HTACL O&Amp M Manual 2012 0831

Operation & Maintenance
Manual
GM 3.0L and 4.3L Gasoline and LPG Powered
Towing Tractor
HTCBACL SDW
Draw Bar Capacity:
3,000 – 6,500 Lbs. (13-29 kN)
HTACLL DDW
Draw Bar Capacity:
7,500 – 10,000 Lbs (33-44 kN)
Revised: August 31, 2012

Harlan Towing Tractor HTAL Series
Harlan Global Manufacturing

27 Stanley Road
Kansas City, KS 66115
Phone Numbers
USA............................................................................800 255-4262
Canada........................................................................800 767-4275
Direct..........................................................................913 342-5650
Fax..............................................................................913 321-5802
Department Extensions
Sales ...........................................................................913 981-0375
Warranty ....................................................................913 981-0407
Non-Warranty Technical Support..............................913 981-0402
Parts and Service Manual Feedback ..........................913 981-0361
e-Mail:
General:......................................................................info@harlan-corp.com
Parts and Service Manuals .........................................pubs@harlan-corp.com
Sales: ..........................................................................sales@harlan-corp.com
Warranty: ...................................................................warranty@harlan-corp.com
Note: To facilitate receipt of updates and corrections to this manual, the office
responsible for maintaining tractor manuals should send an email message
containing a contact address and the tractor model designation to
pubs@harlan-corp.com
Internet
Home Page .....................................................www.harlan-corp.com
Technical Bulletins ........................................www.harlan-corp.com/tech_bulletin.asp
Copyright Notice
The contents of this document are the property of Harlan Global Manufacturing or its component suppliers and are
prepared for Harlan Global Manufacturing Dealers, Distributors, and Customers. Harlan Global Manufacturing
authorizes owners of Harlan Global Manufacturing products to reproduce excerpts of this document as needed to
support maintenance operations only for their internal use. Distribution to third parties is prohibited.
The contents of this document are protected as unpublished works under the Copyright Act of 1976 and 2000, as
amended, and may not be reproduced, copied, distributed, or used to prepare other works, except as specified
above, without Harlan Global Manufacturing's written consent. All rights reserved.
ii August 31, 2012

Operation and Maintenance Manual
Warranty
Harlan offers a standard (1) One Year or 1200 Hour Warranty on its tow tractors.
Original sales contract will have precedence regarding warranty terms. If Harlan
has certified its product for the customer’s application and the product fails to
perform as specified, Harlan will make the changes required to bring the product
into conformance with specifications.
WARRANTY CLAIM PROCEDURE

To expedite immediate action for your warranty claim on your Harlan Tractor,
please notify us with all (or as much as possible of) the following information:
Customer Name and Shipping Address,
• Tractor Serial Number (five digit number located on the tractor I.D. plate),
• Number of Hours on the Hour Meter,
• Brief, specific description of the problem and part number(s) needed,
• Any other pertinent information related to the problem, and
• Contact name, phone and fax numbers, and e-mail address.
PRODUCT SUPPORT DEPARTMENT

Toll Free Telephone: ...............................................800-255-4262 ext. 258 (In the U.S.A.)
Local Telephone .......................................................................... 913-981-0409
Fax .......................................................................................... 913-321-5802
Warranty Manager e-Mail.............................................. warranty@harlan-corp.com
August 31, 2012 iii

Disclaimer
Harlan Corporation, herein after called Harlan, warrants each tractor is free from defects in
materials and/or workmanship for the warranty period deemed at time of sale. This warranty begins
on the date of first sale. In order to keep this warranty in effect, the vehicle must have all preventive
maintenance records. (This maintenance is at the owner’s expense, see preventive maintenance
schedules in the maintenance manual). Failure to provide the required information will void the
warranty in its entirety.
To obtain service under this warranty, the vehicle defect must be brought, upon discovery to the
attention of Harlan. Harlan will, without charge for parts, either repair or replace said part(s). The
decision to repair or replace said part(s) is solely the prerogative of Harlan. Parts for which
replacements are made become the property of Harlan. Harlan’s obligation under this warranty is
limited to repair or replacement of parts only which have been returned to Harlan freight prepaid,
and after inspection are deemed by Harlan to be defective. Harlan hereby excludes incidental and
consequential damages, including loss of time, inconvenience, or loss of use of the vehicle, for any
breach of any express or implied warranty, including the implied warranty of merchantability,
applicable to this product.
This warranty does not apply to damage caused by negligence, improper accident damage repairs,
or improper use. Damage attributable to failure to perform required inspections/maintenance at the
specified intervals in accordance with Harlan’s required preventive maintenance schedules would
void the warranty. (Example, spark plugs, lubricants, fluids, engine tune-ups, filters and coolant).
Proof must be provided by a paid invoice and/or appropriate maintenance logs. (See maintenance
manual).
Harlan will not accept any liability for parts, modifications or installation of any performance
accessories or components attached to the vehicle which alters the original engineering or
operating specifications, which result in damage to any components. Items which are subject to
wear and tear or deterioration due to driving habits or conditions, such as brake pads, brake discs,
filters, upholstery, trim, paint finish, drive belts, glass, batteries, tires and similar items, are
specifically limited to defects in material or workmanship. Damage which results from negligence,
improper operation of the vehicle, improper repair, lack of or improper maintenance, environmental
influences, flood, accident or fire damage, road salt corrosion, use of improper or contaminated fuel,
or act of god.
This warranty supersedes all other warranties expressed or implied and no person, or agent of
Harlan is authorized to give any other warranties on behalf of Harlan.
Harlan Global manufacturing, LCC. 27 Stanley Rd. Kansas City, KS 66115
Phone: 913-342-5650 | Fax: 913-342-2773 | 800-255-4262 U. S | 800-767-4275 Canada
For Information: Info@Harlan-corp.com
Copyright © Harlan Corporation
Last modified: June 16, 2005
iv August 31, 2012

Table of Contents
WARRANTY ............................................................................................................................................................................................ III
WARRANTY CLAIM PROCEDURE ...........................................................................................................................III
PRODUCT SUPPORT DEPARTMENT.................................................................................................................... iii
DISCLAIMER...........................................................................................................................................................................................IV
ABOUT THIS MANUAL ..........................................................................................................................................................................XII
NOTES, CAUTIONS, AND WARNINGS .............................................................................................................................. XII
SECTION 1, OPERATING INSTRUCTIONS............................................................................................................................................ 1
GENERAL INFORMATION...................................................................................................................................................1
PURPOSE OF EQUIPMENT ..................................................................................................................................................1
DESCRIPTION ....................................................................................................................................................................1
ENGINE .............................................................................................................................................................................2
TRANSMISSION .................................................................................................................................................................2
DRIVE TRAIN ....................................................................................................................................................................2
STEERING .........................................................................................................................................................................2
BRAKES ............................................................................................................................................................................2
ELECTRICAL SYSTEM........................................................................................................................................................2
SAFETY RULES AND PRACTICES .......................................................................................................................................3
Operator Responsibility ..............................................................................................................................................3
CONTROLS AND GAUGES ..................................................................................................................................................4
OPERATING THE TRACTOR................................................................................................................................................6
Starting the Tractor.....................................................................................................................................................6
Driving the Tractor .....................................................................................................................................................6
Stopping the Tractor ...................................................................................................................................................7
Tires and Valves..........................................................................................................................................................8
COOLING SYSTEM.............................................................................................................................................................8
BATTERY OPERATION IN EXTREME COLD WEATHER .......................................................................................................8
SHIPPING AND STORAGE .................................................................................................................................................10
Preparation for Shipping ..........................................................................................................................................10
Preparation for Storage ............................................................................................................................................11
SECTION 2, PREVENTIVE MAINTENANCE ......................................................................................................................................... 13
TABLE 1, FLUID CAPACITIES ..........................................................................................................................................13
HT GM ENGINE MAINTENANCE INTERVAL SHEET .........................................................................................................14
HT GM-POWERED TRACTOR MAINTENANCE INTERVAL SHEET .....................................................................................15
HT GM DAILY INSPECTION INSTRUCTIONS ....................................................................................................................16
HT GM 3.0L AND 4.3L DAILY INSPECTION LOG ............................................................................................................17
Tire Pressures ...........................................................................................................................................................17
HT GM 3.0L AND 4.3L 100 HOUR INSPECTION REQUIREMENTS ....................................................................................18
HT GM 3.0L AND 4.3L 100 HR. INSPECTION LOG ..........................................................................................................19
HT GM 3.0L AND 4.3L 200 HR. INSPECTION INSTRUCTIONS ..........................................................................................20
HT GM 3.0L AND 4.3L 2000 INSPECTION INSTRUCTIONS ..............................................................................................26
HT GM 3.0L AND 4.3L 2000 HR INSPECTION LOG .........................................................................................................27
BRAKE WEAR STANDARDS .............................................................................................................................................27
SECTION 3, MECHANICAL TROUBLE SHOOTING ............................................................................................................................. 28
August 31, 2012 v

AXLE LEAKAGE. .............................................................................................................................................................28

Axle Vent ...................................................................................................................................................................28
Hub Leakage .............................................................................................................................................................29
Installing the sleeve...................................................................................................................................................29
Adjusting the Outer Wheel Bearings .........................................................................................................................31
Drop Box Leakage.....................................................................................................................................................32
BRAKE SYSTEM TROUBLESHOOTING ..............................................................................................................................33
Brakes Will Not Release............................................................................................................................................33
Pulsating Brake Pedal...............................................................................................................................................35
Hard Brake Pedal .....................................................................................................................................................35
Spongy Brake Pedal ..................................................................................................................................................36
Brake Pedal Goes to the Floor..................................................................................................................................36
Manual Bleeding .......................................................................................................................................................37
TRANSMISSION ...............................................................................................................................................................38
Checking Transmission Fluid....................................................................................................................................38
Shifter and Cable.......................................................................................................................................................38
Tractor will not Move................................................................................................................................................39
SECTION 4, ELECTRICAL TROUBLESHOOTING ............................................................................................................................... 40
CIRCUIT BREAKER PANEL ..............................................................................................................................................40
TRACTOR WILL NOT CRANK ..........................................................................................................................................40
Old Style Starter Solenoid Switching Testing............................................................................................................42
Neutral Switch Check and Adjustment ......................................................................................................................43
TRACTOR STARTS THEN DIES .........................................................................................................................................45
TRACTOR WILL NOT START ...........................................................................................................................................46
ENGINE STARTS, BUT TRACTOR WILL NOT MOVE..........................................................................................................48
BACK-UP LIGHT INOPERATIVE .......................................................................................................................................49
Bulb ...........................................................................................................................................................................49
Fuse...........................................................................................................................................................................49
Backup Light Assembly .............................................................................................................................................50
Push Pull Switch .......................................................................................................................................................51
Neutral / Backup Switch............................................................................................................................................51
Cannon Plug..............................................................................................................................................................52
Broken Wire ..............................................................................................................................................................52
BRAKE-LIGHTS INOPERATIVE .........................................................................................................................................53
Electrical System.......................................................................................................................................................53
Fuse...........................................................................................................................................................................53
Bulb ...........................................................................................................................................................................54
Relay..........................................................................................................................................................................54
Switch ........................................................................................................................................................................55
Brake Light Switch Relocation ..................................................................................................................................56
Procedure Steps ........................................................................................................................................................57
TAIL LIGHT ASSEMBLY...................................................................................................................................................59
HOUR METER PRESSURE SWITCH ...................................................................................................................................60
Cannon Plug Inspection ............................................................................................................................................60
Broken Wire ..............................................................................................................................................................60
HEAD-LIGHTS WON'T WORK ..........................................................................................................................................62
SECTION 5, GENERAL OVERHAUL PRACTICES ............................................................................................................................... 65
REMOVAL PROCEDURES .................................................................................................................................................65
DISASSEMBLY INSTRUCTIONS .........................................................................................................................................66
CLEANING INSTRUCTIONS...............................................................................................................................................67
INSPECTION PROCEDURES ...............................................................................................................................................68
REPAIR AND REPLACEMENT PROCEDURES......................................................................................................................68
REASSEMBLY INSTRUCTION............................................................................................................................................69
vi August 31, 2012

INSTALLATION INSTRUCTIONS ........................................................................................................................................69

SECTION 6, SPECIFIC OVERHAUL PROCEDURES ........................................................................................................................... 70
A, FRAME AND SHEET METAL ........................................................................................................................................70
B, ENGINE AND TRANSMISSION ......................................................................................................................................70
Engine and Transmission Removal ...........................................................................................................................70
Engine and Transmission Repair ..............................................................................................................................71
Engine and Transmission Replacement ....................................................................................................................71
GENERAL WARNINGS AND CAUTIONS ............................................................................................................................72
Radiator and Radiator Mounts .................................................................................................................................73
Exhaust System..........................................................................................................................................................73
Installing Exhaust Wrap on the Exhaust Header ......................................................................................................73
C, FUEL SYSTEM.............................................................................................................................................................75
Accelerator Pedal Operation ....................................................................................................................................75
Air Cleaner................................................................................................................................................................75
Fuel Lines..................................................................................................................................................................75
D, ENGINE-TRANSMISSION INTERFACE ..........................................................................................................................76
Engine-Transmission Interface .................................................................................................................................76
Assembling the Engine and Transmission.................................................................................................................77
Installing Torque Converter Nuts .............................................................................................................................80
E, TRANSMISSION ...........................................................................................................................................................81
Transmission Control Removal.................................................................................................................................81
Transmission Control Repair....................................................................................................................................81
Transmission Control Replacement ..........................................................................................................................81
Transmission Cooling Lines......................................................................................................................................81
Installing the Neutral Switch.....................................................................................................................................85
F, DRIVE TRAIN ..............................................................................................................................................................86
Removing the Drive Axle...........................................................................................................................................86
Drive Axle Disassembly ............................................................................................................................................89
Removing the Third Member and Drop Box Assembly .............................................................................................90
Replacing the Input Pinion Bearing..........................................................................................................................94
Removing the Input Pinion Bearing ..........................................................................................................................98
Installing a Input Pinion Bearing..............................................................................................................................99
Reassembling the Third Member.............................................................................................................................102
Adjusting the Bearings ............................................................................................................................................104
QA Check ................................................................................................................................................................105
Locking the Bearing Adjusting Nuts and Bearing Cap Bolts ..................................................................................107
Installing the Thrust Pin .........................................................................................................................................108
Reassembling the Third Member and Drop Box Housing.......................................................................................109
Installing the Drop Box Output Gear......................................................................................................................111
Installing the Drop Box Case Cover .......................................................................................................................112
Assembling the Differential Case to the Axle..........................................................................................................113
Installing the Drive Axle .........................................................................................................................................115
Axle Shaft Repair ....................................................................................................................................................117
Axle Shaft Replacement...........................................................................................................................................117
Input Shaft Seal Replacement..................................................................................................................................118
Drive Shaft Assembly Removal ...............................................................................................................................118
Rear Springs............................................................................................................................................................118
Rim and Wheel Maintenance ..................................................................................................................................119
Wheel and Tire Examination...................................................................................................................................119
Tire Maintenance ....................................................................................................................................................119
Single Rear Wheels and Tires .................................................................................................................................121
Single 2-Piece Drive Wheel Removal and Installation ...........................................................................................122
G, BRAKE SYSTEM .......................................................................................................................................................124
Brake System Master VAC Unit ..............................................................................................................................124
Removing the Master Cylinder................................................................................................................................127
August 31, 2012 vii

Removing the Power Brake and Master Cylinder Assembly ...................................................................................127

Inspecting the Master-VAC .....................................................................................................................................127
Push Rod Adjustment Procedure.............................................................................................................................128
Complete Master-VAC Installation .........................................................................................................................128
System Test..............................................................................................................................................................129
Hydro-Boost Systems...............................................................................................................................................130
Master Cylinder Repair...........................................................................................................................................135
Master Cylinder Cleaning.......................................................................................................................................135
Master Cylinder Inspection.....................................................................................................................................135
Master Cylinder Piston Overhaul ...........................................................................................................................137
Master Cylinder Reassembly...................................................................................................................................137
Bench Bleeding a Dual System Master Cylinder.....................................................................................................138
Front Brake Assembly Removal ..............................................................................................................................138
Brake Assembly Repair ...........................................................................................................................................139
Brake Assembly Replacement..................................................................................................................................139
Brake Lines and Hoses............................................................................................................................................140
Brake Pedal and Linkage ........................................................................................................................................140
Brake System Bleeding ............................................................................................................................................140
Pressure Bleeding ...................................................................................................................................................140
Manual Bleeding .....................................................................................................................................................140
Rear Brake Installation ...........................................................................................................................................142
Tightening the Banjo Bolt on Dual Brake Drive Axles ...........................................................................................143
Rear Disc Brake Pad Replacement .........................................................................................................................144
Park Brake Assembly ..............................................................................................................................................145
H, STEERING AND FRONT AXLE ....................................................................................................................................148
Drag Link and Pitman Arm.....................................................................................................................................148
Front Wheel and Tire ..............................................................................................................................................148
Steering Gear ..........................................................................................................................................................148
Steer Axle ................................................................................................................................................................150
Steer Axle Hub.........................................................................................................................................................152
Steering Adjustments ...............................................................................................................................................158
Toe-In Adjustment ...................................................................................................................................................159
Tire Maintenance ....................................................................................................................................................162
J, ELECTRICAL SYSTEM ................................................................................................................................................166
Instrument Panel .....................................................................................................................................................167
Back Up Lamp Bulb Removal .................................................................................................................................167
Battery and Cables ..................................................................................................................................................167
Electrical Components ............................................................................................................................................167
Stop and Tail Lamp .................................................................................................................................................167
Battery and Cables ..................................................................................................................................................168
Electrical Components ............................................................................................................................................168
K, OPTIONS ...................................................................................................................................................................169
Hitch........................................................................................................................................................................169
Seat Assembly..........................................................................................................................................................169
Cab Accessories ......................................................................................................................................................169
Cab Assembly ..........................................................................................................................................................169
Cab Door Hinge Removal .......................................................................................................................................169
Cab Door Hinge Repair ..........................................................................................................................................169
Cab Door Hinge Replacement ................................................................................................................................169
Cab Heater ..............................................................................................................................................................169
Windshield Wiper ....................................................................................................................................................169
Cab Removal ...........................................................................................................................................................170
Cab Installation.......................................................................................................................................................174
Window Removal.....................................................................................................................................................177
Window Installation ................................................................................................................................................177
viii August 31, 2012

WINDSHIELD WIPER .....................................................................................................................................................177

WINTERIZATION KIT.....................................................................................................................................................177
APPENDIX A. GM 3.0L ENGINE, OPERATION AND MAINTENANCE............................................................................................... 179
APPENDIX B, GENERAL TRANSMISSION SERVICE......................................................................................................................... 181
GENERAL INFORMATION .............................................................................................................................................181
Overhaul and Rebuild Kits......................................................................................................................................181
Transmission Identification.....................................................................................................................................181
DIAGNOSIS AND TESTING ............................................................................................................................................181
AUTOMATIC TRANSMISSION TESTS ..............................................................................................................................181
Accelerator Linkage and Operation........................................................................................................................181
Kickdown Linkage...................................................................................................................................................181
Manual Linkage ......................................................................................................................................................182
Transmission Fluid Level Check .............................................................................................................................182
Room Temperature Fluid Level Checking Procedures ...........................................................................................182
Transmission Fluid Condition Check......................................................................................................................182
High or Low Fluid Level .........................................................................................................................................183
Transmission Fluid Leakage Checks.......................................................................................................................183
Fluid Leakage in Converter Area............................................................................................................................184
Converter Leakage Check .......................................................................................................................................186
Engine Idle Speed Check.........................................................................................................................................186
CONTROL PRESSURE TEST ............................................................................................................................................186
ENGINE VACUUM PROCEDURE .....................................................................................................................................187
Vacuum Supply Test ................................................................................................................................................188
Vacuum Diaphragm Test-On Vehicle .....................................................................................................................188
Vacuum Diaphragm Tests-Off Vehicle....................................................................................................................189
STALL TEST ..................................................................................................................................................................190
Governor Check ......................................................................................................................................................191
Transmission Fluid Cooler Flow Check .................................................................................................................191
Shift Point Checks ...................................................................................................................................................192
FORCED DOWNSHIFTS ..................................................................................................................................................193
In Shop ....................................................................................................................................................................193
Air Pressure Checks................................................................................................................................................194
Forward Clutch.......................................................................................................................................................195
Governor .................................................................................................................................................................195
Reverse-High Clutch ...............................................................................................................................................195
Intermediate Servo ..................................................................................................................................................195
Low-Reverse Servo..................................................................................................................................................195
Low-Reverse Clutch ................................................................................................................................................195
DIAGNOSIS GUIDES ......................................................................................................................................................196
REMOVAL AND INSTALLATION .....................................................................................................................................202
Vacuum Diaphragm ................................................................................................................................................202
Transmission Fluid Drain and Refill ......................................................................................................................202
Oil Cooler Tube ......................................................................................................................................................203
CLEANING AND INSPECTION .........................................................................................................................................203
Transmission ...........................................................................................................................................................203
Control Valve Body.................................................................................................................................................204
Intermediate Servo ..................................................................................................................................................204
Extension Housing ..................................................................................................................................................204
Governor .................................................................................................................................................................204
Front Pump .............................................................................................................................................................205
Reverse-High Clutch ...............................................................................................................................................205
Forward Clutch.......................................................................................................................................................206
Low-Reverse Clutch ................................................................................................................................................206
Converter and Oil Cooler .......................................................................................................................................206
August 31, 2012 ix

CONVERTER END PLAY AND ONE-WAY CLUTCH CHECK .............................................................................................207

End Play Check .......................................................................................................................................................207
Converter One-Way Clutch Check ..........................................................................................................................208
Stator To Impeller Interference Check ....................................................................................................................209
Stator To Turbine Interference Check.....................................................................................................................210
Pinion Carriers .......................................................................................................................................................210
Stator Support .........................................................................................................................................................211
Case.........................................................................................................................................................................211
C-6 AUTOMATIC TRANSMISSION SERVICE..................................................................................................................................... 213
DESCRIPTION .....................................................................................................................................................................213
ADJUSTMENTS ..............................................................................................................................................................214
INTERMEDIATE BAND ADJUSTMENT. ............................................................................................................................214
Removal and Installation ........................................................................................................................................216
Removal...................................................................................................................................................................216
Installation ..............................................................................................................................................................217
CONTROL VALVE BODY ...............................................................................................................................................218
Removal....................................................................................................................................................................218
Installation ..............................................................................................................................................................218
INTERMEDIATE SERVO ..................................................................................................................................................219
Removal...................................................................................................................................................................219
Installation ..............................................................................................................................................................219
EXTENSION HOUSING BEARING OR BUSHING AND REAR SEAL .....................................................................................220
Removal...................................................................................................................................................................220
Installation ..............................................................................................................................................................220
EXTENSION HOUSING ...................................................................................................................................................221
Removal...................................................................................................................................................................221
Installation ..............................................................................................................................................................221
GOVERNOR ...................................................................................................................................................................222
Removal...................................................................................................................................................................222
Installation ..............................................................................................................................................................222
DISASSEMBLY AND ASSEMBLY ....................................................................................................................................222
TRANSMISSION .....................................................................................................................................................222
Disassembly.............................................................................................................................................................222
Assembly..................................................................................................................................................................226
CONTROL VALVE BODY ...............................................................................................................................................228
Disassembly.............................................................................................................................................................228
Assembly..................................................................................................................................................................230
INTERMEDIATE SERVO DISASSEMBLY ..........................................................................................................................232
GOVERNOR ...................................................................................................................................................................233
Disassembly.............................................................................................................................................................233
Assembly..................................................................................................................................................................233
DOWNSHIFT AND MANUAL LINKAGE DISASSEMBLY ....................................................................................................234
Assembly..................................................................................................................................................................235
SERVO APPLY LEVER....................................................................................................................................................235
Disassembly.............................................................................................................................................................235
Assembly..................................................................................................................................................................235
FRONT PUMP.................................................................................................................................................................236
Disassembly.............................................................................................................................................................236
Assembly..................................................................................................................................................................237
REVERSE–HIGH CLUTCH ..............................................................................................................................................238
Disassembly.............................................................................................................................................................238
Assembly..................................................................................................................................................................241
FORWARD CLUTCH .......................................................................................................................................................243
Disassembly.............................................................................................................................................................243
x August 31, 2012

Assembly .................................................................................................................................................................245
Input Shell and Sun Gear ........................................................................................................................................246
Assembly .................................................................................................................................................................246
Output Shaft Hub and Ring Gear............................................................................................................................247
Disassembly ............................................................................................................................................................247
Assembly .................................................................................................................................................................247
Figure 52 Output Shaft Hub and Ring Gear...................................................................................................................247
ONE-WAY CLUTCH ......................................................................................................................................................247
Disassembly ............................................................................................................................................................247
Assembly .................................................................................................................................................................247
LOW—REVERSE CLUTCH PISTON DISASSEMBLY .........................................................................................................248
Assembly .................................................................................................................................................................249
Transmission Fluid Capacity ..................................................................................................................................249
Selective Thrust Washers (Front Pump Support)....................................................................................................249
Clutch Snap Rings...................................................................................................................................................249
Checks and Adjustments..........................................................................................................................................250
Torque Specifications..............................................................................................................................................251
GENERAL TORQUE SPECIFICATIONS ............................................................................................................................................. 252
August 31, 2012 xi

About this Manual

This manual explains and illustrates operating and maintenance procedures for the Harlan tractor
model specified on the front cover. It focuses on mechanical and electrical procedures, so it includes
any frame type, draw bar capacity and drive wheel configuration that use the same engine and the
same transmission.
Notes, Cautions, and Warnings

Notes provide information other than procedure steps, that us useful for successful
completion of the procedure. For example:
Note: Commercial Use - DOT 3 Brake fluid; Military Use - MIL-B-46176A
Caution notices provide information that if not heeded, could cause damage to the
equipment. For Example:
Do not mix brake fluid with other fluids. Only use fluid that meets
DOT 3 specifications.
CAUTION
Warnings provide important safety information that if not headed, could injure or kill
somebody. For example:
If the engine is hot, never open the radiator cap
without checking to see if the radiator hoses are
pressurized.
Without pressure, coolant boils at 212○F (10○C) at sea
level, declining 1.5○F (1○C) for each 1,000 of
Warning elevation. Pressure increases the boiling temperature.
Releasing the pressure while the coolant is hot can
cause very rapid boiling and severe scalds.
xii August 31, 2012

The manual is divided into the following sections:

Section 1, Operating Instructions
This section explains and illustrated how to drive the tractor and how to use the tractor
equipment.
Section 2, Preventive Maintenance
This section specifies the periodic maintenance intervals and inspection requirements. It
also contains reproducible master check lists for each periodic inspection.
Section 3, Mechanical Trouble Shooting
This section explains troubleshooting procedures for the tractor mechanical systems such
as axles, brakes, and transmission linkage.
Section 4, Electrical Troubleshooting
This section explains and illustrates electrical troubleshooting procedures such as starting
and lighting problems.
Section 5, General Overhaul Practices
This section provides general procedures for removal, cleaning and installation of tractor
mechanical assemblies.
Section 6, Specific Overhaul Procedures
This section contains detailed instructions for removal, inspection, disassembly, repair
add installation of the tractor mechanical assemblies that are manufactured by Harlan
Global Manufacturing. It does not include engine and transmission systems.
Appendix A, Engine Operating and Maintenance Instructions
Engine operating and maintenance instructions are provided in a separate publication by
the engine manufacturer.
Appendix B, General Transmission Service
C-6 Automatic Transmission Service
Transmission Operating and Service Instructions are published by the transmission
manufacturer and reproduced in this manual.
General Torque Specifications
Use this section to look up torque values that are not specified elsewhere.
August 31, 2012 xiii

Intentional Blank Page
xiv August 31, 2012

Operation and Maintenance Manual Section 1, Operating Instructions
Section 1, Operating Instructions
Figure 1, HTCBACL and HTACL Tractors
General Information
This handbook contains operation and service information, including parts breakdown, for the
warehouse tractor manufactured by Harlan Global Manufacturing, Kansas City, Kansas.
Purpose of Equipment
The warehouse tractor is designed for the towing of loaded carts, airplanes, and other heavy
equipment. The tractor is a self-contained, enclosed, rider-type mechanized vehicle.
This tractor is designed for towing, not pushing

airplanes. If you push hard enough on an airplane tow bar
connected to a front hitch, you could lift the front wheels
Warning off the ground, allowing the tractor to turn suddenly.
Description
The warehouse tractor has a gasoline driven engine, rear wheel drive, front wheel steering and
pneumatic tires. The electrical system is a 12-volt negative ground type with alternator, voltage
regulator, and a positive engagement starter with anti-restart system. The following paragraphs
describe the major components of the warehouse tractor.
August 31, 2012 1

Engine
The tractor is powered by a pressure-lubricated, water cooled, four cylinder valve-in-head engine. V-
belt drives from the crankshaft pulleys supply power to the engine-contained water pump and the
engine-mounted alternator. The engine is composed of three major assemblies: the crankcase
assembly, the cylinder head assembly, and camshaft/valve train assembly.
Transmission
The three speed automatic transmission provides automatic shifting through the three forward gears,
or manual selection of first, second, and reverse gears. The transmission is controlled by, the
operator’s shift selector and the vacuum modulator valve. The automatic transmission is composed
of the front oil pump, the three-speed valve assembly, the clutch packs, and the torque converter.
Drive Train
The transmission output is carried by the drive shaft to the transfer case. The transfer case reduces
the gear ratio to the differential, which provides a low speed output capability. The major
components of the drive train consist of the drive shaft, the universal joints, the transfer case, and the
differential and axle assembly.
Steering
The front wheel steering is available with power assist or fully hydrostatic systems.
Brakes
Operation of the foot brake pedal activates the power assist unit, which forces fluid from the dual
master cylinder reservoir. One reservoir fluid supply operates the front brakes and the other reservoir
fluid supply operates the rear brakes. Loss of one fluid supply does not affect the other. For parking,
the handbrake mechanically operates a drum parking brake in the transmission.
The major components of the foot brake system are the power assist unit, the master cylinder, the
front drum or calipers, and the rear discs. The major components of the hand brake assembly are the
brake lever and the drum assembly.
Electrical System
The engine-mounted, belt-driven alternator provides power to the ignition system, the windshield
wipers (optional), the heater fan (optional), the instruments, and the lights. A safety interlock switch
prevents the starter motor from engaging when the transmission selector is in a position other than
neutral. The fuses protect the electrical circuitry. An anti-restart system prevents unsafe starter motor
operation. A safety interlock switch has been incorporated into the electrical system that will shut the
engine down if the parking brake is engaged when the transmission is in any position other than
neutral. The major components of the electrical system are the alternator, the battery, and the starter
motor.
2 August 31, 2012

Safety Rules and Practices

Operator Responsibility
• Safe operation is the responsibility of the operator.

• This equipment can be dangerous if not used properly. The operator must develop safe
work habits and must be aware of hazardous conditions in order to protect himself, other
personnel, the tow tractor, and other material.
• The operator shall be familiar with the operation and function of all controls and
instruments before undertaking the operation of the tow tractor.
• Before operating any tow tractor, the operator must read and be familiar with operator’s
manual for the particular tow tractor being operated and must abide by the safety rules
and practices.
General Rules
• Do not start or operate the tow tractor from any position other than from the designated
operator’s position.
• Keep hands and feet inside the operator’s designated position. Do not put any part of the
body outside of this position.
• Learn the limitations of the tractor and operate it in a safe manner. Doing so will prevent
injury to personnel. Be on the watch for pedestrians at all times. Do not drive a tow
tractor up to anyone standing in front of an object. Exercise extreme caution at cross
aisles, doorways, and other locations where pedestrians may step into the path of the
tractor.
• Do not permit passengers to ride on any tractor unless a safe place to ride has been
provided by the manufacturer.
• A tow tractor is considered to be "attended" when the operator is less than 25 ft (7.6 m)
from it and when the tractor remains in his view. Do not leave a running tow tractor
unattended.
• A tow tractor is considered to be "unattended" when the operator is more than 25 ft (7.6
m) from the tow tractor or when the operator leaves the tractor and it is not in his view.
• Maintain a safe distance from the edge of ramps, platforms, and other similar edged
surfaces.
• In areas classified as hazardous, use only tow tractors approved for those areas.
• Report all accidents involving personnel, building structures, and equipment to the proper
authority immediately.
• Do not add to or modify the tow tractor.
• Do not block access to fire aisles, emergency exits, stairways, and fire equipment.
August 31, 2012 3

Controls and Gauges
The following controls and indicators are typical. Not all panels look exactly like the one shown and
not all tractors have all the options shown here.
18
14
15 16
13
3 4 5
12
17
1
11
8
6
7 10
9
Figure 2, Controls and Gauges
4 August 31, 2012

1. Engine Start and “Ignition” Switch. 6. Accelerator Pedal

Turn past spring pressure to start engine. If 7. Brake Pedal
engine does not start within 15 seconds,
8. Transmission Shift Lever. There are two
turn switch off and wait one minute before
options available: F-N-R proves only
trying again.
Forward, Neutral, and Reverse positions.
2. Engine Coolant Temperature
P-R-N-D-3-2-1 provides 4 forward speeds
If temperature exceeds 225○, shut down and a ark position in additional to Neutral
engine and check coolant level. and Reverse.
3. Fuel Level: Avoid running until out of fuel. 9. Park Brake Lever.
4. Volt Meter: Normal = 13V with engine at 10. Headlight Switch.
idle or stopped, not over 14.5V with engine 11. Heater Fan Switch
above idle. Avoid operating tractor
voltages above or below normal. 12. Heater. The hot water supply control
valve on the front of the engine where
5. Hour Meter. Hours increase while oil the water hose connects to it.
pressure is greater than zero.
13. Windshield Wiper
14. Windshield Wiper Switch
15. Optional Switch, usually for beacon light
16. Optional Switch, alternate location for
Work Light.
17. Optional Switch, usually for Work Lights
18. Cab Fan and Switch. Caution: This
switch may be connected to the
battery. If so, avoid running the fan
too long with the engine off or you
may deplete the battery.
If the engine is hot, never open the radiator cap

without checking to see if the radiator hoses are
pressurized.
Without pressure, coolant boils at 212○F (10○C) at sea
level, declining 1.5○F (1○C) for each 1,000 of elevation.
Warning Pressure increases the boiling temperature.
Releasing the pressure while the coolant is hot can
cause very rapid boiling and severe scalds.
August 31, 2012 5

Harlan Towing Tractor
Operating the Tractor

This section contains instructions for operating the tractor under normal conditions. The operator must have a
complete understanding of the location and function of all of the operating controls before attempting to
operate the warehouse tractor.
Starting the Tractor
1. Check oil, coolant and fuel levels. See Fig. 8 and Table 1 for these fluid level indicators
locations.
2. Remove all obstructions from in front of and behind the tires.
3. Sit in the operator’s seat.
4. Make sure that the shift lever is in the Neutral position (N).
5. Step on the brake pedal.
6. If the tractor has an “Override” button on the dash, hold it while starting the engine.
7. Turn ignition switch to the START position until the engine starts.
The starter motor is limited to 15 seconds of cranking time. If all of the necessary components are in working
order, the engine will start.. If the engine does not start during that time or if you release the switch before the
engine starts, and turn ignition switch off and try again. If the engine does not start after two 15-second
attempts, see Section 4, Electrical Troubleshooting, Tractor Cranks but Will Not Start, on Page 57.
After the engine starts, check that all gauges and indicators are within the proper operating ranges.
Driving the Tractor
Note: Pay attention to gauges and indicators while the tractor is in operation.
Complete these steps to drive the tractor:
1. Apply the brakes by depressing the brake pedal and release the hand brake.
2. Release pressure on the accelerator pedal to allow the engine to idle.
3. Select the proper gear with the transmission selection lever. Be sure that the gear selected is
suitable to move the intended load.
4. Release the pressure on the brake pedal and slowly depress the accelerator pedal to put the tractor
into motion.
Do not shift between forward and reverse while the tractor is moving except
in a brake failure emergency. Do not shift into forward or reverse with the
engine running faster than idle.
Both of these actions can damage the transmission, drive line, and drive
Caution axle. Harlan Global Manufacturing reserves the right to refuse warranty
service for such damage.
5. Any time the tractor is stopped for longer than a minute with the engine running, be sure that the
transmission is in the neutral position (N).
November 13, 2012

6
Stopping the Tractor

Complete these steps to stop the tractor:
1. Stop applying pressure to the accelerator pedal.
2. Press the brake pedal so that the tractor decelerates smoothly.
3. When the tractor comes to a halt, put the shift lever in the neutral position (N).
4. To park the tractor, turn OFF the ignition switch and apply the park brake. If you park on
a flight deck, put chocks in their proper places to secure the wheels. The park brake has a
safety feature: an automatic shutdown mechanism. If the park brake is engaged while the
transmission selector is in any position other than neutral OR if the shift selector is
moved from neutral while the hand brake is applied, then the engine will shut down.
Do not exceed the tractor’s Draw Bar Pull

capacity. Getting the load moving is not your
main concern. You still have to stop. The load you
are towing has a major effect on stopping
Warning
distance.
• Do not ride the brake pedal. Doing so causes the transmission

clutch packs to slip, which will result in overheating and
unnecessary wear of the transmission.
• After operating the engine at high power, allow it to idle for
two minutes before turning it off to equalize the internal
engine temperatures and prevent unnecessary wear and
Caution damage to the engine.
• Do not operate the engine if the oil level is below the ADD
mark on the oil dipstick.
August 31, 2012 7

Harlan Towing Tractor
Tires and Valves

Dual Drive Wheels have separate
valves for inner and outer tires.
Correct tire pressures vary with the
tire option and will be written on
the tire sidewall. When replacing
tires, replace them in pairs
whenever feasible. Never mix tires
with different operating pressures. Outside
Inside
Figure 3, Dual Wheel Tire Valves
Cooling System
The warehouse tractor’s cooling system is thermostatically controlled. The engine-mounted water pump
forces coolant through the radiator when the thermostat opens. The fan pulls air through the radiator for
additional cooling when the tractor is idling or during low speed operation. The coolant also passes through
the heater (optional) to provide warm air to the cab for driver comfort. The major components of the cooling
system are the water pump and the radiator.
If the oil pressure is erratic or if it falls below the

recommended range for the tractor’s operation, stop the
engine immediately and find the cause of the problem.
Failure to do so could result in serious damage to the
Caution engine and its internal parts.
Battery Operation in Extreme Cold Weather
Do not expose the battery to extremely cold weather while discharged. A

fully charged battery can withstand temperatures as low as -92o F (-69o C),
but a discharged battery may freeze at 32o F (0o C). Refer to the table below.
Caution
Battery Approximate Battery Approximate

State of Charge Freezing Point State of Charge Freezing Point
o o o o
% F C % F C
100 -92 -69 50 -14 -26
90 -90 -68 40 -1 -18
80 -70 -57 30 9 -13
70 -48 -44 20 17 -8
60 -30 -34 10 24 -4
0 32 0
November 13, 2012

8
Battery Safety
Because the alternator and regulator are designed for use with a one-polarity system, the following
precautions must be observed when working on the charging circuit. Failure to observe these
precautions could result in serious damage to the electrical equipment.
• When installing a battery, always be sure that the ground polarity of the battery and the
ground polarity of the alternator are the same.
• When connecting a booster battery, be sure that the negative battery terminal is connected
to the tractor engine block and that the positive battery terminals are connected together.
• When connecting a charger to the battery, connect the charger’s positive lead to the
battery’s positive terminal and the negative lead to the battery’s negative terminal.
• Never operate the alternator on an open circuit. Be sure that all connections in the circuit
are secure.
• Do not short across or ground any of the terminals on the alternator.
• Do not attempt to polarize the alternator.
Traveling
• Observe all traffic regulations, including authorized speed limits. Under normal traffic
conditions, keep to the correct side of the road. Maintain a safe distance, based on speed
of travel, from the vehicle ahead, and keep the tow tractor under control at all times.
• Slow down and sound the audible warning device(s) at cross aisles and other locations
where vision is obstructed.
• Always face in the direction of travel. Keep a clear view of the path of travel and observe
for other traffic, personnel, and safe clearances.
• At all times, operate the tow tractor at a speed that will permit an emergency stop that can
be executed in a safe manner.
• Do not indulge in stunt driving or horseplay. Avoid reckless driving, a towing tractor can
be dangerous if operated in an unsafe manner.
• Slow down when operating the tractor on wet and slippery floors and roadways.
• When negotiating turns, reduce speed to a safe level, and turn the hand steering
mechanism in a smooth, sweeping motion. Except when maneuvering at a very low
speed, turn the hand steering mechanism at a moderate, even rate.
Note: If the tow tractor is in need of repair, or if it is in any way unsafe to operate, or if it
in any way contributes to an unsafe condition, the situation must be reported
immediately to the proper personnel. The tow tractor must not be operated until it
has been restored to a safe operating condition.
August 31, 2012 9

Shipping and Storage

Preparation for Shipping
If the tractor is being shipped by air, no crating or special preservation is required. If it is being
shipped by flat-bed truck, a cover must be used to protect the tractor from rocks, sand, dirt, and
adverse weather conditions. Perform these procedures before loading the tractor.
1. Check all of the lubricant and fluid levels. Refer to Table 4, HT GM 3.0L and 4.3L Daily
Inspection Instructions, for details.
2. Check the tractor for damage and missing components. Repair all damage and replace all
missing parts.
3. Prepare a shipping document. Include the date the tractor was prepared for shipping and the
serial number of the tractor. Put a copy of the document in the cab or put a copy in a weather-
resistant envelope and securely attach it to the steering column of units without cabs.
If the tractor is shipped with any deficiencies, they must be noted on the shipping document.
10 August 31, 2012

Preparation for Storage

When preparing the tractor for storage, be sure that the tractor is protected from local climatic
conditions. These storage procedures are guidelines for normal weather conditions, make appropriate
adjustments to meet local requirements.
The preparation for storage is determined the length of time the tractor will be in storage and the
location of the tractor during storage. Short term storage is from one to six months. Long term
storage is over six months or indefinite storage. A tractor stored indoors will not require as much
external protection as a vehicle stored outdoors under cover or outdoors in the open.
Short Term Storage.

To prepare a tractor for storage from one to six months, perform the following procedures:
1. Check the tractor for damage and missing components. Repair or replace all damaged items
and replace all missing parts.
2. Check all of the lubricant and fluid levels. Refer to Table 4, HT GM 3.0L and 4.3L Daily
Inspection Instructions for details. Be sure that the anti-freeze will protect the cooling system
and engine to the lowest temperature expected during storage.
3. Be sure that all caps, lids, and dipsticks are installed and tightened.
4. Drain ail of the water from the air tanks of all tractors that are so equipped.
5. Remove the fire extinguishers and exterior mirrors from all tractors that are so equipped.
Wrap the mirrors and all attaching parts in paper and seal the wrapping with tape. Store the
fire extinguishers and mirrors on the floor of the cab. e. Check all controls and accessories to
be sure that they are turned off. Leave the key in the ignition.
6. Disconnect the battery cables from the battery. Wrap the cable terminals with masking tape,
Coat the battery terminals with a preservative to prevent corrosion.
7. Check the pressure of all tires. Be sure that they are inflated to specifications.
8. Clean the interior surfaces, the engine compartment, and the exterior surfaces. Remove sand
and road salt from the chassis. Allow the tractor to air dry.
9. Close all windows and air vents.
10. Complete a storage document and put a copy in the cab. The document should contain this
information:
• A description and the serial number of the tractor.
• The date the tractor was prepared for storage.
• The date the tractor was placed in storage.
• The organization and the personnel that prepared the tractor for storage.
• The special preparations that were performed for local conditions.
• All defects that were not corrected before the tractor was put into storage
• Make any preparations needed to protect the tractor from local condition.
• If the tractor is stored outside, cover it with a tarp or other protective material to keep
direct sunlight out of the operator's compartment.
August 31, 2012 11

Long Term Storage.

To prepare a tractor for storage for six months or longer, perform the following procedures:
1. Complete all Short Term Storage Procedures as outlined above.
2. Wrap or cover all of the exterior lights, the radiator grill, and the air vents with moisture-
resistant paper and secure the paper with tape.
3. Remove the battery from the engine compartment. Store it in accordance with local fire
regulations.
4. Spray all exterior surfaces and the chassis with a preservative compound.
12 August 31, 2012

Operation and Maintenance Manual Section 2, Preventive Maintenance
Section 2, Preventive Maintenance

HT Gasoline Tractor Lubrication and Fluid Service Points
Table 1, Fluid Capacities

Description Quantity
U.S. Metric
Anti-Freeze 4.0 GL 15.1 L
Brake Fluid (DOT 3) 0.25 GL .945 L
Engine Oil (Citgard 500 15W-40) 7.0 QT 6.6 L
Fuel, Gasoline 16.0 GL 60.5 L
Grease, Litholene H EP-2 AR AR
Locktite 660 for Steer Bushing 0.25 EA
Loctite 271 Threadlocker 250 M 0.20 OZ 60 ML
Oil Hypoid SAE 80W-90 9.0 QT 8.5 L
Transmission Fluid, Hydraulic Fluid, Power Steering Fluid:
11 3/4 QT 11.1 L
Dexron® III, or IV, Mercon® AFT, or equivalent
®Dexron is a registered trademark of General Motors Corporation. Mercon is a registered trademark of Form
Motor Company.
August 31, 2012 13

HT GM Engine Maintenance Interval Sheet

Install Interval Hours
General Maintenance Section Daily 200 400 800 1000 1250 1500 1750 2000
Date
Visual check for leaks X
Check engine oil level X
Check coolant level X
Change engine oil and filter Every 150 hours or 120 days of operation
Check fuel system for leaks Prior to any service or maintenance activity
Inspect accessory drive belts X X
Inspect electrical system X
Inspect all vacuum lines and fitting X
Engine Coolant Section
Clean debris from radiator core Every 100 hours or 60 days of operation
Change coolant X
Inspect coolant hoses for cracks,
X X
swelling or deterioration
Engine Ignition System
Inspect Battery case for damage X X
Check all electrical connectors X X
Replace Spark Plug Wires X
Replace Distributor Cap & Rotor X
Replace spark plug wires X
Fuel System Maintenance
Replace fuel filter X X
Leak check fuel Lines X
Inspect/Drain EPR/LPR for oil
Every 150 hours or 120 days of operation
build up
Inspect LPR for coolant leaks Annually or every 2000 hours
Check air induction for leaks X
Check manifold for vacuum leaks X
Replace PCV Valve X
Check injector & rails for leaks X
Inspect air cleaner Every 200 hours, or every 100 hours in dusty environment
Replace filter element Every 400 hours, or every 200 hours in dusty environment
Engine Exhaust System
Inspect exhaust manifold for leaks X
Inspect exhaust piping for leaks X
Inspect catalyst inlet and outlet X
Check HEGO sensors connections X
Table 2, HTAL and HTACL Maintenance Interval Sheet
Last Updated on 5/18/09 by Bob Becker
The maintenance schedule represents manufacturers recommended maintenance intervals to
maintain proper engine/equipment function. Specific state and federal regulations may require
equipment operators to conduct comprehensive engine/equipment inspections at more periodic
intervals than those specified above
14 August 31, 2012

HT GM-Powered Tractor Maintenance Interval Sheet
Every 4 Years,
After First 50
200 HOURS
Maximum
2000 Hrs
400 Hrs.
800 Hrs.
Hours
Daily
Inspection
Brake System Service & Parking X

Transmission Oil Level X
Tires X
Steering System X
Battery X
Lights / Gauges / Horn X
Windshield Wipers Inspection X
Heater Inspection X X X X X X
Tires X X X X X
Steering X X X X X
Grease Steer Axle/Drive Line X X X X X
Hand Brake X X X X X
Exhaust System X X X X X
Transmission Filter Screen X X X
Rear Brake Inspection X X X X
General Equipment Inspection X X X X
Battery X X X X
Electrical System X X X X
Transmission Oil Change X X
Drive Axle Lube Change X X X
F&R Axle Bearings Inspection/Service X X X
Engine Cooling System X X X
Check Exhauster of Compressor X X
Rear Brake Pads X X
Table 3, Tractor Maintenance Intervals
Last Updated on 5/03/07 By Bob Becker
*GM recommends that this operation is done by an authorized GM Distributor. Depending on the quality of fuel used, it may be
necessary to renew the filter element more frequently.
August 31, 2012 15

HT GM Daily Inspection Instructions

Inspection Period: Each Shift
Inspection Item Service Required
Battery Check loose or corroded terminals, overall condition.
Before the tractor is started, remove master cylinder cover to
Brake Fluid Level
ensure the fluid is no more than 1/4" below the top of the cylinder.
Check brake firmness with engine at in idle and the transmission
Brake System / Service and selector at N (neutral) position by depressing the pedal and holding
Parking for 10 seconds. If the pedal does not remain firm, report to
maintenance personnel.
Check visually for oil, fuel or Check all fuel, coolant, transmission, and hydraulic hoses and lines
coolant leaks for signs of leaks.
Check coolant level when engine is cold or 45 minutes after engine
turn-off. Add coolant as necessary without overfilling. Make a visual
Engine Coolant Level
check under the tractor for evidence of coolant leaks. Report any
problems to maintenance.
Check the oil level with engine cold or 15 minutes after engine has
Engine Oil Level
been turned off.
Start the tractor, pull the switches, ensure all lights, gauges, along
with the horn are in good operating condition. Check all
Lights / Gauges / Horn
instruments, controls and warning lights. Check hot and cold
starting functions
Operator should turn the wheel fully to the left and to the right. This
Steering System will ensure that the steering system does not bind and there is not
excessive free play.
Pneumatic Tires: Check tires for proper inflation.
All Tires: Pry out of treads any objects that could cause
Tire Pressure / Lug Nuts damage. Check for loose lug nuts.
Front Lug Nuts: 100 Lb-Ft or 135 NM
Rear Lug Nuts: 200 Lb-Ft or 270 NM
Check transmission fluid level at normal operating temperature with
Transmission Oil Level engine at idle, hand brake set and selector in N (neutral). Add
Dextron transmission fluid without overfilling.
Turn the windshield wiper switch on and observe. Replace blade if
worn or defective. Bring the engine up to operating temperature
Windshield Wipers / Heater
and turn heat switch ON. Observe the fan operation and warm air
discharge. Report problems to maintenance personnel.
Table 4, HT GM 3.0L and 4.3L Daily Inspection Instructions
16 August 31, 2012

HT GM 3.0L and 4.3L Daily Inspection Log

Date
Operator
System Date
Condition Condition Fill Amount or
Acceptable Unacceptable Replaced Part No.
Battery
Brake Fluid Level
Brake System Service &
Parking
Check visually for oil, fuel
or coolant leaks
Engine Coolant Level
Engine Oil Level
Light / Gauges / Horn
Steering System
Tire Pressure / Lug Nuts
Transmission Oil Level
Windshield Wipers
Inspection
Table 5, Daily Inspection Log
Tire Pressures
In most cases, inflate tires to the pressure specified on the tire sidewall. The exception is when tires designed
and rated for highway operation are used for low speed operation. This allows higher load ratings and higher
pressures. This applies only to the tires listed below:
Harlan Part Max Pressure
Brand Tire
Number psi kpa
Geo Trac LT215/85R16, 10 ply ‐ Rear 02030‐0314 90 621
Goodride LT215/80R16, All Season, Rad Rear 02030‐0031 51 351
Hankook Dynapro AS LT215/75R15 02030‐0360 60 414
Super Tripper LT215/85R16 90 621
Wrangler HT LT215/75R15 75 517
Source: Tire and Rim Association Handbook
August 31, 2012 17

HT GM 3.0L and 4.3L 100 Hour Inspection Requirements

If the tractor is operated in a dusty or desert environment, complete these items at 100 our intervals.
Air Filter Element Clean and check. Replace if necessary.
Oil / Filter Change Check the oil on the oil dip-stick. If the oil is dirty, change the oil
and oil filter.
Radiator Clean debris from radiator core
Table 6, 100 Hour Inspection Requirements
18 August 31, 2012

HT GM 3.0L and 4.3L 100 Hr. Inspection Log

Date
Operator

System
Air Filter Element
Inspection
Oil, Oil Filter
Radiator
Table 7, 100 Hour Inspection Log
August 31, 2012 19

HT GM 3.0L and 4.3L 200 Hr. Inspection Instructions

Daily Inspection Requirements Complete all items in Daily Inspection Schedule
100 Hour Inspection Complete all items in 100 Hour Inspection Requirements.
Fuel Filter *Check dry fuel filter element and renew as necessary.
Lug Nuts Check lug nuts for correct tightness.
Front Lug Nuts: 100 Lb-Ft or 135 NM
Rear Lug Nuts: 200 Lb-Ft or 270 NM
Park Brake Disconnect drive shaft and remove park brake drum. Replace
brake shoes if worn.
Power Brake Back-up Pressure With engine off, pump the brake pedal hard until the pedal feel
indicates power brakes are no longer available. The back-up
pressure should last for a least two power brake applications.
Maintain brake pedal pressure and start the engine. The pedal
should sink under pressure as the back-up cylinder
repressurizes, then it should return to normal.
Power Brake Noise Hissing noise during moderate to heavy brake application
(Above 40 lbs. or 18 Kg) is normal. Noise with less than normal
brake pedal indicates air or foreign matter in hydraulic fluid.
Grease Steer Axle / Drive Line Clean and lubricate with specified compound.
Hand Brake Inspect parts and linkage for excessive wear. Repair as needed.
Heater Verify operation.
Oil / Filter Change Remove the drain plug and allow the crankcase to empty into a
shallow (8 quart minimum) pan.
Oil Filler Cap Check condition of the oil filler cap. Replace if damaged.
Steering Inspect steering linkage, steering gear box and wheel bearings.
Repair, adjust or replace parts as necessary.
Tires Check tires for wear and replace as needed. If tire wear
indicates further maintenance action, action is required.
20 August 31, 2012


Date
Operator

System
Air Filter Element Inspection
Coolant, oil, fuel, and vacuum
hoses/pipes
Exhaust System
Grease Steer Axle/Drive Line
Hand Brake
Heater
Oil Filler Cap
Steering
Tires
Fuel Filter
Lug Nuts
Park Brake
Power Brake Back-up
Pressure
Power Brake Noise
Exhaust System
Hand Brake
Heater
Oil Filler Cap
Steering
Tires
August 31, 2012 21


Daily Inspection Complete all items in Daily Inspection Schedule
Requirements
Grease Steer Axle / Drive Clean and lubricate with specified compound.
Line
Oil / Filter Change Remove the drain plug and allow the crankcase to empty into a
shallow (8 quart minimum) pan.
Fuel Filter Element Remove and Replace
Replacement
Exhaust System Inspect exhaust system for leaks, broken clamps and defective
hangers. Replace defective parts as necessary.
Rear Brakes Inspect the rear calipers for excessive play and leaks. Repair as
needed.
General Equipment Steam clean the tractor engine and undercarriage. Check tractor for
loose bolts, nuts and capscrews. Check brake, fuel and vacuum lines
for chafing. Check all belts for wear and proper tension.
Battery Clean and reset terminals.
Electrical System Check wiring for loose connections, frayed insulation, and exposed
conductors.
22 August 31, 2012


Date
Operator
Fill Amount or
Condition Condition
System Replaced Part
Acceptable Unacceptable
No.
Air Filter Element Inspection
Coolant, oil, fuel, and vacuum
hoses/pipes
Exhaust System
Hand Brake
Heater
Oil Filler Cap
Steering
Tires
Belts
Fuel Filter
Grease Steer Axle / Drive Line
Oil / Filter Change
Oil Filler Cap
Fuel Filter Element Replacement
Hand Brake
Exhaust System
Rear Brakes
General Equipment
Battery
Electrical System
August 31, 2012 23


Table 12, HT GM 3.0L and 4.3L 800 Hr. Inspection Instructions
Daily Inspection
Complete all items in Daily Inspection Schedule
Requirements
Air Filter Element Replace
Belts Check condition and adjust tension of drive belt(s)
Battery Clean and reset terminals.
Inspect the rear calipers for excessive play and leaks. Repair as
Brakes
needed.
Ignition System:
Replace Distributor Cap & Rotor
Distributor
Ignition System: Spark
Replace spark plugs
Plugs
Drive Assembly Drain and refill transfer case and differential.
Check wiring for loose connections, frayed insulation, and exposed
Electrical System
conductors.
Pressure test the system, including radiator cap. Check hoses for
Engine Cooling System
deterioration.
Steam clean the tractor engine and undercarriage. Check tractor for
General Equipment loose bolts, nuts and capscrews. Check brake, fuel and vacuum lines
for chafing. Check all belts for wear and proper tension.
Grease Steer Axle / Drive
Clean and lubricate with specified compound.
Line
Coolant, oil, fuel, and Check coolant, oil, fuel, exhaust and vacuum hoses/pipes for leaks,
vacuum hoses/pipes damage, deterioration and correct routing. Check all visible electrical
wiring for security, correct routing and evidence of chafing or heat
damage.
Inspect steering linkage, steering gear box and wheel bearings.
Steering
Repair, adjust or replace parts as necessary.
Check tires for wear and replace as needed. If tire wear indicates
Tires
further maintenance action, action is required.
Transmission Filter Drain transmission pan and clean filter.
Check the transmission fluid for discoloration and burnt odor. Drain
Transmission Fluid
converter pan and replace.
Clean and repack with medium weight, high temperature wheel
Wheel Bearings
bearing grease that has a melting point of 250 degrees or higher.
24 August 31, 2012


Date
Operator
Fill Amount or
Condition Condition
System Replaced Part
Acceptable Unacceptable
No.
All 100Hour, 200 Hour, and 400
Hour Inspection Items plus:
Air Filter Element
Battery
Belts
Brake Inspection
Drive Axle Lube Change
Electrical System
Engine Cooling System
Fuel Filter Element
General Equipment
Hand Brake
Hoses
Ignition System: Distributor
Ignition System: Spark Plugs
Oil Filler Cap
Steering
Tires
Transmission Filter
Transmission Fluid
Transmission Screen
Wheel Bearings
August 31, 2012 25

HT GM 3.0L and 4.3L 2000 Inspection Instructions

100 Inspection Complete 100 Hour Inspection Requirements.
Brake Pads STEP 1.Jack the tractor up off the ground. Place jack stand under frame.
Remove rear wheel assembly by loosening wheel nuts. Remove wheel
assembly from tractor.
STEP 2.
a. To replace disc brake pads, remove thru bolts, back bolts
out of caliper, pull bolts out of housing.
b. Remove caliper from the axle mounting plate. Avoid hanging
the caliper from the hose attached to the caliper.
STEP 3.
a. Retract the pads and the pistons by prying between each pad
and the rotor with a large screw driver. Use caution to avoid
scratching the rotor. The pistons must be fully into the caliper
hosing to permit installation of the new thicker pads. If the rotor is
scored or undercut, it should be replaced or resurfaced.
b. Check the piston seal for signs of leaks. If all items are ok,
install new pads. One side has a spring clip to hold it to the piston.
c. Reinstall caliper onto the mounting plate. Reinstall thru bolts to
caliper housing and tighten both bolts securely.
d. If the pistons were removed. bleed the system.
Exhaust System • Inspect exhaust system for leaks, broken clamps and defective
hangers.
• Inspect exhaust manifold for leaks
• Inspect exhaust piping for leaks
• Inspect catalyst inlet and outlet
• Check HEGO sensors connections
• Replace defective parts as necessary.
Ignition System: Replace spark plug wires

Spark Plug Wires
26 August 31, 2012

HT GM 3.0L and 4.3L 2000 Hr Inspection Log

Date
Operator

System Acceptable Unacceptable Replaced Part No.
All 100Hour, 200 Hour, 400
Hour, and 800 Hour
Inspection Items plus:
Brake Pads
Exhaust System
Spark Plug Wires
Brake Wear Standards

Item Standard Dimension Minimum Thickness
Inches or MM Inch MM Inch MM
Front Brake Shoes, 02026-0178 0.18
Wheel Cylinders, 02026-0013
Standard Steer Axle Rotor, 02023-0521
Standard Steer Axle Pads, 02026-0276 .20
Heavy Duty Steer Axle Rotor, 02023-1083 .25 6.35 .230 5.84
Heavy Duty Steer Axle Pads, 563974537
Drive Axle Rotor, 02025-0205 1.125 28.575 1.070 27.178
Drive Axle Pads, 02026-0179 .434
Park Brake Shoes, 02027-0071
Item Standard Dimension Maximum Oversize

Inches or MM Inch MM Inch MM
Front Drum Assembly, 02026-0016
Park Brake Drum, 02027-0036
August 31, 2012 27

Section 3, Mechanical Trouble Shooting

Axle Leakage.
Axle Vent
1. Inspect the axle vent to
ensure the vent is not
clogged over and inspect for 1
proper operation.
Figure 4
2. Check the oil level to ensure

the axle is not overfilled,
remove the top front plug.
The oil level should be level
with the bottom of the fill
hole. When you reinstall the
plug, seal the threads with
Teflon® tape.
Figure 5
28 August 31, 2012

Operation and Maintenance Manual Section 3, Mechanical Trouble Shooting
Hub Leakage
1. Inspect and replace sleeves if
required.
Installing the sleeve
2. Install the sleeves, part number
#00700113854, on the axle arms.
Figure 6, Axle Sleeve
3. Pack the inner bearings, items 15

and 16 in Figure 8, with grease.
Figure 7, Packing Wheel Bearings
August 31, 2012 29

Figure 8
4. Install the inner bearings (16 and 17) into the hub and rotor assembly.
5. Install the inner seal, part number #00700220294. See Figure 8.
6. Repeat this step on the second hub.
7. Attach the brake caliper backing plate (4), part number #02025-0094, using 6 bolts, (13) part
number #02011-24C620 and lock washers (14), to the axle arm.
8. Use a drop of thread locking compound on each bolt.
9. Tighten the bolts in a criss-cross pattern to 35 Lb-Ft.
10. Apply grease to lubricate the area where the inner seal (15) contacts the axle arm.
30 August 31, 2012

11. Lift the hub and rotor assembly and slide the assembly onto the axle arm. Do not force the
hub because it is easy to damage the seal, which may cause the seal to leak. If the inside
wheel bearing catches on the axle arm, gently strike the outer face of the hub slides on to the
arm. Refer to Figure 8 and 5.
12. Install grease packed outer bearing part number #02025-0029 onto the axle arm and into the
cup in the hub.
13. Apply grease to the inside of the hub,

14. Insert the outer grease seal (24), part
number 02025-0050, with the key
lining up with the key way in the axle
arm.
15. Follow this with one of the bearing
adjusting nuts (25), part number 02025-
0051.
Figure 9, Wheel Hub Grease
Adjusting the Outer Wheel Bearings

1. Tighten the inner nut while spinning the hub to center the wheel bearing.
2. Loosen the nut (25) part number #02025-0051, and then tighten it to zero clearance.
3. Install the lock washer (26), part number 02025-0052, onto the axle arm, with the key lines
up with the keyway in the axle arm.
4. Install the hub second nut (26),
5. Tighten the outer nut and bend one lock washer tabs over of the inner nut and one over the
outer nut.
6. Repeat this procedure on the other hub.
7. Apply gasket sealer to the mating surfaces of the hub and the axle shaft, part number 02025-
0120.
8. Wash the bolts, part number #02025-0073, in alcohol and let dry.
9. Apply one drop of thread locking compound to each bolt and install in all the holes. Four of
the holes will require alignment dowels, part number #02025-0054.
10. Using a criss-cross pattern torque each bolt to 70 Lb-Ft or 95 NM.
11. Repeat this procedure for the other axle shaft.
August 31, 2012 31

Drop Box Leakage
Input Seal
The most common problem is oil running down
the front of the drop box noticeable on the freeze
plug. Remove the rear of the drive-line and
remove the input flange and change the seal.
When installing the flange ensure the flange has
been coated with a small amount of grease. To
avoid seal failures make sure there is a good
finish on the output flange. The part number for
the seal is #02029-0010.
Figure 10
1. Raise the rear of the tractor and place on suitable jack stands.
2. Disconnect the rear of the driveline.
3. Remove the drop box rear cover.
4. Remove the cotter pin and output gear. There will be a small amount of gear grease lost.
5. Remove the lock wire from the drop box mounting bolts.
6. Remove the drop box and clean all parts and reassemble.
For further information, see the rear axle assembly procedures.
Call the Factory for further assistance 1-00-255-4262
32 August 31, 2012

Brake System Troubleshooting

If the first item does not solve the problem proceed to the next trouble shooting Instruction until the
problem is corrected.
Brakes Will Not Release
Pillow Blocks
Inspect the pillow block for proper operation
and lubrication. Replace if needed.
Part Number #02026-0095
Figure 11
Check Valve
Whenever a new master is installed, it
must have the check valves removed that
operate the disc brake calipers. If the
valves are installed it will cause pressure
to build until the tractor will not move.
Figure 12
Push Rod Adjustment

This adjustment is critical if the push rod is maladjusted. It will allow brake line pressure to build to
the point the tractor will not move.
August 31, 2012 33

Brake Fluid Contamination
Only approved brake fluids are

permitted. Anytime the master
cylinder cap seal swells it is an
indication that the system has been
compromised. If this has occurred the
system should be drained, all seals
inspected and replaced if needed, new
brake fluid needs to be installed
(approved) and the system completely
bled.
Figure 13
Note: Commercial Use - DOT 3 Brake fluid; Military Use - MIL-B-46176A
Over Filling of the Master

Cylinder
This will be visible during maintenance or
inspections due to the deterioration of
paint on the frame directly under the
master cylinder.
Figure 14
34 August 31, 2012

Pulsating Brake Pedal

The rotors or the brake drums are
untrue and they need to be removed
and turned. Do not exceed the
minimum specifications. Replace if
required.
Figure 15
Hard Brake Pedal

This is an indication of a HydroBoost failure.
Refer to Master Cylinder Repair on page 135.
On Hydro-Boost systems, inspect the

hydraulic fluid supply for contamination.
Figure 16
August 31, 2012 35

Spongy Brake Pedal

This is an indication that there is air in the
system.
1. Inspect for cracked or broken lines,
Figure 17
broken hoses and fittings.
2. After insuring the system is completely
sealed, bleed per specifications.
3. Refer to the Bleeding Procedure.
Figure 18
Brake Pedal Goes to the Floor

This is an indication that the system has a leak.
1. Add brake fluid as required, pressurize
the system and locate the leak.
2. Inspect all fittings, hoses and lines
insuring all bleeder screws are tight and
undamaged.
3. Inspect the rear of the master cylinder for
signs of leakage.
Figure 19
36 August 31, 2012

Master Cylinder Failure

It is common that when a master cylinder fails,
brake fluid passes past the piston seals and leaks
out the rear of the master cylinder.
1. Replace master cylinder.
2. Bleed the brakes as required.
Figure 20
Manual Bleeding
Damage may occur during manual bleeding if the piston is bottomed

out inside the master cylinder. Use extreme caution when manually
CAUTION bleeding. Call the factory for further assistance 1-800-255-4262
August 31, 2012 37

Transmission
Checking Transmission Fluid
With the engine warm and the shifter selector in park or neutral, check the transmission fluid. The
fluid level should be within the acceptable level on the dipstick.
Shifter and Cable

1. Raise the rear of the tractor
until the tires do not
touch the ground and
put safety jack stands
under the rear plate.
2. Turn the driveline by hand
and inspect it for
damage.
3. Start the tractor, and move
the selector to drive,
and verify that the
driveline turns.
4. If the driveline does not
turn, disconnect the
shifter linkage from the
transmission and
manually shift into
gear.
5. If the driveline turns, adjust Figure 21
the shifter as required
and inspect all parts as
required.
38 August 31, 2012

Tractor will not Move
If the driveline does not turn, see

Trouble Shooting and Repairs related
to the Rear Axle.
Possible needed replacement parts:
• P-R-N-D-3-2-1 shifter #02045-
0046
• P-R-N-D-3-2-1 shifter cable
#02045-0161
• FNR shifter #02045-0076
• FNR shifter cable #02000005595
Figure 22
Call the factory for further assistance: 1-800-255-4262
August 31, 2012 39

Section 4, Electrical Troubleshooting
Gauges Horn Lights Cab Cab Lights Horn Gauges B+
Batt
Turn Sig Heater
Option
Heater
Starter
Relay Turn Sig
Figure 23, Circuit Breaker Panel
Circuit Breaker Panel

The circuit breaker replaces the fuse panel used before 2009 and later when specified by customers.
All the breakers are fast open when short circuits occur. The 10, 20, and 30 ampere breakers are
manual reset types and their buttons protrude when open to give a visual indication. The 40-Ampure
Starter Relay breaker will reset within 3 – 5 seconds after an overload and remain set if the overload
was momentary. A persistent short circuit will immediately reopen the circuit breaker and after
several cycles, permanently open it.
If an overload appears to be momentary, you can reset the manual-reset circuit breakers once. If it
opens again, the overload is not momentary and must be repaired before you reset the circuit breaker
again.
Tractor Will Not Crank

Note: If the first item does not solve the problem proceed to the next trouble shooting
Instruction until the problem is corrected.
1. Turn the ignition switch to the off position.

2. Turn the ignition switch to the start position. This resets the anti restart.
3. If the tractor now starts, this is normal.
4. With the ignition switch on and the engine off, turn on the headlights.
5. Check for proper operation and battery condition. If the lights are dim or do not come on at
all, check the battery cable terminals and clean them if indicated.
40 August 31, 2012

Operation and Maintenance Manual Section 4, Electrical Troubleshooting
6. If the tractor has a battery disconnect switch, make sure it is on.

7. Connect a battery charger onto the battery and try to start. Set the park brake, apply the
brakes, then move the shift selectors through the shift positions and try to start the tractor. If
the tractor starts, adjust the neutral switch.
Note: If the Starter Relay looks like Figure 26 Old Style Starter Relay, skip Steps 9 and 10.
8. Measure voltage between the #26 and 15-Sec
#26 15-Sec
Relay terminals of the Starter Relay. There must
Relay
be a 12VDC for 15 seconds after you turn the
Ignition Switch to start. If there is not, test for
+12 VDC at #26.
9. If +12 VDC is at #26, test for ground at the
15-Sec Relay terminal for 15 seconds after you
turn the Ignition Switch to Start. If there is no or
low voltage, go to Step 10.
a. If there is no ground, the 15-Second Relay
may be bad or disconnected.
b. If there is ground as required, test for #33
+12VDC between the Batt and #33
terminals.
• If there is +12 VCD, the Starter Relay
may be bad. Use a screw driver to Batt
momentarily short the Batt and #33
terminals together.
• If the engine cranks, replace the Starter
Relay. Figure 24, Starter Relay
10. While trying to crank the engine, measure the

voltage drop between the Batt and Starter Relay
terminals of 40-Amp circuit breaker in the
Circuit Breaker panel. There should be near zero
volts drop. Batt
If there is more than a fraction of a volt, replace
this circuit breaker.
Starter
Relay
August 31, 2012 41

Old Style Starter Solenoid Switching Testing

If the Starter Relay looks like the one in Figure 24, Starter Relay, skip this step.
1. With the use of a jumper wire, a

minimum wire gauge of 12, jump from
one side of the starter solenoid to the
other as shown in Figure 26. This should
be accomplished by touching the wires to
the starter relay posts.
2. If the tractor cranks, further testing is
required, see next step.
3. If it does not crank, replace the starter.
Figure 26 Old Style Starter Relay
1. Using a voltmeter, check for 12 Volts at

wire terminal #26 located on the starter
relay. When the key switch is in the start
position, there should be 12 volts.
2. If there is no voltage indicated, remove
the starter relay, sand, grind or brush all
paint and/or rust from the frame and
reinstall the relay. Insuring a good
ground test again.
3. If the unit still does not crank, replace the
relay
Figure 27
42 August 31, 2012

Neutral Switch Check and Adjustment

To check the Neutral Switch:
1. Disconnect plug “a”.
2. Connect an Ohm meter between pins a-1 and a-4.
3. Move the shift lever through it’s positions.
• F-N-R shifters should close the connection (near 0 Ohms) only in Neutral.
• P-R-N-D-3-2-1 shifters should close the connection in Park and Neutral.
• If the connection between a-1 and a-4 remains closed throughout the shift range or if the
there is no connection in any shifter position, replace the switch.
• If the switch closes in the wrong position, adjust the switch.
To adjust the switch:
1. Put the shift lever in neutral. b
2. Loosen the mounting bolts “b” c

shown in 2 places in Figure 28.
3. Rotate the switch body until the
connection between a-1 and a-4
closes.
4. Insert a 5/32 IN or 4 MM pin b
into the hole “c”. to lock the
switch in this position.
5. Tighten mounting bolts to hold
the switch in place. a
6. Remove the pin and connect the
neutral switch plug.
7. Verify that the engine will start a-1
in either Neutral or Park. a-4
Figure 28
August 31, 2012 43

#26 15-Sec
Relay
8. If no power at #26, check wire

number #19 at the neutral switch
connection. It can be identified as the
purple wire with orange stripe exiting
from the neutral start switch. With the
key switch in the start position, there #33
should be 12volts at this terminal.
Batt
Figure 29, Starter Relay
9. If you do not have 12 volts at the

terminal, replace the neutral switch.
Figure 30
10. Remove the ignition switch from the

dash, test wire #19 with the key in the
start position, wire #19 should have
12volts.
11. If it does not, replace the ignition
switch.
12. If the tractor still won’t crank, call the
Factory for further assistance.
1-800-255-4262 Figure 31
44 August 31, 2012

Tractor Starts Then Dies

1. With a voltmeter, check the #20 wire at

the ignition patch harness. It will have
12 volts when the key is in the run
position.
2. Inspect the cannon plug on firewall for
bent or recessed pins and a proper
connection.
Figure 32
Use only gentle force when reconnecting. The pins are easy to bend.
Caution
3. Check the ignition switch with the key in

the run position. There should be 12volts
on the ignition terminal. Replace the
switch if required.
4. If the problem persists, call the factory
for further assistance. 1-800-255-4262
Figure 33
August 31, 2012 45

Tractor Will Not Start

1. Check for fuel in the fuel tank. The fuel

pickup tube sets 1" above the bottom of
the tank.
2. Add fuel if needed.
3. Connect a battery charger onto the battery,
and charge. Try to start.
4. Install a spark tester in place of the spark
plug, insuring there is a spark at the
plugs.
5. If a spark is present continue to look for a
fuel-related problem.
6. Check all fuel lines, and hoses for loose
connections or cracks.
7. Also inspect all filters.
8. With a voltage test meter, test #31 wire
located on the starter relay. This wire Figure 34
will have 12volts at the terminal end
during cranking. If there is no power,
replace the solenoid
Figure 35 Figure 36
9. With a voltage test meter, test Ohms resistance for #31 wire at its connection with the ignition
patch harness and at the start solenoid. There should be 0.00 to 0.01 Ohms resistance, if
greater resistance is indicated replace or fix the broken wire.
46 August 31, 2012

10. With a voltmeter check the

#20 wire at the ignition
patch harness connection. It
should have 12 volts when
the key is in the On position.
Figure 37
11. Inspect the cannon plug for

a poor connection repair or
replace if required
Figure 38
Note: We recommend a tester consisting of an ignition patch harness and an ignition

module.
12. Disconnect the existing ignition patch harness, connect #31 and #20 wires into the test
harness.
13. Try to start the tractor. If the tractor starts, remove the tester ignition module and plug in the
tractor ignition module.
14. Try to start. Replace the ignition patch harness or ignition module as required. If the tractor
still won't start, call the Plant for further assistance. 1-800-255-4262
August 31, 2012 47

Engine Starts, but Tractor Will Not Move.

Note: If the first item does not solve the problem, proceed to the next trouble shooting
instruction until the problem is corrected.
1. Check Park Brake.

2. If engine does not respond to accelerator, check accelerator operation.
3. Check the transmission fluid level.
a. If the transmission fluid level is normal, check the fluid color and condition.
b. If the transmission fluid is contaminated or contains filings, refer to transmission
overhaul procedures.
4. Verify shifter operation.
a. Shifter Linkage Connected to transmission.
b. Transmission Shift Lever turns with shifter control movement.
5. Check the universal joints.
6. Verify drive shaft rotation.
a. If the drive shaft turns, turn off the engine and use a fiber optic probe to inspect the inside
of the drop box and the rear axle.
b. If the drive shaft does not turn, turn off the engine and remove the inspection cover at the
bottom of the adapter plate. Inspect the flywheel and adapter plate.
48 August 31, 2012

Back-Up Light Inoperative

NOTE: If the first item does not solve the problem proceed to the next trouble shooting
Bulb
1. Remove the lens cover,
2. Remove and inspect the bulb.
3. Replace the bulb if required.
The bulb part number is 00700943224
Figure 39
Note: If the tractor has the Circuit Breaker Panel shown in Figure 23, skip this step.
Fuse
1. Set the key to the on position.
2. Using a volt meter to test for 12 volts at
the top and bottom of fuse number #3.
3. If not, clean or replace the fuse to ensure
there is no corrosion inside the terminal
of the fuse block.
4. Apply a small amount of electrical
contact grease, onto the fuse and
reinstall the fuse.
The fuse part number is 02060-0033-15.
Figure 40
Note: The following causes the most common failures:

1. Instrument lights falling out of their sockets and lying on top of a gauge.
2. Shorting after driving over rough ground.
3. Push - Pull switch failures.
August 31, 2012 49

Backup Light Assembly

1. Remove the lens cover.
2. Remove the suspect bulb.
3. Turn on the key but do not start the
engine.
4. Place the shift selector in reverse or
activate the optional push pull switch.
5. Use volt meter to check for 12 volts at
the back up light socket.
6. If you are getting 12 volts at the light
socket, replace the bulb. Part number
for the bulb #00700943224
7. If not, remove the back-up light
assembly check for 12 volts at wire
number #7 terminal. Figure 41
8. If yes, replace the backup light

assembly. Part number for the backup
light assembly #02060-0005
Figure 42
50 August 31, 2012

Push Pull Switch

1. With the key in the on position using a
12-volt test meter check for 12 volts at
wire terminal number #6 located on the
back up light switch.
2. If yes, with the 12-volt test meter check
wire terminal #7 located on the back up
light switch.
3. If you are not getting any power, replace
the light switch.
4. If there is still no power, see FUSE. Part
number for the tail light switch #02060-
0026.
Figure 43
Neutral / Backup Switch
1. With the key in the run position, but the

tractor not running, place the shifter
selector in reverse. Ensure the park
brake is applied. Use a 12-volt test
meter, check for 12 volts at terminal
wire number #7 on the neutral switch.
2. If not, see CANNON PLUG.
3. If yes, check wire terminal number 7A
located on the neutral switch for 12
volts. If you are not getting the 12 volts,
replace the neutral switch. Part number
for the neutral switch #02045-0037 Figure 44
August 31, 2012 51

Cannon Plug
1. With the use of a 12-volt test meter to
ensure there is 12 volts at the terminal
wire number #6 located at the stop light
switch.
2. If you are getting 12 volts, test the to
switch.
3. If not, inspect the cannon plug on the
firewall to ensure proper connections.
Inspect all pins to ensure a secure fit. A
minimal amount of contact grease
should be used in the cannon plug. Figure 45
Broken Wire
To test for a broken wire or bad connection:
3, 4
1. Disconnect the circuit under test to
isolate it. It will prevent getting any false
readings and protect the meter from
overload.
2. Set the meter for a low Ohms (Σ) range.
If the meter offers an audio signal for 0
Σ, select it.
3. Check the meter by measuring directly
from lead to lead. This is the zero
reference.
4. Measure the resistance between the two 2
points under test. A reading near 0 Σ
indicated a good connection. A flashing
reading or all 9s indicates no connection. Figure 46
Anything in between indicated a poor
connection.
5. Repair as required.
Call the Factory for further assistance 1-800-255-4262
52 August 31, 2012

Brake-Lights Inoperative
This procedure applies only when the braking

operation is normal and the only problem is the
brake lights. If the brakes are less effective than
Warning normal, go to Brake System Troubleshooting.
Electrical System
1. Make sure the key switch is on.
If the tractor has a fuse block, go to Step 3.
2. Make sure the Lights circuit breaker is not
open.
2
If the tractor has a circuit breaker panel, skip
Steps 3 and 4.
Fuse
3. Test for 12 volts at the top and bottom of
fuse number #3.
4. If not, clean or replace the fuse to ensure
there is no corrosion inside the terminal of
the fuse block. Apply a small amount of
electrical contact grease, onto the fuse and
reinstall the fuse.
Part Number for the Fuse is 02060-0033-15.
Figure 48, Fusel Block
August 31, 2012 53

Bulb
5. Remove the stop light lens cover. Remove
the bulb and inspect for broken filament.
6. If yes, replace bulb. Part number for the
bulb #02000005645
Figure 49
Relay
7. If the tractor has a Brake Light relay, put
your finger on the relay and have someone
step on the brake pedal. Verify that you
can feel the relay energize when the
brakes are applied.
If there is no Brake Light relay, the brake light
switch output powers the brake lights directly.
8. If applying the brakes neither lights the
brake lights nor energizes the relay, go to
Switch.
9. If the relay energizes but the brake lights 9
don’t light, check for 12 VDC at the relay
Figure 50, Brake Light Relay
output, Pin-87, Wire #27.
10. If there is not 12 VDC output from the
relay, replace the relay.
11. If 12 VDC appears at the relay output, go

to Step 12.
Note: If the tractor has the Brake Light

Relay shown in Figure 50, Brake
Light Relay, then Wires #6 and #27
are as shown in Figure 51, Brake
Light Relay Wiring.
Figure 51, Brake Light Relay Wiring
54 August 31, 2012

Switch
12. Remove the wires from the brake light
switch.
Note: On tractors that do not have a 6

brake light relay, Wires #6 and
#27 are connected directly to the
brake light switch.
27
Figure 52, Brake Light Control Switch
13. Connect an Ohm meter across the switch

terminals and step on the brake pedal.
14. If stepping on the brake pedal does not close
the brake light switch, replace the switch.
The part number for the switch is 02060-0034.
15. Check for 12 VDC at Wire #6. If there is
not 12 VDC on Wire #6, go to Cannon
Plug.
Figure 53, Testing the Brake Light Switch
August 31, 2012 55

Brake Light Switch Relocation

Technical Bulletin 2010-02 advises relocating the brake light switch if there is any difficulty
installing the brake light switch. The purpose of this bulletin is for maintainability improvement. If
the tee is properly tightened in the correct position, no action is required.
Figure 54 Figure 55
When the tee is installed and properly tightened, Small variations in the threads in the master
the hole for the tee should be on the bottom, cylinder body and the tee, and the way the sealing
between 4:00 and 8:00 O’Clock, as shown in tape is applied may cause the tee to tighten with
Figure 54. the hole on top, causing the brake light switch to
interfere with the master cylinder body, leaving no
way to position the switch correctly unless you
either over tighten or under tighten the tee.
Possible Failure
Under tightening invites leaks. Over tightening can strip the threads or crack the tee.
Correction Procedure
If you install the tee tighten it to the correct torque and it stops as shown in Figure 55, it may
be easier to complete the procedure described below that to find a tee that stops in the desired
position.
56 August 31, 2012

Procedure Steps
1. Remove the Left Hood Side Panel
2. Disconnect the wires on the brake

light switch (e).
3. Remove the following parts:
a. Bolt, 1/4-20 x 1 IN,
b. Lock Washer, 1/4 IN,
c. Clamp(s),
d. Brake Line, Tee to Union,
e. Brake Light Switch,
f. Tee, Brake Light Switch.
Note: The Brake Light Relay and

Harness is a recent revision
and may not be installed in
older tractors.
4. Assemble the following Parts:

a. 102016-0255 Block,
b. 02016-0256 Coupling,
c. Brake Light Switch, 02060-
0034 c
d. 02026-0657 Brake Line; M/C
Rear to Tee, 1/4 IN,
e. 02026-0658 Brake Line, Rear,
Tee to Union; 1/4 IN.
5. Install the new parts in the tractor
as follows:
e a d
b
August 31, 2012 57

a. Seal all pipe threads with Teflon® tape.

b. Install the coupler to the tee by hand starting the coupler by hand to ensure that the threads
are not cross threaded.
c. Tighten the coupler with a torque wrench to a torque value of 55-60 in-lbf. or 6.2-6.8 NM.
d. Install the brake switch by hand into the coupler, ensuring that the threads are not cross-
threaded.
e. Hold the coupler in place with a 9/16” open end box wrench and tighten the brake switch
with a 1-1/16” socket and torque wrench to a torque value of 65-70 in-lbf or 7.3-7.9 NM.
6. Reinstall the brake line

clamp(s) and hardware (f, g, and
h).
7. Reconnect the wires to the
brake light switch.
8. Bleed the brake system.
9. Operationally check the
hydraulic and brake system.
10. Reinstall the hood side panel.
11. Return tractor to service.
® Teflon is a registered trademark of the DuPont Corporation
58 August 31, 2012

Tail Light Assembly
1. Remove the tail light assembly from the

truck, disconnect wire number #27 with
the use of a 12 volt test meter. You will
need to ensure that you have 12 volts at
the harness.
2. If yes, replace tail light assembly. Part
number for the tail light assembly
#02060-0007
3. If not, see broken wire.
Figure 56
Broken Wire
1. With the use of an OHM meter, check for continuity between wire numbers #27 located at
the stop light switch and the connection of the rear harness.
2. If the first item does not solve the problem proceed to the next trouble shooting Instruction
until the problem is corrected.
3. With the key in the on position use a 12-volt test meter to ensure there is 12 volts at the top
and bottom of fuse number #1.
4. If not, and the tractor has a fuse block,

clean or replace the fuse to ensure there
is no corrosion inside the terminal of the
fuse block. Apply a small amount of
electrical contact grease, onto the fuse
and reinstall the fuse. The fuse part
number is 02060-0033-10.
Figure 57
The following causes the most common failures are:

1. Instrument lights falling out of their sockets and lying on top of a gauge, shorting every time
the unit hits a bump.
2. Push - Pull switch failures.
August 31, 2012 59

Hour Meter Pressure Switch
1. (Normally open switch) use a 12 volt test

meter to ensure there is 12 volts at the
number #18 wire located on the hour
meter pressure switch.
2. If not, see Cannon Plug Inspection
Figure 58
Cannon Plug Inspection

1. Check continuity of number #16 wire
from the fuse block to the hour meter
pressure switch.
2. If not, inspect the cannon plug on the
firewall to ensure proper connections.
3. Inspect for bent or recessed pins. A
minimal amount of contact grease
should be used in the cannon plug.
Figure 59
Broken Wire
4. Inspect for broken connections by using
a OHM-meter to check continuity. This
should be done by disconnecting
circuits to ensure they are isolated. It
will also ensure you are not getting any
false readings.
5. Repair as required.
6. Start the unit.
Figure 60
60 August 31, 2012

7. Check for proper operation of the hour

meter pressure switch. Replace switch
if needed. Part Number #02060-0030
8. Use a 12-volt test meter to test terminal
end number #22 located on the back of
the fuel gauge insuring there are 12
volts.
Figure 61, Oil Pressure Switch
9. If not, see Cannon Plug Inspection

10. If not in Cannon Plug see BROKEN
WIRE
11. If not in Broken Wire check all gauges
for 12 volts. Then See Broken Wire.
Gauge Ground:
12. Use of a ground wire from the ground
terminal of the gauge to an adequate
frame grounding point.
Figure 62
13. Check to ensure the gauge ground is

connected at the hour meter wire
number #17 runs through the cannon
plug and grounded onto the engine.
14. Test for continuity of wire number #17
at the cannon plug.
15. If still inoperable call the Factory for
further assistance, 1-800-255-4262
Figure 63
August 31, 2012 61

Head-Lights Won't Work

1. Turn on the key switch.

2. If the tractor has a circuit breaker
panel, check the Lights circuit breaker.
2
3. If the tractor has a fuse panel, use a 12-

volt test meter to ensure there is 12
volts at the top and bottom of fuse
number #3.
Figure 65
4. If not, then you need to clean or

replace the fuse to ensure that there is
no corrosion inside the terminal of the
fuse block.
5. Apply a small amount of electrical
contact grease to the fuse and reinstall.
6. Use a volt meter to test for 12 volts at
wire terminal #9 (Left Headlight) and
number #10 (Right Headlight) located
at the headlight wire connection.
7. Repeat this step through terminals #9
and #10 and the headlamp.
Figure 66
62 August 31, 2012

8. If yes, check the ground described in

Item 3.
9. If not, replace the headlight
Figure 67
10. Use a 12-volt test meter to ensure a

proper ground on headlight. Insert the
probe inside the terminal connection
and use the headlight-mounting base as
the ground. It should read 12 volts.
Figure 68
11. Test for 12 volts on wire terminal

number #5 on the headlight switch.
Figure 69
August 31, 2012 63

12. If there is not, locate and repair the

broken connection. Test for 12 volts on
wire terminal number #9 and number
#10 on the headlight switch
Figure 70
13. If not, replace the headlight switch.

14. Inspect the cannon plug on firewall for
bent or recessed pins and a proper
connection.
15. If the headlights still don’t work, call
the Factory for further assistance. 1-
800-255-4262.
Figure 71
64 August 31, 2012

Operation and Maintenance Manual Section 5, General Overhaul Practices
Section 5, General Overhaul Practices

Removal Procedures
Maintenance personnel should never perform

overhaul operations on the vehicle without the
immediate presence or assistance of another
person who is capable of rendering aid.
Warning!
1. Before removing any item, refer to the troubleshooting guide to determine if the problem is
actually the suspected component. The information contained in these charts will help isolate
problems to a specific component.
2. Before removing any component, be sure that the system is not energized or pressurized.
Disconnect the battery ground cable and be sure that all controls are in the "OFF" position
before beginning any overhaul operation.
3. Be sure that adequate clearance exists for removal of component. Disassemble adjacent
components and structure as necessary to provide adequate removal clearance.
4. Before removing exterior parts, clean mud, tar, grease or ether foreign materials from them.
This will assist in the inspection and disassembly processes. Exterior surfaces can be cleaned
using a vapor pressure, spray-rinse cleaner.
5. Use a chain hoist, jack, or other suitable tool to lift the heavier components, position and
attach the lifting device to the component to remove ail strain from the mounting hardware
before the hardware is removed.
6. To make installation easier, apply identifying tags to the mating ends of components as they
are removed or disconnected. Identify parts of similar configuration to be sure that they are
returned to their proper locations.
7. Make a note or diagram of the original position of components before removing. During
reinstallation, be sure the original position is restored.
8. Treat all components, even if defective, as valuable items because of possible reclamation or
salvage value.
August 31, 2012 65

Disassembly Instructions
1. To avoid contamination of the internal parts of the components, keep the work area as clean
as possible.
2. Replace all gaskets, packings, and seals that are removed in the course of overhaul operations
with new ones whenever possible. These items are usually damaged or destroyed during the
process of disassembly. Replace all lock wires, spring washers, cotter pins, and like items
during reassembly.
3. Do not use a metal tool to pry, pick or scrape off gaskets, packings or seals. Using metal
tools will scratch the sealing surfaces adjacent to these items. Instead, use a pointed wooden
dowel to remove packings from their grooves. Use wood or plastic scrapers on gasket
surfaces.
4. Before disassembling any component, study the exploded-view illustration. Pay close
attention to the relationship of internal parts. Being familiar with construction will speed up
disassembly and help avoid improper reassembly.
5. To prevent moisture and foreign material from entering open housings and lines, install
protective plugs or covers as soon as possible after disassembly. Wrap parts in clean paper or
dip parts in preservation oil.
6. Remove only parts requiring repair or replacement. Do not disassemble a component any
further than necessary to complete needed repairs.
66 August 31, 2012

Cleaning Instructions
Never dip or soak electrical components, packings, rubber, plastic, or

Teflon® parts in a cleaning solvent.
Clean these parts with a clean, lint-free cloth only. Cleaning solvents can
react with these materials and cause severe damage to or destruction of
CAUTION
these parts.
1. Use cleaning solvent in well-ventilated areas or in spray booths. Do not use gasoline for
cleaning parts.
2. After soaking parts in cleaning solvent, wash away deposits by flushing or spraying with
additional solvent. Use a soft-bristled, nonmetallic brush dipped in solvent when
necessary.
3. Dry all parts except bearings using filtered, compressed air after cleaning.
4. Unless specifically noted in the OVERHAUL PROCEDURES section, do not use metal
scrapers, wire brushes, abrasive wheels, or compounds when cleaning parts.
5. Put ball or roller bearings in a basket that is suspended in a container of cleaning solvent
overnight. Use a soft bristle brush dipped in cleaning solvent to remove caked grease and
chips. To prevent damaging balls and races, do not rotate the bearing before solid
particles are removed. After cleaning, immediately spin bearings in a light lubricating oil
to remove the solvent. Allow the excess oil to drip off.
6. Check all oil passages and cavities for cleanliness and freedom from foreign material.
Run a thin, flexible wire through oil passages to make certain they are not clogged. Clean
dirty or clogged passages with a pressure spray gun and dry cleaning solvent.
7. Clean electrical parts, such as relays, switches, terminals, etc., with a cloth moistened in
dry cleaning solvent.
8. Clean exterior surfaces of the battery with a weak solution of baking soda and water.
Apply the solution with a soft bristle brush to remove corrosive build up on the battery
cable terminals.
9. Wash painted surfaces of the vehicle with warm, soapy water. Rinse with clean water and
dry with a clean cloth or allow to air dry.
August 31, 2012 67

Inspection Procedures
1. Check all surfaces that come in contact with gaskets, packings or seals for nicks, burrs,
and scratches that can damage the new parts during reassembly.
2. Check bearings for rusted or pitted balls, races and separators. Check balls and races for
1
brinelling, abrasions and discoloration. Excluding defects which may cause bearing
binding or misalignment, nicks or gouges outside the race load areas are not cause for
rejection. Reject bearings only for cuts or grooves that run parallel to ball or roller
rotation, fatigue pits (not minor machine marks or scratches), or cracks that are detected
during magnetic particle inspection.
3. Check all hoses for broken or frayed fabric, damaged fitting threads, and breaks or leaks
caused by sharp bends or rubbing against other parts of the vehicle. Be sure that the
clamps do not crimp the hoses.
4. Check all wires and wiring harnesses for damaged insulation, cuts, and breaks. Check
terminals and connectors for loose connections, corrosion, and broken parts.
5. Check all cap screws, nuts, fittings and tapped holes for distortion and for stripped or
corroded threads.
6. Check painted surfaces for cracked, peeling or chipped paint.
7. Check exterior parts and chassis for cracks.
Repair and Replacement Procedures

1. Remove nicks, burrs or scratches from surfaces that come in contact with gaskets, packings
or seals with a fine file or emery cloth. Do not change the shape or form of any part.
2. Hoses with broken or frayed fabric, damaged fitting threads or leaks must be replaced
immediately. Replace all cracked or burnt electrical parts and all wires that have several
broken strands. Minor cuts in the wiring harness covers can be repaired with electrical tape
so long as the internal wires are not damaged.
3. Replace all damaged caps crews, nuts, and fittings. Minor damage to tapped holes can be
repaired with the same sized tap. Do not change the size or thread type. Replace all self-
locking fasteners during reassembly procedures.
4. Cracked, peeling or chipped paint can be removed using standard body part procedures.
1
Brinelling is a surface fatigue caused by overloading or repeated impact. It is a sign of impending
bearing failure, possibly caused by contamination or over-tightened bearings.
68 August 31, 2012

Reassembly Instruction
1. Remove all protective coatings from new parts.
2. Lubricate bearings with the same type of lubricant that is normally used or as directed in the
OVERHAUL PROCEDURES section.
3. Reassemble preformed packings as follows:
a. Lubricate the packing with mineral oil or the specified lubricant.
b. Dovetail the groove. Then stretch the packing and put it into position.
c. Rotate the part on a flat surface and apply pressure downward to seat the
packing.
4. Lubricate the lips of oil seals with same type of lubricant normally used in the component or
as specifically directed in the OVERHAUL PROCEDURES section.
5. Install oil seals, with lip facing in, by applying an even force to the outer edge of seal.
6. Coat both sides of gaskets with gasket sealing compound. Be sure all old gaskets and sealant
are removed from parts before installing new gaskets.
7. Rethread caps crews of a part by hand until snug then tighten in a crisscross pattern to final
torque. Install all caps crews, nuts and fasteners dry unless specifically directed to do so in
the OVERHAUL PROCEDURES section.
8. Seal all pipe threads with Teflon® tape.
Installation Instructions
1. Be sure components are placed in the same position that they were in when removed.
2. Check all identifying tags for the correct connection of all lines and hoses.
3. Check the level of lubricant or fluid. Add or drain as required.
4. Perform a test run on the vehicle and inspect the repaired component(s) for proper
adjustment, leaks, vibration, noise or misalignment. Correct any problems immediately.
August 31, 2012 69

Section 6, Specific Overhaul Procedures

A, Frame and Sheet Metal
Refer to Section 5, General Overhaul and Repair Practices to remove and replace damaged or worn
parts.
B, Engine and Transmission

Engine and Transmission Removal
1. Disconnect the negative battery cable from the battery.
2. Remove the four hood bolts and remove the hood. Remove the bolts and lock-washers from
the exhaust pipe mounting flange.
3. Remove the wiring harness from the engine. Start by disconnecting the wires at the hour
meter pressure switch, the oil pressure sender, and the water temperature sender. Disconnect
the two ignition wires that are at the engine ignition loom connection. Disconnect the
positive battery cable from the starter. Disconnect the positive and ground wires that are
connected to the alternator.
4. Remove the Master-VAC vacuum hose.
5. Remove the accelerator rod/cable.
If the engine is hot, never open the radiator cap without
checking to see if the radiator hoses are pressurized.
Without pressure, coolant boils at 212○F (10○C) at sea level,
declining 1.5○F (1○C) for each 1,000 of elevation. Pressure
increases the boiling temperature.
Warning Releasing the pressure while the coolant is hot can cause
very rapid boiling and severe scalds.
6. Drain the radiator and disconnect the transmission cooling lines from the radiator.
Disconnect the radiator hoses from the engine. Remove the four radiator mounting bolts and
lift the radiator and radiator hoses out of the truck.
7. Disconnect the drive shaft by removing the four bolts that connect the drive shaft to the drive
train. Securing the drive line to the transmission wilt keep transmission fluid from leaking
while the engine and transmission are being removed.
8. Disconnect the shifter cable and the neutral safety switch from the transmission. Remove the
two nuts and lock-washers from the transmission mount. Remove the nut from the front of
the motor mounts. The engine and transmission may now be lifted from the truck.
70 August 31, 2012

Operation and Maintenance Manual Section 6, Specific Overhaul Procedures
Use only a hoist or lifting mechanism that is specifically

designed for this task.
Warning
Engine and Transmission Repair
Refer to the repair and overhaul appendices for the engine and the transmission for detailed
instructions.
Engine and Transmission Replacement
1. Install the radiator, the radiator hoses, and the transmission cooling lines at the same time.
Route the transmission cooling fines through the three clamps and secure them. Do not over
tighten the four bolts that hold the radiator and insulators to the frame. Always use new lock
nuts when replacing the radiator.
2. Using a suitable hoist, lower the engine, the transmission, and the drive shaft into place. Be
sure that the engine is straight in the mounts. Align the engine as necessary before
proceeding. Replace the nuts and lock-washers on the transmission mount. Always use new
locknuts on the engine mount studs when remounting the engine.
3. Bolt the drive shaft to the drive axle with the four bolts, nuts, and lock-washers that were
removed during disassembly.
4. Reconnect and adjust the transmission shift cable according to the instructions.
5. Plug the neutral switch wire loom into the neutral safety switch on the transmission.
6. Reconnect the transmission cooling lines. Seal all pipe threads with Teflon® tape.
7. Reconnect positive battery cable to the starter motor.
8. Reconnect the exhaust pipe to the exhaust manifold.
9. Reconnect the radiator hoses to the engine and tighten the clamps. Fill the radiator with
coolant according to specifications.
10. Reconnect the wiring harness to the alternator, the water temperature sender, the oil pressure
sender, and the hour meter pressure switch. Reconnect the two ignition wires to the ignition
harness.
11. Replace the accelerator rod/cable. Be sure that the full throttle opening and the accelerator
stop are property adjusted.
12. Reconnect the vacuum hose to the HydroVac.
13. Replace the hood and reattach the hood assist cylinder.
14. Reconnect the negative battery cable to the battery.
August 31, 2012 71

General Warnings and Cautions

Follow each step in this procedure in the specified sequence and observe all values.
Failure to comply with these specifications is likely to cause this assembly procedure to fail
and, at the least, be rejected by quality assurance. Worse, it can cause a defective tractor
to be shipped to our customers. Defective tractors diminish Harlan’s reputation, incur
warranty and recall expenses, can cause litigation and personal injury. Mistakes that
seem small can have big consequences. Examples:
• When a torque setting is specified, use a torque wrench. Incorrect torque
values cause nuts and bolts to strip or loosen and can damage parts.
• Use dowel pins as specified. Failure to dowel pins as specified causes poorly
aligned assemblies premature wear and failures.
• Look for dirty and damaged mating surfaces. Poor mating surfaces cause
leaks, premature wear, and failures.
• Use lock washers and flat washers as specified. Missing lock washers cause
bolts and nuts to become loose. Using lock washers where not specified
damages surfaces and can cause cracks the
spread and cause parts to fail. Missing flat
washers cause poor fit, damaged surfaces and
failures.
• Use sealants as specified. Too much can be
worse that too little. Excessive sealants can
cause clogged passageways in transmissions
and lubrication systems.
• Use lifting equipment properly. Here is an
example of improper use. This was taken while a
transmission was hanging from the lift. You
need to turn the nut until at least one full thread
extends beyond the nut.
72 August 31, 2012

Radiator and Radiator Mounts

parts.
Exhaust System
parts.
Installing Exhaust Wrap on the Exhaust Header
1. Soak a roll of 02014-0874 Exhaust Wrap material in

water for a few minutes.
2. Slide a #40 Hose

Clamp onto the outlet 3
end of the exhaust
header.
3. Start wrapping the
exhaust wrap material
around the header pipe
from the inlet end. 4
4. Slide a second #40
Hose Clamp onto the 2
inset end of the exhaust
header.
August 31, 2012 73

5. Tighten the #40

clamp at the inlet
end.
6. Continue to wrap
the exhaust wrap
material around the 6
header pipe with
about 50% overlap.
7. When you reach the
end of the flexible 7
portion, cut the
exhaust wrap
material.
8. Tighten the #40
hose clamp around
the end of the 8
exhaust wrap
material.
9. The exhaust header is

ready to install in the
tractor.
74 August 31, 2012

C, Fuel System
Accelerator Pedal Operation
Refer to On Board Diagnostics Procedures.
Air Cleaner
parts.
Fuel Lines
parts.
August 31, 2012 75

D, Engine-Transmission Interface
Engine-Transmission Interface
Engine-Transmission Interface Parts List
Reference
Description Quantity Part Number
Number
D Kit, Adapter C6 Trans to GM 3.0L, 38030255-2 1 Ea
1 Adapter, C6 Transmission 3.0L 1 Ea 02035-1192
2 Bolt, 3/8-16 x 3, Socket Head Fl Thread G5 5 Ea 0070073G648
3 Pin, Dowel 1/2 IN X 1 1/4 IN 2 Ea 02035-0384
4 Plate, Cover, C-6-Flexplate 1 Ea 02035-1194
5 Bolt, 1/4-20 x 5/8, Flange Hex Head 2 Ea NSS
6 Bolt, 7/16-14 X 2 1/4 Hex Hd Grade 5, 6 Ea 02011-1C736
7 Washer, Lock 7/16 6 Ea 02011-23E7
8 Plate, Flywheel Cover 3.0L 1 Ea 02035-1194
9 Bolt, 1/4-20 x ½ IN 4 Ea 02011-1C408
10 Washer, Lock ¼ IN SAE 4 Ea 02011-23E4
11 Spacer, TC 3.0L 1 Ea 02035-1196
12 Bolt, 7/16-20 x 2 1/2 Socket Head G5 6 Ea 0070074G740
13 Flywheel and Ring Gear Assembly 1 Ea 02035-1197
14 Flexplate, Flywheel 1 Ea 02035-0086
15 Plate, Flexplate to Flywheel 1 Ea 02035-0068
16 Bolt, 7/16-20 x 1 IN, Hex Head 6 Ea 02011-18C716
17 Torque Converter 1 Ea 0700999641
18 Nut, 3/8-24, Self Locking, Flange Head 4 Ea 02011-0382
76 August 31, 2012

Assembling the Engine and Transmission
I.1
1. Attach the Transmission Hoist to the Transmission.
Make sure all four bolts are fully seated under the
transmission lifting tabs and tight. Failure to properly tighten
these bolts could allow the transmission to fall from the hoist.
Warning
2. Lift the transmission and bring it to the engine. Set its height to the same as the engine.
3. Move the transmission into position facing the flywheel.
August 31, 2012 77

J.4
I.4
4. Rotate the torque converter until the studs in the Torque Converter line up with the holes in
the flex plate.
J.5
J.6
5. Line up the transmission with the dowel pins in the engine.

6. Recheck the flywheel and torque converter alignment. Adjust as necessary.
7. Close the gap between the engine and the transmission.
78 August 31, 2012

8. Apply Locktite 271® to 4 02011-1C736 bolts and 3 02011-1C736 bolts.

9. Bolt the engine and transmission together in 3 places with:
• 1 Ea, 02011-1C736 Bolt
• 1 Ea, 25E17 Flat Washer
• 1 Ea, 02011-23E10 Lock Washer.
1
2
10. Install 1, 2 and 3, with a ground strap under Bolt 2, in the sequence shown above.
11. Insert the dipstick tube into the transmission as shown and install Bolt 4.
August 31, 2012 79

Installing Torque Converter Nuts
1. Install the nuts through the slow at the bottom between the transmission and the adapter
plate.
2. Turn the flywheel until a torque converter stud is accessible in the slot.
3. Fasten the Torque Converter and Flexplate together with four 02011-0382 nuts.
4. Bolt the 02035-1194 Cover to the adapter plate with a 02011-1C412 bolt and 02011-23E4
lock washer in two places.
80 August 31, 2012

E, Transmission
Refer to the transmission appendix for overhaul and maintenance procedures.
Transmission Control Removal
1. Raise the front of the tractor with a suitable lift and support it by placing jack stands under
the front plate.
2. Remove the nut, the lock-washer, and the ball joint from transmission shift lever.
3. Remove the bulkhead jam nut from the shifter cable and remove cable from bracket Cable
Items.
4. Disconnect the shutdown system wire from the shifter switches.
5. Remove the six screws that hold the plate to the tractor. Remove the shifter assembly and
cable from the tower.
Transmission Control Repair
parts.
Transmission Control Replacement
1. Put the transmission control assembly back into the shifter tower. Replace the plate and the
six securing screws.
2. Reconnect the shutdown system wire to the shifter.
3. Put shift lever into the neutral position "N" Be sure that shift lever on the transmission is in
neutral.
4. Thread the ball joint into transmission shift lever.
5. Reattach the lock-washer and the nut to the ball joint.
6. Return the cable to the cable-mounting bracket and tighten the bulkhead jam nut.
Note: Be sure that the shift lever on the transmission is in the "NEUTRAL DÉTENTE"
position when cable adjustments are being made.
Transmission Cooling Lines

parts.
August 31, 2012 81

Installing Neutral Switch Plugs
02060-0413 02045-0037
There are two types of Neutral Safety switch assemblies that have been used on C-6 transmissions.
The switches are identical. The only difference is the plug arrangement. Use the single-plug or two-
plug that matches the harness on your tractor. If you have a switch that does not have the correct
plug configuration, rewire it as follows:
To wire a 02045-0037 Switch
26, red and white
19, red and white
7, Black and White
7a, purple and brown
1. Shorten the Neutral Switch wires to 18” and remove 3” of cable cover.
82 August 31, 2012

2
2. Install Weatherpack Seals and
Weatherpack male Pins on wires 7 and
7a.
3. Install Weatherpack Seals and

Weatherpack female pins on wires 19 3
and 26.
Note: Wires 19 and 26 are

interchangeable at this point.
Wire 26 Pin B Plug
Pin A
Wire 7a Wire19 Receptacle
Pin B
Pin A
Wire 7
a. Insert Wire 7, (black and white) into a Pin A of a 2-Pin Weatherpack receptacle.
b. Insert Wire 7a, (purple and brown) into a Pin B of a 2-Pin Weatherpack receptacle.
c. Insert Wire 19 (red and white) into a Pin A of a 02060-0735 2-Pin Weatherpack plug.
August 31, 2012 83

4. Insert Wire 26 (red and white) into a Pin B of a 2-Pin Weatherpack plug.
To wire a 02060-0413 Switch

1. Insert Wire 7a, the purple and brown wire, into a Pin-a of a 4-Pin Weatherpack plug.
2. Insert Wire 7, the black and white wire, into a Pin-b of a 4-Pin Weatherpack plug.
3. Insert Wire 19, a red and white wire, into a Pin-c of a 4-Pin Weatherpack plug.
4. Insert Wire 26, a red and white wire, into a Pin-d of a 4-Pin Weatherpack plug.
Note: Wires 19 and 26 are interchangeable until you insert them in the plug. The wire in
Pin-c becomes Wire 19. The Wire in Pin-d becomes Wire 26.
5. Connect the Weatherpack plug to corresponding connector on the Rear Frame Harness
Wire19 Wire 26
Wire 7
Wire 7a
d
a b c
84 August 31, 2012

Installing the Neutral Switch

2. Apply Locktite 271® to
one 02011-1C516 bolt and
two 02045-0168 bolts.
3. Bolt the Shifter Arm to the
Neutral Switch control 4
lever with the following
hardware sequence:
a. 02011-1C516 Bolt,
b. 02045-0092 Shifter
Arm,
c. 02011-23E5 Lock
3
Washer, and
d. 02011-1D5 Nut.
4. Bolt the Neutral Switch-
Shifter Arm assembly to the
transmission with a 02045-
0168 bolt in 2 places.
5. Route the Neutral Safety

Switch cable between the
bracket and the
transmission as shown.
August 31, 2012 85

F, Drive Train
Removing the Drive Axle
To remove the drive axle:
1. Put chocks in front of the

front wheels.
2. Jack up the rear of the
tractor and put safety
jack stands under the rear
plate.
3. Lower the tractor onto
the safety jack stands.
4. Remove the wheels and
tires.
5. Disconnect the axle

brake(s) from the frame
brake line(s).
86 August 31, 2012

6. Plug the brake line(s).
7
7. Drain the oil from the
axle housing.
8. Disconnect the driveshaft

from the drop box input
flange.
August 31, 2012 87

Never allow any part of your body under the axle or springs during
the remainder of this procedure.
WARNING
9. Position a fork lift behind the tractor and adjust the forks so that they are directly under the
spring bolts.
9
11
10
10. Place a pallet under the rear axle as shown.
11. Slowly lift the axle as you turn the bolt and nut sets at the front of the springs. The correct
lifting force will minimize the torque needed to turn the bolt and nut sets. Bolt wrench size = 1
3/8 IN; nut = 1 7/16 IN.
Two people are required for this step.
Caution
12. Remove the 4 bolt and nut sets that attach the springs to the spring hangers.
13. Lower the axle onto the pallet.
14. Move the axle out from under the tractor.
15. Remove the driveshaft from the drop box input flange.
88 August 31, 2012

Drive Axle Disassembly

Complete the following steps on each side of the axle assembly.
1
1. Remove the 14 bolts that
fasten the axle shafts to the
rotor assemblies. Keep track
of which bolts have tapered
dowels and which have lock
washers.
2. Move the Axle Shafts outward

from the axle assembly about
12 IN or 30 CM.
August 31, 2012 89

Removing the Third Member and Drop Box Assembly
1. Remove the 12 bolts

(5/8 socket) that fasten
the Differential
Housing to the Axle
Housing.
2. Use a rubber mallet to
break the seal between
the third member
housing and the axle.
3. Remove the third

member and drop box
assembly from the axle.
90 August 31, 2012

4. Remove the 13 Bolts

(9/16 Socket) from the
drop box cover and
remove the cover
5. Remove the cotter pin

from the output gear
nut.
August 31, 2012 91

6. Remove the output gear nut (1

1/2 IN Socket).
7. Remove the output gear from

the pinion shaft.
92 August 31, 2012

8. Remove the lock wire

from the bolts that
fasten the drop box to
the third member.
9. Lower the third

member and drop box
assembly to the work
bench or floor.
10. Remove the bolts that
fasten the drop box to
the third member.
August 31, 2012 93

11. Use a rubber mallet as needed to break

the seal between the drop box to the
third member.
12. Separate the drop box to the third
member.
12
Replacing the Input Pinion Bearing
1. Fasten the Third Member

to the work stand.
94 August 31, 2012

2. Flatten the locking tabs on

the star washer.
3. Remove the jam nut and star washer

from the Thrust Pin. Hold the thrust pin 3
with a 1/2 IN wrench while you loosen
the jam nut with a 1 1/4 IN wrench.
4. Discard the star washer.
August 31, 2012 95

5. Remove the Thrust Pin

from the axle housing.
6. Mark the bearing cap

on one side.
7. Remove the lock wires
from both bearing cap
bolts.
8. Remove bearing cap
bolts (15/16 Socket)
and bearing caps.
96 August 31, 2012

9. Remove the differential assembly from

the differential carrier.
If the third member has a

tapered input pinion bearing
(part number 02025-0448),
replace it with the 02025-
0026 bearing.
Complete steps 10 through
12 to remove the input
pinion bearing and steps 13
through 16 to install the
02025-0026 Bearing.
02025-0026 Straight Bearing
02025-0448 Tapered Bearing
August 31, 2012 97

Removing the Input Pinion Bearing
10
10. Use a brass rod to drive

the pinion shaft out of
the differential housing.
11. Use a steel drive pin to drive the

bearing race out of the differential
housing.
11
98 August 31, 2012

12. Remove the tapered

inner pinion bearing
from the pinion shaft.
Installing a Input Pinion Bearing
Important
Check the replacement

bearing to identify the
top and the bottom.
Make sure you install it
with the top side facing
up.
August 31, 2012 99

13. Use a 1 IN or 25MM

socket to drive the
inner race of the Inner
Pinion Bearing
downward until it seats
on the Pinion Shaft.
14. Use a 1 1/4 IN or 32

MM socket to drive the
outer race of the Inner
Pinion Bearing
downward until it seats
on the inner race.
100 August 31, 2012

15
16
15. Rotate the Pinion Shaft
and verify that the 16
bearing rollers turn
freely. If the pinion
does not turn freely
remove the pinion shaft
and press off the
bearing assembly
(02025-0021).
Substitute bearing 16
spacer that is .001”
thicker and reinstall the
bearing and pinion
assembly. Repeat until
the pinion turns freely.
16. Use a hammer and punch to peen the edges of the hole in several places to lock the Bearing
Race in place.
17
17
Important
17. If the housing surface is chamfered
around the bearing hole, make sure
the peening extends below the
chamfered edge enough to raise the
inside surface and lock the bearing
in place.
August 31, 2012 101

Reassembling the Third Member
1. Put Differential Assembly in

the Differential Carrier.
2. Push the bottom Bearing Race
until the Ring and Pinion
Gears are fully meshed.
2
2
3. Reinstall the bearing caps,

matching up the marks you
5a 5b
made before you removed the
caps
4. Thread in the bolts enough the
keep the caps in place.
5. Install a Bearing Adjusting
Nut on each side. Hand
tighten nut (a) first, then nut
(b).
6. Use a small pry-bar to thread
the Bearing Adjusting Nuts 3
towards each other, rotating
each one the same amount,
until they are snug against the
Bearing Races.
102 August 31, 2012

7. Check the differential

rotational friction. Spin the
Ring Gear sharply. It should
coast about one half a turn. If
it is too tight, loosen each
Bearing Adjusting Nut one
notch and test again.
8. Check the Differential end-
8
play. If you need to reduce
endplay, tighten each Bearing
Adjusting Nut in one notch at
a time. You need to reduce
end play an much as you can
without making the bearings 7
tight enough to prevent the
differential from turning
freely.
To tighten the Ring Gear, adjust the bearings:
To the loosen Ring Gear, adjust the bearings:
Note After you have adjusted the Differential Bearings to achieve the proper tightness
and end-play, all further bearing adjustments must be equal and opposite on
each side to avoid tightening or loosening the bearings. For example, when you
tighten one bearing one notch, you must also loosen the other bearing one notch.
This adjusts the distance between the Ring Gear and the Pinion Gear.
August 31, 2012 103

Adjusting the Bearings
1a
1. Set a dial indicator (a) against

a Ring Gear tooth to measure
the backlash.
2. Hold the Pinion Gear (b)

firmly and check how the
Ring Gear (c) can turn without
moving the pinion gear.
3. Read the dial indicator. It
should be between.008
and.012 inches.
4. Do one of the following: Turn 2b
the Bearing Adjusting Nuts
one notch at a time:
a. If the dial indicator
reads more than.012
inches, move the ring
gear towards the
pinion gear to reduce
backlash.
b. If the dial indicator
reads lass than.008 2c
inches, move the ring
gear away from the
pinion gear to increase
backlash.
5. When the backlash is
between.008 and.012 inches,
tighten cap bolts to 120 Lb-Ft
or 169 NM.
104 August 31, 2012

QA Check
1. Paint four teeth on the

ring gear.
2. Turn the pinion shaft until
the painted ring gear teeth
pass under the pinion
gear.
3. Check the contact marks

that the Pinion Gear made
in the paint. The marks
should be between middle
and top (outside) of the
gears.
August 31, 2012 105

To raise the To the lower

Ring Gear, Ring Gear,
adjust the adjust the
bearings: bearings:
4. If the contact point is between middle and top (outside) of the gears, go to Step 5. If you need
to make any adjustments, loosen the cap bolts and do one of the following:
(a) If the contact point is too low (too close to gear center), adjust the Bearing Adjusting
Nuts one notch at a time to raise the Ring Gear (towards the Pinion Gear).
(b) If the contact point is too high (too close to outside of gear), adjust the Bearing
Adjusting Nuts one notch at a time to lower the Ring Gear (away from the Pinion
Gear).
5. Do one of the following:
(a) If you made any adjustments, retighten cap bolts to 120 Lb-Ft or 163 NM and go
back to Step 1.
(b) If no adjustments were required, lock the adjusting nuts.
106 August 31, 2012

Locking the Bearing Adjusting Nuts and Bearing Cap Bolts
1
2
1. Insert the locking pin in
the cap and tap down if
necessary until the
holes align.
2. Install the cotter pin.
3. Install lock wire

between the carrier cap
bolts as shown.
August 31, 2012 107

Installing the Thrust Pin

1. Turn differential
sideways so that hole
for thrust pin is facing
upwards.
2. Apply RTV Silicone
Gasket on one end of 3
the Thrust Pin.
3. Screw the Thrust Pin
into the Differential
Carrier.
4. Tighten the Thrust Pin
while turning the
differential until you
feel an increase in
friction. Then loosen it
just enough to
eliminate that increased
friction.
5. Install the star washer

and nut to thrust pin
and tighten the nut.
6. Bend one tab up and 1
or 2 tabs down. 5
108 August 31, 2012

Reassembling the Third Member and Drop Box Housing
2
1. Turn the carrier so the 2
Pinion Gear is on top.
2. Tap the dowels into
holes opposite each
other.
3. Apply a layer of silicon
gasket around the Input
Pinion Shaft.
3
4
4. Place 2-3 gaskets on
the RTV Silicone
Gasket.
5. Apply another layer of
RTV Silicone Gasket
on the top paper gasket.
5
August 31, 2012 109

6. Apply Loctite the 6 6

bolts.
7. Bolt the drop box and
the differential
together.
8. Tighten the bolts to 100 8

Lb-Ft or 135 NM.
9. Lock the bolts in the
Drop Box with lock
wire as shown.
110 August 31, 2012

Installing the Drop Box Output Gear
1. Install the output gear

on the pinion shaft.
2. Install the washer.

3. Install the nut.
4. Tighten the nut to 175
Lb-Ft or 237 NM with
a torque wrench and
1 1/2 IN socket.
5. Lock the nut with a
cotter pin.
2 3
August 31, 2012 111

Installing the Drop Box Case Cover
1. Inspect the inside of the

Drop Box Cover, for
burrs or rough spots.
File them smooth as
needed.
2. Apply a layer of RTV

Silicone Gasket on the 2
Drop Box Case-to-
Cover mating surface.
3. Place the paper Gasket
on the Drop Box Case-
to-Cover mating
surface.
4. Apply a layer of RTV
Silicone Gasket on the
Drop Box Gasket.
5. Install the Cover.

6. Fasten the cover to the
case with 13 3/8-16 X ¾
Bolts.
112 August 31, 2012

Assembling the Differential Case to the Axle
1. Apply a bead of silicone gasket around the axle mating surface.

2. Put the gasket on the mating surface.
3. Apply another bead of silicone gasket on the paper gasket.
August 31, 2012 113

4. Apply LockTite to 12 bolts.

5. Bolt the Differential Housing to the Axle Housing.
6. Tighten the bolts to 35 Lb-Ft or 47 NM.
7. Fill the Axle with 6.5 Quarts (6 Liters)

of 90W Gear Oil.
8. Seal the plug threads with Teflon® 7
tape and install the plug.
9. Attach the driveshaft to the drop box
input flange.
114 August 31, 2012

Installing the Drive Axle
Two people are required for this step.
Caution
1. Position the axle along side of the tractor with the front of the spring aligned with the spring
hangers.
If the same axle and rear springs are to be reinstalled, the spring tie bolts should remain tight.
If a new axle or spring is installed, tighten the spring tie bolts and nuts until they are snug,
but loose enough so that the springs may be moved to align them with spring hangers.
2. Move the axle to under the tractor center.
Never allow any part of your body under the axle or springs during
the remainder of this procedure.
WARNING
August 31, 2012 115

4
4
3. Move the forklift to behind the tractor and raise the axle until you can insert the front spring
bolt and nut sets into the lower holes in the spring hangers.
4. Support the axle and install the four 3/4 IN bolt and nut sets that attach the springs to the
spring hangers and tighten the nuts and bolts to 325-350 Lb-Ft / 440-475 NM.
5. If the springs and axles were separated, be sure that the spring tie bolt head is in the slot at
the top of the axle housing. Tighten the nuts to a torque of 150 Lb-Ft. or 203 NM, using an
alternating front to rear tightening sequence.
6. Attach the driveshaft to the transmission.
116 August 31, 2012

7. Remove the protective plugs from the ends of brake hoses. Reconnect the brake lines.
8. Install the rear wheels and tires.
9. Jack the tractor enough to remove the safety jack stands. Remove the safety jack stands and
lower the tractor onto its wheels.
10. Tighten the lug nuts to a torque of 200 Lb-Ft. / 270 NM.
11. Bleed the brakes to remove air from the brake lines.
12. Operate the tractor in forward and reverse to check for any abnormal noises.
13. Inspect the rear axle for leaks.
14. Return the tractor to service.
Axle Shaft Repair
Follow general overhaul practices as described in Section 5 to inspect and clean the axle shaft.
Replace the axle shaft, if necessary.
Axle Shaft Replacement
1. Put a new hub gasket (5) on the axle shaft and hold it in place using gasket sealant. Insert the
axle shaft into the axle housing.
2. Replace the bolts, lock-washers, and dowels (5). Tighten the bolts to a torque of 70 Lb-Ft or
95 NM.
August 31, 2012 117

Input Shaft Seal Replacement

1. Remove the drive shaft from the input flange.
2. Remove the locknut and flat washer that holds the input flange to the input pinion gear and
remove the input flange.
3. Carefully pry the oil seal out of its seat. Do not damage the area that surrounds the oil seal
seat. Note the direction of the lip on the oil seal.
4. Install a new oil seal. Be sure that the lip of the new seal faces the proper direction.
5. Replace the flat washer and locknut. Reattach the drive shaft to the input flange.
Drive Shaft Assembly Removal
1. Remove the bolts, the lock-washers, and the nuts from rear of the drive shaft.
2. Remove the cap screws, the lock-washers, and the straps from front of the drive shaft. Lower
the drive shaft from the tractor.
Drive Shaft Disassembly

Remove the retaining rings, the journals, and the bearings to remove the flange yoke and the slip
yoke.
Drive Shaft Repair

Follow general overhaul practices as described in Section 5 to remove and replace damaged or worn
parts.
Drive Shaft Reassembly

Reinstall the bearings and the journals on the shaft. Replace the bearings on the flange yoke and the
slip yoke. Secure these items with the retaining rings.
Drive Shaft Assembly Replacement

1. Replace the straps, t cap screws, and the lock-washers that secure the transmission output
flange to the carrier and drop box assembly.
2. Replace the nuts, the lock-washers, and the cap-screws.
Rear Springs
Follow general overhaul practices as described in Section 5 to remove, clean, inspect and replace
damaged or worn pads.
118 August 31, 2012

Rim and Wheel Maintenance

Remove damaged rims or wheels immediately. Always
deflate the tires before removing rims or wheel from the
tractor. Failure to do so could result in serious injury or
Warning even death.
Wheel and Tire Examination
1. Check for the following types of damage:
a. Fatigue cracks in metal.
b. Bent flanges.
c. Deep rim tool marks.
d. Loose, missing or damaged lug nuts.
e. Bent or stripped studs.
f. Excessive rust or corrosion.
2. Mark damaged or hazardous areas with chalk to indicate the parts that are to be removed for
servicing. Replace all damaged parts.
3. Clean the wheels thoroughly. Remove dust, dirt, and other foreign materials from all
surfaces.
4. The bead seat areas should be free from rust and rubber deposits.
The rim can be painted using brush-on or spray paint. Always use a fast-drying metal primer on bare
surfaces before applying the final coat. All surfaces must be clean and dry prior to painting. Be sure
that bare metal areas on both the outside and the inside are well coated with paint.
Tire Maintenance
Failure to follow these warnings could result in serious injury

or even death.
• Remove the valve core and completely deflate all tires
before removing them from the wheels.
• Always allow all of the air to escape from a tire before
Warning removing any of the rim components. Be sure that the
valve cores are removed from the tires. Run a piece of
wire through the valve stem to make sure it is not
dogged.
• Never weld a wheel with an inflated tire on it.
August 31, 2012 119

1. Check the rim components for fatigue cracks periodically. Replace all cracked, badly worn,
damaged, and severely rusted components.
2. Clean and repaint the rims to stop the detrimental effects of corrosion. Use a filter on the tire
inflation equipment to remove moisture from the air. This will help prevent corrosion. Check
the filter periodically to make sure that it is working properly.
3. Double check all components to make sure that they are properly seated prior to inflation.
4. Do not overload or over inflate tires.
5. Do not reinflate a tire that has been gone flat without inspecting the tire, rim, and wheel
assembly first.
6. Do not use undersized rims.
7. Do not hammer on an inflated or partially inflated tire and rim assemblies.
8. Do not allow persons who do not have proper training to mount or demount tires.
9. Never sit or stand in front of a tire and rim assembly that is being inflated. Use a clip-on
chuck and be sure that the inflation hose is long enough to permit the person inflating the tire
to stand to one side of the tire during inflation.
10. Do not rework, weld, heat, or braze any rim component that is cracked, broken, or damaged.
Replace damaged parts with new parts that are the same size, typo, and make.
11. Always put hardwood blocks under the jack when changing tires. It is not possible to visually
determine whether or not the ground is safe for the removal operation.
12. Wedge a block between the ground and the tire that is on the outer side of the tractor before
positioning jack. Always immobilize the tractor with blocks to prevent slippage and possible
injury.
13. Use bead breakers and rams to apply pressure to the bead flanges. Slant the bead breaker at
an angle of about 110 degrees to keep it firmly in place. Always stand to one side of the tire
when applying hydraulic pressure.
14. When using a cable or chain sting, stand clear of the tractor when a cable or chain sling is
being used to suspend the tractor, Serious injury or death may result if the cable or chain
snaps.
15. Inspect the tires and wheels regularly for cuts, breaks, alignment, and tightness of lug nuts.
Check the tires for proper inflation frequently.
16. The rear wheel assemblies are one piece with tubeless tires. The front wheel assemblies are
two piece with tires and inner tubes.
120 August 31, 2012

Single Rear Wheels and Tires
Figure 72, 1-Piece Single Drive Wheel Figure 73, Tire Changing Machine
Single drive wheels are available in 1-piece and 2-piece versions. The 1-piece wheels may be fitted
with tubeless tires and use standard passenger car tire installation equipment and procedures. Follow
the instructions supplied by the equipment manufacturer.
The 2-piece wheels require tube-type truck tires

and can be installed with only hand tools.
Figure 74, 2-Piece, Single Drive Wheel
August 31, 2012 121

Single 2-Piece Drive Wheel Removal and Installation
1 Hub
2
Figure 75, Single 2-Piece Rear Wheel
To remove a single 2-piece drive wheel:
1. Jack up the rear of the tractor and install safety jack stands under the rear plate.
2. Remove the 12 lug nuts that fasten each wheel and tire assembly to the axle.
3. Remove the wheel and tire assembly from the axle.
4. Remove the valve core from each tube (3) and deflate the tire. Make sure each tire is
completely deflated before you proceed.
5. Pry the lock-ring from each wheel.
6. Remove the tire (2), tube (3), and flap (4) from the wheel (1).
122 August 31, 2012

To reassemble the rear wheel and tire:

1. Check to see if the tire contains any markings that should be on the outside.
2. Put the tube (3) in the tire (2) with the valve facing towards the outside.
3. Put the flap (4) in the tire so it will be between
the tube and the wheel. There is a hole in the
flap that the valve will pass through. The hole
is nearer to one side of the flap.
4. Position the flap so the hole is nearer to the
outside of the tire.
5. Pass the valve through the hole and spread the
flap and tube evenly around the tire. It may
help to partially inflate the tube.
Figure 76, Valve and Flap Positions
6. Pass the valve through the inner and outer slots

in the wheel.
Figure 77, Valve and Outer Slot Positions
7. Install the lock-ring on the wheel and walk

around the lock-ring to force it over the ridge
on the outside of the wheel.
Figure 78, Installing the Lock-Ring
8. Inflate the tire.

9. Install the wheel and tire assembly on the axle.
10. Tighten the lug nuts to 200 Lb-Ft. / 270 NM in
a criss-cross pattern.
August 31, 2012 123

G, Brake System
Brake System Master VAC Unit
This section applies only to tractors with HydroVac brakes.
Figure 79, HydroVac Assembly
If your tractor has Hydro-Boost brakes, skip this section. Go to

Hydro-Boost Systems on Page 130.
Figure 80, HydroBoost Assembly
General Description
The Bendix Tandem Diaphragm Master-VAC is a self-contained vacuum-hydraulic unit for power
braking that uses engine manifold vacuum and atmospheric pressure for its power. It permits the use
of a low brake pedal, and provides reduced pedal effort, compared to the conventional (non-power)
hydraulic braking system.
The dual system hydraulic section of the Master-VAC is similar to the manually operated dual-
system master cylinder except that the hydraulic push rod is a part of the power section. The separate
hydraulic systems provided by this master cylinder prevent a hydraulic failure of either system from
affecting the other system. If a hydraulic failure does occur, the driver is aware of it, either
immediately, when it happens, or on the next brake application because of the increased pedal travel
required to get braking action. In addition, vehicle deceleration with only the front or rear brakes
functioning will, usually, be less effective, requiring either greater pedal effort for the same stopping
distance or greater distance.
124 August 31, 2012

Figure 81, HydroVac Cross Section
The Bendix Tandem Diaphragm Master-VAC consists of three basic elements combined into a
single unit. These three basic elements are:
• A vacuum power chamber consists of a front and rear shell, a center plate, a front and rear
diaphragm and plate assembly, an hydraulic push rod and a vacuum diaphragm and plate
return spring.
• A manually actuated control vane integral with the vacuum power diaphragm and plate hubs
that controls the degree of power brake application or release in accordance with the foot
pressure applied to the valve operating rod through the brake pedal linkage. The control
valve consists of a single poppet with an atmospheric port and a vacuum port. The vacuum
port seat is formed in the hub of the rear diaphragm plate. The atmospheric port seat is part of
the valve plunger, which moves within the vane-housing hub of the diaphragm plates.
August 31, 2012 125

• A hydraulic dual-system master cylinder that provides two hydraulic fluid reservoirs, cast
integrally with and connected to the bore through separate sets of compensating and fluid
inlet (bypass) ports. Both reservoirs are sealed by a rubber diaphragm inside the bale-type
cover. A primary piston assembly with secondary seal, primary cup, protector, spring, screw
and spacer; a secondary piston with two "back to back" secondary seals, primary cup
protector, spring and spring retainer; a piston stop screw and o-ring seal; and one check valve
(residual pressure), springs and tube seat retainers mounted in the two outlet ports provide
the operating components of the two separate hydraulic systems.
The vacuum power diaphragm plates and parts that make up the valve assembly are connected to the
brake pedal through the valve operating rod. The valve operating rod is connected to the valve
plunger which moves within the hub of the power diaphragm and plate assembly. A valve return
spring returns the valve plunger and valve rod to the released position when the brake pedal is
released. The valve poppet is of the flexible rubber type and is supported by the valve body hub of
the rear diaphragm plate. In the released position, the poppet return, spring holds the poppet against
the atmospheric port seat (valve plunger). A special type of seal is used to seal the opening between
the valve body sleeve and the rear shell.
Vacuum is supplied to the power brake unit through a vacuum check valve mounted in the front
shell.
Air for operation is admitted through silencer-filters within the valve housing. At its front end, the
power section incorporates another special seal to close the opening between the front shell and
hydraulic push rod. The hydraulic push rod is the link between the vacuum diaphragm and plate
assembly and the hydraulic pistons in the master cylinder. The center plate, located between the two
diaphragms, divides the power unit into four chambers. A long, threaded hub on the front plate slides
through the center hole in the center plate and is screwed into the hub of the rear plate to maintain a
set separation between the two diaphragms as the front and rear plates and diaphragms sealed by a
vacuum seal that is permanently installed in the stationary center plate. Two drilled air passages
intersect in the mounting flange of the master cylinder to provide "free breathing" for this cavity
during braking.
Principles of Operation
With the engine running and the brakes released, vacuum from the intake manifold is admitted
through the vacuum check valve to the vacuum chamber. This maintains vacuum availability long
enough to stop the tractor should the engine stop running before while the tractor is moving.
Dual fluid reservoirs, cast integrally with the master cylinder, supply fluid pressure to the front and
rear brakes independently.
Loss of Vacuum Power

In the event of engine failure, the vacuum chambers within the power brake provide adequate
vacuum reserve for two or three brake applications. If the vacuum check valve is defective or after
braking has depleted the vacuum reserve, the driver can still operate the brakes by pushing straight
through the power cylinder, but pushing the pedal will be noticeably more difficult.
126 August 31, 2012

Removing the Master Cylinder

1. Disconnect the hydraulic lines at the master cylinder. Cover the master cylinder outlet ports
and the ends of the brake tubes to prevent foreign matter from entering the assembly.
2. Remove the nuts and lock-washers from the vacuum power cylinder studs that extend
through the master cylinder mounting flange.
3. Remove the master cylinder from the power section.
Removing the Power Brake and Master Cylinder Assembly
1. Disconnect the vacuum hose from the check valve that is in the front shell of the power
section.
2. Disconnect the hydraulic lines at the master cylinder. Cover the master cylinder outlet ports
and the ends of the brake tubes to prevent foreign matter from entering the assembly.
3. Disconnect the valve rod from the brake pedal.
4. Disconnect the stop light switch wires.
5. Remove the nuts and lock-washers from the studs that secure the power section to the
firewall. Remove the entire Master-VAC assembly.
6. Clean the exterior of Master-VAC unit and drain the reservoirs and the bore of the master
cylinder.
Inspecting the Master-VAC
1. Inspect all parts for damage or excessive wear. The power diaphragms must be free of kinks,
cracks, and tears.
2. Replace all damaged, worn, or chipped parts.
Note: Before mounting the master cylinder, check the distance from the end of the
hydraulic push rod to the master cylinder mounting surface on the front shell (see
distance "A" in g). Distance "A" should be between.980 and.995 inches.
August 31, 2012 127

Push Rod Adjustment Procedure
The self-locking adjustment screw on the

outer end of the hydraulic push rod is set to
the correct dimension 'A" at the time of
manufacture and no further adjustment
should be needed. However, if the
adjustment has been changed or a new push
rod has been installed, then an adjustment
may be required.
1. Make a sheet metal gauge as shown in
Figure 82, Push Rod Gauge.
Figure 82, Push Rod Gauge
Nut
2. Check the push rod length with the

gauge as shown in Figure 83, Using the Push
Rod Gauge.
3. To adjust the push rod, turn nut
clockwise or counterclockwise until the
push rod is within specifications. Do not
scratch the machined shaft of the push
rod.
Gauge
Figure 83, Using the Push Rod Gauge

Complete Master-VAC Installation
1. Put the Master-VAC in its mounting location on the firewall and secure the power section
studs or brackets with nuts and lock-washers. Attach the valve rod or pedal linkage to the
brake pedal before tightening the firewall mounting nuts to a torque of 25-30 Lb-Ft or
34-40 NM.
2. Reconnect the stoplight switch and/or wires and adjust the switch position if necessary.
3. Attach the vacuum hose to the vacuum check valve.
128 August 31, 2012

4. Attach the hydraulic lines to the output ports.
Note: Air may be trapped in the output ports when the plugs are removed to attach the
hydraulic lines. To remove this air, see Brake System Bleeding on Page 140.
5. Bleed the rest of the hydraulic system.

System Test
To test the system:
1. Park the tractor and chock the wheels.
2. Turn the engine off.
3. Apply the brakes twice.
There must be enough reserve vacuum to provide brake boost for at least two stops.
4. Hold the brake pedal in the applied position and start the engine.
The brake pedal should drop or "fall away" slightly under steady pressure, but then should
remain firm without further travel or sponginess.
5. If the pedal fails to "fall away", check the vacuum hose connection.
6. If the pedal falls to the floor, check and tighten all hydraulic connections and bleed screws.
7. Repeat step 6.
8. If the pedal is spongy, bleed the remaining air out of the hydraulic system.
Figure 84, Simplified HydroVac Unit
Simplified HydroVac and Master Cylinder Assembly
August 31, 2012 129

Hydro-Boost Systems
The Hydro-Boost system provides improved braking

performance over vacuum boost and air brakes. Like the
vacuum boost and air brake systems it reduced pedal
effort and pedal travel over manual braking.
Additionally, it includes a ration-changing feature that
automatically changes the internal leverage to increase
the mechanical advantage when manual (non-power)
braking becomes necessary.
Figure 85, HydroBoost and Master Cylinder Assembly
The Hydro-Boost system uses hydraulic pressure from a standard hydraulic pump on industrial
engines or the power steering pump on vehicle engines. In either case, the Hydro-Boost unit supplies
hydraulic fluid to the power steering system in addition to powering the brakes.
The Hydro-Boost unit has a gas-pressurized piston to provide a two or three back-up power brake
applications if the engine stops or hydraulic pressure is lost while the tractor is still moving. This
should be tested periodically during scheduled maintenance.
Hydro-Boost System Operation
Figure 86, Hydro-Boost System Connections
130 August 31, 2012

Hydraulic pressure supplied from engine-driven the hydraulic pump (1) through the tee-fitting (2) to
the pressure relief valve (3). The regulated pressure is connected to the Hydro-Boost unit (4) at it’s
import port (5).
The Hydro-Boost unit isolates the hydraulic fluid supply (Dexron III) from the brake system
reservoir (filled with DOT-3 Brake Fluid) as it amplifies the driver’s braking effort. When the driver
applies the brakes, the fluid from the master cylinders is forced into the brake lines connected at the
master cylinders brake line connections (6).
For power assist steering, the Hydro-Boost unit supplies hydraulic fluid pressure to the steering
gearbox (8) at its pressure input (7). The hydraulic fluid exits the steering gearbox at (9) and returns
to the Hydro-Boost unit at (10).
A low-pressure return line exits the Hydro-Boost unit at (11), joins the return line from the pressure
relief valve (3) and returns to the hydraulic reservoir (12) at (13).
Hydro-Boost Unit Internal Operation

A sectioned view of the Hydro-Boost unit at rest is shown in Figure 87, Hydro-Boost Unit Internal
Construction. Hydraulic fluid from the supply pump is communicated to the Hydro-Boost through the Pump
Inlet Port. Flow is directed through an open center spool valve with a pressure drop of no more than 15 PSI
with the unit at rest. An integral charging relief valve supplies pressure to the Pneumatic Accumulator
whenever steering or booster pressure is developed. A separate "dump" valve releases the accumulated
pressure upon demand when normal power operation is interrupted.
The boost cavity contains the power piston, reaction rod, and ratio changing levers. The power piston slides in
a lip seal held in the housing, with a smaller lip seal on the reaction rod. This rod slides in the reaction bore of
the housing cover. Selection of various reaction and power piston diameters will vary the booster effort level
and power output for different vehicle applications.
Movement of the input levers by the input (reaction) rod moves the spool creating a restriction to the fluid
flow and subsequent boost pressure. The power piston moves and balances the spool to provide the operator
with a fine degree of modulation. The pressure, built by the nitrogen charged all-aluminum pneumatic
accumulator spool, is communicated via the interior of the spool into the boost cavity.
August 31, 2012 131

Figure 87, Hydro-Boost Unit Internal Construction
Unit at Rest
The major components are labeled with an enlarged view of the ports identifying the ports, lands,
laps, and gaps of the valve in the "at rest" position. Oil flows from the inlet or pump port, across the
number 3 land and out the gear port. In the position shown, steering pressure created by the steering
gear and pump is isolated from the boost cavity by the spool valve and does not affect braking.
Lands 2 and 4 block this steering pressure avoiding activation of the unit.
132 August 31, 2012

Pivot
Figure 88, HydroBoost Internal Operation
Normal Power Operation

Figure 88, HydroBoost Internal Operation, illustrates the brake pedal applied (Input travel A). The
ratio lever movement operates the spool valve creating hydraulic pressure due to the restriction at
land 3. Fluid traverses land 2 and flows through the center of the spool into the boost cavity. This
pressure acts against the power piston to give the power assist and against the reaction rod,
amplifying the brake pedal effort.
During the normal power operation, the input travel (A) is less than the output travel (B) travel. The
ratio lever attaches to the power piston, input rod, and spool valve with it’s pivot point at the spool
valve (Pivot).
August 31, 2012 133

The lower enlarged view of the spool valve shows the relationship of the valve lands during normal
power operation. Land 1 is closed blocking the oil flow to the reservoir. Land 3 meters the flow of
oil from the supply pump to the steering gear and generates the hydraulic pressure that is metered
across land 2 to apply the brakes.
The upper enlarged view of the valve shows the same operation except pressure is generated by the
steering gear and is also being used for braking. During this mode of operation, the spool travel is
slightly less than the first case.
It is important to note that braking and steering pressures are not additive and that full pump flow is
available to the steering gear at all braking pressures less than power runout.
Pivot
Figure 89, Hydro-Boost Reserve Power Operation
Reserve Power Operation

Figure 89, Hydro-Boost Reserve Power Operation, shows the reserve power operation mode. If for
any reason the pump system would fail, a nitrogen charged pneumatic accumulator supplies the fluid
for a power assisted stop. In this mode of operation, the primary (spool) valve shifts, transferring the
pivot point to the bottom of the Ratio Lever. A secondary (sleeve) valve is shifted on a journal of the
primary valve and operates the accumulator valve to give power assist.
134 August 31, 2012

Reserve Power Operation

Figure 89, Hydro-Boost Reserve Power Operation, shows the reserve power operation mode. If for
any reason the pump system would fail, a nitrogen charged pneumatic accumulator supplies the fluid
for a power assisted stop. In this mode of operation, the primary (spool) valve shifts, transferring the
pivot point to the bottom of the Ratio Lever. A secondary (sleeve) valve is shifted on a journal of the
primary valve and operates the accumulator valve to give power assist.
System Test
To test the system:
1. Park the tractor and chock the wheels.
2. Turn the engine off.
3. Apply the brakes several times.
4. Hold the brake pedal in the applied position and start the engine.
The brake pedal should drop or "fall away" for a few seconds, but then push back upward as
the hydraulic pressure recharges the reserve accumulator.
5. If the pedal fails to "fall away" or return to normal height, replace the Hydro-Boost unit.
Master Cylinder Repair
Always use the correct master cylinder repair kit when overhauling a Bendix Dual System master
cylinder.
Always replace all rubber parts when overhauling a Bendix Dual System master cylinder. Metal
parts cleaner MUST NOT be used on any part used in the hydraulic system. Use a Stoddard Type
cleaning solvent to clean and rinse all master cylinder parts, and use crocus cloth to polish them, if
necessary. If the bore contains rust, corrosion, or pitted areas, a master cylinder hone may be used.
However, never attempt to reuse a master cylinder if the resulting bore is more than ,006 IN over
standard size after honing.
Master Cylinder Cleaning
Wash all hydraulic system parts in Stoddard Type cleaning solvent. Remove spots, deposits or pitted
areas inside the master cylinder with a crocus cloth or hone, and then re-wash the master cylinder
thoroughly with CLEAN Stoddard Type cleaning solvent to remove all dust. DO NOT attempt to re-
use a master cylinder if the resulting bore is more than .006" oversize. Discard all rubber parts,
except for the filler diaphragm.
Master Cylinder Inspection
Inspect all metal parts for damage or wear. Replace any damaged or worn parts.
August 31, 2012 135

Figure 90, Master Cylinder Pistons

Seal Kit, Master Cylinder 02026-0619
Ref. Num. Description Quantity

1 Cup, Primary, Inner 2 Ea
2 O-Ring 1 Ea
3 Cup, Secondary 1 Ea
4 Cup, Primary, Outer 1 Ea
5 Diaphragm, Filler 1 Ea
136 August 31, 2012

Figure 91, Master Cylinder Reassembly
Master Cylinder Piston Overhaul
The 02026-0619 Seal Kit can be used only in brake systems using DOT-3 brake
fluid. Do not use it with electric tractors, which use Automatic Transmission
Fluid (ATF) in the master cylinder.
Caution
1. Clamp the master cylinder in a vise with the hub end tilted slightly upward.
2. Remove the snap ring (h) and the pistons.
3. Disassemble the primary and secondary pistons. Retain all metal parts (Figure 90, a to h).
Discard all the rubber parts (Figure 90, 1 to 5).
4. Dip all the new seals in clean brake fluid.
5. Install new seals on the Secondary Piston (c):
a. Install an Inner Primary Cup (1) in the secondary piston inner groove (spring end).
b. Slide the O-Ring (2) in the secondary piston middle groove.
c. Install the Secondary cup (3) onto the secondary piston outer groove.
d. Install the Cup Retainer (b) and spring (a).
6. Install new seals on the Primary Piston (g):
a. Install an Inner Primary Cup (1) in the Primary Piston inner groove (spring end).
b. Install the Cup Retainer (b), Spring (f), Spring Retainer (e), and screw (d).
c. Install the Outer Primary Cup (4) in the Primary Piston outer groove.
7. Dip piston assemblies in clean brake fluid.
Master Cylinder Reassembly
1. Slide the secondary piston and spring assembly onto the master cylinder bore. When the skirt
on the seal reaches the cylinder surface, press on the skirt and twist piston to ease the cup
into the bore and past the snap ring groove.
2. Slide the Primary Piston and Spring Assembly into the bore using the same technique to get
the skirt on the seal past the snap ring groove.
3. Press against the rear piston with the handle of a small screw driver to compress the return
springs. DO NOT use a sharp-edged tool because this will damage the push rod seat inside
the piston. Install the snap ring (h) in the groove just inside the bore while maintaining
pressure on the piston. Be sure that the snap ring is seated securely in the groove before you
release the pressure on the piston.
4. Install the filler diaphragm (5) and cover and plug the ports temporarily to prevent the entry
of dust or dirt. The holes are.395 IN diameter.
5. Remove the master cylinder from the vise.
August 31, 2012 137

Bench Bleeding a Dual System Master Cylinder
Note: The dual system master cylinder must be bench bled to remove all air from the
master cylinder bore before returning the master cylinder to service.
1. Clamp the master cylinder in a vise with the front end tilted slightly downward. Fill the
reservoirs with clean brake fluid. Install a plug in each output port.
2. Insert a rod with a smooth rounded end into the primary piston and press on the rod to
compress the piston returns springs. Release the pressure from the rod. Continue to compress
and release the springs as long as bubbles appear in the fluid in the reservoirs.
3. Reposition the master cylinder in the vise so that the front end is tilted slightly upward. Insert
the rod into the primary piston once again and compress and release the springs as tong as
bubbles appear in the fluid in the reservoirs.
4. Refit the reservoir diaphragm and the cover.
Front Brake Assembly Removal
1. Remove the tires and hubs. Refer to the part titled Steer Axle Hub Removal for complete
details on tire and hub removal.
2. Remove the brake hoses from the brake lines. Remove the nuts that mount brake hoses on the
frame.
3. Plug the hoses and brake lines to prevent contamination.
138 August 31, 2012

Figure 93 Standard Axle Caliper
Figure 92, Drum Brake
Figure 94 Heavy Duty Axle Caliper
4. Remove the mounting hardware that attaches drum brake backing plate or brake calipers to
spindle/knuckle 5. This hardware is #10, 11, 12, and 13 in Figure 92, Drum Brake, #10 and 11 in
Figure 93 Standard Axle Caliper, and #12 and 13 in Figure 94 Heavy Duty Axle Caliper.
5. Remove the brake assembly.
Brake Assembly Repair

parts.
Brake Assembly Replacement
1. Position the brake assembly on the axle.
2. Install the mounting hardware that attaches drum brake backing plate or brake calipers to
spindle/knuckle. This hardware is #11 in Figure 92, Drum Brake, #10 in Figure 93 Standard Axle
Caliper, and #12 in Figure 94 Heavy Duty Axle Caliper.
3. Tighten mounting hardware to 47 Lb-Ft or 64 NM.
4. Reconnect brake hoses to their respective lines.
5. Refer to the part titled Steer Axle Hub Replacement on this page to reinstall the hub and tire.
August 31, 2012 139

Brake Lines and Hoses

parts.
Brake Pedal and Linkage
parts.
Brake System Bleeding
Hydraulic brake systems must be bled to remove air that has entered the system. The entire brake
system may require bleeding if air has entered because of low fluid supply or disconnecting brake
lines at the master cylinder.
Disconnecting the brake line at any wheel cylinder or brake caliper may require bleeding at only the
one wheel. Then brake system may be bled by using either the pressure bleeding method or the
manual bleeding method. Brake operations must be fully tested after performing bleeding procedure.
Do not use any vehicle that does not have properly functioning brakes.
Do not mix brake fluid with other fluids. Only use fluid that meets
DOT 3 specifications.
CAUTION
Pressure Bleeding
Pressure bleeding is recommended. Carefully follow the instructions that are included with pressure
bleeding equipment.
Manual Bleeding
1. Clean the master cylinder and the surrounding area. Remove the master cylinder cover and
be sure that the master cylinder is full.
2. Apply steady pressure on the brake pedal. Loosen the brake lines at the master cylinder.
Once solid fluid flow is obtained, tighten the brake lines.
3. It may be necessary to perform this procedure several times in order to obtain a solid flow of
fluid. The brake fluid level must be checked frequently during the bleeding procedure.
4. Attach a clear bleeder hose to the first wheel cylinder being bled. See the bleeding sequence
in Step 5, below. Put the other end of the bleeder hose into a container that is partially filled
with clean brake fluid. Be sure that the bleeder hose end is submerged in the brake fluid.
5. The brakes must be bled in the proper sequence to remove all of the air. The bleeding
sequence is: right rear first, left rear second, right front third, and left front last.
6. Slowly depress the brake pedal one time and hold it down. Open the bleeder screw on the
wheel cylinder that is being bled and examine the fluid flow. The bleeder screw cannot be
just cracked. It must be opened just enough to allow the fluid to flow and remove the trapped
air.
140 August 31, 2012

7. Close the bleeder screw once the fluid flow is free from air bubbles or when the pressure has
subsided. Close the bleeder screw then release the brake pedal. DO NOT release the brake
pedal before the bleeder screw is closed.
8. It may be necessary to perform this procedure several times in order to obtain a solid flow of
fluid. The brake fluid level must be checked frequently during the bleeding procedure. Bleed
the remaining wheel cylinders or calipers in the proper sequence. See Step 5 above.
To prevent corrosion of the internal components of the brake system,

bleed and flush the brake system at least once a year.
CAUTION
9. Apply pressure to the pedal again and if it falls to the floor again, there is a hydraulic leak in
the system. Locate and repair the leak.
10. If the pedal is spongy, bleed the remaining air out of the hydraulic system.
August 31, 2012 141

Rear Brake Installation
Figure 95, Rear Brakes Only
Figure 96, Rear Brakes with Front and Rear Brakes
142 August 31, 2012

Rear Brake Installation Parts List
Reference
Number
1 Caliper, Disk Brake, all positions, complete 2 or 4 Ea 02026-0544

2 Hose, Tee-to-Brake Line 1 or 2 Ea 02015-0001
3 Hose, Brake, Tee To Caliper 2 or 4 Ea 02015-0002
4 Washer, Brake Hose (Copper) 2 or 4 Ea 00700957225
5 Tee, Brake Line 1 or 2 Ea 02016-0150
6 Bolt, 5/16-18 x 3/4 IN, Gr 5, Hex Hd 1 Ea 02011-1C512
7 Lock Washer, 5/16 1 Ea 02011-23E5
Dual Caliper Mod for w/ Front Brakes 1 Ea 02026-0594
8 Brake Line, Caliper-to-Caliper 2 Ea 02026-0574
9 Bolt, Hollow, (Brake Fitting) 4 Ea 02000056171
10 Washer, Brake Hose (Copper) 8 Ea 02026-0438
Note: Tractors offer 2 rear brake options:

• Dual rear calipers only, as shown in Figure 95, Rear Brakes Only. This is
standard on tractors with 3,000 to 5,000 lbs. or 16 to 22 kN towing capacity.
• Dual rear calipers for tractors with front and rear brakes, as shown in Figure
96, Rear Brakes with Front and Rear Brakes. This is standard on tractors with
6,000 or 27 kN and greater towing capacity and optional on lighter tractors.
Tightening the Banjo Bolt on Dual Brake Drive Axles
1. Install the banjo bolt (Item 9) into the banjo fitting with a copper washer (Item 10) on either
side of the banjo fitting.
2. Finger tighten the bolt into the brake caliper.
3. Adjust the banjo fitting to ensure that the copper washer seats in the “pocket” on both sides
of the banjo fitting.
4. Tighten the banjo bolt with a torque wrench to a torque value of 60-65 Lb-Ft or 81-88 NM.
August 31, 2012 143

Rear Disc Brake Pad Replacement

1. Raise the rear of the tractor with a suitable lift. Support the tractor with jack stands under the
rear plate.
2. Remove the rear tires and wheels by removing the lug nuts. Refer to the part titled Tire
Maintenance for complete details on tire removal.
Piston
Caliper Housing
Figure 97, Rear Brake Installation

3. Remove the Disk Brake Pins (2) that fasten the caliper housings to the backing plates.
4. Retract the pads and piston by prying between the pad and the rotor with a large screwdriver.
Do not scratch the rotor. The piston must be fully retracted into the caliper housing to permit
the installation of the new pads.
5. Remove the caliper housings from the axle backing plates. Do not disconnect the hoses or
allow the calipers to hang on the hoses.
6. Replace or resurface the rotor if it is scored or undercut.
7. Check the piston seal for leaks. If the caliper assembly is in good condition, install the new
pads (1).
8. One pad has a spring clip to hold it to the piston. The other pad is held in place by the
through bolts.
9. Reinstall caliper on to the backing plate. Insert the disk brake pins into the caliper housings
and tighten both pins to 70 Lb-Ft or 95 NM,
10. If the piston was removed or if the brake line was detached from the caliper housing, you
must bleed the brake system.
144 August 31, 2012

Park Brake Assembly

Three Park Brake configurations are shown in this section:
Standard Diesel Tractors
Standard diesel tractors use a long park brake handle with a fine adjustment twist-handle. The
handle passes through the transmission center tunnel and connects to the transmission bell crank
via a horizontal rod.
Low Profile Diesel Tractors
Low Profile Diesel Tractors use a short park brake handle that passes through a console directly
above the transmission park brake actuator lever. The rod between the handle and the actuator
lever on the transmission is vertical.
GM 3.0L Powered Tractors
GM 3.0L-powered tractors use a long handle that passes through a console. It connects to the bell
crank on the transmission via a cable.
Park Brake Adjustment on GM 3.0L Powered Tractors
2
3
Figure 98, Park Brake Control, GM 3.0L-Powered Tractors

1. If adjustment of the knob on the park brake lever (1) is not enough to fully activate the park
brake then a major adjustment is required.
2. Put the handbrake lever into the fully released position.
3. Turn the adjustment knob on the park brake lever counterclockwise as far as possible.
August 31, 2012 145

4. Adjust the park brake cable length by turning the nuts on the cable where the cable passes
through the cable-mounting bracket.
5. Test the adjustment by putting the park brake lever into the fully applied position. The
tension on the cable should be enough to make the lever hesitate in its center position when
pulling the lever from the fully released position to the fully applied position.
Park Brake Control Removal

1. Raise the front of the tractor with a suitable lift. Support the tractor with jack stands under the
front plate.
2. Remove the transmission control as detailed.
3. Disconnect the clevis from the park brake bell crank. Remove the clevis from the brake
cable. Loosen and remove the rear jam nut that is on the brake cable and remove the cable
from the cable mount bracket.
4. Loosen and remove the four bolts, lock-washers and flat-washers from the center tunnel.
5. Lift the center tunnel off to gain access to the park brake handle mounting bolts, lock-
washers, and nuts.
6. Loosen and remove the two nuts, lock-washers, and bolts from the park brake handle. Note
the location of the three spacers.
7. The park brake control can now be lifted out of the tractor.
Park Brake Control Replacement

1. Put the park brake hand lever in the slot that is in the center tunnel.
2. Replace the two bolts, the three spacers, the two lock-washers, and the two nuts that attach
the park brake handle to the center tunnel.
3. Put the center tunnel into its proper position in the tractor. Feed the park brake cable through
the hole in the cable mount bracket. Be sure that the cable is not kinked.
4. Put the rear jam nut back onto the park brake cable and tighten it until it is against the cable
mount bracket.
5. Return the clevis to the end of the park brake cable and reattach the clevis to the brake bell
crank.
6. Replace the center tunnel securing bolts.
7. Replace the transmission control as detailed.
8. Adjust the park brake cable as detailed.
Park Brake Shoe Replacement

1. Loosen the adjustment knob on the park brake lever by rotating it in a counterclockwise
direction.
2. Remove the nuts and lock-washers from the rear of the park brake drum. Move the drum
toward the rear of the vehicle to expose the park brake shoes.
146 August 31, 2012

3. Remove the three brake shoe return springs that are on the brake shoes to release the shoes
from the backing plate.
4. Put new park brake shoes on the backing plate and reattach the return springs to the brake
shoes.
5. Replace the brake drum lock-washers, and tighten the drum retaining nuts.
6. Rotate the adjustment knob on the park brake hand lever in a clockwise direction until it is
moderately tight.
7. Adjustments to the park brake should be made when it is in a fully released position. Test the
adjustment by applying the lever to set the brake. If the park brake holds an idling tractor that
is in gear, then it is set properly. If the park brake does not hold, then tighten the adjusting
knob further and perform this test again.
Use extreme caution when performing this test. A park brake that is not adjusted
properly can cause serious injury to people and serious damage to property.
CAUTION
August 31, 2012 147

H, Steering and Front Axle

Drag Link and Pitman Arm
Refer to Section 5, General Overhaul and Repair Practices to remove, clean, inspect and replace
damaged or worn parts.
Front Wheel and Tire
Refer to Section 5, General Overhaul and Repair Practices to remove, inspect, and
Steering Gear
Steering Gear Removal
1 2
1. Remove the horn button kit.

Carefully note the order and position
of each item during removal.
2. Remove the steering wheel nut and
lift the steering wheel off of the
steering column.
3. Disconnect the horn button wire.
4. Remove the column clamp bolts and
the column clamp.
4
3
148 August 31, 2012

5. Remove the pitman arm locknut and

washer. Disconnect the pitman arm 6
from the steering gear shaft and set it
aside. 5
6. Loosen and remove the frame

mounting bolls.
7. Remove the steering gear and
column assembly by carefully lifting
up and pulling forward so that the
column and gear passes through the
hole in the firewall.
Steering Gear Repair

Refer to the repair and overhaul appendix for the steering gear for detailed instructions.
Steering Gear Replacement.

1. Carefully lower the steering gear and column through the opening in the firewall.
2. Start one of the mounting bolts into the top hole of the frame mount and steering gear mount.
Reinstall another of the mounting bolts in one of the lower steering gear mounting holes. If a
gap appears between the steering gear and the mounting bracket at the top hole, remove the
top bolt and reinstall it with a flat-washer.
3. Reinstall the pitman arm, the locknut, and the washer.
4. Replace the column clamp and the clamp bolts.
5. Reconnect the horn wire.
6. Mount the steering wheel. Be sure that one of the spokes is pointing towards the rear of the
tractor.
7. Replace the steering wheel nut and flat-washer.
8. Reinstall the horn button kit.
August 31, 2012 149

Steer Axle
Steer Axle Removal

3
1. Raise the front of the tractor with a
suitable lift. Support the tractor with
jack stands under the front plate.
2. Remove the front tires and wheels by
removing the lug nuts. Refer to the
part titled Tire Maintenance for
complete details on tire removal.
3. Disconnect the brake hoses from the
brake lines at the frame brackets.
Remove the nuts that are shown as
Item 11 in 6. Plug the hoses and
brake lines to prevent contamination.
3
Figure 99, Disconnecting Brake Lines
4. Remove the cotter pin from the drag

link socket assembly. Loosen the
adjustable cup so that the socket arm
can be lifted off of the steering arm
bail stud.
4
150 August 31, 2012

5. Place a jack or suitable lift under the

axle to remove tension the spring
hanger bolts. Remove the rear nuts
and bolts. Lower the rear portion of 5
the front springs
6. Remove the front spring hanger nuts
and bolts. The steer axle assembly
can now be removed to be repaired 6
or replaced.
Steer Axle Repair

Refer to applicable paragraphs to repair or replace particular steer axle components and to properly
reassemble them.
Steer Axle Replacement

1. Replace the bolts and nuts. Tighten the nuts until they are snug. Do not over tighten the bolts
because this wilt distort the spring hangars.
2. Replace the drag link socket assembly.
3. Reconnect the hoses to their respective brake lines.
4. Mount the tires. Tighten the lug nuts to a torque of 100 Lb-Ft or 135 NM.
5. Adjust the toe in according to the instructions.
6. Set the steering stops according to the instructions.
August 31, 2012 151

Steer Axle Hub
Figure 100, Standard Axle Hub Figure 101, Heavy Duty Axle Hub
Part List for Figure 100, Standard Axle Hub
Quantity
Reference
Description per Part Number
Number
Knuckle
1 Cap, Hub 1 Ea 02023-0046
2 Nut, 5/8-18, Slotted, 1 Ea 02011-4D10
3 Cotter Key, 1 Ea 02011-1F420
4 Thrust Washer, Hub Bearing 1 Ea 02023-0036
5 Bearing Set, Outer Wheel 1 Ea 02023-0878
6 Hub and Rotor 1 Ea 02023-0521
6a Stud for 02011-0521 5 Ea 02011-0487
7 Bearing Set, Inner Wheel 1 Ea 02023-0877
8 Grease Seal, Front (See Photograph) 1 Ea 02023-0038
9 Knuckle
10, 11, 12 Brake Parts
Part List for Figure 101, Heavy Duty Axle Hub
Reference
Number
1 Hub 1 Ea 02023-1091
2 Bearing Cup 2 Ea 18520
3 Bearing Cone 2 Ea 18590
4 Seal 1 Ea 00700224287
5 Keyed Washer 1 Ea 02023-1086
6 Nut 2 Ea 02023-1087
7 Washer 1 Ea 02023-1088
8 Gasket 1 Ea 02023-1085
9 Cover 1 Ea 02023-1084
10 Bolt, 3/8-16 X 1 1/4, Grade 5 6 Ea 02011-1C620
11 Lock washer, 3/8, Spring Type 6 Ea 02011-23E6
152 August 31, 2012

Steer Axle Hub Removal

1. Raise the front of the tractor with a suitable lift. Support the tractor with jack stands under the
front plate.
2. Remove the front tires and wheels. Refer to the part titled Tire Maintenance for complete
details on tire removal.
3. Remove the hubcap, the cotter pin, and the nut.
4. Remove the hub, the thrust washer, and the outer bearing cone.
5. Remove the hub seal and the inner-bearing cone.
6. The hub can now be removed to be repaired or replaced.
Steer Axle Hub Repair

parts.
Steer Axle Hub Replacement

1. Replace the inner bearing cone and install a new grease seal.
2. Put the hub on the spindle. Replace the outer bearing cone and the retaining washer.
3. Rethread the nut. Tighten it until the inner and outer bearing cones are seated and the hub
drags when it is being rotated by hand. Either tighten or loosen the nut until the slot is
aligned with the hole in the spindle.
4. Install a new cotter pin and replace the nub cap.
5. Mount the tires. Tighten the lug nuts to a torque of 100 Lb-Ft or 135 NM.
August 31, 2012 153

Steer Axle Springs:
12. Set the park brake and chock the

rear wheels.
13. Jack up the front of the tractor and
put safety jack stands under the
front plate.
14. Remove the front wheels and tires.
15. Move the jack pad to the center of
the steer axle.
Figure 102
16. Remove the 8 nuts from the U-

Bolts that fasten the axle to the
front springs.
17. Lower the axle about 6 inches or
30 CM.
18. Put another pair of jack stands
under the axle.
Do not allow the axle 16

to hang on the brake
Figure 103
Caution lines.
19
19. Remove the 4 bolts that fasten the

springs to the spring hangars. 19
20. Remove the springs.
Figure 104
154 August 31, 2012

21. When reinstalling the springs,

tighten the spring hanger bolts to
135 Lb-Ft or 180 NM.
Figure 105
22. When reinstalling the axle onto the

springs, on Standard and
Crossbreed frame tractors only,
insert a 02023-1105 Wedge in 2
places between the axle and the
springs with the small end facing
front.
23. Tighten the nuts on the U-Bolts to
60 Lb-Ft or 80 NM.
Figure 106
August 31, 2012 155

Steer Knuckle Removal
1. Remove the tires and hubs. Refer to the 4

part titled Steer Axle Hub Removal for
complete details on tire and hub
removal.
7
2. Refer to the part titled Brake Assembly
Removal to remove the brake assembly.
3. Remove the tie rod end cotter pin and
nut. Remove the tie rod end.
4. If the left-hand knuckle is being
repaired, remove the cotter pin from the
drag link socket assembly. Loosen the
adjustable cup so that the socket arm can 3
be lifted off of the steering arm ball stud.
5. Remove the steer knuckle plug with a

chisel and discard it.
6. Tap out the kingpin key with suitable
driver.
3 6
9
156 August 31, 2012

Do not strike hardened steel parts directly with a steel hammer.

CAUTION
7. Drive out the kingpin from the top with a suitable driver.
8. Lift out the knuckle, the thrust bearing, and the shims.
9. Remove worn king pin bushing with a suitable driver.
Steer Knuckle Repair

1. Install new bushings using a suitable driver.
2. Ream the bushings with an expandable reamer to a diameter of 1.125 - 1.126inches.
Steer Knuckle Replacement

1. Put the knuckle and the thrust bearing over the end of the axle. Partially insert the king pin
and determine the number of shims that will be required.
2. Install the shims and finish inserting the kingpin until it is fully seated. Be sure that the
groove on the kingpin is in line with the kingpin keyhole that is in the axle.
3. Reinstall the kingpin key.
4. Install new plugs and secure them with a chisel.
5. Put the tie rod end into the arm. Replace the nut and the cotter pin.
6. Refer to the part titled Brake Assembly Replacement to reinstall the brake assembly.
7. Refer to the part titled Steer Axle Hub Replacement to reinstall the hub and tire.
August 31, 2012 157

Steering Adjustments
Special Tool
If you don’t have any front end alignment equipment available, make a pair of Toe-In measuring
bars as specified in Figure 107. Make the bars from iron or mild steel.
Figure 107, Toe-In Bars
Toe-In Measurement
1. Raise the front of the only

enough to lift the front wheels
about one inch or 25 MM off
the floor.
2. Install safety jack stands.
Figure 108
3. Remove the front wheels and

install the Toe-In bars as
shown in Figure 109.
Figure 109, Install Toe-In Bars
158 August 31, 2012

Figure 110
4. Position the steering so that the bars are parallel with the tractor.
5. Measure the distance between the fronts of the bars (Distance A) and the backs of the bars
(Distance B).
• Toe-In = Distance A is less than Distance B. Toe-Out = A is greater than B
• The correct setting is between 0.0625 and.1875 inches (1.6 – 4.8 MM) of Toe-In.
Toe-In Adjustment
1. If the Toe-In is out of the
specified limits, loosen the Tie- 1 1
Rod Jam Nuts.
2
Note: The threads on the Tie-Rod
Rod-Ends are opposite.
One side has a right hand
thread, the other side has a
left hand thread.
2. Turn the Tie-Rod to adjust its
length longer to increase Toe-In
or shorter to decrease Toe-In and
repeat the measurement until the
Toe-In is between 0.0625
and.1875 inches (1.6 – 4.8 MM). Figure 111
3. Tighten the lock nuts.
4. Put the wheels back on the tractor.
5. Lower the tractor from the jack stands.
August 31, 2012 159

Steering Stop Measurement

Tractors have primary and secondary steering stops that must be coordinated. Tractors with power
assist steering have primary steering stops that limit the steering gearbox travel. Tractors that have
hydrostatic steering primary limits built into the hydraulic steering cylinder. All tractors have
secondary steering stops in the steer axles. It is important that both sets of stops be set to the same
limits. If the primary steering stops allow too much travel, the power steering can apply damaging
force to the steering linkage. If the secondary steering stops are too loose, hitting a curb or bump can
also transmit damaging loads to the steering linkage.
Adjust steering stops in the following sequence:
• When decreasing travel, set the primary stops to the specified angle and set the secondary
stops to match.
• When increasing travel, loosen the secondary stops, set the primary stops for the specified
angle, then set the secondary stops to match.
NOTE: The steering stop adjustment must be done with normal tractor weight on the
wheels.
1. Turn the hand wheel fully right

and turn off the engine.
2. Measure the angle between the
right wheel and the side of the
tractor. The angle should be 29-31
degrees.
3. Turn the wheel full right and
measure the angle. It should be
between 29 and 31 degrees.
160 August 31, 2012

Steering Gear Box Limit Adjustment

1. If adjustments are required, adjust
the steer stop bolts as follows:
a. Loosen the rear jam nut.
1a, Right Limit
b. Turn the rear stop bolt 1b
inward to increase the
steering travel or outward to
decrease it.
c. Tighten the steer stop jam
nut.
2. Repeat Steps a, b, and c for the
front steer stop bolt.
Adjusting the Secondary Steer Stops
1. With the wheel at the left stop, adjust the

left secondary stop so that the adjusting Surface
bolt touches the surface.
Bolt
Bolt
2. With the wheel at the right stop, adjust the Surface

right secondary stop so that the adjusting
bolt touches the surface.
August 31, 2012 161

Tire Maintenance
Failure to follow these warnings could result in serious

injury or even death.
• Remove the valve core and completely deflate all tires
before removing them from the wheels.
• Always allow all of the air to escape from a tire before
removing any of the rim components. Be sure that the
valve cores are removed from the tires. Run a piece of
wire through the valve stem to make sure it is not
clogged.
• Never weld a wheel with an inflated tire on it.
WARNING • Do not overload or over inflate tires.
• Do not reinflate a tire that has been gone flat without
inspecting the tire, rim, and wheel assembly first.
• Do not use undersized rims.
• Do not hammer on an inflated or partially inflated tire
and rim assemblies.
• Do not allow persons who do not have proper training
to mount or demount tires.
1. Check the rim components for fatigue cracks periodically. Replace all cracked, badly worn,
damaged, and severely rusted components.
2. Clean and repaint the rims to stop the detrimental effects of corrosion. Use a filter on the tire
inflation equipment to remove moisture from the air. This will help prevent corrosion. Check
the filter periodically to make sure that it is working properly.
3. Double check all components to make sure that they are properly seated prior to inflation.
4. Never sit or stand in front of a tire and rim assembly that is being inflated. Use a clip-on
chuck and be sure that the inflation hose is long enough to permit the person inflating the tire
to stand to one side of the tire during inflation.
5. Do not rework, weld, heat, or braze any rim component that is cracked, broken, or damaged.
Replace damaged parts with new parts that are the same size, typo, and make.
6. Always put hardwood blocks under the jack when changing tires. It is not possible to visually
determine whether or not the ground is safe for the removal operation.
162 August 31, 2012

7. Wedge a block between the ground and the tire that is on the outer side of the tractor before
positioning jack. Always immobilize the tractor with blocks to prevent slippage and possible
injury.
8. Use bead breakers and rams to apply pressure to the bead flanges. Slant the bead breaker at
an angle of about 110 degrees to keep it firmly in place. Always stand to one side of the tire
when applying hydraulic pressure.
9. When using a cable or chain sting, stand clear of the tractor when a cable or chain sling is
being used to suspend the tractor, Serious injury or death may result if the cable or chain
snaps.
10. Inspect the tires and wheels regularly for cuts, breaks, alignment, and tightness of lug nuts.
Check the tires for proper inflation frequently.
11. The rear wheel assemblies are one piece with tubeless tires. The front wheel assemblies are
two piece with tires and inner tubes.
Tapered lug nuts, 02030-0101, are to be used on countersunk wheels

(02030-00304) only. Do not use them with flat wheels. Flat wheels, such as
02030-0143 require flanged lug nuts (02030-0035).
Caution
August 31, 2012 163

Front Wheel and Tire Removal and Installation
Front Wheels and Tires

Front Wheels are two-piece rims, bolted together
by ten bolts, washers, and nuts. The outer bolts
(1) hold the wheels halves together. There are
five lug nuts (2) on each wheel that fasten the
wheels to the axle.
Never loosen the outer nuts or bolts (1) while the tire is inflated.
That could cause a sudden decompression and serious injury.
Warning
164 August 31, 2012

To disassemble the front wheel and tire:

6 (10 places)
3
4
4
2
1 (5 places)
7, 8 (10 places)
1. Jack up the front if the tractor and install safety jack stands under the front plate.
2. Remove the 5 lug nuts (1) that fasten the wheel and tire assembly to the axle. Remove the
wheel from the axle.
3. Remove the valve core and deflate the tire. Make sure the tire is completely deflated before
you proceed.
4. Remove the 10 bolts (6), nuts (7) and washers (8) that fasten the wheel halves together.
5. Remove the tire (2), tube (3) and flap (4) from the wheel.
6. To reassemble the wheel and tire, reverse steps 5 through 1.
Lug Nut Tightening

1. Tighten the lug nuts to 100 Lb-Ft or
135 NM in a criss-cross pattern.
August 31, 2012 165

J, Electrical System
1. Disconnect the headlamp power wire.
2. Remove the mounting nut, the lock-
washer, and the bolt.
3. Remove the headlamp assembly from the
frame.
4. Remove the lamp cover by removing the
screw that is located at the bottom front
of the headlamp assembly.
5. Remove the lamp retaining spring clips
(not shown). Remove the lamp from the
headlamp assembly.
6. Put the lamp back into the assembly.
7. Replace the lamp retaining spring clips.
8. Guide the power wire through the
headlamp housing and connect it to the
lamp.
9. Put the lamp cover back onto the housing
and replace the screw.
10. Put the headlamp assembly back into the Figure 112, Old Style Headlamp with Replaceable Sealed
Beam
bracket. Install the mounting bolt, the
lock-washer, and the nut.
11. Reconnect the power wire to the
headlamp.
1. Disconnect the headlamp power wire.

2. Remove the mounting nut, the lock-
washer, and the bolt.
3. Remove the headlamp assembly from the
frame.
4. Splice a new bullet terminal onto the
headlight power wire.
5. Splice a new ring terminal onto the
headlight ground wire.
6. Put the headlamp assembly back into the
bracket. Install the mounting bolt, the
lock-washer, and the nut.
7. Reconnect the power and ground wires.
Figure 113, New Style, Integrated Headlight
166 August 31, 2012

Instrument Panel
Refer to Section 5, General Overhaul and Repair Practices to remove, inspect, and replace damaged
or worn parts.
Back Up Lamp Bulb Removal
1. Remove the retaining ring.
2. Remove the lens and the gasket.
3. Gently push on the bulb and rotate it counter-clockwise at the same time to remove it from
the socket.
4. Insert the light bulb into the socket. Gently push on the bulb and turn it clockwise at the same
time.
5. Install the gasket and the lens.
6. Install the lens retaining ring ,
Battery and Cables
parts.
Electrical Components
or worn parts.
Stop and Tail Lamp
Stop Lamp, and Tail Lamp and Backup Lamp Bulb Replacement
1, 6 2,25
1. Remove the retaining ring. 3, 4
2. Remove the lens and the gasket.

3. Gently push on the bulb and rotate it
counter-clockwise at the same time to
remove it from the socket.
4. Insert the light bulb into the socket.
Gently push on the bulb and turn it
clockwise at the same time.
5. Install the gasket and the lens.
6. Install the lens retaining ring.
Figure 114, Incandescent Rear Lights
August 31, 2012 167

LED Stop, Tail, and Backup Light Service
8,811
7. Disconnect the LED from the
wiring harness.
8. Remove the retaining hardware.
9. Remove the LED Light
Assembly.
7, 12
10. Install a replacement LED light
assembly. 9, 10
11. Reinstall the retaining hardware.

12. Connect the LED Light
Assembly to the harness.
Figure 115, LED Rear Lights
Battery and Cables

parts.
Electrical Components
or worn parts.
168 August 31, 2012

K, Options
Hitch
Refer to Section 5, General Overhaul and Repair Practices remove, inspect, and replace damaged or
worn parts.
Seat Assembly
or worn parts.
Cab Accessories
Refer to 5 to remove, inspect, and replace damaged or worn parts.
Cab Assembly
or worn parts.
Cab Door Hinge Removal
1. Remove the door check chain bolt.
2. Remove the door by lifting the door from the female hinge tube.
3. Remove the bolts in the female tube and remove the female half from the cab door post.
4. Remove the nuts, washer, and bolts from the male hinge half.
Cab Door Hinge Repair
or worn parts.
Cab Door Hinge Replacement
1. Install the male hinge half using the bolt, washer, and nut. Leave the bolts loose so that
adjustments can be made.
2. Install the female hinge half and tighten the bolts.
3. Install the door. Adjust the hinge so that the door fits properly. Tighten all of the bolts and
nuts.
4. Install the door check chain bolt.
Cab Heater
or worn parts.
Windshield Wiper
or worn parts.
August 31, 2012 169

Cab Removal
1. Under the dash panel, between the

steering column and the pass-
through hole, locate the wire that
supplies electrical power to the
cab. 2
2. Cut the wire tie and disconnect the

wire that supplies electrical power
to the cab.
3. Disconnect both door restraints at

one end.
170 August 31, 2012

4. Lift the doors off the hinges. See

Step 5 if the doors bind on the
hinge posts.
5. If the doors bind on the hinge posts,

loosen the nuts inside the door that
fasten the hinge posts to the doors.
6. If the tractor has a hitch release bar,

disconnect it.
August 31, 2012 171

7a
7. Remove the four bolts that fasten

the front frame corners (a) and the
three bolts that fasten the rear
frame (b) to the tractor.
7b
8. Position a forklift with the forks

extending through the cab. Make
sure the forks are directly against
the cab frame, clear of the mirror,
windshield wiper panel, dome light,
and any other objects built into the
cab.
9. Lift the cab off the frame.
172 August 31, 2012

10. To set the cab down, put a jack

stand set to about 11 IN / 28 CM
high under the rear cab frame rail
to keep it level.
August 31, 2012 173

Cab Installation
1. Position a forklift with the forks

extending through the cab. Make
sure the forks are directly against
the cab frame, clear of the
windshield wiper panel, dome light
and any other objects built into the
cab.
2. Raise the cab off the floor and
position it over the tractor.
3. Lower the cab to the tractor and

align the holes.
4a
4. Install the four bolts that fasten the

front frame corners (a) and the three
bolts that fasten the rear frame (b)
to the tractor.
4b
174 August 31, 2012

5. If the tractor has a hitch release bar,

connect it.
6. Put the doors into the hinges.
7. If you loosened the nuts inside the

door that fasten the hinge posts to
the doors, tighten them now.
August 31, 2012 175

8. Connect the door restraints.
9. Connect the wire that supplies

10
electrical power to the cab.
10. Replace the wire tie.
176 August 31, 2012

Window Removal
1. Remove 24 screws (3) that
fasten the inner window frame
(2) to the outer window frame
(1).
2. Pull the outer frame away from
the cab.
Window Installation
1. Place the window glass and outer
frame assembly (1) in the cab.
2. Put the inner window frame into
position.
Caution, be careful before
installing screws not to dislodge
the window glass.
3. Install the first screws in the
upper corners, then install the
remaining screws.
Windshield Wiper
or worn parts.
Winterization Kit
or worn parts.1. Battery Healer 2. Coolant Healer 3. Oil Heater 4. Junction Box 5. Power Cable6.
Thermostat Cord Set
August 31, 2012 177

Engine Service
Appendix A. GM 3.0L Engine, Operation and

Maintenance
Operating and periodic maintenance information is provided in this separate book.
August 31, 2012 179

Unscheduled maintenance and repair information is provided in this book.
180 August 31, 2012

General Automatic Transmission Service
Appendix B, General Transmission Service

General Information
Overhaul and Rebuild Kits
Kit Description Part ID #
Bushing Kit, C-6 Tran

Overhaul Kit, C-6 Trans 2280 2281 2282
Bushing Kit, C-6 Trans
Transmission Identification
All vehicles are equipped with a Vehicle

Certification Label affixed to the left (driver's) side
door lock post. Refer to the stamped code in the
space marked "Trans." and to Fig. 1 below for
proper transmission identification.
All automatic transmissions are equipped with high temperature resistant seals. This includes those seals
used on the manual and kickdown levers, the 0-rings and oil pan gasket. Under no conditions should older
design seals be used on the transmissions, except the regular service replacement of oil pan gasket, which is of
special leak prevention design. This should still be used.
Diagnosis and Testing

Troubleshooting and the automatic transmission is simplified by using the proven methods of
diagnosis. One of the most important things to remember is that there is a definite procedure to
follow.
The following procedures are recommended for checking and/or verifying that the various components are
adjusted and operating properly.
Automatic Transmission Tests

Accelerator Linkage and Operation
The linkage must be free and must return to idle when released. Refer to Part 24-60-Carburetor Throttle
Linkage for linkage adjustment and this part for dashpot adjustment.
Kickdown Linkage
Check for wide open accelerator linkage. The accelerator stop must be contacted by the throttle linkage
and there must be a slight amount of movement left in the downshift linkage. Be sure the downshift linkage
return spring is connected and the downshift lever returns to a closed position.
August 31, 2012 181

Manual Linkage
Correct manual linkage adjustment is necessary to position the manual valve for proper fluid pressure
direction to the different transmission components.
Improperly adjusted manual linkage may cause cross-leakage and subsequent transmission failure. Refer to
Linkage Adjustments in Part 17-02, Shift Control Linkage for detailed manual linkage adjustment procedures.
Transmission Fluid Level Check
The automatic transmissions designed to operate with the fluid level between the 'add' and 'full' mark on
the dipstick, at an operating temperature of 65° C-76° C (150°-170° F) and should be checked under these
conditions. The operating temperatures may be obtained by driving 24-32 km (15-20 miles) of city type driving
with the outside temperature above 10° C (50° F).
If the Transmission is not at an operating temperature of 65°-76° C (150°-170° F) and it becomes necessary to
check the fluid level, the fluid may be checked at room temperature 21 °-35° C (70°-95° F). (Dipstick cool to
touch).
Room Temperature Fluid Level Checking Procedures
1. With transmission in Park, 'P' position, engine at curb idle RPM, foot brakes applied, and vehicle on level surface,
move transmission selector through each range, allowing time in each range to engage transmission. Return to Park,
'P' position, and apply parking brake.
2. Clean all dirt from the transmission fluid dipstick cap before removing the dipstick from the filler tube.
3. Pull the dipstick out of the tube, wipe it clean and push it all the way back in the tube. Be sure it is fully seated.
4. Pull the dipstick out of the filler tube again and check the fluid level. The level should be between the middle and top
holes of the dipstick. If the level is below the middle hole or above the top hole. Add or remove fluid to bring the level
between the middle hole and the top hole.
5. If it becomes necessary to add fluid to a transmission, be sure to use the correct fluid, as specified on the transmission
dipstick.
6. Install the dipstick, making sure it is fully seated in the tube.
If the transmission fluid level is correctly established at 21 °-35° C (70°-95° F), it will appear between the 'Add'
and 'Full' mark on the dipstick when the transmission reaches an operating temperature of 65°-70° C (150°-
170° F). Do not over-fill or under-fill.
Overfill can cause the fluid to foam and spill out through the transmission vent with resultant transmission
malfunction.
If the transmission fluid level is checked when the fluid is cold, the dipstick could indicate that fluid should
be added. If the fluid is added at this time, an overfill condition could result when the fluid reaches an operating
temperature of 65°-76° C (150°-170° F) (Dipstick hot to touch).
Transmission Fluid Condition Check
1. Make the normal fluid check according to the above procedure.
2. Observe color and odor of the fluid. It should be red not-brown, or black. A burnt odor can sometimes indicate that
there is an overheating condition or clutch disc or band failure.
3. Use an absorbent white paper (Kleenex, etc.) to wipe.the dipstick.: Examine the stain for evidence of solids (specks
of any kind) and for antifreeze signs (gum or varnish on dipstick).
182 August 31, 2012

If specks are present in the oil or there is evidence of antifreeze, the transmission oil pan must be removed for
further inspection. If fluid contamination or transmission failure is confirmed by further evidence of coolant or
excessive solids in the oil pan, the transmission must be disassembled and completely cleaned and repaired.
This includes cleaning the torque converter and transmission cooling system. It would be a waste of time to
perform any further checks before cleaning and repairing the transmission. During disassembly and assembly,
all overhaul checks and adjustments of clearances and end play must be made.
High or Low Fluid Level
A fluid level that is too high will cause the fluid to become aerated. Aerated fluid will cause low control
pressure, and the aerated fluid may be forced out of the vent.
A fluid level that is too low can affect the operation of the transmission. Low level may indicate
fluid leaks that could cause transmission damage.
Fluid Level High Before Starting Engine-Ok During Normal Check
1. Check for correct operation of drain-back valve in stator support.
2. Check pump bushing.
3. Replace or repair pump if required.
Transmission Fluid Leakage Checks
Check the speedometer cable connection at the transmission. Replace the rubber seal if necessary (if so
equipped).
Leakage at the oil pan gasket often can be stopped by tightening the attaching bolts to the proper torque. If
necessary, replace the gasket.
Check the fluid filler tube connection at the transmission case. If leakage is found, install a new 0-ring or
tighten the fitting to the specified torque as listed at the end of this Part.
Check the fluid lines and fittings between the transmission and the cooler in the radiator tank for looseness,
wear, or damage. If leakage is found, tighten the fitting, or replace the damaged parts.
Check the engine coolant in the radiator. If transmission fluid is present in the coolant, the cooler in the radiator is
probably leaking.
The cooler can be further checked for leaks by disconnecting the lines from the cooler fittings and
applying 345-517 kPa (50-75 psi) air pressure to the fittings. Remove the radiator cap to relieve the pressure
build up at the exterior of the oil cooler tank. If the cooler is leaking an/or will not hold pressure, the cooler must be
replaced. Cooler replacement is described in the Cooling System Section of Group 27.
If leakage is found at either the downshift control lever or the manual lever shaft, replace either or both seals.
Inspect the pipe plug on the left front side of the transmission case. If the plug shows leakage, tighten the plug
to specifications. If leakage continues, replace the plug. On a C-6 transmission, inspect the TV pressure plug on
the right rear side of the case.
If the plug shows leakage, coat the threads with Motorcraft Sealing Compound or equivalent and tighten the
plug to specification as listed at the end of the appropriate transmission part. If leakage continues, replace the
plug.
August 31, 2012 183

When a converter drain plug leaks, remove the drain plug with a six-point wrench. Coat the threads with
Motorcraft Sealing Compound or equivalent and install the plug. Tighten the drain plug to specification as
listed at the end of this part. Fluid leakage from the converter housing may also be caused by engine oil
leaking past the rear main bearing, or from oil galley plugs, or power steering oil leakage from steering
system. Be sure to determine the exact cause of the leak before starting repair procedures.
Oil-soluble aniline or fluorescent dyes premixed at the rate of 1/2 teaspoon of dye powder to 0.23 liter
(1/2 pint) of transmission fluid have proven helpful in locating the source of fluid leakage. Such dyes may
be used to determine whether an engine oil or transmission fluid leak is present, or if the fluid in the oil
cooler leaks into the engine coolant system. A black light must be used with the fluorescent dye
solution.
Fluid Leakage in Converter Area
In diagnosing and correcting fluid leaks in the front pump and converter area, use the following
procedures to locate the exact cause of the leakage. Leakage at the front of transmission, evidenced
by fluid around the converter housing, may have several sources.
By careful observation, it is possible in many instances to pinpoint the source of the leak before
removing the transmission from the vehicle. The paths which the fluid takes to reach the bottom of
the converter housing are shown in Fig.2.
1. Fluid leaking by the front pump seal lip will tend to move along the drive hub and onto the
back of the impeller housing. Except in the case of a total seal failure, fluid leakage by the lip
of the seal will be deposited on the inside of the converter housing only, near the outside
diameter of the housing.
2. Fluid leakage by the outside diameter of the seal and front pump body will follow the same
path which the leaks by the front pump seal follow.
3. Fluid that leaks by a front pump-to-case bolt will be deposited on the inside of the converter
housing only. fluid will not be deposited on the back of the converter.
4. Leakage by the front pump-to-case gasket may cause fluid to be deposited inside the
converter housing, or it may seep down between the front of the case and converter housing.
5. Fluid leakage from the converter drain plugs will appear at the outside diameter of the
converter on the back face of the flywheel, and in the converter housing only near the
flywheel.
6. Converter-to-flywheel stud weld leak.
184 August 31, 2012

Engine oil leaks are sometimes

improperly diagnosed as transmission
front pump seal leaks. The following
areas of possible leakage should also
be checked to determine if engine oil
leakage is causing the problem.
FIG. 2 Converter Leakage-Fluid Pat

Leakage at the rocker arm cover (valley cover) may allow oil to flow over the converter housing or
seep down between the converter housing and cylinder block, causing oil to be present in or at the
bottom of the converter housing.
a. Oil galley plug leaks will allow oil to flow down the rear face of the block to the bottom of
the converter housing.
b. Leakage by the crankshaft seal will work back to the flywheel, and then into the converter
housing.
Fluid leakage from other areas, such as the power steering system forward of the transmission, could
cause fluid to be present around the converter housing due to blow back or road draft. The following
procedures should be used to determine the use of the leakage before any repairs are made.
a. Remove the transmission dipstick and note the color of the fluid. Original factory-fill fluid is
dyed red, to aid in determining if leaking is from the engine or transmission. Unless a
considerable amount of makeup fluid has been added or the fluid has been changed, the color
should assist in pinpointing the leak. Since road draft may cause leaking power steering fluid
to be present on the transmission, this leakage, if present, should be eliminated before
checking the transmission for fluid leakage.
b. Remove the converter housing cover. Clean off any fluid from the top and bottom of the
converter housing, front of the transmission case, and rear face of the engine and engine oil
pan. Clean the converter area by washing with a suitable non-flammable solvent, and blow dry
with compressed air.
c. Wash out the converter housing, the front of the flywheel, and the converter drain plugs. The
converter housing may be washed out using cleaning solvent and a squirt-type oil can. Blow
all washed areas dry with compressed air.
d. Start and run engine until the transmission reaches its normal operating temperature.
Observe the back of the block and top of the converter housing for evidence of fluid leakage..
Raise the vehicle on a hoist and run the engine at fast idle, then at engine idle, occasionally
shifting to the drive and reverse ranges to increase pressure within the transmission. Observe
the front of the flywheel; back of the block (in as far as possible), and inside the converter
August 31, 2012 185

housing and front of the transmission case. Run the engine until fluid leakage is evident and
the probable source of leakage can be determined.
Converter Leakage Check
If welds on the torque converter indicate leakage, remove the converter and make the following check.
FIG. 3 Rotunda Torque Converter Leak Detector Kit-72-

0004
FIG. 4 Torque Converter Leak Detector Installed
Assemble a Rotunda 72-0004 Torque Converter Leak Detector (Fig. 3) or an equivalent to the converter as
shown in Fig. 4. Test the converter for leaks following the directions supplied with the detector kit.
Engine Idle Speed Check
If the idle speed is too low, the engine will run roughly. An idle speed that is too high will cause the vehicle
to creep, have harsh engagements and harsh closed-throttle downshifts.
Check and, if necessary, adjust engine idle speed to specifications shown on the engine decal with the
headlights on, A/C turned off and transmission in drive range, using the procedure given in the appropriate
carburetor part in Group 24.
On vehicles equipped with an Exhaust Gas Recirculation (EGR) system, it is important to check the system
for proper operation and for a possible restricted condition.
Anti-Stall Dashpot Clearance Check
After the engine idle has been properly adjusted, check the ant-stall dashpot clearance. Follow the
procedure given in Group 24 for checking and adjusting this clearance.
Control Pressure Test

There are two methods of performing the control pressure test. One is to perform the test using the engine
vacuum. The second method is to use a remote vacuum source such as the one provided in the distributor tester.
Engine Vacuum Pressure
When the vacuum diaphragm unit is operating properly and the manual and downshift linkage is adjusted
properly, all the transmission shifts (automatic and kickdown) should occur within the road speed limits listed
in the GM 3.0L Truck Performance Specifications book.
186 August 31, 2012

If the shifts do not occur within limits, or the transmission slips during shift point, use the following
procedure to determine whether the engine, transmission, linkage, vacuum diaphragm unit or valve body is causing
the condition.
Engine Vacuum Procedure
Fig. 6 Typical Diaphragm And Control Pressure Connecting

Point
FIG. 5 Typical Vacuum Test Line Connections
1. Using the appropriate automatic transmission tester, attach the tachometer to the engine and the vacuum
gauge to the transmission vacuum line at the manifold vacuum port (Fig. 5).
FIG. 7 Control Pressure Connecting Point-C-6 Transmission

FIG. 8 Testing Transmission Vacuum Unit for Leakage
2. Attach the pressure gauge to the control pressure outlet at the transmission (Figs. 6 and 7).
3. Firmly apply the parking brake and start the engine.
4. Adjust the engine idle speed to the specified rpm, using the carburetor idle adjustment screw. If the
engine idle speed cannot be brought within limits, check the throttle and downshift linkage for a binding
condition. If linkage is satisfactory, check for vacuum leaks in the transmission diaphragm unit (Fig. 8) and
its connecting tubes and hoses. Check all other vacuum operated units (such as the power brake) for
vacuum leaks. Refer to Brake-Section Group 12.
5. Refer to the two control pressure diagnostic guides in Fig.9 to show what components are inoperative when
the control pressure is not within specifications. Do not proceed with the main diagnosis guide until you
August 31, 2012 187

have made any repairs, as required, and the control pressure is within specifications as listed in the GM
3.0L Truck Performance Specifications book.
Vacuum Pump Method
Install the Automatic Transmission Tester. Disconnect and temporarily plug the vacuum line at the vacuum
diaphragm unit. Apply both the parking and service brakes. Start the engine and vacuum pump. Set the
vacuum at 15 inches, read and record the control pressure in all positions. Run the engine up to 1000 rpm, and
reduce the vacuum to 10 inches. Read and record the control pressure in D, 2 and 1. Keep the engine rpm at
1000 and reduce the vacuum to 1 inch. Read and record the control pressure in D, 1, 2 and R.
Refer to the two control pressure diagnostic guides in Fig. 9 to show what components are inoperative when
the control pressure test is not within specifications. Do not proceed with the main diagnosis guide until you have
made any repairs, as required, and the control pressure is within specifications as listed in the GM 3.0L Truck
Performance Specifications book.
Vacuum Supply Test
The vacuum supply to the vacuum diaphragm unit and the diaphragm itself must be checked. To check the
supply, disconnect the vacuum line at the diaphragm unit and connect it to a vacuum gauge. With the engine
idling,
the gauge must have a steady acceptable vacuum reading for the altitude at which the test is being performed. If the
vacuum reading is low, check for a vacuum leak or poor engine vacuum. If the vacuum reading is OK, rapidly
accelerate the engine momentarily. The vacuum reading must drop rapidly at acceleration and return
immediately upon release of the accelerator. If the vacuum reading does not change or changes slowly, the
transmission vacuum line is plugged, restricted or connected to a reservoir supply. Correct as required.
Vacuum Diaphragm Test-On Vehicle
To check the vacuum diaphragm unit, start the vacuum pump and set the regulator knob so that the vacuum
gauge reads 18 inches with the end of the vacuum hose blocked. Then connect the vacuum hose to the diaphragm
unit. If the gauge still reads 18 inches, the vacuum diaphragm is not leaking. If the reading does not remain at 18
inches, but drops, the vacuum diaphragm is leaking. Replace the vacuum diaphragm unit. Also, if automatic
transmission fluid is present in the vacuum side of the diaphragm or in the vacuum hose, the diaphragm is
leaking and must be replaced.
188 August 31, 2012

Vacuum Diaphragm Tests-Off Vehicle

To check the vacuum unit for diaphragm leakage, remove the unit from the transmission. Use a distributor
tester equipped with a vacuum pump (Fig. 8). Set the regulator knob until the vacuum gauge reads 18 inches with
the end of the vacuum hose blocked off.
Connect the vacuum hose to the manifold vacuum port as shown in Fig. 8. If the gauge still reads 18 inches, the
vacuum unit diaphragm is not leaking. A second leakage check can be made as the hose is removed from the
transmission vacuum unit. Hold a finger over the end of the control rod. When the hose is removed, the internal
spring of the vacuum unit should push the control rod outward. If the vacuum diaphragm needs replacing,
install a new unit that has been released for service. Vacuum diaphragm assembly identification is given at the
end of this part.
August 31, 2012 189

Stall Test
Refer to Fig. 11.
Start the engine to allow it to reach normal operating temperature. Apply both the parking and service brakes
while stepping on the accelerator to reach the specified rpm for the stall test.
The stall test is made in D (DRIVE), 1 (FIRST) or R (REVERSE) at full throttle to check engine
performance, converter clutch operation or installation, and the holding ability of the forward clutch, reverse-high
clutch and low-reverse band or low-reverse clutch, and the gear train one-way clutch.
FIG. 10, deleted
FIG. 11 Stall Diagnosis Test
Do not hold the throttle open for more than five seconds at a time while making this test.
Caution
190 August 31, 2012

After the test, move the selector to N (NEUTRAL) and run engine at 1000 rpm for about 15 seconds to cool the
converter before making the next test. If the engine speed recorded by the tachometer exceeds the maximum
limits listed in the GM 3.0L Truck Performance Specifications book, release the accelerator immediately because
the clutch or band slippage is indicated.
Governor Check
The governor can be checked at the same time as the Control Pressure Test is performed and in the
same manner.
Raise the vehicle with an axle or frame hoist so that the rear wheels are clear of the floor. Disconnect
and plug the vacuum line to the vacuum diaphragm unit. Connect the line from the distributor tester to
the vacuum diaphragm unit. Install the Automatic Transmission Tester.
Never exceed 48 km (30 mph) speedometer speed.
CAUTION
Place the transmission in manual 2, no load on the engine and apply 10 inches of vacuum to the
vacuum diaphragm unit. Increase the speed slowly and watch the speedometer. Check the mph at which
the control pressure cutback occurs. It should occur between 8-16 km (5-10 mph).
Decrease the vacuum at the vacuum diaphragm to 0.2 inches. Repeat the check. Control pressure
cutback should occur between 24-40 km (15-25 mph).
The governor is good if the cutback occurs within these specifications. If the cutback does not occur
within specifications, check shift speeds to verify that it is the governor and not a stuck cutback
valve, then repair or replace the governor.
Transmission Fluid Cooler Flow Check
The linkage, fluid level and control pressure must be within specifications before performing this
flow check. Remove the transmission dipstick from the filler tube.
Place a funnel in the transmission filler tube. Raise the vehicle, remove the cooler return line from its
fitting in the case. Attach a hose to the cooler return line and fasten the free end of the hose in the
funnel installed in the filler tube.
Start the engine and set idle speed at 1000 rpm with the transmission in neutral.
Observe the fluid flow at the funnel. When the flow is "solid" (air bleeding has been completed), the
flow should be liberal. If there is not a liberal flow at 1000 rpm in neutral, low pump capacity, main
circuit system leakage, or cooler system restriction is indicated.
To separate transmission trouble from cooler system trouble, observe the flow at the transmission
case converter-out fitting.
August 31, 2012 191

Shift Point Checks
Road Test
Check the minimum throttle up shifts in D (DRIVE). The transmission should start in first gear, shift to second,
and then shift to third, within the shift points listed in the GM 3.0L Truck Performance Specifications book.
With the transmission in third gear, depress the accelerator pedal through the detent (to the floor) The
transmission should shift from third to second or third to first, depending on the vehicle speed.
Check the closed throttle downshift from third to first by coasting down from about 24 km (15 mph) in third
gear. The shift should occur within the limits listed in the Specifications.
When the selector lever is at 2 (SECOND), the transmission can operate only in second gear.
With the transmission in third gear and road speed over 24 km (15 mph) the transmission should shift to
second gear when the selector lever is moved from D (DRIVE) to 2 (SECOND) to 1 (FIRST). This check will
determine if the governor pressure and shift control valves are functioning properly.
The transmission will downshift from second or third to first gear when this same manual shift is made below
approximately 24 km (15 mph) with a C-6 transmission.
Shift Test
A shift test can be performed to check shift valve operation, governor circuits, shift delay pressures, throttle
boost and downshift valve action.
Raise the vehicle with an axle or frame hoist so that the rear wheels are clear of the floor. Disconnect and
plug the vacuum line to the vacuum diaphragm unit. Connect the line from the distributor tester vacuum pump
to the vacuum diaphragm unit.
1. To check the shift valves and governor circuits, apply 18 inches of vacuum to the transmission vacuum
diaphragm unit. Place the transmission in Drive and make a minimum throttle 1-2 and 2-3 shift test. At the
point of shift you will see the speedometer needle make a momentary surge and feel the driveline bump.
If the shift points are within specifications, the 1-2 and 2-3 shift valves and governor are OK. If the shift
points are not within specifications, perform a "Governor Check" to isolate the problem.
NOTE: After each test, move the selector lever to neutral and run the engine at 1000 rpm
to cool the transmission.
2. To check the shift delay pressures and throttle boost, decrease the vacuum at the vacuum diaphragm to 0-2
inches. Make a 1-2 shift test. If the shift point raises to specifications, the throttle boost and shift delay
systems are functioning.
NOTE: After each test, move the selector lever to neutral and run the engine at 1000 rpm
to cool the transmission.
To check downshift valve action, leave the vacuum to the vacuum diaphragm at 0-2 inches. Position the
downshift linkage in the wide open throttle position (through the detent) and repeat the 1-2 shift test. The speed
at the shift point should be higher.
192 August 31, 2012

Forced Downshifts
With the transmission in high gear depress the accelerator pedal to the floor. The transmission should
downshift depending on vehicle road speed.
Closed Throttle Down-Shifts
Closed throttle down-shifts should be extremely difficult to detect. It may be necessary to attach pressure
gauges to the forward and direct clutch pressure taps (Fig. 8) in order to detect 4-3 and 3-2 coast-down shifts.
With gauges attached a 4-3 coast (closed throttle), down-shift is signified by the application of the forward
clutch and 3-2 coast down-shift is signified by the release of the direct clutch. A 2-1 coast down-shift should be
unperceivable. The coast down-shifts should occur within the limits set forth in the GM 3.0L Truck
Performance Specifications book.
When the shift selector is in manual low (1) the transmission can operate only in first gear.
When the shift selector is moved from (D) to the manual low (1) position, the transmission will down-shift
into first gear.
The overdrive band is applied when the transmission is in manual second. The low-reverse band is applied in
manual-low.
In Shop
A shift test can be performed in the shop to check shift valve operation, governor circuits, shift delay
pressures, throttle boosts and down-shift valve action.
Raise the vehicle with an axle or frame hoist so that the rear wheels are clear of the floor. Disconnect and
plug the vacuum line to the vacuum diaphragm unit. Connect the line from the distributor tester vacuum pump
to the vacuum diaphragm unit.
1. To check the shift valves and governor circuits, apply 18 inches of vacuum to the transmission
vacuum diaphragm unit. Place the transmission in Drive and make a minimum throttle 1-2. At the
shift points you will see the speedometer needle make a momentary surge and feel the driveline bump.
If the shift points are within specification, the 1-2 and 2-3 shift valves and governor are OK.
If the shift points are not within specification, perform a Governor Check to isolate the problem.
Note: After each test, move the selector lever to Neutral, run the engine at 1000 rpm to
cool the transmission.
2. To check the shift delay pressures and throttle boost, decrease the vacuum at the vacuum diaphragm
to 0-2 inches. Make a 1-2 shift test. If the shift point raises to specification, the throttle boost and shift
delay systems are functioning.
NOTE: After each test, move the selector lever to Neutral, run the engine at 1000 rpm to
cool the transmission.
3. To check downshift valve action, leave the vacuum to the vacuum diaphragm at 0-2 inches. Position
the downshift linkage in the wide open throttle position (through the detent) and repeat the 1-2 shift
test. The speed at the shift point should be higher.
August 31, 2012 193

Air Pressure Checks

A NO DRIVE condition can exist, even with correct transmission pressure, because of inoperative clutches or
bands. On automatic transmissions, an erratic shift can be caused by a stuck governor valve. The inoperative units
can be located through a series of checks by substituting air pressure for fluid pressure to determine the
location of the malfunction.
When the selector lever is at 2, a NO DRIVE condition may be caused by an inoperative forward clutch. a NO
DRIVE condition at D may be caused by an inoperative forward clutch or one-way clutch. When there is no
drive in 1, the difficulty could be caused by improper functioning of the forward clutch or simultaneous
malfunction of the low-reverse band and the one-way clutch. Failure to drive in reverse range could be caused by
a malfunction of the reverse-high clutch or low reverse' band or clutch.
When you have a slip problem but don’t know whether it is in the valve body or in the hydraulic system
beyond the valve body, the air pressure tests can be very valuable.
FIG. 14, Fluid Passage Hole Identification- AOD
Fig. 13, Case Fluid Passage Hole Identification – C-6

Automatic
To make the air pressure checks, drain the transmission fluid and remove the oil pan and the control valve
body assembly. The inoperative clutches or bands can be located by introducing air pressure into the various
transmission case passages (Figs. 12, 13 and 14).
194 August 31, 2012

Forward Clutch
Apply air pressure to the transmission case forward clutch or front clutch passages (Fig. 12). A dull thud can
be heard when the clutch piston is applied. If no noise is heard, place the fingertips on the input shell and again
apply air pressure to the forward or front clutch passage. Movement of the piston can be felt as the clutch is
applied.
Governor
Apply air pressure to the control pressure to governor passage (Figs. 12, 13 or 14) and listen for a sharp
clicking or whistling noise. The noise indicates governor valve movement.
Reverse-High Clutch
Apply air pressure to the reverse-high clutch (Figs. 12, 13, or 14.) A dull thud indicates that the reverse-high
or rear clutch piston has moved to the applied position. If no noise is heard, place the fingertips on the clutch
drum and again apply air pressure to detect movement of the piston.
Intermediate Servo
Hold the air nozzle in the front servo apply tube or the intermediate servo apply passages (Figs. 12 or 13).
Operation of the servo is indicated by a tightening of the front or intermediate band around the drum on C-6
Transmissions. Continue to apply air pressure to the servo apply tube or passage, and introduce air pressure into
the front release tube or the intermediate servo release pressure. The front or intermediate servo should release
the band against the apply pressure.
Low-Reverse Servo
Apply air pressure to the low-reverse servo (Figs. 12 or 13).
If the servos do not operate, disassemble, clean, and inspect them to locate the source of the trouble.
If air pressure applied to either of the clutch passages fails to operate a clutch or operates both clutches at
once, remove, and with air pressure, check the fluid passages in the case and front pump to detect
obstructions.
Low-Reverse Clutch
Apply air pressure to the low-reverse clutch apply passage (Fig. 14). A dull thud should be heard if the
clutch is operating properly. If the passages are clear, remove the clutch assemblies, and clean and inspect the
malfunctioning clutch to locate the trouble.
August 31, 2012 195

Diagnosis Guides
The following guides can be used as an aid when diagnosing automatic transmissions.
Diagnosis - Automatic Transmission
Condition Possible Causes Resolution

• Slow initial • Improper fluid level. • Add fluid as required.
engagement. • Damaged or improperly adjusted linkage. • Service or adjust linkage.
• Contaminated fluid. • Perform fluid level check.
• Improper clutch and band application, or oil control • Perform control pressure test
pressure. • Service as required.
• Damaged 2-3 Accumulator.
• Rough initial • Improper fluid level. • Perform fluid level check.
engagement in either • High engine idle. • Adjust idle to specifications.
forward or reverse. • Automatic choke on (warm temperature). • Disengage choke.
• Looseness in the dnveshaft, U-joints or engine mounts. • Service required.
• Incorrect linkage adjustment. • Service or adjust linkage.
• Improper clutch or band application, or oil control • Perform control pressure test
pressure. • Service as required.
• Damaged 2-3 Accumulator. • • Clean, repair or replace valve body.
• Sticking or dirty valve body.
• No drive in any gear • Improper fluid level. • Add fluid.
• Damaged or improperly adjusted linkage. • Check linkage.
pressure. • Check and repair as required.
• Intimae leakage. • Tighten to specification.
• Valve body loose. • Service as required.
• Damaged or worn clutches. • Clean, repair or replace valve body.
• Sticking or dirty valve body.
• No drive forward - • Improper fluid level. • Perform fluid level check
reverse OK. • Damaged or improperly adjusted linkage. • Service or adjust linkage.
pressure. • Perform air pressure test.
• Damaged or worn forward clutch or governor. • Tighten to specification.
• Valve body loose. • Clean, service or replace valve body.
• Dirty or sticking valve body. • Service as required.
• Damaged 2-3 Accumulator.
• No drive, slips or • Improper fluid level. • Perform fluid level check
chatters in reverse, • Damaged or improperly adjusted linkage. • Service or adjust linkage.
forward OK. • Looseness in the driveshaft, U-joints or engine mounts. • Service as required.
• Reverse bands out of adjustment or damaged reverse • Service clutches as required.
clutches. • Perform control pressure test
• Improper oil pressure control. • Perform air pressure test
• Damaged or worn reverse clutch or shim. • Tighten to specifications.
• Valve body loose. • Clean, service or replace valve body.
• Dirty or sticking valve body.
• No drive, slips or
chatters in first gear
• Damaged or worn one-way clutch. • Service or replace one-way clutch.
in D. All other gears
normal.
196 August 31, 2012


• Improper fluid level. • Check fluid level
• Damaged or improperly adjusted linkage. • Service or adjust linkage.
• Intermediate band put of adjustment (except AOD) • Adjust intermediate band.
• No drive, slips or • Improper band or clutch application, or oil pressure • Perform control pressure test
chatter in second control. • Perform air pressure test.
gear. • Damaged or worn servo and/or internal leaks. • Clean, service or replace valve body
• Dirty or sticking valve body. • Replace or service as required.
• Polished, glazed intermediate band or drum (except
AOD).
• Improper fluid level. • Perform fluid level check
• Damaged or improperly adjusted linkage clutch • Service or adjust linkage.
• Improper band and/or clutch application, or oil control • Perform control pressure test.
1. Starts up in 2nd or pressure.
• Damaged or worn governor, or sticking governor. • Perform Gove or check, replace or service
governor
• Valve body loose. • clean screen.
• Dirty or sticking valve body. • Tighten to specification.
• Cross leaks between valve body and case mating • Clean, service or replace valve body.
surface. • Replace valve body and/or case as required.
• Improper fluid level. • Perform fluid level check.
• Improper vacuum hose routing or leaks (except AOD). • Correct hose routing.
• Improper operation of EGR system (except AOD). • Service or replace as required.
• Linkage out of adjustment (AOD). • Service or adjust linkage.
• Throttle linkage out of adjustment • Service or adjust linkage.
• Shift points incorrect.
• Improper speedometer gear installed. • Replace gear.
• Improper clutch or band application, or oil pressure • Perform shift test an control pressure test.
control system.
• Damaged or worn governor. • Service or replace governor- clean screen.
• Dirty or sticking valve body. • Clean, service or replace valve body.
• Vacuum leak to diaphragm unit. • Service vacuum line or hose.
• No up shift at any • Linkage out of adjustment • Service or adjust linkage.
speed in ( 3 or D • Throttle linkage AOD. • Service as required.
for AOD. • Improper band or clutch application, or oil pressure • Perform control pressure test
control system.
• Damaged or worn governor. • Service or replace governor- clean screen.
• Improper fluid !wet. • Perform fluid level check.
• Intermediate band out of adjustment. • Adjust band.
• Intermediate friction or one-way clutch (AOD). • Service.
• Damaged intermediate servo and/or internal leaks • Perform air pressure test. Service front servo
• Shifts 1-3 in D. (except AOD). and/or internal leaks.
• Polished, glazed band or drum (except AOD). • Service or replace band or drum.
• Improper band or clutch application, or oil pressure • Perform control pressure test
control system.
August 31, 2012 197


• Linkage out of adjustment. • Service or adjust linkage.
• Engine over- • Throttle linkage (AOD). • Service or adjust
speeds on 2-3 • Improper band or clutch application, or oil pressure • Perform control pressure test
shift. control system.
• Damaged or worn high clutch and/or intermediate • Perform air pressure test. Service as
servo. required.
• Dirty or sticking valve body. • Clean, service or repair valve body.
• Improper fluid level. • Add fluid as required.
• Incorrect engine performance. • Tune engine and adjust engine idle.
• Improper linkage adjustment. • Service or adjust linkage.
• Intermediate band out of adjustment (except AOD). • Adjust intermediate band (except AOD).
• Mushy 1-2 shift • Improper band or clutch application, or oil pressure • Perform control pressure test
• control system. • Perform air pressure test Service as
• Damaged high clutch and/or intermediate servo or required.
band (except AOD). • Service or replace as required.
• Polished, glazed band or drum (except AOD). • Clean, service or replace valve body.
• Incorrect engine idle or performance. • Tune engine and adjust engine idle.
• Intermediate band out of adjustment (except AOD). • Adjust intermediated (except AOD).
• Rough 1-2 shift • Improper band or clutch application, or oil pressure • Perform control pressure test
control system. • Air pressure check intermediate servo.
• Damaged intermediate servo (except A00). • Clean, service or replace valve body.
• Improper fluid level. Perform fluid level check
• Incorrect engine performance. Tune engine and adjust engine idle.
• Damaged 2-3 accumulator. Service as required.
• Improper band or clutch application, or 61 control Perform control pressure test
• Rough 2-3 shift pressure system. Air pressure test the intermediate servo apply
• Damaged or worn intermediate servo release and high and
clutch piston check ball (except AOD). release, and the high clutch piston ball check.
• Dirty or sticking valve body. Service
as required.
Clean, service or replace valve body.
• Incorrect engine idle or performance. • Tune engine and adjust engine idle.
• Rough 3-1 shift at • Improper linkage adjustment. • Service or adjust linkage.
closed throttle in D • Improper band or clutch application, or 61 control • .Perform control pressure test
(except AOD). • pressure system. • Perform governor test Service as required.
• Improper governor operation. • Clean, service or replace valve body.
198 August 31, 2012


• Incorrect engine performance. • Tune engine and adjust engine idle.
• Mushy 3.4 or rough • Damaged 3-4 accumulator. • Service as required.
4-3 shift (AOD • Improper linkage adjustment. • Service or adjust linkage.
only). • Improper band application. • Perform control pressure test
• Damaged or glazed reverse clutch drum. • Service as required.
• Polished or glazed band. • Service as required.
• Rough or mushy 4- • Improper fluid level. • Perform fluid level check.
2 or 3-1 shift 9-- • Incorrect engine performance. • Tune engine and adjust engine idle.
• Improper throttle or manual linkage adjustment • Service or adjust linkage.
• W.O.T. (wide open
• Improper application of intermediate fiction and one- • Service as required.
throttle) (AOD
way clutch.
only).
• Damaged 3-4 accumulator. • Service as required.
• Rough or mushy 4- • Incorrect engine performance. • Tune engine and adjust engine idle.
3shift (AOD only). • Improper throttle linkage adjustment. • Service or adjust linkage.
• Dirty or sticking valve body or governor. • Service as required.
• Clean, service or replace valve body or
governor.
• Improper fluid level • Perform fluid level check.
• Linkage out of adjustment (external). • Service or adjust linkage.
• Improper clutch or band application, or oil pressure • Perform control pressure test
• No forced control system.
downshifts • Damaged internal kickdown linkage. • Service internal linkage.
• Dirty or sticking governor. • Clean, service or replace governor
assembly.
• Improper fluid level.' • Perform fluid level check.
• Intermediate band out of adjustment • Adjust intermediate band.
• Runaway engine • Improper band or clutch application, one-way clutch or • Perform control pressure test or service
on 3-2 downshift. oil pressure control system. clutch.
• Damaged or worn intermediate servo. • Air pressure test the intermediate shim.
• Polished, glazed band or drum. Service servo and/or seals.
• Dirty or sticking valve body. • Service or replace as required.
• Clean, service or replace valve body.
• No engine braking • Linkage out of adjustment • Service or adjust linkage.
in manual first gear • Bands out of adjustment • Check low-reverse clutch.
(except AOD). • Oil pressure control system. • Perform control pressure test
• Damaged or worn am. • Perform air pressure test of servo.
• Polished, glazed band or drum. • Service or replace as required.
August 31, 2012 199


• No engine breaking • Intermediate band out of adjustment. • Adjust intermediate band.
in manual second • Improper band or clutch application, or oil pressure • Perform control pressure test
gear. • control system. • Perform air pressure test of intermediate
• Intermediate servo leaking. servo for
• Polished or glazed band or drum. • leakage. Service as required.
• Service or replace as required.
• Transmission • Improper fluid level. • Perform fluid level check.
noisy- valve • Linkage out of adjustment. • Service or adjust linkage.
resonance. • Improper band or clutch application, or oil pressure • Perform control pressure test
NOTE: Gauges may control system.
aggravate any hydraulic • Cooler lines grounding. • Free up cooler lines.
resonance. Remove • Dirty or sticking valve body. • Clean, service or replace valve body.
gauge and check for • Internal leakage or pump cavitations. • Service as required.
resonance level.
• Improper fluid Level • Perform fluid level check.
• Incorrect engine idle or performance. • Tune or adjust engine idle.
• Transmission • Improper clutch or band application, or oil pressure • Perform control pressure test
overheats. control system.
• Restriction in cooler or lines. • Service restriction.
• Seized converter one-way clutch. • Replace one-way clutch.
• Leakage at gasket, seals, etc. • Remove all traces of lube on exposed
• Transmission fluid surfaces of transmission. Check the vent for
leaks. free breathing. Operate transmission at
normal temperatures and inspect for
• Vacuum diaphragm unit leaking. leakage. Service as required.
• Replace diaphragm.
• Shift rod out of adjustment. • Check manual linkage for correct
• P-R-N-D-2-1 adjustment Refer to part 17-02: Sift control
pointer misaligned. • P-R-N-D-2-1 pointer is adjusted incorrectly. linkage.
• Adjust P-R-N-D-2-1
• Shift Rod within Tube.
200 August 31, 2012

August 31, 2012 201

Removal and Installation
Vacuum Diaphragm
1. Disconnect the hoses from the vacuum unit.
2. Remove the vacuum unit retaining bracket bolt
and bracket (Fig. 15). Do not pry or bend the
bracket.
Pull the vacuum unit from the transmission case.
3. Remove the vacuum unit control rod from the
transmission case.
4. Install the vacuum unit control rod in the
transmission case.
5. Push the vacuum unit into the case and secure
with the retaining bracket and bolt. Tighten the bolt
to 12-16 Lb-Ft or 17-21 NM.
6. Install the vacuum unit hoses to their respective
connectors.
Fig. 15, Vacuum Diaphragm Installed
Transmission Fluid Drain and Refill

Normal maintenance and lubrication requirements do not necessitate periodic automatic transmission fluid
changes.
If a major repair, such as a clutch band, bearing, etc., is required in the transmission, it will have to be
removed for service. At this time the converter, transmission cooler and cooler lines must be
thoroughly flushed to remove any dirt.
On light trucks equipped with automatic transmissions the following should apply:
When used under continuous or severe conditions, the transmission and the torque converter
should be drained and refilled with the specified fluid at intervals directed in the maintenance or
owners manual.
Refer to the Truck Performance Specifications book for fluid requirements.
NOTE: Fluid level indicator should be used to determine actual fluid requirements. Check fluid level
when the transmission is at normal operating temperature. Do not overfill.
Procedures for partial drain and refill, due to in-vehicle repair operation, are as follows:
202 August 31, 2012

1. Raise the vehicle on a hoist or jack stands.

2. Place a drain pan under the transmission.
3. Loosen the pan attaching bolts and drain the fluid
4. from the transmission.
5. When the fluid has drained to the level of the pan flange, remove the rest of the pan bolts working from
the rear and both sides of the pan to allow it to drop and drain slowly.
6. When all fluid has drained from the transmission, remove and thoroughly clean the pan and the screen.
Discard the pan gasket.
7. Place a new gasket on the pan, and install the pan on the transmission.
8. Add 2.8 liters (3 quarts) of fluid to the transmission through the filler tube.
9. Check the fluid level.
Oil Cooler Tube
When fluid leakage is found from the oil cooler, the cooler must be replaced. Cooler replacement is described in
the Cooling System section.
When one or more of the fluid cooler steel tubes must be replaced, each replacement tube must be fabricated from
the same size steel tubing as the original line.
Using the old tube as a guide, bend the new tube as required. Add the necessary fittings, and install the tube.
After the fittings have been tightened, add fluid as needed, and check for fluid leaks.
Cleaning and Inspection

Transmission
Clean the parts with suitable solvent and use moisture-free air to dry off all the parts and clean out fluid
passages.
The composition clutch plates, control valve body to-screen gasket, bands and synthetic seals should
not be cleaned in a vapor degreaser or with any type of detergent solution. To clean these parts, wipe
them off with a lint-free cloth. New clutch plates or bands should be soaked in transmission fluid specified
for that transmission type for fifteen minutes before being assembled.
August 31, 2012 203

Control Valve Body

1. Clean all parts thoroughly in clean solvent, and blow dry with moisture-free compressed air. If the valve
body-to-screen gasket is removed on a C-6 Automatic, the gasket should not be cleaned in a
degreaser, solvent or any type of detergent solution. To clean the gasket, wipe it off with a lint-free
cloth.
2. Inspect all valve and plug bores for scores. Check all fluid passages for obstructions. Inspect the check
valve for free movement. Inspect all mating surfaces for burrs or distortion. Inspect all plugs and valves for
burrs or scores. Use crocus cloth to polish valves and plugs. Avoid rounding the sharp edges of the valves
and plugs with the cloth.
3. Inspect all springs for distortion. Check all valves and plugs for free movement in their respective bores.
Valves and plugs, when dry, must fall from their own weight in their respective bores.
4. On a C-6 transmission, inspect the separator plate screen for obstructions. The screen must be clean and
free of foreign material. If contaminated, remove
it from separator plate, clean in a suitable solvent, and thoroughly blow clean with compressed air.
5. Roll the manual valve on a flat surface to check for bent condition.
Intermediate Servo
1. Inspect the servo bore for cracks and the servo piston for damage, and the piston bore and the servo piston
stem for scores. Check fluid passages for obstructions. Replace damages seals.
2. Check servo spring and servo band strut(s) for distortion.
3. Inspect the cover seal and gasket cover sealing surface for damage.
Extension Housing
1. Inspect the housing for cracks. Inspect the gasket 3. surface for burrs or warpage.
2. Inspect the bushing for scores or wear. Replace if 4. required.
3. Inspect the rear seal for hardness, cracks or wear. If the seal shows wear or deterioration, replace the seal.
4. Inspect the seal counterbore and remove all burrs and scores with crocus cloth.
Governor
1. Inspect the governor valves and bores for scores. Minor scores may be removed from the valves with
crocus cloth. Replace the governor if the valves or body is deeply scored.
2. On AOD transmission, inspect the governor screen for obstructions. The screen must be free of foreign
material. If contaminated, clean thoroughly in a suitable solvent and blow dry with compressed air.
3. Check for free movement of the valves in the bores. The valves should slide freely of their own weight in
the bores when dry. Inspect fluid passages in the valve body and counterweight for obstructions. all fluid
passages must be clean.
4. Inspect the mating surfaces of the governor body and governor distributor for burrs and distortion. Mating
surfaces must be smooth and flat.
204 August 31, 2012

Front Pump
1. Inspect the mating surfaces of the pump body and cover for burrs.
2. Inspect the drive and driven gear bearing surface for scores and check gear teeth for burrs.
3. Check the fluid passages for obstructions. If any parts are' found damaged or worn, replace the pump as a
unit. Minor burrs and scores may be removed with a crocus cloth.
4. On a C-6 and AOD transmission, check the large
seal ring groove of the pump b y for damage.
5. Check the gasket mating surface of the pump body
for damage.
Reverse-High Clutch
1. Inspect the drum band surface, the bushing, and thrust surfaces for scores. Minor scores may be removed
with crocus cloth. Badly scored parts must be replaced.
2. Inspect the clutch piston bore and the piston inner and outer bearing surfaces for scores. Check the air
bleed ball valve in the clutch piston for free movement.
3. Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
4. Inspect the clutch plates for wear, scoring, and fit on the clutch hub splines. Replace all plates that are
badly scored, worn, or do not fit freely in the hub serrations.
5. Inspect the clutch pressure plate for scores on the clutch plate bearing surface. Check the clutch release
spring(s) for distortion.
6. Check the clutch release spring for distortion and cracks. Replace spring if it is distorted or cracked.
August 31, 2012 205

Forward Clutch
1. Inspect the clutch cylinder thrust surfaces, piston
bore, and clutch plate serrations for scores or
burrs. Minor scores or burrs may be removed
with crocus cloth. Replace the clutch cylinder if it
is badly scored or damaged.
2. Check the fluid. passage in the clutch cylinder
for obstructions. Clean out all fluid passages.
Inspect the clutch piston for scores and replace if
necessary. Inspect the piston check bal l for freedom
of movement and proper. seating (Fig. 16).
3. Inspect the composition clutch plates, steel
clutch plates and clutch pressure plate for worn
or scored bearing surfaces. Replace all parts that
are deeply scored.
4. deleted
5. Check the clutch hub thrust surfaces for scores
and the clutch hub splines for wear.
6. Check the splines on the stator for wear.
Replace shaft if the splines are excessively
worn. Inspect the bushing in the stator
Fig. 16 Clutch Piston Check Valve
support for scores. Check the input shaft for
damaged or worn splines.
Low-Reverse Clutch
1. Inspect the clutch cylinder piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs
may be removed with crocus cloth. Replace the case if it is badly scored or damaged.
2. Check the fluid passage in the case for obstructions (Figs. 12 and 13). Clean out all fluid passages. Inspect
the clutch piston for scores and replace if necessary.
3. Check the piston return springs for distortion. Check the piston return spring retainer for flatness.
4. Inspect the compositions clutch plates, steel clutch
5. plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply
scored.
6. Check the clutch hub splines.
Converter and Oil Cooler
When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or
band material may have been carried into the converter and oil cooler. These contaminants are a major cause of
recurring transmission troubles and MUST be removed from the system before the transmission is put back into
service.
Whenever a transmission has been disassembled to replace worn or damaged parts or because the valve
body sticks from foreign material, the converter and oil cooler MUST be cleaned by using the Rotundra torque
206 August 31, 2012

Converter Cleaner (model 140028) or equivalent. Under NO circumstances should an attempt be made to clean
converters by hand agitation with solvent.
Converter End Play and One-Way Clutch Check
The tools shown in Fig. 17 are used to check

the converter and one-way clutch.
End Play Check
Fig. 17, Converter One-Way Clutch Check Tools

1. Insert tool T77L-7902-D into the converter
pump drive hub until it bottoms.
2. Expand the sleeve in the turbine spline by
tightening the threaded inner post (Fig. 18),
until the tool is securely locked into the
spline.
3. Attach a dial indicator to the tools (Figs. 18
and 19). Position the indicator button on the
converter pump drive hub and set the dial
face at 0 (zero).
3. Lift the tool upward as far as it will go and
note the indicator reading. The indicator
reading is the total end play which the turbine
and stator share. Replace the converter unit if
the total end play exceeds the limits. End play
specifications are listed at the end in the
specifications section of this part.
4. Loosen the threaded inner post to free the tool Fig. 18, End Play Checking Tool Installed
and then remove the tool from the converter.
August 31, 2012 207

Converter One-Way Clutch Check

1. Insert the one-way clutch holding tool (Fig.
19) into one of the grooves in the stator thrust
washer.
Fig. 19, Checking Converter One-Way Clutch
2. Insert the one-way clutch torquing tool (T77L-

7902-B) in the converter pump drive hub so as
to engage the one-way clutch inner race (Fig.
20).
3. Attach a torque wrench to the one-way clutch
torquing tool. With the. one-way clutch
holding tool held stationary, turn the torque
wrench counterclockwise. The converter one-
way clutch should lock up and hold a
10 Lb-Ft or 14 NM force. The converter one-
way clutch should rotate freely in a clockwise
direction. Try the clutch for lockup and hold
in at least five different locations around the
converter.
4. If the clutch fails to lock up and hold 10 Lb-Ft
or 14 NM of torque, replace the converter
unit.
Fig. 20, Checking Stator and Turbine End May
208 August 31, 2012

Stator To Impeller Interference

Check
1. Position the front pump assembly on a bench
with the spline end of the stator shaft pointing
up (Fig. 21). Mount a converter on the pump
with the splines on the one-way clutch inner
race engaging the mating splined of the stator
support. The converter hub will then engage
the pump drive gear.
2. Hold the pump stationary and try to rotate
the converter counterclockwise. The
converter should rotate freely without any
signs of interference or scraping within the
converter assembly.
3. If there is an indication of scraping, the
trailing edges of the stator blades may be
interfering with the leading edges of the
impeller blades. In such cases, replace the
converter.
Fig. 21, Stator to Impeller Interference Check
August 31, 2012 209

Stator To Turbine Interference

Check
1. Position the converter on the bench front side
down.
2. Install a front pump assembly to engage the
mating splines of the stator support and stator,
and pump drive gear lugs.
3. Install the input shaft, engaging the splines
with the turbine hub (Fig. 22).
4. Hold the pump stationary and attempt to
rotate the turbine with the input shaft. The
turbine should rotate freely in both directions
without any signs of interference or scraping
noise.
5. If interference exists, the stator front thrust
washer may be worn, allowing the stator to hit
the turbine. In such cases, the converter must
be replaced.
6. Check the converter crankshaft pilot for nicks
or damaged surfaces that could cause
interference when installing the converter
into the crankshaft. Check the converter front
pump drive hub for nicks or sharp edges that
would damage the pump seal.
Fig. 22, Stator to Turbine Interference Check
Pinion Carriers
Individual parts of the planet carriers are not serviceable.
Check the pins and shafts in the planet assemblies for loose fit and/or complete disengagement. Use a new
planet assembly if either condition exists. Before installing a planet assembly, the shaft retaining pins should
be checked for adequate staking. If necessary, restake the pins before installation. When restaking, the
retaining pins must not be driven into the carrier any further than 1.01 mm (0.040 inch) below the surface
of the
210 August 31, 2012

carrier.
Fig. 23, Roller Type Planetary Clutch, Carrier and Center Support - Automatic Overdrive Transmissions
2. Inspect the pinion gears for damaged or excessively worn teeth.
3. Check for free rotation of the pinion gears.
Stator Support
1. Inspect the stator support splines for burrs and wear.
2. Check the oil ring grooves in the stator support for nicks, burrs or damaged edges.
Case
Inspect the case for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs.
Check the vent for obstructions, and check all fluid passages for obstructions and leakage. (Figs. 13, 14, and
15).
Inspect the case bushing for scores. Check all parking linkage parts for wear or damage.
If a transmission case thread is damaged, service kits may be purchased from local jobbers. To repair a
damaged thread, the following procedures should be carefully followed.
1. Drill out the damaged threads using the same drill size as the thread outside diameter. For example, use
a 5/16 inch drill for a 5/16-18 thread.
2. Select the proper special tap and tap the drilled hole. The tap is marked for the size of the thread being
repaired. Thus, the special tap marked 5/16-18 will not cut the same thread as a standard 5/16-18 tap. It
does not cut a thread large enough to accommodate the insert, and after the insert is installed, the original
thread size (5/16-18) is restored.
3. Select the proper coil inserting tool. These tools are marked with the thread size being repaired. Place the
insert on the tool and adjust the sleeve to the length of the insert being used. Press the insert against the face
of the tapped hole. Turn the tool clockwise and wind the insert into the hole until the insert is 1/2 turn
below the face.
4. Working through the insert, bend the insert fang straight up and down until it breaks off at the notch.
Improperly installed inserts can be removed with the extractor tool. Place the extractor tool in the insert
with the blade resting against the top coil 1/4 to 1/2 turn away from the end of the coil. Tap the tool sharply
August 31, 2012 211

with a hammer until the blade cuts into the insert. Exert downward pressure on the tool and turn it
counterclockwise until the insert is removed.
VACUUM DIAPHRAM ASSEMBLY SPECIFICATIONS

Throttle Valve Rod
Part No.
Diaphragm Type Diaphragm Part No. Identification Length Identification
(7A380)
HAD D7AP-7A377-AA Part No. Stamped C4AP-A 1.677 1.667
. No Color
D10-BA 1.727-1.717 Purple Daub
SAD D70P 7A377-BA 1 Green Stripe
D30-DA 1.611-1.601 Yellow Daub
D30-EA 1.644-1.634 Blue Daub
SAD D4TP-7A377-BA 1 Black Stripe
D30-FA 1.660-1.650 Green Daub
D3AP-GA 1.710-1.700 White Daub
SAD DSAP-7A377 AA 1 Purple Stripe
D8AP-AA 1.694-1.684 Brown Daub
# Selective fit rods.
SAD - Single Area Diaphragm
S-SAD - Super Single Area Diaphragm
S-HAD - Super High Altitude Diaphragm
HAD - High Altitude Diaphragm
SS-HAD - Super High Altitude Diaphragm.
SPECIAL TOOLS
Number Description
T76L-7902-C
Torque Converter One-Way Clutch Tool
T77L-7902-A
T76L-7902-D Torque Converter End Play Checking Tool
ARE-2905 Automatic Transmission Tester
140028 Torque Converter Cleaner
72-0004 Torque Converter Leak Tester
Tool 4201-C Dial Indicator
T8OL-77030-B Servo Piston Remover
Transmission Converter Stall Speeds

Type Engine Size Minimum Maximum
C-6 4.9L 17 1525 1776
TORQUE-CONVERTER END-PLAY
Converter End-Play
New or Rebuilt Converter Used Converter
mm Inches mm Inches
0.533 Max. 0.021 Max. 1.01 Max. 0.040 Max.
212 August 31, 2012

C-6 Transmission Service
C-6 Automatic Transmission Service

Description
The C-6 transmission is a three speed unit capable of providing automatic up shifts and downshifts through the
three forward gear ratios. The transmission is also capable of providing manual selection of first and second
gears.
Fig. 2 shows the location of the converter, front

pump, clutches, gear train and most of the internal
parts used in the C-6 transmission. The
identification tag (Fig. 1), attached to the
intermediate servo (Fig. 5) lower front cover bolt,
includes the model prefix, suffix and serial
number.
The first line on the tag shows the transmission model prefix and suffix. A number appearing after the suffix
indicates that the internal parts in the transmission have been changed after initial production start-up. For
example, a PGD-BN model transmission that has been changed internally would read PGD-BN1. Both
transmissions are basically the same, but some service parts in the PGD-BN transmission are slightly different
than the PGD-BN1 transmission. Therefore, it is important that the codes on the transmission
identification tag be checked when ordering parts or making inquiries about the transmission.
The hydraulic control system schematic is shown in Fig. 4. The converter housing and the fixed splines which
engage the splined outside diameter of the low-reverse clutch steel plates, are both cast integrally into the case.
Only one (intermediate) band is used in the C-6 transmission. This, along with the forward clutch, is used to
obtain intermediate gear.
To check end play, exert force on checking tool to compress turbine to cover thrust washer wear plate. Set
indicator at zero.
August 31, 2012 213

Figure 2, Automatic Transmission -- Sectional
Adjustments
The only adjustment on the transmission is the
intermediate band.
To prevent damage to the transmission and to assure
proper band adjustment, it is essential that the tools and
procedures described here are used whenever the band is
adjusted.
Intermediate Band Adjustment.

1. Raise the vehicle on a hoist or jack
stands.
2. Clean all 'the dirt- from the band adjusting
screw. Remove and discard locknut.
3. Install a new locknut and tighten the adjusting
screw to 10 Lb-Ft or 14 NM torque (Fig. 3).
Fig 3, Adjusting Intermediate Band
4. Back off the adjusting screw exactly 1-1/2
turns.
5. Hold the adjusting screw from turning and
tighten the locknut to 40 Lb-Ft or 54 NM.
6. Lower the vehicle.
214 August 31, 2012

August 31, 2012 215

Removal and Installation

Removal
1. Park the vehicle on a hoist, but do not raise it.
2. Remove the two upper converter housing-to-engine bolts.
3. Remove the bolt securing the fluid filler tube to the engine.
4. Raise the vehicle on a hoist or stands.
5. Place the drain pan under the transmission fluid pan.
6. Starting at the rear of the pan and working toward the front, loosen the attaching bolts and allow
the fluid to drain. Finally remove all of the pan attaching bolts except two at the front, to
allow the fluid to further drain. With fluid drained, install two bolts on the rear side of the pan
to temporarily hold it in place.
7. Remove the converter drain plug access cover from the lower end of the converter housing.
8. Remove the converter-to-flywheel attaching nuts. Place a wrench on the crankshaft pulley
attaching bolt to turn the converter to gain access to the nuts.
9. With the wrench on the crankshaft pulley attaching bolt, turn the converter to gain access to the
converter drain plug. Place a drain pan under the converter to catch the fluid and remove the
plug. After the fluid has been drained, re-install the plug.
10
10. Disconnect the U-joints at both ends of the

driveshaft.
11. Disconnect the downshift and manual linkage rods from the levers at the transmission.
12. Disconnect the oil cooler lines from the transmission.
13. Remove the vacuum hose from the vacuum diaphragm unit. Remove the vacuum line
retaining clip.
14. Disconnect the cable from the terminal on the starter motor. Remove the three attaching bolts
and remove the starter motor.
15. Remove the two engine rear support and insulator assembly-to-attaching bolts.
216 August 31, 2012

16. Remove the 'two' engine rear support and insulator assembly-to-extension housing attaching
bolts.
17. Remove the six bolts securing the No. 2 cross member to the frame side rails.
18. Raise the transmission with a transmission jack and remove both cross members.
19. Secure the transmission to the jack with a safety chain.
20. Remove the remaining converter housing-to-engine attaching bolts.
21. Move the transmission away from the engine. Lower the jack and remove the converter and
transmission assembly from under the vehicle.
Installation
1. Tighten the converter drain plug to specifications as listed at the end of this Part.
2. Position the converter on the transmission making sure the converter drive flats are fully
engaged in the pump gear.
3. With the converter properly installation place the transmission on the jack. Secure the
transmission to the jack with a safety chain.
4. Rotate the converter until the studs and drain plug are in alignment with their holes in the
flywheel.
5. Move the converter and transmission assembly forward into position, using care not to
damage the flywheel and converter pilot. The converter must rest squarely against the
flywheel. This indicates that the converter pilot is not binding in the engine crankshaft.
6. Install and tighten the converter housing-to-engine attaching bolts to specifications listed at
the end of this Part.
7. Remove the transmission jack safety chain around the transmission.
8. Position the No. 2 cross member to the frame side rails. Install and tighten the attaching bolts
to specifications listed at the end of this Part.
9. Install transfer case on F-150 - F-250 (4x4) and Bronco. Refer to Part 16-82, New Process
Gear 208 Transfer Case, or Part 16-86, Borg Warner 1345 Transfer Case.
10. Position the engine rear support insulator assembly above the cross member. Install the rear
support insulator assembly-to-extension housing mounting bolts and tighten the bolts to
specifications as listed at the end of this Part.
11. Lower the transmission and remove jack.
12. Secure the engine rear support and insulator assembly to the cross member with the attaching
bolts and tighten them to specifications as listed at the end of this Part.
13. Connect the vacuum line to the vacuum diaphragm making sure that the line is in the
retaining clip.
14. Connect the oil cooler lines to the transmission.
15. Connect the downshift and manual linkage rods to their respective levers on the transmission.
Refer to Part 17-02 Shift Control Linkage, Removal and Installation.
August 31, 2012 217

16. Connect the speedometer cable to the extension housing.

17. Secure the starter motor in place with the attaching bolts. Connect the cable to the terminal
on the starter.
18. Install a new 0-ring on the lower end of the transmission filler tube and insert the tube in the
case.
19. Secure the converter-to-flywheel attaching nuts and tighten them to specifications as listed at
the end of this Part.
20. Install the converter housing access cover and secure it with the attaching bolts.
21. Connect the drive shaft.
22. Adjust the shift control linkage as required. Refer to Part 17-02, Shift Control Linkage.
23. Lower the vehicle. Then install the two upper converter housing-to-engine bolts and tighten
them to specifications as listed at the end of this Part.
24. Position the transmission fluid filler tube to the cylinder head and secure with the attaching
bolt.
25. Make sure the drain pan is securely attached and fill the transmission to the correct level with
the specified fluid.
Control Valve Body

Refer to Figs. 12 and 20.
Removal
1. Raise the vehicle on a hoist or jack stands.
2. Place a drain pan under the transmission and loosen the bolts holding the transmission pan to
drain the fluid from the transmission.
3. Remove the transmission pan attaching bolts from both sides and the rear to allow the fluid
pan to drain further. Finally, remove the remainder of the attaching bolts. Remove the pan
and gasket. Remove and discard the nylon shipping plug from the filler tube hole. This plug
is used to retain transmission fluid within the transmission during shipment and should be
discarded when the oil pan is removed.
4. Remove the valve body attaching bolts and remove the valve body from the case.
Installation
1. Position the valve body to the case making sure that the selector and downshift levers are
engaged. Install and tighten the attaching bolts to specifications as listed at the end of this
Part.
2. Clean the transmission pan and gasket surfaces thoroughly.
3. Using a new pan gasket, install attaching bolts securing the pan to the transmission case.
Tighten the attaching bolts to specifications as listed at the end of this Part.
4. Lower the vehicle and fill the transmission to the correct level with the specified fluid.
218 August 31, 2012

Intermediate Servo
Removal
2. Remove the bolts that secure the engine rear support to the transmission extension rear support and
insulator assembly to cross member.
3. Remove the two cross member-to-frame attaching bolts, and the bolts attaching the gussets to the
cross member, if so equipped.
4. Raise the transmission high enough to remove the weight from the cross member and remove the
cross member.
5. Disconnect the muffler inlet pipe from the exhaust manifolds and allow the pipe to hang.
6. Place a drain pan under the servo. Remove the bolts that attach the servo cover to the transmission case.
7. Remove the cover, piston, spring and gasket from the case, screwing the band adjusting screw inward
as the piston is removed. This places enough tension on the band to keep the struts properly engaged in
the band end notches while the piston is removed.
8. Apply air pressure to the port in the

servo cover to remove the piston and
rod.
9. Replace the complete piston and rod
assembly if the piston or piston sealing
lips are damaged (Fig. 5).
10. Remove the seal from the cover
Fig. 5, Intermediate Servo Disassembled - Typical
Installation
1. Dip the new seal in transmission fluid.
2. Install a new seal on the cover.
3. Coat new gasket with petroleum jelly, and position on the servo cover.
4. Dip the piston in transmission fluid and install it in the cover.
5. Position the servo spring on the piston rod.
6. Insert the servo piston and cover in the case and secure the cover to the case with the attaching
bolts, taking care to back off the band adjusting screw as the cover bolts are tightened. Make
sure that the service identification tag is in place.
7. Connect the muffler inlet pipe to the exhaust manifolds.
8. Raise the transmission high enough to install the cross member. Secure the cross member to
the rear support with the attaching bolts. Lower the transmission as required to install the cross
member to frame and gussets attaching bolts. Tighten the attaching bolts to specifications as
listed at the end of this Part.
August 31, 2012 219

9. Remove the jack from the transmission. Adjust the band as detailed in the Adjustment
section at the beginning of this Part.
10. Lower the vehicle and replenish the fluid as required. Refer to Part 17-01 of the General
Automatic Transmission Service.
Extension Housing Bearing or Bushing and Rear Seal

Removal
1. Raise the vehicle and disconnect the
drive shaft at the transmission.
2. When only the rear seal needs
replacing, carefully remove it with a
tapered chisel or the tools shown in
Fig. 6. Remove the bushing as shown
in Fig. 7. Use the bushing remover
carefully so that the spline seal is
not damaged.
Installation
1. When installing a new bushing use
the special tool as shown in Fig. 8.
2. Before installing a new seal, inspect
the sealing surface of the universal
joint yoke for scores. If scores are
found, replace the yoke.
3. Inspect the counterbore of the
housing for burrs. Remove burrs with
crocus cloth.
4. Install the seal into the housing with
the tool shown in Fig. 9. The seal
should be firmly seated in the bore.
Coat the inside diameter of the end of
the seal with C1AZ-19590-B (ESA-
M1C75-B) or an equivalent lubricant.
5. Coat the front universal joint spline
with C1 AZ-19590-B (ESA-M1 C75-
B) or an equivalent lubricant and
install the drive shaft.
220 August 31, 2012

Extension Housing
Removal
2. Disconnect the drive shaft from the rear axle flange and remove it from the transmission.
3. Disconnect the speedometer cable from the extension housing.
4. Remove the engine rear support and insulator assembly-to-extension housing attaching bolts.
5. Place a jack under the transmission and raise it just enough to remove the weight from the
engine rear support.
6. Remove the bolts that secure the engine rear support to the cross member and remove the
support.
7. Place a drain pan under the rear of the transmission case.
8. Lower the transmission and remove the extension housing attaching bolts. Slide the extension
housing off the output shaft and allow the fluid to drain.
Installation
1. Clean the mounting surface on the transmission case and on the extension housing. Position a
new gasket on the transmission case.
2. Hold the extension housing in place and secure it with the attaching bolts.
3. Raise the transmission high enough to position the engine rear support on the cross member.
4. Secure the support to the cross member with the attaching bolts and nuts. Tighten the bolts to
specification as listed at the end of this Part.
5. Lower the transmission and remove the jack. Install the engine rear support-to-extension
housing attaching bolts. Tighten the bolts to specification as listed at the end of this Part. On
4x4 vehicles, install the transfer case. Refer to Part 16-82 or 16-86.
6. Secure the speedometer cable to the extension housing with the attaching bolt.
7. Install the drive shaft and lower the vehicle to the floor.
8. Fill the transmission to the correct level with the specified fluid.
August 31, 2012 221

Governor
Removal
1. Remove the extension housing as
outlined in this section.
2. Remove the governor-to-oil-collector
attaching bolts (Fig. 10).
3. Remove the governor from the
flange.
4. Refer to the Disassembly and
Assembly section of this Part for
governor repair operations.
Installation
1. Secure the governor (Fig. 10) to the oil
collector flange with the attaching
bolts. Tighten the bolts to
specification as listed at the end of
this Part.
Figure 10, Governor Installed
2. Re-install the extension housing as
outlined in this section.
Disassembly and Assembly

TRANSMISSION
Before removing any of the subassemblies, clean the outside of the transmission thoroughly to prevent dirt from
entering the mechanical parts.
During the repair of the subassemblies, certain general instructions which apply to all units of the transmission
must be followed. Following these instructions will avoid unnecessary repetition.
Handle all transmission parts carefully to avoid nicking or burring the bearing or metal surfaces. Lubricate all
internal parts of the of the transmission with clean automatic transmission fluid before assembly.
Do not use any other lubricants except on gaskets
and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and
seals when assembling a transmission. Refer to General Automatic Transmission Service for cleaning and
inspection procedures.
Tighten all bolts and screws to the recommended torque as outlined in specifications at the end of this Part.
Disassembly
222 August 31, 2012

1. Remove the converter, and mount the

transmission in holding fixture T64L-
6001-A (Fig. 11).
2. Remove the 17 fluid pan attaching bolts.
Remove the pan and gaskets.
Figure 11, Transmission in Holding Fixture
3. Remove the eight valve body attaching

bolts. Lift the valve body (Fig. 12)
from the transmission case.
4. Attach a dial indicator to the front
pump as shown in Fig. 13. Install Tool
T61L-7657-B in the extension housing
to center the output shaft.
Figure 12, Transmission with Pan Removed
5. Pry the gear train to the rear of the case

and at the same time, press the input
shaft inward until it bottoms (Fig. 13).
Set the dial indicator to read zero.
6. Pry the gear train forward (Fig. 13),
and note the amount of gear train end
play on the dial indicator. Record the
end play to facilitate assembling the
transmission. Remove the dial indicator
from the pump and the tool from the
extension housing.
Figure 13, Checking Gear Train End Play
August 31, 2012 223

7. Remove the vacuum diaphragm, rod

and the primary throttle valve from the
bore in the rear of the case. Slip the
input shaft out of the front pump.
8. Remove the front pump attaching bolts.
Pry the gear train forward as shown in
Fig. 14 to remove the pump.
Figure 14, Removing the Front Pump
9. Loosen the band adjustment screw and

remove the two struts.
10. Rotate the band 90 degrees
counterclockwise to align the ends with
the slot in the case (Fig. 15). Slide the
band off the reverse-high clutch drum.
Figure 15, Removing or Installing Band
11. Remove the forward part of the gear

train as an assembly as shown in Fig.
16.
12. Remove the bolts that attach the servo
cover to the transmission case.
13. Remove the cover, piston, spring and
gasket from the case.
14. Remove the large snap ring that
secures the reverse planet carrier in
the low-reverse clutch hub. Lift the
thrust washers and planet carrier from
the drum.
Figure 16, Removing or Installing Forward part of Gear Train
224 August 31, 2012

15. Remove the snap ring (Fig. 17) that

secures the reverse ring gear and hub
on the output shaft. Slide the ring
gear and hub off the shaft. Remove
the thrust washer.
16. Rotate the low-reverse clutch hub in a
clockwise direction and, at the same
time, withdraw it from the case.
17. Remove the reverse clutch snap ring
from the case, then remove the clutch
discs, plates and pressure plate from
the case.
Figure 17, Removing or Installing Reverse Ring Gear Hub and
18. Remove the extension housing Snap Ring
attaching bolts and vent tube from the
case. Remove the extension housing
and gasket.
19. Slide the output shaft (with governor
and oil collector) assembly from the
transmission case.
20. Remove the distributor sleeve
attaching bolts and remove the sleeve,
parking pawl gear and the thrust
washer.
If the thrust washer is staked in place,
use a sharp chisel and cut off the
metal from behind the thrust washer.
Be sure to clean the rear of the case
with air pressure or a suitable solvent Figure 18, Compressing Reverse Clutch Springs
to remove any metal particles.
21. Compress the reverse clutch piston
release spring with Tool T65L-
77515-A (Fig. 18). Remove the snap
ring. Remove the tool and the springs
and retainer assembly.
August 31, 2012 225

22. Remove the one-way clutch inner

race attaching bolts from the rear of
the case. Remove the inner race from
inside of the case.
23. Remove the low-reverse clutch piston
from the case as shown in Fig. 19.
Figure 19, Removing Low-Reverse Piston
Assembly
1. Place the transmission case in a holding fixture.
2. Tap the low-reverse piston into place in the case with a clean rubber hammer.
3. Hold the one-way clutch inner race in position and install the attaching bolts. Tighten bolts to
specifications as listed at the end of this Part.
4. Install the low-reverse clutch return spring and retainer assembly in the clutch piston.
5. Position the retainer snap ring in place on the one-way clutch inner race.
6. Install the compressing tool shown in Fig. 18 and compress the springs just enough to install
the low-reverse clutch piston snap ring.
7. Install the snap ring, then remove the compressing tool.
8. Place the transmission case on the bench with the front end facing the downward.
9. Position the parking gear thrust washer and the gear on the case (Fig. 28). Do not re-stake the
thrust washer.
10. Position the collector and tubes in place on the rear of the case. Install the attaching bolts and
torque to specifications as listed at the end of this Part.
11. Install the output shaft and governor as an assembly.
12. Place a new gasket on the rear of the transmission case. Position the extension housing on the
case and install the attaching bolts. Tighten the attaching bolts to specifications as listed at
the end of this Part. Install the vent tube.
13. Place the transmission case in the holding fixture.
14. Coat two new gaskets with petroleum jelly and position them on the servo cover.
15. Position the servo spring on the piston rod.
226 August 31, 2012

16. Insert the servo piston rod in the case. Install the servo cover with the attaching bolts, making
sure that the identification tag is in place. Tighten the attaching bolts to specifications as
listed at the end of this Part.
17. Align the low-reverse clutch hub and one-way clutch with the inner race at the rear of the
case. Rotate the low-reverse clutch hub clockwise while applying pressure to seat it on the
inner race.
18. Install the low-reverse clutch plates, starting with the wave plate next to the piston and
following with steel and friction plates alternately. Retain them with petroleum jelly. Five (5)
steel and five (5) friction plates are required for all models. If new composition plates are
being used, soak them in clean transmission fluid (ES P-M2C138 CJ, Dexron II, Series D, or
equivalent) for fifteen minutes before installation. Install the pressure plate and the snap ring.
Test the operation of the low-reverse clutch by applying air pressure at the clutch pressure
apply hole in the case.
19. Install the reverse planet ring gear thrust washer and the ting gear and hub assembly. Insert
the snap ring in the groove in the output shaft.
20. Assemble the front and rear thrust washers onto the reverse planet assembly and retain with
petroleum jelly. Insert the assembly into the ring gear and install the snap ring.
21. Set the reverse-high clutch on the bench with the front end facing down. Install the thrust
washer on the rear end of the reverse-high clutch assembly. Retain the thrust washer with
petroleum jelly and insert the splined end of the forward clutch into the open end of the
reverse-high clutch with splines engaging the direct clutch friction plates (Fig. 37).
22. Install the thrust washers and retain them with petroleum jelly on the front end of the forward
planet ring, gear and hub. Insert the ring gear into the forward clutch.
23. Install the thrust washer on the front end of the forward planet assembly. Retain the washer
with petroleum jelly' and insert the assembly into the ring gear. Install the input shell and sun
gear assembly.
24. Install the reverse-high clutch, forward clutch, forward planet assembly, drive input shell and
sun gear as an assembly into the transmission case.
25. Insert the intermediate band into the case around the reverse-high clutch cylinder. Install the
struts and tighten the band adjusting screw sufficiently to retain the band.
26. Place a selective thickness bronze thrust washer on the rear shoulder of the stator support and
retain it with petroleum jelly. If the end play was not within specifications when checked
prior to disassembly, replace the washer with one of proper thickness. Refer to the
specifications at the end of this Part for selective thrust washer thicknesses.
Using two 5/16-inch bolts three inches long, make two alignment studs. Cut the heads from the bolts
and grind a taper on the cut end. Temporarily install the two studs opposite each other in the
mounting holes of the case. Slide a new gasket onto the studs. Being careful not to damage the
large seal on the outside diameter of the pump housing, position the pump on the case while
removing the aligning studs.
Install six of the seven mounting bolts and tighten to specifications as listed at the end of this Part.
27. Adjust the intermediate band as detailed under the Adjustments and install the input shaft with
the long splined end inserted into the forward clutch assembly.
August 31, 2012 227

28. Install Tool 4201-C at the seventh pump mounting bolt (Fig. 13) and check the transmission
end play as in steps 4, 5 and 6 of Disassembly (see specifications at the end of this Part).
Remove the tool.
29. Install the seventh pump mounting bolt and tighten to specifications. Install the main control
on the case, making sure that the levers engage the valves properly. Install the primary throttle
valve, rod and the vacuum diaphragm in the case.
30. Install a new pan gasket and the pan. Tighten the bolts to specifications.
31. Install the converter assembly.
32. Install the transmission in the vehicle as detailed under Removal and Installation.
Control Valve Body

Disassembly
The valve body-to-screen gasket should not be cleaned in a degreaser solvent or any type of detergent
solution when disassembling the main control. To clean the gasket, wipe it off with a lint free cloth.
1. Remove the nine screws that attach the screen to the lower valve body (Fig. 20) and remove
screen and gasket (Fig. 21).
2. Remove the five upper-to-lower valve body and hold-down plate attaching screws. Remove the
seven attaching screws from the underside of the lower valve body (Fig. 20).
3. Separate the bodies and remove the separator plate and gasket. Be careful not to lose the
check valves and springs. Remove and clean the separator plate screen if necessary (Fig. 21).
4. Remove the manual valve plunger retaining pin from the upper valve body and remove the
plunger (Fig. 22).
5. Slide the manual valve (Fig. 22) out of the valve body.
6. Cover the downshift valve port with a finger. Then, working from the underside of the body,
remove the downshift valve retainer. Remove the spring and 10. downshift valve (Fig. 22).
228 August 31, 2012

7. Apply hand pressure on the pressure boost valve sleeve end and remove the sleeve retaining
clip from 11. the under side of the body. Slowly release hand pressure and remove the sleeve
and the pressure boost valve. Remove the two springs the spring retainer, and the main
regulator valve from the bore.
8. Apply pressure on the throttle boost valve retaining 12. plate and remove the two attaching
screws. Slowly release the pressure and remove plate, throttle 13. pressure boost valve and
spring, and the manual low 2-1 scheduling valve and spring from the body (Fig. 22).
9. Apply pressure on the remaining valve retaining plate and remove the eight attaching screws.
10. Hold the valve body so that the plate is facing upward. Slowly release the pressure and remove
the plate.
11. When removing the various valves from the control valve body, keep all parts covered with
your fingers except the bore the valve is being removed from. Remove the spring and the
intermediate servo modulator valve (Fig. 22) from the valve body.
12. Remove the intermediate servo accumulator valve and springs.
13. Remove the 2-3 back-out valve, spring, and 3-2 shift timing valve plug. Do not remove the 3-2
shift timing valve plug (Fig. 22) if it is found to be peened, thus preventing its removal. This
condition will not affect transmission operation and is not cause for replacement of the main
control.
14. Remove the 2-3 shift valve, spring, and the throttle modulator valve.
15. Remove the 1-2 shift valve, DR-2 shift valve, and the spring from the valve body.
16. Remove the line pressure coasting regulator valve (Fig. 22) from the body.
17. Remove the cutback control valve to complete the disassembly of the control valve.
August 31, 2012 229

Assembly
1. Place the 3-2 shift timing valve plug in the valve body if it was previously removed.
230 August 31, 2012

2. Place the downshift valve and spring in

the valve body. Compress the spring
and install the retainer from the
underside of the body (Fig. 23).
3. Place the valve body on a clean surface with the
passage side facing up. Place the converter relief
valve spring in its bore (Fig. 23). Coat the
converter pressure relief valve with petroleum
jelly and place it on top of the spring. Place the 2-3
shift valve check ball in its cavity. Place the throttle
pressure relief valve spring in its bore (Fig. 23).
Coat the throttle pressure relief valve check ball
with petroleum jelly and place it on top of the Fig. 23 Converter Pressure Relief Valve, Throttle Pressure
spring. Relief Valve, and 2-3 Shift Check Valve Location
4. Install the separator screen in the separator plate if it was previously removed. Be sure the
screen tabs are flush with the separator plate surface. Carefully position the separator plate
and new gasket on the lower valve body. Place the two hold-down plates on the separator plate
and install the attaching screws finger tight.
5. Place the lower body and plate assembly on the upper valve body (Fig. 20) and install the
attaching screws finger tight.
6. Install the oil screen screws loosely, without the screen, to properly align the upper and lower
valve bodies, gasket, and separator plate.
7. Tighten the two bolts that are covered by the screen to specifications as listed at the end of
this Part.
8. Remove the oil screen attaching screws and place the gasket and oil screen in position on the
lower valve body. Re-install the screen attaching screws (Fig. 20).
9. Tighten all the valve body and screen attaching screws to specifications as listed at the end of this Part.
10. Place the cutback control valve (Fig. 22) and the line pressure coasting regulator valve in the valve body.
11. Place the one spring, DR-2 shift valve, and the 1-2 shift valve in the body.
12. Place the throttle modulator valve and spring and the 2-3 shift valve in the valve body.
13. Place the spring and the 2-3 back-out valve in the valve body.
14. Place the two springs and the intermediate servo accumulator valve in the valve body.
15. Place the intermediate servo modulator valve and spring in the body.
16. Carefully place the valve retaining plate on the body and secure it with the eight attaching
screws. Tighten the screws to specifications as listed at the end of this Part.
17. Place the throttle pressure boost valve and spring in the valve body. Place the manual low2-1
scheduling valve and spring in the valve body and install the retaining plate. Tighten the
attaching screws to specifications as listed at the end of this Part.
August 31, 2012 231

18. Place the spring retainer on the stem of the main regulator valve so that the retainer flange is
next to the valve shoulder. Place the main regulator valve, two springs, pressure boost valve,
and sleeve in the bore. Apply hand pressure on the end of the pressure boost valve sleeve and
install the spring clip retainer in the groove on the under side of the body so that the clip is
inserted into the end groove in the sleeve. Be sure that the pressure boost valve is free in its
bore.
19. Place the manual valve in the valve body and install the plunger and the retaining pin in the
body.
Intermediate Servo Disassembly

(Refer to Fig. 5).
1. Apply air pressure to the part in the servo cover to remove the piston and rod.
2. Replace the complete piston and rod assembly if the piston or piston sealing lips are
unserviceable or damaged.
3. Remove the seals from the cover.
232 August 31, 2012

Governor
1. Dip the new seals in transmission fluid.
2. Install new seals on the cover
3. Dip the piston in transmission fluid and install it in the cover.
Disassembly
1. Remove the governor attaching bolts and remove the governor
2. Remove the snap ring that secures the governor oil collector body on the output shaft (Fig. 24)
and slide it off the front of the shaft.
3. Remove the seal rings from the oil collector body.
Assembly
1. Carefully install new seal rings on the oil collector body.
2. Working from the front end of the output shaft, slide the governor oil collector body into
place on the shaft. Install the snap ring to secure it. Make sure that the snap ring is seated in
the groove.
3. Position the governor on the oil collector body (Fig. 24) and secure it with the attaching
screws.
August 31, 2012 233

Downshift and Manual Linkage Disassembly
1. Remove the nut and lock

washer that secure the outer
downshift lever to the
transmission and remove the
lever.
2. Slide the inner downshift lever
assembly out from the inside
of the case (Fig. 25). Remove
the seal from the recess in the
manual lever shaft.
3. On E-100- E-350, remove the

two bolts retaining the backup
lamp switch, and remove the
switch (Fig. 26).
4. Remove the C-ring securing
the parking pawl actuating rod
to the manual lever. Remove
the rod from the case.
5. Remove the nut securing the
inner manual lever to the
shaft. Remove the inner lever
from the shaft. Slide the outer
lever and shaft from the case.
6. Remove the seal from the case
with tools T59L-100-B and
T58L-101-A.
234 August 31, 2012

Assembly
1. Dip the new seal in transmission
fluid and install it in the case as
shown in Fig. 27.
2. Slide the outer manual lever and
shaft in the transmission case.
3. Position the inner lever on the shaft,
making sure the leaf spring roller is
positioned in the inner manual lever
detent. Install the =aching nut.
Tighten the nut to specifications as
listed at the end of this Part. Install
the parking pawl actuating rod and
secure it to the inner manual lever
with a C-ring.
4. On E-100 - E-350 slide the backup lamp switch on the outer lever shaft and install the bolts in
the case. With the transmission manual lever in neutral, rotate the switch and install the gauge
pin (No. 43 drill) into the gauge pin hole (Fig. 26). Tighten the bolts to specifications as listed
at the end of this Part.
5. Install a new downshift lever seal in the recess of the outer lever shaft. Slide the downshift
lever and shaft into position.
6. Place the outer downshift lever on the shaft and secure it with a lock washer and nut.
Servo Apply Lever

Disassembly
Working from the inside of the transmission
case, carefully drive on the servo apply lever
shaft to remove the cup plug. The shaft
(Fig 30) can be withdrawn from the case by
hand.
Assembly
1. Hold-the servo apply lever in position
and install the new shaft.
2. Using the fabricated tool show in
Fig. 30, drive the cup plug into
position in the case. Be sure the plug is
flush with the shoulder of the Figure 30, Servo Apply Lever Installation
counterbore. The cup plug may be
coated with Loctite, Part No. EOAZ-
19554-A or equivalent, before
installation.
August 31, 2012 235

Front Pump
Fig. 31 Removing Front Pump Seal
Figure 32, Installing the Front Pump Seal
The front seal can be replaced after the pump has been installed on the transmission (Figs. 31 and 32).
Disassembly
1. Remove the two seal rings and the selective thrust washer (Fig. 33).
Figure 33, Front Pump Assembly

2. Remove the large square-cut seal from the outside diameter of the pump housing.
3. Remove the five bolts that secure the stator support to the pump housing. Lift the support
from the housing.
4. Remove the drive and the driven gear from the housing.
236 August 31, 2012

5. If the pump housing bushing is worn or

damaged, replace it using the handle tool
shown in Fig. 34.
6. Place the new bushing in position, making
sure the half moon slot in the bushing is on
top and in line with the oil tube hole near
the seal bore. Press the bushing in 1.52 -
2.03 mm (0.060 - 0.080 inch) below the
front face of the bushing bore. Use Tool
T66L-7003-B9 and handle to seat the
bushing properly. After assembly, the half
moon slot must be in past the tube hole to
provide proper lubrication.
Figure 34, Replacing Front Pump Housing Bushing
Assembly
1. Install the drive and driven gears in the pump housing. Each gear has either an
identification mark or chamfered teeth on one face. The identification mark or the
chamfered surface must be installed toward the front of the pump housing.
2. Position the stator support in the pump housing and install the five attaching bolts. Torque
bolts to specifications as listed at the end of this Part.
3. Carefully install two new seal rings on the stator support. Make sure that the ends of the rings
are engages to lock them in place. Install a new square-cut seal on the outside diameter of the
pump housing.
4. Install the selective thrust washer. Make sure that the correct thickness selective washer is
being used to obtain the specified end play. Refer to the specifications as listed at the end of
this Part.
5. Place the pump on the converter, making sure that the drive gear engages the converter hub.
Rotate the pump to make sure the gears rotate freely.
August 31, 2012 237

Reverse–High Clutch
Disassembly
1. Separate the drive train as shown in Fig. 35.
Remove the pressure plate snap ring as
shown in Fig. 36.
2. Remove the pressure plate and the drive and
driven (internal and external spline) clutch plates
(Fig. 37).
Figure 36, Removing or Installing the Reverse-High

Clutch Pressure Plate Snap Ring
Figure 37, Reverse-High Clutch Disassembled

238 August 31, 2012

Figure 35, Drive Train Disassembled – Typical

1.Front Pump Seal Ring - 7d441 14. Forward Planet Ring and Hub 28. One-Way Clutch Inner Race - 70171
2.Front Pump - 7a103 Assembly - 7d392 29. Snap Ring
3.Gasket-7a136 15. Number 5 Thrust Washer 30. Low-Reverse Clutch
4.Seal Rings 16. Forward Planet Assembly -7a298 31. Snap Ring
5.Number 1 Thrust Washer (Selective) 17. Input Shell - 70064 and Sun Gear 32. Low-Reverse Piston Return Spring
6.Strut Intermediate Brake Band - Assembly – 70063 and Retainer - 7d406
7d029 18. Number 6 Thrust Washer Needle 33. Low-Reverse Piston –70402
7.Intermediate Brake Band Assembly - Bearing 34. Inner Seal
70029 19. Snap Ring 35. Outer Seal
8.Strut Intermediate Brake Band 20. Number 7 Thrust Washer 36. Case – 7005
Anchor - 70430 21. Reverse Planet Assembly - 7d006 37. Number 10 Thrust Washer
9.Reverse High Clutch Assembly 22. Number 8 Thrust Washer 38. Parking Gear - 7a233
10. Number 2 Thrust Washer 23. Reverse Ring Gear and Hub 39. Governor Distributor Sleeve –
a. Forward Clutch Seal Rings Retaining Ring 40. Snap Ring
11. Forward Clutch Assembly 24. Reverse Ring Gear -7a153 and Hub 41. Governor Collector – 70220
12. Number 3 Thrust Washer Needle 70164 42. Governor - 7c063
Bearing 25. Number 9 Thrust Washer 43. Output Shaft – 7060
13. Number 4 Thrust Washer 26. Low-Reverse Clutch Hub - 78067
27. One-Way Clutch - 7a0897c232
August 31, 2012 239

3. Install Tool T65L-77515-A (Fig. 38) on

the reverse-high clutch drum. Make sure
that the legs clear the snap ring enough to
remove it. Remove both snap rings and
remove the tool.
4. Remove the spring retainer and the piston
return springs.
Figure 38, Removing or Installing Reverse-High Clutch

Piston Snap Ring
5. Apply air pressure to the piston apply

hole in the clutch hub (Fig. 39) and
remove the piston.
6. Remove the piston outer seal from the
piston and the inner seal from the
clutch drum (Fig. 37).
Figure 39, Removing the Reverse-High Clutch Piston

7. Remove the front and rear bushings
from the clutch drum' if they are worn
or damaged. To remove the front
bushing, use a cape chisel and cut along
the bushing seam until the chisel breaks
through the bushing wall. Pry the loose
ends of the bushing up with an awl and
remove the bushing. To remove the rear
bushing, use the tool shown in Fig. 40,
and press the bushing from the drum.
Figure 40, Replacing the Reverse-High Clutch Rear
240
Bushing
Assembly
1. If the clutch drum bushings were
removed, position the drum in a press
and press new bushings into the drum
with the tools shown in Figs 40 and 41.
2. Dip the new seals in transmission fluid
and install one on the drum and one on
the piston.
3. Install the piston in the clutch drum.
Figure 41, Install Reverse-High Clutch Front

Bushing
4. Position the piston return springs in the

piston sockets (Fig. 42). Place the spring
retainer on the springs.
5. Install Tool T65L-77515-A (Fig. 38)
and compress the springs. Make certain
that the spring retainer is centered while
compressing the springs. Install the snap
ring. Before releasing the pressure on
the tool, make certain that the snap ring
is positioned inside of the four snap ring
guides on the spring retainer.
Figure 42, Reverse-High Clutch Front Bushing
241
6. Clutch plate usage vanes with each

model, refer to the specifications at the
end of this Part for the number of plates
required. Dip the clutch plates in clean
transmission fluid. Install the clutch
plates alternately starting with a steel
drive (internal) plate (Fig. 37). When
new composition clutch plates are used,
soak the plates in automatic
transmission fluid (spec. ESP-M2C138
CJ) for 15 minutes before they are
assembled.
7. After all clutch plates have been Figure 43, Checking Reverse-High Clutch Snap
installed, position the pressure plate in Ring Clearance
the clutch drum. Install the pressure
plate (selective) snap ring.
8. With a feeler gauge, check the clearance
between the pressure plate and snap ring.
(Fig. 43).
9. The pressure plate should be held
downward as the clearance is checked.
Refer to the specification at the end of
the part for the proper clearance. If the
clearance is not within specifications,
selective thickness snap rings are
available in the following thicknesses:
a. 1.42 - 1.52mm (0.056 - 0.060 inch),
b. 1.65 - 1.75mm (0.065 - 0.069 inch),
c. 1.87 - 1.98mm (0.074 - 0.078 inch),
d. 2.10 - 2.20mm (0.083 - 0.087 inch),
e. 2.33 - 2.43mm (0.092 - 0.096 inch),
f. 2.79 - 2.89mm (0.110 - 0.114 inch), and
g. 3.25 - 3.35mm (0.128 - 0.132 inch).
10. Install the correct size snap ring and
recheck the clearance.
242
Forward Clutch
Disassembly
Figure 44, Removing Forward Clutch Pressure Plate Snap Ring

1. Remove the clutch pressure plate snap ring (Fig. 44).
2. Remove the rear pressure plate, the drive and driven plates, wave plate, and the forward
pressure plate from the clutch hub (Fig. 45).
Figure 45, Forward Clutch Disassembled
243
3. Remove the snap ring (Fig. 46) that

secures the disc spring in the clutch
cylinder. Remove the disc spring.
Figure 46, Removing or Installing Disk Spring
4. Apply air pressure to the clutch cylinder

(Fig. 47) to remove the piston.
5. Remove the seal from the piston and the
seal from the clutch hub (Fig 45).
Figure 47, Removing Forward Clutch Piston
244
Assembly
1. Dip two new seals in transmission fluid.
Install the smaller seal on the clutch hub and
the lip seal on the clutch piston.
2. Install the clutch piston and lip seal with
installation tool T77L-77548-A (Fig. 48).
3. Position the installation tool in the forward
clutch cylinder so that the bore of the tool is
aligned with the piston bore in the cylinder.
Press the piston into the cylinder until it
bottoms in the bore. Remove the installation
tool.
4. Make sure that the steel pressure ring is in the
groove on the piston. Position the disc spring
in the cylinder with the dished face Figure 48, Installing Forward Clutch Piston and Lip
Seal
downward. Install the spring as shown in Fig.
46. Secure the disc with the retaining snap
ring.
5. Install the forward pressure plate with the flat

side up and the beveled side downward. Dip
the clutch plates in clean transmission fluid
(specification ESPM2C 138-J or equivalent).
Next, install the wave plate, then a steel plate,
and a composition driven plate. Install the
remaining plates in this sequence (see Fig.
45).
Refer to the specifications at the end of this part
for the number of plates required. The last plate
installed will be the rear pressure plate. Install the
snap ring and make certain that it seats fully in
the groove. When new composition clutch plates
are used, soak the plates in automatic transmission
fluid for 15 minutes before they are assembled.
6. With a feeler gauge, check the clearance between
the snap ring and the pressure plate (Fig. 49). Figure 49, Pressure Plate Clearance
Downward pressure on the plate should be
maintained when making this check. Refer to the
specifications at the end of this Part for the proper
clearance.
245
7. If the clearance is not within specifications, selective snap rings are available in the following
thicknesses:
a. 1.42 - 1.52mm (0.056 - 0.060 inch),
b. 1.65 - 1.75mm (0.065 - 0.069 inch),
c. 1.87 - 1.98mm (0.074 - 0.078 inch),
d. 2.10 - 2.20mm (0.083 - 0.087 inch),
e. 2.33 - 2.43m m (0.092 - 0.096 inch),
f. 2.79 - 2.89mm (0.110 - 0.114 inch), and
g. 3.25 - 3.35mm (0.128 - 0.132 inch).
8. Insert the correct size snap ring and recheck the clearance.
Input Shell and Sun Gear
Disassembly
1. Remove the external snap ring from the

sun gear as shown in Fig. 50.
Figure 50, Removing the Sun Gear Snap Ring
2. Remove the thrust washer from the

output shell and sun gear (Fig. 51).
3. Working from the inside of the input
shell, remove the sun gear. Remove the
snap ring from the gear.
Assembly
1. Install the forward snap ring on the
forward end (short end) of the sun gear
(Fig. 51). Working from the inside of
the input shell, slide the sun gear and
snap ring into place making sure that the
Figure 51, Input Shell and Sun Gear Disassembled
longer end is at the rear (Fig. 51).
2. Place the No. 6 thrust washer on the sun gear
and install the rear snap ring.
246
Output Shaft Hub and Ring Gear
Disassembly
1. Remove the hub snap ring (Fig. 52)
from the ring gear.
2. Lift the hub from the ring gear.
Assembly
1. Position the hub in the ring gear.
2. Secure the hub with the snap ring.
Make certain that the snap ring is fully
engaged with the groove.
Figure 52 Output Shaft Hub and Ring Gear
One-Way Clutch
Disassembly
1. Remove the snap ring and bushing from
the rear of the low—reverse clutch hub
(Fig. 53).
2. Remove the rollers from the spring
assembly and lift the spring assembly
from the hub.
3. Remove the remaining snap ring from
the hub.
Assembly
1. Install a snap ring in the forward snap
ring groove of the low—reverse clutch Figure 53, One-Way Clutch Disassembled
hub.
247
2. Place the low—reverse clutch hub on

the bench with the forward end down
(Fig. 54).
3. Install the one—way clutch spring
assembly on top of the snap ring.
4. Install a roller into each of the spring
assembly compartments.
5. Install the bushing on top of the spring
assembly.
6. Install the remaining snap ring at the
rear of the low—reverse clutch hub to
secure the assembly (Fig. 53).
Figure 54, One-Way Clutch Installed
Low—Reverse Clutch Piston Disassembly

Fig. 52 Output Shaft Hub and Ring Gear
Remove the inner and the outer seal from the lower reverse clutch piston (Fig. 35).
248
Assembly
1. Dip the two new seals in clean transmission fluid.
2. Install the seals on the piston.
Transmission Fluid Capacity
U.S. Quarts Imperial Quarts Liters
11-3/4 9-3/4 11.1
Selective Thrust Washers (Front Pump Support)

Thickness
Identification Color
mm Inch
Blue 1.42 -1.52 0.056 - 0.060
Natural (white) 1.85 -1.95 0.073 - 0.077
Transmission Clutch Plate Usage

Thickness
Transmission Model Steel Friction
mm Inch
Forward Clutch
41 4 0.533 - 1.168 0.021 - 0.046
PGD, PJA, PJD
High Clutch
3 3 0.558 - 0.914 0.022 - 0.036
PGD, PJA, PJD
Reverse Clutch
52 5 -
PGD, PJA, PJD
1.
Plus a waved plate (7E457) next to inner pressure plate.
2.
Plus a waved plate next to the piston.
Clutch Snap Rings
Part Thickness
Pa
mm Inch Forward High
Number
377434 1.52 -1.42 0.060 - 0.056 X X
377126 1.75 -1.62 0.069 - 0.064 X
377127 1.98 -1.87 0.078 - 0.074 X X
377128 2.20 - 2.10 0.087 - 0.083 X
377444 2.43 - 2.33 0.096 - 0.092 X X
386841 2.89 - 2.79 0.114 - 0.110 X
386842 3.35 - 3.25 0.132 - 0.128 X
249
Checks and Adjustments

Operation Specifications Operation Specifications
Transmission End 0.203 - 1.117mm (0.008 - 0.044 inch) 1.42 - 1.52mm (0.056 - 0.060 inch)
Play (Selective thrust washers available) 1.62 - 1.75mm (0.064 - 0.069 inch)
Torque Converter New or rebuilt 0.533mm (0.021 inch) max. 1.87 - 1.98mm (0.074 - 0.078 inch)
Selective Snap Ring
End Play Used 1.016mm (0.040 inch) max.' 2.10 – 2.20mm (0.083 – 0.087 inch)
Thickness
2.33 - 2.43mm (0.092 - 0.096 inch)
Remove and discard locknut Install new 2.79 - 2.89mm (0.110 - 0.114 inch)
locknut. Adjust screw to 10 Lb-Ft or 14 3.25 - 3.35mm (0.128 - 0.132 inch)
Intermediate Band
NM of torque, then back off 1-1/2 turns. Reverse-High Clutch
Adjustment
Hold screw and tighten locknut to 40 Lb-Ft Pressure 0.558 - 0.914mm ( 0.022 - 0.036
or 54 NM. Plate-to-Snap Ring inch)
Clearance
Forward Clutch 1.42 - 1.52mm (0.056 - 0.060 inch)
Pressure 1.62 - 1.75mm (0.064 - 0.069 inch)
Plate - to - Snap 1.87 - 1.98mm (0.074 - 0.078 inch)
Selective Snap Ring
Ring 0.558 - 0.914mm (0.021 - 0.046 inch) 2.10 - 2.20mm (0.083 - 0.087 inch)
Thickness
Clearance 2.33 - 2.43mm (0.092 - 0.096 inch)
2.79 - 2.89mm (0.110 - 0.114 inch)
3.25 - 3.35mm (0.128 - 0.132 inch)
To check end play, exert force on checking tool to compress turbine to cover thrust washer wear plate. Set indicator at zero.
Converter Stall Speed
Vehicle Engine Size Type V
Size Min Max Range
E F-100150 50S 4.9L (300 CID) I-6 12.00 1387 1661 275
E F-250 50S 4.9L (300 CID) I-6 12.00 1405 1655 250
E F-350 50S 4.9L (300 CD) I-6 12.00 1366 1597 231
250
Torque Specifications
Item Lb-Ft. NM Item Lb-Ft. NM
Converter to Flywheel 20 - 30 28 - 40 Pressure Gauge Tap 9 -15 12.5 - 20
Front Pump to Transmission Case 16 - 30 22 - 40 Band Adjustable Screw Locknut to Case 35 - 45 48 - 61
Overrunning Clutch Race to Case 18 - 25 25 - 33 Cooler Tube Connector Lock 20 - 35 28 - 47
Oil Pan to Case 12 -16 17 - 21 Converter Drain Plug 14 - 28 19 - 37
Stator Support to Pump 12 -16 17 - 21 Manual Valve Inner Lever to Shaft 30 - 40 41 - 54
Converter Cover to Converter
12 -16 17 - 21 Downshift Lever to Shaft 12 -16 17 - 21
Housing
Guide Plate to Case 12 -16 17 - 21 Filler Tube to Engine 20 - 25 28 - 33
Intermediate Servo Cover to Case 14 - 20 19 - 27 Transmission to Engine 40 - 50 55 - 67
Diaphragm Assembly to Case 12 -16 17 - 21 Rear Engine Support to Transmission 55 - 65 75 - 88
Extension Housing to
Distributor Sleeve to Case 12 -16 17 - 21 35 - 50 48 - 67
Bearing Retainer Stud
Extension Assembly to Transmission
25 - 35 34 - 47 Bearing Retainer to Extension Assembly 35 - 45 48 - 61
Case
Rear Cover Plate to Converter
20 - 30 28 - 40 Plug Case - Throttle Pressure 6 -12 8.5 -16
Housing
5/16* Fitting - Cooler Line Connector to
Plug - Case TRS Switch Port 6 -12 8.5 -16 Case -Front and Rear (Case Fitting) 10 -16 14 -16
Plug - Case Front Pump or Line 5/16' Tube Nut - Cooler Line to
12 -18 17 - 24
Pressure 6 -12 8.5 - 16 Transmission Case Fitting
Converter Housing Cover to Converter
End Plates to Body 20 - 45 2.5 - 5 Housing 30 - 60 3.5 - 6.5
Inner Downshift Lever Stop 20 - 45 2.5 - 5 Control Assembly to Case 95 -125 11 -14
Reinforcement Plate to Body 20 - 45 2.5 - 5 Governor Body to Collector Body 80 -120 9.5 -13.5
Screen and Lower to Upper Valve 7 -13.5
40 - 55 5 - 6.2 Oil Tube Connector 60 -120
Body
Yoke to Output Shaft (4x4) 100 -150 11.5 -16.5 Detent Spring to Case 80 -120 9.5 -13.5
Shift Valve Plate to Upper Body 20 - 45 2.5 - 5 Rear Engine Support to Frame 40 - 60 5 - 6.5
Upper to Lower Body 40 - 55 5 - 62 Neutral Switch to Case 5575 6.58
Reinforcing Right Side Plate to
20 - 45 2.5 - 5
Lower Body
251

Use these values when torque values are not specified for fasteners.
Thread SAE Grade 5 SAE Grade 8
Size Plain Zinc Plated Plain Zinc Plated

Lb-Ft Lb-Ft Lb-Ft Lb-Ft
1/4-20. 9 10 13 14
1/4-28. 10 12 15 16
5/16-18. 19 21 27 29
5/16-24. 21 23 30 33
3/8-16. 33 37 47 52
3/8-24. 38 42 54 59
7/16-14. 53 59 76 83
7/16-24. 60 66 85 93
1/2-13. 82 90 116 127
1/2-20. 92 101 131 144
9/16-12. 118 129 167 184
9/16-18. 131 144 186 205
5/8-11. 162 179 231 254
5/8-14. 184 202 261 287
3/4-10. 288 317 409 450
3/4-16. 322 354 457 503
252
Conversion Of Various Units Of Torque

Convert Convert
From To Multiply From To Multiply
lb.-in. oz.-in. 16 oz.-in. lb.-in. .0625
lb.-in. lb.-ft. .08333 lb.-ft. lb.-in. 12
lb.-in. kg-cm. 1.1519 kg-cm. lb.-in. .8681
lb.-in. kg-m. .011519 kg-m. lb.-in. 86.81
lb.-in. N•m .133 N•m lb.-in. 8.85
lb.-in. dN•m 1.13 dN•m lb.-in. .885
lb.-ft. kg-m. .1382 kg-m. lb.-ft. 7.236
lb.-ft. N•m 1.356 N•m lb.-ft. .7376
N•m dN•m 10 dN•m N•m .10
N•m kg-cm. 10.2 kg-cm. N•m .09807
N•m kg-m. .102 kg-m. N•m 9.807
253
Tractors and Ground Support Equipment
Charger Hybrid: Up to 4,500 Charger Electric: Up to 4,500 Streamline: Gasoline, LPG, or

Lbs. Draw Bar Lbs. Draw Bar Diesel
Up to 8,000 Lbs. Drawbar
Classic: Gasoline, LPG, or

Diesel, Classic with Snowplow Option Hercules: Turbo-Diesel
Up to 10,000 Lbs. Draw Bar Up to 20,000 Lbs. Draw Bar
Delta II Aircraft Heater Ground Power Units

Harlan Belt Loader, Electric
Harlan Global Manufacturing builds tractors and ground
support equipment to customers’ specifications. For special
needs, call Harlan Global Manufacturing, 800-255-4262

HTACL O&Amp M Manual 2012 0831

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HTACL O&Amp M Manual 2012 0831

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Operation & Maintenance

Revised: August 31, 2012

Harlan Global Manufacturing

ii August 31, 2012

WARRANTY CLAIM PROCEDURE

PRODUCT SUPPORT DEPARTMENT

August 31, 2012 iii

iv August 31, 2012

August 31, 2012 v

AXLE LEAKAGE. .............................................................................................................................................................28

vi August 31, 2012

INSTALLATION INSTRUCTIONS ........................................................................................................................................69

August 31, 2012 vii

Removing the Power Brake and Master Cylinder Assembly ...................................................................................127

viii August 31, 2012

WINDSHIELD WIPER .....................................................................................................................................................177

August 31, 2012 ix

CONVERTER END PLAY AND ONE-WAY CLUTCH CHECK .............................................................................................207

x August 31, 2012

August 31, 2012 xi

About this Manual

Notes, Cautions, and Warnings

Note: Commercial Use - DOT 3 Brake fluid; Military Use - MIL-B-46176A

xii August 31, 2012

The manual is divided into the following sections:

August 31, 2012 xiii

Intentional Blank Page

xiv August 31, 2012

Section 1, Operating Instructions

Figure 1, HTCBACL and HTACL Tractors

This tractor is designed for towing, not pushing

August 31, 2012 1

2 August 31, 2012

Safety Rules and Practices

• Safe operation is the responsibility of the operator.

August 31, 2012 3

Controls and Gauges

Figure 2, Controls and Gauges

4 August 31, 2012

1. Engine Start and “Ignition” Switch. 6. Accelerator Pedal

If the engine is hot, never open the radiator cap

August 31, 2012 5

Operating the Tractor

November 13, 2012

Stopping the Tractor

Do not exceed the tractor’s Draw Bar Pull

• Do not ride the brake pedal. Doing so causes the transmission

August 31, 2012 7

Tires and Valves

If the oil pressure is erratic or if it falls below the

Battery Operation in Extreme Cold Weather

Do not expose the battery to extremely cold weather while discharged. A

Battery Approximate Battery Approximate

November 13, 2012

August 31, 2012 9

Shipping and Storage

10 August 31, 2012

Preparation for Storage

Short Term Storage.

August 31, 2012 11

Long Term Storage.

12 August 31, 2012

Section 2, Preventive Maintenance