644H and 644H MH Repair TM1638

Return to INDEX
644H and 644H MH

Loader Repair
TECHNICAL MANUAL
644H and 644H MH Loader Repair
TM1638
TM1638 15JAN04 (ENGLISH)
For complete service information also see:

644H and 644H MH Loader Operation and
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM1637
8.1 L Engine Repair . . . . . . . . . . . . . . . . . . . . CTM86
8.1 L Engine Operation and Diagnostics . . . CTM134
Alternators and Starting Motors . . . . . . . . . . CTM77
Electronic Fuel Injection Systems . . . . . . . . CTM68
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
DX,TMIFC –19–29SEP98–1/1
TM1638 (15JAN04) 644H and 644H MH Loader

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Introduction
Technical Information Feedback Form
We need your help to continually improve our technical

publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO: John Deere Dubuque Works

P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538
FAX NUMBER: 563-589-5800
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TX,TM,FAX –19–03JUL01–1/1

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Introduction

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Contents
00
SECTION 00—General Information SECTION 17—Frame Or Supporting Structure
Group 0001—Safety Information Group 1740—Frame Installation
Group 1746—Frame Bottom Guards
SECTION 01—Wheels Group 1749—Chassis Weights
Group 0110—Powered Wheels And Fasteners 01
SECTION 18—Operator’s Station
SECTION 02—Axles And Suspension Systems Group 1800—Removal And Installation
Group 0200—Removal And Installation Group 1810—Operator Enclosure
Group 0225—Axle Shafts And U-Joints Group 1830—Heating And Air Conditioning
Group 0250—Axle Shaft, Bearings, Reduction Group 1899—Dealer Fabricated Tools
Gears 02
Group 0260—Hydraulic System SECTION 19—Sheet Metal And Styling
Group 1910—Hood Or Engine Enclosure
Group 1921—Grille And Grille Housing
SECTION 03—Transmission
Group 0300—Removal And Installation
SECTION 31—Loader
Group 0350—Gears, Shafts, Bearings And Power 03
Group 3102—Bucket
Shift Clutch
Group 3140—Frames
Group 0360—Hydraulic System
Group 0399—Dealer Fabricated Tools
SECTION 04—Engine 04
SECTION 05—Engine Auxiliary Systems

Group 0505—Cold Weather Starting Aids
Group 0510—Cooling System
05
Group 0515—Speed Controls
Group 0520—Intake System
Group 0530—External Exhaust System
Group 0560—External Fuel Supply Systems
SECTION 07—Dampener Drive 07

Group 0752—Elements
SECTION 09—Steering System

09
SECTION 10—Service Brakes
Group 1011—Active Elements
SECTION 11—Park Brake 10

All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice. 11
COPYRIGHT  2004
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  1998, 2000
TM1638 (15JAN04) i 644H and 644H MH Loader

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TM1638 (15JAN04) ii 644H and 644H MH Loader

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INDX
TM1638 (15JAN04) iii 644H and 644H MH Loader

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TM1638 (15JAN04) iv 644H and 644H MH Loader

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00
Section 00
General Information
Contents
Page Page
Group 0001—Safety Information Handle Fuel Safely—Avoid Fires. . . . . . . . .00-0001-11

4WD Loader Safety Features . . . . . . . . . . . .00-0001-1 Prepare for Emergencies. . . . . . . . . . . . . . .00-0001-11
Recognize Safety Information . . . . . . . . . . . .00-0001-2 Handle Starting Fluid Safely . . . . . . . . . . . .00-0001-12
Understand Signal Words . . . . . . . . . . . . . . .00-0001-2 Clean Trash from Machine . . . . . . . . . . . . .00-0001-12
Follow Safety Instructions . . . . . . . . . . . . . . .00-0001-2 Protect Against Flying Debris . . . . . . . . . . .00-0001-12
Avoid Injury from Rollover Accidents Wear Protective Clothing. . . . . . . . . . . . . . .00-0001-13
-------------------------------- Wear Your Seat Protect Against Noise . . . . . . . . . . . . . . . . .00-0001-13
Belt -------------------------------- Do Not Handle Chemical Products Safely . . . . . . . .00-0001-13
Attempt to Jump Clear of Tipping Use Safety Lights and Devices . . . . . . . . . .00-0001-14
Machine—Serious or Fatal Crushing Keep ROPS Installed Properly . . . . . . . . . .00-0001-14
Injuries Will Result -------------------------------- Warn Others of Service Work . . . . . . . . . . .00-0001-15
Machine Will Tip Over Faster Than You Practice Safe Maintenance . . . . . . . . . . . . .00-0001-16
Can Jump Free . . . . . . . . . . . . . . . . . . . . .00-0001-3 Support Machine Properly . . . . . . . . . . . . . .00-0001-16
Avoid Injury from Backover Accidents Remove Paint Before Welding or
------------------------------------ Before Moving Heating . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-17
Machine, Be Sure All Persons are Clear of Avoid Heating Near Pressurized Fluid
Area ------------------------------------ Always Be Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-17
Alert for Bystanders Moving into the Work Avoid High-Pressure Fluids . . . . . . . . . . . . .00-0001-18
Area. Use Horn or Other Signal to Warn Clean the Machine Regularly . . . . . . . . . . .00-0001-18
Bystanders Before Moving Machine Service Cooling System Safely . . . . . . . . . .00-0001-19
------------------------------------ When Using a Store Attachments Safely . . . . . . . . . . . . . .00-0001-19
Signal Person, Keep Person in View at all Dispose of Waste Properly . . . . . . . . . . . . .00-0001-19
Times. Be Sure Signal Person is Clear
Before Backing Up. . . . . . . . . . . . . . . . . . .00-0001-4
Avoid Injury from Rollaway Accidents
------------------------------------ To Prevent
Rollaway, Always Make Sure Machine is
Properly Secured Before Leaving
Operator’s Seat ------------------------------------
Death or Serious Injury May Result if
You Attempt to Mount or Stop a Moving
Machine. . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-5
Inspect Machine . . . . . . . . . . . . . . . . . . . . . .00-0001-5
Use Handholds and Steps. . . . . . . . . . . . . . .00-0001-6
Prevent Machine Runaway . . . . . . . . . . . . . .00-0001-6
Use Seat Belt Properly . . . . . . . . . . . . . . . . .00-0001-6
Maintain Seat Belt . . . . . . . . . . . . . . . . . . . . .00-0001-7
Secondary Exits . . . . . . . . . . . . . . . . . . . . . .00-0001-7
Travel Safely . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-8
Drive Machine Safely . . . . . . . . . . . . . . . . . .00-0001-8
Operate Machine with Caution . . . . . . . . . . .00-0001-9
Operating on Slopes . . . . . . . . . . . . . . . . . . .00-0001-9
Carrying Loads . . . . . . . . . . . . . . . . . . . . . .00-0001-10
Avoid Power Lines . . . . . . . . . . . . . . . . . . .00-0001-10
Beware of Exhaust Fumes . . . . . . . . . . . . .00-0001-10
Keep Riders Off Machine . . . . . . . . . . . . . .00-0001-11
TM1638 (15JAN04) 00-1 644H and 644H MH Loader

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Group 0001
Safety Information
00
4WD Loader Safety Features 0001
1
–19–04NOV98
T111699
TX,05,JC2303 –19–09NOV98–1/1
TM1638 (15JAN04) 00-0001-1 644H and 644H MH Loader

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Safety Information
00
0001 Recognize Safety Information
2
This is a safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the
potential for personal injury.
–UN–07DEC88
Follow recommended precautions and safe operating
practices.
T81389
DX,ALERT –19–29SEP98–1/1
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—is

used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
–19–30SEP88
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187
DX,SIGNAL –19–03MAR93–1/1
Follow Safety Instructions
Carefully read all safety messages in this manual and on

your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
–UN–23AUG88
available from your John Deere dealer.
Learn how to operate the machine and how to use

controls properly. Do not let anyone operate without TS201
instruction.
Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
If you do not understand any part of this manual and need

assistance, contact your John Deere dealer.
DX,READ –19–03MAR93–1/1

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Safety Information
00
Avoid Injury from Rollover Accidents 0001
3
--------------------------------
Wear Your Seat Belt
--------------------------------
Do Not Attempt to Jump Clear of Tipping
Machine—Serious or Fatal Crushing Injuries
Will Result
--------------------------------
Machine Will Tip Over Faster Than You Can
Jump Free
To avoid rollovers:
Be careful when operating on a slope.
Avoid sharp turns.
Balance loads so weight is evenly distributed and load is

stable.
–19–22FEB90
Carry tools and loads close to the ground to aid visibility
and lower center of gravity.
T7242EA
Reduce speed before turning or swinging load.
Know capacity of machine. Do not overload.
Be careful when operating at the edge of an excavation,

trench, or drop-off, and loading or unloading from a trailer.
Read and understand the operating instructions in this

operator’s manual.
TX,05,DH1525 –19–21JUN91–1/1

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Safety Information
00
0001 Avoid Injury from Backover Accidents
4
------------------------------------
Before Moving Machine, Be Sure All Persons
are Clear of Area
------------------------------------
Always Be Alert for Bystanders Moving into
–UN–21FEB90
the Work Area. Use Horn or Other Signal to
Warn Bystanders Before Moving Machine
------------------------------------
T7241AY
When Using a Signal Person, Keep Person in
View at all Times. Be Sure Signal Person is
Clear Before Backing Up
To avoid backover accidents:
Always look around before you back up. Be sure that

everyone is in the clear.
Keep bystanders away from pivot area of an articulated

machine.
Keep reverse warning alarm in working condition, if

equipped.
Use a signal person when backing up if view is

obstructed. Always keep signal person in view.
Learn the meaning of all flags, signs, and markings used

on the job, and who has the responsibility for signaling.
Keep windows, mirrors, and lights clean and in good

condition.
Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper lighting.

TX,05,DH1573 –19–18MAR91–1/1

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Safety Information
00
Avoid Injury from Rollaway Accidents 0001
5
------------------------------------
To Prevent Rollaway, Always Make Sure
Machine is Properly Secured Before Leaving
Operator’s Seat
------------------------------------
–UN–21FEB90
Death or Serious Injury May Result if You
Attempt to Mount or Stop a Moving Machine
T7241AZ
To avoid rollaways:
Select level ground when possible to park machine.
Move transmission control lever to neutral "N", engage

neutral lock, and push park brake switch to ON.
Lower all equipment to ground.
Stop the engine.
Block all wheels if you must park on a grade. Position

machine to prevent rolling.
Park a reasonable distance from other machines.

TX,05,JC1888 –19–18FEB97–1/1
Inspect Machine
Inspect your machine carefully each day by walking

around it before you start it. (See Pre-Start Inspection
Chapter.) –UN–18OCT88
T6607AQ
T82,BHSA,CL –19–14MAR90–1/1

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Safety Information
00
0001 Use Handholds and Steps
6
Falling is one of the major causes of personal injury.
When you get on and off the machine, always maintain a

three point contact with the steps and handrails, and face
–UN–15JUN89
the machine. Do not use the steering wheel or any
controls as handholds.
Never jump on or off the machine. Never mount or
T6981AN
dismount a moving machine.
Be careful of slippery conditions on platforms, steps, and

handrails when leaving the machine.
TX,05,DH553 –19–18MAR91–1/1
Prevent Machine Runaway
Avoid possible injury or death from a runaway machine.
DO NOT start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.
–UN–20OCT88
Never start engine while standing on ground. Start engine
only from operator’s seat with transmission control lever
locked in neutral and park brake engaged.
T6642EB
TX,05,DH2281 –19–06OCT92–1/1
Use Seat Belt Properly
Overturns may occur if proper operating instructions are

not followed.
Use your seat belt.

–UN–23AUG88
TS175
TX,05,JC1044 –19–12JAN96–1/1

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Safety Information
00
Maintain Seat Belt 0001
7
It is important to use the seat belt on ROPS equipped

machines to minimize the chance of injury from an
accident such as an overturn. Keep the seat belt in good
condition.
The complete seat belt assembly should be replaced

after three years of usage, regardless of appearance.
Between replacement intervals:
Carefully examine buckle, webbing, and attaching

hardware.
Be sure that the retractor, if equipped, locks to prevent

belt extension after latching buckle.
Be sure that attaching hardware is in place. Tighten, if

necessary.
Replace the seat belt if it does not operate properly, or if it

is damaged, worn, or deteriorated.
TX,05,JC242 –19–03MAR95–1/1
Secondary Exits
Machines equipped with cabs are equipped with

secondary exits. For additional secondary exit information,
see “Opening Side Window/Secondary Exit” in chapter 10
of this manual.
TX,05,JC1753 –19–09DEC96–1/1

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Safety Information
00
0001 Travel Safely
8
Know the location of bystanders before moving the

machine.
Always keep the reverse warning alarm in working
–UN–20DEC88
condition. It warns people when the machine starts to
move in reverse.
Use a signal person when moving the machine in
T6964AD
congested areas. Coordinate hand signals before starting
the machine.
TX,05,DH496 –19–02AUG89–1/1
Drive Machine Safely
Walk around machine to clear all persons from area of

operation and machine movement.
Always check area to rear before shifting to reverse.
–UN–25OCT88
Drive carefully in congested areas, over rough ground,
near ditches for excavations, and on slopes or curves.
T6582AS
Keep machine in gear when going down hills.
Use accessory lights and devices to warn operators of

other vehicles.
TX,05,DH1931 –19–21JUN91–1/1

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Safety Information
00
Operate Machine with Caution 0001
9
Check location of cables, gas lines, and water mains

before digging.
Keep loading area smooth.
–UN–18OCT88
Never lower a loaded bucket with the boom and bucket
control lever in the float position.
T6642EF
Increase the power gradually when pulling a heavy load or
when driving out of a ditch or excavation.
TX,05,DH1932 –19–06JUN91–1/1
Operating on Slopes
Avoid side slope travel whenever possible. Drive up slope

in forward and down in reverse. The danger of tipping is
always present.
In steep slope operation, do not allow engine to

overspeed. Select low gear speed before starting down
slope.
The grade of the slope you should attempt will be limited

by such factors as ground condition, and load being
handled.
–UN–03AUG89
T7050AB
TX,05,RR,171 –19–27APR89–1/1

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Safety Information
00
0001 Carrying Loads
10
Carry loader bucket as low as possible for better stability

and visibility.
Handle only those loads which are properly arranged. Do
–UN–03AUG89
not overload.
Do not start, stop, or turn quickly when transporting a

load.
T7050AA
Do not change forward or reverse directions quickly when
carrying a load.
TX,05,RR,172 –19–03JUN92–1/1
Avoid Power Lines
Serious injury or death can result from contact with

electric lines.
Never move any part of the machine or load closer to
–UN–20JUN89
electric line than 3 m (10 ft) plus twice the line insulator
length.
T6642EG
02T,05,J18 –19–06JUN91–1/1
Beware of Exhaust Fumes
Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
If you must operate in a building, be sure there is

–UN–18OCT88
adequate ventilation. Either use an exhaust pipe extension

to remove the exhaust fumes or open doors and windows
to bring enough outside air into the area.
T6458AO
TX,DH,2 –19–09FEB89–1/1

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Safety Information
00
Keep Riders Off Machine 0001
11
Only allow the operator on the machine. Keep riders off.
Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off of the
machine. Riders also obstruct the operator’s view resulting
–UN–23AUG88
in the machine being operated in an unsafe manner.
TS290
DX,RIDER –19–03MAR93–1/1
Handle Fuel Safely—Avoid Fires
Handle fuel with care: it is highly flammable. Do not refuel

the machine while smoking or when near open flame or
sparks.
Always stop engine before refueling machine. Fill fuel tank
–UN–23AUG88
outdoors.
Prevent fires by keeping machine clean of accumulated

trash, grease, and debris. Always clean up spilled fuel.
TS202
DX,FIRE1 –19–03MAR93–1/1
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88
hospital, and fire department near your telephone.

TS291
DX,FIRE2 –19–03MAR93–1/1

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Safety Information
00
0001 Handle Starting Fluid Safely
12
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
–UN–18OCT88
Remove container from machine if engine does not need
starting fluid.
T6464AV
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
TX,05,FF2281 –19–22FEB91–1/1
Clean Trash from Machine
Keep engine compartment, radiator, batteries, hydraulic

lines, fuel tank, and operator’s station clean.
Temperature in engine compartment may go up

immediately after engine is stopped. BE ON GUARD FOR
–UN–23AUG88
FIRES DURING THIS PERIOD.
Open access door(s) to cool the engine faster, and clean

engine compartment.
TS227
02T,05,J33 –19–13JUN00–1/1
Protect Against Flying Debris
When you drive connecting pins in or out, guard against

injury from flying pieces of metal or debris; wear goggles
or safety glasses.
–UN–18OCT88
T6642DK
02T,05,J45 –19–30MAY90–1/1

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Safety Information
00
Wear Protective Clothing 0001
13
Wear close fitting clothing and safety equipment

appropriate to the job.
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
–UN–23AUG88
while operating machine.
TS206
DX,WEAR2 –19–03MAR93–1/1
Protect Against Noise
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
–UN–23AUG88
uncomfortable loud noises.
TS207
DX,NOISE –19–03MAR93–1/1
Handle Chemical Products Safely
Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
–UN–26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a TS1132
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical

products used with John Deere equipment.)
DX,MSDS,NA –19–03MAR93–1/1

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Safety Information
00
0001 Use Safety Lights and Devices
14
Operators of machines that travel below normal highway

speeds should take special precautions to avoid collision
with other vehicles.
–UN–10FEB89
Before driving on public roads, check state and local laws
that may apply to tractors, self-propelled machines, and
towed equipment. Additional lights, mirrors, SMV
emblems, or reflectors may be required.
N36564
Install and use all safety lights and devices necessary to
assure safe operation and local compliance. Keep these A—Lights
safety items in good condition. Replace missing or B—Slow Moving Vehicle Emblem
damaged parts immediately. C—Reflector Tape
D—Reflectors
TX,05,DH1729 –19–26JAN91–1/1
Keep ROPS Installed Properly
A damaged roll-over protective structure (ROPS) should

be replaced, not reused.
The protection offered by ROPS will be impaired if ROPS

is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
bending, drilling, or cutting.
If ROPS was loosened or removed for any reason, inspect

it carefully before operating the machine again.
To maintain the ROPS:
• Replace missing hardware using correct grade

hardware.
• Check hardware torque.
• Check isolation mounts for damage, looseness or wear;
replace them if necessary.
• Check ROPS for cracks or physical damage.
TX,05,DH1846 –19–14MAY91–1/1

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Safety Information
00
Warn Others of Service Work 0001
15
Unexpected machine movement can cause serious injury.
Before performing any work on the machine, attach a "DO

NOT OPERATE" tag to the steering wheel.
–19–22APR91
T7447AO
TX,05,DH1820 –19–14MAY91–1/1

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Safety Information
00
0001 Practice Safe Maintenance
16
Understand service procedure before doing work. Keep

area clean and dry.
Never lubricate, service, or adjust machine while it is

moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be

raised for service work.
Keep all parts in good condition and properly installed. Fix

damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground

cable (-) before making adjustments on electrical systems
–UN–23AUG88
or welding on machine.
On towed implements, disconnect wiring harnesses from

tractor before servicing electrical system components or
TS218
welding on machine.
DX,SERV –19–17FEB99–1/1
Support Machine Properly
Always lower the attachment or implement to the ground

before you work on the machine. If the work requires that
the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
–UN–23AUG88
Do not support the machine on cinder blocks, hollow tiles,

or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
TS229
Follow recommended procedures in this manual.
When implements or attachments are used with a

machine, always follow safety precautions listed in the
implement or attachment operator’s manual.
DX,LOWER –19–24FEB00–1/1

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Safety Information
00
Remove Paint Before Welding or Heating 0001
17
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
–UN–23AUG88
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area

to be affected by heating. If paint cannot be removed,
TS220
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is well ventilated to carry toxic

fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–24JUL02–1/1
Avoid Heating Near Pressurized Fluid Lines
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
–UN–15MAY90
accidentally cut when heat goes beyond the immediate

flame area.
TS953
DX,TORCH –19–03MAR93–1/1

011504
PN=25
Safety Information
00
0001 Avoid High-Pressure Fluids
18
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
X9811
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID –19–03MAR93–1/1
Clean the Machine Regularly
Remove any grease, oil, fuel, or debris build-up to avoid

possible injury or machine damage.
High pressure washing [greater than 1379 kpa (13.8 bar)
–UN–18OCT88
(200 psi)] can damage freshly painted finishes. Paint
should be allowed to air dry for 30 days minimum after
receipt of machine before cleaning with high pressure.
Use low pressure wash operations until 30 days have
elapsed. T6642EJ
Do not spray oil cooler fins at an angle. Fins may bend.
TX,05,FF2787 –19–27JUL94–1/1

011504
PN=26
Safety Information
00
Service Cooling System Safely 0001
19
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88
to relieve pressure before removing completely.
TS281
DX,RCAP –19–04JUN90–1/1
Store Attachments Safely
Stored attachments such as dual wheels, cage wheels,

and loaders can fall and cause serious injury or death.
Securely store attachments and implements to prevent

falling. Keep playing children and bystanders away from
–UN–23AUG88
storage area.
TS219
DX,STORE –19–03MAR93–1/1
Dispose of Waste Properly
Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into TS1133
any water source.
Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN –19–03MAR93–1/1

011504
PN=27
Safety Information
00
0001
20

011504
PN=28
Section 01
Wheels
Contents 01
Page
Group 0110—Powered Wheels And Fasteners

Wheel
Remove and Install . . . . . . . . . . . . . . . . . .01-0110-1
Tire
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-2
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-4

011504
PN=1
Contents
01

011504
PN=2
Group 0110
Powered Wheels And Fasteners
Remove And Install Wheel
1. Raise machine and place 10-ton shop stand under

axle.
01
CAUTION: Use a lifting device for heavy 0110
1
components.
2. Place wheel lift under wheel. Fasten safety chain

around upper part of tire.
TX,01,111685 –19–23OCT02–1/2
3. Remove cap screws (A) to remove wheel.
4. Clean mounting surface on wheel and axle flange.

Install wheel.
Tighten cap screws.
Remove and Install Wheel—Specification

Wheel Retainer Cap Screws—Dry
Torque ......................................................................... 620 N•m (460 lb-ft)
A—Cap Screw (14 used)
–UN–24MAY90
T7134FA
TX,01,111685 –19–23OCT02–2/2

011504
PN=31
Remove Tire
CAUTION: Explosive separation of a tire and

rim parts can cause serious injury or death.
01
0110 Only attempt to mount a tire if you have the
2
proper equipment and experience to perform
the job. Have it done by your John Deere dealer
or a qualified repair service.
Always maintain the correct tire pressure. Do

not inflate the tires above the recommended
pressure.
When inflating tires, use a clip-on chuck and

extension hose long enough to allow you to
stand to one side and NOT in front of or over
the tire assembly. Use a safety cage if available.
Inspect tires and wheels daily. Do not operate

with low pressure, cuts, bubbles, damaged rims
–UN–23AUG88
or missing lug bolts and nuts.
CAUTION: Failure to follow proper procedures
TS211
when demounting a tire from a wheel or rim can
produce an explosion which may result in
serious bodily injury. DO NOT attempt to
demount a tire unless you have proper
equipment and experience to perform the job
safely. Have it done by a qualified tire repair
service.
NOTE: See John Deere Off-The-Road Tire Maintenance

Manual to remove tire from wheel.
Tire can be removed without removing wheel.
Continued on next page TX,01,111686 –19–15MAY98–1/2

011504
PN=32
Before attempting any demounting operation, always

completely deflate tire. Remove cap (A) and valve core
(B) from valve. Remove valve nut (C).
Inspect all parts for damage. Replace parts as necessary.

01
–UN–22OCT92
0110
A—Cap 3
B—Valve Core
C—Valve Nut
T7751GU
TX,01,111686 –19–15MAY98–2/2

011504
PN=33
Install Tire
CAUTION: Failure to follow proper procedures

when mounting a tire from a wheel or rim can
01 produce an explosion which may result in
0110
–UN–22OCT88
serious bodily injury. DO NOT attempt to mount
4
a tire unless you have proper equipment and
experience to perform the job safely. Have it
done by a qualified tire repair service.
T6564BR
NOTE: See John Deere Off-The-Road Tire Maintenance
Manual to mount the tire on the wheel.
A—Front Flange
To prevent slipping of the wheel under load, the inside B—Bead Seat Band
and outside wheel must be free of paint, rust, oil, grease, C—Lock Ring
dirt or other foreign material before installation. D—O-Ring
E—Cap
Install valve stem in rim base and tighten retaining nut.
Specification
Valve Stem Retaining Nut—
Torque .............................................................................. 6 N•m (50 lb-in.)
CAUTION: Serious bodily injury can occur from

explosion when mounting and inflating tires if
safe procedures are not followed.
Use only recommended air pressure. Pressure over this

limit can cause explosion.
Inflate tire.
Apply John Deere Non-Soap Lubricating Grease, or an

equivalent, on threads of cap (E). Install cap on valve
stem shield.
Specification
Wheel Mounting Cap Screw—
Torque ......................................................................... 675 N•m (500 lb-ft)
TX,01,111687 –19–15MAY98–1/1

011504
PN=34
Section 02
Axles And Suspension Systems
Contents
Page Page
Group 0200—Removal And Installation Limited Slip Differential

Front Axle and Differential Cross-Sectional View. . . . . . . . . . . . . . . .02-0250-61 02
Remove and Install . . . . . . . . . . . . . . . . . .02-0200-1 Disassemble and Inspect . . . . . . . . . . . . .02-0250-62
Rear Axle and Differential Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-69
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-5 Limited Slip Differential
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-10 Measure End Play Gap . . . . . . . . . . . . . .02-0250-72
Axle Oscillating Supports Limited Slip Differential
Disassemble and Assemble. . . . . . . . . . .02-0200-12 Continue Assembly . . . . . . . . . . . . . . . . .02-0250-74
Input Pinion Shaft
Group 0225—Axle Shafts And U-Joints Cross-Sectional View. . . . . . . . . . . . . . . .02-0250-76
Universal Joint and Drive Shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-77
Remove and Install . . . . . . . . . . . . . . . . . .02-0225-1 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-80
Disassemble, Inspect and Assemble . . . . .02-0225-2 Differential Drive Shaft
Cone Point Shim Pack Adjustment . . . . .02-0250-81
Input Drive
Group 0250—Axle Shaft, Bearings, Reduction Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-82
Gears Input Pinion Shaft
Essential Tools . . . . . . . . . . . . . . . . . . . . . . .02-0250-1 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-84
Service Equipment And Tools . . . . . . . . . . . .02-0250-4 Input Shaft
Other Material . . . . . . . . . . . . . . . . . . . . . . . .02-0250-6 Continue Installation . . . . . . . . . . . . . . . .02-0250-87
Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0250-7 Axle Disconnect Input Shaft
Final Drive Assembly Cross-Section View . . . . . . . . . . . . . . . . .02-0250-90
Install in Repair Stand . . . . . . . . . . . . . . . .02-0250-9 Remove and Install Disconnect . . . . . . . .02-0250-91
Remove from Repair Stand . . . . . . . . . . .02-0250-10 Disassemble, Inspect and Assemble . . . .02-0250-91
Oscillating Support Wear Sleeves
Remove and Install . . . . . . . . . . . . . . . . .02-0250-12 Group 0260—Hydraulic System
Final Drive Assembly Differential Lock Solenoid Valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-12 Remove and Install . . . . . . . . . . . . . . . . . .02-0260-1
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-15
Disassemble . . . . . . . . . . . . . . . . . . . . . .02-0250-17
Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-23
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-26
Replace Brakes. . . . . . . . . . . . . . . . . . . . . .02-0250-30
Differential Case Cover
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-32
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-32
Differential
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-33
Adjust Preload and Backlash . . . . . . . . . .02-0250-34
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-40
Hydraulic Diff-Lock Differential
Cross-Sectional View. . . . . . . . . . . . . . . .02-0250-41
Disassemble, Inspect, and Assemble. . . .02-0250-42
Standard Differential
Cross-Sectional View. . . . . . . . . . . . . . . .02-0250-54
Disassemble, Inspect, and Assemble. . . .02-0250-55

011504
PN=1
Contents
02

011504
PN=2
Group 0200
Removal And Installation
Remove And Install Front Axle And
Differential
1. Apply park brake.
2. Install frame locking bar (A).
–UN–03OCT96
CAUTION: The approximate weight of unit is
644H—17 393 kg (38,345 lb), 644H MH—17 442
T101610
kg (38,453 lb). 02
0200
Specification 1
644H Unit—Weight .................................................. 17 393 kg (38,345 lb)
A—Frame Locking Bar
644H MH Unit—Weight ........................................... 17 442 kg (38,453 lb)
B—Floor Stand
3. Raise front of unit. Install floor stands (B) under loader

frame.
4. Install boom lock. Move bucket to dumped position and

lower. This will provide clearance to remove cap
screws.
5. Stop engine.
CAUTION: Prevent possible injury from

unexpected boom or bucket movement when
equipped with ride control. Ride control
accumulator energy must be discharged when
working on hydraulic components. With boom
raised slightly, turn ignition switch to ON
position. Cycle the ride control switch from OFF
to ON (center position). Boom will jump up
unexpectedly if ride control accumulator is
energized. Press boom enable switch and move
the control lever into the float position and hold
for 5 seconds.
6. If equipped with ride control. With boom raised slightly,

turn ignition switch to ON position. Cycle the ride
control switch from OFF to ON (center position). Boom
will jump up unexpectedly if ride control accumulator is
energized. Press boom enable switch and move the
control lever into the float position and hold for 5
seconds.
7. Drain differential. Approximate oil capacity is 27 L (29

qt).
Continued on next page CED,OUOE002,1492 –19–14MAY98–1/6

011504
PN=37
Specification
Axle and Differential Oil—
Capacity .............................................................. 27 L (29 qt) approximate
CAUTION: The approximate weight of bottom

guard is 73 kg (160 lb).
Weight may increase significantly due to

buildup of mud or debris.
02 Specification
0200 Frame Bottom Guard—Weight ........................ 73 kg (160 lb) approximate
2
8. Remove bottom guard, if equipped.
CED,OUOE002,1492 –19–14MAY98–2/6
9. Disconnect lines (A) and (B—C) if equipped. Install

caps and plugs in ports and hoses.
10. Remove cap screws to disconnect drive shaft.
CAUTION: Use a lifting device for heavy
–UN–19MAR97
components.
11. Remove wheels using a wheel lift.
T108293
A—Front Differential-to-Brake Valve Line
B—Front Differential-to-Differential Lock Line
C—Front Differential-to-Axle Disconnect Line

011504
PN=38
CAUTION: The approximate weight of axle and

differential is 885 kg (1950 lb).
Specification
Axle and Differential—Weight ..................... 885 kg (1950 lb) approximate
–UN–03OCT96
12. Install low-lift jack (B) under axle and differential.
13. Remove nuts (A) to remove cap screws. Lower axle

and differential.
T101609
02
0200
14. Repair or replace axle or differential. (See procedure
3
in this group.)
A—Nut
B—Low-Lift Jack
15. Clean mounting surface on axle housings and loader
frame.
16. Install axle and differential.
Install a washer under head of cap screws and a

washer under the nuts. Hold the cap screws and
tighten the nuts.
Specification
Frame-to-Axle Housing Cap
Screw and Nut—Torque .............................................. 675 N•m (500 lb-ft)

011504
PN=39
IMPORTANT: To properly check oil level, do not

thread dipstick into port. Allow 10
minutes for oil to stabilize in each sump
before checking.
NOTE: Each differential housing has three separate
–UN–29JAN97
components. To expedite filling differential,
remove right axle plug.
17. Fill differential adding oil slowly through port (A) on
T106373B
02 the left axle. Check oil level after waiting 10 minutes.
0200 Make sure machine is level. See Drain and Refill
4 Left Front Differential Axle
Capacities—644H/H MH. (Operation and Test.)
A—Differential Oil Port
IMPORTANT: DO NOT reuse drive shaft universal
joint cap screws. Replace cap screws to
avoid machine damage.
18. Connect drive shaft. Install new drive shaft universal

joint cap screws. Tighten cap screws.
Specification
Drive Shaft Universal Joint Cap
Screw—Torque ................................................................ 78 N•m (58 lb-ft)
CED,OUOE002,1492 –19–14MAY98–5/6
19. Connect lines (A—C).
20. Remove jack.
21. Install wheels. Tighten cap screws.

–UN–19MAR97
Specification
Wheel-to-Axle Flange Cap
Screw—Torque ............................................................ 675 N•m (500 lb-ft)
NOTE: No bleeding of brakes is necessary. They are self

T108293
bleeding.
22. Install bottom guard, if equipped. A—Front Differential-to-Brake Valve Line

B—Front Differential-to-Differential Lock Line
C—Front Differential-to-Axle Disconnect Line
CED,OUOE002,1492 –19–14MAY98–6/6

011504
PN=40
Remove Rear Axle And Differential
1. Apply park brake. the ride control switch from OFF to ON (center
position). Boom will jump up unexpectedly if ride
2. Install frame locking bar. control accumulator is energized. Press boom
enable switch and move the control lever into the
3. Raise boom and install boom lock. Move bucket to float position and hold for 5 seconds.
dump position.
CAUTION: The approximate weight of
4. Stop engine. Release hydraulic pressure by
transmission bottom guard is 78 kg (172 lb).
operating loader control while holding boom enable 02
switch. 0200
Weight may increase significantly due to 5
buildup of mud or debris on guard.
unexpected boom or bucket movement when Specification
equipped with ride control. Ride control Transmission Bottom Guard—
Weight ....................................................... 78 kg (172 lb) approximate
accumulator energy must be discharged
when working on hydraulic components.
6. Remove transmission bottom guard if equipped.
With boom raised slightly, turn ignition
switch to ON position. Cycle the ride control
7. Drain differential. Approximate oil capacity is 27 L
switch from OFF to ON (center position).
(29 qt).
Boom will jump up unexpectedly if ride
control accumulator is energized. Press Specification
boom enable switch and move the control Axle and Differential Oil—
lever into the float position and hold for 5 Capacity ....................................................... 27 L (29 qt) approximate
seconds.
5. If equipped with ride control. With boom raised

slightly, turn ignition switch to ON position. Cycle

011504
PN=41
CAUTION: The approximate weight of unit is

644H—17 393 kg (38,345 lb), 644H MH—17 442
kg (38,453 lb).
Specification
644H Unit—Weight .................................................. 17 393 kg (38,345 lb)
–UN–20FEB90
approximate
644H MH Unit—Weight ........................................... 17 442 kg (38,453 lb)
approximate
T7134HD
02 8. Raise rear of unit using floor jack. Install floor stands
0200 (A) under frame on each side and at under rear
6 corners of frame.
CAUTION: Use a lifting device for heavy

components.
9. Remove wheels using wheel lift.
10. Remove caps screws to disconnect drive shaft.
CAUTION: The approximate weight of axle and

differential with front and rear oscillating
supports is 1012 kg (2229 lb).
Specification
Axle and Differential with Front
and Rear Oscillating Supports—
Weight........................................................ 1012 kg (2229 lb) approximate
11. Install low-lift jack under axle and differential.
A—Floor Stand
–UN–06MAR90
T7134HE
CED,OUOE002,1493 –19–14MAY98–2/5
12. Disconnect lines (A and B) if equipped.
A—Rear Differential-to-Brake Valve Line

B—Rear Differential-to-Differential Lock Line
–UN–02APR97
T108810

011504
PN=42
02
0200
7

011504
PN=43
02
0200
8
–UN–27JUL98
T115428
Oscillating Supports And Lubrication Lines

011504
PN=44
1—Special Jam Nut (2 used) 8—Thrust Bearing (6 used) 14—Cap Screw (6 used) 20—Elbow Fitting
2—Fitting (2 used) 9—Thrust Plate 15—Cap Screw (6 used) 21—Lubrication Fitting (2
3—Pipe Plug 10—Washer (4 used) 16—Seal (2 used) used)
4—Hydraulic Hose 11—Cap Screw (4 used) 17—Cap Screw (4 used) 22—Washer (10 used)
5—Elbow Fitting (3 used) 12—O-Ring 18—Front Oscillating Support 23—Bushing (2 used)
6—Rear Oscillating Support 13—Cover 19—Hydraulic Hose 24—Lubrication Fitting
7—Bushing (2 used)
13. Disconnect hydraulic hoses (4 and 19) from front 17. Remove cap screws (14 and 11) from pivot cover
and rear oscillating supports. (13) and thrust plate (9).
14. Remove cap screws (17 and 15) from oscillating 18. Remove rear oscillating support (6) from 02
supports. differential assembly. 0200
9
15. Lower supports, axle and differential assembly. 19. Repair or replace axle. See this group for repair.
16. Remove front oscillating support (18) from

differential assembly.
CED,OUOE002,1493 –19–14MAY98–5/5

011504
PN=45
Install Rear Axle And Differential
02
0200
10
–UN–27JUL98
T115428


011504
PN=46
1. Install front and rear oscillating supports. 6. Connect drive shaft. Install new drive shaft
universal joint cap screws. Tighten cap screws.
2. Tighten thrust plate cap screws (11) and pivot cover
cap screws (14). Specification 02
Drive Shaft Universal Joint Cap 0200
Specification Screw—Torque ......................................................... 78 N•m (58 lb-ft) 11
Thrust Plate-to-Axle Cap
Screw—Torque ..................................................... 350 N•m (255 lb-ft) NOTE: No bleeding of brakes is necessary. They are
Pivot Cover-to-Rear Oscillation self bleeding.
Support Cap Screw—Torque ............................... 140 N•m (105 lb-ft)
7. Connect lubrication lines.
3. Install axle and differential.
8. Install wheels. Tighten cap screws.
4. Tighten cap screws (15 and 17).
Specification
Specification Wheel-to-Axle Flange Cap
Axle Support-to-Frame Cap Screw—Torque ..................................................... 675 N•m (500 lb-ft)
Screw—Torque ..................................................... 675 N•m (500 lb-ft)
9. Remove floor stands.

5. Connect lines to differential.
10. Install bottom guard, if equipped.
joint cap screws. Replace cap
screws to avoid machine damage.
CED,OUOE002,1494 –19–14MAY98–2/3
IMPORTANT: To properly check oil level, do not

thread dipstick into port. Allow 10
minutes for oil to stabilize in each sump
before checking.
NOTE: Each differential housing has three separate

–UN–29JAN97
components. To expedite filling differential,

remove right axle plug.
11. Fill differential adding oil slowly through port (A) on

T106373B
the left axle. Check oil level after waiting 10 minutes.

Make sure machine is level. See Drain and Refill
Capacities—644H/H MH. (Operation and Test.) Left Front Differential Axle
A—Differential Oil Port
CED,OUOE002,1494 –19–14MAY98–3/3

011504
PN=47
Disassemble And Assemble Axle Oscillating Supports
02
0200
12
–UN–27JUL98
T115428


011504
PN=48
NOTE: Axle oscillation support assembly does not 1. Remove rear axle and differential assembly. See
contain any shims for setting end play. If this group.
excessive end play is incurred due to wear,
end play should be no greater than 0.762 mm 2. Remove front oscillating support. 02
(0.03 in). This can be checked with dial 0200
indicator measuring between front support and 3. Remove cap screws (14 and 11) from pivot cover 13
the differential housing. If greater than 0.762 (13) and thrust plate (9) in rear oscillating support.
mm (0.03 in.) thrust bearings should be
replaced. Also check thrust plate (between 4. Remove rear oscillating support.
both thrust bearings) for wear on front side.
Disk should not have more than 0.254 mm 5. Repair and replace parts as necessary.
(0.01 in.) wear step on face that contacts front
thrust bearings. If out of specification, replace 6. Inspect thrust bearings (8) and bushings (7) for
thrust plate and thrust bearings. wear.
Specification 7. Lube thrust bearings and bushings with grease and

Axle-to-Oscillation Support—
pack cavity of cover (13).
End Play ............................................... 0.762 mm (0.03 in) maximum

011504
PN=49
NOTE: If bushings were removed in front or rear

oscillation supports note proper location of
bushing (C) grease slots (D) in relation to the
grease fitting (B). Slots should be facing up
toward the grease fitting to allow proper
lubrication of pivot area.
–UN–04APR97
8. Press bushings into front and rear supports being
careful not to damage.
T108815B
02 9. Install rear and front oscillating supports to differential.
0200
14
10. Tighten thrust plate (9) cap screws to (11) and pivot
cover (13) cap screws (14). A—Oscillating Support
B—Grease Fitting
C—Bushing
Specification
D—Grease Slots
Thrust Plate-to-Axle Cap Screw—
Torque ......................................................................... 350 N•m (255 lb-ft)
Pivot Cover-to-Rear Oscillation
Support—Torque ......................................................... 140 N•m (105 lb-ft)
11. Install rear axle and differential assembly. See this

group.
CED,OUOE002,1495 –19–14MAY98–3/3

011504
PN=50
Group 0225
Axle Shafts And U-Joints
Remove And Install Universal Joint And Universal Drive Shaft
02
0225
1
–19–15JUN98
T115440
3. Install new drive shaft universal joint cap screws.
unexpected machine movement. Place Specification
blocks front and rear of tires to prevent Front and Rear Drive Shaft
machine from rolling. Universal Joint Cap Screw—
Torque....................................................................... 77 N•m (57 lb-ft)
IMPORTANT: DO NOT reuse drive shaft universal Engine Drive Shaft
Universal-to-Transmission Cap
joint cap screws. Replace cap Screw—Torque ......................................................... 77 N•m (57 lb-ft)
screws to avoid machine damage. Engine Drive Shaft-to-Damper
Cap Screw—Torque ............................................... 130 N•m (95 lb-ft)
1. Remove drive shaft universal joint cap screws.
2. Inspect and replace parts as necessary.
CED,OUOE002,1496 –19–14MAY98–1/1

011504
PN=51
Disassemble, Inspect, And Assemble Universal Joint And Universal Drive Shaft
02
0225
2
–19–15JUN98
T115441
Transmission-To-Differential And Engine Shafts
1—Cap Screw (4 used) 3—Clamp (14 used) 5—Drive Shaft 7—Drive Shaft
2—Cap Screw (28 used) 4—Drive Shaft 6—Cap Assembly (3 used) 8—Drive Shaft
1. Remove drive shaft universal joint cap screws.

unexpected machine movement. Place
blocks front and rear of tires to prevent
machine from rolling.

joint cap screws. Replace cap
screws to avoid machine damage.

011504
PN=52
3. Install new drive shaft universal joint cap screws. Engine Drive Shaft
Universal-to-Transmission Cap
Specification Screw—Torque ......................................................... 77 N•m (57 lb-ft)
Front and Rear Drive Shaft Engine Drive Shaft-to-Damper
Universal Joint Cap Screw— Cap Screw—Torque ............................................... 130 N•m (95 lb-ft)
Torque....................................................................... 77 N•m (57 lb-ft)
02
0225
CED,OUOE002,1497 –19–15MAY98–2/2 3

011504
PN=53
02
0225
4

011504
PN=54
Group 0250
Axle Shaft, Bearings, Reduction Gears
Essential Tools
NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).
02
0250
SERVICEGARD is a trademark of Deere & Company. CED,OUOE003,1002 –19–25JUN98–1/18 1
Axle Support Bracket . . . . . . . . . . . . . . . . . . JT073221
–UN–10JAN97
To support axle assembly during repair.
RW25611
1
Use with D05223ST Rollover Stand.
CED,OUOE003,1002 –19–25JUN98–2/18
RW25612 –UN–10JAN97
Spanner Wrench . . . . . . . . . . . . . . . . . . . . . JDG1150
To remove and install axle shaft retaining nut.
CED,OUOE003,1002 –19–25JUN98–3/18
Input Shaft Remover and Axle Housing Tool. . . JDG1093
To remove input shaft and remove and adjust axle

housing.
–UN–10JAN97
RW25614
Continued on next page CED,OUOE003,1002 –19–25JUN98–4/18

011504
PN=55
RW25852 –UN–20OCT97
Guide Ring . . . . . . . . . . . . . . . . . . . . . . . . JDG1191
To install axle O-ring seals.
CED,OUOE003,1002 –19–25JUN98–5/18
RW25851 –UN–20OCT97
Driver Ring . . . . . . . . . . . . . . . . . . . . . . . . JDG1190
To install axle O-ring seals.

02
0250
2 CED,OUOE003,1002 –19–25JUN98–6/18
RW25853 –UN–20OCT97
Locator Ring . . . . . . . . . . . . . . . . . . . . . . . JDG11921
To install axle O-ring oil seals.
1
Used with JDG1126 Differential Housing Bearing Preload Measuring
Bar.
CED,OUOE003,1002 –19–25JUN98–7/18
RW25643 –UN–28FEB97
Lifting Screw . . . . . . . . . . . . . . . . . . . . . . . JDG1125
To remove and install differential case cover.
CED,OUOE003,1002 –19–25JUN98–8/18
RW25644 –UN–28FEB97
Housing Preload Measuring Bar . . . . . . . . . . . JDG1126
To determine differential housing bearing preload shim

pack.
CED,OUOE003,1002 –19–25JUN98–9/18
RW25707 –UN–03JUN97
Stand-Off Gauge Block. . . . . . . . . . . . . . . . . JDG11561
To measure differential housing preload.
1
Used with JDG1126 Differential Housing Bearing Preload Measuring
Bar.

011504
PN=56
RW25383 –UN–02APR96
Yoke Holding Tool . . . . . . . . . . . . . . . . . . . . JDG1090
To remove and install yoke retaining nut.
CED,OUOE003,1002 –19–25JUN98–11/18
RW18963 –UN–24FEB92
Rolling Torque Tool with Backlash Bar . . . . . . JDG712A
To measure rolling drag (torque) and backlash.

02
0250
CED,OUOE003,1002 –19–25JUN98–12/18 3
RW25089 –UN–16MAR94
Differential Pinion Seal Installer . . . . . . . . . . . . JDG873
To install input quill oil seal.
CED,OUOE003,1002 –19–25JUN98–13/18
RW25613 –UN–10JAN97
Bearing Installer Set . . . . . . . . . . . . . . . . . . JDG1155
To install bearing cups.
CED,OUOE003,1002 –19–25JUN98–14/18
RW25381 –UN–14JUN95
Bearing Installer . . . . . . . . . . . . . . . . . . . . . . JDG926
To install bearings.
CED,OUOE003,1002 –19–25JUN98–15/18
RW25388 –UN–15JUN95
Seal Installer . . . . . . . . . . . . . . . . . . . . . . . JDG1151
To install input shaft seal.
CED,OUOE003,1002 –19–25JUN98–16/18
RW25781 –UN–19JUN97
Spanner Wrench . . . . . . . . . . . . . . . . . . . . . JDG1142
To remove and install auxiliary yoke retaining nut.
CED,OUOE003,1002 –19–25JUN98–17/18
RW25780 –UN–19JUN97
Bearing Installer Tool . . . . . . . . . . . . . . . . . . JDG1141
To install disconnect input shaft outer bearing.
CED,OUOE003,1002 –19–25JUN98–18/18

011504
PN=57
Service Equipment And Tools

European Microfiche Tool Catalog (MTC). Some
tools may be available from a local supplier.
02
0250
4 SERVICEGARD is a trademark of Deere & Company. CED,OUOE003,1003 –19–25JUN98–1/14
Lifting Brackets . . . . . . . . . . . . . . . . . . . . . . . . JDG19
To remove and install components.
CED,OUOE003,1003 –19–25JUN98–2/14
Axle Mounting Stand . . . . . . . . . . . . . . . . . . JDG1008
To support final drive during repair.
CED,OUOE003,1003 –19–25JUN98–3/14
Planetary Lifting Tool . . . . . . . . . . . . . . . . . . JDG890A
To remove and install planetary assembly.
CED,OUOE003,1003 –19–25JUN98–4/14
Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . JDG1089
To install outer bearing cup.
CED,OUOE003,1003 –19–25JUN98–5/14
Driver Disk (5-3/4 in.) . . . . . . . . . . . . . . . . . . JDG1152
To install inner bearing cup.
CED,OUOE003,1003 –19–25JUN98–6/14
Metric Lifting Eyebolt . . . . . . . . . . . . . . . . . . . JT05550
For component removal and installation.

011504
PN=58
Driver Disk (5-1/4 in.) . . . . . . . . . . . . . . . . . . . JDG986
To install differential bearing cup.
CED,OUOE003,1003 –19–25JUN98–8/14
Install ring gear cover bearing cup

02
0250
CED,OUOE003,1003 –19–25JUN98–9/14 5
Driver Disk (2-3/4 in.)
To remove differential lock piston.
CED,OUOE003,1003 –19–25JUN98–10/14
To install differential housing bearing cup.
CED,OUOE003,1003 –19–25JUN98–11/14
Remove oil dam.
CED,OUOE003,1003 –19–25JUN98–12/14
Install shield into counterbore.
CED,OUOE003,1003 –19–25JUN98–13/14
Driver Disk (5-1/2 in.) . . . . . . . . . . . . . . . . . . . JDG135
To remove snap ring.
CED,OUOE003,1003 –19–25JUN98–14/14

011504
PN=59
Other Material
Number Name Use
TY24311 (U.S.) Thread-lock (Low Strength) Apply to cover-to-case socket head

cap screw threads.
TY16021 (U.S.) Form-in-Place Gasket Apply to outer diameter of oil seal.
PT506 (U.S.) NEVER-SEEZ Lubricant To lubricate shaft threads.

02
0250
6
NEVER-SEEZ is a trademark of Emhart Chemical Group. CED,OUOE003,1004 –19–25JUN98–1/1

011504
PN=60
Specifications
Item Measurement Specification
Final Drive Assembly:
Axle Housing-to-Differential Case Torque 310 N•m (228 lb-ft)

Cap Screw
Axle Shaft Outer Bearing Surface Diameter 114.357—114.383 mm

(4.502—4.503 in.) new 02
0250
7
Axle Housing Retaining Nut Torque 271 N•m (200 lb-ft)
Rolling Drag Torque 30—38 N•m (22—28 lb-ft)
Brakes:
Disk Thickness 2.92 mm (0.114 in.) new
Plate Thickness 3.05 mm (0.120 in.) new
Differential Case Cover:
Differential Cover-to-Case Torque 10 N•m (7 lb-ft)

Retaining Screw
Differential:
Differential-to-Pinion Backlash 0.19—0.38 mm

(0.0075—0.015 in.)
Hydraulic Diff-Lock Differential:
Clutch Disk Thickness 2.92 mm (0.114 in.) new
Clutch Plate Thickness 3.05 mm (0.120 in.) new
Actuator Plate Return Spring Free Length 65 mm (2.559 in.) approximate

(New) Test Length 55 mm at 225—275 N
(2.165 in. at 50—62 lb-force)
Cover-to-Ring Gear-to-Housing Torque 375 N•m (277 lb-ft)

Cap Screw

011504
PN=61
Standard Differential:

Cap Screw
Limited Slip Differential:
02 Friction Pack Wear Tolerance End Play 0.81 mm (0.032 in.) minimum
0250 End Play 0.20—0.51 mm
8
(0.008—0.020 in.) new

Cap Screw
Input Pinion Shaft:
Input Pinion Shaft Nut Torque 604 N•m (445 lb-ft)
Input Shaft Retaining Nut Torque 360 N•m (267 lb-ft)
Pinion Shaft Pins Preload 0.013—0.089 mm

(0.0005—0.0035 in.)
Special Locking Nut Torque 360 N•m (267 lb-ft)
Axle Disconnect Input Shaft:
Disconnect-to-Differential Case Torque 310 N•m (230 lb-ft)

Cap Screw
Disconnect Input Shaft Retaining Torque 360 N•m (267 lb-ft)

Nut
Collar Engagement Spring Free Length 73 mm (2.874 in.) approximate

Test Length 44.45 mm at 352—431 N
(1.750 in. at 78—96 lb-force)
Auxiliary Yoke-to-Drive Shaft Nut Torque 360 N•m (267 lb-ft)
CED,OUOE003,1005 –19–25JUN98–2/2

011504
PN=62
Install Final Drive Assembly In Repair Stand
Install JT07322 Axle Support Bracket (A) to D05223ST

Engine Rollover Stand.
Drain oil and remove axle from vehicle.
–UN–02JAN97
A—JT07322 Axle Support Bracket
RW36093
02
0250
TX,02,111706 –19–15MAY98–1/4 9
Remove fittings and/or plugs and install support bracket

mounting screws (A) as illustrated.
Install the axle assembly to the support bracket as

illustrated.
A—Mounting Screw (3 used)
–UN–02JAN97
RW36094
TX,02,111706 –19–15MAY98–2/4
Install mounting screw nuts and washers (A).
A—Mounting Nut and Washer (3 used)
–UN–02JAN97
RW36095

011504
PN=63
Remove straps and/or chains.
–UN–02JAN97
RW36096
02
0250
10 TX,02,111706 –19–15MAY98–4/4
Remove Final Drive Assembly From Repair

Stand
Install straps and attach to overhead hoist.

TX,02,111707 –19–15MAY98–1/3
Remove retaining nuts and washers (A) from support

bracket mounting screws.
Remove axle assembly from support bracket.
A—Mounting Nut and Washer (3 used)
–UN–02JAN97
RW36095

011504
PN=64
Remove support bracket mounting screws (A) from axle

assembly and install plugs and fittings.
Install axle in vehicle.
A—Mounting Screw (3 used)
02
–UN–02JAN97
0250
11
RW36094
TX,02,111707 –19–15MAY98–3/3

011504
PN=65
Remove And Install Oscillating Support Wear Sleeves
02
0250
12
–UN–02JAN97
RW36097
A—Wear Sleeve B—Wear Sleeve
Inspect wear sleeves (A and B). (300°F). Plan a safe handling procedure to
avoid burns.
Remove sleeves as necessary taking care to avoid
damage to differential case. Install sleeves on case making sure sleeves fit tight
against shoulders.
CAUTION: Heat parts in a bearing heater.
Use a thermometer and do not exceed 150°C
TX,02,111702 –19–15MAY98–1/1
Remove Final Drive Assembly
Install axle in repair stand.
Attach sling and overhead hoist to final drive assembly.

011504
PN=66
Remove axle housing-to-differential case cap screws (A).
NOTE: Fabricate two guide pins by removing the heads

from 19M8190 cap screws (16 mm diameter x
180 mm length).
Install guide pins.
02
–UN–02JAN97
0250
13
RW36098
TX,02,111708 –19–15MAY98–2/6
Remove final drive assembly (B) and ring gear (C).
A—Guide Pin
B—Final Drive Assembly
C—Ring Gear
–UN–31AUG98
RW36099

011504
PN=67
Remove sun pinion shaft (A) and brake pack (B).
Attach sling and overhead hoist to final drive assembly.
A—Sun Pinion Shaft

B—Brake Pack
02
0250
14
–UN–02JAN97
RW36100
TX,02,111708 –19–15MAY98–4/6
Remove cap screws (A).
Install guide pins and remove final drive assembly (B) and
ring gear (C).

B—Final Drive Assembly
C—Ring Gear
–UN–02JAN97
RW36101

011504
PN=68
Remove sun pinion shaft (A) and brake pack (B).
A—Sun Pinion Shaft

B—Brake Pack
02
0250
15
–UN–07JAN97
RW36102
TX,02,111708 –19–15MAY98–6/6
Install Final Drive Assembly
Install O-ring packing (A) on ring gear.
A—O-Ring Packing on Ring Gear
–UN–02JAN97
RW36103

011504
PN=69
Install ring gear (A) to axle housing (B) aligning the

mounting cap screw holes and with the O-ring against the
axle housing flange.
Install the brake separator plates and disks beginning with

two plates against the ring gear.
–UN–09JAN97
Alternately install the four disks and remaining four plates.
Align the separator plate ears (C).
RW36104
02
0250 Install the sun pinion shaft (D).
16
Install guide pins. A—Final Drive Ring Gear

B—Axle Housing
C—Brake Separator Plate Ears
Install ring gear-to-case cover gasket and/or the ring D—Sun Pinion Shaft
gear-to-case gasket.
NOTE: Make sure that the axle to mounting surface of

the final drive housings are installed in the correct
direction on the non-oscillating axle.
Install the final drive assembly to the case/cover

making sure that the brake pack ears align with
the slots in the case/cover.
Remove guide pins.
TX,02,111709 –19–15MAY98–2/3
Install cap screws (A).
Specification
Axle Housing-to-Differential Case
Cap Screw—Torque .................................................... 310 N•m (228 lb-ft)
Remove sling and overhead hoist.
Remove axle from repair stand.

–UN–09JAN97

RW36228
TX,02,111709 –19–15MAY98–3/3

011504
PN=70
Disassemble Final Drive Assembly
Remove final drive assemblies. See Remove Final Drive

Assemblies in this group.
CED,OUOE002,1499 –19–15MAY98–1/13
Install two JDG19 Lifting Brackets (A) and attach a chain

and overhead hoist.
Install the final drive assembly to JDG1008 Axle Mounting 02

0250
Stand (B).
17
Install three cap screws (C) through the stand to the axle
flange.
Remove chain and lifting brackets.
A—Lifting Bracket
B—Axle Mounting Stand
C—Cap Screw (3 used)
–UN–02JAN97
RW36105
CED,OUOE002,1499 –19–15MAY98–2/13
Remove final drive ring gear (A).
Inspect final drive ring gear.
A—Final Drive Ring Gear –UN–03JUL97

RW36106

011504
PN=71
Remove and replace O-ring packing (A).
A—O-Ring Packing
–UN–02JAN97
RW36103
02
0250
18 CED,OUOE002,1499 –19–15MAY98–4/13
Remove thrust washer (A).
A—Thrust Washer
–UN–08JAN97
RW36145
CED,OUOE002,1499 –19–15MAY98–5/13
Inspect thrust washer for excessive galling.
Replace as necessary.
–UN–09JAN97
RW36146

011504
PN=72
Remove carrier-to-axle shaft snap ring (A).
A—Snap Ring
–UN–02JAN97
02
RW36107
0250
19
CED,OUOE002,1499 –19–15MAY98–7/13
Remove planetary carrier assembly using JDG890A

Planetary Lifting Tool and an overhead hoist.
–UN–02JAN97
RW36108

011504
PN=73
NOTE: Remove one pinion shaft and pinion at a time.
Remove snap ring (A) to remove pinion shaft (B).
Remove planet pinion (C) with bearing rollers and thrust

washers as an assembly. Be careful not to lose any
bearing rollers.
A—Snap Ring
B—Pinion Shaft
–UN–02JAN97
02 C—Planet Pinion
0250
20
RW36109
CED,OUOE002,1499 –19–15MAY98–9/13
Inspect OD of shaft (A) and ID of pinion (D) for pits or

scratches.
Inspect thrust washer (B) for wear.
Inspect needle rollers (C) for pits or scratches.
NOTE: Use petroleum jelly, or an oil soluble grease on

thrust washers (B) and bearing rollers (C) to hold
them in place during assembly.
Apply grease and install rollers with original pinion. If any

bearing roller is lost or damaged, replace the entire set for
that pinion.
A—Planet Pinion Shaft

B—Thrust Washer
C—Needle Bearing Rollers –UN–02JAN97
D—Pinion Gear
RW36110

011504
PN=74
Position planet pinion shaft thrust washers on each side of

planet pinion (D).
Make sure there is clearance between thrust washers and

pinion after assembly. Pinions should rotate freely.
Install planet pinion shafts (A), with grooves toward the

snap ring (E).
Install the snap ring.

02
0250
A—Planet Pinion Shaft 21
B—Thrust Washer
C—Needle Bearing Rollers
D—Pinion Gear
E—Snap Ring
–UN–02JAN97
RW36110
–UN–02JAN97
RW36112

011504
PN=75
Remove retaining nut (A) using correct spanner wrench.
A—Retaining Nut
–UN–02JAN97
RW36113
02
0250
22 CED,OUOE002,1499 –19–15MAY98–12/13
IMPORTANT: Use a disk (A) between jack and axle

shaft to avoid damage to end of shaft.
Press axle shaft through inner bearing using a disk (A),

hydraulic jack, and JDG1093 Axle Housing Removal Tool
(B).
Remove hydraulic jack, disk, and tool and remove bearing

cone (C).
Remove axle housing from axle shaft using a hoist with a

chain or strap attached to the tool.
A—Disk
B—Axle Housing Removal Tool
–UN–10JAN97
C—Bearing Cone
RW36114
CED,OUOE002,1499 –19–15MAY98–13/13

011504
PN=76
Inspect Final Drive Assembly
Inspect oil seals (A) for wear or defects.
Inspect bearing cone (B) and cup (C).
Remove and replace as necessary.
A—Oil Seal (2 used)

B—Bearing Cone
C—Cup 02
0250
23
–UN–08JAN99
RW36115
–UN–21OCT97
RW36147A

011504
PN=77
IMPORTANT: DO NOT use a torch to remove axle

bearing cones. Heating to temperatures
as low as 204°C (400°F) will cause early
axle failure.
NOTE: A hydraulic bottle jack may be substituted for the

forcing screw.
Remove bearing cone using puller tools.
02
A—Bearing Puller
0250
B—Puller Legs
24
C—Puller
D—4-1/4 in. Disk
–UN–03JAN89
R37835
CED,OUOE002,1500 –19–15MAY98–2/4
Remove inner and outer bearing cups using puller tools.
Install outer bearing cup tight to bottom of bore using

correct driver disk.
Install inner bearing cup tight to bottom of bore using

–UN–23MAY96
RW35875

011504
PN=78
02
0250
25
–UN–02JAN97
RW36111
A—Axle Shaft Outer Bearing
Surface Diameter
Inspect axle shaft outer bearing adjoining surface. Replace parts as required.
Specification Inspect and clean seal bore in axle shaft. Bore must
Axle Shaft Outer Bearing
be clean and free of foreign material.
Surface—Diameter ......................................... 114.357—114.383 mm
(4.502—4.503 in.) new
CED,OUOE002,1500 –19–15MAY98–4/4

011504
PN=79
Assemble Final Drive Assembly
CAUTION: Heat parts in a bearing heater. Use a

thermometer and do not exceed 150°C (300°F).
Plan a safe handling procedure to avoid burns.
–UN–08OCT97
Heat bearing cone (A) to 80°—150°C (175°—300°F) and
install on shaft so bearing cone (A) is tight against
shoulder.
RW36557
02
0250 Install proper guide ring (B) into axle shaft bore with the
26 inner diameter taper toward the top.
Apply a light coat of oil to the seal O-ring (C) and place
seal in the guide ring.
Position the proper driver ring (D) on the seal.
–UN–08OCT97
Apply a downward force on the driver ring using firm
pressure on directly opposite sides of the driver ring while
moving around the circumference of the driver ring. Force
the driver ring and seal downward until driver ring bottoms
RW36558
out against the guide ring completely around the diameter
of the driver ring.
Remove the tools. A—Axle Shaft Bearing Cone

B—Guide Ring
Wipe lapped surface of seal clean and apply a thin film of C—Oil Seal O-Ring
clean. D—Driver Ring
Inspect and clean seal bore in axle housing. Bore must be

clean and free of foreign material.

011504
PN=80
Install proper locator ring (A) onto axle housing.
Install proper guide ring (B) into locator ring with the inner
diameter taper toward the top.
Apply a light coat of oil to the seal O-ring (C) and place
–UN–08OCT97
seal in the guide ring.
Position proper driver ring (D) on the seal.
RW36555
Apply a downward force on the driver ring using firm 02
pressure on directly opposite sides of the driver ring while 0250
27
moving around the circumference of the driver ring.
Force the driver ring and seal downward until driver ring
bottoms out against the guide ring completely around the
diameter of the driver ring.
Remove the tools.
–UN–08OCT97
Wipe lapped surface of seal clean and apply a thin film of
clean oil.
RW36556
A—Locator Ring
B—Guide Ring
C—Oil Seal O-Ring
D—Driver Ring
CED,OUOE002,1501 –19–15MAY98–2/8
Install JDG19 Lifting Brackets (A) and attach to an

overhead hoist.
Lift axle housing vertically over axle shaft.
Carefully lower axle housing over shaft.

–UN–10JAN97
Remove lifting brackets.

RW36117

A—Lifting Bracket
Install heated inner bearing cone (B). B—Bearing Cone

011504
PN=81
Install axle retaining nut and tighten using correct spanner

wrench (A).
Specification
Axle Housing Retaining Nut—
Torque ......................................................................... 271 N•m (200 lb-ft)
–UN–08JAN97
IMPORTANT: DO NOT rotate the axle housing.
Pour 120—150 mL (4—5 oz) of oil (B) through inner
RW36148
bearing and into axle housing assembly to fill outer seal
02
0250 cavity.
28
A—Spanner Wrench
B—Oil
CED,OUOE002,1501 –19–15MAY98–4/8
Install JDG1093 Axle Housing Removal Tool (A).
NOTE: Establishing the correct axle housing rolling drag

will provide preload on the axle bearings.
Tighten the axle housing retaining nut so that rolling drag

torque is to specification using correct spanner wrench
(B).
Specification
Axle Housing Retaining Nut—
Rolling Drag Torque ......................................... 30—38 N•m (22—28 lb-ft)
Measure the rolling drag using a bending beam torque
–UN–10JAN97
wrench (C).
Remove the tool.

RW36118
A—Axle Housing Removal Tool
B—Spanner Wrench
C—Bending Beam Torque Wrench

011504
PN=82
Align the lug on the bottom of the planetary carrier with

notch in axle shaft retaining nut.
Install planetary carrier assembly using JDG890A

Planetary Lifting Tool and an overhead hoist.
02
0250
29
–UN–02JAN97
RW36108
CED,OUOE002,1501 –19–15MAY98–6/8
Install carrier to axle shaft snap ring (A).
A—Snap Ring
–UN–02JAN97
RW36107

011504
PN=83
Install thrust washer (A).
Remove final drive assembly from axle mounting stand

and place horizontally on floor using JDG19 Lifting
Brackets.
–UN–08JAN97
Remove lifting brackets.
Install final drive assemblies to differential case. See

Install Final Drive Assemblies in this group.
RW36145
02
0250
30 A—Thrust Washer
CED,OUOE002,1501 –19–15MAY98–8/8
Replace Brakes
Remove final drive assemblies and brake packs. See

Remove Final Drive Assemblies, Group 15.
RX,444H1020,1 –19–15MAY98–1/4
Remove brake piston (A) from case/cover using

compressed air at the brake pressure inlet.
NOTE: A rolling head pry bar may be used to remove the

piston.
Inspect six separator plate retaining slots (B).
Check the slots for galling or wear that might restrict the
movement of the separator plates. Smooth the slots using
a file or grinder. If there is too much wear, replace the –UN–02JAN97
differential case.
A—Brake Piston
B—Retaining Slot (6 used)
RW36119
Continued on next page RX,444H1020,1 –19–15MAY98–2/4

011504
PN=84
Inspect brake piston (A).
Remove packing rings (B) and (C).
Replace piston as necessary.
Inspect parts (D) and (E).
Check the tabs on the separator plates for distortion or

wear that might restrict their movement. Smooth the tabs
using a file or grinder or replace the plates. 02
–UN–08JAN97
0250
Specification 31
Disk—Thickness .................................................. 2.92 mm (0.114 in.) new
Plate—Thickness ................................................. 3.05 mm (0.120 in.) new
RW36120
Inspect the brake disk splines (F) on the planetary carrier.
Replace parts as necessary.

A—Brake Piston
B—OD Packing Ring
Install packing rings to brake piston. C—ID Packing Ring
D—Brake Separator Plates (6 used)
E—Brake Disks (4 used)
F—Planetary Carrier Brake Disk Splines
RX,444H1020,1 –19–15MAY98–3/4
Install brake piston (A) into differential case piston bore.
Install final drive assemblies. See Install Final Drive

A—Brake Piston
–UN–08JAN97
RW36150
RX,444H1020,1 –19–15MAY98–4/4

011504
PN=85
Remove Differential Case Cover
Remove final drive assembly. See Remove Final Drive

Rotate differential case to vertical position.
–UN–24FEB97
Remove cover-to-case retaining screws (A).
Remove brake pressure inlet fittings or plugs and install
RW36248
02 JDG1125 Lifting Screws (B).
0250
32
Install JDG19 Lifting Brackets (C), washers, and nuts.
A—Cover-to-Case Retaining Screws
Remove differential case cover (D). B—JDG1125 Lifting Screw
C—JDG19 Lifting Bracket
D—Differential Case Cover
Remove gasket ring (E). E—Differential Case Gasket Ring
TX,02,111704 –19–15MAY98–1/1
Install Differential Case Cover
Install JDG19 Lifting Brackets (A) using JDG1125 Lifting

Screws (B) with washers and nuts.
–UN–26AUG98
A—Lifting Bracket
B—Lifting Screw
RW36249
TX,02,111705 –19–15MAY98–1/4
Install guide pins (A).
Install case-to-cover gasket ring (B).
A—Guide Pin
B—Gasket Ring
–UN–24FEB97
RW36250

011504
PN=86
Install cover so that oil deflector (A) is pointed toward

input shaft (B).
Remove lift brackets and lifting screws.
Apply TY24311 Low Strength Threadlock to the
–UN–26FEB97
cover-to-case socket head cap screw threads.
A—Oil Deflector
B—Input Shaft
RW36251
02
0250
TX,02,111705 –19–15MAY98–3/4 33
Install cover-to-case retaining screws (A) and tighten.
Specification
Differential Cover-to-Case
Retaining Screw—Torque ................................................. 10 N•m (7 lb-ft)
–UN–24FEB97
Install final drive assembly. See Install Final Drive
A—Screw (2 used)
RW36252
TX,02,111705 –19–15MAY98–4/4
Remove Differential
Remove differential case cover. See Remove Differential

Case Cover in this group.
TX,02,111611 –19–15MAY98–1/2
Install JT05550 Metric Lifting Eyebolts (A).
Attach chain and hoist and remove differential housing

assembly.
–UN–18FEB97
A—Lifting Eyebolts
RW36243
TX,02,111611 –19–15MAY98–2/2

011504
PN=87
Adjust Differential Preload And Backlash
IMPORTANT: Differential preload and backlash must

be adjusted whenever any of the
following parts are replaced.
• Differential Housing
• Differential Housing Cover
• Differential Housing Cups or Cones
• Differential Case
02 • Differential Case Cover
0250 • Ring Gear and Pinion
34
• Differential Drive Shaft Cups or Cones
NOTE: Axles with differential lock have a bearing cone in

the differential case. If equipped with standard or
limited slip, there is a bearing cup in the
differential case.
–UN–10JAN97
IMPORTANT: The initial shim pack is purposely
oversize to make sure there is backlash.
The shim pack is adjusted by removing
RW36202
shims from the differential case bearing
cup/cone and adding the same
thickness of shims to the differential Differential Lock
case side cover bearing cup/cone after
preload and backlash measurements
are taken.
1. Measure each shim individually and install 1.5 mm

(0.059 in.) initial shim pack (A) under non ring gear
side cup/cone (B).
–UN–18FEB97
RW36244
2. Heat bearing cone to 150° C (300° F) and install in All Others

differential case.
A—Shim Pack
B—Cup/Cone
Install cup/cone tight against shim pack (A).
Install bearing cup using correct driver disk.

011504
PN=88
3. Install differential. See Install Differential in this group.
Rotate the differential housing several times in both

directions to seat and roll-in the bearings.
–UN–18FEB97
RW36242
02
0250
CED,OUOE002,1502 –19–15MAY98–2/10 35
4. Install JDG1156 Stand-Off Gauge Blocks (A) and

JDG1126 Housing Preload Measuring Bar (B) on
differential case cover surface (C).
5. Record 142.88 mm (5.625 in.) nominal dimension from

top of bar to differential case cover surface.
NOTE: The nominal dimension of preload measuring bar

is 127 mm (5.000 in.). The nominal dimension of
the gauge block is 15.88 mm (0.625 in.).
–UN–19JUN97
6. Measure and record distance from top of bearing cone
surface (D) to top of bar using a depth micrometer (E).
Measure in four different locations around the cone
RW36508
surface and average the readings.
7. Subtract the dimension from Step 5 from the average

dimension from Step 6. The result is bearing cone A—JDG1156 Stand-Off Gauge Block
surface-to-cover surface dimension. B—JDG1126 Housing Preload Measuring Bar
C—Differential Case Cover-to-Case Surface
D—Bearing Cone Surface
E—Depth Micrometer

011504
PN=89
8. Remove the differential case cover-to-differential case

gasket ring and install the loose bearing cone (A) into
the bearing cup that is installed in the differential
housing. Rotate cone several times in both directions,
applying a downward force, to seat and roll-in the
bearings.
–UN–24FEB97
9. Install JDG1126 Housing Preload Measuring Bar (B)
on differential case surface (D).
02 10. Record 127 mm (5.000 in.), distance from top of bar
RW36254
0250 to differential case surface (D).
36
NOTE: The nominal dimension of preload measuring bar

is 127 mm (5.000 in.) A—Bearing Cone
B—JDG1126 Housing Preload Measuring Bar
C—Depth Micrometer
11. Measure and record distance from top of bearing D—Differential Case Surface
cone to top of bar using a depth micrometer (C).
Measure in four different locations around the cone
and average the readings.
12. Subtract the average dimension from Step 11 from

the dimension from Step 10. The result is bearing
cone-to-case surface dimension.
13. Record the bearing cone growth dimension of 0.05

mm (0.002 in.).
14. Subtract the dimensions from Steps 12 and Step 13

from dimension in Step 7.
15. Add the desired preload dimension 0.10 mm (0.004

in.). The result is the correct ring gear side cone shim
pack thickness.
EXAMPLE
Step 7 28.000 mm Cone to Cover
Step 12 - 27.000 mm Cone to Case
Step 13 - 0.050 mm Bearing Growth Dimension
Step 14 = 0.950 mm
Step 15 + 0.100 mm Desired Preload
= 1.050 mm Preliminary Shim Pack

Thickness

011504
PN=90
IMPORTANT: After preload and backlash

measurements are taken, shims will be
removed from differential case side
bearing cup/cone and the same
thickness of shims will be added to the
differential case side cover bearing
–UN–24FEB97
cone.
16. Measure each shim individually and install the shim

pack (A) previously calculated. Install the bearing
RW36255
cone (B) onto the differential case cover. 02
0250
37
Heat bearing cone to 150°C (300°F) and install in
differential case. A—Shim Pack
B—Bearing Cone
Install cone tight against shim pack.
CED,OUOE002,1502 –19–15MAY98–5/10

17. Install JDG19 Lifting Brackets (A) using JDG1125
–UN–26AUG98
Lifting Screws (B) with washers and nuts.
A—Lifting Bracket
B—Lifting Screw
RW36249
CED,OUOE002,1502 –19–15MAY98–6/10
18. Install guide pins (A).
19. Install cover so that oil deflector (B) is pointed toward

input shaft (C).
20. Remove lift brackets and lifting screws.

–UN–26FEB97
A—Guide Pin
B—Oil Deflector
C—Input Shaft
RW36256

011504
PN=91
21. Install equally spaced cover-to-case cap screws (A)

with flat washers and tighten.
–UN–24FEB97
RW36257
02
0250
38 CED,OUOE002,1502 –19–15MAY98–8/10
22. Install JDG1090 Yoke Holding Tool (A).
Rotate the pinion shaft to seat and roll-in the

bearings.
Hold the tool so that the pinion shaft will not rotate. A
–UN–07JAN97
pry bar (B) or similar tool may be installed to the
support bracket (C) to hold the tool.
RW36211
A—JDG1090 Yoke Holding Tool
B—Pry Bar
C—Support Bracket

011504
PN=92
23. Install JDG712A Backlash Tool (A) into the differential

housing assembly.
24. Install a dial indicator with magnetic base (B).
The indicator extension pointer (C) must rest against

the backlash bar (D) 204 mm (8.040 in.) from the
center of the tool (or at the 1400 marking on the tool
bar).
25. Move the differential back and forth carefully using a 02

pry bar, noting the backlash while holding the pinion 0250
39
shaft stationary. Check the backlash in at least three
–UN–05MAR97
locations 120° apart. Average the three readings.
Specification
Differential-to-Pinion—Backlash ........................................ 0.19—0.38 mm
(0.0075—0.015 in.)
RW36258
NOTE: A 0.1 mm (0.003 in.) desired change in backlash
will require approximately 0.1 mm (0.003 in.)
change in shim pack thickness. A—JDG712A Backlash Tool
B—Dial Indicator
C—Dial Indicator Extension Pointer
26. To decrease backlash, remove shims from non ring D—Backlash Bar
gear side of housing. Add the same thickness of
shims to ring gear side (differential case side cover).
Recheck backlash until correct backlash is

established.
27. Remove tools and case cover.
CED,OUOE002,1502 –19–15MAY98–10/10

011504
PN=93
Install Differential
Install JT05550 Metric Lifting Eyebolts (A).
Attach chain and hoist and install differential housing

assembly.
–UN–18FEB97
Remove chain and eyebolts.
Install differential case cover. See Install Differential Case
RW36243
02 Cover in this group.
0250
40
A—JT05550 Metric Lifting Eyebolts
TX,02,111615 –19–15MAY98–1/1

011504
PN=94
Hydraulic Diff-Lock Differential Cross-Sectional View
02
0250
41
–19–19FEB97
T107165
CED,OUOE002,1515 –19–19MAY98–1/1

011504
PN=95
Disassemble, Inspect, And Assemble

Hydraulic Diff-Lock Differential
Remove differential. See Remove Differential in Group 30.

CED,OUOE002,1516 –19–19MAY98–1/30
Remove cover-to-housing cap screws (A).

02
0250
42
–UN–18FEB97
RW36233
CED,OUOE002,1516 –19–19MAY98–2/30
Install M12 x 1.75-6H x 50 cap screws (A).
Tighten the cap screws against the ring gear and remove
the cover (B).

B—Cover
–UN–18FEB97
RW36234

011504
PN=96
Inspect bearing cone (A) on case cover.
NOTE: The differential bearing preload shims are under

the cone. DO NOT lose or misplace.
Remove cone and shims if necessary.
A—Bearing Cone
–UN–18FEB97
02
0250
43
RW36235
CED,OUOE002,1516 –19–19MAY98–4/30
Inspect housing cover and bearing cup (A).
Install bearing cup tight against bottom surface using

A—Bearing Cup
–UN–24FEB97
RW36259

011504
PN=97
Inspect the ring gear (A) and replace as necessary.
IMPORTANT: Differential ring gear and pinion shaft

are serviced as a matched set. Be sure
number stamped on ring gear and
pinion end of shaft are the same. Make
all pinion shaft and differential
adjustments when replacing ring gear
and pinion shaft.
02 Remove ring gear from housing by striking the underside
–UN–18FEB97
0250 of the ring gear with a soft hammer.
44
Remove bevel pinion gear (B) and thrust washer (C).
RW36236
A—Ring Gear
B—Bevel Pinion Gear
C—Thrust Washer
CED,OUOE002,1516 –19–19MAY98–6/30
Remove pinion shaft retaining pins (A).
Remove parts (B—G).
A—Pinion Shaft Retaining Pins

B—Long Pinion Shaft
C—Half Pinion Shaft
D—Hub
E—Conical Thrust Washers (4 used)
F—Pinion Gear with Needles and Needle Thrust
Washer (4 used)
G—Tanged Needle Thrust Washer (4 used) –UN–18FEB97
RW36237

011504
PN=98
Remove differential lock bevel gear (A).
A—Differential Lock Bevel Gear
02
–UN–18FEB97
0250
45
RW36238
CED,OUOE002,1516 –19–19MAY98–8/30
Remove thrust washer (A).
A—Thrust Washer
–UN–18FEB97
RW36239
CED,OUOE002,1516 –19–19MAY98–9/30
Remove needle roller bearing (A) and needle bearing

thrust washer (B).
A—Needle Roller Bearing

B—Thrust Washer
–UN–02JAN97
RW36121

011504
PN=99
Remove differential lock piston (A) using a 2-3/4 in. driver

disk.
Inspect differential lock piston and replace as necessary.
A—Differential Lock Piston
–UN–31AUG98
02
0250
RW36129
46
CED,OUOE002,1516 –19–19MAY98–11/30
Remove and replace packing rings (A).
Install piston anti-rotation pin (B) into piston until a

minimum of 14.5 mm (0.570 in.) of pin protrudes.
If pin bottoms out during installation, a maximum of 15.5
–UN–02JAN97
mm (0.610 in.) may protrude.
A—Packing Ring (2 used)

B—Anti-Rotation Ring
RW36130
CED,OUOE002,1516 –19–19MAY98–12/30
Inspect differential tapered roller bearing cone (A) and

replace as necessary.

Remove cone using a hammer and drift at slots (B)

–UN–02JAN97
making sure that force is applied only against the bearing

race.

RW36131

Install differential bearing preload shims on case bottom A—Tapered Roller Bearing Cone
B—Slot
shoulder.

011504
PN=100
Install bearing cone (A) tight against shims.
Apply lubricant and install differential lock piston (B) in

bore making sure that anti-rotation pin (C) aligns with hole
(D) in case.
A—Bearing Cone
–UN–02JAN97
B—Differential Lock Piston
C—Piston Anti-Rotation Pin
D—Piston Anti-Rotation Hole in Case
02
RW36132
0250
47
CED,OUOE002,1516 –19–19MAY98–14/30
Apply oil to needle bearing thrust washer (B) and install.
Apply oil to needle roller bearing (A) and install.

B—Thrust Washer
–UN–02JAN97
RW36121
CED,OUOE002,1516 –19–19MAY98–15/30
IMPORTANT: Use extreme care when removing cup

and spacer to avoid damage to actuator
plate (C).
Remove bearing cup (A) and spacer ring (B).
Inspect bearing cup and replace as necessary.

–UN–05MAR97
A—Bearing Cup
B—Spacer Ring
C—Actuator Plate
RW36240

011504
PN=101
Remove actuator plate (A).
A—Actuator Plate
–UN–26FEB97
RW36260
02
0250
48 CED,OUOE002,1516 –19–19MAY98–17/30
Remove return springs, plates, and disks.
–UN–24FEB97
RW36261
CED,OUOE002,1516 –19–19MAY98–18/30
Inspect differential housing.
–UN–24FEB97
RW36262

011504
PN=102
Inspect separator plates and disks.
Specification
Clutch Disk—Thickness....................................... 2.92 mm (0.114 in.) new
Clutch Plate—Thickness ..................................... 3.05 mm (0.120 in.) new
–UN–18FEB97
02
RW36241
0250
49
CED,OUOE002,1516 –19–19MAY98–20/30
Inspect actuator plate (A) and springs (B).
Specification
Actuator Plate Return Spring
(New)—Free Length ................................. 65 mm (2.559 in.) approximate
Test Length............................................................. 55 mm at 225—275 N
(2.165 in. at 50—62 lb-force)
–UN–24FEB97
A—Actuator Plate
B—Spring (3 used)
RW36263
CED,OUOE002,1516 –19–19MAY98–21/30
Install thrust washer (A).
A—Thrust Washer
–UN–18FEB97
RW36239

011504
PN=103
Install differential lock bevel gear (A).
A—Differential Lock Bevel Gear
02
–UN–18FEB97
0250
50
RW36238
CED,OUOE002,1516 –19–19MAY98–23/30
Install parts (B—G).
Install pinion shaft retaining pins (A).

D—Hub
Washer (4 used)
G—Tanged Needle Thrust Washer (4 used)
–UN–18FEB97
RW36237

011504
PN=104
Install ring gear (B).
Install M16 x 2.6 H x 50 cap screws (C) with flat washers

directly across from each other.
Remove guide pins and install two more cap screws with
flat washers (C).
Alternately tighten the cap screws a small amount at a 02

time until the ring gear is correctly positioned on the 0250
–UN–24FEB97
51
housing.
Remove the two cap screws.
RW36264
Install pinion gear (D) and thrust washer (E).
Install housing cover and remove the guide pins.

A—Guide Pin (2 used)
B—Ring Gear
C—Temporary Cap Screws
D—Pinion Gear
E—Thrust Washer
CED,OUOE002,1516 –19–19MAY98–25/30
NOTE: The housing cover cap screws have pre-applied

LOCTITE on the threads. Use only the specified
cap screws.
Install and tighten cap screws (A).
Tighten cover-to-ring gear-to-housing cap screws.
Specification
Cover-to-Ring Gear-to-Housing
–UN–18FEB97
RW36233
LOCTITE is a trademark of Loctite Corp. Continued on next page CED,OUOE002,1516 –19–19MAY98–26/30

011504
PN=105
Install disks (A) and separator plates (B) alternately,

beginning with a disk against the housing.
A—Disk (7 used)
B—Separator Plate (6 used)
02
0250
52
–UN–08JAN97
RW36154
CED,OUOE002,1516 –19–19MAY98–27/30
Install return springs (A).
A—Return Spring (3 used)
–UN–24FEB97
RW36265
CED,OUOE002,1516 –19–19MAY98–28/30
Install actuator plate (A) into housing.
A—Actuator Plate
–UN–26FEB97
RW36260

011504
PN=106
Install spacer ring (A).
Install bearing cup (B) using correct driver disk.
Install differential. See Install Differential in Group 30.
A—Spacer Ring
–UN–24FEB97
B—Bearing Cup
02
RW36266
0250
53
CED,OUOE002,1516 –19–19MAY98–30/30

011504
PN=107
Standard Differential Cross-Sectional View
02
0250
54
–UN–18FEB97
RW36230
A—Bearing Cup E—Half Pinion Shaft (2 used) I—Bearing Cone N—Needle Roller (104 used)
B—Differential Housing Cover F—Differential Housing J—Bevel Side Gear O—Needle Thrust Washer (4
C—Thrust Washer G—Conical Thrust Washer (4 K—Pinion Shaft used)
D—Pinion Shaft Retaining Pin used) L—Hub
(3 used) H—Bevel Gear (4 used) M—Tanged Needle Thrust
Washer (4 used)
TX,02,111625 –19–21JUL97–1/1

011504
PN=108
Disassemble, Inspect, And Assemble

Standard Differential
Remove differential. See Remove Differential in this

group.
02
0250
CED,OUOE002,1517 –19–19MAY98–1/13 55
Inspect bearing cup (A) in case.

the cup. DO NOT lose or misplace.
Remove cup and shims if necessary.
–UN–08JAN97
Install shims in place and install new cup tight against
shims using correct driver disk.
RW36159
A—Bearing Cup
CED,OUOE002,1517 –19–19MAY98–2/13
Remove cover-to-housing cap screws (A).
–UN–18FEB97
RW36233

011504
PN=109
the cover (B).

B—Cover
–UN–18FEB97
02
0250
56
RW36234
CED,OUOE002,1517 –19–19MAY98–4/13


–UN–18FEB97
Install shims and heat cone and install on shims tight

against bottom surface.
RW36235
A—Bearing Cone

011504
PN=110
Install bearing cup tight against bottom surface.
A—Bearing Cup
–UN–24FEB97
02
0250
RW36259
57
CED,OUOE002,1517 –19–19MAY98–6/13
Inspect the ring gear (A) and replace as necessary.

all pinion shaft and differential
and pinion shaft.
Remove ring gear from housing by striking the underside
–UN–18FEB97
of the ring gear with a soft hammer.
Remove bevel pinion gear (B) and thrust washer (C).
RW36236
A—Ring Gear
B—Bevel Pinion Gear
C—Thrust Washer

011504
PN=111
Remove pinion shaft retaining pins (A).
Remove parts (B—G).

D—Hub
Washer (4 used)
02 G—Tanged Needle Thrust Washer (4 used)
0250
58
–UN–18FEB97
RW36237
CED,OUOE002,1517 –19–19MAY98–8/13
Remove differential bevel gear (A) and thrust washer.
A—Differential Bevel Gear and Thrust Washer
–UN–18FEB97
RW36238

011504
PN=112
Install thrust washer and bevel gear (A).
A—Thrust Washer and Bevel Gear
02
–UN–18FEB97
0250
59
RW36238
CED,OUOE002,1517 –19–19MAY98–10/13
Install parts (B—G).
Install pinion shaft retaining pins (A).

D—Hub
Washer (4 used)
G—Tanged Needle Thrust Washer (4 used)
–UN–18FEB97
RW36237

011504
PN=113

flat washers (C).
02 Alternately tighten the cap screws a small amount at a

0250 time until the ring gear is correctly positioned on the
–UN–24FEB97
60
housing.
RW36264
Install pinion gear (D) and thrust washer (E).

A—Guide Pin
B—Ring Gear
C—Temporary Cap Screw
D—Pinion Gear
E—Thrust Washer
CED,OUOE002,1517 –19–19MAY98–12/13

cap screws.
Specification
Cap Screw—Torque .................................................... 375 N•m (277 lb-ft) –UN–18FEB97

RW36233
LOCTITE is a trademark of Loctite Corp. CED,OUOE002,1517 –19–19MAY98–13/13

011504
PN=114
Limited Slip Differential Cross-Sectional View
02
0250
61
–19–24JAN97
T106224
CED,OUOE002,1518 –19–19MAY98–1/1

011504
PN=115
Disassemble And Inspect Limited Slip

Differential

CED,OUOE002,1519 –19–19MAY98–1/20
Inspect bearing cone (A) on differential assembly.
Remove bearing cone and replace as necessary.

02
0250
62 CAUTION: Heat parts in a bearing heater. Use a
Install bearing cone tight against bottom shoulder.
–UN–08JAN97
A—Bearing Cone
RW36160
CED,OUOE002,1519 –19–19MAY98–2/20
Inspect bearing cup (A) in case.

the cup. DO NOT lose or misplace.
Remove cup and shims if necessary.
–UN–08JAN97
Install shims and install new cup tight against shims using
RW36159
A—Bearing Cup

011504
PN=116
Remove cover to housing cap screws (A).
02
–UN–18FEB97
0250
63
RW36233
CED,OUOE002,1519 –19–19MAY98–4/20
the cover (B).

B—Cover
–UN–18FEB97
RW36234

011504
PN=117
NOTE: Tabbed washer may be located on top of bevel

side gear.
Remove tabbed thrust washer (A) from cover.
A—Thrust Washer
02
0250
–UN–18FEB97
64
RW36245
CED,OUOE002,1519 –19–19MAY98–6/20


–UN–18FEB97
Install shims and heat cone and install on shims tight

against bottom surface.
RW36235
A—Bearing Cone

011504
PN=118
Remove cup and replace as necessary.
Install bearing cup tight against bottom surface using

A—Bearing Cup
–UN–24FEB97
02
0250
RW36259
65
CED,OUOE002,1519 –19–19MAY98–8/20
NOTE: Tabbed thrust washer may come out with the

cover.
Remove tabbed thrust washer (A) and thrust spacer (B).
Inspect the thrust spacer (B) and replace as necessary.
Inspect the ring gear (C) and replace as necessary.

–UN–19FEB97
all input shaft and differential
RW36246
and pinion shaft.
Remove ring gear from housing by striking the underside

of the ring gear with a soft hammer. A—Thrust Washer
B—Thrust Spacer
C—Ring Gear

011504
PN=119
Remove friction pack (A), actuator housing (B), and bevel

side gear (C).
A—Friction Pack
B—Actuator Housing
C—Bevel Side Gear
–UN–07JAN97
02
RW36166
0250
66
CED,OUOE002,1519 –19–19MAY98–10/20
Separate bevel side gear (A), friction pack (B), and

actuator housing (C).
A—Bevel Side Gear

B—Friction Pack
C—Actuator Housing
–UN–07JAN97
RW36167
CED,OUOE002,1519 –19–19MAY98–11/20
Remove pinion gear and shaft assembly (A).
A—Pinion Gear and Shaft Assembly –UN–07JAN97

RW36168

011504
PN=120
Remove actuator housing (A) and bevel side gear (B).
A—Actuator Housing
B—Bevel Side Gear
–UN–07JAN97
RW36169
02
0250
CED,OUOE002,1519 –19–19MAY98–13/20 67
Remove friction pack (A) and tabbed thrust washer (B).
A—Friction Pack
B—Thrust Washer
–UN–07JAN97
RW36170
CED,OUOE002,1519 –19–19MAY98–14/20
Inspect friction pack separator plates (A) and disks (B).
A—Separator Plate
B—Disk
–UN–07JAN97
RW36171

011504
PN=121
Measure and make sure friction pack (A) thicknesses are

symmetrical within 0.10 mm (0.004 in.).
IMPORTANT: If replacement of friction packs is

required, follow the instructions for
Measure End Play Gap—New Friction
–UN–07JAN97
Packs.
Replace both friction packs if not symmetrical. (See

Measure End Play Gap in this group.)
RW36172
02
0250
68 A—Friction Pack (2 used)
CED,OUOE002,1519 –19–19MAY98–16/20
Inspect both actuator housings.
–UN–07JAN97
RW36173
CED,OUOE002,1519 –19–19MAY98–17/20
Inspect both bevel side gears.

–UN–10JAN97
RW36174

011504
PN=122
Inspect both tanged washers.
–UN–07JAN97
RW36175
02
0250
CED,OUOE002,1519 –19–19MAY98–19/20 69
Inspect bevel pinion gears and bevel pinion shafts.
–UN–07JAN97
RW36176
CED,OUOE002,1519 –19–19MAY98–20/20
Assemble Differential
Coat both sides of tanged thrust washer with clean oil and
install.
Install friction pack alternately, beginning with a separator

plate against the housing and tanged thrust washer.

011504
PN=123
Install actuator housing (A).
02
–UN–07JAN97
0250
70
RW36178
CED,OUOE002,1532 –19–19MAY98–2/6
Install bevel side gear (A).
A—Bevel Side Gear
–UN–09JAN97
RW36179

011504
PN=124
Coat gears and shafts (A) with clean oil and assemble
and install in place.
A—Gear and Shaft
–UN–07JAN97
02
RW36168
0250
71
CED,OUOE002,1532 –19–19MAY98–4/6
Install bevel side gear (A).
A—Bevel Side Gear
–UN–07JAN97
RW36180
CED,OUOE002,1532 –19–19MAY98–5/6
Install actuator housing (A).
Install friction pack alternately, beginning with a disk (B)

against the actuator housing.
–UN–07JAN97
B—Disk
RW36181
CED,OUOE002,1532 –19–19MAY98–6/6

011504
PN=125
Measure End Play Gap Limited Slip

Differential
Install the housing assembly in a press.

CED,OUOE002,1520 –19–19MAY98–1/4
Place a JDG873 Seal Driver (A) on the friction pack

separator plate.
02 Install a dial indicator with a magnetic base with the

0250
indicator tip resting on the face of the housing (B) next to
72
the separator plate tang.
Zero the dial indicator.
Apply 907 Kg (2000 lb) of force to the friction pack

assemblies.
–UN–07JAN97
A—JDG873 Seal Driver
B—Housing
RW36182

011504
PN=126
Move the dial indicator tip to the top of the separator tang
(A) and record the end play gap reading.
For OLD Friction Packs, begin with Step 1.
1. If the gap is less than 0.81 mm (0.032 in.), and if the

friction plates are acceptable, no replacement is
needed.
Specification
Friction Pack Wear Tolerance— 02
–UN–07JAN97
End Play ...................................................... 0.81 mm (0.032 in.) minimum 0250
73
If the gap measurement is greater than 0.81 mm (0.032
in.) or replacement is needed, replace the friction packs
RW36183
with size marked on housing and continue to Step 2.
For NEW Friction Packs, begin with Step 2.

A—Separator Tang
2. If the gap is 0.20—0.51 mm (0.008—0.020 in.), the
end play gap meets specifications. Proceed to Step 4.
Specification
Friction Pack Wear Tolerance—
End Play ............................................................................ 0.20—0.51 mm
(0.008—0.020 in.) new

in.) and THIN friction packs were installed, remove and
replace them with THICK friction packs and measure end
play gap.

in.) and THICK friction packs were installed, proceed to
Step 3.
3. Replace the spider shafts and/or both actuator

housings and install correct friction packs so that the
gap measurement is 0.20—0.51 mm (0.008—0.020 in.)
and proceed to Step 4.
Specification
Friction Pack Wear Tolerance—
End Play ............................................................................ 0.20—0.51 mm
(0.008—0.020 in.) new

011504
PN=127
4. If the friction packs were changed from the size

marked on the housing, replace the existing mark (B)
with the NEW friction pack size for future reference.
B—Friction Pack Existing Size
–UN–27AUG98
RW36184
02
0250
74 CED,OUOE002,1520 –19–19MAY98–4/4
Proceed With Differential Assembly

flat washers (C).
–UN–07JAN97
Alternately tighten the cap screws a small amount at a
time until the ring gear is correctly positioned on the
housing.
RW36185
A—Guide Pin (2 used)

B—Ring Gear
C—Cap Screw and Washer (2 used)

011504
PN=128
Install thrust spacer (B) and tabbed thrust washer (A).
A—Thrust Washer
B—Thrust Spacer
02
–UN–27FEB97
0250
75
RW36273
CED,OUOE002,1521 –19–19MAY98–2/3

cap screws.
Specification
–UN–18FEB97
RW36233
LOCTITE is a trademark of Loctite Corp. CED,OUOE002,1521 –19–19MAY98–3/3

011504
PN=129
Input Pinion Shaft Cross-Sectional View
02
0250
76
–UN–10JAN97
RW36227
A—Special Locking Nut F—Oil Seal J—Pinion Shaft Preload Shim M—Oil Deflector
B—Yoke G—Bearing Cone Pack N—Cone Point Shim Pack
C—Washer H—Bearing Cup K—Spacer O—Bearing Cup
D—Oil Ring I—Differential Case L—Input Pinion Shaft P—Bearing Cone
E—Dust Seal
TX,02,111659 –19–21JUL97–1/1

011504
PN=130
Remove Input Shaft
Rotate differential case to horizontal position.
02
0250
CED,OUOE002,1533 –19–19MAY98–1/8 77
Install JDG1090 Yoke Holding Tool (A).
Remove nut from shaft.
Remove yoke spacer, and O-ring from shaft.
–UN–08JAN97
RW36139
CED,OUOE002,1533 –19–19MAY98–2/8
Remove seal (A).
A—Seal
–UN–02JAN97
RW36140

011504
PN=131
Install JDG1093 Input Shaft Removal Tool (A) to the axle

support bracket.
Install a bottle jack (B) on the top of the input shaft (C).
Remove the input shaft from the case and the bearing
cone while supporting the shaft inside the case to prevent
shaft from falling.
Remove the tool and jack.

02
0250
78 A—JDG1093 Input Shaft Removal Tool
B—Bottle Jack
C—Input Shaft
–UN–10JAN97
RW36212
CED,OUOE002,1533 –19–19MAY98–4/8
Remove the bearing cone (A) from the case.
Remove shim pack (B) and spacer (C).
Inspect bearing and shaft for wear.
A—Bearing Cone
–UN–17APR97
B—Shim Pack
C—Spacer
RW36141

011504
PN=132
Remove bearing (A) from shaft, if necessary, using a

bearing splitter.
A—Bearing
02
0250
79
–UN–07JAN97
RW36187
CED,OUOE002,1533 –19–19MAY98–6/8
Remove inner bearing cup (A), shims (B), and outer

bearing cup (C).
A—Inner Bearing Cup

B—Shim
C—Outer Bearing Cup
–UN–02JAN97
RW36142

011504
PN=133
Inspect the shaft oil dam shield (A).
Remove the oil dam, if necessary, using correct driver

disk.
A—Oil Dam Shield
02
0250
80
–UN–10JAN97
RW36229
CED,OUOE002,1533 –19–19MAY98–8/8
Install Input Pinion Shaft


all input shaft and differential
and pinion shaft. Make sure the shaft
and ring gear teeth are coated with
clean oil.
–UN–07JAN97
Heat bearing cone (A) to 150°C (300°F) and install on

shaft.
A—Bearing
RW36187

011504
PN=134
Install outer bearing cup (B) to bottom of bore using small

driver disk from JDG1155 Bearing Installer Set.
IMPORTANT: Make the following adjustments when

replacing any of the bearing cups,
bearing cones, ring gear, input pinion
shaft, or differential case.
Adjustments to be made:
• Cone Point 02
• Pinion Shaft Preload 0250
81
• Differential Preload
• Differential Backlash
–UN–09JAN97
• Tooth Contact Pattern
B—Outer Bearing Cup
RW36188
CED,OUOE002,1522 –19–19MAY98–2/2
Determine Differential Drive Shaft Cone Point

Shim Pack
NOTE: The constant dimension consists of the nominal

case dimension, (distance between centerline of
differential cross bores and the face of case
cover) and the nominal cover dimension, (distance
between the cover surface and the bearing cup
seat).
1. Record constant dimension:
• 257.80 mm (10.150 in.).

011504
PN=135
2. Record the bearing with cup width (A):
• 46.152 mm (1.817 in.)
3. Record the bearing growth dimension 0.04 mm (0.0016

in.) which allows for increased width of bearing when
–UN–10JAN00
cup is pressed into housing/cover.
A—Bearing Dimension
RW13192
02
0250
82 CED,OUOE002,1523 –19–19MAY98–2/3
4. Record the metric dimension (A) etched or stamped on

the pinion end of the spiral bevel shaft.
5. Subtract dimensions from Step 2, 3, and 4 from

constant dimension in Step 1. The result is the correct
shim pack thickness.
–UN–10JUL97
EXAMPLE
Step 1 217.560 mm Constant Dimension
Step 2 - 30.264 mm Bearing Width
RW36189A
Step 3 - 0.040 mm Bearing Growth Dimension
Step 4 - 186.470 mm Dimension on Shaft
Step 5 = 0.786 mm Shim Pack Thickness

A—Metric Dimension
NOTE: Shims must always be measured individually due
to slight variations in thickness. Never measure an
entire shim pack.
CED,OUOE002,1523 –19–19MAY98–3/3
Assemble Input Drive
Measure each shim separately to equal the shim pack

required.
Clean the OD of the differential drive shaft oil dam shield

–UN–31OCT88
and the adjoining surface.

T77781

011504
PN=136
NOTE: Install shield (A) as illustrated, with rough edge

(B) facing inward.
Install shield into the counterbore behind the pinion end

bearing bore.
A—Shield
B—Rough Edge
02
0250
83
–UN–09JAN97
RW36143
CED,OUOE002,1524 –19–19MAY98–2/3
Install the shim pack (A) previously calculated.
Install the inner bearing cup (B) using correct bearing

installer set.
Install cup tight against the shims.
A—Shim Pack
B—Inner Bearing Cup
–UN–09JAN97
RW36190
CED,OUOE002,1524 –19–19MAY98–3/3

011504
PN=137
Adjust Input Pinion Shaft
IMPORTANT: Make input pinion shaft adjustment with

shaft in vertical position (pinion end
down). Oil seals must not be installed
on assembly. Front bearing cone spacer
and shims must not be installed.
NOTE: Cone point adjustment must be done before input

pinion shaft adjustment.
02
0250 Obtain and use an R48776 nut during adjustment
84
procedure. USE the specified locking nut at final
tightening.
1. Install yoke, washer, and R48776 nut.
TX,02,111669 –19–30JUN98–1/6
2. Install JDG1090 Yoke Holding Tool (A). Tighten nut.

Rotate the shaft several times in both directions to seat
and roll-in the bearings. Tighten nut again.
Specification
Input Pinion Shaft Nut—Torque .................................. 604 N•m (445 lb-ft)
–UN–08JAN97
RW36139
Continued on next page TX,02,111669 –19–30JUN98–2/6

011504
PN=138
3. Remove nut and yoke. Press shaft (C) out of housing

using JDG1093 Input Shaft Removal Tool (A) and a
bottle jack (B).
A—JDG1093 Input Shaft Removal Tool

B—Bottle Jack
C—Shaft
02
0250
85
–UN–10JAN97
RW36212
TX,02,111669 –19–30JUN98–3/6
4. Install bevel pinion shaft (A) through case.
5. Hold the shaft in position using a bottle jack under the

pinion shaft.
IMPORTANT: Install spacer (C) first with ID chamfer
–UN–07JAN97
facing away from shims and then
shims.
NOTE: Newer spacers (C) have a chamfer on both sides.
RW36213
Older spacers have a chamfer on one side only.
Suggested shim pack of 1.50 mm (0.059 in.) plus

spacer. The suggested shim pack is OVERSIZE A—Bevel Pinion Shaft
to provide enough end play so that a B—Shim Pack
C—Spacer
measurement may be taken.
6. Install 1.50 mm (0.059 in.) shim pack (B) with spacer

against spiral bevel shaft shoulder to provide end play.
7. Install outer bearing cone onto the shaft.

011504
PN=139
8. Install JDG1093 Input Shaft Removal Tool (A) to axle

support bracket.
9. With the bottle jack inside the differential case holding

the pinion shaft in position press outer bearing cone
onto spiral bevel shaft using a second bottle jack (B)
and JDG926 Bearing Installer (C).
10. Remove both bottle jacks.
02 11. Rotate the pinion shaft several times in both

0250 directions to roll-in the bearings.
86
12. Repeat Steps 1 and 2.
–UN–10JAN97
13. Loosen nut to less than 272 N•m (200 lb-ft) and then
tighten.
Specification
Input Shaft Retaining Nut—
RW36214
Torque ......................................................................... 360 N•m (267 lb-ft)
14. Rotate the pinion shaft several times in both

directions. A—JDG1093 Input Shaft Removal Tool
B—Bottle Jack
C—JDG926 Bearing Installer

011504
PN=140
15. Install a dial indicator with magnetic base (A) with the
pointer against the end of the shaft.
16. Measure the end play using pry bars (B) to apply an
upward pressure.
17. Remove pinion shaft and remove the correct

thickness of shims to obtain the specified preload.
Specification
–UN–19JUN97
Pinion Shaft Pins—Preload ........................................... 0.013—0.089 mm 02
(0.0005—0.0035 in.) 0250
87
18. Install bevel pinion shaft, spacer, and shim pack.
RW36507
19. Install bearing cone onto shaft.
20. Remove tools, yoke, and R48776 Nut.
A—Dial Indicator
B—Pry Bar (2 used)
TX,02,111669 –19–30JUN98–6/6
Continue Input Shaft Installation
Apply TY16021 Form-in-Place Gasket to the OD of the oil

seal. Apply oil on sealing lips of yoke seal. With spring
side (A) of seal facing away from driver install seal flush
with adjoining housing surface using correct seal installer
–UN–14NOV97
(B), with JDG926 Bearing Installer (C).
A—Spring Side
B—Seal Installer
RW35960
C—JDG926 Bearing Installer
–UN–07JAN97
RW36216

011504
PN=141
IMPORTANT: DO NOT apply oil to the seal or the

yoke recess.
Install the dust seal (A) into the yoke recess.
A—Dust Seal
02
–UN–09JAN97
0250
88
RW36191
CED,OUOE002,1525 –19–19MAY98–2/4
Install yoke (A).
NOTE: Be sure no part of the oil ring is out of the

chamfer on the yoke.
Install the oil ring (B).
Install washer (C).
Apply PT506 NEVER-SEEZ lubricant to the shaft

threads.
–UN–10JAN97
IMPORTANT: Install special locking nut by hand.
Install special locking nut (D) by hand until the locking
RW36217
member engages at least one thread on shaft.
A—Yoke
B—Oil Ring
C—Washer
D—Special Locking Nut
NEVER-SEEZ is a trademark of Emhart Chemical Group. Continued on next page CED,OUOE002,1525 –19–19MAY98–3/4

011504
PN=142
Tighten nut.
Specification
Special Locking Nut—Torque...................................... 360 N•m (267 lb-ft)
Remove tools.

02
A—JDG1090 Yoke Holding Tool 0250
89
–UN–08JAN97
RW36139
CED,OUOE002,1525 –19–19MAY98–4/4

011504
PN=143
Axle Disconnect Input Shaft Cross-Sectional View
02
0250
90
–UN–17MAR97
RW36308
A—Disconnect Input Shaft H—Collar Assembly N—Nut T—Needle Roller Bearing (2
B—Nut Anti-Rotation Plug O—Spacer Washer used)
C—Spacer Washer I—Collar Assembly Housing P—Piston Assembly Packing U—Collar
D—Input Yoke J—Piston Housing Ring (2 used) V—Input Shaft Bearing Set
E—Disconnect Housing K—Housing-to-Differential Q—Piston Packing Ring (4 W—Input Shaft Seal
F—Collar Engagement Spring Case Sealing Ring used) X—Dust Seal
(4 used) L—Disconnect Auxiliary Yoke R—Piston (4 used) Y—Oil Ring
G—Collar Assembly Spring M—Differential Drive Shaft S—Needle Bearing Thrust
Retainer Plate Washer
TX,02,111673 –19–21JUL97–1/1

011504
PN=144
Remove And Install Disconnect Axle

Disconnect Input Shaft
NOTE: Axle assembly is removed from vehicle.
Loosen retaining cap screw (A).
Install JDG1125 Lifting Screw (B) and JDG19 Lifting

Bracket (C) and attach to an overhead hoist.
Remove the disconnect assembly from the axle assembly. 02

0250
91
Install in reverse order.
–UN–17MAR97
Install disconnect assembly onto differential case quill until
a positive stop is achieved.
Tighten the retaining cap screw.
RW36289
Specification
Disconnect-to-Differential Case
Cap Screw—Torque .................................................... 310 N•m (230 lb-ft) A—Cap Screw
B—JDG1125 Lifting Screw
C—JDG19 Lifting Bracket
TX,02,111675 –19–21JUL97–1/1
Disassemble, Inspect, And Assemble Axle

Disconnect Input Shaft
Remove disconnect assembly from axle assembly. (See

Remove and Install Disconnect in this group.)
–UN–17MAR97
Inspect disconnect auxiliary yoke (A) on differential drive
shaft and remove and replace as necessary.
Install JDG1142 Spanner Wrench and remove nut (B).
Remove spacer washer and disconnect auxiliary yoke RW36290

from differential drive shaft.
A—Auxiliary Yoke
B—Nut
Install in reverse order.
Tighten nut.
Specification
Disconnect Input Shaft Retaining
Nut—Torque ................................................................ 360 N•m (267 lb-ft)

011504
PN=145
Install JDG1090 Yoke Holding Tool (A) to input shaft

yoke.
Remove nut and spacer from shaft.
Remove yoke and oil ring from shaft.
–UN–17MAR97
RW36291
02
0250
92 CED,OUOE002,1526 –19–19MAY98–2/25
Remove input shaft seal (A).
A—Input Shaft Seal
–UN–17MAR97
RW36292
CED,OUOE002,1526 –19–19MAY98–3/25
Remove housing-to-differential case sealing ring (A).
A—Sealing Ring
–UN–17MAR97
RW36293

011504
PN=146
Install disconnect assembly in a press and place correct

driver disk and handle (A) on top of the piston housing.
Force the piston downward and remove snap ring (B).
–UN–17MAR97
A—Driver Disk and Handle
B—Snap Ring
RW36294
02
0250
CED,OUOE002,1526 –19–19MAY98–5/25 93
Remove piston housing assembly (A) using a 3-jaw puller

and a slide hammer.
A—Piston Housing Assembly
–UN–17MAR97
RW36295
CED,OUOE002,1526 –19–19MAY98–6/25
Remove pistons from housing by tapping the backside of

the housing with a hammer.
Inspect housing (A), pistons (B), and packing rings (C).
Replace parts as necessary.
Install pistons with packing rings into the piston housing.

–UN–17MAR97
A—Housing
B—Piston (4 used)
C—Packing Ring (4 used)
RW36296

011504
PN=147
Remove piston packing rings (A).
Remove collar assembly anti-rotation plug (B).
Remove collar assembly (C) from disconnect assembly.
A—Piston Packing Ring (2 used)

B—Plug
C—Collar Assembly
02
0250
94
–UN–17MAR97
RW36297
CED,OUOE002,1526 –19–19MAY98–8/25
Remove the collar assembly spring return plate (A) from

the collar assembly housing.
A—Spring Return Plate
–UN–17MAR97
RW36298

011504
PN=148
Remove parts (A—C) from housing (D).
Inspect parts and replace as necessary.
Assemble in reverse order.
–UN–17MAR97
B—Shift Collar
C—Needle Roller Bearing Thrust Washer
RW36299
D—Collar Assembly Housing
E—Collar Assembly Spring Retainer Plate 02
0250
95
CED,OUOE002,1526 –19–19MAY98–10/25
Remove collar engagement springs (A) from housing.
Inspect springs.
Specification
Collar Engagement Spring—Free
Length ..................................................... 73 mm (2.874 in.) approximate
Test Length........................................................ 44.45 mm at 352—431 N
(1.750 in. at 78—96 lb-force)
A—Collar Engagement Spring (4 used)
–UN–17MAR97
RW36300

011504
PN=149
Place the disconnect assembly in a press.
Remove the input shaft (A) from the housing and outer
bearing cone while supporting the shaft inside the case to
prevent shaft from falling.
A—Input Shaft
–UN–17MAR97
02
0250
96
RW36301
CED,OUOE002,1526 –19–19MAY98–12/25
Remove outer bearing cone (A) from housing.
A—Outer Bearing Cone
–UN–17MAR97
RW36302

011504
PN=150
NOTE: The input shaft bearings are supplied as a

matched set. When replacement is required,
replace all parts.
Inspect and if necessary remove inner and outer bearing

cups (A) from housing (B).
Inspect bearing cup spacer snap ring (C) and remove if

necessary.
Install new bearing cup spacer snap ring in housing. 02
–UN–17MAR97
0250
97
Install new bearing cups in housing using correct driver
disk and a press.
RW36303
A—Inner and Outer Bearing Cup
B—Housing
C—Snap Ring
CED,OUOE002,1526 –19–19MAY98–14/25
Inspect disconnect input shaft (A), inner bearing cone (B),

and bearing spacer (C) and replace as necessary.
If necessary, remove bearing spacer (C) from shaft and

remove inner bearing (B) using a knife-edge puller and a
press.
–UN–17MAR97
RW36304
Heat bearing cone to 150° C (300° F) and install on shaft.

A—Input Shaft
B—Inner Bearing Cone
C—Bearing Spacer

011504
PN=151
NOTE: JDG1141-1 Centering Tool is part of the JDG1141

Bearing Installer Set.
Install the disconnect housing in a press using JDG1141-1

Centering Tool (A) to support the input shaft (B) that is
installed through the housing.
A—JDG1141-1 Centering Tool

B—Input Shaft
02
0250
98
–UN–11APR97
RW36310
CED,OUOE002,1526 –19–19MAY98–16/25
NOTE: JDG1141-2 Driver is part of the JDG1141 Bearing

Installer Set.
Install the outer bearing cone (A) onto the shaft using
JDG1141-2 Driver (B).
A—Outer Bearing Cone

–UN–17MAR97
B—JDG1141-2 Driver
RW36305

011504
PN=152
Install collar engagement springs (A) into disconnect

housing.
A—Collar Engagement Spring (4 used)
02
0250
99
–UN–17MAR97
RW36300
CED,OUOE002,1526 –19–19MAY98–18/25
Install collar assembly (C) into housing aligning the

anti-rotation slot in the collar assembly housing with the
opening in disconnect housing for the anti-rotation plug.
Install anti-rotation plug (B).
Install piston packing rings (A).
Apply oil to the piston packing rings.
A—Piston Packing Ring (2 used)

B—Anti-Rotation Plug
C—Collar Assembly
–UN–17MAR97
RW36297

011504
PN=153
Install piston assembly (A) and snap ring (C) in housing.
Place correct driver disk and handle (B) on top of the

snap ring.
Force the snap ring and piston downward using a shop
–UN–17MAR97
press.
A—Piston Assembly
B—Driver Disk and Handle
RW36306
02 C—Snap Ring
0250
,100
CED,OUOE002,1526 –19–19MAY98–20/25
NOTE: Make sure snap ring seats in first groove.
Install housing-to-differential case sealing ring (A).
A—Sealing Ring
–UN–17MAR97
RW36293

011504
PN=154
Install input shaft seal (A) using correct seal installer along
with JDG926 Bearing Installer.
A—Input Shaft Seal
–UN–17MAR97
02
0250
,101
RW36292
CED,OUOE002,1526 –19–19MAY98–22/25
IMPORTANT: DO NOT apply oil to the seal or the

yoke recess.
Install the dust seal (A) into the yoke recess.
Install yoke onto the shaft.
A—Dust Seal
–UN–09JAN97
RW36191

011504
PN=155
NOTE: Be sure no part of the oil ring is out of the

chamfer on the yoke.
Install oil ring (A) and spacer washer.
Apply PT506 NEVER-SEEZ lubricant to the shaft
–UN–17MAR97
threads.
IMPORTANT: Install special locking nut by hand.
RW36307
02 Install special locking nut by hand until the locking
0250 member engages at least one thread on shaft.
,102
A—Oil Ring
NEVER-SEEZ is a trademark of Emhart Chemical Group CED,OUOE002,1526 –19–19MAY98–24/25
Tighten yoke retaining nut.
Specification
Auxiliary Yoke-to-Drive Shaft
–UN–17MAR97
Remove tool.
RW36291
Install disconnect assembly to axle assembly.
CED,OUOE002,1526 –19–19MAY98–25/25

011504
PN=156
Group 0260
Hydraulic System
Remove And Install Differential Lock
Solenoid Valve
1. Operate controls to release hydraulic pressure.
2. Disconnect electrical connector.
–UN–12JUN98
3. Remove differential lock solenoid (A).
4. Remove parts (C—E).
T115517
02
0260
5. Remove parts (F—K). Plug opening to prevent dirt
1
from entering manifold.
6. Inspect for dirty, worn or damaged parts. Check that

spool inside solenoid valve moves freely. If spool does
not move freely or if valve looks worn or damaged,
replace complete solenoid assembly.
–UN–09NOV92
7. Install solenoid valve using new O-rings and backup
rings.
8. Install parts (C—K). Tighten nut (C).
T7751LI
Specification
Differential Lock Solenoid Nut—
Torque ............................................................................... 7 N•m (62 lb-in) A—Differential Lock Solenoid
C—Nut
D—Washer
9. Connect electrical connector. E—Coil
F—Solenoid Valve
G—O-Ring
H—Backup Ring
I—O-Ring
J—O-Ring
K—Backup Ring
CED,OUOE002,1535 –19–20MAY98–1/1

011504
PN=157
Hydraulic System
02
0260
2

011504
PN=158
Section 03
Transmission
Contents
Page Page
Group 0300—Removal And Installation Converter Relief Valve

Transmission Remove, Disassemble and Install . . . . . .03-0360-19
Remove and Install . . . . . . . . . . . . . . . . . .03-0300-1 Replace Oil Pipes And Tubes . . . . . . . . . . .03-0360-21

Group 0350—Gears, Shafts, Bearings And Power
DFT1149 Pre-Load Clutch Pack Compression
Shift Clutch
Ring Tool . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-1 03
Torque Converter
DFT1063 Lifting Bracket . . . . . . . . . . . . . . . .03-0399-2
Remove (Engine Removed). . . . . . . . . . . .03-0350-1
DFT1158 Torque Converter Adapter
Install (Engine Removed). . . . . . . . . . . . . .03-0350-3
Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-3
Torque Converter and Housing
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-6
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-8
Clutches, Input and Output Shafts
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-11
Clutches, Output and Input Shafts
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-18
Clutch Pack KV and KR
Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-26
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-29
Clutch Pack K1, K2 and K3
Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-36
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-39
Clutch Pack K4
Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-48
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-49
Input Shaft
Dissasemble . . . . . . . . . . . . . . . . . . . . . .03-0350-56
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-57

Transmission Pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-1
Converter Minimum Pressure Regulator
Valve
Transmission Pump
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-4
Hydraulic Control Valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-6
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-7
Cross Section View . . . . . . . . . . . . . . . . . .03-0360-9
Transmission Control Valve
Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0360-10
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-13

011504
PN=1
Contents
03

011504
PN=2
Group 0300
Remove And Install Transmission
1. Remove ROPS or cab. (See procedure in Group

1800.)
2. Drain hydraulic reservoir. Collect oil in clean container

for reuse. Approximate capacity is 117 L (31 gal).
Specification
Hydraulic Reservoir with Filters—
Capacity .......................................................... 117 L (31 gal) approximate
CED,OUOE002,1540 –19–20MAY98–1/6
3. Disconnect transmission drive shafts (A—C).

03
0300
A—Engine-to-Transmission Drive Shaft
1
B—Transmission-to-Rear Axle Drive Shaft
C—Transmission-to-Front Axle Drive Shaft
–UN–10MAR97
T107803

011504
PN=161
NOTE: Tag and cap all lines for identification and to

prevent contamination.
4. Remove transmission filter hoses (F and E) from

transmission.
5. Drain transmission. Collect oil in container and dispose

of properly. Approximate capacity is 27 L (29 qt).
Specification
Transmission—Capacity ..................................... 27 L (29 qt) approximate
6. Remove dipstick tube (C).
7. Remove and cap park brake hoses (G and D).
03 8. Remove cooler hoses (A and B).

0300
2
A—Converter In Hose from Cooler
B—Converter Out Hose to Cooler
C—Dipstick Tube
–UN–24NOV97
D—Return Hose from Park Brake to Transmission
E—Return from Filter to Transmission Hose
F—Hose to Oil Filter from Transmission
G—Hose to Park Brake from Transmission
T112003

011504
PN=162
9. Remove hose (E) going to the control valve and case

drain return hose (D) to manifold from the hydraulic
pump.
10. Remove load sense hose (A) from hydraulic pump.
11. Remove suction hose (B) at reservoir and hydraulic

pump inlet hose (C).
12. Remove pressure reducing valve hose (G) and

steering hose (F) from hydraulic pump.
A—Load Sense Hose

B—Suction Hose
C—Pump Inlet Hose
D—Case Drain Hose
E—Pressure-to-Control Valve Hose 03
F—Pressure-to-Steering Valve Hose 0300
G—Hose to Pressure Reducing Valve 3
–UN–12JUN98
T115526

011504
PN=163
03
0300
4
–UN–12JUN98
T115527
A—Transmission Isolator Cap B—Transmission Mounting C—Transmission Mounting D—Transmission Isolator Cap
Screw (Rear) Bracket-to-Transmission Bracket-to-Transmission Screw (Front)
Cap Screw (Rear) Cap Screw (Front)
16. Carefully remove transmission and place in repair

CAUTION: Use hoist to lift transmission. The
stand using JDG1129 Transmission Mounting
approximate weight of transmission is 557
Bracket.
kg (1227 lb) with hydraulic pump installed.
Specification 17. Remove hydraulic pump from transmission.

Transmission with Hydraulic
Pump—Weight ...................................... 557 kg (1227 lb) approximate 18. After transmission repair, install hydraulic pump on
transmission before installing transmission in
13. Install hoist on transmission lifting brackets and machine. Inspect hydraulic pump-to-transmission
support transmission. O-ring before installing pump.
14. Remove isolator cap screws (A and D). 19. Install transmission in machine.
15. Remove transmission front mount cap screws (C) 20. Connect all hoses and lines to transmission and
and remove mounts from transmission. hydraulic pump.
NOTE: Rear transmission mount does not have to be

removed from transmission.

011504
PN=164
21. Fill transmission and hydraulic reservoir to Transmission Mounting

specifications. Bracket-to-Transmission Cap
Screw (Front)—Torque ......................................... 433 N•m (320 lb-ft)
Transmission Mounting
Specification Bracket-to-Transmission Cap
Hydraulic Reservoir with Screw (Rear)—Torque.......................................... 318 N•m (235 lb-ft)
Filters—Capacity...................................... 117 L (31 gal) approximate
Output Drive Shaft Universal
Transmission—Capacity .............................. 27 L (29 qt) approximate
Joint Cap Screw—Torque ........................................ 78 N•m (58 lb-ft)
Input Drive Shaft Universal
NOTE: Do NOT reuse drive shaft cap screws, replace Joint Cap Screw—Torque ........................................ 78 N•m (58 lb-ft)
with new when removed. Engine-to-Transmission Shaft
Universal Joint Cap Screw—
Torque....................................................................... 78 N•m (58 lb-ft)
22. Install transmission drive shafts using new cap
screws.
23. Install ROPS or cab. (See procedure in Group
Specification 1800.)
Transmission Isolator Cap
03
0300
5
CED,OUOE002,1540 –19–20MAY98–6/6

011504
PN=165
03
0300
6

011504
PN=166
Group 0350
Gears, Shafts, Bearings And Power Shift Clutch
Remove Torque Converter (Engine Removed)
1. Stop engine. Lower boom and bucket to ground.
2. Remove battery negative ground strap or turn battery

disconnect switch “Off”, if equipped.
3. Remove engine. (See procedure in Group 0400).
4. Remove transmission bottom guard, if equipped.
5. Jack up and support transmission.
03
0350
1
CED,OUOE002,1541 –19–20MAY98–1/9
6. Remove transmission bracket cap screws. Remove

bracket (A).
A—Transmission Mounting Bracket
–UN–12JUN98
T115533
CED,OUOE002,1541 –19–20MAY98–2/9
7. Remove ten torque converter housing cap screws and

nuts (A). Leave in two cap screws. Place a mark on
cover and housing for ease of assembly and proper
alignment.
–UN–12JUN98
CAUTION: Component weighs more than 23 kg

(50 lb). Use hoist to remove.
8. Install DFT1063 Lifting Bracket.

T115534
9. Remove two cap screws. Remove torque converter

housing and converter as an assembly.
A—Cap Screw and Nut (10 used)

011504
PN=167
10. Remove lock plate and hex head screws from input
flange washer.
11. Remove washer and pry input flange from the shaft
seal.
–UN–17APR97
T108721
CED,OUOE002,1541 –19–20MAY98–4/9
12. Press input shaft with converter out of the housing.

03
0350
2
–UN–17APR97
T108724
CED,OUOE002,1541 –19–20MAY98–5/9
13. Remove snap ring and remove bearing from housing.
–UN–17APR97
T108717
CED,OUOE002,1541 –19–20MAY98–6/9
14. Remove hex head screws and separate drive plate

from converter.
–UN–05DEC97
T112416

011504
PN=168
15. Remove hex head screws and separate input shaft

from drive plate.
–UN–05DEC97
T112415
CED,OUOE002,1541 –19–20MAY98–8/9
16. Remove speed sensor (A) from converter housing.

03
17. Remove cap screws (B) and remove converter 0350
housing, if necessary. 3
–UN–12JUN98
A—Speed Sensor
B—Cap Screw (17 used)
T115535
CED,OUOE002,1541 –19–20MAY98–9/9
Install Torque Converter (Engine Removed)
1. Fasten converter housing using cap screws (B), if

removed.
–UN–12JUN98
A—Speed Sensor
T115535
CED,OUOE002,1542 –19–27JUL98–1/8
2. Fasten input shaft to plate with hex head screws and

tighten.
Specification
Input Shaft-to-Drive Plate
(M12/10.9) Hex Head Screw—
Torque ........................................................................... 115 N•m (85 lb-ft)
–UN–05DEC97
T112415
Continued on next page CED,OUOE002,1542 –19–27JUL98–2/8

011504
PN=169
3. Install input shaft plate assembly to converter using

hex head screws and flat washers.
Apply T43513 thread lock and sealer (high strength) to

screws and tighten.
–UN–05DEC97
Specification
Input Shaft Plate
Assembly-to-Converter
Torque ........................................................................... 115 N•m (85 lb-ft)
T112416
CED,OUOE002,1542 –19–27JUL98–3/8
4. Insert ball bearing until contact is obtained in bore and

03 install snap ring.
0350
4
–UN–15APR97
T109099
CED,OUOE002,1542 –19–27JUL98–4/8
5. Assemble converter in housing cover.
Install input flange, washer and draw cover down with

hex head screws evenly against shoulder.
NOTE: Line up alignment marks on housings that were
–UN–15APR97
made while disassembling for proper assembly.
T109100
Shown Removed For Clarity

011504
PN=170
6. Install converter and cover until contact is made.
NOTE: Speed pickup disk in the converter must be

centered to the bore of the speed sensor. This
insures that the converter is seated properly.
–UN–12JUN98
A—Cap Screw and Nut (10 used)
T115534
CED,OUOE002,1542 –19–27JUL98–6/8
7. Install cover with hex head screws and nuts on the

converter housing. Tighten. 03
0350
Specification 5
Torque Converter Top Cover Hex
Head Screw—Torque ...................................................... 46 N•m (34 lb-ft)
–UN–15APR97
T109101
Shown Removed For Clarity
CED,OUOE002,1542 –19–27JUL98–7/8
8. Fasten input flange with hex head screws and tighten.
Specification
Input and Output Flange-to-Drive
Plate Hex Head Screw—Torque ..................................... 34 N•m (25 lb-ft)
–UN–02MAY97
Install locking plate using hammer and two deep well

sockets (A) taped together with a hex nut between them
for proper spread.
T109147B
9. Install speed sensor in converter housing.
A—Deep Well Socket (2 used) Output Flange Shown
CED,OUOE002,1542 –19–27JUL98–8/8

011504
PN=171
Remove Torque Converter And Housing
CAUTION: Approximate weight of transmission

is 504 kg (1110 lb).
–UN–19DEC97
Specification
Transmission—Weight................................. 504 kg (1110 lb) approximate
NOTE: Earlier JDG1129 Transmission Mounting Brackets

require the right side bracket revised. Note
T112589
bracket sketch showing revised mounting hole (A).
Revise hole by elongating the existing hole as
Bracket Sketch Showing Revised Mounting Hole (A)
required.
A—Mounting Hole
1. Install transmission in repair stand using JDG1129
03 Mounting Brackets (A).
0350
6
A—JDG1129 Mounting Bracket (2 used)
–UN–26JAN98
T109146B
CED,OUOE002,1543 –19–20MAY98–1/10
2. Remove lock plate and hex head screws from input

flange washer.
3. Remove washer and pry input flange from the shaft.
–UN–17APR97
T108721
CED,OUOE002,1543 –19–20MAY98–2/10
4. Remove torque converter housing cap screws.
NOTE: Place a mark on the cover and housing for ease

of assembly and proper alignment later.
–UN–17APR97
T108722

011504
PN=172
CAUTION: Component weighs more than 23 kg

(50 lb). Use hoist to remove.
5. Separate torque converter with cover from gearbox,

using a hoist and eye bolt.
–UN–17APR97
T108723
CED,OUOE002,1543 –19–20MAY98–4/10
6. Press input shaft with converter out of the housing.

03
0350
7
–UN–17APR97
T108724
CED,OUOE002,1543 –19–20MAY98–5/10
7. Remove snap ring and remove bearing from housing.
–UN–17APR97
T108717
CED,OUOE002,1543 –19–20MAY98–6/10
8. Remove hex head screws and separate drive plate

from converter.
–UN–05DEC97
T112416

011504
PN=173
9. Remove hex head screws and separate input shaft

from drive plate.
–UN–05DEC97
T112415
CED,OUOE002,1543 –19–20MAY98–8/10
10. Remove speed sensor from converter housing.

03
0350
8
–UN–17APR97
T108720
CED,OUOE002,1543 –19–20MAY98–9/10
11. Remove hex head screws and remove converter

lower housing.
–UN–17APR97
T108729
CED,OUOE002,1543 –19–20MAY98–10/10
Install Torque Converter And Housing
1. Fasten converter housing using hex head screws.

Tighten screws.
Specification
–UN–15APR97
Converter Housing (M10/10.9)

Hex Head Screw—Torque .............................................. 68 N•m (50 lb-ft)
T109095
Continued on next page TX,0350,RB228 –19–20MAY98–1/8

011504
PN=174
2. Fasten input shaft to plate with hex head screws and

tighten.
Specification
Input Shaft-to-Drive Plate
Torque ........................................................................... 115 N•m (85 lb-ft)
–UN–05DEC97
T112415
TX,0350,RB228 –19–20MAY98–2/8
3. Install input shaft plate assembly to converter, using

hex head screws and flat washers. 03
0350
Apply T43513 thread lock and sealer (high strength) to 9
cap screws and tighten.
–UN–05DEC97
Specification
Input Shaft Drive Plate-to-Torque
Converter Cap Screw—Torque ..................................... 115 N•m (85 lb-ft)
T112416
TX,0350,RB228 –19–20MAY98–3/8
4. Install converter in housing until contact is made
NOTE: Speed pickup disk in the converter must be

centered to the bore of the speed sensor. See art
with arrow showing. This insures that the
converter is seated properly.
–UN–05DEC97
T112417
–UN–30APR97
T109098

011504
PN=175
5. Insert ball bearing until contact is obtained in bore and

install snap ring.
–UN–15APR97
T109099
TX,0350,RB228 –19–20MAY98–5/8
6. Assemble housing.
03
0350 Install input flange, washer and draw cover down with
10 hex head screws evenly against shoulder.
NOTE: Line up alignment marks on housings that were
–UN–15APR97
made while disassembling for proper assembly.
T109100
TX,0350,RB228 –19–20MAY98–6/8
7. Install cover with hex head screws and nuts on the

converter housing. Tighten screws.
Specification
Torque Converter Top Cover Hex
Head Screw—Torque ...................................................... 46 N•m (34 lb-ft)
–UN–15APR97
T109101

011504
PN=176
8. Fasten input flange with hex head screws and tighten.
Specification
Input and Output Flange-to-Drive
Plate Hex Head Screw—Torque ..................................... 34 N•m (25 lb-ft)
–UN–02MAY97
Install locking plate using hammer and two deep well
sockets (A) taped together with a hex nut between them
for proper spread.
T109147B
A—Deep Well Socket (2 used)
Output Flange Shown
03
0350
11
TX,0350,RB228 –19–20MAY98–8/8
Remove Clutches, Input And Output Shafts
Remove lock plate, loosen hex head screws, and pry the
rear output flange from the shaft.
Now, pry shaft seal out of the housing bore.
–UN–18APR97
Turn gearbox 180° and remove front output flange in
same manner.
T108778
TX,0350,ME280 –19–20MAY98–1/19
Remove three sensors.
–UN–29APR97
T108779
Continued on next page TX,0350,ME280 –19–20MAY98–2/19

011504
PN=177
Loosen hex nuts and remove the two small manifold

covers (Arrows).
Remove cap screws from transmission cover.
–UN–29APR97
T108780
TX,0350,ME280 –19–20MAY98–3/19
Drive both dowel pins (one on each end of transmission

03 cover) down far enough to clear cover for removal of the
0350 cover.
12
–UN–29APR97
T108781
TX,0350,ME280 –19–20MAY98–4/19
Separate housing cover carefully from gearbox housing

using lifting device.
–UN–18APR97
T108774

011504
PN=178
Figure shows the proper position of the single clutches as

well as of the input and output.
KV—Low Range Forward Clutch

KR—Reverse Clutch
K1—First Speed Clutch
–UN–29APR97
K2—Second Speed Clutch
K3—Third Speed Clutch
K4—High Range Forward Clutch
AN—Input
AB—Output
T108775
03
0350
13
TX,0350,ME280 –19–20MAY98–6/19
NOTE: For the removal of clutches, the output shaft must

be removed first.
Loosen socket head screws from covers and remove

output shaft with covers.
–UN–18APR97
IMPORTANT: Remove sealing rings from clutch pack
shafts (cover side only) before installing
cover. Sealing rings may be damaged
while removing and installing clutch
T108776
packs later.
Place cover back on transmission until it contacts the

mounting surface so clutch packs can be removed from
housing for repair or inspection.

011504
PN=179
NOTE: Six 24H1300 flat washers and M10 hex nuts are
substituted for special handles shown in photo.
Install six (24H1300) flat washers (A) and six (M10) hex
nuts on end of clutch packs. This will hold packs in place
while mounting cover in roll over repair stand.
–UN–30APR97
NOTE: Transmission cover is used to properly remove
packs from transmission housing.
T108777
This method must be used to remove clutch pack from
transmission housing.
Special Handles Shown
A—24H1300 Flat Washers and (M10) Hex Nuts (6 A—Special Handle (6 used)
used)
03
0350
14
–UN–09MAY97
T109149B
TX,0350,ME280 –19–20MAY98–8/19
24H1300 And M10 Hardware Shown
Separate housing cover along with all clutch packs from

gearbox housing using lifting device.
–UN–18APR97
T108786

011504
PN=180
Remove transmission housing from repair stand.
Install transmission cover with packs into stand using

JDG1129 Mounting Brackets (A). Using shop hardware
(B) (cap screws, washers and nuts) fasten cover to
JDG1129 Mounting Brackets (A).
–UN–09MAY97
A—JDG1129 Mounting Bracket (2 used)
B—Cap Screw, Washer and Nut (4 used)
T109149C
03
0350
15
–UN–15DEC97
T112547B
TX,0350,ME280 –19–20MAY98–10/19
Turn cover in stand so clutch packs are facing up. This

will allow them to be removed from cover.
Remove six M10 nuts and six washers from clutch packs.
–UN–18APR97
T108788
TX,0350,ME280 –19–20MAY98–11/19
Clutch pack layout viewed from torque converter side of

transmission.

KR—Reverse Clutch
–UN–15DEC97

T112548B

011504
PN=181
CAUTION: Use special care while removing

clutch packs from cover due to closeness of
packs and spline engagement to each other.
Remove clutch K1 by slightly lifting up K4 and K3 with a
–UN–17DEC97
pry bar to allow clearance.
T112553B
TX,0350,ME280 –19–20MAY98–13/19
Remove clutch K2.

03
0350
16
–UN–17DEC97
T112554B
TX,0350,ME280 –19–20MAY98–14/19
Remove clutch K3.
–UN–18APR97
T108783
TX,0350,ME280 –19–20MAY98–15/19
Remove clutch K4. Lift input slightly at the same time.

–UN–18APR97
T108784

011504
PN=182
Separate clutches KV and KR together with input from the

housing cover.
–UN–18APR97
T108785
TX,0350,ME280 –19–20MAY98–17/19
Remove bearing outer race and pull output shaft out of

the housing bore. 03
0350
17
–UN–18APR97
T108790
TX,0350,ME280 –19–20MAY98–18/19
Squeeze the square snap ring out and separate ball

bearing from shaft.
–UN–29APR97
T108791
TX,0350,ME280 –19–20MAY98–19/19

011504
PN=183
Install Clutches, Input, And Output Shafts
NOTE: If bearings are reused, they must be assembled in

same bores.
Insert all bearing outer races into the housing cover until
contact is obtained.
–UN–30APR97
KR—Reverse Clutch
T109004
AN—Input
AB—Output
03
0350
18
CED,OUOE003,1009 –19–25JUN98–1/32
Insert clutch-KR, input shaft and clutch-KV into the

housing cover.

KR—Reverse Clutch
AN—Input
–UN–29APR97
T109005
CED,OUOE003,1009 –19–25JUN98–2/32
Install clutch-K4.

–UN–29APR97
T109006

011504
PN=184
Install clutch-K3.
–UN–09MAY97
T109007
CED,OUOE003,1009 –19–25JUN98–4/32
Position clutch-K2.
03
0350
19
–UN–17DEC97
T112554B
CED,OUOE003,1009 –19–25JUN98–5/32
Insert clutch-K1.
–UN–17DEC97
T112553B
CED,OUOE003,1009 –19–25JUN98–6/32
Figure on the right shows the installation position of the

single clutches in the housing cover.

KR—Reverse Clutch
–UN–29APR97

T109010

011504
PN=185
Retain all clutches using six M10 hex nuts and six
24H1300 flat washers.
–UN–09MAY97
T109011
CED,OUOE003,1009 –19–25JUN98–8/32
Install sealing rings (7 used) on clutch pack shafts.

03
0350 Grease sealing rings and align.
20
–UN–29APR97
T109012
CED,OUOE003,1009 –19–25JUN98–9/32
Turn housing cover 180°.
Mount eyebolts.
Remove transmission cover with clutch packs from repair

stand.
–UN–29APR97
Install transmission housing into repair stand.
T109013
CED,OUOE003,1009 –19–25JUN98–10/32
Install alignment studs in housing.
NOTE: Pay attention to the engagement of the oil pipes

with the bores in the housing cover.
Install cover with clutch packs carefully onto housing.

–UN–09MAY97
Make sure all components are properly seated.

T109014

011504
PN=186
Remove M10 hex nuts and 24H1300 flat washers (A) from
clutch packs.
A—M10 Hex Nuts and 24H1300 Flat Washers
–UN–09MAY97
T109149B
CED,OUOE003,1009 –19–25JUN98–12/32
Remove housing cover from gearbox housing.

03
0350
21
–UN–09MAY97
T109016
CED,OUOE003,1009 –19–25JUN98–13/32
Output Shaft
Assemble oil cover onto shaft and press both bearing

inner races against shoulder until contact is obtained.
–UN–15APR97
T109066
CED,OUOE003,1009 –19–25JUN98–14/32
Insert bearing outer race into the housing bore until

contact is obtained.
–UN–29APR97
T109068

011504
PN=187
Position inner oil cover.
–UN–15APR97
T109069
CED,OUOE003,1009 –19–25JUN98–16/32
Install output shaft with cover in housing.

03
0350
22
–UN–15APR97
T109070
CED,OUOE003,1009 –19–25JUN98–17/32
NOTE: Insert socket head cap screws with thread lock

and sealer (medium strength).
Fasten both covers by means of socket head screws.
Specification
–UN–15APR97
Output Shaft Socket Head
T109071
CED,OUOE003,1009 –19–25JUN98–18/32
Install sealing rings (6 used) into the recesses of the

clutch shafts and hook them in.
Grease sealing rings and align.

–UN–29APR97
T109072

011504
PN=188
Lubricate and install both O-rings into the groove of the oil
pipes.
–UN–29APR97
T109075
CED,OUOE003,1009 –19–25JUN98–20/32
Apply TY16021 High Flex Form-In-Place Gasket to

mounting face of cover. 03
0350
NOTE: Pay attention to the engagement of the oil pipe 23
with the bores in the housing cover.
–UN–15APR97
Install housing cover carefully against gearbox housing
until contact is obtained, using lifting device.
T109076
CED,OUOE003,1009 –19–25JUN98–21/32
Install dowel pins.
–UN–29APR97
T109077
CED,OUOE003,1009 –19–25JUN98–22/32
NOTE: Locate hanger in same position as it was

removed.
Install housing cover using hex head screws.
Specification
–UN–15APR97
Housing Cover Hex Head

T109078

011504
PN=189
NOTE: Grease sealing lip.
Install shaft seal with the seal lip facing inward, using
proper driver. Drive until seated. Do not over drive.
–UN–15APR97
T109079
CED,OUOE003,1009 –19–25JUN98–24/32
NOTE: Apply TY16021 High Flex Form-In-Place Gasket

03 to contact area of washer.
0350
24 Heat the output flange to a maximum of 90°C (194°F).
Specification
–UN–15APR97
Output Flange—Temperature............................... 90°C (194°F) maximum
Install flange and washer with cap screws.
T109080
Specification
Output Flange Cap Screw—
Torque ............................................................................. 34 N•m (25 lb-ft)
CED,OUOE003,1009 –19–25JUN98–25/32
Install locking plate using two 5/8 in. deep well sockets.
Install flange in same manner on opposite side.
A—Deep Well Socket (2 used)

–UN–02MAY97
T109147B

011504
PN=190
If removed, install flat gasket and cover. Fasten with hex

head screws.
Specification
Flat Gasket and Cover Hex Head
–UN–15APR97
T109094
CED,OUOE003,1009 –19–25JUN98–27/32
Install O-ring into groove of two oil feed covers.

03
0350
25
–UN–15APR97
T109115
CED,OUOE003,1009 –19–25JUN98–28/32
Install cover onto transmission studs with hex nuts.
Tighten nuts.
Specification
Cover-to-Transmission Stud
Screw—Torque ............................................................... 25 N•m (18 lb-ft.)
–UN–15APR97
T109116
CED,OUOE003,1009 –19–25JUN98–29/32
Install oil level tube and tighten screw.
Specification
Oil Level Tube Screw—Torque ....................................... 23 N•m (18 lb-ft)
–UN–15APR97
T109117

011504
PN=191
Install engine speed sensor (48), middle gear speed

sensor (47) and turbine speed sensor (21). Tighten
sensors.
Specification
Engine Speed Sensor—Torque ...................................... 30 N•m (22 lb-ft)
Middle Gear Clutch Sensor—
–UN–29APR97
Torque ............................................................................. 30 N•m (22 lb-ft)
Turbine Speed Sensor—Torque ..................................... 30 N•m (22 lb-ft)
Install breather (shown at arrow head).
T109119
21—Turbine Speed Sensor
47—Middle Gear Speed Sensor
48—Engine Speed Sensor
03
0350
26
CED,OUOE003,1009 –19–25JUN98–31/32
Install drain plug.
Tighten drain plug.
Specification
Oil Drain Plug—Torque ............................................... 140 N•m (100 lb-ft)
–UN–15APR97
T109120
CED,OUOE003,1009 –19–25JUN98–32/32
Disassemble Clutch Pack KV And KR
Remove sealing ring.

–UN–29APR97
T108792

011504
PN=192
Pull tapered roller bearing from the shaft using JDG1134

Bearing Puller and JDG1035 Mandrel.
Remove opposite tapered roller bearing on KV.
Remove opposite bearing on KR with JDG1197 Bearing
–UN–18APR97
Puller and JDG1134 Mandrel.
T108793
CED,OUOE002,1544 –19–20MAY98–2/9
Separate plate carrier from shaft.

03
0350
27
–UN–18APR97
T108794
CED,OUOE002,1544 –19–20MAY98–3/9
Remove plates.
–UN–18APR97
T108795
CED,OUOE002,1544 –19–20MAY98–4/9
Preload compression spring with DFT1149 tool in press

and remove snap ring.
Remove piston from carrier.

–UN–17APR97
T108761

011504
PN=193
Remove both O-rings from piston.
–UN–29APR97
T108758
CED,OUOE002,1544 –19–20MAY98–6/9
Remove inner circle snap ring.

03
0350
28
–UN–17APR97
T108759
CED,OUOE002,1544 –19–20MAY98–7/9
Remove idler gear from shaft using a press.
Remove released needle bearing.
–UN–17APR97
T108752
–UN–17APR97
T108753

011504
PN=194
Remove circle snap ring and remove bearing.
–UN–17APR97
T108754
CED,OUOE002,1544 –19–20MAY98–9/9
Assemble Clutch Pack KV And KR

03
IMPORTANT: Check function of the drain valve. 0350
Check function of drain ball. Ball must 29
move freely. If ball does not move
freely, check for contamination or
–UN–29APR97
replace.
NOTE: Clutch KV and KR are assembled in the same

manner. Art shown in the following story is similar
T108981
to both clutch packs.
Install both new O-rings (arrows) into the ID and OD of

the piston and oil them.
CED,OUOE002,1545 –19–20MAY98–1/18
Assemble piston until it bottoms out in plate carrier.
Pay attention to proper installation.
–UN–10APR97
T108662

011504
PN=195
Install spring and two guides.
–UN–10APR97
T108663
CED,OUOE002,1545 –19–20MAY98–3/18
Press spring with DFT1149 Compression Tool in press

03 and install snap ring into plate carrier groove.
0350
30
–UN–10APR97
T108664

011504
PN=196
03
0350
31
–UN–20NOV97
T112158
Clutch Packs KV And KR
1—Plate Carrier 3—Disk (Friction) (One side 4—Plate (Separator) (10 used) 6—Snap Ring
2—Piston fiber coated) 5—Disk (Friction) (10 used) 7—End Shim

011504
PN=197
IMPORTANT: Install one sided friction disk (3) with

the fiber side always facing toward
plate. Smooth side should be against
piston.
NOTE: Plate and disk position is the same for Clutch KV
–UN–10APR97
and KR.
For proper adjustment of plate clearance install

disk and plates temporarily without being oiled.
T108665
Install one sided fiber disk into carrier with the fiber side
facing out or away from piston.
Install plate and then disk alternately until eight plates and
eight disks are installed in carrier.
03
0350
32 Install two plates, then two disks.
CED,OUOE002,1545 –19–20MAY98–6/18
Install end shim and snap ring.
–UN–10APR97
T108666

011504
PN=198
Adjust plate clearance to specification.
Specification
KV and KR Clutch Pack Plate—
Clearance .............................................................................. 2.7—2.9 mm
(0.106—0.114 in.)
–UN–10APR97
NOTE: For the adjustment of the plate clearance there
are snap rings of different thickness available
through parts system that can be used if proper
clearance is unable to be obtained. To ensure
T108667
proper measuring results, install plates temporarily
without oil.
Press end shim and measure the dimension from the end
face/plate carrier to the end shim with depth gauge.
Record Dimension No. 1. 03
0350
Press end shim against snap ring (upward) until contact 33
and measure with gauge. Record Dimension No. 2.
–UN–10APR97
Example for Clutch Pack Clearance Check
Dimension No. 1 7.25 mm (0.285 in.)
T108668
Difference = Plate Clearance 2.7 mm (0.106 in.)
Specification = Pack Clearance 2.7—2.9 mm (0.106—0.114 in.)
If a clutch pack clearance is not in specification, correct by

using the proper corresponding snap ring from service
parts to increase or decrease clearance. Snap rings come
in various sizes.
After proper clearance is obtained remove disks and

plates from assembly.
Add oil to plates and disks.
Reassemble clutch pack assembly.

011504
PN=199
Install idler gear until all inner plates are engaged. This
step makes later assembling of the idler gear easier.
Remove idler gear from clutch pack assembly.
–UN–10APR97
T108669
CED,OUOE002,1545 –19–20MAY98–9/18
Apply thread lock and sealer (medium strength) to stud.

03
0350 Install stud on end of shaft if removed in assembly and
34 tighten.
Specification
–UN–10APR97
Clutch Pack Shaft Stud—Torque ................................. 17 N•m (150 lb-in.)
T108670
CED,OUOE002,1545 –19–20MAY98–10/18
Insert ball bearing until seated and install snap ring.
–UN–10APR97
T108671
CED,OUOE002,1545 –19–20MAY98–11/18
Install needle bearing.

–UN–10APR97
T108672

011504
PN=200
NOTE: Push against inner race of bearing.
Press idler gear against shoulder.
–UN–10APR97
T108673
CED,OUOE002,1545 –19–20MAY98–13/18
Retain idler gear by means of snap ring.

03
0350
35
–UN–10APR97
T108674
CED,OUOE002,1545 –19–20MAY98–14/18
NOTE: Clutch-KR, there is no recess in the

shaft-assemble snap ring until contact on the
bearing inner race is obtained.
Assemble pre-assembled plate carrier until all plates are

engaged.
–UN–10APR97
T108675
CED,OUOE002,1545 –19–20MAY98–15/18
Make sure carrier face is flush with shaft spline.

–UN–10APR97
T108676

011504
PN=201
Press tapered roller bearing against shoulder
Install opposite tapered roller bearing with press.
–UN–10APR97
T108677
CED,OUOE002,1545 –19–20MAY98–17/18
Check function of clutch by means of compressed air.

03
0350 NOTE: When you have correctly installed components,
36 the clutch packs will move freely as you will be
able to hear them moving while inducing
compressed air.
–UN–10APR97
T108678
CED,OUOE002,1545 –19–20MAY98–18/18
Disassemble Clutch Pack K1, K2, And K3
NOTE: The following art shows the disassembly of clutch

K3. K1 and K2 are similar in disassembly
methods.
–UN–29APR97
Remove rectangular sealing ring from shaft.
T108755
CED,OUOE002,1546 –19–20MAY98–1/9
Pull tapered roller bearing from both ends of the shaft

using mandrel and puller as shown.
–UN–17APR97
T108764

011504
PN=202
Remove disk, needle bearing and washer.
–UN–17APR97
T108765
CED,OUOE002,1546 –19–20MAY98–3/9
Remove idler gear.

03
0350
37
–UN–17APR97
T108766
CED,OUOE002,1546 –19–20MAY98–4/9
Remove both needle bearings as well as axial bearing.
–UN–17APR97
T108767
CED,OUOE002,1546 –19–20MAY98–5/9
Remove snap ring and remove plates and disks.

–UN–17APR97
T108760

011504
PN=203
Preload compression spring using DFT1149 Pre-Load

Clutch Pack Compression Ring Tool.
Squeeze snap ring out and remove components.
–UN–17APR97
T108761
CED,OUOE002,1546 –19–20MAY98–7/9
Press piston out of the plate carrier, using compressed

03 air.
0350
38
–UN–17APR97
T108762
CED,OUOE002,1546 –19–20MAY98–8/9
Pry plate carrier from the shaft.
–UN–17APR97
T108763
CED,OUOE002,1546 –19–20MAY98–9/9

011504
PN=204
Assemble Clutch Pack K1, K2, And K3
NOTE: Clutch K1, K2 and K3 are assembled in similar

manner. All the following assembly story art show
clutch K3.
–UN–10APR97
Install stud on end of shaft and tighten.
T108679
Specification
03
0350
39
CED,OUOE002,1547 –19–20MAY98–1/23
Assemble plate carrier until bottomed.
–UN–10APR97
T108680
CED,OUOE002,1547 –19–20MAY98–2/23
IMPORTANT: Check function of the drain valve.

Check function of drain ball. Ball must
move freely. If ball does not move
freely, check for contamination or
replace. –UN–29APR97

the piston and oil them.
T108981

011504
PN=205
Install piston in carrier until seated.
Note proper position.
–UN–10APR97
T108734
CED,OUOE002,1547 –19–20MAY98–4/23
Install compression spring, two spring guides, into plate

03 carrier.
0350
40
–UN–10APR97
T108735
Spring Type Shown May Vary
CED,OUOE002,1547 –19–20MAY98–5/23
Using DFT1149 Pre-Load Clutch Pack Compression Ring

Tool, install snap ring into plate carrier groove for clutch.
–UN–10APR97
T108736

011504
PN=206
03
0350
41
–UN–20NOV97
T112161
Clutch Packs K1
CED,OUOE002,1547 –19–20MAY98–7/23

piston.
NOTE: For proper adjustment of plate clearance, install

–UN–10APR97
T108737
Install plate and then disk alternately until nine plates and
nine disks are installed in carrier.

011504
PN=207
–UN–10APR97
T108738
CED,OUOE002,1547 –19–20MAY98–9/23

03
0350 Specification
42 K1 Clutch Pack—Clearance .................... 2.4—2.6 mm (0.094—0.102 in.)
–UN–10APR97
clearance is unable to be obtained. To ensure
proper measuring result, install plates temporarily
T108739
without oil.
Record dimension (No 1).

011504
PN=208
Press end shim against snap ring (upward) until contact

and measure with gauge. Record dimension (No 2).

Dimension No 1 8.50 mm (0.335 in.)
Dimension No 2 6.00 mm (0.236 in.)
–UN–09MAY97
T108740
in various sizes.

plates from assembly. 03
0350
43

011504
PN=209
03
0350
44
–UN–20NOV97
T112160
Clutch Packs K2 And K3
CED,OUOE002,1547 –19–20MAY98–12/23

piston.
NOTE: Plate and Disk position is the same for Clutch K2

–UN–10APR97
and K3.
For proper adjustment of plate clearance, install

T108737
Install plate and then disk alternately until seven plates

and seven disks are installed in carrier.

011504
PN=210
–UN–10APR97
T108738
CED,OUOE002,1547 –19–20MAY98–14/23

03
Specification 0350
K2 and K3 Clutch Pack— 45
Clearance ................................................ 1.8—2.0 mm (0.071—0.079 in.)
–UN–10APR97
clearance is unable to be obtained! To ensure
T108739
without oil.
Record dimension (No. 1).

011504
PN=211

and measure with gauge. Record dimension (No. 2).

–UN–09MAY97
T108740
in various sizes.

03 plates from assembly.
0350
46
CED,OUOE002,1547 –19–20MAY98–16/23
Assemble thrust disk (1), thrust bearing (2), and thrust

washer (3).
1—Thrust Disk
2—Thrust Bearing
3—Thrust Washer
–UN–09MAY97
T108741
CED,OUOE002,1547 –19–20MAY98–17/23
Install both needle bearings

–UN–09MAY97
T108742

011504
PN=212
Install idler gear until all inner plates are engaged with
splines.
–UN–09MAY97
T108743
CED,OUOE002,1547 –19–20MAY98–19/23
Install thrust washer (3), thrust bearing (2), and thrust

disk. 03
0350
NOTE: Install disk (1) with chamfer facing the thrust 47
bearing.
–UN–09MAY97
To assure proper assembly, top surface of thrust disk
must be flush with shaft step.
1—Thrust Disk
T108744
2—Thrust Bearing
3—Thrust Washer
CED,OUOE002,1547 –19–20MAY98–20/23
Press tapered roller bearing against shoulder.
–UN–09MAY97
T108745

011504
PN=213
–UN–09MAY97
T108746
CED,OUOE002,1547 –19–20MAY98–22/23

03
0350 NOTE: When you have correctly installed components,
48 the clutch packs will move freely in carrier, as you
will be able to hear them moving while inducing
compressed air.
–UN–09MAY97
T108747
CED,OUOE002,1547 –19–20MAY98–23/23
Disassemble Clutch Pack K4
Remove sealing ring.
Pull tapered roller bearing from the shaft with JDG1035

mandrel and pullers JDG1134 and JDG1197.
–UN–17APR97
Remove opposite tapered roller bearing accordingly.
T108768
CED,OUOE002,1548 –19–20MAY98–1/4
Remove snap ring and plate carrier from shaft.

–UN–17APR97
T108769

011504
PN=214
Remove snap ring and remove plates and disks.
–UN–18APR97
T108770
CED,OUOE002,1548 –19–20MAY98–3/4
Preload compression spring using DFT1149 Pre-Load

Clutch Pack Compression Ring Tool. 03
0350
Remove snap ring and remove components. Remove 49
piston.
–UN–14APR97
T108983
CED,OUOE002,1548 –19–20MAY98–4/4
Assemble Clutch Pack K4
NOTE: Gear is very tight press fit. Shaft or gear may be

damaged if pressed apart.
Cool shaft to -80°C (-112°F). Heat gear to 120°C (248°F)
–UN–14APR97
and install it until bottomed.
T108748
CED,OUOE002,1549 –19–15JUN98–1/21
Install snap ring to retain gear.

–UN–14APR97
T108749

011504
PN=215
Install stud on end of shaft and tighten.
Specification
–UN–29APR97
T108750
CED,OUOE002,1549 –19–15JUN98–3/21
IMPORTANT: Check function of the drain valve.

03 Check function of drain ball. Ball must
0350 move freely. If ball does not move
50 freely, check for contamination or
replace.
–UN–29APR97
the piston and oil them!
T108981
CED,OUOE002,1549 –19–15JUN98–4/21
Assemble piston until it bottoms out in disk carrier.
Pay attention to proper installation.
–UN–14APR97
T108982
CED,OUOE002,1549 –19–15JUN98–5/21
Install compression spring, two spring guides, into disk

carrier.
–UN–14APR97
T108983

011504
PN=216
03
0350
51
–UN–20NOV97
T112159
Clutch Packs K4 (Earlier Machines)
1—Plate Carrier 3—Disk (Friction) (One Side 4—Plate (Separator) (5 used) 6—Snap Ring
2—Piston Fiber Coated) 5—Disk (Friction) (5 used) 7—End Shim
Press spring with DFT1149 Pre-Load Clutch Pack

Compression Ring Tool and install snap ring into disk
carrier groove.

011504
PN=217
03
0350
52
–UN–15JUN98
T115844
Clutch Packs K4 (Later Machines)
CED,OUOE002,1549 –19–15JUN98–8/21

piston.
NOTE: For proper adjustment of plate clearance later

–UN–14APR97
install disk and plates temporarily without being

oiled.
T108984
Install plate and then disk alternately until five (six) plates
and five (six) disks are installed in carrier.

011504
PN=218
–UN–09MAY97
T108985
CED,OUOE002,1549 –19–15JUN98–10/21

03
Specification 0350
K4 Clutch Pack—Clearance .................... 1.2—1.4 mm (0.047—0.055 in.) 53
–UN–14APR97
clearance is unable to be obtained! To ensure
T108986
without oil.
Record dimension (No. 1).


011504
PN=219

in various sizes.
After proper clearance is obtained remove disk and plates
–UN–14APR97
from assembly.
T108987

and measure with gauge. Record dimension (No 2).
03
0350
54
CED,OUOE002,1549 –19–15JUN98–12/21
Install idler gear until inner plates are meshed with

splines.
NOTE: This will make it easier for installing idler gear

later.
–UN–14APR97
Remove idler gear.
T108988
CED,OUOE002,1549 –19–15JUN98–13/21
Install thrust washers and thrust bearing.
–UN–14APR97
T108989

011504
PN=220
Install two needle bearings.
–UN–14APR97
T108990
CED,OUOE002,1549 –19–15JUN98–15/21
Assemble idler gear.

03
0350
55
–UN–14APR97
T108991
CED,OUOE002,1549 –19–15JUN98–16/21
Install thrust washer (3), thrust bearing (2), and thrust disk
(1).
1—Thrust Disk
2—Thrust Bearing
3—Thrust Washer
–UN–29APR97
T108992
CED,OUOE002,1549 –19–15JUN98–17/21
NOTE: Install thrust disk (1) with the chamfer facing the
thrust washer.
Assemble K4 carrier assembly onto shaft until seated and

all plates are engaged.
–UN–14APR97
T108993

011504
PN=221
Install snap ring to retain plate.
–UN–14APR97
T108994
CED,OUOE002,1549 –19–15JUN98–19/21

03
0350 Install opposite tapered roller bearing.
56
–UN–14APR97
T108995
CED,OUOE002,1549 –19–15JUN98–20/21
NOTE: When you have correctly installed components,

the clutch packs will move freely in carrier, as you
will be able to hear them moving while inducing
compressed air.
–UN–14APR97
T108996
CED,OUOE002,1549 –19–15JUN98–21/21
Disassemble Input Shaft
NOTE: The turbine shaft is axially fixed by means of a

snap ring which will be destroyed when pressing
out.
–UN–18APR97
If necessary, press turbine shaft out of the input shaft.

T108772
Continued on next page TX,0350,ME287 –19–12JUN98–1/2

011504
PN=222
Remove rectangular ring out.
Pull off the tapered roller bearing using JDG1035 Mandrel

and JDG1134 Bearing Puller.
Pull off the opposite tapered roller bearing.
–UN–18APR97
NOTE: The separation of input shaft and gear is not
possible (press fit).
T108773
TX,0350,ME287 –19–12JUN98–2/2
Assemble Input Shaft

03
Cool the input shaft to about -80°C (-112°F) heat gear to 0350
about +120°C (250°F) and assemble to shaft until seated. 57
–UN–14APR97
T108997
TX,0350,ME292 –19–12JUN98–1/8
Install snap ring to retain gear.
–UN–14APR97
T108998
TX,0350,ME292 –19–12JUN98–2/8
Install snap ring into the recess of the turbine shaft.

–UN–14APR97
T108999

011504
PN=223
Install turbine shaft until the snap ring snaps into the
groove of the input shaft to retain turbine shaft.
–UN–14APR97
T109000
TX,0350,ME292 –19–12JUN98–4/8
Press both bearing inner races against shoulder.

03
0350
58
–UN–09MAY97
T109001
TX,0350,ME292 –19–12JUN98–5/8
Install ball bearing.
Install sealing ring.
–UN–29APR97
T109002
TX,0350,ME292 –19–12JUN98–6/8
Install output shaft into the housing bore until seated.

–UN–09MAY97
T109003

011504
PN=224
NOTE: If bearings are reused, they must be assembled in

same bores.
Insert all bearing outer races into transmission housing

bores.
–UN–10APR97
T108657
TX,0350,ME292 –19–12JUN98–8/8
03
0350
59

011504
PN=225
03
0350
60

011504
PN=226
Group 0360
Hydraulic System
Remove Transmission Pump
Loosen socket head screws.
–UN–17APR97
T108730
TX,0360,ME278 –19–21MAY98–1/5
Placing a puller on the splines runout of the stator shaft,

pull pump assembly out of the housing bore. 03
0360
1
–UN–17APR97
T108731

011504
PN=227
Hydraulic System
03
–UN–15APR97
0360
2
TP55490
Oil Pump Assembly
1—O-Ring 4—Shim 6—Ring 8—O-Ring (10 used)

2—Snap Ring 5—Needle Bearing 7—Pump Assembly 9—Cap Screw (10 used)
3—Seal
TX,0360,ME278 –19–21MAY98–3/5
Separate transmission pump from stator.
Separate cam plate from pump. Make note of drive gear

spline location and two small dowel pins.
NOTE: If traces of wear should be encountered in the

–UN–17APR97
pump housing or the cam disk, the complete

pump has to be replaced.
Inspect and replace parts as required.

T108732
Install cam disk and retain it by means of grooved pins

(2x).

011504
PN=228
Hydraulic System
Loosen hex. head screws and remove oil feed housing.
Remove flat gasket.
–UN–17APR97
T108725
TX,0360,ME278 –19–21MAY98–5/5
Remove And Install Converter Minimum

Pressure Regulator Valve 03
0360
3
Remove converter minimum pressure regulator valve out
of the housing bore.
–UN–05JAN98
T112686
TX,0350,ME279 –19–21MAY98–1/2
Inspect and replace parts as required.
NOTE: Install pressure plate facing toward lock plate as

show in photo.
Install converter minimum pressure regulator valve into
–UN–05JAN98
housing bore.
1—Piston
2—Compression Spring
T112685
3—Pressure Plate
4—Lock Plate
Minimum Pressure Regulator Valve
TX,0350,ME279 –19–21MAY98–2/2

011504
PN=229
Hydraulic System
Install Transmission Pump
Install alignment studs and install flat gasket.
–UN–05JAN98
T112687
TX,07,ME297 –19–18JAN01–1/8
IMPORTANT: Screw hex head screws until contact is

03 obtained. DO NOT TIGHTEN.
0360
4 Install oil feed housing, washers and hex head screws.
Leave loose at this time. This allows for oil pump
–UN–15APR97
alignment later in assembly.
T109086
TX,07,ME297 –19–18JAN01–2/8
NOTE: Pay attention to the overlapping of the bores.
Install alignment studs and stator shaft until it is bottomed

in housing.
–UN–15APR97
T109087
TX,07,ME297 –19–18JAN01–3/8
Lubricate and install O-ring.

–UN–29APR97
T109088
Continued on next page TX,07,ME297 –19–18JAN01–4/8

011504
PN=230
Hydraulic System
Install transmission pump.
–UN–15APR97
T109089
TX,07,ME297 –19–18JAN01–5/8
NOTE: Grease O-rings.

03
Install socket head screws with new O-rings. 0360
5
–UN–29APR97
T109090
TX,07,ME297 –19–18JAN01–6/8
Install transmission pump and socket head screws.
Specification
Transmission Pump Socket Head
–UN–15APR97
T109091
TX,07,ME297 –19–18JAN01–7/8
NOTE: Note locations of hanger strap from original

location.
Tighten cap screws.
Specification
–UN–15APR97
Transmission Pump Cap Screw—

Torque ............................................................................. 25 N•m (18 lb-ft)
T109092
TX,07,ME297 –19–18JAN01–8/8

011504
PN=231
Hydraulic System
Remove Transmission Hydraulic Control

Valve
1. Loosen socket head screws, install two alignment

studs and separate control valve from manifold plate.
–UN–17APR97
T108709
TX,0350,ME276 –19–18JAN01–1/3
2. Remove both gaskets (9 ,11) and center plate (10).

03
0360
6
–UN–17APR97
T108710
TX,0350,ME276 –19–18JAN01–2/3
3. Loosen socket head screws and hex nuts.
4. Separate manifold plate from transmission housing.
5. Remove gasket.
–UN–17APR97
T108714
TX,0350,ME276 –19–18JAN01–3/3

011504
PN=232
Hydraulic System
Install Transmission Hydraulic Control Valve
03
0360
7
–UN–08APR98
TP60304
1—Stud (14 used) 5—Nut (16 used) 8—Cap Screw (39 used) 11—Gasket
2—Gasket 6—O-Ring 9—Gasket 12—Cap Screw (23 used)
3—Manifold Plate 7—Plug 10—Plate (Center) 13—Cap Screw (2 used)
4—Washer (16 used)
Continued on next page TX,0360,ME282 –19–18JAN01–1/4

011504
PN=233
Hydraulic System
1. Install gasket, manifold plate, and fasten it with socket

head screws hex nuts and washers. Tighten socket
head screws.
Specification
Manifold Plate-to-Transmission
Housing Socket Head Screw—
–UN–15APR97
Torque ............................................................................. 25 N•m (18 lb-ft)
T109106
03
0360
8
–UN–15APR97
T109107
TX,0360,ME282 –19–18JAN01–2/4
2. Install two alignment studs. Install gasket (9), plate (10)

and gasket (11).
–UN–15APR97
T109109
TX,0360,ME282 –19–18JAN01–3/4
3. Install complete control valve unit on the manifold plate

with socket head screws.
IMPORTANT: Pay attention to the installation and

position of the different gaskets.
–UN–15APR97
4. Tighten screw.
Specification
Control Valve-to-Manifold Plate
T109110
Socket Head Screw—Torque ......................................... 9.5 N•m (85 lb-in)
TX,0360,ME282 –19–18JAN01–4/4

011504
PN=234
Hydraulic System
Transmission Hydraulic Control Valve Cross Section View
03
0360
9
–19–07JUL99
T122180
A—Pressure Regulating C—Connector—Wiring E—Valve Block—Control Valve H—Solenoid Valve—
Valve—Piston Harness F—Housing (2 used) Proportional (6 used)
B—Pressure Reducing Valve— D—Cover (2 used) G—Modulation Circuit I—Transmission Control Valve
Piston
TX,0360,ME273 –19–17JAN01–1/1

011504
PN=235
Hydraulic System
Disassemble Transmission Control Valve
03
0360
10
–UN–20JAN01
T137510

011504
PN=236
Hydraulic System
1—Cap Screw (32 used) 11—Piston (Dampening Valve) 20—Gasket 30—Spring (6 used)
2—Clamp (Clip) (6 used) 21—Housing 31—Orifice (6 used)
3—Cover 12— Spring (6 used) 22—Plate (3 used) 32—Gasket
4—Wiring Harness 13—Spring 23—Cap Screw (3 used) 33—Plate (Center)
5—Gasket 14—Piston—System Pressure 24—Gasket 34—Gasket
6—Solenoid Valve— Reducing Valve 25—Cover 35—Manifold Plate
Proportional (3 used) 15—Valve Block (Control) 26—Cap Screw (14 used) 36—Cap Screw (18 used)
7—Cap Screw (3 used) 16—O-Ring (8 used) 27—Solenoid Valve— 37—Screen (Transmission S.N.
8—Plate (3 used) 17—Drain Plug (8 used) Proportional (3 used) 000588—)(6 used)
9—Housing 18— Spring 28—Cap Screw (18 used)
10—Gasket 19— Piston (System Pressure 29—Piston (Pressure Control
Regulating Valve) valve) (6 used)
TX,0360,ME274 –19–21MAY98–2/7
1. Remove screws (26) and cover (25) and gasket (24).

03
2. Disconnect connectors to solenoid valves (27). 0360
11
3. Remove screws (23) and retaining plates (22), and
remove three solenoid valves (27).
–UN–16APR97
T108686
Hydraulic Control Valve
–UN–16APR97
T108687

011504
PN=237
Hydraulic System
4. Loosen screw to housing (21), remove housing and

gasket (20).
5. Remove three pressure control valve pistons (29) and

compression springs (30).
–UN–12JAN01
6. Remove three damping valves pistons (11) and
7. Remove system pressure valve piston (19)
T135928
compression spring (18).
Remove Housing And Valves
03
0360
12
TX,0360,ME274 –19–21MAY98–4/7
8. Remove clamp (clip) (2) from wire harness connector.
–UN–16APR97
T108689
Clamp Removal from Harness Connector
TX,0360,ME274 –19–21MAY98–5/7
9. Remove screws and cover (3) and gasket (5).
10. Disconnect connectors to solenoid valves (6).
11. Remove screws (7) and retaining plates (8). Pull

solenoid valves (6).
–UN–16APR97
T108682

011504
PN=238
Hydraulic System
12. Loosen screw to housing (9), remove housing and

gasket (10).
13. Remove three pressure control valve pistons (29) and

–UN–16APR97
14. Remove three damping valves pistons (11) and
15. Remove pressure reducing valve piston (14)
T108683
03
0360
13
TX,0360,ME274 –19–21MAY98–7/7
Assemble Transmission Control Valve
1. Check all components for damage and replace if

necessary.
2. Prior to the installation, check free travel of moving
–UN–09MAY97
parts in the housing.
3. Oil components prior to the reassembly.
T108684
4. Insert orifices (31) (if removed) until contact is obtained
(6 pieces, see arrows).
5. Install screens (37) if removed (Transmission S.N.

000588—)
TX,0360,ME275 –19–21MAY98–1/21
6. Install three pressure control valve pistons (29) and

7. Install three damping valve pistons (11) and

–UN–16APR97
8. Install system Pressure reducing valve piston (14)

T108683

011504
PN=239
Hydraulic System
9. Screw two alignment studs in valve housing. Install

gasket, assemble flat gasket (10).
NOTE: To aid assembly of solenoid housing, push spools

into bore and retain by using a 5mm pin or screw.
–UN–16APR97
T108694
TX,0360,ME275 –19–21MAY98–3/21
10. Install housing (9) while routing wire harness (4) into
03 position.
0360
14
–UN–16APR97
T108695
TX,0360,ME275 –19–21MAY98–4/21
11. Fasten housing (9) with screws (1) and tighten

evenly. Remove assembly aid pins or screws. Tighten
(M5/10.9) screw.
Specification
Housing-to-Control Valve
(M5/10.9) Screw—Torque ................................................ 5 N•m (44 lb-in.)
–UN–16APR97
T108696
TX,0360,ME275 –19–21MAY98–5/21
12. Insert three solenoid valves (6) into housing (9),

equipped with O-ring, and fasten by means of
retaining plate (8) and screws (7).
NOTE: Install retaining plate with the claw facing the

housing bottom.
–UN–16APR97
T108697

011504
PN=240
Hydraulic System
13. Install housing with solenoid valves onto control valve

(15) and fasten with screws. Tighten (M5/8.8) screw.
Specification
Solenoid Valve (M5/8.8) Screw—
Torque .............................................................................. 5 N•m (44 lb-in.)
–UN–16APR97
T108698
TX,0360,ME275 –19–21MAY98–7/21
14. Install wire harness connectors to solenoid valves.

03
0360
15
–UN–16APR97
T108691
TX,0360,ME275 –19–21MAY98–8/21
15. Screw two alignment studs in, and assemble flat

gasket (5) and cover (3).
16. Tighten screws (M5/10.9) 5 N•m (44 lb-in.)
Specification
–UN–16APR97
Solenoid Cover-to-Housing
(M5/10.9) Screw—Torque ................................................ 5 N•m (44 lb-in.)
T108692
TX,0360,ME275 –19–21MAY98–9/21
17. Install Wire harness connector (4) with clamp-clip (2)

to cover (3).
NOTE: Make sure clamp snaps in.

–UN–16APR97
T108693

011504
PN=241
Hydraulic System
18. Install three pressure control valve pistons (29) and

springs 30).
19. Install three dampening valve pistons (11) and

–UN–12JAN01
20. Install system pressure regulating valve (19), and
spring (18).
T135928
TX,0360,ME275 –19–21MAY98–11/21
21. Push spools of the pressure control valves (29) into

03 position. A straight pin (5 mm) may be used as an
0360 assembly aid.
16
–UN–16APR97
T108703
TX,0360,ME275 –19–21MAY98–12/21
22. Screw two alignment studs in, assemble gasket (20)

and housing (21).
–UN–16APR97
T108704

011504
PN=242
Hydraulic System
23. Install housing and tighten evenly.
24. Tighten (M5/10.9) screw.
Specification
Housing-to-Control Valve Block
Screw (M5/10.9)—Torque ................................................ 5 N•m (44 lb-in.)
–UN–16APR97
T108705
03
0360
17
TX,0360,ME275 –19–21MAY98–14/21
25. Insert three solenoid valves (6), equipped with O-ring,

and fasten by means of retaining plate (22) and screw
(23).
NOTE: Install retaining plate with the claw facing the

housing bottom.
–UN–16APR97
Specification
T108698
Solenoid Valve-to-Retaining Plate
Screw—Torque ................................................................. 5 N•m (44 lb-in.)
TX,0360,ME275 –19–21MAY98–15/21
27. Fasten harness connectors to solenoid valves.
28. Screw two alignment studs in housing and assemble

flat gasket (24) and cover (25). Tighten (M5/10.9)
screw (26).
–UN–30APR97
Specification
Alignment Stud-to-Cover Screw—
Torque .............................................................................. 5 N•m (44 lb-in.)
T108699

011504
PN=243
Hydraulic System
29. Install diagnostic plugs with O-rings, in ports, if

removed during disassembly.
30. Tighten (M10/1) screw.
Specification
–UN–16APR97
Diagnostic Plug-to-Port (M10/1)
Screw—Torque ................................................................. 6 N•m (55 lb-in.)
T108700
TX,0360,ME275 –19–21MAY98–17/21
31. Screw two (2) alignment studs in and assemble (first)

03 flat gasket (32).
0360
18
–UN–16APR97
T108701
TX,0360,ME275 –19–21MAY98–18/21
32. Assemble intermediate plate (33).
–UN–16APR97
T108706
Intermediate Plate Assembly

011504
PN=244
Hydraulic System
33. Assemble second gaske (34).
–UN–09MAY97
T108707
TX,0360,ME275 –19–21MAY98–20/21
34. Assemble manifold plate (35) to valve body with

screws (36) and (remove alignment screws). 03
0360
NOTE: Tightening order of the screw start with inboard 19
screws at first and continuing toward the outside.
–UN–17APR97
Specification
Manifold Plate-to-Valve Body
T108708
(M6/10.9) Screw—Torque ............................................. 9.5 N•m (85 lb-in.)
TX,0360,ME275 –19–21MAY98–21/21
Remove, Disassemble, And Install Converter

Relief Valve
1. Pull converter relief valve out of the housing bore.
–UN–17APR97
T108715

011504
PN=245
Hydraulic System
2. Remove preload compression spring carefully, remove

cylindrical pin as required to inspect and replace parts
as needed.
1—Plate
2—Ball
–UN–30APR97
3—Compression Spring
4—Valve Insert
5—Valve Sleeve
6—Roll Pin
T109103
Converter Relief Valve
03
0360
20
TX,0360,ME277 –19–21MAY98–2/3
3. Insert converter relief valve into the housing bore until

it bottoms.
–UN–15APR97
T109105
TX,0360,ME277 –19–21MAY98–3/3

011504
PN=246
Hydraulic System
Replace Oil Pipes And Tubes
NOTE: The installation of all lubrication pipes, tubes and

lines require special tools. It is very important to
have these tools if repair or replacement is
necessary. If repair is needed contact DTAC
(Dealer Technical Assistance Center) for
assistance.
1—Suction Tube
2—Pressure Pipe (2 used)
3—Pressure Lubrication Pipe (Transmission S.N. —
2496)
03
0360
21
–UN–09MAY97
T108652
–UN–09MAY97
T108658
Cover Showing Two Oil Pipes

011504
PN=247
Hydraulic System
03
0360
22
–UN–09DEC97
TP55763
1—Pipe (Transmission S.N. — 3—Pipe 6—Pressure Pipe 9—Pressure Pipe Extension (2
2496) 4—Cap Screw 7—Pipe used)
2—Suction Tube 5—Pressure Pipe 8—O-Ring (4 used) 10—Cap Screw (2 used)
TX,0360,ME293 –19–21MAY98–2/2

011504
PN=248
Group 0399
Dealer Fabricated Tools
DFT1149 Pre-Load Clutch Pack Compression Ring Tool
03
0399
1
–UN–07MAY97
T109434
The Clutch Pack Compression Ring Tool is used to Material is standard pipe (see dimensions above) with
compress the piston compression ring so snap ring window cut out to allow for access when removing
can be removed. snap ring.
TX,0399,ME296 –19–08MAY97–1/1

011504
PN=249
DFT1063 Lifting Bracket
03
0399
2
–19–10JAN95
T8360AM
Tool used to remove and install torque converter. • 1/2 in. 1020 Steel
• 5/8 in. x 5 in. Cap Screw
Material required: • 3/8 in. x 1-1/2 in. Cap Screw with Nut (4 used)
• 1-1/2 in. x 3 in. x 3/16 in. Square Tube
CED,OUOE002,1560 –19–21MAY98–1/1

011504
PN=250
DFT1158 Torque Converter Adapter Plate
03
0399
3
–19–15JUN98
T115559
Tool used to remove and install torque converter. • 2-1/2 in x 2-1/2 in. x 3/16 in. Square Tube
• 1/2 in. 1020 Steel
Material required:
CED,OUOE002,1561 –19–21MAY98–1/1

011504
PN=251
03
0399
4

011504
PN=252
Section 04
Engine
Contents
Page

6081 John Deere Engine
Use CTM86 . . . . . . . . . . . . . . . . . . . . . . . .04-0400-1
Use CTM134 Operation and
Diagnostics. . . . . . . . . . . . . . . . . . . . . . .04-0400-1
Remove and Install Engine . . . . . . . . . . . . . .04-0400-1
04

011504
PN=1
Contents
04

011504
PN=2
Group 0400
6081 John Deere Engine—Use CTM86
For additional engine information, the component technical

manual (CTM) is also required.
Use the CTM in conjunction with this machine manual.
–UN–07SEP88
M44215
TX,9010,BA1886 –19–24JUL96–1/1
6081 John Deere Engine—Use CTM134

Operation And Diagnostics
For additional engine information, the component technical

manual (CTM) is also required.
–UN–07SEP88
Use the CTM in conjunction with this machine manual.
04
0400
1
M44215
CED,TX17864,23 –19–24MAR98–1/1
Remove and Install Engine
1. Stop engine. Lower boom and bucket to ground.
2. Remove battery negative (-) ground strap or turn

battery disconnect switch “Off” if equipped.
Continued on next page CED,OUOE002,1562 –19–03SEP02–1/10

011504
PN=255
CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious
burns.
Shut off engine. Only remove filler cap when

cool enough to touch with bare hands. Slowly
–UN–23AUG88
loosen cap to first stop to relieve pressure
before removing completely.
3. Attach hose to radiator drain. Drain engine coolant.
TS281
Specification
Engine Coolant—Capacity ...................................................... 29 L (31 qt)
4. Remove hood with air cleaner and turbocharger inlet

hose. (See Group 1910 for hood removal.) (See Group
0520 for air cleaner removal.)
5. Remove muffler with muffler mounting brackets. (See

Group 0530.)
04 6. Remove lower left side shield on machines (S.N. —

0400
585560) only.
2

011504
PN=256
04
0400
3
–UN–12JUN98
T115576
A—Fuel Inlet Hose C—Fan Hydraulic Pump E—Serpentine Belt G—Wiring Harness
B—Fuel Return Hose D—Oil Cooler Bracket F—Alternator
7.

011504
PN=257
04
0400
4
–UN–03SEP02
T159074B
A—Fuel Inlet Hose C—Fan Hydraulic Pump F—Alternator G—Wiring Harness
B—Fuel Return Hose E—Serpentine Belt
Remove oil cooler bracket (D) on machines (S.N. — 11. Remove alternator (F). Move alternator out of the
585561) only. way.
8. Remove serpentine belt (E). 12. Disconnect coolant temperature sensor, oil
pressure sensor, engine timing sensor, and fuel
9. Remove fan hydraulic pump (C) cap screws. Move injector connectors.
pump out of the way.
13. Remove wiring harness (G) from engine.
10. Disconnect fuel inlet (A) and return (B) lines.

011504
PN=258
04
0400
5
–UN–12JUN98
T115577
A—Upper Air-to-Air Cooler D—Cab Inlet Heater Hose G—Battery Cables J—Lower Radiator Hose
B—Upper Radiator Hose E—Fuel Starting Aid Line H—Lower Air-to-Air Cooler
C—Cab Return Heater Hose F—Ground Strap I—Air Conditioning
Compressor
14.

011504
PN=259
04
0400
6
–UN–03SEP02
T159075B
A—Upper Air-to-Air Cooler E—Fuel Starting Aid Line H—Lower Air-to-Air Cooler J—Lower Radiator Hose
B—Upper Radiator Hose F—Ground Strap I—Air Conditioning K—Intake Manifold Air
C—Cab Return Heater Hose G—Battery Cables Compressor Temperature Sensor
D—Cab Inlet Heater Hose
Remove air conditioning compressor (I) cap screws (if 19. Disconnect cab heater hoses (C and D).
equipped). Move compressor out of the way.
20. Disconnect upper and lower radiator hoses (B and
15. Disconnect battery cables (G) and E01 white wires J).
from starter.
21. Disconnect intake manifold air temperature sensor
16. Disconnect engine ground strap (F). (K) on machines (S.N. 585561—) only.
17. Disconnect fuel starting aid line (E).
18. Remove upper and lower air-to-air cooler tubes (A

and H). Remove air cooler tube clamp from engine
block.

011504
PN=260
22. Remove four cap screws from engine-to-transmission

drive shaft U-joints (at torque converter side.)
23. Install D01043AA Load Positioning Sling to engine.
24. Remove two rear (front of engine) engine mounting
–UN–21MAR97
cap screws.
25. Remove two front (rear of engine) engine mounting

cap screws.
T108384B
CAUTION: The approximate weight of the
engine is 753 kg (1660 lb). A—Cap Screw (4 used)
Specification
Engine—Weight ........................................... 753 kg (1660 lb) approximate
26. Install engine.
27. Inspect engine mounting parts. Replace as needed.
04
0400
7

011504
PN=261
04
0400
8
–UN–12JUN98
T115562
A—Cap Screw (4 used) D—Support Bracket G—Washer (12 used) J—Washer (4 used)
B—Washer (4 used) E—Support Bracket H—Cap Screw (12 used) K—Nut (4 used)
C—Isolator (4 used) F—Support Bracket I—Support Bracket
28. Install two front (rear of engine) engine mounting 29. Install two rear (front of engine) engine mounting
cap screws (A) and tighten to specification. cap screws (A) and tighten to specification.
Specification Specification
Front Engine Mounting Bracket Rear Engine Mounting Bracket
Cap Screw—Torque ............................. 434 ± 87 N•m (320 ± 64 lb-ft) Cap Screw—Torque ............................. 434 ± 87 N•m (320 ± 64 lb-ft)

011504
PN=262
30. Install four new engine-to-transmission drive shaft

U-joint cap screws (A). Tighten cap screws.
Specification
Engine-to-Transmission Drive
Shaft U-Joint Cap Screw—Torque .................................. 78 N•m (58 lb-ft)
–UN–21MAR97
31. Install wiring harness.
32. Connect coolant temperature sensor, oil pressure
T108384B
sensor, engine timing sensor, and fuel injector
connectors.
33. On machines (S.N. 585561—) connect intake A—Cap Screw (4 used)

manifold air temperature sensor.
34. Connect fuel inlet and return lines.
35. Install alternator.
36. Install fan hydraulic pump.

04
37. Connect upper and lower radiator hoses. 0400
9
38. Install upper and lower air-to-air cooler tubes.
39. Connect fuel starting aid line.
40. Connect engine ground strap.
41. Connect battery cables and E01 white wires from

starter.
42. Install air conditioning compressor cap screws (if

equipped).
43. Install serpentine belt.
44. On machines (S.N. —585560) install oil cooler

bracket.
45. On machines (S.N. —585560) install lower left side

shield.
46. Install muffler with muffler brackets. (See Group

0530.)
47. Install hood with air cleaner and turbocharger inlet

hose. (See Group 1910 and Group 0520.)

011504
PN=263
48. Fill radiator with coolant.
49. Connect battery negative (-) ground strap or turn

battery disconnect switch “On” if equipped.
50. Check engine rpm. (See Group 0515.)
CED,OUOE002,1562 –19–03SEP02–10/10
04
0400
10

011504
PN=264
Section 05
Engine Auxiliary Systems
Contents
Page
Group 0505—Cold Weather Starting Aids

Fluid Starting Aid Assembly
Engine Coolant Heater
Group 0510—Cooling System

Serpentine Belt
Fan and Fan Drive
Remove And Install Radiator, Oil, And Air
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-7
Disassemble And Assemble Radiator, Oil,
And Air Cooler (S.N. —585560). . . . . . . .05-0510-18
Group 0515—Speed Controls

Speed Control Linkage
05
Group 0520—Intake System

Air Cleaner
Group 0530—External Exhaust System

Muffler
Group 0560—External Fuel Supply Systems

Fuel Tank

011504
PN=1
Contents
05

011504
PN=2
Group 0505
Cold Weather Starting Aids
Remove And Install Fluid Starting Aid
Assembly
1. Disconnect start aid solenoid connector that is located

on sump tank harness.
–19–17APR97
T108966
CED,OUOE002,1567 –19–26MAY98–1/4
05
0505
1
2. Open left engine access door. Remove starting aid
components (A—D).
3. Disconnect electrical connector (E).
A—Starting Aid Canister

B—Clamp
C—Starting Aid Solenoid
D—Line
E—Electrical Connector
–UN–12JUN98
T115587

011504
PN=267
4. Remove nozzle (C) from holder (B).
5. Clean or replace nozzle as required.
IMPORTANT: Nozzle must be secure in holder to

prevent engine damage from dust. Do
–UN–08OCT97
not overtighten or nozzle may break.
6. Carefully tighten nozzle in nozzle holder.
T104622
7. Apply thread lock and sealer (high strength) to threads
of nozzle holder.
A—Fitting In Intake Manifold
8. Install nozzle holder so nozzle is toward center of air
B—Nozzle Holder
inlet so fluid is sprayed into incoming air flow. Arrow on C—Nozzle
hex flat indicates direction of nozzle.
CED,OUOE002,1567 –19–26MAY98–3/4
IMPORTANT: When operating machine without

starting aid container installed, protect
components from possible damage.
Install starting aid plug (C) in starting
aid base.
05
0505 9. Install starting aid components. Remove safety cap
2
from new fluid starting aid canister (A). Turn canister
clockwise in starting aid base to install.
10. Tighten clamp (B).
–UN–12JUN98
A—Fluid Starting Aid Canister
B—Clamp
C—Starting Aid Plug
T115589
CED,OUOE002,1567 –19–26MAY98–4/4

011504
PN=268
Remove And Install Engine Coolant Heater
CAUTION: Coolant may be hot. Wait until

radiator is cool to the touch before draining.
1. Drain cooling system.
–UN–01NOV88
Specification
Cooling System—Capacity ...................................................... 29 L (31 qt)
T6642EK
2. Remove power cord (A). Loosen nut (C) and pull
heating element (G) from block.
CAUTION: DO NOT plug coolant heater into

electrical power unless heating element is
immersed in coolant. Sheath could burst and
result in personal injury.
–UN–21OCT88
Use a heavy-duty grounded cord to connect
coolant heater to electrical power.
3. Disassemble parts (B—G).
T6427AO
4. Replace parts as necessary.
5. Assemble parts (A—G). Put heating element in cylinder A—Power Cord

block so flats on threaded portion of element are B—Cap 05
C—Nut 0505
vertical.
D—Adapter 3
E—Gasket
6. Turn element clockwise and then counterclockwise F—O-Ring
until element contacts casting. Move element to the G—Heating Element
center position.
7. Hold element using a wrench. Tighten nut.
Specification
Engine Coolant Heater Nut—
Torque ............................................................................. 34 N•m (25 lb-ft)
8. Install power cord (A).

011504
PN=269
Refill Cooling System
IMPORTANT: Use only permanent-type, low silicate,

ethylene glycol base antifreeze in
coolant solution. Other types of
antifreeze may damage cylinder seals.
FREEZING TEMPERATURES: Fill with permanent-type,

low silicate, ethylene glycol antifreeze (without stop-leak
additive) and clean, soft water. Add TY16004 John Deere
Coolant Conditioner or equivalent.
NOTE: All machines are shipped from the factory with a

50-50 mixture for protection to -34°C (-30°F).
Adjust mixture accordingly to provide freeze
protection for your machine.
• Fill radiator to the bottom of the radiator fill neck.

• Fill the recovery tank to the FULL mark.
Deaeration
The cooling system requires several warm-up and cool

down cycles to deaerate. It will NOT deaerate during
normal operation. Only during warm-up and cool down
cycles will the system deaerate.
05
0505 • Start engine. Run engine until coolant reaches a warm
4 temperature.
• Stop engine. Allow coolant to cool.
• Check coolant level at recovery tank.
• Repeat Steps 1—3 until recovery tank coolant level is
repeatedly at the same level (stabilized).
NOTE: The level of the coolant in the cooling system

MUST BE repeatedly checked after all drain and
refill procedures to insure that all air is out of the
system which allows the coolant level to stabilize.
Check coolant level only when the engine is cold.
CED,OUOE002,1568 –19–26MAY98–2/2

011504
PN=270
Group 0510
Cooling System
Remove And Install Serpentine Belt
1. Check belt (A) regularly for wear, especially for cracks

at the bottom of grooves and for frayed edges.
IMPORTANT: If belt is stretched to the point that the

belt tensioner is against its stop, belt
must be replaced.
2. Replace belt if needed per diagram.
Replace belt if worn.
A—Belt
–UN–12JUN98
T115590
CED,OUOE002,1571 –19–26MAY98–1/2
05
0510
1
3. Hold tension adjuster assembly away from belt.
4. Remove belt.
5. Install new belt and release tensioner.
–19–14MAY98
1—Crankshaft
2—Idler
3—Air Conditioning Compressor
4—Idler
T115379
5—Alternator
6—Tensioner
–19–27JUL98
T115592
CED,OUOE002,1571 –19–26MAY98–2/2

011504
PN=271
Cooling System
Remove And Install Fan And Fan Drive
1. Remove fan guard.
CED,OUOE002,1570 –19–23AUG02–1/6
05
–UN–23OCT97
0510
2
T111703
A—Drive Hub B—Hex Nut C—Washer D—Label
2.
Continued on next page CED,OUOE002,1570 –19–23AUG02–2/6

011504
PN=272
Cooling System
05
0510
3

011504
PN=273
Cooling System
05
0510
4
–UN–27AUG02
T158725

011504
PN=274
Cooling System
1—Flange Nut 4—Cap Screw 7—Washer 10—Hub

2—Flange Nut 5—Cap Screw 8—Washer 11—Support
3—Lock Nut 6—Cap Screw 9—Fan
Remove fan and fan drive hub.
3. Remove hoses from fan drive motor, remove fan

drive motor.
05
0510
5

011504
PN=275
Cooling System
05
0510
6
–UN–27AUG02
T158724

011504
PN=276
Cooling System
1—Flange Nut 6—Adapter 11—O-ring 16—O-ring

2—Cap Screw 7—Adapter 12—O-ring 17—O-ring
3—Cap Screw 8—Elbow Fitting 13—O-ring 18—Shaft Key
4—Washer 9—Fan Pump 14—Gasket 19—Relief Valve
5—Elbow Fitting 10—Fan Motor 15—O-ring
4. Repair as necessary. Seal kits are available for the 8. Apply John Deere NEVER-SEEZ (PT569) to shaft
pump and motor. of drive motor. Install fan drive hub and fan. Tighten
fan hub hex nut to specification.
5. Install fan drive motor bolts and tighten to
specification. Specification
Fan-to-Drive Hub Hex Nut—
Torque....................................................................... 81 N•m (60 lb-ft)
Specification
Fan Drive Motor Housing Bolt—
Torque.................................................................... 55 N•m (40.5 lb-ft) 9. Install fan shroud, leave cap screws loose. Adjust
clearance between shroud and fan blade tips to
6. Install relief valve and tighten to specification. specification. Move shroud for left-right adjustment
and use fan support for up-down adjustment.
Specification Tighten cap screws. Install fan guard.
Fan Drive Motor Relief Valve—
Torque.................................................................... 32 N•m (23.5 lb-ft) Specification
Fan Tip-to-Shroud—Clearance ......... 4.8—9.4 mm (0.189—0.386 in.)
7. Tighten fan drive pump housing bolts to
specification.
Specification
Fan Drive Pump Housing
Bolt—Torque .......................................................... 55 N•m (40.5 lb-ft)
05
0510
7
NEVER-SEEZ is a trademark of Emhart Chemical Group. CED,OUOE002,1570 –19–23AUG02–6/6
Remove And Install Radiator, Oil, And Air

Cooler
(S.N. —585560)
Remove and Install is located later in this procedure.

011504
PN=277
Cooling System
CAUTION: Do not remove radiator filler cap

unless engine is cool Then turn cap slowly to
the stop, then remove.
NOTE: Approximate capacity of cooling system is 29 L
–UN–12JUN98
(31 qt).
Specification
Cooling System—Capacity ...................................................... 29 L (31 qt)
T115610
1. Remove radiator cap. Attach hose to radiator drain
cock (A). Drain engine coolant into a container.
Remove hose and tighten drain cock. A—Radiator Drain Cock
2. Remove coolant recovery tank from hood.
CAUTION: Approximate weight of hood, air

cleaner, and exhaust pipe is 77 kg (167 lb).
Specification
Hood, Air Cleaner, and Exhaust
Pipe Assembly—Weight .................................. 77 kg (167 lb) approximate
3. Remove hood with air cleaner and exhaust pipe.
4. Disconnect electrical harness connectors for coolant

05 level sensor and lights in grille.
0510
8
CAUTION: Approximate weight of grille housing
and grille is 111 kg (244 lb).
Specification
Grille Housing and Grille
Assembly—Weight ........................................ 111 kg (244 lb) approximate
5. Remove grille and grille housing. (See Group 1921.)

011504
PN=278
Cooling System
6. Disconnect upper (B) and lower (E) radiator hoses and

hose to coolant recovery reservoir.
7. Disconnect transmission and hydraulic oil cooler hoses

(C, D, G, and H).
8. Disconnect upper (A) and lower (F) air-to-air cooler

tubes.
A—Upper Air-to-Air Cooler Tube
B—Upper Radiator Hose
C—Oil Cooler Outlet House
–UN–12JUN98
D—Transmission Cooler Outlet Hose
E—Lower Radiator Hose
F—Lower Air-to-Air Cooler Tube
G—Oil Cooler Inlet Hose
T115607
H—Transmission Cooler Inlet Hose
05
0510
–UN–12JUN98
9
T115608
–UN–27JUL98
T116508

011504
PN=279
Cooling System
9. Remove fan guard.
10. Remove fan shroud.
11. Remove hydraulic lines (A and B).
12. Remove fan and fan motor.
A—Inlet Hose
B—Outlet Hose
–UN–12JUN98
T115609
05
0510
10

011504
PN=280
Cooling System
–19–15JUN98
T115604
05
A—Side Plate-to-Grille D—Angle Bracket H—Side Plate K—Radiator 0510
Housing Cap Screw E—T Bracket I—Air Deflector L—Fan Shroud 11
B—Hex Nut, Rod F—Bracket to Frame J—Air-to-Air Cooler M—Fan Guard
C—Side Plate-to-Frame Cap G—Hydraulic and
Screw Transmission Oil Cooler
13. Remove cap screws from air deflector brackets.

Remove air deflector (I).

011504
PN=281
Cooling System
14. Remove cap screws (A) from air conditioner

condenser.
NOTE: Air conditioning system does NOT have to be

discharged to remove radiator oil, and air coolers.
–UN–23OCT97
T111807B
CED,OUOE002,1572 –19–23AUG02–6/12
05
0510
12
15. Remove cap screws (B). Do not disconnect air
conditioning hoses from condenser. Lay air
conditioning condenser forward and secure with rope.
–UN–23OCT97
T111806B

011504
PN=282
Cooling System
CAUTION: Approximate weight of radiator,

hydraulic and transmission oil cooler and air
cooler assembly is 76 kg (156 lb).
Specification
Radiator, Hydraulic and
Transmission Oil Cooler and Air
Cooler Assembly—Weight............................... 76 kg (156 lb) approximate
16. Attach hoist to radiator, oil, and air cooler assembly.

Remove cap screws attaching assembly to frame.
17. Carefully remove assembly.
18. Make necessary repairs.
19. Install radiator, oil, and air cooler assembly.
–UN–01MAY97
T109372B
544H Shown 05
0510
13

011504
PN=283
Cooling System
–19–15JUN98
T115604
05
0510 A—Side Plate-to-Grille D—Angle Bracket H—Side Plate K—Radiator
14 Housing Cap Screw E—T Bracket I—Air Deflector L—Fan Shroud
20. Install side plate-to-frame cap screws (C) and 25. Connect transmission and hydraulic oil cooler
washers. Tighten cap screws. hoses.
Specification 26. Connect radiators hoses and coolant recovery

Side Plate-to-Frame Cap reservoir hose.
Screw—Torque ....................................................... 129 N•m (95 lb-ft)
27. Install upper and lower air-to-air cooler tubes.

21. Install fan and fan motor.
28. Install fan hydraulic pump hoses.
22. Replace foam strips on fan shroud (L). Install fan
shroud leaving cap screws loose.
29. Install grille and grille housing. (See Group 1921.)
23. Adjust fan tip-to-shroud clearance evenly around
30. Install hood.
fan to specification. Tighten shroud cap screws.
Specification 31. Fill radiator with correct coolant mixture.

Fan Tip-to-Shroud—Clearance ......... 4.8—9.4 mm (0.189—0.386 in.)
Specification
Cooling System—Capacity ............................................... 29 L (31 qt)
24. Install fan guard (M).

011504
PN=284
Cooling System
32. Cooling system must be deaerated to remove air 1. Drain cooler fluids into a proper container, as
from system and to properly fill it with coolant. See needed.
Operator’s Manual for deaeration of cooling
system procedures. 2. Remove coolant recovery tank.
33. Check transmission and hydraulic oil level and 3. Remove air cleaner pipe-to-turbo, exhaust pipe
refill as needed. clamp, and air cleaner sensor wire.
(S.N. 585561—)
CAUTION: Heavy component; use a hoist.
NOTE: Coolers may be removed separately or as an Remove and Install Coolers—Specification
assembly. Hood—Weight........................................... 79 kg (175 lb) approximate
CAUTION: Explosive release of fluids from 4. Remove hood. See Hood Remove and Install.
pressurized cooling system can cause (Group 1910.)
serious burns.
5. Disconnect electrical harness connectors for lights
Shut off engine. Only remove filler cap when in grille.
cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve 6. Remove fan and dust guards.
pressure before removing completely.
7. Remove fan.
NOTE: Approximate capacity of cooling system is 22 L
(23 qt). Radiator holds 11 L (12 qt), hydraulic
oil cooler 5 L (5 qt), transmission cooler 6 L (6
qt).
05
0510
15

011504
PN=285
Cooling System
–UN–13JUN02
T156120B
1—Cooler-to-Turbo Hose 2—Radiator Hose 3—Condenser 4—Transmission Cooler Hose
8. Remove top cooler hoses.

CAUTION: Heavy component; use a hoist.
NOTE: Air conditioner system does NOT have to be Remove and Install Coolers—Specification
discharged to remove coolers. Grille Housing—Weight .......................... 128 kg (282 lb) approximate
05
0510
16 9. Remove condenser (3). 11. Remove grille housing.
10. Remove cooler-to-grille housing cap screws.

011504
PN=286
Cooling System
–UN–13JUN02
T156117B
Lower Hoses
1—Radiator Hose 2—Air Cooler Hose 3—Hydraulic Cooler Hose
12. Remove lower cooler hoses. 19. Install condenser.
13. Remove bottom cooler mount cap screws. 20. Install upper cooler hoses.
05
21. Install fan. See Remove and Install Fan and Fan 0510
CAUTION: Check for clearance of fan motor 17
Drive for torque specifications. (Group 510.)
lines before removing cooler.
22. Install fan and dust guard.
14. Remove necessary cooler.
23. Connect electrical harness connectors for lights in
15. Install cooler using bottom cooler capscrews.
grille.
Remove and Install Coolers—Specification
Cooler-to-Bottom Plate— 24. Install hood.
Torque....................................................................... 73 N•m (54 lb-ft)
25. Install air cleaner pipe to turbo, exhaust pipe
16. Install lower cooler hoses. clamp, and air cleaner sensor wire.
17. Install grille housing. 26. Install coolant recovery tank.
Remove and Install Coolers—Specification 27. Refill coolers as necessary. See Drain and Refill
Grill Housing-to-Frame Cap
Capacities for refill capacities. (Go to Operator’s
Screw—Torque ....................................................... 129 N•m (95 lb-ft)
Manual.)
18. Install cooler-to-grille cap screws.
Remove and Install Coolers—Specification

Cooler-to-Grill Cap Screw—
Torque....................................................................... 73 N•m (54 lb-ft)
CED,OUOE002,1572 –19–23AUG02–12/12

011504
PN=287
Cooling System
Disassemble And Assemble Radiator, Oil,

And Air Cooler (S.N. —585560)
Disassembly and assembly procedure for later machines

is located in Remove and Install Radiator, Oil, And Air
Cooler procedure. (Group 0510.)
TX,05,RP3341 –19–23AUG02–1/7
05
0510
18
–19–15JUN98
T115604
A—Side Plate-to-Grille D—Angle Bracket H—Side Plate K—Radiator

Housing Cap Screw E—T Bracket I—Air Deflector L—Fan Shroud
1. Remove radiator, oil, air cooler assembly per 2. Disassemble radiator, oil, air cooler assembly.
procedures in this group. Replace parts as necessary.
Continued on next page TX,05,RP3341 –19–23AUG02–2/7

011504
PN=288
Cooling System
3. Apply foam strips (A) to both sides of radiator (4 pieces

required).
A—Foam Strip (4 used)
–UN–19NOV97
T111950
TX,05,RP3341 –19–23AUG02–3/7
05
0510
19
4. Assemble side plate (B) to oil cooler (C).
B—Side Plate
C—Oil Cooler
–UN–30APR97
T109356B

011504
PN=289
Cooling System
5. Thread four rods (D) with fixed nuts into oil cooler side
member. Tighten rods.
6. Assemble brackets (E) and straps with isolators (F)

loosely to oil cooler and rods.
–UN–30APR97
7. Thread hex nuts (G) on rods.
D—Rod (4 used)
T109357B
E—Bracket (4 used)
F—Isolator (3 used)
G—Hex Nut (4 used)
05
0510
20

011504
PN=290
Cooling System
8. Assemble side plate (H) to air cooler (I).
NOTE: For ease of assembly, cut a rod (L) 1092 ± 4 mm

(43 ± 0.2 in.) to measure distance between
radiator, oil, and air cooler side plates.
9. Assemble radiator, oil, and air cooling package. Adjust

jam nuts on threaded rods so cooling package is to
specification, measured inside the side plates and
tighten rod hex nuts.
–UN–30APR97
Specification
Radiator, Oil, and Air Cooling
Package—Width .............................................. 1092 ± 4 mm (43 ± 0.2 in.)
dimension inside side plate
T109358B
Rod Hex Nut—Torque ................................................... 122 N•m (90 lb-ft)
10. Tighten cooler-to-rod mount bracket cap screws.

H—Side Plate
Specification I—Air Cooler
Cooler-to-Rod Mount Bracket Cap J—Bracket (4 used, front shown)
Screw—Torque ................................................................ 46 N•m (34 lb-ft) K—Cap Screw (3 used)
11. Replace foam strips on top and bottom of fan shroud.
12. Install radiator, oil, and air cooler assembly on

machine. Tighten radiator, oil, and air cooler
assembly-to-frame cap screws.
05
Specification 0510
Radiator, Oil, and Air Cooler 21
Assembly-to-Frame Cap Screw—
Torque ........................................................................... 129 N•m (95 lb-ft)

011504
PN=291
Cooling System
–UN–23OCT97
T111703
05
0510 A—Drive Hub B—Nut C—Washer D—Label
22
13. Install fan motor and fan. Tighten fan-to-fan drive 16. Tighten fan shroud cap screws.
hub nut (B).
17. Install grille housing. (See Group 1921). Install
Specification grille housing-to-frame cap screws and tighten.
Fan-to-Fan Drive Hub Nut—
Torque....................................................................... 81 N•m (60 lb-ft)
Specification
Grille Housing-to-Frame Cap
14. Install shroud on radiator, leaving cap screws Screw—Torque ....................................................... 129 N•m (95 lb-ft)
loose.
18. Install side plate-to-grille housing cap screws and
15. Adjust fan tip-to-shroud clearance to 4.8—9.4 mm tighten.
(0.189—0.370 in.) evenly around fan.
Specification
Specification Side Plate-to-Grille Housing
Fan Tip-to-Shroud—Clearance ......... 4.8—9.4 mm (0.189—0.370 in.) Cap Screw—Torque ................................................. 73 N•m (54 lb-ft)
Move shroud for left-right adjustment and fan support

for up-down adjustment.
TX,05,RP3341 –19–23AUG02–7/7

011504
PN=292
Group 0515
Speed Controls
Remove And Install Speed Control Linkage
–UN–27JUL98
T116509
05
0515
1
1—Spring 3—Bracket 5—Clip 7—Boot
2—Linkage 4—Sensor 6—Screw
1. Remove front and right cab shields. 6. Install assembly.
2. Disconnect wiring connectors to throttle position 7. Install cap screws.

sensors (4).
8. Connect wiring connectors.
3. Remove cap screws (6).
9. Adjust speed throttle control sensors. (See Speed
4. Remove assembly (1, 2, 3, and 5). Control Linkage Adjustment.)
5. Repair or replace as necessary. 10. Install shields.
TX,0515,RB158 –19–12AUG96–1/1

011504
PN=293
Speed Controls
05
0515
2

011504
PN=294
Group 0520
Intake System
05
0520
1

011504
PN=295
Intake System
Remove And Install Air Cleaner
05
0520
2
–UN–06NOV96
TP48541

011504
PN=296
Intake System
1—Band (2 used) 6—Valve 11—O-Ring 14—Filter Element

2—Washer (4 used) 7—Clamp 12—Air Filter Restriction 15—Cover
3—Screw (4 used) 8—Cap Sensor 16—Valve
4—Air Cleaner Housing 9—Elbow Fitting 13—Filter Element 17—Air Cleaner Assembly
5—Clamp 10—Adapter
(S.N.—585560) 4. Inspect elements for wear or damage and replace

as necessary.
1. Remove four screws (3) and bands (1).
5. Install parts.
2. Disconnect wiring harness connector from air filter
restriction switch. 6. Connect wiring harness connector to air filter
restriction switch.
3. Remove and install parts as needed.
TX,0520,111296 –19–27MAY98–2/6
7. Tighten hose clamps (A and B) until air intake hose

protrudes around clamp band.
8. Test air intake system. (See Air Intake System

Leakage Test. (Group 9010.)
05
–UN–17MAR97
0520
A—Clamp 3
B—Clamp
T108196

011504
PN=297
Intake System
25
20
24
23 23
22
19
18 18
7 6
21 3 3
2
5
9
10
05
1
0520 14 12
4
4
1
13
7
15
17
–UN–12JUL02
16
T157094
T157094

011504
PN=298
Intake System
1—Band (2 used) 8—Cap 14—Filter Element 20—Nut

2—Washer (4 used) 9—Elbow Fitting 15—Cover 21—Clamp
3—Screw (4 used) 10—Adapter 16—Valve 22—Precleaner
4—Air Cleaner Housing 11—O-Ring 17—Air Cleaner Assembly 23—Screw (4 used)
5—Clamp 12—Air Filter Restriction 18—Nut (4 used) 24—Tube
6—Valve Sensor 19—Plate 25—Spring
7—Clamp 13—Filter Element
(S.N. 585561—) 4. Inspect elements for wear or damage and replace

as necessary.
1. Remove four screws (3) and bands (1).
5. Install parts.
2. Disconnect wiring harness connector from air filter
restriction switch. 6. Connect wiring harness connector to air filter
restriction switch.
3. Remove and install parts as needed.
TX,0520,111296 –19–27MAY98–5/6
7. Tighten hose clamps (A and B) until air intake hose

protrudes around clamp band.
8. Test air intake system. (See Air Intake System

Leakage Test in this group.)
05
–UN–17MAR97
0520
A—Clamp 5
B—Clamp
T108196
TX,0520,111296 –19–27MAY98–6/6

011504
PN=299
Intake System
05
0520
6

011504
PN=300
Group 0530
External Exhaust System
05
0530
1

011504
PN=301
Remove And Install Muffler
05
0530
2
–UN–02JUL98
T115618

011504
PN=302
1—Screw, M10 x 30 (8 used) 4—Lock Nut (4 used) 7—Screw M10 x 30 (4 used) 10—Bracket
2—Exhaust Pipe (Black) 5—Muffler 8—Screw, M12 x 30 11—Exhaust Pipe (Chrome)
3—Washer (12 used) 6—Bracket 9—Clamp
(S.N. —585560) 7. Install clamp (9) that connects muffler inlet to

turbocharger. Tighten clamp until connection is
snug, but inlet pipe can still rotate.
CAUTION: Muffler may be hot. Allow muffler
to cool before removing.
8. Adjust muffler position so that muffler body is level
and tighten mounting screws to keep it level.
CAUTION: Approximate weight of hood, air
cleaner and exhaust pipe is 76 kg (167 lb). 9. Tighten cap screws (1, 7, and 8).
Specification Specification
Hood, Air Cleaner, and Exhaust Exhaust Pipe-to-Hood Cap
Pipe Assembly—Weight ........................... 76 kg (167 lb) approximate Screw—Torque ......................................................... 73 N•m (54 lb-ft)
Bracket-to-Muffler Cap Screw—
1. Remove hood. Torque....................................................................... 73 N•m (54 lb-ft)
Bracket-to-Engine Cap Screw—
Torque....................................................................... 73 N•m (54 lb-ft)
2. Remove clamp (9).
10. Tighten clamp (9).
3. Remove cap screws (1) and washers (3).
11. Install hood.
4. Remove cap screws (7 and 8) to remove brackets
(6 and 10).
5. Replace if necessary.
05
6. Install bracket-to-engine cap screws (7 and 8), 0530
screws (1) and washers (3). Do not tighten at this 3
time.

011504
PN=303
05
0530
4
–UN–20JUN02
T156383
T156383

011504
PN=304
1—Nut, M10 Flange (4 used) 6—Washer, 10.7 x 21 x 2.5 mm 9—Pipe, Exhaust 13—Clamp
2—Cap Screw, 3/8” x 1” 7—Washer, 10.5 x 30 x 2.5 mm 10—Muffler 14—Support
3—Cap Screw, 5/8” x 1-1/2” (4 used) 11—Bracket 15—U-Bolt
4—Cap Screw, 5/8” x 5-3/4” 8—Washer, 17 x 30 x 3 mm (2 12—Lock Nut
5—Screw, M10 x 25 (4 used) used)
(S.N. 585561—) 9. Replace parts if necessary.
10. Install U-bolt (15) and lock nuts (12). Do not

CAUTION: Muffler may be hot. Allow muffler
tighten at this time.
to cool before removing.
11. Install clamp (13). Tighten clamp until connection
CAUTION: Heavy component; use a hoist. is snug, but inlet pipe can still rotate.
Hood, air cleaner, coolant recovery bottle, and exhaust pipe 12. Adjust muffler position so that muffler body is
assembly—Specification
level. Tighten U-bolt lock nuts (12) to specification.
Hood, air cleaner, coolant
recovery bottle, and exhaust
pipe assembly—Weight ............................ 76 kg (167 lb) approximate Specification
U-Bolt-to-Bracket Lock Nut—
Torque....................................................................... 34 N•m (25 lb-ft)
1. Remove clips holding coolant recovery hose from
hood. 13. Install hood.
2. Remove coolant recovery bottle overflow hose. 14. Tighten clamp (13).
3. Disconnect coolant recovery hose from radiator and 15. Connect air cleaner hose to turbocharger and
clamp end. tighten clamp.
4. Loosen air cleaner hose clamp on turbocharger. 16. Connect air filter restriction switch to harness. 05
0530
5. Disconnect air filter restriction switch from harness. 5
17. Install overflow hose to coolant recovery bottle.
Connect coolant recovery hose to radiator
6. Remove hood with air cleaner, coolant recovery
bottle, and exhaust pipe attached. 18. Install clips holding coolant recovery hose to hood.
7. Remove clamp (13).
8. Remove lock nuts (12) to remove U-bolt (15).
CED,OUOE002,1586 –19–29AUG02–4/4

011504
PN=305
05
0530
6

011504
PN=306
Group 0560
External Fuel Supply Systems
05
0560
1

011504
PN=307
Remove And Install Fuel Tank
05
0560
2
–UN–26JUN97
TP55593

011504
PN=308
1—Fuel Tank 9—Sender 17—Bolt (4 used) 25—Clamp

2—Drain Valve 10—Screw (5 used) 18—Flange Nut (4 used) 26—Hose
3—Elbow Fitting (2 used) 11—Clamp 19—Screw (2 used) 27—Screw
4—Clamp (2 used) 12—Hose (as needed) 20—Clamp (2 used) 28—Clamp
5—Clamp (8 used) 13—Filler Neck 21—Hose 29—Adapter
6—Elbow Fitting 14—Hose Fitting (2 used) 22—Clamp (2 used) 30—Filler Neck Assembly
7—Elbow Fitting 15—Filler Cap 23—Hose (as needed) 31—Fuel Tank
8—Gasket 16—O-Ring 24—Hydraulic Hose
05
0560
3

011504
PN=309
05
0560
4
–UN–11JUL02
T156989
T156989

011504
PN=310
1—Cap Screw (9 used) 10—Screw (4 used) 19—Elbow Fitting 28—Tie Band (5 used)
2—Screw (3 used) 11—Filler Cap 20—Fuel Sender 29—Fuel Line (2 used)
3—Washer (9 used) 12—Clamp 21—Fuel Line 30—Gasket
4—Clip 13—Clamp 22—Seal (2 used) 31—Hose
5—Clamp (10 used) 14—Hose Fitting 23—Fuel line 32—Hose
6—Clamp (2 used) 15—Elbow Fitting 24—Hose 33—Clamp
7—Clamp 16—Fuel Tank 25—Hose 34—Hose Clamp
8—Housing 17—Valve (4 used) 26—Hose 35—Breather
9—Flange Nut (4 used) 18—Clamp (4 used) 27—Hose Clamp (2 used)
1. Turn battery disconnect switch off (if equipped) or 6. Disconnect wiring leads from fuel gauge sending
disconnect battery ground strap. unit (9).
2. Disconnect hose (23) from filler neck.

fuel tank (without fuel) is 21 kg (47 lb).
3. Disconnect hose (21) at tank.
Approximate weight of fuel tank and fuel
tank bottom guard is 230 kg (508 lb).
CAUTION: Remove fuel to reduce weight of
the fuel tank. Capacity of fuel tank is 265 L Specification
(70 gal). Fuel Tank (without fuel)—
Weight ......................................................... 21 kg (47 lb) approximate
Fuel Tank and Bottom Guard—
Specification
Weight ..................................................... 230 kg (508 lb) approximate
Fuel Tank—Capacity .................................................... 341 L (90 gal)
7. Support fuel tank and bottom guard with a lifting

4. Disconnect hose (24) at primary fuel filter and drain
table or floor jack.
fuel into clean container or pump fuel out of the
tank.
5. Disconnect hose (12) at leak-off line on engine 05

0560
head.
5

011504
PN=311
05
0560
6
–UN–11APR02
T153924
1—Cap Screw (2 used) 3—Guard 5—Cap Screw (8 used) 7—Clamp (3 used)

2—Strap (2 used) 4—Washer (8 used) 6—Lock Nut (2 used)

011504
PN=312
8. Remove cap screws (5) and washers (4) from 12. Raise fuel tank into place with lifting device. Install
bottom guard and lower tank to floor. cap screws (5) and washers (4).
9. Remove straps to remove fuel tank from guard (3). 13. Connect wiring leads to fuel level sending unit.
10. Replace parts as necessary. 14. Connect hoses to fuel tank.
11. Install straps. Tighten cap screws (5).
Specification
Fuel Tank Strap Cap Screw—
Torque................................................................... 318 N•m (235 lb-ft)
CED,OUOE002,1588 –19–27MAY98–6/7
IMPORTANT: If fuel tank vent hose is plugged or

pinched, the fuel tank could collapse
and engine performance will be
affected.
15. Check fuel tank vent hose (A) for being plugged or 05
pinched. Clean, reposition or replace hose. 0560
7
16. Connect battery ground strap. Turn battery disconnect

switch on (if equipped).
A—Fuel Tank Vent Hose
–UN–27AUG97
T111244B
CED,OUOE002,1588 –19–27MAY98–7/7

011504
PN=313
05
0560
8

011504
PN=314
Section 07
Dampener Drive
Contents
Page
Group 0752—Elements
Dampener
07

011504
PN=1
Contents
07

011504
PN=2
Group 0752
Elements
Remove And Install Dampener
1. Open engine side shields.
2. Remove drive shaft.
–UN–27OCT88
3. Remove covers (A) and dampener (B).
Specification
Dampener-to-Flywheel Cap
T6564AS
Drive Shaft-to-Dampener—
Torque ........................................................................... 130 N•m (95 lb-ft)
Drive Shaft-to-Torque Converter
Input Yoke—Torque ........................................................ 78 N•m (58 lb-ft) A—Cover (2 used)
B—Dampener
TX,07,JC2342 –19–27MAY98–1/1
07
0752
1

011504
PN=317
Elements
07
0752
2

011504
PN=318
Section 09
Steering System
Contents
Page

Essential Tools . . . . . . . . . . . . . . . . . . . . . . .09-0960-1
Service Equipment and Tools . . . . . . . . . . . .09-0960-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . .09-0960-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . .09-0960-2
Steering Valve
Steering Column
Steering Cylinder
Disassemble and Assemble Steering
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-10
Steering Cylinder Bushings
Remove and Install . . . . . . . . . . . . . . . . .09-0960-10
09

011504
PN=1
Contents
09

011504
PN=2
Group 0960
Hydraulic System
Essential Tools
Order tools according to information given in the U.S.

SERVICEGARD Catalog or from the European
Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company OUT3019,00000A2 –19–27AUG03–1/1
Service Equipment and Tools
Order tools according to information given in the U.S.

SERVICEGARD Catalog or from the European
Microfiche Tool Catalog (MTC). Some tools may be
available from a local supplier.
SERVICEGARD is a trademark of Deere & Company OUT3019,00000A3 –19–27AUG03–1/1
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVER-SEEZ Apply to steering column tilt pivots
Lubricant and threads on steering shaft.
09
0960
1
NEVER-SEEZ is a trademark of Emhart Chemical Group. OUT3019,00000A6 –19–27AUG03–1/1

011504
PN=321
Hydraulic System
Specifications
Hydraulic Reservoir Capacity 117 L (31 gal) approximate
Steering Valve Isolator Cap Screw Torque 57 N•m (42 lb-ft)
Valve-to-Plate Cap Screw Torque 27 N•m (20 lb-ft)
Steering Wheel-to-Steering Column Torque 68 N•m (50 lb-ft)

Nut
Isolator Cap Screw Torque 57 N•m (42 lb-ft)
Steering Cylinder Weight 65 kg (143 lb) approximate
OUT3019,00000A7 –19–27AUG03–1/1
09
0960
2

011504
PN=322
Hydraulic System
Remove And Install Steering Valve
–19–23JUL97
–19–23JUL97
unexpected machine movement. Install frame
locking bar before working in frame hinge area.
T110749
T110750
1. Install frame locking bar.
2. Stop engine.
–19–23JUL97
unexpected boom or bucket movement. Ride
T110754
control accumulator MUST be discharged when
working on hydraulic components.
Engine OFF.
With boom raised slightly, turn ignition switch

to ON position. Cycle the ride control switch
from OFF to ON (center position). Boom will
jump up unexpectedly if ride control
accumulator is energized. Press boom enable
switch and move the control lever into the float
position and hold for 5 seconds.
3. Engine OFF.
With boom raised slightly, turn ignition switch to ON

position. Cycle the ride control switch from OFF to ON
(center position). Boom will jump up unexpectedly if
ride control accumulator is energized. Press boom
enable switch and move the control lever into the float
If not equipped with ride control, press pilot

enable/boom down switch to BOOM DOWN position,
move the control lever into FLOAT position and hold
09
for 5 seconds to relieve any residual hydraulic 0960
pressure. 3
4. Drain hydraulic reservoir or connect a vacuum pump to

the reservoir by removing the vent filter and attaching
the vacuum pump to its fitting in the reservoir.
Specification
Hydraulic Reservoir—Capacity....................... 117 L (31 gal) approximate
Continued on next page TX,0960,JC2036 –19–30JUN98–1/5

011504
PN=323
Hydraulic System
5. Remove front cab shield.
TX,0960,JC2036 –19–30JUN98–2/5
–UN–23JUL97
T110783
A—Return C—Right Turn D—Left Turn E—Pressure
B—Load Sense
6. Disconnect and label hoses. Plug or cap hoses and

fittings.
09
0960
4

011504
PN=324
Hydraulic System
09
0960
5

011504
PN=325
Hydraulic System
09
0960
6 –UN–08MAY97
T109458

011504
PN=326
Hydraulic System
1—Isolator 4—Bracket 7—Lock Nut (3 used) 10—Cap Screw (3 used)

2—Cap Screw (4 used) 5—Washer (4 used) 8—Washer (3 used) 11—Cap Screw (2 used)
3—Washer (4 used) 6—Steering Column 9—Rubber Mount (3 used)
7. Remove cover from steering column. 12. Repair or replace parts as necessary.
8. Remove lock nuts (7), washers (8), rubber mounts Specification

Steering Valve Isolator Cap
(9) and cap screws (10).
Screw—Torque ......................................................... 57 N•m (42 lb-ft)
Valve-to-Plate Cap Screw—
9. Remove cap screw (11). Torque....................................................................... 27 N•m (20 lb-ft)
10. Remove steering valve.
11. Remove cap screws (2) and washers (3) to

remove bracket (4) from steering column (6).
TX,0960,JC2036 –19–30JUN98–5/5
09
0960
7

011504
PN=327
Hydraulic System
Remove And Install Steering Column
–19–25JUL97
T110814
1—Cover 6—Steering Wheel 11—Dowel Pin 16—Cover
2—Spring Assembly 7—Snap Ring 12—Screw (2 used) 17—Steering Column
3—Nut 8—Seal 13—Bolt (2 used) 18—Steering Column Tilt
4—Lock Washer (2 used) 9—Screw (4 used) 14—Brush Set Pivots
5—Knob 10—Spring 15—Isolator 19—Steering Shaft
1. Remove steering column cover. 7. Apply John Deere NEVER-SEEZ lubricant or

equivalent to steering column tilt pivots (18) and
2. Remove shift selector and turn signal switch. threads on steering shaft (19).
09
0960 3. Disconnect spring (10). 8. Assemble parts (1—17).
8
4. Remove cap screws (9).
5. Remove parts (1—8) and (10—17).
6. Repair or replace parts as needed.
Specification
Steering Wheel-to-Steering
Column Nut—Torque ................................................ 68 N•m (50 lb-ft)
Isolator Cap Screw—Torque .................................... 57 N•m (42 lb-ft)
NEVER-SEEZ is a trademark of Emhart Chemical Group. TX,0960,MA15 –19–30JUN98–1/1

011504
PN=328
Hydraulic System
Remove And Install Steering Cylinder

unexpected machine frame movement. Install
frame locking bar to both frames before you
work in the frame pivot area.
–UN–23AUG88
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard
by relieving pressure before disconnecting
X9811
hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with
a piece of cardboard. Protect hands and body
from high pressure fluids.
If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be
surgically removed within a few hours or
–UN–21MAY96
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgeable medical source. Such
information is available from Deere & Company
T101186
Medical Department in Moline, Illinois, U.S.A.
1. Install frame locking bar (C). Stop engine.

A—Pin
2. Turn steering wheel back and forth to release hydraulic B—Retaining Ring
C—Frame Lock Bar
pressure in the system.
3. Disconnect lines from cylinder. Close all openings

using caps and plugs.

steering cylinder is 28 kg (61 lb).
Specification
Steering Cylinder—Weight .............................. 65 kg (143 lb) approximate
09
0960
4. Remove pin from rod and head end of cylinder.
9
5. Remove cylinder from unit.
6. See Disassemble Cylinder. TMH120A. (Group 01) See

Assemble Cylinder. TMH120A. (Group 01)
7. Install cylinder and connect lines.

011504
PN=329
Hydraulic System
8. Install one spacer under cylinder head end. If required,

install one spacer above cylinder head end. Install
head end pin.
9. Fill gap under rod end with spacers, then install one
additional spacer. Fill gap over rod end with spacers.
Install rod end pin.
CED,OUOE002,1592 –19–27MAY98–2/2
Disassemble and Assemble Steering

Cylinder
See Disassemble Cylinder in TMH120A. (Group 01.) See

Assemble Cylinder in TMH120A. (Group 01.)
OUT3019,000009A –19–19AUG03–1/1
Remove And Install Steering Cylinder

Bushings
Remove and install bushing (A) using disks from driver

set.
–UN–09NOV88
A—Bushing
09
0960 T90813
10
TX,0960,RB91 –19–27MAY98–1/1

011504
PN=330
Section 10
Service Brakes
Contents
Page

External Service Brakes
Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1011-1
Brake Assembly

Brake Valve
Brake Accumulator
10

011504
PN=1
Contents
10

011504
PN=2
Group 1011
Active Elements
Inspect External Service Brakes
Do first inspection at 5000 hours followed by 1000 hours

inspection intervals after the first 5000 hours inspection.
–UN–02NOV98
If the service brakes are subjected to severe duty, inspect
more frequently.
1. Remove plug form brake inspection port.
T105193B
2. Start engine and run for one minute.
3. Stop and apply the brakes. Block pedal or have

someone hold brakes on.
4. Using a feeler gauge (A), measure the thickness of

disks at dimension (B). Check dimension of two
different disks.
–UN–25FEB97
Specification
Thickness.................................................................... 2.29 mm (0.090 in.)
minimum used
T105767B
5. If either of the disks thickness at dimension (B) is less
than the minimum specification, the brake packs must
be replaced. A—Feeler Gauge
B—Dimension
CED,OUOE003,1094 –19–01JUL98–1/1
10
1011
1

011504
PN=333
Active Elements
Remove And Install Brake Assembly
1. Remove differential and axle assembly. (See Group

0225.)
2. Remove final drive assemblies and brake packs. (See

Group 0250.)
NOTE: A rolling head pry bar may be used to remove the

piston.
–UN–02JAN97
3. Remove brake piston (A) from case/cover using
compressed air at the brake pressure inlet.
4. Inspect six separator plate retaining slots (B). Check
RW36119
the slots for galling or wear that might restrict the
movement of the separator plates. Smooth the slots
using a file or grinder. If there is too much wear,
replace the differential case. A—Brake Piston
B—Retaining Slot (6 used)
TX,1011,JC2282 –19–06MAY97–1/3
5. Inspect brake piston (A).
6. Remove and replace packing rings (B) and (C).
7. Replace piston as necessary.
8. Inspect parts (D) and (E). Check the tabs on the

separator plates for distortion or wear that might
restrict there movement. Smooth the tabs using a file
or grinder or replace the plates.
–UN–08JAN97
Specification
Separator Plate—Thickness ................................ 3.05 mm (0.120 in.) new
10 9. Inspect the brake disk splines (F) on the planetary

RW36120
1011
carrier.
2

A—Brake Piston
B—OD Packing Ring
C—ID Packing Ring
D—Brake Separator Plates (6 used)
E—Brake Disks (4 used)
F—Planetary Carrier Brake Disk Splines
Continued on next page TX,1011,JC2282 –19–06MAY97–2/3

011504
PN=334
Active Elements
11. Install brake piston (A) into differential case piston

bore.
12. Install final drive assemblies. (See Group 0250.)
13. Install differential and axle assembly. (See Group

0225.)
A—Brake Piston
–UN–08JAN97
RW36150
TX,1011,JC2282 –19–06MAY97–3/3
10
1011
3

011504
PN=335
Active Elements
10
1011
4

011504
PN=336
Group 1060
Hydraulic System
Remove And Install Brake Valve
–UN–14JAN97
T103102
10
1060
1

011504
PN=337
Hydraulic System
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
–UN–23AUG88
Protect hands and body from high pressure
fluids.
X9811
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
1. Stop engine.
2. Lower boom to ground, push pilot enable switch to

boom down position and hold control lever in float
position.

for 5 seconds.

10 seconds.
1060
2

011504
PN=338
Hydraulic System
Specification
Brake Accumulator Nitrogen
Charge—Pressure ...................................... 1137 kPa (11.4 bar) (165 psi)
4. With machine OFF apply brakes approximately 30

times to discharge both brake accumulators.
5. Remove shielding trim on front and right side of cab for

access.
6. Remove clamp and return hose from brake valve.
TX,1060,JC2284 –19–25JUN98–3/4
7. Pinch off return hose (A) with vise grip to stop reservoir
hydraulic oil from draining back.
8. Disconnect hoses and electric connectors.
9. Remove cap screws and brake valve.
11. Install brake valve.
–UN–21NOV97
12. Connect hoses and electric connectors.
13. Check for slight clearance between brake valve
T112343B
plunger and roller spinning freely on brake pedal.
A—Return Hose
TX,1060,JC2284 –19–25JUN98–4/4
10
1060
3

011504
PN=339
Hydraulic System
Remove And Install Brake Accumulator
CAUTION: Oil pressure must be released from

brake accumulator before disconnecting lines
or removing fittings. Accumulator inlet check
valve seat is the inlet fitting. Removing
–UN–23AUG88
accumulator inlet fitting will release oil pressure
causing possible injury.
1. Stop engine.
X9811
2. Lower bucket to ground. With bucket level, push pilot
enable switch to boom down position and hold control
lever in float position.

for 5 seconds.

seconds.
Specification
Brake Accumulator Nitrogen
Charge—Pressure ...................................... 1137 kPa (11.4 bar) (165 psi)
4. With machine OFF apply brakes approximately 30

times to discharge both brake accumulators.
10
1060
4

011504
PN=340
Hydraulic System

–UN–28AUG02
fluids.
T158950
gangrene may result. Doctors unfamiliar with A—Accumulator-to-Brake Valve Line
this type of injury should reference a B—Brake/PRV Accumulator
knowledgeable medical source. Such C—Cap Screw (2 used)
information is available from Deere & Company D—Brake Accumulator
E—Brake/PRV Accumulator-to-Main Hydraulic
Pump
F—Brake/PRV Accumulator-to-Pressure Reducing
5. Slowly loosen connections and disconnect lines (A, E Valve
F, and G). G—Brake/PRV Accumulator-to-Brake Accumulator
H—Check Valve
6. Remove cap screws (C). Remove accumulators (B—
D).
NOTE: Accumulator is not repairable. New accumulator is

already charged. Attach new decal.
NOTE: Check Valve (H) may be an adapter on older

units. Sub check valve for adapter.
8. Install accumulators and connect lines.
TX,10,JC2344 –19–25JUN98–2/2
10
1060
5

011504
PN=341
Hydraulic System
10
1060
6

011504
PN=342
Section 11
Park Brake
Contents
Page

Park Brake
Disassemble and Assemble. . . . . . . . . . . .11-1111-4

Park Brake Release Solenoid Valve
Park Brake Pressure Switch
11

011504
PN=1
Contents
11

011504
PN=2
Group 1111
Active Elements
Remove And Install Park Brake

unexpected machine movement. Never rely on
loader bucket to keep machine from moving.
Machine can unexpectedly roll, resulting in
death or serious injury. Always block wheels to
hold machine when working on park brake.
1. Park machine on level surface.
3. Lower bucket to ground.
4. Stop engine. This will engage park brake.
5. Place blocks in front and behind tires.
11
1111
1

011504
PN=345
Active Elements

–UN–23AUG88
fluids.
X9811
–UN–01OCT96
6. Remove park brake hydraulic line (C).
7. Remove drive shafts (A and D).
T104177
8. Remove mounting cap screws (E).
CAUTION: The approximate weight of the park A—Front Drive Shaft

brake assembly is 60 kg (132 lb). B—Park Brake
C—Park Brake Hydraulic Line
Specification D—Articulation Drive Shaft
Park Brake Assembly—Weight ....................... 60 kg (132 lb) approximate E—Cap Screw (4 used)
9. Remove park brake (B).
11
1111
2

011504
PN=346
Active Elements
IMPORTANT: Do not overfill park brake. Fill only to

port. Capacity of the park brake is 0.60
L (20 oz).
Specification
Park Brake Oil—Capacity ................................................... 0.60 L (20 oz)
10. Check park brake oil level at port and add oil as
necessary in port. Allow oil to drain to bottom of level
plug before installing plug to prevent overfilling.
11. Install new park brake. Tighten mounting cap screws.
Specification
Mounting Cap Screw—Torque .................................... 319 N•m (235 lb-ft)
12. Place NEVER-SEEZ lubricant on park brake shaft

(B).
13. Install universal yoke on park brake shaft such that

holes between front and rear yokes are in alignment.
–UN–03NOV97
Install drive shafts.

joint cap screws. Replace cap screws to
T112115C
avoid machine damage.
14. Install new drive shaft universal joint cap screws.

Tighten cap screws. A—Oil and Fill Level Plug
B—Shaft
Specification
Drive Shaft Cap Screw—Torque ..................................... 78 N•m (58 lb-ft)
15. Install park brake hydraulic line.
NEVER-SEEZ is a trademark of Emhart Chemical Group. CED,OUOE002,1600 –19–27MAY98–3/3
11
1111
3

011504
PN=347
Active Elements
Disassemble And Assemble Park Brake
11
–UN–09SEP97
1111
4
TP55599

011504
PN=348
Active Elements
1—Brake 10—Washer 19—O-Ring (2 used) 27—Screw (6 used)

2—Plate 11—Yoke 20—Spring (16 used) 28—Brake Disk (7 used)
3—Gasket 12—Washer 21—Compression Spring (18 29—Brake Disk (7 used)
4—Housing 13—Nut used) 30—Washer (4 used)
5—Bearing (2 used) 14—Retainer 22—Pin (2 used) 31—Cap Screw (4 used)
6—Bearing Cup 15—Seal (2 used) 23—Brake Disk 32—Yoke
7—Bearing Cone 16—Seal (2 used) 24—Piston 33—Elbow Fitting
8—Universal Driveshaft 17—Fitting (2 used) 25—O-Ring 34—O-Ring
9—Snap Ring 18—Relief Valve 26—O-Ring 35—O-Ring
1. Remove nut (13), washer (12) and yoke (11). 6. Remove springs (20), compression springs (21) and
spring retainer (14).
CAUTION: Cover and cap screws are under
7. Remove seals (15 and 16) from housing.
pressure. Remove cap screws evenly to
avoid possible injury.
8. Remove bearing cup (6).
2. Remove cap screws (27) evenly.
9. Remove piston (24) from cover plate.
3. Remove cover plate (2) from housing (4).
10. Remove O-rings (25 and 26) from piston.
4. Remove shaft with brake disks (28) and separator
11. Remove seals (15 and 16) and bearing cup (6)
plates (29).
from cover plate.
5. Remove brake disk (23) from housing.
CED,OUOE002,1601 –19–27MAY98–2/7
12. Remove bearing cone (A) using a bearing puller from

one end of shaft.
13. Remove bearing, disks, and plates from shaft.
14. Press other bearing off shaft.
16. Press bearing cup (6) against shoulder in cover plate.
17. Lubricate O-rings (25 and 26) and piston (24) with
J20C oil. Install inner and outer O-rings on piston.
A—Bearing Cone
–UN–06NOV97
11
1111
5
T112152

011504
PN=349
Active Elements
18. Install piston (A) in cover so that dowel pins are

centered between slots.
19. Press bearing cup (6) against shoulder in housing.
20. Install spring retainer (14), springs (20) and

21. Remove dowel pins (22) from cover plate and install
in housing.
22. Install brake disk (23).
23. Install bearing cone (7) on shaft end with long spline.
24. Dip brake disks and separator plates in J20C oil.

Install brake disk (28) then alternate between
separator plate (29) and brake disk ending with a
separator plate on top.
–UN–03OCT96
25. Install bearing cone (7) against shoulder.
26. Insert shaft with brake disks and separator plates with
long spline end first into housing. Align separator
T101611
plates on dowel pins.
27. Install two M12 aligning studs into housing.

A—Piston
28. Install gasket (3) on cover plate.
29. Install cover making sure dowel pins align in cover

onto housing using cap screws.
30. Tighten cap screws (27) evenly.
31. Tighten cap screws.
Specification
Park Brake Housing Cap Screw—
Torque ........................................................................... 122 N•m (90 lb-ft)
NOTE: Bearing and race are a select pair to create a

shaft end play of 0.051—0.305 mm (0.002—0.012
in.).
32. Install seals (15 and 16) against shoulder in housing.
33. Install seals (2 and 3) against shoulder in cover plate.
11
1111
6

011504
PN=350
Active Elements
34. Install snap ring (9) and snap ring retainer (10) on
universal driveshaft (8).
35. Place NEVER-SEEZ lubricant on shaft splines.
36. Install yoke (11), washer (12) and nut (13). Tighten
nut.
Specification
Yoke-to-Universal Driveshaft
NEVER-SEEZ is a trademark of Emhart Chemical Group. CED,OUOE002,1601 –19–27MAY98–5/7
IMPORTANT: Do not overfill park brake. Fill only to

port (A). Capacity of the park brake is
0.60 L (20 oz).
Specification
Park Brake Oil—Capacity ................................................... 0.60 L (20 oz)
37. Fill park brake at port with 0.60 L (20 oz) of oil. Allow
oil to drain to bottom of level plug before installing
plug to prevent overfilling.
38. Bench test the park brake.
39. Install a porta-power to the park brake.
40. Slowly increase pressure until the shaft rotates freely.

Acceptable range is 896—1068 kPa (8.9—10.6 bar)
(130—155 psi).
41. Increase the pressure to 3450 kPa (34.5 bar) 500 psi. –UN–03NOV97
42. Slowly release brake pressure until free rotation of the

shaft stops. Acceptable range not more than 210 kPa
(2.1 bar) (30 psi) less than the release pressure.
T112115B
A—Fill Plug
B—Drain Plug
11
1111
7

011504
PN=351
Active Elements
43. Align yokes of park brake.
NOTE: Replace all drive line hardware when ever drive

line is disassembled.
–UN–06NOV97
T112153
CED,OUOE002,1601 –19–27MAY98–7/7
11
1111
8

011504
PN=352
Group 1160
Hydraulic System
Remove And Install Park Brake Release
Solenoid Valve

–UN–23AUG88
Protect hands and body form high pressure
X9811
fluids.

11
1160
1

011504
PN=353
Hydraulic System
2. Disconnect electrical connector (A).


6. Install solenoid valve using new O-rings and backup

rings.
Specification
Park Brake Release Solenoid
Valve Nut—Torque ........................................................... 7 N•m (62 lb-in.)
–UN–06SEP96
8. Connect electrical connector.
A—Electrical Connector
T103614C
B—Nut
C—Nut
D—Washer
E—Coil
F—Solenoid Valve
G—O-Ring
H—Backup Ring
I—O-Ring
J—O-Ring
K—Backup Ring
–UN–09NOV92
T7751LI
TX,1160,RB184 –19–27MAY98–2/2
11
1160
2

011504
PN=354
Hydraulic System
Remove And Install Park Brake Pressure

Switch

–UN–23AUG88
Protect hands and body form high pressure
X9811
fluids.

2. Disconnect electrical connector (A).
3. Remove switch (B).
5. Install switch. Connect electrical connector.
–UN–06SEP96
A—Electrical Connector
B—Switch
T103614B
TX,1160,RB185 –19–27MAY98–1/1
11
1160
3

011504
PN=355
Hydraulic System
11
1160
4

011504
PN=356
Section 17
Frame Or Supporting Structure 17
Contents
Page
Group 1740—Frame Installation

Major Structure
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-1
Engine and Loader Frame
Separate . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-2
Upper Pivot Bearing and Seals
Lower Pivot Bearing and Seals
Group 1746—Frame Bottom Guards

Fuel Tank Guard
Front Axle Guard
Transmission Bottom Guard
Transmission Side Guards
Group 1749—Chassis Weights

Counterweights

011504
PN=1
Contents
17

011504
PN=2
Group 1740
Frame Installation
Weld Major Structure
17
CAUTION: Avoid potentially toxic fumes and 1740
dust. Hazardous fumes can be generated when 1
paint is heated by welding, soldering, or using a
torch. Do all work outside or in a well ventilated
–UN–23AUG88
area. Dispose of paint and solvent properly.
If you sand or grind paint, avoid breathing the

dust. Wear an approved respirator> If you use
TS220
solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent
or paint stripper containers and other
flammable material from area. Allow fumes to
disperse at least 15 minutes before welding or
heating.
Remove paint before welding.
IMPORTANT: Disconnect battery ground strap or turn

battery disconnect switch to OFF (if
applicable).
Disconnect both negative and positive

battery cables and microprocessor unit
(if applicable).
IMPORTANT: Have only a qualified welder do this job.

Connect welder ground clamp close to
each weld area so electrical current
does not pass through any bearings.
Remove or protect all parts that can be

damaged by heat or weld splatter.
Use one of the following weld processes:
• AWS-E-7018 covered electrode with shielded metal arc

welding (SMAW) process.
• AWS-ER-70S-3f wire electrode with gas metal arc
welding (GMAW) process.
• AWS-E70T-1 or E71T-1 wire electrode with flux core
arc welding (FCAW) process.
Continued on next page TX,17,RP3351 –19–04JUN98–1/2

011504
PN=359
Frame Installation
Specification
Weld Metal Specification—Tensile
17 Strength ................................................................ 482.6 mPa (70 000 psi)
1740 Yield Strength ....................................................... 413.7 mPa (60 000 psi)
2 Elongation ............................................................................................ 22%
Preheat area to be repaired to allow better weld

penetration.
To repair weld metal failure, remove failed weld metal

using arc or grinding equipment. Thoroughly clean area to
be welded. Preheat structural assemblies to a minimum of
38°C (100°F). Preheat structural ground engaging tools
(cutting edges, skid shoes, and teeth shanks) to 177°C
(350°F).
To repair base metal failure remove enough material to

allow weld to penetrate to the bottom of crack. Preheat
structural ground engaging tools (cutting edges, skid
shoes, and teeth shanks) to 177°C (350°F).
TX,17,RP3351 –19–04JUN98–2/2
Separate Engine And Loader Frame
1. Park machine on smooth level surface and align

frames.
2. Install chain around bucket and connect to boom.

Place service jack under center of bucket. Service jack
wheels must roll freely and straight ahead when loader
frame is moved forward.
3. Stop engine.
4. Connect hoist to loader frame using chains.
5. Install shop stands under front and rear of engine

frame.
6. Hold down Boom Lower Switch and move pilot control

lever to release hydraulic pressure. Depress brake
pedal 40 times to discharge brake accumulator.
7. Remove Cab. (See Procedure in Group 1800)

011504
PN=360
Frame Installation
8. Disconnect electrical connectors.
9. Drain hydraulic reservoir. Approximate capacity of 17

1740
reservoir is 117 L (31 gal). 3
Specification
Hydraulic Oil Reservoir—
Clearance ....................................................... 117 L (31 gal) approximate
A—Loader Frame Harness Connector X8 to Load

Center Harness
B—Loader Frame Harness Connector X7 to Load
Center Harness
C—Loader Frame Harness Connector X9 to Load
Center Harness
D—Loader Frame Harness Connector X25 to Load
Center Harness
–UN–23OCT97
T111829

011504
PN=361
Frame Installation
17
1740
4
–UN–28JUL98
T115967

011504
PN=362
Frame Installation
A —Ride Control Manifold Left D —Left Auxiliary Right G —Right Auxiliary Left J—Boom Raise From Pilot
Forward Top Port-to-Boom Port-to-Pilot Controller Port-to-Pilot Controller Controller
Valve Right Port Line E —Right Auxiliary Right H —Left Auxiliary Left K—To Hydraulic Return Filter 17
B —Boom Lower From Pilot Port-to-Pilot Controller Port-to-Pilot Controller L—Pilot Pressure From 1740
Controller F —Valve Inlet From Hydraulic I —Bucket Roll Back From Pressure Reducing Valve 5
C —Bucket Dump From Pilot Pump Pilot Controller M—Load Sense to Pump
Controller
10. Disconnect lines (A—M).
CED,OUOE002,1697 –19–22JUN98–4/7
11. Disconnect lines (A, B, E, and F).
12. Disconnect drive shaft U-joints (C and D).
A—Brake Pressure
B—Differential Lock
C—Front Drive Shaft U-Joint
D—Center drive Shaft U-Joint
E—Park Brake Return
F—Park Brake Pressure
–UN–07MAR97
T107858

011504
PN=363
Frame Installation
13. Remove steering cylinder pins (B).
17 14. Remove cap screw (E), plate (F) and spacer (D).
1740
6
Remove lower pivot pin (C).
15. Remove upper pivot pin (A).
A—Upper Pivot Pin

B—Steering Cylinder Pins
C—Lower Pivot Pin
D—Spacer
E—Cap Screw
F—Plate
–UN–11MAR97
T108046

011504
PN=364
Frame Installation
16. Have a service technician at each front tire. Push on

tires and slowly move overhead hoist forward. Make
sure service jack rolls forward with bucket. 17
1740
7
18. Attach loader frame to engine frame.
19. Connect lines and electrical connectors.

joint cap screws or bearing retainer
straps. Replace cap screws and bearing
retainer straps to avoid machine
damage.
20. Connect drive shafts. Install new drive shaft universal

joint cap screws and bearing retainer straps. Tighten
cap screws.
–UN–24OCT88
Specification
Universal Joint Cap Screw—
Torque ............................................................................. 78 N•m (58 lb-ft)
21. Connect steering cylinders. Install maximum number
T77721
of washers between loader frame and steering
cylinder rod end. Install equal number above and
below rod end.
22. Install cab. (See Group 1800.)
23. Add hydraulic oil. See Drain and Refill Capacities—

644H/H MH. (Operation and Test.)
24. Start machine and check for leaks.
CED,OUOE002,1697 –19–22JUN98–7/7

011504
PN=365
Frame Installation
Remove And Install Upper Pivot Bearing And Seals

17
1740
8
–UN–13MAR97
T107940
A—Pin D—Cover G—Bearing (2 used) J—Engine Frame

B—Engine Frame E—Shim (as needed) H—Lower Seal Spacer K—Bearing Spacer
C—Upper Seal F—Loader Frame I—Lower Seal L—Cap Screw (6 used)
1. Remove upper and lower pivot pins and separate 2. Remove seal (I) from seal spacer (H).
frames. Remove cap screws (L) cover (D) with
upper seal (C). Remove parts (G, H, I and K) from 3. Replace parts as necessary.
loader frame bore using a puller disk against lower
seal spacer with seal (H). 4. Apply a light coat of JDM J13E4 grease to rollers in
bearings (G).
NOTE: Lower seal cannot be pushed through spacer.
Remove seal spacer to remove seal.

011504
PN=366
Frame Installation
5. Press lower seal (I) into seal spacer (H) with lips 11. Install upper seal (C) into cover with lip facing out.
facing out. The seal must seat against seal spacer Press seal to cover shoulder.
shoulder. 17
1740
12. Hold cover in place, measure gap between cover 9
6. Install seal spacer (H) in bottom of loader frame and frame, take readings in three places. Cover
bore. must contact top of bearing. Calculate the average
of these three reading to determine shim pack
7. Press first bearing cup into bore against seal required.
spacer.
Specification
IMPORTANT: Do not apply load to bearing cone Upper Pivot Joint Bearing—
Preload........................................................................ 0.03—0.13 mm
when pressing in cup. Use old (0.001—0.005 in.)
bearing race to apply load on new
bearing cup to prevent bearing 13. Install shims to obtain specified preload on upper
damage. pivot bearings.
8. Install first bearing cone in cup. 14. Apply grease to the top of bearing, fill cavity above
bearing to machined surface, to prevent moisture
IMPORTANT: Use the same spacer (K) which was from entering bearing through shims.
removed from the bearing set.
Spacer is not interchangeable with 15. Tighten bearing cover-to-loader frame cap screws
other bearings. (L). Rotate inner race of bearing after tightening.
9. Install bearing spacer. Specification

Bearing Cover-to-Loader Frame
10. Press second bearing cup into bore against Cap Screw—Torque ............................................... 128 N•m (95 lb-ft)
spacer. Install second bearing cone. Then press
second bearing cup into bore against spacer.
CED,OUOE002,1622 –19–04JUN98–2/2

011504
PN=367
Frame Installation
Remove And Install Lower Pivot Bearing And Seals

17
1740
10
–UN–11MAR97
T107966
Lower Pivot Bearing And Seals (S.N.—583402)
A—Pin Retaining Cap Screw F—Spacer (Engine Frame) J—Shims (as needed) N—Spacer Seal
B—Cap Screw (6 used) G—Cover Seal K—Loader Frame O—Spacer
C—Plate H—Cap Screw (6 used) L—Bearing Spacer P—Loader Frame
D—Engine Frame I—Cover M—Bearing (2 used) Q—Lower Pivot Pin
E—Spacer (Engine Frame)
Continued on next page CED,OUOE002,1623 –19–18APR02–1/3

011504
PN=368
Frame Installation
17
1740
11
–UN–18APR02
T154053
Lower Pivot Bearing and Seal (S.N 583403—)
A—Pin Retaining Cap Screw F—Spacer (Engine Frame) K—Loader Frame O—Spacer
B—Cap Screw (6 used) G—Cover Seal L—Bearing Spacer P—Loader Frame
C—Plate H—Cap Screw (6 used) M—Bearing (2 used) Q—Lower Pivot Pin
D—Engine Frame I—Cover N—Spacer Seal R—Nut
E—Spacer (Engine Frame) J—Shims (as needed)
1. Remove pin retaining cap screw (A), cap screws 5. Replace parts as necessary.
(B) and plate (C). Remove pivot pin (Q) and
separate machine frames. 6. Press spacer (E) into engine frame bore flush with
bottom of frame.
2. Remove cap screws (H), cover (I) with seal (G) and
spacers (J). 7. Apply a light coat of JDM J13E4 grease to rollers in
bearings (M).
NOTE: Spacer seal can not be pushed through
spacer. Remove seal and spacer to remove 8. Press seal into seal spacer, with lips facing out.
seal. Seal must seat against the seal spacer shoulder.
3. Remove (L, M, N and O) from engine frame, using 9. Install seal spacer to bottom of bore.
a puller disk against seal spacer (O). Remove seal
(N) from seal spacer (O). 10. Press first bearing cup into engine frame bore
against spacer.
4. Remove spacer (E) from engine frame bore.
Continued on next page CED,OUOE002,1623 –19–18APR02–2/3

011504
PN=369
Frame Installation
IMPORTANT: Use the same bearing spacer (L) 17. Apply grease to the top of bearing, fill cavity above
which was removed from the bearing bearing to machined surface, to prevent moisture
17 set. Spacer is not interchangeable from entering bearing through shims.
1740
12
with other bearings. Do not apply
load to bearing cone when pressing 18. Tighten cap screws (H). Rotate inner race of
in cup. Use old bearing race to apply bearing after tightening.
load on new bearing cup to prevent
bearing damage. Specification
Bearing Cover-to-Engine Frame
Cap Screw—Torque ............................................... 128 N•m (95 lb-ft)
11. Install first bearing cone.
19. Install spacer (F) into cover (I).
12. Install bearing spacer.
20. Move frames together and install pivot pin (Q) and
13. Press second bearing cup in engine frame bore.
plate (C). Install pin retaining cap screw (A) and
Install second bearing cone.
cap screws (B) finger tight before torquing.
14. Install seal into bearing cover (I) with lips facing
21. Tighten plate-to-loader frame cap screws (B).
out. Press seal to cover shoulder.
Tighten lower pivot pin retaining cap screw (A),
steel dowels or cap screws may be inserted into
15. Hold bearing cover in place, measure gap
holes in top of pivot pin and a bar inserted
between cover and frame, take readings in three
between them to prevent pin from turning during
places. Bearing cover must contact top of bearing.
tightening of cap screw.
Calculate the average of these three reading to
determine shim pack required. Specification
Plate-to-Loader Frame Cap
16. Install shims (J) to obtain a preload of 0.03—0.13 Screw—Torque ..................................................... 140 N•m (103 lb-ft)
mm (0.001—0.005 in.) on bearings. Plate-to-Lower Pivot Pin Cap
Screw—Torque ................................................. 2129 N•m (1570 lb-ft)
Specification
Lower Pivot Joint Bearing—
Preload................................................ 0.03—0.13 mm (0.001—0.005
in.)
CED,OUOE002,1623 –19–18APR02–3/3

011504
PN=370
Group 1746
Frame Bottom Guards
Remove And Install Fuel Tank Guard
17
CAUTION: Approximate weight of fuel tank 1746
guard is 209 kg (461 lb). 1
Weight may increase due to build up of mud
–UN–12MAR97
and debris.
Full tank full of fuel 341 L (90 gal) will add 288
kg (636 lb) to fuel tank and guard total weight.
T108116
Drain fuel tank before removing guard.
Specification
Fuel Tank Guard—Weight............................. 209 kg (461 lb) approximate
Fuel Tank Guard with Full Tank
of Fuel—Weight ............................................. 288 kg (636 lb) approximate
Drain fuel into a clean container for reuse.
Remove fuel tank guard and fuel tank.
CED,OUOE002,1627 –19–04JUN98–1/1
Remove And Install Front Axle Guard
CAUTION: Approximate weight of front axle

guard is 73 kg (160 lb).
–UN–12MAR97
and debris.
Specification
Front Axle Guard—Weight .............................. 73 kg (160 lb) approximate
T108117
CED,OUOE002,1628 –19–04JUN98–1/1

011504
PN=371
Frame Bottom Guards
Remove And Install Transmission Bottom

Guard
17
1746
2 CAUTION: Approximate weight of transmission
bottom guard is 78 kg (172 lb).
–UN–12MAR97
and debris.
T108118
Specification
Transmission Bottom Guard—
Weight.............................................................. 78 kg (172 lb) approximate
CED,OUOE002,1629 –19–04JUN98–1/1
Remove And Install Transmission Side

Guards
CAUTION: Approximate weight of transmission

side guard is 15 kg (32 lb).
Specification
Transmission Side Guard—
Weight................................................................ 15 kg (32 lb) approximate
If a guard is bent, heat with a torch and straighten.
–UN–12JUN98
Weld any cracks using E7018 electrodes.
T115757
CED,OUOE002,1630 –19–04JUN98–1/1

011504
PN=372
Group 1749
Chassis Weights
Remove And Install Counterweights
17
1749
1
–UN–12MAR97
T108108
A—Secondary Counterweight B—Main Counterweight C—Washer (6 used) D—Cap Screw (6 used)
Draw counterweight against engine frame with upper

CAUTION: The approximate weight of
two screws first, then lower screws. Torque to
counterweight components are:
specifications in same pattern.
Secondary Counterweight (A)—472 kg (1040 Specification
lb). Counterweight Attaching Cap
Screw—Torque ................................................... 1150 N•m (850 lb-ft)
Main Counterweight (B)—789 kg (1740 lb).
Specification
Secondary Counterweight—
Weight ................................................... 472 kg (1040 lb) approximate
Main Counterweight—Weight ............... 789 kg (1740 lb) approximate
CED,OUOE002,1633 –19–05JUN98–1/1

011504
PN=373
Chassis Weights
17
1749
2

011504
PN=374
Section 18
Operator’s Station
Contents
Page Page 18
Group 1800—Removal And Installation Remove And Install Fresh Air Filter. . . . . . .18-1830-27
Cab or Canopy Recirculating Air Filter
Remove and Install . . . . . . . . . . . . . . . . . .18-1800-1 Remove and Install . . . . . . . . . . . . . . . . .18-1830-30
Compressor
Group 1810—Operator Enclosure Remove and Install . . . . . . . . . . . . . . . . .18-1830-32
Front Windshield Wiper Compressor Clutch
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Disassemble and Assemble. . . . . . . . . . .18-1830-34
Compressor
Group 1830—Heating And Air Conditioning Check Clutch Hub Clearance. . . . . . . . . .18-1830-35
R134a Refrigerant Cautions . . . . . . . . . . . . .18-1830-1 Compressor Manifold
R134a Compressor Oil Charge Check . . . . .18-1830-1 Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-36
R134a Compressor Oil Removal . . . . . . . . . .18-1830-2 Compressor
R134a Component Oil Charge . . . . . . . . . . .18-1830-3 Disassemble, Inspect, and Assemble. . . .18-1830-37
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-4
Refrigerant Hoses and Tubing Inspection . . .18-1830-4 Group 1899—Dealer Fabricated Tools
R134a Refrigerant DFRW20 Compressor Holding Fixture. . . . . .18-1899-1
Recovery, Recycling and Charging Station
Installation . . . . . . . . . . . . . . . . . . . . . . .18-1830-5
R134a System
Recover . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6
Evacuate . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7
Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-9
Air Conditioner System Cleaning
Procedures . . . . . . . . . . . . . . . . . . . . . . .18-1830-10
Purge Air Conditioner System . . . . . . . . . . .18-1830-11
Flush Air Conditioner System . . . . . . . . . . .18-1830-12
Air Conditioning Module With
Heater/Evaporator Coil. . . . . . . . . . . . . . .18-1830-14
Heater/Evaporator Coil
Expansion Valve
Freeze Control Switch
Bench Test . . . . . . . . . . . . . . . . . . . . . . .18-1830-20
Heater Control Valve
Leak Check . . . . . . . . . . . . . . . . . . . . . . .18-1830-22
Main Blower Assembly
Pressurizer Motor Assembly
Receiver-Dryer and Condenser
High and Low Pressure Switches

011504
PN=1
Contents
18

011504
PN=2
Group 1800
Remove And Install Cab Or Canopy
Cab or canopy can be removed for servicing of

transmission and hydraulic pumps.
1. Stop engine.
2. With boom raised slightly, turn ignition switch to ON 18

position. Cycle the ride control switch from OFF to ON 1800
(center position). Boom will jump up unexpectedly if 1
CAUTION: Prevent unexpected machine

movement and possible injury. Install frame
4. Turn battery disconnect switch OFF (if equipped) or

disconnect battery ground.
5. Remove steps and platforms from both sides of

machine.
6. Remove front, left and right bottom cab shields.

011504
PN=377
7. Remove two defroster ducts (A) located under front of

cab floor.
8. Remove windshield wiper/washer hoses.
9. Remove brake accumulator line-to-pressure reducing

valve.
18
1800 A—Defroster Duct (2 used)
2
–UN–07MAR97
T104544B

011504
PN=378

–UN–23AUG88
fluids. 18
1800
3
X9811
10. Disconnect the five hoses (A) from steering valve.

Plug and cap hoses.
A—Hose (5 used)
–UN–07MAR97
T104543C
CED,OUOE002,1635 –19–05JUN98–3/7
11. Disconnect brake valve return hose (A) and brake

valve work port hoses (B). Plug and cap hoses.
A—Brake Valve Return Hose

B—Brake Valve Work Port Hose
–UN–24MAR97
T107920B

011504
PN=379
12. Disconnect hydraulic hoses from hydraulic pilot

controllers.
–UN–12DEC96
18
1800
T104524B
4
CED,OUOE002,1635 –19–05JUN98–5/7
NOTE: Machines equipped with air conditioning will

require that the A/C system be evacuated. See
R134A Refrigerant Recovery/Recycling and
Charging procedure in Group 1830. Disconnect
A/C hoses under cab, not shown.
–UN–07MAR97
13. Shut off heater hose shut off valves on engine.
Disconnect heater hoses under cab. Disconnect three
wiring connectors (A) on right side of cab and wiring
connectors to loader frame (B) and disconnect the
T104541D
red, white and black wires from starter.
CAUTION: The approximate weight of the cab is

808 kg (1781 lb).
Specification
Cab—Weight ............................................... 808 kg (1781 lb) approximate
–UN–24OCT96
14. Remove four cap screws from top of cab roof and
install four JT01748 Lifting Brackets to the cab roof.
Attach chains and hoist to lifting brackets.
T104544C
15. Remove cab mounting cap screws.
16. Remove cab.

A—Wiring Connector (3 used)
17. Do necessary repairs. B—Wiring Connector (4 used)
18. Inspect cab mounting parts. Replace as needed.

011504
PN=380
19. Install cab. Install and tighten mounting cap screws.
Specification
Cab Isolator Cap Screw—Torque ............................. 1150 N•m (850 lb-ft)
20. Remove lifting brackets from cab roof and install cap
screws.
18
21. Connect wiring connectors and red, white and black 1800
wires to starter. 5
22. Connect heater hoses and turn on heater shut-off

valves.
23. Connect hydraulic pilot controller hoses.
24. Connect brake valve return hose and brake valve

work port hoses.
25. Connect steering valve hoses.
–19–27MAR97
26. Install defroster ducts.
27. Install front, left and rear bottom cab shields.
T108598
28. Install steps and platforms.
29. Turn battery disconnect switch ON (if equipped) or

1—Nut
connect battery ground strap. 2—Washer (6 used)
3—Washer (4 used)
4—Rubber Mount (4 used)
5—Cap Screw (M24 x 150) (2 used)
6—Cap Screw (M24 x 120) (2 used)
CED,OUOE002,1635 –19–05JUN98–7/7

011504
PN=381
18
1800
6

011504
PN=382
Group 1810
Operator Enclosure
Adjust Front Windshield Wiper
CAUTION: Keep hands away from linkage when

the motor is in operation. DO NOT adjust park
position when the motor is in operation. Never
start a windshield wiper when the blade is
frozen to the windshield or manually stop the
blade when the wiper is operating. 18
1810
1
1. If the blade does not park in the required position,
adjust the wiper blade.
2. Loosen nut.
3. Reposition drive arm on shaft.
4. Tighten nut.
Specification
Wiper Arm Mounting Nut—Torque .................... 8—9 N•m (72—86 lb-in.)
5. Start wiper motor, shut it off and note the new park
position.
6. If blade does not park in the correct position, repeat

steps 2 through 6 until the correct park position is
obtained.
TX,1810,RB128 –19–05JUN98–1/1

011504
PN=383
Operator Enclosure
18
1810
2

011504
PN=384
Group 1830
Heating And Air Conditioning
R134a Refrigerant Cautions
develop high pressure which can burst the

CAUTION: DO NOT allow liquid refrigerant to
container.
contact eyes or skin. Liquid refrigerant will
freeze eyes or skin on contact. Wear
Keep refrigerant containers away from heat
goggles, gloves and protective clothing.
sources. Store refrigerant in a cool place.
If liquid refrigerant contacts eyes or skin, DO 18
DO NOT handle damp refrigerant container 1830
NOT rub the area. Splash large amounts of 1
with your bare hands. Skin may freeze to
COOL water on affected area. Go to a
container. Wear gloves.
physician or hospital immediately for
treatment.
If skin freezes to container, pour COOL
water over container to free the skin. Go to a
DO NOT allow refrigerant to contact open
physician or hospital immediately for
flames or very hot surfaces such as electric
treatment.
welding arc, electric heating element and
lighted smoking materials.
DO NOT heat refrigerant over 52°C (125°F) in

a closed container. Heated refrigerant will
TX,9031,HH1465 –19–19AUG94–1/1
R134a Compressor Oil Charge Check
Remove compressor if R134a leakage was detected 3. Flush the complete system with TY16134 air
and repaired. See Remove and Install Compressor in conditioning flushing solvent.
this group.
4. If the compressor is serviceable, pour flushing
Drain oil from the compressor and record the amount. solvent in the manifold ports and internally wash out
See Compressor Oil Removal procedure in this group. the old oil.
NOTE: Drain oil and save if this is a new compressor. 5. Install a new receiver-dryer.
If the oil drained from a compressor removed from 6. Install required amount of TY22025 refrigerant oil in
operation is very black or the amount of oil is less than the compressor. (See R134a Component Oil
6 mL (0.2 fl oz), perform the following: Charge in this group.)
1. Remove and discard the receiver-dryer. 7. Connect all components, evacuate and charge the
system.
2. Remove, clean, but do not disassemble the valve.
TX,9031,QQ2366 –19–01JUL98–1/1

011504
PN=385
R134a Compressor Oil Removal
1. Remove compressor from machine. See Remove and

Install Compressor in this group.
2. Remove inlet/outlet manifold from compressor, and

clutch dust cover.
18
1830 3. Drain oil into graduated container while rotating
2 compressor shaft.
4. Record measured oil and discard oil properly.
5. Install new oil. See R134a Component Oil Charge in

this group.
6. Install compressor. See Remove and Install

Compressor in this group.
TX,9015,QQ2299 –19–17JUN94–1/1

011504
PN=386
R134a Component Oil Charge
• New compressor from parts depot, drain and

CAUTION: All new compressors are charged
return 45 mL (1.5 fl oz) of oil to the compressor.
with a mixture of nitrogen, R134a refrigerant
(See Compressor Oil Removal procedure in this
and TY22025 (R134a) refrigerant oil. Wear
group.)
safety goggles and discharge the
• Used compressor removed from operation and oil
compressor slowly to avoid possible injury.
drained, (See Compressor Oil Removal 18
procedure in this group.) Add 45 mL (1.5 fl oz) of 1830
Compressors can be divided into three categories 3
new oil.
when determining the correct oil charge for the system.
• Used compressor removed from operation, oil
drained, and flushed add 60 mL (2.0 fl oz) of new
• New compressor from parts depot
oil.
• Used compressor removed from operation
• Compressor internally washed with flushing solvent
NOTE: Components listed below which have been
removed, drained or flushed, require the
Use the following procedure to determine the
removal of the compressor to determine the
amount of system oil charge prior to installation of
correct oil charge. Use the following as a guide
compressor on a machine.
for adding oil to components:
1. When the complete system, lines, and components Specification
were flushed add the correct amount of oil as Evaporator Oil—Capacity ....................................... 158 mL (5.4 fl oz)
described. Condenser Oil—Capacity .................................. 100.55 mL (3.4 fl oz)
Receiver-Dryer Oil—Capacity................................. 37 mL (1.25 fl oz)
• New compressor from parts depot contains the Hose Oil—Capacity ............................................ 115 mL (3.889 fl oz)
amount of new oil of 230 ± 20 mL (7.7 ± .7 fl oz).
System requires an additional amount of new oil NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft).
of 240 mL (8 fl oz) of new oil. Approximate total length equals 727 cm (24 ft)
• Used compressor removed from operation, oil
drained, and flushed requires 365 mL (12.35 fl If any section of hose is removed and flushed or
oz) of new oil. replaced, measure the length of hose and use the
formula to determine the correct amount of oil to be
Specification added.
Air Conditioning System Oil—
Capacity ................................................. 470 mL (15.7 ± .7 fl oz) new
Capacity ..................................................... 410 mL (13.85 fl oz) used CAUTION: DO NOT leave the system or
R134a compressor oil containers open. This
oil easily absorbs moisture. DO NOT spill
R134a compressor oil on acrylic or ABS
plastic. This oil will deteriorate these
2. When the complete system was not flushed add the materials rapidly. Identify R134a oil
correct amount of oil for the compressor plus the containers and measures to eliminate
amount of oil for each component that was accidental mixing of different oils.
serviced.
TX,9015,QQ3025B –19–24JUL98–1/1

011504
PN=387
Leak Testing
1. Inspect all lines, fittings and components for oily or 3. If a leak detector is used, move the leak detector
dusty spots. When refrigerant leaks from the probe under the hoses and around the connections
system, a small amount of oil is carried out with it. at a rate of 25 mm (1 in.) per second.
2. A soap and water solution can be sprayed on the 4. Some Freon manufacturers add dye to Freon to aid
18 components in the system to form bubbles at the in leak detection.
1830 source of the leak.
4
TX,1830,MM3175 –19–19OCT96–1/1
Refrigerant Hoses And Tubing Inspection
IMPORTANT: Hose used for air conditioning material. If such contamination is present in hoses,
systems contains special barriers in tubing, or fittings and cannot be removed by cleaning,
its walls to prevent migration of then replace parts.
refrigerant gas.
Fittings that have grease or dirt on them should be
DO NOT use hydraulic hoses as wiped clean with a cloth dampened with alcohol.
replacement hoses in the air Chlorinated solvents (such as trichloroethylene) are
conditioning system. Use ONLY contaminants, and must not be used for cleaning.
certified hose meeting SAE J51b
requirements. To assist in making leak-proof joints in R134a
systems, use a small amount of clean
When a component is disconnected from the system, polyakyleneglycol (PAG) refrigerant oil on all hoses
special care should be given to inspecting hoses and and tube connections. Dip O-rings in PAG oil before
tubing for moisture, grease, dirt, rust, or other foreign assembly.
TX,1830,MM3176 –19–19OCT96–1/1

011504
PN=388
R134a Refrigerant Recovery, Recycling And

Charging Station Installation Procedure
CAUTION: Do not remove high pressure relief

valve (A). Air conditioning system will
discharge rapidly causing possible injury.
18
IMPORTANT: Use correct refrigerant recovery, 1830
recycling and charging stations. DO 5
NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.
NOTE: JT02046 and JT02050 recovery and charging

stations can be substituted for the JT02045
station.
1. Close both high and low pressure valves on refrigerant

recovery, recycling and charging station (H).
2. Remove cap from low pressure test port (G).
–UN–09JUL97
3. Connect low pressure blue hose (D) from refrigerant
recovery, recycling and charging station (H) to low
T110345
pressure test port (G) on compressor.
4. Connect high pressure red hose (C) to high pressure

quick disconnect (B). A—High Pressure Relief Valve
B—High Pressure Test Port
5. Follow the manufacturer’s instructions when using the C—Red Hose
refrigerant recovery, recycling and charging station. D—Blue Hose
E—High Pressure Hose
F—Low Pressure Hose
G—Low Pressure Test Port
H—Refrigerant Recovery/Recycling and Charging
Station
CED,OUOE003,1026 –19–24JUL98–1/1

011504
PN=389
Recover R134a System

IMPORTANT: Use correct refrigerant recovery,

18 recycling and charging stations. DO
1830
6
NOT mix refrigerant, hoses, fittings,

station.
Run the air conditioning system for three minutes

to help in the recovery process. Turn air
conditioning system off before proceeding with
recovery steps.
–UN–09JUL97
1. Connect refrigerant recovery, recycling and charging
station. (See installation procedure in this group.)
2. Follow the manufacturer’s instructions when using the
T110345
refrigerant recovery, recycling and charging station.
A—High Pressure Relief Valve

B—High Pressure Test Port
C—Red Hose
D—Blue Hose
E—High Pressure Hose
Station
CED,OUOE003,1027 –19–24JUL98–1/1

011504
PN=390
Evacuate R134a System


1830
NOT mix refrigerant, hoses, fittings, 7
IMPORTANT: Do not run compressor while

evacuating.

station.
1. Connect refrigerant recovery, recycling and charging

station. (See installation procedure in this group.)
–UN–09JUL97
2. Open low and high pressure valves on refrigerant
recovery, recycling and charging station.
T110345
3. Follow the manufacturer’s instructions and evacuate
the system.
A—High Pressure Relief Valve
NOTE: The vacuum specifications listed are for sea level B—High Pressure Test Port
conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) C—Red Hose
from 98 kPa (980 mbar) (29 in. Hg) for each 300 D—Blue Hose
m (1000 ft) elevation above sea level. E—High Pressure Hose
4. Evacuate system until low pressure gauge registers 98 H—Refrigerant Recovery/Recycling and Charging
kPa (980 mbar) (29 in. Hg) vacuum. Station
If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be

obtained in 15 minutes, test the system for leaks. (See
Leak Testing, 9031-25). Correct any leaks.
5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close

low-side and high-side valves. Turn vacuum pump off.
6. If the vacuum decreases more than 3.4 kPa (34 mbar)

(1 in. Hg) in 5 minutes, there is a leak in the system.
7. Repair leak.

011504
PN=391
8. Start to evacuate.
9. Open low-side and high-side valves.
10. Evacuate system for 30 minutes after 98 kPa (980

mbar) (29 in. Hg) vacuum is reached.
18 11. Close low-side and high-side valves. Stop evacuation.

1830
8 12. Charge the system. (See procedure in this group.)
CED,OUOE003,1028 –19–24JUL98–2/2

011504
PN=392
Charge R134a System


1830
NOT mix refrigerant, hoses, fittings, 9

station.
1. Connect JT02045 R134a refrigerant recovery, recycling

and charging station. (See installation procedure in this
group.)
2. Evacuate the system. (See Evacuate Air Conditioning
–UN–09JUL97
System, this group.)
NOTE: Before beginning to charge air conditioning

system, the following conditions must exist:
T110345
Engine STOPPED, the pump must be capable of
pulling at least 28.6 in. Hg vacuum (sea level).
Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa A—High Pressure Relief Valve
(980 mbar) (29 in. Hg) for each 300 m (1000 ft) B—High Pressure Test Port
elevation above sea level. C—Red Hose
D—Blue Hose
3. Follow the manufacturer’s instructions and charge the E—High Pressure Hose
system. G—Low Pressure Test Port
4. Add refrigerant until system is charged with 3.289 kg Station
(7.25 lb).
5. Do air conditioner checks and tests. See R134A Air

Conditioning System Test. (Group 9031-25.) Leak
Testing.
CED,OUOE003,1029 –19–24JUL98–1/1

011504
PN=393
Air Conditioner System Cleaning Procedures
Flushing: Flushing the system or component is a

cleaning process using a liquid solvent to remove oil and
debris. Purging is always necessary after flushing to
remove solvent from the system or component.
18 Following is a list of situations that require a flushing

1830 procedure be done:
10
1. The compressor has an internal failure.
2. No oil remains in used compressor.
3. Oil drained from compressor appears or smells
overheated.
4. System was contaminated with a mixture of refrigerant
oils.
5. System was left open to the atmosphere long enough
for dirt, moisture, or debris to enter the tubing or
components.
6. System has an internal blockage.
The following solvent is recommended for flushing air

conditioner systems. Use only solvents with an equivalent
MSDS.
• TY16134 John Deere Air Conditioning System Flushing

Solvent
Purging: Purging the system or a component is a

cleaning process using a gas to force liquid from the
system. Purging alone will not remove refrigerant oil from
the system.
Following is a list of situations that require a purging

procedure be done:
• After flushing system with solvent, to prevent oil dilution

• System was contaminated with nitrogen or two
refrigerants.
• System was left open to the atmosphere and flushing
could not be performed.
• Installation of new lines, condenser, or evaporator was
required.
Evacuating: Evacuating the system is a process to

remove air and moisture from the system, creating a
vacuum.
TX,1830,MM3158 –19–17OCT96–1/1

011504
PN=394
Purge Air Conditioner System
IMPORTANT: Air compressors used for purging

systems require a water separator.
Purging without a separator adds
moisture, creating hydrofluoric acid
when combined with refrigerant oil.
Acid is corrosive to metal tubing. 18
1830
1. Connect dry nitrogen hose to gauge manifold center 11
hose.
2. Connect gauge manifold suction hose to compressor

suction port, and open valves.
3. Connect gauge manifold discharge hose to compressor

discharge post, and open valve. Disconnect discharge
hose from gauge manifold to allow purging nitrogen to
atmosphere.
4. Open nitrogen tank valve and adjust regulator to 275

kPa (40 psi) (2.75 bar). Purge system for two minutes.
Disconnect nitrogen supply.
Specification
Nitrogen Tank Valve Regulator—
Pressure ......................................................... 275 kPa (40 psi) (2.75 bar)
5. Evacuate system. (See procedure in this group.)
CED,OUOE003,1030 –19–24JUL98–1/1

011504
PN=395
Flush Air Conditioner System
Add flushing solvent to system with JT02075 Flusher IMPORTANT: DO NOT attempt to flush through
and JT02098 Fitting Kit. compressor or receiver-dryer.
Flushing through expansion valve is
NOTE: Flushing can be performed on vehicle. acceptable if refrigerant oil has
normal odor and appearance.
18 1. Recover refrigerant. (See procedure in this group.)
1830 6. To Flush/Purge Condenser:
12 2. Remove compressor and measure oil drained from
both manifold ports. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102 Adapter.
3. Clean compressor as follows:
7. Attach a return hose and aerator nozzle to outlet
a. Pour 240 mL (8 fl oz) of flushing solvent into end of receiver-dryer inlet hose using JT03197
suction port and 120 mL (4 fl oz) into discharge Adapter. Put nozzle in container to collect flushing
port. Plug both ports in compressor manifold, solvent.
using JT02099 and JT02100 with JT03194
Caps. 8. Fill flusher tank with 4 L (1 gal) of solvent and
fasten all connections.
b. Turn compressor end for end and roll it side to
side. NOTE: Air pressure must be at least 620 kPa (6.2
bar) (90 psi) for flushing and purging.
c. Remove both plugs from manifold ports and
drain solvent from compressor. 9. Connect a supply line of moisture-free compressed
air or dry nitrogen to flusher air valve.
d. Connect battery power to compressor clutch coil.
Rotate pulley at least five revolutions to move 10. Open air valve to force flushing solvent into
solvent out of cylinders. condenser circuit. Flusher tank is empty when
hose pulsing stops. Additional flushing cycles are
e. Invert compressor, roll end for end, and side to required if system is heavily contaminated with
side. Drain thoroughly. burned oil or metal particles.
f. Let compressor sit inverted for three to five NOTE: Purging the condenser circuit takes 10—12
minutes. minutes to thoroughly remove solvent.
g. Repeat previous two steps at least three times. 11. Disconnect hose from aeration nozzle to check
circuit for solvent. Hold hose close to a piece of
4. Remove and discard receiver-dryer. cardboard; continue purging until cardboard is dry.
5. Divide system into two circuits: 12. Go to Step 13 to flush evaporator. Go to Step 22 if
evaporator does not require flushing.
a. Condenser, including inlet and outlet hoses.
(Steps 6—12) 13. To Flush Evaporator:
b. Evaporator, including inlet and outlet hoses.

(Steps 13—26)
Continued on next page TX,1830,MM3159 –19–09JUN98–1/2

011504
PN=396
If system is contaminated with burned refrigerant 20. Repeat Steps 8, 9 and 10 to flush evaporator.
oil or debris, remove and bench flush evaporator.
Go to Step 18 to flush evaporator through NOTE: Purging the evaporator circuit takes 12—15
expansion valve, if oil appears normal. Remove minutes to thoroughly remove solvent.
evaporator. (See procedure in this group.)
21. Disconnect hose from aeration nozzle to check
14. Force flushing solvent through evaporator inlet circuit for solvent. Hold hose close to a piece of
with compressed air. cardboard. Continue purging until cardboard is dry. 18
1830
15. Purge system until dry. 22. Install a new receiver-dryer compatible with R134a 13
refrigerant. Fasten connections and mounting
16. Reinstall evaporator. bracket.
17. Go to Step 22. 23. Add required oil. (See procedure in this group.)
18. To Flush Evaporator Through Expansion 24. Install compressor, and connect refrigerant lines to
Valve: manifold.
Connect flusher outlet hose to connection of 25. Connect clutch coil wire. Install drive belt.
receiver-dryer outlet hose using JT03188 Adapter.
26. Purge system. (See procedure in this group.)
19. Attach a hose and aerator nozzle to compressor
inlet line using JT02101 Adapter. Put nozzle in a
container to collect solvent.
TX,1830,MM3159 –19–09JUN98–2/2

011504
PN=397
Air Conditioning Module With Heater/Evaporator Coil
18
1830
14
–UN–15OCT97
TP55703

011504
PN=398
1—Nut 18—Resistor 35—Bolt 52—O-Ring

2—Seal 19—Cover 36—Hose 53—Ring
3—Impeller 20—Housing, Heater Module 37—Plate 54—O-Ring
4—Pressurizer Blower Motor 21—Screw 38—Housing 55—O-Ring
5—Cap Screw 22—Isolator 39—Valve 56—A/C Low Pressure Switch
6—Tube 23—Filter 40—Valve 57—Grommet
7—Screw 24—Nut 41—Hose 58—Grommet
8—Clamp 25—Housing 42—Tube 59—Clip
9—Tube 26—Latch 43—Clamp 60—Cable
10—Bracket 27—Rivet 44—Tube 61—Lock Washer 18
11—Air Duct 28—Filter Element 45—Tube 62—Nut 1830
12—Tie Band 29—Pressurizer Blower Motor 46—Tube 63—Knob 15
13—Clip 30—Seal 47—A/C High Pressure Switch 64—Control
14—Thermostat 31—Evaporator Core 48—Screw 65—Seal
15—Air Duct 32—Air Duct 49—Plate 66—Hose
16—Air Plenum 33—Hose 50—Screw 67—Gasket
17—Screw 34—Knob 51—Plug
CED,OUOE003,1031 –19–24JUL98–2/2

011504
PN=399
Remove And Install Heater/Evaporator Core
18
1830
16
–UN–29OCT96
T104545
A—Pressurizer Motor E—Resistor H—Cap Screws L—Heater Valve
B—Inlet Plenum F—Main Blower Motor I—Lower Housing M—Air Conditioning Lines
C—Expansion Valve G—Heater/Evaporator Core J—Heater/Evaporator Core N—Housing
D—Freeze Control Switch Top Cover K—Heater Hoses (2 used) O—Knob
1. Recover refrigerant from the system. (See Recover 8. Remove upper two cap screws attaching inlet
R134a System, in this group.) plenum (B) to heater/evaporator core top cover (G).
2. Open left-hand cab service door. Remove fresh air 9. Remove cab left-hand shelf.
filter. (See Fresh Air Filter, Remove, in this group.)
10. Remove cap screws from heater/evaporator core
3. Remove knob (O) to remove housing (N). top cover (G); remove cover.
4. Remove rear cover behind seat. 11. Remove freeze control switch (D) probe from core.
5. Remove seat cap screws and move seat forward to 12. Remove upper two cap screws from main blower
access air conditioning/heater components. motor (F).
6. Disconnect wire harness from freeze control switch, 13. Shut off heater hose shut-off valves on engine.
blower motor and blower resistor.
14. Disconnect air conditioning lines (M) from
7. Remove cab recirculating filter. (See Recirculating expansion valve (C) and heater hoses (K) from
Filter, Remove in this group.) core.
Continued on next page TX,1830,MM3160 –19–24JUL98–1/2

011504
PN=400
15. Remove expansion valve. 27. Install cab recirculating filter.
16. Remove heater/evaporator core (J). 28. Install rear cover behind seat.
17. Install expansion valve on heater/evaporator core. 29. Move seat back and install and tighten cap
screws.
18. Check lower housing (I) to make sure drain tube is
not plugged. 30. Install housing and knob. 18
1830
19. Install heater/evaporator core. 31. Install fresh air filter. 17
20. Connect air conditioner lines and heater hoses. 32. If the system is contaminated, each component in
the system must be flushed and purged
21. Open heater hose shut-off valves on engine. individually. (See procedures in this group.)
22. Install freeze control switch in core. 33. Drain oil from compressor. (See procedure in this
group.)
23. Install main blower motor.
34. If system was not completely flushed, see flushing
24. Connect wire harness to freeze control switch, procedure in this group.
blower motor and blower resistor.
35. Purge, evacuate, and charge the system. (See
25. Install evaporator top cover and cab left-hand procedures in this group.)
shelf.
26. Install inlet plenum to heater/evaporator core top

cover.
TX,1830,MM3160 –19–24JUL98–2/2

011504
PN=401
Remove And Install Expansion Valve
1. Remove rear cover behind seat.
2. Remove pressurizer motor (A). (See Pressurizer Motor,

Remove in this group.)
18 3. Disconnect air conditioning lines (C) from expansion

1830 valve.
18
4. Remove expansion valve and replace.
5. Install expansion valve.
6. Connect air conditioning lines to expansion valve.
7. Install pressurizer motor.
8. Install rear cover behind seat.
–UN–29OCT96
A—Pressurizer Motor
B—Expansion Valve
C—Conditioning Lines
T104605
TX,1830,MM3161 –19–09JUN98–1/1
Remove And Install Freeze Control Switch
1. Remove rear cover behind seat.
2. Remove probe (B) of freeze control switch (A) from

heater/evaporator core.
–UN–23SEP96
3. Disconnect wire leads from freeze control switch and
remove switch from cover.
T103844
4. Test freeze control switch. (See Freeze Control Switch,
Bench Test in this group.)
A—Switch
B—Probe
Continued on next page TX,1830,MM3162 –19–19OCT96–1/2

011504
PN=402
5. Attach freeze control switch (A) to heater/evaporator

core top cover.
6. Connect wiring leads to freeze control switch.
7. Route freeze control switch line (B) as shown. Route
–UN–08AUG97
under foam on module.
18
IMPORTANT: Freeze switch line is a capillary tube 1830
filled with refrigerant. A generous bend 19
T110752D
radius is required to ensure proper
operation. DO NOT kink freeze switch
line when bending.
A—Switch
B—Line
8. Carefully bend the end of the freeze control switch line
at a 90 degree angle. Insert last 88.9 mm (3.5 in.) into
evaporator core starting 190 mm (7.5 in.) from the left
end and 114 mm (4.5 in.) from the bottom. Push freeze
control switch line down into evaporator core at a 45
degree angle. Freeze switch line should slide smoothly
between the tubes in the evaporator core.
9. Install rear cover behind seat.
TX,1830,MM3162 –19–19OCT96–2/2

011504
PN=403
Bench Test Freeze Control Switch
1. Connect ohmmeter to freeze control switch terminals.

Put end of probe into an ice and salt water solution.
2. Switch must open at test specification.
–UN–08NOV88
Specification
18
Freeze Control Switch—
1830
Temperature ...................................................... Opens at -0.56° ± 0.84°C
20
(31° ± 1.5°F)
T83921
3. Warm the water.
4. Switch must close at test specification.
Specification
Freeze Control Switch—
Temperature ...................................................... Closes at -2.22° ± 0.84°C
(36° ± 1.5°F)
If switch operates within specifications, reinstall switch and

connect leads.
If switch does not operate within specifications, replace

with new switch and connect leads.
TX,1830,MM3163 –19–19OCT96–1/1

011504
PN=404
Remove And Install Heater Control Valve
1. Open left-hand side door. Remove cab fresh air filter

housing. (See Fresh Air Filter, Remove in this group.)
2. Shut off the heater hose shut-off valves on the engine

block.
18
3. Remove rear cover behind seat. 1830
21
4. Disconnect temperature control switch cable from
heater control valve.
5. Remove heater control valve (B) and test. (See Heater

Control Valve, Leak Check in this group.)
6. Inspect heater hoses and replace as required.
IMPORTANT: Heater valve will leak if arrow on valve

is not in the direction of coolant flow.
–UN–29OCT96
7. Install heater control valve with flow arrow (direction of
coolant flow) on valve towards heater inlet (bottom
port).
T104607
8. Connect the temperature control cable. Tighten all
hose connections.
A—Hose
9. Install rear cover behind seat. B—Heater Control Valve
10. Turn on the heater hose shut-off valve.
11. Install cab fresh air filter housing.
12. Add coolant to the radiator. Start engine and run the
heating system to check for leaks.
13. Add more coolant to account for coolant in the heater

circuit.
TX,1830,MM3164 –19–19OCT96–1/1

011504
PN=405
Heater Control Valve Leak Check
1. Connect water pressure hose to control valve inlet and

turn the valve arm to the closed position.
2. Check for leakage from the valve outlet.
18 NOTE: The heater control valve is not serviceable.

1830
22 3. Replace heater control valve if required.
TX,1830,MM3165 –19–09JUN98–1/1

011504
PN=406
Remove And Install Main Blower Assembly
18
1830
23
–UN–29OCT96
T104545
A—Pressurizer Motor E—Resistor H—Cap Screws L—Heater Valve
B—Inlet Plenum F—Main Blower Motor I—Lower Housing M—Air Conditioning Lines
C—Expansion Valve G—Heater/Evaporator Core J—Heater/Evaporator Core N—Housing
D—Freeze Control Switch Top Cover K—Heater Hoses (2 used) O—Knob
1. Remove rear cover behind seat. 8. Remove heater/evaporator core top cover (G).
2. Remove upper two screws attaching inlet plenum 9. Remove lower two screws from main blower motor
(B) to heater/evaporator core top cover (G). (F).
3. Disconnect main blower motor cooling tube from 10. Remove and inspect main blower motor assembly.
heater/evaporator top cover (G).
11. Check lower housing (I) to make sure drain tube is
4. Remove screws from heater/evaporator core top plugged for the heater unit, or that drain tube is
cover (G). not plugged for the air conditioning unit.
5. Remove freeze control switch (D) probe from core. 12. Attach main blower motor assembly to lower
housing (I) using two screws.
6. Remove upper two cap screws from main blower
motor (F). 13. Install heater/evaporator core top cover.
7. Disconnect wire harness from freeze control switch 14. Connect wiring harness to resistor and freeze
(D) and resistor (E). control switch.
Continued on next page TX,1830,MM3166 –19–09JUN98–1/2

011504
PN=407
15. Attach two upper screws to main blower motor. 17. Install upper two screws attaching inlet plenum to
heater/evaporator core top cover.
16. Connect cooling tube to heater/evaporator top
cover. 18. Install rear cover behind seat.
TX,1830,MM3166 –19–09JUN98–2/2
18 Remove And Install Pressurizer Motor

1830 Assembly
24
1. Remove cab left-hand shelf.
2. Disconnect cooling tube (B).
3. Remove four screws from pressurizer motor (A).
4. Disconnect wiring harness from pressurizer motor.
5. Remove and inspect pressurizer motor.
6. Attach pressurizer motor assembly using screws.
7. Install cab left-hand shelf.
A—Pressurizer Motor
B—Cooling Tube
–UN–29OCT96
T104610
TX,1830,MM3167 –19–09JUN98–1/1

011504
PN=408
Remove And Install Receiver-Dryer And Condenser
18
1830
25
–19–06JAN98
T112716
1—O-Ring (4 used) 5—Hinge 9—Screw 13—Screw
2—Hose 6—Vapor Condenser 10—Screw 14—Bracket
3—Receiver-Dryer 7—Nut, Flange 11—Bracket 15—O-Ring
4—Hose 8—Washer 12—Washer
Receiver Dryer: 5. Apply refrigerant oil to new O-rings. Remove plugs

from receiver-dryer and immediately connect lines
1. Recover refrigerant. (See procedure in this group.) (2 and 4).
2. Discharge the system. 6. Add 15 mL (0.5 fl. oz.) refrigerant oil to system. See
procedure in this group.)
3. Disconnect lines (2 and 4) from receiver-dryer.
7. Evacuate and charge the system. (See procedure
4. Remove receiver-dryer. in this group.)
IMPORTANT: A new receiver-dryer must always be Condenser:

installed after purging the system.
DO NOT use a flushed or used 1. Recover refrigerant. (See procedure in this group.)
receiver/dryer. Contamination of
system can cause component 2. Disconnect the condenser-to-compressor hose and
failure. condenser-to-receiver-dryer hose.

011504
PN=409
3. Remove mounting cap screws. Remove condenser. 6. Evacuate and charge the air conditioning system.
(See procedure in this group.)
5. Install condenser and connect hoses
18
1830
26
CED,OUOE003,1032 –19–24JUL98–2/2
Remove And Install High And Low Pressure

Switches
1. Remove left-hand shelf.
2. Remove fresh air filter assembly. (See procedure in

this group.)
NOTE: The high pressure switch has a male connector;

the low pressure switch has a female connector.
3. Disconnect wiring harness from the high pressure

switch (A) and the low pressure switch (B).
NOTE: A Schrader valve is located in the connection to

prevent the air conditioning from discharging when
the switches are removed.
4. Remove switches. Inspect and replace as required.
–UN–29OCT96
Specification
Low Pressure Switch—Pressure .......................... Opens at 173 ± 35 kPa
(1.73 ± 0.3 bar) (25 ± 5 psi)
Pressure ............................................................... Closes at 345 ± 35 kPa
(3.45 ± 0.3 bar) (50 ± 5 psi)
High Pressure Switch—Pressure ..................... Opens at 2760 ± 138 kPa T104619
(27.6 ± 1.38 bar) (400 ± 20 psi)
Pressure ........................................................... Closes at 1310 ± 138 kPa
(13.11 ± 1.38 bar) (190 ± 20 psi) A—High Pressure Switch
closing B—Low Pressure Switch
TX,1830,MM3168 –19–09JUN98–1/1

011504
PN=410
Remove And Install Fresh Air Filter
1. Open cab fresh air filter door by pulling up on lever (A)

to the left of the operator’s seat.
–UN–12DEC96
A—Lever
18
1830
T105479B
27
TX,18,111479 –19–09JUN98–1/4
2. Remove filter assembly by turning knob (A).
A—Knob
–UN–12DEC96
T103187C

011504
PN=411
NOTE: If operating in dusty conditions, cab fresh air filter

should be checked and cleaned as necessary.
3. Release clips (B).
B—Clip (2 used)
18
1830
28
–UN–12DEC96
T105493B

011504
PN=412
4. Remove filter (C). Replace if damaged.
5. Clean filter in one of these ways:
–UN–12DEC96
CAUTION: Prevent possible injury from flying
chips if compressed air is more than 210 kPa
(2.1 bar) (30 psi). Reduce compressed air to 18
less than 210 kPa (2.1 bar) (30 psi) when using 1830
T105494B
for cleaning purposes. Clear area of bystanders, 29
guard against flying chips, and wear personal
protection equipment including eye protection.
C—Filter
• Tap filter on a flat surface with the dirty side down.
• Use compressed air opposite to the normal air flow.
• Wash the filter in warm, soapy water. Flush the filter.
Let it dry before using the heater, defroster, or air
conditioner.
6. Remove dust from filter housing.
7. Install filter and filter duct work.
8. Install filter assembly. Close cab fresh air filter door.
TX,18,111479 –19–09JUN98–4/4

011504
PN=413
Remove And Install Recirculating Air Filter
NOTE: The cab recirculating air filter is located behind

the seat.
1. Loosen latch (A) holding grille. Remove grille.
18 2. Remove filter.
1830
30
CAUTION: Reduce compressed air to less than
210 kPa (2 bar) (30 psi) when using for cleaning
purposes. Clear area of bystanders, guard
against flying chips, and wear personal
protection equipment, including eye protection.
3. Clean filter in one of these ways:
• Tap it on a flat surface with the dirty side down.

• Use compressed air opposite to the normal air flow.
• Wash the filter in warm, soapy water. Flush the filter
–UN–12DEC96
and let it dry before using the air conditioner.
4. Install filter.
T103539C
5. Install grille.
A—Latch
TX,1830,MM3169 –19–09JUN98–1/1

011504
PN=414
18
1830
31

011504
PN=415
Remove And Install Compressor
18
1830
32
–19–15MAY98
T115378

011504
PN=416
A—Discharge Hose G—Pin Spring (2 used) M—Washer Hardened Q—Support (Idler)

B—Suction Hose H—Spacer N—Nut (3 used) R—Screw Hex Head (2 used)
C—O-Ring I—Idler Pulley O—Screw Hex Head S—Spacer
D—O-Ring J—Sleeve (2 used) P—Mounting T—Idler Pulley
E—Compressor K—Hose Bracket-Compressor U—Screw Hex Flanged
F—Cap Screw Flanged (3 L—Screw Hex Head
used)
1. Recover refrigerant from the system. (See Specification

Compressor Belt Cap Screw— 18
procedure in this group.) 1830
Torque....................................................................... 26 N•m (19 lb-ft)
33
2. Loosen belt adjuster and remove drive belt.
7. Reconnect refrigerant lines. Tighten suction line (B)
and discharge line (A) fitting.
3. Disconnect hoses (A and B). Remove compressor
belt cap screw. Specification
Compressor Suction Line—
4. Disconnect electrical connector. Torque....................................................................... 31 N•m (23 lb-ft)
Compressor Discharge Line—
Torque........................................................................... 22•m (16 lb-ft)
5. Remove compressor.
6. Install compressor and tighten cap screws to 26 8. Connect wiring lead.

N•m (19 lb-ft).
CED,OUOE003,1042 –19–28JUL98–2/3
9. Install serpentine belt by holding tensioner back with

1/2 in. socket extension.
10. If compressor was replaced due to an internal failure,

flush and purge each component in the air
conditioning system individually. (See procedures in
–19–14MAY98
this group.)
11. Add compressor oil. (See procedure in this group.)
T115379
IMPORTANT: Do not flush receiver/dryer or install a
used one. Always install a new
receiver/dryer.
12. Remove existing receiver/dryer and install a new one.

(See procedure in this group.)
13. Evacuate and charge the system. (See procedure in

this group.)
CED,OUOE003,1042 –19–28JUL98–3/3

011504
PN=417
Disassemble And Assemble Compressor

Clutch—R134a
18
1830
34
–UN–24JUN92
RW21157
–UN–09MAY97
T107716
A—JDG747 Compressor C—Clutch Hub E—Pulley G—Clutch Coil

Clutch Spanner D—Pulley Snap Ring F—Clutch Coil Snap Ring H—Shims
B—Clutch Shaft Bolt
1. Mount compressor on DFRW20 Compressor 2. Remove dust cover.

Holding Fixture using two 6 in. x 1/4 in. eye bolts
with nuts as illustrated. (See procedure in this
group.)
Continued on next page TX,18,DY5297 –19–09MAY97–1/2

011504
PN=418
3. Hold the clutch hub using JDG747 Compressor 8. Install the clutch coil and new snap ring with flat
Clutch Spanner (A) and remove the clutch shaft bolt side of the snap ring down. Connect the clutch coil
(B). lead wire.
4. Remove the clutch hub (C). Remove the shims (H) 9. Install the pulley and new snap ring with flat side of
from the clutch hub and save for installation. the snap ring down. Apply grease to the shims (H)
and install to the clutch hub.
5. Remove and discard snap ring (D). Remove the 18
pulley (E) using a plastic hammer or JDG220 10. Install clutch hub and shaft bolt and tighten. Install 1830
Puller, JDG748 Jaws, and JDG771 Forcing Screw. dust cover. 35
6. Disconnect the clutch coil lead wire. Remove and Specification

discard the snap ring (F) and remove the clutch coil Clutch Hub Shaft Bolt—Torque ............................. 14 N•m (120 lb-in.)
Compressor Clutch Coil—
(G). Current Draw .................................... 2.8—3.5 amps at 24 Volts 20°C
(68°F)
NOTE: The bearing in the pulley is NOT serviceable. Resistance ........................................... 2.8—4.5 ohms at 20°C (68°F)
Compressor Relief Valve—
Pressure.................................................. Opens at 3030 kPa (30 bar)
7. Check pulley bearing operation. Replace pulley and
(440 psi)
bearing as required.
TX,18,DY5297 –19–09MAY97–2/2
Check Clutch Hub Clearance—R134a
NOTE: The clutch coil is NOT polarity sensitive.
1. Check pulley-to-clutch hub clearance using a dial

indicator. Mount the gauge to the pulley as illustrated
and connect a set of jumper wires from the compressor
to a 12V battery.
2. Rotate the pulley and check clearance in three equally

spaced locations around the clutch hub. Correct
clearance is 0.35—0.65 mm (0.014—0.026 in). Add or
remove shims as required.
Specification
Pulley-to-Clutch Hub—Clearance......... 0.35—0.65 mm (0.014—0.026 in)
3. Tighten clutch shaft bolt to 14 N•m (120 lb-in.) after

correct clearance is obtained.
Specification
–UN–24JUN92
Clutch Hub Shaft Bolt—Torque .................................... 14 N•m (120 lb-in.)

RW21159
TX,1830,BA636 –19–26MAR93–1/1

011504
PN=419
Inspect Compressor Manifold—R134a
1. Remove cap screws (A) and the manifold (B).
2. Remove and discard seal (C). Inspect porting surfaces.
3. Lubricate and install a new seal (C).

18
1830 4. Install manifold and tighten cap screws to 26 N•m (19
36 lb-ft).
Specification
Compressor Manifold Cap
–UN–24JUN92
A—Manifold Cap Screw
B—Manifold
C—Manifold Seal
RW21160
TX,1830,BA637 –19–11MAY94–1/1

011504
PN=420
Disassemble, Inspect, And Assemble Compressor—R134a
18
1830
37
–UN–24JUN92
RW21161
A—Rear Pins G—Rear O-Ring L—Front Gasket Q—Felt Holder
B—Rear Housing H—Front O-Ring M—Snap Ring R—Felt
C—Rear Gasket I—Front Suction Reed Valve N—Lip Seal S—Front Housing
D—Rear Discharge Reed Valve J—Front Valve Plate O—Washer T—Front Pins
E—Rear Valve Plate K—Front Discharge Reed P—Through Bolt
F—Rear Suction Reed Valve Valve
1. Clean the compressor using solvent before NOTE: The valve plates, reed valves, cylinders, and
disassembly. Mount compressor on holding fixture cylinder housing are NOT serviceable. Some
and remove clutch. (See Disassemble and cylinder scuffing (light scratches) is normal.
Assemble Compressor Clutch in this group.)
3. Inspect the valves for an even wear pattern and the
IMPORTANT: When removing front and rear cylinders for scoring or excessive wear. Replace
housing, be careful NOT to damage compressor as required.
the sealing surfaces.
4. Remove the shaft seal snap ring (M). Turn the
2. Disassemble the compressor as illustrated and housing over and remove the felt holder (Q) and felt
discard the O-rings, gaskets, lip seal, snap ring, (R) from the front housing (S).
and through bolt washers. Replace parts from
service kits.
Continued on next page TX,18,DY5026 –19–12MAR97–1/4

011504
PN=421
5. Remove the shaft lip seal (N) from the front housing 6. Wash all parts in clean solvent and dry before
(S) using a small tool with 5/8 in. OD. assembly.
18
1830
38

011504
PN=422
18
1830
39
–UN–24JUN92
–UN–24JUN92
RW21162
RW21163
IMPORTANT: Lubricate O-rings, gaskets, and lip 11. Install pins (T) and new O-ring (H) in the front
seal using only TY22025 (R134a) cylinder.
refrigerant oil during assembly.
Other oils could damage the NOTE: The front valve plate is marked with an “F” and
compressor. is installed face up.
7. Apply R134a oil to the bore of the front housing and 12. Install parts (I—K) over the pins on the front
install new lip seal (N) to the bottom of the bore cylinder.
using a socket. Install new snap ring (M) flat side
down. 13. Install a new gasket (L) flat side down. Put
JDG746 lip seal protector on the shaft and
IMPORTANT: Bushing spacer (U) must be in lubricate with R134a oil.
position before assembling the
compressor. 14. Install the front housing (S) on the front cylinder
and remove the lip seal protector. Install through
8. Install pins (A) and new O-ring (G) in the rear bolts (P) and new washers (O).
cylinder.
15. Partially tighten the through bolts and then tighten
NOTE: The rear valve plate is marked with an “R” and to 26 N•m (19 lb-ft).
is installed face up.
Specification
9. Install parts (F—D) over the pins on the rear Compressor Through Bolts—
Torque....................................................................... 26 N•m (19 lb-ft)
cylinder.
16. Install the felt (R) and felt holder (Q) using the
10. Install a new gasket (C) flat side down and the
clutch hub.
rear housing (B) on the rear cylinder. Mount the
compressor onto the holding fixture.

011504
PN=423
17. Install the pulley-clutch hub and check clearance.

(See Disassemble and Assemble Compressor
Clutch, this group.)
TX,18,DY5026 –19–12MAR97–4/4
18
1830
40

011504
PN=424
Group 1899
DFRW20 Compressor Holding Fixture
18
1899
1
–UN–20SEP89
RW13619
A—102 mm (4 in.) D—6.4 mm (0.25 in.) G—254 mm (10 in.) J—Weld
B—76 mm (3 in.) E—19 mm (0.75 in.) H—114 mm (4.5 in.) K—Two Holes
C—70 mm (2.75 in.) F—152 mm (6 in.) I—178 mm (7 in.)
This tool is used to hold the air conditioning • Two pieces of threaded rod, 13 mm (1/2 in.) threads
compressor during disassembly and assembly. x 178 mm (7 in.) long and four lock washers and
nuts.
Materials required are:
• Two pieces of steel plate, approximately 70 x 120

mm (2—3/4 in.) and 152 x 254 mm (6 x 10 in.).
TX,18,1111100 –19–22NOV97–1/1

011504
PN=425
18
1899
2

011504
PN=426
Section 19
Sheet Metal And Styling
Contents
Page
Group 1910—Hood Or Engine Enclosure

Remove And Install Hood . . . . . . . . . . . . . . .19-1910-1
Remove And Install Engine Side Shields. . . .19-1910-2
Group 1921—Grille And Grille Housing 19

Remove And Install Grille And Grille
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . .19-1921-1

011504
PN=1
Contents
19

011504
PN=2
Group 1910
Hood Or Engine Enclosure
Remove And Install Hood 1
3
1—Hood 2
2—Washer (4 used)
3—Screw (4 used)
–UN–17SEP02
T159101
TX,19,1111039 –19–05JUN98–1/1
19
1910
1

011504
PN=429
Remove And Install Engine Side Shields
19
1910
2
–UN–07MAY97
TP55500

011504
PN=430
1—Latch (2 used) 5—Screw (6 used) 8—Plate (2 used) 12—Spring Locking Pin (4

2—Latch 6—Washer (4 used) 9—Cap Screw (2 used) used)
3—Rivet (4 used) 7—Door (R.H. and L.H.) (L.H. 10—Washer (6 used) 13—Washer (2 used)
4—Shield (R.H. and L.H.) (L.H. Not Illustrated) 11—Screw (6 used) 14—Rod (2 used)
Not Illustrated)
Specification
CAUTION: Each engine side shield weighs Engine Side Shield—Weight ...................... 25 kg (55 lb) approximate
approximately 25 kg (55 lb).
CED,OUOE002,1640 –19–05JUN98–2/2
19
1910
3

011504
PN=431
19
1910
4

011504
PN=432
Group 1921
Grille And Grille Housing
Remove And Install Grille And Grille Housing
1. Disconnect battery ground strap or turn battery

disconnect switch “Off” if equipped.
2. Remove hood. (See Group 1910.)
3. Remove battery box covers.

19
1921
1

011504
PN=433
19
1921
2
–UN–12JUN98
T115763
A—Grille Housing-to-Frame B—Fuel Tank Filler Neck with C—Fan Guard E—Baffle Cap Screw (4 used)
Cap Screw (2 used) Hose D—Wiring Harness Connector
4. Remove fan guard (C). Grille screen weighs approximately 23 kg (50 lb).
5. Disconnect rear wiring harness connector (D) at Specification

Grill Screen—Weight .................................. 23 kg (50 lb) approximate
grille housing.
6. Remove fuel tank filler neck with hose (B). 8. Install two 12 mm eye bolts in tapped holes in top
of grille housing.
7. Remove four cap screws (E) and remove radiator
baffle plate. 9. Attach a chain and hoist to the eyebolts.
10. Remove two grille housing-to-frame cap screws

CAUTION: Grille housing weighs (A).
approximately 111 kg (244 lb).
Specification
Grille Housing—Weight .......................... 111 kg (244 lb) approximate

011504
PN=434
11. Remove two radiator and oil cooler outside

frame-to-grille housing cap screws (C).
12. Remove two door striker plates (B).
13. Carefully lift grille housing until it clears top of radiator

and oil cooler.
14. Install grille housing using eyebolts, in conjunction

with a chain and a hoist.
15. Install and tighten two bottom grille housing-to-engine

frame cap screws.
19
1921
16. Install and tighten two radiator and oil cooler outside 3
frame-to-grille housing cap screws.
17. Install two door striker plates.
18. Install and tighten two grille housing-to-frame cap
–UN–06JAN98
screws.
19. Connect rear wiring harness connector.
T112441B
20. Install fuel tank filler neck with hose.
21. Install fan guard.

A—Radiator and Oil Cooler Outside
22. Install battery box covers. Frame-to-Grille Housing Cap Screw (2 used)
B—Door Striker Plate (2 used)
23. Install hood. (See Group 1910.) C—Bottom Grille Housing-to-Engine Frame Cap
Screw (2 used)
24. Connect battery ground strap or turn battery

disconnect switch On, if equipped.
25. Install engine side shields. (See Group 1910.)
26. Install hood. (See Group 1910.)
27. Connect battery ground strap or turn battery

disconnect switch “On” if equipped.
CED,OUOE002,1643 –19–05JUN98–3/3

011504
PN=435
19
1921
4

011504
PN=436
Section 31
Loader
Contents
Page Page
Group 3102—Bucket Bucket Circuit Relief Valve

Ride Control Accumulator Disassemble and Assemble. . . . . . . . . . .31-3160-39
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3102-1 Load Sense Relief Valve
Bucket Tooth Shanks and Tips Disassemble and Assemble. . . . . . . . . . .31-3160-40
Remove and Install . . . . . . . . . . . . . . . . . .31-3102-2 Boom Circuit Relief Valve
Bucket Disassemble and Assemble. . . . . . . . . . .31-3160-40
Remove and Install . . . . . . . . . . . . . . . . . .31-3102-4 Disassemble and Assemble Boom and
Welded Bucket Cutting Edge Bucket Cylinder—185 Series . . . . . . . . . .31-3160-41
Remove and Install . . . . . . . . . . . . . . . . . .31-3102-5 Boom and Bucket Cylinder Bushings and
Bolt-on Bucket Cutting Edge Seals 31
Remove and Install . . . . . . . . . . . . . . . . . .31-3102-6 Remove and Install . . . . . . . . . . . . . . . . .31-3160-41
Cutting Edge
Hydraulic Reservoir
Repair Cracks . . . . . . . . . . . . . . . . . . . . . .31-3102-8
Hydraulic Oil Clean-Up With Filter
Group 3140—Frames Caddy . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-43
Service Equipment And Tools . . . . . . . . . . . .31-3140-1 Pilot Controller Repair (Single Lever
Other Material . . . . . . . . . . . . . . . . . . . . . . . .31-3140-1 Controller) . . . . . . . . . . . . . . . . . . . . . . . .31-3160-44
Specifications . . . . . . . . . . . . . . . . . . . . . . . .31-3140-2 Pilot Controller Repair (Two Lever Controller)
Bucket Tilt Linkage
(S.N. —585560). . . . . . . . . . . . . . . . . . . .31-3160-63
Pilot Controller Repair (Two Lever
Bucket Linkage Seals and Bushings
Controller) (S.N. 585561—) . . . . . . . . . . .31-3160-67
Pressure Reducing Valve Manifold
Loader Boom Bushings and Seals
Pressure Reducing Valve
Disassemble and Assemble. . . . . . . . . . .31-3160-73
Other Material . . . . . . . . . . . . . . . . . . . . . . . .31-3160-1
Boom Down Solenoid Valve
Specifications . . . . . . . . . . . . . . . . . . . . . . . .31-3160-2
Loader Hydraulic Pump
Differential Lock Solenoid Valve
Hydraulic Pump
Disassemble, Inspect and Assemble . . . .31-3160-10 Pilot Enable Solenoid Valve
Hydraulic Pump Control Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-76
Remove and Install . . . . . . . . . . . . . . . . .31-3160-30 Ride Control
Disassemble and Assemble. . . . . . . . . . .31-3160-32 Remove and Install . . . . . . . . . . . . . . . . .31-3160-77
Hydraulic Pump Stroke Limiter Ride Control Valve
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-33 Disassemble and Assemble. . . . . . . . . . .31-3160-79
Loader Control Valve Ride Control Accumulator
Remove and Install . . . . . . . . . . . . . . . . .31-3160-34 Disassemble and Assemble. . . . . . . . . . .31-3160-81
Disassemble and Assemble. . . . . . . . . . .31-3160-36 Charge. . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-84
Auxiliary Valve Section and Bucket Section Pin Disconnect/Axle Disconnect Valve
Disassemble and Assemble. . . . . . . . . . .31-3160-37 Remove and Install . . . . . . . . . . . . . . . . .31-3160-86
Boom Valve Section Pin Disconnect Valve
Disassemble and Assemble. . . . . . . . . . .31-3160-38 Disassemble and Assemble. . . . . . . . . . .31-3160-87
System Relief Valve
Disassemble and Assemble. . . . . . . . . . .31-3160-39 Continued on next page

011504
PN=1
Contents
Page
Axle Disconnect Valve

Disassemble and Assemble. . . . . . . . . . .31-3160-88

Dealer Fabricated Tool
DFT1132 Hydraulic Pump Tool . . . . . . . . .31-3199-1
31

011504
PN=2
Group 3102
Bucket
Ride Control Accumulator Safety
1. Stop engine.

equipped with ride control. Always be sure the
ride control accumulator energy is discharged
when working on hydraulic components. To do
this: With boom raised slightly, turn ignition
switch to ON position. Cycle the ride control
switch from OFF to ON (center position). Boom
will jump up unexpectedly if ride control
accumulator is energized. Press boom enable
switch and move the control lever into the float
2. If equipped with position). Boom ride control. With

boom raised slightly, turn ignition switch to ON 31
3102
position. Cycle the ride control switch from OFF to ON 1
(center will jump up unexpectedly if ride control
accumulator is energized. Press boom enable switch
and move the control lever into the float position and
hold for 5 seconds.
TX,31,RP3118 –19–30APR97–1/1

011504
PN=439
Bucket
Remove And Install Bucket Tooth Shanks And Tips
31
3102
2
–UN–22OCT97
T111849
1—Cutting Edge Segment (7 3—Cap Screw (2 used) 6—Tooth Tip (8 used) 9—Washer (24 used)
used) 4—Washer (2 used) 7—Washer (8 used) 10—Nut (26 used)
2—Adapter (Shank) 5—Pin (8 used) 8—Cap Screw (12 used) 11—Bolt (14 used)
Remove cap screws to remove tooth shanks and Specification

Cutting Edge-to-Center Tooth
cutting edge segments.
Shank Cap Screw—Torque ................................ 1193 N•m (880 lb-ft)
End Tooth Shank-to-Bucket
IMPORTANT: Shanks must be seated against Cap Screw—Torque ........................................... 1171 N•m (790 lb-ft)
cutting edge as nuts are tightened. Cutting Edge-to-Segment Cap
This places the load on the cutting Screw—Torque ................................................... 1193 N•m (880 lb-ft)
edge and not on the cap screws.
To remove tooth tip, drive pin (5) out from the left side
Install tooth shanks. of machine.
Install cutting edge segments between tooth shanks. To install tooth tip, install retaining washer (4) in
recess on left side of tooth shank. Drive tip on shank
Install cap screws in center tooth shanks and cutting until pin can be assembled or until center of hole in
edge segments with cap screw heads on bottom. shank aligns with center of slot in tooth tip.
Install cap screws to corner tooth shanks with cap Drive pin (5) through tip and shank from left side. Pin
screw heads to outside. must not contact front edge of tooth tip slot.

011504
PN=440
Bucket
NOTE: Pin may fail if in contact with front edge of

tooth tip slot. Try a different tooth tip or grind
slot in tooth tip longer.
CED,OUOE002,1649 –19–09JUN98–2/2
31
3102
3

011504
PN=441
Bucket
Remove And Install Bucket
31
3102
4
–UN–26NOV97
T108202
A—Shim, Bucket Link to C—Spacer (3 used) F—Grease Fitting (2 used) H—Shim, Bucket to Boom (as
Bucket (as needed) D—Washer (3 used) G—Pin, Bucket to Boom (2 needed)
B—Pin, Bucket Link to Bucket E—Cap Screw (3 used) used)
3. Remove bucket.
CAUTION: Approximate weight of 2.7 M (3.5
yd) bucket; 658 kg (1450 lb).
4. Align boom ends with bucket. Install shims (H)
between boom ends and bucket as needed to
Approximate weight of 3.3 M (4.25 yd)
obtain maximum clearance.
bucket; 726 kg (1600 lb).
Specification
Approximate weight of 3.4 M (4.5 yd) bucket; Boom End-to-Bucket—
748 kg (1650 lb). Clearance.................................................... 1 mm (0.04 in.) maximum
Specification Install an equal number of shims ± 1 on each side of

2.7 M (3.5 yd) Bucket—Weight ............ 658 kg (1450 lb) approximate
boom end.
3.3 M (4.25 yd) Bucket—
Weight ................................................... 726 kg (1600 lb) approximate
3.4 M (4.5 yd)—Weight ........................ 748 kg (1650 lb) approximate Install pins (G), spacers (C), washers (D) and cap
screws (E).
1. Lower bucket to the ground.
5. Align bucket link with bucket. Install shims (A)
2. Remove cap screws (E), washers (D), spacers (C), between bucket link and bucket to obtain maximum
and pins (B) and (G). clearance.

011504
PN=442
Bucket
Specification Install pin (B), spacers (C), washers (D) and cap
Bucket Link-to-Bucket—
screws (E).
Clearance.................................................... 2 mm (0.08 in.) maximum
Install an equal number of shims ± 1 on each side of

bucket link.
CED,OUOE002,1650 –19–09JUN98–2/2
Remove And Install Welded-On Bucket Cutting Edges
1. Perform welding in an environment with a minimum 5. Tack weld preheated plates starting at center of
ambient temperature of 10°C (50°F). bucket and working toward the outside ends.
31
2. Clean all joints to be welded of all foreign matter 6. Final weld preheated plates starting at the center of 3102
5
such as dirt, rust, mill scale, oil, etc. with grinders the front edge of the bucket backing plate and
and/or solvents. working toward the outside ends.
3. Use dry AWS-E7018 low hydrogen electrodes or Repeat this operation at back edge of loader blade.
either of the following equivalent low hydrogen wire
feed electrodes: gas metal arc welding (CO2 or Tack welds may be incorporated into the final weld,
argon CO2) AWS-E70S6 or flux cored arc welding providing they have been made with electrodes that
AWS-E70T1. meet the requirements of the final welds and no
cracking has occurred in the weld metal. Tack
4. Preheat parts to be welded (both tack and final welds not meeting these requirements must be
welds) to minimum of 204°C (400°F). PREHEAT completely removed by grinding or air arc gouging
TEMPERATURE MUST BE THROUGHOUT THE just prior to making the final weld in that area.
ENTIRE THICKNESS OF THE PARTS JOINED
AND AT LEAST 51 mm (2 in.) BACK FROM THE 7. Do not remove bucket from welding environment
JOINT. Maintain preheat throughout the entire until weld metal temperature has dropped to the
welding operation. Tempilstiks should be used if ambient temperature. Do not force cooling rate of
possible. weld metal.
TX,31,ME120 –19–09JUN98–1/1

011504
PN=443
Bucket
Remove And Install Bolt-On Cutting Edges And Wear Plates
31
–UN–17APR96
3102
6
TP48319
1—Nut (12 used) 2—Cutting Edge (2 used) 3—Bolt (12 used) 4—Cutting Edge (2 used)

011504
PN=444
Bucket
31
3102
7
–UN–29APR97
T109256
1—Wear Plate 2—Bolt (8 used) 3—Washer (8 used) 4—Nut (8 used)
2. To install, hold cutting edge in position and install

CAUTION: Approximate weight of cutting
new hardware.
edge segments is 66 kg (145 lb).
Specification
Specification
Cutting Edge-to-Bucket Cap
Cutting Edge Segment—Weight............... 66 kg (145 lb) approximate
Wear Plate-to-Bucket Cap
1. Remove hardware and cutting edge from bucket. Screw—Torque ..................................................... 300 N•m (225 lb-ft)
Remove hardware from wear plates and install new

wear plates and hardware.
TX,31,RP3077 –19–09JUN98–2/2

011504
PN=445
Bucket
Repair Cracked Cutting Edge
1. If cutting edge has any cracks, clean the area to find

end of crack.
2. Drill a small hole at end of crack to prevent spreading.
3. Grind V-grooves along crack on top and bottom of

cutting edge.
4. Preheat the cracked area to approximately 149—260°C

(300—500°F).
5. Fill the V-grooves with weld. Use E7018 electrodes.

Extend the weld approximately 13 mm (0.5 in.) beyond
end of crack.
31
3102 TX,31,ME122 –19–09JUN98–1/1
8

011504
PN=446
Group 3140
Frames
Service Equipment And Tools

European Microfiche Tool Catalog (MTC). Some
tools may be available from a local supplier.
SERVICEGARD is a trademark of Deere & Company. CED,OUOE003,1108 –19–02JUL98–1/2
Bushing Bearing and Seal Driver Set
Used to remove and install bushings and seals.
31
CED,OUOE003,1108 –19–02JUL98–2/2 3140
1
Other Material
Number Name Use
PT569 (U.S.) NEVER-SEEZ Lubricant To provide a light seal between

surfaces.
NEVER-SEEZ is a trademark of Emhart Chemical Group. CED,OUOE003,1109 –19–02JUL98–1/1

011504
PN=447
Frames
Specifications
Bellcrank with Bushings Weight 366 kg (806 lb) approximate
Bellcrank Pivot Pin Weight 12 kg (26 lb) approximate
Bucket Link with Bushings Weight 34 kg (75 lb) approximate
Bellcrank-to-Bucket Link Clearance 3 mm (0.12 in.) maximum
Bellcrank-to-Bucket Cylinder Clearance 3 mm (0.12 in.) maximum
Bellcrank-to-Loader Boom Clearance 3 mm (0.12 in.) maximum
Bucket Cylinder Weight 162 kg (358 lb) approximate
31 Boom Weight 1243 kg (2741 lb) approximate

3140
2
CED,OUOE003,1110 –19–02JUL98–1/1

011504
PN=448
Frames
Remove And Install Loader Bucket Tilt Linkage
31
3140
3
–19–03APR97
T108207
A—Bucket Cylinder E—Grease Fitting (3 used) H—Pin K—Cap Screw (2 used)
B—Shim (As Required) F—Seal (4 used) I—Spacer (2 used) L—Pin
C—Bellcrank G—Bucket Link J—Washer (2 used) M—Loader Boom
D—Shim (As Required)
Lower bucket to the ground. Remove parts as necessary.
Install shims (B) bellcrank-to-bucket link and

CAUTION: Approximate weight of bellcrank
bellcrank-to-bucket cylinder (D) bellcrank-to-loader
with bushings is 366 kg (806 lb).
boom to obtain maximum clearance.
Approximate weight of bellcrank pivot pin is Specification
12 kg (26 lb). Bellcrank-to-Bucket Link—
Approximate weight of bucket link with Bellcrank-to-Bucket Cylinder—
bushings is 34 kg (75 lb). Clearance.................................................... 3 mm (0.12 in.) maximum
Bellcrank-to-Loader Boom—
Specification
Bellcrank with Bushings—
Weight ..................................................... 366 kg (806 lb) approximate Apply NEVER-SEEZ Lubricant or an equivalent to
Bellcrank Pivot Pin—Weight ....................... 12 kg (26 lb) approximate bore of bellcrank pivot pin.
Bucket Link with Bushings—
Weight ......................................................... 34 kg (75 lb) approximate

011504
PN=449
Frames
Remove And Install Bucket Linkage Seals And Bushings
31
3140
4
–19–26NOV97
T108214
A—Bellcrank C—Bucket Link E—Bushing (2 used) G—Bushing
B—Seal (2 used) D—Seal (4 used) F—Shim (As Required)
1. Remove bushings and seals from bucket link and 4. Install seals (D) into bores against bushings or flush
bellcrank using disks from driver set. with surface of bucket link and bellcrank.
2. Apply NEVER-SEEZ Lubricant or an equivalent

new bushings and bushing bores.
3. Install bucket link and bellcrank bushings 6.4 mm

(0.25 in.) minimum below surface, or centered in
bushing bore.
NEVER-SEEZ is a trademark of Emhart Chemical Group. TX,3140,RP3044 –19–09JUN98–1/1

011504
PN=450
Frames
Remove And Install Loader Boom Bushings And Seals
31
3140
5
–UN–26NOV97
T108266
A—Bushings B—Seals C—Loader Boom
1. Lower bucket to the ground and remove bucket 4. Remove boom pivot pins from machine frame and
from boom. remove boom.
5. Remove bushings from boom using discs from

CAUTION: Approximate weight of bucket
bearing bushing driver set.
cylinder is 162 kg (358 lb).
Specification 6. Apply NEVER-SEEZ Lubricant or an equivalent on

Bucket Cylinder—Weight ........................ 162 kg (358 lb) approximate outer surface of new bushings and bores. Center
new bushings in boom bores and press seals
2. Remove bucket cylinder and linkage. against bushings with lips outward.
3. Disconnect boom cylinders from boom. 7. Install boom and cylinders on machine. Install
shims as needed in loader frame to boom joint.
CAUTION: Approximate weight of boom is
1243 kg (2741 lb).
Specification
Boom—Weight .................................... 1243 kg (2741 lb) approximate

011504
PN=451
Frames
31
3140
6

011504
PN=452
Group 3160
Hydraulic System
Other Material
Number Name Use
T43513 (U.S.) Thread Lock and Sealer (High Apply to threads of spool assembly
TY9474 (Canadian) Strength) components.
271 (LOCTITE)
T43513 (U.S.) Thread Lock and Sealer (High Apply to threads of spool assembly
TY9474 (Canadian) Strength) components.
271 (LOCTITE)
PT569 (U.S.) NEVER-SEEZ Lubricant To provide a light seal between

surfaces.
T43513 (U.S.) Thread Lock and Sealer (High Apply to threads on pilot controller
TY9474 (Canadian) Strength) lever assembly.
271 (LOCTITE)
31
T43513 (U.S.) Thread Lock and Sealer (High Apply to threads on pilot controller 3160
TY9474 (Canadian) Strength) lever assembly. 1
271 (LOCTITE)
LOCTITE is a trademark of Loctite Corp.

NEVER-SEEZ is a trademark of Emhart Chemical Group. OUT3019,00000A8 –19–27AUG03–1/1

011504
PN=453
Hydraulic System
Specifications
Hydraulic Pump Weight 53 kg (117 lb) approximate
Guide Plate Cap Screw Torque 10 N•m (90.0 lb-in.)
Valve Plate-to-Pump Housing Hex Torque 95 N•m (70 lb-ft)

Head Cap Screw
Socket Head Screw Torque 95 N•m (70 lb-ft)
Control Housing-to-Pump Cap Screw Torque 60 N•m (44 lb-ft)
Control End Cap-to-Control Housing Torque 40 N•m (30 lb-ft)

31 Screw
3160
2 Load Sense Module (Valve)-to-End Torque 6 N•m (57 lb-in.)
Cap Screw
Loader Control Valve Weight 41 kg (90 lb) approximate
Loader Control Valve Tie Bolt Nut Torque 102 N•m (75 lb-ft)
Auxiliary Valve Section:
Circuit Relief Lock (B) Torque 20 N•m (175 lb-in.)
Circuit Relief Housing (C) Torque 102 N•m (75 lb-ft)
Compensator Cap (F) Torque 102 N•m (75 lb-ft)
Hex Head Screw (J) Torque 11 N•m (100 lb-in.)
Lift Check Hex Head Cap (O) Torque 169 N•m (125lb-ft)
Socket Head Screw (S) Torque 11 N•m (100 lb-in.)
Port Plug (T) Torque 20 N•m (175 lb-in.)
Circuit Relief Cap (V) Torque 115 N•m (85 lb-ft)
Boom Valve Section:
Compensator Cap (D) Torque 102 N•m (75 lb-ft.)
Continued on next page OUT3019,00000AB –19–27AUG03–1/4

011504
PN=454
Hydraulic System
Plug (H) Torque 102 N•m (75 lb-ft.)
Nut (I) Torque 20 N•m (175 lb-in.)
Hex Head Cap Screw (J) Torque 102 N•m (75 lb-ft.)
Plug (K) Torque 12 N•m (100 lb-in.)
Stripper Bolt (M) Torque 20 N•m (175 lb-in.)
Check Hex Head Cap (P) Torque 102 N•m (75 lb-ft.)
Socket Head Cap Screw (U) Torque 20 N•m (175 lb-in.)
Plug (V) Torque 12 N•m (100 lb-in.)
Plug (W) Torque 102 N•m (75 lb-ft.) 31

3160
3
Hydraulic Reservoir-to-Frame Cap Torque 624 N•m (460 lb-ft)
Screw
Lever Housing-to-Valve Housing Torque 8.5 N•m (75 lb-in.)

Allen Screw
Lever Adjuster Sleeve Hex Nut Torque 11 N•m (100 lb-in.)
Pilot Controller Lever Torque 8.5 N•m (75 lb-in.)

Housing-to-Valve Housing Allen
Screw
Pilot Controller Universal Joint Hex Torque 28 N•m (250 lb-in.)

Nut
Pilot Controller Lever Adjuster Torque 11 N•m (100 lb-in.)

Sleeve Hex Nut
Pilot Controller Lever Torque 8.5 N•m (75 lb-in.)

Hosing-to-Valve Housing Allen Screw
Pilot Controller Lever Adjuster Torque 11 N•m (100 lb-in.)

Sleeve Hex Nut
Oil Temperature 40 ± 6°C (100 ± 10°F)

011504
PN=455
Hydraulic System
Engine Speed Slow Idle
Boom Float Detent Pressure 4137—4480 kPa (41—45 bar)

(600—650 psi)
Feel Position Pressure As the control lever is moved from

neutral, the pilot pressure will
suddenly jump up to approximately
90 psi at 3/4—1 in. travel. The
pressure should then increase
smoothly to the specification at the
FEEL position (or 75% lever travel),
and then jump up to 600—650 psi as
the lever is moved into detent.
Boom Power Down Pressure 1860—2082 kPa (19—21 bar)

31 (270—302 psi)
3160
4 Boom Raise Pressure 1882—2227 kPa (19—22 bar)
(273—323 psi)
Bucket Rollback Pressure 2110—2455 kPa (21—25 bar)

(306—356 psi)
Bucket Dump and Auxiliary Valve Pressure Pressure must increase smoothly to
2110—2455 kPa (21—25 bar)
(306—356 psi) at 3/4 lever travel and
then increase to 4140—4480 kPa
(41.4—44.8 bar) (600—650 psi) as
the lever is moved past 80—90%
travel
Begin Metering 3/8—5/8 in. of lever travel (Measured

at top end of lever.)
Boom Float Detent Pressure 4137—4480 kPa (41—45 bar)

(600—650 psi)

011504
PN=456
Hydraulic System
Feel Position Pressure As the control lever is moved from

neutral, the pilot pressure will
suddenly jump up to approximately
90 psi at 3/4—1 in. travel. The
pressure should then increase
smoothly to the specification at the
FEEL position (or 75% lever travel),
and then jump up to 600—650 psi as
the lever is moved into detent.
Boom Power Down Pressure 1860—2082 kPa (19—21 bar)

(270—302 psi)
Boom Raise Pressure 1882—2227 kPa (19—22 bar)

(273—323 psi)
Bucket Rollback Pressure 2110—2455 kPa (21—25 bar) 31

(306—356 psi) 3160
5
Bucket Dump and Auxiliary Valve Pressure Pressure must increase smoothly to
2110—2455 kPa (21—25 bar)
(306—356 psi) at 3/4 lever travel and
then increase to 4140—4480 kPa
(41.4—44.8 bar) (600—650 psi) as
the lever is moved past 80—90%
travel
Boom Down Solenoid Valve Torque 7 N•m (62 lb-in.)

Retaining Nut
Differential Lock Solenoid Valve Torque 7 N•m (62 lb-in.)

Retaining Nut
Pilot Enable Solenoid Valve Torque 7 N•m (62 lb-in)

Retaining Nut
Ride Control Accumulator Approximate Weight 40 kg (80 lb)
Valve Solenoid Retaining Nut Torque 8 N•m (72 lb-in)
Oil Temperature 40°C (104°F)
Ride Control Accumulator Charge Pressure 2068 ± 138 kPa (20 ± 1 bar) (300 ±
20 psi)
OUT3019,00000AB –19–27AUG03–4/4

011504
PN=457
Hydraulic System
Remove And Install Loader Hydraulic Pump
IMPORTANT: Do Hydraulic Pump Flow Test in Group

9025-25, Operation and Test Manual
before removing hydraulic pump for
repair. If pump does not meet test
specification, replace it, do not rebuild
pump.
Procedure will require two mechanics to

remove and install hydraulic pump.
1. Stop engine.
2. Lower all equipment to the ground.
3. Move pilot enable/boom down switch to boom lower

and move hydraulic control lever to boom float. With
31 Key switch ON, move ride control switch OFF then ON,
3160 move hydraulic control lever to boom float.
6
CAUTION: Prevent unexpected machine

movement and possible injury. Install frame
5. Turn battery disconnect switch off (if equipped) or

disconnect battery ground strap.
6. Remove left and right cab stairs and service panels.
7. Remove lower front, left and right side trim shields

from cab.

011504
PN=458
Hydraulic System

–UN–23AUG88
fluids.
X9811
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
9. Drain hydraulic reservoir. Approximately 117 L (31 gal).

31
Specification 3160
Hydraulic Reservoir—Capacity....................... 117 L (31 gal) approximate 7
10. Remove transmission filter assembly (A). Move out of
–UN–12JUN98
the way.
11. Disconnect transmission connector (B).
T115788
A—Transmission Filter Assembly
B—Transmission Connector

011504
PN=459
Hydraulic System
12. Disconnect and cap lines (A—G).
A—Load Sense Hose

B—Suction Hose
C—Pump Inlet
D—Case Drain
E—Pressure to Control Valve
F—Pressure to Steering Valve
G—Hose to Pressure Reducing Valve
31
3160
–UN–12JUN98
8
T115526

011504
PN=460
Hydraulic System
NOTE: Open cab door to prevent damage to window.
13. Attach M12 1-5/16 eyebolt (A) and DFT1132

Hydraulic Pump Removal Tool (B) to hydraulic pump
housing.
14. Remove hydraulic pump mounting cap screws.
CAUTION: Approximate weight of hydraulic

pump is 53 kg (117 lb).
–UN–12JUN98
Specification
Hydraulic Pump—Weight ................................ 53 kg (117 lb) approximate
T115780
15. Remove hydraulic pump.
16. Repair and replace parts as necessary.

A—Eyebolt
17. Install new gasket. B—DFT1132 Hydraulic Pump Removal Tool 31
3160
18. Install pump with cap screws. 9
19. Fill pump body with hydraulic oil through case drain
line (D) to assure lubrication for start up.
20. Connect lines and fittings.
21. Install transmission filter assembly.
22. Connect transmission connector.
23. Fill hydraulic reservoir.
24. Switch battery disconnect on (if equipped) or install

battery ground cable.
25. Do Hydraulic Pump Margin and Low Standby

Pressure Adjustment Test.
CED,OUOE002,1659 –19–09JUN98–4/4

011504
PN=461
Hydraulic System
Inspect And Assemble Hydraulic Pump

Disassemble
CAUTION: Reduce compressed air to less than

210 kPa (2.1 bar) (30 psi) when using for
–UN–04NOV96
cleaning purposes. Clear area of bystanders,
guard against flying chips, and wear personal
protection equipment including eye protection.
T103480
Approximate weight of hydraulic pump is 53 kg
(117 lb).
Specification
Hydraulic Pump—Weight ................................ 53 kg (117 lb) approximate
IMPORTANT: Use only diesel fuel to clean pump

parts. Solvents can damage internal
components.
31
3160 Perform Hydraulic Pump Case Drain
10
Test in Group 9025-25, Operation and
Test Manual before removing hydraulic
pump for repairs. If pump does not
pass the test, replace it, DO NOT
rebuild it.
1. Mount pump on D01006AA Bench Mounted Holding

Fixture as shown.
2. As pump parts are removed wash in diesel fuel and

dry using compressed air.

011504
PN=462
Hydraulic System
3. Remove socket head cap screws and lift the control

group assembly straight up from the top of the pump
assembly. Remove control pin from swashblock.
31
3160
–UN–04NOV96
11
T103478
CED,OUOE002,1661 –19–09JUN98–2/44
4. Remove valve plate by removing four cap screws and

lifting it away from main pump assembly.
–UN–04NOV96
T103480
CED,OUOE002,1661 –19–09JUN98–3/44
5. Remove O-ring (A).
A—O-Ring
–UN–24JUN91
T7553BG

011504
PN=463
Hydraulic System
6. Remove gasket (A).
A—Gasket
–UN–24JUN91
T7553BA
CED,OUOE002,1661 –19–09JUN98–5/44
7. Make sure pump is in a horizontal position.
Remove rotating group by turning input shaft slowly

while pulling the cylinder barrel from the pump’s
31 housing.
3160
–UN–04NOV96
12
T103482
CED,OUOE002,1661 –19–09JUN98–6/44
8. Number each pump piston shoe assembly (B) and its

respective bore in cylinder barrel (A) and shoe retainer
(C) while disassembling. This will assure the same
parts are installed to the respective bore in the retainer
and barrel.
A—Cylinder Barrel
B—Pump Piston Shoe Assembly
C—Shoe Retainer
–UN–04NOV96
T104036

011504
PN=464
Hydraulic System
Remove shoe retainer (B) with pistons (A) and shoe

retainer spring (C).
A—Piston (9 used)
B—Shoe Retainer
C—Shoe Retainer Spring
–UN–24JUN91
T7553BB
CED,OUOE002,1661 –19–09JUN98–8/44
9. Remove hydrodynamic locking screw (A).
A—Locking Screw
31
3160
13
–UN–04NOV96
T104801

011504
PN=465
Hydraulic System
NOTE: Later pump models may not incorporate this

retaining ring.
10. Remove retaining ring (A) with flat head screwdriver

(B).
A—Retaining Ring
B—Flat Head Screwdriver
–UN–04NOV96
31
3160
T104037
14
–UN–04NOV96
T104041

011504
PN=466
Hydraulic System
11. Remove hydrodynamic bearing by pulling it out of the

pump’s housing evenly.
–UN–04NOV96
T104028
31
3160
15
CED,OUOE002,1661 –19–09JUN98–11/44
12. Remove drive shaft bearing retainer ring with snap

ring pliers.
–UN–04NOV96
T103483

011504
PN=467
Hydraulic System
13. Remove outboard end of drive shaft and pull out from
pump housing. Remove shaft seal retainer.
A—Shaft Seal Retainer
–UN–12AUG97
T104805
CED,OUOE002,1661 –19–09JUN98–13/44
14. Remove shaft seal from housing only if necessary.

This is not reusable.
A—Shaft Seal
31
3160
–UN–24JUN91
16
T7553AL

011504
PN=468
Hydraulic System
15. Remove flat head screws with a 5/32 Allen wrench

and remove guide plate (A).
A—Guide Plate
–UN–04NOV96
31
3160
T104799
17
–UN–04NOV96
T103484

011504
PN=469
Hydraulic System
16. Remove the swashblock from pump housing.
–UN–04NOV96
T103485
31
3160
18
CED,OUOE002,1661 –19–09JUN98–16/44
17. Remove the saddle bearings (A) from pump housing.
A—Saddle Bearing (2 used)
–UN–31JAN94
T8170AE

011504
PN=470
Hydraulic System
18. Clean all parts thoroughly. Inspect all seals and

O-rings for hardening, cracking or deterioration and
replace if necessary.
Inspect valve plate group.
–UN–24JUN91
Inspect the valve plate surface that mates with the
pump’s cylinder barrel for excessive wear or scoring.
Remove minor defects by lightly stoning the surface
with a hard stone that is flat to within 0.001". Be sure
T7553AS
to stone lightly. Any excessive stoning will remove the
hardened surface. If wear or damage is extensive,
replace the valve plate.
Check drive shaft bushing for abnormal wear.
31
CED,OUOE002,1661 –19–09JUN98–18/44 3160
19
19. Inspect Suction Inlet Tube for cracks and damage

from handling. If any cracks or damage, part must be
replaced.
–UN–04NOV96
T103486

011504
PN=471
Hydraulic System
20. Rotating Group
Inspect cylinder barrel piston bores and the face that

mates with valve plate for wear and scoring. Remove
minor defects on the face by lightly stoning the
surface. If defects can not be removed by this
–UN–24JUN91
method, cylinder barrel is unusable.
21. Inspect all piston and shoe assemblies to be sure

they ride properly on the swashblock.
T7553AT
CED,OUOE002,1661 –19–09JUN98–20/44
22. Check each piston shoe for smooth pivot action on

the piston. Contaminates or burrs can cause them to
stick.
31
3160
–UN–24JUN91
20
T7553AO
CED,OUOE002,1661 –19–09JUN98–21/44
23. Check piston shoe wear. All shoes must be equal

within 0.025 mm (.001 in) at outer dimension.
Check piston shoe end play. End play must not

exceed .152 mm (.006 in).
–19–08NOV96
T104804

011504
PN=472
Hydraulic System
24. Hydrodynamic Bearing
Inspect for contaminate damage or extreme wear.
31
3160
–UN–04NOV96
21
T104798
CED,OUOE002,1661 –19–09JUN98–23/44
25. Swashblock Group
Inspect the swashblock for wear and scoring. If

defects are minor, stone the swashblock lightly. If
damage is extensive, swashblock should be rejected.
–UN–24JUN91
Check that the very small holes in the face of the
swashblock are open. These holes provide "porting"
for the hydrostatic balance fluid (of the piston/shoe
assembly) to be channeled through the swashblock to
T7553AQ
the face of the saddle bearing (providing pressure
lubrication).

011504
PN=473
Hydraulic System
26. Check bearing mating surface of swashblock for

cracks or excessive wear. Swashblock movement in
saddle bearings must be smooth. Replace if
necessary.
–UN–04NOV96
T104033
CED,OUOE002,1661 –19–09JUN98–25/44
27. Compare saddle bearing thickness in worn area to

thickness in an unworn area. Replace saddle
bearings if difference is greater than 0.4 mm (.016
inches).
31
3160
–UN–04NOV96
22
T104803
CED,OUOE002,1661 –19–09JUN98–26/44
IMPORTANT: Bearing locate pins must not protrude

through swashplate bearing. See sketch
below for proper installation of pins.
28. Inspect bearing locate pins in housing. Pins (B) must

be able to hold bearing in place without protruding
–UN–08NOV96
through bearing.
Pins should extend 1.3 mm to 1.6 mm (.050 to .065

in) (distance A) into the bearing locating hole.
T104810
A—Distance (A)
B—Pin (2 used)
–UN–04NOV96
T103488

011504
PN=474
Hydraulic System
29. Drive Shaft Group
Check shaft bearing for galling, pitting, binding,

roughness.
Check seal of bearing for grease containment. If seal
–UN–04NOV96
is worn or broken. Replace shaft and bearing.
Check shaft and it’s splines for wear. If worn, replace

shaft and bearing.
T104034
CED,OUOE002,1661 –19–09JUN98–28/44
30. Check shaft seal for deterioration or cracks. Replace

(press out) if necessary.
31. Pump assembly

31
NOTE: Install new gaskets, seals and O-rings. Apply a 3160
–UN–24JUN91
23
thin film of CLEAN grease or hydraulic fluid to
sealing components to ease assembly. Apply fluid
generously to all wear surfaces.
T7553AL
CED,OUOE002,1661 –19–09JUN98–29/44
32. Shaft Seal
If removed, press shaft seal into front of pump

housing with a 50 mm disk and seal driver.
–UN–24JUN91
T7553AU

011504
PN=475
Hydraulic System
33. Swashblock Group
Position pump with drive shaft facing down. Grease

back side of saddle bearings and place on the locator
pins to locate the bearings (A) in pump case. Pins
must not protrude through the bearing’s locator hole.
–UN–04NOV96
Plastic bearing (C) position should be installed on
opposite of control pin side (B) of swashblock.
T104809
A—Bearing (2 used)
B—Control Pin Side
C—Plastic Bearing
31
3160 CED,OUOE002,1661 –19–09JUN98–31/44
24
34. Loader Pump (130PVG) Only
Partially insert swashblock into rear of pump housing

and insert guide plate into the pump’s housing, so flat
head cap screws (A) can be used to fasten the guide
plate to the housing. Place the swashblock on the
guide plate making sure the guide plate is in the
groove of the swashblock. Install guide plate screws
and torque. Make sure swashblock swivels in the
saddle bearings smoothly.
Specification
Guide Plate Cap Screw—Torque ................................ 10 N•m (90.0 lb-in.)
35. Hydraulic Pump (75PVG) Only Insert swashblock

into rear of pump housing. Make sure swashblock
–UN–04NOV96
swivels in the saddle bearings smoothly.
A—Cap Screw
T104799
–UN–04NOV96
T103484

011504
PN=476
Hydraulic System
36. Hydrodynamic Bearing
Bearing should be positioned with “scarf” cuts

positioned top and bottom. Bearing should fit into
place with a little difficulty and be square to the axis
of the pump. Tap bearing into place if necessary
using extreme care not to damage the bearing.
31
3160
–UN–04NOV96
25
T104798
CED,OUOE002,1661 –19–09JUN98–33/44
37. Insert hydrodynamic lock screw (A) and hand tighten.
NOTE: Insert retaining ring to hold bearing in place on

older models.
A—Lock Screw
–UN–04NOV96
T104801

011504
PN=477
Hydraulic System
38. Drive shaft Group-Pump in Horizontal Position
Install shaft seal retainer.
A—Shaft Seal Retainer
–UN–12AUG97
T104805
CED,OUOE002,1661 –19–09JUN98–35/44
39. Insert drive shaft and bearing assembly into pump

housing and lock in place with drive shaft bearing
retainer ring.
31
3160
26
–UN–04NOV96
T103483

011504
PN=478
Hydraulic System
40. Rotating Group
Place the cylinder barrel, wear surface down on a

clean cloth. Place the shoe retainer spring in the
center of the barrel with the fulcrum ball on top of it.
Insert pistons into their corresponding (numbered)
holes of the shoe retainer. As a unit, fit the pistons
into their corresponding (numbered) bores in the
cylinder barrel. DO NOT FORCE.
A—Respective Piston Bore

B—Shoe Assembly
C—Shoe Retainer
31
3160
–UN–04NOV96
27
T104036
CED,OUOE002,1661 –19–09JUN98–37/44
41. Support the weight of the cylinder barrel as cylinder

spline is passed over the tail shaft, to avoid
scratching or damage. Push cylinder forward until the
cylinder spline reaches the drive shaft spline and
rotate the cylinder slightly to engage shaft splines.
Continue to slide cylinder forward until it encounters
–UN–04NOV96
the cylinder bearing. Lifting the tail shaft slightly helps
cylinder and cylinder bearing engagement. Continue
pushing cylinder forward until the piston shoes
contact the swashblock.
At this point, the back of the cylinder should be T103482
located approximately 10.2 mm (0.4 in) outside the

back of the pump housing.
NOTE: Make sure the rotate group has spring action.

This assures correct assembly in relation to the
spline.

011504
PN=479
Hydraulic System
42. Valve Plate Group
With the drive shaft facing down install O-ring (A) in

pump housing.
With the drive shaft facing down install gasket (B) on
–UN–24JUN91
pump housing.
A—O-Ring
B—Gasket
T7553BG
31
–UN–26NOV97
3160
28
T112369
CED,OUOE002,1661 –19–09JUN98–39/44
43. Position valve plate on housing pins, making sure tail

end of shaft engages shaft bushing in valve plate (B).
Finger tighten hex head cap screw closest to O-ring
first. Alternately hand tighten the other cap screws
(A).
A—Cap Screw
B—Valve Plate (4 used)
–UN–04NOV96
T104800

011504
PN=480
Hydraulic System
44. With control pin (A) in swashblock, move swashblock

slowly to left side of pump housing until control pin
stops at housing.
A—Control Pin
–UN–04NOV96
T103487
CED,OUOE002,1661 –19–09JUN98–41/44
45. Tighten valve plate cap screws to specification.
Specification
Valve Plate-to-Pump Housing
Hex Head Cap Screw—Torque....................................... 95 N•m (70 lb-ft)
31
Socket Head Screw—Torque .......................................... 95 N•m (70 lb-ft)
3160
–UN–04NOV96
29
T103480
CED,OUOE002,1661 –19–09JUN98–42/44
46. Install new control gasket and O-ring. Place control

on pump housing making sure control pin fits into
control piston slot. Loosen end cap (A) to remove
spring pressure to aid in assembling of control
housing.
A—End Cap
–UN–04NOV96
T104806

011504
PN=481
Hydraulic System
47. Install control valve cap screws and tighten to

specification.
Specification
Control Housing-to-Pump Cap
31
3160
–UN–04NOV96
30
T103478
CED,OUOE002,1661 –19–09JUN98–44/44
Remove And Install Hydraulic Pump Control

Valve
1. Mount pump on D01006AA Bench Mounted Holding

Fixture as shown.
2. Remove socket head cap screws and lift the control

group assembly straight up from the top of the pump
assembly. Remove control pin from swashblock.
3. Install new control gasket and O-ring. Place control on

pump housing making sure control pin fits into control
piston slot.
–UN–04NOV96
T103478

011504
PN=482
Hydraulic System
4.
Loosen end cap (A) to remove spring pressure to aid

in assembling of control housing
5. Install control valve cap screws and tighten to

specification.
Specification
–UN–04NOV96
A—End Cap
T104806
31
TX,31,ME137 –19–09JUN98–2/2 3160
31

011504
PN=483
Hydraulic System
Disassemble And Assemble Hydraulic Pump Control Valve
31
3160
32
–UN–09SEP97
TP55618
NOTE: Control valve is serviced as module (valve) Disassemble, inspect, clean, and replace parts as
(1—3) or complete control valve (4) as shown. necessary.

011504
PN=484
Hydraulic System
Specification
Screw—Torque ......................................................... 60 N•m (44 lb-ft)
Control End Cap-to-Control
Housing Screw—Torque........................................... 40 N•m (30 lb-ft)
Load Sense Module
(Valve)-to-End Cap Screw—
Torque........................................................................ 6 N•m (57 lb-in.)
TX,31,ME138 –19–09JUN98–2/2
Hydraulic Pump Stroke Limiter Adjustment
IMPORTANT: Maximum theoretical pump

displacement is 130 cc/rev. Pump
displacement after adjustment is 100 31
cc/rev. Turning the adjusting screw one 3160
33
turn changes pump displacement by
about 10%. Adjustment other than as
specified will reduce machine
productivity or economy.
1. Loosen lock nut (A) and turn adjusting screw (B)

counter clockwise until no resistance is felt.
2. Turn adjusting screw (B) clockwise until it just contacts

internal control piston. Then turn adjusting screw IN an
additional 1 turn.
3. Tighten lock nut (A).
–UN–05SEP97
A—Lock Nut
B—Adjusting Screw
T111276B
CED,OUOE002,1662 –19–09JUN98–1/1

011504
PN=485
Hydraulic System
Remove And Install Loader Control Valve
1. Install boom locking bar.
2. Stop engine.
3. Drain hydraulic reservoir. Approximate capacity of

hydraulic reservoir is 117 L (31 gal).
Specification
4. Remove control valve access panel.
5. Loosen hold-down clamps on bucket and boom

cylinder lines.
31
3160 Continued on next page CED,OUOE002,1663 –19–09JUN98–1/3
34

011504
PN=486
Hydraulic System
31
3160
35
–19–12MAR98
T114191
6. Disconnect all lines. 7. Remove cap screws.


011504
PN=487
Hydraulic System

loader control valve is 41 kg (90 lb).
10. Install loader control valve and connect all lines.
Specification
Loader Control Valve—Weight ................... 41 kg (90 lb) approximate
8. Slide control valve forward. Remove loader control

valve.
CED,OUOE002,1663 –19–09JUN98–3/3
Disassemble And Assemble Loader Control

Valve
1. Remove nuts and washers. Separate valve sections.

31
3160
36
3. Install seals (F).
4. Assemble sections. Tighten nuts to specification.
Specification
Loader Control Valve Tie Bolt
Nut—Torque .................................................................. 102 N•m (75 lb-ft)
A—Inlet Manifold
B—Auxiliary Section Valve
C—Bucket Section Valve
D—Boom Section Valve
E—Outlet Manifold
F—Seal (13 used)
–19–09APR97
T108899
TX,31,ME140 –19–09JUN98–1/1

011504
PN=488
Hydraulic System
Disassemble And Assemble Auxiliary Valve Section And Bucket Section
31
3160
37
–19–05DEC97
T112438
Bucket Section Shown
NOTE: Bucket valve section shown. 4. Torque components to specification.
1. Disassemble valve. Auxiliary Valve Section:—Specification

Circuit Relief Lock (B)—Torque............................. 20 N•m (175 lb-in,)
Circuit Relief Housing (C)—
IMPORTANT: Coat all internal surfaces with clean Torque..................................................................... 102 N•m (75 lb-ft)
hydraulic oil. Compensator Cap (F)—Torque .............................. 102 N•m (75 lb-ft)
Hex Head Screw (J)—Torque ............................... 11 N•m (100 lb-in.)
2. Replace all O-rings and backup rings. Lift Check Hex Head Cap (O)—
Torque..................................................................... 169 N•m (125lb-ft)
Socket Head Screw (S)—
3. Apply thread lock and sealer (high strength) to the Torque.................................................................... 11 N•m (100 lb-in.)
following components: Port Plug (T)—Torque ........................................... 20 N•m (175 lb-in.)
Circuit Relief Cap (V)—Torque............................... 115 N•m (85 lb-ft)
• Cap Screws (L and V).
• Stripper Bolt-to-Spool (N).
TX,31,RP3377 –19–09JUN98–1/1

011504
PN=489
Hydraulic System
Disassemble And Assemble Boom Valve Section
31
3160
38
–19–05DEC97
T112439
1. Disassemble valve. 4. Torque components to specification.
IMPORTANT: Coat all internal surfaces with clean Boom Valve Section:—Specification
Compensator Cap (D)—Torque ............................ 102 N•m (75 lb-ft.)
hydraulic oil.
Plug (H)—Torque................................................... 102 N•m (75 lb-ft.)
Nut (I)—Torque ...................................................... 20 N•m (175 lb-in.)
2. Replace all O-rings and backup rings. Hex Head Cap Screw (J)—
Torque.................................................................... 102 N•m (75 lb-ft.)
3. Apply thread lock and sealer (high strength) to the Plug (K)—Torque ................................................... 12 N•m (100 lb-in.)
following components: Stripper Bolt (M)—Torque ..................................... 20 N•m (175 lb-in.)
Check Hex Head Cap (P)—
Torque.................................................................... 102 N•m (75 lb-ft.)
• Nut (I) Socket Head Cap Screw (U)—
• Hex Head Screws (J) Torque.................................................................... 20 N•m (175 lb-in.)
• Stripper Bolt-to-Spool (M) Plug (V)—Torque ................................................... 12 N•m (100 lb-in.)
• Socket Head Screws (S) Plug (W)—Torque .................................................. 102 N•m (75 lb-ft.)
TX,31,RP3376 –19–09JUN98–1/1

011504
PN=490
Hydraulic System
Disassemble And Assemble Relief Valve
Remove the adjusting screw (E).
Inspect parts for wear or damage.
–UN–22OCT96
O-rings, backup ring and spring are the only repair parts
available.
Assemble relief valve.
T104612
Check the pressure setting. (See Loader Relief and Circuit
Relief Valve Pressure Test in Group 9025-25).
A—Return
B—Inlet
C—Poppet
D—Floating Seat
E—Adjuster
F—Plunger 31
3160
39
TX,3100,RP3060 –19–09JUN98–1/1
Disassemble And Assemble Bucket Circuit

Relief Valve
Remove adjusting screw from body.
–19–11APR97
available.
T108956
TX,3100,RP3062 –19–09JUN98–1/1

011504
PN=491
Hydraulic System
Disassemble And Assemble Load Sense Relief Valve
31
3160
40
–19–12FEB97
T106959
Remove adjusting screw from body. O-rings, backup ring and spring are the only repair
parts available.
TX,3100,RP3061 –19–09JUN98–1/1
Disassemble And Assemble Boom Circuit

Relief Valve
Separate retainer from body.

–UN–22OCT96
available.
T104611
A—Return
B—Inlet
C—Poppet
TX,3100,RP3063 –19–09JUN98–1/1

011504
PN=492
Hydraulic System
Disassemble and Assemble Boom and

Bucket Cylinder—185 Series
See Disassemble Cylinder in TMH185A. (Group 01.) See

Assemble Cylinder in TMH185A (Group 01.)
OUT3019,000009B –19–19AUG03–1/1
Remove And Install Boom And Bucket

Cylinder Bushings And Seals
1. Remove seals (B).

31
3160
2. Remove bushings (A).
–UN–27OCT88
41
3. Install and center new bushings in bore.
4. Install new seals. Press seals into bore tight against
T6172BE
bushing with lip facing outward.
5. For initial lubrication, apply NEVER-SEEZ Lubricant or

A—Bushing
an equivalent to bushings and seals.
B—Seal
Remove And Install Hydraulic Reservoir
1. Remove hood and engine side shields.
2. Remove loader steps and stairs.
3. Release hydraulic pressure by holding pilot

enable/boom down switch and moving hydraulic control
lever to boom float.
4. Drain reservoir. (See Operators Manual, Group 87,

Change Hydraulic System Oil). Approximate capacity is
117 L (31 gal).
Specification

011504
PN=493
Hydraulic System
5. Drain reservoir.
6. Disconnect lines (A—F).
7. Remove wiring harness.
8. Remove starting aid or air heater (if equipped).
CAUTION: The approximate weight of reservoir

is 127 kg (280 lb).
–UN–12JUN98
Specification
Hydraulic Reservoir—Weight ........................ 127 kg (280 lb) approximate
T115810
9. Install lifting strap around reservoir and attach hoist.
10. Remove four cap screws to remove reservoir.

A—Hydraulic Reservoir-to-Main Hydraulic Pump
31 11. Replace parts as necessary. Inlet Port Line
3160 B—Hydraulic Reservoir-to-Steering Pump Inlet
42 12. Install reservoir. Tighten reservoir-to-frame Port Line
C—Hydraulic Reservoir-to-Fan Pump Drive Inlet
capscrews. Port Line
D—Hydraulic Reservoir-to-Main Hydraulic Pump
Specification Middle Top Port Line
Hydraulic Reservoir-to-Frame E—Hydraulic Reservoir-to-Oil Cooler Top Port
Cap Screw—Torque .................................................... 624 N•m (460 lb-ft) Line
F—Hydraulic Filter Out Port-to-Hydraulic
13. Connect hydraulic lines. Reservoir Inlet Port Line
NOTE: If reservoir shows signs of contamination, perform

Hydraulic Oil Clean-up Procedure in this group.
14. Fill hydraulic reservoir. See Drain and Refill

Capacities—644H/H MH. (Operation and Test.)
TX,31,ME151 –19–09JUN98–2/2

011504
PN=494
Hydraulic System
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy
IMPORTANT: Brake system uses oil from Leave filter caddy operating for the next steps.
hydraulic reservoir. Flush all lines in
the brake, pilot, differential lock, and NOTE: Filtering time for reservoir is 0.089 minute x
clutch cutoff system. Disassemble number of liters (0.33 minute x number of
and clean pressure reducing valve gallons). Reservoir capacity is 117 L (31 gal).
and pilot controller. Remove and
clean pilot caps from main control Specification
valve. Brake components may fail if Hydraulic Reservoir—Capacity ................ 117 L (31 gal) approximate
brake system is not cleaned after
hydraulic reservoir contamination. 6. Start the engine and run it at high Idle.
1. If hydraulic system is contaminated due to a major IMPORTANT: For the most effective results,
component failure, remove and disassemble cleaning procedure must start with
steering cylinders to clean debris from cylinders. the smallest capacity circuit then
proceed to the next largest capacity
2. Install new return filter elements. circuit.
31
IMPORTANT: To prevent cavitation of filter caddy 7. Operate all functions, one at a time, through a 3160
pump, the minimum I.D. of connector complete cycle in the following order: clam, 43
is 1/2 in. steering, bucket, and boom. Also include all
auxiliary hydraulic functions.
NOTE: For a failure that creates a lot of debris,
remove access cover from reservoir. Drain Repeat procedure until the total system capacity
reservoir and connect filter caddy suction line has circulated through filter caddy seven times,
to drain port. Add a minimum of 19 L (5 gal) of approximately 30 minutes. Each function must go
oil to reservoir. Operate filter caddy and wash through a minimum of three complete cycles for a
out the reservoir. thorough cleaning of oil.
3. To minimize oil loss, pull a vacuum in reservoir NOTE: Filtering time for complete hydraulic system is
using a vacuum pump. Connect filter caddy suction 0.158 minute x number of liters (0.6 minute x
line to drain port at bottom of reservoir using number of gallons). Complete hydraulic system
connector and quick disconnect fitting. Check to be capacity is approximately 256 L (67 gal).
sure debris has not closed drain port. Filtering time for machines with auxiliary
hydraulic functions must be increased because
4. Put filter caddy discharge line into reservoir filler system capacity is larger.
hole so end is as far away from drain port as
possible to obtain a thorough cleaning of oil. 8. Stop the engine. Remove the filter caddy.
5. Start the filter caddy. Check to be sure oil is flowing 9. Install new return filter elements.
through the filters.
10. Check oil level in reservoir; add oil if necessary.
Operate filter caddy approximately 15 minutes so oil See Drain and Refill Capacities—644H/H MH.
in reservoir is circulated through filter a minimum of (Operation and Test.)
four times.
TX,31,ME152 –19–05AUG96–1/1

011504
PN=495
Hydraulic System
Pilot Controller Repair (Single Lever

Controller)
Remove and Install

TX,31,ME155 –19–04SEP02–1/29
31
3160
44
–UN–01MAY97
T109108
Bucket Rollback
A—Control Lever E—“C” Port I—Spring Guide L—Pull Plate

B—Plunger F—“P” Port J—Electric Coil M—Shim, Spool Metering
C—Metering Spring G—“A” Port K—Push Bar N—Shim, Spool Position
D—Spool Assembly H—Return Spring
Continued on next page TX,31,ME155 –19–04SEP02–2/29

011504
PN=496
Hydraulic System
1. Stop engine and relieve hydraulic pressure by using

boom lower switch and placing controller in boom float
position.
2. Remove air vent filter from hydraulic oil reservoir and

plug vent.
3. Place a vacuum on the hydraulic oil reservoir tank.
4. Open load center service door.
6. Disconnect lines (A—H).
7. Remove four cap screws. Remove pilot controller.

31
9. Install pilot controller. Connect lines and electrical 3160
–UN–01OCT96
connectors. 45
Disassemble and Assemble
T104166
Before Pilot Control Valve is disassembled the following
checks should be done first to help isolate confirm the
problem is in the pilot controller. Perform Pilot Control
Valve Pressure Test. (See Section 9025-25.) Perform
Pressure Reducing Valve Pressure Test. (See Section
9025-25.)
A—Auxiliary Pilot Controller-to-Auxiliary Valve

B—Pilot Controller-to-Bucket Valve Bucket Dump
–UN–01OCT96
C—Pilot Controller-to-Hydraulic Reservoir
D—Pilot Controller-to-Boom Valve Boom Lower
E—Pilot Controller-to-Bucket Valve Bucket Rollback
F—Pilot Controller-to-Boom Valve Boom Raise
T104168
G—Pilot Controller-to-Pressure Reducing Manifold
H—Auxiliary Pilot Controller-to-Auxiliary Valve

011504
PN=497
Hydraulic System
31
3160
46
–UN–15MAR97
TP55415
Single Lever (Joystick) Assembly

011504
PN=498
Hydraulic System
1—Grip 19—Push Bar 35—Retainer (2 used) (Tool 46—Spring

2—Sleeve 20—Grommet (4 used) Carrier 3 used) 47—Spring
3—Nut 21—Strap (4 used) 36—Plunger (2 used) (Tool 48—Housing
4—Retainer 22—Terminal Nipple (8 used) Carrier 1 used) 49—O-Ring
5—Boot 23—Washer 37—Plunger (2 used) (Tool 50—Plug
6—Nut (4 used) 24—Pin contact (8 used) Carrier 3 used) 51—Plug (2 used)
7—Lever 25—Nut 38—Shim (as required) (0.1 52—Valve
8—Set Screw 26—connector mm / .004 in) 53—Label
9—Washer 27—O-Ring 39—Shim (as required) (0.2mm 54—O-Ring (6 used)
10—Washer 28—Electrical Coil (3 used) / .007 in) 55—Adapter (5 used)
11—Plug 29—Retainer (3 used) 40—Shim (as required) (0.4mm 56—O-Ring (6 used)
12—Plate 30—Tube / .015 in) 57—Adapter
13—Washer 31—Back Up Ring 41—Spool (2 used) 58—Plate
14—Nut 32—Seal 42—Spool 59—Screw (4 used)
15—U-Join (center post) 33—Ring (2 used) 43—Spool 60—Locknut (3 used)
16—Ball joint socket (3 used) 34—Retainer (2 used) (Tool 44—Spring 61—Nut
17—Cap Screw (4 used) Carrier 1 used) 45—Feel Position Kit 62—Spool
18—Housing (top)
Lever Housing-to-Valve Housing Torque 8.5 N•m (75 lb-in.) 31

Allen Screw 3160
47
Lever Adjuster Sleeve Hex Nut Torque 11 N•m (100 lb-in.)
Universal Joint Hex Nut Torque 28 N•m (250 lb-in.)
TX,31,ME155 –19–04SEP02–5/29
Replacing Quickshift Switch In Controller Lever
1. Remove Pilot Controller from machine.
2. Place controller in bench vice. –UN–19DEC96
3. Slide boot and retainers (B) down with hands from grip
at (A).
T105756B
A—Grip
B—Boot and Retainer

011504
PN=499
Hydraulic System
4. Lift up bottom of boot and remove four allen screws (A)

from lever housing.
A—Allen Screw (4 used)
–UN–19DEC96
T105757B
TX,31,ME155 –19–04SEP02–7/29
IMPORTANT: Scribe a mark along side of the lever

housing and valve housing of the
controller before disassembling. The
mark will be used when aligning the
31 controller housings during the
3160 assembly procedure. If correct
48
alignment is not done while assembling
incorrect operation and/or damage to
controller may occur.
5. Remove lever housing (A) from valve housing (B).
6. Cut switch wire at bottom side of lever housing by tie

band. Remove tie band and pull wire out of lever and
housing.
7. Remove grommet from lever housing.
A—Lever Housing
B—Valve Housing
–UN–19DEC96
T105758B

011504
PN=500
Hydraulic System
NOTE: The position of the lever in relation to the wire

opening in lever for proper assembly.
8. Loosen hex jam nut (A) and then turn complete grip
with switch assembly (B) to remove.
–UN–19DEC96
9. Inspect parts and replace as necessary.
10. Apply thread lock and sealer (high strength) to lever

threads.
T105756C
11. Place new boot retainers over lever for installing later.
12. Install new grip with switch assembly on lever noting A—Hex Jam Nut
B—Switch Assembly
the proper index, then tighten hex jam nut.
13. Place shrink tube on wire and fish wire down through
lever handle and center of universal joint. Position
shrink tube so it is centered between the area it goes 31
into the lever and out the universal joint. Pull back 3160
wire and heat shrink tube on wire. Return wire to the 49
proper position in lever assembly.

011504
PN=501
Hydraulic System
14. Feed wire through the housing passage and install

grommet at (A) noting the position of wire. Wire (B)
should be positioned so it clears the coil bore. Wire
should have approximately a 51 mm (2.0 in.) loop.
15. Place clear wire protective sleeve over wire and

install two terminals (C) with JDG783 Packard
Crimping tool. Install wire with terminals in connector
(D).
16. Install lever assembly on valve housing with four allen

screws. Note scribe marks for proper index. Tighten
lever housing to valve housing allen screws.
Specification
Pilot Controller Lever
Screw—Torque .............................................................. 8.5 N•m (75 lb-in.)
31 17. Pull up boot and position on grip assembly. Install two

3160 shrink retainers by heating with heat blow gun.
–UN–19DEC96
50
18. Install lever assembly in tractor.
T105759B
A—Grommet
B—Wire
C—Terminal (2 used)
D—Connector
E—Shrink Tube

011504
PN=502
Hydraulic System
Replace Pilot Control Lever Boot (Single Lever)
1. Cut the tie band off around base of lever housing.
2. Slide boot and retainers (B) down with hands from grip
at (A).
–UN–19DEC96
3. Remove grip by sliding up and off of lever.
4. Remove boot.
T105756B
5. Install new boot and retainers over lever.
6. Install grip on lever. A—Grip

B—Boot and Retainer
7. Pull up boot and position on grip with two shrink

retainers. Heat retainers with heat blow gun.
8. Install new tie band around base of boot and lever 31

housing. 3160
51
TX,31,ME155 –19–04SEP02–11/29
Replace Universal Joint
1. Remove Pilot Controller from machine.
2. Place controller in vice and pull boot up.
–UN–19DEC96
3. Remove four allen screws (A) in lever housing.
T105757B

011504
PN=503
Hydraulic System

controller housings during the
assembly procedure. If correct
controller may occur.
5. Cut quickshift wire off right behind connector and pull

wire out of housing, up through universal joint and
lever.
6. Remove lever from universal joint by using 1/2 wrench

on flats of lever.
31
3160 NOTE: Make note of position of the ball sockets
–UN–19DEC96
52 assembly in relationship to coil bores.
7. Remove ball socket assembly with plate and washers.
T105758B
8. Remove hex nut from bottom side of universal joint
and housing.
9. Replace parts as necessary. A—Lever Housing

B—Valve Housing
10. Apply thread lock and sealer (high strength) to
universal joint threads.
11. Install universal joint in bottom of housing with hex

nut and washer. Index to the 12 o’clock position in
relation to coil bores. Tighten controller lever universal
joint hex nut.
Specification
Pilot Controller Universal Joint
Hex Nut—Torque.......................................................... 28 N•m (250 lb-in.)
12. Install washers, ball sockets with plate over universal

joint. Note proper index of ball sockets to relationship
of coil bores. On Joystick controller the bore without
coil should be in the 3 o’clock position.

011504
PN=504
Hydraulic System
13. Install grip/switch assembly along with boot and new

shrink retainers on universal joint. Note proper index
of grip handle. Must be in 12 o’clock position. Also
note the index of the passage way hole for the
quickshift wire in the housing should be in the one
o’clock position. Tighten controller lever-to-universal
joint hex nut.
Specification
Pilot Controller Universal Joint
Hex Nut—Torque.......................................................... 28 N•m (250 lb-in.)
31
TX,31,ME155 –19–04SEP02–14/29 3160
53
14. Feed quickshift wire from grip assembly down through

handle, center of universal joint and housing. Make
sure protective shrink tube (E) is properly positioned
on wire, centered through lever and universal joint.
Pull wire back out and heat the shrink tube onto wire
and return wire to proper position.
15. Slide clear plastic sleeve on wire that sticks out of

housing and install terminals (C) on wire with JDG783
Packard Crimping tool. Install in connector (D).
16. Install grommet in housing and tie band at area (A)

on wire. Position wire (B) so it clears coil bores as
shown. Approximately a 51 mm (2 in.) loop.
17. Install lever housing assembly onto valve housing.

Note index marks scribed when disassembly for
proper alignment to proper ports. Tighten four lever
housing-to-valve housing allen screws. –UN–19DEC96
Specification
T105759B
A—Grommet
B—Wire
C—Terminal (2 used)
D—Connector
E—Shrink Tube

011504
PN=505
Hydraulic System
18. Adjust ball socket (A) to zero clearance. Lever must

be perpendicular to mounting surface when finished.
Use allen wrench to turn set screw (B) while holding
adjuster sleeve (C). After adjusted, lock in place by
tightening hex nut (D) with torque wrench while
–UN–19DEC96
holding adjuster sleeve with open end wrench. Note
special tool (E) is used in manufacturing only.
Specification
Pilot Controller Lever Adjuster
T105761B
Sleeve Hex Nut—Torque ............................................. 11 N•m (100 lb-in.)
19. Install lever housing assembly with four allen screws

onto valve housing. Note index scribe marks made
before disassembly.
20. Install pilot controller in unit.
–UN–12JUN98
A—Ball Socket
31
B—Set Screw
3160
C—Adjuster Sleeve
54
D—Hex Nut
E—Special Tool
T105760B
TX,31,ME155 –19–04SEP02–16/29
Replace Seals on Spool Retainers and Inspect Spool

Assembly
1. Remove pilot controller from machine.)
2. Place controller in bench vice.
–UN–19DEC96
3. Lift up bottom of boot and remove four allen screws (A)
from lever housing.
T105757B

011504
PN=506
Hydraulic System

controller housings during the
assembly procedure. If correct
controller may occur. Also note spool
placement to bore for reassembly.
When servicing it is important keep the
representative retainer and spool
assembly in there same bore.
A—Lever Housing
B—Valve Housing
31
3160
–UN–19DEC96
55
T105758B
TX,31,ME155 –19–04SEP02–18/29
5. Remove coil (A) and let hang on side of valve housing.

Remove coil retainer. Remove spool retainer (B) with
pliers from valve housing.
A—Coil
–UN–19DEC96
B—Spool Retainer
T105762B

011504
PN=507
Hydraulic System
6. Remove old seals and install new in retainer:
• Lubricate wiper seal (D) with petroleum jelly.

• Install seal in bore along with seal retainer (E).
• Slightly bend tangs on stop ring (F) to allow for ease
of installation to keep the ring centered in bore.
–UN–06JAN97
Note, stop ring comes from factory with slightly
concave or bent tangs. Make sure bending is done
in the same direction. Tangs must face out when
installing. Install stop ring in retainer by using an
T105841
11mm socket as driver. Be sure to have stop ring (F)
centered in bore so it does not contact push bar or
ball socket pins.
A—Backup Ring
B—O-Ring
C—Retainer
D—Wiper Seal
E—Seal Retainer
31 F—Stop Ring
3160
56

011504
PN=508
Hydraulic System
IMPORTANT: When removing spool retainer do not

lose shims located between retainer
and spool spring guide.
7. Remove spool assembly and springs (B, C, D, E, F, G,

I, and J). If equipped remove feel position assembly
–UN–19DEC96
(H).
8. Inspect and replace parts as necessary
T105763B
9. Apply KRYTOX GPL202 fluorinated grease to sliding
surfaces of adjuster sleeves and push bar top where it
contacts the adjusting screw. Controller Spool Assembly With Retainer With Feel Position
A—Retainer (With Seals)

10. Install spool assembly and retainer in same bores if B—Shims (Spool Positioning)
using existing parts. C—Guide (Spring)
D—Spool
11. Install retainers and (coils if equipped). E—Shims (Metering Adjustment)
F—Spring (Spool)
G—Retainer Plate (Spool Spring) 31
12. Install lever housing assembly onto valve housing. H—Feel Assembly 3160
Note index marks scribed when disassembly for I—Spring (Feel Position) 57
proper alignment to proper ports. Tighten four allen J—Spring (Return)
screws to 8.5 N•m (75 lb-in.)
Specification
Hosing-to-Valve Housing Allen
KRYTOX is a trademark of E.I. DuPont, DeNemours and Co. Inc. Continued on next page TX,31,ME155 –19–04SEP02–21/29

011504
PN=509
Hydraulic System
13. Adjust ball socket (A) to zero clearance. Lever must

be perpendicular to mounting surface when finished.
Use allen wrench to turn set screw (B) while holding
adjuster sleeve (C). After adjusted, lock in place by
tightening hex nut (D) with torque wrench while
–UN–19DEC96
holding adjuster sleeve with open end wrench. Note
special tool (E) is used in manufacturing only.
Specification
Pilot Controller Lever Adjuster
T105761B
Sleeve Hex Nut—Torque ............................................. 11 N•m (100 lb-in.)
14. Install lever housing assembly with four allen screws Ball Socket Assembly
onto valve housing. Note index scribe marks made
before disassembly.
15. Do bench test on controller to check valve pressures

using tractor as pressure source. See Pilot Control
Valve Pressure Test (Bench). (This Group.)
–UN–12JUN98
31
3160
58
A—Ball Socket
T105760B
B—Set Screw
C—Adjuster Sleeve
D—Hex Nut
E—Special Tool
TX,31,ME155 –19–04SEP02–22/29
Pilot Control Valve Pressure Test (Bench)
1. Place controller valve assembly in vice.
2. Plug all ports not being tested in controller and cap

lines from tractor (if pressure source is being used
–UN–19DEC96
from same unit controller is being repaired on).
3. Place quick coupler in drain port, inlet pressure port

T105766B
and outlet port to be tested in controller.
4. Connect test hose with quick couplers from drain port

to reservoir or bucket.

011504
PN=510
Hydraulic System
5. Connect test hose (B) to Pressure Reducing Valve

(right side below operator station) quick coupler (A) to
inlet Presssure port on controller.
6. Connect 6 895 kPa (69 bar) (1 000 psi) test gauge to

port being tested quick coupler.
–UN–19DEC96
7. Run engine at idle, boom down with Park Brake ON.
Check pilot controller pressures to specification.
T105765B
Specification
Oil—Temperature ................................................... 40 ± 6°C (100 ± 10°F)
Engine—Speed ............................................................................ Slow Idle
Boom Float Detent—Pressure ................... 4137—4480 kPa (41—45 bar)
(600—650 psi)
Feel Position—Pressure .............................. As the control lever is moved
from neutral, the pilot pressure
will suddenly jump up to
approximately 90 psi at 3/4—1 in.
travel. The pressure should then
–UN–19DEC96
increase smoothly to the 31
specification at the FEEL position 3160
(or 75% lever travel), and then 59
jump up to 600—650 psi as the
lever is moved into detent.
T105766B
Boom Power Down—Pressure................... 1860—2082 kPa (19—21 bar)
(270—302 psi)
Boom Raise—Pressure .............................. 1882—2227 kPa (19—22 bar)
(273—323 psi)
Bucket Rollback—Pressure ........................ 2110—2455 kPa (21—25 bar)
(306—356 psi)
Bucket Dump and Auxiliary
Valve—Pressure ................................... Pressure must increase smoothly
to 2110—2455 kPa (21—25 bar)
(306—356 psi) at 3/4 lever travel
and then increase to 4140—4480
kPa (41.4—44.8 bar) (600—650
psi) as the lever is moved past
80—90% travel

011504
PN=511
Hydraulic System
31
3160
60
–UN–03DEC96
T105535
A—Shims (Spool positioning) B—Shims (metering C—Housing
adjustment)
8.
TX,31,ME155 –19–04SEP02–25/29
If controller is not in specification check for proper shims

in spool assembly. Note the nominal shim pack total is
approximately 0.1 mm (0.037 in.) on both sides of spool
spring guide.

–UN–19DEC96
Pilot Control Valve Pressure Test In Machine

T105764B
A—Retainer
B—Spring
C—Shims (metering adjustment)
D—Spring Guide
E—Spool
F—Shims (spool positioning)

011504
PN=512
Hydraulic System
Specification
Oil—Temperature ................................................... 40 ± 6°C (100 ± 10°F)
Engine—Speed ............................................................................ Slow Idle
Begin—Metering ............................................... 3/8—5/8 in. of lever travel
(Measured at top end of lever.)
Boom Float Detent—Pressure ................... 4137—4480 kPa (41—45 bar)
(600—650 psi)
Feel Position—Pressure .............................. As the control lever is moved
from neutral, the pilot pressure
will suddenly jump up to
approximately 90 psi at 3/4—1 in.
travel. The pressure should then
increase smoothly to the
specification at the FEEL position
(or 75% lever travel), and then
jump up to 600—650 psi as the
lever is moved into detent.
Boom Power Down—Pressure................... 1860—2082 kPa (19—21 bar)
(270—302 psi)
Boom Raise—Pressure .............................. 1882—2227 kPa (19—22 bar)
(273—323 psi)
Bucket Rollback—Pressure ........................ 2110—2455 kPa (21—25 bar)
(306—356 psi) 31
Bucket Dump and Auxiliary 3160
–UN–12JUN98
Valve—Pressure ................................... Pressure must increase smoothly 61
to 2110—2455 kPa (21—25 bar)
(306—356 psi) at 3/4 lever travel
and then increase to 4140—4480
kPa (41.4—44.8 bar) (600—650
T115824
psi) as the lever is moved past
80—90% travel
This test will determine if adequate pilot pressure is A—Cap

available to move the loader control valve spools. B—Union
C—Adapter
NOTE: The FEEL position is when lever is moved to feel
the ramp of the detent before lever passes into
detent position.
1. Lower boom to ground.
2. Connect test fittings and gauge to the pilot pressure

port of function to be checked control valve.
3. Use monitor display unit.
4. Heat hydraulic oil to specification. (See Hydraulic Oil

Warm-Up Procedure in this group.)
5. Run engine at specification. Activate function to be

checked and record pressure reading.

011504
PN=513
Hydraulic System
6. If pressure is still not to specification, perform Pressure

Reducing Valve Pressure Test. (See Section 9025-25.)
7. If pressure reducing valve pressure is to specification

and pilot control pressure is still not to specification
check for loose or worn ball and socket assembly. If
service is required see repair in this group.
TX,31,ME155 –19–04SEP02–28/29
31
3160
62
–UN–03DEC96
T105535
A—Shims (spool positioning) B—Shims (metering C—Housing

adjustment)
8. If pressure reducing valve is to specification, add or To adjust pressure to specification for feel
remove shims to reach the correct pilot pressure as positions and pressure at 3/4 level travel, add or
follows: remove spool metering shims (B).
To adjust lever travel specification to begin Shims are available in following sizes (0.004 in,
metering add or remove spool position shims (A). 0.007 in and 0.015 in).
TX,31,ME155 –19–04SEP02–29/29

011504
PN=514
Hydraulic System
Pilot Controller Repair (Two Lever Controller)

(S.N. —585560)
Remove And Install
1. Stop engine and relieve hydraulic pressure by using

boom lower switch and placing controller in boom float
position.
2. Remove air vent filter from hydraulic oil reservoir and

plug vent.
3. Place a vacuum on the hydraulic oil reservoir tank.
4. Open load center service door.
31
Continued on next page LS10960,0000029 –19–28OCT02–1/4 3160
63

011504
PN=515
Hydraulic System
6. Disconnect lines (A—H).
7. Remove four cap screws. Remove pilot controllers.
9. Install pilot controller. Connect lines and electrical

connectors.
A—Auxiliary Pilot Controller-to-Auxiliary Valve

B—Pilot Controller-to-Bucket Valve Bucket Dump
C—Pilot Controller-to-Hydraulic Reservoir
D—Pilot Controller-to-Boom Valve Boom Lower
E—Pilot Controller-to-Bucket Valve Bucket Rollback
F—Pilot Controller-to-Boom Valve Boom Raise
G—Pilot Controller-to-Pressure Reducing Manifold
H—Auxiliary Pilot Controller-to-Auxiliary Valve
31
3160
–UN–05NOV96
64
T104845
–UN–01OCT96
T104167
Continued on next page LS10960,0000029 –19–28OCT02–2/4

011504
PN=516
Hydraulic System
31
3160
65

011504
PN=517
Hydraulic System
31
3160
66
–UN–15MAR97
TP55416
Continued on next page LS10960,0000029 –19–28OCT02–3/4

011504
PN=518
Hydraulic System
1—Grip 16—Plate 31—Seal 46—Feel Position Kit

2—Grip (with quickshift) 17—Nut 32—Backup Ring 47—Spring
3—Hex Nut 18—Bar 33—Retainer 48—Spring
4—Retainer 19—Universal Joint 34—Retainer 49—Housing
5—Tie Band 20—Ball Joint Socket 35—Fitting 50—Weatherpack Nipple
6—Boot 21—Strap 36—Grommet 51—Terminal
7—O-Ring 22—Grommet 37—Plunger 52—Connector
8—Set Screw 23—Cap Screw 38—Plunger 53—Two Lever Controller
9—Nut 24—Lever Housing 39—Shim (0.4mm /.015 in) Assembly
10—Plug 25—Lever Housing 40—Shim (0.2mm /.007 in) 54—Nut
11—Lever 26—Washer 41—Shim (0.1mm / .004 in) 55—Washer
12—Nut 27—Tube 42—Spool 56—Sleeve
13—Washer 28—Coil 43—Spool 57—Universal Joint
14—Adjuster Sleeve 29—Retainer 44—Spool 58—Spool
15—Lever 30—Stop Ring 45—Spring
Disassemble And Assemble See Pilot Controller Valve (Single Lever Controller),
Disassemble and Assemble in this group.
Perform Pilot Control Valve Pressure Test. (See
Section 9025-25.)
Perform Pressure Reducing Valve Pressure Test. (See 31

3160
Section 9025-25.) 67
LS10960,0000029 –19–28OCT02–4/4
Pilot Controller Repair (Two Lever Controller)

(S.N. 585561—)
SERVICE EQUIPMENT AND TOOLS
JDG1385 STC Fitting Disconnect Tool
Remove and Install
1. Stop engine.
2. Relieve hydraulic pressure by using boom lever switch

and place controller in boom float position.
Continued on next page LS10960,0000024 –19–04SEP02–1/5

011504
PN=519
Hydraulic System
3. Remove side console cover (1).
4. Disconnect, label and cap pilot lines for ease of

assembly.
5. Remove nuts and washers on top cover plate. (4 used

each)
IMPORTANT: Do not twist control lever knobs,

damage may occur to wires.
–UN–31JUL02
6. Remove pilot controller.
T158220B
8. Install pilot controller.
9. Connect pilot lines and connect electrical connectors.

1—Side Console Cover
31 See Hydraulic System Component Location. (Group
3160 9025-15.)
68
Disassemble and Assemble
1. Pull rubber boots over linkage.
2. Disconnect pilot controller connector.
NOTE: Label all wiring to aid in assembly.
3. Remove all pins from connector. See Replace

DEUTSCH Connector and See Install DEUTSCH
Contact. (Group 9015-20.)
Continued on next page LS10960,0000024 –19–04SEP02–2/5

011504
PN=520
Hydraulic System
4. Label electromagnet detents (1), with controller and pin

location.
NOTE: Two dowel pins for electromagnetic detent (1).
5. Remove electromagnet detents (1).
6. Remove control lever knobs.
–UN–31JUL02
7. Remove rubber boots.
1—Electromagnet Detents
2—Dowel Pins
T158221B
3—Top Plate
4—Wire Harnesses
31
LS10960,0000024 –19–04SEP02–3/5 3160
69
8. Loosen lock nut (1) and remove control lever.
9. Remove clip clamps (2) on pivot pin (3).
10. Drive out pivot pin (3).
–UN–31JUL02
1—Lock Nut
2—Circlip (2 used)
3—Pivot Pin
T158222B
LS10960,0000024 –19–04SEP02–4/5
11. Disassemble parts as shown, replace if necessary.
IMPORTANT: Control valve is serviced as an

assembly.
12. Assemble control valve.
13. See Pilot Controller Adjustment (Two Lever). (Group

9025-20.)
–UN–31JUL02
T158223B
LS10960,0000024 –19–04SEP02–5/5

011504
PN=521
Hydraulic System
Remove And Install Pressure Reducing Valve

Manifold
1. Engine OFF. Operate controls 20 times while holding

pilot enable/boom down switch ON to release hydraulic
pressure from brake and brake/PRV accumulators.
2. Drain reservoir or pull a vacuum. Approximate capacity

of reservoir is 117 L (31 gal).
Specification
Hydraulic Reservoir—Capacity............................................ 117 L (31 gal)
31
3160 Continued on next page CED,OUOE002,1672 –19–11JUN98–1/2
70

011504
PN=522
Hydraulic System

–UN–23AUG88
fluids.
X9811
–UN–12JUN98
4. Disconnect lines (A—H). 31
3160
71
5. Remove cap screws. Remove manifold.
T115827
7. Install manifold
A—Pressure Reducing Manifold-to-Hydraulic
Pump Port Line
8. Connect all lines and electrical connectors. B—Pressure Reducing Manifold-to-Axle and Pin
Disconnect Valve Middle Port Line
9. Fill reservoir with oil to proper level. See Drain and C—Pressure Reducing Manifold-to-Pilot Controller
Refill Capacities—644H/H MH. (Operation and Test.) Port Line
D—Pressure Reducing Manifold-to-Front
Differential Port Line
E—Pressure Reducing Manifold-to-Boom Raise
Port Line
F—Pressure Reducing Manifold-to-Hydraulic
Return Tube Tee Port Line
G—Pressure Reducing Manifold-to-Accumulator
Tee Port Line
H—Pressure Reducing Valve Tee-to-Loader
Control Valve Tee Port Line
CED,OUOE002,1672 –19–11JUN98–2/2

011504
PN=523
Hydraulic System
Remove And Install Pressure Reducing Valve
1. Engine OFF. Operate controls 20 times while holding

pilot enable/boom down switch ON to release hydraulic
pressure from brake and brake/PRV accumulators.
–UN–23AUG88
2. Discharge ride control accumulator to prevent escaping
fluid under pressure. (See Ride Control Accumulator
Safety in this group.)
X9811
3. Remove pressure reducing valve (B) from manifold (A).
Plug opening to prevent dirt from entering manifold.
A—Boom Down Solenoid

B—Differential Lock Solenoid
C—Pilot Enable Solenoid
D—Pressure Reducing Valve
–UN–12JUN98
31
3160
72
T115828
CED,OUOE002,1673 –19–11JUN98–1/1

011504
PN=524
Hydraulic System
Disassemble And Assemble Pressure

Reducing Valve
NOTE: Pressure Reducing Valve cannot be taken apart.

If O-rings are OK, and orifice is OK, but pilot
pressure cannot be adjusted within specifications,
replace Pressure Reducing Valve.
1. Inspect for dirty, worn or damaged parts.
2. Remove orifice from inside Pressure Reducing

Manifold and inspect for damage or clogging.
3. Replace orifice if damaged.
4. Install new O-rings and back up rings on pressure

reducing valve and install parts in manifold.
5. Adjust pilot pressure. (See Pressure Reducing 31

Pressure Test in Group 9025-25.) 3160
73
–UN–15APR97
A—Orifice (inside Pressure Reducing Valve Manifold)
B—Backup Ring (2 used)
C—O-Ring
T109134
D—Backup Ring (2 used)
E—O-Ring
F—Backup Ring (2 used)
G—O-Ring
H—O-Ring
I—Pressure Reducing Valve
TX,31,RP3068 –19–11JUN98–1/1

011504
PN=525
Hydraulic System
Remove And Install Boom Down Solenoid

Valve
1. Discharge ride control accumulator to release hydraulic

pressure from loader and pilot circuit. (See Ride
Control Accumulator Safety in this group).
–UN–23AUG88
X9811

–UN–12JUN98
31
3160 6. Install solenoid valve using new O-rings and backup
74 rings.
T115829
Specification
Boom Down Solenoid Valve
Retaining Nut—Torque ..................................................... 7 N•m (62 lb-in.)
A—Boom Down Solenoid

B—Pressure Reducing Manifold
–UN–09NOV92
C—Nut
D—ID Plate
E—Coil
F—Solenoid Valve
T7751LI
G—O-Ring
H—Backup Ring
I—O-Ring
J—O-Ring
K—Backup Ring
CED,OUOE002,1674 –19–11JUN98–1/1

011504
PN=526
Hydraulic System
Remove And Install Differential Lock

Solenoid Valve

Control Accumulator Safety in this group).
–UN–23AUG88
X9811

–UN–12JUN98
31
6. Install solenoid valve using new O-rings and backup 3160
rings. 75
T115830
Specification
Differential Lock Solenoid Valve
Retaining Nut—Torque ..................................................... 7 N•m (62 lb-in.)
A—Differential Lock Solenoid

–UN–09NOV92
C—Nut
D—ID Plate
E—Coil
F—Solenoid Valve
T7751LI
G—O-Ring
H—Backup Ring
I—O-Ring
J—O-Ring
K—Backup Ring
CED,OUOE002,1675 –19–11JUN98–1/1

011504
PN=527
Hydraulic System
Remove And Install Pilot Enable Solenoid

Valve

Control Accumulator Safety in this group.)
–UN–23AUG88
X9811

–UN–12JUN98
31
3160 6. Install solenoid valve using new O-rings and backup
76 rings.
T115831
Specification
Pilot Enable Solenoid Valve
Retaining Nut—Torque ...................................................... 7 N•m (62 lb-in)
A—Pilot Enable Solenoid

–UN–09NOV92
C—Nut
D—ID Plate
E—Coil
F—Solenoid Valve
T7751LI
G—O-Ring
H—Backup Ring
I—O-Ring
J—O-Ring
K—Backup Ring
CED,OUOE002,1676 –19–11JUN98–1/1

011504
PN=528
Hydraulic System
Remove And Install Ride Control
CAUTION: Hydraulic oil may escape at pressure

high enough to penetrate skin from
components in the Ride Control solenoid circuit
if components are removed without discharging
–UN–23AUG88
the accumulator. Hydraulic oil in accumulator
can be stored at pressures equal to or above
system relief pressures.
X9811
If ride control is NOT operational, the ride
control accumulator must be discharged by
releasing gas charge before starting repair of
control valve or any of it’s components
If ride control is operational: With boom raised

slightly, turn ignition switch to ON position.
Cycle the ride control switch from OFF to ON
(center position). Boom will jump up 31
3160
unexpectedly if ride control accumulator is 77
for 5 seconds.
1. With boom raised slightly, turn ignition switch to ON

position. Cycle the ride control switch from OFF to ON
(center position). Boom will jump up unexpectedly if

011504
PN=529
Hydraulic System
31
3160
–UN–12JUN98
78
T115832
A—Bucket Cylinder D—Ride Control Manifold Left G—Ride Control Manifold Left H—Ride Control Accumulator
B—Ride Control Manifold Forward Top Port-to-Boom Bottom Port-to-Boom I—Boom Cylinder (2 used)
Front Bottom Port-to-Ride Valve Right Port Line Cylinder Rod End Tee J—Ride Control Pressure
Control Accumulator Port E—Ride Control Manifold Fitting Line Switch
Line F—Ride Control Manifold Left
C—Ride Control Manifold Rear Top Port-to-Boom
Front Top Port-to-Loader Cylinder Head End Tee
Control Valve T Port Line Fitting Line
2. Replace ride control parts as required.

CAUTION: Approximate weight of ride
control accumulator is approximately 40 kg
(80 lb), use hoist to remove.
Specification
Ride Control Accumulator—
Approximate Weight ........................................................ 40 kg (80 lb)
CED,OUOE002,1677 –19–11JUN98–2/2

011504
PN=530
Hydraulic System
Disassemble And Assemble Ride Control Valve
31
3160
79
–UN–12JUN98
T115834
A—Valve (3 used C—Nut (4 used) E—O-Ring G—Valve
B—Coil (4 used) D—Seal F—Plug H—Housing

011504
PN=531
Hydraulic System
NOTE: Valve components can be replaced while valve is

on machine. Internal parts of solenoid and check
valves are not serviceable.

–UN–23AUG88
X9811
system relief pressures.

releasing gas charge before starting repair of
control valve or any of it’s components

31 slightly, turn ignition switch to ON position.
3160
80
(center position). Boom will jump up
for 5 seconds.
1. Remove and inspect solenoids. Replace O-rings and

backup rings as required.
2. Boom Solenoid valve cannot be repaired, replace

O-rings and valve as required.
3. Remove check valve and inspect. Replace O-rings and

backup rings as required.
4. Remove nut (C) and replace solenoid (A and G) as

required.
5. Assemble solenoid and tighten nut.
Specification
Valve Solenoid Retaining Nut—
Torque ............................................................................... 8 N•m (72 lb-in)
CED,OUOE002,1678 –19–11JUN98–2/2

011504
PN=532
Hydraulic System
Disassemble And Assemble Ride Control

Accumulator
CAUTION: Ride control circuit may be

pressurized if accumulator is on the machine.
Lower boom to ground by pressing boom lower
switch and put control lever in float detent.

releasing gas charge before starting repair of it
or any of it’s components

31
energized. Press boom enable switch and move 3160
the control lever into the float position and hold 81
for 5 seconds.
1. Remove accumulator from machine. (See Remove and

Install Ride Control in this group.)

011504
PN=533
Hydraulic System
CAUTION: The gas end of accumulator is gas

charged and will cause end cap to blow out
with deadly force if disassembly is attempted.
Bleed off accumulator charge before attempting
to disassemble accumulator.
NOTE: Loosen only the top special nut. The bottom "nut"
is actually the accumulator gas valve.
2. Loosen special nut (A) (counterclockwise) 2 and 1/2

turns to open gas valve in accumulator and bleed off
gas charge. (Resistance may be felt at approximately 1
and 1/2 turns.)
3. Remove gas fitting (E).
NOTE: Both ends of accumulator are removed the same

way, piston can be removed from either end.
31
3160
4. Remove end cap using spanner wrench and remove
–UN–20NOV92
82
piston.
A—Cap
B—Accumulator Barrel
T7893AJ
C—Piston
D—End Cap
E—Gas Valve

011504
PN=534
Hydraulic System
5. Remove old seals from piston (E).
6. Install center O-ring (C), then a split backup ring (B) on

each side of it.
7. Install O-ring (D) in outer groove, then install wear ring

(A) on top of it.
8. Repeat previous step for other side.
A—Wear Ring (2 used)

B—Split Backup Ring (2 used)
C—Special O-Ring Seal
D—Inner O-Ring Seal (2 used)
E—Piston
31
3160
–UN–20NOV92
83
T7893AL
TX,31,ME164 –19–11JUN98–3/5
9. Remove O-ring and backup ring.
10. Install backup ring (B) with flat surface to inside of

groove.
11. Install O-ring (C) next to curved surface of backup
–UN–20NOV92
ring.
A—End Cap
B—Backup Ring
T7893AK
C—O-Ring

011504
PN=535
Hydraulic System
IMPORTANT: Put piston next to gas valve end to

reduce amount of air in accumulator
before charging.
12. Install piston (C), with hollow end toward gas valve, in
barrel (B).
13. Install end cap (D) and gas valve (E). Install other
end cap if removed.
14. Charge accumulator. (See Charge Ride Control

Accumulator in this group.)
15. Install accumulator on machine. (See Remove and

Install Ride Control in this group.)
A—Cap
B—Accumulator Barrel
31 C—Piston
3160 D—End Cap
E—Gas Valve
–UN–20NOV92
84
T7893AJ
TX,31,ME164 –19–11JUN98–5/5
Charge Ride Control Accumulator
NOTE: Ride control can not be discharged if switch is

CAUTION: Hydraulic oil may escape at
in automatic position unless machine is moving
pressure high enough to penetrate skin from
above 5 kmh (3 mph), use On position to
components in the Ride Control solenoid
discharge accumulator during this procedure.
circuit if components are removed without
discharging this accumulator. Hydraulic oil
1. If accumulator is to be charged on machine and
in accumulator can be stored at pressures
has some nitrogen pressure left. With boom raised
equal to or above system relief pressures.
slightly, turn ignition switch to ON position. Cycle
the ride control switch from OFF to ON (center
IMPORTANT: Charge accumulator using only dry
position). Boom will jump up unexpectedly if ride
nitrogen. Dry nitrogen does not mix
control accumulator is energized. Press boom
with oil and is non-combustible. It
enable switch and move the control lever into the
will not cause oxidation or
float position and hold for 5 seconds.
condensation inside accumulator
and is not harmful to piston seal. DO
2. Remove cover and cap from top of accumulator.
NOT use air or any combustible gas
as these can cause oxidation and
3. Turn handle on gas cock fully counterclockwise.
condensation. Oxidation and
Attach gas cock, hose, and regulator to
condensation are harmful to piston
accumulator.
seal and accumulator.

011504
PN=536
Hydraulic System
CAUTION: Loosen only the top special nut. The

bottom "nut" is actually the accumulator gas
valve fitting. Do Not loosen bottom fitting.
Loose fitting under pressure can cause injury.
4. Loosen special nut (A) (counterclockwise) 2 1/2 turns

to open gas valve in accumulator. (Resistance may be
felt at approximately 1 1/2 turns.)
5. Slowly open regulator valve to pressurize accumulator

to specification.
Specification
Oil—Temperature .................................................................. 40°C (104°F)
Ride Control Accumulator—
Charge Pressure .................................. 2068 ± 138 kPa (20 ± 1 bar) (300
± 20 psi)
6. If accumulator is to be charged on machine and has

31
NO nitrogen pressure left. With boom raised slightly, 3160
–UN–10SEP91
85
T7594AA
seconds.
7. Check that accumulator is pressurized to

specifications. Adjust regulator as required.
8. Tighten nut until snug to close gas valve.
9. Close the control on the nitrogen tank.
–UN–10SEP91
10. Slowly loosen the connector at pressure regulator
valve to release pressure from hose.
11. Remove gas cock from accumulator. Install cap.
T7594AB
Cross Section Of Gas Valve Fitting
CED,OUOE002,1679 –19–11JUN98–2/2

011504
PN=537
Hydraulic System
Remove And Install Pin Disconnect/Axle

Disconnect Valve

system relief pressures. With boom raised
for 5 seconds.
31
3160
Lower equipment to the ground.
86
CAUTION: If ride control switch is pushed,
boom may unexpectedly move up.
Discharge ride control accumulator.
CAUTION: Brake accumulators supply pressure

oil to pin disconnect valve when engine is OFF.
Discharge brake accumulators before working
on Pin Disconnect/Axle Disconnect Valve.
Discharge brake accumulators by pushing brake pedal 40

or more times. Brake accumulator pressure can be read
using the Monitor Basic Display. Go to menu d 052
(Clutch Cutoff Pressure).

011504
PN=538
Hydraulic System
Mark hoses and harness connectors for reference during

assembly. Disconnect hoses and harness connectors.
Remove capscrews (B) and remove valve.
Replace O-Rings, install valve and connect hoses and

harness connectors.
A—Nut (2 used)
B—Valve
C—Capscrew (2 used)
D—Axle Disconnect Solenoid
E—Pin Disconnect Solenoid
31
3160
87
–UN–18APR97
T109182
TX,31,RP3070 –19–11JUN98–2/2
Disassemble And Assemble Pin Disconnect

Valve
1. Remove solenoid coil and spool. Inspect for damage or

wear.
–UN–28APR97
2. Replace parts as needed. Replace O-Rings and
backup rings.
T109214B
A—Nut
B—Identification Plate
C—Cover
D—Coil
E—Bottom Plate
F—Spool
G—O-Ring
H—Backup Ring
I—O-Ring
J—O-Ring
K—Backup Ring
L—O-Ring
M—Backup Ring
TX,31,RP3069 –19–11JUN98–1/1

011504
PN=539
Hydraulic System
Disassemble And Assemble Axle Disconnect

Valve
1. Remove solenoid coil and spool. Inspect for damage or

wear.
–UN–09NOV92
2. Replace parts as needed. Replace O-Rings and
backup rings.
C—Nut
T7751LI
D—Identification Plate
E—Coil
F—Spool
G—O-Ring
H—Backup Ring
I—O-Ring
J—O-Ring
K—Backup Ring
31
3160
88
TX,31,RP3071 –19–11JUN98–1/1

011504
PN=540
Group 3199
DFT1132 Hydraulic Pump Removal And Installation Tool
31
3199
1
–UN–10JUL95
T8366AC
A—1 in. Nut C—Pipe 457 mm (18 in.) long E—Pipe G—Pipe
B—Pipe 2134 mm (7 ft) long D—1 in. ID heavy Wall Steel F—Weld
Pipe
This tool is used to remove hydraulic motor from • 1 in. piece heavy wall steel pipe 8 ft. x 6 in. long
machine. • Weld (E) to (G)
Material required:
CED,OUOE002,1681 –19–11JUN98–1/1

011504
PN=541
31
3199
2

011504
PN=542

644H and 644H MH Repair TM1638

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644H and 644H MH

For complete service information also see:

TM1638 (15JAN04) 644H and 644H MH Loader

Technical Information Feedback Form

We need your help to continually improve our technical

SEND TO: John Deere Dubuque Works

FAX NUMBER: 563-589-5800

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Dealer Acct. No.:

TM1638 (15JAN04) 644H and 644H MH Loader

TM1638 (15JAN04) 644H and 644H MH Loader

SECTION 05—Engine Auxiliary Systems

SECTION 07—Dampener Drive 07

SECTION 09—Steering System

SECTION 11—Park Brake 10

All information, illustrations and specifications in this manual are based on

TM1638 (15JAN04) i 644H and 644H MH Loader

TM1638 (15JAN04) ii 644H and 644H MH Loader

TM1638 (15JAN04) iii 644H and 644H MH Loader

TM1638 (15JAN04) iv 644H and 644H MH Loader

Group 0001—Safety Information Handle Fuel Safely—Avoid Fires. . . . . . . . .00-0001-11

TM1638 (15JAN04) 00-1 644H and 644H MH Loader

TM1638 (15JAN04) 00-2 644H and 644H MH Loader

TM1638 (15JAN04) 00-0001-1 644H and 644H MH Loader

This is a safety-alert symbol. When you see this symbol

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is

DANGER or WARNING safety signs are located near

Follow Safety Instructions

Carefully read all safety messages in this manual and on

Learn how to operate the machine and how to use

Keep your machine in proper working condition.

If you do not understand any part of this manual and need

TM1638 (15JAN04) 00-0001-2 644H and 644H MH Loader

Be careful when operating on a slope.

Avoid sharp turns.

Balance loads so weight is evenly distributed and load is

Know capacity of machine. Do not overload.

Be careful when operating at the edge of an excavation,

Read and understand the operating instructions in this

TM1638 (15JAN04) 00-0001-3 644H and 644H MH Loader

To avoid backover accidents:

Always look around before you back up. Be sure that

Keep bystanders away from pivot area of an articulated

Keep reverse warning alarm in working condition, if

Use a signal person when backing up if view is

Learn the meaning of all flags, signs, and markings used

Keep windows, mirrors, and lights clean and in good

Dust, heavy rain, fog, etc., can reduce visibility. As

Read and understand the operating instructions in this

TM1638 (15JAN04) 00-0001-4 644H and 644H MH Loader

Select level ground when possible to park machine.

Move transmission control lever to neutral "N", engage

Lower all equipment to ground.

Stop the engine.

Block all wheels if you must park on a grade. Position

Park a reasonable distance from other machines.

Read and understand the operating instructions in this

Inspect your machine carefully each day by walking

TM1638 (15JAN04) 00-0001-5 644H and 644H MH Loader

Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain a