SHOP MANUAL FORD MODELS 5640-6640-7740-7840-8240-8340 The tractor identification plate is located on right side under the tractor hood. Serial and model numbers of the tractor, engine, transmission, rear axle, hydraulic pump and the hydraulic lift are recorded on this identification plate. If equipped with front-wheel drive, a similar plate is attached to the rear surface of the front drive axle housing. INDEX (By Starting Paragraph) BRAKES ENGINE AND COMPONENTS Adjustment. . 226 Cam Followers ..... 45 Brake Discs and Actuating Assembly. oe 0) Camshaft and Bearings........ 44 Master Cylinder........ dooce Connecting Rods and Bearings............. 52 System Bleeding ... soi sie Connecting Rod and Piston Units... 46 CLUTCH, ENGINE Crankshaft and Main Bearings seoees BB Clutch Assembly, R&R. vee 198 Crankshaft Oil Seals.....0000 00.2. cece. 54 Clutch Linkage. . oe vee 124 Cylinder Head is Clutch Master Cylinder 22: + Engine Balaneer (5640, 6640, 7740) 2 56 Clutch Release Bearing : 137 Engine, R&R...... cs tees BL ‘Tractor Split...... : anos sda Oa Exhaust Valve Rotators... 21.1.0... 37 COOLING SYSTEM Flywheel...... ress ABT Radiator ...... ve. 87 Oil Pump and Relief Valve. 59 Radiator Pressure Cap and Thermostat....., 86 Oil Sump. . + 58 Water Pump...... frecect cae OR Pistons and Rings... 47 DIESEL FUEL SYSTEM Pistons and Cylinders 48 Adjustments..........00..2065 - 88 Piston Fine - + 61 Filters and Bleeding i 70 Rocker Arms. ......... + 83 Fuel Injection Pump . + 80 ‘Timing Gear Cover... + 88 Fuel Injectors a) ‘Timing Gears ....... - 39 Fuel Tanks... fn. 66 ‘Turbocharger (7740 and 8340) 61 Injection Pump Drive Gear | Valve Clearance «+. ....+. 34 ‘Troubleshooting . . 69 Valve Guides and Springs + 86 DIFFERENTIAL, MAIN DRIVE BEVEL Valves, Stem Seals and Seats . + 35 GEARS, FINAL DRIVE AND REAR AXLES FRONT AXLE (Two-Wheel Drive) _ Bevel Pinion... es 222 Alo Center Merobes, Pivot Pina and Bushings. 4 Differential and Differential Lock 220 Front Support. .. 5 Rear Axle and Final Drive.......... 224 Spindles, Axle Extentions and Bushings ...... 3 ‘Tractor Rear Split 219 Tie Rod, Toe-Out and Tread Adjustment - 2 sterol DUAL POWER (16 x 4 Transmission) Wheels and Bearings. .... Control Valve . . 144 FRONT-WHEEL DRIVE Dual Power Unit . ‘ i ‘Adjustments 6 Lubrication... . Axle Pivot Bearings .. 4 Pressure Test. Bevel Pinion Gear Ww ‘Troubleshooting... Differential, . 15 ELECTRICAL SYSTEM Drive Shaft... . tahoe Alternator and Regulator ....... Front Drive Axle. 5 10 Instrumentation. Front Support. ..... 20 Starting Motor ‘ Steering Knuckle Housing. 13 ELECTRICAL WIRING DIAGRAMS 300 ‘Transfer Gearbox . .. 18‘Wheel Hub and Planetary (5640, 6640, 7740). 11 Wheel Hub and Planetary (7840, 8240, 8340). 12 HYDRAULIC LIFT (Electronic Draft Control) Electronic Draft Control Valve . » 280 Hydraulic Lift Cover ...... 3 278 Operation ......6600cceeeeeeeeeeeeeeees 270 ‘Troubleshooting... - 271 HYDRAULIC LIFT (Top Link Sensing) External Linkage Adjustment. ... 291 Hydraulic Lift Cover and Cylinder......... 285 Internal Linkage Adjustment ++ 288 Lift Assist Cylinder . 294 Operation 281 Priority Valve Pack ..... 283 ‘Troubleshooting ...... 282 Unloading Valve. .... 284 HYDRAULIC SYSTEM Hydraulic Fluid and Filters ...... 240 HYDRAULIC SYSTEM (Closed Center Load Sensing) Operation : - 241 Pressure Testing, = Pump Overhaul ‘Troubleshooting . HYDRAULIC SYSTEM (Open Center), Engine Mounted Auxiliary Gear Pump ..... 269 Ope es ea canvas vvnwane 04 258 Pressure Testing. 259 ‘Transmission Mounted Tandem Gear Pump . 268 HYDROSTATIC STEERING Fluid and Bleeding. Power Cylinder. Pump........- Steering Valve ..... ‘Tests and Adjustment . ‘Troubleshooting POWER TAKE-OFF Operating Principles ..... Pto Clutch and Control Valve (Mechanically Operated)... : Pto Clutch and Control Valve (Electric Solenoid Operated)... . - Pto Output Shafts and Gears 237 vos 238 + 234 ‘Troubleshooting . - 233 REDUCTION GEARBOX. 0.2.0... 148 REMOTE CONTROL VALVES Adjustments... . one 296 Remote Control Valve 2 298 Remote Valve Couplers ..... + 299 TRANSMISSION (8 x 2 Constant Mesh) Lubrication.........+5 wen ev UML Overhaul....... 133 Remove and Reinstall... 132 ‘TRANSMISSION (16x 16 Powershift Built Prior To September 1993) Clutch Calibration . amram 178 Electrical Component Description v7 Gearshift Cover « : teseeeeee 193 Gearshift Linkage » 192 Pressure Testing... +. 184 ‘Transmission Control Valve. .........++++- 190 ‘Transmission Overhaul - 194 ‘Troubleshooting Electronic Control System... 188 ‘Troubleshooting Transmission System...... 189 TRANSMISSION (16 x 16 "Quad Mod’ Power- shift Built September 1993 And After) Clutch Fill Time Calibration ......... 206 Clutch Spring Pressure Calibration . ++ 204 Gear Shift Control Cables - ‘ 216 Pressure Testing. .... sees 208 ‘Transmission Control Valve. see 216 ‘Transmision Overhaul 218 Troubleshooting Electronic Control System. . 212 TRANSMISSION (1212 Synchro-Shift) Lubrication 151 Overhaul... - 153 Remove and Reinstall 152 ‘TRANSMISSION (12 x 12 Synchro-Shift With Dual Power) Clutch Calibration ..... 163 Dual Power Unit ‘ 174 Electro-Hydraulie System .. 162 Lubrication Control Valve z a; TB Pressure Testing. . capnesees TEL ‘Transmission Control Valve. ia, OB ‘Troubleshooting Electronic Control System. . 167 DUAL DIMENSIONS This service manual provides specifications in both U.S. Customary and Metric (SI) systems of measurement. The first specification is given in the measuring system perceived by us to be the preferred system when servicing a particular component, while the second specification (given in parenthesis) is the converted measurement. For instance, a specification of 0.011 inch (0.28 mm) would indicate that we fee! the preferred measurement in this instance is the U.S. Customary system of measurement and the Metric equivalent of 0.011 inch is 0.28 mm.CONDENSED SERVICE DATA Displacement . Compression Ratio.......... TUNE-UP Firing Order. .... ‘Valve Clearance, Cold — Inlet ..... Exhaust ..... Compression Pressure — Minimum.............. Injector Opening Pressure. . Engine Low Idle RPM. Engine High Idle RPM Engine Rated Speed RPM... . Engine Rated Power atPto...... Battery — Voltage . . Ground. SIZES Crankshaft Main Journal Diameter .. . Crankshaft Crankpin Diameter ..... Piston Pin Diameter Valve Seat Angle — Inlet . Exhaust .... Valve Face Angle — Inlet Exhaust es Valve Stem Diameter — Inlet... 2... Exhaust .... Cylinder Bore Diameter ..... 5640 6640 7740 7840 8240 8340 4 111.8 mm (4.4 in.) 18mm = —127.0mm— —11.8mm = — 127. 0 mm—— (4.4 in.) (6.0 in.) (4.4 in.) (5.0 in.) 4390 cc =» ——4987 ee — 6585 cc |= ——— 7480 cc —— (268 cu. in.) (304 cu. in.) (401 cu. in.) (456 cu. in.) 17.5:1 13-42: 15-3-6-2-4 ).36-0.46 mm: (0.014-0.018 in.) .43-0.53 mm: (0.017-0.021 in.) 2585 kPa: (375 psi) 23,995-24,755 kPa —— 29, 165-29,995 kPa (3480-3590 psi) (4230-4350 psi) 725 - 175 — 2295-2375 —— 2195-2275 —— 2200 2100: 49kW = 56.5KW 64 kW. 67kW = 7L5kW 83.5 kW (66hp) (76 hp) += (86 hp) (90hp)- (9Bhp) (112 hp) 12. Negative: See Paragraph 53: See Paragraph 52- ——38.095- 41.270- ~— —— 38,095- 41.270- 38.10 mm — 41.275 mm 38.10mm— 41.275 mm (1.4998- (1.6248- (1.4998- (1,6248- 1.500 in.) 1.6250 in.) 1.500 in.) 1.6250 in.) :30.0-30.5° 45.0-45.5° 29.25-29.5° 44.25-44.5° 9.426-9.446 mm (0.3711-0.3719 in.) 9.401-9.421 mm. (0.3701-0.3709 in.) 111.778-111.841 mm (4,4007-4.4032 in.)CONDENSED SERVICE DATA (Cont.) CLEARANCES Main Bearing, Diametral Clearance Rod Bearing, Diametral Clearance. Camshaft Bearing, Diametral Clearance......- Crankshaft End Play. ... CAPACITIES Cooling System Crankease — With Filter Fuel tank ‘Transmission/Hydraulic — 8x2and16x4 540 Pto. 540/1000 Pto . 12x12... 16x16 semen Front Drive Axle . Front Drive Hub (each). . TIGHTENING TORQUES Cylinder Head . Connecting Rod . ‘Main Bearings ...... Intake Manifold... Exhaust Manifold Flywheel. .... Crankshaft Pulley . OilPan...... Camshaft idler Gear... Camshaft Gear. Fuel Injectors Water Pump 5640 6640 740 7840 8240 8340 0,055-0.117 mm. (0.0021-0.0046 in.) 0.035-0.094 mm (0.0014-0.0037 in.) 0.025-0.076 mm (0.001-0.003 in.) 0.10-0.20 mm: (0.004-0.008 in.) 16 L ———— ———215L (16.9 US. qt.) (22.7 US. at.) 1.4 L——— ——— 209L (12.1 US. qt.) (22.1 US. qt) 94.6 L Std. ——— 217.7 L Std. (25.0 US. gal.) (67.5 US. gal.) 62L (65.5 US. at.) 66 L (69.7 US. at.) 8L_———__. ——_.... —— (15.0 US. gal.) 60.6 L (16.0 US. gal.) 621. ————_ 8.0L (66 US. qt.) (85 US. at.) 3.0L 2.6L (8.2US. qt.) (2.7US. at.) 217 Nem (160 ft.-Ibs.) 149 Nem (110 ft-lbs.) 197 Nem (145 ft.-Ibs.) —85 Nem (28 ft.-Ibs.) 38 N.m (28 ft-lbs. 197 Nem (145 ft.-Ibs.) 224 Nem (165 ft.-Ibs.) 38 Nem (28 ft.-Ibs.) 237 Nem (175 ft.-Ibs.) 69 Nem (51 ft.lbs. —23 Nem (17 ft-lbs.) 65 Nim (50 ft-tbs.MODELS 5640, 6640, 7740, 7840, 8240 & 8340 Paragraphs 1-3 FRONT AXLE SYSTEM (TWO-WHEEL DRIVE) FRONT AXLE ASSEMBLY AND STEERING LINKAGE Two-Wheel Drive Models 1. WHEELS AND BEARINGS. To remove front wheel hub and bearings, first raise and support the front axle extension, then unbolt and remove the tire and wheel assembly. Remove the cap (1—Fig. 1), cotter pin (3), slotted nut (2), washer (4) and outer bearing cone (5). Slide the hub assembly (6) from spindle axle shaft (10). Remove grease retainer (8) and inner bearing cone (7). Hub is slotted to facilitate removal of bearing cups. Pack wheel bearings liberally with Ford M1C137- A, MIC75-B or equivalent grease. Reassemble by Fig. 1—Exploded view of front whee! hub used on two whee! drive models. Mud shield (9) Is used only on 8240 and 8340 models. 1. Cap 6. Hub 2 Slatted nut 17. Inner bearing cone 8. Cotter pin e retainer 4. Washer 5. Outer bearing cone reversing disassembly procedure. Grease retainer (8) and inner bearing cone (7) should be positioned on spindle, then install wheel hub (6). Tighten slotted nut (2) to a torque of 27-40 Nem (20-30 ftIbs.), then, rotate hub several turns. Tighten nut (2) to 61-74Nem (45-50 ft.-Ibs.), then back nut off less than one flat and install cotter pin (3). Be sure to install cap (1) se~ curely. 2, TIE ROD, TOE-OUT AND TREAD ADJUST- MENT. All models are equipped with one tie rod extending between left. and right steering arms. The hydrostatic steering cylinder (19 Fig. 2) is attached between the front axle and the center of the tie rod. Left end (18) of tie rod and both ends of steering cylinder are automotive type and should be renewed if wear is excessive. The procedure for removing and stalling the ends is self evident. Automotive end of right tie rod is renewable only as an assembly with the right tie rod. Alll two-wheel drive models are equipped with ad- justable tread axle, Tie rod is equipped with locating screws (15) for quick adjustment of tie rod length when changing tread width. To adjust tread width, raise and support front axle. Remove tie rod locating, screws (15) and clamp screws (9) from axle extensions (and 12), then slide axle extensions in or out of axle center member (8). Tighten the track adjusting clamp screws (9) which attach axle extensions inside the axle center section to 400 Nem (300 ft.-Ibs.) torque. ‘Tighten tie rod locating screws (15) to 150 Nem (110 ft-lbs.) torque and locknuts to 75 Nem (55 ft.-lbs.) torque. After resetting axle tread width, check and adjust front wheel toe-out as described below. ‘Recommended front wheel toe-out is 0-13 mm (0- yin.) for two-wheel drive models. To check toe-out, turn steering wheel so that front wheels are in straight ahead position. Measure distance (A—Fig. 8) between wheel rims on centerline of axle, parallel to ground. Rotate wheels 4 turn, then measure tween wheels at front of wheels in position (B). mension (A) should be 0-13 mm (0-¥% in.) smaller than dimension (B). To adjust toe-out, remove locat- ing bolt (15—Fig. 2) from left end of tie rod tube (16). Loosen clamp bolt in left tie rod end (18). Turn threaded section of tie rod (17) in or out to obtain desired toe-out. Tighten tie rod locating bolt to 150 Nom (110 ft.-Ibs) torque and clamp bolt to 75 Nem (55 ft-lbs.) torque. 3. SPINDLES, AXLE EXTENSIONS AND BUSHINGS. To remove spindle (1—Fig. 2), first remove the wheel and hub, then disconnect tie rod end from steering arm (7 or 13). Check threaded endParagraph 3 (Cont.) Fig. 3—On two-wheel drive models, front wheels should be toed out 0-13 mm (0-1/2 in.). of spindle and steering arm for alignment marks (M—Fig. 4) before removing steering arm. Note that, it may be necessary to use a thread file to clean the threads of spindle since they are deformed during assembly at the factory in order to lock the spindle nut in place. Remove nut retaining steering arm (7 or 13—Fig. 2), then pull steering arm from splines of spindle. Lower spindle (1) from axle extension (5 or 12), Remove thrust bearing 3) and chamfered washer (2) from spindle. Clean and inspect parts for wear or other damage and renew as necessary. When reassembling, lubricate bushings (4) and pack thrust bearing (3) with Ford M1C137-A, 10 FORD Fig. 2—Exploded view of adjustable axle typical of two-wheel drive models. 1. Spindle 2 Washer 3. Thrust bearing 4 Bushings 5, Left axle extension 6, Felt sealing washer 7. Left steering arm 8. Axle center member 9, Track clamp bolt 10, Bushings 11, Washers 12, Axle right extension 13. Right steering arm MA, Right tie rod 15, Locking screws 16. Tie rod tube V7. Left tie rod 18. Tie rod end 19, Power steering cylinder Fig. 4—Marks (M) are provided on the spindles and the steering arms to assist in correct assembly. ‘MIC75-B or equivalent grease. Install washer (2) with chamfered edge down toward boss of spindle, then install thrust bearing (3) on spindle so that numbered side of bearing is facing upward. Insert spindle through axle extension. Install new felt washer (6), then locate steering arm on top of spindle. Align marks on threaded end of spindle and steering arm as shown (M—Fig. 4). Tighten steering arm retaining nut to 488-597 N.m (360-440 ft--Ibs.)MODELS 5640, 6640, 7740, 7840, 8240 & 8340 torque, then stake threads to prevent loosening. Re- fer to paragraph 2 for tread width and toe-out adjust- ment. Balance of reassembly is the reverse of disassembly. Tighten the track adjusting clamp screws (9—Fig. 2) which attach axle extensions inside the axle center section to 400 Nem (300 ft-lbs.) torque. Tighten tie rod locating bolts (15) to 150 Nem (110 ft-lbs.) torque and locknuts to 75 N-m (55 ft.-bs.) torque. Tighten left tie rod end clamp bolt to 100 Nem (75 ft-lbs.) torque after toe-out is correctly set. 4, AXLE CENTER MEMBER, PIVOT PIN AND BUSHINGS. To remove front axle assembly, raise front of tractor in such a way that it will not interfere with the removal ofthe axle. A hoist may be attached to front support or special stands can be attached to sides. Removal of the axle center member (8—Fig. 2) may be easier if the axle extension and spindle as- sembly is first removed from each side; however, the complete assembly can be removed as a unit. Remove front wheels and weights, then support the axle with a suitable jack or special safety stand to prevent tipping while permitting the axle to be lowered and moved safely. Disconnect hoses from the steering cylinder and cover openings to prevent the entry of dirt, Unbolt and remove the front axle pivot pin. Lower axle until axle is free from front support, then carefully roll axle away from under tractor. Paragraphs 4-7 Check axle pivot bushings (10) and renew if neces- sary. Reverse removal procedure when assembling. Lubricate pivot bushings with Ford M1C137-A, MIC75-B or equivalent grease. Tighten screws re- taining the axle pivot pin to 70-90 N.m (52-66 ft.-Ibs.) torque, then bend locking tabs around screws to pre- vent loosening. 5. FRONT SUPPORT. To remove the front sup- port, the axle must be removed, the radiator must be removed from the support and the front support must. be unbolted from the front of engine. The front axle, the front support and the remainder of the tractor must each be supported separately while removing, while separated and while assembling. Be sure that sufficient equipment is available before beginning. Refer to paragraph 67 and remove the main fuel tank, then refer to paragraph 87 and remove the radiator. Support front of tractor in such a way that it will not interfere with removal of either the front support or the front axle, Remove axle as outlined in paragraph 4. Attach a hoist or other supporting de- vice to the front support, then unbolt and separate the front support from the front of the engine. Be careful not to lose or damage shims located between front support and engine. Keep shims separate and label for installation in same loc FRONT-WHEEL DRIVE Mechanical front-wheel drive is available which uses a front drive axle manufactured by Carraro. ‘Models 5640, 6640, 7740 and 7840 are equipped with standard type 709 axle; Models 8240 and 8340 are equipped with heavy duty type 709 axle. Some differ- ences in the front-wheel drive systems will be noted in the following service instructions. ‘The transfer gearbox engagement is controlled by an electric solenoid/hydraulic valve which directs oil pressure to move a dog clutch and engage the front wheel drive. The transfer gearbox is attached to the bottom of the rear axle center housing of all models. Addrive shaft connects the transfer gearbox to front axle. ADJUSTMENTS All Four-Wheel Drive Models 6. FRONT WHEEL TREAD WIDTH. Front- wheel drive axle is a fixed assembly. However, track width can be adjusted by changing the wheel rim relative to the center disc, the rim and/or disc relative to axle hub or by interchanging the front wheels. The drawings shown in Fig. 6 illustrate different wheel rim and dise positions relative to the hub and the resulting track width settings. NOTE: When interchanging front wheels from side to side, make sure that “V" of tire tread is pointing in the direction of forward travel. ‘Tighten disc to hub mounting nuts to 475 N-m (350 ft-lbs.) torque and disc to rim mounting nuts to 240 Nem (177 ft.-bs.) torque. Recheck the dise and rim mounting nut torque after driving the tractor about 200 meters (200 yards), after one hour of operation, after eight hours of operation and at 50 hour inter- vals. After resetting track width, check toe-in setting as outlined in paragraph 7 and steering stop setting as, outlined in paragraph 8. 7. TIE RODS AND TOE-IN. Tie rod ends are not adjustable for wear and faulty units must be re- newed. To check toe-in, first turn steering wheel so that front wheels are in straight ahead position. ‘Measure distance between front wheels at front and rear of wheels from rim flange to rim flange at hub height, Distance measured at front of wheels should be 0-6 mm (0-4 in.) less (toed in) than distance ‘measured at rear of wheels. To adjust, loosen clamp nParagraph 8 ‘Track Setting DiseiRim Position | 24 in. 28 i wheels wheels 556in. | 54.7in 1412 mm) | (1389 mm) 597in. | 588in (1516 mm) | (1493 mm) 636in, | 627 in, (1615 mm) } (1592 mm) Fig. 6—View of toe-in adjustment points for four-wheel- drive models. Be sure to adjust both sides equally. Refer totext. 617 668 in. (1718 mm) } (1696 mm) niin, | 71.9 in, (1812 mm) | (1825 mm) 7sain. | 759in (1916 mm) } (1929 mm) 79.3in, | 799in (2015 mm) | (2028 mm) 834in. | 839i (2119 mm) | (2132 mm) Fig. 5—Front-wheel drive axle track width is adjusted by changing position of whee! rim and disc. 12 Fig. 7—Steering stop screws (S) should be adjusted to prevent tires from touching any part of tractor when Wheels are turned. bolt (2—Fig. 6), then turn tie rod (1) in or out of tie rod end (3) as required. Adjust both sides evenly. ‘When adjustment is correct, tighten clamp bolt (2) to 56 Nem (41 ft.-bs.) torque. 8. STEERING STOPS AND ARTICULATION. ‘The front axle is provided with adjustable steering and articulation stops to prevent the front tires from contacting the tractor. Adjusted setting should not change during operation, but different tire sizes or tread and changes in track width may make adjust- ment necessary. The steering stop screws (S—Fig. 7) should be adjusted to provide a minimum clearance of 20 mm (% in.) between tire and frame. TightenMODELS 5640, 6640, 7740, 7840, 8240 & 8340 Fig. 8—Articulation stops (1) can be installed using the center and rear (2) mounting holes as shown or the center and front (3) threaded holes can be used. Refer to text. Jocknut to 150 Nem (110 ft.-Ibs.) torque when adjust- ment is correct. Articulation stops (1—Fig. 8) should prevent the tires from contacting the tractor when the front axle is tipped against stops. When stop is attached to the rear two screws (2) as shown, the axle should be limited to approximately 8° of movement. When the stop is attached to the center and front hole (3), articulation is limited to about 12° from horizontal. Stops (1) should be positioned at same location on both sides, DRIVE SHAFT All Four-Wheel Drive Models 9. REMOVE AND REINSTALL. Two different drive shafts have been used as shown in Fig. 9, depending upon transmission used. ‘To remove drive shaft (5), first unbolt and remove the shield assembly (1). To remove drive shaft shown in the lower view, remove screw (4) and slide cou- plings (2 and 3) until drive shaft can be withdrawn. Clamps (7) must be removed before front universal joint can be separated from yoke (6) of models with 8 x2 and 16x 4 transmissions. When installing drive shaft on models with 12 x 12 and 16 x 16 speed transmissions, grease coupling splines, slide couplings onto drive shaft, position drive shaft, then slide couplings into position and install screws (4). On models with 8 x 2 and 16 x 4 speed transmis- sions, grease rear coupling splines before installing drive shaft. Tighten clamp bolts of front universal Joint to 57 Nom (42 ft.-Ibs.) torque. Paragraphs 9-10 Fig. 9—The drive shaft and shield at top are typical of ‘models with 8x 2and 16x 4 transmissions. The drive shatt and shield shown in the lower view are typical of models with transmissions providing 12 12 and 16 x 16 speed transmissions. 1. Shield 2, Front splined coupling 8. Yoke 8. Rear splined coupling 7. Clamp 4. Serew 8, Yoke retaining serew 5. Drive shaft 9. Bracket FRONT DRIVE AXLE All Four-Wheel Drive Models 10.R&R ASSEMBLY. First remove the drive shaft and shield as outlined in paragraph 9. If differential unit is to be serviced, it is recommended that the bevel pinion shaft nut be loosened at this time. Pry ut pinion shaft cil seal, then loosen nut using special pinion nut wrench FT3168 or equivalent. Remove front weights. Raise front of tractor in such a way that it will not interfere with the removal of the axle. A hoist may be attached to front support or special stands can be attached to sides. Remove front wheels, then support the axle with a suitable jack or special safety stand to prevent tipping while permitting the axle to be lowered and moved safely. Disconnect hoses from the steering cylinder and cover openings to prevent the entry of dirt. Unbolt and remove front and rear pivot brackets (1 and 17—Fig. 10), lower axle until free, then carefully roll axle away. Reinstall front drive axle by reversing the removal procedure. Tighten screws attaching front and rear pivot brackets (1 and 17) to 317-388 N.m (234-286 13Paragraphs 11-12 Fig. 11—View of “OIL LEVEL" mark (L) and drain plug (1) of front whee! drive front hub. fi.lbs.) torque. Tighten steering hose connections to, 34 Nem (26 ft-lbs.) torque if removed or disconnected. WHEEL HUB AND PLANETARY Models 5640-6640-7740 11. R&R AND OVERHAUL. Either front wheel hub and planetary can be serviced without removing, the steering knuckle housing from axle. Support front. axle housing and remove front wheel. Remove drain plug (I—Fig. 11) from planet carrier and drain oil from hub assembly, Remove the two Allen screws from planet carrier (2—Fig. 12) and lift planet carrier from knuckle housing (30). Remove snap rings (7) and retainer plate (8). Mark: shafts (4) and planet gears (6), then keep bearings (5) and thrust washers (3) separate so that they can be reinstalled as a set in the same location. Before removing the ring gear (14), mark relative position of ring gear (14) and steering knuckle hous- ing (80) to facilitate installation in same location. Remove snap ring (10), sun gear (11), spacer (12) and washer (13). Unscrew retaining screws (16), then use four of the removed screws as jackscrews in threaded holes of the ring gear carrier (18) to push carrier (18) and ring gear (14) from hub (21). 14 FORD Fig. 10—View of front and rear pivot brackets (1 & 17) installed. Four screws are used fo attach each bracket to front Support. Bump hub (21) from steering knuckle (30), Remove cups for bearings (20 and 22) and seal (23) from hub. If necessary, remove inner bearing cone from knuckle housing. Clean and inspect all parts for excessive wear or other damage and renew as necessary. When reassembling, drive cups for bearings (20 and 22) and oil seal (23) into hub (21). If removed, install cone for inner bearing (22) on knuckle housing (30), Install hub (21) and cone for outer bearing (20) onto knuckle housing. Assemble ring gear (14) to carrier (18) and secure with retaining ring (19). In- stall ring gear (14) and gear carrier (18) and tighten mounting cap screws (16) to 220 Nem (162 ft-lbs.) torque. Install washer (13), spacer (12), sun gear (11) and snap ring (10). Stick thrust washer (9) in place on carrier (2) with “Loctite 638” or equivalent and install new “O” ring (15) in groove of hub (2). Install thrust washers (3), bearings (5), planet gears (6) and retainer plate (8), then secure with snap rings (7). Install planetary carrier assembly. Install the two ‘Allen screws. Fill hub and planetary to the level of opening for drain/fill plug (1—Fig. 11) in carrier with “OIL LEVEL” mark (L) on carrier horizontal. Fill with Ford ESN-M2C134-D or equivalent, Install front wheel and tighten disc to hub nuts to 270 Nem (200 ft.-Ibs.) torque. Dise to wheel rim nuts should be tightened to 240 Nem (177 ft.-Ibs.) torque. Models 7840-8240-8340 12, R&R AND OVERHAUL. Either front wheel hub and planetary can be serviced without removing the steering knuckle housing (30—Fig. 13). Support front axle housing and remove front wheel. Remove drain plug (1—Fig. 11) from planet carrier and drain oil from hub assembly. Remove the two Allen screws from planet carrier (2—Fig, 13) and lift planet carrier from knuckle housing (30). Remove planet gear retaining screws and washers (8—Fig. 13). Mark planet gears (6) and shafts (4), then remove planet gears, bearings (5) and thrust washers (3). Keep bearings (5) and thrust washers (3) separate with their respective planet gears so that they can be reinstalled as a set in the same location.MODELS 5640, 6640, 7740, 7840, 8240 & 8340 Paragraph 12 (Cont.) Fig. 12—Exploded view of front-wheel drive steering knuckle and standard planetary assembly. Refer to Fig. 13 for heavy duty planetary assembly. Axles will not be equipped with both shims (26) and Belleville washers (29). Early axles use shims (26) to adjust vertical play of steering knuckle and later models use Belleville washers (29). 1. Magnetic drain plug 10, Snap ring 2 Planet carrier AL Sun ge 3. Thrust washer 12. Spacer 4 Planet shaft 18, Thrust washer 5. Needle rollers (30/gear) 14. Ring gear 6, Planet gear 15, "0" ring 7. Snap ring 16, Screws (M10 x30) 8. Planet carrier plate 17. Bushing 9. Thrust pad 18, Ring gear carrier Before removing the ring gear (14), mark relative position of ring gear (14) and steering knuckle hous- ing (30) to facilitate installation in same location. Remove snap ring (10) from drive shaft sun gear. Unscrew retaining screws (16), then use four of the removed screws as jackscrews in threaded holes of the ring gear carrier (18) to push carrier (18) and ring gear (14) from hub (21) Bump hub (21) from steering knuckle (30). Remove cups for bearings (20 and 22) and seal (23) from hub, 19, Retaining ring 28. Boaring 20. Bearing 29, Belleville washer 21. Hub 30, Steering knuckle 22. Bearing 431. Upper retainer 23. Oi seal 82, Bushing 24, Grease fitting 33. Seal 25. Lower retainer 84, Axle shaft assy. 26. Shims (0.10, 0.19, 0:35 men) 35, Seal 2, Seal 36. Bushing Tfnecessary, remove inner bearing cone from knuckle housing. Clean and inspect all parts for excessive wear or other damage and renew as necessary. When reassembling, drive cups for bearings (20 and 22) and oil seal (23) into hub (21). If removed, install cone for inner bearing (22) on knuckle housing (30). Install hub (21) and cone for outer bearing (20) onto knuckle housing. Assemble ring gear (14) to carrier (18) and secure with retaining ring (19). In- stall ring gear (14) and gear carrier (18) and tighten, 15Paragraph 13 Fig. 13—Exploded view of front- wheel drive steering knuckle and heavy duty planetary assembly. Refer to illustration of standard ‘duty planetary assembly in Fig. 12 for legend except the following. 5. Needle rollers (28/gear) 7. Dowel pi 8. Thrust washers mounting cap screws (16) to 220 Nem (162 ft-Ibs torque. Install washer (12) and snap ring (10). Stick ‘thrust washer (9) in place on carrier (2) with “Loctite 638” or equivalent and install new “O” ring (15) in groove of hub (2). Install thrust washers (3), bearings, (5), planet gears (6) and thrust washers (8), then secure with retaining screws. Install planetary car- rier assembly and secure with the two Allen screws. Fill hub and planetary to the level of opening for drain/fill plug (1—Fig. 11) in carrier with “OTL LEVEL” mark (L) on carrier horizontal. Fill with Ford ESN-M2C134-D or equivalent. Install front ‘wheel and tighten dise to hub nuts to 270 N-m (200 ft-lbs.) torque. Disc to wheel rim nuts should be tightened to 240 Nom (177 ft-Ibs.) torque. STEERING KNUCKLE HOUSING All Four-Wheel Drive Models 13. R&R AND OVERHAUL. To remove either steering knuckle housing (0—Fig. 12 or Fig. 13), first remove planetary and wheel hub as outlined in 16 FORD paragraph 11 or 12. Disconnect tie rod from steering knuckle arm. Unbolt and remove steering knuckle retainers (25 and 31). Note that early axles use shims (26) to adjust vertical play of steering knuckle (30) and thickness of shims (26) located under each re- tainer should be recorded when disassembling to aid in reassembly. Later models are equipped with Belleville washers (29) that automatically adjust ver- tical play. The upper Belleville washer is the thicker of the two washers. Carefully remove steering knuckle housing (30) from all models. Axle shaft. and double “U” joint assembly (34) may be withdrawn with knuckle hous- ing. Lower bearing cone (28) may fall from lower retainer (25). Remove upper bearing cone (28), cap (81) and seal (27). Bearing cups can be removed if necessary. If desired, axle shaft and “U” joint assembly can be withdrawn for inspection or repair. If renewal is re- quired, oil seal (35) and bushing (36) can be removed from knuckle housing (30). Oil seal (33) and bushing (32) can be removed from axle housing. Bushings (32 and 36) should be pressed into position with externalMODELS 5640, 6640, 7740, 7840, 8240 & 8340 Fig. 14—Adjust the king pin bearings to obtain free play 0f 0-0.10 mm (0-0.004 in.). Refer to text. groove toward top and internal arrow-shaped grooves pointing toward inside of oil-filled housing (away from seal). Be careful not to damage seals (33 and 35) when installing axle and knuckle housing. Reassemble by reversing the disassembly proce- dure. On early axle originally equipped with shims (26), sufficient thickness of shims must be installed to provide king pin with 0-0.1 mm (0-0.016 in.) free play. To determine shim pack thickness required to set free play within specified limits, first position knuckle housing on axle housing and install upper retainer (31) without shims. Install lower retainer (25) with enough shims (26) to provide some end play and tighten upper and lower retainer mounting screws to 190 Nem (140 ft-lbs.) torque. Position a dial indicator as shown in Fig. 14 and check vertical play Paragraph 14 of king pin bearings. For example, if measured end play is 0.15 mm (0.006 in.), remove 0.10 mm (0.004 in.) shim to obtain end play within the desired limits. Divide shims (26—Fig. 13) equally at top and bottom, to center the assembly. Shims are available in 0.10, 0.19 and 0.35 mm (0.0039, 0.0075 and 0.0138 in.) thicknesses, Vertical play of steering knuckles on later models is controlled by Belleville washers (29) located be- tween axle center housing and cup of bearings (28) and no adjustment is necessary. The thicker of the two Belleville washers is installed on top knuckle bearing. Refer to paragraph 11 or paragraph 12 when reas- sembling hub and planetary. AXLE PIVOT BEARINGS All Four-Wheel Drive Models 14, REMOVE AND REINSTALL. To remove the axle pivot bearings, refer to paragraph 9 and remove the drive shaft, then refer to paragraph 10 and lower the front axle assembly. The front pivot bracket (1— Fig. 15) and rear pivot bracket (17) can be withdrawn, from the axle. Clean all parts, complete disassembly, if required, and inspect all parts for wear or damage. Use new “O” rings and seals when assembling. Tighten screws attaching front and rear pivot brackets (1 and 17) to 317-388 N-m (234-286 ft.-Ibs.) torque. Tighten steer- ing hose connections to 34 N.m (25 ft.-Ibs.) torque. Fig. 15—Partially exploded view of front-wheel drive pivot brackets. 1. Front pivot bracket 7.*0" ring 2. Bushing 8. Bushing 8. Sleeve 9, Oil seal 4. Thrust washer 10, Locating dowel 5. Thrust washer 17. Rear pivot 6. Sleeve bracket, 7Paragraphs 15-16 Fig. 16—View of removed differential assembly, showing marks (M) on the caps (C) and housing. Mark the caps so that they can be quickly identified for assembly to the correct side and in the correct position. DIFFERENTIAL All Four-Wheel Drive Models 15. REMOVE AND REINSTALL. To remove the differential assembly, refer to paragraph 9 and re- move the drive shaft. Refer to paragraph 10 and remove the front axle assembly. Refer to paragraph 13 and remove steering knuckle (30—Fig. 12 or Fig. 13) and axle shaft assembly (34) from both sides. Some mechanics prefer to remove the steering knuck- les and axle shafts before removing the axle from the tractor, to reduce the weight of the unit. The differen- tial housing contains the hydrostatic steering eylin- der which must be removed as outlined in paragraph 27. Unbolt and remove the differential carrier hous- ing (1—Fig. 17) from the axle center housing. When installing, apply Loctite 510 or equivalent sealer to mating surface of differential carrier hous- ing and axle housing. Tighten the ten retaining screws to 169 N.m (125 ft.-Ibs.) torque. Remainder of assembly and installation is reverse of disassembly procedure. 16. OVERHAUL. Before disassembling, mark both bearing eaps and housing as shown at (M—Fig. 16) to facilitate alignment when reassembling. Straighten tabs of both lock plates (13—Fig. 17), then. remove both cap serews (12), washers and lock plates. Loosen, but do not remove, the four screws attaching caps (C—Fig. 16), then unscrew adjusting rings (14). Remove both bearing caps and lift differential, bear- ing cups and adjusting rings from housing. Mark halves of differential case (16) before disas- sembling to facilitate alignment when reassembling. 18 FORD Remove screws (17) and remove ring gear (11). Case halves can be separated after removing screws (17). Assembly of original parts is easier if side gears (22) and clutch parts (23, 24 and 25) are kept together for each side and not mixed. Clean and inspect all parts for wear or other dam- ‘age. Lubricate all parts while assembling. Alternate the five external splined plates (24) and four internal splined discs (25). The internally splined thrust dise (28) is thicker (2.8 mm) than other dises and should be assembled next to side gear (2). Install thrust, washers (18), pinions (19) and shaft (20). Drive pin (21) in from ring gear side of differential case on two pinion differential. When assembling all models, align any previously affixed marks. Install ring gear (11), applying Loctite 270 or equivalent to screws (17) and tightening to 78 Nam (58 ft.-Ibs.) torque. Press bearing cones (15) onto case (16) until seated. When installing the differential and ring gear as- sembly, its necessary to check and adjust both back- lash and carrier bearing preload as follows: First measure rotating drag of bevel pinion shaft (10) using a spring scale with a string wrapped around the pinion shaft as shown in Fig. 18. Do not measure starting torque (force necessary to start pinion shaft turning), only measure the force necessary to keep pinion turning. Record the rotating drag measure- ment for later use, then install differential assembly in carrier housing and tighten bearing cap (C—Fig. 16) bolts tight enough to hold caps in place but allow adjuster rings (14) to be rotated. Turn adjuster rings to remove all free play between ring gear and bevel pinion gear. Preload of differential carrier bearings and gear backlash are both adjusted by turning ad- justing rings (14 and 14R). Backlash between bevel pinion and ring gear should 0.18-0.25 mm (0.007- 0.010 in.) and can be measured at face of ring gear with a dial indicator (D—Fig. 19). Turn adjuster rings (14) by equal amounts to move ring gear (11) away from pinion gear until desired backlash is obtained. Adjuster rings (14L and 14R—Fig. 17) should be tight and differential should rotate freely in carrier bear- ings (15) when checking backlash. Carrier bearing preload is correct when 3.2-4.7 Kg. (7-10 Ibs.) more rotational force is necessary to turn the pinion shaft than was necessary to turn only the pinion shaft when previously measured. Turn adjuster ring (14L) ‘opposite ring gear to increase or decrease bearing preload. It is important to check both rotational drag (as shown in Fig. 18) and bevel pinion to ring gear backlash (Fig. 19) after changing the position of either adjusting ring (14L or 14R—Fig. 17). ‘Tighten bearing cap (C—Fig. 16) bolts to 266 Nem (196 ft.-Ibs,) torque. Install adjuster ring lock plates (13—Fig. 17 or Fig. 18) and tighten locking plate retaining screws to 12 N.m (9 ft.-Ibs.) torque.MODELS 5640, 6640, 7740, 7840, 8240 & 8340 1. Housing 8. Bearing cup & cone 2 Nat (Same.s 4) 13. Lock washer 9, Shim (2.5-8.4 mm) 4. Bearing cup & cone 10. Bevel pinion (Same as 8) AL Ring gear 65, Washer (Same as 7) 12. Serewn 6. Spacer 13, Locking elips 1. Washer (Same as 5) 14. Adjusting ring BEVEL PINION GEARS All Four-Wheel Drive Models 17. REMOVE AND REINSTALL. To remove the bevel pinion gears (10 and 11—Fig. 17), refer to paragraph 9 and remove the drive shaft. Pry out pinion shaft oil seal (9—Fig. 15), then loosen pinion shaft nut (2—Fig. 17) using pinion nut wrench FT3168 or equivalent. Refer to paragraph 15 and remove the differential assembly. Refer to paragraph 16 and remove ring gear from differential. ‘To remove the bevel pinion (10—Fig. 17), remove ‘nut (2) and washer (3), then push pinion out toward inside. Cone of bearing (4) will slide from shaft as pinion is removed. The bevel pinion and ring gear must be renewed as a set. ‘Thickness of shims (9) should be selected to adjust mesh position of bevel pinion (10) if gear set (10 and 11), pinion bearings (4 and 8) and/or differential hous- Paragraph 17 \ @ oOo y. Hydrostatic steering cylinder is attached to housing pinion differential assembly shown in inset is used with AR, Adjusting ring 15, Bearing cup & cone 16, Differential ease 21. Roll pin 22, Side gears 223. Spacor (1 each side) 24, External spline plates (cach side) 18. Thrust washers 25, Internal spline dies 19, Pinion gears (Geach side) 20, Pinion shaft 26. Belleville washer Fig. 18—Measure rolling drag of bevel pinion shaft (10) using a spring scale (M) and string (S) as shown. 19Paragraph 17 (Cont.) Fig. 19—Measure backlash between ring gear and bevel pinion gear using a dial indicator. D. Dial indicator 11 Ring gear 1 a, __——G pL Blas Fig. 20—Cross section of differential housing showing ‘measurements required to accurately set pinion position. Refer to text for measuring distance (C) from bearing Inner race to center of carrier bearing bore. G. Depth gauge 1. Differential housing R Bearing retainer 4. Pinion bearings 8. Bar gauge 8. Pinion bearing ing (1) is renewed or if previous mesh position is questioned. Install cups for bearings (4 and 8) in housing (1), then position bearing cones in cups as shown in Fig. 20. Use a retainer as shown at (R) to hold cones tight in cups while measuring. Install both. carrier bearing caps and tighten the retaining nuts securely. Measure the diameter of the bearing bores, (A). Both bearing bores should be the same diameter, Position bar gauge (S), part of tool No. 3135, in bearing bores. Note that bar gauge can be fabricated using a metal or wooden dowel with a hole drilled through it so that depth gauge (G) can be inserted 20 Fig. 21—Bevel pinion mesh dimension (in millimeters) is etched on end of pinion shaft 1). Pinion serial number (2) is also etched on end of shaft. through the gauge as shown in Fig. 20, Measure the distance from the bar gauge to the inner flange of bearing (8) as shown at (B). Determine distance (C) from the center of the bearing bore to the bearing flange using formula B - D + (A+ 2)=C. ‘The following is an example of the shim thickness calculation: Divide bearing bore (A) diameter by 2, subtract diameter of gauge bar (D) from measure- ment (B), then add the results of these two calcula- tions to obtain dimension (C). If measurement (A) is 90,00 mm, measurement (B) is 90.35 mm and meas- urement (D) is 25 mm; 90.35 mm -25 mm +45 mm = 110.85 mm (C). ‘Th determine the thickness of shims to be installed at (9—Fig. 17), subtract the value (1—Fig. 21) stamped on pinion face from the calculated distance (C—Fig. 20). The result is the correct thickness of shim (9—Fig. 17). Example: 110.35 mm (C) - 107.25 mm (value on pinion gear) = 3.10 mm (shim thickness required). Install selected shim (9—Fig. 17) on pinion shaft (10) with chamfer toward pinion gear. Remove carrier bearing caps and bearing cones (4 and 8) from carrier housing (1). Install inner bearing cone (8) on pinion (10) against selected shim. Install washer (7), new (not yet collapsed) spacer (6) and washer (5) on pinion shaft (10) and insert into housing through the installed bearing cups. Install cone for bearing (4), lockwasher (3) and nut (2). ‘Tighten nut (2) until all play in bearings is just taken up, then measure rotating drag with a spring scale and string wrapped around the pinion shaft as shown in Fig. 18. Do not measure starting torque (force necessary to start pinion shaft turning), only meas- ure force necessary to keep pinion turning. Correct amount of rotational force measured by the springMODELS 5640, 6640, 7740, 7840, 8240 & 8340 Fig, 22—View of front-wheel drive transfer case installed. Solenoid energizing wire (1) is routed through tube to housing. Bracket (6) attaches drive shaft shield. seale should be within the range of 10.1-15.2 Kg. (22-83 Ibs.). Tighten nut (2—Fig. 17) to tighten bear- ings and increase rotational force. Note that bearing. adjustment is accomplished by crushing spacer (6), 16 5 al is: Paragraphs 18-19 and nut (2) should not be loosened unless a new spacer is installed. TRANSFER GEARBOX All Four-Wheel Drive Models 18. On SL and SLE model tractors, drive from the 12 12 or 16x 16 transmission to power front wheel drive axle is incorporated in the transmission. Refer to appropriate transmission paragraphs for service. Drive from transmission for front drive axle is from a transfer gearbox attached to bottom of transmission housing of models with 82 and 16 x4 transmissions (S model tractors). Refer to the following paragraphs for service to the transfer gearbox. Models With 8 x 2 And 16 x 4 Transmissions 19. R&R AND OVERHAUL. To remove the trans- fer gearbox, remove drain plug (38—Fig. 22) and allow cil to drain. Remove drive shaft as described in paragraph 9. Remove cover, disconnect wire (1) from the solenoid and disconnect wiring tube from side of housing. Detach hydraulic lines (6), position floor jack Fig. 23—Exploded view of four-wheel drive transfer gearbox used on mod- els with 8x 2and 16x 4 transmissions. 2. Control solenoid 24. Snap ring 4. Cover 25, Spring keeper 8. External oil line 26. Springs (4 used) 9. Retainer 21. Dog clutch, 10. Shim coupler 1. Bearing 28. *O" ring 12. Idler goar 29. °O" ring 13. Shim 30, Output shaft 14, Spacer 81. Gear and clutch 15, Bearing 82 Pilot valve 16. ‘assembly 7. Shaft 38. Thrust washer 34. Tapered roller bearing 95. *O" ring 36. Oil transfor tube 37, Bnd plate 28. Tapered 88. Drain plug roller bearing 39. Housing 21Fig. 24—Use appropriate sized sockets (S) and levers (L) to press against spring keeper (25) so that snap ring (24) ccan be removed. under the transfer gearbox, remove retaining screws ‘and lower transfer gear case from the tractor. ‘To disassemble the unit, remove the external oil line (8—Fig. 23), remove the nut from the solenoid and remove solenoid coil (2). After the solenoid coil is removed, the core and valve assembly can be removed from the housing. Remove socket head screw (18). It may be necessary to heat nut end (9) of screw to soften thread locking compound. Mark front side of idler gear (12) to assist reinstallation with same side toward front, then bump shaft (17) out. After shaft is removed, idler gear and shaft assembly (9-17) can be lifted out. Unbolt and remove output shaft end plate (20), being careful to collect and identify shims (22) to assist assembly. Unbolt and remove end plate (37) and oil transfer tube (36). Gently bump the output shaft (30) toward front, then toward rear to remove outer races of tapered roller bearings (23 and 34). Use sockets (S—Fig. 24) of a suitable size and levers (L) to depress spring keeper (25) far enough to remove snap ring (24). Remove the four springs (26—Fig. 23) after snap ring is removed from groove. Support gear (31) with spacers located between front of gear and front of housing (39), then, press shaft (30) toward front out of bearing (34). Remove bearing, thrust washer (33) and gear (31). With shaft extending from front, use a suitable puller to remove bearing (28). Slide snap ring (24) forward on shaft until it is removed. Move shaft (30) out toward rear, while removing spring keeper (25) and clutch coupler (27). Be careful not to lose or damage pilot valve (32). Clean and inspect all parts and renew any showing excessive wear or other damage. Pilot valve assembly (82) can be removed by blowing into the cross passage 22 FORD with compressed air. Springs (26) should be 48 mm (1.889 in.) long and must not be distorted. When reassembling, renew all “O” rings, seals and gaskets. Be sure that pilot valve assembly (32) is installed in end of output shaft (30) so that oil will pass through valve from transfer tube in end cover (37)into the shaft toward dog clutch (27), but will not flow the other direction. Reassemble by reversing disassembly procedure. Use oil on seals and make sure that “O” rings are not damaged while assem- ling. Assemble using shims (22) which were origi- nally used, but without oil seal (19) and “O” ring (21). Install and tighten cap screws retaining end plates (20 and 37) to 51 Nam (38 ft-lbs.) torque. Add or remove sufficient shims (22) to provide 0.1 mm (0.004 in.) preload. Check for correct bearing adjustment by ‘using a string wrapped around shaft and spring scale tomeasure rolling torque of shaft as shown in Fig. 25. When properly assembled using the correct thickness of shims (22—Fig. 23), measured rolling torque with- out seal (19) will be 1.9-4.5 Kg, (4.2-9.9 Ibs.). When correct shims have been selected, remove plate (20), install and lubricate new seal (19) and “O” ring (21), then reassemble. Tighten retaining screws to 51 Nem (88 ft-lbs.) torque, Install transfer tube and solenoid (2). Special tool T3169 (available from Ford) or equivalent is neces- sary to check and adjust idler gear bearings. Thick- ness of shims (13) adjust bearings (11 and 15) and thickness of shims (10 and 16) adjusts for fit between, lugs of housing (39). Make sure that outer races of bearings (11 and 15) are pressed tightly against shoulders of gear (12). Assemble bearings (11 and 15), spacer (14) and approximately 0.3 mm (0.012 in.) thickness of shims (13) on special tool. Make sure that screw of tool is tightened to 68 Nem (50 ft.-Ibs.) clamping bearing inner races, spacer and shims Fig. 25—Check rolling torque of transfer gearbox output shaft with string (S) and scale as shown.MODELS 5640, 6640, 7740, 7840, 8240 & 8340 Fig, 26—Check rolling torque of idler gear as described in text. Special too! FT 3169 is shown at (7). 11,15 Fig. 27—Measuring distance between idler gear bearing races. tightly together, then clamp the tool in a vise and check rolling torque as shown in Fig. 26. Correct rolling resistance is 0.45-1 Kg (1.0-2.2 Ibs.) and is, changed by varying the thickness of shims (18—Fig. 23). After the measured rolling resistance has been correctly set by installing the proper thickness of shims, measure distance between inner races as shown in Fig, 27. Measure distance between mount- ing lugs of housing as shown in Fig. 28, Subtract the thickness of bearings from the distance between lugs, then add shims (10 and 16—Fig. 23) equal to the result. Shims should be evenly divided (10 and 16) to center the gear. After selecting shims (10, 13 and 16), remove gear and bearing assembly from special tool and install | Paragraph 20 Fig. 28—Measuring width of idler gear mounting lugs. using the correct shims and shaft (17). Tighten screw (18) to 80 Nem (59 ft-lbs.) torque. Reinstall transfer gearbox by reversing the re- moval procedure. Use only approved gasket between transfer gearbox and rear axle center housing, be- cause its thickness sets the mesh position of idler gear (12) and mating gear. Tighten transfer gearbox re- taining screws to 66 Nem (49 ft.-Ibs.) torque. Apply Loctite 542 or equivalent thread locking compound to threads of drive shaft retaining screws and tighten to, 57 Nem (49 ft-lbs.) torque. Fill rear axle center hous- ing to level of dipstick with Ford ESN-M2C134-D or equivalent. FRONT SUPPORT All Four-Wheel Drive Models 20, REMOVE AND REINSTALL. ‘To remove the front support, the axle must be removed, the radiator must be removed from the support. and the front support must be unbolted from the front of engine. ‘The front axle, the front support and the remainder of the tractor must each be supported separately while removing, while separated and while assem- bling. Be sure that sufficient equipment is available before beginning. Refer to paragraph 67 and remove the main fuel tank, then refer to paragraph 87 and remove the radiator. Support front of tractor in such a way that it will not interfere with removal of either the front ‘support or the front axle. Refer to paragraph 9 and remove the drive shaft, then refer to paragraph 10 and remove the front axle assembly. Attach a hoist or 23Paragraphs 21-22 other supporting device to the front support, then unbolt and separate the front support from the front of the engine. Be careful not to lose or damage shims FORD located between front support and engine. Keep shims separate and label for installation in same location. HYDROSTATIC STEERING 21, Hydrostatic steering system is used on all mod- els and consists of a steering valve assembly, and one double-acting steering cylinder. In the event of hy- Graulic failure or engine stoppage, manual steering can be accomplished by the gerotor pump in the steering valve. FLUID AND BLEEDING All Models 22, Recommended steering fluid is Ford ESN- ‘M2C134-D hydraulic fluid or equivalent, which is contained in the rear axle center housing. The same fluid is also used for the transmission, rear axles and hydraulic lift system. Maintain fluid level between marks on dipstick (D—Fig. 29). Drain and refill res- ervoir with new fluid every 1200 hours of operation or once each year. Drain plug is located at bottom center of rear axle center housing. It is recommended that hydraulic filters be changed every 300 hours of ‘operation or whenever fluid is suspected of contami- nation ‘On models with tandem gear pumps, main hydrau- lic system filter (1—Fig. 30) is located on right side under the floor. Auxiliary hydraulic filter (2—Fig. 31) Fig. 29—The transmission, rear axles and hydraulic lift system share @ common fluid that uses the rear axle ‘center housing as a reservoir. Maintain fluid level between ‘marks on dipstick (D) and fll through opening for plug (F). 24 Fig. 30—View of main hydraulic system filter installed on ‘models with tandem gear pump. Auxiliary filter (2—Fig. 31) Is installed on these models if also equipped with ‘engine mounted auxiliary pump. Filter is located on right ‘side under floor. Switch (V) Indicates blocked filter, and switch (7) is the low temperature switch which stops blocked filter indicator from lighting when temperature is. below 40° C (104" F). Low pressure switch Is located to the rear ot switch (7). Fig. 31—View of auxiliary hydraulic filter installed on models with tandem gear pump and engine mounted ‘auxiliary pump. Filter is located on left side under floor.MODELS 5640, 6640, 7740, 7840, 8240 & 8340 Fig. 32—View of system filters for models equipped with CCLS (Closed Center Load Sensing) hydraulic system. Steering pump inlet filter is located at (1), charge pump inlet filter is located at (2) and charge system pressure filter is located at (3). Filters are located on right side. is located on left side under the floor of models with tandem gear pumps and engine mounted auxiliary pump. On models with CCLS (Closed Center Load Sens- ing) hydraulic system, the three hydraulic filters are located on right side under the floor as shown in Fig. 32, The steering pump inlet filter is located at (1) and charge pump inlet and pressure filters are located at (2 and 3). All hydraulic systems use the same fluid and all filters should be renewed at the same time. ‘The hydrostatic steering system is self bleeding. When the unit has been disassembled, refill with new oil, start engine, then cycle the system several times by turning the steering wheel from lock to lock. Re- check fluid level (Fig. 29) and add fluid as required. TROUBLESHOOTING All Models: 23. Some of the problems which may occur during ‘operation of power steering and their possible causes are as follows: 1. Steering wheel hard to turn. Could be caused by: a. Air in system. Check for loose connections or damaged lines, especially on inlet side. Also check for low fluid level. b. Low system pressure. Check steering relief valve setting, . Worn or otherwise defective power steering pump. 4. Leaking steering cylinder. e, Broken or damaged steering column coupling. £ Worn, binding or otherwise damaged control valve (metering) spool and sleeve. Paragraphs 23-24 g. Mechanical parts of front steering system bind- ing. 2. Steering wheel turns on its own. Could be caused by: a, Leaf springs in control valve weak or broken. 3, Steering wanders or steering surges when steering. Could be caused by: a. Excessive play in steering joints. b, Leaking steering cylinder. ¢. Worn or otherwise damaged control valve (me- tering) spool and sleeve. 4. Tractor steers in wrong direction. Could be caused by: a. Hoses to steering cylinder incorrectly con- nected. b. Incorrect timing of control (metering) valve drive shaft to rotor. TESTS AND ADJUSTMENT All Models 24, SYSTEM PRESSURE AND FLOW. The pres- sure relief valve for the hydrostatic steering system is located in the steering control valve. Oil returning from the steering control valve is directed to the lubrication circuit for the 16 x 16 transmission (via the oil cooler) or the pto clutch lubrication circuit. A by-pass valve (2—Fig. 33) is installed to redirect oil flow if the cooler is blocked, or if the oil temperature is lower (colder) than 68° C (155° F). Return oil will by-pass the oil coolerif pressure is above 690 kPa (100 psi. A simple test of steering system pressure can be performed as follows. Run engine at 1000 rpm and turn steering wheel from lock to lock. If system is Fig. 33—View of oll cooler by-pass valve (2). Line (1)routs oll from the steering control valve to the by-pass valve, line (3) directs oil to cooler and line (4) is return oll from cooler. Line (5) delivers oll to the transmission and rear axle lubrication circuit. 25Paragraph 24 (Cont.) Fig. 34—To check steering pump flow on tractors equipped with fixed displacement tandem gear pumps, disconnect tubes to steering valve and connect flow me- ler fo pressure and return fittings (1 and 2). operating satisfactorily, the steering should react quickly, with no time delay. If steering is slow or imprecise, make sure that tractor, especially front axle, is not overloaded. The system relief valve should be heard to blow when steering is against either lock and engine speed will normally fall slightly when relief valve is opening. More precise tests of steering pressure and flow are possible with pressure gauge and flow meter. To check pump flow, proceed as follows: On models equipped with variable displacement CCLS hydraulic pump, disconnect all four lines (1, 3, 4 and 5—Fig. 33) from the oil cooler by-pass valve and cover lines (3 and 4) to oil cooler to prevent entrance of dirt. Attach flow meter between the return line (1) from steering con- trol valve and line (5) to the transmission lubrication circuit. On models equipped with fixed displacement tandem gear pumps, disconnect pressure line (1— Fig, 35—Attach pressure gauge (G) as shown to steering ine (L) which has been detached from cylinder. 26 FORD Fig. 34) to steering motor and return line (2) from steering motor. Connect flow meter inlet to pressure fitting and flow meter outlet to return fitting. NOTE: Flow meter used to check steering pump. flow on models equipped with fixed displacement tandem gear pumps must be capable of withstand- ing 2000 kPa (300 psi) back pressure. On all models, make sure that flow meter valve is open, then start engine and operate at 2100 rpm. Run engine until hydraulic oil temperature reaches nor- mal operating temperature of approximately 68° C (155° F). Tarn the front wheels to one extreme against lock, and observe gauge reading indicating volume of flow. CAUTION: When checking system flow or reliet pressure, hold the steering wheel against lock only ong enough to observe pressure indicated by gauge. Pump may be damaged if steering wheel is held in this position too long or if flow is otherwise stopped. Specifie volume of output is different between vari- ous tractors, but pump should be removed from all models and serviced if flow is less than 31 L/minute (8.2 gpm) ‘To check relief pressure, first turn steering wheel fully to the left and stop engine. Disconnect left turn hose (L—Fig. 35) from steering cylinder and attach a suitable (G) pressure gauge as shown. Start engine and set engine speed to 1450 rpm, turn steering wheel to full left: turn lock and observe the indicated pres- wre. Correct pressure is 15,300-16,300 kPa (2220- 2370 psi) for two-wheel drive 5640, 6640, 7740 and 7840 models. Correct pressure is 18,000-19100 kPa (2620-2770 psi) for all other models. ‘To change relief valve setting, it is first necessary to remove the steering control valve as outlined in paragraph 29, Turning the relief valve spring seat (34—Fig. 36) IN, increases the pressure against spring (35) and increases system relief pressure. Spring seat (34) is accessible after removing plug (32). To adjust relief pressure, fabricate hoses to connect from tractor pressure line (P) and return line (T) to pressure and return ports of steering control valve. Install tee fittings with pressure gauges (A and B) in the fabricated hoses. Cap the other two (steering cylinder) ports (E) of steering control valve. With engine running at 1500 rpm, turn steering motor shaft (21) to full lock position. Pressure gauge (A) reading should be approximately 16,000 kPa (2350 psi) for two-wheel drive models and 19,000 kPa (2750, psi) for four-wheel drive models. Gauge (B) reading should be about 1725 kPa (250 psi) for all models. If pressure readings are not correct, adjust relief valve spring seat (34) as necessary to obtain desired pres- sure setting. Half a turn of spring seat should change pressure setting approximately 1400 kPa (200 psi). Once pressure is correctly set, apply small amount ofMODELS 5640, 6640, 7740, 7840, 8240 & 8340 Fig. 36—To adjust steering relief pressure, steering con- trol valve must be removed from tractor. Turn spring seat (34) inward to increase pressure. Refer to text for com- plete procedure. A. Pressure gauge B. Pressure gauge 21. Steering motor shaft C: Pressure line 82. Ping D, Return line 34, Spring seat EB, Steering cylinder ports 35. Spring F Stooring cylinder lines 36. Relief valve poppet @i;z2 Paragraphs 25-26 thread locking compound to spring seat to lock it in place. PUMP All Models 25. The pump for the hydrostatic steering is incor- porated with the main hydraulic pump. Refer to the appropriate paragraph 254 or 268 for removal and service. POWER CYLINDER ‘Two-Wheel Drive Models 26, R&R AND OVERHAUL. The steering cylin- der is attached between axle center member and the tie rod. To remove the cylinder, disconnect hydraulic hoses at steering cylinder and cover openings to pre- vent entrance of dirt, then detach both ends of the steering cylinder. Clamp rod end (1—Fig. 37) in a vise or holding fixture, remove clamp screw (2) and unscrew piston rod (8) from rod end. Remove clamp (13) and rod end (15) from opposite end of piston rod. Clamp cylinder (3) in a holding fixture that will not crush or other- wise deform cylinder, then unscrew extension tube and gland assembly (12). Pull piston and piston rod (8) from the cylinder. Inspect cylinder and piston for wear or damage Renew all “O” rings and seals. Heating piston seal (5) in hot water or oil will make assembly onto piston Fig. 37—Exploded view of steering cy!- inder used on two-wheel drive models. 1. Rod end 9, Bushing 2. Clamp serew 10, *0" ring 3. Cylinder LL. Back-up ring 4. Wear ring 12, Extension tube 5. Piston seal & gland assy, 8. *0" ring 413, Clamp 7. Rod seal 414. Clamp screw 8. Piston & rod 15, Rod end 15Paragraph 27 Fig. 38—View of left end of four-wheel drive steering cylinder, showing the correct location of Allen screw (A) and cap screws (S). easier, Allow seal to contract before installing piston into cylinder. When assembling, lubricate all seals and “O" rings with clean hydraulic fluid. Tighten gland (12) to eyl- inder to 271 Nem (200 ft.-Ibs.) torque. After installing cylinder, turn wheels to full right turn lock, then adjust steering cylinder length so that ends are aligned when steering rod is extended 4-10 mm (0.15-0.4 in.) from fully compressed position. Start engine and turn wheels from lock to lock several times to purge air from cylinder. Check front wheel toe-out as outlined in paragraph 2. FORD Four-Wheel Drive Models 27. REMOVE AND REINSTALL. The double-act- ing hydrostatic steering cylinder used on four-wheel drive models is attached to the front drive differential housing by four screws as shown at (A and S—Fig. 38). To remove the steering cylinder, loosen the four attaching screws approximately two turns, then turn the steering wheel to the left to unseat the cylinder. Jack up front of tractor and remove the left front wheel. Loosen bolts (2—Fig. 39) that clamp tie rod ends (3) onto balll joint rods (4). Detach rod ends from both steering arms, then remove ball joint ends from both ends of steering cylinder rod. Disconnect steer- ing hoses from cylinder and remove fitting from right end of cylinder. Remove cylinder retaining screws (A and S—Fig. 38), then withdraw complete cylinder from left side. When reinstalling, reverse removal procedure. In- stall the three hex head retaining screws (S) in the locations shown in Fig. 38 and tighten to 94 Nem (69 ft-lbs.) torque. Apply Loctite 542 or equivalent to threads of the Allen head retaining screw (A), install screw and tighten to 94 Nem (69 ft-lbs.) torque. Reattach rod ends to steering cylinder rod and tighten to 176 Nem (130 ft-lbs.) torque. Attach rod ends to steering arms and tighten nuts to 176 Nem (130 fe-Ibs.) torque. Reconnect steering hoses and tighten connections to 34 Nm (25 ft.-Ibs.) torque Refer to paragraph 7 to adjust front wheel toe-in, Fig, 39—Exploded view of power steer- ing cylinder used on four-wheel drive models. 1. Cap serew 17. End plate 2 Clamp bolt 8, Seal ring 3, Tie rod 9, Piston & rod 4, Ball joint rod 10. Seal ring 5. Wiper seals 11. Gylinder 6. Piston rod seals 12, Carrier housingMODELS 5640, 6640, 7740, 7840, 8240 & 8340 28, OVERHAUL. To disassemble removed steer- ing eylinder, unscrew ball joint ends (4—Fig. 39) from, ‘each end of steering rod (1). NOTE: Ball joint ends (4) may be locked with “Loctite” and heat must be applied to area before unscrewing from piston rod (8). Pull on end of piston rod (9) to remove end plate (7) and other internal parts from cylinder (11). Remove the piston seal and expander from piston, Remove wiper seals (5) and piston rod seals (6). Clean and inspect all parts for excessive wear, scoring or other damage and renew as necessary. Note that piston rod (9) and cylinder (11) are serviced as an assembly. Reassemble cylinder by reversing the disassembly procedure, observing the following: Always use new “O” rings, scraper rings and seals when reassembling. Aer installing piston seal on piston, allow seal to contract before installing piston in cylinder. Lubri- cate parts with clean hydraulic fluid during assembly. ‘Tighten the three retaining cap screws and one Allen, head screw (4) to 94 Nem (69 ft-lbs.) torque. Reattach rod ends to steering cylinder rod and tighten to 176 Nem (130 ft.-Ibs.) torque. Tighten slot- ted nuts of tie rod ends attached to steering knuckles to 1760 N.m (130 ft-lbs.) torque. If necessary, adjust. toe-in to 0-13 mm (0-0.5 in.) as outlined in paragraph 7, Tighten clamp screw nuts (2) to 43 Nem (82 ft-lbs.) torque. STEERING VALVE All Models With Hydrostatic Steering 29, REMOVE AND REINSTALL. The steering control valve is located at the base of the steering wheel shaft. To remove the steering control valve, first remove the exhaust pipe, engine side panels and hood. Unbolt and remove the combination brake and clutch reservoir, starter relay, and battery ground cable from the firewall. Remove the three screws attaching firewall to the cylinder head. If equipped with cab, the three firewall to cylinder head screws, will be accessible through side of steering console from inside cab, Detach the four lines from steering, control valve and remove the roll pin attaching steer- ing shaft to steering valve drive collar. Cover open- ings in lines and passages to prevent entry of dirt. Remove the instrument panel, then unbolt and re- move the steering control valve through the engine compartment. Reinstall by reversing the removal procedure. ‘Tighten all mounting screws and steering hoses to 18-20 Nem (10-15 ft.-Ibs.) torque. Start engine and purge air from the system by turning the steering Paragraphs 28-30 wheel from lock to lock until the system operates properly. 30. OVERHAUL. Remove steering valve as de- scribed in paragraph 29, then thoroughly clean exte- rior of unit. Unbolt and remove steering column, then, place steering valve in a special holding fixture, Re- move the seven cover retaining screws (10—Fig. 40). Fig. 40—Exploded view of hydrostatic steering valve with integral pressure relief valve (34 through 36). Notice that the two outer springs (235) are straight. 1. Drive shaft 17. Bearing race 2 Spacer 18, Thrust bearing 8.0" ring 19, 4. Distributor plate 20, 5.0" ring 21 6 Rotor 2, 1. Stator 28. Leaf springs (4) 8.*O" ring 238, Flat leaf springs (2) 9, End cover 24, Retainer ring 10. Cap serow (7) 32. Plog 11, Seal rings 38. ‘O° ing 12, Seal 34. Adjusting plug 418, Check valve ball 36, Relief valve spring 14, Cheek valve plug 36. Relief valve 15, Housing 837, Suction valve ball 16, Seal 838, Suction valve pin 29Paragraph 30 (Cont.) BS Fig. 41—Arch of the four center leaf springs (23) should bbe together and the flat springs (23S) should be on the outside as shown. Remove cover (9), stator (7), rotor (6), spacer ring (2), and “O" rings (6 and 8). Remove distributor plate (4), drive shaft (1) and “O” ring (3). Suction valve parts (87 and 38) will fall from threaded holes. Unscrew check valve plug (14) and remove check valve ball (13), Hold steering valve vertically and turn valve spool and sleeve to align cross pin (20) parallel to flat, side of housing. With cross pin in this position and housing in horizontal position, remove sleeve (22), spool (21), thrust bearing (18) and bearing races (17 and 19) from housing. Remove cross pin (20) from rotary valve and separate spool (21) from sleeve (22). Remove leaf springs (23 and 23S) from spool. Remove oil seal (12) from valve body. If necessary, the pressure relief valve (32 through 36) can be removed after unscrewing plugs (32 and 34); however, pressure must be checked and adjusted. if plug (34) is turned. Steering relief pressure is, adjusted by turning plug (34). Clean and inspeet all parts for excessive wear or other damage and renew parts as necessary. Housing (15), spool (21) and sleeve (22) are available only as an assembly. Use all new “O” rings and seals when reassembling. Lubricate all interior parts with clean, hydraulic fluid. Insert spool (21) into sleeve (22), aligning leaf spring slots and insert eross pin (20) into sleeve and spool. Insert the four arched springs (23) between the two flat springs as shown in Fig. 41. Insert flat springs, slide arched springs in position, then install retainer (24—Fig. 40) over the leaf springs. Place thick bearing race (19), thrust bearing (18) and thin 30 FORD Pin Center Line Fig. 42—The center line of pin (20—Fig. 40) should aligned perpendicular to the port face of housing shown when assembling. Refer to text. @® ON (0) @) o © @ ® Fig. 43—The one screw with pin attached should be In- ‘stalled in position (7). Numbers indicate the order which screws should be tightened. bearing race (17) on spool. Be sure that bearing race (19) is installed with chamfer toward valve sleeve (22). Use Danfoss No. SJ.150-9000-11 tool or equiva- lent to install the seal assembly (12 and 16) into position in the steering valve housing (15), then in- sert the complete valve spool assembly into housing. Lubricate the “O” ring (3) and install in groove of housing, followed by valve plate (4). Make sure that all ofthe holes in valve plate and housing are aligned. Turn the valve spool assembly so that pin (20) is perpendicular to the flat port face of housing (15) where hoses attach. Insert the check valve ball (13) and plug (14) into the hole indicated in Fig. 42. Insert the suction valve balls (37) and pins (38) into the two holes indicated. Scribe a reference line across splined end of rotor shaft (1) parallel with the groove at otherMODELS 5640, 6640, 7740, 7840, 8240 & 8340 end for pin, Be sure that valve spool pin is still perpendicular to the port face of the housing and install the rotor shaft as shown in Fig. 42. When correctly assembled, two lobes of the rotor (6) will be positioned evenly toward port face (up in Fig. 42) when pin center line is located as shown. Install “O” ring (5—Fig. 40), pump body (7) and pump rotor (6). Install spacer (2), “O” ring (8) and end cover (9). Install the seven retaining screws (10). The one screw with the pin attached should be in location identified as “7” in Fig. 43. Tighten the screws in the order shown in Fig. 43, first to 11 N.m (8 ft.-Ibs.), then to Fig. 44—Disconnect points on right side of tractor for split ‘between engine and transmission. 1. Support bracket 2. Heater hose 3. Starter 4 Foel supply 5, Fuel shut-off cable 6. Throttle cable 7. Heater shutoff valve Fig. 45—Disconnect points on right side of tractor for split between engine and transmission. 1. Steering lines 2 Transmission ol cooler ines 8. Engine oil cooler lines Paragraph 31 28.4 Nem (21 ft-lbs.) torque. Install relief valve as- sembly (32 through 36—Fig. 40) ifremoved. Ifsetting of plug (34) has been disturbed, refer to paragraph 24 for checking and adjusting relief valve pressure, ENGINE AND COMPONENTS R&R ENGINE AND CLUTCH All Models 31. Disconnect battery cables. Remove engine side panels, exhaust pipe, hood top panels and engine fan side shields. Disconnect wiring harness from starter motor, then unbolt and remove starter motor (3—Fig. 44), Disconnect engine wiring harness from mein harness at connector located at rear of engine, or disconnect wiring from alternator, engine sensors, radiator and fuel tank and move wiring clear of the engine. Disconnect fuel supply line (3). Disconnect the foot throttle control cable (5) and hand throttle control cable (6). If equipped with mechanical fuel shut-off, disconnect fuel shut-off cable. Remove bolts attaching support bracket (1) to engine rear plate. Disconnect hydrostatic steering lines (1—Fig. 45) to steering cylinder. Disconnect transmission oil cooler lines (2). If engine is to be separated from front end, disconnect engine oil cooler line (3). On models with cab, close heater water control valve (7—Fig. 44) and disconnect and plug the heater supply hose (2) and return hose (6—Fig. 46). If Fig. 46—Disconnect points on left side of tractor for spilt between engine and transmission. 1. Fuel transfor tube 2. Hydraulic inlet tube 8. Hydraulic outlet tube 5. Heater hose 6, Fuel return line 7. Engine oil cooler line 31 4. Air conditioner self sealing fittingsParagraph 32 equipped with air conditioner, disconnect refrigerant lines at self-sealing fittings (4) Ifequipped with side mounted fuel tank, drain fuel and disconnect fuel transfer hose (1—Fig. 46) located between side tank and front tank. Disconnect fuel return line (6). If equipped with engine mounted hydraulic pump, disconnect pump inlet tube (2) and outlet tube (3). Ifengine is to be separated from front end, disconnect engine oil cooler line (7). Use split support stands designed for this series of tractors, if available. Remove weights from front end. Insert wedges hetween front axle and front support to prevent tipping. If equipped with front-wheel drive, remove the front axle drive shaft. Place sup- ports under the front end of transmission housing ‘and support engine so that engine and front axle ‘assembly can be moved forward away from transmis- sion, Remove the engine to transmission housing cap screws, then carefully move engine and front axle assembly straight forward away from transmission and rear part of tractor. ‘To separate engine from front axle support, discon- nect fuel supply and return lines. Drain cooling sys- tem, then disconnect radiator hoses. If equipped with air conditioner, unbolt and remove air conditioner compressor from engine. Note that it is not necessary to disconnect refrigerant lines from compressor. Move and secure the compressor so that it can be removed with the front axle support. Be sure that both the engine and front axle are securely supported, then remove serews attaching engine to front axle support and separate. Reassemble tractor by reversing the disassembly procedure. Note that it may be necessary to rotate the flywheel or transmission input shaft slightly to align shaft splines with clutch disc splines during reassem- bly. CYLINDER HEAD All Models REMOVE AND REINSTALL. To remove the cylinder head, proceed as follows: Disconnect battery cables. Remove engine side panels. Remove the ex- haust pipe and mufller. Remove the hood panels. Drain engine coolant, then disconnect radiator top hose. If equipped with cab, close heater hose shut-off valves, then disconnect and plug heater hoses. Re- move the air cleaner to intake manifold tube. Remove the air cleaner assembly. Remove the turbocharger from 7740 and 8340 models. On all models, close fuel supply valve at tank and remove the complete fuel filter assembly. Remove fuel injectors as outlined in paragraph 78. Remove the intake manifold. Remove the alternator. Remove air conditioner compressor, if equipped, from engine. It is not necessary to discon- nect refrigerant lines from the compressor, Remove 32 FORD radiator as outlined in paragraph 87, then remove water pump as outlined in paragraph 88. Detach ventilation tube from rocker cover, remove rocker cover, then remove rocker arm assembly and push rods. Remove the eylinder head retaining screws, then lift cylinder head from engine. NOTE: If cylinder head gasket has failed, check the mating surfaces of the cylinder head and block for flatness or evidence of erosion. Cylinder head should be flat within 0.03 mm (0.001 in,) in any 25.4 mm (1 in,) length or a maximum of 0.127 mm (0,005 in.) overall. Cylinder head surface may be machined lightly if not within specified flat- ness or surface is rough, but valves must not be too close to gasket surface and cylinder head retaining screws must not bottom in threaded holes in block. Depth of inlet valve face from head gasket surface of cylinder head should be within the range of 0.86- 1.32 mm (0.034-0.052 in.). Depth of exhaust valve face should be within the range of 1.2-1.6 mm (0.047- 0.065 in.). Check cylinder head mounting screws for bottom- ing as follows: Turn crankshaft until none of the pistons are at TDC, then install cylinder head on block without gasket. Install and hand tighten eylin- der head retaining screws, including those which pass through rocker shaft stands. Measure clearance between bottom face of each bolt head and cylinder head by attempting to insert a 0.25 mm (0.010 in.) feeler gauge between screw and cylinder head. If clearance exceeds 0.25 mm (0,010 in.), use a %g-13 UNC-2A thread tap to increase the thread depth, or renew cylinder head. Cylinder block should be flat within 0.03 mm (0.001 in.) in any 152 mm (6 in.) length or a maximum of 0.08 mm (0.003 in.) overall. Cylinder block may be machined lightly if not within specified flatness, but top of piston at TDC must not stand more than 0.58, mm (0.023 in.) above the gasket surface of naturally aspirated engines, or more than 0.3 mm (0.012 in.) above gasket surface of turbocharged engines. If block is surfaced, be sure to check head retaining screws for bottoming as described in the previous paragraph, ‘Do not use gasket sealer or compound when reas- sembling and be sure that head gasket is correctly positioned on the two dowel pins. Install rocker arms and shaft as outlined in paragraph 33. Lubricate cylinder head retaining screws before installing, then tighten in three steps following sequence shown in Fig. 47 or Fig. 48. First tighten serews to 156 N-m (116 ft-Ibs.); second tighten all screws to 190 Nem (140 ft.-Ibs.); then tighten screws to 217 Nem (160 ft-lbs.) final torque. Cylinder head retaining screws should only be tightened when engine is cold. Adjust valve clearance as described in paragraph 34. Reas- semble by reversing disassembly procedure. TightenMODELS 5640, 6640, 7740, 7840, 8240 & 8340 Paragraphs 33-34 Fig. 47—Cylinder head retaining screws for four-cylinder engines should be tightened in sequence ‘shown. Reler to text for torque value and procedure. Fig. 48—Cylinder head retaining screws for six-cylinder engines should be tightened In sequence ‘shown. Refer fo text for torque value FRO inlet manifold retaining screws to 35 N.m (26 ft.-Ibs.), exhaust manifold screws to 38 N-m (28 ft.-Ibs.) and exhaust pipe to flange nuts to 31 Nem (23 ft-lbs.) torque. Reinstall rocker arm cover retaining screws to 24 Nem (18 ft-lbs.) torque. Bleed fuel injection system as outlined in paragraph 71 ROCKER ARMS All Models 93, The rocker arms can be removed after removing rocker arm cover. Loosen the cylinder head screws that retain the rocker arm assembly (Fig. 49) evenly and alternately. Five screws are used on four cylinder ‘even screws on six cylinder models. Lift the cylinder head bolts, shaft and rocker arms away from. the engine as an assembly. Remove the cylinder head bolts from rocker sup- ports, then separate components from rocker shaft. Rocker arms and shaft should not show excessive wear. Inside diameter of new rocker arm is 25.48- 25.50 mm (1.003-1.004 in.) and diameter of new shaft is 25.40-25.43 mm (1.000-1.001 in.). Inside diameter of supports should be 25.45-25.50 mm (1.002-1.004 in). When reassembling, be sure that notch (N—Fig. 49) is up and toward frontend of engine so that rocker arm oiling holes will be correctly positioned. Back each of the rocker arm adjusting screws (4) out two turns before installing on engine. Tighten the rocker and procedure. support retaining screws evenly until seated against, head, then tighten to the recommended torque as outlined in paragraph 32. Adjust valve clearance as, described in paragraph 34. Reinstalll rocker arm cover retaining screws to 24 N.m (18 ft-Ibs.) torque. VALVE CLEARANCE All Models 84, CHECK AND ADJUST. Valve clearance (tap- pet gap) should be set with engine cold. Correct clearance is 0.36-0.46 mm (0.014-0.018 in.) for inlet; 0,430.53 mm (0.017-0.021 in.) for exhaust valves. ‘There are two different procedures that can be used when checking and adjusting valve clearance. The following procedure requires stopping the crankshaft at four specific positions for four eylinder models (firing order 1-3-4-2), or six specific positions for six cylinder models (firing order 1-5-3-6-2-4). To adjust, loosen flywheel timing hole cover retaining screw (located on right side of engine rear plate) and swing cover out of the way. Turn crankshaft until 0° mark on flywheel is aligned with timing hole, then check the two front (No. 1 cylinder) rocker arms. If rocker arms are loose (valves closed), front (No. 1) piston is, at top dead center of compression stroke, If two front rocker arms are not loose, rotate crankshaft one com- plete turn and recheck rocker arms. Use a feeler gauge (1—Fig. 50) to measure clearance between rocker arm (2) and valve stem end (3) for No. 1 33