air guidance Check the cooling system
Charge air line leaking Check charge air line
Charge air cooler soiled Check/clean
Air filter maintenance switch / maintenance indicator defective Check/replace
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
© 2008 57
Faults Fault table
7 Faults
Engine output is deficient
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil
Lubricating oil cooler fins soiled Clean
Engine stop lever still in stop position Stop magnet defective (release circuit)
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Charge air cooler soiled Clean
Heat short-circuit in the cooling air guidance Check the cooling system
Resistance in cooling system is too high / flow volume too low Check the cooling system
Injection valve defective Check fuel injector
Engine performs poorly and diagnos- Engine electronics reduce performance Check error according to error code and
tic lamp lights eliminate error if necessary
Engine does not run on all cylinders Injection line leaks Check injection line
Lube oil level too high Check lube oil level, if necessary drain off.
Engine lubricating oil pressure is non- Lubricating oil level too low Fill up lube oil
existant or excessively low Excessive inclination of engine Check engine mounting / reduce inclination
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
58 © 2008
Fault table Faults

Faults
Engine lubricating oil consumption
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
7
excessive Excessive inclination of engine Check engine mounting / reduce inclination
Lubricating oil in the exhaust system Engine operated continuously with too low a load (< 20-30%) Check load factor
Engine producing blue smoke Lube oil level too high Check lube oil level, if necessary drain off.
Excessive inclination of engine Check engine mounting / reduce inclination
Engine producing white smoke Below starting limit temperature Check
Engine producing black smoke Air filter clogged / turbocharger defective Check/replace
Charge air pressure-dependent full load stop defective Check
© 2008 59
Faults Engine management
7 Diagnostic key and error lamp

The diagnostic key (1) and the error lamp (2) are ac-
z Switch off prompt for the operator. Attention:
Failure to do so will lead to loss of guarantee!
commodated in the vehicle drive stand. The blink- z Automatic shutdown of the engine after a short
code release can be activated using the diagnostic warning time, possibly in connection with a start
key (1). lock.
1 z Engine forced to run at low idle speed to cool the
The error lamp can release the following signals: engine, with automatic shutdown if necessary.
z Function test z Start lock
– Ignition on, error lamp lights up for approx. 2
seconds and then goes out. Please contact your DEUTZ-partner in case of mal-
2 functions and sare parts inquiries. Our specially
3 – Check the error lamp if there is no reaction trained personnel will ensure fast, professional re-
after switching on the ignition. pairs using original DEUTZ spare parts in case of
damage.
z The lamp does not light
– After the lamp test an extinguished lamp indi-
Engine protection function of the EMR2 system cates an error-free and trouble-free operat-
ing state within the scope of the control
Optional possibility.
Depending on the design of the monitoring functions,
the EMR2 system (3) can protect the engine in cer- z Steady light
tain problematical situations by monitoring important – Error in the system.
limit values during operation and checking the cor- – Operation continued with restrictions.
rect function of the system components. – The engine must be checked by a DEUTZ
partner.
z Flashing
– Serious error in the system.
– The engine has reached switch-off condition.
– The switch-off process has been accom-
plished.
z Blink code
– Errors that may occur can be classified.
– The blink codes can only be interpreted by a
DEUTZ partner.
The flashing error lamp may have the following
meaning depending on the engine configuration:
60 © 2008
Engine management Faults

z
z
Gear oil pressure
Battery voltage 7
z Accelerator position
z Fuel consumption
Error messages are displayed in clear text and
acoustically; the error memory of the control unit can
be read out.
For a detailed description, refer to the operating in-
structions enclosed with the DEUTZ Electronic Dis-
play.
DEUTZ Electronic Display

In order to show measured values and error messag-
es of the EMR control unit, a CAN display is option-
ally available, which can be integrated into the
dashboard of the driver´s position of working ma-
chines.
All data sent from the EMR control unit through CAN
can be displayed.
z Engine speed
z Engine torque (current)
z Lubricating oil temperature
z Coolant temperature
z Suction intake air temperature
z Exhaust gas temperature
z Gear oil temperature
z Lubricating oil pressure
z Coolant pressure
z Charge air pressure
z Fuel pressure
© 2008 61
Transport and storage Transport
8
1
Suspension equipment
Danger to life!
z Always use proper suspension equipment when The engine may tip over or fall down if sus-
transporting the engine. pended incorrectly!
z The suspension device (1) must be adjustable
z The fastening attachment cannot be fixed se-
for the engine's centre of gravity.
curely above the centre of gravity (1).
z After transportation and before commissioning of
engine: remove attachment eyes (2). z The fastening attachment can slip, the engine
swings backwards and forwards (1).
z Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
damage it.
62 © 2008
Protecting the engine against corrosion Transport and storage

General
Engines contain the following types of corrosion pro-
by wetting of the walls with the implemented cor-
rosion protection agent in a corrosion protection
suction system after shutting down the engine
until it emerges visibly from the pressure nozzle. 8
run of the engine.
tection: Cooling system
z The corrosion protection run can be performed
z Interior corrosion protection once to protect the different systems: z Depending on the series the engines are
z Exterior corrosion protection equipped with cooling air, cooling oil or cooling
Fuel system fluid system (cooling water with cooling system
Your DEUTZ partner has the right corro-
protection agent).
sion protection agent for your needs. Close the fuel/tank/supply line to the en-
z Cooling air system, see the Exterior corrosion
gine so that the system is protected against
protection section.
The following measures for corrosion protection af- dirt and dust. Protect the electronics
against moisture and corrosion. z In engines of the oil-cooled series the circulating
ter taking the engine out of operation meet the re- lubricating oil serves simultaneously for cooling.
quirements for 12 months corrosion protection. The cooling chambers are protected automati-
z Fill the fuel tank with a mixture of:
The following corrosion protection work may only be – 90 % distilled fuel cally against corrosion with the lube oil system.
carried out by persons familiar with it and instructed – 10 % corrosion protection oil SAE 20W-20
in the potential dangers. D/TD/TCD 2011 w
z Perform a corrosion protection run with no load
If these measures are deviated from by exposing the for at least 5 minutes. z If a coolant with corrosion protection properties is
corrosion-protected engines or parts to unfavourable poured into liquid-cooled engines, no further ac-
conditions (installation outdoors or storage in damp, Lubricating oil system tion is necessary after draining.
badly aired places) or damage to the corrosion pro- z Drain lubricating oil from warm engine. z If not, the coolant must be drained and, to ensure
tection layer, a shorter corrosion protection duration the formation of a covering layer on the inside
z Thoroughly clean lube oil tray, cylinder head with
is to be expected. surfaces of the cooling system, a corrosion pro-
rocker arms, valves, valve springs with diesel
The engine corrosion protection should be checked fuel or cleaning agent. tection run performed with a mixture of:
about every 3 months by opening the covers. If cor- z Fill the engine with corrosion protection oil SAE – 95 % treated water
rosion is detected, the corrosion protection should 20W-20 up to the MAX mark and perform a cor- – 5 % corrosion protection agent
be renewed. rosion protection run for at least 5 minutes so z The duration of the corrosion protection run and
At the end of the corrosion protection work the crank that all the components of the lubricating oil sys- the concentration of the corrosion protection
drive may no longer be turned so that the corrosion tem are wetted or wet all accessible parts with agent are specified by the manufacturer of the
protection agent in the bearings, bearing liners and corrosion protection oil and pump corrosion pro- corrosion protection agent.
cylinder liners is not scraped off. tection oil through the engine with a separate z Then drain the coolant.
Before operating a corrosion protected engine, the pump until all bearings and bearing liners are
corrosion protection must be removed. wetted.
Interior corrosion protection Air compressor
z Interior corrosion protection is always provided z If a compressor is installed, a corrosion protec-

tion agent must be sprayed into the compressor
© 2008 63
Transport and storage Protecting the engine against corrosion
8 Air intake pipes

z After the corrosion protection run, remove the
z Toothed belts for engine control may not be re-
moved.
fuel.
Lubricating oil system
cylinder head cover and deinstall injectors. The Engine openings
respective piston must be set to LT. z Unscrew the lube oil drain screw, drain oil.
z All engine openings must be fitted with air-tight, z Fill the engine with lubricating oil via the lubricat-
z The accessible part of the cylinder liner should
water-tight covers to delay the vapourisation ing oil filler neck.
be coated with corrosion protection oil with a
process of the corrosion protection agents.
spray lance through the opening. Coolant system
z With installed air compressor, the suction and
z Spray corrosion protection oil SAE 20W-20 into
pressure connection must be sealed by a cap. D/TD/TCD 2011 w
the suction air intake line.
z Air should be excluded to avoid ventilation of the z If the implemented corrosion protection agent is
Exterior corrosion protection engine (chimney effect) for the suction from an compatible with the intended cooling system pro-
air supply pipe. tection agent, this can be filled directly into the
z The engine must be cleaned thoroughly with a
cleaning agent before exterior corrosion protec- Storage and packaging coolant system as specified.
tion. Any signs of corrosion and damage to the z If it is uncertain whether the implemented corro-
paintwork must be removed. z After being protected against corrosion, the en- sion protection agent is compatible with the cool-
gine must be stored in a dry, ventilated hall and ing system protection agent, the cooling system
Cooling air system in air-cooled engines suitably covered. should be purged with fresh water for about 15
z The air guidance compartment of the engines is z The cover must be placed loosely over the en- minutes before filling.
unpainted and must be sprayed with a corrosion gine so that the air can circulate around it to pre-
vent condensation from forming. Use a desiccant Removal of exterior corrosion protection
protection agent.
if necessary. z All areas and components coated with corrosion
Bare exterior surfaces and parts protection agent must be washed off with dis-
Removal of corrosion protection
z Coat or spray all bare exterior parts and surfaces tilled fuel or a suitable cleaning agent.
z The corrosion protection must be removed from z Wash out grooves of V-belt pulleys if necessary.
(e.g. flywheel, flange faces) with corrosion pro-
the corrosion protected engine before starting.
tection agent. z Mount V-belts or V-rib belts as specified.
z The packaging and all covers over the closed z Fill with coolant.
Rubber parts openings must be removed.
z Any corrosion deposits and paint damage should
z Rubber parts (e.g. muffs) which are not painted
be remedied.
over must be rubbed down with talcum powder.
Fuel system
Belt drive
z Remove V-belts and V-rib belts and store If there is a mixture of diesel fuel/corrosion pro-
tection oil in the fuel tank, drain it.
packed.
z Spray V-belt pulleys and tension rollers with cor- z Connect fuel/tank/supply line to the engine. Pay
rosion protection agent. attention to cleanliness.
z Fill the fuel tank and fuel system with the proper
64 © 2008
Engine and setting data Technical data

General technical data
9
Engine type Dimension D 2011 L02 i D 2011 L03 i D 2011 L04 i TD 2011 L04 i
Working principle Four-stroke diesel engine
Charging Suction motor Exhaust gas turbo-
charger
Type of cooling oil-cooled (integrated cooler)
Cylinder arrangement in series
No. of cylinders 2 3 4 4
Bore/stroke [mm] 94/112 96/125
Total displacement [cm3] 1554 2331 3619
Combustion process Direct injection
Injection system Pump-pipe-nozzle
Exhaust gas recirculation without without external internal
Valves per cylinder 2 2 2 2
Valve clearance: Inlet/outlet [mm] 0,3+0,1 / 0,5+0,1
Firing order of the engine 1-2 1-2-3 1-3-4-2
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [rpm] see engine rating plate
Injection timing [°BTDC] see engine rating plate
Lubricating oil filling volume (without/with filter) ≈ [l] 6/6,5* 5,5/6* 11,3/11,8*
Lube oil temperature in the lube oil tray, maximum [°C] 130
Lubricating oil pressure minimum (low idle, engine [kPa/bar] 150/1,5
warm)
V-belt tension Pre-tensioning/Re-tensioning
V-belt AVX 10 [N] 450±50/300±20
Weight without cooling system according to DIN ≈ [kg] 175 217 261 258
70020-A
© 2008 65
Technical data Engine and setting data
9 Engine type Dimension D 2011 L02 o D 2011 L03 o

Charging Suction motor
Type of cooling oil-cooled
No. of cylinders 2 3
Bore/stroke [mm] 94/112
Total displacement [cm3] 1554 2331
Exhaust gas recirculation without without
Valves per cylinder 2 2
Firing order of the engine 1-2 1-2-3
Lubricating oil filling volume (without/with filter) ≈ [l] 6/6,5* 5,5/6,0*
Lubricating oil pressure minimum (low idle, engine [kPa/bar] 150/1,5
warm)
V-belt AVX 10 [N] 450±50/300±20
Weight without cooling system according to DIN 70020- ≈ [kg] 169 210
A
66 © 2008

Engine type Dimension D 2011 L04 o TD 2011 L04 o 9
Charging Suction motor Exhaust gas turbocharger
Type of cooling oil-cooled
No. of cylinders 4 4
Total displacement [cm3] 3619
Exhaust gas recirculation external internal
Valves per cylinder 2 2
Firing order of the engine 1-3-4-2
Lubricating oil filling volume (without/with filter) ≈ [l] 10*/10,5*
Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 150/1,5
V-belt AVX 10 [N] 450±50/300±20
Weight without cooling system according to DIN 70020-A ≈ [kg] 253 255
© 2008 67
Technical data Engine and setting data
9 Engine type Dimension D 2011 L04 w TD 2011 L04 w TCD 2011 L04 w
Charging Suction motor Exhaust gas turbocharger Turbocharger with charge air
cooling
Type of cooling water-cooled
No. of cylinders 4 4 4
Total displacement [cm3] 3619
Exhaust gas recirculation external internal internal
Valves per cylinder 2 2 2
Firing order of the engine 1-3-4-2
Coolant volume (only engine content without cooler / ≈ [l] 2,9
hoses and pipes)
Permissible continuous coolant temperature [°C] max. 110
Temperature difference between coolant inlet/outlet [°C] 4-6
Start of thermostat opening [°C] 88
Thermostat fully open [°C] 92
Lubricating oil filling volume (without/with filter) ≈ [l] 8,0*/8,5*
68 © 2009

Engine type
Lubricating oil pressure minimum (low idle, engine
Dimension
[kPa/bar]
D 2011 L04 w TD 2011 L04 w
150/1,5
TCD 2011 L04 w 9
warm)
Charge air temperature outlet at rated power [°C] 50
V-belt AVX 10 [N] 450±50/300±20
Weight without cooling system according to DIN 70020- ≈ [kg] 266 268
A
*specified lubricating oil filling volumes apply for standard versions. In engines which deviate from the standard, for example different lubricating oil pans/dipstick variants
and/or special inclined versions, the lubricating oil volume may vary. The lubricating oil dipstick mark is always decisive.
© 2008 69
Technical data Tools
9 Tool ordering
The special tools described in this chapter can be or-
dered from:
WILBÄR - Wilhelm Bäcker GmbH & Co. KG

Taubenstrasse 5
42857 Remscheid
Germany
Phone: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: info@wilbaer.de
www.deutz-tools.com
Torx tool V-belt tension measuring instrument
Order number: Order number:
8189 8115
The Torx screw system is used in engines in this se- Measuring instrument for checking the specified V-
ries among other things. This system was introduced belt tensions.
for a number of reasons:
z Excellent accessibility
z High force transmission when loosening and
tightening
z Slipping or breaking of the key and risk of injury
are practically excluded.
70 © 2008
Tools Technical data

9
Special tools for removing the water collection Special wrench

vessel.
Order number:
Order number:
170050
8192
For loosening changeable filters.
On Racor filters, only loosen the water collection
vessel with a special tool.
© 2008 71
DEUTZ Oil
DEUTZ Oil DQC II-05 DEUTZ Oil DQC III-05 DEUTZ Oil DQC IV-05 (Synthetic)
ACEA E5-02 / E3-96 / B3-04 ACEA E7-04 / E5-02 / E3-96 / B4-04 / A3-04 ACEA E7-04 / E5-02 / E4-99
API CG-4 API CI-4 / SL GLOBAL DHD-1
TLS-15W40D TLX-10W40FE DEUTZ Oel DQC IV-5W30

(DQC II-05) (DQC III-05) (DQC IV-05)
5L 0101 6331 5L 0101 6335 5L -
20 L 0101 6332 20 L 0101 6336 20 L 0101 7849
209 L 0101 6333 209 L 0101 6337 209 L 0101 7850
DEUTZ AG
Supporthouse Information Systems
Ottostraße 1
51149 Köln
Germany
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
E-Mail: info@deutz.com
www.deutz.com
Printed in Germany
© 02/2008
All rights reserved
Order number:
The engine company. 0312 3547 en

®
DEUTZ
ETL no.: 0505 1747 Fan Constr. Group: 39 SERPIC © 02.10
Equipment: 00011055045 Engine type: TD 2011 L04
Output: 0000055,9 kW Speed: 2600 1/min
ETL scope: EU605839
Item Material Kit MS VS Quant UnitOrd Designation (en) Designation (en) Remark
1 04172005 Kit ? 1 ST Suction fan Suction fan

®
DEUTZ
ETL no.: 0505 1930 Rocker arm bracket Constr. Group: 11 SERPIC © 02.10
ETL scope: EU605839
1 01107727 Kit ? 2 ST Circlip Circlip

2 02109628 Kit ? 2 ST Rocker arm Rocker arm
3 02109636 Kit ? 2 ST Adjusting screw Adjusting screw
4 02109637 Kit ? 2 ST Hexagon nut Hexagon nut
6 01181417 Kit ? 50 2 ST Torx-head bolt Torx-head bolt
7 04174058 Kit ? 1 ST Rocker arm bracket Rocker arm bracket WITH ITEM....
(1-4)
®
DEUTZ
ETL no.: 0506 3108 Companion flange Constr. Group: 41 SERPIC © 02.10
ETL scope: EU605839
1 04172490 Kit ? 1 ST Flange Flange

2 01153346 Kit ? 3 ST Stud Stud
3 01122477 Kit ? 20 20 3 ST Hexagon nut Hexagon nut
4 04172446 Kit ? 1 ST Gasket Gasket
®
DEUTZ
ETL no.: 0506 3419 Blanking parts Constr. Group: 22 SERPIC © 02.10
ETL scope: EU605839
1 01124759 Kit ? 1 ST Screw plug Screw plug

2 01118737 Kit ? 1 ST Sealing ring Sealing ring
®
DEUTZ
ETL no.: 0506 3447 Narrow v-belt Constr. Group: 39 SERPIC © 02.10
ETL scope: EU605839
1 01179565 Kit ? 1 ST Narrow v-belt Narrow v-belt 1125 mm

®
DEUTZ
ETL no.: 0506 4134 Power take-off Constr. Group: 05 SERPIC © 02.10
ETL scope: EU605839
1 04173227 Kit ? 90 90 1 ST V-grooved pulley V-grooved pulley

4 04270814 Kit ? 1 ST Flanged hub Flanged hub
5 04172761 Kit ? 2 ST Plain washer Plain washer
6 01139357 Kit ? 4 ST Hexagon bolt Hexagon bolt
®
DEUTZ
ETL no.: 0506 4400 Lubric. oil filter Constr. Group: 15 SERPIC © 02.10
ETL scope: EU605839
1 01174416 Kit ? 1 ST Spin-on oil filter Spin-on oil filter

®
DEUTZ
ETL scope: EU605839

®
DEUTZ
ETL no.: 0506 7612 Filler cap Constr. Group: 08 SERPIC © 02.10
ETL scope: EU605839
1 04281390 Kit ? 1 ST Filler cap Filler cap

®
DEUTZ
ETL no.: 0506 7616 Control rod Constr. Group: 27 SERPIC © 02.10
ETL scope: EU605839
1 04179809 Kit ? 90 90 1 ST Control rod Control rod

2 04176057 Kit ? 1 ST Locating pin Locating pin
3 04170886 Kit ? 1 ST Compression spring Compression spring
®
DEUTZ
ETL no.: 0506 7625 Oil suction line Constr. Group: 16 SERPIC © 02.10
ETL scope: EU605839
1 04178205 Kit ? 10 10 1 ST Oil suction pipe Oil suction pipe

2 01181422 Kit ? 90 90 2 ST Torx-head bolt Torx-head bolt
234 01016024 Kit ? 1 ST Packing compound Packing compound
®
DEUTZ
ETL no.: 0506 7639 Screw plug Constr. Group: 17 SERPIC © 02.10
ETL scope: EU605839
1 01110433 Kit ? 90 90 1 ST Screw plug Screw plug

®
DEUTZ
ETL no.: 0506 7647 Fuel line Constr. Group: 21 SERPIC © 02.10
ETL scope: EU605839
1 01398209 Kit ? 1 ST Rubber hose Rubber hose LONG

1000 MM
2 01180014 Kit ? 2 ST Hose clip Hose clip
®
DEUTZ
ETL no.: 0506 8013 Sectional rubber Constr. Group: 40 SERPIC © 02.10
ETL scope: EU605839
1 04178358 Kit ? 90 90 1 ST Sectional rubber Sectional rubber

2 01115426 Kit ? 2 ST Straight pin Straight pin
®
DEUTZ
ETL no.: 0506 8145 Radiator connect. Constr. Group: 16 SERPIC © 02.10
ETL scope: EU605839
1 04179775 Kit ? 10 10 2 ST Radiator connect. Radiator connect.

®
DEUTZ
ETL scope: EU605839

®
DEUTZ
ETL no.: 0506 9080 Glow plug Constr. Group: 63 SERPIC © 02.10
ETL scope: EU605839
1 01180400 Kit ? 1 ST Glow plug Glow plug

®
DEUTZ
ETL no.: 0506 9151 Fuel filter Constr. Group: 20 SERPIC © 02.10
ETL scope: EU605839
1 04270708 Kit ? 1 ST Bracket Bracket

2 01174482 Kit ? 1 ST Spin-on fuel filt. Spin-on fuel filt.
®
DEUTZ
ETL no.: 0506 9171 Transfer pipe Constr. Group: 22 SERPIC © 02.10
ETL scope: EU605839
1 04271258 Kit ? 1 ST Reducer Reducer

3 01173940 Kit ? 90 90 1 ST Hose clip Hose clip
®
DEUTZ
ETL no.: 0506 9183 Exhaust manifold Constr. Group: 41 SERPIC © 02.10
ETL scope: EU605839
1 04271176 Kit ? 90 90 1 ST Exhaust manifold Exhaust manifold

3 01181756 Kit ? 8 ST Torx-head bolt Torx-head bolt
169 01016116 Kit ? 20 20 1 KG Fitting compound Fitting compound UP TO MNFG MONTH
15.02.2001
®
DEUTZ
ETL no.: 0507 2493 Plug-in connector Constr. Group: 48 SERPIC © 02.10
ETL scope: EU605839
1 04199602 Kit ? 1 ST Plug-in connector Plug-in connector WITH ITEM....

(2-5)
2 04189582 Kit ? 1 ST Housing cover Housing cover
4 04190860 Kit ? 15 ST Blank plug Blank plug
5 04190852 Kit ? 21 ST Jack Jack
®
DEUTZ
ETL scope: EU605839
1 04199615 Kit ? 1 ST Plug-in connector Plug-in connector

®
DEUTZ
ETL no.: 0507 4055 Adapter housing Constr. Group: 52 SERPIC © 02.10
ETL scope: EU605839
1 04271659 Kit ? 1 ST Adapter housing Adapter housing

2 02109066 Kit ? 2 ST Clamping bush Clamping bush
3 01103341 Kit ? 20 20 4 ST Hexagon bolt Hexagon bolt
®
DEUTZ
ETL no.: 0507 4151 Flywheel Constr. Group: 05 SERPIC © 02.10
ETL scope: EU605839
1 04272425 Kit ? 1 ST Flywheel Flywheel WITH ITEM....

(2)
2 04272421 Kit ? 1 ST Gear rim Gear rim
3 02109988 Kit ? 8 ST Screw/bolt Screw/bolt
®
DEUTZ
ETL no.: 0507 4179 Oil pan Constr. Group: 02 SERPIC © 02.10
ETL scope: EU605839
1 02931263 Kit ? 1 ST Oil pan Oil pan WITH ITEM....

(4-6)
10 01017932 Kit ? AR 10 L Engine oil Engine oil Material no.: only for
quantity
calculation
®
DEUTZ
ETL no.: 0507 4209 Protection hood Constr. Group: 83 SERPIC © 02.10
ETL scope: EU605839
25 04280352 Kit ? 1 ST Protection hood Protection hood WITH ITEM....

(27)
27 01398414 Kit ? 90 90 1 M Sealing section Sealing section
®
DEUTZ
ETL no.: 0507 4210 Crankcase breather Constr. Group: 01 SERPIC © 02.10
ETL scope: EU605839
1 04280347 Kit ? 1 ST Breather pipe Breather pipe

®
DEUTZ
ETL scope: EU605839
1 01164286 Kit ? 1 ST Plug Plug

®
DEUTZ
ETL no.: 0507 4237 Accessories Constr. Group: 05 SERPIC © 02.10
ETL scope: EU605839

2 04280135 Kit ? 1 ST Lube deflector Lube deflector
3 04173550 Kit ? 60 1 ST Synchr.belt pulley Synchr.belt pulley
4 04174497 Kit ? 1 ST Synchr.belt pulley Synchr.belt pulley
5 04280164 Kit ? 1 ST Adapter Adapter
®
DEUTZ
ETL no.: 0507 4269 Tacho-generator Constr. Group: 51 SERPIC © 02.10
ETL scope: EU605839
1 04364426 Kit ? 20 20 1 ST Tacho-generator Tacho-generator

3 04280747 Kit ? 1 ST Spacer sleeve Spacer sleeve
®
DEUTZ
ETL no.: 0507 4273 Clutch sleeve Constr. Group: 83 SERPIC © 02.10
ETL scope: EU605839
1 04280529 Kit ? 1 ST Clutch sleeve Clutch sleeve

201 01016126 Kit ? 1 ST Graphite grease Graphite grease
®
DEUTZ
ETL no.: 0507 7779 Protective hose Constr. Group: 63 SERPIC © 02.10
ETL scope: EU605839
1 04194349 Kit ? 1 ST Protective hose Protective hose

®
DEUTZ
ETL no.: 0507 7896 Bracket Constr. Group: 15 SERPIC © 02.10
ETL scope: EU605839
1 04287677 Kit ? 1 ST Bracket Bracket WITH ITEM....

(4-8)
2 04281205 Kit ? 90 90 1 ST Gasket Gasket
5 04258757 Kit ? 1 ST Control valve Control valve
6 04258759 Kit ? 1 ST Temperature sensor Temperature sensor
®
DEUTZ
ETL scope: EU605839

2 04281324 Kit ? 1 ST Two-hole flange Two-hole flange
®
DEUTZ
ETL no.: 0507 7923 Limit stop Constr. Group: 27 SERPIC © 02.10
ETL scope: EU605839
56 04286813 Kit ? 1 ST Fll load stop Fll load stop

187 01016123 Kit ? 20 20 1 KG Safety/lock.agent Safety/lock.agent
®
DEUTZ
ETL scope: EU605839
2 04281429 Kit ? 20 20 1 ST Fuel line Fuel line WITH ITEM....

(10,11)
3 01177045 Kit ? 20 20 1 ST Rubber hose Rubber hose
4 01182135 Kit ? 1 ST Connecting piece Connecting piece
8 01176435 Kit ? 1 ST Clamping band Clamping band
10 01119241 Kit ? 4 ST Hollow screw Hollow screw
®
DEUTZ
ETL no.: 0507 9011 Turbocharger Constr. Group: 43 SERPIC © 02.10
ETL scope: EU605839
1 04281437 Kit ? 1 ST Turbocharger Turbocharger

®
DEUTZ
ETL no.: 0507 9021 Fastenings Constr. Group: 10 SERPIC © 02.10
ETL scope: EU605839

4 02112403 Kit ? 1 ST Locking screw Locking screw
®
DEUTZ
ETL scope: EU605839
1 01177045 Kit ? 20 20 1 ST Rubber hose Rubber hose

3 01404943 Kit ? 90 90 1 ST Hose Hose
®
DEUTZ
ETL no.: 0507 9110 Accessories Constr. Group: 83 SERPIC © 02.10
ETL scope: EU605839
9 02931482 Kit ? 1 ST Repair kit Repair kit

21 01153887 Kit ? 1 ST O-seal O-seal
25 04280529 Kit ? 1 ST Clutch sleeve Clutch sleeve
201 01016126 Kit ? 1 ST Graphite grease Graphite grease
®
DEUTZ
ETL no.: 0507 9131 Generator Constr. Group: 44 SERPIC © 02.10
ETL scope: EU605839
1 01340485 Kit ? 1 ST Gasket set Gasket set

2 01181859 Kit ? 1 ST Fan Fan
3 01182187 Kit ? 1 ST V-grooved pulley V-grooved pulley
4 01183455 Kit ? 1 ST Generator Generator WITH ITEM....
(1,2,5-8)
5 01183471 Kit ? 1 ST Voltage regulator Voltage regulator
8 01182010 Kit ? 90 90 1 ST Supporting ring Supporting ring
®
DEUTZ
ETL no.: 0507 9148 Front cover/govern Constr. Group: 27 SERPIC © 02.10
ETL scope: EU605839
1 04286243 Kit ? 1 ST Metering unit Metering unit

5 04174542 Kit ? 1 ST Tension spring Tension spring
6 04287201 Kit ? 90 90 1 ST Lever/arm Lever/arm
8 04175629 Kit ? 2 ST Sleeve Sleeve
10 04175945 Kit ? 1 ST Lever/arm Lever/arm
17 04178839 Kit ? 1 ST Profile washer Profile washer
18 01179835 Kit ? 3 ST Cheese head screw Cheese head screw
21 04280156 Kit ? 1 ST Lever shaft Lever shaft
23 04287491 Kit ? 1 ST Roller lever Roller lever
24 01137646 Kit ? 2 ST Ball bearing Ball bearing
25 01180059 Kit ? 90 90 2 ST Clevis pin Clevis pin
26 01115316 Kit ? 1 ST Notched nail Notched nail
27 04178202 Kit ? 1 ST Axle Axle
28 04179754 Kit ? 90 90 1 ST Lever/arm Lever/arm
®
DEUTZ
ETL no.: 0507 9148 Front cover/govern Constr. Group: 27 SERPIC © 02.10
ETL scope: EU605839

33 04270491 Kit ? 1 ST Sleeve Sleeve
36 04281898 Kit ? 1 ST Torsion spring Torsion spring
40 01151181 Kit ? 1 ST Set screw Set screw
46 01105091 Kit ? 1 ST Parallel pin Parallel pin
47 04281188 Kit ? 1 ST Front cover Front cover
49 04178572 Kit ? 1 ST Breather valve Breather valve
50 04175435 Kit ? 1 ST Rot.shaft lip seal Rot.shaft lip seal
66 04178895 Kit ? 1 ST Cover Cover
®
DEUTZ
ETL no.: 0507 9187 Actuator Constr. Group: 56 SERPIC © 02.10
ETL scope: EU605839

12 04286363 Kit ? 1 ST Actuator Actuator
®
DEUTZ
ETL no.: 0507 9188 Rear end cover Constr. Group: 01 SERPIC © 02.10
ETL scope: EU605839
1 04287142 Kit ? 90 90 1 ST Rear end cover Rear end cover WITH ITEM....
(3)
®
DEUTZ
ETL no.: 0507 9193 Temperature sensor Constr. Group: 48 SERPIC © 02.10
ETL scope: EU605839
1 04213210 Kit ? 1 ST Temper.transmitter Temper.transmitter

®
DEUTZ
ETL scope: EU605839

2 04271246 Kit ? 2 ST Bush Bush
®
DEUTZ
ETL no.: 0507 9198 Protection hood Constr. Group: 10 SERPIC © 02.10
ETL scope: EU605839

(3+5)
(3,4,7)
3 01398465 Kit ? 1 M Sealing section Sealing section
4 04280144 Kit ? 1 ST Rubber grommet Rubber grommet
5 04280126 Kit ? 1 ST Shaped packing Shaped packing
®
DEUTZ
ETL no.: 0507 9231 Interconnect.cable Constr. Group: 48 SERPIC © 02.10
ETL scope: EU605839
1 04213235 Kit ? 1 ST Interconnect.cable Interconnect.cable

®
DEUTZ
ETL scope: EU605839
7 04287286 Kit ? 1 ST Wire fastener Wire fastener

®
DEUTZ
ETL scope: EU605839

®
DEUTZ
ETL no.: 0507 9291 Pressure pick-up Constr. Group: 48 SERPIC © 02.10
ETL scope: EU605839
1 04213707 Kit ? 20 20 1 ST Pressure sensor Pressure sensor

®
DEUTZ
ETL no.: 0511 3203 Accelerator pedal Constr. Group: 48 SERPIC © 02.10
ETL scope: EU605839
1 04406063 Kit ? 1 ST Accelerator pedal Accelerator pedal WITH ITEM....

(2)
®
DEUTZ
ETL scope: EU605839

®
DEUTZ
ETL no.: 0511 3631 Fuel inject. pump Constr. Group: 17 SERPIC © 02.10
ETL scope: EU605839
1 04286967 Kit ? 90 90 1 ST Fuel inject. pump Fuel inject. pump WITH ITEM....
(2)
2 01340402 Kit ? 20 20 1 ST O-ring O-ring
10 01340403 Kit ? 1 ST Fuel inject. pump Fuel inject. pump Pumpenklasse - A -
11 01340404 Kit ? 1 ST Fuel inject. pump Fuel inject. pump Pumpenklasse - B -
12 01340405 Kit ? 1 ST Fuel inject. pump Fuel inject. pump Pumpenklasse - C -
13 01340406 Kit ? 1 ST Fuel inject. pump Fuel inject. pump Pumpenklasse - D -
®
DEUTZ
ETL no.: 0511 3678 Fuel supply pump Constr. Group: 20 SERPIC © 02.10
ETL scope: EU605839
1 04287258 Kit ? 90 90 1 ST Fuel supply pump Fuel supply pump WITH ITEM....
(2,4-6)
5 02111897 Kit ? 1 ST Hand pump Hand pump
6 01340488 Kit ? 1 ST Repair kit Repair kit
®
DEUTZ
ETL no.: 0511 3695 Camshaft drive Constr. Group: 10 SERPIC © 02.10
ETL scope: EU605839
1 04286428 Kit ? 1 ST Synchr.belt pulley Synchr.belt pulley

2 04270070 Kit ? 1 ST Hexagon screw Hexagon screw
10 02931485 Kit ? 20 20 1 ST Repair kit Repair kit
®
DEUTZ
ETL no.: 0511 4510 Valve drive Constr. Group: 11 SERPIC © 02.10
ETL scope: EU605839
1 04286946 Kit ? 2 ST Pushrod Pushrod

2 04178075 Kit ? 2 ST Valve tappet Valve tappet
®
DEUTZ
ETL no.: 0511 4511 High pressure pipe Constr. Group: 21 SERPIC © 02.10
ETL scope: EU605839
1 04287469 Kit ? 1 ST High pressure pipe High pressure pipe

®
DEUTZ
ETL no.: 0511 4517 Crankshaft Constr. Group: 05 SERPIC © 02.10
ETL scope: EU605839
1 04287161 Kit ? 1 ST Crankshaft Crankshaft

2 04270238 Kit ? 5 ST Main bearing Main bearing
3 02928961 Kit ? 1 ST Thrust washer Thrust washer
6 06218864 Kit ? 8 ST Threaded insert Threaded insert
951 04270242 Kit ? 1 ST Main bearing Main bearing 1ST OVERSIZE
952 04270247 Kit ? 1 ST Main bearing Main bearing 2ND OVERSIZE
953 02928962 Kit ? 1 ST Thrust washer Thrust washer 1ST OVERSIZE
®
DEUTZ
ETL no.: 0511 4518 Connecting rod Constr. Group: 06 SERPIC © 02.10
ETL scope: EU605839
1 04286940 Kit ? 1 ST Connecting rod Connecting rod WITH ITEM....

(2-4)
2 04286942 Kit ? 2 ST Big end bolt Big end bolt
3 04103655 Kit ? 1 ST Bearing shell Bearing shell STANDARD (A)MM RD, FOR
OVERSIZE SEE ITEM (B)
Pos.( B ) 954,955
4 04170393 Kit ? 1 ST Big end bush Big end bush STANDARD (A)MM RD, FOR
OVERSIZE SEE ITEM (B)
A 33,07-33,11
B 953
953 04170394 Kit ? 1 ST Big end bush Big end bush OVERSIZE
33,32-33,36MM
954 04103656 Kit ? 1 ST Bearing shell Bearing shell 1ST UNDERSIZE
955 04103657 Kit ? 1 ST Bearing shell Bearing shell 2ND UNDERSIZE
®
DEUTZ
ETL scope: EU605839
1 04270815 Kit ? 10 ST Cylinder head bolt Cylinder head bolt

2 04178611 Kit ? 2 ST Spiral pin Spiral pin GASKET THICKNESS DEPEND
ING
ON MEASUREMENT RESULT
-DELIVERY COND. (A)=...
MM
-INSTALLATION COND. (B)
=...MM
DIFF.THICKNESSES SEE IT
EM (C)
3 04102011 Kit ? 1 ST Cylind.head gasket Cylind.head gasket GASKET THICKNESS DEPEND
ING
MM
=...MM
EM (C)
A = 1,47 +/- 0.09
®
DEUTZ
ETL scope: EU605839
B = 1,51
C = POS.4,5
ING
MM
=...MM
EM (C)
A = 1,57 +/- 0.09
B = 1,61
C = POS.3,5
ING
MM
=...MM
EM (C)
A=1.67 +/- 0.09
B=1.71
C= POS. 3.4
®
DEUTZ
ETL no.: 0511 4785 Fuel injector Constr. Group: 19 SERPIC © 02.10
ETL scope: EU605839
1 04102137 Kit ? 1 ST Fuel injector Fuel injector

3 04281147 Kit ? 1 ST Claw Claw
®
DEUTZ
ETL no.: 0511 4786 Charge air pipe Constr. Group: 22 SERPIC © 02.10
ETL scope: EU605839
1 04300295 Kit ? 1 ST Suction pipe Suction pipe

2 01175634 Kit ? 1 ST Rubber sleeve Rubber sleeve
4 01178747 Kit ? 2 ST Spring band clamp Spring band clamp
®
DEUTZ
ETL no.: 0511 4822 Oil return line Constr. Group: 16 SERPIC © 02.10
ETL scope: EU605839
1 04287333 Kit ? 1 ST Oil return line Oil return line

2 04207255 Kit ? 1 ST Screw-in nipple Screw-in nipple
8 04271160 Kit ? 1 ST Retaining plate Retaining plate
®
DEUTZ
ETL no.: 0511 4823 Lubricat. oil line Constr. Group: 16 SERPIC © 02.10
ETL scope: EU605839
1 04287309 Kit ? 90 90 1 ST Lubricat. oil line Lubricat. oil line WITH ITEM....
(2,3)
®
DEUTZ
ETL no.: 0511 4825 Camshaft Constr. Group: 10 SERPIC © 02.10
ETL scope: EU605839
1 04173067 Kit ? 1 ST Thrust washer Thrust washer

3 04102236 Kit ? 1 ST Camshaft Camshaft
®
DEUTZ
ETL no.: 0511 4858 Pilot line Constr. Group: 16 SERPIC © 02.10
ETL scope: EU605839
1 04102224 Kit ? 1 ST Pilot line Pilot line WITH ITEM....

(10,11)
®
DEUTZ
ETL scope: EU605839

8 01171262 Kit ? 2 ST Pipe clamp Pipe clamp
®
DEUTZ
ETL no.: 0511 4863 Cable harness Constr. Group: 48 SERPIC © 02.10
ETL scope: EU605839
1 04215021 Kit ? 1 ST Cable harness Cable harness

®
DEUTZ
ETL scope: EU605839

®
DEUTZ
ETL scope: EU605839

®
DEUTZ
ETL no.: 0511 4881 Lubricat. oil pump Constr. Group: 14 SERPIC © 02.10
ETL scope: EU605839
1 04102478 Kit ? 1 ST Lubricat. oil pump Lubricat. oil pump WITH ITEM....
(2,3)
2 01148815 Kit ? 1 ST Set screw Set screw
5 04178612 Kit ? 2 ST Spiral pin Spiral pin
®
DEUTZ
ETL no.: 0511 4903 Generator mounting Constr. Group: 44 SERPIC © 02.10
ETL scope: EU605839

4 04172296 Kit ? 1 ST Clamping strap Clamping strap
®
DEUTZ
ETL no.: 0511 4943 Heater connection Constr. Group: 16 SERPIC © 02.10
ETL scope: EU605839
1 04272641 Kit ? 3 ST Valve Valve

7 04178229 Kit ? 1 ST Adapter nipple Adapter nipple
8 04272614 Kit ? 1 ST Adapter nipple Adapter nipple
®
DEUTZ
ETL no.: 0511 4988 Engine block Constr. Group: 01 SERPIC © 02.10
ETL scope: EU605839
1 04287158 Kit ? 1 ST Engine block Engine block WITH ITEM....

(2-19)
2 04178155 Kit ? 2 ST Wrapped bear. bush Wrapped bear. bush
3 04178154 Kit ? 3 ST Wrapped bear. bush Wrapped bear. bush
4 04287999 Kit ? 2 ST Guide sleeve Guide sleeve
7 04179928 Kit ? 90 90 1 ST Thermostat Thermostat
10 04178218 Kit ? 1 ST Tube Tube
19 03362279 Kit ? 10 ST Bush Bush
®
DEUTZ
ETL no.: 0511 4988 Engine block Constr. Group: 01 SERPIC © 02.10
ETL scope: EU605839

25 04178452 Kit ? 8 ST Piston cool.nozzle Piston cool.nozzle
26 01148153 Kit ? 1 ST Cover Cover
27 04179960 Kit ? 1 ST Pin Pin
189 01319910 Kit ? 1 ST Safety/lock.agent Safety/lock.agent
®
DEUTZ
ETL no.: 0511 8175 Control unit Constr. Group: 27 SERPIC © 02.10
ETL scope: EU605839
1 02959601 Kit ? 1 ST Control unit Control unit programmiert , programm

ed
950 04218027 Kit ? 1 ST Control unit Control unit nicht programmiert , no
t programmed
®
DEUTZ
ETL scope: EU605839
1 04102954 Kit ? 1 ST Fuel line Fuel line WITH ITEM....

(2,3)
®
DEUTZ
ETL no.: 0511 9030 Engine oil Constr. Group: 90 SERPIC © 02.10
ETL scope: EU605839
10 01016331 Kit ? AR 5 L Engine oil Engine oil Lubricating oil specifi

cations apply for
standard engines withou
t particle
filter!
cations apply for
t particle
filter!
cations apply for
t particle
filter!
cations apply for
t particle
filter!
®
DEUTZ
ETL no.: 0511 9030 Engine oil Constr. Group: 90 SERPIC © 02.10
ETL scope: EU605839

cations apply for
t particle
filter!
cations apply for
t particle
filter!
cations apply for
t particle
filter!
cations apply for
t particle
filter!
cations apply for
standard engines with p
articel filter!
cations apply for
standard engines with p
articel filter!
®
DEUTZ
ETL scope: EU605839

5 04103175 Kit ? 1 ST Joint plate Joint plate
6 04199234 Kit ? 1 ST Cable clamp Cable clamp
7 04199292 Kit ? 1 ST Terminal bolt Terminal bolt
®
DEUTZ
ETL no.: 0511 9065 Piston Constr. Group: 07 SERPIC © 02.10
ETL scope: EU605839
1 04102854 Kit ? 1 ST Piston Piston COMPLETE

KOMPRESSIONSHOEHENKLASS
E "A"
2 04173414 Kit ? 1 ST Piston pin Piston pin
3 01139875 Kit ? 2 ST Snap ring Snap ring
4 04287811 Kit ? 1 ST Set of pist. rings Set of pist. rings
950 04102856 Kit ? 1 ST Piston Piston 1ST OVERSIZE (A) MM RD,
STANDARD SEE ITEM (B)
A=96,5
B= Pos 001
®
DEUTZ
ETL scope: EU605839

®
DEUTZ
ETL no.: 0511 9122 Dipstick Constr. Group: 01 SERPIC © 02.10
ETL scope: EU605839
1 04103285 Kit ? 1 ST Dipstick Dipstick WITH ITEM....

(2)
®
DEUTZ
ETL no.: 0511 9142 Valve mechan.cover Constr. Group: 08 SERPIC © 02.10
ETL scope: EU605839
1 04103302 Kit ? 1 ST Valve mechan.cover Valve mechan.cov.. WITH ITEM....

(2-5)
3 04271850 Kit ? 1 ST Breather valve Breather valve
5 04103304 Kit ? 1 ST Oil separator Oil separator
®
DEUTZ
ETL scope: EU605839
1 04103289 Kit ? 1 ST Roller tappet Roller tappet

4 04287618 Kit ? 1 ST Shim Shim GASKET THICKNESS DEPEND
ING
ON MEASUREMENT RESULT (
A)= MM
EM (B)
A = 0,35 mm
B = 950-965
950 04287619 Kit ? 1 ST Shim Shim ....MM THICKNESS
0,40 mm
0,45 mm
0,50 mm
0,55 mm
®
DEUTZ
ETL scope: EU605839

0,60 mm
0,65 mm
0,70 mm
0,75 mm
0,80 mm
0,85 mm
0,90 mm
0,95 mm
1,00 mm
1,05 mm
1,10 mm
1,15 mm
1,20mm
1,30mm
®
DEUTZ
ETL no.: 0511 9172 Starter Constr. Group: 44 SERPIC © 02.10
ETL scope: EU605839
1 01183404 Kit ? 90 90 1 ST Starter Starter R 12V 2,6KW

WITH ITEM....
(3)
3 01340626 Kit ? 1 ST Relay Relay
®
DEUTZ
ETL no.: 0511 9213 Gasket set Constr. Group: 90 SERPIC © 02.10
ETL scope: EU605839
1 02937594 Kit ? 1 ST Gasket set Gasket set The gasket set may not
contain all
gaskets, see SM 0199-99
-9449
®
DEUTZ
ETL no.: 0511 9224 Control unit Constr. Group: 48 SERPIC © 02.10
ETL scope: EU605839
1 04103669 Kit ? 1 ST Gl.time contr.unit Gl.time contr.unit

3 04217705 Kit ? 1 ST Base/pedestal Base/pedestal
®
DEUTZ
ETL no.: 0511 9239 Cylinder head Constr. Group: 08 SERPIC © 02.10
ETL scope: EU605839
1 04103841 Kit ? 1 ST Cylinder head Cylinder head WITH ITEM....

(2-17)
2 04287670 Kit ? 4 ST Valve seat insert Valve seat insert
3 04287672 Kit ? 4 ST Valve seat insert Valve seat insert
4 04280049 Kit ? 4 ST Exhaust valve Exhaust valve
5 04280404 Kit ? 4 ST Inlet valve Inlet valve
10 04153728 Kit ? 8 ST Valve stem seal Valve stem seal
12 04280921 Kit ? 8 ST Spring cap Spring cap
13 02108102 Kit ? 16 ST Valve collet Valve collet
®
DEUTZ
Assembly group directory SERPIC © 02.10
ETL scope: EU605839
CG ETL-No. Designation (en) Designation (en)

1 Crankcase
1 0507 4210 Crankcase breather Crankcase breather
1 0507 7901 Blanking parts Blanking parts
1 0507 9188 Rear end cover Rear end cover
1 0511 4988 Engine block Engine block
1 0511 9122 Dipstick Dipstick
2 Oil pan
2 0507 4179 Oil pan Oil pan
5 Crankshaft
5 0506 4134 Power take-off Power take-off
5 0507 4151 Flywheel Flywheel
5 0507 4237 Accessories Accessories
5 0511 4517 Crankshaft Crankshaft
6 Connecting rod
6 0511 4518 Connecting rod Connecting rod
7 Piston
7 0511 9065 Piston Piston
8 Cylinder head
8 0506 7612 Filler cap Filler cap
8 0511 4563 Fastenings Fastenings
8 0511 9142 Valve mechan.cover Valve mechan.cover
8 0511 9239 Cylinder head Cylinder head
10 Camshaft
10 0507 9198 Protection hood Protection hood
10 0511 3695 Camshaft drive Camshaft drive
10 0511 4825 Camshaft Camshaft
11 Timing gears
11 0505 1930 Rocker arm bracket Rocker arm bracket
11 0511 4510 Valve drive Valve drive
14 Lube oil pump
14 0511 4881 Lubricat. oil pump Lubricat. oil pump
15 Lube oil/-cooler
15 0506 4400 Lubric. oil filter Lubric. oil filter
15 0507 7896 Bracket Bracket
16 Oil pipes
16 0506 7625 Oil suction line Oil suction line
16 0506 8145 Radiator connect. Radiator connect.
16 0511 4822 Oil return line Oil return line
16 0511 4823 Lubricat. oil line Lubricat. oil line
16 0511 4858 Pilot line Pilot line
16 0511 4943 Heater connection Heater connection
17 Injection pump
17 0506 7639 Screw plug Screw plug
17 0511 3631 Fuel inject. pump Fuel inject. pump
®
DEUTZ
SERPIC © 02.10
ETL scope: EU605839

19 Injector
19 0511 4785 Fuel injector Fuel injector
20 Fuel filter
20 0506 9151 Fuel filter Fuel filter
20 0507 9099 Fuel line Fuel line
20 0511 3678 Fuel supply pump Fuel supply pump
21 Fuel pipes/fuel tank
21 0511 4511 High pressure pipe High pressure pipe
22 Suction pipe/air cleaner
22 0506 9171 Transfer pipe Transfer pipe
22 0511 4786 Charge air pipe Charge air pipe
27 Speed control
27 0506 7616 Control rod Control rod
27 0507 7923 Limit stop Limit stop
27 0507 9148 Front cover/govern Front cover/govern
27 0511 8175 Control unit Control unit
39 Cooling air blower
39 0505 1747 Fan Fan
39 0506 3447 Narrow v-belt Narrow v-belt
40 Cooling air ducting
40 0506 8013 Sectional rubber Sectional rubber
41 Exhaust manifold
41 0506 3108 Companion flange Companion flange
41 0506 9183 Exhaust manifold Exhaust manifold
43 Turbocharger
43 0507 9011 Turbocharger Turbocharger
44 Alternator/starter motor
44 0507 9131 Generator Generator
44 0511 4903 Generator mounting Generator mounting
44 0511 9172 Starter Starter
48 Electrical accessories
48 0507 2493 Plug-in connector Plug-in connector
48 0507 9193 Temperature sensor Temperature sensor
48 0507 9231 Interconnect.cable Interconnect.cable
48 0507 9291 Pressure pick-up Pressure pick-up
®
DEUTZ
SERPIC © 02.10
ETL scope: EU605839

48 0511 3203 Accelerator pedal Accelerator pedal
48 0511 4863 Cable harness Cable harness
48 0511 9224 Control unit Control unit
51 Measuring instruments
51 0507 4269 Tacho-generator Tacho-generator
52 Clutch
52 0505 1756 Cover plate Cover plate
52 0507 4055 Adapter housing Adapter housing
56 Engine shutdown
56 0507 9187 Actuator Actuator
63 Starting aid
63 0506 9080 Glow plug Glow plug
63 0507 7779 Protective hose Protective hose
83 Hydraulic pump
83 0507 4209 Protection hood Protection hood
83 0507 4273 Clutch sleeve Clutch sleeve
83 0507 9110 Accessories Accessories
90 Set of parts
90 0511 9030 Engine oil Engine oil
90 0511 9213 Gasket set Gasket set
98 Optional extras
98 0118 0396 Blind rivet Blind rivet
98 0211 2403 Locking screw Locking screw
98 0417 4748 Compression spring Compression spring
98 0421 3290 Protecting cap Protecting cap
307-01-1 Automatic Transmission — 4R70E/4R75E 307-01-1
SPECIFICATIONS
General Specifications (Continued)
Item Specification
General Specifications
Lubricants
Item Specification
Multi-Purpose Grease ESR-M1C159-A
Fluid XG-4
MERCON V is not interchangeable at this time with High Strength WSK-M2G351-A6
the current MERCON service fluids. Check the Threadlocker TA-26
transmission fluid level indicator to determine the
correct fluid and refer to the Workshop
Information/Owner publication to determine the correct Torque Converter Stall Speed
service interval for the specific vehicle.
Engine Min Max
Motorcraft MERCON V MERCON V
Automatic Transmission 4.2L 1,976 2,356
Fluid XT-5-QM 4.6L 2,125 2,488
Fluid Capacities 5.4L 2,404 2,842
Refill Capacity Liters 13.2L (13.9 quarts)
(Quarts)
All applications Torque Converter End Play
Fluid Filter Item Specification
In-line Transmission Fluid — New or rebuilt mm (inch) 0.355-1.04 (0.014-0.041)
Filter Kit
XC3Z-7B155-AA Used mm (inch) 0.355-1.87 (0.014-0.074)
In-line Transmission Fluid —

Filter XC3Z-7B155-AB
Band and Clutch Application Chart A

Intermed- Low/
Overdrive iate Reverse Reverse Forward Direct
Gear Band Clutch Band Clutch Clutch Clutch
REVERSE A A
1st GEAR MANUAL LOW A A
2nd GEAR MANUAL LOW A A A
1st GEAR (D) (Overdrive) A
2nd GEAR (D) (Overdrive) A A
3rd GEAR (D) (Overdrive) A A A
4th GEAR (D) (Overdrive) A A A
A = Applied
Band and Clutch Application Chart B

Intermediate Planetary One-Way
One-Way Clutch Clutch Solenoid States
Gear Drive Coast Drive Coast SSA SSB TCC
PARK ON OFF HDa
REVERSE NEb ON OFF HDa
NEUTRAL ON OFF HDa
1st GEAR MANUAL LOW Hc ON OFF HDa
Copyright  2004, Ford Motor Company

Last updated: 8/2/2004 2005 F-150, 10/2004
SPECIFICATIONS (Continued)
Band and Clutch Application Chart B (Continued)
Intermediate Planetary One-Way
One-Way Clutch Clutch Solenoid States
Gear Drive Coast Drive Coast SSA SSB TCC
2nd GEAR MANUAL LOW Hc OFF OFF ECd
1st GEAR (D) (Overdrive) Hc ORe ON OFF HDa
2nd GEAR (D) (Overdrive) Hc ORe ORe OFF OFF ECd
3rd GEAR (D) (Overdrive) ORe ORe OFF ON ECd
4th GEAR (D) (Overdrive) ORe ORe ORe ON ON ECd
a HD = Hydraulically Disabled
b NE = No Effect
c H = Hold
d EC = Electronically Controlled
e OR = Overrunning
Shift Speeds
NOTE: Shift speed ranges are approximate for all applications. For specific applications (engine,
axle ratio, tire size and application), refer to the Automatic Transmission Specification booklet.
Always drive the vehicle in a safe manner according to driving conditions and obey all traffic
laws.
Throttle Position Shift MPH Km/H
Light Throttle 1-2 9-17 14-27
TP Voltage 2-3 15-35 24-56
1.25 Volts 3-4 19-47 31-76
Closed Throttle 4-3 11-25 18-40
3-2 11-25 18-40
2-1 4-12 6-19
Wide Open Throttle 1-2 32-48 51-77
2-3 60-88 97-142
3-2 58-88 93-142
2-1 29-39 46-62
Sensor Resistance Readings Selective Thrust Washer No. 1

Component Readings (ohm) Item Specifications
SSA 20-30 ohms Green thickness mm 1.217-1.371 (0.050-0.054)
SSB 20-30 ohms (inch)
EPC 2.48-5.66 ohms Yellow thickness mm 1.727-1.828 (0.068-0.072)

(inch)
TCC 10-16 ohms
Natural thickness mm 2.159-2.260 (0.085-0.089)
OSS 400-500 ohms (inch)
TSS 480-590 ohms Red thickness mm (inch) 2.590-2.692 (0.102-0.106)
Blue thickness mm (inch) 3.022-3.124 (0.119-0.123)
2005 F-150, 10/2004

Forward Clutch Pack Torque Specifications (Continued)
Item Specifications Description Nm lb-ft lb-in
Clearance mm (inch) 1.83-2.29 (0.072-0.090) Front pump bolts 27 20 —
Snap ring thickness mm 1.727-1.828 (0.068-0.072) Front pump support 23 17 —
(inch) 1.930-2.032 (0.076-0.080) bolts
2.133-2.235 (0.084-0.088) Harness electrical 5 — 44
2.336-2.438 (0.092-0.096) connector bolt
Inspection cover bolts 34 25 —
Reverse Clutch Pack Main control valve 10 — 89
Item Specifications body bolts
Clearance mm (inch) 1.27-1.94 (0.050-0.076) Main control valve 10 — 89
body cover plate bolts
Snap ring thickness mm 1.727-1.828 (0.068-0.072)
(inch) 1.880-1.981 (0.074-0.078) Main control valve 10 — 89
2.235-2.337 (0.088-0.092) body separator plate
2.591-2.692 (0.102-0.106) bolts
Main control valve 10 — 89
body reinforcement
Direct Clutch Pack plates
Item Specifications Manual lever shaft 31 23 —
inner nut
Clearance mm (inch) 1.65-2.08 (0.065-0.082)
Manual lever shaft 33 24 —
Snap ring thickness mm 1.270-1.372 (0.050-0.054) outer nut
(inch) 1.625-1.727 (0.064-0.068)
1.981-2.083 (0.078-0.082) Transmission fluid 31 23 —
2.337-2.438 (0.092-0.096) cooler tube case fittings
Transmission fluid 18 13 —
cooler tube nut fittings
Intermediate Clutch Pack
Transmission fluid 15 11 —
Item Specifications cooler bolts
Clearance mm (inch) 41.7322-42.5958 Pressure tap plugs 10 — 89
(1.643-1.677) Rear driveshaft bolts 103 76 —
Selective steel plate mm 1.702-1.803 (0.067-0.071) Starter bolts 26 19 —
(inch) 1.956-2.057 (0.077-0.081)
2.210-2.311 (0.087-0.091) Battery ground wire 23 17 —
2.464-2.565 (0.097-0.101) Starter electrical 12 9 —
connector
Torque Specifications Starter electrical 6 — 53
connector (small
Description Nm lb-ft lb-in terminal)
Transmission 90 66 — TCC solenoid bolt 10 — 89
crossmember bolts
Torque converter nuts 36 27 —
Shift cable bracket 25 18 —
bolts Digital transmission 9 — 80
range (TR) sensor bolts
Transmission mount 103 76 —
nuts Transmission case 48 35 —
retaining bolts
Transmission mount 80 59 —
bolts Output shaft speed 12 9 —
(OSS) sensor bolt
Transmission fluid pan 14 10 —
bolts Turbine shaft speed 11 8 —
(TSS) sensor bolt
Front driveshaft bolts 103 76 —
2005 F-150, 10/2004

Torque Specifications (Continued) Torque Specifications (Continued)
Description Nm lb-ft lb-in Description Nm lb-ft lb-in
Rear transmission 80 59 — Extension housing bolts 27 20 —
support bolts Transmission floor 7 — 62
Floor shifter retaining 12 9 — shifter retaining bolts
bolts Exhaust heat 15 11 —
Transmission vent tube 20 15 — shield-to-crossmember
Manual control valve 10 — 89 bolt
detent lever spring bolt
2005 F-150, 10/2004

DESCRIPTION AND OPERATION

Identification Tags Identification Tag
All vehicles are equipped with a Vehicle

Certification Label, located on the driver side door
lock post. For correct transmission identification,
refer to the code in the space marked TR.
For model, service ID level or build date
information, refer to the transmission service ID tag
located on the transmission case.
Item Part Number Description

1 — Model number
2 — Assembly number
3 — Serial number
4 — Model and serial number

Last updated: 8/2/2004 2005 F-150, 10/2004

Range Selection Neutral
The transmission has six range positions: P, R, N, In the NEUTRAL position:
(D) , 2 and 1. • there is no powerflow through the transmission.
Column Shift • the output shaft is not held and is free to turn.
• the engine can be started.
Overdrive
Overdrive is the normal position for most forward
driving.
The OVERDRIVE position provides:
• Automatic shifts.
• Apply and release of the torque converter clutch.
• Maximum fuel economy during normal operation.
Second Position
This position provides:
Park
In the PARK position: • Second gear start and hold.
• The torque converter clutch can apply and release.
• there is no powerflow through the transmission.
• Improved traction and engine braking on slippery
• the parking pawl locks the output shaft to the roads.
case.
• Engine braking for descending steep grades.
• the engine can be started.
• the ignition key can be removed. First Position
If this position is selected at normal road speeds,
Reverse the transmission will shift into second gear, then
In the REVERSE position: into first when the vehicle reaches a speed below
approximately 45 km/h (28 mph).
• the vehicle can be operated in a rearward
direction, at a reduced gear ratio. This position provides:
• engine braking will occur. • First gear operation only.
• Engine braking for descending steep grades.

Last updated: 8/2/2004 2005 F-150, 10/2004

Shift Patterns Torque Demand
The torque demand downshift occurs (automatically)
Upshifts during part throttle acceleration when the demand
Transmission upshifting is controlled by the for torque is greater than the engine can provide at
powertrain control module (PCM). The PCM that gear ratio. If applied, the transmission will
receives inputs from various engine or vehicle disengage the TCC to provide added acceleration.
sensors and driver demands to control shift
scheduling, shift feel and torque converter clutch Kickdown
(TCC) operation. For maximum acceleration, the driver can force a
downshift by pressing the accelerator pedal to the
Downshifts floor. A forced downshift into a lower gear is
Under certain conditions the transmission will possible below calibrated speeds. Specifications for
downshift automatically to a lower gear range downshift speeds are subject to variations due to
(without moving the gearshift lever). There are 3 tire size, engine and transmission calibration
categories of automatic downshifts; Coastdown, requirements.
Torque Demand and Forced or Kickdown shifts.
Coastdown
The coastdown downshift occurs when the vehicle
is coasting down to a stop.

Last updated: 8/2/2004 2005 F-150, 10/2004
DESCRIPTION AND OPERATION (Continued)
2005 F-150, 10/2004

Item Part Number Description Item Part Number Description
1 7902 Converter assembly (model 25 7A089 Clutch assembly
dependent) —intermediate one-way
2 7A103 Pump and piston assembly — clutch
fluid 26 7D044 Drum assembly — reverse
3 7A248 Seal assembly — fluid pump clutch
4 7A248 Seal — Fluid pump 27 7D403 Seal — reverse clutch piston
outer
5 7B258 Bushing — Fluid pump
28 7D402 Piston assembly — reverse
6 N605789-S101 Bolt — M8-1.25 x 35 hex clutch
head (7-attaches 7A103 to
7005) 29 7D404 Seal reverse clutch piston
inner
7 7A106 Body assembly — fluid pump
(part of 7A103) 30 7D256 Ring — reverse clutch piston
pressure
8 7A136 Gasket — front pump
31 7B070 Spring — reverse clutch
9 7H169 Gear — pump inner gerotor piston return
(part of 7A103)
32 7A577 Spring — reverse clutch
10 7H169 Gear — pump outer gerotor piston spring
(part of 7A103)
33 7B066 Plate — reverse clutch front
11 7A108 Support assembly — front pressure
pump
34 7B164 Plate — reverse clutch
12 N605787-S1000 Bolt — M8-1.25 x 25 hex internal spline (friction)
flange head (5-attaches
7A108 to 7A103) 35 7B442 Plate — reverse clutch
external spline (steel)
13 7D020 Seals — reverse clutch
cylinder (2 required) 36 7B066 Plate — reverse clutch rear
pressure
14 7D019 Seals — forward clutch
cylinder (2 required) 37 7B497 Seals — input shaft (2
required)
15 7E005 Piston and valve assembly —
intermediate clutch 38 7D483 Retainer — reverse clutch
pressure plate — (select fit)
16 7D014 Washer — front pump
support thrust — select fit 39 7A166 Bearing and race assembly —
No. 1 forward clutch No. 2
17 7B070 Spring — intermediate clutch 40 7F207 Cylinder and input shaft
piston return assembly — forward clutch
18 7G154 Support — intermediate 41 7A548 Seal — forward clutch piston
clutch piston return spring outer
19 7A609 Anti-rattle clip — 42 7C099 Seal — forward clutch piston
intermediate clutch (model inner
dependent) 43 7A262 Piston — forward clutch
20 7B442 Plate — intermediate clutch 44 7A480 Spring — forward clutch
external spline (select fit) piston return
(steel) 45 7A527 Retainer return spring —
21 7B164 Plate assembly — forward clutch
intermediate clutch internal 46 388099-S Snap ring — retaining —
spline (friction) 1-59/64 (retains 7A529 in
22 7B066 Plate — intermediate clutch 7F207)
pressure 47 7E085 Spring — rear clutch pressure
23 7F196 Band assembly — overdrive plate (model dependent)
24 391267-S Ring —3-21/64 retains type 48 7B442 Plate — forward clutch
SU external (retains 7F262 to external spline (steel)
7F215) (Continued)
(Continued)
2005 F-150, 10/2004

49 7B164 Plate — forward clutch 75 7A262 Piston assembly — direct
internal spline (friction) clutch
50 7B066 Plate — forward clutch 76 7C099 Seal — direct clutch piston
pressure inner
51 7D483 Snap ring — retaining (select 77 7A548 Seal — direct clutch piston
fit) outer
52 7F231 Bearing and race assembly — 78 7F283 Cylinder assembly — direct
forward clutch front No. 3 clutch
53 7B067 Hub — forward clutch 79 7F274 Seals — output shaft small
54 7F351 Shaft — intermediate stub — direct clutch (2 required)
55 7C096 Bearing and race assembly — 80 7F240 Bearing and race assembly —
forward clutch hub No. 4 direct clutch outer No. 8
56 7A019 Gear assembly — reverse 81 7060 Shaft assembly — output
clutch sun (model dependent)
57 7D234 Bearing and race assembly — 82 7F273 Seal — output to case shaft
forward clutch sun gear No. 5 large (3 required)
58 388501-S Retaining ring — center 83 87054-S94 Seal — O-ring (piloted output
support — 7-7/92 shaft only) (model dependent)
59 7A399 Gear assembly — forward 84 7A233 Gear — output shaft ring
clutch sun 85 7D164 Hub — output shaft
60 7F277 Spring — case to planet 86 97713-S Snap ring — 1-13/16
support retaining (retains 7D164 to
61 7A130 Support assembly — 7060)
planetary gear 87 7C122 Snap ring — retaining
62 7A089 OWC cage spring and roller (retains 7D164 to 7A153)
assembly — planetary 88 7025 Bushing — rear case
63 7A398 Planetary assembly (model 89 7F242 Bearing and race assembly —
dependent) case rear No. 9
64 7D095 Band assembly — reverse 90 7005 Case assembly
65 392004-S300 Retaining ring — 0.58 thick 91 7086 Gasket — extension (model
(locates reverse band during dependent)
assembly) 92 N803747-S102 Bolt — M8-1.25 x 30
66 7F236 Hub — direct clutch (6-attaches 7A039 to 7005)
67 7F243 Bearing and race assembly — (model dependent)
direct clutch inner No. 7 93 7A039 Extension housing assembly
68 7F237 Support — direct clutch inner (model dependent)
bearing 94 7A034 Bushing — extension housing
69 7D483 Retaining ring — direct (part of 7A039)
clutch pressure plate (select 95 7052 Seal assembly — extension
fit) housing (model dependent)
70 7B066 Plate — direct clutch pressure 96 7H183 Plug assembly —
71 7B164 Plate — direct clutch internal transmission extension
spline (friction) housing
72 7B442 Plate — direct clutch external 97 57621-S2 Bolt and washer assembly —
spline (steel) speedometer plug
73 388104-S Retainer ring — 1-19/32 98 390318-S100 Pipe plug — 1/8-27 Dryseal
(retains 7F235 to 7F283) tapered (5 required)
74 7F235 Retainer and spring assembly 99 7F295 Pin — overdrive band anchor
— direct clutch 100 388142-S Pin — reverse band anchor
(Continued) (part of 7005)
(Continued)
2005 F-150, 10/2004

101 7A246 Vent assembly — case 127 7A232 Rod assembly — park pawl
102 7H398 Plug — non TSS applications actuating
103 W700005-S309 Bolt — M6-1.0X25 hex 128 7A115 Lever assembly — manual
flange HD (attaches TSS valve detent lever
sensor to case) 129 N800287-S536 Nut — M14 x 1.5 hex
104 7M101 Sensor assembly — intermediate detent lever
transmission turbine shaft (attaches 7A115 to 7A256)
speed sensor 130 7H188 Piston assembly — overdrive
105 N811757-S100 Seal — 14.0 x 1.78 O-ring servo
106 N605771-S427 Bolt — M6-1.0 x 14 hex 131 7F201 Spring — overdrive servo
head (attaches output shaft piston
speed sensor to case) 132 7F203 Rod — overdrive servo
107 7H103 Sensor assembly — actuating
transmission output shaft 133 7H179 Washer — backup overdrive
speed servo belleville
108 W500015-S309 Bolt and washer assembly — 134 7G277 Spring — bellville overdrive
M6-1.0 x 25 mm (1 in) cushion spring
(2-attaches 7F293 to 7005) 135 7F200 Piston assembly — overdrive
(model dependent) servo
109 7F293 Sensor — transmission range 136 97411-S Ring — retaining
110 7A256 Lever assembly — manual 137 391377-S Ring — 2.85 retaining type
control (model dependent) TVP ‘‘H’’ internal (retains
111 7H296 Link assembly — manual 7H188 to 7005)
control (model dependent) 138 7D031 Spring — reverse band servo
112 7C493 Shaft — transmission manual piston
control lever (model 139 7D189 Piston assembly — reverse
dependent) band servo
113 N808737-S427 Nut — M10-1.5 (attaches 140 7D036 Cover assembly — reverse
7A256 to 7C493) band servo piston
114 7B498 Seal assembly — manual 141 388215-S100 Retaining ring internal —
control lever 3-13/16
115 373907-S2 Nut — 1/4 spring (retains 142 7H292 Piston and seal assembly —
identification tag to 7000) 2-3 accumulator (bonded
116 7B148 Tag — identification (part of seals)
7005) 143 7F285 Ring — 2-3 shift accumulator
117 7D273 Connector assembly — fluid piston (model dependent)
tube (2 required) 144 7B264 Retainer — 2-3 shift
118 7N171 Plug — converter housing accumulator spring
access 145 7F284 Spring — 1-2 shift
119 7B210 Pin — manual lever shaft accumulator (model
retainer dependent)
120 391131 Seal — 0.426 x 0.070 O-ring 146 7F251 Piston assembly — 1-2 shift
121 N805862 Seal — 14.0 x 1.78 O-ring accumulator (bonded seals)
122 7G383 Solenoid valve — 147 7F284 Spring — 1-2 shift
transmission pressure control accumulator
123 7A441 Pawl — parking pawl 148 7F284 Nested spring — 1-2 (inner
spring) (vehicle dependent)
124 7D071 Shaft — parking pawl
149 7F247 Cover and seal assembly —
125 7D419 Cup — park rod guide (part 1-2 accumulator
of 7A039) (Continued)
126 7D070 Spring — parking pawl return
(Continued)
2005 F-150, 10/2004

150 7384 Ring — 2-1/16 retaining type 168 N807179-S1000 Bolt — M6-1.0 x 52 hex
HU internal (retains 7H300 to flange head (12-attaches
7005) 7A100 to 7005)
151 N807178-S1000 Bolt — M6-1.0 x 18 hex 169 7H111 Retainer — solenoid
head (12-attaches reinforcing 170 7E195 Ball — 1/4 diameter coast
plate to valve body) booster valve shuttle (8
152 7F282 Plate — valve body required)
reinforcing (part of 7A100) 171 7H187 Screen — solenoid pressure
153 7C155 Gasket — valve body supply
separator upper 172 N800670-S1000 Bolt — M6-1.0 x 40 hex
154 7A008 Plate — control valve body flange head (13-attaches
separator (part of 7A100) 7A100 to 7005)
155 7D100 Gasket — valve body 173 7E332 Spring assembly — manual
separator lower valve detent
156 7D174 Valve — converter drainback 174 7Z276 Seal — 0.864 x 0.070 O-ring
157 7A091 Body assembly — main (2 required)
control 175 7G276 Bulkhead assembly — wiring
158 7H173 Gasket — valve body cover connector
plate 176 7G276 Bulkhead assembly —
159 7C034 Plate — valve body cover connector (molded lead
(part of 7A100) frame)
160 N807178-S1000 Bolt — M6-1.0 x 18 hex 177 7Z484 Seal — 6.07 x 1.70 O-ring (2
head (11-attaches 7C034 to required)
7A100 (part of 7A100) 178 7G484 Solenoid valve —
161 7A100 Control assembly — main transmission shift
(model dependent) 179 7G136 Solenoid valve —
162 7A098 Filter and seal assembly — transmission torque converter
fluid clutch
163 7A191 Gasket — transmission pan 180 N807178-S1000 Bolt — M6-1.0 x 16 hex
head (retains 7D136 and
164 7A194 Pan — transmission 7G484 to 7A100)
165 N605785-S1036 Bolt — M8-1.25 x 18 hex 181 7Z136 Seal — 0.489 x 0.070 O-ring
7A194 to 7005) 182 7Z484 Seal — 0.176 x 0.070 O-ring
166 7L027 Magnet — ceramic case (part A — Intermediate clutch assembly
of 7A194) B — Intermediate one-way clutch
167 N808947-S1300 Bolt — M8-1.25 x 46 hex C — Reverse clutch assembly
shoulder pilot (2-attaches D — Forward clutch assembly
7C034 to 7A100)
(Continued)
E — Direct clutch assembly
2005 F-150, 10/2004


Disassembled Views
Automatic Transmission — Disassembled View

Last updated: 8/2/2004 2005 F-150, 10/2004
2005 F-150, 10/2004

1 7902 Converter assembly (model 25 7A089 Clutch assembly
dependent) —intermediate one-way
2 7A103 Pump and piston assembly — clutch
fluid 26 7D044 Drum assembly — reverse
3 7A248 Seal assembly — fluid pump clutch
4 7A248 Seal — Fluid pump 27 7D403 Seal — reverse clutch piston
outer
5 7B258 Bushing — Fluid pump
28 7D402 Piston assembly — reverse
6 N605789-S101 Bolt — M8-1.25 x 35 hex clutch
head (7-attaches 7A103 to
7005) 29 7D404 Seal reverse clutch piston
inner
7 7A106 Body assembly — fluid pump
(part of 7A103) 30 7D256 Ring — reverse clutch piston
pressure
8 7A136 Gasket — front pump
31 7B070 Spring — reverse clutch
9 7H169 Gear — pump inner gerotor piston return
(part of 7A103)
32 7A577 Spring — reverse clutch
10 7H169 Gear — pump outer gerotor piston spring
(part of 7A103)
33 7B066 Plate — reverse clutch front
11 7A108 Support assembly — front pressure
pump
34 7B164 Plate — reverse clutch
12 N605787-S1000 Bolt — M8-1.25 x 25 hex internal spline (friction)
7A108 to 7A103) 35 7B442 Plate — reverse clutch
external spline (steel)
13 7D020 Seals — reverse clutch
cylinder (2 required) 36 7B066 Plate — reverse clutch rear
pressure
14 7D019 Seals — forward clutch
cylinder (2 required) 37 7B497 Seals — input shaft (2
required)
15 7E005 Piston and valve assembly —
intermediate clutch 38 7D483 Retainer — reverse clutch
pressure plate — (select fit)
16 7D014 Washer — front pump
support thrust — select fit 39 7A166 Bearing and race assembly —
No. 1 forward clutch No. 2
17 7B070 Spring — intermediate clutch 40 7F207 Cylinder and input shaft
piston return assembly — forward clutch
18 7G154 Support — intermediate 41 7A548 Seal — forward clutch piston
clutch piston return spring outer
19 7A609 Anti-rattle clip — 42 7C099 Seal — forward clutch piston
intermediate clutch (model inner
dependent) 43 7A262 Piston — forward clutch
20 7B442 Plate — intermediate clutch 44 7A480 Spring — forward clutch
external spline (select fit) piston return
(steel) 45 7A527 Retainer return spring —
21 7B164 Plate assembly — forward clutch
intermediate clutch internal 46 388099-S Snap ring — retaining —
spline (friction) 1-59/64 (retains 7A529 in
22 7B066 Plate — intermediate clutch 7F207)
pressure 47 7E085 Spring — rear clutch pressure
23 7F196 Band assembly — overdrive plate (model dependent)
24 391267-S Ring —3-21/64 retains type 48 7B442 Plate — forward clutch
SU external (retains 7F262 to external spline (steel)
7F215) (Continued)
(Continued)
2005 F-150, 10/2004

49 7B164 Plate — forward clutch 75 7A262 Piston assembly — direct
internal spline (friction) clutch
50 7B066 Plate — forward clutch 76 7C099 Seal — direct clutch piston
pressure inner
51 7D483 Snap ring — retaining (select 77 7A548 Seal — direct clutch piston
fit) outer
52 7F231 Bearing and race assembly — 78 7F283 Cylinder assembly — direct
forward clutch front No. 3 clutch
53 7B067 Hub — forward clutch 79 7F274 Seals — output shaft small
54 7F351 Shaft — intermediate stub — direct clutch (2 required)
55 7C096 Bearing and race assembly — 80 7F240 Bearing and race assembly —
forward clutch hub No. 4 direct clutch outer No. 8
56 7A019 Gear assembly — reverse 81 7060 Shaft assembly — output
clutch sun (model dependent)
57 7D234 Bearing and race assembly — 82 7F273 Seal — output to case shaft
forward clutch sun gear No. 5 large (3 required)
58 388501-S Retaining ring — center 83 87054-S94 Seal — O-ring (piloted output
support — 7-7/92 shaft only) (model dependent)
59 7A399 Gear assembly — forward 84 7A233 Gear — output shaft ring
clutch sun 85 7D164 Hub — output shaft
60 7F277 Spring — case to planet 86 97713-S Snap ring — 1-13/16
support retaining (retains 7D164 to
61 7A130 Support assembly — 7060)
planetary gear 87 7C122 Snap ring — retaining
62 7A089 OWC cage spring and roller (retains 7D164 to 7A153)
assembly — planetary 88 7025 Bushing — rear case
63 7A398 Planetary assembly (model 89 7F242 Bearing and race assembly —
dependent) case rear No. 9
64 7D095 Band assembly — reverse 90 7005 Case assembly
65 392004-S300 Retaining ring — 0.58 thick 91 7086 Gasket — extension (model
(locates reverse band during dependent)
assembly) 92 N803747-S102 Bolt — M8-1.25 x 30
66 7F236 Hub — direct clutch (6-attaches 7A039 to 7005)
67 7F243 Bearing and race assembly — (model dependent)
direct clutch inner No. 7 93 7A039 Extension housing assembly
68 7F237 Support — direct clutch inner (model dependent)
bearing 94 7A034 Bushing — extension housing
69 7D483 Retaining ring — direct (part of 7A039)
clutch pressure plate (select 95 7052 Seal assembly — extension
fit) housing (model dependent)
70 7B066 Plate — direct clutch pressure 96 7H183 Plug assembly —
71 7B164 Plate — direct clutch internal transmission extension
spline (friction) housing
72 7B442 Plate — direct clutch external 97 57621-S2 Bolt and washer assembly —
spline (steel) speedometer plug
73 388104-S Retainer ring — 1-19/32 98 390318-S100 Pipe plug — 1/8-27 Dryseal
(retains 7F235 to 7F283) tapered (5 required)
74 7F235 Retainer and spring assembly 99 7F295 Pin — overdrive band anchor
— direct clutch 100 388142-S Pin — reverse band anchor
(Continued) (part of 7005)
(Continued)
2005 F-150, 10/2004

101 7A246 Vent assembly — case 127 7A232 Rod assembly — park pawl
102 7H398 Plug — non TSS applications actuating
103 W700005-S309 Bolt — M6-1.0X25 hex 128 7A115 Lever assembly — manual
flange HD (attaches TSS valve detent lever
sensor to case) 129 N800287-S536 Nut — M14 x 1.5 hex
104 7M101 Sensor assembly — intermediate detent lever
transmission turbine shaft (attaches 7A115 to 7A256)
speed sensor 130 7H188 Piston assembly — overdrive
105 N811757-S100 Seal — 14.0 x 1.78 O-ring servo
106 N605771-S427 Bolt — M6-1.0 x 14 hex 131 7F201 Spring — overdrive servo
head (attaches output shaft piston
speed sensor to case) 132 7F203 Rod — overdrive servo
107 7H103 Sensor assembly — actuating
transmission output shaft 133 7H179 Washer — backup overdrive
speed servo belleville
108 W500015-S309 Bolt and washer assembly — 134 7G277 Spring — bellville overdrive
M6-1.0 x 25 mm (1 in) cushion spring
(2-attaches 7F293 to 7005) 135 7F200 Piston assembly — overdrive
(model dependent) servo
109 7F293 Sensor — transmission range 136 97411-S Ring — retaining
110 7A256 Lever assembly — manual 137 391377-S Ring — 2.85 retaining type
control (model dependent) TVP ‘‘H’’ internal (retains
111 7H296 Link assembly — manual 7H188 to 7005)
control (model dependent) 138 7D031 Spring — reverse band servo
112 7C493 Shaft — transmission manual piston
control lever (model 139 7D189 Piston assembly — reverse
dependent) band servo
113 N808737-S427 Nut — M10-1.5 (attaches 140 7D036 Cover assembly — reverse
7A256 to 7C493) band servo piston
114 7B498 Seal assembly — manual 141 388215-S100 Retaining ring internal —
control lever 3-13/16
115 373907-S2 Nut — 1/4 spring (retains 142 7H292 Piston and seal assembly —
identification tag to 7000) 2-3 accumulator (bonded
116 7B148 Tag — identification (part of seals)
7005) 143 7F285 Ring — 2-3 shift accumulator
117 7D273 Connector assembly — fluid piston (model dependent)
tube (2 required) 144 7B264 Retainer — 2-3 shift
118 7N171 Plug — converter housing accumulator spring
access 145 7F284 Spring — 1-2 shift
119 7B210 Pin — manual lever shaft accumulator (model
retainer dependent)
120 391131 Seal — 0.426 x 0.070 O-ring 146 7F251 Piston assembly — 1-2 shift
121 N805862 Seal — 14.0 x 1.78 O-ring accumulator (bonded seals)
122 7G383 Solenoid valve — 147 7F284 Spring — 1-2 shift
transmission pressure control accumulator
123 7A441 Pawl — parking pawl 148 7F284 Nested spring — 1-2 (inner
spring) (vehicle dependent)
124 7D071 Shaft — parking pawl
149 7F247 Cover and seal assembly —
125 7D419 Cup — park rod guide (part 1-2 accumulator
of 7A039) (Continued)
126 7D070 Spring — parking pawl return
(Continued)
2005 F-150, 10/2004

150 7384 Ring — 2-1/16 retaining type 168 N807179-S1000 Bolt — M6-1.0 x 52 hex
HU internal (retains 7H300 to flange head (12-attaches
7005) 7A100 to 7005)
151 N807178-S1000 Bolt — M6-1.0 x 18 hex 169 7H111 Retainer — solenoid
head (12-attaches reinforcing 170 7E195 Ball — 1/4 diameter coast
plate to valve body) booster valve shuttle (8
152 7F282 Plate — valve body required)
reinforcing (part of 7A100) 171 7H187 Screen — solenoid pressure
153 7C155 Gasket — valve body supply
separator upper 172 N800670-S1000 Bolt — M6-1.0 x 40 hex
154 7A008 Plate — control valve body flange head (13-attaches
separator (part of 7A100) 7A100 to 7005)
155 7D100 Gasket — valve body 173 7E332 Spring assembly — manual
separator lower valve detent
156 7D174 Valve — converter drainback 174 7Z276 Seal — 0.864 x 0.070 O-ring
157 7A091 Body assembly — main (2 required)
control 175 7G276 Bulkhead assembly — wiring
158 7H173 Gasket — valve body cover connector
plate 176 7G276 Bulkhead assembly —
159 7C034 Plate — valve body cover connector (molded lead
(part of 7A100) frame)
160 N807178-S1000 Bolt — M6-1.0 x 18 hex 177 7Z484 Seal — 6.07 x 1.70 O-ring (2
head (11-attaches 7C034 to required)
7A100 (part of 7A100) 178 7G484 Solenoid valve —
161 7A100 Control assembly — main transmission shift
(model dependent) 179 7G136 Solenoid valve —
162 7A098 Filter and seal assembly — transmission torque converter
fluid clutch
163 7A191 Gasket — transmission pan 180 N807178-S1000 Bolt — M6-1.0 x 16 hex
head (retains 7D136 and
164 7A194 Pan — transmission 7G484 to 7A100)
165 N605785-S1036 Bolt — M8-1.25 x 18 hex 181 7Z136 Seal — 0.489 x 0.070 O-ring
7A194 to 7005) 182 7Z484 Seal — 0.176 x 0.070 O-ring
166 7L027 Magnet — ceramic case (part A — Intermediate clutch assembly
of 7A194) B — Intermediate one-way clutch
167 N808947-S1300 Bolt — M8-1.25 x 46 hex C — Reverse clutch assembly
shoulder pilot (2-attaches D — Forward clutch assembly
7C034 to 7A100)
(Continued)
E — Direct clutch assembly
2005 F-150, 10/2004


Bushings, Bearing and Thrust Washer
Locator

1 7D014 Pump No.1 thrust washer 9 7F242 Outer bearing and race
(select fit) assembly — rear No. 9
2 7A166 Forward clutch No. 2 bearing 10 — Extension bushing (part of
and race assembly 7A039)
3 7F231 Forward clutch bearing and 11 7025 Case bushing
race assembly — front No. 3 12 7B233 Output shaft bushing
4 7F244 Forward clutch hub bearing 13 7B375 Planet carrier bushing — rear
and race assembly No. 4
14 7F209 Forward clutch sun gear
5 7F244 Forward clutch sun gear bushing
bearing and race assembly
No. 5 (2 piece) 15 7N193 Reverse clutch sun gear
bushing
6 7F241 Planet assembly bearing and
race No. 6 16 7B374 Carrier bushing — front
7 7F243, 7F237 Direct clutch inner bearing, 17 7A132 Planetary support bushing
race assembly No. 7 and 18 7F218 Reverse clutch drum bushing
direct clutch inner bearing — rear
support No. 7 19 7B261 Front pump support bushing
8 7F240 Direct clutch outer bearing 20 7F217 Reverse clutch drum bushing
and race assembly No. 8 — front
(Continued) (Continued)

Last updated: 8/2/2004 2005 F-150, 10/2004
21 7B258 Front pump bushing 22 7B261 Front pump support bushing
(Continued)
2005 F-150, 10/2004


Seals, Rings and Gasket Locator

Last updated: 8/2/2004 2005 F-150, 10/2004
1 7A248 Front pump seal assembly 18 7C099 Forward clutch piston inner
2 7A248 Front pump seal seal
3 7A136 Front pump gasket 19 7A548 Forward clutch piston outer
seal
4 7D020 Reverse clutch cylinder seal
(2 required) 20 7B498 Manual control lever seal
assembly
5 7C099 Direct clutch piston inner seal
21 7D403 Reverse clutch piston outer
6 7D019 Forward clutch cylinder seal
7 7A548 Direct clutch piston outer seal 22 7D404 Reverse clutch piston inner
8 7F274 Output shaft to direct clutch seal
cylinder seal (2 required) 23 7F224 Intermediate clutch piston
9 87054-S94 O-ring seal (piloted) (model outer seal
dependent) 24 7F225 Intermediate clutch piston
10 7086 Extension gasket inner seal
11 7052 Extension housing seal 25 391308-S Fill tube level indicator seal
assembly 26 7Z484 TCC solenoid seal (large)
12 7C155 Control valve body upper 27 7Z136 TCC solenoid seal (small)
gasket
28 7Z484 Shift solenoid seal (2
13 7D100 Valve body separator plate required)
lower gasket
29 N811757-S100 Output shaft speed sensor seal
14 7H173 Valve body cover plate gasket
30 7Z276 Bulkhead seal (1 required)
15 7A191 Transmission pan to case
gasket 31 N805862-S Pressure control solenoid seal
(large)
16 7F273 Output shaft to case seal (3
required) 32 391131 Pressure control solenoid seal
(small)
17 7B497 Input shaft seal (2 required)
(Continued)
2005 F-150, 10/2004


Main Components and Functions
Transmission Main Components — Sectional View

1 7902 Torque converter 7 7F351 Shaft — intermediate stub
2 7B164 Intermediate clutch (friction) 8 7060 Output shaft
3 7B164 Reverse clutch (friction) 9 7A089 Planetary one-way clutch
4 7B164 Forward clutch (friction) 10 7D095 Reverse clutch band
5 7B164 Direct clutch (friction) 11 7F196 Overdrive band
6 7F207 Forward clutch cylinder and 12 7A089 Intermediate one-way clutch
shaft
(Continued)

Last updated: 8/2/2004 2005 F-150, 10/2004

Torque Converter
The torque converter transmits and multiplies
torque. The torque converter is a 4-element device:
• Impeller assembly
• Turbine assembly
• Reactor assembly
• Clutch and damper assembly
The standard torque converter components operate
as follows:
• Rotation of the converter housing and impeller set
the fluid in motion.
• The turbine reacts to the fluid motion from the
impeller, transferring rotation to the geartrain
through the input shaft.
• The reactor redirects fluid going back into the
impeller, allowing for torque multiplication.
• The clutch and damper assembly dampens
powertrain torsional vibration and provides a
direct mechanical connection for improved
efficiency.
• Power is transmitted from the torque converter to
the planetary gearsets and other components
through the input shaft. Item Part Number Description
1 — Converter clutch and damper
(part of 7902)
2 — Reactor (part of 7902)
3 — Turbine (part of 7902)
4 — Impeller (part of 7902)
5 — Fluid motion
6 — Transmission input rotation
7 — Input shaft
8 — Engine rotation

Last updated: 8/2/2004 2005 F-150, 10/2004

Geartrain Planetary Gearset
Power is transmitted from the torque converter to The planetary gearset in the transmission is a
the Ravigneaux geartrain components through the Ravigneaux-type set consisting of the following
input shaft and forward clutch cylinder. components:
• The geartrain contains a Ravigneaux planetary set • Forward clutch sun gear
connected by dual pinion gears. • Reverse clutch sun gear
• By holding or driving certain components of the • Pinion carrier
gearset, 4 forward ratios and 1 reverse ratio are • Long and short pinions
obtained and transmitted to the output shaft. The
ratios are as follows: • Output ring gear
Components are held or driven to produce forward
Gear Ratio and reverse gear ratios.
1st 2.84 to 1
Input Shaft
2nd 1.55 to 1
The forward clutch cylinder and shaft transfers
3rd 1.00 to 1
speed and torque from the converter turbine to the
4th 0.70 to 1 geartrain. This shaft is splined to the turbine on one
Reverse 2.32 to 1 end and to the forward clutch sun gear and stub
shaft on the other end.
• Components of the geartrain can be held by bands Stub Shaft
or clutches and driven by clutches only.
The stub shaft transfers power from the input shaft
The transmission uses: to the planet carrier (through the direct clutch)
• 2 bands. during 3rd and 4th gear operation.
• 2 one-way clutches (one roller, one mechanical Output Shaft
diode).
The output shaft provides torque to the driveshaft
• 4 friction clutches. and rear axle assembly. It is driven by the ring gear
of the planetary gearset.

Last updated: 8/2/2004 2005 F-150, 10/2004

Apply Components Clutch — Direct
There are 8 apply components used to drive or hold For component location, refer to Disassembled
the planetary gearset components. Views in this section.
The direct clutch couples the input shaft to the
Band — Overdrive planet carrier through the stub shaft in 3rd and 4th
For component location, refer to Disassembled gears.
Views in this section.
Clutch — Reverse
The overdrive band holds the reverse clutch drum
stationary in 4th gear and manual 2. This action For component location, refer to Disassembled
causes the reverse sun gear to be held in these Views in this section.
ranges. The reverse clutch couples the input shaft to the
reverse sun gear, applied in reverse range only.
Band — Low and Reverse
For component location, refer to Disassembled One-Way Clutch — Planetary (Low)
Views in this section. For component location, refer to Disassembled
The low and reverse band holds the pinion carrier in Views in this section.
reverse. The reverse band also applies in manual 1 The planetary (low) one-way clutch is a roller
position to provide engine braking. clutch that holds the planetary gearset in 1st gear,
(D) and D ranges. During automatic coasting
Clutch — Intermediate downshifts into 1st gear ((D) and D ranges), the
For component location, refer to Disassembled planetary one-way clutch freewheels so there is no
Views in this section. engine braking.
The intermediate clutch works with the intermediate
One-Way Clutch — Intermediate
one-way clutch to hold the reverse sun gear
stationary in 2nd gear. The intermediate clutch For component location, refer to Disassembled
remains applied in 3rd and 4th gears, but does not Views in this section.
transmit power. The intermediate one-way clutch works with the
intermediate friction clutch to hold the reverse
Clutch — Forward clutch drum and reverse sun gear stationary in 2nd
For component location, refer to Disassembled gear during acceleration. The intermediate one-way
Views in this section. clutch freewheels in 3rd gear and during coasting
The forward clutch couples the forward clutch in 2nd gear, (D) and D ranges.
cylinder and input shaft to the forward sun gear in
1st, 2nd and 3rd gears. The forward clutch is not
applied in 4th gear.

Last updated: 8/2/2004 2005 F-150, 10/2004

Hydraulic System Accumulators
For component location, refer to Disassembled
Fluid Pump Views in this section.
For component location, refer to Disassembled The transmission uses 2 accumulators:
The transmission uses a gerotor-type design front • 1-2 Accumulator — The 1-2 accumulator is used
pump support and gear. The pump provides the to soften the 1-2 shift by absorbing some of the
volume of fluid needed to charge the torque pressure directed to the intermediate clutch.
converter, main control assembly, cooling system Constant line pressure is applied to the middle
and lube system. Pump pressure is regulated by the section of the 1-2 accumulator piston, opposing
main regulator valve. The pump has an internal the intermediate clutch pressure, until the pressure
boost circuit which is more efficient at lower engine is high enough to overcome line pressure. The top
speeds. of the piston is exhausted to the sump.
• 2-3 Accumulator — The 2-3 accumulator is used
Filter to soften the 2-3 shift by absorbing some of the
For component location, refer to Disassembled direct clutch pressure. Forward clutch pressure is
Views in this section. applied to the top side of the 2-3 accumulator
All fluid drawn from the transmission pan by the piston, holding the piston down until clutch
pump passes through the filter. The filter and its pressure is high enough to overcome it. The
accompanying seal are part of the fluid path from middle section of the piston is exhausted to the
the sump (pan) to the fluid pump. sump.
Main Control
For component location, refer to Disassembled
The main control valve body houses 3 electronic
solenoids:
• 2 shift solenoids
• 1 torque converter clutch solenoid (TCC solenoid)

Last updated: 8/2/2004 2005 F-150, 10/2004

Transmission Electronic Control Transmission Control Switch (TCS) and
Transmission Control Indicator Lamp (TCIL)
System
The transmission control switch (TCS) is a
Electronic System Description momentary contact switch. When the switch is
The powertrain control module (PCM) and its pressed, a signal is sent to the PCM to allow
input/output network control the following automatic shifts from 1st through 4th gears or 1st
transmission operations: through 3rd gears only. The PCM energizes the
transmission control indicator lamp (TCIL) when
• shift timing the switch is off. The TCIL indicates overdrive
• line pressure (shift feel) cancel mode activated (lamp on) and electronic
• torque converter clutch pressure control (EPC) circuit shorted (lamp
flashing) or a monitored sensor failure.
The transmission control is separate from the engine
control strategy in the PCM, although some of the Output Shaft Speed (OSS) Sensor
input signals are shared. When determining the best The output shaft speed (OSS) sensor is a magnetic
operating strategy for transmission operation, the pickup, located at the output shaft ring gear, that
PCM uses input information from certain sends a signal to the powertrain control module to
engine-related and driver-demand related sensors indicate transmission output shaft speed. The OSS is
and switches. used for torque converter clutch control, shift
In addition, the PCM receives input signals from scheduling and to determine electronic pressure
certain transmission-related sensors and switches. control.
The PCM also uses these signals when determining
transmission operating strategy. Turbine Shaft Speed (TSS) Sensor
Using all of these input signals, the PCM can The turbine shaft speed (TSS) sensor is a magnetic
determine when the time and conditions are right pickup, that sends a signal to the powertrain control
for a shift or when to apply or release the torque module to indicate transmission turbine shaft speed.
converter clutch. It will also determine the best line The TSS is mounted externally on the case. The
pressure needed to optimize shift feel. To PCM uses the TSS signal to help determine
accomplish this the PCM uses hydraulic solenoids appropriate operating pressure and torque converter
to control transmission operation. clutch (TCC) operation.
The following provides a brief description of each Digital Transmission Range (TR) Sensor
of the sensors and actuators used to control
The digital transmission range (TR) sensor is
transmission operation.
located on the outside of the transmission at the
Mass Air Flow (MAF) Sensor manual lever. The digital TR sensor completes the
start circuit in PARK and NEUTRAL, the back-up
The mass air flow sensor (MAF) measures the mass
lamp circuit in REVERSE and the neutral sense
of air flowing into the engine. The MAF sensor
circuit (4x4 only) in NEUTRAL. The digital TR
output signal is used by the powertrain control
sensor also opens and closes a set of 4 switches that
module (PCM) to calculate injector pulse width. For
are monitored by the powertrain control module
transmission strategies the MAF sensor is used to
(PCM) to determine the position of the manual lever
regulate electronic pressure control EPC, shift and
(P, R, N, D, 2, 1).
torque converter clutch scheduling.
Powertrain Control Module (PCM)
The operation of the transmission is controlled by
the powertrain control module (PCM). Many input
sensors provide information to the PCM. The PCM
then controls actuators which determine transmission
operation.

Last updated: 8/2/2004 2005 F-150, 10/2004
Transmission Fluid Temperature (TFT) Electronic Pressure Control (EPC) Solenoid
Sensor The electronic pressure control (EPC) solenoid
The transmission fluid temperature (TFT) sensor is regulates transmission pressure. EPC valve pressure
located on the lead frame assembly near the shift is used to control line pressure.
solenoids on the main control valve body. It is a
temperature sensitive device called a thermistor. It Shift Solenoid — SSA, SSB
sends a voltage signal to the PCM. The voltage Two on/off shift solenoids provide gear selection of
signal varies with transmission fluid temperature. 1st through 4th gears by controlling the pressure to
The PCM uses this signal to determine whether a the 3 shift valves. One unit containing the 2 shift
cold start shift schedule is necessary. The shift solenoids is located in the main control valve body.
schedule is compensated when the transmission The shift solenoids are 2-way normally open style.
fluid temperature is cold. The PCM also inhibits
TCC operation at low transmission fluid
temperatures and corrects electronic pressure
control.
Solenoid Operation Chart
Gear Lever PCM Commanded Solenoids

Position Gear SSA SSB TCC
P/R/N 1 ON OFF HD
(D) 1 ON OFF HD
(D) 2 OFF OFF EC
(D) 3 OFF ON EC
(D) 4 ON ON EC
w/OD OFF
1 1 ON OFF HD
2 2 OFF OFF EC
3 3 OFF ON EC
Manual 2 2 OFF OFF EC
Manual 1 1 ON OFF HD
1a 2 OFF OFF EC
a When a manual pull-in occurs above a calibrated speed, the transmission will not downshift from the higher gear
until the vehicle speed drops below this calibrated speed.
EC = Electronically Controlled. Brake Pedal Position (BPP) Switch
HD = Hydraulically Disabled. The brake pedal position (BPP) switch tells the
powertrain control module (PCM) when the brakes
Torque Converter Clutch (TCC) Solenoid are applied. The torque converter clutch disengages
The torque converter clutch (TCC) solenoid is used when the brakes are applied. The BPP switch closes
to control the apply and release of the TCC. when the brakes are applied and opens when they
are released.
4x4 Low (4x4L) Switch
The 4x4 low (4x4L) range switch is located on the
transfer case cover. It provides an indication of
when the 4x4 transfer case gear system is in the
low range. The PCM then modifies shift schedule
for 4x4L operation.
2005 F-150, 10/2004

Electronic Ignition (EI) System Intake Air Temperature (IAT) Sensor
The electronic ignition consists of a crankshaft The intake air temperature (IAT) sensor provides
position sensor, two 4-tower ignition coils and the the sequential fuel injection (SFI) system mixture
powertrain control module (PCM). The ignition temperature information. The IAT sensor is used
control module operates by sending crankshaft both as a density corrector for air flow calculation
position information from the crankshaft position and to proportion cold enrichment fuel flow. The
sensor to the ignition control module. The ignition IAT sensor is installed in the air cleaner outlet tube.
control module generates a profile ignition pickup The IAT sensor is also used in determining
(PIP) signal (engine rpm) and sends it to the PCM. electronic pressure control (EPC) pressures.
The PCM uses PIP signal in the transmission
strategy, wide-open throttle (WOT) shift control, Engine Coolant Temperature (ECT) Sensor
torque converter clutch control and EPC pressure. The engine coolant temperature (ECT) sensor
detects temperature of engine coolant and supplies
Air Conditioning (A/C) Clutch the information to the powertrain control module
An electromagnetic clutch is energized when the (PCM). The ECT sensor is used to control torque
clutch cycling pressure switch closes. The switch is converter clutch (TCC) operation. The ECT is
located on the suction accumulator/drier. The installed in the heater outlet fitting or cooling
closing of the switch completes the circuit to the passage on the engine. For engine control
clutch and draws it into engagement with the applications, the ECT signal is used to modify
compressor driveshaft. When the A/C clutch is ignition timing, EGR flow and air-to-fuel ratio as a
engaged, electronic pressure control (EPC) is function of engine coolant temperature.
adjusted by the PCM to compensate for additional
load on the engine. Throttle Position (TP) Sensor
The throttle position (TP) sensor is a potentiometer
mounted on the throttle body. The TP sensor detects
the position of the throttle plate and sends this
information to the powertrain control module
(PCM). The TP sensor is used for shift scheduling,
electronic pressure control and torque converter
clutch (TCC) control.
2005 F-150, 10/2004

GENERAL PROCEDURES
Transmission Fluid Drain and Refill 3. With the engine running and the transmission at
normal operating temperature 66-77°C
Special Tool(s) (150-170°F), check and adjust the transmission
fluid level and check for any leaks. If fluid is
Automatic Transmission Flush needed, add fluid in increments of 0.24-liter
and Fill Machine (0.5-pint) until the correct level is achieved
211-00018
(fluid should be in the cross-hatched area of the
Automatic Transmission Flush
and Fill Machine fluid level indicator).
199-00010 or equivalent
Draining, all vehicles not using a suitable
flush and fill machine
Material 1. With the vehicle in NEUTRAL, position it on a

Item Specification hoist. For additional information, refer to
MERCON V Automatic MERCONV Section 100-02.
Transmission Fluid
XT-5-QM 2. Loosen the transmission fluid pan bolts and
allow the fluid to drain.
Draining, all vehicles using a suitable flush
and fill machine
CAUTION: Always refer to the

instructions supplied with the flush and fill
machine.
NOTE: Draining fluid from the transmission by

removing only the fluid pan is acceptable for
normal or severe duty fluid maintenance.
1. With the vehicle in NEUTRAL, position it on a

hoist. For additional information, refer to
Section 100-02.
3. After the fluid has drained, remove the
2. Use a suitable flush and fill machine to change transmission fluid pan.
the fluid.
3. When connecting the flush and fill machine,

connect the machine to the fluid cooler tube
after the fluid cooler on the cooler return line.
This will help remove any foreign material
trapped in the fluid coolers.
Refill
1. Use only clean automatic transmission fluid.
2. Once the fluid exchange has been completed,

disconnect the flush and fill machine.
Reconnect any disconnected fluid cooler tubes. 4. Do not remove the fluid filter. It is not
necessary to change the fluid filter during a
normal maintenance fluid change.

Last updated: 8/2/2004 2005 F-150, 10/2004
GENERAL PROCEDURES (Continued)
5. Clean and inspect the transmission fluid pan, 2. NOTE: The fluid pan gasket is reusable, clean
transmission fluid pan gasket and magnet. and inspect for damage. If not damaged, the
gasket should be reused.
Install the fluid pan and gasket.
1 Position the fluid pan with the gasket in
place.
2 Install the bolts.
6. Thoroughly flush the cooler tubes. For

additional information, refer to Transmission
Fluid Cooler — Backflushing and Cleaning in
this section.
Refill
3. CAUTION: The use of any other
1. Position the magnet into the transmission fluid transmission fluid can result in the
pan. transmission failing to operate in a normal
manner or transmission failure.
Fill the transmission.
• Add 4.7 liters (5 qts) of clean automatic
transmission fluid to the transmission
through the fluid filler tube.
4. Start the engine. Move the transmission range

selector lever through all the gear ranges,
checking for engagements.
5. With the engine running and the transmission at

normal operating temperature 66-77°C
(150-170°F), check and adjust the transmission
fluid level and check for any leaks. If fluid is
needed, add fluid in increments of 0.24-liter
(0.5-pint) until the correct level is achieved
(fluid should be in the cross-hatched area of the
fluid level indicator).
2005 F-150, 10/2004

GENERAL PROCEDURES
Transmission Fluid In-Line Filter
Material
Item Specification
MERCON V Automatic MERCONV
Transmission Fluid
XT-5-QM
Transmission Fluid In-line Filter — with a

OTA cooler
NOTE: Use the following guidelines for installing

the transmission fluid in-line filter:
4. NOTE: Be sure the cooler tube is fully seated
• If the transmission was overhauled and the vehicle in the body of the fitting before final tightening
was equipped with an in-line fluid filter, install a of the ferrule nut.
new in-line fluid filter. Install the tubing ferrule hose assembly
• If the transmission was overhauled and the vehicle connector onto the end of the steel fluid cooler
was not equipped with an in-line fluid filter, tube. Finger-tighten the ferrule nut, then tighten
install a new in-line fluid filter kit. the nut an additional 1-1/2 turns to seat the
• If the transmission is being installed for a ferrule in the connector.
non-internal repair, do not install an in-line filter
or filter kit.
• If installing a new or a Ford-authorized
remanufactured transmission, install the in-line
transmission fluid filter that is supplied.

Section 100-02.
2. If equipped, remove the bolts and the skid

plate.
3. Remove the section of the rubber hose and steel

line as illustrated.
• Clean and de-burr the end of the steel line.

Last updated: 8/2/2004 2005 F-150, 10/2004
5. CAUTION: The filter has a bypass 7. If equipped, install the skid plate and the bolts.
valve in it. The red arrow on the filter
indicates the direction of fluid flow through
the filter. The filter must be installed in the
fluid cooler return line with the red arrow
on the filter pointing away from the
transmission fluid cooler and toward the
transmission (the return line has fluid
coming out of the cooler going to the
transmission). If the fluid filter is not
installed correctly, it will cause internal
transmission damage.
CAUTION: Do not install any rubber
hoses or steel tubing with a bend entering
the filter greater than 60 degrees. 8. Fill the transmission with clean automatic
Using a suitable length of hose install the filter. transmission fluid.
Tighten the hose clamps. • Verify for correct operation.
• Check the filter for leaks.
Transmission Fluid In-line Filter — without a
OTA cooler
NOTE: Use the following guidelines for installing

the transmission fluid in-line filter:
• If the transmission was overhauled and the vehicle
was equipped with an in-line fluid filter, install a
new in-line fluid filter.
• If the transmission was overhauled and the vehicle
was not equipped with an in-line fluid filter,
install a new in-line fluid filter kit.
6. Clean a section of the transmission fluid pan • If the transmission is being installed for a
and install the sticker. non-internal repair, do not install an in-line filter
or filter kit.
• If installing a new or a Ford-authorized
remanufactured transmission, install the in-line
transmission fluid filter that is supplied.

Section 100-02.
2005 F-150, 10/2004

2. Remove the cooler tubes retainers.
5. CAUTION: The filter has a bypass

valve in it. The red arrow on the filter
3. Remove the section of the steel tube as indicates the direction of fluid flow through
illustrated. the filter. The filter must be installed in the
• Clean and de-burr the end of the steel tubes. fluid cooler return line with the red arrow
on the filter pointing away from the
transmission fluid cooler and toward the
transmission (the return line has fluid
coming out of the cooler going to the
transmission). If the fluid filter is not
installed correctly, it will cause internal
transmission damage.
CAUTION: Do not install any rubber
hoses or steel tubing with a bend entering
the filter greater than 60 degrees.
Using a suitable length of hose install the filter.
Tighten the hose clamps.
4. NOTE: Be sure the cooler tube is fully seated

in the body of the fitting before final tightening
of the ferrule nut.
Install the tubing ferrule hose assembly
connector onto the end of the steel fluid cooler
tubes. Finger-tighten the ferrule nut, then
tighten the nut an additional 1-1/2 turns to seat
the ferrule in the connector.
2005 F-150, 10/2004

6. Install one cooler tube retainer as illustrated. 8. Clean a section of the transmission fluid pan
and install the sticker.
7. Secure the cooler tubes together with a tie

strap. 9. Fill the transmission with clean automatic
transmission fluid.
• Verify for correct operation.
• Check the filter for leaks.
2005 F-150, 10/2004

GENERAL PROCEDURES
Transmission Range (TR) Sensor
Adjustment
Special Tool(s)
Alignment Gauge, TR Sensor
307-351 (T97L-70010-A)
Material 4. Loosen the digital TR sensor bolts.

Item Specification
High Strength WSK-M2G351-A6
Threadlocker
TA-26

Section 100-02.
2. CAUTION: Do not pry on the swivel

tube to disconnect the transmission shift
linkage.
Disconnect the manual lever shift control cable.
5. NOTE: The manual lever must be in the
NEUTRAL position.
Using the special tool, align the digital TR
sensor slots. The tool is designed to fit snug.
3. CAUTION: Discard the outer manual

control lever shaft nut. Do not reuse. The old
nut will not retain the torque specification.
Remove the manual control lever.
1 Remove the nut.
2 Remove the lever.

Last updated: 8/2/2004 2005 F-150, 10/2004
6. CAUTION: Tightening one screw
before tightening the other may cause the
sensor to bind or become damaged.
sensor and tighten the screws in an alternating
sequence.
8. With the manual lever in overdrive connect the

shift lever control cable.
7. Install the manual control lever.

1 Position the manual control lever.
2 Install a new manual lever shaft outer nut.
9. Lower the vehicle.
2005 F-150, 10/2004

GENERAL PROCEDURES
Torque Converter
1. A new or remanufactured torque converter must

be installed if one or more of the following
statements is true:
• A torque converter malfunction has been
determined based on complete diagnostic
procedures.
• Converter stud or studs, impeller hub or
bushing are damaged.
• Discoloration (due to overheating).
• Evidence of transmission assembly or fluid
contamination due to the following
transmission or converter failure modes:
X Major metallic failure.
X Multiple clutches or clutch plate failures.
X Sufficient component wear which results
in metallic contamination.
X Internal torque converter contamination
present. For additional information refer
to Torque Converter Contamination
Inspection in this section.

Last updated: 8/2/2004 2005 F-150, 10/2004
GENERAL PROCEDURES
Torque Converter Contamination 3. Observe the color and odor of the fluid. The
Inspection fluid should be red, not brown or black. Odor
may indicate an overheating condition such as
clutch disc or band failure.
CAUTION: Do not use water-based
cleaners or mineral spirits to clean or flush the 4. Examine the stain on the tissue for evidence of
torque converter or transmission damage will particles (spec of any kind). Examine the fluid
occur. Use only clean automatic transmission level indicator for signs of antifreeze (gum or
fluid designated for the transmission and varnish). If particles are present in the fluid or
converter being serviced. there is evidence of engine coolant or water, a
new torque converter must be installed.
CAUTION: The torque converter drain
plug and seal are not reusable. If equipped, 5. If there are no particles or contamination
discard the drain plug and seal, then install a present, drain the remainder of the transmission
new drain plug assembly. fluid from the torque converter.
1. If a new or remanufactured torque converter is 6. Add 1.9 liter (2 qt.) of clean automatic
not being installed, the following steps must be transmission fluid into the converter and agitate
completed. by hand.
2. With the torque converter on a bench, pour a 7. Thoroughly drain the fluid.
small amount of transmission fluid from the
torque converter onto an absorbent white tissue
or through a paper filter and examine the fluid.

Last updated: 8/2/2004 2005 F-150, 10/2004
DIAGNOSIS AND TESTING

Diagnostic Strategy Preliminary Inspection
Troubleshooting an electronically controlled • Know and understand the customer’s concern.
automatic transmission is simplified by using the • Verify the concern by operating the vehicle.
proven method of diagnosis. One of the most
important things to remember is that there is a • Check the fluid levels and condition.
definite procedure to follow. • Check for non-factory add-on items.
NOTE: Do not take any short cuts or assume that • Check shift linkages for proper adjustment.
critical checks or adjustments have already been • Check TSBs and OASIS messages regarding the
made. concern.
Follow the procedures as written to avoid missing
critical components or steps. Diagnostics
To correctly diagnose a concern, have the following • Carry out on-board diagnostic procedures key on
publications available: engine off (KOEO) and key on engine running
(KOER).
• Transmission Reference Manual.
• Record all diagnostic trouble codes (DTCs).
• Powertrain Control/Emissions Diagnosis (PC/ED)
manual. • Repair all non-transmission codes first.
• TSBs and OASIS Messages. • Repair all transmission codes second.
• Wiring Diagram. • Erase all continuous codes and attempt to repeat
them.
These publications provide the information required
when diagnosing transmission concerns. • Repair all continuous codes.
Use the Diagnostic Flow Chart as a guide and • If only pass codes are obtained, refer to Diagnosis
follow the steps as indicated. By Symptom for further information and
diagnosis.
Follow the diagnostic sequence to diagnose and
repair the concern the first time.

Last updated: 8/2/2004 2005 F-150, 10/2004

Diagnostic Flow Chart
• Know and understand the customer concerns Yes • REPAIR all hard diagnostic trouble codes.
• Check the fluid level and condition FOLLOW the pinpoint tests. REFER to the
• Verify the concern by operating the vehicle Powertrain Control/Emissions Diagnosis
• Check for non-factory-installed items and (PC/ED) manual first, then this Workshop
verify correct installation Manual.
• Check the shift linkage adjustments
• Check TSBs and OASIS messages for vehicle
concerns
• Carry out quick test both KOER and KOEO
• Record all codes
1) Did you record any diagnostic trouble
codes?
No • REFER to Diagnosis By Symptom in this

section, then GO to Step 5.
2) Are any continuous test memory codes Yes • CLEAR codes and CARRY OUT drive cycle
present? test.
No • GO to Step 4.
3) Did the continuous test memory codes Yes • REPAIR all continuous test memory codes.
reappear? FOLLOW the pinpoint tests. REFER to the
Powertrain Control/Emissions Diagnosis
(PC/ED) manual then the transmission
reference manual, then this workshop manual,
then GO to Step 4.
4) Is the concern repaired? Yes • CARRY OUT the final quick test to verify
that no diagnostic trouble codes are present.
CLEAR memory codes.
No • REFER to Diagnosis By Symptom in this

section.
5) Are there any electrical concerns? Yes • INSTALL the diagnostic tool and CARRY
OUT the output state control test, then GO to
Step 6.
No • REFER to the hydraulic and mechanical

routine to diagnose and REPAIR the concern,
then GO to Step 7.
6) Was the transmission concern corrected Yes • REFER to the Powertrain Control/Emissions
when the diagnostic tool was installed? Diagnosis (PC/ED) manual, intermittent fault
diagnosis section and use the diagnostic tool
to diagnose cause of concern in the processor,
vehicle harness or external inputs (sensors or
switches).

Last updated: 8/2/2004 2005 F-150, 10/2004
DIAGNOSIS AND TESTING (Continued)
No • REFER to the hydraulic and mechanical
routine to diagnose the concern, then GO to
Step 7.
7) Is the concern repaired? Yes • CARRY OUT the final quick test to verify
that no diagnostic trouble codes are present.
CLEAR memory codes.
No • Get assistance from technical hotline.
2005 F-150, 10/2004


Preliminary Inspection • Noise/vibration — check for dependencies, either
rpm dependent, vehicle speed dependent, shift
The following items must be checked prior to
dependent, gear dependent, range dependent or
beginning the diagnostic procedures:
temperature dependent.
Know and Understand the Concern
Check Fluid Level and Condition
In order to correctly diagnose a concern, first
understand the customer complaint or condition. Fluid Level Check
Customer contact may be required in order to begin
CAUTION: The vehicle should not be
to verify the concern. Understand the conditions as
driven if the fluid level indicator shows the fluid
to when the concern occurs, for example:
below the DO NOT DRIVE mark or internal
• Hot or cold vehicle temperature. failure could result.
• Hot or cold ambient temperature. NOTE: If vehicle has been operated for an
• Vehicle driving conditions. extended period of time at highway speeds, in city
traffic, in hot weather or when pulling a trailer, the
• Vehicle loaded/unloaded. fluid needs to cool down to obtain an accurate
After understanding when and how the concern reading.
occurs, proceed to Verification of Condition. NOTE: The fluid level reading on the indicator will
Verification of Condition differ from operating and ambient temperatures. The
correct reading should be within the normal
This section provides information that must be used operating temperature range.
in both determining the actual cause of customer
concerns and carrying out the appropriate Under normal circumstances, the fluid level should
procedures. be checked during normal maintenance. If the
transmission starts to slip, shifts slowly or has signs
The following procedures must be used when of fluid leaking, the fluid level should be checked.
verifying customer concerns for the transmission.
1. With the transmission in (P) PARK, the engine
Determine Customer Concern at idle, foot pressed on the brake, move the
NOTE: Some transmission conditions can cause range selector lever through each gear and
engine concerns. An electronic pressure control allow engagement of each gear. Place the range
short circuit can cause engine misfiring. The torque selector lever in the PARK position.
converter clutch not disengaging will stall the 2. Wipe the fluid level indicator cap and remove
engine. the indicator.
Determine customer concerns relative to vehicle use 3. Wipe the indicator with a clean cloth.
and dependent driving conditions, paying attention 4. Install the indicator back in the filler tube until
to the following items: it is fully seated, then remove the indicator. The
• Hot or cold vehicle operating temperature. fluid level should be within the normal
operating temperature range.
• Hot or cold ambient temperatures.
• Type of terrain.
• Vehicle loaded/unloaded.
• City/highway driving.
• Upshift.
• Downshift.
• Coasting.
• Engagement.

Last updated: 8/2/2004 2005 F-150, 10/2004
Item Description Fluid Condition Check
1 Do not drive if below mark 1. Check the fluid level.
2 Fluid Level at Operating Temperature 2. Observe the color and the odor. The color
66°C-77°C (150°F-170°F) under normal circumstances should be dark
3 Fluid Level at Room Temperature reddish, not brown or black or have a burnt
21°C-35°C (70°-95°F) odor.
4 Overfill 3. Hold the fluid level indicator over a white
facial tissue and allow the fluid to drip onto the
facial tissue and examine the stain.
High Fluid Level
4. If evidence of solid material is found, the
A fluid level that is too high may cause the fluid to
transmission fluid pan should be removed for
become aerated due to the churning action of the
further inspection.
rotating internal parts. This will cause erratic control
pressure, foaming, loss of fluid from the vent tube 5. If the stain is a foamy pink color, this may
and possible transmission malfunction and/or indicate coolant in the transmission. The engine
damage. If an overfill reading is indicated drain and cooling system should also be inspected at this
refill the transmission. time.
6. If fluid contamination or transmission failure is
Low Fluid Level
confirmed by the sediment in the bottom of the
A low fluid level could result in poor transmission fluid pan, the transmission must be
engagement, slipping, malfunction and/or damage. disassembled and completely cleaned. This
This could also indicate a leak in one of the includes the torque converter, coolers and
transmission seals or gaskets. cooler lines.
Adding Fluid 7. Carry out diagnostic checks and adjustments;
refer to Diagnosis By Symptom in this section.
CAUTION: The use of any type of
transmission fluid other than specified could
result in transmission malfunction and/or
damage.
If fluid needs to be added, add fluid in 0.25L (1/2
pint) increments through the filler tube. Do not
overfill the fluid. For fluid type, refer to the General
Specifications chart.
2005 F-150, 10/2004


Road Testing Vehicle
NOTE: Always drive the vehicle in a safe manner
according to the driving conditions and obey all
traffic laws.
The shift point road test and torque converter
operation tests provide diagnostic information on
transmission shift controls and torque converter
operation.

Last updated: 8/2/2004 2005 F-150, 10/2004

Shift Point Road Test 5. Press accelerator pedal to floor, wide open
throttle (WOT). Transmission should shift from
NOTE: Shift speed ranges are approximate for all
3rd to 2nd gear or 3rd to 1st, depending on
applications. For specific applications (engine, axle
vehicle speed. Torque converter clutch should
ratio, tire size and application), refer to the
disengage and then reapply.
Automatic Transmission Specification booklet.
6. With the transmission in (D) position and
This test verifies that the shift control system is
speed above 80 km/h (50 mph) and less than
operating correctly.
half throttle, move the transmission range
1. Bring engine and transmission up to normal selector lever from (D) position to manual 2
operating temperature. position and remove pressure from the
2. Operate vehicle with transmission range selector accelerator pedal. Transmission should
lever in (D) position. immediately downshift into 2nd gear. With
3. Apply minimum throttle and observe speeds at vehicle remaining in manual 2 position, move
which upshift occurs and torque converter the transmission range selector lever into
engages; refer to the Shift Speeds Chart in this manual 1 position and release accelerator pedal.
section. Transmission should downshift into 1st gear at
speeds approximately below 45-56 km/h (28-35
4. With the transmission in Overdrive (4th gear), mph).
press the transmission control switch. The
transmission should downshift to 3rd gear. 7. If transmission fails to upshift/downshift or
Release the accelerator pedal; engine braking torque converter clutch does not apply and
should occur. release, refer to Diagnosis By Symptom in this
section.
Shift Speeds
Throttle Position Shift MPH Km/H
Light Throttle 1-2 9-17 14-27
TP Voltage 2-3 15-35 24-56
1.25 Volts 3-4 19-47 31-76
Closed Throttle 4-3 11-25 18-40
3-2 11-25 18-40
2-1 4-12 6-19
Wide Open Throttle 1-2 32-48 51-77
2-3 60-88 97-142
3-2 58-88 93-142
2-1 29-39 46-62

Last updated: 8/2/2004 2005 F-150, 10/2004

Torque Converter Diagnosis 1. Carry out Quick Test with diagnostic tool. For
additional information, refer to the Powertrain
Prior to installing new or remanufactured torque
Control/Emissions Diagnosis (PC/ED) manual.
converters, all diagnostic procedures must be
Check for DTCs.
followed. This is to prevent the unnecessary
installation of new or remanufactured torque 2. Connect a tachometer to the engine.
converters. Only after a complete diagnostic 3. Bring the engine to normal operating
evaluation can the decision be made to install a temperature by driving the vehicle at highway
new or remanufactured torque converter. speeds for approximately 15 minutes in (D)
Begin with the normal diagnostic procedures as position.
follows: 4. After normal operating temperature is reached,
1. Preliminary inspection. maintain a constant vehicle speed of about 80
km/h (50 mph) and tap brake pedal with the
2. Know and understand the customer’s concern.
left foot.
3. Verify the condition — carry out the torque
5. Engine rpm should increase when brake pedal
converter operation test.
is tapped and decrease about 5 seconds after
4. Carry out diagnostic procedures. pedal is released. If this does not occur, see
• Carry out on-board diagnostics; refer to torque converter operation concerns. For
Diagnostics. additional information, refer to Diagnosis By
Symptom in this section.
— Repair all non-transmission related DTCs
first. 6. If the vehicle stalls in (D) or manual 2 at idle
with vehicle at a stop, move the transmission
— Repair all transmission DTCs. range selector lever to manual 1 position. If the
— Rerun on-board diagnostic to verify repair. vehicle stalls, see torque converter operation
• Carry out Line Pressure Test. For additional concerns. For additional information, refer to
information, refer to Special Testing Diagnosis By Symptom in this section. If the
Procedures in this section. vehicle does not stall in (D) , refer to Diagnosis
By Symptom in this section.
• Carry out Stall Speed Test. For additional
information, refer to Special Testing 7. If the vehicle exhibits a vibration during the
Procedures in this section. road test, complete the Road Test Evaluation
Form. This form will aid the technician in
• Carry out Diagnostic Routines. For additional
determining the source of the vibration.
information, refer to Diagnosis By Symptom
in this section. NOTE: The following is a list of common vehicle
concerns that have been misdiagnosed as torque
— Use the Diagnosis by Symptom Index to
converter clutch shudder. For diagnosis of the
locate the appropriate routine that best
following items refer to the appropriate sections of
describes the symptom(s). The routine will
the workshop manual and the Powertrain
list all possible components that may
cause or contribute to the symptom.
Check each component listed; diagnose • Spark plugs — check for cracks, high resistance
and repair as required before changing or broken insulators.
the torque converter. • Plug wires.
Torque Converter Operation Test • Fuel injector — filter may be plugged.
This test verifies that the torque converter clutch • Fuel contamination — engine runs poor.
control system and the torque converter are • EGR valve — valve may let in too much exhaust
operating correctly. gas and cause engine to run lean.
• Vacuum leak — engine will not get correct
air/fuel mixture.
• MAP/MAF sensor — incorrect air/fuel mixture.
Last updated: 8/2/2004 2005 F-150, 10/2004
• HO2S sensor — too rich/lean air/fuel mixture. • Engine mounts — loose/damaged mounts can
• Fuel pressure — may be too low. cause vibration concerns.
• Axle joints — check for vibration.
Torque Converter Road Evaluation Form

1) Does the torque converter Yes • GO to Step 2.
engage/disengage?
No • REFER to Diagnosis By Symptom — Torque

Converter No Apply Routine 240/340 and
Always Applied Routine 241/341 in this
section for further diagnosis information.
REPAIR as required, VERIFY converter
operation and then continue.
2) Does vibration occur during 3-4 or 4-3 shift Light • May be torque converter clutch shudder. GO
at: light, medium or heavy throttle? to Step 3.
Medium • May be torque converter clutch shudder. GO

to Step 3.
Heavy • Not torque converter clutch shudder —

converter does not engage due to PCM
strategy. REFER to Section 100-04 and
Diagnosis By Symptom — Noise/Vibration
Routine 254/354 in this section for further
diagnosis.
3) Is the problem vehicle speed dependent, Yes • Not torque converter clutch shudder, REFER
operating at steady speed, i.e., 64 km/h (40 to Section 100-04 and Diagnosis By Symptom
mph) regardless of transmission range? Verify — Noise/Vibration Routine 254/354 in this
by manually selecting 2nd, OD cancel and OD. section for further diagnosis.
4) Is the problem engine-rpm dependent Yes • Not torque converter clutch shudder, REFER
(occurs at the same engine rpm independent of to Section 100-04 and Diagnosis By Symptom
transmission gear)? Verify by holding same rpm — Noise/Vibration Routine 254/354 in this
in each transmission gear. section for further diagnosis.
5) Does the problem occur in coast, steady Yes • Not torque converter clutch shudder, REFER
speed or reverse range? to Section 100-04 and Diagnosis By Symptom
— Noise/Vibration Routine 254/354 in this
section for further diagnosis.
6) Does vibration occur during extended light Yes • Not torque converter clutch shudder, REFER
brake application? to Section 100-04, Section 206-00 and
Diagnosis By Symptom — Noise/Vibration
Routine 254/354 in this section for further
diagnosis.
2005 F-150, 10/2004

Torque Converter Road Evaluation Form
7) If one of the driving modes in Step 2
identifies a vibration which is not present in
Steps 3-6, then there is a strong possibility that
the vibration is caused by the torque converter
clutch function. Carry out Torque Converter
Diagnosis procedure, refer to Torque Converter
Diagnosis in this section.
2005 F-150, 10/2004


Visual Inspection Shift Linkage Check
This inspection will identify modifications or Check for a misadjustment in shift linkage by
additions to the vehicle operating system that may matching the detents in the transmission range
affect diagnosis. Inspect the vehicle for non-Ford selector lever with those of the manual lever in the
factory add-on devices such as: transmission. If they match, the misadjustment is in
the indicator. Do not adjust the shift linkage.
• electronic add-on items:
Hydraulic leakage at the manual control valve can
— air conditioning cause delay in engagements and/or slipping while
— generator (alternator) operating if the linkage is not correctly adjusted.
— engine turbo Check TSBs and OASIS
— cellular telephone Refer to all technical service bulletins (TSB) and
— cruise control OASIS messages which pertain to the transmission
— CB radio concern and follow the procedure as described.
— linear booster Carry Out On-Board Diagnostics (KOEO,
— backup alarm signal KOER)
— computer After a road test, with the vehicle warm and before
disconnecting any connectors, carry out the Quick
• vehicle modification: Test using the diagnostic tool. Refer to the
These items, if not installed correctly, will affect the Powertrain Control/Emissions Diagnosis (PC/ED)
powertrain control module (PCM) or transmission manual.
function. Pay particular attention to add-on wiring
splices in the PCM harness or transmission wiring
harness, abnormal tire size or axle ratio changes.
• leaks; refer to Leak Inspection.
• correct linkage adjustments.

Last updated: 8/2/2004 2005 F-150, 10/2004

Diagnostics Special Tool(s)
Transmission Tester
Special Tool(s) 307-F016 (007-00130) or
equivalent
Transmission Fluid Pressure
Gauge
307-004 (T57L-77820-A)
Trans Tester TR/MLP Overlay

and Manual
Air Test Plate, Transmission
307-246 (T92P-7006-A)
73 III Automotive Meter

105-R0057 or equivalent
307-351 (T97L-70010-A)
UV Leak Detector Kit

Breakout Box, EEC-V Control
System
418-049 (T94L-50-EEC-V) or
equivalent
Diagnosing an electronically controlled automatic

transmission is simplified by using the following
MLP-TR Cable procedures. One of the most important things to
418-F107 (007-00111) or remember is that there is a definite procedure to
equivalent follow. DO NOT TAKE SHORT CUTS OR
ASSUME THAT CRITICAL CHECKS OR
ADJUSTMENTS HAVE ALREADY BEEN
MADE. Follow the procedures as written to avoid
missing critical components or steps. By following
Worldwide Diagnostic System the diagnostic sequence, the technician will be able
(WDS) to diagnose and repair the concern the first time.
Vehicle Communication Module
(VCM) with appropriate
adapters, or equivalent
diagnostic tool
(Continued)

Last updated: 8/2/2004 2005 F-150, 10/2004
On-Board Diagnostics With Diagnostic Tool • Quick Test 5.0 - Key On, Engine Running
NOTE: For detailed instruction and other diagnostic (KOER)
methods using the diagnostic tool, refer to the — Special Test Mode
diagnostic tool tester manual and the Powertrain — Wiggle Test
These quick tests should be used to diagnose the — Output Test Mode
powertrain control module (PCM) and should be — PCM Reset Mode
carried out in order. — Clearing DTCs
• Quick Test 1.0 - Visual Inspection — OBD II Drive Cycle
• Quick Test 2.0 - Set Up • Other Diagnostic Tool Features
• Quick Test 3.0 - Key On, Engine Off (KOEO) For further information on other diagnostic testing
• Quick Test 4.0 - Continuous Memory features using the diagnostic tool, refer to the
Powertrain Control/Emissions Diagnosis (PC/ED)
manual. Other diagnostic methods include the
following:
— Parameter Identification (PID) Access Mode
— Freeze Frame Data Access Mode
— Oxygen Sensor Monitor Mode
2005 F-150, 10/2004


Output State Control (OSC) Mode • LINEDSD - Directs PCM to command line
pressure to either 345, 517, 689, 862, 1,034,
Special Tool(s) 1,207, 1,379 kPa (50, 75, 100, 125, 150, 175, 200
Worldwide Diagnostic System psi). The PCM will command the appropriate
(WDS) EPC current to obtain the commanded line
Vehicle Communication Module pressure.
adapters, or equivalent SSA, SSB and TCC in BENCH MODE
diagnostic tool These OSC functions are used to command SSA,
SSB and TCC solenoids OFF and ON when
carrying out an electrical circuit check.
Output State Control (OSC) using the NGS or WDS
The OSC functions for parameters SSA, SSB and
diagnostic tool allows the technician to easily and
TCC allow the technician to choose the following
quickly control the main functions and components
options:
of this transmission. OSC is used to help test the
electrical, hydraulic or mechanical concerns related • OFF - Directs PCM to command the solenoid
to the transmission. The NGS or WDS also provides OFF
PID information, along with the OSC functions, to • ON - Directs PCM to command the solenoid ON
accurately diagnose the transmission. For example,
OSC allows the technician to shift the transmission • XXX - Cancels OSC command for that particular
or engage the converter clutch or command line solenoid (returns to normal operation)
pressure or turn a solenoid off and on. The requirements for SENDING an OSC value for
SSA, SSB or TCC are as follows:
Output State Control (OSC) Procedures
• Key on and engine not running or key on and
Retrieve the continuous codes, carry out a KOEO
engine running at idle
and KOER On-Demand Self Test before using OSC.
Any Diagnostic Trouble Codes (DTCs) related to • Gear selector in PARK or NEUTRAL
the transmission range (TR) sensor or the output The vehicle requirements must be met when sending
shaft speed (OSS) sensor must be fixed or the PCM the OSC value for SSA, SSB and TCC solenoids. If
will not allow OSC to operate. the vehicle requirements are not met when sending
Using the NGS, OSC has 2 menus for operation, the the OSC value, an error message will appear. When
BENCH MODE and the DRIVE MODE. the error message is received, OSC is aborted and
must be restarted. After sending the OSC value, if
OSC — BENCH MODE the vehicle requirements are no longer met, the
The BENCH MODE is functional only when the error message will not appear but the OSC value
vehicle range selector is in PARK or NEUTRAL. will be cancelled by the PCM (monitor
The BENCH MODE may be used when the engine corresponding PID). The OSC value XXX may be
is either ON (running) or OFF (not running). The sent anytime to cancel OSC.
BENCH MODE allows the technician to function
the following components:
• SSA - Directs PCM to command Shift Solenoid 1
OFF or ON
• SSB - Directs PCM to command Shift Solenoid 2
OFF or ON
• TCC - Directs PCM to command the Torque
Converter Solenoid OFF or ON (OFF = 0% duty
cycle and ON = 100% duty cycle)

Last updated: 8/2/2004 2005 F-150, 10/2004
LINEDSD in BENCH MODE The vehicle requirements must be met when sending
The LINEDSD in BENCH MODE may be used the OSC value for EPC. If the vehicle requirements
when carrying out an electrical check on the EPC are not met when sending the OSC value, an error
solenoid or used to test the functionality of the message will appear. When the error message is
transmission’s electronic control of the line pressure. received, OSC is aborted and must be restarted.
When testing the EPC for controlling the line After the OSC value for EPC is sent, if the vehicle
pressure, the technician is required to run the engine requirements are no longer met, the error message
greater than 1,500 rpm. The installation of a will not appear but the OSC value will be cancelled
hydraulic pressure gauge is required to actually test by the PCM (monitor corresponding PID). The OSC
whether the transmission line pressure is correct. value XXX may be sent anytime to cancel OSC.
This will test whether the hydraulic pump, the
OSC — DRIVE MODE
pressure regulator and the EPC solenoid and other
associated mechanical and hydraulic components are The DRIVE MODE allows control of 2
working correctly. transmission functions. Each OSC function has a
unique set of vehicle operating requirements that the
When carrying out an electrical test on the EPC
technician is required to meet before being allowed
solenoid, set LINEDSD to 1,379 kPa (200 psi) to
to operate OSC. The recommended procedure, when
command the EPC solenoid OFF and 345 kPa (50
using the DRIVE MODE, is to command one
psi) to command the EPC solenoid ON.
parameter at a time. The DRIVE MODE allows the
Commanding 1,379 kPa (200 psi) may not
technician to control the following OSC functions
electrically turn the pressure solenoid completely
on the transmission:
off and commanding 345 kPa (50 psi) may not
electrically turn the pressure solenoid completely on. • OSCGEAR - Directs the PCM to upshift or
The OSC functions for the parameter LINEDSD downshift
allow the technician to choose the following • OSCTCC - Directs the PCM to lock or unlock the
options: torque converter clutch
• 50 - Directs PCM to command line pressure to OSCGEAR in DRIVE MODE
345 kPa (50 psi)
The OSC function is used to test the transmission
• 75 - Directs PCM to command line pressure to gear changes. The advantage of using OSC for
517 kPa (75 psi) changing gears is to allow the technician to easily
• 100 - Directs PCM to command line pressure to test a specific gear and/or upshift or downshift that
689 kPa (100 psi) has been identified as the customer complaint.
When using OSC to command a shift change, the
• 125 - Directs PCM to command line pressure to
PCM should command the correct or normal
862 kPa (125 psi)
pressure for that shift. The transmission will remain
• 150 - Directs PCM to command line pressure to in the gear that OSC has commanded until OSC
1,034 kPa (150 psi) commands another gear or OSC is cancelled.
• 175 - Directs PCM to command line pressure to The OSC functions for the OSCGEAR parameter
1,207 kPa (175 psi) allow the technician to choose the following
• 200 - Directs PCM to command line pressure to options:
1,379 kPa (200 psi)
• 1 - Directs PCM to command 1st gear
• XXX - Cancels OSC command for line pressure
• 2 - Directs PCM to command 2nd gear
(returns to normal operation)
• 3 - Directs PCM to command 3rd gear
The vehicle requirements for sending an OSC value
for LINEDSD in BENCH MODE is as follows: • 4 - Directs PCM to command 4th gear
• XXX - Cancels OSC command for GEAR
• Key on and engine off or key on engine running
(returns to normal operation)
(engine speed greater than 1,500 rpm)
• Range selector in PARK or NEUTRAL
2005 F-150, 10/2004

The vehicle requirements must be met when sending The vehicle requirements must be met when sending
the OSC value for GEAR. If the vehicle the OSC value for TCC. If the vehicle requirements
requirements are not met when sending the OSC are not met when sending the OSC value, an error
value, an error message will appear. When the error message will appear. When the error message is
message is received, OSC is aborted and must be received, OSC is aborted and must be restarted.
restarted. After the OSC value for GEAR is sent, if After the OSC value for TCC is sent, if the vehicle
the vehicle requirements are no longer met, the requirements are no longer met, the error message
error message will not appear but the OSC value will not appear but the OSC value will be cancelled
will be cancelled by the PCM (monitor by the PCM (monitor corresponding PID). The OSC
corresponding PID). The OSC value XXX may be value XXX may be sent anytime to cancel OSC.
sent anytime to cancel OSC. The vehicle requirements for sending the TCC value
It is recommended to use the OSCTCC parameter in OFF are as follows:
OSC to 1st turn off the converter clutch when
• Engine is running
testing the transmission gear changes. This will
allow the technician to evaluate just the gear • Gear selector is in OVERDRIVE
changes. If the torque converter clutch is not turned • Vehicle speed is greater than 3 km/h (2 mph)
off, then the PCM may command the torque
The vehicle requirements for sending the TCC value
converter clutch to lock during a shift. This could
ON are as follows:
make it more difficult for the technician to
determine whether a bad shift is the result of the • Engine is running
torque converter engaging or the actual gear change. • Gear selector is in OVERDRIVE
The vehicle requirements for sending a OSCGEAR • Vehicle speed is greater than 3 km/h (2 mph)
value is as follows:
• Transmission fluid temperature (TFT) is between
• Engine is running 16-116°C (60-240°F)
• Gear selector is in OVERDRIVE • Brake is off when vehicle speed is below 32 km/h
• Vehicle speed is greater than 3 km/h (2 mph) (20 mph)
• Vehicle speed must be lower than 48 km/h (30 • Not an excessive load on the engine
mph) to command a downshift to 1st gear • Not during an upshift or downshift
• Vehicle speed must be lower than 97 km/h (60 • Engine speed is greater than 1,500 rpm
mph) to command a downshift to 2nd gear
Using Output State Control (OSC) and
• Vehicle speed must be lower than 145 km/h (90 Monitoring PIDs
mph) to command a downshift to 3rd gear
To confirm that the OSC value was sent by the
• Vehicle speed must be greater than 48 km/h (30 NGS and the PCM has accepted the OSC command,
mph) to command an upshift to 4th gear a corresponding PID for each OSC parameter must
TCC in DRIVE MODE be monitored. After sending the OSC value, the
corresponding PID value should be the same as the
The OSC function is used to test whether the torque OSC value. Additional PIDs should be monitored
converter clutch (TCC) is locking and unlocking to help the technician accurately diagnose the
correctly. transmission. The following is a list of PIDs to
The OSC functions for the TCC parameter allows monitor while using OSC.
the technician to choose the following:
OSC Corresponding Additional
• ON - Commands TCC solenoid ON (100% duty Parameter PID PIDs
cycle) to lock the TCC SSA SS1 SS1F
• OFF - Commands TCC solenoid OFF (0% duty SSB SS2 SS2F
cycle) to unlock the TCC
LINEDSD LINEDSD EPC
• XXX - Cancels OSC for TCC (returns to normal
operation)
2005 F-150, 10/2004

OSC Corresponding Additional PID Name PID Description
Parameter PID PIDs SSB Shift Solenoid No. 2 commanded state
OSCTCC OSCTCC TCC, TCCF, (not actual) — ON or OFF
TCCCMD, SS1F Shift Solenoid No. 1 circuit fault —
TCCACT YES or NO
OSCGEAR OSCGEAR GEAR, TP, SS2F Shift Solenoid No. 2 circuit fault —
RPM, TSS, YES or NO
OSS, TR, TFT,
TRANRAT and TCCACT Torque Converter Clutch slippage
VS (engine speed minus turbine speed) —
rpm
TCCCMD Torque Converter Clutch Solenoid
PID Name PID Description commanded state — duty cycle
EPC Electronic Pressure Control commanded TCCF Torque Converter Clutch Solenoid
pressure (not actual) — psi circuit fault — YES or NO
GEAR GEAR commanded state (not actual) — TFT Transmission Fluid Temperature —
1st, 2nd, 3rd or 4th degrees F or voltage
LINEDSD Line Pressure commanded (not actual) TP Throttle Position — voltage
OSS Output Shaft Speed Sensor Input — TR Transmission Range Sensor — Park,
rpm Reverse, Neutral, OD, etc.
RPM Engine Speed Sensor Input — rpm TRANRAT Actual Transmission Gear ratio
SSA Shift Solenoid No. 1 commanded state TSS Turbine Shaft Speed Sensor input —
(not actual) — ON or OFF rpm
2005 F-150, 10/2004


Transmission Drive Cycle Test After On-Board Diagnostic
NOTE: Always drive the vehicle in a safe manner NOTE: The vehicle wiring harness, PCM and
according to driving conditions and obey all traffic non-transmission sensors may affect transmission
laws. operations. Repair these concerns first.
NOTE: The Transmission Drive Cycle Test must be After the on-board diagnostic procedures are
followed exactly. Malfunctions must occur 4 times completed, repair all DTCs.
consecutively for shift error DTC code to be set and Begin with non-transmission related DTCs, then
5 times consecutively for continuous TCC code to repair any transmission related DTCs. Use the
set. diagnostic trouble code chart for information on
NOTE: When carrying out the Transmission Drive condition and symptoms. This chart will be helpful
Cycle Test, refer to the Solenoid Application Chart in referring to the correct manual(s) and aids in
for correct solenoid operation. diagnosing internal transmission concerns and
external non-transmission inputs. The pinpoint tests
After carrying out the Quick Test, use the
are used in diagnosing transmission electrical
Transmission Drive Cycle Test for checking
concerns. Make sure that the vehicle wiring harness
continuous codes.
and the PCM are diagnosed as well. The
1. Record and then erase Quick Test codes. Powertrain Control/Emissions Diagnosis (PC/ED)
2. Warm engine to normal operating temperature. manual will aid in diagnosing non-transmission
electronic components.
3. Make sure transmission fluid level is correct.
4. With transmission in OVERDRIVE, moderately
accelerate from stop to 80 km/h (50 mph). This
allows the transmission to shift into 4th gear.
Hold speed and throttle open steady for a
minimum of 15 seconds.
5. With transmission in 4th gear and maintaining
steady speed and throttle opening, lightly apply
and release brake to operate stoplamps. Then
hold speed and throttle steady for a minimum
of 5 seconds.
6. Brake to a stop and remain stopped for a
minimum of 20 seconds.
7. Repeat steps 4 through 6 at least 5 times.
8. Carry out Quick Test and record continuous
DTCs.
• If the DTCs are still present, refer to the
Diagnostic Trouble Code Chart. Repair all
non transmission DTCs first as they can
directly affect the operation of the
transmission. Repeat the Quick Test and the
Road Test to verify the correction. Erase
the DTCs, carry out the Drive Cycle Test
and repeat the Quick Test after completing
repair on the DTC.
• If the continuous test passes and a concern
is still present, refer to Diagnosis By
Symptom in this section, OASIS messages
and TSBs for concerns.

Last updated: 8/2/2004 2005 F-150, 10/2004
Before Pinpoint Tests
NOTE: Prior to entering pinpoint tests, check the
PCM wiring harness for tight connections, bent or
broken pins, corrosion, loose wires, correct routing,
correct seals and their condition. Check the PCM,
sensors and actuators for damage. Refer to the
Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
NOTE: If a concern still exists after electrical
diagnosis has been carried out, refer to Diagnosis
By Symptom in this section.
If DTCs appear while carrying out the on-board
diagnostics, refer to the Diagnostic Trouble Code
Charts for the appropriate repair procedure. Prior to
entering pinpoint tests, refer to any TSBs and
OASIS messages for transmission concerns.
2005 F-150, 10/2004


Diagnostic Trouble Code Charts
Diagnostic Trouble Code Chart
Five Digit
DTC Component Description Condition Symptom Action
P0102 MAF MAF concerns MAF system has a High or low EPC Refer to the
P0103 malfunction which pressure, incorrect Powertrain
P1100 may cause a shift schedule. Control/Emissions
P1101 transmission Incorrect torque Diagnosis (PC/ED)
concern. converter clutch manual.
engagement
scheduling.
Symptoms similar
to a throttle
position (TP)
failure.
P0112 IAT IAT indicates Voltage drop Incorrect EPC Refer to the
125°C (257°F) across IAT exceeds pressure, either Powertrain
(grounded) scale set for high or low, results Control/Emissions
temperature 125°C in harsh or soft Diagnosis (PC/ED)
(257°F). shifts. manual.
P0113 IAT IAT indicates Voltage drop Incorrect EPC Refer to the
-40°C (-40°F) across IAT exceeds pressure, either Powertrain
(open circuit) scale set for high or low, results Control/Emissions
temperature -40°C in harsh or soft Diagnosis (PC/ED)
(-40°F). shifts. manual.
P0114 IAT IAT out of IAT temperature Rerun on-board Refer to the
on-board higher or lower diagnostic at Powertrain
diagnostic range than expected normal operating Control/Emissions
during KOEO and temperature. Diagnosis (PC/ED)
KOER. manual.
P0117 ECT ECT indicates Voltage drop Torque converter Refer to the
125°C (257°F) across ECT clutch will always Powertrain
exceeds scale set be off, resulting in Control/Emissions
for temperature reduced fuel Diagnosis (PC/ED)
125°C (257°F) economy. manual.
(grounded).
P0118 ECT ECT indicates Voltage drop Torque converter Refer to the
-40°C (-40°F) across ECT clutch will always Powertrain
exceeds scale set be off, resulting in Control/Emissions
for temperature reduced fuel Diagnosis (PC/ED)
-40°C (-40°F) economy. manual.
(open circuit).
P0122 TP TP concern PCM has detected Harsh Refer to the
P0123 an error that may engagements, firm Powertrain
P1120 cause a shift feel, abnormal Control/Emissions
transmission shift schedule, Diagnosis (PC/ED)
concern. torque converter manual.
clutch does not
engage, torque
converter clutch
cycling.

Last updated: 8/2/2004 2005 F-150, 10/2004
Diagnostic Trouble Code Chart (Continued)
Five Digit
P0300- Electronic EI system EI system has a Harsh engagements Refer to the
P0308 Ignition (EI) concerns malfunction which and shifts, late Powertrain
P0320 may cause a WOT shifts, no Control/Emissions
P0340 transmission torque converter Diagnosis (PC/ED)
P1351- concern. clutch engagement. manual.
P1364
P1702 Digital TR Intermittent DTC Refer to DTC Refer to DTC GO to Pinpoint
codes P0705 or codes P0705 or codes P0705 or Test C.
P0708 P0708 condition. P0708 symptom.
P1704 Digital TR Digital TR Digital TR sensor Wrong commanded GO to Pinpoint
circuit reading in or shift cable EPC pressure. Test C.
between gear incorrectly Digital TR reading
position during adjusted; or digital the wrong gear
KOEO/KOER TR circuit failure. position.
P0705 Digital TR Digital TR Digital TR circuits, Increase in EPC GO to Pinpoint
circuit failure indicating an pressure (harsh Test C.
invalid pattern in shifts). Defaults to
TR D. Condition (D) or D for all
caused by a short gear positions. In
to ground or an (D) position trans,
open in TR4, stuck in D or
TR3A, TR2 and or manual 2.
TR1 circuits. This
DTC cannot be set
by an incorrectly
adjusted digital TR
sensor.
P0708 Digital TR Digital TR Digital TR sensor Increase in EPC GO to Pinpoint
sensor circuit circuit TR3A pressure. Defaults Test C.
TR3A open reading 2.6v - 5.0v to (D) or D for all
(open circuit). This gear ranges.
DTC cannot be set
by an incorrectly
adjusted digital TR
sensor.
P1705 Digital TR Digital TR self Vehicle not in Rerun on-board GO to Pinpoint
test was not PARK or diagnostic in Test C.
carried out in NEUTRAL during PARK or
PARK or on-board NEUTRAL.
NEUTRAL diagnostic.
P0715 TSS Insufficient input PCM detected a Harsh shifts, harsh GO to Pinpoint
from turbine loss of TSS signal torque converter Test F.
shaft speed during operation. clutch activation
sensor and harsh
engagements.
P0717 TSS Turbine shaft PCM has detected Harsh shifts, harsh GO to Pinpoint
speed sensor an intermittent TSS torque converter Test F.
signal signal. clutch activation
intermittent and harsh
engagements.
2005 F-150, 10/2004

Five Digit
P0718 TSS Turbine shaft PCM has detected Harsh shifts, harsh GO to Pinpoint
speed sensor a noisy TSS signal. torque converter Test F.
signal noisy clutch activation
and harsh
engagements.
P0720 OSS Insufficient input PCM detected a Harsh shifts, GO to Pinpoint
from output shaft loss of OSS signal abnormal shift Test E.
speed sensor during operation. schedule, no torque
converter clutch
activation.
P0721 OSS OSS sensor PCM has detected Harsh shifts, GO to Pinpoint
signal noisy an erratic OSS abnormal shift Test E.
signal. schedule, no torque
converter clutch
engagement.
P0722 OSS wiring Insufficient input PCM has detected Harsh shifts, GO to Pinpoint
from OSS a loss of OSS abnormal shift Test E.
signal. schedule, no torque
converter clutch
engagement.
P0731 SSA, SSB or 1st gear error No 1st gear. Incorrect gear Use the Solenoid
internal parts selection, Operation Chart,
depending on refer to Pinpoint
failure or mode and Tests — OSC
manual lever Equipped Vehicles.
position. Shift GO to Pinpoint
errors may also be Test A.
due to other
internal
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected.
P0732 SSA, SSB or 2nd gear error No 2nd gear. Incorrect gear Use the Solenoid
due to other
internal
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected.
2005 F-150, 10/2004

Five Digit
P0733 SSA, SSB or 3rd gear error No 3rd gear. Incorrect gear Use the Solenoid
due to other
internal
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected.
P0734 SSA, SSB or 4th gear error No 4th gear. Incorrect gear Use the Solenoid
due to other
internal
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected.
P0741** TCC, internal TCC slippage The PCM picked TCC Refer to Diagnosis
components detected up an excessive slippage/erratic or By Symptom in
amount of slippage no torque converter this section.
during normal clutch operation.
vehicle operation. Flashing
Transmission
Control Indicator
Lamp (TCIL).
P0743* TCC, wiring, TCC solenoid TCC solenoid Short circuit: GO to Pinpoint
PCM circuit failure circuit fails to engine stalls in Test A.
during on-board provide voltage second (OD, 2
diagnostic drop across range) at low idle
solenoid. Circuit speeds with brake
open or shorted or applied.
PCM driver failure Open circuit:
during on-board torque converter
diagnostic. clutch never
engages. May flash
TCIL.
2005 F-150, 10/2004

Five Digit
P0750* SSA, wiring, SSA solenoid SSA circuit failed Incorrect gear GO to Pinpoint
PCM circuit failure to provide voltage selection depending Test A.
drop across on condition mode
solenoid. Circuit and manual lever
open or shorted or position. See
PCM driver failure Solenoid On/Off
during on-board Chart.
diagnostic.
P0753 SSA, wiring, SSA electrical SSA circuit fails to Incorrect gear GO to Pinpoint
PCM failure provide voltage depending on Test A.
drop across condition mode and
solenoid. Circuit manual lever
during on-board Chart. May flash
diagnostic. TCIL.
P0755* SSB, wiring, SSB solenoid SSB circuit fails to Incorrect gear GO to Pinpoint
PCM circuit failure provide voltage selection depending Test A.
drop across on condition mode
solenoid. Circuit and manual lever
during on-board Chart.
diagnostic.
P0758* SSB, wiring, SSB electrical SSB circuit fails to Incorrect gear GO to Pinpoint
PCM circuit failure provide voltage depending on Test A.
drop across condition mode and
solenoid. Circuit manual lever
during on-board Chart. May flash
diagnostic. TCIL.
P1714 SSA, internal SSA malfunction Mechanical failure Incorrect gear GO to Pinpoint
components of the solenoid selection depending Test G.
detected. on condition, mode
and manual lever
position. See
Solenoid Operation
Chart.
P1715 SSB SSB malfunction Mechanical failure Incorrect gear GO to Pinpoint
of the solenoid selection depending Test G.
detected. on condition, mode
and manual lever
position. See
Solenoid Operation
Chart.
2005 F-150, 10/2004

Five Digit
P0781 ** SSA or internal 1-2 shift error Engine rpm drop Incorrect gear Refer to Solenoid
parts not detected when selection depending Operation Chart,
1-2 shift was on failure or mode then GO to
commanded by and manual lever Pinpoint Test A.
PCM. position. Shift
errors may also be
due to other
internal
transmission
concerns (stuck
valves, damaged
friction material).
P0782** SSA, SSB or 2-3 shift error Engine rpm drop Incorrect gear Refer to Solenoid
internal parts not detected when selection depending Operation Chart,
errors may also be
due to other
internal
transmission
concerns (stuck
valves, damaged
friction material).
P0783** SSA, SSB or 3-4 shift error Engine rpm drop Incorrect gear Refer to Solenoid
internal parts not detected when selection depending Operation Chart,
errors may also be
due to other
internal
transmission
concerns (stuck
valves, damaged
friction material).
— TCIL TCIL circuit TCIL circuit open Failed on, OD Refer to the
failure or shorted. cancel mode on. Powertrain
No flashing TCIL Control/Emissions
for EPC failure or Diagnosis (PC/ED)
sensor. Failed off, manual.
OD cancel mode
never indicated. No
flashing TCIL for
EPC sensor failure.
P1116 ECT ECT out of ECT temperature Rerun on-board Refer to the
on-board higher or lower diagnostic at Powertrain
diagnostic range than expected normal operating Control/Emissions
during KOEO and temperature. Diagnosis (PC/ED)
KOER. manual.
2005 F-150, 10/2004

Five Digit
P1124 TP TP voltage TP was not in the Rerun at Refer to the
high/low for correct position for appropriate throttle Powertrain
on-board on-board position per Control/Emissions
diagnostic diagnostic. application. Diagnosis (PC/ED)
manual.
P1460 A/C A/C clutch A/C or defrost on DTC set during Refer to the
cycling pressure condition may on-board Powertrain
switch error result from A/C diagnostic, repeat Control/Emissions
clutch being on with A/C off. Diagnosis (PC/ED)
during on-board Failed on, EPC manual.
diagnostic. pressure slightly
low with A/C off.
P1636 PCM PCM detected — — Refer to the
internal error Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
P1703 BPP BPP switch Brake ON/OFF Failed on or not Refer to the
circuit failed circuit failure. connected — Powertrain
torque converter Control/Emissions
clutch will not Diagnosis (PC/ED)
engage at less than manual.
1/3 throttle. Failed
off or not
connected —
torque converter
clutch will not
disengage when
brake is applied.
P1703 BPP Brake not Brake not cycled Failed off or not Refer to the
actuated during during KOER. connected — Powertrain
on-board torque converter Control/Emissions
diagnostic clutch will not Diagnosis (PC/ED)
engage at less than manual.
1/3 throttle. Failed
off or not
connected —
torque converter
clutch will not
disengage when
brake is applied.
P0713 TFT, wiring, -40°C (-40°F) Voltage drop Firm shift feel. GO to Pinpoint
PCM indicated TFT across TFT sensor Test B.
sensor circuit exceeds scale set
open for temperature
-40°C (-40°F).
P1711 TFT TFT out of Transmission not at Warm vehicle to GO to Pinpoint
on-board operating normal operating Test B.
diagnostic range temperature during temperature.
on-board
diagnostic.
2005 F-150, 10/2004

Five Digit
P0712 TFT, wiring, 157°C (315°F) Voltage drop Firm shift feel. GO to Pinpoint
PCM indicated TFT across TFT sensor Test B.
sensor circuit exceeds scale set
grounded for temperature of
157°C (315°F).
P1713 TFT wiring PCM TFT continually TFT sensor in Firm shift feel. GO to Pinpoint
reading cold range low failure. Substitute ECT for Test B.
TFT
P1783 TFT Transmission Transmission fluid Increase in EPC GO to Pinpoint
over temperature temperature pressure. Test B.
condition exceeded 127°C
indicated (270°F).
P1718 TFT, wiring, TFT continually TFT sensor in Firm shift feel. GO to Pinpoint
PCM reading hot range high failure. Substitute ECT for Test B.
TFT.
P0740 TCC, wiring, TCC electrical TCC circuit fails to Short circuit, GO to Pinpoint
PCM failure provide voltage engine stalls in Test A.
drop across SECOND ((D) , 2
solenoid. Circuit range) at low
open, shorted or speeds with brake
PCM driver failure applied. Open
during on-board circuit, torque
diagnostics. converter clutch
never engages.
May flash TCIL.
P1740 TCC TCC malfunction Mechanical failure Failed on — GO to Pinpoint
of the solenoid Engine stalls in Test G.
detected. 2nd (O/D, Manual
2 ranges) at low
idle speeds with
brake applied.
Failed off —
Torque Converter
never applies.
P1741** TCC, internal Excessive torque Excessive Engine rpm GO to Pinpoint
components converter clutch variations in slip oscillation is Test A.
engagement error (engine speed present in 3rd gear.
surge) across the
torque converter
clutch.
P1742 TCC, internal TCC solenoid TCC solenoid has Harsh shifts. GO to Pinpoint
components failed on failed on by Test A.
electric, mechanical
or hydraulic
concern.
P1743 TCC, internal TCC solenoid TCC solenoid has Harsh shifts. GO to Pinpoint
components failed on failed on by Test A.
electric, mechanical
or hydraulic
concern.
2005 F-150, 10/2004

Five Digit
P1744 TCC TCC The PCM picked TCC Refer to Diagnosis
up an excessive slippage/erratic or By Symptom in
amount of TCC no torque converter this section.
slippage during clutch operation.
normal vehicle
operation.
P1746* EPC, wiring, EPC solenoid Voltage through Open circuit causes GO to Pinpoint
P0960 PCM open circuit EPC solenoid is maximum EPC Test D.
checked. An error pressure, harsh
will be noted if engagements and
tolerance is shifts.
exceeded.
P1747* EPC, wiring, EPC solenoid Voltage through Short circuit causes GO to Pinpoint
P0962 PCM circuit failure, EPC solenoid is minimum EPC Test D.
shorted circuit or checked. An error pressure (minimum
output driver will be noted if capacity) and limits
tolerance is engine torque
exceeded. (alternate firm).
P1760 EPC, wiring, EPC solenoid PCM detected a Unexpected GO to Pinpoint
PCM circuit failure, loss of EPC during reduction in engine Test D.
shorted circuit or operation. torque.
output driver
P1780 TCS TCS not TCS not cycled Rerun on-board Refer to the
changing states during self-test. diagnostic and Powertrain
TCS circuit open cycle switch. No Control/Emissions
or shorted. OD cancel when Diagnosis (PC/ED)
switch is cycled. manual.
P17811 4x4 low switch 4x4 low switch 4x4 low switch Failed on — early Refer to the
closed closed or 4x4 low shift schedules in Powertrain
indicator lamp 4x2 and 4x4 HI Control/Emissions
circuit open. range. Failed off Diagnosis (PC/ED)
— shifts delayed in manual.
4x4 low.1
P0963 EPC solenoid EPC solenoid Voltage through Maximum EPC GO to Pinpoint
short to power EPC solenoid is pressure, harsh Test D.
(Vbat) circuit checked. An error engagements and
failure will be noted if shifts.
tolerance is
exceeded.
P0748** EPC solenoid EPC solenoid Voltage through Short circuit results GO to Pinpoint
circuit failure EPC solenoid is in minimum EPC Test D.
checked. An error pressure (minimum
will be noted if capacity) and limits
tolerance is engine torque
exceeded. (alternate firm).
Not all gears
present. Open
circuit: maximum
PC A pressure,
harsh engagements
and shifts.
2005 F-150, 10/2004

Five Digit
P1729 4x4L 4x4 low switch 4x4 low switch Early shifts, harsh Refer to the
failure failure during shifts, increase in Powertrain
normal vehicle electronic pressure Control/Emissions
operation. control valve. Diagnosis (PC/ED)
manual.
P1728 Trans Transmission slip The PCM has Transmission Refer to Diagnosis
error detected an slippage erratic or By Symptom in
excessive amount no torque converter this section.
of slippage during clutch operation.
normal operation.
P0500 ABS Insufficient VSS PCM detected a No transmission Refer to the
P0503 input from ABS loss of VSS signal symptom I.P. Powertrain
P1502 through SCP link through SCP link speedometer may Control/Emissions
from ABS. be affected. Diagnosis (PC/ED)
manual.*
U1039 PCM Data Insufficient VSS No VSS input to Refer to the
communication input to instrument instrument panel. Powertrain
link error panel via SCP link. Control/Emissions
Diagnosis (PC/ED)
manual.*
* Output circuit check, generated only by electrical symptoms.
** May also be generated by some other non-electric transmission hardware system.
1 If the 4x4 low indicator light fuse is blown, the transmission will shift according to the 4x4 low shift scheduling
regardless of the transfer case position.
Rotunda Transmission Tester
The Rotunda Transmission Tester is used to
diagnose the digital transmission range sensor and is
used in conjunction with the pinpoint tests. The
tests should be carried out in order. Installing the
Rotunda Transmission Tester allows separation of
the vehicle electronics from transmission electronics.
For additional information, refer to the Rotunda
Transmission Tester manual for these tests.
• Digital Transmission Range (TR) Sensor Testing
• Resistance/Continuity Test
• Voltage Test - PARK/NEUTRAL, REVERSE
Lamp and Optional Circuits
2005 F-150, 10/2004


Transmission Connector Layouts Transmission Internal Harness Connector
Transmission Vehicle Harness Connector
Pin
Number Circuit Function
1 NOT USED
2 Signal Return
3 Torque Converter Clutch (TCC)
Solenoid
4 Vehicle Power
5 Transmission Fluid Temperature (TFT)
Input
6 Electronic Pressure Control (EPC)
Solenoid
7 SSA Pin
8 SSB
1 NOT USED
9 NOT USED
2 Signal Return Transmission Fluid
10 NOT USED Temperature (TFT)
3 Torque Converter Clutch (TCC)
4 Vehicle Power To Solenoid
6 Electronic Pressure Control
7 SSA
8 SSB
9 NOT USED
10 NOT USED

Last updated: 8/2/2004 2005 F-150, 10/2004
Digital Transmission Range (TR) Sensor Connector Turbine Shaft Speed (TSS) Sensor Harness Connector
Pin Pin
Number Circuit Function Number Circuit Function
1 NOT USED 1 Turbine Shaft Speed (TSS) Sensor
2 Signal Return 2 Signal Return
3 TR3A
4 TR1 Powertrain Control Module (PCM) Harness
5 TR2 Connector
6 TR4
7 NOT USED
8 NOT USED
9 Fused Power Feed
10 Starter Control
11 Reverse
12 Starter to Starter Interrupt Relay
Output Shaft Speed (OSS) Sensor Harness Connector
Pin
4 Vehicle Power
14 Output Shaft Speed (OSS) Sensor
15 Turbine Shaft Speed (TSS) Sensor
17 Transmission Range (TR) Sensor TR1
18 Transmission Range (TR) Sensor TR2
19 Transmission Range (TR) Sensor TR3A
Sensor
Pin 32 Transmission Range (TR) Sensor TR4
Number Circuit Function 36 Torque Converter Clutch (TCC)
1 Output Shaft Speed (OSS) Sensor 37 Shift Solenoid 2 (SSB)
2 Signal Return 38 Shift Solenoid 1 (SSA)
2005 F-150, 10/2004

Pin
39 Electronic Pressure Control (EPC)
Solenoid
43 Signal Return
Digital Transmission Range (TR) Sensor Diagnosis Chart

PID:
TR V
PID: TR D (volts)
Selector Position PID: TR TR4 TR3A TR2 TR1 TR3A
PARK P/N 0 0 0 0 0.0 Volts
In Between REV 0 1 0 0 1.3-1.8
Volts
REVERSE REV 1 1 0 0 1.3-1.8
Volts
In Between REV 0 1 0 0 1.3-1.8
Volts
NEUTRAL NTRL 0 1 1 0 1.3-1.8
Volts
In Between O/Da 1 1 1 0 1.3-1.8
Volts
OVERDRIVE O/Da 1 1 1 1 1.3-1.8
Volts
In Between Man 2 1 0 1 1 0.0 Volts
Manual 2 Man 2 1 0 0 1 0.0 Volts
In Between Man 2 1 0 1 1 0.0 Volts
Manual 1 Man 1 0 0 1 1 0.0 Volts
a Will read ‘‘Drive’’ if O/D is canceled.
2005 F-150, 10/2004

A. TR V is the voltage at the PCM pin 19 (TR3A
circuit) to signal return.
B. ‘‘In Between’’ reading could be caused by a
shift cable or digital TR sensor misaligned or a
digital TR sensor circuit failure of TR1, TR2,
TR3A or TR4.
C. TR D: 1= Open Digital TR switch, 0= Closed
Digital TR switch.
D. Readings taken from PCM signal pins for TR1,
TR2, TR3A, TR4 to signal return.
— Voltages for TR1, TR2, TR4:
— 0 = 0.0 volts.
— 1 = 9.0-14.0 volts.
— Voltage for TR3A:
— 0 = 0.0 volts.
— 1 = 1.3-1.8 volts.
Wiggle Test Information For Open/Shorts
• TR4, TR3A, TR2 and TR1 are all closed in PARK.
PARK is a good position to check for intermittent open
circuits (with diagnostic tool monitoring TR D).
• TR4, TR3A, TR2 and TR1 are all open in
OVERDRIVE, so OVERDRIVE is a good position to
check for shorts to ground. To determine the shorted
components while observing TR D, unplug the TR
and see if the short goes away. If the short is still
present, unplug the transmission harness and see if the
short goes away. If the short is still present, then the
short is in the PCM or vehicle harness. Remove the
suspect circuit(s) wire from the PCM vehicle harness.
If the short is still present, then the PCM has an
internal failure. Otherwise the failure is in the vehicle
harness.
2005 F-150, 10/2004


Pinpoint Tests — OSC Equipped Any time an electrical connector or solenoid body is
Vehicles disconnected, inspect the connector for pin
condition, corrosion and contamination. Also inspect
Special Tool(s) the connector seal for damage. Clean, repair or
install a new connector or component as required.
MLP-TR Cable
418-F107 (007-00111) or Shift Solenoids Pre-Diagnosis
equivalent Use the following shift solenoid operation
information when carrying out Pinpoint Test A.
Solenoid Operation Chart
Gear Lever PCM Comm- Solenoids

Worldwide Diagnostic System Position anded Gear SSA SSB TCC
(WDS)
Vehicle Communication Module P/R/N 1 ON OFF HD
(VCM) with appropriate (D) 1 ON OFF HD
adapters, or equivalent (D) 2 OFF OFF EC
diagnostic tool
(D) 3 OFF ON EC
(D) 4 ON ON EC
Transmission Tester (D)
w/OD OFF
1 1 ON OFF HD
2 2 OFF OFF EC
3 3 OFF ON EC
Manual 2 2 OFF OFF EC
Trans Tester TR/MLP and
Manual Overlay Manual 1 1 ON OFF HD
007-00131 or equivalent 1a 2 OFF OFF EC
a When a manual pull-in occurs above a calibrated
speed the transmission will downshift from the
higher gear until the vehicle speed drops below this
calibrated speed.
105-R0057 or equivalent EC = Electronically controlled.
HD = Hydraulically disabled.
Shift Solenoid Failure Mode Chart ‘‘Always
Off’’
Failed off due to powertrain control module and or
vehicle wiring concerns, shift solenoid electrically
Gauge, Transmission Solenoid or hydraulically stuck off.
Connectors
307-426 Gear Lever Position
SSA ALWAYS
OFF: (D) 2 1
PCM Gear Actual Gear
Commanded Obtained
1 2 2 2
2 2 2 2

Last updated: 8/2/2004 2005 F-150, 10/2004
SSA ALWAYS Gear Lever Position SSA ALWAYS Gear Lever Position
OFF: (D) 2 1 ON: (D) 2 1
3 3 2* 2* PCM Gear Actual Gear
4 3 2* 2* Commanded Obtained
1 1 1 1
*No engine braking. 2 1 1 1
3 4 2* 2*
SSB ALWAYS Gear Lever Position
4 4 2* 2*
OFF: (D) 2 1
PCM Gear Actual Gear *No engine braking.
Commanded Obtained
1 1 1 1 SSB ALWAYS Gear Lever Position
2 2 2 2 ON: (D) 2 1
3 2 2 2 PCM Gear Actual Gear
4 1 1 1 Commanded Obtained
1 4 2* 2*
Shift Solenoid Failure Mode Chart ‘‘Always On’’ 2 3 2* 2*
Failed on due to powertrain control module and or 3 3 2* 2*
vehicle wiring concerns, shift solenoid electrically 4 4 2* 2*
or hydraulically stuck on.
*No engine braking.
PINPOINT TEST A: SHIFT AND TORQUE CONVERTER CLUTCH SOLENOIDS

NOTE: Read and record all DTCs. All Digital TR Sensor and VSS DTCs must be repaired
before entering Output State Control (OSC).
NOTE: Refer to the Transmission Internal Harness illustration preceding these pinpoint tests.
NOTE: Refer to the Transmission Vehicle Harness Connector illustration preceding these
pinpoint tests.
Test Step Result / Action to Take
A1 ELECTRONIC DIAGNOSTICS
• Select PARK.
• Key in OFF position.
• Check to make sure the transmission harness connector is fully
seated, pins are fully engaged in connector and in good
condition before proceeding.
• Connect the diagnostic tool.
• Key in ON position.
• Enter the following diagnostic mode on the diagnostic tool:
Diagnostic Data Link.
• Enter the following diagnostic mode on the diagnostic tool: PCM. Yes
• Enter the following diagnostic mode on the diagnostic tool: GO to A2.
Active Command Modes. No
• Enter the following diagnostic mode on the diagnostic tool: REPEAT procedure to enter Trans-Bench
Output State Control (OSC). Mode. If vehicle did not enter Trans-Bench
• Enter the following diagnostic mode on the diagnostic tool: Mode, REFER to the Powertrain
Trans-Bench Mode. Control/Emissions Diagnosis (PC/ED)
• Does vehicle enter Trans-Bench Mode? manual for diagnosis of PCM.
A2 WIGGLE TEST
• Select PIDs to be monitored.
(Continued)
2005 F-150, 10/2004

PINPOINT TEST A: SHIFT AND TORQUE CONVERTER CLUTCH SOLENOIDS (Continued)
A2 WIGGLE TEST (Continued)
PID Command PID Actual

SSA SS1F
SSB SS2F
TCC TCCF
• Select ‘‘ON’’ to turn suspect solenoid on.
• Press ‘‘SEND’’.
• Wiggle all wiring and connectors to the transmission. Monitor the Yes
Solenoid State for changes. REPAIR open or short in the vehicle
• Select ‘‘OFF’’ to turn solenoid off. harness or connector.
• Press ‘‘SEND’’. No
• Does the suspect solenoid(s) fault state change? GO to A3.
A3 SOLENOID FUNCTIONAL CHECK
• Monitor each solenoid state. Yes
• Turn each solenoid ON and OFF. GO to A4.
• Does the solenoid turn ON and OFF when commanded and No
can solenoid activation be heard? GO to A5.
A4 OSC TRANS-DRIVE MODE (GR CM OR TCC)
• Carry out OSC Trans-Drive Mode. Yes
• Select GR CM for Shift Solenoids or follow procedures for CLEAR all DTCs. ROAD TEST to verify if
GR CM as listed. concern is still present. If concern is still
• Select TCC for Torque Converter Clutch Solenoid. Follow present, REFER to Diagnosis By Symptom
procedures of TCC in Drive Mode as listed. in this section to diagnose shift or torque
• Does the transmission upshift and downshift or torque converter concern.
converter engage/disengage when commanded? No
GO to A5.
A5 CHECK FOR BATTERY VOLTAGE
• Remove transmission fluid pan.
• Visually inspect the lead frame and connectors for damage.
• Measure the voltage with the positive lead to VPWR solenoid
pin and negative lead to a good ground.
Yes
GO to A6.
No
CHECK for open or short circuit in
• Is the voltage greater than 10 volts? harness or solenoid.
(Continued)
2005 F-150, 10/2004

A6 ELECTRICAL SIGNAL CHECK
• Measure the voltage with the positive lead connected to VPWR
solenoid pin and the negative lead to the signal pin of the
appropriate solenoid.

Trans-Bench Mode.
• Select Parameter SSA, SSB or TCC.
• Select ‘‘ON’’.
• Turn the solenoids ON and OFF, while monitoring the voltage,
solenoid state on the diagnostic tool (ON and OFF) and listen
for the solenoid to activate (click).
• Measure the voltage with the positive lead to VPWR pin and the
negative lead to the TCC pin.

Select Parameter TCC.
• Select ‘‘ON’’.
• Turn the solenoid ON and OFF, while monitoring the voltage, Yes
solenoid state on the diagnostic tool (ON and OFF) and listen GO to A7.
for the solenoid to activate (click). No
• Select ‘‘OFF’’, press ‘‘SEND’’. CHECK for open or short circuit in
• Does the voltage and solenoid state change? harness, solenoid or a PCM concern.
A7 CHECK THE MOLDED LEAD FRAME CONNECTIONS
• Disconnect: Molded Lead Frame.
• Inspect for damaged or pushed out pins, corrosion, etc.
(Continued)
2005 F-150, 10/2004

A7 CHECK THE MOLDED LEAD FRAME CONNECTIONS
(Continued)
• Using special tool, check each of the molded lead frame
connector pins.
Yes
INSTALL a new molded lead frame. GO to
A8.
• Does the special tool go through the molded lead frame No
connector pins? GO to A8.
A8 CHECK THE SOLENOID RESISTANCE AT THE SOLENOID
• Measure the resistance between the pins of the solenoid.
(Continued)
2005 F-150, 10/2004

A8 CHECK THE SOLENOID RESISTANCE AT THE SOLENOID
(Continued)
•
• Measure the resistance for each solenoid (SSA, SSB or TCC)

as follows:
Solenoid Resistance (ohms)

SSA 20-30
SSB 20-30 Yes
TCC 10-16 GO to A9.
No
• Are the resistances correct? INSTALL a new solenoid.
A9 CHECK THE SOLENOID FOR A SHORT TO GROUND
• Check for continuity between the engine ground and the
appropriate solenoid pin with an ohmmeter or other low current
tester (less than 200 milliamps). Connection should show infinite
resistance (no continuity).
Solenoid Terminal
SSA +/-
SSB +/-
TCC +/-
(Continued)
2005 F-150, 10/2004

A9 CHECK THE SOLENOID FOR A SHORT TO GROUND
(Continued)
•
Yes
INSTALL a new solenoid.
No
REFER to Diagnosis By Symptom in this
section for diagnosis of shift or torque
• Is there continuity? converter concerns.
PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR

NOTE: Refer to the Transmission Connector Layouts preceding these pinpoint tests.
B1 ELECTRONIC DIAGNOSTICS
• Key in ON position. Yes
• Select Diagnostic Data Link. GO to B2.
• Select PCM. No
• Select PID/Data Monitor and Record. REPEAT procedure to enter PID. If vehicle
• Enter the following diagnostic mode on the diagnostic tool: PIDs; did not enter PID, REFER to the
TFT, TFTV. Powertrain Control/Emissions Diagnosis
• Does the vehicle enter PID/Data Monitor and Record? (PC/ED) manual for diagnosis of PCM.
B2 WARM-UP/COOL-DOWN CYCLE
• While monitoring the TFT PIDs, carry out the following test: If Yes
transmission is cold, run transmission to warm it up. If If the TFT PIDs increase as the
transmission is warm, allow transmission to cool down. transmission is warmed or decrease as
• Do the TFT PIDs increase as the transmission is warmed up the transmission is cooled, CLEAR all
or decrease as the transmission is cooled or does the TFT DTCs. ROAD TEST to verify if concern is
or TFTV drop in and out of range? still present. If concern is still present,
section to diagnose transmission
overheating.
If the TFT or TFTV drop in and out of
range, INSPECT for intermittent concern in
the internal/external harness, sensor or
connector.
No
GO to B3.
B3 ELECTRICAL SIGNAL CHECK
• Visually inspect the molded lead frame and connectors for
damage.
(Continued)
2005 F-150, 10/2004

PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR (Continued)
B3 ELECTRICAL SIGNAL CHECK (Continued)
• Measure the voltage with the positive lead to the positive TFT at
the sensor pin and the negative lead to a good ground.
Yes
GO to B4.
No
CHECK for open or short circuit in vehicle
harness, internal harness or a PCM
• Is the voltage present? concern.
B4 CHECK RESISTANCE OF TFT SENSOR
• Disconnect: Transmission Harness.
• Measure the resistance between the positive TFT and negative
TFT pins at the transmission connector, using the following:
Transmission Fluid Temperature

°C °F Resistance (Ohms)
-40 to -20 -40 to -4 967K - 284K
-19 to -1 -3 - 31 284K - 100K
0 - 20 32 - 68 100K - 37K
21 - 40 69 - 104 37K - 16K
41 - 70 105 - 158 16K - 5K
71 - 90 159 - 194 5K - 2.7K
91 - 110 195 - 230 2.7K - 1.5K
111 - 130 231 - 266 1.5K - 0.8K
131 - 150 267 - 302 0.8K - 0.54K
Yes
section to diagnose an overheating
concern.
No
INSTALL a new internal harness (sensor
• Is the resistance correct? is part of harness).
2005 F-150, 10/2004

PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR
NOTE: Refer to the Digital Transmission Range (TR) Sensor Connector illustration preceding
these pinpoint tests.
NOTE: Refer to the Digital Transmission Range (TR) Sensor Diagnosis Chart preceding these
pinpoint tests.
C1 VERIFY DIAGNOSTIC TROUBLE CODES
• Select PARK.
• NOTE: DTC codes P0705 and P0708 cannot be set by an Yes
incorrectly adjusted digital TR sensor. GO to C4.
Carry out on-board diagnostic test. No
• Are only DTC codes P0705, P0708 present? GO to C2.
C2 VERIFY DIGITAL TRANSMISSION RANGE SENSOR ALIGNMENT
• Check to make sure the digital TR sensor harness connector is
fully seated, pins are fully engaged in connector and in good
condition before proceeding. Yes
• Apply the parking brake. GO to C3.
• Select NEUTRAL. No
• Disconnect the shift cable/linkage from the manual lever. ADJUST the digital TR sensor. PLACE
• Verify that the TR Sensor Alignment Gauge fits in the transmission range selector lever in P and
appropriate slots. CLEAR DTCs. REPEAT OBD Tests. GO
• Is the digital TR sensor adjustment OK? to C3.
C3 VERIFY SHIFT CABLE/LINKAGE ADJUSTMENT
• Place the manual lever in the OVERDRIVE position. Yes
• Select DRIVE. GO to C4.
• Reconnect the shift cable/linkage. No
• Verify that the shift cable/linkage is adjusted OK. ADJUST the shift cable/linkage. REFER to
• Is the shift cable/linkage adjusted OK? Section 307-05.
C4 CHECK ELECTRICAL SIGNAL OPERATION
• Select PARK.
• Disconnect: Digital TR Sensor.
CAUTION: Do not pry on connector. This will damage

Yes
REPAIR as required. CLEAR DTCs and
the connector and result in a transmission concern. REPEAT OBD Tests.
Press the button and pull out on the digital TR harness
connector. No
• Inspect both ends of the connector for damage or pushed-out If diagnosing a DTC, GO to C5.
pins, corrosion, loose wires and missing or damaged seals. If diagnosing a starting concern or a
• Are the connector, pins and harness damaged? reversing lamp concern, GO to C10.
C5 CHECK ELECTRICAL SYSTEM OPERATION (DIGITAL TR AND
PCM)
• Connect: Digital TR Sensor.
• Enter the following diagnostic mode on the diagnostic tool: TR
PIDS TR, TR D, TR V.
• Move transmission range selector lever into each gear and stop.
• Observe any of the following PIDs, TR and TR D, TR V Yes
(vehicle dependent) while wiggling harness, tapping on sensor or The problem is not in the digital TR sensor
driving the vehicle. Use PIDs TR and TR D for DTCs P0705, system. REFER to Diagnosis By Symptom
P1704 and P1705. Use PIDs TR and TR V for DTC P0708. in this section for further diagnosis.
• Compare the PIDs to the Digital Transmission Range (TR)
Sensor Diagnosis Chart. No
• Do the PIDs TR, TR D and TR V match the Digital If TR D changes when wiggling harness,
Transmission Range (TR) Sensor Diagnosis chart and does tapping on the sensor or driving the
the TR D PID remain steady when the harness is wiggled, vehicle, the problem may be intermittent.
the sensor is tapped or the vehicle driven? GO to C6.
(Continued)
2005 F-150, 10/2004

PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR (Continued)
C6 CHECK DIGITAL TRANSMISSION RANGE SENSOR OPERATION
CAUTION: Do not pry on the connector. This will

damage the connector and result in a transmission concern.
• Connect: TR-E Cable to Transmission Tester. Yes
• Connect: TR-E Cable to Digital TR Sensor. Concern is not in the digital TR sensor,
• Place the Digital TR Overlay onto Transmission Tester. GO to C7.
• Carry out Sensor Test as instructed on the Digital TR Overlay. No
• Does the status lamp on the tester TRS-E cable match the INSTALL a new digital TR sensor. CLEAR
selected gear positions? DTCs and REPEAT OBD Tests.
C7 CHECK THE PCM HARNESS CIRCUITS FOR OPENS
• Disconnect: Powertrain Control Module (PCM).
• Inspect for damaged or pushed-out pins, corrosion or loose
wires.
CAUTION: Do not pry on the connector. This will

damage the connector and result in a transmission concern.
Disconnect the digital TR sensor connector.
• Measure the resistance between PCM test pin 43 and signal
return circuit pin 2 at digital TR sensor connector harness side.
• Measure the resistance between PCM test pin 17 and TR1

circuit pin 4 at digital TR sensor connector harness side.
(Continued)
2005 F-150, 10/2004

C7 CHECK THE PCM HARNESS CIRCUITS FOR OPENS
(Continued)

• Measure the resistance between PCM test pin 19 and TR3A

Yes
GO to C8.
No
REPAIR open circuit(s). RECONNECT all
components. CLEAR DTCs. REPEAT
• Are all resistances less than 5 ohms? OBD Tests.
(Continued)
2005 F-150, 10/2004

C8 CHECK THE PCM HARNESS CIRCUITS FOR A SHORT TO
GROUND OR POWER
• Measure the resistance between PCM test pin 43 and chassis
ground.

ground.

ground.
(Continued)
2005 F-150, 10/2004

C8 CHECK THE PCM HARNESS CIRCUITS FOR A SHORT TO
GROUND OR POWER (Continued)
ground.

ground.
Yes
GO to C9.
No
REPAIR short circuit(s). RECONNECT all
• Are all resistances greater than 10,000 ohms? OBD Tests.
C9 CHECK FOR A SHORT BETWEEN THE TR/PCM INPUT SIGNAL
CIRCUITS
• Measure the resistance between PCM test pin 17 and PCM test
pins 18, 19 and 32.
(Continued)
2005 F-150, 10/2004

C9 CHECK FOR A SHORT BETWEEN THE TR/PCM INPUT SIGNAL
CIRCUITS (Continued)
pins 17, 19 and 32.
pins 17, 18 and 32.
pins 17, 18 and 19.
Yes
INSTALL a new PCM. REFER to Section
303-04A, Section 303-04B or Section
303-04C. RECONNECT all components.
CLEAR DTCs. REPEAT OBD Tests.
No
REPAIR shorts on circuits having less
than 10,000 ohms between other TR/PCM
input signal circuits. RECONNECT all
• Are all the resistances greater than 10,000 ohms? OBD Tests.
(Continued)
2005 F-150, 10/2004

C10 CHECK THE NON-PCM INTERNAL CIRCUITS OF SENSOR
• Connect: TRS-E Cable to Transmission Tester. Yes
• Connect: TRS-E Cable to Digital TR Sensor. Concern is not in the digital TR sensor.
• Place the Digital TR Overlay onto Transmission Tester. For starting system concerns, REFER to
• Carry out Switch Test as instructed on the Digital TR Overlay. Section 303-04A, Section 303-04B or
• Does the status lamp on the tester indicate RED for the Section 303-04C. For reversing lamp
correct gear position? concerns, REFER to Section 417-01. For
optional circuits, REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED)
manual for diagnosis.
No
INSTALL a new digital TR sensor. CLEAR
DTCs. REPEAT OBD Tests.
PINPOINT TEST D: ELECTRICAL PRESSURE CONTROL (EPC) SOLENOID

NOTE: Refer to the Transmission Internal Harness illustration preceding these pinpoint tests.
NOTE: Read and record all DTCs. All Digital TR Sensor and VSS DTCs must be repaired
before entering Output State Control (OSC).
D1 ELECTRONIC DIAGNOSTICS
• Select PARK.
seated, pins are fully engaged in the connector and in good
Diagnostic Data Link.
• Enter the following diagnostic mode on the diagnostic tool: PCM. Yes
• Enter the following diagnostic mode on the diagnostic tool: GO to D2.
Active Command Modes. No
• Enter the following diagnostic mode on the diagnostic tool: REPEAT procedure to ENTER
Output State Control (OSC). Trans-Bench Mode. If vehicle did not enter
• Enter the following diagnostic mode on the diagnostic tool: OSC, REFER to the Powertrain
Trans-Bench Mode. Control/Emissions Diagnosis (PC/ED)
• Does the vehicle enter the Trans-Bench Mode? manual for diagnosis of PCM.
D2 SOLENOID FUNCTIONAL TEST
• Install 2,060 kPa (300 psi) pressure gauge into EPC tap.
• Monitor pressure gauge.
Parameter; EPC.
• Select value - 15, 30, 45, 60, 70 or 90 psi.
• Select another value ‘‘0-90 psi’’.
• Enter the following diagnostic mode on the diagnostic tool: XXX. Yes
• Press ‘‘SEND’’. CLEAR DTCs. REPEAT OBD Tests.
• Does the pressure reading match the commanded No
pressure? GO to D3.
D3 CHECK FOR VOLTAGE
• Disconnect: Transmission Harness Connector.
(Continued)
2005 F-150, 10/2004

PINPOINT TEST D: ELECTRICAL PRESSURE CONTROL (EPC) SOLENOID (Continued)
D3 CHECK FOR VOLTAGE (Continued)
• Measure the voltage on pin 6 at the transmission harness
connector to chassis ground.
Yes
GO to D4.
No
• Is the voltage less than 5 volts? REPAIR the circuit.
D4 CHECK FOR BATTERY VOLTAGE
• Visually inspect the lead frame connectors for damage.
• Measure the voltage with positive lead to VPWR solenoid pin
and negative lead to a good ground.
Yes
GO to D5.
No
REPAIR the circuit. CLEAR the DTCs.
• Is voltage greater than 10 volts? REPEAT the OBD Tests.
D5 ELECTRICAL SIGNAL CHECK
• Measure the voltage with positive lead connected to VPWR
solenoid pin and connect negative lead to the signal pin of the
EPC solenoid.
(Continued)
2005 F-150, 10/2004

D5 ELECTRICAL SIGNAL CHECK (Continued)
• Turn the solenoids ON and OFF, while monitoring the voltage
reading, solenoid state on the diagnostic tool (ON and OFF),
listen for the solenoid to activate (click).
Trans-Bench Mode.
Parameter EPC.
• Select a value ‘‘0-90 psi’’.
• Select another value ‘‘0-90 psi’’. Yes
• Press ‘‘SEND’’. GO to D6.
• Enter the following diagnostic mode on the diagnostic tool: XXX. No
• Press ‘‘SEND’’. CHECK for open or short circuit in
• Does the voltage and solenoid state change? harness or PCM.
D6 CHECK LEAD FRAME SOLENOID CONNECTIONS
• Disconnect: Caption Lead Frame.
• Inspect the lead frame for damage, pushed out pins, corrosion,
etc.
• Using the special tool, check each of the lead frame connector
pins.
Yes
INSTALL a new lead frame. GO to D7.
• Does the special tool go through the lead frame connector No
pins? GO to D7.
D7 CHECK SOLENOID RESISTANCE AT SOLENOID
• Measure the resistance of the EPC solenoid.
Yes
GO to D8.
No
INSTALL a new solenoid. CLEAR the
• Is the resistance between 2.48 and 5.66 ohms? DTCs. REPEAT the OBD Tests.
(Continued)
2005 F-150, 10/2004

D8 CHECK SOLENOID FOR SHORT TO GROUND
• Check for continuity between engine ground and the EPC
solenoid terminals with ohmmeter or other low current tester
(less than 200 milliamps). Connection should show infinite
resistance (no continuity).
Yes
INSTALL a new solenoid. CLEAR the
DTCs. REPEAT the OBD Tests.
No
• Is there continuity? section for diagnosis of pressure concerns.
PINPOINT TEST E: OUTPUT SHAFT SPEED (OSS) SENSORS

NOTE: Refer to the Output Shaft Speed (OSS) Sensor Harness Connector illustration preceding
these pinpoint tests.
E1 ELECTRONIC DIAGNOSTICS
• Enter the following diagnostic mode on the diagnostic tool: GO to E2.
Diagnostic Data Link. No
• Enter the following diagnostic mode on the diagnostic tool: PCM. REPEAT procedure to ENTER PID. If
• Select PID/Data Monitor and Record. vehicle did not enter PID, REFER to the
• Select the PID OSS. Powertrain Control/Emissions Diagnosis
• Does vehicle enter PID/Data Monitor and Record? (PC/ED) manual for diagnosis of PCM.
E2 DRIVE CYCLE TEST
• While monitoring the OSS Speed PID, drive the vehicle so that Yes
the transmission upshifts and downshifts through all gears. CLEAR all DTCs. ROAD TEST to verify if
• Does the OSS Speed PID increase and decrease with engine concern is still present. If concern is still
and vehicle speed? present, REFER to Diagnosis By Symptom
in this section.
No
If the OSS Speed PID does not increase
and decrease with engine and vehicle
speed, INSPECT for open or short in
vehicle harness, sensor, a PCM concern
or internal hardware concern.
If the sensor signal is erratic, INSPECT for
intermittent concern in the internal/external
harness, sensor or connector.
If the sensor signal is steady, GO to E3.
E3 CHECK THE RESISTANCE OF THE OSS SENSOR
• Disconnect the vehicle harness connector from the OSS sensor.
(Continued)
2005 F-150, 10/2004

PINPOINT TEST E: OUTPUT SHAFT SPEED (OSS) SENSORS (Continued)
E3 CHECK THE RESISTANCE OF THE OSS SENSOR (Continued)
• Measure the resistance between the OSS sensor pins.
Yes
section for concern diagnosis.
• Record the resistance. No
• Is the resistance within 400-500 ohms at 77°F (25°C)? INSTALL a new OSS sensor.
PINPOINT TEST F: TURBINE SHAFT SPEED (TSS) SENSORS

NOTE: Refer to the Turbine Shaft Speed (TSS) Sensor Harness Connector illustration
preceding these pinpoint tests.
F1 ELECTRONIC DIAGNOSTICS
• Enter the following diagnostic mode on the diagnostic tool: GO to F2.
Diagnostic Data Link. No
• Enter the following diagnostic mode on the diagnostic tool: PCM. REPEAT procedure to ENTER PID. If
• Select PID/Data Monitor and Record. vehicle did not enter PID, REFER to the
• Select the PID TSS. Powertrain Control/Emissions Diagnosis
• Does vehicle enter PID/Data Monitor and Record? (PC/ED) manual for diagnosis of PCM.
F2 DRIVE CYCLE TEST
• While monitoring the TSS Speed PID, drive the vehicle so that Yes
the transmission upshifts and downshifts through all gears. CLEAR all DTCs. ROAD TEST to verify if
• Does the TSS Speed PID increase and decrease with engine concern is still present. If concern is still
and vehicle speed? present, REFER to Diagnosis By Symptom
in this section.
No
If the TSS Speed PID does not increase
and decrease with engine and vehicle
speed, INSPECT for open or short in
vehicle harness, sensor, a PCM concern
or internal hardware concern.
If the sensor signal is erratic, INSPECT for
intermittent concern in the internal/external
harness, sensor or connector.
If the sensor signal is steady, GO to F3.
F3 CHECK THE RESISTANCE OF THE TSS SENSOR
• Disconnect the vehicle harness connector from the TSS sensor.
(Continued)
2005 F-150, 10/2004

PINPOINT TEST F: TURBINE SHAFT SPEED (TSS) SENSORS (Continued)
F3 CHECK THE RESISTANCE OF THE TSS SENSOR (Continued)
• Measure the resistance between the TSS sensor pins.
Yes
• Record the resistance. No
• Is the resistance within 480-590 ohms? INSTALL a new TSS sensor.
PINPOINT TEST G: SOLENOID MECHANICAL FAILURE

NOTE: Repair all other DTCs before repairing the following DTCs: P1714, P1715, P1740.
G1 ELECTRONIC DIAGNOSIS
• Connect the diagnostic tool. Yes
• Carry out KOEO Test. REPAIR the other DTCs first. CLEAR
• If any of the following DTCs are present, continue with this test: DTCs and CARRY OUT Transmission
P1714, P1715, P1740. Drive Cycle Test. REPEAT Quick Test.
• Are other DTCs present for TFT or shift solenoids? No
INSTALL a new solenoid and or body.
REFER to the Diagnostic Trouble Code
Charts in this section for code description.
GO to G2.
G2 TRANSMISSION DRIVE CYCLE TEST
• Carry out transmission drive cycle test. Yes
• Carry out on-board diagnostic test. GO to G3.
• Does the vehicle upshift and downshift OK? No
section to diagnose shift concerns.
G3 RETRIEVE DTCs
• Connect the diagnostic tool. Yes
• Carry out KOEO Test until continuous DTCs have been INSTALL a new PCM. REFER to Section
displayed. 303-04A, Section 303-04B or Section
• Are DTCs P1714, P1715, P1740 still present? 303-04C. ROAD TEST and REPEAT
Quick Test.
No
Testing completed. If a concern still exists,
2005 F-150, 10/2004


Special Testing Procedures Line Pressure Test
The special tests are designed to aid the technician CAUTION: Carry out the Line Pressure
in diagnosing the hydraulic and mechanical portion Test prior to carrying out the Stall Speed Test. If
of the transmission. the line pressure is low at stall, do not carry out
Stall Speed Test or further transmission damage
Engine Idle Speed Check will occur. Do not maintain wide open throttle
Refer to the Powertrain Control/Emissions Diagnosis (WOT) in any transmission range for more than
(PC/ED) manual for diagnosis and testing of the five seconds.
engine idle speed. This test verifies that the line pressure is within
specification.
1. Connect a pressure gauge to the line pressure
tap.
2. Start the engine and check line pressures. Refer
to the Line Pressure Chart to determine if line
pressure is within specification.

1 — Direct clutch pressure tap
2 — Forward clutch pressure tap
3 — Electronic pressure control
(EPC) pressure tap
4 — Intermediate clutch pressure
tap
5 — Line pressure tap

Last updated: 8/2/2004 2005 F-150, 10/2004
Line Pressure Chart
Idle WOT Stall
Application Range EPC Line Pressure EPC Line Pressure
4.2L/4.6L P, N, OD, 2, 1 69-276 kPa 330-689 kPa 689-758 kPa 1,310-1,448 kPa
(10-40 psi) (48-100 psi) (100-110 psi) (190-210 psi)
4.2L/4.6L R 138-207 kPa 551-689 kPa 586-655 kPa 1,723-2,068 kPa
(20-30 psi) (80-100 psi) (85-95 psi) (250-300 psi)
5.4L P, N, OD, 2, 1 69-276 kPa 551-689 kPa 689-793 kPa 1,172-1,585 kPa
(10-40 psi) (80-100 psi) (100-115 psi) (170-230 psi)
5.4L R 138-207 kPa 551-689 kPa 586-655 kPa 1,723-2,068 kPa
(20-30 psi) (80-100 psi) (85-95 psi) (250-300 psi)
3. Place the ignition switch in the OFF position. If 6. If the EPC pressure is not within specification,
line pressure is not within specification, check GO to Pinpoint Test E to diagnose the EPC
EPC pressure. operation. If the EPC operation is OK, refer to
4. Connect a pressure gauge to the EPC pressure the Line Pressure Diagnosis Chart for line
tap. pressure concern causes.
5. Start the engine and check EPC pressure. Use
the line pressure chart for specifications.
Line Pressure Diagnosis Chart
Test Results Possible Source
HIGH at Idle in All Positions • Wiring Harnesses
• Run Quick Test. Refer to the Powertrain
• EPC Solenoid
• Main Regulator Valve
LOW at Idle in All Positions • Low Fluid Level
• Restricted Inlet Filter
• Damaged Inlet Tube Seal on Inlet Filter
• Loose Main Control Valve Bodies
• Sticking Main Regulator Valve
• Excessive Leakage in Pump
• Damaged Gaskets on Separator Valve
• Case Bolts
• Case
• Separator Plate
• EPC Solenoid
LOW in Park ONLY • Valve Body
• Low/Reverse Servo
LOW in Reverse ONLY • Separator Plate
• Low/Rear Servo or Valve Body
• Reverse Clutch
LOW in Neutral ONLY • Valve Body
LOW in Overdrive ONLY • Forward Clutch
• Valve Body
LOW in First Position • Forward Clutch
• Valve Body
• Low/Reverse Servo
LOW in Second Position • Intermediate Clutch
• Valve Body
• Forward Clutch
2005 F-150, 10/2004

Stall Speed Test Stall Speed Chart
WARNING: Apply the parking brake Engine Stall Speed RPM

firmly as well as the foot brake while carrying 4.2L 1,976-2,356
out each stall test. 4.6L 2,125-2,488
CAUTION: Carry out Line Pressure Test 5.4L 2,404-2,842
prior to carrying out Stall Speed Test. If the line
pressure is low at stall, do not carry out Stall 2. Connect a tachometer to the engine.
Speed Test or further transmission damage will
occur. 3. NOTE: If the rpm recorded by the tachometer
exceeds the maximum limits, release the
The Stall Speed Test checks: accelerator pedal immediately because clutch or
• Torque converter clutch operation and installation. band slippage is indicated.
• Holding ability of the forward clutch. In each of the following ranges (D) , 2, 1, R,
press the accelerator pedal to the floor and hold
• Reverse clutch (the low-reverse bands).
it just long enough to let the engine get to wide
• Planetary one-way clutch. open throttle (WOT). While making this test, do
• Engine driveability. not hold the throttle open for more than 5
Conduct this test with the engine coolant and seconds at a time.
transmission fluid at correct levels and at normal 4. Note the results in each range.
operating temperature. 5. After each range, move the shift control
Apply the parking brake firmly for each Stall Speed selector lever to NEUTRAL and run the engine
Test. at 1,000 rpm for about 15 seconds to cool the
1. Find the specified stall rpm for the vehicle. For torque converter before making the next test.
additional information, refer to the Stall Speed 6. Refer to the Stall Speed Diagnosis Chart for
Chart. Use a grease pencil to mark the rpm on corrective actions.
the dial of a tachometer.
Stall Speed Diagnosis Chart
Selector Position Stall Speeds High Stall Speeds Low
(D) Planetary One-Way Clutch
(D) , 2 and 1 Forward Clutch or Intermediate
Clutch
(D) , 2, 1 and R Carry Out Pressure Test Torque Converter Stator, One-Way
Clutch, or Engine Driveability
Concerns
R Reverse Clutch or Low Reverse Band
or Servo
2005 F-150, 10/2004

Air Pressure Tests NOTE: Use only dry, regulated 276 kPa (40 psi)
Transmission Air Test Plate maximum air pressure.
Apply air to the appropriate passage(s). A dull thud
should be felt or heard, or movement could be
observed when the clutch component applies. There
should be no hissing sound when the component is
applied.
Cover the vent hole in the test plate with a clean,
lint-free shop towel to prevent spray when the air is
applied. Plugging the vent hole during testing will
result in inaccurate results.
1. Drain the transmission fluid and remove the
transmission fluid pan.
2. Remove the main control valve body.
3. Install the transmission test plate and gasket.
1 — Converter bypass Tighten the bolts to 10 Nm (89 lb-in).
2 — Direct clutch 4. NOTE: Do not apply air to the test plate vent
3 — Forward clutch hole.
4 — 2-3 accumulator, top Apply air to the appropriate clutch port (refer to
5 — 2-3 accumulator, bottom the Transmission Air Test Plate illustration). A
6 — Reverse servo dull thud may be heard or movement felt when
7 — Overdrive servo, apply the component is applied or released. If clutch
8 — Overdrive servo, release seals or check balls are leaking, a hissing sound
9 — Intermediate clutch may be heard.
10 — Reverse clutch If the servos do not operate, disassemble, clean and
11 — 1-2 accumulator, apply inspect them to locate the source of the concern.
If air pressure applied to the clutch passages fails to
A no-drive condition can exist even with correct operate a clutch, or operates clutches
transmission fluid pressure because of inoperative simultaneously, inspect the fluid passages in the
clutches or bands. An erratic shift can be located case.
through a series of checks by substituting air
pressure for fluid pressure to determine the location If air pressure applied to the accumulator fails to
of the malfunction. operate an accumulator, remove and inspect case
passages and piston.
Follow the procedure to determine the location of
the inoperative clutch or band by introducing air
pressure into the various test plate passages.
Clutch Pressure Test
Clutch Pressure Chart 4.2L/4.6L

Transmission Pressures with TP at 1.5 Volts and Vehicle Speed Above 8 Km/h (5 MPH)
Line Pressure Forward Intermediate Direct Clutch
Gear EPC Tapa Tap Clutch Tap Clutch Tap Tap
M1 124-241 kPa 517-655 kPa 413-586 kPa 0-34 kPa (0-5 0-34 kPa (0-5
(18-35 psi) (75-95 psi) (60-85 psi) psi) psi)
M2 275-344 kPa 689-813 kPa 620-744 kPa 648-779 kPa 0-34 kPa (0-5
(40-50 psi) (100-118 psi) (90-108 psi) (94-113 psi) psi)
2005 F-150, 10/2004

Clutch Pressure Chart 4.2L/4.6L (Continued)
1 124-241 kPa 496-606 kPa 413-606 kPa 0-34 kPa (0-5 0-34 kPa (0-5
2 275-344 kPa 662-772 kPa 662-772 kPa 662-778 kPa 0-34 kPa (0-5
3 275-344 kPa 717-772 kPa 717-772 kPa 717-772 kPa 717-772 kPa
(40-50 psi) (104-112 psi) (104-112 psi) (104-112 psi) (104-112 psi)
4 241-310 kPa 606-717 kPa 0-34 kPa (0-5 606-717 kPa 606-717 kPa
(35-45 psi) (88-104 psi) psi) (88-104 psi) (88-104 psi)
a EPC readings will vary due to EEC strategy. These values are approximate pressures depending on circuit leakage.
Actual clutch apply pressures should be within 0-103 kPa (0-15 psi) of line pressure. For additional information on
testing, refer to the Clutch Pressure Test in this section.
Clutch Pressure Chart 5.4L

M1 275-344 kPa 689-827 kPa 620-758 kPa 0-34 kPa (0-5 0-34 kPa (0-5
M2 241-310 kPa 620-689 kPa 551-689 kPa 586-724 kPa 0-34 kPa (0-5
1 275-344 kPa 689-827 kPa 620-758 kPa 0-34 kPa (0-5 0-34 kPa (0-5
2 241-310 kPa 620-689 kPa 551-689 kPa 586-724 kPa 0-34 kPa (0-5
3 241-310 kPa 620-689 kPa 551-689 kPa 586-724 kPa 551-689 kPa
(35-45 psi) (90-100 psi) (80-100 psi) (85-105 psi) (80-100 psi)
4 241-310 kPa 620-689 kPa 0-34 kPa (0-5 586-724 kPa 551-689 kPa
(35-45 psi) (90-100 psi) psi) (85-105 psi) (80-100 psi)
a EPC readings will vary due to EEC strategy. These values are approximate pressures depending on circuit leakage.
Actual clutch apply pressures should be within 0-103 kPa (0-15 psi) of line pressure. For additional information on
testing, refer to the Clutch Pressure Test in this section.
The Clutch Pressure Test will diagnose a

low-pressure condition or leakage in a clutch circuit.
A difference of 103 kPa (15 psi) or more between
the clutch pressure and line pressure will prevent a
normal shift.
2005 F-150, 10/2004

1. CAUTION: Pressure gauges affect the 3. If the difference in pressures is less than 103
shift quality of the transmission. Care must kPa (15 psi), the corresponding clutch circuit
be taken not to accelerate or decelerate does not have a pressure loss. The gauges on
rapidly. Possible transmission failure can the line pressure tap and appropriate clutch
result. pressure tap can be switched to confirm that
gauge calibration differences are not the cause.
Attach 0-2068 kPa (0-300 psi) pressure gauges
to the line pressure tap and the appropriate 4. If the difference is greater than 103 kPa (15
clutch pressure tap according to the psi), there is a leak in the corresponding clutch
Band/Clutch Application Chart. Gauges must be pressure circuit. The gauges on the line pressure
accurate enough to distinguish a 103 kPa (15 tap and clutch pressure tap can be switched to
psi) difference. (If this test is done in confirm that gauge calibration differences are
conjunction with a control pressure test, not the cause. Carry out the appropriate
pressure gauges will be attached to all pressure procedure to correct the clutch leak problem.
taps.) Have sufficient flexible hose available to
read the gauges in the vehicle.
2. Drive the vehicle. When pressure is applied to
the clutch, note the difference between the line
pressure gauge and the corresponding clutch
pressure gauge.
2005 F-150, 10/2004


Leakage Inspection If the leak continues, install a new cooler tube
fitting and tighten to specification. The same
CAUTION: Do not try to stop the fluid procedure should be followed for fluid leaks
leak by increasing the torque beyond between the radiator cooler and the cooler tube
specifications. This may cause damage to the case fittings.
threads.
Check the engine coolant in the radiator. If
Check the fluid filler tube connection at the transmission fluid is present in the coolant, the
transmission case. If leakage is found here, install a cooler in the radiator is probably leaking.
new grommet.
The cooler can be further checked for leaks by
Check the fluid lines and fittings between the disconnecting the tubes for the cooler fittings and
transmission and the cooler in the radiator tank for applying no more than 345 kPa (50 psi) air pressure
looseness, wear or damage. If leakage cannot be to the fittings. Remove the radiator cap to relieve
stopped by tightening a fluid tube nut, install new the pressure buildup at the exterior of the oil cooler
parts. When fluid is found leaking between the tank. If the cooler is leaking and/or will not hold
case and cooler tube fitting, check for a missing or pressure, install a new cooler.
damaged O-ring, then tighten the fitting to
maximum specification. If leakage is found at the transmission range
selector lever, install a new seal.
If leakage is found at the transmission internal
harness connector, install a new O-ring.
External Sealing

Last updated: 8/2/2004 2005 F-150, 10/2004
1 7902 Torque converter
2 7A248 Front pump seal
3 7A248 Front pump seal
4 N605789-S101 Bolt
5 7A106 Front pump body assembly
6 7A136 Pump gasket
7 390318-S2 Pipe plug — 1/8-27 Dryseal
tapered
8 7005 Case
9 7H103 Turbine shaft speed (TSS)
sensor
Possible
10 7034 Vent Leak Path Symptom Source
11 N811757-S100 Speed sensor seal 1, 2 and 4 Leak at the front Pump lip seal
12 7H103 Output shaft speed (OSS) of the
sensor transmission
13 7B498 Manual control lever seal 1, 2 and 4 Leak at the front Vent
assembly of the
14 7086 Extension housing gasket transmission
15 7A039 Extension housing (4x2) 1, 2 and 4 Leak at the front Converter hub
of the weld
16 N803737-S1101 Bolt — M8-1.25 x 30 transmission
17 7052 Oil seal 1, 2 and 4 Leak at the front External pump
18 7Z276 Seal — bulkhead assembly of the seal (large)
19 7G276 Bulkhead assembly wiring transmission
connector 1, 2 and 4 Leak at the front Pump-to-case
20 7G276 Molded lead frame of the screws
transmission
21 7A194 Transmission fluid pan
22 7A191 Gasket 1, 2 and 4 Leak at the front Pump gasket
of the
23 7D273 Transmission fluid tube case transmission
fittings
3 Leak at the front Torque
of the converter seal
Fluid Leakage In Torque Converter Area transmission weld
Leakage at the front of the transmission, as 3 Leak at the front Torque
evidenced by fluid around the torque converter of the converter stud
housing part of the case, may have several sources. transmission
By careful observation, it is possible in many 5 Leak at the front Engine oil leak;
instances to pinpoint the source of the leak before of the rear main seal
removing the transmission from the vehicle. transmission
The paths, which the fluid takes to reach the bottom 5 Leak at the front Engine valve
of the cover
of the torque converter housing part of the case, are transmission
shown in the illustration. The 5 numbers in the
illustration correspond with the 5 flow path steps.
2005 F-150, 10/2004

Possible
Leak Path Symptom Source
5 Leak at the front Oil galley
of the
transmission
5 Leak at the front Engine oil
of the pressure sensor
transmission
2005 F-150, 10/2004


Transmission Fluid Cooler 3. Position the vehicle on a hoist. For additional
information, refer to Section 100-02.
CAUTION: Whenever a transmission has
been disassembled to install new parts, the 4. Remove the cooler return line (top fitting) from
transmission fluid cooler tubes and the in-tank the fitting on the transmission case.
cooler if equipped must be cleaned and 5. Connect one end of a hose to the cooler return
backflushed. Use a suitable torque converter/fluid line and route other end of the hose up to a
cooler cleaner. point where it can be inserted into the funnel at
NOTE: If the vehicle is equipped with a oil-to-air the fluid filler tube.
(OTA) cooler, a new OTA must be installed. 6. Remove the safety stands and lower the vehicle.
NOTE: Cleaning and backflushing the transmission Insert end of hose into the funnel.
fluid cooling system along with following all the 7. Start the engine and run it at idle with the
normal cleaning and inspection procedures in this transmission in NEUTRAL.
section during disassembly and reassembly will 8. When fluid flows from the hose in a steady
keep contamination from reentering the transmission stream, a liberal amount of fluid should be
and causing a repeat repair. observed. ‘‘Liberal’’ is about 1 liter (1 quart)
When internal wear or damage has occurred in the delivered in 15 seconds. If a liberal flow is
transmission, metal particles, clutch plate material or observed, the test is complete.
band material may have been carried into the torque 9. If the flow is not liberal, stop the engine.
converter and transmission fluid cooler. These Disconnect the hose from the cooler return line
contaminants are a major cause of recurring and connect it to the converter outlet fitting
transmission troubles and must be removed from the (bottom fitting) on the transmission case.
system before the transmission is put back into use.
10. Repeat steps 6 and 7. If flow is now
Transmission Fluid Cooler Flow Test approximately 1 liter (1 quart) in 15 seconds,
refer to Transmission Fluid Cooler —
NOTE: The transmission linkage/cable adjustment,
Backflushing and Cleaning in this section. If
fluid level and line pressure must be within
the flow is still not approximately 1 liter (1
specification before carrying out this test. Refer to
quart) in 15 seconds, repair or install pump and
Section 307-05 for adjustments.
or converter.
1. Remove fluid level indicator from fluid filler
For the installation of new transmission fluid cooler
tube.
or tubes, refer to Section 307-02.
2. Place funnel in fluid filler tube.

Last updated: 8/2/2004 2005 F-150, 10/2004

Diagnosis By Symptom Special Tool(s)
Trans Tester TR/MLP Overlay
Special Tool(s) and Manual
Transmission Fluid Pressure
Gauge
307-004 (T57L-77820-A)

307-246 (T92P-7006-A)
UV Leak Detector Kit

Breakout Box, EEC-V Control
System
418-049 (T94L-50-EEC-V) or
equivalent
The Diagnosis by Symptom charts give the

technician diagnostic information, direction and
MLP-TR Cable suggest possible components, using a symptom as a
418-F107 (007-00111) or starting point.
equivalent
The Diagnosis by Symptom charts are divided into
two categories: Electrical Routines, indicated by 200
series numbers and Hydraulic/Mechanical Routines,
indicated by 300 series numbers. The Electrical
Routines list the possible electrical components that
Worldwide Diagnostic System could cause or contribute to the symptom described.
(WDS) The Hydraulic/Mechanical Routines list the possible
Vehicle Communication Module hydraulic or mechanical components that could
adapters, or equivalent cause or contribute to the symptom described.
diagnostic tool
Diagnosis by Symptom Chart Directions
1. Using the Diagnosis by Symptom Index, select
Transmission Tester the Concern/Symptom that best describes the
307-F016 (007-00130) or condition.
equivalent
2. Refer to the routine indicated in the Diagnosis
by Symptom Index.
3. Always begin diagnosis of a symptom with:
a. preliminary inspections.
(Continued)
b. verifications of condition.
c. checking the fluid levels.
d. carrying out other test procedures as
directed.

Last updated: 8/2/2004 2005 F-150, 10/2004
4. NOTE: Not all concerns and conditions with 5. The Hydraulic/Mechanical Routines list possible
electrical components will set a diagnostic hydraulic or mechanical components that could
trouble code (DTC). Be aware that the cause the concern. These components are listed
components listed may still be the cause. Verify in the removal sequence and by most probable
correct function of these components prior to cause. All components listed must be inspected
proceeding to the Hydraulic/Mechanical to make sure of correct repair.
Routine listed.
Begin with the Electrical Routine, if indicated.
Follow the reference or action required
statements. Always carry out the on-board
diagnostic tests as required. Never skip steps.
Repair as required. If the concern is still present
after electrical diagnosis, then proceed to the
Hydraulic/Mechanical Routine listed.
Diagnosis by Symptom Index
Routines
Hydraulic/
Title Electricala Mechanical
Engagement Concerns
No Forward 201 301
No Reverse 202 302
Harsh Reverse 203 303
Harsh Forward 204 304
Delayed/Soft Reverse 205 305
Delayed/Soft Forward 206 306
Shift Concerns
Some/All Shifts Missing 210 310
Timing Concerns
— Early/Late 211 311
— Erratic/Hunting 212 312
Feel
— Soft/Slipping 213 313
— Harsh 214 314
No 1st Gear, Engages in Higher Gear 215 315
No Manual 1st Gear 216 316
No Manual 2nd Gear 217 317
Torque Converter Operation Concerns
No Apply 240 340
Always Applied/Stalls Vehicle 241 341
Cycling/Shudder/Chatter 242 342
Other Concerns
No Engine Braking in 2nd Gear, Manual 2nd or Manual 1st 250 350
Position
Gearshift Lever Efforts High 251 351
2005 F-150, 10/2004

Diagnosis by Symptom Index (Continued)
Routines
Hydraulic/
Title Electricala Mechanical
External Leaks 252 352
Vehicle Driveability Concerns 253 353
Noise/Vibration in Forward or Reverse 254 354
Engine Will Not Crank 255 355
No Park (P) Range 256 356
Overheating 257 357
a Carry out electrical routine first.
Diagnostic Routines
Engagement Concern: No Forward

Possible Component Reference/Action
201 — ELECTRICAL ROUTINE
• No electrical concerns.
301 — HYDRAULIC/MECHANICAL ROUTINE
Fluid
• Incorrect level • Adjust fluid to correct level.
• Condition • Inspect as under Fluid Condition Check. Refer to
Verification of Condition.
Shift Linkage
• Damaged or incorrectly adjusted • Inspect and repair as required. Verify transmission
shift cable adjustment. Refer to Section 307-05.
Adjust transmission shift cable as necessary. After
repairing transmission shift cable, verify the digital
transmission range (TR) sensor is correctly adjusted.
Adjust the digital TR sensor as necessary. Refer to
Transmission Range (TR) Sensor Adjustment in this
section.
Incorrect Pressures
• Low forward clutch pressure, low line pressure • Check pressure at line and forward clutch tap. Refer
to the Line Pressure Chart and the Clutch Pressure
Chart for specification. Refer to Special Testing
Procedures in this section. If pressures are low,
check the following components: oil filter and seal
assembly, main controls, pump assembly, forward
clutch assembly.
Fluid Filter and Seal Assembly
• Plugged, damaged • Install a new filter and seal assembly.
• Filter seal damaged.
Main Controls
• 3-4 shift valve, main regulator valve, manual valve — • Inspect for damage. Repair as required.
stuck, damaged
2005 F-150, 10/2004

Engagement Concern: No Forward (Continued)
• Bolts not tightened to specifications • Tighten bolts to specifications.
• Gaskets damaged • Inspect gaskets for damage and install a new gasket.
• 2-3 accumulator and seals damaged • Inspect piston, seals and bore for damage. Repair as
required.
• Pressure regulator valve • Inspect the diameter for wear.
Pump Assembly
• Porosity/cross leaks/ball missing or leaking, plugged • Inspect for porosity and leaks. Repair as required.
hole
• No. 3 and No. 4 seal rings damaged • Inspect seals for damage. Repair as required.
• Gaskets damaged • Inspect for damage and install a new gasket.
Forward Clutch Assembly
• Seals, piston damaged • Inspect seals for damage. Repair as required.
• Check balls damaged, missing, mislocated, not seating • Inspect for mislocation, poor seating, damage. Install
correctly a new cylinder as required.
• Friction elements damaged or worn • Check for abnormal wear, damage. Repair as
required.
One-Way Clutch Assembly (Planetary)
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as required.
Output Shaft
• Damaged • Inspect for damage. Install new components as
required.
Engagement Concern: No Reverse

Fluid
• Condition • Inspect condition of fluid.
Shift Linkage
repairing transmission shift cable, verify that the
digital TR sensor is correctly adjusted. Adjust the
digital TR sensor as necessary. Refer to Transmission
Range (TR) Sensor Adjustment in this section.
Incorrect Pressures
2005 F-150, 10/2004

Engagement Concern: No Reverse (Continued)
• Low reverse clutch pressure, low reverse band • Check pressure at line pressure tap. Refer to the Line
pressure, low line pressure Pressure Chart for specifications. Refer to Special
Testing Procedures in this section. If pressures are
low, check the following components: oil filter and
seal assembly, main controls, reverse servo, pump
assembly, reverse clutch assembly.
Main Controls
• No. 6 shuttle ball, manual valve, main regulator • Inspect for damage. Repair as required.
valve, 1-2 accumulator seals stuck or damaged
• Loose bolts • Tighten bolts to specifications.
• Gasket damaged • Inspect for damage and install a new gasket.
Low/Reverse Servo
• Seals (piston and cover) damaged • Inspect for damage. Repair as required.
• Servo cover retaining ring damaged
• Anchor pins (case) damaged
Pump Assembly
• Loose bolts • Tighten bolts to specifications.
• Porosity/cross leaks/ball missing or leaking, plugged • Inspect pump assembly. Install new as required.
hole
• No. 1 and 2 seal rings damaged • Inspect for damage. Repair as required.
Reverse Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as required.
• Check ball missing or damaged
• Friction elements damaged or worn
Low/Reverse Band
• Band, servo, anchor pins damaged or worn • Inspect for damage. Repair as required.
Engagement Concern: Harsh Reverse

Powertrain Control System
• Electrical inputs/outputs, vehicle wiring harnesses, • Carry out Self-Test. Refer to the Powertrain
PCM, TFT sensor, EPC solenoid Control/Emissions Diagnosis (PC/ED) manual for
diagnosis and testing of the Powertrain Control
System. Carry out engagement test, EPC test and GO
to Pinpoint Test B or GO to Pinpoint Test D. Check
idle speed. Repair as required. Clear DTCs, road test
and repeat the Self-Test.
Fluid
2005 F-150, 10/2004

Engagement Concern: Harsh Reverse (Continued)
Engine Driveline
• Looseness in the driveshaft, U-joints or the engine • Repair as required.
mounts
Shift Linkage
Incorrect Pressures
• High line pressure, high EPC pressure • Check pressure at line and EPC pressure taps. Refer
to the Line Pressure Chart for specifications. Refer to
Special Testing Procedures in this section. If high,
check the following components: main controls, oil
filter and seal assembly.
• Plugged or damaged • Install a new filter and seal assembly.
• Filter seal damaged
Main Controls
• No. 6 shuttle ball, No. 5 check ball, manual valve, • Inspect for damage. Repair as required.
main regulator valve stuck, damaged or missing
• EPC solenoid stuck or damaged • Inspect for damage, contamination. Carry out EPC
test in Routine No. 203. Repair as required.
Low Reverse Servo
• Servo cover retaining ring assembled incorrectly
• Anchor pins (case) damaged
Pump Assembly
• Porosity/cross leaks • Inspect pump assembly. Install new as required.
• No. 1 and No. 2 seal rings damaged • Inspect for damage. Repair as required.
• Friction elements damaged, worn
• Return spring piston damaged, worn
2005 F-150, 10/2004

Engagement Concern: Harsh Reverse (Continued)
Low Reverse Band
• Band, servo, anchor pin damaged or worn • Inspect for damage. Repair as required.
Engagement Concern: Harsh Forward

PCM, TFT sensor, EPC solenoid Control/Emissions Diagnosis (PC/ED) manual for
System. Carry out engagement test and EPC test. GO
to Pinpoint Test B or GO to Pinpoint Test D. Check
idle speed. Repair as required. Clear DTCs, road test
and repeat Self-Test.
Fluid
Engine Driveline
• Looseness in the driveshaft, U-joints or the engine • Repair as required.
mounts
Incorrect Pressures
• High forward clutch pressure, high line pressure, high • Check pressure at line, EPC and forward pressure
EPC pressure taps. Refer to the Line Pressure Chart and the Clutch
Pressure Chart for specifications. Refer to Special
high, check the following possible components: main
controls, pump assembly.
Main Controls
• Main regulator valve stuck, damaged • Inspect and repair as required.
• EPC solenoid stuck or damaged • Inspect for damage or contamination. Carry out EPC
test in Routine 204. Repair as required.
Case
• 2-3 accumulator seal/retainer stuck, damaged • Inspect for damage. Repair as required.
Pump Assembly
• Porosity/cross leaks • Inspect for porosity/leaks. Install a new pump as
required.
• Check balls missing or damaged • Inspect for mislocation, poor seating, damage. Install
a new forward clutch cylinder.
2005 F-150, 10/2004

Engagement Concern: Harsh Forward (Continued)
• Friction element damaged or worn • Inspect for damage. Repair as required.
• Forward clutch wave spring damaged • Inspect for damage. Repair as required.
• Forward clutch return spring damaged • Inspect for damage. Repair as required.
Engagement Concern: Delayed/Soft Reverse

Fluid
Shift Linkage
Incorrect Pressures
• Low reverse clutch pressure, low reverse band • Check pressure at line tap. Refer to the Line Pressure
pressure, low line pressure Chart for specifications. Refer to Special Testing
Procedures in this section. If pressures are low, check
the following components: main controls, pump
assembly, reverse clutch assembly, reverse servo.
• Filter seal damaged.
Main Controls
• No. 6 shuttle ball, manual valve, main regulator valve • Inspect for damage. Repair as required.
stuck or damaged
Case
• 1-2 accumulator seals stuck or damaged • Inspect for damage. Repair as required.
Low Reverse Servo
• Servo cover retaining ring assembled incorrectly
Pump Assembly
• Bolts not tightened to specification • Tighten bolts to specification.
• Porosity/cross leaks/ball missing or leaking • Inspect pump assembly. Install new as required.
2005 F-150, 10/2004

Engagement Concern: Delayed/Soft Reverse (Continued)
• Seals, piston damaged • Inspect for damage. Install new components as
required.
• Friction elements damaged, worn
• Return spring and piston damaged, worn
Low Reverse Band
• Damaged, worn • Inspect for damage. Repair as required.
Engagement Concern: Delayed/Soft Forward

Fluid
Shift Linkage
Incorrect Pressures
• Low forward clutch pressure, low line pressure, low • Check pressure at line, forward clutch and EPC taps.
EPC pressure Refer to the Line Pressure Chart and the Clutch
low, check the following components: oil filter and
seal assembly, main controls and pump assembly.
• Filter seal damaged
Main Controls
• 3-4 shift valve, main regulator valve stuck or • Inspect and repair as required.
damaged
• Gaskets damaged • Inspect for damage and repair as required.
Case
• 2-3 or 1-2 accumulator, bore damaged or stuck • Inspect for damage. Repair as required.
2005 F-150, 10/2004

Engagement Concern: Delayed/Soft Forward (Continued)
Pump Assembly
• Bolts not tightened to specification • Tighten bolts to specifications.
• Porosity/cross leaks • Inspect pump assembly. Repair as required.
• Gaskets damaged • Inspect for damage. Repair as required.
• Check balls missing, damaged • Inspect for mislocation, poor seating, damage. Install
a new cylinder as required.
• Friction elements damaged, worn • Check for damage. Repair as required.
Shift Concerns: Some/All Shifts Missing

PCM, shift solenoids, output shaft speed (OSS) Control/Emissions Diagnosis (PC/ED) manual for
sensor, digital TR sensor diagnosis and testing of the Powertrain Control
System. GO to Pinpoint Test A, GO to Pinpoint Test
C or GO to Pinpoint Test E. Repair as required.
Clear DTCs, road test and repeat the Self-Test.
Fluid
Shift Linkage, Digital TR Sensor
• Refer to the following shift routine(s) for further
diagnosis:
— Shift 1-2, Routine 220/320
2005 F-150, 10/2004

Shift Concerns: Timing Concerns — Early/Late
PCM, shift solenoids, EPC solenoid, TFT sensor, OSS Control/Emissions Diagnosis (PC/ED) manual for
System. GO to Pinpoint Test A, GO to Pinpoint Test
C or GO to Pinpoint Test E. Repair as required.
Clear DTCs, road test and repeat the Self-Test.
Other
• Tire size change, axle ratio change • Verify vehicle has original equipment. Refer to
Certification Label and Safety Standard Certification
Label. Changes in tire size or axle ratio will affect
shift timing.
Fluid
• Engine driveability concerns • Refer to Routine 253.
Incorrect Pressures
• Line pressure, EPC pressure • Check pressure at line and EPC taps. Refer to the
Line Pressure Chart for specifications. Refer to
Special Testing Procedures in this section. If not OK,
check the main controls. If OK, refer to the shift
routine(s) for further diagnosis:
— Shift 1-2, Routine 320
Main Controls
• EPC solenoid, stuck or damaged hydraulically or • Inspect for damage, contamination. Carry out EPC
mechanically tests in Routine No. 211. Repair as required.
• Valves, accumulators, seals stuck or damaged or • Inspect for damage. Repair as required.
assembled incorrectly
• Solenoid screen blocked or damaged • Clean or install a new screen.
Shift Concerns: Timing Concerns — Erratic/Hunting

2005 F-150, 10/2004

Shift Concerns: Timing Concerns — Erratic/Hunting (Continued)
PCM, shift solenoids, torque converter clutch (TCC) Control/Emissions Diagnosis (PC/ED) manual for
solenoid, digital TR sensor, output shaft speed (OSS) diagnosis. GO to Pinpoint Test A, GO to Pinpoint
Test C or GO to Pinpoint Test E. Repair as required.
Clear DTCs, road test and repeat Self-Test.
• Poor engine performance • Refer to Routine 253.
Fluid
Main Controls
• Valves, accumulators, seals, assembled wrong, stuck • Inspect for damage. Repair as required.
or damaged
Torque Converter Clutch
• Torque converter • Refer to Torque Converter Operation Concerns:
Cycling/Shudder/Chatter Hydraulic/Mechanical
Routine 342.
Specific Shifts
• Refer to the following shift routine(s) for further
diagnosis:
Shift Concerns: Feel — Soft/Slipping

PCM, EPC solenoid, OSS Control/Emissions Diagnosis (PC/ED) manual for
System. GO to Pinpoint Test D or GO to Pinpoint
Test E. Repair as required. Clear DTCs, road test
Fluid
Incorrect Pressures
2005 F-150, 10/2004

Shift Concerns: Feel — Soft/Slipping (Continued)
• Low line pressure, low EPC pressure • Check pressures at line and EPC taps. Refer to the
Special Testing Procedures in this section. If pressures
are low or all shifts are soft/slipping, go to main
controls. If pressures are OK and a specific shift is
soft/slipping, refer to the following routine(s) for
further diagnosis:
Main Controls
• Main regulator valve, overdrive servo regulator valve • Inspect for damage. Repair as required.
stuck, damaged or assembled incorrectly
• EPC solenoid stuck or damaged • Inspect for damage and contamination. Carry out EPC
tests in Routine 213. Repair as required.
Case
• 1-2 accumulator stuck or damaged • Inspect for damage. Repair as required.
Filter and Seal Assembly
• Filter plugged, damaged • Inspect for damage. Install a new filter as required.
• Seal damaged or cut • Inspect for damage. Install new as required.
Shift Concerns: Feel — Harsh

PCM, EPC solenoid, OSS Control/Emissions Diagnosis (PC/ED) manual for
System. GO to Pinpoint Test D or GO to Pinpoint
Fluid
Incorrect Pressures
2005 F-150, 10/2004

Shift Concerns: Feel — Harsh (Continued)
• High line pressure, high EPC pressure • Check pressures at line and EPC taps. Refer to the
are high or all shifts are harsh, go to Main Controls.
If pressures are OK and a specific shift is harsh, refer
to the following shift routine(s) for further diagnosis:
Main Controls
• Main regulator valve, overdrive servo regulator valve • Inspect for damage. Repair as required.
stuck, damaged or assembled incorrectly
• EPC solenoid stuck or damaged • Inspect for damage or contamination. Carry out EPC
tests in Routine 214. Repair as required.
Shift Concerns: No 1st Gear, Engages In Higher Gear

PCM, shift solenoids, digital transmission range TR Control/Emissions Diagnosis (PC/ED) manual for
sensor diagnosis and testing of the Powertrain Control
System. GO to Pinpoint Test A or GO to Pinpoint
Test C. Repair as required. Clear DTCs, road test
Incorrect Pressures
• Low reverse clutch pressure, low reverse band • Check for which pressures are on and refer to Band
pressure, low line pressure and Clutch Application Chart and corresponding
• Forward Off, Intermediate Off, Direct X routines.
• Forward Off, Intermediate X, Direct Off — 324, 301
• Forward Off, Intermediate X, Direct X — 325, 301
• Forward X, Intermediate Off, Direct X — 323, 324, 325, 301
• Forward X, Intermediate X, Direct Off — 324
• Forward X, Intermediate X, Direct X — 325
• Forward X, Intermediate Off, Direct Off — 323, 324, 325
— Refer to appropriate mechanical diagnosis.
2005 F-150, 10/2004

Shift Concerns: No 1st Gear, Engages In Higher Gear (Continued)
Mechanical
• Bands, clutches or seals damaged or worn • Refer to Transmission Disassembly and Transmission
Assembly in this section.
X = pressure applied
Shift Concerns: No Manual 1st Gear

PCM, shift solenoids, digital TR sensor Control/Emissions Diagnosis (PC/ED) manual for
Shift Linkage, Cable, Digital TR Sensor
Incorrect Pressures
• Low reverse clutch pressure, low reverse band • Check pressure at line and EPC pressure taps. Refer
pressure, low line pressure, low EPC pressure to the Line Pressure Chart for specifications. Refer to
are low, check the following components: oil filter
and seal assembly, main controls, reverse clutch
assembly and reverse servo assembly.
• Plugged or damaged • Install a new filter and seal assembly.
Main Controls
• No. 6 shuttle ball, manual valve, main regulator • Inspect for damage. Repair as required.
valve, low servo modulator valve stuck, damaged or
Low Reverse Servo
• Servo cover retaining ring assembled incorrectly.
• Anchor pins (case) damaged.
2005 F-150, 10/2004

Shift Concerns: No Manual 2nd Gear
PCM, shift solenoids, digital TR sensor Control/Emissions Diagnosis (PC/ED) manual for
Shift Linkage, Cable, Digital TR Sensor
Main Controls
• 3-4 shift valve, 1-2 and 2-3 shift valve, 3-4 capacity • Inspect for damage. Repair as required.
modulator valve stuck, damaged or assembled
incorrectly
Shift Concerns: 1-2 Shift (Automatic)

PCM, shift solenoids, OSS Control/Emissions Diagnosis (PC/ED) manual for
• Poor engine driveability concerns • Refer to Routine 253.
Incorrect Pressures
2005 F-150, 10/2004

Shift Concerns: 1-2 Shift (Automatic) (Continued)
• Intermediate clutch pressure, line pressure • Check pressure at line and intermediate clutch taps.
Refer to the Line Pressure Chart and the Clutch
Testing Procedures in this section. If not OK, check
the main controls.
Main Controls
• 1-2 shift valve, stuck or damaged • Inspect for damage. Repair as required.
• Bolts not tightened to specifications • Tighten bolts to specification.
• Shift solenoid SSA malfunction • Activate solenoid using diagnostic tool. If solenoid
operation cannot be felt when placing hand on
solenoid, install a new solenoid. Inspect O-rings for
damage. Repair as required.
• No. 8 ball not seating • Inspect for damage. Repair as required.
Case
• 1-2 accumulator stuck or damaged • Inspect for damage. Repair as required.
Pump
• Porosity/cross leaks, balls missing, damaged or • Inspect for porosity/leaks, balls missing. Install a new
leaking pump as required.
Intermediate Clutch Assembly
• Seals damaged • Inspect for damage. Repair as required.
• Piston damaged • Inspect for damage. Repair as required.
• Friction elements damaged or worn • Inspect for damage. Repair as required.
Intermediate One-Way Clutch Assembly
• Not holding or damaged • Inspect for damage. Repair as required.
Planetary One-Way Clutch Assembly
• Not overrunning or damaged • Inspect for damage. Repair as required.
1-2 Accumulator
• Damaged accumulator piston • Inspect for damage. Repair as required.
• Springs damaged or broken • Inspect for damage. Repair as required.
• Case bore scored • Inspect for damage. Repair as required.

PCM, shift solenoids, OSS Control/Emissions Diagnosis (PC/ED) manual for
and repeat the Self-Test.
2005 F-150, 10/2004

Shift Linkage
Incorrect Pressures
• Direct clutch pressure • Check pressure at direct clutch tap. Refer to the
Clutch Pressure Chart for specifications. Refer to
Special Testing Procedures in this section. If not OK,
check the main controls.
Main Controls
• 2-3 shift valve, check ball No. 9 or No. 3, solenoid • Inspect for damage. Repair as required.
pressure regulator valve, damaged or assembled
incorrectly
• Shift solenoid SSB malfunction • Activate solenoid using diagnostic tool. If solenoid
• Output shaft seals damaged or cup plug leaking or • Inspect for damage and repair as required.
missing
• 2-3 accumulator damaged or stuck • Inspect piston seal and bore for damage. Repair as
required.
• Solenoid screen (in main control) blocked or damaged • Clean or install a new screen.
Intermediate One-Way Clutch Assembly
• Not overrunning or damaged • Inspect for damage. Repair as required.
Output Shaft
• Seal rings damaged • Inspect for damage. Repair as required.
• Cup plug damaged or missing
Direct Clutch Assembly
• Seals or piston damaged • Inspect for damage. Repair as required.
• Friction elements worn or damaged • Inspect for damage. Repair as required.
• Check ball not seating • Inspect for damage. Repair as required.
• Return spring assembly damaged • Inspect for damage. Repair as required.
Case
• Output shaft rear seals leaking or damaged • Inspect for damage. Repair as required. Inspect case
for damaged seal area. If damaged, install a new case.
2-3 Accumulator
• Damaged accumulator piston • Inspect for damage. Repair as required.
2005 F-150, 10/2004

• Springs damaged or broken • Inspect for damage. Repair as required.
• Case bore scored • Inspect for damage. Repair as required.

PCM, shift solenoids, OSS, transmission control Control/Emissions Diagnosis (PC/ED) manual for
switch (TCS) diagnosis and testing of the Powertrain Control
Incorrect Pressures
• Forward clutch pressure, direct clutch pressure, line • Check line, direct and forward clutch pressures at
pressure appropriate taps. Refer to the Clutch Pressure Chart
for specifications. Refer to Special Testing Procedures
in this section. If pressures are out of specification,
check main controls.
Main Controls
• 3-4 shift valve, solenoid pressure regulator valve, OD • Inspect for damage. Repair as required.
servo regulator, 3-4 capacity modulator valve, 1-2 and
2-3 shift valves stuck, damaged or assembled
incorrectly
• SSA or SSB malfunction • Activate solenoid using diagnostic tool. If solenoid
• OD servo rod and piston cushion spring or seals • Inspect for damage. Repair as required.
damaged
• Worn or damaged OD servo anchor pins • Inspect for damage. Repair as required.
• No. 2, No. 4, No. 7 and No. 9 check balls damaged • Inspect for damage. Repair as required.
or missing
2005 F-150, 10/2004

Pump
• Gaskets damaged • Inspect for damage. Install new gaskets as required.
OD Band
• OD band and reverse clutch drum assembly damaged, • Inspect for damage. Repair as required.
worn or assembled incorrectly
• Intermediate one-way clutch assembly damaged • Inspect for damage. Repair as required.
• Friction elements worn or damaged • Inspect for damage. Repair as required.
• Check ball stuck, damaged or not seating correctly • Inspect for damage. Repair as required.
Input Shaft

PCM, shift solenoids, transmission control switch Control/Emissions Diagnosis (PC/ED) manual for
(TCS) diagnosis and testing of the Powertrain Control
System. GO to Pinpoint Test A. Repair as required.
Incorrect Pressures
• Forward clutch pressure, line pressure • Check line and forward clutch at pressure taps. Refer
to the Clutch Pressure Chart for specifications. Refer
to Special Testing Procedures in this section. If out of
specification, check the main controls.
Main Controls
• 3-4 shift valve, solenoid pressure regulator valve, OD • Inspect for damage. Repair as required.
servo regulator, 3-4 capacity modulator, 1-2 and 2-3
shift valves stuck, damaged or assembled incorrectly
• Check balls No. 2, No. 7, No. 9 damaged, missing or • Inspect for damage. Repair as required.
not seating correctly
• Bolts not tightened to specifications • Tighten bolts to specification.
• SSA malfunction • Activate solenoid using diagnostic tool. If solenoid
• OD servo, seal, rod damaged • Inspect for damage. Repair as required.
2005 F-150, 10/2004

Pump
• Seal rings damaged • Inspect for damage. Repair as required.
Overdrive Band
• OD band and reverse clutch assembly damaged, worn • Inspect for damage. Repair as required.
or assembled incorrectly
• Intermediate one-way clutch assembly damaged • Inspect for damage. Repair as required.
• Friction elements damaged, worn • Inspect for damage. Repair as required.
• Forward clutch piston and return spring damaged • Inspect for damage. Repair as required.
Input Shaft

PCM, shift solenoids Control/Emissions Diagnosis (PC/ED) manual for
Incorrect Pressures
• Direct clutch • Check pressure at direct clutch tap. Refer to the
Special Testing Procedures in this section. If not
within specification, check the main controls.
Main Controls
• 2-3 shift valve stuck or damaged • Inspect for damage. Repair as required.
• Check balls damaged or missing • Inspect for damage. Repair as required.
• SSB malfunction • Activate solenoid using diagnostic tool. If solenoid
Intermediate One-Way Clutch
2005 F-150, 10/2004

• Intermediate one-way retaining clutch snap ring not • Inspect for damage. Repair as required.
seated
Direct Clutch Assembly
• Friction element damaged, worn • Inspect for damage. Repair as required.

PCM, shift solenoids Control/Emissions Diagnosis (PC/ED) manual for
Incorrect Pressures
• Intermediate clutch • Check pressure at intermediate clutch tap. Refer to the
Special Testing Procedures in this section. If not
within specifications, check main controls and pump.
Main Controls
• 1-2 shift valve, 1-2 accumulator solenoid pressure • Inspect for damage. Repair as required.
regulator valve stuck, damaged or assembled wrong
• SSA malfunction • Activate solenoid using diagnostic tool. If solenoid
damage; repair as required.
Pump
• Porosity/cross leaks • Inspect for leak/porosity. Install a new pump as
required.
Intermediate Clutch Assembly
• Piston damaged • Inspect for damage. Repair as required.
• Friction elements damaged, worn • Inspect for damage. Repair as required.
• End clearance incorrect • Inspect and correct. Refer to Transmission Assembly
in this section.
• Damaged • Inspect for damage. Repair as required.
• Intermediate one-way clutch retaining snap ring not • Inspect for damage. Repair as required.
seated
2005 F-150, 10/2004

Planetary One-Way Clutch
Torque Converter Clutch Operation Concerns: No Apply

PCM, torque converter clutch (TCC) solenoid, TFT Control/Emissions Diagnosis (PC/ED) manual for
sensor, OSS diagnosis and testing of the Powertrain Control
System. GO to Pinpoint Test B or GO to Pinpoint
Test E. Repair as required. Clear codes, road test and
repeat Self-Test.
Shift Linkage
Incorrect Pressures
• Low line pressure, low EPC pressure • Check pressure at line and EPC taps. Refer to the
Special Testing Procedures in this section. If pressure
is low, check EPC and main regulator valve. If
within specifications, check the main controls.
Main Controls
• Solenoid pressure regulator valve, manual valve, • Inspect for damage. Repair as required.
bypass clutch control valve and plunger, converter
pressure limit valve, drain back valve stuck, damaged
or assembled incorrectly
• TCC solenoid malfunction • Activate solenoid using diagnostic tool. If solenoid
Pump Assembly
• Porosity/cross leaks, balls leaking • Inspect for porosity/leaks, ball missing. Install a new
pump as required.
Input Shaft
2005 F-150, 10/2004

Torque Converter Clutch Operation Concerns: No Apply (Continued)
• Seals damaged • Inspect for damage. Repair as necessary.
Torque Converter Assembly
• Leakage, friction material damaged, internal seals • Inspect torque converter. Repair or install a new or
damaged remanufactured torque converter as required.
Torque Converter Clutch Operation Concerns: Always Applied/Stalls Vehicle

PCM, torque converter clutch (TCC) solenoid, TFT Control/Emissions Diagnosis (PC/ED) manual for
sensor diagnosis and testing of the Powertrain Control
System. GO to Pinpoint Test B or GO to Pinpoint
Test A. Repair as required. Clear DTCs, road test
Main Control
• Drain back valve, torque converter clutch (TCC) and • Inspect for damage. Repair as required.
plunger stuck, damaged or assembled incorrectly
• No. 7 ball incorrect seating • Inspect for damage. Repair as required.
Pump Assembly
• Ball missing, leaking, porosity/cross leaks • Inspect for porosity/leaks, balls missing. Install a new
pump as required.
Input Shaft
Torque Converter Assembly
• No end clearance • Inspect converter and install a new or remanufactured
torque converter as required.
• Piston plate damaged or stuck to cover • If cover is heat-stained, install a new converter and
determine the cause of the overheat condition.
Torque Converter Clutch Operation Concerns: Cycling/Shudder/Chatter

2005 F-150, 10/2004

Torque Converter Clutch Operation Concerns: Cycling/Shudder/Chatter (Continued)
PCM, torque converter clutch (TCC) solenoid, OSS Control/Emissions Diagnosis (PC/ED) manual for
System. GO to Pinpoint Test E. Repair as required.
• Speed control equipped vehicles • Evaluate with speed control off.
Fluid
• Condition • Inspect fluid condition. If burnt, drain fluid and
converter. Install a new fluid and filter assembly.
Bring vehicle to normal operating temperature. Carry
out the Transmission Drive Cycle Test. Refer to
Transmission Drive Cycle Test in this section. Carry
out Transmission Self-Test. If condition still exists,
continue diagnostics.
Main Controls
• Solenoid pressure regulator valve, No. 7 check ball, • Inspect for damage. Repair as required.
bypass clutch control valve and plunger, converter
pressure limit valve stuck, damaged or assembled
incorrectly
Pump Assembly
• Bolts not tightened to specification • Tighten bolts to specification.
• Porosity/cross leaks, missing balls or leaking • Inspect for porosity/leaks or missing balls. Install a
new pump as required.
Input Shaft
Torque Converter
• Excessive end clearance • Inspect converter. Install a new or remanufactured
torque converter as required.
Other Concerns: No Engine Braking In Manual 2nd Or Manual 1st Position

Shift Linkage
2005 F-150, 10/2004

Other Concerns: No Engine Braking In Manual 2nd Or Manual 1st Position (Continued)
Main Controls
• 3-4 shift valve, 1-2 and 2-3 shift valve, gaskets, 3-4 • Inspect for damage. Repair as required.
capacity modulator valve, stuck or damaged or
• OD servo assembly damaged or stuck in manual 2nd • Inspect cover, piston and seal for damage. Repair as
only. required.
• Low/Reverse servo assembly damaged or stuck in • Inspect cover, piston and seal for damage. Repair as
manual 1st only required.
Overdrive
• Reverse band, manual 1st (only) damaged • Inspect for damage. Repair as required.
• OD band, reverse clutch drum assembly worn or • Inspect for damage. Repair as required.
damaged (manual 2nd only)
Reverse Band (Manual 1st Only)
• Damaged or incorrectly adjusted • Inspect for damage. Repair as required.
Other Concerns: Shift Lever Efforts High

• Brake shift interlock system, solenoid damaged • Refer to Section 307-05.
Manual Lever
• Retaining pin damaged, nut loose, detent spring bent • Inspect for damage. Repair as required.
or damaged or Park mechanism damaged
Main Controls
• Manual valve stuck or damaged • Inspect for damage. Repair as required.
2005 F-150, 10/2004

Other Concerns: External Leaks
• Electrical inputs/outputs, sensor seals leaking (digital • Inspect for leakage and repair as required.
TR, OSS, vehicle speed sensor VSS, if equipped or
transmission connector)
Case
• Case vent, case porosity, case cracked • Check the vent for free breathing. Check the fluid
level. Check the transmission for overheat conditions.
Repair as required.
Seals/Gaskets
• Leakage at gaskets, seals, etc. (refer to external • Remove all traces of lubricant on exposed surfaces of
sealing illustration for potential leak locations) the transmission. Check the vent for free breathing.
Operate the transmission at normal temperatures and
perform fluid leakage check. Repair as required.
Other
• Cooler fitting, cooler lines pressure tap, converter • Locate the source of the leak. Repair as required.
drain plug, band anchor pins
Other Concerns: Poor Vehicle Performance

shift solenoids, digital TR sensor, torque converter Control/Emissions Diagnosis (PC/ED) manual for
clutch (TCC) solenoid, transmission fluid temperature diagnosis and testing of the Powertrain Control
(TFT) sensor System. GO to Pinpoint Test A, GO to Pinpoint Test
B or GO to Pinpoint Test C. Repair as required.
Clear codes, road test and repeat Self-Test. Also refer
to Routines 241/341 Torque Converter Operation
Concern: Always Applied.
• Engine driveability concerns • Inspect air intake/air filter system. Check the fuel
system and fuel pressure. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual. Inspect
the exhaust system for restriction. Refer to Section
309-00.
Verify Correct Shift Scheduling and Engagements
• See Reference/Action • Go to the appropriate diagnostic routines.
2005 F-150, 10/2004

Other Concerns: Poor Vehicle Performance (Continued)
Torque Converter Clutch Always Applied
• See Reference/Action • Go to Hydraulic/Mechanical Routine 241/341.
• Damaged • Inspect torque converter. Install a new or
remanufactured torque converter as outlined.
Other Concerns: Noise/Vibration — Forward Or Reverse

For Noises/Vibrations That Change With Engine Speed
• Converter components/balance weight • Locate source of disturbance. Repair as required.
• Fluid level (low) pump cavitation
• Pump assembly
• Engine drive accessories
• Cooler lines grounding out
• Flexplate
For Noises/Vibrations That Change With Vehicle Speed
• Engine mounts loose or damaged • Locate source of disturbance and repair as required.
• Driveline concerns: • Refer to the following shift routine(s) for further
— U-joints diagnosis:
— Rear axle — Shift 1-2, Routine 320
— Suspension — Shift 2-3, Routine 321
— Modifications — Shift 3-4, Routine 322
— Torque Converter Cycling 242/342
• 1st Gear:
— Low one-way clutch
— Gearset
— Friction elements
• 2nd Gear:
— Intermediate one-way clutch
— Intermediate clutch piston bleed hole out of 12
o’clock position
• 3rd Gear:
— Torque converter
— Case to planet support spring
• 4th Gear:
— Gear set
— Torque converter
2005 F-150, 10/2004

Other Concerns: Noise/Vibration — Forward Or Reverse (Continued)
• Reverse:
— Gear set
• Output shaft splines worn or damaged
Other Noises/Vibrations
• Main controls, valve resonance
• Shift cable: • Locate source of disturbance and repair as required.
— Vibration
— Grounding
— Cooler lines
— Grounding
Other Concerns: Engine Will Not Crank

engine starting system hardware, digital TR sensor Control/Emissions Diagnosis (PC/ED) manual for
System. GO to Pinpoint Test C. Repair and adjust as
required.
Other Concerns: No Park (P) Range

2005 F-150, 10/2004

Other Concerns: No Park (P) Range (Continued)
Park Mechanism
• Output shaft ring, parking brake pawl, parking pawl • Inspect for damage or incorrect assembly and repair
return spring, park rod guide cup, parking pawl shaft, as required.
parking pawl actuating rod, manual lever detent
spring damaged or assembled incorrectly
Other Concerns: Overheating

Refer to Routine 240/340, Torque Converter Operation Concern: No Apply
Fluid
Other
• Damaged, blocked or reversed cooler lines or • Inspect for damage and correct installation. Repair as
restriction in the transmission oil cooler required.
Vehicle Concerns Causing Engine Overheating
• Refer to the appropriate engine cooling section.
Main Controls
• Drain back valve, torque clutch control valve, • Inspect for damage and repair as required.
converter limit valve stuck, damaged or assembled
incorrectly
• No apply • Refer to Routine 240/340.
2005 F-150, 10/2004

DISASSEMBLY
Transmission Special Tool(s)
Remover, Transmission Fluid
Special Tool(s) Pump
307-221 (T89T-70010-A)
Retainer, Torque Converter
307-346 (T97T-7902-A)
Remover/Installer, Servo Piston

307-251 (T92P-70023-A)
Slide Hammer
100-001 (T50T-100-A)
Remover, Torque Converter

Fluid Seal
307-309 (T94P-77001-BH)
Holding Fixture, Transmission
307-003 (T57L-500-B)
Remover, Bearing Cup

308-047 (T77F-1102-A)
Slide Hammer
307-005 (T59L-100-B)
1. If equipped, remove the vent tube.
Remover, Transmission Fluid 2. Remove the special tool.

Seal
307-048 (T74P-77248-A)
Handle, Torque Converter

307-091 (T81P-7902-C)
(Continued)

Last updated: 8/2/2004 2005 F-150, 10/2004
DISASSEMBLY (Continued)
3. Using the special tools, remove torque 6. Clean the transmission fluid pan and pan
converter. magnet.
4. Using the special tool, mount the transmission 7. CAUTION: If installing a new filter
to the bench. and the grommet remains in the main
control bore, carefully use a small
screwdriver to remove the grommet. Use
care not to damage the main control bore.
NOTE: If the transmission is being repaired for
a contamination-related failure, use a new filter
and seal. The filter can be reused if no
excessive contamination is present.
Remove the fluid filter and grommet.
5. NOTE: If the transmission fluid pan gasket is

not damaged, it can be reused.
Remove the transmission fluid pan and
transmission fluid pan gasket.
1 Remove the bolts.
2 Remove the transmission fluid pan and
transmission fluid pan-to-case gasket.
2005 F-150, 10/2004

8. CAUTION: Do not pull on the plastic
lead frame. This may cause damage to the
connector ends. Carefully pry up on the
locking tabs to disconnect the solenoids.
Disconnect the molded lead frame from the
solenoids.
solenoids.
1 Disconnect the shift solenoid SSA and SSB.
2 Disconnect the torque converter clutch
(TCC).
3 Disconnect the electronic pressure control
(EPC) solenoid. 10. CAUTION: Discard the manual lever
shaft outer nut. Do not reuse.
4 Disconnect the bulkhead inter-connector.
Remove the outer manual control lever.
1 Remove the manual lever shaft outer nut.
2 Remove the outer manual control lever.
11. Remove the digital transmission range (TR)

sensor.
1 Remove the digital TR sensor bolts.
2 Remove the digital TR sensor.
9. Remove the speed sensors.

1 Remove the output shaft speed (OSS)
sensor bolt.
2 Remove the OSS sensor.
3 Remove the turbine shaft speed (TSS)
sensor bolt.
4 Remove the TSS sensor bracket and sensor.
2005 F-150, 10/2004

12. Remove the manual control valve detent lever 15. NOTE: Use a shop cloth to protect the
spring. transmission case surface.
1 Remove the manual control valve detent Remove the manual lever shaft retaining pin.
lever spring bolt.
2 Remove the manual control valve detent
lever spring.
16. Remove the manual lever shaft inner nut.

• Slide the manual control lever shaft out of
the case while removing the inner nut.
13. Remove the 24 main control valve body bolts
and the main control valve body.
17. Remove the parking lever actuating rod.

1 Remove the manual valve detent.
14. Remove and discard the pump outlet screen.
2 Remove the parking lever actuating rod.
2005 F-150, 10/2004

18. CAUTION: Use care not to damage
the manual control lever shaft bore. If the
bore is damaged the new seal may leak.
Remove the manual control lever shaft seal.
22. Using the special tool, remove the reverse band

servo retaining ring.
19. Remove the EPC solenoid.
23. Remove the reverse band servo.

1 Remove the reverse band servo cover.
2 Remove the reverse band servo piston and
rod assembly.
20. Remove the 2-3 accumulator spring retainer.
3 Remove the reverse band servo spring.
21. Remove the 2-3 accumulator piston.

1 Remove the 2-3 accumulator spring.
2 Remove the 2-3 accumulator piston.
2005 F-150, 10/2004

24. CAUTION: If the tool is not available,
extreme care must be taken. Spring pressure
will force the overdrive servo piston
assembly out of the case. Case bore damage
may result from trying to pry on the internal
retaining ring.
Using the special tool, compress the piston
spring, then remove the overdrive servo piston
retainer.
27. Remove the 1-2 accumulator upper spring.

1 Remove the 1-2 accumulator spring cover.
2 Remove the inner and outer 1-2
accumulator springs.
3 Remove the 1-2 accumulator.
4 Remove the 1-2 accumulator upper spring.
25. Remove the overdrive servo piston.

1 Remove the overdrive servo piston.
2 Remove the overdrive servo piston return
spring.
28. Using the special tools, remove the extension

housing seal.
26. Compress the 1-2 accumulator cover and

remove the 1-2 accumulator piston retaining
ring.
2005 F-150, 10/2004

29. NOTE: The 4x2 extension is shown, the 4x4 31. Rotate the transmission to the vertical position
extension housing is similar. with the output shaft toward the floor.
NOTE: These bolts have been coated with a
sealant. High break torque may be required to 32. CAUTION: Extreme care must be
remove these bolts. taken during transmission connector
removal. Do not pull on wires or use a
Remove the extension housing.
hammer on the connector body.
1 Remove the 4 bolts and 2 nuts.
Place a screwdriver on the flat portion of the
2 Remove the extension housing and the connector and push the connector out through
extension housing gasket. the bottom of the case.
30. Remove the parking pawl. 33. Using the special tools, remove the front pump
1 Remove the parking pawl shaft. seal.
2 Remove the parking pawl return spring.
3 Remove the parking pawl.
2005 F-150, 10/2004

34. NOTE: These bolts have been coated with
sealant. High break torque may be required to
remove the bolts.
Remove the front bolts.
38. CAUTION: Remove the assembly

carefully to prevent damage to the overdrive
band friction material by the reverse clutch
drive lugs.
Remove the following components as an
35. Using the special tools, remove the front pump assembly:
support.
• Intermediate clutch pack
• Intermediate one-way clutch
• Reverse clutch
• Forward clutch assembly
36. Remove and discard the pump gasket.

• Remove the intermediate clutch piston return
spring.
• Remove the intermediate clutch piston return
spring support. 39. Disengage and remove the overdrive band.
37. If equipped, remove the intermediate clutch

anti-rattle clip.
2005 F-150, 10/2004

40. Remove the forward clutch hub and the No. 3 43. Remove the following components as an
forward clutch hub front bearing. assembly:
• forward clutch sun gear
• No. 5 forward clutch sun gear bearing
• reverse clutch sun gear
• No. 4 forward clutch hub bearing
41. Remove the intermediate stub shaft.
44. Remove the center support retaining ring and

note location for assembly.
42. Align the reverse sun shell with the overdrive

band anchor pin for removal.
45. Remove the case-to-planet support spring.
2005 F-150, 10/2004

46. Remove the planetary gear support and 49. Remove the direct clutch pack.
planetary as an assembly.
50. Remove the No. 8 bearing.

47. Remove the reverse clutch band.
51. Remove the output shaft and output shaft ring

48. Remove the retaining ring. gear assembly.
2005 F-150, 10/2004

52. Remove the No. 9 case rear bearing. 53. Inspect and if necessary, using the special tools,
remove the rear case bushing.
2005 F-150, 10/2004

DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Main Control Valve Body
Disassembly
Main Control Valve Body Disassembled View

Last updated: 8/2/2004 2005 F-150, 10/2004
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
1 — Valve plug retainer (part of 24 — 2-3 back out valve (part of
7A100) 7A100)
2 — Main pressure booster valve 25 — 2-3 back out valve spring
sleeve (part of 7A100) (part of 7A100)
3 — Main pressure booster valve 26 — Spring retaining plate (part of
(part of 7A100) 7A100)
4 — Main pressure regulator valve 27 — Spring retaining plate (part of
spring (part of 7A100) 7A100)
5 — Main regulator valve (part of 28 — Pressure regulator valve
7A100) spring (part of 7A100)
6 7A100 Main control valve body 29 — Pressure regulator valve (part
assembly of 7A100)
7 7E195 Check ball (8 required) 30 — Control manual valve (part of
8 7H171 Converter drain back valve 7A100)
9 — Pressure regulator valve (part 31 — Retaining ring (part of
of 7A100) 7A100)
10 — Pressure regulator valve 32 — Solenoid screen
spring (part of 7A100) 33 — 1-2 shift valve (part of
11 — Regulator boost plunger (part 7A100)
of 7A100) 34 — 2-3 shift valve spring (part of
12 — Regulator boost sleeve (part 7A100)
of 7A100) 35 — 2-3 valve (part of 7A100)
13 — Valve retainer (part of 36 — Valve retaining plug (part of
7A100) 7A100)
14 — Capacity modulator valve 37 — Valve plug retainer (part of
(part of 7A100) 7A100)
15 — Capacity modulator valve 38 — Spring retaining plate (part of
spring (part of 7A100) 7A100)
16 — Spring retaining plate (part of 39 — Pressure regulator valve
17 — Capacity modulator valve 40 — Pressure regulator valve (part
(part of 7A100) of 7A100)
18 — Capacity modulator valve 41 — Bypass clutch control valve
spring (part of 7A100) (part of 7A100)
19 — Spring retaining plate (part of 42 — Bypass clutch control valve
20 — 3-4 shift valve (part of 43 — Bypass clutch control valve
7A100) plunger (part of 7A100)
21 — 3-4 shift valve spring (part of 44 — Bypass clutch control plunger
7A100) sleeve (part of 7A100)
22 — Valve retainer plug (part of 45 — Control valve plate (part of
7A100) 7A100)
23 — Valve plug retainer (part of
7A100)
(Continued)
2005 F-150, 10/2004

1. Remove the torque converter clutch (TCC) 3. Remove the separator plate and discard the
solenoid and the shift solenoid. gaskets.
1 Remove the retaining bolt.
2 Remove the shift solenoid.
3 Remove the TCC solenoid.
2. Remove the 2 reinforcement plates.

1 Remove the bolts.
2 Remove the plates.
2005 F-150, 10/2004

4. NOTE: Note the location of the eight coasting
booster valve shuttle balls for assembly.
Remove the 8 coasting booster valve shuttle
balls.
2005 F-150, 10/2004

5. Remove the converter drain back valve and
solenoid pressure supply screen.
6. Remove the main control valve body cover

plate.
1 Remove the 13 main control valve body
cover plate bolts.
2 Remove the main control valve body cover
plate.
2005 F-150, 10/2004

Assembly
CAUTION: Before beginning assembly,

carry out and inspect the following:
When building up subassemblies and assembling
the transmission, ALWAYS use new gaskets and
seals.
All fasteners must be tightened to the torque
specification indicated. In addition to appearing
in the section, the necessary torque
measurements can be found in the General
Specifications Chart.
When building up subassemblies, each 2. Tighten all the bolts in the sequence shown.
component part should be lubricated with clean
transmission fluid. It is also good practice to
lubricate the subassemblies as they are installed
in the case.
Needle bearings, thrust washers and seals should
be lightly coated with petroleum jelly during
subassembly buildup or transmission assembly.
Many components and surfaces in the
transmission are precision machined. Careful
handling during disassembly, cleaning, inspection
and assembly can prevent unnecessary damage to
machined surfaces.
NOTE: Inspect the shift solenoid O-rings and TCC

solenoid O-rings for damage.
1. Install the valve body cover plate.

1 Position the valve body cover plate gasket
and cover plate.
2 Loosely install the 2 guide pin bolts.
3 Loosely install the remaining bolts.
2005 F-150, 10/2004

3. Install the 8 coasting booster valve shuttle balls.
2005 F-150, 10/2004

4. Install the converter drain back valve and
solenoid pressure supply screen.
5. Install the separator plate and gaskets.
6. Install the 2 reinforcement plates.

1 Position the plates.
2 Install the reinforcement plate bolts.
2005 F-150, 10/2004

7. Install the shift solenoid.
1 Position the TCC solenoid.
2 Position the shift solenoid.
3 Install the bolt.
2005 F-150, 10/2004


OF SUBASSEMBLIES
Pump and Intermediate Clutch Piston
Special Tool(s)
Installer, Front Pump Fluid Seal
307-014 (T63L-77837-A)
Pump and Intermediate Clutch Spring and Support — Disassembled View

1 7902 Torque converter 9 7B070 Intermediate clutch piston
2 7A248 Front pump O-ring return
3 N605789-S101 Bolt 10 7G154 Intermediate clutch piston
wave spring
4 — Pump body assembly
11 7A108 Pump support
5 N605787-S1000 Front pump support bolt
12 — Pump outer gerotor gear
6 7D014 No. 1 pump support thrust
washer 13 — Pump inner gerotor gear
7 7D020 Reverse clutch cylinder seal 14 7A136 Pump gasket
8 7D019 Forward clutch cylinder seal 15 — Pump bushing
(Continued) 16 7A248 Pump inner seal

Last updated: 8/2/2004 2005 F-150, 10/2004
Disassembly 4. NOTE: Note that the new seals on this pump
are square cut on the ends.
1. Remove the No. 1 selective pump support Remove the seal rings.
thrust washer.
5. Remove the inner and outer pump gerotor

2. NOTE: Note the location of the bleed hole gears.
during disassembly for assembly.
Remove the intermediate clutch piston.
6. Remove and discard the front pump seal.
3. Remove the bolts and remove the front pump

support.
2005 F-150, 10/2004

Assembly
1. Using the special tool, install the front pump

seal assembly.
4. Install a new front pump seal.
2. NOTE: The flats on the inner fluid pump gear

have steps that must face the pump body or
damage will result.
Install the inner and outer fluid pump gerotor
gears.
5. Assemble the front pump.

1 Position the pump support to the pump
body assembly.
3. NOTE: The reverse clutch cylinder seal rings

are larger than the forward clutch cylinder
seals.
NOTE: Note that the new seals are square cut
on the ends.
Install the seal rings.
2005 F-150, 10/2004

6. CAUTION: The piston bleed hole must 7. Once the pump is installed correctly, the bleed
be aligned with the half moon shape in the hole will be aligned with the pump body as
pump body. Shift problems may occur if shown.
installed incorrectly.
NOTE: The piston bleed hole is the only round
hole in the pump body.
Install the intermediate clutch.
2005 F-150, 10/2004


OF SUBASSEMBLIES
Intermediate Clutch Cylinder Disassembled View
Assembly
Item Part Number Description 1. NOTE: The intermediate one-way clutch must
rotate counterclockwise when installed on the
1 391267-S Retaining ring reverse clutch drum and will make a ratchet
2 7A089 Intermediate one-way clutch sound.
assembly
Install the intermediate one-way clutch.
3 7D044 Reverse clutch drum
1 Install the intermediate one-way clutch.
Disassembly 2 Install the snap ring.
1. NOTE: One tab that locks the reverse clutch

drum into the reverse sun shell may be
removed. This is done for balancing purposes.
Remove the intermediate one-way clutch.
1 Remove the snap ring.
2 Remove the intermediate one-way clutch.

Last updated: 8/2/2004 2005 F-150, 10/2004

OF SUBASSEMBLIES
Reverse Clutch Special Tool(s)
Protector, Transmission Reverse
Special Tool(s) Clutch Inner Fluid Seal
307-425
Dial Indicator Gauge with
Holding Fixture
100-002 (TOOL-4201-C)
Compressor, Clutch Spring

307-086 (T80L-77405-A)

307-015 (T65L-77515-A)
Material
Item Specification
Protector, Transmission Reverse
Clutch Outer Fluid Seal MERCON V Automatic MERCON V
307-424 Transmission Fluid
XT-5-QM
(Continued)
Reverse Clutch Disassembled View

Last updated: 8/2/2004 2005 F-150, 10/2004
Item Part Number Description 6. Check clutch hub thrust surfaces for scores and
1 7D044 Reverse clutch drum clutch hub splines for wear.
2 7D403 Reverse clutch piston outer 7. Remove the No. 2 forward clutch bearing.
seal
3 7D402 Reverse clutch piston
4 7D404 Reverse clutch piston inner
seal
5 7D256 Reverse clutch piston spring
pressure ring
6 7B070 Reverse clutch piston spring
7 7A577 Reverse clutch piston spring
ring
8 7B066 Reverse clutch front pressure
plate
9 7B442 Reverse clutch external spline
plates (steel)
10 7B164 Reverse clutch internal spline
plates (friction) 8. Remove the reverse clutch selective retaining
11 7B066 Reverse clutch rear pressure ring.
plate
12 7D483 Reverse clutch retaining ring
(select fit)
Disassembly
1. Inspect the clutch cylinder thrust surfaces,

piston bore and clutch plate serrations for
scores or burrs. Minor scores or burrs can be
removed with a crocus cloth. Install a new
clutch cylinder if badly scored or damaged.
2. Check fluid passages in the clutch cylinder for

obstructions. Clean out all fluid passages.
Inspect the clutch piston for scores and install 9. Remove the reverse clutch pack.
new if necessary. Inspect check balls for
freedom of movement and correct seating.
3. Check the clutch release spring for distortion

and cracks. Install a new spring (including the
wave spring) if distorted or cracked.
4. Inspect the composition clutch plates, steel

clutch plates and clutch pressure plate for worn
or scored bearing surfaces. Install new parts if
they are deeply scored or burred.
5. Check the clutch plates for flatness and fit on

clutch hub serrations. Discard any plate that
does not slide freely on serrations or that is not
flat.
2005 F-150, 10/2004

10. Using the special tools, compress the reverse
clutch piston spring.
13. NOTE: To ease reverse clutch piston removal,

it may be necessary to apply air pressure to the
reverse clutch drum. Block the opposite hole.
Remove the reverse clutch piston.
11. Remove the reverse clutch piston spring

retaining ring.
14. Remove the reverse clutch piston inner and
outer seals.
12. Remove the reverse clutch piston spring

pressure ring.
1 Remove the reverse clutch piston spring.
2 Remove the reverse clutch piston spring
pressure ring.
2005 F-150, 10/2004

Assembly 8. NOTE: Coat the reverse clutch piston inner
seal, outer seal, drum sealing area and special
1. NOTE: One tab that locks the reverse clutch tools with petroleum jelly.
drum into the reverse sun shell may be Using the special tools, install the reverse
removed. This is done for balancing purposes. clutch piston using even pressure to push it to
Inspect the clutch cylinder thrust surfaces, the bottom of the reverse clutch drum.
scores or burrs. Minor scores or burrs may be
removed with crocus cloth. Install a new clutch
cylinder if badly scored or damaged.
2. Check the fluid passages in the clutch cylinder

for obstructions. Clean out all fluid passages.
Inspect clutch piston for scores and install new
if necessary. Inspect the check balls for

and cracks. Install a new spring (including
9. NOTE: The dished side of the reverse clutch
4. Inspect the composition clutch plates, steel piston spring must face the reverse clutch
clutch plates and clutch pressure plate for worn piston.
or scored bearing surfaces. Install new parts if Install the reverse clutch piston spring.
1 Install the reverse clutch piston spring
5. Check the clutch plates for flatness and fit on pressure ring.
the clutch hub serrations. Discard any plate that 2 Install the reverse clutch piston spring.
flat.
6. Check the clutch hub thrust surfaces for scores

and clutch hub splines for wear.
7. NOTE: The piston check ball must be present

and moving freely.
Install new reverse clutch piston inner and outer
seals.
2005 F-150, 10/2004

10. Using the special tools, compress the reverse 12. CAUTION: Install the pressure plates
clutch piston spring. with the flat sides facing the clutch pack.
NOTE: Before assembly, soak the new clutch
discs in clean automatic transmission fluid.
Install the reverse clutch front pressure plate,
clutch pack and reverse clutch rear pressure
plate.
13. Install the reverse clutch pressure plate retainer

snap ring.
11. Install the reverse clutch piston spring retaining

ring.
2005 F-150, 10/2004

14. Install the special tool on the reverse clutch
pack.
• Push downward on the clutch pack.
• Release pressure and zero the dial indicator.
16. Check the clutch for correct operation.

• Apply air pressure to the reverse clutch
drum. The clutch should be heard and felt to
work without leakage.
15. Using the special tool check the reverse clutch

pack clearance.
1 Lift up on the clutch pack until it fully seats
against the reverse clutch pressure plate
retainer.
2 Read the dial indicator.
X If clearance is not within specifications,
install the correct size retaining ring.
Selective Retaining Rings
Specification
1.52-1.62 mm (0.060-0.064 inch)
1.87-1.98 mm (0.074-0.078 inch)
2.23-2.33 mm (0.088-0.092 inch)
2.59-2.69 mm (0.102-0.106 inch)
2005 F-150, 10/2004


OF SUBASSEMBLIES
Forward Clutch Cylinder Special Tool(s)
Protector, Piston Seal
Special Tool(s) 307-020 (T68P-7D158-A2)

Holding Fixture
100-002 (TOOL-4201-C) or
equivalent

307-078 (T80L-77140-A)

307-096 (T81P-70235-A)
Material
Item Specification
(Continued)
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM, XT-5-DM
Forward Clutch — Disassembled View

1 7F207 Forward clutch cylinder and 3 7A480 Forward clutch piston return
shaft spring
2 7A548 Forward clutch piston outer 4 7A527 Forward clutch retainer return
seal spring
(Continued) (Continued)

Last updated: 8/2/2004 2005 F-150, 10/2004
Item Part Number Description 6. Check the clutch hub thrust surfaces for scores
5 7B442 Forward clutch external spline and clutch hub splines for wear.
plate (steel)
6 7D483 Retaining snap ring 7. NOTE: The forward clutch hub may remain in
the shell during disassembly.
7 7B067 Forward clutch hub
8 7F231 No. 3 forward clutch hub Remove the forward clutch hub and the No. 3
front bearing forward clutch hub front bearing.
9 7B066 Forward clutch pressure plate
10 7B164 Forward clutch internal spline
plates (friction)
11 7E085 Forward clutch pressure
spring
12 388099-S Retaining snap ring
13 7A262 Forward clutch piston
14 7C099 Forward clutch piston inner
seal
15 7A166 No. 2 forward clutch bearing
16 7B497 Input shaft seal
Disassembly
8. NOTE: To aid handling, the forward clutch
1. Inspect the clutch cylinder thrust surfaces, assembly may be set in the extension housing
piston bore and clutch plate serrations for or a hole in the work bench.
scores or burrs. Minor scores or burrs may be Remove the forward clutch pack selective
removed with crocus cloth. Install a new clutch retaining ring.
cylinder if it is badly scored or damaged.
2. Check the fluid passage in the clutch cylinder

for obstructions. Clean out all the fluid
passages. Inspect the clutch piston for scores
and install a new piston if necessary. Inspect
check balls for freedom of movement and
correct seating.

and cracks. Install a new spring (including
4. Inspect the composition clutch plates, steel

clutch plates and clutch pressure plate for worn
or scored bearing surfaces. Install new parts if

clutch hub serrations. Discard any plate that
flat.
2005 F-150, 10/2004

9. Remove the following components.
1 Remove the pressure plate.
2 Remove the clutch pack.
3 Remove the pressure spring.
13. NOTE: Air pressure may be required to

remove the forward clutch piston.
Remove the forward clutch piston.
10. CAUTION: Apply only enough

pressure to release pressure on the retaining
ring. If too much pressure is applied, the
spring may break.
Using the special tool, remove the forward
clutch retaining ring.
14. Remove the inner and outer forward clutch

piston seals.
11. Slowly release the press and remove the

forward clutch from the press.
12. Remove the forward clutch retainer and the

return spring.
2005 F-150, 10/2004

15. NOTE: The seals are solid seals, however, 4. Inspect composition clutch plates, steel clutch
when installing new seals use scarf-cut seals. plates and clutch pressure plate for worn or
Remove the forward clutch input shaft seals. scored bearing surfaces. Install new parts if

the clutch hub serrations. Discard any plate that
flat.

and the clutch hub splines for wear.
7. NOTE: To aid handling, the forward clutch

assembly may be set in the extension housing
or a hole in the work bench.
Install the inner and outer forward clutch piston
16. Make sure the check ball in the clutch cylinder seals. Note the direction of the sealing rings
is free and clean. Check for correct seating. before installation.
Assembly 8. NOTE: Coat the piston seals and clutch drum

sealing area with petroleum jelly.
1. Inspect the clutch cylinder thrust surfaces, Position the special tools on the clutch piston.
scores or burrs. Minor scores or burrs may be
removed with crocus cloth. Install a new clutch
cylinder if badly scored or damaged.
2. Check the fluid passage in the clutch cylinder

Inspect the clutch piston for scores and install a
new piston if necessary. Inspect check balls for

and cracks. Install a new spring (including the
2005 F-150, 10/2004

9. Using the special tools, install the forward
clutch piston into the clutch drum.
• Push the piston to the bottom of the drum
using even pressure.
13. Install the clutch pack retaining ring.
10. Using the special tool, compress the piston

return spring and install the retaining ring.
14. Install the special tool on the forward clutch

pack.
• Push downward on the clutch pack.
• Release pressure and zero the dial indicator.
11. Slowly release the press pressure and remove

the forward clutch.
12. NOTE: Before assembly, soak the new clutch

discs in clean automatic transmission fluid for
15 minutes.
Install the clutch pack assembly.
1 Install the pressure ring.
2 Install the clutch pack.
3 Install the pressure plate.
2005 F-150, 10/2004

15. Using the special tool, check the clutch pack
clearance.
• Lift up on the clutch pack until it fully seats
against the clutch pressure plate retainer.
• Read the dial indicator.
X If the clearance is not within
specifications, install the correct size
retaining ring.
Selective Retaining Ring
Specification
1.72-1.82 mm (0.068-0.072 inch)
17. Install the 2 scarf-cut seals on the input shaft.
1.93-2.03 mm (0.076-0.080 inch)
2.13-2.23 mm (0.084-0.088 inch)
2.33-2.43 mm (0.092-0.096 inch)
18. Install the No. 3 forward clutch hub front

bearing and the forward clutch hub.
16. NOTE: Make sure the scarf-cut seals are mated

correctly.
Slide the 2 scarf-cut seals on the input shaft.
2005 F-150, 10/2004


OF SUBASSEMBLIES
Planetary Gear Support Assembly
and Planetary One-Way Clutch
2. Remove the planetary one-way clutch.

1 7A130 Planetary gear support
2 7A089 Planetary one-way clutch
3 7A398 Planetary assembly
Disassembly and Assembly
1. NOTE: Inspect the outer and inner races for

scores or damaged surface areas where rollers
contact the races. Inspect the rollers and springs
for excessive wear or damage. Inspect the
spring and cage for bent or damaged spring 3. To assemble, reverse the disassembly procedure.
retainers.
Rotate the center support counterclockwise and
lift to remove the planetary gear support.

Last updated: 8/2/2004 2005 F-150, 10/2004

OF SUBASSEMBLIES
Reverse Sun Gear
Disassembly
2. Remove the forward clutch sun gear assembly

and the No. 5 forward clutch sun gear bearing
and race.

1 7C096 Forward clutch hub bearing
No. 4
2 7D234 Forward clutch sun gear
bearing No. 5 (two piece
bearing)
3 7A399 Forward clutch sun gear
4 7A019 Reverse sun gear assembly
1. Remove the reverse clutch sun gear assembly

and the No. 4 forward clutch hub bearing and
race.
Assembly
1. The forward clutch sun gear and reverse sun

gear assembly are assembled as part of the
transmission assembly procedure.

Last updated: 8/2/2004 2005 F-150, 10/2004

OF SUBASSEMBLIES
Output Shaft and Direct Clutch Special Tool(s)
Cylinder Assembly Pusher
307-516-3
Special Tool(s)
307-015 (T65L-77515-A)
Sizer, Seal
307-516-4

307-080 (T80L-77234-A)
Material
Item Specification
Protector, Transmission Direct Transmission Fluid
Clutch Outer Fluid Seal XT-5-QM
307-422
Teflon Seal Installer

307-516 (kit consists of
307-516-1, 307-516-2,
307-516-3 and 307-516-4)
Protector Pilot, Seal

307-516-1
Protector, Seal
307-516-2
(Continued)

Last updated: 8/2/2004 2005 F-150, 10/2004
Output Shaft and Hub Disassembled View

1 7F274 Output shaft to direct clutch 5 87054-S94 O-ring seal
cylinder seal (2 required) 6 7A233 Output shaft ring gear
2 7F240 Direct clutch outer bearing assembly
and race assembly No. 8 7 7D164 Output shaft hub
3 7060 Output shaft 8 97713-S Retaining snap ring
4 7F273 Output shaft-to-case seal (3 9 7C122 Snap ring
required)
(Continued)
Direct Clutch Disassembled View
2005 F-150, 10/2004

1 7F236 Direct clutch hub
2 7F243 No. 7 direct clutch bearing
3 7D483 Direct clutch pressure plate
retaining ring
4 7F237 Direct clutch inner bearing
support
5 7B066 Direct clutch pressure plate
6 7B442 Direct clutch external spline
plates (steel)
7 7B164 Direct clutch internal spline
plates (friction)
8 388104-S2 Retaining ring
9 7F235 Direct clutch retainer and
spring assembly
10 7A262 Direct clutch piston
11 7C099 Direct clutch piston inner seal
12 7A548 Direct clutch piston outer seal
13 7F283 Direct clutch cylinder
Disassembly
1. NOTE: The index mark on the output shaft

must be aligned with the index mark on the
output shaft ring gear during the assembly
procedure. 2. Separate the ring gear and output shaft.
Remove the ring gear snap ring.
2005 F-150, 10/2004

3. Remove the 3 output shaft seal rings.
7. Inspect the clutch cylinder thrust surfaces,

4. Remove the output shaft hub snap ring and the scores or burrs. Minor scores or burrs may be
output shaft hub. removed with a crocus cloth. Install a new
clutch cylinder if badly scored or damaged.
8. Check the fluid passages in the clutch cylinder

Inspect the clutch piston for scores and install
new if necessary. Inspect the check balls for
9. Check clutch release spring for distortion and

cracks. Install a new spring (including wave
spring) if distorted or cracked.
10. Inspect composition clutch plates, steel clutch

plates and clutch pressure plate for worn or
5. Remove the 2 direct clutch seal rings. scored bearing surfaces. Install new parts if

the clutch hub serrations. Discard any plate that
does not slide freely on the serrations or that is
not flat.

and clutch hub splines for wear.
6. Remove the No. 7 direct clutch inner bearing

support.
1 Remove the direct clutch hub.
2 Remove the No. 7 direct clutch inner
bearing support.
2005 F-150, 10/2004

13. Remove the direct clutch pack. 15. WARNING: Wear safety glasses when
1 Remove the selective retaining ring. using compressed air.
2 Remove the direct clutch pack. NOTE: If necessary, use regulated compressed
air 207 kPa (30 psi) maximum pressure to
remove the clutch piston.
Remove the support and spring assembly and
piston.
16. Remove the inner piston seal.

return spring and remove the snap ring.
17. Remove the outer piston seal.
2005 F-150, 10/2004

Assembly 3. NOTE: Coat the inner and outer direct clutch
piston seals, clutch cylinder sealing area and
1. NOTE: Lubricate the direct clutch piston inner piston inner sealing area with petroleum jelly.
seal and seal protector with petroleum jelly. Using the special tool, install the direct clutch
Using the special tool, install the inner piston piston.
seal.
• Install the seal with sealing lip facing down.
4. Install the piston return spring and retainer

assembly.
2. Install the clutch piston outer seal so that when
the piston is installed the sealing lip points
return spring and install the retaining ring.
toward the bottom of the cylinder.
2005 F-150, 10/2004

6. NOTE: Before assembly, soak new clutch discs
in clean automatic transmission fluid.
Install the clutch pack retaining ring.
1 Alternate external spline (steel) plates and
internal spline (friction) plates, starting with
a steel plate and ending with the friction
plate.
2 Install the clutch pack retaining ring.
8. Install the direct clutch hub.

1 Install the No. 7 direct clutch inner bearing
support.
2 Install the direct clutch hub.
NOTE: Inspect the output shaft bearing surfaces for

scores. Inspect the output shaft splines for wear.
Inspect all bushings.
9. Using the special tool install the 1st direct

7. Use a feeler gauge to check the clearance clutch seal ring.
between the clutch pack selective retaining ring
and the pressure plate.
• If the clearance is not within specifications,
install the correct size retaining ring and
recheck the clearance.
Selective Retaining Ring
Specification
1.52-1.62 mm (0.060-0.064 inch)
1.87-1.98 mm (0.074-0.078 inch)
2.23-2.69 mm (0.086-0.106 inch)
2.59-2.69 mm (0.102-0.106 inch)
2005 F-150, 10/2004

10. Using the special tool install the 2nd direct 13. Install the 3 output shaft seal rings.
clutch seal ring.
14. CAUTION: The index mark on the

11. After both new seals have been installed, use output shaft must be aligned with the index
the special tool to size the seals. mark on the output shaft ring gear.
Align the index marks on output shaft and the
output shaft ring gear and install the ring gear
on the output shaft.
12. Install the output shaft hub.

• Position the output shaft hub.
• Install the retaining ring.
2005 F-150, 10/2004

ASSEMBLY
Transmission Special Tool(s)
Installer, Servo Piston
Special Tool(s) 307-073 (T80L-77030-A)

Holding Fixture
100-002 (TOOL-4201-C)
Remover/Installer, Transmission
Extension Housing
307-077 (T80L-77110-A)
Rubber Tip Air Nozzle
100-D009 (D93L-7000-A)
Handle, Torque Converter

307-091 (T81P-7902-C)

307-351 (T97L-70010-A)
Test Plate Screw Set,

Transmission
307-126 (T82P-7006-C)
Slide Hammer
100-001 (T50T-100-A)

307-246 (T92P-7006-A)
Installer, Shift Shaft Fluid Seal

307-050 (T74P-77498-A)

307-251 (T92P-70023-A)
Shim Selection Gauge

307-072 (T80L-77003-A)
(Continued)
(Continued)

Last updated: 8/2/2004 2005 F-150, 10/2004
ASSEMBLY (Continued)
Special Tool(s)
CAUTION: Before beginning assembly,
Installer, Transmission carry out and inspect the following:
Extension Housing Oil Seal
308-002 (T61L-7657-A) When building up subassemblies and assembling
the transmission, ALWAYS use new gaskets and
seals.
All fasteners must be tightened to the torque
specification indicated. In addition to appearing
Gauge, Transmission Solenoid in the section, the necessary torque
Connectors measurements can be found in the General
307-426 Specifications Chart.
When building up subassemblies, each
component part should be lubricated with clean
transmission fluid. It is also good practice to
lubricate the subassemblies as they are installed
in the case.
Material
Needle bearings, thrust washers and seals should
Item Specification be lightly coated with petroleum jelly during
MERCON V Automatic MERCON V subassembly buildup or transmission assembly.
Transmission Fluid
XT-5-QM Many components and surfaces in the
transmission are precision machined. Careful
Multi-Purpose Grease ESR-M1C159-A
XG-4 handling during disassembly, cleaning, inspection
and assembly can prevent unnecessary damage to
machined surfaces.
1. Use the special tools to install the rear case

bushing if removed.
1 Position the rear case bushing and the
special tool inside the case.
2 Assemble the special tools through the back
of the case.
2. Place the transmission in the vertical position.
2005 F-150, 10/2004

3. Coat the No. 9 case rear bearing with petroleum
jelly and install on the case boss.
7. NOTE: The reverse band support retaining ring

is used for assembly purposes during
production. The reverse band support retaining
4. CAUTION: Be sure the No. 7 needle ring is not required during assembly, it will not
bearing and direct clutch hub are installed as affect the operation of the transmission.
shown in the Subassembly section. Internal Install the reverse band support retaining ring.
damage and shift problems may occur.
Install the output shaft and output shaft ring
gear.
8. NOTE: Make sure the band is seated on the

anchor pins.
Install the reverse band.
5. Install the No. 8 bearing.
6. Install the direct clutch.
2005 F-150, 10/2004

9. NOTE: The planetary assembly and planetary
gear support cannot be installed unless the
notch cut in the planetary gear support is
aligned with the overdrive band anchor pin.
NOTE: The top of the planetary gear support
must be below the snap ring groove.
Install the planetary assembly and planetary
gear support as a unit.
• Rotate the output shaft to fully seat the
planetary assembly.
12. Install the forward clutch sun gear, No. 5

forward clutch sun gear bearing (2-piece) and
the reverse sun gear.
10. NOTE: The planet support spring must be

compressed and installed below the snap ring
groove. When the planet support spring is
installed correctly both ends of the spring will
be visible.
Install the case to planet support spring located 13. Install the No. 4 forward clutch hub bearing.
at the 1 o’clock position.
11. Install the center support retaining ring.

• Reference the retaining ring tabs to the band
anchor pin location.
2005 F-150, 10/2004

14. Install the intermediate stub shaft.
18. Install the overdrive band.

• Position the overdrive band pocket onto the
15. Install the forward clutch hub and the No. 3 anchor pin.
forward clutch hub front bearing.
19. Install the overdrive servo spring.

16. Install the forward clutch assembly.
1 Install the overdrive servo piston return
spring.
2 Install the overdrive servo piston.
17. NOTE: Make sure the reverse clutch cylinder

lugs are completely seated in the notches of the
reverse sun gear.
Install the reverse clutch cylinder assembly.
1 Install the reverse clutch cylinder assembly.
2 Install the No. 2 forward clutch bearing.
2005 F-150, 10/2004

20. Verify the tip of the piston assembly engages
the pocket of the overdrive band.
24. Using the special tool, check the intermediate

clutch clearance.
1 Position the special tool on the pump case
21. Using the special tool, compress the overdrive mounting surface.
servo assembly and install the overdrive servo
retaining ring. 2 Maintaining downward pressure, use a depth
micrometer to measure and verify
intermediate clutch clearance is within
specification.
If the intermediate clutch is not within
specification, install a correct selective
plate.
Selective Steel Plates
Specification
1.80-1.7 mm (0.071-0.067 inch)
2.05-1.95 mm (0.081-0.077 inch)
2.31-2.20 mm (0.091-0.087 inch)
2.56-2.46 mm (0.101-0.097 inch)
22. Install the intermediate clutch pressure plate.
23. NOTE: Before assembly, soak the new clutch

discs in clean automatic transmission fluid.
Install the intermediate clutch pack and
selective steel plate.
2005 F-150, 10/2004

25. Using the special tool, measure end clearance
for the No. 1 front pump thrust washer.
1 Position the special tool on the pump case
mounting surface.
2 Maintaining downward pressure, use a depth
micrometer to measure end play clearance.
Use the No. 1 thrust washer chart to select
the correct washer.
No.1 Thrust Washer Chart
Depth Thickness Color Code
37.706-38.184 1.270-1.372 mm Green
mm (0.050-0.054 27. Install the intermediate clutch return spring
(1.485-1.503 inch) support and the wave spring.
inch)
38.185-38.641 1.727-1.829 mm Yellow 28. Install the No. 1 front pump support thrust
mm (0.068-0.072 washer.
(1.504-1.521 inch) • Use petroleum jelly to hold the washer in
inch)
place.
38.642-39.073 2.159-2.261 mm Natural
mm (0.085-0.089
(1.522-1.538 inch)
inch)
39.074-39.505 2.591-2.692 mm Red
mm (0.102-0.106
(1.539-1.555 inch)
inch)
39.506-40.165 3.023-3.124 mm Blue
mm (0.119-0.123
(1.556-1.581 inch)
inch)
29. NOTE: The alignment pin is a fabricated M8 x

1.25 mm (0.05 in) bolt with the head removed.
Install an alignment pin at the top of the case.
26. If equipped, install the intermediate clutch

anti-rattle clip.
2005 F-150, 10/2004

30. NOTE: Make sure the gasket is positioned
correctly and the case passages are not covered.
Install the pump gasket.
31. NOTE: To aid assembly, shake the input shaft

while pushing down on the pump.
Install the pump assembly.
35. Install a new extension housing gasket and the

extension housing.
1 Position the extension housing.
2 Install the 4 bolts and 2 nuts.
32. Remove the alignment pin and install the front

pump bolts.
• Alternate bolt tightening to set the pump.
36. NOTE: Position the seal in the housing with

the drain hole at the 6 o’clock position.
Using the special tool, install a new extension
housing seal.
33. Rotate the transmission to the horizontal

position.
34. Install the parking pawl.

1 Position the parking pawl return spring.
2 Position the parking pawl.
3 Install the parking pawl shaft.
2005 F-150, 10/2004

37. Install the speed sensors. 40. Install the manual valve detent lever and
1 Install the turbine shaft speed (TSS) sensor parking lever actuating rod.
and bracket.
2 Install the TSS sensor bolt.
3 Install the output shaft speed (OSS) sensor.
4 Install the OSS sensor bolt.
41. Install the manual control lever shaft.

1 Slide the manual control shaft into the case.
2 Install the manual lever shaft inner nut.
3 Install the manual lever shaft retaining pin.
38. Using the special tool, install the manual
control lever seal.
39. Lubricate the electronic pressure control (EPC)

solenoid and install it into the case.
2005 F-150, 10/2004

42. Install the 1-2 accumulator piston assembly.
1 Install the 1-2 accumulator spring.
2 Install the 1-2 accumulator.
3 Install the inner and outer 1-2 accumulator
springs.
4 Install the 1-2 accumulator cover and seal.
45. Install the special tool.

• Tighten the bolt.
43. Install the 1-2 accumulator springs and install

the accumulator piston retaining ring.
46. Install the special tool.

• Position the indicator stem on the flat
portion of the reverse servo piston and zero
the dial indicator.
44. NOTE: This is not an ordinary installation

procedure and does not compensate for band
wear. When a new piston and rod assembly
becomes necessary or when a new reverse band
has been installed, the reverse piston and rod
length must be adjusted.
NOTE: Lubricate the reverse piston seal to
facilitate assembly and prevent damage to the
seal.
Install the reverse servo piston and return
spring.
2005 F-150, 10/2004

47. Loosen the bolt until the piston stops against 50. Remove the special tools.
the tool.
51. Install the reverse servo assembly.

48. Verify the amount of piston travel on the dial 1 Install the rod.
indicator is within specification.
2 Install the piston assembly.
3 Install the reverse servo piston cover and
seal.
49. If piston travel is not within specification, select

and install the correct servo assembly to bring
the servo piston travel within specification.
1 One groove 52. Using the special tool, install the reverse servo
retaining ring.
2 Two grooves
1 Compress the reverse band servo.
3 Three grooves
2 Install the reverse band servo retaining ring.
2005 F-150, 10/2004

53. Install the 2-3 accumulator assembly. 56. NOTE: The alignment bolts are valve body
1 Install the accumulator piston. assembly bolts and are in the valve body.
2 Install the accumulator piston spring. Align the main control valve body alignment
bolts and position the main control valve body.
3 Install the accumulator spring retainer.
57. NOTE: The main control valve body bolts will

54. Using the special tools apply regulated air be tightened in later steps.
pressure to the test ports. Verify that the
components are applied and released. Loosely install the 11 long main control valve
body bolts.
55. NOTE: The tab on the electrical connector is

secured by the main control valve body.
Install the electrical connector into the case.
2005 F-150, 10/2004

58. NOTE: Lubricate the electronic pressure 61. Tighten the bolts in the sequence shown.
control (EPC) solenoid O-rings with clean
automatic transmission fluid.
Install the EPC solenoid bracket and loosely
install the bolt.

be tightened in later steps.
Loosely install the 12 short main control valve
body bolts.
62. Inspect the lead frame for damage.

• Using the special tool, check all lead frame
solenoid connections. The gauge should fit
tightly and not fall out after being inserted.
• If the special tool passes through any lead
frame connector pins or does not feel like it
makes a good contact, install a new lead
frame.
60. Install the manual control valve detent lever
spring and loosely install the bolt.
2005 F-150, 10/2004

63. Connect the molded lead frame to the
solenoids.
• Connect the bulkhead inter-connector by
pressing it in place by hand and fully
seating the connector in place.
• Connect the EPC solenoid by pressing it in
place by hand and fully seating the
connector in place. Make sure that the
terminals pass fully through the connector
slots.
• Connect the TCC by pressing it in place by
hand and fully seating the connector in
place. Make sure that the terminals pass 65. Position the pan magnet onto the fluid pan.
fully through the connector slots.
• Connect the shift solenoid SSA and SSB by
seating the connector in place. Make sure
that the terminals pass fully through the
connector slots.
66. NOTE: The pan gasket is reusable; clean and

inspect for damage. If not damaged, the gasket
should be reused.
Install the fluid pan and gasket.
1 Position the transmission fluid pan with the
gasket in place.
64. Install the fluid filter and seal assembly.
2005 F-150, 10/2004

67. Install the digital transmission range (TR)
sensor.
1 Install the digital TR sensor.
2 Loosely install the digital TR bolts.

1 Install the manual control lever.
2 Install the nut.
68. NOTE: The tool is designed to fit snug.

NOTE: Manual shift lever must be in the
NEUTRAL position.
sensor slots.
71. Install the transmission vent tube, if equipped.
72. Lightly lubricate the converter hub with clean


Tighten the bolts.
2005 F-150, 10/2004

73. WARNING: The torque converter can 74. Lubricate the torque converter pilot hub with
fall out if the transmission is tipped. multi-purpose grease.
CAUTION: Make sure the converter

hub is fully engaged in the front pump
support and gear and rotates freely. Do not
damage the hub seal.
CAUTION: If the torque converter
slides out, the hub seal may be damaged.
Using special tools, install the torque converter.
2005 F-150, 10/2004

INSTALLATION
Transmission — 4x2 2. CAUTION: To position the
transmission in the vehicle, put the
Special Tool(s) transmission into a nose-down position on
the transmission jack. This allows the tail
307-346 (T97T-7902-A) shaft to go over the exhaust system. The
converter housing is piloted into position by
dowels in the rear of the engine block. The
torque converter must rest squarely against
the flexplate. This indicates that the
converter pilot is not binding in the engine
crankshaft.
Material Position and secure the transmission on the
Item Specification high-lift transmission jack. Raise and position
the transmission into the vehicle. Once the
MERCONV Automatic MERCONV
Transmission Fluid transmission is in position, place the
XT-5-QM transmission in a horizontal position.
Installation
1. Install the special tool if not done in the

assembly procedure.
3. NOTE: Do not remove the special tool until

the transmission is in a horizontal position.
Remove the special tool.

Last updated: 8/2/2004 2005 F-150, 10/2004
INSTALLATION (Continued)
4. NOTE: Make sure the torque converter is fully
seated in the transmission before aligning the
transmission to the engine.
With the transmission in a horizontal position
move it toward the engine. Align the orange
balancing marks between the torque converter
studs and the flexplate bolt holes.
5. NOTE: Install the transmission retaining bolts

in their correct locations made during removal.
Install the LH transmission retaining bolts.
7. Connect the solenoid body connector and

connect the harness retainer to the transmission.
8. Connect the output shaft speed (OSS) sensor,

the digital TR sensor connectors and connect
the harness retainer to the transmission.
6. NOTE: Install the transmission retaining bolts

in their correct locations made during removal.
Install the RH transmission retaining bolts.
2005 F-150, 10/2004

9. Install the rear transmission support. 13. Install the RH exhaust shield bolt.
10. Position the rear crossmember in place and 14. Install the LH exhaust shield bolt.
install the rear transmission support nuts.
15. Install the bolts retaining the exhaust hanger to

11. Position the rear crossmember in place and the crossmember.
install the bolts.
12. Remove the transmission jack.
2005 F-150, 10/2004

16. Position the transmission fluid fill tube into the
transmission and install the retaining bolt on the
RH cylinder head.
20. Install the plastic starter motor electrical

connector cap.
17. Connect the transmission fluid cooler tubes.
21. Install the 4 torque converter nuts.

• Rotate the crankshaft to access all the torque
converter nuts.
18. Install the starter motor and install 3 bolts.
19. Install the starter motor electrical connectors

and the ground wire.
2005 F-150, 10/2004

22. Install the rubber access plug. 25. Install the fuel line bracket.
23. Install the flexplate inspection cover 26. NOTE: The output shaft and the driveshaft are
a balanced assembly.
Install the driveshaft.
• Align the yellow dots and position the
driveshaft on the transmission.
• Position the driveshaft to the rear
differential.
24. Install the shift cable end and the bracket.
2005 F-150, 10/2004

27. NOTE: To maintain initial driveshaft balance, 28. Use the following guidelines for the in-line
align the index marks made during removal. transmission fluid filter:
Install the rear driveshaft. • If the transmission was overhauled and the
1 Position the driveshaft. vehicle was equipped with an in-line fluid
filter, install a new in-line fluid filter.
2 Install the 4 bolts.
• If the transmission was overhauled and the
vehicle was not equipped with an in-line
fluid filter, install a new in-line fluid filter
kit.
• If the transmission is being installed for a
non-internal repair, do not install an in-line
filter or filter kit.
• If installing a Ford authorized
remanufactured transmission, install the
in-line transmission fluid filter that is
supplied
Prior to lowering the vehicle, install a new
in-line transmission filter or a filter kit. For
additional information, refer to Transmission
Fluid In-Line Filter in this section.
29. Connect the battery ground cable.
30. Fill the transmission with clean automatic

transmission fluid and inspect for correct
operation. For additional information, refer to
Transmission Fluid Drain and Refill in this
section.
2005 F-150, 10/2004

REMOVAL
Transmission — 4x2
Special Tool(s)
307-346 (T97T-7902-A)
Removal
5. NOTE: It is not necessary to torque the
1. With the vehicle in NEUTRAL, position it on a transmission fluid pan bolts in this step.
Section 100-02. Install the transmission fluid pan.
2. Disconnect the battery ground cable. For

additional information, refer to Section 414-00.
3. NOTE: If transmission disassembly is required,

drain the transmission fluid.
Loosen the transmission fluid pan bolts and
allow the fluid to drain.
6. Mark the driveshaft flange and rear axle pinion

flange for correct alignment during installation.
4. After the fluid has drained, remove the

transmission fluid pan and drain the remaining
fluid from the pan.

Last updated: 8/2/2004 2005 F-150, 10/2004
REMOVAL (Continued)
7. Remove the rear driveshaft. 10. Remove the flexplate inspection cover.
1 Remove the 4 bolts.
2 Remove the driveshaft.
11. Remove the rubber access plug.
8. Remove the fuel line bracket from the extension

bolt.
12. Remove and discard the 4 flexplate-to-torque

converter nuts.
9. Disconnect the shift cable end and remove the

shift cable bracket.
2005 F-150, 10/2004

REMOVAL (Continued)
13. Remove the plastic starter motor electrical
connector cap.
17. Remove the bolt from the RH cylinder head for

the transmission filler tube and position the
filler tube aside.
14. Remove the starter motor electrical connectors
and the ground wire.
18. Remove the 2 bolts for the exhaust hanger.
15. Remove the 3 bolts and the starter motor.
16. Disconnect the transmission cooler lines and

position them aside.
2005 F-150, 10/2004

REMOVAL (Continued)
19. Remove the RH exhaust shield bolt.
24. Remove the rear transmission support.
20. Remove the LH exhaust shield bolt.
25. Disconnect the transmission electrical

connectors.
21. NOTE: Make sure that the transmission is 1 Disconnect the digital transmission range
securely fastened to the transmission jack. (TR) sensor.
Position a suitable high-lift transmission jack 2 Disconnect the output shaft speed (OSS)
under the transmission. sensor.
22. Remove the rear crossmember bolts.
23. Remove the rear transmission retainer nuts and

remove the crossmember.
2005 F-150, 10/2004

REMOVAL (Continued)
26. Disconnect the solenoid body assembly
electrical connector.
29. CAUTION: To remove the

transmission from the vehicle, it will be
necessary to put the transmission into a
27. NOTE: If the transmission fluid has not been nose-down position to clear the flexplate and
drained, position a drain pan and install a the exhaust system.
suitable plug into the transmission.
NOTE: Make sure that the special tool is in
NOTE: Note the length and the location of the place and the transmission is securely fastened
bolts during removal. to the transmission jack before tilting the
Remove the seven transmission-to-engine bolts. transmission.
Lower the transmission from the vehicle.
28. WARNING: The torque converter is

heavy and can result in injury if it falls out 30. If the transmission is to be overhauled or if
of the transmission. Secure the torque installing a new transmission, carry out
converter in the transmission. transmission backflushing and cleaning. Carry
Leaving the transmission in a horizontal out transmission fluid cooler backflushing and
position, slide it back far enough to install the cleaning. For additional information, refer to
special tool. Install the special tool. Transmission Fluid Cooler — Backflushing and
Cleaning in this section.
2005 F-150, 10/2004

REMOVAL (Continued)
31. Remove the special tool.
2005 F-150, 10/2004

IN-VEHICLE REPAIR
Fluid Pan, Gasket and Filter
Material
Item Specification
Transmission Fluid
XT-5-QM
Removal
CAUTION: Do not use any supplemental

transmission fluid additives or cleaning agents.
The use of these products could cause internal 4. Pull down evenly and remove the transmission
transmission components to fail; this will effect fluid filter and seal.
the operation of the transmission.
Use of a fluid other than specified could result in
transmission failure.
NOTE: Normal maintenance requires periodic

automatic transmission fluid changes. If a major
repair, such as a clutch, band, bearing, etc., is
required, the automatic transmission will need to be
removed for repair. The transmission fluid needs to
be changed if evidence of fluid contamination is
found.

Section 100-02. 5. Clean and inspect the transmission fluid pan,
gasket and magnet.
2. Drain transmission fluid.
• Loosen the transmission fluid pan bolts and
allow fluid to drain. After fluid is drained
remove the bolts.
3. Remove the transmission fluid pan and

transmission fluid pan gasket.

Last updated: 8/2/2004 2005 F-150, 10/2004
IN-VEHICLE REPAIR (Continued)
Installation 3. NOTE: The transmission fluid pan gasket is
reusable. Clean and inspect for damage; if not
1. CAUTION: If installing a new filter damaged, the gasket should be reused.
and the seal remains in the main control Install the transmission fluid pan and gasket.
bore, carefully use a small screwdriver to 1 Position the transmission fluid pan and
remove the seal. Use care not to damage the gasket.
main control bore.
2 Install the transmission fluid pan bolts.
NOTE: If transmission is being repaired for a
contamination-related failure, use a new filter
and seal. The filter may be reused if no
excessive contamination is present.
Install a new fluid filter and seal as required.
4. NOTE: When filling a dry transmission and

converter, start with a minimum of 4.7 liters (5
quarts).
Fill the transmission to the correct level with
clean automatic transmission fluid.
2. Position the pan magnet into the transmission
fluid pan.
2005 F-150, 10/2004

IN-VEHICLE REPAIR
Transmission Filler Tube
Removal and Installation
1. Remove the transmission fluid filler tube bolt

from the side of the RH cylinder head.
3. To install, reverse the removal procedure.
2. Remove the fluid filler tube.

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IN-VEHICLE REPAIR
Main Control Valve Body
Special Tool(s)
Gauge, Transmission Solenoid
Connectors
307-426
Removal
1. Drain transmission fluid and remove the

transmission fluid pan and filter. For additional
information, refer to Fluid Pan, Gasket and
Filter.
2. CAUTION: Do not pull on the molded

lead frame. This may cause damage to the
connector ends. Carefully pry up on the
locking tabs to disconnect the solenoids.
solenoids.
solenoids. 3. Remove the manual control valve detent lever
1 Disconnect the shift solenoid SSA and SSB. spring.
2 Disconnect the torque converter clutch 1 Remove the bolt.
(TCC). 2 Remove the manual control valve detent
3 Disconnect the electronic pressure control lever spring.
(EPC) solenoid.
4 Disconnect the bulkhead inter-connector.

Last updated: 8/2/2004 2005 F-150, 10/2004
4. Remove the 25 valve body-to-case bolts and the
EPC bracket bolt.

Loosely install the 10 long main control valve
5. Remove the main control valve body and body bolts.
discard the pump outlet screen.
Installation 3. NOTE: Lubricate the electronic pressure

control (EPC) solenoid O-rings with clean
1. NOTE: Make sure that the drive pin of the
manual valve detent lever assembly engages the Install the EPC solenoid.
manual valve in the correct location prior to 1 Install the EPC solenoid.
installing the bolts. 2 Install the EPC solenoid bracket and bolt.
Position the main control valve body gasket and
main control valve body using the 2 alignment
bolts as a guide.
2005 F-150, 10/2004

Loosely install the 12 short main control valve
body bolts.
5. Install the manual control valve detent lever

spring.
1 Position the manual control valve detent
lever spring.
2 Install the bolt.

frame.
6. Tighten the main control valve body bolts in

the sequence shown.
2005 F-150, 10/2004

8. Connect the molded lead frame to the
solenoids.
• Connect the bulkhead inter-connector by
seating the connector in place.
• Connect the EPC solenoid by pressing it in
slots.
place. Make sure that the terminals pass
connector slots.
9. Install the transmission filter and pan. For

additional information, refer to Fluid Pan,
Gasket and Filter in this section.
2005 F-150, 10/2004

IN-VEHICLE REPAIR
Extension Housing Gasket
Material
Item Specification
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a 4x4 vehicles

Section 100-02. 4. Remove the transfer case. For additional
4x2 vehicles information, refer to Section 308-07B.
All vehicles
2. NOTE: To maintain initial driveshaft balance,
mark the rear driveshaft yoke and axle flange 5. Use the high-lift jack to support the
so they may be installed in their original transmission.
positions.
Mark the driveshaft flange and the rear pinion 6. NOTE: RH shown, LH similar.
flange for correct alignment during assembly. Remove the 2 bolts retaining the heat shield to
the transmission support crossmember.
3. Remove the rear driveshaft.

1 Remove the 4 bolts.
2 Remove the rear driveshaft.

Last updated: 8/2/2004 2005 F-150, 10/2004
7. Loosen, but do not remove the
transmission-to-crossmember nuts.
11. Remove the 2 bolts, the rear transmission

mount and the exhaust hanger.
8. Remove the 6 crossmember-to-frame nuts and

bolts (3 on each side).
12. Lower the transmission to access the extension

housing bolts.
9. Remove the transmission mount-to-crossmember 13. NOTE: 4x2 shown, 4x4 similar.
nuts and remove the crossmember. Remove the extension housing and gasket.
1 Remove the nuts and bolts.
2 Remove the extension housing and gasket.
X Allow fluid to drain into suitable
container.
5.4L engines
10. Remove the nut from the exhaust bracket.
2005 F-150, 10/2004

Installation
All vehicles
1. NOTE: 4x2 shown, 4x4 similar.

Install the extension housing and a new gasket.
1 Position the extension housing gasket and
the extension housing.
2 Install the bolts and nuts.
5. Position the crossmember and loosely install the

transmission mount-to-crossmember nut.
2. Raise and position the transmission.
3. Position the exhaust hanger, the rear

transmission insulator and install the bolts.
6. NOTE: RH shown, LH similar.

Install the 6 crossmember-to-frame nuts and
bolts (3 on each side).
4. Install the exhaust bracket nut.
2005 F-150, 10/2004

7. Lower the transmission on the crossmember and 4x2 vehicles
tighten the rear mount nuts.
11. NOTE: The output shaft and the driveshaft are
a balanced assembly.
• Align the yellow dots and position the
8. NOTE: 4x2 shown, 4x4 similar.

Remove the high-lift transmission jack.
12. Install the rear driveshaft.

1 Position the driveshaft.
2 Install the 4 bolts.
9. Install the 2 bolts retaining the heat shield to

the transmission support crossmember.
All vehicles
13. Lower the vehicle.
4x4 vehicles
10. Install the transfer case. For additional

information, refer to Section 308-07B.
2005 F-150, 10/2004

14. Fill the transmission with clean automatic
transmission fluid.
• Verify for correct operation.
• Check for leaks.
2005 F-150, 10/2004

IN-VEHICLE REPAIR
Extension Housing Seal
Special Tool(s)
Slide Hammer
100-001 (T50T-100-A)
Remover, Transmission Fluid

Seal
307-048 (T74P-77248-A) 3. Remove the 4 driveshaft bolts.
Installer, Transmission
Extension Housing Fluid Seal
308-002 (T61L-7657-A)
Material
Item Specification
MERCON V Automatic MERCON V 4. Slide the driveshaft back enough to index-mark
Transmission Fluid the driveshaft, the extension housing and the
XT-5-QM output shaft. Separate the driveshaft from the
transmission.
Removal

Section 100-02.
2. NOTE: The output shaft and driveshaft are a

balanced assembly.
Mark the driveshaft flange and the rear pinion
flange for correct alignment during assembly.

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5. Using the special tools, remove the extension 2. NOTE: The output shaft and the driveshaft are
housing seal. a balanced assembly.
• Align all the index marks and position the
• Install the driveshaft.
Installation
1. NOTE: When installing the new seal, make

sure that the drain hole in the seal is in the 6
o’clock position.
Using the special tool, install a new extension 3. NOTE: To maintain driveshaft balance, install
housing seal. the driveshaft yoke and flange in the original
position that was marked during removal.
Install the 4 retaining bolts.
4. Check the level of the transmission fluid, add

clean automatic transmission fluid as necessary.
2005 F-150, 10/2004

IN-VEHICLE REPAIR
Electronic Pressure Control (EPC)
Solenoid
Special Tool(s)
Gauge, Transmission Solenoid
Connectors
307-426
Removal
CAUTION: Do not pull on the molded lead

frame. This may cause damage to the connector
ends. Carefully pry up on the locking tabs to
disconnect the solenoids. Disconnect the molded
lead frame from the solenoids.

Section 100-02.
2. Drain transmission fluid and remove the

information, refer to Fluid Pan, Gasket and 4. Remove the electronic pressure control (EPC)
Filter. solenoid.
1 Remove the EPC solenoid bolt.
3. Disconnect the molded lead frame from the 2 Remove the EPC solenoid.
solenoids.
1 Disconnect the shift solenoid SSA and SSB.
2 Disconnect the torque converter clutch
(TCC).
3 Disconnect the electronic pressure control
(EPC) solenoid.
4 Disconnect the bulkhead interconnector.

Last updated: 8/2/2004 2005 F-150, 10/2004
Installation 3. Connect the molded lead frame to the
solenoids.
1. Install the electronic pressure control (EPC) • Connect the bulkhead interconnector by
solenoid. pressing it in place by hand and fully
1 Install the EPC solenoid. seating the connector in place.
2 Install the EPC solenoid bolt. • Connect the EPC solenoid by pressing it in
slots.
place. Make sure that the terminals pass
connector slots.
frame.
2005 F-150, 10/2004

IN-VEHICLE REPAIR
Manual Control Lever Shaft and Seal 3. NOTE: Index mark the front and rear flange.
NOTE: It is not necessary to remove the front
Special Tool(s) driveshaft from the vehicle.
Alignment Gauge, TR Sensor On 4x4 vehicles, index mark the front and rear
307-351 (T97L-70010-A) flange, disconnect the front driveshaft and
position aside.
Installer, Shift Shaft Fluid Seal

307-050 (T74P-77498-A)
Removal and Installation
CAUTION: Use care not to damage the 4. Loosen, but do not remove the transmission
manual control lever shaft bore. The new seal fluid pan bolts and allow the fluid to drain.
can leak. Once the fluid has drained, remove the bolts.
CAUTION: Discard the outer manual

control lever nut.
NOTE: When removing the manual control lever

shaft retaining pin, use a soft cloth to protect the
surface of the case.

Section 100-02.
2. On 4x4 vehicles, remove the front driveshaft

shield nuts and remove the shield.
5. Remove the transmission fluid pan and gasket.

Last updated: 8/2/2004 2005 F-150, 10/2004
6. Disconnect the digital transmission range (TR)
electrical connector.
10. Remove the manual control valve detent lever

spring.
7. Disconnect the shift cable end. lever spring bolt.
lever spring.
8. Remove the manual control lever.

1 Remove the manual control lever nut.
2 Remove the manual control lever. 11. Remove the manual shaft retaining pin.
9. Remove the digital TR sensor.

1 Remove the 2 retaining bolts.
2 Remove the digital TR sensor.
2005 F-150, 10/2004

12. Remove the inner manual control lever shaft
nut and slide the manual control lever shaft out
of the case.
3. Install the manual control lever shaft.

1 Install the manual control lever shaft.
2 Install the inner manual control lever shaft
13. Remove the manual control lever shaft seal. and nut.
3 Install the manual valve detent lever spring
bolt.
Installation
1. Using the special tool, install the manual 4. Install the manual valve detent lever spring.
control lever seal. 1 Install the manual valve detent lever spring.
2 Install the manual valve detent lever spring
bolt.
2. Install the manual valve detent lever into the

manual valve.
2005 F-150, 10/2004

5. Install the digital TR sensor. 8. Install the manual control lever.
1 Install the digital TR sensor. 1 Position the manual control lever.
2 Loosely install the bolts. 2 Install a new manual control lever nut.
6. NOTE: The manual lever must be in the 9. Connect the shift cable end to the manual lever
NEUTRAL position. with the lever in the (D) position.
10. Instal the digital TR sensor electrical connector.

Tighten the digital TR sensor bolts.
2005 F-150, 10/2004

11. Position the pan magnet into the transmission 14. On 4x4 vehicles, install the front driveshaft and
fluid pan. align the index marks made during removal.
12. NOTE: The transmission fluid pan gasket is 15. Install the front driveshaft shield and install the
reusable. Clean and inspect for damage. If not 2 nuts.
damaged, the gasket should be reused.
Install the transmission fluid pan and gasket.
1 Position the transmission fluid pan gasket.
2 Position the transmission fluid pan.
13. Install the transmission fluid pan bolts.
2005 F-150, 10/2004

16. NOTE: Start by filling the transmission with
4.7 liters (5 quarts) of clean automatic
transmission fluid.
Fill the transmission to the correct level with
clean automatic transmission fluid.
2005 F-150, 10/2004

IN-VEHICLE REPAIR
Digital Transmission Range (TR)
Sensor
Special Tool(s)
307-351 (T97L-70010-A)
Item Part Number Description Removal

1 14A464 Digital TR sensor electrical
connector NOTE: Manual shift lever must be in the
2 — Transmission shift cable end NEUTRAL position.
(part of 7E395)
3 N808737-S427 Manual control lever outer
nut hoist. For additional information, refer to
Section 100-02.
4 7A256 Manual control lever
5 N806933-S102 Digital TR sensor bolts
6 7A247 Digital TR sensor

Last updated: 8/2/2004 2005 F-150, 10/2004
2. Disconnect the digital TR electrical connector.
5. Remove the digital TR sensor bolts and the

digital TR sensor.
3. CAUTION: Do not pry on the swivel
tube to disconnect the transmission shift
linkage.
Disconnect the manual control lever shift
control cable.
Installation
1. Install the digital TR sensor and loosely install

the bolts.
4. CAUTION: Discard the outer manual

control lever shaft nut. Do not reuse the nut.
Remove the manual control lever.
1 Remove the nut.
2 Remove the lever.
2005 F-150, 10/2004

2. Using the special tool, align the digital TR
5. With the manual control lever in NEUTRAL,

connect the shift control cable.

Tighten the bolts.
6. Install the digital TR electrical connector.

1 Install the lever.
2 Install a new nut.
2005 F-150, 10/2004

IN-VEHICLE REPAIR
Reverse Servo Assembly 3. Remove the reverse servo assembly.
1 Remove the reverse band servo cover.
Special Tool(s) 2 Remove the reverse band servo piston and
Dial Indicator Gauge with rod.
Holding Fixture 3 Remove the reverse band servo spring.
100-002 (TOOL-4201-C)

307-251 (T92P-70023-A)
Installer, Servo Piston

307-073 (T80L-77030-A)
Installation
NOTE: This is not an ordinary installation

procedure and does not compensate for band wear.
1. NOTE: Lubricate the reverse piston seal to

Removal facilitate assembly and prevent damage to the
seal.
1. Remove the main control valve body. For Install the reverse servo return spring and
additional information, refer to Main Control piston.
Valve Body in this section. • Do not install the piston cover.
2. Using the special tool, remove the reverse band
servo retaining ring.
1 Compress the servo spring.
2 Remove the reverse band servo retaining
ring.

Last updated: 8/2/2004 2005 F-150, 10/2004
2. Install the special tool and tighten the band
apply bolt.
6. If piston travel is not within specification, select

and install the correct servo piston assembly to
bring the servo piston travel within
3. Attach the special tool to the transmission. specification.
• Position the indicator stem on the flat 1 One groove
portion of the reverse servo piston and zero 2 Two groove
the dial indicator.
3 Three groove
4. Loosen the bolt until the piston stops against

the tool. 7. Remove the dial indicator and servo selection
tool.
5. Verify that the amount of piston travel on the

dial indicator is within specification.
2005 F-150, 10/2004

8. Install the correct reverse servo assembly. 9. Using the special tool, install the reverse servo
1 Install the reverse band servo spring. retaining ring.
2 Install the reverse band servo piston and 1 Compress the servo spring.
rod. 2 Install the reverse band servo retaining ring.
3 Install the reverse band servo cover.
10. Install the main control valve body. For

additional information, refer to Main Control
Valve Body in this section.
2005 F-150, 10/2004

IN-VEHICLE REPAIR
Overdrive Servo
Special Tool(s)
307-251 (T92P-70023-A)
Removal
Installation
hoist. For additional information, refer to 1. Install the overdrive servo piston assembly.
Section 100-02.
1 Install the overdrive servo piston return
2. Remove the main control valve body. For spring.
additional information, refer to Main Control 2 Install the overdrive servo piston assembly.
3. NOTE: If the tool is not available, extreme

care must be taken. Spring pressure will force
overdrive servo piston assembly out of case.
Case bore damage may result from trying to pry
on overdrive servo internal retaining ring.
Using the special tool, compress the servo
spring to remove the overdrive servo retaining
ring.
2. Use the special tool to install the overdrive

servo piston retaining ring.
4. Remove the overdrive servo piston and return

spring.

Last updated: 8/2/2004 2005 F-150, 10/2004
IN-VEHICLE REPAIR
1-2 Accumulator Installation
Removal 1. Install the 1-2 shift accumulator assembly.

1 Install the 1-2 accumulator upper spring.
1. With the vehicle in NEUTRAL, position it on a 2 Install the 1-2 accumulator piston.
3 Install the 1-2 accumulator inner and outer
Section 100-02.
springs.
2. Drain transmission fluid and remove the 4 Install the 1-2 accumulator cover.
information, refer to Fluid Pan, Gasket and
Filter.
3. Compress the 1-2 accumulator piston and

remove the accumulator piston retaining ring.
4. Remove the 1-2 shift accumulator assembly.

1 Remove the 1-2 accumulator cover.
2 Remove the 1-2 accumulator inner and
outer springs.
3 Remove the 1-2 accumulator piston.
4 Remove the 1-2 accumulator upper spring.

Last updated: 8/2/2004 2005 F-150, 10/2004
2. Compress the 1-2 accumulator piston and
remove the accumulator piston retaining ring.
2005 F-150, 10/2004

IN-VEHICLE REPAIR
2-3 Accumulator Installation
Removal 1. Install the 2-3 accumulator assembly.

1 Install the accumulator piston.
1. Remove the main control valve body. For 2 Install the accumulator piston spring.
3 Install the accumulator spring retainer.
2. Remove the 2-3 accumulator piston retainer.
2. Install the main control valve body. For

3. Remove the accumulator piston and spring. Valve Body in this section.

Last updated: 8/2/2004 2005 F-150, 10/2004
IN-VEHICLE REPAIR
Transmission Insulator and Retainer Installation
Removal 1. Install the rear transmission mount and the

bolts.
Section 100-02.
2. Remove the rear transmission support nuts.
2. Lower the transmission onto the crossmember

and install the nuts.
3. Install a suitable transmission jack.
4. Slightly raise the rear of the transmission and

remove the bolts. Remove the rear transmission
mount.

Last updated: 8/2/2004 2005 F-150, 10/2004
IN-VEHICLE REPAIR
Speed Sensors
NOTE: Only remove the affected sensor.

1 — Output shaft speed (OSS) 6 7M101 Turbine shaft speed (TSS)
sensor electrical connector sensor
2 N605771-S427 Output shaft speed (OSS)
sensor bolt Removal and Installation
3 7H103 Output shaft speed (OSS)
sensor 1. With the vehicle in NEUTRAL, position it on a
4 — Turbine shaft speed (TSS) hoist. For additional information, refer to
sensor electrical connector Section 100-02.
5 W700005-S309 Turbine shaft speed (TSS)
sensor bolt 2. To install, reverse the removal procedure.
(Continued)

Last updated: 8/2/2004 2005 F-150, 10/2004
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PowerView
Model PV-101-C
User’s Guide
Version 3.2
08-08-11 00-02-0796
Catalog Section 78
Table of Contents
Introduction............................................................................. 1
Engine and Transmission Parameters ................................................................. 2
Faceplate Features .............................................................................................. 3
Navigation and Keypad Functions ....................................................................... 4
First Time Start Up ................................................................. 8
Main Menu Options .............................................................. 11
Go to 1-Up Display/Go to 4-Up Display.............................................................. 11
DPF Regen* ...................................................................................................... 11
Selecting a Language ........................................................................................ 14
Stored Codes ..................................................................................................... 14
Engine Configuration ......................................................................................... 14
Setup 1-Up Display ............................................................................................ 15
Setup 4-Up Display ............................................................................................ 17
Service Reminders ............................................................................................ 20
Select Units ....................................................................................................... 22
Backlight Adjustment ......................................................................................... 22
Contrast Adjustment .......................................................................................... 22
Utilities Menu ........................................................................ 23
Gage Data ......................................................................................................... 23
Remove All Gages ............................................................................................. 23
Software Version ............................................................................................... 23
Fault Conversion................................................................................................ 24
Analog Input ...................................................................................................... 25
Engine Speed Control ........................................................................................ 25
OEM Menu ............................................................................. 27
MODBUS Setup .............................................................................................. 27
CANBUS Data Rate........................................................................................... 28
Select Engine ECU ............................................................................................ 29
Set Source Address ........................................................................................... 30
Restore All Defaults ........................................................................................... 30
Clear Machine Hours ......................................................................................... 30
Set Machine Hours ............................................................................................ 30
Clear Fault Codes .............................................................................................. 31
Fuel Setpoints .................................................................................................... 31
DPF Regen Menu ON/OFF................................................................................ 32
ENG SPD CTRL Menu ON/OFF ........................................................................ 32
Faults and Warnings............................................................ 33
Auxiliary Gage Fault .......................................................................................... 34
Active Fault Codes............................................................................................. 34
Derate / Shutdown Codes .................................................................................. 35
Acknowledging Fault Codes .............................................................................. 36
Troubleshooting ................................................................... 37
In order to consistently bring you the highest quality, full
featured products, we reserve the right to change our
specifications and designs at any time. The latest version of
this manual can be found at www.fwmurphy.com.
Warranty - A limited warranty on materials and

workmanship is given with this FW Murphy product. A copy
of the warranty may be viewed or printed by going to
www.fwmurphy.com/warranty
BEFORE BEGINNING INSTALLATION OF THIS
MURPHY PRODUCT:
 Disconnect all electrical power to the machine.
 Make sure the machine cannot operate during
installation.
 Follow all safety warnings of the machine
manufacturer.
 Read and follow all installation instructions.
Introduction
Congratulations on purchasing your PowerView display, a
multifunction tool that provides a window into the many
parameters and service codes of modern electronic engines
and transmissions.
This guide is intended to help you set up your PowerView

display and identify navigation basics and product features.
The display’s simple navigation and powerful features allow
you to quickly master the product.
Additional information, and documents referenced in this

manual, can be found on our website at
www.fwmurphy.com/pv101/.
00-02-0796 -1- 08-08-11

Engine and Transmission Parameters
The following are some of the engine and transmission
parameters which can be displayed in standard or metric
units as well as in English, Spanish, French, Italian or
German languages (when applicable, consult engine or
transmission manufacturer for SAE J1939 supported
parameters):
 Engine RPM  Transmission oil

 Engine hours pressure
 System voltage  Transmission oil
 Percent engine load at temperature
current RPM  Transmission gear
 Coolant temperature position
 Oil pressure  Engine
 Fuel economy configuration
 Throttle position parameters
 Engine manifold air  Active fault codes
temperature  Stored fault codes
 Current fuel consumption
00-02-0796 -2- 08-08-11

Faceplate Features
00-02-0796 -3- 08-08-11

Navigation and Keypad Functions
The keypad on the PowerView display is a capacitive touch
sensing system. There are no mechanical switches to wear
or stick. The keys on the keypad perform the following
functions:
Menu – Enter or exit menu screens.
Left Arrow – Scroll the screen or move

the parameter selection to the left or
upward.
Right Arrow – Scroll the screen and
move the parameter selection to the right
or downward.
Enter Key – Select a menu or parameter

or hide/view an active fault code.
00-02-0796 -4- 08-08-11

Basic Navigation
1. When Menu is touched, the Main menu items display.
2. Touch the Arrow Keys to move the selection bar to

other menu items.
00-02-0796 -5- 08-08-11

3. Some menus have multiple pages. Scroll to the top or
bottom item on the current page to see other menu
items on additional pages.
00-02-0796 -6- 08-08-11

4. When the desired item is highlighted by the cursor,
touching Enter selects that item and displays the
corresponding screen.
00-02-0796 -7- 08-08-11

First Time Start Up
1. When power is first applied to the display, the Murphy
logo is displayed.
NOTE: Expect a 20-minute warm up for the

display with temperatures at or below
o o
-29 C/-20 F.
00-02-0796 -8- 08-08-11

2. If the Engine ECU is broadcasting a ‘Wait to Start'
message, the screen below is shown. Engine
manufacturers typically recommend against starting the
engine while this message is showing. Once the ECU
stops broadcasting the message, this screen is no
longer displayed.
00-02-0796 -9- 08-08-11

3. Once the engine has started, the single engine
parameter is displayed with the engine RPM. Touching
the Right Arrow Key displays the coolant temperature.
The screen can be changed to other parameters by
touching Menu.
00-02-0796 - 10 - 08-08-11
Main Menu Options
This section describes the features listed on the Main menu
of the PowerView. These menu options display whenever
you touch Menu. The Arrow Keys allow you to scroll
through items. Enter selects the highlighted option.
Go to 1-Up Display/Go to 4-Up Display

If you want to go to a different display, touch Enter. The
alternate view is displayed.
DPF Regen*
*Murphy products are compliant with requirements for U.S. EPA Emission
Standard ‒ Tier 4 Interim and EU Emissions Standard ‒ Stage IIIB for
diesel engines. These engines when fitted with a DPF (Diesel Particulate
Filter) can self-clean the filter of particulates. This self-cleaning is known as
Regeneration. PowerView offers 3-CAN options when DPF REGEN is
enabled and available in the engine ECU. For more information, find
document # 1110836 on the Murphy Web site (www.fwmurphy.com).
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Unless selected in the OEM Menu, DPF REGEN does not
display in the Main Menu. When available, the following
options are presented:
1. AUTO DPF REGEN – This is the factory default. Select

and PowerView sends a CAN message to the ECU to
perform DPF Regeneration (regen) automatically
whenever needed.
2. REQUEST DPF REGEN – Select this and a second
screen, REQUEST DIESEL PARTICULATE FILTER
REGEN, displays. Use this to force a regen when auto-
regen is not due or is inhibited by PowerView. Touch
YES (Enter) and PowerView sends a request for a
regen every second for 10 seconds. If the engine does
not respond, PowerView defaults back to Auto DPF
Regen. You may send the request again or exit without
sending a request by touching CANCEL (Menu). You
return to the Main menu.
3. INHIBIT DPF REGEN – In cases where regen cannot
be performed due to restrictions, select this to eliminate
the possibility of a regen occurring. The inhibit lamp
displays when the engine ECU responds to this inhibit
request from PowerView. Once this option is selected, it
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remains in place through power cycles. When inhibit is
no longer needed, you can select a different option.
The following ISO symbols indicate regen status. In each
case, the symbol displays when the parameter’s lamp status is
broadcast from the ECU back to the PowerView.
DPF Regen ISO Symbols

Icon PGN SPN Description
64892 3697 High Exhaust Temperature
(HEST) lamp indicates
regeneration in process.
64892 3703 DPF Particulate Filter Restricted
lamp indicates a Regen is
needed.
64892 3698 DPF Inhibit lamp indicates an

inhibited Regen status.
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Selecting a Language
From LANGUAGES, you may select ENGLISH, ESPANOL,
FRANCAIS, ITALIANO, or DEUTSCH. An asterisk to the
right of the language indicates it is selected.
Stored Codes
Select this and PowerView requests and displays stored
fault codes from the engine ECU. If the engine does not
support this function, a “Timeout ECU Not Responding”
message displays.
Engine Configuration
This allows you to scroll through and view the engine’s
configuration data. If the engine does not support this
function, a “No Engine Configuration Data” message
displays.
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Setup 1-Up Display
Touch Menu and use the Arrow Keys to highlight SETUP
1-UP DISPLAY, and then touch Enter. Three options are
available for modification of the 1-Up display:
1. Use Defaults – This option contains a set of engine
parameters: Engine Hours, Engine RPM, System
Voltage, Battery Voltage, % Engine Load at Current
RPM, Coolant Temperature, and Oil Pressure.
To select USE DEFAULTS, highlight the option and
touch Enter. A message indicating “RESTORED TO
DEFAULTS” is displayed.
2. Custom Setup – In this option, select the parameters

and order in which they will be displayed. The list is
long; continue to scroll until you have seen all available
parameters. To select Custom Setup, highlight and
touch Enter. A list of engine parameters displays.
NOTE: The PV101 must see the parameter being broadcast

over J1939 in order to select the parameter from the list.
To select a parameter, use the Arrow Keys to scroll

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and highlight the parameter, then touch Enter.
Selected parameters are indicated by a number to the

right of it. The numbers represent the order in which the
parameters will be displayed.
To deselect a parameter and remove it from the list of

displayed parameters, highlight the parameter and
touch Enter.
Continue to scroll and select additional parameters for

the CUSTOM 1-UP DISPLAY. Touch Menu at any time
to return to the CUSTOM SETUP menu.
3. Automatic Scan – (Default is OFF) Selecting the
AUTOMATIC SCAN ON function will cause the 1-up
display to scroll through the selected set of parameters
one at a time.
Once the Use Defaults, Custom Setup and Automatic
Scan functions are set, touch Menu once to return to the
Main menu, or twice to display the 1-up display screen.
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Setup 4-Up Display
There are two 4-up display screens available. Each option
can place parameter data into one of four areas on the
screen known as quadrants. ▪ Factory defaults for the first
4-up display includes coolant temperature, engine speed, oil
pressure, and battery voltage. ▪ Factory defaults for the
second 4-up display includes DEF (diesel exhaust fluid)
Level, DPF (diesel particulate filter) active regen status,
exhaust filter inlet temperature, and exhaust filter outlet
temperature. You can customize each 4-up display with the
parameter you define for each quadrant.
1. Touch Menu and use the Arrow Keys to highlight

SETUP 4-UP DISPLAY, and touch Enter.
2. To select USE DEFAULTS, highlight the option and

touch Enter. A message indicating “RESTORED TO
DEFAULTS” is displayed, the default parameters listed
above will be displayed.
3. To select CUSTOM SETUP, highlight the option and

touch Enter. The 4-up display appears.
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4. Use the Arrow Keys to switch between the two 4-up
displays.
5. To edit a 4-up display, touch Enter while that 4-up
displays on screen.
6. Use the Arrow Keys to select which quadrant to edit.
7. Once you select a quadrant, touch Enter and you move
to a list of parameters.
NOTE: The PowerView must see the parameter being
broadcast over J1939 in order to select the parameter from
the list.
8. The parameter highlighted is the selected parameter for

the screen. The number to the right of the parameter
indicates in which quadrant it displays.
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1 = upper left 3 = upper right
quadrant quadrant
2 = lower left 4 = lower right

quadrant quadrant
9. Use the Arrow Keys to highlight the new parameter to

be placed in the selected quadrant. Touch Enter.
10. Touch Menu to return to the SETUP 4-UP CUSTOM

SETUP screen.
11. The parameter in the selected quadrant has changed to

the parameter selected in the previous screen.
12. Repeat the parameter selection process until you fill all
quadrants.
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Service Reminders
SERVICE REMINDERS permit you to RESET REMINDERS
or MODIFY REMINDERS for changing engine oil, air filters,
and hydraulic oil or for servicing the engine and/or machine.
NOTE: Service Reminders are internal reminders within
PowerView. Once a Service Reminder is active, warnings
will show SPN 916 and FMI 17. Check PowerView Service
Reminders prior to calling Technical Support.
1. Use the Arrow Keys to highlight Service Reminders

and touch Enter.
2. The Service Reminders options display. Use the

Arrow Keys to select either Reset Reminders or
Modify Reminders, and then touch Enter.
3. If you select Reset Reminders, use the Arrow Keys to

highlight the Reminder you wish to edit. Touch Enter.
4. The Reminder name appears at the top of the screen.

The action (ON or OFF) displays mid-screen, and two
choices display at screen bottom. Touch Menu to
Cancel the action. Touch Enter to choose Reset.
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5. If you select Modify Reminders, use the Arrow Keys
to highlight the Reminder to modify and touch Enter.
6. The Reminder name appears at top screen. The hour

value displays mid-screen and allows you to set the
number of hours to elapse before a Reminder prompts.
Bottom screen shows Cancel and Save. Touch Cancel
to discard changes and return to Reminders list.
7. Use the right Arrow Key to increment the highlighted

number. Use the left Arrow Key to move to the next
number space.
8. Touch Save. The Modify Service Reminder screen

displays. Touch YES to save or NO to return to the
Reminders list.
9. A modified Reminder displays a (+) at right of

Reminder name when successfully completed. Follow
the above steps to modify other Reminders.
When finished, touch Menu to return to the Main Menu.
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Select Units
From SELECT UNITS, you may select how information is
displayed:
▪ ENGLISH for Imperial units (PSI, F)
▪ METRIC KPA
▪ METRIC BAR for IS units (kPa, Bar, C).
Backlight Adjustment
ADJUST BACKLIGHT – Use the Arrow Keys to brighten or
darken the backlight intensity.
Contrast Adjustment
ADJUST CONTRAST – Use the Arrow Keys to lighten or
darken the text and graphics.
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Utilities Menu
UTILITIES is the last item on the Main Menu. The Utilities
menu provides troubleshooting features and other
information about the PowerView configuration.
Gage Data
View data for optional connected PVA gages. When Slave
Active is enabled, gage data is not available.
Remove All Gages

Reset the gage memory on the PowerView. When Slave
Active is enabled, this function is not available.
Software Version
This screen lists Configuration, Firmware, Languages, and
Bootloader versions for this PowerView unit. You may need
this information if requesting assistance from Technical
Support.
00-02-0796 - 23 - 08-08-11
Fault Conversion
View/Edit the J1939 fault code version. Use the Arrow
Keys to move between Versions, and then touch Enter to
select a version.
NOTE: There are four methods for converting fault

codes. The PowerView always looks for J1939-Version
4.
However, PowerView can be set to read one of three
other J1939 versions, if Version 4 is not
used/unavailable. Most ECU’s use Version 4, so
adjustment of this menu option is rarely required.
Upon receiving an unrecognizable fault, change to a

different J1939 Version in the list. If the fault SPN does not
change when the version is changed, the ECU generating
the fault is using Fault Conversion Method 4. If the SPN
number does change, but is still unrecognizable, try
changing to another unused J1939 Version and continue to
check the SPN number.
00-02-0796 - 24 - 08-08-11
Analog Input
With Analog Input highlighted, press Enter. You can select
between two settings:
1) BACKLIGHT DIMMER, this is in factory default
upon first use. The unit accepts an optional
backlighting dimmer (0-1k Ω potentiometer).
2) FUEL LEVEL, touch Enter to reach SET LOW
FUEL LEVEL screen. Then, touch Enter to reach
LOW FUEL % screen. Use the right Arrow Key to
increase, and left Arrow Key to decrease the
percentage of remaining fuel at which to send a
warning. The default is 20%.
NOTE: The PowerView accepts optional Murphy
fuel sender (recommend Model ES2F) for fuel level
information. A custom setup for a non-Murphy fuel
sender is available. For more information, see
FUEL SETPOINTS, page 31 (OEM Menu).
Engine Speed Control

This option must be ON in the OEM Menu for functionality
to be available from the Utilities Menu.
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1) From the Engine Speed Control screen, touch Enter
to reach the Speed Control screen.
2) To change the setting of the engine speed via TSC1;
use the right Arrow Key to increase or left Arrow key
to decrease the throttle setting.
3) Once the target speed is reached, select ENABLE
(Enter) to turn ON the TSC1 throttling control. (Use
Disable to turn throttling control OFF and discard changes).
NOTE: Once enabled Engine Speed Control will stay

enabled even through power cycles. To turn OFF, you must
disable the feature from the SPEED CTRL screen.
00-02-0796 - 26 - 08-08-11
OEM Menu
The OEM menu is the last item on the Utilities menu. You
must have a password to access the OEM menu. Once in
the OEM Menu, select an item by highlighting it and touch
Enter to reach additional screens.
ENTER PASSWORD screen – Enter 3482 in the numeric

spaces provided. Start at the furthest left numeric value and
use the Left Arrow Key to increment the number and the
Right Arrow Key to move to the next numeric position. If
the Murphy standard key does not work, contact the OEM
from whom the engine or machine was purchased. If you
have access, the password is user changeable via the
PV101-C Config Tool application.
The following items are in the OEM Menu.
MODBUS Setup
To set the MODBUS, highlight MODBUS SETUP and touch
Enter.
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1) There are four selections: Use Factory Defaults,
Serial Port Setup, Slave Address Setup, and Master
Active/Slave Active. You can toggle between Slave
Active (which is SCADA/remote Modbus master)
and Master Active (which is Auxiliary gages).
Highlight your selection and touch Enter.
2) If in Slave Active, select SERIAL PORT SETUP
and touch Enter.
3) Scroll through the Serial Port Setup list and make
selections for BAUD RATE, PARITY, DATA BITS,
and STOP BITS to configure the serial port
parameters for your Modbus slave application.
CANBUS Data Rate

Touch Enter to reach the six CANBUS data rates. Use the
Arrow Keys to highlight your choice and touch Enter to
make the selection.
00-02-0796 - 28 - 08-08-11
Select Engine ECU
Highlight Select Engine ECU and touch Enter.
1) The message “LISTEN TO ECU: ALL” displays as
the default setting. This message indicates the
PV101 is listening to all devices on the network.
2) To change the setting to a specific address, touch
the Arrow Keys to scroll through the selections (0-
253, and ALL).
3) Once the target address displays, touch Enter.
4) A confirmation screen displays; selecting NO
(Menu) returns to the SELECT ENGINE ECU
screen. Selecting YES (Enter) stores the selected
address and returns to the OEM menu.
00-02-0796 - 29 - 08-08-11
Set Source Address
Allows setting the source claim address for the PowerView
on the CAN Network. Options are Auto Claim or 0 to 253.
Restore All Defaults

PowerView automatically resets after the restore defaults
is complete. RESTORING ALL FACTORY DEFAULTS
displays when this is selected.
Clear Machine Hours

Use this to clear machine hours internal to PowerView
outside of ECU hours.
Set Machine Hours

Machine hours calculate internally when the RPM is greater
than 50 and the engine is not broadcasting hours. Use this if
you want to track hours for just the machine.
00-02-0796 - 30 - 08-08-11
Clear Fault Codes
Use this to clear stored fault codes in the ECU. This action
should only be performed by a qualified service
technician.
Fuel Setpoints
Highlight and touch Enter to select Fuel Setpoints.
1) Touch Enter to turn Fuel Setpoints ON or OFF.
2) Choose Set Empty Setpoint, Set Fuel Setpoint,
Show Fuel Setpoints, Clear Fuel Setpoints, or
choose to set ¼, ½ and ¾ fuel points.
Fuel Setpoints must be ON to work with a non-Murphy fuel

sender. Modifying fuel setpoints is a complex process. To
configure for a Murphy Fuel Sender or program for a non-
Murphy Sender, find document #1110833, PowerView –
Model PV101-C V3.2 Fuel Sender Calibration on the FW
Murphy Web site at www.fwmurphy.com/pv101.
00-02-0796 - 31 - 08-08-11
DPF Regen Menu ON/OFF
Highlight and touch Enter to turn this option ON or OFF.
Turn this option ON to have it available in the Main menu or
OFF for no availability in the Main menu.
ENG SPD CTRL Menu ON/OFF

This option must be ON in the OEM Menu for functionality
to be available in the Utilities Menu. Highlight and touch
Enter. The Speed Control can be Enabled (ON) or Disabled
(OFF).
00-02-0796 - 32 - 08-08-11
Faults and Warnings
The PowerView provides two means for detecting faults and
warnings: visual LEDs on the casing (Amber in the upper
left corner, and Red in the upper right corner) and fault
indicators on the display.
Visual Indication
 Amber LED (Warning)
 Red LED (Derate / Shutdown)
Fault Indicators
00-02-0796 - 33 - 08-08-11
Auxiliary Gage Fault
Murphy PVA Gages can be attached to the PowerView. If
an auxiliary gage should fail, the 1-up or 4-up display will be
replaced with a fault message: GAGE NOT RESPONDING.
NOTE: A fault can only be cleared by correcting the cause

of the condition (See Troubleshooting in this document).
Active Fault Codes

When the PowerView receives a fault code from an engine,
the 1-up or 4-up display is replaced with the active fault
codes message. See following fault example:
00-02-0796 - 34 - 08-08-11
Example: Active Fault Code screen
Derate / Shutdown Codes

When the PowerView receives a severe fault code from an
engine control unit the 1-up or 4-up display is replaced with
the SHUTDOWN message.
00-02-0796 - 35 - 08-08-11
Acknowledging Fault Codes
1. To acknowledge and hide the fault and return to the
1-up or 4-up display, touch Enter. The display will
return to the 1-up or 4-up display, but the display will
contain the warning or shutdown icon.
2. Touch Enter to redisplay the hidden fault. Touch Enter

once again hides the fault and returns the screen to the
1-up or 4-up display.
00-02-0796 - 36 - 08-08-11
Troubleshooting
 WAIT TO START PREHEATING is displayed
The ECU is broadcasting a 'Wait to Start' message. Engine
manufacturers typically recommend against starting the
engine while the ECU is broadcasting this message. Once
the ECU stops broadcasting this message, this screen will
no longer be displayed on the PowerView.
 CANBUS FAILURE is displayed

The PowerView has not received any valid J1939 CAN
messages for at least 30 seconds. Check wiring, CANBUS,
termination resistors, and Engine ECU address in the OEM
Menu.
 TIMEOUT ECU NOT RESPONDING is displayed

The PowerView sent a request to the ECU for Stored Fault
Code (DM2) information, and the ECU did not respond to
the request. This message on the PowerView indicates the
ECU may not support Stored Fault Code (DM2) functionality
over J1939.
00-02-0796 - 37 - 08-08-11
 NO STORED CODES is displayed
The PowerView sent a request to the ECU for Stored Fault
Code (DM2) information. The ECU responded: There are
zero stored codes.
 NO GAGE DATA is displayed

The PowerView has no record of gages connected to the
RS485 bus.
 NO DATA is displayed in place of a parameter value

The PowerView has not received data for the selected
parameter for at least 5 seconds.
 NOT SUPPORTED is displayed in place of a parameter

value
This means the data received for this parameter is not valid
or not supported.
00-02-0796 - 38 - 08-08-11
 DATA ERROR is displayed in place of a parameter
value
The ECU is sending a message that there is a data error
with this parameter. Alternatively, (PV101 only) FUEL
LEVEL has been selected for display, ANALOG INPUT has
been set to FUEL LEVEL, but no Murphy Fuel Sender has
been connected to the analog input.
 One of the 4-UP quadrants is empty

No parameter has been selected for display in this
quadrant.
 Display is not readable, either very dim or very dark

The LCD contrast may have been over or under adjusted.
Press and hold the MENU key for approximately 5 seconds.
This will reset the LCD contrast setting to factory default.
 PVA Gages not working

When PVA Gages are connected and do not seem to work, go
to the Utilities menu and select Remove all Gages.
00-02-0796 - 39 - 08-08-11
IMPORTANT!
Before returning your PV101 for Warranty, please

call our Technical Support team to further trouble-
shoot any issues.
(918) 317-4100
NOTES
00-02-0796 - 40 - 08-08-11
Murphy, the Murphy logo, and PowerView are registered and/or
common law trademarks of Murphy Industries, LLC. This
document, including textual matter and illustrations, is copyright
protected by Murphy Industries, Inc., with all rights reserved. (c)
2011 Murphy Industries, LLC. Other third party product or trade
names referenced herein are the property of their respective
owners and are used for identification purposes only.
www.fwmurphy.com/pv101

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MODEL MR

MID-RANGE TOW TRACTOR

NOTE: The information contained in this publication is intended exclusively

NOTE: The information contained in this document is intended to be

City: State: Zip Code:

Date of original publication: March 2012

Revision Number Date Brief Description

LIST OF EFFECTIVE PAGES

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

1-4- 1 Orig 2-2- 1 Orig

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

Chapter-Section Page Revision Chapter-Section Page Revision

MANUAL TABLE OF CONTENTS

SAFETY ............................................................................................................................... SAFETY-i

Chapter 1: General Information and Operating Instructions

H. Air Intake System ................................................................................................. 1-1-4

SECTION 2: OPERATION .......................................................................................................... 1-2-1

7. Power Steering Reservoir ....................................................................... 1-2-19

SECTION 3: SPECIFICATIONS ................................................................................................. 1-3-1

D. Drive Axle ............................................................................................................. 1-3-2

SECTION 4: SHIPPING .............................................................................................................. 1-4-1

SECTION 5: STORAGE ............................................................................................................. 1-5-1

4. Lubrication ................................................................................................ 1-5-2

SECTION 1: SERVICING ........................................................................................................... 2-1-1

SECTION 2: TROUBLESHOOTING ........................................................................................... 2-2-1

E. Electrical Schematics ......................................................................................... 2-2-11

SECTION 3: REMOVAL/INSTALLATION................................................................................... 2-3-1

(a) Removal ........................................................................................ 2-3-9

(a) Removal ...................................................................................... 2-3-21

(a) Removal ...................................................................................... 2-3-32

(b) Installation ................................................................................... 2-3-41

(a) Removal ...................................................................................... 2-3-51

2. Oil Cooler (Deutz) ................................................................................... 2-3-61

8. Oil Filter Element .................................................................................... 2-3-92

1. Axle Assembly ...................................................................................... 2-3-108

(i) Brake Hose Removal/Installation .............................................. 2-3-125

SECTION 2: FRONT (STEER) AXLE ......................................................................................... 3-2-1

Chapter 4: Illustrated Parts List

SECTION 2: ILLUSTRATED PARTS LIST ................................................................................ 4-2-1

Figure 2-37. Drain Plugs. Rear ( Drive ) Axle .................................................... 4-2-78

Figure 2-74. Oil Cooling System (Kubota) ....................................................... 4-2-152

SECTION 3: NUMERICAL INDEX .............................................................................................. 4-3-1

SECTION 4: ALPHABETICAL INDEX ....................................................................................... 4-4-1

SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS ................................................ 5-2-1

This manual is copyrighted as an unpublished work.

© Copyright 2007 by TUG Technologies Corporation. All rights reserved.

TUG TECHNOLOGIES CORPORATION

If applicable, enter your company identification number

TUG Technologies Corporation

TUG Technologies Corporation

AIRCRAFT GROUND SUPPORT EQUIPMENT

IN THE EVENT OF A FAILURE

TUG Technologies Corp.

HOW TO USE THIS MANUAL

SAFETY NOTES THAT MUST BE FOLLOWED TO AVOID SERIOUS

SAFETY NOTES THAT NEED TO BE FOLLOWED TO PREVENT

Note Relevant information for the reader, that is not hazard-related.