TM1941 (Manual de Taller Jhon Deere 350 y 400D

350D and 400D Articulated
Dump Truck
BELL—(200311-201811)
Tier2;
DW—(601341-608489)
REPAIR TECHNICAL MANUAL
Articulated Dump models 350D, 400D Bell-(200311—201811) DW-

(601341—608489)
TM1941 09 FEB 15 (ENGLISH)
For complete service information also see:

350D and 400D Articulated Dump Truck BELL—(200311-201811) Tier2;
TM1940
DW—(601341-608489) Diagnostic
Super Caddy Oil Cleanup Procedure CTM310
120 Series Hydraulic Cylinders CTM120519
120 Series Hydraulic Cylinders CTM114319
COOLANT HEATER SERVICE MANUAL CTM10090X19
John Deere Construction and Forestry

Pinted by Belgreen
TM1941-REPAIR TECHNICAL MANUAL (g) by Belgreen v2.5
Table of contents
FOREWORD
TECHNICAL INFORMATION FEEDBACK FORM
Section 00 - GENERAL INFORMATION
Group 0001 - Safety
Section 01 - WHEELS
Group 0110 - Removal and Installation
Section 02 - AXLES AND SUSPENSION SYSTEMS
Group 0210 - Differential or Bevel Drive
Group 0225 - Input Drive Shafts and U-Joints
Group 0242 - Axle Mounting Parts
Group 0250 - Axle Shaft, Bearings, and Reduction Gears
Section 03 - TRANSMISSION
Group 0350 - Gear, Shafts, and Power Shift Clutches
Group 0360 - Hydraulic System
Section 04 - ENGINE
Group 0401 - Crankshaft, Main Bearings, and Flywheel
Group 0402 - Camshaft and Timing Gear Train
Group 0403 - Cylinder Block, Liners, Pistons and Rods
Group 0407 - Lubrication System
Group 0409 - Cylinder Head and Valves
Group 0410 - Exhaust System
Group 0413 - Fuel Injection System
Group 0414 - Air Intake Manifold System
Group 0416 - Turbocharger
Group 0417 - Cooling System
Group 0418 - Thermostats, Housing and Water Piping
Section 05 - ENGINE AUXILIARY SYSTEM
Group 0520 - Intake System
Group 0530 - External Exhaust Systems
Group 0540 - Engine Mounting
Group 0560 - External Fuel Supply Systems
Section 07 - CONNECTOR DRIVE (FLEXPLATE)
Group 0752 - Elements
Section 08 - TRANSFER DRIVE
Group 0851 - Gear Shafts and Bearings
Section 09 - STEERING SYSTEM
Group 0930 - Secondary Steering
Section 10 - SERVICE BRAKES
Group 1011 - Active Elements
Section 11 - PARK BRAKE
Section 17 - FRAME AND SUPPORTING STRUCTURE
Group 1740 - Frame Installation
Section 18 - OPERATOR′S STATION
<- Go to Global Table of contents TM1941-REPAIR TECHNICAL MANUAL
Group 1810 - Operator Enclosure

Group 1821 - Seat and Seat Belt
Group 1830 - Heating and Air Conditioning
Section 19 - SHEET METAL AND STYLING
Group 1910 - Hood or Engine Enclosure
Section 21 - MAIN HYDRAULIC SYSTEM
Section 22 - PNEUMATIC SYSTEMS
Group 2261 - Pumps and Drives
Group 2262 - Control Valves
Group 2264 - Reservoir, Filter, and Trap
Group 2265 - Cylinders
Section 35 - HAULAGE DEVICE
Group 3540 - Frames
Section 99 - DEALER FABRICATED TOOLS
Group 9900 - Dealer Fabricated Tools

Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified
in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text
of the manual.
CAUTION:
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for
personal injury.
Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.
Operation and tests sections help you identify the majority of routine failures quickly.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are
summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service
parts kits, specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information
needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of
troubleshooting, general maintenance, and basic type of failures and their causes.

GENERAL INFORMATION (g) by Belgreen v2.0
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.
Technical Manual Fax
SEND TO: John Deere Dubuque Works
18600 South John Deere Road
Attn: Publications, Dept. 324
Dubuque, IA 52004-0538
USA
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<- Go to Section TOC Section 00 page 1 TM1941-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Table of contents
Group 0001 - Safety ................................................................................................................................. 1
Recognize Safety Information ............................................................................................................... 1
Follow Safety Instructions ..................................................................................................................... 1
Operate Only If Qualified ...................................................................................................................... 1
Wear Protective Equipment .................................................................................................................. 3
Avoid Unauthorized Machine Modifications .......................................................................................... 3
Inspect Machine ................................................................................................................................... 3
Stay Clear of Moving Parts ................................................................................................................... 4
Avoid High-Pressure Oils ...................................................................................................................... 4
Beware of Exhaust Fumes .................................................................................................................... 5
Prevent Fires ........................................................................................................................................ 5
Prevent Battery Explosions ................................................................................................................... 6
Handle Chemical Products Safely ......................................................................................................... 6
Dispose of Waste Properly .................................................................................................................... 6
Prepare for Emergencies ...................................................................................................................... 7
Use Steps and Handholds Correctly ..................................................................................................... 7
Start Only From Operator′s Seat ........................................................................................................... 8
Use and Maintain Seat Belt .................................................................................................................. 8
Prevent Unintended Machine Movement .............................................................................................. 8
Avoid Work Site Hazards ...................................................................................................................... 9
Keep Riders Off Machine ...................................................................................................................... 9
Avoid Backover Accidents .................................................................................................................. 10
Avoid Machine Tip Over ...................................................................................................................... 10
Operating on Slopes ........................................................................................................................... 11
Operating Or Traveling On Public Roads ............................................................................................ 12
Inspect and Maintain ROPS ................................................................................................................. 12
Add and Operate Attachments Safely ................................................................................................ 12
Park And Prepare For Service Safely .................................................................................................. 12
Service Tires Safely ............................................................................................................................ 14
Service Cooling System Safely ........................................................................................................... 14
Remove Paint Before Welding or Heating ........................................................................................... 15
Make Welding Repairs Safely ............................................................................................................. 15
Drive Metal Pins Safely ....................................................................................................................... 16

Section 00 - GENERAL INFORMATION Group 0001: Safety
Group 0001 - Safety

Recognize Safety Information
Safety Alert Symbols
Safety Alert Symbols
This is the safety alert symbol. When this symbol is noticed on the machine or in this manual, be alert for the
potential of personal injury.
Follow the precautions and safe operating practices highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious
hazards.
On the machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and
WARNING signs are located near specific hazards. General precautions are on CAUTION labels.
Follow Safety Instructions
Follow Safety Instructions
Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them
frequently.
Be sure all operators of this machine understand every safety message. Replace operator′s manual and safety labels
immediately if missing or damaged.
Operate Only If Qualified

Do not operate this machine unless the operator′s manual has been read carefully, and you have been qualified by supervised

training and instruction.

Operator should be familiar with the job site and surroundings before operating. Try all controls and machine functions with the
machine in an open area before starting to work.
Know and observe all safety rules that may apply to every work situation and work site.

Wear Protective Equipment
Protective Equipment
Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs
or earplugs to protect against objectionable or uncomfortable loud noises.
Avoid Unauthorized Machine Modifications

Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability,
and may create a hazard for the operator or others near the machine.
Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of
the machine, or that alter machine controls, performance or reliability.
Inspect Machine
Inspect Machine

Inspect machine carefully each day by walking around it before starting.

Inspect and Clean the Polycarbonate Windows. See Inspect and Clean Polycarbonate Windows. (Section 4-1.)
Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts
immediately. Pay special attention to hydraulic hoses and electrical wiring.
Stay Clear of Moving Parts
Stay Clear Of Moving Parts
Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is
complete.
Avoid High-Pressure Oils
Avoid High Pressure Oils
Avoid High-Pressure Oils
This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.
Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop
engine and relieve pressure before disconnecting lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within
hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in
Moline, Illinois, U.S.A.
Beware of Exhaust Fumes
Beware Of Exhaust Fumes
Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring outside air into the area.
Prevent Fires
Handle Fuel Safely
Clean Machine Regularly
Carry A Fire Extinguisher
Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks
or flame.
Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines,
hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine

compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine
electrical wiring and connectors frequently for damage.
Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use
extinguisher properly.
Prevent Battery Explosions
Battery Explosions
Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery.
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Handle Chemical Products Safely
Handle Chemical Products Safely
Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives
used with this machine may be hazardous.
If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data
Sheet (MSDS). The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for
chemical substances. Follow MSDS recommendations to handle chemical products safely.
Dispose of Waste Properly

Dispose Of Waste Properly
Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may
be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center
to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your dealer for more
information.
Prepare for Emergencies
First Aid Kit
Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Use Steps and Handholds Correctly
Use Handholds and Steps
Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails. Never use
machine controls as handholds.
Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never
jump when exiting machine. Never mount or dismount a moving machine.
Start Only From Operator′s Seat
Operate Only From Operators Seat
Avoid unexpected machine movement. Start engine only while sitting in operator′s seat. Ensure all controls and working tools
are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid
terminals.
Use and Maintain Seat Belt
Use and Maintain Seat Belt
Use seat belt when operating machine . Remember to fasten seat belt when loading and unloading from trucks and during
other uses.
Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does
not function properly.
The complete seat belt assembly should be replaced every 3 years, regardless of appearance.
Prevent Unintended Machine Movement
Park Brake Control

Be careful not to accidentally actuate controls when co-workers are present.

Ensure dump body is lowered during work interruptions. Place transmission control in neutral, engage park brake and stop
engine before allowing anyone to approach the machine.
Follow these same precautions before standing up, leaving the operator′s seat, or exiting the machine.
Avoid Work Site Hazards
Work Site Hazards
Work Site Hazards
Prepare work site properly . Avoid operating near structures or objects that could fall onto the machine. Clear away debris
that could move unexpectedly if run over.
Avoid contact with overhead obstacles or overhead electrical lines. Never move any part of machine or load closer
than 3 m (10 ft) plus twice the line insulator length to overhead wires.
Keep bystanders clear at all times. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal
person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate
hand signals before starting machine.
Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or
excavations, or when dump body is in raised position.
Avoid working on stockpiles that could collapse under machine.
Use caution when backing up to berms.

Keep Riders Off Machine
Keep Riders Off Machine
Use seat belt at all times.

Only allow operator on machine except when necessary for instruction or short periods of observation.
Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects.
They also may obstruct operator’s view or impair his ability to operate machine safely.
Use the instructional seat only to accommodate trainers or persons needing to observe machine operation for short periods.
Avoid Backover Accidents
Backover Warning
Before moving machine, be sure all persons are clear of machine path. Where conditions permit, raise dump body for
better visibility to the rear. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted,
and in good repair.
Be certain backup alarm is working properly.
Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all
times. Use prearranged hand signals to communicate.
Avoid Machine Tip Over

Use Seat Belt
Avoid Machine Tip Over
Use seat belt at all times. Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush
you.
Use extra care when dump body is raised. Machine stability is greatly reduced when dump body is raised. Drive slowly.
Avoid sharp turns and uneven ground.
Be careful on slopes and soft, rocky, or frozen ground. Traction and stability are reduced by slopes and adverse terrain.
Avoid piles of dirt and banks or excavations that may cave in and cause the machine to tip or fall.
Do not overload the machine. Oversize loads reduce machine stability, increase tire flex, and erode travel surfaces. Braking
capability and brake life are also reduced.
If machine tips, carefully inspect brake and hydraulic lines, electrical wiring, and machine structure before operating.
Operating on Slopes
Operating on Slopes
Avoid sideslope travel whenever possible.

Check service brake condition frequently when operating on slopes.

Select low gear speed before starting down slope. The maximum slope you can operate on will be limited by ground conditions
and load being handled.
Use transmission retarder (if equipped) or exhaust brake and service brakes, to control speed. Sudden brake application with a
loaded dump body could cause loss of machine control.
Operating Or Traveling On Public Roads
Operating or Traveling On Public Roads
Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to
assure they are visible to other drivers. Mirrors are especially important for the operator when on roadways.
Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the
machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices
clean and in working condition.
Inspect and Maintain ROPS

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.
Add and Operate Attachments Safely

Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect
machine stability or reliability, and may create a hazard for others near the machine.
Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or
recommended. Verify that all connections are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions,
carefully operate attachment to learn its characteristics and range of motion.
Park And Prepare For Service Safely

Do Not Operate Tag
Support Machine Properly
Warn others of service work. Always park and prepare your machine for service or repair properly.
Park machine on a level surface.

Lower dump body unless raised position is required for service.
Engage park brake.
Stop engine and remove key.
Attach a “Do Not Operate” tag in an obvious place in the operator′s station.
Install the articulation safety locking bar.
Install service locks if dump body or cab are raised for service.
Securely support machine before working under it.

Install wheel chocks to ensure machine cannot move backward or forward during service.
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the
engine must be running for service work.

Service Tires Safely
Explosive Tire and Rim Parts
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a
wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally
weaken or deform the wheel.
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.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
Service Cooling System Safely

Cooling System
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 to relieve
pressure before removing completely.
Remove Paint Before Welding or Heating
Toxic Fumes
Hazardous fumes can be generated when paint is heated by welding or using a torch. Dust from sanding or grinding paint can
also be hazardous.
Remove paint to at least 76 mm (3 in.) from area to be heated. Wear an approved respirator when sanding or grinding paint. If
a solvent or paint stripper is used, wash area with soap and water. Remove solvent or paint stripper containers from work area,
and allow fumes to disperse at least 15 minutes before welding or heating.
Work outside or in a well-ventilated area. Dispose of waste, paint, and solvents properly.
Make Welding Repairs Safely
Avoid Heating Near Pressurized Fluid Lines

WHEELS (g) by Belgreen v2.0
IMPORTANT:
Disable electrical power before welding. Turn off main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and vehicle microprocessors.
Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines
fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure
there is good ventilation. Wear eye protection and protective equipment when welding.
Drive Metal Pins Safely
Hardened Metal Parts
Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering
hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and object to prevent chipping.

Section 01 - WHEELS
Table of contents
Group 0110 - Removal and Installation ................................................................................................ 1
Remove and Install Wheel .................................................................................................................... 1
Remove and Install Tire ........................................................................................................................ 3

Section 01 - WHEELS Group 0110: Removal and Installation

Remove and Install Wheel
[1] -
CAUTION:
Always chock at least one other wheel when raising a wheel off the ground.
Park the machine on firm level ground. Chock wheels.
[2] -
LEGEND:
1 Flange Nut and Washer (12 used)
Flange Nuts
Loosen flange nuts (1) one full turn.
[3] -
CAUTION:
Components are heavy. Use lifting devices.

Item Measurement Specification

350D Articulated Dump Truck Weight 26 725 kg (58,919 lb)
400D Articulated Dump Truck Weight 28 850 kg (63,603 lb)
Tire and Rim Weight 771 kg
(1700 lb) approximate
Raise wheel. Support axle housing with an 18-t (20 ton) floor stand.
[4] -

LEGEND:
2 Wheel Lift
Wheel Jack
Attach wheel lift (2) to wheel. Secure tire with safety chain.
[5] - Remove flange nuts and washers. Remove wheel.
[6] - Clean threads of wheel bolts and flange nuts. Clean mating surfaces of flange nuts, washers, rim, and hub.
[7] -
IMPORTANT:
Re-check torque on flange nuts after five hours. Tighten as necessary. Re-check torque every 50 hours
thereafter.
IMPORTANT:
Check tire diameter before installing wheel. Difference in tire diameter must be within 2% across axles
and between axles. Excessive differences in tire rollout will cause drivetrain malfunctions.
Install wheel. Install washers and flange nuts. Tighten flange nuts to specification in a crisscross pattern.

Flange Nut Torque 650 N˙m
(480 lb-ft)

Remove and Install Tire

[1] -
CAUTION:
Service Tires Safely . (See Group 0001.)
→NOTE:
Tire can be removed without removing wheel from machine.
3-Piece Rim

5-Piece Rim
LEGEND:
1 Rim
2 Side Ring (2 used)—5-Piece Rims Only
3 Tire
4 Bead Seat Ring
5 Lock Ring
6 Driver Block
7 Valve Stem
8 Seal Nut
Remove valve core from valve stem (7) to deflate tire (3). Check valve stem for plugging by inserting a probe.
[2] - Inspect and replace parts as necessary.
[3] -
IMPORTANT:
To prevent slippage between tire and rim during machine operation, clean all contact surfaces thoroughly
before assembly.
Thoroughly clean all parts before assembly.
[4] - Apply soap lubricant to beads of tire (3). Assemble wheel set (1—6). Ensure that all components are properly aligned and
seated.
[5] - Install valve stem (7). Hand-tighten seal nut (8).
[6] - Install pressure-regulating valve, clip-on chuck, and extension hose on valve stem.
[7] -
CAUTION:
Clear area of all persons. Stand aside while inflating tire. DO NOT stand in front of tire.
Use only recommended air pressure. Pressure over this limit can cause explosion.

AXLES AND SUSPENSION SYSTEMS (g) by Belgreen v2.0
Add air until tire beads slide out against seats.
[8] - Re-check proper alignment of wheel set components around entire circumference before fully inflating tire.
[9] - Inflate tire to specification. Check air pressure in tire using an accurate gauge with 7 kPa (0.07 bar) (1 psi) graduations.
See Inspect Tires, Check Pressure (Operator′s Manual, Section 3-3).
Tire Pressure Gauge With 7 kPa (0.07 bar) (1 psi) Graduations
Inflate tires to specification.

Section 02 - AXLES AND SUSPENSION SYSTEMS

Table of contents
Axles ..................................................................................................................................................... 1
Group 0210 - Differential or Bevel Drive .............................................................................................. 5
Axle Differential .................................................................................................................................... 5
Group 0225 - Input Drive Shafts and U-Joints ................................................................................... 26
Drive Shafts ........................................................................................................................................ 26
Group 0242 - Axle Mounting Parts ...................................................................................................... 35
Axle Links, Stabilizers, and Struts Remove and Install ....................................................................... 35
Recharge Front Suspension Strut ....................................................................................................... 39
Front Suspension Strut Disassemble and Assemble ........................................................................... 45
Replace Links and Stabilizer Bushings ................................................................................................ 52
Front Axle Pivot .................................................................................................................................. 54
Middle and Rear Axle Walking Beams ................................................................................................ 56
Group 0250 - Axle Shaft, Bearings, and Reduction Gears ............................................................... 63
Axle Outboard Planetaries .................................................................................................................. 63
Axle Shafts ......................................................................................................................................... 66
Axle Hubs ........................................................................................................................................... 67

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0200: Removal and Installation

Axles
Remove and Install Front Axle
[1] - Support machine front frame with 20-ton shop stands. Chock middle and rear wheels securely.
[2] -
CAUTION:
Component is heavy. Use lifting device.

Axles
Front Axle Weight 2019 kg (4450 lb) approximate
Attach a lifting device to axle.
[3] - Remove wheels. See Remove and Install Wheel . (Group 0110.)
[4] - Remove drive shaft. See Drive Shafts (Group 0225.)
[5] - Relieve brake accumulator pressure. Pump service brake pedal at least 100 strokes.
[6] - Disconnect brake line(s) at top of differential housing. Plug or cap open line(s).
Dry caliper service brakes: Disconnect brake pressure line.

Wet disk brakes: Disconnect brake pressure line, brake cooling oil delivery line, and brake cooling oil return line. Close all
openings with caps and plugs.
[7] -
Front Axle Removal

LEGEND:
1 Clamping Block (2 used)
2 Suspension Strut (2 used)
3 Front Axle Stabilizer
Remove stabilizer (3) and struts (2). See Axle Links, Stabilizers, and Struts (Group 0242).
[8] - Remove clamping blocks (1). Remove spacers from both sides of pivot pin.
[9] - Lower axle with lifting device.
[10] - Inspect parts and replace or repair as necessary. See Front Axle Pivot (Group 0242).
[11] - Raise axle with lifting device.
[12] - Install spacers on pivot pin. Install clamping blocks.
[13] - Install struts and stabilizer.
[14] - Connect brake line(s) at top of differential housing.
[15] - Install drive shaft. See Drive Shafts (Group 0225).
[16] - Install wheels. See Remove and Install Wheel (Group 0110).
[17] - Bleed Service Brake Hydraulic System . (See Group 1060.)
Remove and Install Middle or Rear Axle
[1] - Support machine rear frame with 20-ton shop stands. Chock front wheels securely.
[2] -
Axle Blocking
On axle not removed, put wood blocks between axle housing and frame on both sides to support walking beams when wheels
are removed from other axle.
[3] - Remove wheels. See Remove and Install Wheel (Group 0110).
[4] - Remove drive shaft(s). See Drive Shafts (Group 0225).

[5] - Relieve brake accumulator pressure. Pump service brake pedal at least 100 strokes.
[6] - Disconnect brake line(s) at top of differential housing. Close open line(s) using caps or plugs.
Dry caliper service brakes: Disconnect brake pressure line.

Wet disk brakes: Disconnect brake pressure line, brake cooling oil delivery line, and brake cooling oil return line.
[7] -
Middle and Rear Axles

LEGEND:
1 Walking Beam (2 used)
2 Rubber Mount (2 used per axle)
3 Upper Link (1 used per axle)
4 Stabilizer (1 used per axle)
5 Drag Link (2 used per axle)
6 Middle Axle-to-Rear Axle Drive Shaft
7 Park Brake-to-Middle Axle Drive Shaft
Remove upper link (3), stabilizer (4), and drag links (5). See Axle Links, Stabilizers, and Struts (Group 0242).
[8] -
CAUTION:

Axles
Middle Axle Weight 1565 kg (3450 lb) approximate
Rear Axle Weight 1474 kg (3250 lb) approximate
[9] - Remove socket head cap screws from rubber mounts (2).

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0210: Differential or Bevel Drive
[10] - Lower axle from walking beams with lifting device.
[12] - Raise axle to walking beams with lifting device.
[13] - Install socket head cap screws in rubber mounts.
[14] - Install drag links (5), stabilizer (4), and upper link (3). See Axle Links, Stabilizers, and Struts (Group 0242).
[15] - Connect brake line(s).
[16] - Install drive shaft(s). See Drive Shafts (Group 0225).
[18] - Bleed Service Brake Hydraulic System . (See Group 1060.)

Group 0210 - Differential or Bevel Drive

Axle Differential
Specifications
SPECIFICATIONS
Axle Differential
284 kg
Front Axle Differential Weight (approximate)
625 lb
284 kg
Middle Axle Differential Weight (approximate)
625 lb
227 kg
Rear Axle Differential Weight (approximate)
500 lb
1100 N·m
Yoke Retaining Nut Torque
811 lb.-ft.
0.203—0.457 mm
Ring Gear Backlash with No Pinion Movement Distance
0.008—0.018 in.
0.076—0.178 mm
Input Shaft End Play (new parts)
0.003—0.007 in.
0.33—0.43 mm
Input Shaft (used parts)
0.013—0.014 in.
149—176 N·m
Spider Housing Cap Screw Torque
110—130 lb.-ft.
264—332 N·m
Ring Gear Cap Screw Torque
195—245 lb.-ft.
475—580 N·m
Ring Gear Bearing Cap Cap Screw Torque
350—428 lb.-ft.
Pinion Shaft Bearing Initial Shim Thickness 0.185 in.
16.8—17.7 t
Input Shaft Bearing Preload Pressure
18.5—19.5 tons
2—3 kg
Input Pinion Shaft Bearing Rolling Drag Force
2—7 lb
1100 N·m
Input Pinion Nut Torque
811 lb.-ft.
2—5 kg
Input Pinion Shaft Bearing Rolling Drag Torque
5—12 lb
0.203—0.457 mm
Ring Gear Backlash
0.008—0.018 in.
80 N·m
Power Divider Housing Cap Screw Torque
59 lb.-ft.
330 N·m
Differential to Axle Mounting Cap Screw Torque
243 lb.-ft.
Service Equipment and Tools
SERVICE EQUIPMENT AND TOOLS
JT01642A Low Lift Transmission Jack
DFT1194 Bearing Puller
D01290AA Puller Bar
D01003AA Repair Stand
D01274AA Bearing Puller
D01267AA Bearing Puller
D01045AA Bushing Bearing Seal Driver Set
JDG94 Spring Scale

Other Material
OTHER MATERIAL
T43514 U.S. Rigid Form-In-Place Gasket
TY9475 Canadian Rigid Form-In-Place Gasket
277 LOCTITE ™ Rigid Form-In-Place Gasket
Gear Wear Pattern Marking Compound
SAE 80W90 U.S. Axle Oil
Remove and Install
[1] - Relieve pneumatic pressure. See Relieve Pneumatic Pressure (Operator′s Manual, Section 3-2).
[3] - Remove drive shaft(s) from axle. See Drive Shafts (Group 0225).
[4] - Drain axle housing. See Change Axle Oil (Operator′s Manual, Section 3-7).
[5] - Drain planetaries. See Change Final Drive Oil (Operator′s Manual, Section 3-7).
[6] -
→NOTE:
Leave axle shafts installed until differential lock has been manually engaged.
Remove planetary covers. See Axle Outboard Planetaries (Group 0250).
[7] - Remove Differential Lock Actuator (Group 2262).
[8] -
IMPORTANT:
Differential lock must be fully engaged to remove differential from axle housing.
LEGEND:
1 Differential Lock Shifting Fork Arm
2 Differential Lock Actuator Mounting Stud

Differential Lock Actuator Removed

Manually engage differential lock.
a. Note alignment of differential lock actuator mounting stud (2) and shifting fork arm (1). When arm is parallel to stud,
differential lock is fully engaged.
b. Hold one axle shaft and turn the other while pushing shifting fork arm outward. Differential lock will engage and arm will
be parallel with stud.
[9] - Remove axle shafts. See Axle Shafts (Group 0250).
[10] -
CAUTION:

Axle Differential
Front Axle Differential Weight 284 kg (625 lb) approximate
Middle Axle Differential Weight 284 kg (625 lb) approximate
Rear Axle Differential Weight 227 kg (500 lb) approximate
LEGEND:
1 JT01642A Low Lift Transmission Jack
2 Nut (8 used)
3 Washer (8 used)
Middle Differential Shown

Connect a lifting device like JT01642A Low Lift Transmission Jack (1) to differential.
Low Lift Transmission Jack
JT01642A
Remove differential from axle
[11] - Differential cover has rigid form-in-place gasket on it. Tap cover with lead hammer to break it loose.
[12] - For front and rear axles, remove differential assembly from axle housing.
For middle axle, press through-shaft from output-side bearing and remove differential assembly from axle housing.

a. Remove middle axle output yoke.
b.
Middle Differential Removal
Install DFT1194 Bearing Puller and D01290AA Puller Bar from D01173AA Puller Set across middle axle output shaft.
Tighten nuts on DFT1194 to press shaft and differential out of middle axle housing.
Bearing Puller
DFT1194
Puller Bar
D01290AA
[13] - Inspect parts and replace or repair as necessary.
[14] - Manually engage differential lock.
[15] - Apply rigid form-in-place gasket to differential housing flange and studs.
Number Name Use

• T43514 (us)
Apply to differential housing mating Apply to differential housing
• TY9475 (canadian) Rigid Form-In-Place Gasket
surfaces. studs.
• 277 LOCTITE ™ (loctite)
[16] - Install differential in axle housing. For middle axle, ensure output shaft is firmly seated in bearing.
[17] - Install lock washers, cap screws, and nuts to secure differential to axle housing. Tighten hardware to specification.
Differential to Axle Mounting Cap Screws and Nuts Torque 330 N·m
243 lb.-ft.
[18] - Install yoke(s). Apply rigid form-in-place gasket to yoke retaining nut(s) and tighten to specification.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to yoke retaining nut.
Axle Differential
Yoke Retaining Nut Torque 1100 N·m (811 lb.-ft.)
[19] - Install Differential Lock Actuator . (Group 2262).

[20] - Install axle shafts. See Axle Shafts (Group 0250).
[21] - Install planetary covers. See Axle Outboard Planetaries (Group 0250).
[22] - Refill planetaries. See Change Final Drive Oil (Operator′s Manual, Section 3-7).
[23] - Refill axle housing. See Change Axle Oil (Operator′s Manual, Section 3-7).
[24] - Install drive shaft(s) on axle. See Drive Shafts (Group 0225).
Check Gear Tooth Contact Pattern
[1] -
Ring Gear Wear Pattern

Coat several ring gear teeth with marking compound.
Number Name Use

Gear Wear Pattern Marking Compound Adjust ring gear and pinion contact point.
[2] - Turn ring gear so pinion gear leaves a wear pattern through marking compound.
[3] -
LEGEND:
1 Face Width
2 Tooth Depth
3 Heel
4 Top Land
5 Root
6 Toe
Gear Tooth Nomenclature

Inspect wear pattern.
The length and shape of contact pattern varies, especially for used gears.
The position of contact pattern is important for all gears. Wear pattern must not be too much toward tooth heel (3), and must
not run off of toe (6). Pattern should be centered between top land (4) and root (5).
[4] -

LEGEND:
1 Wear Pattern
2 Pattern Centered between Top Land and Root
3 Pattern Up Slightly from Toe
Correct Wear Pattern for New Gears
Typical Wear Pattern for Used Gears

Compare wear pattern to examples.
A correct pattern is up slightly from the toe (3) and centers evenly (2) along the face width.
Wear patterns for used gears typically vary in shape and length. Wear patterns should not run off of toe, and should not be too
close to root or land of tooth.
When reassembling used gear sets, adjust as necessary to produce the same gear tooth contact pattern as before
disassembly.
[5] - To adjust the tooth contact pattern, the positions of the ring gear and pinion gear are adjusted.

LEGEND:
1 Pattern too Close To Top Land
2 Pattern too Close To Root
a.
Incorrect Shimming between Pinion Bearing Housing
and Carrier
Shims between the pinion bearing housing and carrier control where the wear pattern is between the top land and root.
If wear pattern is too close to top land, use thinner shim(s) between pinion bearing housing and carrier to move pinion
toward ring gear.
If wear pattern is too close to root, use thicker shim(s) between pinion bearing housing and carrier to move pinion away
from ring gear.

LEGEND:
1 Pattern Too Close To Heel
2 Pattern Running Off Of Toe
b.
Incorrect Adjustment of Ring Gear Bearing Adjusters
Adjusters on the ring gear bearings control where the wear pattern is between tooth heel and toe.
If wear pattern is too close to tooth heel, adjust ring gear position toward teeth side to move ring gear toward pinion.
If wear pattern is too close to tooth toe, adjust ring gear position toward back side to move ring gear away from pinion.
c. Adjust backlash to specifications after any adjustment or shim change.
Disassemble
[1] -
Differential In Repair Stand

Install differential in a repair stand like D01003AA Repair Stand. Differential must be able to rotate 360 degrees.

Repair Stand
D01003AA
Hold differential for repair
[2] - Check gear tooth contact pattern. If the wear pattern runs off the teeth and/or heavy wear is evident, the gear set must
be replaced.
[3] -
Differential
LEGEND:
2 Ring Gear Bearing Cap—Teeth Side
3 Ring Gear Bearing Cap—Back Side
4 Ring Gear and Pinion
5 Plug
6 Screw
7 Nut
8 Retainer (4 used)
9 Bearing Cap Cap Screw (4 used)
10 Washer (4 used)
11 Lock Plate (2 used)

12 Cotter Pin (2 used)

13 Bushing (2 used)
14 Adjuster—Teeth Side
15 Adjuster—Back Side
16 Ring Gear Bearing Cup—Teeth Side
17 Ring Gear Bearing Cup—Back Side
18 Ring Gear Bearing Cone—Teeth Side
19 Ring Gear Bearing Cone—Back Side
20 Spider
21 Ring Gear Cap Screw (16 used)
22 Nut (16 used)
23 Spider Housing
24 Spider Housing Cap Screw (12 used)
25 Bevel Gear (2 used)
26 Thrust Washer
28 Thrust Washer (4 used)
29 Input Shaft Inner Bearing Cup
30 Input Shaft Outer Bearing Cup
31 Input Shaft Inner Bearing Cone
32 Input Shaft Outer Bearing Cone
33 Input Shaft—Front and Rear Axles Only
33 Through Shaft—Middle Axles Only
34 Power Divider Upper Gear
35 Power Divider Housing
36 Lock Washer (10 used)
37 Power Divider Housing Cap Screw
38 Power Divider Housing Cap Screw (9 used)
39 Shim (as required)
40 Input Shaft Outer Bearing Housing
41 Input Shaft Seal
42 Washer
43 Input Yoke Retaining Nut
44 Input Shaft Outer Bearing Housing Cap Screw (5 used)
45 Pinion Pilot Bearing
46 Pinion Shaft Bearing Cone (2 used)
47 Spacer
49 Pinion Shaft Bearing Cup (2 used)
51 Pinion Shaft Bearing Housing
52 Washer (6 used)
53 Dowel Pin (2 used)
54 Power Divider Lower Gear
55 Power Divider Lower Gear Roller Bearing
56 Nut
57 Snap Ring
58 Dowel Pin
59 Pinion Shaft Bearing Housing Cap Screw (6 used)
60 Snap Ring
61 Gear
62 Differential Lock Outside-Splined Disk (7 used)
63 Differential Lock Inside-Splined Disk (7 used)
64 Pressure Plate
65 Snap Ring
66 Compression Spring (12 used)
67 Differential Lock Housing Half
68 Differential Lock Shaft
69 Thrust Washer
70 Washer (2 used)—Middle Axles Only
71 Output Yoke Retaining Nut (2 used)—Middle Axles Only
72 Differential Lock Actuator Fork
73 Stud
74 Fork and Spring Kit
75 Washer (2 used)
76 Nut (2 used)
77 Carrier

78 Through Shaft Assembly—Middle Axle Only

79 Input Shaft Assembly—Front and Rear Axles Only
If ring gear and pinion will be reused, record backlash. Differential must be returned to identical backlash when reassembled.
a. Install a magnetic base with dial indicator on carrier. Position dial indicator at extreme heel of a ring gear tooth,
perpendicular to tooth surface.
b. Hold pinion shaft to prevent it from turning. Rotate ring gear. Measure distance tooth heel is free to travel. Compare
distance to backlash specification.
Axle Differential
Ring Gear Backlash with No Pinion Movement Distance 0.203—0.457 mm (0.008—0.018 in.)
[4] -
End Play Check

Record input shaft end play. Install a dial indicator on the input shaft. Lift yoke with a pry bar and record end play. Compare
input shaft end play to specifications.
Axle Differential
Input Shaft End Play 0.076—0.178 mm (0.003—0.007 in.) with new parts
0.33—0.43 mm (0.013—0.014 in.) with used parts
If end play is not to specification, determine shim pack changes.
Shim Adjustment
Add shims to increase end play.
0.076—0.178 mm
Desired end play (new parts).
0.003—0.007 in.
0.025—0.025 mm
Measured end play (example).
0.001—0.001 in.
0.051—0.152 mm
Add shims for desired end play.
0.002—0.006 in.
Remove shims to decrease end play.
0.381—0.381 mm
Measured end play (example).
0.015—0.015 in.
0.076—0.178 mm
Desired end play (new parts).
0.003—0.007 in.
0.305—0.203 mm
Remove shims for desired end play.
0.012—0.008 in.
[5] -

LEGEND:
2 Bearing Cap—Teeth Side
3 Bearing Cap—Back Side
74 Differential Lock Actuator Fork and Spring Kit
Teeth Side—Middle Differential Shown
Differential Lock Side

Mark bearing adjuster positions for reference during reassembly.
[6] - Mark bearing caps (2 and 3) for installation on the same bearings.
[7] - Remove input yoke.
[8] - Remove input shaft outer bearing housing (40), power divider housing (35), and shaft (33). Note thickness of shim(s) (39)
for input yoke end-play adjustment during reassembly.
[9] -

Shift Fork Pivot Expansion Plug

Remove expansion plugs. Remove shift fork pivot shaft.
[10] - Rotate differential on stand so carrier (77) is at bottom. Remove actuator fork (72), seal and spring (74). Remove
differential lock shaft (68).
[11] - Remove lock plates (11). Remove bearing caps (2 and 3) and adjusters (14 and 15).
[12] -
Remove Differential
Lift differential assembly from carrier with a nylon sling.
[13] -
Remove Pinion Shaft

Remove pinion shaft (4) and bearing housing (51). Drive pinion shaft and pilot bearing (45) out of carrier.
[14] -

Remove Pinion Bearing

Remove pinion pilot bearing (45) using a press and a knife-edged bearing puller like D01274AA Bearing Puller.
Bearing Puller
D01274AA
Remove bearing from pinion shaft
[15] - Disassemble differential lock clutch pack.
CAUTION:
Springs inside differential lock housing are under load.
Remove two nuts (22) and cap screws (21). Install longer cap screws on nuts. Remove remaining cap screws (21). Loosen
longer cap screws evenly to relieve spring pressure. Remove ring gear (4) from spider housing (23).
b. Separate differential lock housing half (67) from spider housing (23). Remove springs (66). Note arrangement of inside-
splined disks (63), outside-splined disks (62), and pressure plate (64). Remove disks from housing.
c. Remove ring gear bearing cone (19) from differential lock housing half (67) with a bearing puller such as D01267AA
Bearing Puller.
Bearing Puller
D01267AA
Remove bearing from differential housing.
[16] - Disassemble spider housing.
a. Mark spider housing halves (23) to ensure same alignment for reassembly.
b. Remove cap screws (24). Separate spider housing halves.
c. Disassemble thrust washers (26, 28, and 69), bevel gears (25 and 27), and spider (20).
d. Remove ring gear bearing cone (18) from spider housing half (23).
[17] - Inspect parts and replace as necessary.
Assemble
[1] -

Differential
LEGEND:
2 Ring Gear Bearing Cap—Teeth Side
3 Ring Gear Bearing Cap—Back Side
4 Ring Gear and Pinion
5 Plug
6 Screw
7 Nut
8 Retainer (4 used)
9 Bearing Cap Cap Screw (4 used)
10 Washer (4 used)
12 Cotter Pin (2 used)
13 Bushing (2 used)
16 Ring Gear Bearing Cup—Teeth Side
17 Ring Gear Bearing Cup—Back Side
18 Ring Gear Bearing Cone—Teeth Side
19 Ring Gear Bearing Cone—Back Side
20 Spider
21 Ring Gear Cap Screw (16 used)
22 Nut (16 used)

23 Spider Housing
24 Spider Housing Cap Screw (12 used)
26 Thrust Washer
29 Input Shaft Inner Bearing Cup
30 Input Shaft Outer Bearing Cup
31 Input Shaft Inner Bearing Cone
32 Input Shaft Outer Bearing Cone
33 Input Shaft—Front and Rear Axles Only
33 Through Shaft—Middle Axles Only
34 Power Divider Upper Gear
35 Power Divider Housing
37 Power Divider Housing Cap Screw
38 Power Divider Housing Cap Screw (9 used)
40 Input Shaft Outer Bearing Housing
41 Input Shaft Seal
42 Washer
43 Input Yoke Retaining Nut
44 Input Shaft Outer Bearing Housing Cap Screw (5 used)
45 Pinion Pilot Bearing
46 Pinion Shaft Bearing Cone (2 used)
47 Spacer
49 Pinion Shaft Bearing Cup (2 used)
51 Pinion Shaft Bearing Housing
52 Washer (6 used)
53 Dowel Pin (2 used)
54 Power Divider Lower Gear
55 Power Divider Lower Gear Roller Bearing
56 Nut
57 Snap Ring
58 Dowel Pin
59 Pinion Shaft Bearing Housing Cap Screw (6 used)
60 Snap Ring
61 Gear
62 Differential Lock Outside-Splined Disk (7 used)
63 Differential Lock Inside-Splined Disk (7 used)
64 Pressure Plate
65 Snap Ring
66 Compression Spring (12 used)
67 Differential Lock Housing Half
69 Thrust Washer
70 Washer (2 used)—Middle Axles Only
71 Output Yoke Retaining Nut (2 used)—Middle Axles Only
72 Differential Lock Actuator Fork
73 Stud
74 Fork and Spring Kit
75 Washer (2 used)
76 Nut (2 used)
77 Carrier
78 Through Shaft Assembly—Middle Axle Only
79 Input Shaft Assembly—Front and Rear Axles Only
Assemble spider housing.
a. Install ring gear bearing cone (18) on spider housing half (23).
b. Assemble spider (20), bevel gears (25 and 27), and thrust washers (26, 28, and 69).
c. Install spider assembly in spider housing half. Align housing halves. Install cap screws (24). Tighten to specification.
Axle Differential

Spider Housing Cap Screw Torque 149—176 N˙m (110—130 lb-ft)
[2] - Assemble differential lock and ring gear.
a. Install bearing cone (19) on differential lock housing half (67).

b. Install ring gear (4) on housing (23).
c. Install snap ring (60) and gear (61).
→NOTE:
Apply SAE 80W90 gear oil to each clutch disk during assembly.
Number Name Use
⚬ SAE 80W90 (us) Axle Oil Apply to controlled traction clutch disks
Install one outside-splined disk (62) into housing (23), then alternate inside-splined disks (63) and outside-splined disks
(62) until seven of each are installed. Install pressure plate (64).
e. Using a press, push against pressure plate (64) and install snap ring (65).
f. Install compression springs (66) on pressure plate (64). Position springs inward as far as possible to allow easier
installation of housing half (67).
g. Install differential lock housing half (67) over springs.
h. Install shaft (68) through housing half (67) and inside-splined disks.
i. Compress housing half (67) against spider housing (23) with a press. Install cap screws (21) with heads on ring gear side.
Install nuts (22).
Axle Differential
Ring Gear Cap Screw Torque 264—332 N˙m 195—245 lb-ft
[3] - Lubricate ring gear bearing cones (18 and 19) with axle oil.
[4] -
Differential Installation
Lower differential into carrier with hoist.
[5] -
→NOTE:
When installing ring gear bearing caps, it may be necessary to tap them with a hammer to fully seat
them.
Hand-tighten cap screws in bearing caps for bearing preload adjustment, then final-tighten.
Install ring gear bearing caps (2 and 3). Install washers (10) and cap screws (9). Hand-tighten only.

[6] - Install bearing adjusters (14 and 15). If the ring gear and pinion are being reused, tighten adjusters to same positions as
when removed. Install locks (11).
If a new ring gear and pinion set are being used, adjust bearing pre-load.
LEGEND:
4 Ring Gear
14 Teeth-Side Adjuster
15 Back-Side Adjuster
a.
Differential Bearing Preload Adjustment
Turn teeth-side adjuster (14) until one thread shows.
b. Tighten back-side adjuster (15) until back-side bearing cup firmly contacts back-side bearing cone.
c. Facing teeth-side of ring gear, push against ring gear assembly to check bearing-to-bearing movement of ring gear. There
should be no free movement. Tighten back-side adjuster (15) and recheck free movement, if necessary. Bearing cones
and cups should be firmly seated on both sides of ring gear.
d. Tighten teeth-side adjuster (14) another two or three more notches to preload ring gear bearings.
e. Install locks (11).
[7] - Tighten cap screws (9) to specification.

Axle Differential
Ring Gear Bearing Cap Cap Screw Torque 475—580 N·m (350—428 lb.-ft.)
[8] - Assemble pinion bearings in housing. Use rolling drag test in a hydraulic press to determine correct shim thickness.
a. Press bearing cups (49) into bearing housing (51) using a correct-sized disk from D01045AA Bushing/Bearing Seal Driver
Set. Press cups to bottom of bores.
Bushing/Bearing Seal Driver Set
D01045AA
Install bearing cups in pinion shaft bearing housing.
→NOTE:
Use a shim 4.7 mm (0.185 in.) thick for initial setup. Adjust shim thickness as necessary for correct
rolling drag.
Lubricate bearing cones (46) with axle oil. Assemble shim(s) (48) as required, spacer (47), and pinion shaft bearings (46)
into bearing housing (51).
Axle Differential
Pinion Shaft Bearing Initial Shim Thickness 0.185 in.

LEGEND:
1 Press Ram
2 Disk
3 Bearing Housing
4 Spring Scale
c.
Measure Preload On Input Shaft
Install pinion shaft bearing housing with bearings in a press.
d. Put disks from D01045AA Bushing/Bearing Seal Driver Set over bearing races. DO NOT push on bearing cages.
Bushing Bearing Seal Driver Set
D01045AA
Apply pressure to pinion shaft bearings for preload adjustment.
e. Attach a spring scale such as JDG94 Spring Scale to bearing housing by wrapping a soft wire around the housing at least
once.
Spring Scale
JDG94
Measure differential input shaft bearing preload.
f. Press on disk with ram to preload bearings to specification.

Axle Differential
Input Shaft Bearing Preload Pressure 16.8—17.7 t (18.5—19.5 tons)
g. Pull the spring scale to turn the housing. Write down force indicated on the spring scale. Compare to specification.
Axle Differential
Input Pinion Shaft Bearing Rolling Drag Force 2—3 kg (2—7 lb)
h. Install a different shim, if necessary, and repeat rolling drag test. A thicker shim will decrease preload.
→NOTE:
Bearings may “grow” when pressed onto input shaft. Use a slightly thicker shim for final assembly
than was used for rolling drag test.
When spring scale force is within specification, write down shim thickness. Add 0.025 mm (0.001 in.) to shim thickness for
final assembly.
[9] - Assemble pinion shaft assembly (4, 45—49, 51). Check rolling drag for final pinion shaft assembly.
a. Install pilot bearing (45) on pinion shaft (4).

b. Press bearing cone (46) on pinion shaft.
c. Install spacer (47), shim (48), and cup (49) on shaft.
d. Install shaft into housing (51).
e. Press bearing cone (46) onto shaft.
f. To check bearing preload of pinion shaft final assembly, install a driveline yoke on pinion shaft instead of helical gear.
Tighten nut to specification.

Axle Differential
Input Pinion Nut Torque 1100 N˙m (811 lb-ft)
g.
Input Pinion Shaft Bearing Preload Check
Install the input shaft assembly in a vise. Tighten vise on driveline yoke.
h. Attach a spring scale to the housing by wrapping a soft wire around the housing at least once.
Spring Scale
JDG94
Measure differential input shaft bearing preload
i. Pull the spring scale to turn the housing. Record force indicated on the spring scale. Compare to specification.
Axle Differential
Input Pinion Shaft Bearing Rolling Drag Torque 2—5 kg (5—12 lb)
j. If bearing preload is not within specifications, disassemble input shaft assembly and install a different shim (48). A thicker
shim will reduce preload.
k. When preload is correct, remove driveline yoke and install power divider lower gear (54), bearing (55), nut (56), and pin
(58) on pinion shaft.
l. Install bearing cup (55) and snap ring (57) in power divider housing (35).
[10] - Install pinion shaft assembly into carrier. If ring gear and pinion shaft are being reused, use same shim(s) (50).
If new ring gear and pinion shaft are used, install shim(s) (50) as necessary to obtain correct backlash and gear tooth wear
pattern.
Axle Differential
Ring Gear Backlash 0.203—0.457 mm (0.008—0.018 in.)
[11] - Check backlash and gear tooth contact pattern. Adjust pinion with shims (50), if necessary. Adjust ring gear with
adjusters (14 and 15), if necessary.
a. If backlash is less than specification or contact pattern is too close to tooth root, move ring gear one notch away from
pinion and recheck.
b. If backlash is greater than specification or contact pattern is too close to tooth top land, move ring gear one notch toward
pinion and recheck.
c. If contact pattern runs off of tooth toe, move pinion outward with thicker shim(s).
d. If contact pattern is too far from tooth toe, move pinion inward with thinner shim(s).
[12] - Assemble differential lock actuator fork and spring kit (72—76).
[13] - Install shaft (33) and power divider housing (35). Tighten power divider housing cap screws to specification.

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0225: Input Drive Shafts and U-Joints
Power Divider Housing Cap Screw Torque 80 N·m
59 lb.-ft.
[14] - Install input shaft outer bearing housing (40). Adjust thickness of shim(s) (39) for correct input yoke end play.


Drive Shafts
Drive Shafts
LEGEND:
3 Park Brake Disk
4 Oscillation Joint-to-Park Brake Drive Shaft
5 Transfer Case-to-Oscillation Joint Drive Shaft
6 Transfer Case-to-Front Axle Drive Shaft
7 Transmission-to-Transfer Case Drive Shaft
8 Engine-to-Main Hydraulic Pump Drive Shaft
Remove and Install Transfer Case-to-Front Axle Drive Shaft or Transfer Case-to-Oscillation Joint
Drive Shaft
[1] -
CAUTION:
Release torsion on drive shaft before removal.
Drive machine backwards and forwards without turning.
[2] - Stop machine and chock wheels.
[3] -
→NOTE:
There should be slight movement from backlash of differentials.
Release brakes. Lever the drive shaft to see if there is movement.
[4] -
CAUTION:
Prevent possible crushing injury. Use appropriate lifting device.
Release torsion from drive shaft by lifting the effected tire off the ground. Once Tire is raised tire should turn releasing torsion
on drive shaft.
[5] -

CAUTION:
Prevent possible crushing injury. Use appropriate lifting device.

Transfer Case-to-Front Axle Drive Shaft Weight 25 kg (55 lb) approximate
Transfer Case-to-Oscillation Joint Drive Shaft Weight 25 kg (55 lb) approximate
LEGEND:
1 Drive Shaft Assembly
2 Cross and Bearing Assembly (2 used)
3 Drive Shaft
4 Cap Screw (16 used)
Transfer Case-to-Front Axle Drive Shaft or Transfer

Case-to-Oscillation Joint Drive Shaft
Remove cap screws (4) and drive shaft assembly (1).
[6] - Remove cross and bearing assemblies (2) from drive shaft (3).
[8] -
IMPORTANT:
Assemble drive shaft so yokes on ends of the shaft are aligned. If yokes are not aligned, severe vibration
and machine damage may result.
Assemble drive shaft so yokes are aligned.
[9] - Install cross and bearing assembles on drive shaft.
[10] - Install drive shaft assembly.
[11] - Apply rigid form-in-place gasket to cap screws. Install cap screws and tighten to specification.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to drive shaft cap screws.
Remove and Install Transfer Case-to-Front Axle Drive Shaft or Transfer Case-to-Oscillation Joint Drive Shaft
Cross and Bearing Torque 142 N˙m (104 lb-ft)

Remove and Install Oscillation Joint-to-Park Brake Drive Shaft
[1] - Remove transfer case-to-oscillation joint drive shaft.
[2] - Remove park brake-to-middle axle drive shaft.
[3] -
Oscillation Joint-to-Park Brake Drive Shaft

LEGEND:
1 Nut (2 used)
2 Washer (2 used)
3 Output Yoke
4 Seal (2 used)
5 Grease Elbow
6 Bearing Cover (2 used)
7 Bearing (2 used)
8 Bearing Retainer Ring
9 Washer (8 used)
11 Drive Shaft
13 Washer (16 used)
14 Grease Elbow
15 Input Yoke
16 Front of Machine
Disconnect grease lines from grease elbows (14 and 5).
[4] - Remove nut (2), washer (1), and input yoke (15) from front of drive shaft (11).
[5] - Remove cap screws (12) and washers (13) from rear bearing cover (6).
[6] -
CAUTION:
Component is heavy. Use hoist.

Oscillation Joint-to-Park Brake Drive Shaft and Rear Bearing Assembly Weight 68 kg (150 lb) approximate
Install two cap screws into threaded holes in rear bearing cover, to push rear bearing assembly away from oscillation tube.
Remove drive shaft and rear bearing assembly from oscillation tube.

[7] - Remove cap screws (12) and washers (13) from front bearing cover.
[8] - Install two cap screws into threaded holes in front bearing cover, to push front bearing cover away from oscillation tube.
Remove front bearing cover from oscillation tube.
[9] - Remove nut (2), washer (1), and output yoke (3) from drive shaft.
[10] - Remove cap screws (10) and washers (9) from bearing retainer ring (8). Remove rear bearing cover from drive shaft.
[11] - Remove seals (4) from front and rear bearing covers.
[12] - Clean bearing covers and cap screws.
[14] -
Cover Seal
Using a 109 mm (4.312 in.) diameter seal driver, install seals in front and rear bearing covers. Drive each seal to bottom of
bore, with open side of seal facing outward.
01044AA Driver Set
Disk 27552
Install seal in cover
[15] - Remove front and rear bearings (7) from drive shaft.
[16] - Using DFT1187 Bearing Driver , install bearings on drive shaft. Drive bearings onto drive shaft until they are against
shoulder.
Bearing Driver
DFT1187
Install bearing on drive shaft.
[17] -

Cover
Apply rigid form-in-place gasket to flange of rear bearing cover.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to flange of rear bearing cover.
[18] - Install rear bearing cover on drive shaft. Apply rigid form-in-place gasket to cap screws (10). Install washers (9) and cap
screws through bearing retainer ring and into rear bearing cover.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to bearing retainer ring cap screws.
[19] - Apply rigid form-in-place gasket to nut. Install output yoke, washer, and nut on drive shaft. Tighten nut to specification.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to output yoke retaining nut.
Yoke Retaining Nut Torque 1100 N˙m (811 lb-ft)
[20] - Install drive shaft and rear bearing assembly into oscillation tube. Apply rigid form-in-place gasket to rear bearing cover
cap screws. Install washers and cap screws.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to rear bearing cover cap screws.
[21] - Apply rigid form-in-place gasket to flange of front bearing cover.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to flange of front bearing cover.
[22] - Install front bearing cover on drive shaft and oscillation tube. Apply rigid form-in-place gasket to cap screws (12). Install
washers (13) and cap screws in front bearing cover.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to front bearing cover cap screws.
[23] -

IMPORTANT:
Input and output yokes must be aligned to ensure smooth operation. If yokes are not aligned, severe
vibration may occur in driveline during operation.
Apply rigid form-in-place gasket to nut. Install input yoke, washer, and nut on drive shaft. Ensure that input yoke and output
yoke are aligned with each other. Tighten nut to specification.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to input yoke retaining nut.
Yoke Retaining Nut Torque 1100 N˙m (811 lb-ft)
[24] - Connect grease lines on grease elbows (5 and 14).
[25] - Install park brake-to-middle axle drive shaft.
[26] - Install transfer case-to-oscillation joint drive shaft.
Remove and Install Park Brake-to-Middle Axle Drive Shaft
[1] -
CAUTION:
Support park brake disk with a lifting device.
[2] -
CAUTION:

Park Brake-to-Middle Axle Drive Shaft Weight 40 kg (87 lb) approximate
→NOTE:
Removing front cross and bearing assembly from machine also disconnects park brake disk.

LEGEND:
Park Brake-to-Middle Axle Drive Shaft

[3] - If park brake is not engaged, remove disk from machine. See Park Brake (Group 1111).
[4] - Remove cross and bearing assemblies (2) from drive shaft.
[6] -
IMPORTANT:
Number Name Use

• T43514 (us)
Remove and Install Park Brake-to-Middle Axle Drive Shaft

[9] - Install drive shaft assembly. Install park brake disk, if removed. See Park Brake (Group 1111).
[10] - Apply rigid form-in-place gasket to cap screws. Install cap screws.
Number Name Use

• T43514 (us)

Remove and Install Middle Axle-to-Rear Axle Drive Shaft
[1] -
CAUTION:

Middle Axle-to-Rear Axle Drive Shaft Weight 68 kg (150 lb) approximate
LEGEND:
Middle Axle-to-Rear Axle Drive Shaft

[2] - Remove cross and bearing assemblies (2) from drive shaft.
[4] -
IMPORTANT:
[6] - Install drive shaft assembly.
Number Name Use

• T43514 (us)
Remove and Install Middle Axle-to-Rear Axle Drive Shaft

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0242: Axle Mounting Parts

Group 0242 - Axle Mounting Parts

Axle Links, Stabilizers, and Struts Remove and Install
→NOTE:
If replacing or rebuilding suspension struts see DTAC Solution 62580 to aid in identifying the proper strut
used.
Remove and Install Links and Stabilizers
[1] -
CAUTION:
Components are heavy. Use hoist.

Axle Links, Stabilizers, and Struts

Link or Stabilizer Weight 45.5 kg (100 lb) approximate
Links and Stabilizers—Middle and Rear Axles

Stabilizer—Front Axle
LEGEND:
1 Middle Axle Drag Link (2 used)
2 Middle Axle Stabilizer
3 Middle Axle Upper Link
4 Rear Axle Upper Link
5 Rear Axle Stabilizer
6 Rear Axle Drag Link (2 used)
Remove mounting hardware and component.
[3] - Replace bushings, if necessary.
[4] - Clean cap screw threads.
Number Name Use

• TY16285 (us)
• CXTY16285 (canadian) Cure Primer Clean axle link and stabilizer cap screw threads
[5] - Apply rigid form-in-place gasket to cap screw threads.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to axle link and stabilizer cap screws.
[6] - Install component and mounting hardware.
[7] - Tighten mounting hardware to specification.


Link or Stabilizer Cap Screw and Nut Torque 1295 N˙m (955 lb-ft)

Remove and Install Front Suspension Strut
[1] -
Front Axle Suspension Strut

LEGEND:
1 Suspension Strut (2 used)
Inspect suspension struts (1).
Inspect suspension struts for damage.

Inspect suspension struts for oil leakage. (See Front Suspension Strut Leakage Check (Group 9020-25).
Inspect suspension struts for correct ride height. See Check Front Axle Suspension Struts (Operator′s Manual, Section
3-5.)
[2] - Support machine front frame with 20-ton shop stands. Chock middle and rear wheels securely.
[3] -
CAUTION:


Front Axle Weight 2019 kg (4450 lb) approximate
[4] - Remove wheel. See Remove and Install Wheel (Group 0110).
[5] - Lower axle to relieve tension on strut.
[6] -

CAUTION:
Strut will be under compression. Use care when removing mounting hardware.
Remove mounting hardware and strut.
[7] - Inspect, repair, or replace strut, as necessary.
[8] - Clean cap screw threads.
Number Name Use

• TY16285 (us)
• CXTY16285 (canadian) Cure Primer Clean axle link and stabilizer cap screw threads
[9] - Apply rigid form-in-place gasket to cap screw threads.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to axle link and stabilizer cap screws.
[10] - Install suspension strut and mounting hardware.
[11] - Tighten mounting hardware to specification.


Suspension Strut Cap Screw and Nut Torque 1295 N˙m (955 lb-ft)
[12] - Install wheel. See Remove and Install Wheel (Group 0110).
[13] - Remove lifting device and shop stands.
[14] - Recharge suspension struts, if necessary.

Recharge Front Suspension Strut

Checking the Strut Oil Level
[1] -
→NOTE:
If the strut is not completely recharged, it is always advisable to confirm the correct amount of oil in the
struts.
CAUTION:
To install, check heights or to charge and setup the suspension struts may present an extreme safety
hazard. These actions should only be carried out by suitably qualified personnel and by adherence to
sound workshop safety principles.
Open the gas valve and slowly vent gas out of each strut respectively, lower the struts in small increments to keep the
difference in the strut lengths to within 25 mm.
[2] - Continue lowering the struts until the gas ejected out of the valves changes to gas/oil emulsion. The moment the
emulsion appears, the gas valve should be closed.
[3] - Measure the strut lengths/heights.
[4] - Considering the oil level is likely to be correct if the strut length is approximately 5 to 10 mm longer than the initial
charge (no emulsion) "oil flush length", the correct strut length measurement should be 60 mm—70 mm for both the small
trucks and the large trucks.
Strut Length 60—70 mm
2.4—2.8 in.
→NOTE:
If the oil level appears to be incorrect, a complete strut oil and nitrogen charge is required.
Large and Small Truck Suspension Strut Charge Procedure
[1] -
→NOTE:
All struts must be charged at ambient temperature.
CAUTION:
DO NOT recharge a suspension strut that leaks or appears damaged. Repair or replace strut.
→NOTE:
To obtain correct pressure and ride height, struts must be recharged while installed on machine.
Inspect strut for damage and leakage. See Front Suspension Strut Leakage Check . (Group 9020-25.) Remove, repair or
replace, and install, if necessary. See Front Suspension Strut Remove and Install . (Group 0242.)
[2] - Check ride height. See Check Front Axle Suspension Struts . (Operator′s Manual.)
[3] -

CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device. Lifting heavy
components incorrectly can cause severe injury or machine damage.
Lift the truck front end off the front axle using proper lifting device, until the struts reach the fully extended position. As a
safety precaution, chock the truck front end relative to the axle.
Heavy Duty Wheel Chock
JT07372
Used to block the wheels during repair to prevent machine movement.
[4] -
CAUTION:
Avoid personal injury or death from pressurized gas and fluids.
LEGEND:
2 Guard
3 Fitting Cap
Fitting Guard

Fitting
Remove cap screws (1), guard (2), and fitting cap (3).
[5] -
CAUTION:
DO NOT loosen inner nut on recharge fitting. Personal injury will result. Loosen ONLY outer nut.
Turn outside nut (5) on recharge fitting counterclockwise to open. DO NOT loosen inner nut.
[6] -
→NOTE:
Pictures of the strut shown are with the strut not installed in the truck.
Release the internal strut pressure by opening the gas valve. Once all the gas has been vented close the gas valve.
Strut Charge
[7] - Fill the strut completely with Castrol Transmax S, Z or TransSynd oil through the filler plug located on the end cap as
shown. Take precaution to prevent dirt from being introduced into the strut. Check the condition of the O-ring on the filler plug
and replace if necessary. Refit and tighten the filler plug.

Strut Filler Plug
[8] - Remove the chocks and let the machine weight be transferred on to the strut by lowering the lifting device.
[9] -
(350D and 400D)

Attach a drain tube to the gas valve and slowly lower the struts by letting oil out through the gas valve until the distance from
the rod guide/barrel join line to the flat end of the rod reaches 62 mm (350D and 400D), and on the (250D and 300D) until the
strut has reached the fully closed length. It is advisable to adjust the strut heights incrementally and to limit the difference in
the left hand side strut length and the right hand side strut length to a minimum. Close the gas valve.
[10] -
IMPORTANT:
Use ONLY dry nitrogen to charge strut. Other gases can cause oxidation or condensation.

LEGEND:
4 JT03522 Adapter and Hose
5 Nut
Recharge Adapter and Hose

Remove the drain tube and connect JT03522 Adapter and Hose (4) to recharge fitting on strut. Set the nitrogen pressure
regulator to maximum 60—80 bar (870—1160 psi). Open and close the nitrogen air supply in order to pressurize the charge
hose preventing oil being pushed into the charge hose as the strut gas valve is opened. Open the strut gas valve. Using the
nitrogen unit, open the nitrogen supply valve and inflate struts until fully extended strut position is reached. Close the strut gas
valve and the nitrogen supply valve, vent the supply hose and disconnect from the strut gas valve.
Adapter
JT03522
To recharge suspension strut.
Nitrogen Regulator Pressure 60—80 bar
870—1160 psi
[11] -
CAUTION:
DO NOT loosen inner nut on recharge fitting. Personal injury will result. Loosen ONLY outer nut.
Turn outside nut (5) on recharge fitting counterclockwise to open. DO NOT loosen inner nut.
[12] - Adjust the ride height to the correct length by slowly venting nitrogen out of the strut gas valve. See Check Front Axle
Suspension Struts . (Operator′s Manual.). Ensure gas valve is closed.

→NOTE:
The process of letting gas out has to be done in small increments, between each increment repeating the
Strut Ride Height Measuring Procedure.
→NOTE:
Gas is dissolved into the oil during the initial charge. It is recommended that the strut heights be
rechecked the following day and gas added if required (may then only have to add the gas until correct
height is reached).
→NOTE:
Always recheck heights after all adjustments have been completed.
[13] - Operate machine and apply brakes a few times to cycle the suspension strut rods. Recheck ride height. See Check Front
Axle Suspension Struts . (Operator′s Manual.)
[14] - Install the strut gas valve cap, clamps, guard and rubber boot.

Front Suspension Strut Disassemble and Assemble

[1] -
→NOTE:
The following steps should be carried out to disassemble, inspect and assemble the strut cylinders used
on the ADT machines. Ensure that the work area is dust free and closed from contamination and all
components are washed and kept away from any dirt and dust. Seals should be kept in clean plastic wrap
at all times before use.
Remove internal pressure from the strut and remove the strut from the machine. See Front Suspension Strut Remove and
Install . (Group 0242.)
[2] - Secure strut on work bench.
[3] -
CAUTION:
Strut Disassembly
LEGEND:
1 Bearing
2 Barrel
3 Oil Plug
4 Cap Screw
7 Washer
8 Clamp
9 Boot
10 Hose Clamp
11 Ball
19 Piston and Seals
20 Bracket

21 Rod
22 Charging Valve
23 Valve Cap
24 Valve Guard
27 Nut
28 Rod Guide and O-rings
Discharge nitrogen pressure from strut.
a. Remove valve guard (24) and valve cap (23).
CAUTION:
Slowly loosen outer nut on charging valve (22) to discharge nitrogen pressure. Ensure the valve is fully opened and all the
gas is removed. Remove valve after pressure is released.
[4] - Disassemble strut. Remove components (1—28).
[5] - Unscrew rod guide (28) with C-spanner.
[6] - Remove rod (21) from barrel (2).
Barrel Inspection
[7] - Check that the threads are not damaged.
[8] - Flush out and discard any contaminants from the barrel.
→NOTE:
The solvent used for flushing the barrel should be clean at all times.
[9] - Inspect the barrel for scores, nicks and scratches and if felt with a fingernail, regard as unacceptable.
[10] - Longitudinal scratches wider than 0.127 mm (0.005 in.) and deeper than 0.050 mm (0.002 in.) are not acceptable.

[11] - Spiral scratches wider than 0.25 mm (0.010 in.) measured longitudinally are not acceptable.
→NOTE:
A minimum of 25.4 mm (1 in.) is required between scratches which are between 0.13 mm (0.005 in.) and
0.25 mm (0.010 in.)
[12] - Before assembly, the barrel must be honed to a minimum of 0.3 microns.
[13] - Wash the barrel thoroughly and remove all contaminants.
[14] - Inspect rod (21), piston (19) and rod guide (28).
a. New rods and pistons must be fitted to the struts.

→NOTE:
The upgraded rod can be identified with 2 grooves on the bearing end side.
Machines
MACHINE ROD PISTON
250D/300D 182573 161940
350D/400D 182574 161939
b. Clean the piston and rod thoroughly. Clean the cap screw holes in rod.
→NOTE:
Cleaning should be done with clean solvent and dry with air afterwards.
c. Inspect piston and rod for damage.

d. Check for damage, scores or nicks.
→NOTE:
Any scratches or scores that can be felt by running a finger nail over it is not acceptable.
Longitudinal scratches or scores are more detrimental to seal life than radial scores.
e. Ensure there are no burrs on the non-return valve bores and oil passages. There should be no sharp corners on the orifice
and non-return valve holes on the rod.
→NOTE:
Sharp corners will cut the seals and result in strut failure.
f. If there is evidence of rough machining or contamination in the machining marks in the bore of the rod, the bore should
be honed and washed thoroughly.
Tolerances
ROD DIAMETER TOLERANCES
85 mm (3.35 in.) 84.91-84.964 mm (3.343-3.345 in.)
100 mm (3.94 in.) 99.91-99.964 mm (3.933-3.936 in.)
125 mm (4.92 in.) 124.894-124.957 mm (4.917-4.920 in.)
[15] - Check dimension A. If dimension A is not within tolerance, the rod guide must be replaced.

Rod Guide
Rod Guide Sizes
ROD GUIDE SIZES
350D/400D 125.04-125.08 mm (4.923-4.924 in.)
250D/300D 100.40-100.50 mm (3.953-3.957 in.)
[16] - Clean, inspect, and replace parts as necessary.
[17] - Assemble strut.
→NOTE:
Apply a thin layer of petroleum jelly to all internal components during assembly.
[18] - Ensure that all components and seals are washed thoroughly and kept in a dust free environment. Seals should be kept
in clean plastic wrap at all times before use.
[19] - Ensure that the ports and the inside of the barrel is thoroughly cleaned.
[20] - Remove scratch marks from the rod with fine emery paper. Wash the entire rod thoroughly.
[21] - Assemble seals on to rod guide.
a. Fit the primary seal which consists of an O-ring and a seal. The O-ring should be fitted first and then the seal. Note the
orientation of the seal. To install, carefully bend into a kidney shape, keeping the radius of the corners as big as possible
to prevent damaging the seal. Then clip into seal groove working the kidney shape out of the seal.
Seal
b. Fit the primary seal and the backup ring. The backup ring fits inside the step in the primary seal. The seal is fitted with
the step uppermost.
c. Fit the wear bands into the grooves. Fit the two O-rings on the external of the rod guide, one in the groove and the other
between the flanged section and the thread.
Rod Guide
LEGEND:
1 O-ring
2 backup Ring
3 Wear Band
4 Primary Seal
5 O-ring
6 Secondary Seal
7 Wiper Seal
[22] - Assemble rod, rod guide and piston assembly.
a. Secure the cleaned rod on a work bench.
Rod, Rod Guide and Piston Assembly

b. Ensure that the boot is clean and fit the boot over the rod.
c. Clean the rod again with paper towel.
d. Apply some oil on the external side of the rod. Thoroughly oil the internal of the rod guide.
e. Install the rod guide over the rod.
f. Place the three ball bearings in some petroleum jelly.
g. Fit the three ball bearings in the three recesses in the rod. The petroleum jelly will hold the ball bearings in position.
h. The piston has a shallow and deep bore. The deep bore side is fitted over the rod.
i. Position the piston on the rod. Ensure that the piston sits square to the rod.
j. Using a mallet, carefully tap the piston down until it is seated on the end of the rod.
k. Assemble the bracket (20).
l. Fit the assembled bracket onto the piston (19).
m. Fit two cap screws without washers and thread lock and sealer PM37418
Number Name Use
⚬ PM37418 (us)
⚬ PM38621 (canadian) Thread Lock and Sealer (Medium Strength) Secure Magnet Carrier
⚬ 242 LOCTITE ™ (loctite)
to secure the bracket. Fit the other six cap screws with hardened washers but no thread lock and sealer PM37418.
Tighten the cap screws in a crisscross method to the following torque specs.
250D/300D
Cap Screws Torque 80 N·m
59 lb-ft
350D/400D
Cap Screws Torque 140 N·m
103 lb-ft
n. Fit the red wear bands on the two outer grooves of the piston. Fit the bronze wear band on the two inner / center grooves
of the piston. The gap between the wear band ends must be 3—5 mm (0.118—0.197 in.).
Wear Band Ends Gap 3—5 mm
>0.118—0.197 in.
o. Position each wear band ends at 90° to each other. The ends of each wear band must not sit in line to each other.
→NOTE:
The 350D and 400D use four bronze wear bands. The red wear bands are not used in this
application.
p. With the rod securely positioned in the upright position, carefully lower the barrel over the rod assembly.
q. The barrel should slide over the piston, if not, tap the top of the barrel lightly with a mallet. The barrel will come to rest on
the rod guide.
r. Apply petroleum jelly to the threads of the rod guide.
s. Use a C-spanner and tighten the rod guide onto the barrel.
[23] - Oil filling of strut (bench method).
a. Position the strut cylinder with the barrel above the rod.
b. The oil filled into the strut must be filtered through a 5 micron filter.
c. Fully extend the cylinder.
d. Fill the cylinder with Castrol Transmax S, Z or TransSynd oil until the oil pours out of the barrel through the filler hole.
Allow time for oil to settle.
Number Name Use
Castrol Transmax S, Z or TransSynd oil Fill suspension strut.

e. Compress the cylinder completely by moving the barrel downwards (250D and 300D). Allow the oil to flow out of the
cylinder. Close the filler hole when the cylinder is fully compressed . Compress the cylinder until the barrel is 62 mm
(2.441 in.) from the rod end (350D and 400D). The oil will pour out through the filler hole. Close the filler hole.
(350D and 400D)

f. Ensure O-ring is seated firmly on oil plug. Install oil plug.
[24] - Fit the charging valve (22) on the strut.
[25] - Tighten the inner nut on the valve firmly.
[26] - Turn the outer nut counterclockwise to open the valve.
[27] - Screw the gas pipe onto the valve.
[28] - Do not tighten the pipe on the valve, pipe must only be finger tightened. This is to allow air to escape from the pipe
when the nitrogen is released from the bottle.
[29] - Slowly open the tap and release the nitrogen.
[30] - When the air has expelled, tighten the pipe onto the valve.
[31] - Fully open the gas tap. The strut will extend to full length.
[32] - Tighten the outer nut on the valve to seal the gas in the cylinder.
[33] - Install the cylinder on the machine and set the ride heights. See Front Suspension Strut Remove and Install . (Group
0242.) and see Check Front Axle Suspension Struts . (Operator′s Manual.)
Charge strut. See Recharge Front Suspension Strut . (Group 0242.)
[34] - Install clamps on boot.

Replace Links and Stabilizer Bushings

[1] - Remove axle link, stabilizer, or strut to be repaired. See Axle Links and Stabilizers Remove and Install or Front Suspension
Strut Remove and Install .
[2] - To remove bushings:
a. Old style bushings must be cut out with a torch before bore can be prepared for new style bushings.
1. Grind off lip around eye of bore.
2. Bore must be uniform and free of burrs to ensure an even push.
b. New style bushings can be pressed out.
[3] - Apply a suitable assembly lubricant (if required) to outside diameter of bushing and inside diameter of link eye.
[4] - Bushings need to be pressed into bores within 2 degrees as illustrated.
[5] -
Bushing Angles
LEGEND:
1 Axle End

2 Frame End
3 Middle or Rear Axle Upper Link or Drag Link (6 used)
4 Middle Axle Stabilizer
5 Rear Axle Stabilizer
7 Front Axle Right Strut
8 Front Axle Left Strut
Ensure proper bore alignment by holding bore in line with press ram.
[6] -
DFT1341 In Use
Install bushings using DFT1341 Bushing Driver . Press bushings into bore until centered.
Bushing Driver
DFT1341
Install bushings

Front Axle Pivot

Disassemble and Assemble
[1] -
Front Axle Pivot

LEGEND:
1 Socket Head Cap Screw (8 used)
2 Housing Cover
3 Bore
4 Spacer (2 used)
5 Bushing
6 Pin
Remove front axle. Remove spacers (4) when clamping blocks are removed from pin. See Axles (Group 0200).
[2] - Remove socket head cap screws (1) and housing cover (2).
[3] - Press pin (6) from bushing (5).
[4] -

Bushing Driver
Cut old bushing out with a torch. Bushings cannot be pressed out of bores.
[5] - Press pin into new bushing.
[6] - Align new bushing on bore.
[7] - Install bushing using DFT1196 Bushing Driver . Press bushing into bore until centered.
Bushing Driver
DFT1196
Install bushings
[8] - Install housing cover and socket head cap screws.

Middle and Rear Axle Walking Beams

Remove and Install Beam
[1] - Support machine rear frame with 20-ton shop stands. Chock front wheels securely.
[2] -
CAUTION:
Components are heavy. Use lifting device.


Middle Axle Weight 1565 kg (3450 lb) approximate
Rear Axle Weight 1474 kg (3250 lb) approximate
Attach lifting devices to middle and rear axles.
[4] -

Walking Beam Removal

LEGEND:
2 Taper Plug
3 Rubber Mount (2 used)
4 Spacer
Disconnect walking beam from rubber mounts (3).

[5] - Lower middle and rear axles approximately 2.5 cm (1 in.) from walking beam with lifting devices. Support middle and rear
axles with 20-ton shop stands.
[6] -
CAUTION:


Walking Beam Weight 263 kg (580 lb) approximate
Attach a lifting device to walking beam.
[7] - Remove cap screws (1) and washers and spacer (4) from taper plug (2).
[8] -
Bushing Pusher
Insert DFT1199 Bushing Pusher in threaded holes in taper plug.
Bushing Pusher
DFT1199
Remove walking beam from frame
Turn pushers clockwise evenly until walking beam comes off.
[9] - Replace parts as necessary.
[10] - Install bearings and taper plug on walking beam.
[11] - Install walking beam on machine. Install washers, spacer and 8.8 cap screws.
[12] - Apply anti-seize compound to threads of 8.8 cap screws and mounting area of walking beam.
Number Name Use

• PT569 (us)
• TY6332 (canadian) NEVER-SEEZ ™ Anti-Seize Lubricant Walking beam cap screws and mounting area.
• NA LOCTITE ™ (loctite)
Number Name Use
• 19M7713 (us) 8.8 Cap Screws Walking beam cap screws.
Walking Beam Cap Screw

Walking Beam Taper Plug Cap Screw Torque 752 N·m (555 lb-ft)
[13] - Attach lifting devices to middle and rear axles. Raise axles to walking beam.
[14] - Connect walking beam to rubber mounts.
Remove and Install Bushing
[1] -
Bushings
LEGEND:
1 Bushing (2 used)
Remove bushings (1) by cutting with a hand-held grinder or cutting torch.
[2] - Press new bushings into bores using DFT1200 Bushing Driver . Press bushings below edge of bore per specifications.
Bushing Driver
DFT1200
Install bushings in walking beam

Bushing Installation Distance 3.175 mm (0.125 in.) Below Bushing Bore
[3] - Apply Anti-Seize Lubricant to walking beam pivot shaft and bushing.
Number Name Use

• PT569 (us)
NEVER-SEEZ ™ Anti-Seize Lubricant Apply to walking beam pivot shaft.
• TY6332 (canadian)

Remove and Install Rubber Mount
[1] - Support axle with lifting device and remove wheel. See Remove and Install Wheel (Group 0110).
[2] - Support walking beam with shop stand.
[3] -


Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
Absorber Block
LEGEND:
1 Retainer (2 used)
2 Spacer
3 Chain
4 Rubber Mount
Disconnect rubber mount (4) from walking beam and axle. Lower axle with lifting device. Remove rubber mount.
[5] - Install rubber mount on axle. Raise axle with lifting device. Install rubber mount on walking beam.
[6] - Install wheel. See Remove and Install Wheel (Group 0110).

Group 0250 - Axle Shaft, Bearings, and Reduction Gears

Axle Outboard Planetaries
Remove and Install
[2] - Drain planetary. See Change Final Drive Oil (Operator′s Manual, Section 3-7).
[3] - Drain axle oil. See Change Axle Oil (Operator′s Manual, Section 3-7).
[4] -
→NOTE:
Drain plug must be aligned with cutout in axle housing, or oil will not drain properly.
LEGEND:
1 DFT1195 Stud (2 used)
2 DFT1178 Lifting Tool
Planetary Cover Removal

Mark planetary cover and axle housing to ensure correct assembly.
[5] - Remove two cap screws from planetary cover and install DFT1195 Planetary Alignment Studs (1). Remove remaining cap
screws from planetary cover.
Planetary Alignment Stud
DFT1195
Use to align planetary housing and axle shaft.
[6] -

CAUTION:

Axle Outboard Planetaries

Planetary Cover Weight 93 kg (205 lb) approximate
Install two cap screws into threaded jack screw holes. Tighten cap screws to separate planetary cover from hub. Remove cap
screws from jack screw holes and install DFT1178 Lifting Tool (2). Rotate planetary until lifting tool is at top. Attach lifting tool
to a hoist.
Lifting Tool
DFT1178
Use to remove and install planetary cover.
[7] - Remove planetary cover.
[8] - Inspect parts and repair as necessary. Clean cap screws and mating surfaces.
[9] - Apply rigid form-in-place gasket to mating surfaces of axle housing and planetary cover.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to planetary cover.
[10] - Use DFT1178 Lifting Tool and hoist to align planetary cover on planetary housing. Ensure sun gear and planetary gears
are properly aligned. Push planetary cover into housing until ring gear is partially engaged.
[11] - Remove DFT1195 Planetary Alignment Studs . If axle shaft splines are not engaged in differential, use lifting tool and
planetary cover as leverage on axle shaft, to align splines. Turn opposite wheel hub to assist spline alignment.
[12] - Ensure drain plug in planetary cover and cutout in axle housing are aligned. Push planetary inward by hand until cover is
fully seated.
[13] - Apply rigid form-in-place gasket to cap screws.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to planetary housing cap screws.
[14] - Install and tighten cap screws to specification.

Final Drive Planetary Cover Cap Screws Torque 128 N·m
94 lb.-ft.
[15] - Fill final drive with oil. See Change Final Drive Oil . (Operator′s Manual.)
[1] -

Planetary Disassemble
LEGEND:
1 Pin
2 O-Ring
3 Carrier Cover
4 Snap Ring
5 Thrust Washers (2 used)
6 Spacers (2 used)
7 Bearing Rollers (63 used)
8 Inner Bearing Race
9 Gear
Remove snap ring (4) and press out pin (1). Remove O-ring (2) from pin.
[2] -
CAUTION:
Bearing rollers will fall off sleeve when pulled out of gear.
Remove gear (9) and thrust washers (5).
[3] - Disassemble parts (6—8) as shown.
[4] - Clean and inspect parts for wear or damage.
[5] - Assemble parts (6—8) as shown.

[6] - Install gear and thrust washers.
[7] -
→NOTE:
Maintain the temperature of the pins and carrier by assembling components as quick as possible.
Place pins into a freezer and drop the temperature of the pins to approximately -18°C (0°F) proir to installation.
[8] - Using a heat gun, heat the bore of the carrier where the pin is seated to approximately 100°C (212°F).
[9] - Install O-ring (2) on pin (1).
[10] - Align all components in the bore of the carrier.
[11] - Press pin into carrier cover (3).
[12] - Install snap ring (4).
Axle Shafts
Remove and Install
[1] - Remove planetary cover. See Axle Outboard Planetaries .
[2] - Remove axle shaft.
[3] - Inspect parts and repair as necessary.
[4] - Install axle shaft part way into housing.
[5] - Install planetary cover. Use planetary cover and lifting tool as leverage to align axle shaft splines in differential. See Axle
Outboard Planetaries .

Axle Hubs
Remove and Install—350D
[1] - Remove brake caliper. See Service Brakes—350D . (Group 1011).
[2] - Remove outboard planetary. See Axle Outboard Planetaries . (Group 0250.)
[3] - Remove axle shaft. See Axle Shafts . (Group 0250.)
[4] -
LEGEND:
1 Rotor Shield
Rotor Shield
Remove rotor shield (1).
[5] -
LEGEND:
1 Retaining Ring
2 Pin
Spanner Ring and Pin

Remove retaining ring (1) and pin (2) from spanner nut. Remove spanner nut using JDG1351 Spanner Wrench.
Spanner Wrench
JDG1351
Remove Spanner Nut
[6] -
CAUTION:
Avoid possible injury from crushing. Heavy component; use appropriate lifting device.
Ring Gear—Approximate Weight 45 kg
100 lb
Remove ring gear.

[7] -
CAUTION:
Avoid possible injury from crushing. Heavy component; use appropriate lifting device.
Hub and Brake Disk—Approximate Weight 181 kg
400 lb
Attach sling and hoist to hub. Pry on back side of rotor to aid in removing hub from spindle.
[8] -
LEGEND:
1 Inner Bearing
2 Seal
3 O-Ring
Hub Inner Bearing

Remove inner bearing (1) from spindle using a knife-edge bearing puller.
[9] - Remove seal (2) and O-ring (3).
[10] -
LEGEND:
1 Axle Spindle Socket Head Cap Screw (20 used)
Axle Spindle
If necessary to remove spindle, remove axle spindle socket head cap screws (1). Remove spindle. Install spindle. Tighten axle
spindle socket head cap screws to specification.
Axle Spindle Socket Head Cap Screw Dry Torque 786 N·m
580 lb.-ft.
[11] -

LEGEND:
Brake Disk
If brake disk or carrier seal retainer requires replacement, remove cap screws (1) and replace brake disk. Tighten cap screws to
specification.
Brake Disk
Cap Screw Torque 165 N.m
120 lb-ft
[12] - Replace bearing cups, if necessary.
[13] -
LEGEND:
9 Seal Carrier Cap Screw (12 used)
Seal Carrier Cap Screw

If seal carrier requires replacement, remove seal carrier cap screws (9) and seal carrier.
[14] - Clean and inspect seal carrier to hub mating surface.
[15] - Apply PM37465 Flexible Form-In-Place Gasket to seal carrier mating surface. Install seal carrier flush with hub surface.
Number Name Use

• PM37465 (us)
• PM37465 (canadian) Flexible Form-In-Place Gasket Apply to carrier seal mating surface.
[16] - Install seal carrier cap screws. Tighten to specification.

Seal Carrier Cap Screw Torque 10 N·m
89 lb.-in.
[17] - Clean off any excess PM37465 Flexible Form-In-Place Gasket.
Number Name Use

• PM37465 (us)

[18] - Clean and inspect bearings, bearing cups, and seal surface area on spindle for damage or wear.
[19] - Install O-ring on spindle.
[20] - Install inner hub bearing.
[21] - Apply PM37465 Flexible Form-In-Place Gasket to inner seal carrier mating surface.
Number Name Use

• PM37465 (us)
[22] - Use a 197-mm (7.75-in.) diameter plate and hammer to drive seal into seal carrier.
[23] - Clean off any excess PM37465 Flexible Form-In-Place Gasket.
Number Name Use

• PM37465 (us)
[24] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Hub and Brake Disk Weight (approximate) 181 kg
400 lb.
Attach sling and hoist to hub, and install hub.
[25] - Install outer bearing.
[26] -
CAUTION:
Ring Gear Weight (approximate) 45 kg
100 lb.
Install ring gear.
[27] - Install washer and spanner nut.
[28] - Tighten spanner nut to initial specification while rotating hub. This allows the bearing to be seated into position.
Bearing Spanner Nut Initial Torque 1000 N·m
740 lb-ft
[29] - Loosen spanner nut and ensure that the hub rotates freely.
[30] - Tighten spanner nut to final specification while rotating hub.

Bearing Spanner Nut Final Torque 500 N·m
370 lb-ft

[31] - Align hole in spanner nut to nearest slot in spindle.
[32] - Install DF1002 Rolling Drag Torque Bar in hub. See DF1002 Rolling Drag Torque Bar . (Group 9900.) Check rolling drag
using a beam torque wrench.
Rolling Drag Torque Bar
DF1002
To adjust ring gear rolling drag
Ring Gear Hub Bearings Rolling Drag Torque 25 N·m
18 lb.-ft.
[33] - Install pin in spanner nut hole and install ring in groove on spanner nut.
[34] - Install rotor shield and socket head cap screws.
[35] - Install axle shaft. See Axle Shafts . (Group 0250.)
[36] - Install outboard planetary. See Axle Outboard Planetaries . (Group 0250.)
[37] - Install brake caliper. See Service Brakes—350D (Group 1011).
Remove and Install—400D
[1] - Remove wheel. See Remove and Install Wheel (Group 0110).
[2] -
LEGEND:
1 Brake Cooling Oil Line (2 used)
2 Brake Hydraulic Line
Cooling and Hydraulic Lines

Disconnect brake cooling oil lines (1) and hydraulic line (2). Close all openings with caps and plugs.
[3] - Drain wet disk brake housing. See Change Wet Disk Brake Cooling Oil—400D (Operator′s Manual, Section 3-7).
[4] - Remove planetary cover. See Axle Outboard Planetaries .
[5] - Remove axle shaft. See Axle Shafts .
[6] -

LEGEND:
1 Retaining Ring
2 Pin
Retaining Ring and Pin

Remove retaining ring (1) and pin (2) from spanner nut. Remove spanner nut using JDG1351 Spanner Wrench.
Spanner Wrench
JDG1351
Remove Spanner Nut
[7] -
CAUTION:

Axle Hubs
Ring Gear and Axle Hub Weight 170 kg (370 lb) approximate
IMPORTANT:
Face seal rings and lip seal are fragile. Use care when removing axle hub from spindle.
LEGEND:
1 Axle Hub
2 Ring Gear
3 DFT1178 Lifting Tool
Axle Hub Removal

Install hardware as necessary to retain ring gear (2) in axle hub (1). Attach sling and hoist to axle hub. Install DFT1178 Lifting
Tool (3) on axle hub. Use pry bar between axle hub and brake housing. Remove axle hub from spindle.
Lifting Tool
DFT1178
Use to remove and install axle hub.
[8] -

LEGEND:
1 Face Seal Rubber Ring (2 used)
2 Face Seal Metal Ring (2 used)
3 Lip Seal
Hub Oil Seals

Remove face seal metal rings (2) and face seal rubber rings (1). Remove lip seal (3), if necessary.
[9] - Remove ring gear from axle hub.
[10] - Remove bearing cones and cups, if necessary.
a.
Hub Bearings
LEGEND:
1 Outer Bearing Cone
2 Outer Bearing Cup
3 Inner Bearing Cup
4 Inner Bearing Cone
5 Lip Seal Retainer

Remove outer bearing cone (1).
b. Remove lip seal retainer (5) and inner bearing cone (4).
c. Remove bearing cups (2 and 3).
d. Clean, inspect, and replace parts as necessary.
e. Install bearing cups.
[11] - Remove and install spindle, if necessary.
a. Remove brake housing. See Service Brakes—400D (Group 1011).
CAUTION:
Components are heavy. Use hoist.
Spindle
LEGEND:
1 Brake Housing Cover Plate
2 Spindle
Remove two socket head cap screws and install guide pins. Attach hoist to brake housing cover plate (1) and spindle (2).
Remove remaining socket head cap screws. Remove cover plate and spindle.
c. Clean, inspect, and replace parts as necessary.

d. Install spindle and cover plate. Install socket head cap screws. Remove guide pins and install remaining socket head cap
screws.
e. Apply Loctite PM37465 Flexible Form-in-Place Gasket to lip seal retainer mating surface. Install lip seal retainer flush with
hub surface.
Number Name Use
⚬ PM37465 (us)
⚬ PM37465 (canadian) Flexible Form-In-Place Gasket Apply to lip seal retainer mating surface.
⚬ 58730 LOCTITE ™ (loctite)

TRANSMISSION (g) by Belgreen v2.0
f. Install brake housing. See Service Brakes—400D (Group 1011).
[13] - Install lip seal, if removed. Ensure lip seal is clean. Apply a thin coating of axle oil to seal inner edge.
[14] - With isopropyl alcohol, thoroughly clean and dry face seal rubber rings, face seal metal rings, face seal seat on brake
housing, and face seal seat on axle hub. Install metal rings into rubber rings. Install face seal ring assemblies into seats. Apply
a thin coating of brake cooling oil to wear surfaces of face seal metal rings.
→NOTE:
Face seal is not a press fit it is held in place with Grey Loctite against the back of the spindle.
[15] - Align axle hub and brake disk splines. Install axle hub. Install outer bearing. Install ring gear.
[16] - Install washer and spanner nut.
[17] - Tighten spanner nut to a initial specification while rotating hub. This allows the bearing to be seated into position.
Axle Hubs
Bearing Spanner Nut—Initial Torque 1000 N˙m (740 lb-ft)
[18] - Loosen spanner nut and ensure that the hub rotates free.
[19] - Tighten spanner nut to final specification while rotating hub.

Axle Hubs
Bearing Spanner Nut—Final Torque 500 N˙m (370 lb-ft)
[20] - Align hole in spanner nut to nearest slot in spindle.
[21] - Install DF1002 Rolling Drag Torque Bar in hub. Check rolling drag using a beam torque wrench.
Rolling Drag Torque Bar
DF1002
Adjust ring gear rolling drag
Axle Hubs
Ring Gear Hub Bearings Rolling Drag Torque 25 N˙m (18 lb-ft)
[22] - Install pin in spanner nut hole and install ring in groove on spanner nut.
[23] - Perform wet disk brake cooling oil leakage check. See Service Brakes—400D (Group 1011).
[24] - Install axle shaft. See Axle Shafts .
[25] - Install planetary cover. See Axle Outboard Planetaries .
[26] - Connect wet disk brake cooling lines and hydraulic line.
[27] - Fill axle hub. See Change Final Drive Oil (Operator′s Manual, Section 3-7).
[28] - Fill axle. See Change Axle Oil (Operator′s Manual, Section 3-7).
[29] - Fill wet disk brake housing. See Change Wet Disk Brake Cooling Oil—400D (Operator′s Manual, Section 3-7).

Section 03 - TRANSMISSION
Table of contents
Remove and Install Transmission ......................................................................................................... 1
Group 0325 - Input Drive Shafts and U-Joints ..................................................................................... 2
Remove and Install Transmission-to-Transfer Case Drive Shaft ........................................................... 2
Group 0350 - Gear, Shafts, and Power Shift Clutches ....................................................................... 4
Disassemble Transmission ................................................................................................................... 4
Disassemble and Assemble Torque Converter ................................................................................... 12
Disassemble and Assemble Torque Converter Housing ..................................................................... 19
Disassemble and Assemble Retarder and P3 Planetary ..................................................................... 20
Disassemble and Assemble Main Shaft .............................................................................................. 30
Disassemble and Assemble P2 Planetary ........................................................................................... 32
Disassemble and Assemble P1 Planetary ........................................................................................... 35
Disassemble and Assemble Front Support and Charging Oil Pump .................................................... 39
Disassemble and Assemble C1/C2 Clutch ........................................................................................... 47
Disassemble and Assemble C3/C4 Clutch and Main Housing ............................................................. 56
Disassemble and Assemble Control Valve .......................................................................................... 61
Assemble Transmission ...................................................................................................................... 73
Group 0360 - Hydraulic System ........................................................................................................... 84
Remove and Install Transmission Oil Cooler ....................................................................................... 84
Transmission Retarder Accumulator Remove and Install ................................................................... 85

Section 03 - TRANSMISSION Group 0325: Input Drive Shafts and U-Joints

Remove and Install Transmission
Engine and transmission are removed together. Remove engine and transmission, then remove transmission from engine. (See
Engine in Group 0400.)

Section 03 - TRANSMISSION Group 0325: Input Drive Shafts and U-Joints

Remove and Install Transmission-to-Transfer Case Drive Shaft
[1] - Tilt cab. See Tilt Cab (Operator′s Manual Section 3-2).
[2] -
Transmission-to-Transfer Case Drive Shaft

LEGEND:
1 Nut (8 used)
2 Washer (8 used)
5 Guard (2 used)
6 Nut (4 used)
7 Washer (8 used)
Remove nuts (6), washers (7), cap screws (8), and guards (5).
[3] - Remove cap screws (3), washers (2), and nuts (1) from flanges of drive shaft assembly (4).
[4] -
CAUTION:

Transmission-to-Transfer Case Drive Shaft Weight 91 kg (200 lb) approximate
Remove drive shaft assembly.
[6] -

Section 03 - TRANSMISSION Group 0350: Gear, Shafts, and Power Shift Clutches
IMPORTANT:
[7] - Apply rigid form-in-place gasket to cap screws (3). Install nuts (1), washers (2), and cap screws. Tighten to specification.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to cap screws.
Drive Shaft Universal Joint Cap Screw Torque 210 N˙m (154 lb-ft)
[8] - Install guards, washers, cap screws, and nuts.

Group 0350 - Gear, Shafts, and Power Shift Clutches

Disassemble Transmission
[1] -
Transmission In Repair Stand

Clean and drain transmission to prevent contamination of parts.
[2] -
CAUTION:
The approximate weight of transmission is 499 kg (1100 lb).

Transmission
Transmission Weight 499 kg (1100 lb) approximate
Install JDG1501-6 Main Case Holding Fixture on main housing so dipstick side is away from mounting plate. Fasten holding
fixture to repair stand D05223ST Engine Repair Stand.
Main Case Holding Fixture
JDG1501-6
To mount transmission on engine repair stand.

Engine Repair Stand

Engine Repair Stand
D05223ST
To support transmission during repair.
[3] - Remove all sensors and output flange.
[4] - Position transmission with torque converter up.
[5] - Remove any brackets on torque converter that restrict movement of converter.
[6] -
LEGEND:
1 Plug
2 O-Ring
3 Cap Screw
4 Shim
5 Torque Converter
6 Cap Screw Removal Tool
Torque Converter Removal
Lockup Clutch Test Port

Remove threaded plug (1) and O-ring (2).
[7] - Apply air pressure to lock up test port to hold converter and turbine shaft stationary.
[8] - Use JDG1501-12 Spanner Nut Tool (6) to remove cap screw (3) and shim (4).
Spanner Nut Tool

JDG1501-12
To remove torque converter retaining cap screw.
[9] -
CAUTION:
Heavy componet use hoist.
LEGEND:
8 Eye Bolt
Torque Converter Eye Bolt

Install three eye bolts (8) equally spaced in torque converter cover and lift with hoist.
[10] - Store torque converter on wooden blocks tall enough to keep converter hub from contacting work bench.
[11] -
Torque Converter Housing Removal

LEGEND:
9 Torque Converter Housing
11 Gasket
12 Main Housing
Remove cap screw (10) to remove torque converter housing (9). Remove the seven cap screws from inside the converter
housing using mechanical fingers.
[12] - Position transmission with control valve up.
[13] -

LEGEND:
1 Gasket
2 Standoff and Harness Connector
3 Control Valve
Control Module Removal

Remove cap screws (4) holding control valve.
[14] - Remove harness connector, snap ring, and bracket.
[15] -
CAUTION:
The approximate weight of control valve is 25 kg (56 lb).

Transmission
Control Valve Weight 25 kg (56 lb) approximate
Remove control valve (3) and gasket (1) by either prying up on reinforced tabs or using jack bolts.
[16] - Position transmission with output shaft up.
[17] -
CAUTION:
The approximate weight of Retarder is 34 kg (75 lb).

Transmission
Retarder Weight 34 kg (75 lb) approximate

Retarder Removal
Retarder and Lifting Bracket

LEGEND:
13 Main Housing
14 Gasket
15 Retarder
16 M12 Cap Screw
17 Seal
40 M10 Cap Screw
41 M12 Cap Screw
Remove retarder (15) using M10 lifting eye bolt and hoist. Retarder includes P3 planetary and C5 piston.
[18] -
LEGEND:
18 Main Shaft
19 Shim
20 Thrust Bearing
Main Shaft Removal

Remove thrust bearing (20), shim (19), and main shaft (18).

[19] -
LEGEND:
21 P2 Planetary
22 C5 Clutch Pack
23 Reaction Plates (9 used)
24 Friction Plates (8 used)
P2 Planetary and C5 Clutch Plates
Clutch Plate Cone

Remove P2 planetary (21) from housing
[20] - Remove C5 clutch pack (22) from housing.
[21] - Inspect plates for wear.

Transmission
C5 Friction Plate Minimum Thickness 3.48 mm (0.137 in.)
C5 Friction Plate Oil Groove Minimum Depth 0.20 mm (0.008 in.)
C5 Reaction Plate Minimum Thickness 2.41 mm (0.095 in.)
C5 Plate Cone Maximum Cone 0.25 mm (0.010 in.)
[22] -
LEGEND:
25 P1 Planetary
P1 Planetary
Remove P1 planetary (25) from main housing.

[23] - Position transmission with input shaft up.
[24] -
LEGEND:
26 Cap Screw
27 Front Support
28 Cap Screw
Front Support
Remove front support (27).
[25] -
LEGEND:
29 Turbine Shaft and C1/C2 Clutch Module
C1/C2 Clutch Module Removal

Remove turbine shaft and C1/C2 clutch module (29) from main housing using M16 eye bolt and hoist.
[26] - Store C1/C2 clutch module so that it will not roll and be damaged.
[27] - Position main housing horizontally.
[28] -
LEGEND:
30 C3/C4 Clutch
31 Main Housing
C3/C4 Clutch Removal

Remove cap screws (32) and C3/C4 clutch (30) by sliding it out input end of main housing (31).
[29] - Remove main housing from stand for cleaning and inspection.

[30] - Inspect main housing clutch plate splines.

Transmission
Clutch Plate Splines Maximum Wear 1.15 mm (0.045 in.)

Disassemble and Assemble Torque Converter
Torque Converter--Exploded View

LEGEND:
1 Converter End Plug
2 O-Ring
3 Cap Screw
4 Shim

5 Nut (36 used)

6 Torque Converter Cover (complete)
7 Converter Cover
8 Converter Cover
9 Bushing
10 Lockup Piston Seal Ring
11 Lockup Clutch Piston
13 Dampener
14 Lockup Clutch Backplate
16 Thrust Bearing
17 Turbine
18 Thrust Bearing
19 Star Washer
20 Snap Ring
21 Stator Thrust Plate
22 LH Stator Thrust Washer
23 Stator Race
24 Stator Roller (13 used)
25 Stator Spring (13 used)
26 Stator Cam
27 Shim
28 Pump Thrust Bearing Race
29 Pump Thrust Bearing
30 O-Ring
31 Thrust Bearing Race
32 Torque Converter Pump
33 T-Head Cap Screw (36 used)
[1] - Place torque converter on flat surface with oil pump tangs downward. Support on wooden blocks that keep oil pump tangs
from contacting workbench.
[2] - Scribe a line on converter cover (7) and torque converter pump (32) to maintain converter balance and aid in assembly.
[3] - Disassemble torque converter.
[4] - Measure stator thrust plate (21) thickness.

Torque Converter
Stator Thrust Plate Minimum Thickness 9.45 mm (0.372 in.)
[5] - Measure thickness of lockup clutch backplate (14) wear surface.

Torque Converter
Lockup Clutch Backplate Minimum Thickness 11.79 mm (0.464 in.)
Lockup Clutch Backplate Maximum Distortion 0.15 mm (0.006 in.)
[6] - Remove dampener (13) from converter cover (7).
[7] - Measure thickness across lockup clutch friction surfaces.

Torque Converter
Lockup Clutch Friction Surface Minimum Thickness 8.51 mm (0.335 in.)
Maximum Distortion 0.51 mm (0.020 in.)
[8] - Measure spline wear between turbine (17) and dampener (13).
Torque Converter
Turbine and Dampener Spline Wear Maximum Play 0.38 mm (0.015 in.)
[9] - Remove lockup clutch piston (11).
[10] - Remove seal rings (10 and 12) from lockup clutch piston.

[11] - Measure thickness of lockup clutch piston.

Torque Converter
Lockup Clutch Piston Minimum Thickness 6.53 mm (0.257 in.)
Torque Converter Cover Bushing Maximum Inside Diameter 66.91 mm (2.634 in.)
[12] - Remove thrust bearing (16).
[13] - Inspect all parts for wear or damage. Replace as necessary.
[14] - Install stator race (23) into stator cam (26).
[15] -
Stator and Roller Installation
Stator Assemble
LEGEND:
20 Snap Ring
23 Stator Race
24 Roller
25 Spring
26 Stator Cam
Lubricate and install stator rollers (24) and stator springs (25) into stator cam (26). Install roller into small end of stator cam
pocket.
[16] - Install stator thrust washer (22) and stator thrust plate (21) onto stator cam (26).

[18] -
LEGEND:
7 Converter Cover (Complete)
8 Converter Cover
9 Bushing
13 Dampener
16 Thrust Bearing
17 Turbine
Torque Converter Assemble

If removed, install bushing (9) into bore of cover (8) using bushing installer.
[19] - If new bushing is installed, position turbine (17) into new bushing and check for freedom of movement. Remove turbine
after checking for movement.
[20] - Install lockup clutch piston seal rings (10 and 12).
[21] - Install lockup clutch piston (11), dampener (13) and lockup clutch backplate (14) in cover (8) with cap screws (15).
Torque Converter
Clutch Backplate Cap Screw Torque 30 N˙m (22 lb-ft)
[22] - Install thrust bearing (16) and turbine (17).
[23] -

Torque Converter
LEGEND:
1 Converter End Plug
2 O-Ring
3 Cap Screw
4 Shim
5 Nut (36 used)
6 Torque Converter Cover (complete)
7 Converter Cover
8 Converter Cover
9 Bushing
13 Dampener
16 Thrust Bearing
17 Turbine
18 Thrust Bearing
19 Star Washer
20 Snap Ring
23 Stator Race
24 Stator Roller (13 used)
25 Stator Spring (13 used)
26 Stator Cam
27 Shim
28 Pump Thrust Bearing Race
29 Pump Thrust Bearing
30 O-Ring
31 Thrust Bearing Race
32 Torque Converter Pump
33 T-Head Cap Screw (36 used)
Install parts (27—31).
[24] - Align scribe marks on converter cover and pump.
[25] - Install four nuts (5) and cap screws (33) evenly spaced on torque converter.
Torque Converter
Torque Converter Cover Cap Screw Torque 33 N˙m (24 lb-ft)
[26] -
Torque Converter Turbine Hub Shim Measurement

LEGEND:
A Measurement Without End Play Gauge
B Measurement With End Play Gauge
1 Shim Location
2 End Play Gauge
With converter on flat surface, measure distance from top of torque converter cover to thrust surface of turbine assembly with
depth micrometer. Record as dimension A.
[27] - Place JDG1501-13 End Play Gauge into converter cover and measure again. This is dimension B.
End Play Gauge
JDG1501-13
To measure end play in torque converter
[28] - Subtract dimension B from dimension A to get dimension C.
[29] - Use table to determine proper shim to be used.
→NOTE:
If new shim is required, torque converter must be disassembled and proper shim installed.
Torque Converter Turbine Hub Shims
Dimension C Part Number Shim Thickness
0.153—0.35 mm
— 0.000
(0.006—0.014 in.)
0.36—0.58 mm 0.27 mm
AT256597
(0.014—0.023 in.) (0.011 in.)
0.59—0.81 mm 0.48 mm
AT256596
(0.023—0.032 in.) (0.019 in.)
0.81—1.00 mm 0.711 mm
AT256595
(0.032—0.040 in.) (0.028 in.)
[30] - Install remaining nuts (5) and cap screws (33).

Torque Converter
Torque Converter Cover Cap Screw Torque 33 N˙m (24 lb-ft)

Disassemble and Assemble Torque Converter Housing

LEGEND:
2 Breather
3 Converter Housing
4 Transmission Input Speed Sensor
5 O-Ring
6 Transmission Input Speed Sensor Retainer
7 Cap Screw
Torque Converter Housing
[1] - Remove breather (2) and transmission input speed sensor (4).
Transmission
Transmission Input Speed Sensor Resistance 300 ± 30 ohms
[2] - Inspect all components for wear or damage. Replace if necessary.
[3] - Install breather (2) and transmission input speed sensor (4).
Transmission
Breather Vent Torque 14 N˙m (124 lb-in.)
Transmission Input Speed Sensor Cap Screw Torque 27 N˙m (20 lb-ft)

Disassemble and Assemble Retarder and P3 Planetary

[1] -
Retarder and P3 Planetary

LEGEND:
1 Retarder Housing Gasket


5 Retarder and P3 Planetary Module
6 P3 Planetary Carrier
7 Output Shaft Assembly
8 Bushing
9 Output Shaft
10 Internal Retaining Ring
11 P3 Indexing Ring
13 Thrust Washer
14 External Retaining Ring
15 P3 Planetary Spindle (4 used)
16 P3 Thrust Washer (4 used)
17 P3 Pinion Gear (4 used)
18 Roller Bearing (8 used)
20 Roller Bearing Assembly
21 Retarder Stator Assembly
22 External Retaining Ring
23 Spring and Retainer Assembly
24 C5 Clutch Piston
25 C5 Piston Seal Ring
27 Roller Bearing Cup
28 Retarder Stator
29 O-Ring
30 Retarder Seal Ring
32 Rotor Assembly
34 Retarder Housing Assembly
35 Retaining Ring
36 Valve Plug
37 O-Ring
38 Valve Spring
39 Retarder Valve
40 Spring Pin
41 Tachograph Plug
42 Tachograph Plug Washer
43 Retarder Housing
45 Temperature Sensor Assembly
46 Retainer
47 Cap Screw
48 O-Ring
49 Valve Plug
50 Retaining Ring
52 Lock Nut Retainer
53 Bearing Lock Nut
54 Oil Seal
57 Speed Sensor
58 O-Ring
59 Speed Sensor Retainer
60 Cap Screw
61 Channel Plate Gasket
62 Channel Plate
63 Separator Plate Gasket
64 Solenoid Separator Plate
66 Retarder Control Body Assembly
68 Solenoid Connector
69 Solenoid Cover
70 Solenoid Cover Gasket

71 Retaining Pin
72 Valve Stop
73 Spring
74 Exhaust Back-Fill Valve
75 Retaining Ring
76 O-Ring
77 Plug
78 Spring
79 Retaining Pin
80 Retarder Control Body
81 Retarder Control Valve
82 Solenoid
83 Pressure Tap Plug Assembly
84 Pressure Tap Plug
85 O-Ring
Remove retarder control body (66).
[2] - Remove channel plate (62), solenoid separator plate (64) and gaskets.
[3] - Remove solenoid cover (69) and gaskets.
[4] - Remove retaining pin (79) and solenoid (82) from retarder control body (80).
[5] - Check resistance of retarder solenoid.

Retarder
Control Solenoid Resistance 2—5 ohms
[6] - Remove retarder control valve (81). Inspect for wear or damage.
[7] - Remove pin (71), parts (72—78).
[8] - Remove temperature sensor (45).
[9] - Remove output speed sensor (57) and check resistance.

Retarder
Output Speed Sensor Maximum Resistance 300 ±30 ohms
[10] - Remove tachograph plug (41) and washer.
[11] - Remove plug (49).
[12] - Remove parts (35—39). Remove spring pin (40) only if damaged.
[13] - Remove seal (54).
[14] - Bend tab on lock nut retainer (52) and remove lock nut (53) using Spanner Nut Torque Tool JDG1501-12.
[15] - Support retarder housing to allow P3 carrier removal using JDG1501-12 and press.
[16] - Remove cap screws (55) and retarder gasket (31).
[17] - Remove rotor assembly (32) and inspect splines.

Retarder
Rotor Assembly Splines Maximum Wear 0.38 mm (0.015 in.)
[18] - If replacement is needed remove bearing assembly (51).
[19] - Remove retaining ring (14) and thrust washer (13) to remove output shaft (7).
[20] - Inspect splines.

Retarder
Output Shaft and P3 Carrier Splines Maximum Wear 0.38 mm (0.015 in.)
[21] - If replacement is needed remove bearing assembly (20).
[22] - Measure P3 pinion gear end play with feeler gauge.

P3 Planetary
Pinion Gear End Play 0.94 mm (0.037 in.) Maximum
[23] -
LEGEND:
1 Indexing Flat
2 No Wear
3 Abnormal Wear
Carrier Indexing Ring

Remove retaining ring (10) and inspect indexing ring (11). Check spindles (15) for abnormal wear where the spindles contact
indexing ring.
[24] -
LEGEND:
1 Spindle Edge
5 Output Shaft (Complete)
6 Bushing
7 Output Shaft
8 Retaining Ring
9 Indexing Ring
11 Thrust Washer
12 Retaining Ring
Spindle Wear
Retarder P3 Carrier Exploded View

Inspect planetary spindles. If the planetary spindles have a sharp edge (1) instead of a radius edge, replace spindles.
P3 Planetary
Planetary Spindle Edge Wear Wear Added Radius 0.25—1.50 mm (0.01—0.059)
[25] - Measure thickness of thrust washers (14 and 17).

P3 Planetary
Thrust Washers Minimum Thickness 1.40 mm (0.055 in.)
Thrust Washer Step Wear Maximum Depth 0.12 mm (0.005 in.)
[26] - Inspect bushing (6) inside the end of output shaft (7) for wear or damage.
Retarder
Output Shaft Bushing Maximum Inside Diameter 36.14 mm (1.423 in.)
[27] -
CAUTION:
C5 piston springs are highly compressed. A spring compressor must be used to control the release of
spring force. Personal injury can occur if spring force is not controlled.
LEGEND:
22 Snap Ring
23 Spring and Retainer
24 C5 Clutch Piston
26 Seal Ring
28 Retarder Stator
29 O-Ring
C5 Clutch Piston
Compress spring (23) and remove snap ring (22) using JDG1501-8 C1-C2-C5 Spring Compressor Tool and C5 Spring Compressor
from JDG1501-7 C1 Spring Compressor.
C1-C2-C5 Spring Compressor Tool
JDG1501-8
To compress springs for C1, C2, and C5 clutches.
C1 Spring Compressor
JDG1501-7
[ The JDG1501-7 C1 Spring Compressor includes the C1, C2, and C5 Spring Compressors. ]
→NOTE:
The JDG1501-7 C1 Spring Compressor includes the C1, C2, and C5 Spring Compressors.

[28] - Remove C5 clutch piston (24) from retarder stator (28).
[29] - Remove bearing cup (27) only if replacing bearing (20). Cup is a press fit.
[31] - Install bearing cup (27) if removed.
[32] - Install inner seal rings (25 and 26) onto C5 clutch piston (24).
[33] - Align tab on back of C5 clutch piston (24) with notch for the piston tab in retarder stator (28) and install.
[34] - Align tab on spring retainer with notch in retarder stator.
CAUTION:
C5 piston springs are highly compressed. A spring compressor must be used to control the release of
spring force. Personal injury can occur if spring force is not controlled.
[35] - Compress spring and retainer using the JDG1501-8 C1-C2-C5 Spring Compressor Tool and the C5 Spring Compressor
from JDG1501-7 C1 Spring Compressor.
[36] - Install snap ring (22) so ends clear tab in spring retainer.
[37] -
LEGEND:
5 Output Shaft (Complete)
6 Bushing
7 Output Shaft
8 Retaining Ring
9 Indexing Ring
11 Thrust Washer
12 Retaining Ring
P3 Planetary Pinion Exploded View

Assemble P3 planetary.
[38] - Planetary spindles must not rotate after indexing rings have been installed or lubrication flow may be blocked.
When indexing ring slots are worn on one corner (normal wear condition), flip indexing ring over to obtain new, unworn contact
surface. If both surfaces are worn, replace indexing ring.
[39] - If components were replaced check pinion end play with feeler gauge.
P3 Planetary
[40] -

Retarder Assembly
LEGEND:
5 Retarder and P3 Planetary Assembly
7 Output Shaft Assembly
20 Roller Bearing
21 Retarder Stator Assembly
22 Retaining Ring
23 Spring and Retainer

24 C5 Clutch Piston
25 Piston Seal Ring
26 Seal Ring
28 Retarder Stator
29 O-Ring
32 Rotor Assembly
34 Retarder Housing Assembly
35 Retaining Ring
36 Valve Plug
37 O-Ring
38 Valve Spring
39 Retarder Valve
40 Spring Pin
41 Tachograph Plug
42 Tachograph Plug Washer
43 Retarder Housing
45 Temperature Sensor Assembly
46 Retainer
47 Cap Screw
48 O-Ring
49 Valve Plug
50 Retaining Ring
52 Lock Nut Retainer
53 Bearing Locknut
54 Oil Seal
57 Speed Sensor
58 O-Ring
59 Speed Sensor Retainer
60 Cap Screw
Install O-Ring (29).
[41] - Install output shaft assembly (7) in P3 planetary carrier.
[42] - Install thrust washer (13) and retaining ring (14).
[43] - Install bearing (20) if removed.
[44] - Install bearing cup (44) if removed.
[45] - Place P3 planetary carrier (6) on work table with output shaft up.
[46] - Install retarder stator assembly (21) on output shaft.
[47] - Install seal rings (30 and 33) on rotor (32) and place rotor on output shaft.
[48] - Install two M8 guide pins in retarder housing (43) and place gasket (31) and retarder housing over stator aligning holes.
[49] - Remove guide pins and install cap screws (55) and tighten to specification.
Retarder
Retarder Housing Cap Screw Torque 14 N˙m (124 lb-in.)
[50] - Install output speed sensor (57) and O-ring with bracket and cap screw.
Retarder
Output Speed Sensor Cap Screw Torque 27 N˙m (20 lb-ft)
[51] - Install plug (49) and O-ring (48) with retaining ring (50).

[52] - Install plug and washer (41 and 42).

Retarder
Tachograph Plug Torque 62 N˙m (46 lb-ft)
[53] - Install parts (35—40).
[54] - Install temperature sensor parts (45—47).

Retarder
Temperature Sensor Cap Screw Torque 27 N˙m (20 lb-ft)
[55] -
IMPORTANT:
Press force should not exceed 10 230 N (2300 lb-force). Do not over tighten bearing lock nut (53) 200
N˙m (148 lb-ft). Damage to bearings could occur.
Rotate cover assembly while pressing bearing to position.
Support P3 planetary and install roller bearing (51) into retarder housing with press.
[56] - Install new lock nut retainer (52). Do not use lock nut retainer tabs more than once.
[57] - Install and tighten bearing lock nut (53) with JDG1501-12 Spanner Nut Torque Tool. Tighten lock nut to initial torque
setting. Do not bend tab or install seal at this time.
Retarder
Bearing Lock Nut Initial Torque 200 N˙m (148 lb-ft)
[58] -
P3 Carrier Rolling Drag Torque Check

LEGEND:
1 JDG1501-12 Spanner Nut Torque Tool
Check rolling drag torque of P3 carrier.
Retarder
P3 Carrier Output Bearing Rolling Drag Torque 3 N˙m (27 lb-ft) maximum
[59] -

Retarder Control Valve

LEGEND:
43 Retarder Housing
61 Channel Plate Gasket
62 Channel Plate
66 Retarder Control Body Assembly
68 Solenoid Connector
69 Solenoid Cover
70 Solenoid Cover Gasket
71 Retaining Pin
72 Valve Stop
73 Spring
74 Exhaust Back-Fill Valve
75 Retaining Ring
76 O-Ring
77 Plug
78 Spring
79 Retaining Pin
80 Retarder Control Body
81 Retarder Control Valve
82 Solenoid
83 Pressure Tap Plug Assembly
84 Pressure Tap Plug
85 O-Ring
Install pressure tap plug (84) and O-ring (85).

Pressure Tap Plug Torque 12 N˙m (106 lb-in.)
[60] - Install retarder control valve (81) and parts (75—78) into control valve body (80).

[61] - Install exhaust valve backfill valve parts (72—74).
[62] -
IMPORTANT:
Install solenoid retaining pin (79) in off-center hole in control valve body bore. Installing retaining pin in
centerline bore will destroy solenoid.
Install solenoid (82) and retaining pin (79) smooth end first in off-center hole in control valve body.
[63] - Install parts (67—71) control valve body.


Solenoid Cover Cap Screw Torque 27 N˙m (20 lb-ft)
[64] - Install channel plate and solenoid plate parts (61—66) to retarder housing.

Retarder Control Body Torque 27 N˙m (20 lb-ft)
Disassemble and Assemble Main Shaft

LEGEND:
1 Shim
2 Thrust Bearing
3 Main Shaft
4 Snap Ring
5 P2 Sun Gear
6 Spacer
7 Main Shaft
Main Shaft
[1] - Remove snap ring (4), P2 sun gear (5), thrust bearing (2) and spacer (6).
[2] -
LEGEND:
1 35.92 mm (1.414 in.)
2 52.98 mm (2.086 in.)
3 35.92 mm (1.414 in.)
Main Shaft Journals Measurement

Measure main shaft journals. Inspect all parts for wear or damage. Replace parts as necessary.
Main Shaft Journal

Journal 1 Minimum Diameter 35.92 mm (1.414 in.)

[3] -
→NOTE:
Measurement for selective shim and thrust bearing is performed during final assembly.
Install spacer, thrust bearing, P2 sun gear and snap ring. Snap ring must lock in position.

Disassemble and Assemble P2 Planetary
P2 Planetary
LEGEND:
1 Snap Ring
3 Snap Ring
4 P2 Indexing Ring
6 Bushing
12 Thrust Bearing

13 P3 Planetary Ring Gear

[1] - Remove P3 planetary ring gear (13).
[2] -
LEGEND:
P2 Pinion Gear
Check P2 pinion gear (9) end play in P2 carrier (5) with feeler gauge.
P2 Planetary
[3] - Disassemble P2 planetary.
[4] -
LEGEND:
1 Indexing Flat
2 No Wear
3 Abnormal Wear

Inspect indexing ring and spindles for abnormal wear where spindles (11) contact indexing ring.
[5] -
LEGEND:
1 Sharp Flat Edge (Radius Added on Edge 0.25—1.50 mm)
Planetary Spindle Wear

Inspect planetary spindle. If the planetary spindle has a sharp edge instead of a radius edge, replace spindles.
P2 Planetary
Planetary Spindle Edge Wear Wear Added Radius 0.25—1.50 mm (0.01—0.059 in.)
[6] -
LEGEND:
1 Snap Ring
3 Snap Ring
4 P2 Indexing Ring
6 Bushing
12 Thrust Bearing
13 P3 Planetary Ring Gear
P2 Planetary Exploded View

Measure thickness of thrust washers (7 and 10).
P2 Planetary
Thrust Washers Minimum Thickness 1.40 mm (0.055 in.)
[7] - Measure inside diameter of bushing (6) inside P2 planetary carrier (5) for wear or damage.
P2 Planetary
Bushing Maximum Inside Diameter 53.23 mm (2.096 in.)
[8] - Check spline wear of P2 carrier (2) and P3 planetary ring gear (13).
P2 Planetary
Carrier Spline Wear Maximum Wear 0.38 mm (0.015 in.)
[10] - Assemble planetary.
[11] - Planetary spindles must not rotate after indexing ring has been installed or lubrication flow may be blocked.
[12] - If any components are replaced measure all pinions for end play with feeler gauge.
P1 Planetary
[13] - Install thrust bearing (12) and ring gear (13).

Disassemble and Assemble P1 Planetary
P1 Planetary
LEGEND:
1 P1 Planetary (Complete)
2 Snap Ring
4 Retaining Ring
5 P1 Indexing Ring
6 P1 Pinion Spindle (6 used)
8 P1 Carrier Bushing
10 P1 Pinion Gear
13 Thrust Bearing
14 P2 Ring Gear
[1] - Remove P2 ring gear.
[2] - Check P1 planetary pinions for end play with feeler gauge.
P1 Planetary
[3] - Disassemble P1 planetary.
[4] -
LEGEND:
1 Indexing Flat
2 No Wear
3 Abnormal Wear

Inspect indexing ring for abnormal wear where the spindles (6) contact.
[5] -
LEGEND:
Sharp Flat Edge (Radius Added on Edge 0.25—1.50
1
mm)
2 Snap Ring
4 Retaining Ring
5 P1 Indexing Ring
6 P1 Pinion Spindle (6 used)
8 P1 Carrier Bushing
10 P1 Pinion Gear
13 Thrust Bearing
Planetary Spindle Wear 14 P2 Ring Gear

P1 Planetary
Inspect planetary spindle. If the planetary spindle has a sharp edge (1) instead of a radius edge, replace spindle.
P1 Planetary
Planetary Spindle Edge Wear Wear Radius 0.25—1.50 mm (0.01—0.059 in.)
[6] - Inspect thrust washers (9).

P1 Planetary
Thrust Washer Minimum Thickness 1.40 mm (0.055 in.)
[7] - Inspect bushing (8) inside P1 planetary for wear or damage.

P1 Planetary
Planetary Bushing Maximum Inside Diameter 89.32 mm (3.516 in.)
[8] - If replacement is required press new bushing to correct distance below carrier surface.
P1 Planetary
Planetary Bushing Depth Distance 0.40 mm (0.16 in.)
[9] - Check spline wear of P1 carrier (7) and P2 planetary ring gear (14).
P1 Planetary
Carrier Splines Maximum Wear 0.38 mm (0.015 in.)
[11] - Assemble P1 planetary.

[12] - Planetary spindles must not rotate after indexing rings have been installed or lubrication flow may be blocked.
[13] - If any components are replaced measure all pinions for end play with feeler gauge.
P1 Planetary
Pinion Gear End Play Maximum 0.94 mm (0.037 in.)

Disassemble and Assemble Front Support and Charging Oil Pump
Front Support and Oil Pump

LEGEND:
3 Front Support
4 O-Ring

5 Seal
7 Pump Housing
8 Bushing
9 Pump Housing
10 Pump Gear Set
11 Bushing
12 Wear Plate
14 Front Support (complete)
15 Ground Sleeve
16 Front Support
17 Dowel Pin
18 Front Support Sleeve
19 Ball
20 Spring
21 Dowel Pin
22 Front Support
23 Dowel Pin
24 Seal Ring (3 used)
25 Roller Bearing
[1] - Remove seal rings (24) from front support hub.
[2] - Remove pump housing (7).
[3] - Use JDG1501-11 Main Pressure Relief Spring Compressor to remove pin (21).
Main Pressure Relief Spring Compressor
JDG1501-11
To compress main pressure relief spring.
[4] - Remove spring (20) and ball (19).
[5] -
Gear Cavity Depth in Pump Housing

Measure gear cavity depth in pump housing.
Front Support and Charging Oil Pump

Pump Housing Gear Cavity Maximum Depth 19.04 mm (0.750 in.)
[6] -

Gear Cavity Diameter

Measure gear cavity diameter in pump housing.

Pump Housing Gear Cavity Maximum Inside Diameter 150.25 mm (5.915 in.)
[7] - Inspect bushing (8) inside pump housing for wear or damage. Replace if necessary.

Pump Housing Bushing Maximum Inside Diameter 89.19 mm (3.511 in.)
[8] - Install gear set (10) into pump housing (7).
[9] -
LEGEND:
1 Gear Set
2 Pump Gear
Gear Side Clearance

Measure pump gear side clearance.

Pump Gear Side Clearance Maximum Clearance 0.10 mm (0.004 in.)
[10] -

Gear Tooth Clearance

Measure gear tooth tip clearance.

Gear Tooth Tip Maximum Clearance 0.15 mm (0.006 in.)
[11] -
LEGEND:
1 Pump Housing
2 Driven Gear
Driven Gear Clearance

Measure driven gear-to-pump housing clearance.

Driven Gear-to-Pump Clearance Maximum Clearance 0.30 mm (0.012 in.)
[12] - Replace pump housing and gear set if any measurement is out of specification.
[13] -

Gear Set and Bushing

LEGEND:
10 Gear Set
11 Bushing
Measure inside diameter of bushing (11) inside gear set (10).

Pump Bushing Maximum Inside Diameter 66.93 mm (2.635 in.)
[14] - Replace bushing if damaged or worn.
[15] -
LEGEND:
12 Wear Plate
15 Ground Sleeve
22 Front Support
25 Bearing
Front Support Sleeve and Support

Inspect wear plate (12) for wear or damage. Remove and replace if necessary.
[16] - Inspect bearing (25) for wear or damage. Remove and replace if necessary. Bearing is a press fit.
[17] - Measure front support sleeve (18) diameter. Remove and replace if necessary. Support sleeve is a press fit.

Front Support Sleeve Minimum Outside Diameter 119.81 mm (4.717 in.)
[18] - Replace ground sleeve (15) if worn or damaged by pressing ground sleeve from front support (22).
[19] - Inspect all parts for wear or damage. Replace if necessary.
[20] -

Ground Sleeve Installation
Front Support Sleeve and Support

LEGEND:
1 Flat in Ground Sleeve
2 Cast Arrow
3 Front Support
12 Wear Plate
15 Ground Sleeve
22 Front Support
25 Bearing
If removed, install ground sleeve (15) in front support with press. Machined flat at base of ground sleeve (1) must align with
cast arrow (2) on front support (3).
Transmission
Ground Sleeve Maximum Radial Runout 0.13 mm (0.005 in.)
[21] -
IMPORTANT:
Lubrication hole in support sleeve (18) must be positioned with relief valve bore in bottom of front
support.
Install support sleeve (18) with press. Position lubrication hole in support sleeve with relief valve bore in bottom of front
support.

[22] - Install wear plate (12).


Wear Plate Cap Screw Torque 56 N˙m (42 lb-ft)
[23] - Install bearing (25) using press. Press bearing flush to 0.25 mm (0.010 in.) below surface.
[24] -
Main Pressure Relief Ball and Spring

LEGEND:
19 Ball
20 Spring
21 Dowel Pin
22 Front Support
Install pressure relief ball (19) and pressure relief spring (20).
[25] - Use JDG1501-11 Main Pressure Relief Spring Compressor to compress pressure relief spring (20).
[26] - Install pin (21).
[27] -
LEGEND:
4 O-Ring
5 Seal
8 Bushing
9 Pump Housing
10 Pump Gear Set
11 Bushing
22 Front Support
Front Support and Charging Pump

Install bushing (8) into pump housing.

[28] - Install seal (5) and O-ring (4).
[29] - Install bushing (11) into pump gear. Align staking in bushing with slots in inside gear of gear set.
[30] - Lubricate and install pump gear set (10) into pump housing (9).
[31] - Install pump housing (9) onto front support (22).


Pump Housing Cap Screw Torque 56 N˙m (42 lb-ft)
[32] - Place three seal rings (24) into sealing bore of C1/C2 clutch.
[33] - Measure end gap with feeler gauges.


Sealring End Gap Maximum Gap 1.44 mm (0.057 in.)
[34] - Remove three seal rings from C1/C2 clutch and install onto front support hub.

Disassemble and Assemble C1/C2 Clutch
C1/C2 Clutch Module

LEGEND:
1 C1/C2 Clutch Module (Complete)
2 O-Ring
3 Turbine Shaft
4 Turbine Shaft

5 Turbine Shaft Bushing

7 Rotating Drum
8 Thrust Bearing
9 C1/C2 Clutch Hub and Bushing
10 C1/C2 Clutch Hub Bushing
11 C1/C2 Clutch Hub
12 Thrust Bearing
13 Snap Ring
16 External Seal Ring
17 C2 Piston
18 C2 Spring
19 C2 Spring Plate
20 Retaining Ring
21 C1 Seal Ring
22 C1 Piston
23 C1 Spring
24 Balance Piston
25 Seal Ring
26 Snap Ring
27 C1 Clutch Backplate (2 used)
28 C1 Friction Plate (7 used)
29 C1 Reaction Plate (6 used)
30 Snap Ring
31 C1 Drive Hub
32 Thrust Bearing (2 used)
33 C2 Drive Hub
36 C2 Clutch Backplate
37 Internal Snap Ring
38 Sun Gear (complete)
39 Thrust Bearing
40 Snap Ring
[1] - Disassemble C1/C2 clutch.
[2] - Inspect thrust bearing (39) for wear. Replace if necessary.
[3] -
Clutch Plate Cone

Inspect C1/C2 plates for wear.
C1/C2 Clutch Plates

C1/C2 Backplate Minimum Thickness 7.90 mm (0.31 in.)
Maximum Distortion 0.15 mm (0.006 in.)
C1/C2 Friction Plate Minimum Thickness 2.92 mm (0.115 in.)

C1/C2 Friction Plate Oil Groove Minimum Depth 0.20 mm (0.008 in.)
C1/C2 Friction Plate Cone Maximum Height 0.25 mm (0.010 in.)
C1/C2 Reaction Plate Minimum Thickness 2.41 mm (0.095 in.)
C1/C2 Reaction Plate Cone Maximum Height 0.25 mm (0.010 in.)
C1/C2 Drive Hub Spline Maximum Wear 0.38 mm (0.015 in.)
[4] -
LEGEND:
2 O-Ring
3 Turbine Shaft
4 Turbine Shaft
7 Rotating Drum
8 Thrust Bearing
11 C1/C2 Clutch Hub
12 Thrust Bearing
13 Snap Ring
Turbine Shaft Removal

Remove snap ring (13) and turbine shaft (4).
[5] - Inspect bushing (5) inside end of turbine shaft (4). Replace if necessary.
C1/C2 Clutch
Turbine Shaft Bushing Maximum Inside Diameter 36.14 mm (1.423 in.)
[6] - Remove seal rings (6).
[7] - Remove O-ring (2) from turbine shaft (4).
[8] -
CAUTION:
C1 springs are highly compressed. A spring compressor must be used to control the release of spring
force. Personal injury can occur if spring force is not controlled.

Spring Compressor Tools
C1 Clutch Assembly
LEGEND:
1 JDG1501-8 C1-C2-C5 Spring Compressor Tool
2 Handle
3 Flat Washer
4 Bearing
5 JGD1501-7 C1 Spring Compressor
21 C1 Seal Ring
22 C1 Piston
23 C1 Spring
24 Balance Piston
25 Seal Ring
26 Snap Ring
Compress C1 spring (23) using JDG1501-8 C1-C2-C5 Spring Compressor Tool (1—4) and JDG1501-7 C1 Spring Compressor (5).
C1-C2-C5 Spring Compressor Tool
JDG1501-8
C1 Spring Compressor
JDG1501-7
[ The JDG1501-7 C1 Spring Compressor includes the C1, C2, and C5 Spring Compressors. ]
→NOTE:
[9] - Remove snap ring (26).
[10] - Loosen handle (2) to release the C1 spring force.
[11] - Remove balance piston (24), seal ring (25), and C1 spring (23).
[12] -
CAUTION:
C2 springs are highly compressed. A spring compressor must be used to control the release of spring
force. Personal injury can occur if spring force is not controlled.

LEGEND:
2 Handle
3 Flat Washer
4 Bearing
5 JDG1501-7 C1 Spring Compressor
6 C2 Spring Compressor
7 Rotating Drum
8 Thrust Bearing
11 C1/C2 Clutch Hub
12 Thrust Bearing
Spring Compressor Tools 16 External Seal Ring
17 C2 Piston
18 C2 Spring
19 C2 Spring Plate
20 Retaining Ring
21 C1 Seal Ring
22 C1 Piston
C2 Clutch Assembly
Compress C2 spring (18) using JDG1501-8 C1-C2-C5 Spring Compressor Tool (1—4), C2 Spring Compressor (6), and JDG1501-7
C1 Spring Compressor (5).
→NOTE:
[13] - Remove retaining ring (20).
[14] - Loosen handle (2) to release the C2 spring force.
[15] - Remove C2 spring and spring plate (18 and 19).
[16] - Remove rotating drum (7) from hub assembly (11) and C1 piston (22) and C2 piston (17).
[17] - Inspect clutch splines of rotating drum.

C1/C2 Clutch
Rotating Drum Spline Maximum Wear 0.38 mm (0.015 in.)
[18] - Remove C1 piston (22) and C2 piston (17) from hub (9) by rocking side to side.
[19] - Inspect inside diameter of rotating clutch hub bushing (10). Replace as necessary.
C1/C2 Clutch
Rotating Clutch Hub Bushing Maximum Inside Diameter 120.27 mm (4.735 in.)
[20] - Remove seal rings (14 and 15) from hub.
[21] - Remove C1 piston (22) and seal ring (21) from C2 piston (17) and seal ring (16) by tapping lightly on C1 piston.
[22] - Remove seals from pistons.

[23] - Inspect all parts for wear or damage. Replace if necessary.
[24] -
LEGEND:
1 Lube Port
2 Notch in Cl Piston
7 Rotating Drum
8 Thrust Bearing
11 C1/C2 Clutch Hub
12 Thrust Bearing
16 External Seal Ring
17 C2 Piston
18 C2 Spring
19 C2 Spring Plate
C2 Clutch Assembly 20 Retaining Ring
21 C1 Seal Ring
22 C1 Piston
Lube Port
Apply clean transmission oil to all parts.
[25] - Install C1 piston (22) into center of C2 piston (17). Tap C1 piston lightly until fully seated.
[26] - Notch (2) on C1 piston must align with one of four lube ports (1) in C1/C2 clutch hub (11).
[27] - Install rotating drum (7) over C1/C2 hub (9) and C1 and C2 pistons (22 and 17).
[28] - Install C2 spring (18). Index the spring with the drive hub tangs and the splines on the C2 piston (17). Be sure that C2
spring has made contact with C2 piston. If contact has not been made, remove C2 spring and re-index it in next spline on
rotating drum.
[29] - Install C2 spring plate (19). Index spring plate with drive hub tangs and splines on C2 piston.
[30] -
LEGEND:
2 Handle
3 Flat Washer
4 Bearing
6 C2 Spring Compressor
Spring Compressor Tools

Compress C2 spring (18) using JDG1501-8 C1-C2-C5 Spring Compressor Tool (1—4), C2 Spring Compressor (6), and JDG1501-7
C1 Spring Compressor (5).
[31] - Install snap ring.
[32] -
C1 Clutch Assembly
Alignment Marks
Spring Compressor Tool

LEGEND:
2 Handle
3 Flat Washer
4 Bearing
7 Alignment Marks
21 C1 Seal Ring
22 C1 Piston
23 C1 Spring
24 Balance Piston
25 Seal Ring
26 Snap Ring
Install C1 spring (23).
[33] - Apply clean transmission oil to seal ring (25). Install seal ring on balance piston (24).
[34] - Install balance piston with THIS SIDE UP and alignment mark (7) aligned with alignment mark (notch) in C1 piston.
[35] - Compress C1 spring (23) using JDG1501-8 C1-C2-C5 Spring Compressor Tool (1—4) and JDG1501-7 C1 Spring
Compressor (5).
[37] -
LEGEND:
2 O-Ring
3 Turbine Shaft
4 Turbine Shaft
7 Rotating Drum
8 Thrust Bearing
11 C1/C2 Clutch Hub
12 Thrust Bearing
13 Snap Ring
Turbine Shaft
Install C1/C2 clutch pistons into rotating clutch drum (7).
[38] - Install bushing (5) into turbine shaft (4).
[39] - Install O-ring (2) onto forward end of turbine shaft.
[40] - Install three butt-joint seal rings (6) into the sealing bore of ground sleeve in C1/C2 clutch hub (11).
[41] - Measure end gap with feeler gauges.

C1/C2 Clutch
Ground Sleeve Seal Ring Butt-Joint Maximum End Gap 0.65—1.01 mm (0.026—0.040 in.)
[42] - Remove seal rings from ground sleeve bore and install on turbine shaft (4).
[43] - Install turbine shaft (4), snap ring (13) and thrust bearing (12).
[44] - Position C1/C2 clutch with turbine shaft down.
[45] -

LEGEND:
27 C1 Clutch Backplate (2 used)
30 Snap Ring
31 C1 Drive Hub
32 Thrust Bearing (2 used)
33 C2 Drive Hub
36 C2 Clutch Backplate
37 Internal Snap Ring
38 Sun Gear (complete)
39 Thrust Bearing
40 Snap Ring
Clutch Pack Installation

Install C1 clutch pack. Backplates (27) are installed on both ends of clutch pack. Install clutch plates alternately, starting with a
friction plate (28).
[46] - Install C1 snap ring (30).
[47] - Install thrust bearing (32) on each side of C2 drive hub (33).
[48] - Install C2 drive hub (33) over C1 drive hub (31).
[49] - Install C2 clutch plates (34 and 35). Install clutch plates alternately, starting with steel reaction plate (34).
[50] - Install C2 backplate (36) and C2 snap ring (37).
[51] - Install thrust bearing (39).
[52] - Install P1 sun gear (38) and snap ring (40).

Disassemble and Assemble C3/C4 Clutch and Main Housing
C3/C4 Clutch and Main Housing Exploded View

LEGEND:
1 C3/C4 Clutch (Complete)
3 C3 Backplate (complete)
4 Backplate
5 P1 Ring Thrust Plate (4 used)
6 Rivet (12 used)
7 P1 Ring Gear
10 Return Spring (4 used)
11 Return Plate
12 Spring Retainer
13 Seal Ring
14 Seal Ring
15 C3 Clutch Piston
16 C3 Clutch Housing
17 Rivet

22 Return Spring
23 Return Plate
24 Spring Retainer
25 Seal Ring
26 Seal Ring
27 C4 Clutch Piston
[1] - Inspect clutch splines in interior of main housing.
C3/C4 Clutch and Main Housing

Main Housing Clutch Splines Maximum Wear 1.15 mm (0.045 in.)
[2] - Remove cap screws (2).
[3] - C3 and C4 clutch diassembly is similar.
[4] - Remove C3 backplate (3).
[5] - Inspect thrust plates (5 and 18) and rivets (6 and 17) on clutch backplate (4 and 19).

C3/C4 Thrust Plate Contact Surface Minimum Thickness 2.81 mm (0.111 in.)
C3/C4 Thrust Plate Distortion Maximum Distortion 0.15 mm (0.006 in.)
C3/C4 Thrust Plate Step Wear Maximum Wear Depth 0.13 mm (0.005 in.)
If replacement of backplate is necessary, remove by drilling out rivets.
[6] - Remove P1 ring gear (7) and inspect clutch splines.


P1 Ring Gear Clutch Splines Maximum Wear 0.38 mm (0.015 in.)
[7] - Remove C3 clutch pack (8 and 9).
[8] - Inspect return plates (11 and 23) for wear or damage. Replace as necessary.
C3/C4 Clutch
Piston Return Plate Minimum Thickness 4.91 mm (0.193 in.)
[9] - Remove return spring (10 and 22) assemblies only if damaged and replacement is necessary.
[10] - Remove C3 housing (16).
[11] -

Clutch Plate Cone

LEGEND:
33 Level Surface
34 Clutch Plate
35 Measure Here For Cone
Inspect plates for wear.
C3/C4 Clutch
C3/C4 Friction Plate Minimum Thickness 3.485 mm (0.137 in.)
C3/C4 Friction Plate Oil Groove Minimum Depth 0.20 mm (0.008 in.)
C3/C4 Friction Plate Cone Maximum Cone 0.25 mm (0.010 in.)
C3/C4 Reaction Plate Minimum Thickness 2.41 mm (0.095 in.)
C3 Reaction Plate Cone Maximum Cone 0.40 mm (0.016 in.)
C4 Reaction Plate Cone Maximum Cone 0.25 mm (0.010 in.)
[12] - Inspect splines in C3/C4 clutch housings.

C3/C4 Clutch Housing

C3/C4 Clutch Housing Spline Wear Maximum wear 1.15 mm (0.045 in.)
[13] - Remove all seal rings.
[14] - Remove spring retainer (24) and piston (27) from C4 housing.
[15] -

LEGEND:
22 Return Spring
23 Return Plate
24 Spring Retainer
25 Seal Ring
26 Seal Ring
27 C4 Clutch Piston
C4 Clutch
Install and lubricate seal rings (25 and 26) and piston (27) into C4 housing (28).
[16] - Install return springs (22) if removed.
[17] - Install piston return plate (23) with return springs (22).
[18] - Install C4 clutch pack (20 and 21). Clutch plates are installed alternately, starting with a friction plate (21).
[19] -
LEGEND:
2 Cap Screw
3 C3 Backplate (complete)
4 Backplate
6 Rivet (12 used)
7 P1 Ring Gear
10 Return Spring (4 used)
11 Return Plate
12 Spring Retainer
13 Seal Ring
14 Seal Ring
15 C3 Clutch Piston
17 Rivet
C3 Clutch Complete
If removed, install thrust plates (5 and 18). Thrust plates must not move on housing.
→NOTE:
A correctly formed rivet upset will be 4.00 mm (0.157 in.) in diameter and no more than 1.00 mm (0.039
in.) above the clutch housing surface.
[20] - Install seal rings (13 and 14).
[21] - Lubricate and install C3 clutch piston (15) into C3 clutch housing.
[22] - Install C3 clutch housing (19) with clutch piston (15) on top of assembled C4 clutch housing. Ensure that index tangs are
aligned.

[23] - Install spring retainer (12).
[24] - Install piston return plate (11), return springs and P1 ring gear (7).
[25] - Install C3 clutch pack. Clutch plates are installed alternately, starting with a friction plate (8).
[26] -
LEGEND:
2 Cap Screw
4 Backplate
C3/C4 Clutch Alignment

Install C3 backplate (4). Backplate (4) must be indexed with C3 (19) and C4 (28) housings in order to insert into main housing
correctly.
[27] - Install cap screws (2).

C3/C4 Clutch
C3/C4 Cap Screw Torque 56 N˙m (42 lb-ft)

Disassemble and Assemble Control Valve

IMPORTANT:
Control valve assembly springs and other parts can be mistakenly interchanged. Make identification tags
for each part removed as to its location.
Control valve parts fit together closely and have specific clearances. These parts depend upon smooth
sealing surfaces and may leak if the sealing surface is scratched. Valves, when dry, must move freely by
their own weight in their bores. Carefully handle all such parts. Keep them in clean containers until they
are installed.
LEGEND:
1 Filters
2 Suction Filter
3 Wiring Harness
4 Channel Housing
5 Rotating Clutch Solenoid
6 Stationary Clutch Solenoid
7 Main Valve Body
8 Transmission Oil Level Sensor
Control Valve
Remove control valve from transmission. (See Disassemble and Assemble Control Valve in Group 0350.)
Remove Filters

LEGEND:
1 Channel Housing
2 Filter Cover (2 used)
3 O-Ring (2 used)
4 O-Ring (2 used)
5 Filter (2 used)
6 Cap Screw
7 Face Seal
8 Cap Screw
9 Suction Filter Housing
10 Suction Filter
11 Gasket
Filter Removal
[1] - Remove two filter covers (2) if not previously removed, four O-rings (3 and 4), and two filters (5).
[2] - Remove cap screws (6 and 8).
[3] - Remove suction filter housing (9), seal (7), suction filter assembly (10), and gasket (11).
[4] - Clean and inspect suction filter. Replace as necessary.
Remove Electrical Components and Sensors

Electrical Connector Removal

LEGEND:
1 Harness (Complete)
2 Standoff
4 Wire Harness
[1] - Remove wire harness cover plate.
[2] - Disconnect all connectors. Do not remove wires from wiring harness.
[3] - Remove cap screws (3) and harness (1).
[4] -

LEGEND:
2 Oil Level Sensor
Oil Level Sensor

Remove oil level sensor (2).
Disassemble and Assemble C1/C2 Clutch Solenoid Body

LEGEND:
1 Seal
3 C1/C2 Clutch Solenoid Body
4 Solenoid Normally Open (2 used)
5 Solenoid Normally Closed
6 Valve (3 used)
7 Spring (3 used)
8 Solenoid Retention Pins (3 used)
9 Valve Stop
10 Spring
11 Valve
13 C3 Pressure Switch
14 Retention Pin
Rotating Clutch Solenoid Body
[1] - Remove C1/C2 clutch solenoid body (3) from main valve body.
[2] - Disassemble C1/C2 clutch solenoid body.
[3] - Check C3 pressure switch (13).

C1/C2 Clutch Solenoid Body

C3 Pressure Switch Resistance (Closed) Resistance 2 ohms maximum

C3 Pressure Switch Resistance (Open) Resistance 20,000 ohms minimum
C3 Pressure Switch Open/Close Pressure Pressure 159—255 kPa (23—37 psi)
[4] -
→NOTE:
Solenoids normally open can be identified by a flat rear face. Normally closed solenoids have a recess at
rear face.
Check resistance of C1/C2 solenoids (4—5).


C1/C2 Clutch Solenoids Resistance 2—5 ohms
[6] - Assemble C1/C2 solenoid body.


C3 Pressure Switch Cap Screw Torque 5—8 N˙m (62 lb-in.)
Disassemble and Assemble C3/C4 Clutch Solenoid Body

LEGEND:
1 C3/C4 Clutch Solenoid Body Assembly
3 Seal (2 used)
4 Stationary Clutch Solenoid Body
5 Valve Stop
6 Valve Spring
7 Overdrive Valve
8 Solenoid Normally Closed (3 used)
9 Solenoid Valve (3 used)
10 Spring (3 used)
11 Retention Pin
12 Retaining Pin (3 used)
Stationary Clutch Solenoid
[1] - Remove C3/C4 clutch solenoid (1) from main solenoid valve.
[2] - Disassemble C3/C4 clutch solenoid body.
[3] - Check resistance of solenoids (8).

C3/C4 Clutch
C3/C4 Clutch Solenoid Resistance 2—5 ohms
[4] - Inspect all parts for wear or damage.
[5] - Assemble C3/C4 clutch solenoid body.

Disassemble and Assemble Main Valve Body
Main Valve Body

LEGEND:
1 Main Valve Body Assembly
2 Main Valve Body
4 Retaining Pin
5 Retaining Pin
6 Retaining Pin
7 Retaining Pin
8 Retaining Pin
9 Retaining Pin
10 Retaining Pin
11 Retaining Pin
12 Retaining Pin
13 Lockup Relay Valve
14 Lockup Relay Valve Spring
15 Lockup Relay Valve Stop
16 Lube Regulator Valve
17 Lube Regulator Spring
18 Lube Regulator Stop
19 Main Regulator Valve
20 Main Regulator Spring
21 Main Regulator Stop
22 Solenoid
23 Control Main Valve
24 Control Main Spring
25 Control Main Stop
26 Spring Pin
27 C2 Latch Valve
28 C2 Latch Spring
29 C2 Latch Stop
30 Exhaust Back Valve
31 Exhaust Back Spring
32 Exhaust Back Stop
33 C1 Latching Valve
34 C1 Latching Spring
35 C1 Latching Stop
36 Converter Regulator Valve
37 Converter Regulator Spring
38 Converter Regulator Stop
[1] - Remove main control valve body (1) from oil transfer channel plate.
[2] - Disassemble main control valve body. Check resistance of solenoid (22).
Main Control Valve

Solenoid Resistance 2—5 ohms
[3] -
CAUTION:
Main regulator spring (20) and control main spring (24) are highly compressed. Personal injury can occur
if spring force is not controlled.
LEGEND:
1 JDG1501-4 Main Pressure Spring Remover/Installer
Main Pressure Valve Spring Compressor

Use JDG1501-4 Main Pressure Spring Remover/Installer to compress main regulator spring (20) and control main spring (24).
Main Pressure Spring Remover/Installer
JDG1501-4
To compress main regulator spring and control main spring.
[4] - Clean and inspect all parts for wear or damage. Replace as necessary.
[5] - Assemble main control valve body.
Disassemble and Assemble Channel Housing

LEGEND:
1 Gasket
2 Separator Plate
3 Gasket
4 Dowel Pin
5 Channel Housing
6 Drain Plug
7 Pressure Tap Plug (8 used)
Channel Housing
[1] - Disassemble channel housing.
[2] - Clean and inspect all parts for wear or damage. Replace parts as necessary.
[3] - Install new O-rings on all plugs.
[4] - Install parts in plate.

Channel Housing
Pressure Tap Plug Torque 12 N˙m (106 lb-in.)
Drain Plug Torque 27 N˙m (20 lb-ft)
Assemble Control Valve
[1] -
LEGEND:
1 Main Control Valve Body
Main Control Valve and Separator Plate

C1/C2 and C3/C4 Control Valve

Install main control valve body (1) and solenoid separator plate (3) with gaskets. Tighten cap screws (2) until finger tight.
[2] - Install C1/C2 clutch solenoid body (4) and C3/C4 clutch solenoid body (5).
Control Valve
Main Valve Body Cap Screw Torque 12 N˙m (106 lb-in.)
C1/C2 Clutch Solenoid Body Cap Screw Torque 12 N˙m (106 lb-in.)
C3/C4 Clutch Solenoid Body Cap Screw Torque 12 N˙m (106 lb-in.)
[3] -
Oil Level Sensor

LEGEND:
6 Oil Level Sensor
Install oil level sensor (6).

Control Valve
Oil Level Sensor Cap Screw Torque 12 N˙m (106 lb-in.)
[4] -
Feed Through Harness

LEGEND:
8 Harness (Complete)
9 Standoff
11 Wire Harness
Install harness (8).
Control Valve
Harness Cap Screw Torque 2—3 N˙m (18—27 lb-in.)
[5] - Reconnect all connectors.
[6] - Install standoff.

[7] -
LEGEND:
1 Channel Housing
3 O-Ring (2 used)
4 O-Ring (2 used)
5 Filter (2 used)
6 Cap Screw
7 Face Seal
8 Cap Screw
10 Suction Filter
11 Gasket
Filter Installation
Install gasket (11), seal (7), filter (10) and suction filter housing (9). Do not install lube and main filters at this time.
Control Module
Suction Filter Cap Screw Torque 12 N˙m (106 lb-in.)
Remove and Install Oil Level Sensor
[1] -

Oil Level Sensor

LEGEND:
6 Oil Level Sensor
Remove cap screw (7) and oil level sensor (6).
[3] - Install oil level sensor (6).

Control Valve
Oil Level Sensor Cap Screw Torque 12 N˙m (106 lb-in.)

Assemble Transmission
[1] -
C3/C4 Clutch
LEGEND:
1 C3/C4 Clutch
2 Housing
Position transmission housing horizontally on stand.
[2] - Install C3/C4 clutch (1) through input end of housing (2).
→NOTE:
Align tabs on clutch assembly with the slot in main housing.
[3] - Install two cap screws (3) 180 degrees from each other to hold clutch in place.
[4] - Position transmission housing with output end up.
[5] - Install remaining cap screws (3).

Transmission Housing
C3/C4 Clutch Cap Screw Torque 56 N˙M (42 lb-ft)
[6] - Position transmission housing with input end up.
[7] -

C1/C2 Clutch
LEGEND:
4 C1/C2 Clutch
Install C1/C2 clutch (4) using M16 eye bolt and hoist.
[8] -
Front Support
LEGEND:
5 Cap Screw
6 Cap Screw
7 Front Support
Install front support and charging pump (7) over top of the turbine shaft.
Front Support Cap Screw Torque 56 N˙m (42 lb-ft)
[9] - Position transmission housing with output end up.
[10] -

P1 Planetary
LEGEND:
8 P1 Planetary
Install P1 planetary (8).
→NOTE:
P1 planetary consists of P1 carrier and P2 ring gear.
[11] - Mesh P1 pinion gears with P1 ring gear inside C3/C4 clutch.
[12] -
LEGEND:
9 P2 Planetary
10 C5 Clutch Pack (Complete)
11 Reaction Plate (9 used)
12 Friction Plate (8 used)
P2 Planetary and C5 Clutch Pack

Install P2 planetary (9).
→NOTE:
P2 planetary consists of P2 carrier and P3 ring gear.
[13] - Mesh P2 pinion gears with P2 ring gear during assembly.
[14] - Install C5 clutch pack (10) in main housing.
[15] - Stack all plates with cone facing same direction.
[16] - Start with steel reaction plate (11) and alternate with friction plates (12). Steel reaction plates mesh with main housing
and reaction plates mesh with P3 ring gear.
[17] -

Main Shaft
LEGEND:
13 Main Shaft
14 Shim
15 Thrust Bearing
Install main shaft (13) without shim (14) and thrust bearing (15).
[18] -
Main Shaft Shim Measurement

LEGEND:
1 Straightedge
2 Bearing and Shim Removed
3 Gasket Installed
A Top of Straightedge to Shim Dimension
B Thickness of Straightedge

C A Minus B Dimension
D P3 to Retarder Gasket Dimension
E Thickness of Straightedge Dimension
F D Minus E Dimension
Place a straightedge (1) across retarder housing mounting surface of main housing.
[19] - Measure dimension (A), from top of straightedge (1) to shim thrust surface on main shaft bearing spacer (2).
[20] - Measure dimension (B), thickness of straightedge.
[21] - Subtract dimension (B) from dimension (A)—this is dimension (C).
[22] - Place retarder housing on bench, output end down.
[23] - Install new gasket on mounting surface (3).
[24] - Place a straightedge (1) across P3 planetary carrier.
[25] - Measure dimension (D).
[26] - Measure dimension (E).
[27] - Subtract dimension (E) from dimension (D)—this is dimension (F).
[28] - Subtract dimension (F) from dimension (C)—this is dimension (G).
[29] - Use dimension (G) and table for correct shim thrust bearing.
Shim Thickness
Shim Thickness Dimension (G) Part Number Shim Thickness
4.770—4.843 mm 0.27 mm
AT256516
(0.180—0.190 in.) (0.01 in.)
4.844—5.113 mm 0.54 mm
AT256517
(0.191—0.201 in.) (0.02 in.)
5.114—5.383 mm 0.81 mm
AT256518
(0.202—0.212 in.) (0.03 in.)
5.384—5.653 mm 1.08 mm
AT256519
(0.213—0.223 in.) (0.04 in.)
5.654—5.923 mm 1.35 mm
AT256520
(0.224—0.233 in.) (0.05 in.)
5.924—6.193 mm 1.62 mm
AT256521
(0.234—0.244 in.) (0.06 in.)
6.194—6.380 mm 1.89 mm
AT256522
(0.245—0.251 in.) (0.07 in.)
[30] - Install proper shim and thrust bearing.
[31] -

Retarder
Retarder and Lifting Bracket

LEGEND:
13 Main Housing
14 Gasket
15 Retarder Housing and P3 Planetary
16 M12 Cap Screw
17 Seal
40 M10 Cap Screw (7 used)
41 M12 Cap Screw
Install new retarder gasket (14) on main housing (13).
[32] -
CAUTION:
The approximate weight of retarder is 34 kg (75 lb).

Retarder
Retarder and P3 Planetary Weight 34 kg (75 lb)
Install retarder housing (15) on main housing (13) using hoist and M10 eye bolt or lifting bracket JT01748. Use guide pins to
help with retarder housing installation.
M12 Rear Housing Cap Screw Torque 100 N˙m (75 lb-ft)

M10 Rear Housing Cap Screw Torque 57 N˙m (42 lb-ft)
[33] - Position transmission vertically.
[34] -
Control Module
LEGEND:
31 Gasket
32 Standoff
33 Control Valve
34 Cap Screw
Install new control valve gasket (31) on control valve (33).
[35] -
CAUTION:
The approximate weight of control valve is 25 kg (56 lb).

Transmission
Control Valve Weight 25 kg (56 lb)
Install control valve onto main housing using guide pins.
[36] - Install one cap screw (34) in top center hole.
[37] -

LEGEND:
1 Channel Housing
3 O-Ring (2 used)
4 O-Ring (2 used)
5 Filter (2 used)
6 Cap Screw
7 Face Seal
8 Cap Screw
10 Suction Filter
11 Gasket
Filter Installation
Install O-rings (3 and 4), filters (5), and filter covers (2).
Transmission
Filter Cover Cap Screw Torque 55 N˙m (40 lb-ft)
→NOTE:
Main and lube filters are interchangeable.
[38] - Remove guide pins and install remaining thirty-one cap screws into control valve.
Transmission
Control Valve Cap Screw Torque 55 N˙m (40 lb-ft)
[39] - Position transmission housing with input end up.
[40] -

Torque Converter Housing

LEGEND:
23 Gasket
24 Main Housing
Install new torque converter housing gasket (23) on main housing.
[41] - Install guide bolts to aid torque converter housing (21) installation and keep gasket (23) in place.
[42] - Install seven cap screws (22) into inside of torque converter housing (21) with mechanical fingers.
[43] - Install remaining cap screws (22).

Torque Converter Housing Cap Screw Torque 56 N˙m (42 lb-ft)
[44] - Install torque converter into torque converter housing using eyebolts and hoist.
[45] -
LEGEND:
1 Tool Height (constant)
C1/C2 Turbine Shaft End Play

Install torque converter.
Torque Converter End Play Gauge
JDG1501-13
To measure end play of torque converter.

→NOTE:
Torque converter must be in proper location to engage charge pump prior to measuring for C1/C2 turbine
shaft selective shim.
[46] - Install JDG1501-13 Converter End Play Gauge.
[47] -
IMPORTANT:
Dimension (C) includes correction due to deflection caused by torque. Accurate torque value is critical to
selection of the proper shim.
Tighten torque converter end play gauge attaching cap screw.

Torque Converter End Play Gauge Attaching Cap Screw Torque 30 N˙m (23 lb-ft)
[48] - Measure from top of torque converter end play gauge to face of turbine shaft. Record as dimension (B).
[49] - Subtract dimension (B) from height of tool (A) (100 mm [3.937 in.]). This is dimension (C).
[50] - Remove tool and torque converter.
[51] - Select proper shim from table.
C1/C2 Turbine Shaft Shim Thickness
Dimension (C) Part Number Shim thickness
0.4129—0.6597 mm 4.000 mm
AT256495
(0.016—0.026 in.) (0.157 in.)
0.6598—0.8378 mm 4.203 mm
AT256496
(0.0261—0.033 in.) (0.165 in.)
0.8379—1.0158 mm 4.381 mm
AT256497
(0.0331—0.400 in.) (0.172 in.)
1.0159—1.1938 mm 4.559 mm
AT256498
(0.401—0.0470 in.) (0.179 in.)
1.1939—1.3708 mm 4.736 mm
AT256499
(0.0471—0.054 in.) (0.186 in.)
1.3709—1.5488 mm 4.914 mm
AT256500
(0.0541—0.061 in.) (0.193 in.)
1.5489—1.7268 mm 5.092 mm
AT256501
(0.061—0.068 in.) (0.200 in.)
1.7269—1.9048 mm 5.270 mm
AT256502
(0.068—0.075 in.) (0.207 in.)
1.9049—1.9733 mm 5.448 mm
AT256503
(0.075—0.078 in.) (0.214 in.)
[52] -

Section 03 - TRANSMISSION Group 0360: Hydraulic System
Torque Converter
LEGEND:
25 JDG1501-12
26 Torque converter
27 Shim
28 Cap Screw
29 O-Ring
30 Plug
Install shim (27) with shim step side toward turbine shaft (cupped end down).
[53] - Use JDG1501-12 Torque Converter Nut Torque Tool (25) to install cap screw (28).
Transmission Converter
Torque Converter Retaining Cap Screw Torque 110 N˙m (80 lb-ft)
[54] - Install O-ring (29) on converter end plug (30).

Torque Converter Plug Torque 55 N˙m (40 lb-ft)
[55] - Install torque converter retaining brackets.

Retaining Bracket Cap Screw Torque 55 N˙m (40 lb-ft)
[56] - Install external components.

Yoke Retainer Plug Cap Screw Torque 70—80 N˙m (51—60 lb-ft)
Fill Tube Cap Screw Torque 27 N˙m (20 lb-ft)
Breather Torque 14 N˙m (124 lb-in.)
Input Speed Sensor Torque 27 N˙m (20 lb-ft)


Remove and Install Transmission Oil Cooler
[1] - Remove top and rear covers, right side grille and front access panel from transmission oil cooler housing.
[2] - Remove brake oil cooler (400D only). (See Wet Disk Brake Cooling Oil Cooler in Group 1060.)
[3] -
LEGEND:
1 Transmission Oil Cooler
Transmission Oil Cooler

Disconnect lines from transmission oil cooler (1). Cap and plug all openings.
[4] - Remove 90° fitting from front end of transmission oil cooler. Plug opening.
[5] - Remove cap screws and transmission oil cooler.
[6] - Install transmission oil cooler.
[7] - Install 90° fitting to front end of transmission oil cooler.
[8] - Connect lines to transmission oil cooler.
[9] - Install brake oil cooler (400D only). (See Wet Disk Brake Cooling Oil Cooler in Group 1060.)
[10] - Install top and rear covers, right grille and front access panel to transmission oil cooler housing.

Transmission Retarder Accumulator Remove and Install

[1] - Relieve pneumatic pressure. See Relieve Pneumatic Pressure . (Operator’s Manual.)
[2] - Drain transmission or apply vacuum. See Change Transmission Oil . (Operator’s Manual.)
Transmission Oil Capacity 34 L
9 gal.
[3] -
LEGEND:
3 Accumulator
14 Wiring Harness
Wiring Harness Installation

Disconnect wiring harness (14) from accumulator (3).
[4] -
LEGEND:
3 Accumulator
6 Pipe Fitting
7 Pipe Fitting
10 Air Hose
Air Hose Installation

Disconnect air hose (10) from pipe fitting (6).
[5] -

LEGEND:
1 Bracket
3 Accumulator
4 Mounting Bracket
5 Straight Fitting (2 used)
8 Cap Screw and Washer (2 used)
9 Hydraulic Hose
Accumulator Installation
Disconnect hydraulic hose (9) from straight fitting (5).
[6] - Remove cap screws and washers (8).
[7] - Remove bracket (1), mounting bracket (4), and accumulator (3).
[8] - Remove accumulator (3) from mounting bracket (4).
[9] - Remove fittings from accumulator.
[11] - Install straight fitting (5) to accumulator (3).
[12] -
LEGEND:
3 Accumulator
6 Pipe Fitting
7 Pipe Fitting
10 Air Hose

Install pipe fittings (6 and 7) to accumulator air solenoid.
[13] -

LEGEND:
1 Bracket
3 Accumulator
4 Mounting Bracket
5 Straight Fitting (2 used)
9 Hydraulic Hose
Accumulator Installation
Install accumulator (3) to mounting bracket (4) with cap screws. Tighten cap screws to specification.
Accumulator-to-Mounting Bracket Cap Screws Torque 68 N·m
50 lb.-ft.
[14] - Install mounting bracket (4), accumulator (3), and bracket (1) to bosses in machine frame with cap screws and washers
(8). Tighten cap screws to specification.
Mounting Bracket-to-Frame Cap Screws Torque 50 N·m
37 lb.-ft.
[15] - Connect hydraulic hose (9) to straight fitting (5).
[16] -
LEGEND:
3 Accumulator
6 Pipe Fitting
7 Pipe Fitting
10 Air Hose

Connect air hose (10) to pipe fitting (6).
[17] -

ENGINE (g) by Belgreen v2.0
LEGEND:
3 Accumulator
14 Wiring Harness
Wiring Harness Installation

Connect wiring harness (14) to accumulator (3).
[18] - Check transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.) Also see Transmission and Transfer
Case Oil . (Operator’s Manual.)
Transmission Oil Capacity 34 L
9 gal.
[19] - Check air system for leaks.

Section 04 - ENGINE
Table of contents
Engine .................................................................................................................................................. 1
Group 0401 - Crankshaft, Main Bearings, and Flywheel ................................................................. 13
Crankshaft and Main Bearing Failure Analysis .................................................................................... 13
Crankshaft Oil Seals ........................................................................................................................... 14
Flywheel ............................................................................................................................................. 19
Remove and Install Timing Case Cover .............................................................................................. 22
Remove and Install Timing Case ........................................................................................................ 24
Crankshaft .......................................................................................................................................... 27
Bleed Engine Oil Circuit after Major Overhaul .................................................................................... 38
Group 0402 - Camshaft and Timing Gear Train ................................................................................. 39
Camshaft ............................................................................................................................................ 39
Group 0403 - Cylinder Block, Liners, Pistons and Rods ................................................................... 46
Liner, Piston, and Rod Failure Analysis ............................................................................................... 46
Pistons and Connecting Rods ............................................................................................................. 48
Cylinder Liners .................................................................................................................................... 61
Check Engine Rotation for Excessive Tightness ................................................................................. 71
Group 0407 - Lubrication System ........................................................................................................ 72
Remove and Install Oil Filter Housing ................................................................................................. 72
Remove, Inspect, and Install Engine Oil Cooler .................................................................................. 73
Remove and Install Oil Pan ................................................................................................................. 74
Remove, Inspect and Install Piston Cooling Orifices ........................................................................... 75
Remove and Install Engine Oil Pump .................................................................................................. 77
Remove and Install Oil Pressure Relief Valve ..................................................................................... 78
Group 0409 - Cylinder Head and Valves ............................................................................................. 79
Cylinder Head and Valves Failure Analysis ......................................................................................... 79
Remove and Install Valve Cover ......................................................................................................... 80
Rocker Arms and Shaft ....................................................................................................................... 81
Clean and Inspect Push Rods .............................................................................................................. 83
Cylinder Head ..................................................................................................................................... 84
Remove and Install Engine Exhaust Valve Brake ................................................................................ 87
Intake and Exhaust Valves ................................................................................................................. 88
Valves ................................................................................................................................................. 90
Cylinder Head ..................................................................................................................................... 92
Group 0410 - Exhaust System .............................................................................................................. 97
Remove and Install Exhaust Manifold ................................................................................................. 97
Group 0413 - Fuel Injection System .................................................................................................... 99
Remove and Install Hand Primer Pump .............................................................................................. 99
Remove and Install Fuel Supply Pump ................................................................................................ 99
Remove and Install Electronic Unit Injector (EUI) ............................................................................. 100
Remove and Install Fuel Delivery Nozzle .......................................................................................... 101
Group 0414 - Air Intake Manifold System ........................................................................................ 103
Remove and Install Air Intake Manifold ............................................................................................ 103
Group 0416 - Turbocharger ................................................................................................................ 105
Turbocharger .................................................................................................................................... 105
Turbocharger Seven-Step Inspection ................................................................................................ 108
Group 0417 - Cooling System ............................................................................................................. 113
Water Pump ...................................................................................................................................... 113
Group 0418 - Thermostats, Housing and Water Piping ................................................................. 121
Remove and Install Thermostats and Housing ................................................................................. 121

Section 04 - ENGINE Group 0400: Removal and Installation

Engine
Remove and Install
[1] - Turn battery disconnect switch to OFF.
[2] - Remove hood. (See Hood in Group 1910.)
[3] - Lower frame bottom guards.
[4] - Remove charge air aftercooler and radiator. (See Remove and Install Charge Air Aftercooler in Group 0520.)
[5] -
LEGEND:
1 Cap Screw and Nuts (4 used)
2 Fan Guard (2 used)
Fan Guards
Remove cap screws (1) and fan guard (2) from left and right side.
[6] -
LEGEND:
1 High Pressure Line
2 Low Pressure Line
3 Air Conditioner Compressor
4 Starting Motor
5 Alternator
Alternator, compressor, and starter.

Disconnect wire′s from starting motor (4) and alternator (5). Pull wires from starter through harness tube (6).
[7] -
IMPORTANT:
Recover R134a refrigerant before disconnecting any air conditioning lines. See Recover R134a
Refrigerant . (Group 1830.)
Disconnect high pressure line (1) and low pressure line (2) from A/C compressor (3).
[8] -

Engine removal
LEGEND:
1 Bleed Lines
2 Fill Tube
3 Cold Start Glow Plug Wire Connector
4 Cold Start Solenoid Wire Connector
5 Cold Start Fuel Line
6 Heater Hose
7 Heater Hose
8 Support Bracket
9 Support Bracket
11 Cross Member
12 Air Intake Boot
13 Exhaust Clamp
14 Air Compressor Output Line
Disconnect lines (1 and 2) from expansion tank.
[9] - Disconnect heater hoses (6 and 7). Remove cap screws for bracket (8) and remove with lines (1 and 2).
[10] - Disconnect start aid glow plug wire connector (3), solenoid wire connector (4), and fuel line (5). Remove bracket (9) and
move harness away from engine. Cut wires ties as necessary.
[11] - Remove cap screws (10) that holds cross member (11). Lift up cross member and swing over to right side fender. Install
one cap screw to hold cross member in place.
[12] - Disconnect intake boot (12).
[13] - Remove clamp (13) and disconnect exhaust pipe from exhaust plenum.
[14] - Disconnect steel braided output line (14) from compressor.
[15] -

LEGEND:
1 Fuel Return Line
2 Banjo Bolt
3 Clamp
4 Fuel Controller Wire Connector
5 Fuel Line-to-Pre-Filter
Fuel controller lines

Drain fuel tank. Disconnect fuel lines (1 and 5).
[16] - Remove clamp (3) and move lines (1, 5, and 6) towards right frame rail.
[17] - Disconnect wire connector (4).
[18] - Disconnect output speed sensor, retarder temperature sensor, turbine speed sensor, input speed sensor, retarder
sensor, and transmission control module wire connectors. (See Transmission Harness (W13) Component Location in Group
9015-10.)
[19] -
LEGEND:
1 Line-to-Cooler
2 Line-from-Cooler
Transmission Cooler Hoses

Disconnect line (2) and drain fluid from cooler into suitable container. Disconnect line (1). Close all openings using caps and
plugs.
[20] - Disconnect transmission drive shaft. (See Remove and Install Transmission-to-Transfer Case Drive Shaft in Group 0325.)
[21] -

Main Hydraulic Pump Drive Shaft

LEGEND:
1 Guard (2 used)
2 Lock Nut (6 used)
4 Drive Shaft
Connect Hydraulic pump drive shaft. See Hydraulic Pump Drive Shaft . (Group 2160.)
[22] -
CAUTION:
Prevent possible injury from crushing. Heavy component; use appropriate lifting device. Approximate
weight of engine and transmission is 1613 kg (3555 lb)
Remove and Install Engine

Engine and Transmission Approximate Weight 1613 kg
3555 lb

LEGEND:
1 Front Engine Mount (2 used)
2 Transmission Mount (4 used)
Engine and Transmission Mounts

Attach JDG23 Lifting Beam to suitable hoist and hook to three engine hookup points. Remove cap screws for front engine
mounts (1) and transmission mounts (2). Note location of washers between rubber mounts and frame.
Lifting Beam
JDG23
Remove and install engine.
[23] - Remove engine. Use shop stands or wooden blocks to support the engine and transmission.
[24] -

LEGEND:
1 Flex Plate Cap Screw (12 used)
2 Transmission-to-Engine Cap Screw
Flex Plate Cap Screws
Remove transmission from engine

Using JDG1500-16 turning tool rotate engine until flex plate cap screws (1) appear in access hole. Rotate engine and remove
cap screws.
[25] -
CAUTION:
weight of transmission is 533 kg (1175 lb)

Transmission Approximate Weight 533 kg
1175 lb
Attach JDG1501-6 main case holding fixture tool to transmission. Attach a suitable hoist to tool.
[26] - Remove cap screws (2) and remove transmission from engine.
Remove cap screws holding flexplate adapter to flywheel.
[27] - Repair or replace as necessary.
[28] - Install flexplate adapter to flywheel. Tighten cap screws to specification.


Flexplate Adapter-to-Flywheel Cap Screws Torque 110 N˙m
81 lb-ft
[29] - Before installing the transmission, align one of the cap screw holes in the flex plate discs and one of the tapped holes in
torque converter adapter with hole in flywheel housing. Install transmission to flywheel housing.

[30] - Apply rigid form in place gasket to threads of transmission-to-flywheel housing cap screws. Tighten to specification.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to threads of transmission-to-flywheel housing cap screws.

Transmission-to-Flywheel Housing Cap Screws. Torque 83 N˙m
61 lb-ft
[31] - Apply medium strength thread lock and sealer to threads of cap screws. Rotate engine and install flexplate-to-converter
adapter cap screws. Tighten to specification.
Number Name Use

• T43512 (us)
Thread Lock and Sealer (Medium Apply to threads of flexplate-to-converter adapter cap
Strength) screws.

Flexplate-to-Converter Adapter Cap Screws. Torque 34 N˙m
25 lb-ft
[32] -
CAUTION:
weight of engine and transmission is 1613 kg (3555 lb)

Engine and Transmission Approximate Weight 1613 kg
3555 lb
LEGEND:
1 Front Engine Mount (2 used)
2 Transmission Mount (4 used)
Engine Hoist

Engine Mount Bolts

Using a suitable hoist, attach JDG23 lifting beam to three lifting points on engine. Install engine into frame.
[33] - Note location of rubber mounts and washers and install cap screws through mounts and frame. Tighten to specification.

Engine and Transmission Mounts-to-Frame Cap Screws Torque 410 N˙m
300 lb-ft
[34] - Connect transmission drive shaft. (See Drive Shafts in Group 0325.)
[35] - Connect Hydraulic pump drive shaft. See Hydraulic Pump Drive Shaft . (Group 2160.)
Number Name Use

• PM38655 (us)
• PM38655 (canadian) Rigid Form-In-Place Gasket Apply to cap screw threads.
Cap Screw and Lock Nut Torque 28 N·m
20 lb-ft
[36] -
LEGEND:
1 Line-to-Cooler
2 Line-from-Cooler
Transmission Lines
Connect transmission lines (1 and 2).
[37] - Connect output speed sensor, retarder temperature sensor, turbine speed sensor, input speed sensor, retarder sensor,
and transmission control module wire connectors. (See Transmission Harness (W13) Component Location in Group 9015-10.)
[38] -

LEGEND:
1 Fuel Return Line
2 Banjo Bolt
3 Clamp
4 Fuel Controller Wire Connector
5 Fuel Line-to-Pre-Filter
Fuel Lines
Connect wire connector (4).
[39] - Connect fuel lines (1 and 5). Use new sealing washers and tighten banjo bolt (2) to specification.

Fuel Line-to- Fuel Controller Banjo Bolt Torque 40 N˙m
30 lb-ft
[40] - Install fuel lines (5 and 6) into clamp (3). Tighten cap screw for clamp.
[41] -

Engine Removal
LEGEND:
1 Bleed Lines
2 Fill Tube
3 Cold Start Glow Plug Wire Connector
5 Cold Start Fuel Line
6 Heater Hose
7 Heater Hose
8 Support Bracket
9 Support Bracket
10 Cap Screw and Nut (8 used)
11 Cross Member
12 Air Intake Boot
13 Exhaust clamp
14 Air Compressor Output Line
Connect compressor output line (14) and intake boot (12).
[42] - Connect exhaust pipe and install clamp (13).
[43] - Swing cross member (11) over engine and install cap screws and nuts (10).
[44] - Connect start aid glow plug wire connector (3), solenoid wire connector (4), and fuel line (5). Install bracket (9) and wire
tie harness as required.
[45] - Connect lines (1 and 2) to expansion tank. Connect heater hoses (6 and 7) and install support bracket (8).
[46] -

LEGEND:
1 High Pressure Line
2 Low Pressure Line
3 Air Conditioning Compressor
4 Starting Motor
5 Alternator
Alternator, Compressor, and Starter

Connect low and high pressure lines (1 and 2).
[47] - Pull wires through harness tube (6) and connect wires to starting motor and alternator.
[48] -
LEGEND:
2 Fan Guard (2 used)
Fan Guards
Install fan Guards (2) using cap screws and nuts (1).
[49] - Install charge air aftercooler and radiator. (See Remove and Install Charge Air Aftercooler in Group 0520.)
[50] - Raise frame bottom guards.
[51] - Install hood. (See Hood in Group 1910.)
Install Engine on Repair Stand
[1] -
LEGEND:
1 1-1/2 x 5/8 in. Cap Screw (4 used)
2 2-1/2 x 1/2 in. Cap Screw (2 used)
3 DFT1224 Engine Mounting Adapter
Engine stand
Remove belt, engine fan, fan hub, and crankshaft pulley.

Section 04 - ENGINE Group 0401: Crankshaft, Main Bearings, and Flywheel
[2] - Remove exhaust manifolds. (See Remove and Install Exhaust Manifold in Group 0410.)
[3] - Remove mounts from engine block.
[4] - Fasten DFT1224 Engine Mounting Adapter (3) to D055223ST engine repair stand using cap screws (1 and 2). (See Group
9900 for instruction to make tool.)
[5] -
CAUTION:
weight of engine is 1080 kg (2380 lb)
Install Engine on Repair Stand

Engine Approximate Weight 1080 kg
2380 lb
LEGEND:
1 M14 x 1.50 x 30 mm Long (9 used)
2 3/4 in. x 3 in. Grade 8 Cap Screw and Nut
3 5/8 in. x 3 in. Grade 8 Cap Screw and Nut
Mount engine in stand

Lower engine on repair stand and install cap screws (1) where original engine mounts were.
[6] - Install bracket using cap screws and nuts (2 and 3). Install cap screw (1) into engine .
[7] - Tighten all cap screws and remove hoist.

Group 0401 - Crankshaft, Main Bearings, and Flywheel

Crankshaft and Main Bearing Failure Analysis
Scored Main Bearing:
(Diagnosis also applies to connecting rod bearing.)
Oil starvation.
Contaminated oil.
Engine parts failure.
Excessive heat.
Poor periodic service.
Galled or “Wiped” Bearings:
Fuel in lubricating oil (incomplete combustion).

Coolant in lubrication system (cracked block, liner seal failure, or leaking water pump seal with plugged hole).
Insufficient bearing oil clearance.
Parts not lubricated prior to engine operation.
Wrong bearing size.
Inconsistent Wear Pattern:
Misaligned or bent connecting rod.

Warped or bowed crankshaft.
Distorted cylinder block.
Broken Main Bearing Caps:
Improper installation.
Dirt between bearing and crankshaft journal.
Low oil pressure.
Oil pump failure.
Cracked, Chipped or Broken Bearings:
Overspeeding.
Excessive idling.
Lugging.
Excessive oil clearance.
Improper installation.

Crankshaft Oil Seals

Remove and Install Rear Oil Seal
[1] - Remove the engine. (See Engine in Group 0400.)
[2] - Remove flywheel. (See Flywheel in this group.)
[3] -
LEGEND:
1 Rear Oil Seal
Rear Oil Seal

Carefully remove rear oil seal (1) from timing case.
[4] -
LEGEND:
2 JDG1500-32 Rear Oil Seal Installation Tool Spacer
Installation Tool Spacer

Install spacer (2) from JDG1500-32 Rear Oil Seal Installation Tool on crankshaft.
Rear Oil Seal Installation Tool
JDG1500-32
Install crankshaft rear oil seal into housing.
[5] - Apply engine oil to lip of rear oil seal.
[6] - Install rear oil seal on installation tool. Install seal into housing, over spacer.
Remove and Install Rear Wear Sleeve

[1] -
LEGEND:
1 Wear Sleeve
2 Flywheel
3 JDG1500-33 Crankshaft Race Seal Ring Installation Tool
Wear Sleeve and Flywheel
Installation Tool
Remove flywheel. (See Flywheel in this group.)
[2] - Remove wear sleeve (1) from flywheel (2) using a puller. Discard wear sleeve.
[3] - Heat new wear sleeve to 200°C (392°F). With rounded edge of new wear sleeve to JDG1500-33 Crankshaft Race Seal Ring
Installation Tool (3), use tool to install wear sleeve onto flywheel.
Crankshaft Race Seal Ring Installation Tool
JDG1500-33
Install wear sleeve to flywheel.
[4] - Install flywheel. (See Flywheel in this group.)
Remove and Install Front Oil Seal and Wear Sleeve
[1] - Remove damper.
[2] -

LEGEND:
1 Oil Splash Ring
Oil Splash Ring

Remove oil splash ring (1).
[3] - Remove oil pan. (See Remove and Install Oil Pan in Group 0407.)
[4] -
LEGEND:
Front Housing
Remove cap screws (1) to remove front housing and front oil seal.
[5] - Remove gasket from front housing and discard.
[6] -

LEGEND:
1 Front Oil Seal
Remove Front Oil Seal

Support front housing when removing front oil seal (1).
[7] - Remove front oil seal from front housing using JDG1591 Front Crankshaft Seal Installation Tool.
Front Crankshaft Seal Installation Tool
JDG1591
To remove and install front oil seal from front housing.
[8] - Remove front wear sleeve using JDG1500-34 Front Crankshaft Seal Race Puller.
Front Crankshaft Seal Race Puller
JDG1500-34
To remove seal race from crankshaft.
[9] - Clean seal race surface on crankshaft.
[10] - Heat seal race to approximately 200°C (392°F).
[11] -
LEGEND:
1 JDG1500-33 Front Crankshaft Seal Race Installation Tool
Front Wear Sleeve

Install front seal race on crankshaft using JDG1500-33 Front Crankshaft Seal Race Installation Tool (1).
Front Crankshaft Seal Race Installation Tool
JDG1500-33
To install seal race on crankshaft.

[12] -
Install Front Oil Seal

With front housing flat on an even support install front oil seal flush to the support using JDG1591 Front Crankshaft Seal
Installation Tool.
Front Crankshaft Seal Installation Tool
JDG1591
To remove and install front oil seal from front housing.
[13] - Lubricate front wear sleeve and front oil seal running surfaces with clean engine oil.
[14] - Install new front housing gasket over the dowel pins on crankcase.
[15] - Install front housing cap screws and front housing to crankcase. Tighten front housing cap screws to specification.
Front Housing
Cap Screw Torque 25 N˙m (221 lb-in.)
[16] - Install oil pan. (See Remove and Install Oil Pan in Group 0407.)
[17] - Install splash ring.
[18] - Install damper, and tighten damper cap screws to specification.

Vibration Damper-to-Crankshaft
Cap Screw Torque 200 N·m (148 lb.-ft.)

Flywheel
Remove and Install
[1] - Pull crankshaft position sensor out from timing case approximately 8 mm (0.3 in.).
[2] -
LEGEND:
1 Flywheel Cap Screw (10 used)
Flywheel Cap Screws

Remove flywheel cap screws (1).
[3] -
LEGEND:
2 JDG1500-36 Pilot Bolt (2 used)
Pilot Bolts
Install JDG1500-36 Pilot Bolts (2) evenly spaced into flywheel cap screw holes.
Pilot Bolts
JDG1500-36
Remove and install flywheel.
[4] - Remove flywheel over pilot bolts.
[5] - Install flywheel over pilot bolts.
[6] - Remove pilot bolts.
[7] - Measure the shank length of flywheel cap screws from the end of cap screw to the bottom of cap screw head. Replace all
cap screws if any are longer than specified length.

Flywheel
Cap Screw Shank Length 75 mm (2.95 in.) Maximum
[8] - Install flywheel cap screws and tighten to specification.

Flywheel
Cap Screw Torque 210 N˙m (155 lb-ft)
Torque Turn 90°
[9] - Push crankshaft position sensor to its stops.
Inspect Flywheel and Ring Gear
Examine flywheel for signs of cracking and scoring. Examine ring gear for damaged or worn teeth. Replace flywheel ring gear,
if necessary. (See Remove and Install Ring Gear in this procedure.)
Remove and Install Ring Gear
Ring Gear Removal
[1] -
CAUTION:
DO NOT use heated oil to heat ring gear. Oil fumes or oil can ignite above 193°C (380°F). Use an oven or
flame heat. Plan a safe handling procedure to avoid burns.
If ring gear is damaged, place the flywheel on a solid flat surface.
[2] - Heat ring gear rapidly to 250—280°C (482—536°F). Remove ring gear using a press or with a brass drift and hammer.
[3] -
IMPORTANT:
If flame heat is used, be sure gear is heated uniformly around circumference. DO NOT OVERHEAT.
Overheating may destroy original heat treatment of gear.
Heat new ring gear to 250—280°C (482—536°F) using either oven heat or flame heat.
[4] -

Ring Gear Installation

Install ring gear flush with face of flywheel using wood block and hammer.

Remove and Install Timing Case Cover

[1] - Remove turbocharger. (See Turbocharger in Group 0416.)
[2] - Remove intake manifold. (See Remove and Install Air Intake Manifold in Group 0414.)
[3] -
LEGEND:
1 Compressor Coolant Line (2 used)
2 Fuel Line
4 Timing Case Cover
5 Gasket
6 Camshaft Position Sensor
Timing Case Cover

Remove compressor coolant lines (1).
[4] - Remove fuel line (2) connected to outlet side of fuel pump.
[5] - Disconnect camshaft position sensor (6) at sensor.
[6] - Disconnect crankcase breather hose at crankcase .
[7] - Remove cap screws (3) and timing case cover (4).
[8] - Clean sealing surfaces of timing case cover, timing case and crankcase.
[9] - Seal joints between timing case and crankcase with clear RTV silicone adhesive sealant.
Number Name Use

Clear RTV Silicone Adhesive Seal crankcase and gasket of injection pump flange joint face and
• TY24344 (us)
Sealant crankcase and timing case joint faces.
[10] -

Cap Screw Tightening Sequence

Install new gasket (5), timing case cover and cap screws. Tighten cap screws to specification in the sequence shown.
Timing Case Cover

[11] - Connect crankcase breather hose at crankcase .
[12] - Install coolant lines to crankcase and compressor. Tighten banjo fittings to specification.
Coolant Line
Banjo Fitting at Compressor Torque 30 N˙m (22 lb-ft)
Banjo Fitting at Crankcase Torque 35 N˙m (26 lb-ft)
[13] - Install fuel line. Tighten fittings to specification.

Fuel Line
Banjo Fitting at Fuel Pump Torque 40 N˙m (30 lb-ft)
Connection Between Fuel Lines Torque 45 N˙m (33 lb-ft)
[14] - Connect camshaft position sensor at sensor.
[15] - Install intake manifold. (See Remove and Install Air Intake Manifold in Group 0414.)
[16] - Install turbocharger. (See Turbocharger in Group 0416.)

Remove and Install Timing Case

[1] - Remove engine. (See Engine in Group 0400.)
[2] - Remove timing case cover. (See Remove and Install Timing Case Cover in this group.)
[3] -
LEGEND:
1 Camshaft Position Sensor
2 Oil Pan-to-Timing Case Mounting Cap Screw (3 used)
3 Lifting Eye
4 Bracket
5 Timing Case
6 Oil Line Bracket
7 Fuel Line Bracket
8 Engine Harness Bracket
Timing Case
Remove camshaft position sensor (1).
[4] - Remove lifting eye (3) and bracket (4) from timing case (5).
[5] - Disconnect oil line bracket from timing case (6).
[6] - Remove fuel line bracket (7) from timing case.
[7] - Remove engine harness bracket (8) from timing case.
[8] - Remove starting motor.
[9] - Remove flywheel. (See Flywheel in this group.)
[10] -
→NOTE:
Be careful not to damage oil pan gasket. If gasket is damaged, replace oil pan gasket. (See Remove and
Install Oil Pan in Group 0407.)
Remove cap screws (2) mounting oil pan to timing case. Loosen all other oil pan cap screws.
[11] -

LEGEND:
1 M12 x 57 Timing Case Cap Screw (12 used)
Timing Case
Remove timing case cap screws (1 and 2) and timing case.
[12] - Clean timing case and crankcase sealing surfaces.
[13] - Tighten oil pan cap screws to specification.
[14] - Install new gasket over dowel pins on crankcase and adjust for length.
[15] - Seal joint faces between timing case gasket and oil pan gasket with clear RTV silicone adhesive sealant.
Number Name Use

Seal joint faces between timing gear housing gasket and oil pan
• TY24344 (us) Clear RTV Silicone Adhesive Sealant
gasket.
[16] -
LEGEND:
Timing Case
Install timing case to crankcase with timing case cap screws (1 and 2). Tighten to specification.
Timing Case
M12 x 57 Cap Screw Torque 100 N˙m (74 lb-ft)
M12 x 167 Cap Screw Torque 80 N˙m (59 lb-ft)
[18] - Install camshaft position sensor.
[19] - Install turbocharger oil return lines.

[20] - Install engine lifting eye and bracket to timing case. Tighten cap screw to specification.
Engine Lifting Eye

[21] - Install oil line bracket to timing case.
[22] - Install fuel line bracket to timing case. Tighten cap screw to specification.
Fuel Line Bracket

[23] - Install engine harness bracket to timing case. Tighten cap screw to specification.
Wiring Harness Bracket

[24] - Install timing case cover. (See Remove and Install Timing Case Cover in this group.)
[25] - Install starting motor.
[26] - Install engine. (See Engine in Group 0400.)

Crankshaft
Check Crankshaft End Play
[1] -
IMPORTANT:
Measure crankshaft end play prior to removing crankshaft to determine condition of thrust bearings.
Check Crankshaft End Play

Attach a magnetic base and dial indicator to crankcase.
[2] -
IMPORTANT:
DO NOT apply too much pressure on pry bar. Bearings can be damaged.
Gently pry crankshaft as far to rear of engine as possible using a pry bar.
[3] - Turn the dial indicator zero.
[4] - Gently pry crankshaft as far forward as possible and note dial indicator reading. If end play is not within specifications,
replace crankshaft thrust bearing.
Crankshaft
Axial End Play 0.150—0.351 mm (0.0059—0.0138 in.)
Remove Crankshaft
LEGEND:
1 Main Bearing Vertical Cap Screws
2 Main Bearing Lateral Cap Screws
3 Connecting Rod Cap Screws
Main Bearing and Connecting Rod Cap Screws

[1] - Remove timing case. (See Remove and Install Timing Case in this group.)
[2] - Remove oil pump. (See Remove and Install Engine Oil Pump in Group 0407.)
[3] - Remove front housing. (See Crankshaft Oil Seals in this group.)
[4] - Remove pistons and connecting rods. (See Pistons and Connecting Rods in Group 0403.)
[5] -
IMPORTANT:
Mark main bearing caps and bearings and rod caps and bearings for ease in assembly.
If cylinder head is removed from engine, ensure that pistons do not fall to floor when connecting rod caps
are removed. Put a suitable container with padding under engine.
Rotate crankshaft as required to remove connecting rod cap screws (3) and caps.
[6] - Remove main bearing lateral cap screws (2).
[7] - Remove main bearing vertical cap screws (1). Remove main bearing caps using a soft-face (plastic) hammer, if necessary.
Tap gently, using the minimum force necessary.
[8] -
CAUTION:
Use a lifting device for heavy components.
LEGEND:
1 Pilot Bolt (2 used)
Crankshaft Removal
Install JDG1500-36 Pilot Bolts (1) in ends of crankshaft. Attach a lifting strap.
Pilot Bolts
JDG1500-36
Remove and install crankshaft from crankcase
[9] - Carefully remove crankshaft from block with a hoist.
[10] - Clean crankshaft, especially oil passages. Dry thoroughly.
[11] - Place crankshaft on clean V-blocks.
Inspect Crankshaft

LEGEND:
A Rod Journal Oil Holes
B Journal Fillets
Crankshaft Inspection
[1] - Thoroughly clean crankshaft. Clear restrictions from all oil passages.
[2] - Inspect crankshaft for signs of load stress, cracks, or scratches on journals. Also check each journal for evidence of
excessive overheating or discoloration. If either condition exists, replace crankshaft, since heat treatment has probably been
destroyed.
[3] - Inspect front crankshaft gear for cracks, chipped teeth, or excessive wear. Replace gear as required.
[4] - Inspect the keyway for evidence of cracks or wear. Replace crankshaft as necessary.
[5] - Carefully check the crankshaft for cracks in the area of rod journal oil holes (A) and at journal fillets (B). Replace
crankshaft if any cracks are found.
IMPORTANT:
Small cracks may not be visible to the eye. Use a method such as the Fluorescent Magnetic Particle
method. This method magnetizes the crack, using magnetic particles which are fluorescent and glow
under `black light′. The crankshaft must be demagnetized after inspection.
Measure Crankshaft Bearings and Journals
[1] - With crankshaft removed from engine, install main bearing caps with bearing (if previously removed). Ensure bearings are
installed correctly.
[2] -

Torque Turn
Measure Bearing ID′s

Tighten main bearing cap screws to specification. Tighten main bearing cap screws to their final torque by placing ratchet
handle centerline to crankshaft, then turn clockwise an additional 90°, as shown. Handle should then be perpendicular to
crankshaft centerline.
Crankshaft
Main Bearing Vertical Cap Screw Torque 320 N˙m (236 lb-ft)
Main Bearing Vertical Cap Screw Final Torque Turn 90°
Main Bearing Lateral Cap Screw Torque 125 N˙m (92 lb-ft)
[3] -
→NOTE:
If engine has previously had a major overhaul and undersized bearings were used, ID and OD dimensions
may not be the same as those recorded. However, oil clearance must be as specified in this procedure.
See Crankshaft Grinding Specifications in this procedure for undersize bearing and crankshaft journal
specifications.
Measure ID of all assembled bearings with an inside micrometer in three locations: vertical and 30° above and 30° below joint
face. Compare measurements with the following specifications:

Crankshaft
Main Bearing
ID 108.056—108.102 mm (4.2542—4.2560 in.)
[ See Crankshaft Grinding Specifications in this procedure for undersize bearing and journal specifications. ]
[4] -
Crankshaft Journal Measurement

Measure OD of all respective crankshaft journals in four locations 90° apart. Compare measurements with the following
specifications.
Crankshaft
Main Journal OD 107.98—108.00 mm (4.2512—4.2520 in.)
Main Journal Radial Runout 0.020 mm (0.0008 in.) Maximum
Main Journal Width 42.000—42.016 mm (1.6535—1.6542 in.)
Main Journal and Thrust Bearing Width 42.000—42.062
→NOTE:
If engine has previously had a major overhaul and undersized bearings were used, ID and OD dimensions
may not be the same as those recorded. However, oil clearance must be as specified below. See
Crankshaft Grinding Specifications in this procedure for undersize bearing and crankshaft journal
specifications.
[5] - Determine crankshaft-to-main bearing oil clearance based on bearing ID and journal OD measurements above, and
compare to the following specifications.
Crankshaft
Crankshaft-to-Main Bearing Oil
Clearance 0.056—0.122 mm (0.0022—0.0048 in.)
[6] - Measure connecting rod journal OD and width. Compare to the following specifications.
Crankshaft
Connecting Rod Journal
OD 93.98—94.00 mm (3.7000—3.7008 in.)
Connecting Rod Journal Width 37.000—37.010 mm (1.4567—1.4571 in.)
Grinding Guidelines

IMPORTANT:
Crankshaft grinding should be done ONLY by experienced personnel on equipment capable of maintaining
crankshaft size and finish specifications.
In addition to the standard size bearings, undersize bearings are available for main bearing and rod bearing journals. (See
Crankshaft Grinding Specifications in this procedure for journal and bearing sizes.)
If journals are tapered, out-of-round, scored, or damaged, grind the crankshaft and install the proper undersize bearings.
IMPORTANT:
If undersize bearings are used, check bearing clearance after bearing caps have been tightened to
specified torque. If undersize bearings are too tight and clearance is not within specifications, the journal
and bearing will be wiped clean of all oil. This would result in premature wear of parts.
If the crankshaft is to be reground, use the following recommended guidelines:
[1] - Compare the crankshaft journal measurements taken during inspection and determine the size to which the journals are
to be reground.
[2] - Grind all main journals or all connecting rod journals to the specified size. (See Crankshaft Grinding Specifications in this
procedure.)
[3] -
IMPORTANT:
Care must be taken to avoid localized heating which often produces grinding cracks. Cool the crankshaft
while grinding by using coolant generously. DO NOT crowd the grinding wheel into the work.
Grind crankshaft with journals turning counterclockwise, as viewed from the front end of the crankshaft.
Lap or polish journals in opposite direction of grinding.
Polish or lap the ground surfaces to prevent excessive wear of the journals.
→NOTE:
Production crankshafts are induction hardened and shotpeened at the factory. Field shotpeening is not
recommended due to the equipment required and part geometry.
When thrust surfaces are reground and an oversized bearing is used, crankshaft end play specification
must be maintained. (See Check Crankshaft End Play in this procedure.)
[4] - Stone the edge of all oil holes in the journal surfaces smooth.
[5] - When finished grinding, inspect the crankshaft for cracks with the Fluorescent Magnetic Particle method, or similar
method. Demagnetize crankshaft after inspection.
[6] - Thoroughly clean the crankshaft and oil passages using a volatile, non-petroleum base solvent. Dry the crankshaft.
Grinding Specifications
Main Journal
0.100 mm Undersize OD 107.88—107.90 mm (4.2472—4.2480 in.)
Main Bearing
0.100 mm Undersize ID 107.956—108.002 mm (4.2502—4.2520 in.)

Connecting Rod Bearing Journal

Connecting Rod Bearing

Thrust Bearing and Main Bearing Journal

0.500 mm Oversize Width 42.500—42.562 mm (1.6732—1.6757 in.)
1.00 mm Oversize Width 43.000—43.062 mm 1.6929—1.6953 in.)
Engine
Engine Stroke Length 150 mm (5.91 in.)
Remove and Install Crankshaft Gear
[1] -
→NOTE:
Remove crankshaft gear only if replacement is necessary.
LEGEND:
1 Crankshaft
2 Crankshaft Gear
3 Dowel Pin
Crankshaft Gear Removal

Remove crankshaft gear (2) from crankshaft (1) using a suitable puller.
[2] -
CAUTION:
Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer and do not exceed 182°C (360°F). Do
not allow a heating element to be in direct contact with the oil. Heat the oil in a well-ventilated area.
Plan a safe handling procedure to avoid burns.
IMPORTANT:
If flame heat is used, be sure gear is heated uniformly around circumference. DO NOT OVERHEAT.
Overheating may also destroy original heat treatment of gear.

Heat crankshaft gear to 80°C (176°F), using either heated oil or oven heat.
[3] - If removed, install dowel pin (3) in crankshaft.
[4] - Install gear on crankshaft.
[5] -
IMPORTANT:
When installing gear, do not gouge or nick crankshaft flange. Use only enough force as necessary.
Excessive striking force may damage thrust bearings.
Firmly seat gear against crankshaft flange using a driver. Ensure crankshaft gear locates properly on dowel pin.
[6] - Once gear cools, reseat gear.
Install Main Bearing and Crankshaft

LEGEND:
1 Locating Tab
2 Oil Hole in Bearings
3 Oil Hole in Main Bearing Web
4 Slot
Crankshaft Bearings
IMPORTANT:
If new main or thrust bearings are installed, they must be installed as a matched set.
→NOTE:
If crankshaft gear was removed from crankshaft, install gear before installing crankshaft. (See Remove
and Install Crankshaft Gear in this procedure.)
During assembly, apply a liberal coating of clean engine oil to:
All main bearing webs in block

Both sides of main bearing inserts and thrust bearing
Entire OD of crankshaft main bearing journal
[1] - Install main and thrust bearings in block. Be sure locating tabs (1) on inserts are properly positioned with slot (4) in block
web.
[2] - Check to make sure that oil holes in main bearing web (3) are properly aligned with oil holes in bearing (2).
[3] -
CAUTION:

LEGEND:
1 JDG1500-36 Pilot Bolt
Crankshaft Removal
Carefully position crankshaft onto main bearings using a hoist and JDG1500-36 Pilot Bolt.
Pilot Bolt
JDG1500-36
Remove and install crankshaft from crankcase.
[4] -
IMPORTANT:
Main bearing vertical cap screws are stretched when tightened to specification. Cap screws are usable up
to a maximum shank length of 156 mm (6.14 in.) measured from the end of cap screw to the bottom of
cap screw head. If any cap screw is at or longer than the specification, replace both cap screws for the
that bearing cap.
Measure the shank length of main bearing vertical cap screws from the end of cap screw to the bottom of cap screw head.
Replace both cap screws for that bearing cap if either cap screw is at or longer than the specification.
Crankshaft
Main Bearing Vertical Cap Screw Shank Length 156 mm (6.14 in.) Maximum
[5] -
LEGEND:
1 Main Bearing Vertical Cap Screw and Washer (8 used)
2 Main Bearing Lateral Cap Screw (8 used)
Main Bearing Cap Screws

Dip main bearing cap screws completely in clean engine oil and install them in main bearing caps.
Apply a liberal amount of oil to bearing inserts in caps.

[6] -
→NOTE:
Install bearing caps in the same position as removed. If caps were not marked during removal, there are
stamped numbers on the top of main bearing caps. Although caps are not numbered 1—4, the numbers
are in ascending order starting at the front of the engine and proceeding toward rear of engine. The side
of cap with stamped number must face front of engine.
Install each main bearing cap, main bearing, and main bearing vertical cap screw and washer (1), with the recesses and tabs
aligned, in matching order. Make sure bearing tabs also match up before tightening cap screws.
[7] -
IMPORTANT:
Do not use a pneumatic wrench to install main bearing cap screws, as damage to threads can occur.
LEGEND:
1 Main Bearing Vertical Cap Screw and Washer (8 used)
2 Main Bearing Lateral Cap Screw (8 used)
Torque-Turn Cap Screws
Main Bearing Cap Screws

Tighten main bearing cap screws to specification. Tighten main bearing cap screws to their final torque by placing ratchet
handle centerline to crankshaft, then turn clockwise an additional 90°, as shown. Handle should then be perpendicular to
crankshaft centerline.
Crankshaft
Main Bearing Vertical Cap Screw Torque 320 N˙m (236 lb-ft)
Main Bearing Vertical Cap Screw Final Torque Turn 90°

[8] - Install lateral main bearing cap screw (2) and tighten to specification.
Crankshaft
[9] - Turn crankshaft by hand. If it does not turn easily, disassemble parts and determine the cause.
[10] - Install connecting rod bearings and connecting rod caps. (See Pistons and Connecting Rods in Group 0403.)
[11] - Check crankshaft for specified end play. (See Check Crankshaft End Play in this procedure.)
[12] - Install oil pump. (See Remove and Install Engine Oil Pump in Group 0407.)
[13] - Install timing case. (See Remove and Install Timing Case in this group.)
[14] - Install timing case cover. (See Remove and Install Timing Case Cover in this group.)
[16] - Install engine. (See Engine in Group 0400.)

Section 04 - ENGINE Group 0402: Camshaft and Timing Gear Train
Bleed Engine Oil Circuit after Major Overhaul

IMPORTANT:
After major overhaul of the engine, the oil circuit must be bled to ensure proper lubrication when the
engine is first started.
[1] - Fill a container, that can be pressurized using a hand pump, with clean engine oil.
[2] -
LEGEND:
1 Plug
2 Seal
3 Parker M33-1F80HGS Fitting
4 Cylinder 1
5 Cylinder 2
Bleed Engine Oil Circuit

Remove valve covers from number 1 (4) and number 6 (5) cylinders. (See Remove and Install Valve Cover in Group 0409.)
[3] - Remove plug (1) and seal (2) from oil filter base.
[4] - Install fitting (3). Adapt pump to fitting.

Adapter Fitting
Parker M33-1F80HGS
Adapt hand pump to oil filter base.
[5] - Pressurize container to approximately 300 kPa (3 bar) (43 psi). Open shut-off valve on container and observe rocker arms.
Allow oil to flow until oil from rocker arms is free of bubbles. Maintain at least 150 kPa (1.5 bar) (22 psi) in container during
bleed procedure.
[6] - Disconnect line from oil filter base, remove adapter and install seal and plug. Tighten to specification.
Oil Filter Base

Plug Torque 65 N˙m (48 lb-in.)
[7] - Install valve covers. (See Remove and Install Valve Cover in Group 0409.)

Group 0402 - Camshaft and Timing Gear Train

Camshaft
Check Valve Lift
LEGEND:
1 Magnetic Base Dial Indicator
2 Jam Nuts
3 Adjusting Screws
Check Valve Lift
IMPORTANT:
For a more accurate measurement, it is recommended that valve lift be measured at 0.00 mm (in.) valve
clearance and with engine COLD.
→NOTE:
Measuring valve lift can give an indication of wear on camshaft lobes and cam followers or bent push
rods.
[1] - Remove rocker arm cover. Loosen jam nut (2) on rocker arm. Set valve clearance at 0.00 mm (0.0 in.) on valve being
checked. Tighten lock nut.
[2] - Put dial indicator tip on adjusting screw as shown. Be sure that valve is fully closed.
[3] - Check pre-set on dial indicator. Set dial indicator pointer at zero.
[4] - Manually turn engine in the direction of rotation.
[5] - Observe dial indicator reading as valve is moved to fully open position. Record reading and valve number.
Intake Valve Lift 8.0—8.3 mm (0.314—0.326 in.)
Exhaust Valve Lift 8.3—8.5 mm (0.326—0.334 in.)
[6] - Repeat procedure on all remaining valves.
[7] - Reset valve clearance to specification after measuring lift. Go to Valve Clearance Adjustment. (See procedure in Group
9010-20.)
Check and Measure Camshaft End Play and Gear Backlash
[1] -

LEGEND:
1 Dial Indicator
2 Dial Indicator Tip
3 Timing Case
4 Camshaft Drive Gear
5 Pry Bar
Measuring Camshaft Endplay
Measuring Camshaft Endplay

Remove timing case cover. (See Remove and Install Timing Case Cover in Group 0401.)
[2] - Push on camshaft drive gear (4) in the direction of timing case (3).
[3] - Install magnetic base dial indicator (1) and position tip (2) on front of camshaft drive gear. Set dial indicator to zero.
[4] - Using a pry bar (5) move camshaft back and forth and observe end play reading.
Camshaft End Play Distance 0.2—0.9 mm (0.008—0.035 in.)
[5] - Measure backlash between camshaft drive gear and crankshaft gear in three different positions around the camshaft
gear.
Camshaft Drive Gear-to-Crankshaft Gear Backlash 0.070—0.180 mm (0.0028—0.0071 in.)
[6] - Install timing case cover. (See Remove and Install Timing Case Cover in Group 0401.)
Remove
[1] -

LEGEND:
1 Valve Lifter (12 used)
2 JDG1596 Valve Lifter Removal and Installation Tool
Remove Valve Lifters

Remove timing case. (See Remove and Install Timing Case in Group 0401.)
[2] - Remove cylinder heads. (See Cylinder Head in Group 0409.)
[3] - Remove oil filter housing. (See Remove and Install Oil Filter Housing in Group 0407.)
[4] -
IMPORTANT:
Mark or identify lifters when removing. Lifters should be installed in the same bore they were removed
from.
Remove valve lifters (1) using JDG1596 removal tool (2).

Valve Lifter Removal and Installation Tool
JDG1596
To remove and install engine valve lifters.
[5] -
LEGEND:
1 Crankshaft Gear
2 Camshaft Gear
Timing Marks
Turn engine in the direction of rotation until the timing marks on the crankshaft gear (1) align with the timing marks on
camshaft drive gear (2).
[6] -

IMPORTANT:
When removing camshaft, pull straight out and hold as level as possible to avoid bearing damage.
LEGEND:
1 Camshaft
JDG1593 Camshaft Removal and Installation Guide
2
Sleeve
Remove Camshaft
Install JDG1593 guide sleeve (2) on to camshaft (1) at the fan side of engine.
Camshaft Guide Sleeve
JDG1593
To protect bearings when removing and installing camshaft
[7] -
CAUTION:
Camshaft lobe edges are sharp. Wear protective gloves when handling camshaft to prevent injury to
hands.
Remove camshaft out of flywheel side, guiding wear sleeve through bearings to prevent damage.
Inspect and Measure Camshaft
[1] -

Inspect and measure camshaft

LEGEND:
1 Camshaft Bearing Journals (4 used)
2 Intake Valve Lobe (6 used)
3 Exhaust valve Lobe (6 used)
4 Electronic Unit Injector Lobe (6 used)
Support camshaft on v-blocks. Using a magnetic base dial indicator and measure camshaft.
[2] - Check radial runout of camshaft bearing journals. Measurements must not exceed specification.

Camshaft Bearing Journals Radial Runout 0.050 mm (0.002 in)
[3] - Measure camshaft lobe height for intake lobes (2) and exhaust lobes (3).

Camshaft Intake Lobe Height 8.0—8.3 mm (0.314—0.326 in)
Camshaft Exhaust Lobe Height 8.3—8.5 mm (0.326—0.334 in)
[4] - Measure camshaft lobe height for electronic unit injector lobes (4).

Camshaft Electronic Unit Injectors Lobe Height 17.7—18.0 mm (0.697—0.709 in)
[5] - Compare measurements with specifications. Replace camshaft and bushings as needed.
Install
[1] - Turn engine in the direction of rotation until the No. 1 cylinder is at TDC on the compression stroke so timing marks on
crankshaft gear and camshaft gear can be aligned.
[2] -

IMPORTANT:
When installing camshaft, hold as level as possible and slowly slide through bores to avoid bearing
damage.
CAUTION:
Camshaft lobe edges are sharp. Wear protective gloves when handling camshaft to prevent injury to
hands.
LEGEND:
1 JDG1593 Guide Sleeve
2 Camshaft
Installing Camshaft
Install JDG1593 guide sleeve (1) onto camshaft (2).
[3] - Slide sleeve and camshaft into bearings from the flywheel side of the engine.
[4] -
LEGEND:
1 Crankshaft Gear
2 Camshaft Gear
Timing Marks
Align timing marks on camshaft drive gear (2) and crankshaft gear (1).
[5] - Install oil filter housing. (See Remove and Install Oil Filter Housing in Group 0407.)
[6] -

Section 04 - ENGINE Group 0403: Cylinder Block, Liners, Pistons and Rods
LEGEND:
1 Valve Lifter (12 used)
2 JDG1596 Lifter Installation Tool
Installing lifters
Install lifters in the correct bores using JDG1596 lifter tool
[7] - Install cylinder heads. (See Cylinder Head in Group 0409.)
[8] - Install timing case. (See Remove and Install Timing Case in Group 0401.)

Group 0403 - Cylinder Block, Liners, Pistons and Rods

Liner, Piston, and Rod Failure Analysis
Scuffed or Scored Pistons:
Overheating.
Overfueling.
Insufficient lubrication.
Insufficient cooling.
Improper piston-to-liner clearance.
Coolant leakage into crankcase.
Misaligned or bent connecting rod.
Improperly installed piston.
Low oil level.
Improper operation.
Incorrect connecting rod bearing clearance.
Carbon build-up in ring groove.
Improper engine break-in.
Worn piston.
Contaminated oil.
Distorted cylinder liner.
Plugged piston cooling orifice.
Ingestion of dust through air intake.
Worn or Broken Compression Rings:
Improper ring installation.
Improper timing.
Abrasives in combustion chamber.
Clogged Oil Control Ring:
Improper oil.
Excessive blow-by.
Contaminated oil.
Improper periodic service.
Low operating temperature.
Stuck Rings:
Improper oil classification.

Improper periodic service.
Poor operating conditions.
Coolant leakage into crankcase.
Excessive cylinder liner taper.
Mottled, Grayish or Pitted Compression Rings:
Internal coolant leaks.
Dull Satin Finish and Fine Vertical Scratches on Rings:
Dirt and abrasives in air intake system.
Piston Pin and Snap Ring Failure:
Misaligned connecting rod.

Excessive crankshaft end play.
Incorrect snap rings.

Broken Connecting Rod:
Inadequate piston-to-liner clearance.

Worn connecting rod bearing.
Distorted cylinder line.
Piston pin failure.
Cylinder Liner Wear and Distortion:
Incorrectly installed compression rings.

Uneven cooling around liner.
Inadequate piston-to-liner clearance.
Liner bore damage.
Warped Cylinder Block:

Pistons and Connecting Rods

Remove
[1] - Remove engine oil pump. (See Remove and Install Engine Oil Pump in Group 0407.)
[2] - Remove cylinder head. (See Cylinder Head 0409.)
[3] - Remove any ridges from top of liner bores with a scraper or ridge reamer before removing pistons.
[4] -
IMPORTANT:
Make sure connecting rods and caps are marked before removing caps.
LEGEND:
1 Connecting Rod Cap Stamped Number
2 Connecting Rod Stamped Number
3 Connecting Rod Cap Screw (16 used)
Rod Cap Markings
Rod Cap Screws

Note stamped numbers of connecting rod cap (1) and connecting rod (2).
[5] - Remove cap screws (3) from connecting rod and cap.
[6] - Remove connecting rod caps and cap bearings from crankshaft. Keep bearings with their respective caps.
[7] -

LEGEND:
1 Piston
2 Piston Cooling Nozzle
Piston Cooling Nozzles

Mark piston and rod to ensure they are installed in the same location as removed.
[8] -
IMPORTANT:
When removing piston and rod, be careful not to damage piston cooling nozzles (2).
Rotating engine as required, gently tap piston and rod through top of cylinder block, holding rod to avoid scratching liner.
Disassemble Pistons and Connecting Rods
Disassembling Piston and Rod
[1] - Remove piston snap rings. Remove piston pin and connecting rod from piston.
Discard snap rings, DO NOT reuse.
If checking rings to determine cause of engine trouble, ring end gap should be as follows:

No. 1 Piston Compression Ring End Gap 0.60—0.75 mm (0.024—0.030 in.) new
No. 1 Piston Compression Ring End Gap 1.0 mm (0.039 in.) repair limit
No. 3 Piston Oil Ring End Gap 0.30—0.45 mm (0.012—0.018 in.) new
No. 3 Piston Oil Ring End Gap 0.8 mm (0.031 in.) repair limit
[2] - Remove piston rings using the JDG1500-31 Piston Ring Pliers.
Piston Ring Pliers

JDG1500-31
JDG1500-31
Remove and install piston rings.
Discard all rings.
Measure and Inspect Connecting Rod
[1] -
LEGEND:
2 Connecting Rod Cap
3 Connecting Rod
Inspect and measure connecting rod

Inspect rod and bearings for damage or wear. If any blueing or discoloration is present rod should be discarded.
[2] -
IMPORTANT:
Never use new connecting rod cap screws when checking rod bearing ID. Use new cap screws only for
final assembly of connecting rods.
Install connecting rod cap (2) on to connecting rod (3) with bearings in correct position using cap screws (1). Tighten cap
screws.
[3] - Using an inside micrometer measure rod ID at three places as shown. Compare measurements to specifications.

Connecting Rod-Standard Bearings ID 94.05—94.09 mm (3.702—3.704 in.)
Connecting Rod-0.10 mm Undersize ID 93.95—93.99 mm (3.698—3.700 in.)

Inspect Piston Pins and Bushings

LEGEND:
A Connecting Rod
B Piston Pin
Checking Piston Pin and Rod
[1] - Insert piston pin (B) through piston pin bushing and carefully clamp in a soft-jawed vise.
[2] - Rotate connecting rod (A) back and forth several times to make sure connecting rod moves freely on piston pin.
[3] - Remove piston pin from connecting rod.
[4] -
LEGEND:
A Tapered Bore
B Bell-Mouthed Bore
Piston Pin Bore Inspection

Insert piston pin from either side of rod bushing. If pin is free on one end, but tight on the other, the bore could be tapered (A).
If pin enters freely from both sides, but is tight in the center, bore is bell-mouthed (B).
[5] - Measure rod pin bushings and compare measurements with specifications given below:

Installed Connecting Rod Pin Bushing (After Boring) ID 52.05—52.06 mm (2.049—2.050 in.)
Connecting Rod Pin-to-Bushing Oil Clearance 0.055—0.070 mm (0.002—0.003 in.)
[6] - Replace bushing if required. (See Replace Piston Pin Bushing in Connecting Rod in this procedure.)
Replace Piston Pin Bushing in Connecting Rod

LEGEND:
1 Connecting Rod Bushing
2 Oil Passage
3 Countersunk Oil Bore
4 Connecting Rod Split Joint
Connecting Rod Bushing
Bushing Installation
IMPORTANT:
Installed connecting rod bushings must be line-bored to specification. This should be done ONLY by
experienced personnel on equipment capable of maintaining specifications. Replacement of bushings and
line-boring of bushing bores should be accomplished by a qualified machine shop.
[1] - Press bushing (1) out of connecting rod.
[2] - Cool new bushing by placing in freezer.
[3] - Press new bushing into rod with joint (4) positioned as shown. Be careful not to damage bore.
[4] - Drill a 6 mm (0.236 in.) oil passage (2) through bushing.
[5] - Countersink oil bore (3) with 15 mm (0.590) spherical cutter to a depth of 1 mm (0.39 in.)
[6] - Line bore bushing to specification.


Installed Connecting Rod Pin Bushing (After Boring) ID 52.05—52.06 mm (2.049—2.050 in.)
[7] - Ream bushing to provide proper oil clearance for pin.


Connecting Rod Pin-to-Bushing Oil Clearance (0.055—0.070 mm (0.002—0.003 in.)
Clean
Cleaning Piston Ring Grooves
CAUTION:
Always follow manufacturer′s instructions and safety steps exactly.
[1] - Clean piston ring grooves using a piston ring groove cleaning tool.
[2] -
IMPORTANT:
When washing pistons, always use a stiff bristle brush—NOT A WIRE BRUSH—to loosen carbon residue.
DO NOT bead blast ring groove areas.
Clean pistons by any of the following methods:
Chemical soaking following the manufacturer′s instructions.

Glass bead cleaning following the manufacturer′s instructions.
Hot water with liquid detergent soap.
If cleaning with hot water and liquid detergent, soak pistons in a 50 percent solution of liquid household detergent and hot
water for 30 to 60 minutes. Use a stiff bristle brush—NOT A WIRE BRUSH—to loosen carbon residue. Thoroughly dry the
pistons.
Visually Inspect

LEGEND:
A Cracks in the Piston Head
B Bent or Broken Ring Lands
C Cracks in the Skirt
Piston Imperfections (Exaggerated)
Carefully inspect pistons under magnification. Check for:
Signs of fatigue.
Fine cracks in the piston head (A).
Bent or broken ring lands (B).
Cracks in the skirt (C) at inner and outer ends of piston pin bore.
Excessive piston skirt wear. (Original machining marks must be visible.)
If any imperfections are found, replace the piston and liner as a set.
Install
IMPORTANT:
Pistons must be installed on same connecting rods from which they were removed
New piston pin snap rings must be used.

Piston and Rod
[1] - Apply clean engine oil to piston pins
[2] - Install pistons on connecting rods. Arrow or triangle should point to the flywheel.
[3] -
Piston Pin Installation

Install piston pins using new retaining rings
[4] -
→NOTE:
If old rings were not removed, ensure rings are clean before reinstalling piston, especially center piston
ring.

LEGEND:
1 Feeler Gauge
2 Keystone Ring
3 Taper Face Ring
4 Oil Control Ring
Ring End Gap Measurement
Piston Rings
Piston Ring Pliers
JDG1500-31
JDG1500-31
Remove and install piston rings.
Install new rings into cylinder and check ring end gap using a feeler gauge.


No. 3 Piston Oil Ring End Gap 0.30—0.45 mm (0.012—0.018 in.) new
No. 3 Piston Oil Ring End Gap 0.8 mm (0.031 in.) repair limit
[5] - Apply clean engine oil to rings and install piston rings on piston using JDG1500-31 Piston Ring Pliers.
[6] - Install piston rings in proper grooves as called out in figure. Stagger ring gaps 120°.
[7] -
Piston Installation
Apply clean engine oil to piston, ID of liner and piston ring compressor. Install ring compressor on piston tight enough to where
ring compressor can just be shifted on piston.
[8] -
LEGEND:
1 Connecting Rod Bearing
2 Connecting Rod
3 Connecting Rod Cap Bearing
4 Connecting Rod Cap
Install Rod Bearings

Install bearings (1 and 3) in connecting rod (2) and cap (4). Make sure that tabs (arrows) on bearings are properly seated in rod
and cap recess.
[9] -
IMPORTANT:
Piston and liners have code letters stamped on them. All pistons will not fit all liners. Check code
stampings before installing pistons in liners. (See Cylinder Liners in Group 0403 for identification and
compatibility.)

LEGEND:
1 Piston Ring Compressor
2 Piston
3 Wooden Dowel
Installing Piston
Apply clean engine oil to piston rings and inside of ring compressor (1). Use a piston ring compressor to compress rings into
ring grooves.
[10] - Install piston and rod into liner with the arrow or triangle pointing towards the flywheel. Do not let rod drag on liner or hit
piston cooling nozzles when being installed.
[11] - Tap piston (2) into liner using a wooden dowel (3), rotating crankshaft as required until connecting rod bearing is resting
on journal of crankshaft. Remove piston ring compressor.
[12] -
IMPORTANT:
Connecting rod cap screws are stretched when tightened to specification. Cap screws are usable up to a
maximum shank length of 68.5 mm (2.69 in.) measured from the end of cap screw to the bottom of cap
screw head. If any cap screw is at or longer than the specification, replace both cap screws for the that
bearing cap.
Measure the shank length of connecting rod cap screws from the end of cap screw to the bottom of cap screw head. Replace
both cap screws for that bearing cap if either cap screw is at or longer than the specification.

Connecting Rod Cap Screw Shank Maximum Usable Length 74.5 mm (2.93 in.) replace both cap screws at or longer
[13] -
LEGEND:
1 Connecting Rod Cap Stamped Number
2 Connecting Rod Stamped Number
3 Connecting Rod Cap Screw (16 used)
Install Connecting Rod Cap

Torque Connecting Rod Cap Screws

Oil the running surface of bearing and install bearing into rod cap, ensuring tab on bearing is properly seated in recess of rod.
[14] - Install cap on connecting rod ensuring stamped number on connecting rod cap (1) and stamped number on connecting
rod (2) are towards the same side as shown.
[15] - Dip cap screws (3) into clean engine oil fully coating threads.
[16] - Install cap screws (3) and tighten to specification.


Connecting Rod Cap Screw—First Stage Torque 110 N˙m (81 lb-ft)
Connecting Rod Cap Screw—Final Stage Torque-Turn 90°
[17] - Rotate each piston to TDC and check protrusion above block surface. (See Check Piston Protrusion in this procedure.)
Check Piston Protrusion

LEGEND:
1 Magnetic Base
2 Dial Indicator
3 Piston
Measure Piston Protrusion
[1] -
→NOTE:
Piston protrusion is measured with head gasket removed and block surface clean.
Rotate crankshaft until piston is at TDC.

[2] - Using a magnetic base dial indicator, measure piston protrusion above surface of block. Compare measurement to the
following specifications.
Piston Height Above Block Protrusion 0.27—0.61 mm (0.011—0.024 in.)

Cylinder Liners
Measure Protrusion
[1] -
LEGEND:
1 JDG1594 Liner Preload and Protrusion Measuring Tool
2 Spacer (4 used)
3 Cylinder Head Cap Screw (4 used)
Liner Preload Plate

Remove cylinder head. (See Cylinder Head in Group 0409.)
[2] - Clean area around top of cylinder liner and block.
[3] - Install JDG150094 Liner Preload and Measuring Tool (1) on top of cylinder liner using spacers (2) and cylinder head cap
screws (3).
Liner Preload and Measuring Tool
JDG150094
Preload liner for measurement.
[4] - Tighten cap screws to specification.

Cylinder Liners
Liner Preload Plate Cap Screws Torque 50 N˙m (37 lb-ft)
[5] -
LEGEND:
1 JDG1500-35 Dial Indicator Holder
2 Dial Indicator
Preload measuring tool

Place JDG1500-35 Dial Indicator Holder (1) on plate.

Dial Indicator Holder

JDG1500-35
Use on liner preload and measuring tool to hold dial indicator.
[6] - Install dial indicator (2) into holder so that probe is under preload on the engine block when holder is held tight to plate.
Set dial indicator to zero.
[7] - Slide dial indicator in slot of liner preload and measuring tool and over the top of liner. Observe measurement and
compare to specification.
Cylinder Liners
Cylinder Liner Protrusion Distance 0.245—0.315 mm (0.010—0.012 in.)
[8] - Measure at all four slots in liner preload and measuring tool. Maximum difference between the four measuring points
must not be above specification.
Cylinder Liners
Difference between Four Measuring Spots of Cylinder Liner Protrusion Distance 0.02 mm (0.001 in.) Maximum
[9] - If difference exceeds specification, liner must be removed and inspected.
[10] - If measurement is above specification, liner must be machined by a qualified machine shop. If measurement is below
specification liner shims must be installed. (See Install Liner Shims If Required in this procedure.)
[11] - Remove liner preload and measuring tool.
[12] - Install cylinder head. (See Cylinder Head in Group 0409.)
Remove
[1] -
LEGEND:
1 D01062AA Cylinder Liner Puller
2 Cylinder liner
3 Puller Jaw

Remove Cylinder Liner

Make a mark on the liner and the engine block.
[2] - Install D01062AA Cylinder Liner Remover (1) into cylinder bore and hook the jaws (2) on the bottom of the liner (2).
Cylinder Liner Remover
D01062AA
Remove and install cylinder liners.
[3] - Tighten jaw adjusting nut to tension jaws on the bottom of the liner.
[4] - Using slide hammer knock liner loose from block. Loosen jaw adjusting nut and remove D01062AA Cylinder Liner Remover
from liner.
[5] -
LEGEND:
1 Liner
2 Engine Block
Remove Liner from Block

Remove liner (1) from engine block (2)
Visually Inspect

LEGEND:
A Liner Pitting
B Liner Erosion
C Liner Thickness
D Packing Step
Inspecting Cylinder Liners
IMPORTANT:
If liner pitting has occurred, check condition of coolant.
[1] - Inspect exterior length of liner for pitting (A). Check packing step for erosion (B). If pitting or erosion is observed, measure
depth of pits with a fine wire or needle. Replace piston and liner if depth of any pit (A) is one-half or more of liner thickness (C).
→NOTE:
Liners are reusable if the depth of pits or erosion is less than one-half the amount specified. When
installing reusable liners, rotate 90° from original position. The liners should be also deglazed and new
ring sets installed in pistons.
[2] -

LEGEND:
A Flange Area
B Ring Travel Area
Cylinder Liner Inspection

Visually examine liner ID. Replace piston and liner if:
The crosshatch honing pattern is not visible immediately below the top ring turn-around area.
Liners are pitted or contain deep vertical scratches that can be detected by the fingernail.
[3] - Carefully examine liner for signs of fatigue, such as fine cracks in the flange area (A) and cracks in the ring travel area (B).
[4] - Inspect block for cracks or erosion in the O-ring packing areas.
Deglaze
Deglazing Cylinder Liners
[1] - Secure cylinder liner in a holding fixture.
[2] - Use D17005BR Flexible Cylinder Hone to deglaze cylinder liner. Use honing oil along with flex hone when deglazing liners.
Flexible Cylinder Hone
D17005BR

D17005BR
Hone cylinder liners.
[3] -
Honing Pattern on Cylinder Liners

Use D17006BR Flexible Cylinder Hone according to instructions supplied with tool to obtain a 45 ° cross-hatch pattern.
[4] - Thoroughly clean liners after deglazing.
Clean
[1] - Use a stiff bristle brush to remove all debris, rust, and scale from OD of liners, under liner flange, and in O-ring packing
areas. Make certain there are no nicks or burrs in areas where packings will seat.
[2] -
IMPORTANT:
Do not use gasoline, kerosene, or commercial solvent to clean liners. Solvents will not remove all the
abrasives from liner walls.
Thoroughly clean liner ID with a 50 percent solution of hot water and liquid detergent.
[3] - Rinse thoroughly and wipe dry with a clean rag.
[4] - Swab out liner as many times as necessary with clean 10W engine oil.
[5] - Clean liner until a white rag shows no discoloration.
Measure
[1] -

LEGEND:
1 Code Letter Mark on Piston
2 Code Letter Mark on Cylinder Liner
3 Cylinder Liner ID Measurement
Clyinder Liner Measurements
Piston and Liner Marks

Identify code letter mark on piston (1) and code letter mark cylinder liner (2).
[2] - Take cylinder liner ID measurements (3) at three different places, 90° from each other.
[3] - Compare measurements with specifications.

Cylinder Liners
Cylinder Liner Code Letter “A” ID 129.990—129.995 mm (5.1177—5.1179 in.)
Cylinder Liner Code Letter “B” ID 129.995—130.005 mm (5.1179—5.1182 in.)
Cylinder Liner Code Letter “C” ID 130.005—130.010 mm (5.1182—5.1184 in.)
IMPORTANT:
Not all pistons fit in all cylinder liners. Refer to Piston and Cylinder Liner Selection Table for proper piston
and cylinder liner matches.
Piston and Cylinder Liner Selection Table
Piston and Cylinder Selection Table
Stamped Piston Code Letter Stamped Cylinder Liner Code Letter
BA Will Fit A or B Liner
BC Will Fit B or C Liner
Inspect and Clean Cylinder Block
[1] -
→NOTE:
All components (including piston cooling orifices), water gallery plugs and oil gallery plugs must be
removed from the cylinder block for inspection and cleaning. Refer to the proper group for removal of all
external and internal mounted components.
Remove cylinder head locating dowels, if not previously removed. Clean out all threaded holes for cylinder head mounting cap
screws in top deck of cylinder block using a 14.0 x 2.0 mm tap. Use compressed air to remove any debris or fluid which may be
present in the cap screw hole.
[2] -
IMPORTANT:
If cylinder block is cleaned in a hot tank, be sure to remove any aluminum parts. Aluminum parts can be
damaged or destroyed by hot tank solutions. Remove all serial number plates.
Clean block thoroughly, using cleaning solvent, pressure steam, or a hot tank.
[3] - Inspect liner support flanges for burrs. If burrs are present, use a small half-moon file and LIGHTLY file (in a circular
motion) burr off. DO NOT let file hit top deck of cylinder block while filing.
[4] - Carefully inspect block for cracks or any other physical damage. If a cracked block is suspected, pressure test the block. A
procedure for pressure testing is outlined in FOS (Fundamentals of Service) Manual—ENGINES. Replace block if there is
evidence of a crack or physical damage.
[5] - Check cylinder block flatness using D05012ST-A “Beveled Edge” Straightedge and feeler gauge.
“Beveled Edge” Straightedge
D05012ST-A
Check cylinder head flatness.
Check lengthwise, crosswise, and diagonally in several places.
If any measurement exceeds specification, the cylinder block must be either resurfaced or replaced.
Cylinder Block Top Surface Wave Depth 8—16 micrometer (0.00031—0.00063 in.)

Install Liner Shims If Required
[1] -
LEGEND:
1 Seal
2 O-Ring
3 Cylinder Liner
4 Cylinder Block
5 Cylinder Liner Protrusion
Install Liner Shims

Measure cylinder liner protrusion. (See Measure Cylinder Liner Protrusion in this procedure.)
[2] - Install shims as required between seal (1) and cylinder block (4) to achieve correct cylinder liner protrusion (5).
Install
[1] -
LEGEND:
1 O-Ring (2 used)
2 Seal Grooves in Cylinder Block (2 used)
Install Liner O-Rings

Check seal grooves in cylinder block (2) so that they are clean and free of any nicks or burrs.
[2] - Install new O-rings (1) in seal grooves. Do not lubricate O-rings.
[3] -

LEGEND:
1 Seal
2 O-Ring
3 Cylinder Liner
4 Cylinder Block
5 Cylinder Liner Protrusion
Install Liner Seals

Install seal (1) against collar of cylinder liner (3).
[4] - Install O-ring (2) into upper seal groove of liner.
[5] -
LEGEND:
1 Cylinder Liner
Install Cylinder Liner

Apply liquid soap to cylinder liner lower pilot surface and bevel to aid in liner installation.
[6] - If installing same liner as removed, install liner (1) 90° from marks (arrows) made when removed.
[7] - Slide liner into engine block.
[8] -

Section 04 - ENGINE Group 0407: Lubrication System
LEGEND:
1 JDG1594 Liner Preload and Protrusion Measuring Plate
2 Spacer (4 used)
Preloading Liner
Install plate (1) over liner using spacers (2) and cap screws (3).
[9] - Evenly tighten cap screws to specification.

Cylinder Liners
Liner Preload Plate Cap Screws Torque 50 N˙m (37 lb-ft)
[10] - Measure cylinder liner protrusion. (See Measure Cylinder Liner Protrusion in this procedure.)
[11] - To avoid loosening the liners during piston installation, keep the liner under preload using cap screws, spacers, and
washers.
Check Engine Rotation for Excessive Tightness

[1] - Rotate crankshaft several revolutions to be sure engine rotates without excessive tightness.
[2] - Check liners for deep scratches caused by an improperly installed or broken piston ring.
[3] - Check side clearance of rods. Must have slight side-to-side movement.

Group 0407 - Lubrication System

Remove and Install Oil Filter Housing
[1] - Remove air intake manifold. (See Remove and Install Air Intake Manifold in Group 0414)
[2] - Remove thermostat housing. (See Remove and Install Thermostats and Housing in Group 0418.)
[3] -
LEGEND:
1 Oil Filter Cap and Element
2 Cap Screw
3 Fuel Filter
4 Fuel Line Bracket
5 Fuel Line
6 Engine Oil Filter Housing
7 Engine Harness
8 Cap Screw
9 Cap Screw
10 Cap Screw
11 Cap Screw
12 Air Intake Manifold Bracket
13 Coolant Line
14 Fuel Line Clamp
15 Engine Oil Filter Housing Gasket
Remove Oil Cooler Housing

Disconnect coolant line (13) from engine oil filter housing.
[4] - Remove oil filter cap and element (1).
[5] - Remove cap screw (2) and disconnect fuel filter (3) from engine oil filter housing (6).
[6] - Remove clamp (4) holding fuel line (5) to engine oil filter housing.
[7] - Disconnect engine wiring harness (7) from oil pressure sensor, oil temperature sensor and coolant temperature sensor.
[8] - Remove cap screws (8—11), air intake manifold mounting bracket (12), fuel line clamps (14) and engine oil filter housing.
[9] - Clean sealing surfaces. Install engine oil filter housing (6), new gasket (15), air intake mounting bracket (12), fuel line
clamps (14) and cap screws (8—11). Tighten cap screws to specification.
Engine Oil Filter Housing

[10] - Connect engine wiring harness (7) to oil pressure sensor, oil temperature sensor and coolant temperature sensor.
[11] - Install clamp (4) holding fuel line (5) to engine oil filter housing (6).
Fuel Line Clamp

[12] - Install fuel filter (3) and cap screw (2) to engine oil filter housing.
[13] - Install oil filter cap and element (1). Tighten to specification.
Engine Oil Filter

Cap Torque 40 N˙m (30 lb-ft)
[14] - Connect coolant line (13) to engine oil filter housing.
[15] - Install thermostat housing. (See Remove and Install Thermostats and Housing in Group 0418.)

[16] - Install air intake manifold. (See Remove and Install Air Intake Manifold in Group 0414)
Remove, Inspect, and Install Engine Oil Cooler

[1] - Remove engine oil filter housing. (See Remove and Install Oil Filter Housing in this group.)
[2] -
LEGEND:
1 Engine Oil Cooler
2 Engine Oil Cooler Gasket
3 Cap Screw
Remove Engine Oil Cooler

Remove cap screws (3) and oil cooler (1) from oil cooler housing.
[3] - Inspect engine oil cooler and replace, if necessary. Clean sealing surfaces.
[4] - Install engine oil cooler, gaskets (2) and cap screws. Tighten cap screws to specification.
Engine Oil Cooler

[5] - Install engine oil filter housing. (See Remove and Install Oil Filter Housing in this group.)

Remove and Install Oil Pan

[1] - Loosen tension on serpentine belt and remove belt from A/C compressor.
[2] -
LEGEND:
1 Cap Screw
2 Brace
3 Cap Screw
4 Brace
5 Engine Harness Ducting
6 Cap Screw
7 Cap Screw
8 Cap Screw
9 A/C Compressor
10 Dipstick and Guide
11 Oil Pan
12 Oil Pan Gasket
Remove Oil Pan

Remove dipstick and guide (10).
[3] - Remove cap screws (3) and brace (4).
[4] - Remove cap screws (8) and move A/C compressor (9) aside.
[5] - Remove cap screws (1) and brace (2).
[6] - Remove cap screws (6) and move engine harness ducting (5) aside.
[7] - Remove cap screws (7) and oil pan (11).
[8] - Clean and inspect oil pan. Clean all sealing surfaces.
[9] - Install new gasket, oil pan and cap screws. Tighten to specification.
Oil Pan
[10] - Install engine harness ducting and cap screws.
[11] - Install brace (2) and cap screws.
[12] - Install A/C compressor and cap screws.
[13] - Install brace (4) and cap screws.
[14] - Install dipstick and guide. Tighten to specification.

Oil Pan
Dipstick Guide Torque 50 N˙m (37 lb-ft)
[15] - Install belt on A/C compressor.

Remove, Inspect and Install Piston Cooling Orifices

[1] -
LEGEND:
1 Oil Spray Nozzle (6 used)
Remove Oil Cooling Nozzle

Remove oil pan. (See Remove and Install Oil Pan in this group.)
[2] - Remove cap screws (2) and oil spray nozzles (1) from crankcase.
[3] - Clean oil spray nozzles with solvent. Dry thoroughly.
[4] -
LEGEND:
1 Oil Spray Nozzle
2 Cap Screw
3 Nozzle Adjustment Guide
Oil Spray Nozzle Check Gauge

Install oil spray nozzle (1) and cap screw (2) on JDG1595 Piston Cooling Oil Spray Nozzle Gauge. Adjust nozzle as necessary to
fit nozzle tip into nozzle adjustment guide (3). Adjustment will ensure that nozzle is lubricating piston correctly. Repeat check
for each spray nozzle.
Piston Cooling Oil Spray Nozzle Gauge
JDG1595
Correctly align oil spray nozzle.
[5] - Install oil spray nozzles and cap screw. Ensure locating pins on nozzles align with locating holes on crankcase. Tighten to
specification.
Oil Spray Nozzle

[6] - Install oil pan. (See Remove and Install Oil Pan in this group.)

Remove and Install Engine Oil Pump

[1] - Remove oil pan. (See Remove and Install Oil Pan in this group.)
[2] - Remove oil pressure relief valve. (See Remove and Install Oil Pressure Relief Valve in this group.)
[3] -
LEGEND:
1 Oil Pump Mounting Cap Screw
2 Oil Intake Pipe Mounting Cap Screw (2 used)
3 Washer (2 used)
4 Oil Pump and Intake Pipe Assembly
Oil Pump Assembly

Remove oil pump mounting cap screw (1), oil intake pipe mounting cap screws (2), washers (3) and remove oil pump and
intake pipe assembly (4).
[4] -
LEGEND:
1 Oil Intake Pipe
2 Oil Intake Pipe Cap Screw (2 used)
3 Oil Intake Pipe Gasket
4 Oil Pump
Oil Intake and Oil Pump

Remove oil intake pipe cap screws (2) and oil intake pipe (1) from oil pump (4).
[5] - Remove oil intake pipe gasket (3) and discard.
[6] - Clean oil intake pipe with suitable solvent and dry thoroughly.
[7] - Install new oil intake pipe gasket and install intake pipe to oil pump with oil intake pipe cap screws. Tighten cap screws to
specification.
Oil Pump
Intake Pipe Cap Screws Torque 35 N˙m (26 lb-ft)
[8] - Install oil pump and intake pipe assembly to crankcase with oil intake pipe and oil pump mounting cap screws. Tighten
cap screws to specification.

Section 04 - ENGINE Group 0409: Cylinder Head and Valves
Oil Pump
Mounting Cap Screw Torque 35 N˙m (26 lb-ft)
Oil Intake Pipe Mounting Cap Screw Torque 35 N˙m (26 lb-ft)
[9] - Install oil pressure relief valve. (See Remove and Install Oil Pressure Relief Valve in this group.)
Remove and Install Oil Pressure Relief Valve

[1] - Remove oil pan. (See Remove and Install Oil Pan in this group.)
[2] -
LEGEND:
1 Oil Pressure Relief Valve
2 Oil Pressure Relief Valve Cap Screw (2 used)
Oil Pressure Relief Valve

Remove oil pressure relief valve cap screws (2) and oil pressure relief valve (1).
[3] - Install oil pressure relief valve cap screws and oil pressure relief valve. Tighten oil pressure relief valve cap screws to
specification.
Oil Pressure Relief Valve


Group 0409 - Cylinder Head and Valves

Cylinder Head and Valves Failure Analysis
Make preliminary inspection of cylinder head and valve assembly during disassembly.
Look for the following conditions:
Sticking Valves:
Carbon deposits on valve stem.

Worn valve guides.
Scored valve stems.
Warped valve stems.
Misaligned or broken valve springs.
Worn or distorted valve seats.
Warped, Worn, or Distorted Valve Guides:
Lack of lubrication.
Cylinder head distortion.
Excessive heat.
Unevenly tightened cylinder head cap screws.
Distorted Cylinder Head and Gasket Leakage:
Loss of cylinder head cap screw torque.

Broken cylinder head cap screw.
Overheating from low coolant level operation.
Insufficient liner standout.
Coolant leakage into cylinder causing hydraulic failure of gasket.
Cracked cylinder head.
Cracked cylinder liner.
Damaged or incorrect gasket.
Overpowering or overfueling.
Damaged cylinder head or block surfaces.
Improper surface finish on cylinder head.
Improperly tightened cylinder head cap screws.
Faulty gasket installation (misaligned)
Worn or Broken Valve Seats:
Misaligned valves.
Distorted cylinder head.
Carbon deposits on seats due to incomplete combustion.
Valve spring tension too weak.
Excessive heat.
Improper valve clearance.
Improper valve timing.
Incorrect valve or seat installed.
Burned, Pitted, Worn, or Broken Valves:
Worn or distorted valve seats.

Loose valve seats.
Worn valve guides.
Cocked or broken valve springs.
Improper engine operation.
Improper valve train timing.
Faulty valve rotators.
Warped or distorted valve stems.
“Stretched” valves due to excessive spring tension.
Warped cylinder head.

Bent push rods.
Carbon build-up on valve seats.
Rocker arm failure.
Incorrect valve or seat installed.
Incorrect piston-to-valve clearance.
Improper Valve Clearance:
Inefficient use of fuel.

Engine starts harder.
Maximum engine power will not be achieved.
Shorter service life of valve train.
Greater chance for engine to overheat.
Excessive Valve Recession:
Worn valve guides.

Bent valves.
Debris passed through valve train.
Remove and Install Valve Cover

[1] - Loosen valve cover cap screws and remove valve cover.
[2] - Install new gasket.
[3] - Install valve cover. Tighten valve cover cap screws to specification.
Valve Cover
Cap Screws Torque 20 N˙m (177 lb-in.)

Rocker Arms and Shaft

Remove, Disassemble and Inspect
[1] - Remove valve cover from cylinder head(s). (See Remove and Install Valve Cover in this group.)
[2] -
LEGEND:
1 Cap Screw
2 Rocker Arm Assembly
3 Valve Cradle
4 Push Rod
5 Adjusting Screw
6 Jam Nut
Remove Rocker Arm Assembly

Loosen jam nuts (6) and back off adjusting screws (5).
[3] - Remove push rods (4).
[4] - Remove cap screws (1) and lift off rocker shaft assembly (2) and valve cradles (3).
[5] -
LEGEND:
1 Snap Ring (2 used)
2 Washer (2 used)
3 Rocker Arm (2 used)
4 Rocker Shaft
5 Adjusting Screw (2 used)
6 Jam Nut (2 used)
7 Bushing (2 used)
8 Rocker Shaft Bushing Surface
9 Rocker Arm Lube Hole
Remove Rocker Arm
Rocker Shaft Assembly

Remove snap rings (1) and washers (2).
[6] - Remove rocker arms (3) from rocker shaft.

[7] - Disassemble and inspect parts.
[8] - Measure ID of rocker arm bushing (7) and OD of shaft bushing surface (8). Compare measurements to specification.
Rocker Arm
Shaft OD 24.980 mm (0.983 in.)
Bushings ID 25.005—25.021 mm (0.984—0.985 in.)
[9] - If rocker arm bushings are worn, press out old bushings from rocker arm. Supercool new bushings and press into rocker
arm, ensuring that lube hole in rocker arm (9) is lined up with hole in bushing (7).
Assemble and Install Rocker Arms and Shaft
[1] -
LEGEND:
1 Snap Ring
2 Washer
3 Rocker Arm
Install Rocker Arm on Shaft

Apply engine oil to rocker arm bushings and rocker shafts.
[2] - Install rocker arm (3) onto shaft.
[3] - Install washer (2) and snap ring (1).
[4] - Measure the shank length of rocker shaft cap screws from the end of cap screw to the bottom of cap screw head. Replace
both cap screws for that cylinder head if longer than the specification.

Cap Screw Shank Length 91 mm (3.58 in.) Maximum
[5] -
LEGEND:
1 Cap Screw
2 Rocker shaft Assembly
3 Valve Cradle
4 Push Rod
5 Adjusting Screw
6 Jam Nut
Remove Rocker Arm Assembly

Install valve cradles (3), rocker shaft assembly (2) and cap screws (1). Tighten cap screws to specification.


Torque Turn 90°
[6] - Install push rods (4), making sure push rods are properly seated in cam followers.
[7] - Turn adjusting screws (5) until they just make contact with push rods.
[8] - Adjust valve clearance. (See Valve Clearance Adjustment in Group 9010-20.)
Clean and Inspect Push Rods
Checking Push Rods for Straightness
[1] - Clean push rods with suitable solvent and dry thoroughly.
[2] - Check push rods for straightness by rolling on a flat surface.
[3] - Inspect contact ends for wear and damage.
[4] - Replace damaged or worn push rods.

Cylinder Head
Remove
[1] -
CAUTION:
Steam Caution
Explosive release of fluids from pressurized cooling system can cause serious burns.
Shut off engine. Remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing completely.
Drain engine coolant.
[2] - Remove exhaust manifold. (See Remove and Install Exhaust Manifold in Group 0410.)
[3] - Remove intake manifold. (See Remove and Install Air Intake Manifold in Group 0414)
[4] - Remove valve cover from cylinder head(s). (See Remove and Install Valve Cover in this group.)
[5] - Remove fuel delivery nozzle(s) from cylinder head(s). (See Remove and Install Fuel Delivery Nozzle in Group 0413.)
[6] - Remove rocker arm assembly (4) and valve cradle (5) from cylinder head(s). (See Rocker Arms and Shaft in this group.)
[7] -

LEGEND:
1 Leak-Off Line
2 Exhaust Brake Line
3 Push Rod (2 used)
5 Valve Cradle
6 Cylinder Head Cap Screws
7 Cylinder Head
8 Centering Sleeves (2 used)
9 Head Gasket
Cylinder Head
Remove push rods (3) from cylinder head.
[8] - Disconnect leak-off lines (1).
[9] - Remove exhaust brake line (2).
[10] - Remove cylinder head cap screws (6) and cylinder head (7).
Install
[1] - Use JDG1500-46 Tap and Die for Head Bolt Holes and Bolts to clean up threads in cylinder block and cap screws.
Tap and Die for Head Bolt Holes and Bolts
JDG1500-46
Clean up threads in cylinder block and cylinder head cap screws.
[2] -

LEGEND:
1 Leak-Off Line
2 Exhaust Brake Line
3 Push Rod (2 used)
5 Valve Cradle
6 Cylinder Head Cap Screws (4 used)
7 Cylinder Head
8 Centering Sleeves (2 used)
9 Head Gasket
Cylinder Head
Install centering sleeves (8) into cylinder block.
[3] - Install new head gasket over centering sleeves.
[4] - Install cylinder head (7) onto cylinder block.
[5] -
IMPORTANT:
Cylinder head cap screws are stretched when tightened to specification. Cap screws are usable up to the
maximum shank length specification measured from the end of cap screw to the bottom of cap screw
head. If any cap screw is longer than the specification, replace all cap screws for that cylinder head.
Measure the shank length of cylinder head cap screws from the end of cap screw to the bottom of cap screw head. Replace all
cap screws for that cylinder head if longer than the specification.
Cylinder Head
Cap Screw Shank Length 212.0 mm (8.346 in.) Maximum
[6] -
Cap Screw Tightening Sequence

Oil threads of cap screws with clean engine oil and install cylinder head cap screws (6).

[7] - Tighten cap screws in sequence, 1—4, in six stages to specification.

Cylinder Head
Cap Screws 1st Stage Torque 10 N˙m (89 lb-in.)
Cap Screws 2nd Stage Torque 50 N˙m (37 lb-ft)
Cap Screws 3rd Stage Torque 100 N˙m (74 lb-ft)
Cap Screws 4th Stage Torque 200 N˙m (148 lb-ft)
Cap Screws 5th Stage Torque Turn 90° Clockwise
Cap Screws 6th Stage Torque Turn 90° Clockwise
[8] - Install push rods.
[9] - Install exhaust brake line.
[10] - Connect leak-off line.
[11] - Install rocker arm assembly (4) and valve cradle (5) to cylinder head(s). (See Rocker Arms and Shaft in this group.)
[12] - Install fuel delivery nozzle(s) to cylinder head(s). (See Remove and Install Fuel Delivery Nozzle in Group 0413.)
[13] - Install valve cover to cylinder head(s). (See Remove and Install Valve Cover in this group.)
[14] - Install intake manifold. (See Remove and Install Air Intake Manifold in Group 0414)
[15] - Install exhaust manifold. (See Remove and Install Exhaust Manifold in Group 0410.)
Remove and Install Engine Exhaust Valve Brake

[1] -
LEGEND:
1 Plug
2 O-Ring
3 Piston
4 Retainer Lock
5 Spring Retainer
6 Spring
7 Spring Guide
8 Valve
9 Spacer
10 Cylinder Head
Exhaust Valve Brake

Remove cylinder head. (10). (See Cylinder Head in this group.)
[2] - Remove plug (1) and piston (3).
[3] - Use a spacer (9) to keep valve in closed position. Remove retainer locks (4) using JDG1592 Spring Retainer Depressor.
Spring Retainer Depressor
JDG1592
Remove retainers from spring retainer.
[4] - Remove spring retainer (5), spring (6), spring guide (7), and valve (8). Inspect parts and replace as necessary.
[5] - Install valve, spring guide, spring and spring retainer. Install retainers ensuring they are seated in the valve stem groove.
[6] - Install piston into cylinder head.
[7] - Install plug.
[8] - Install cylinder head. (See Cylinder Head in this group.)

Intake and Exhaust Valves

Remove Intake and Exhaust Valves
[1] - Remove cylinder head. (See Cylinder Head in this group.)
[2] -
LEGEND:
1 Retainer Locks
2 Retainer
3 Valve Spring (4 used)
4 Intake Valve (2 used)
5 Exhaust Valve (2 used)
6 Cylinder Head
Remove Valve Springs

Compress valve springs and remove retainer locks (1).
[3] - Relieve tension and remove retainers (2) and valve springs (3).
[4] - Remove intake valves (4) and exhaust valve (5) from cylinder head (6).
Inspect Valve Springs
[1] -
Valve Spring
Inspect valve springs for alignment, wear, and damage.
[2] - Put springs on a flat surface to see that they are square and parallel.
Inspect Valve Spring Retainers and Retainer Locks
[1] - Inspect valve spring retainers for excessive wear in area where valve springs and retaining locks seat. Replace as needed.
[2] - Inspect retainer locks for excessive wear. Replace as needed.
Install Intake and Exhaust Valves
[1] -

LEGEND:
1 Valve Seal Installation Tool
2 Valve Seal
3 Valve Guide
Valve Seal On Valve Stem

Apply a light film of multi-purpose grease to sleeve of valve seal (2).
[2] - Slide valve seal down sleeve and push firmly onto valve guide (3).
[3] -
LEGEND:
1 Retainer Locks
2 Retainer
3 Valve Spring (4 used)
4 Intake Valve (2 used)
5 Exhaust Valve (2 used)
6 Cylinder Head
Remove Valve Springs

Apply a light film of multi-purpose grease to the stems of intake valve (4) and exhaust valve (5).
[4] - Install valves into head (6) and through valve seals.
[5] - Install valve springs (3) and retainers (2).
[6] - Compress valve spring.
[7] - Apply grease to the insides of retainer locks (1) to hold them in place when being installed.
[8] - Install retainer locks onto valves and release spring tension. Make sure retainer locks stay in the groove on the valve
when spring tension is released.
[9] - Install cylinder head. (See Cylinder Head in this group.)

Valves
Clean
[1] - Hold each valve firmly against a soft wire wheel on a bench grinder.
[2] - Make sure all carbon is removed from valve head, face and stem. Polish valve stem with steel wool or crocus cloth to
remove scratch marks left by wire brush.
IMPORTANT:
Any carbon left on valve stem will affect alignment in refacer if valves need to be refaced.
Inspect and Measure

LEGEND:
A Valve Head OD
B Valve Stem OD
C Valve Retainer Lock Groove
Measuring Valves
[1] - Thoroughly clean and inspect valves to help determine if they can be restored to a serviceable condition. Replace valves
that are burned, cracked, eroded, or chipped.
[2] - Inspect valve retainer lock groove (C) on valve stem for damage. Also inspect stems for signs of scuffing, which may
indicate insufficient valve guide-to-valve stem clearance. Replace if damage is found.
[3] - Measure valve head OD (A). Compare valve stem OD (B) with guide ID to determine clearance, as outlined later in this
group.
Intake and Exhaust Valve

Intake Valve Stem OD 8.935—8.950 mm (0.3518—0.3524 in.)
Exhaust Valve Stem OD 8.925—8.940 mm (0.3514—0.3520 in.)
Intake Valve Head OD 45.4—45.6 mm (1.787—1.795 in.)
Exhaust Valve Head OD 40.9—41.1 mm (1.610—1.618 in.)
Intake and Exhaust Valve Length 145 mm (5.708 in.) Maximum
[4] -

Valve Face Runout Check

Use a valve inspection center to determine if valves are out of round, bent or warped.

Valve Seat-to-Stem Runout 0.03 mm (0.0012 in.)
Valve Head-to-Stem Runout 0.20 mm (0.0079 in.)
Valve Seat Out-of-Round 0.01 mm (0.0004 in.)
Grind (Reface)
LEGEND:
A Valve Face Angle
Valve Face Angle
IMPORTANT:
Valve grinding should only be done by experienced personnel familiar with equipment and capable of
maintaining required specifications.
If necessary to reface valve, grind valve face angle (A) to following specification.

Intake Valve Face Angle 30°
Exhaust Valve Face Angle 45°
Intake Valve Face Width 3.5—3.6 mm (0.138—0.142 in.) new
Exhaust Valve Face Width 3.5—3.6 mm (0.138—0.142 in.) new
IMPORTANT:
When valve faces are ground, DO NOT nick valve head-to-stem radius with facing stone. A nick could
cause the valve to break. Grind all sharp edges to a radius after grinding valves.

Cylinder Head
Remove, Inspect and Install Protective Sleeve
[1] -
→NOTE:
Protective sleeve can be removed with cylinder head installed. If removed with cylinder head installed,
drain coolant and remove fuel delivery nozzle (see Remove and Install Fuel Delivery Nozzle in Group
0413) before removing protective sleeve.
Remove Protective Sleeve

Remove protective sleeve (2) and o-ring (1) using JDG1597 Spanner Socket.
Spanner Socket
JDG1597
Used to remove and install protective sleeves.
[2] - Inspect protective sleeve and o-ring. Replace as necessary.
[3] - Install protective sleeve and o-ring using JDG1597 Spanner Socket.
Spanner Socket
JDG1597
Used to remove and install protective sleeves.
Inspect and Clean
[1] - Inspect combustion face for evidence of physical damage, oil or coolant leakage, or gasket failure prior to cleaning the
cylinder head. Repair or replace cylinder head if there is evidence of physical damage, such as cracking, abrasion, distortion, or
valve seat “torching.” Inspect all cylinder head passages for restrictions.
[2] - Scrape gasket material, oil, carbon, and rust from head. Use a powered brass or copper wire brush to clean sealing
surfaces.
[3] -
IMPORTANT:
Be sure to remove all plugs before cleaning head, as parts can be damaged or destroyed by hot tank
solutions.
Clean cylinder head in a chemical hot tank, or with solvent and a brush.
[4] - Dry with compressed air and blow out all passages.

Check Cylinder Head Combustion Face Flatness
[1] - Check cylinder head flatness using D05012ST-A “Bevelled Edge” Straightedge and feeler gauge.
“Bevelled Edge” Straightedge
D05012ST-A
Check cylinder head flatness.
Check lengthwise, crosswise, and diagonally.
[2] - If any measurement exceeds specification, the cylinder head must be either resurfaced or replaced.
Cylinder Head
Cylinder Head Out-of-Flat 0.015 mm (0.0006 in.) per any 150 mm (5.9 in.) length
Cylinder Head Height 113.85—114.15 mm (4.482—4.494 in.) New Condition
Cylinder Head Height 113.5 mm (4.468 in.) Minimum
Clean, Inspect and Repalce Valve Guides
[1] - Use an appropriate valve guide end brush to clean valve guides before inspection or repair. A few drops of light oil or
kerosene will help to fully clean the guide.
[2] -
LEGEND:
1 Valve Guide (16 used)
2 Cylinder Head (8 used)
3 Projection of Valve Guide from Cylinder Head
4 Valve Guide ID
5 Valve Guide Length
6 Valve Guide OD
Measure Valve Guides

Measure valve guides and compare to specifications. For valve guide ID measurement (4) use a telescoping gauge and
micrometer and take measurement half-way into the valve guide.
Valve Guide
Valve Guides ID 9.000—9.022 mm (0.3543—0.3552 in.)
Standard OD 15.028—15.046 mm (0.5917—0.5924 in.)
0.20 mm Oversize OD 15.228—15.246 mm (0.5924—0.6000 in.)
0.40 mm Oversize OD 15.428—15.446 mm (0.6074—0.6081 in.)
Cylinder Head
Standard Guide Bore ID 15.000—15.018 mm (0.5905—0.5913 in.)
0.20 mm Oversize Guide Bore ID 15.200—15.218 mm (0.5984—0.5991 in.)
0.80 mm Oversize Guide Bore ID 15.400—15.418 mm (0.6063—0.6070 in.)
Projection of Valve Guide Distance 21.1—21.5 mm (0.831—0.846 in.)

Valves Length 61.7—62.3 mm (2.429— 2.453 in.)

[3] -
LEGEND:
1 Valve Guide
2 Cylinder Head Combustion Face
Install valve guides

If valve guide(s) (1) need to be replaced, knock out old valve guide from combustion side of head (2) towards top of cylinder
head.
[4] - Bore out cylinder head valve guide bore to specification for guide size being replaced.
[5] - Press in new valve guide until projection of valve guide from cylinder head specification is achieved.
[6] - Ream out valve guide for proper valve stem-to-guide clearance.
Clean and Inspect Valve Seats
[1] - Use an electric hand drill with D17024BR End Brush or equivalent brush to remove all carbon on valve seats.
End Brush
D17024BR
D172024BR
Used to clean valve seat and bores.
[2] - Check seats for cracks, pits, or excessive wear.
[3] - Check entire combustion face for rust, scoring, pitting, or cracks.
Measure Valve Seats

LEGEND:
1 Valve Seat Angle
2 Valve Seat Width
3 Valve Seat Recess in Cylinder Head
4 Valve Seat Diameter
Measuring Valve Seats
[1] - Measure valve seats for proper specifications listed below.


Intake Valve Seat Angle 30°
Exhaust Valve Seat Angle 45°
Intake Valve Seat Width 4.50 mm (0.177 in.)
Exhaust Valve Seat Width 4.50 mm (0.177 in.)
Intake Valve Seat-to-Cylinder Head Recess 3.60—3.80 mm (0.1417—0.1496 in.)
Exhaust Valve Seat-to-Cylinder Head Recess 2.80—3.00 mm (0.1102—0.1181 in.)
New/Finished Intake Valve Seat Diameter 56.99—57.01 mm (2.2436—2.2444 in.)
New/Finished Exhaust Valve Seat Diameter 48.99—49.01 mm (1.9287—1.9295 in.)
[2] - If valve seat is not within specification, recondition valve seat by grinding, or replace valve seat inserts if reconditioning is
not possible. (See Grind Valve Seats in this procedure.)
Grind Valve Seats
IMPORTANT:
Valve seat grinding should only be done by experienced personnel familiar with equipment and capable
of maintaining required specifications. ALWAYS keep work area clean when grinding valve seats. Be sure
valve guide bores are clean before grinding valve seats.
If valve seats need grinding, only a few seconds are required to recondition the average valve seat. Avoid the tendency to
grind off too much. Do not use excessive pressure on the grinding stone.
[1] - Check the seat width and contact pattern between the seat and valve with bluing. Seat width MUST BE maintained within
specification. Use a vernier caliper or scale to measure seat width. Thoroughly clean seat area after grinding and replace
valves and valve seat inserts as necessary.
→NOTE:
Valve seat width can be reduced with a narrowing stone. This will change the angle at the top of the seat
and increase the diameter. If valve seat width is too narrow, valve may burn or erode. Varying the width
changes the fine contact between valve face and seat.
[2] - Grind valve seats to specification. (See Measure Valve Seats in this group for valve seat specifications.)
Replace Valve Seat Inserts

Section 04 - ENGINE Group 0410: Exhaust System
LEGEND:
1 ID of Cylinder Head Bore for Valve Seat Insert
2 Distance from Cylinder Head Surface-to-Valve Seat
3 Depth of Valve Seat Bore in Cylinder Head
4 Height of Valve Seat Insert
5 Valve Seat Insert OD
Valve Seat Inserts
IMPORTANT:
The lower edge of valve seat must not contact bottom of bore in cylinder head or premature valve and
valve seat failure will occur. Removal and installation of valve seats and valve seat grinding should only
be done by experienced personnel familiar with equipment and capable of maintaining required
specifications.
Install valve seat inserts using the following specifications:

Valve Seat
Mating Surface of Head-to-Valve Seat Intake Valve Seat Insert Distance 3.10—3.40 mm (0.1220—0.1339 in.)
Mating Surface of Head-to-Valve Seat Exhaust Valve Seat Insert Distance 2.80—3.10 mm (0.1102—0.1220 in.)
Bore in Cylinder Head Intake and Exhaust Valve Seat Insert—Standard Depth 10.90—11.10 mm (0.4291—0.4370 in.)
Bore in Cylinder Head Intake and Exhaust Valve Seat Insert—0.20 mm (0.007 in.) Oversize Depth 11.10—11.30 mm (0.4370—0.4449 in.)
Bore in Cylinder Head Intake and Exhaust Valve Seat Insert—0.40 mm (0.015 in.) Oversize Depth 11.30—11.50 mm (0.4449—0.4526 in.)
Valve Seat Insert Intake Valve Seat Insert—Standard Height 7.70—7.80 mm (0.3031—0.3071 in.)
Valve Seat Insert Intake Valve Seat Insert—0.20 mm (0.007 in.) Oversize Height 7.90—8.00 mm (0.3110—0.3150 in.)
Valve Seat Insert Intake Valve Seat Insert—0.40 mm (0.015 in.) Oversize Height 8.10—8.20 mm (0.3189—0.3228 in.)
Valve Seat Insert Exhaust Valve Seat Insert—Standard Height 8.00—8.10 mm (0.3150—0.3189 in.)
Valve Seat Insert Exhaust Valve Seat Insert—0.20 mm (0.007 in.) Oversize Height 8.20—8.30 mm (0.3228—0.3268 in.)
Valve Seat Insert Exhaust Valve Seat Insert—0.40 mm (0.015 in.) Oversize Height 8.40—8.50 mm (0.3307—0.3346 in.)
Valve seat insert OD and cylinder head bore ID specifications are as follows:
Valve Seat
Intake Valve Seat Insert—Standard OD 47.38—47.39 mm (1.8653—1.8657 in.)
Intake Valve Seat Insert—0.2 mm (0.007 in.) OD 47.58—47.59 mm (1.8732—1.8736 in.)
Intake Valve Seat Insert—0.4 mm (0.015 in.) Oversize OD 47.78—47.79 mm (1.8811—1.8815 in.)
Exhaust Valve Seat Insert—Standard OD 43.08—43.09 mm (1.6961—1.6965 in.)
Exhaust Valve Seat Insert—0.2 mm (0.007 in.) Oversize OD 43.28—43.29 mm (1.7039—1.7043 in.)
Exhaust Valve Seat Insert—0.4 mm (0.015 in.) Oversize OD 43.48—43.49 mm (1.7118—1.7122 in.)
Head Intake Valve Seat Bore—Standard ID 47.300—47.325 mm (1.8622—1.8631 in.)
Head Intake Valve Seat Bore—0.2 mm (0.007 in.) Oversize ID 47.500—47.525 mm (1.8701—1.8711 in.)
Head Intake Valve Seat Bore—0.4 mm (0.015 in.) Oversize ID 47.700—47.725 mm (1.8780—1.8789 in.)
Head Exhaust Valve Seat Bore—Standard ID 43.000—43.025 mm (1.6929—1.6939 in.)
Head Exhaust Valve Seat Bore—0.2 mm (0.007 in.) Oversize ID 43.200—43.225 mm (1.7008—1.7018 in.)
Head Exhaust Valve Seat Bore—0.4 mm (0.015 in.) Oversize ID 43.400—43.425 mm (1.7087—1.7096 in.)

Section 04 - ENGINE Group 0410: Exhaust System
Group 0410 - Exhaust System

Remove and Install Exhaust Manifold
[1] -
CAUTION:
Prevent possible injury from hot exhaust pipes. Exhaust pipes can be hot enough to cause burns. Wait
for exhaust pipes to cool before working on the machine.
→NOTE:
Right side shown. Procedure for the left side is the same.
Remove Exhaust Manifold

LEGEND:
1 Exhaust Plenum
2 Nut (3 used)
3 Exhaust Elbow
5 Nut (2 used)
7 Spacer (6 used)
8 Exhaust Manifold
9 Gasket (3 used)
Remove nuts (2) from exhaust plenum (1).
[2] - Remove cap screws (6) and spacers (7).
[3] - Remove exhaust manifold (8) and elbow (3) from engine.
[4] - Remove cap screws (7) and nuts (5) to remove elbow from manifold.
[5] - Install elbow to manifold and tighten Cap screws and nuts to specification.

Section 04 - ENGINE Group 0413: Fuel Injection System

Exhaust Manifold-to-Elbow Cap Screws and Nuts Torque 50 N˙m (37 lb-ft)
[6] - Install manifold to cylinder haeds and exhaust plenum using new gaskets (9). Tighten cap screws and nuts to
specification.

Exhaust Manifold-to-Cylinder Head Cap Screws Torque 50 N˙m (37 lb-ft)
Exhaust Elbow-to-Exhaust Plenum Nuts Torque 50 N˙m (37 lb-ft)

Group 0413 - Fuel Injection System

Remove and Install Hand Primer Pump
[1] -
LEGEND:
1 Inlet Line
2 Outlet Line
3 Cap Screw, Washers, and Nut (2 used)
4 Spacer
5 Primer
Primer
Disconnect inlet line (1) and outlet line (2).
[2] - Remove cap screws, washers, and nuts (3).
[3] - Remove primer (5) and spacer (4).
[4] - Clean, repair, or replace parts as necessary. See Clean Fuel Screen . (See Operator′s Manual, Section 4-1).
[5] - Install spacer, primer, cap screws, washers, and nuts.
[6] - Connect inlet line and outlet line.
[7] - Prime fuel system. See Prime Fuel System . (See Operator′s Manual, Section 4-1).
Remove and Install Fuel Supply Pump

[1] - Raise cab. See Tilt Cab . (See Operator′s Manual Section 3-2)
[2] -
LEGEND:
1 Mounting Cap Screw
2 Fuel Inlet Line
3 Fuel Outlet Line
4 Fuel Supply Pump
Remove Fuel Supply

Disconnect fuel inlet line (2) and fuel outlet line (3).
[3] - Remove cap screws (1) and fuel supply pump (4).
[4] - Install fuel supply pump and cap screws. Tighten cap screws to specification.
Fuel Supply Pump

Mounting Cap Screw Torque 60 N˙m (44 lb-ft)
[5] - Connect fuel inlet line and fuel outlet line. Tighten banjo fittings to specification.
Fuel Supply Pump

Banjo Fittings Torque 40 N˙m (30 lb-ft)
[6] - Lower cab. See Tilt Cab . (See Operator′s Manual Section 3-2)
Remove and Install Electronic Unit Injector (EUI)

[1] - Turn battery disconnect switch to OFF.
[2] - Remove air intake manifold. See Remove and Install Air Intake Manifold . (See Group 0414.)
[3] -
LEGEND:
1 Cap Screw
2 Engine Harness
3 Fuel Line
4 Electronic Injection Unit (EUI)
Remove EUI
Disconnect engine harness from electronic unit injector (EUI).
[4] - Remove fuel line (3) from EUI and cylinder head.
[5] -
→NOTE:
If EUI is difficult to remove, rotate engine in direction of rotation to press EUI out of crankcase.
Remove cap screws (1) and EUI (4).
[6] - Inspect EUI. Replace o-rings, if necessary.
[7] - Install EUI and cap screws.

Electronic Unit Injector (EUI)

[8] - Install fuel line to cylinder head and EUI.
[9] - Connect engine harness to EUI.
[10] - Install air intake manifold. See Remove and Install Air Intake Manifold . (See Group 0414.)

Remove and Install Fuel Delivery Nozzle

[1] - Remove valve cover. See Remove and Install Valve Cover . (See Group 0409.)
[2] - Remove air intake manifold. (See Remove and Install Air Intake Manifold in Group 0414.)
[3] -
LEGEND:
1 High Pressure Fuel Line
2 Thrust Screw
3 High Pressure Pipe
4 Fuel Delivery Nozzle
5 Fuel Delivery Nozzle Retainer
6 Cap Screw
Fuel Delivery Nozzle

Disconnect high pressure fuel injection line (1) at high pressure pipe (3).
[4] - Loosen thrust screw (2) and remove high pressure pipe.
[5] - Remove cap screw (6) and fuel delivery nozzle retainer (5).
[6] - Connect injection nozzle puller to fuel delivery nozzle (4) with adapter. Remove fuel delivery nozzle.
Injection Nozzle Puller
JDG1500-3
Remove and install fuel injection nozzles.
Injection Nozzle Puller Adapter
JDG1598
Remove and install fuel injection nozzles.
[7] - Install new O-ring on fuel delivery nozzle and high pressure pipe.
[8] - Install fuel delivery nozzle, aligning tab with high pressure pipe installation location.
[9] - Install high pressure pipe loosely to ensure proper alignment of fuel delivery nozzle.
[10] - Install fuel delivery nozzle retainer and cap screw. Tighten cap screw to specification
Fuel Delivery Nozzle

Retainer Cap Screw Torque 50 N˙m (37 lb-ft)
Retainer Cap Screw Shank Length 91.0 mm (3.58 in.) maximum
[11] - Tighten high pressure pipe thrust screw to specification.

High Pressure Pipe

Section 04 - ENGINE Group 0414: Air Intake Manifold System
Thrust Screw Torque 40 N˙m (30 lb-ft)
[12] - Connect high pressure fuel injection line. Tighten connector to specification.
High Pressure Fuel Injection Line

Connector Torque 25 N˙m (221 lb-in.)
[13] - Install valve cover. See Remove and Install Valve Cover . (See Group 0409.)

Section 04 - ENGINE Group 0414: Air Intake Manifold System
Group 0414 - Air Intake Manifold System

Remove and Install Air Intake Manifold
[1] -
LEGEND:
1 Fuel Line
2 Glow Plug Wire Connector
Cold Start Connections

Disconnect fuel line (1) and wire connectors (2 and 3).
[2] -
Remove and Install Intake Manifold

LEGEND:
1 Intake Manifold
2 Wire Connector
3 Intake Manifold Air Pressure/Temperature Sensor
4 Nut (5 used)
5 Isolator (5 used)
6 Adapter Tube
7 Gasket (6 used)
8 Stud (5 used)
9 Charge Air Hoses
Disconnect wire connector (2) from intake manifold air pressure/temperature sensor (3).
[3] - Disconnect charge air hoses (9) from intake manifold (1).

Section 04 - ENGINE Group 0416: Turbocharger
[4] - Remove nuts (4) and isolators (5).
[5] - Remove studs (8) from engine block.
[6] - Lift off manifold and disconnect tube (6) from turbocharger.
[7] - Install new gaskets (7) onto cylinder heads. Lower manifold into place, inserting tube (6) into turbocharger and making
sure gaskets remain on cylinder heads.
[8] - Install studs (8) into block and tighten to specification.


Intake Manifold Studs Torque 40 N˙m (30 lb-ft)
[9] - Install isolators (5), and nuts (4). Tighten nuts to specification.

Manifold Retaining Nuts Torque 40 N˙m (30 lb-ft)
[10] - Connect boots (9) and wire connector (2).
[11] - Connect fuel line and wire connector to start aid solenoid.
[12] - Connect wire to glow plug.

Group 0416 - Turbocharger

Turbocharger
Remove and Install
CAUTION:
Prevent possible injury from hot exhaust pipes and turbocharger. Exhaust pipes and turbocharger can be
hot enough to cause burns. Wait for exhaust pipes and turbocharger to cool before working on the
machine.
[1] -
Remove and Install Turbocharger

LEGEND:
1 Intake Pipe
2 Adapter Pipe
3 Cap Screw
4 Boot
5 Compensating Ring
7 Gasket
8 Oil Delivery Pipe
9 Adapter Tube
10 Turbocharger
11 Gasket
12 Oil Return Pipe
14 Nut (4 used)
15 Exhaust Flap Connector Pipe
16 Banjo Bolt
17 Sealing Washer (2 used)
Disconnect boot (4) and connector pipe (15) from turbocharger (10).
[2] - Disconnect oil return line (12).

[3] - Remove oil delivery pipe (8).
[4] - Remove nuts (14) and remove turbocharger.
[5] - Install turbocharger on exhaust plenum and secure with nuts (14). Tighten to specification.

Turbocharger Mounting Nuts Torque 50 N˙m (37 lb-ft)
[6] - Using new gaskets (7 and 11) and sealing washers (17) install oil delivery and return pipes. Tighten hardware to
specification.

Oil Delivery and Return Lines Cap Screws Torque 25 N˙m (221 lb-in.)
Oil Delivery Line Banjo Bolt Torque 35 N˙m (26 lb-ft)
[7] - Connect boot (4) and pipe (15).
Turbocharger Lubrication
Turbocharger Lubrication
IMPORTANT:
Never spin the turbocharger turbine and compressor with compressed air. Damage to the turbine shaft
and bearings can occur because there is no lubrication to the bearings.
Fill oil return (drain) port with clean engine oil. Turn the compressor and turbine by hand to properly lubricate turbine shaft and
bearings.
If turbocharger is to be stored for an extended period of time, lubricate internally and install protective covers on all openings.
Radial Bearing Clearance Check
[1] -
→NOTE:
This test will give an indication of the condition of the radial bearings within the center housing and
rotating assembly.
Radial clearance is determined only at the turbine end of turbocharger.

Check Radial Bearing Clearance

Press turbine wheel to the side. Measure the gap between the turbine wheel and housing using a feeler gauge.
[2] - Press wheel in the opposite direction and measure gap again.
The difference between the first and second measurement is the radial clearance.
KKK Turbocharger Shaft Radial Bearing Clearance 0.45 mm (0.018 in.)
[3] - Perform measurements in at least two places.

If clearance is not within specification, install a new turbocharger.
Axial Bearing End Play Check
Checking Axial Bearing End Play
This test will give an indication of the condition of the thrust bearing within the center housing and rotating assembly.
[1] - Mount magnetic base dial indicator (arrow) so that indicator tip rests on flat surface on turbine end of shaft. Preload
indicator tip and zero dial on indicator.
[2] - Move shaft axially back and forth by hand.
[3] - Observe and record total dial indicator movement.

KKK Turbocharger Shaft Axial Bearing End Play 0.16 mm (0.006 in.)
T45 Turbocharger Shaft Axial Bearing End Play 0.025—0.090 mm (0.001—0.004 in.)
If axial bearing end play is not within specification, install a replacement turbocharger.

Turbocharger Seven-Step Inspection

The following inspection procedure is recommended for systematic failure analysis of a suspected failed turbocharger. This
procedure will help to identify when a turbocharger has failed, and why it has failed so the primary cause of the failure can be
corrected.
Proper diagnosis of a non-failed turbocharger is important for two reasons. First, identification of a non-failed turbocharger will
lead to further investigation and repair of the cause of a performance complaint.
Second, proper diagnosis eliminates the unnecessary expense incurred when a non-failed turbocharger is replaced.
The seven recommended inspection steps, which are explained in detail on following pages, are:
Compressor Housing Inlet and Compressor Wheel.

Compressor Housing Outlet.
Turbine Housing Inlet.
Turbine Housing Outlet and Turbine Wheel.
External Center Housing and Joints.
Internal Center Housing.
Turbocharger Bench Test.
→NOTE: To enhance the turbocharger inspection, an inspection sheet (Form No. DF-2280 available
from Distribution Service Center—English only) can be used that lists the inspection steps in the
proper order and shows potential failure modes for each step. Check off each step as you complete
the inspection and record any details or problems obtained during inspection. Retain this with the
work order for future reference.
Compressor Housing Inlet and Compressor Wheel

LEGEND:
A Compressor Wheel
Checking Inlet and Compressor Wheel
[1] - Check compressor inlet and compressor wheel (A) for foreign object damage.
→NOTE:
Foreign object damage may be extensive or minor. In either case, the source of the foreign object must
be found and corrected to eliminate further damage.
[2] - Mark findings on your checklist and continue the inspection.
[3] -
→NOTE:
You will need a good light source for this check.

Checking Compressor Inlet

Check compressor inlet for wheel rub on the housing (arrow). Look very closely for any score marks on the housing itself and
check the tips of the compressor wheel blades for damage.
Compressor Housing Outlet

LEGEND:
A Compressor Housing Outlet
Checking Compressor Outlet
[1] - Check compressor housing outlet (A). The outlet should be clean and free of dirt or oil.
[2] - Mark it on your checklist if dirt or oil is found and continue the inspection.
Turbine Housing Inlet
Checking Turbine Housing Inlet Ports
Check the turbine housing inlet ports (arrow) for oil in housing, excessive carbon deposit or erosion of center walls.
→NOTE:
If the inlet is wet with oil, or has excessive carbon deposits, an engine problem is likely. Center wall
erosion (cracking or missing pieces), indicate excessive exhaust temperature.
Turbine Housing Outlet and Turbine Wheel

LEGEND:
A Turbine Housing Outlet
B Blades
Checking Turbine Wheel and Outlet
[1] - Use a flashlight to look up inside the turbine housing outlet (A) and check blades (B) for foreign object damage.
[2] -
Checking Turbine Wheel Blades

Inspect the wheel blades and housing for evidence of wheel rub (arrow). Wheel rub can bend the tips of the blades with the
housing showing wear or damage.
External Center Housing and Joints
Checking Center Housing
Visually check the outside of the center housing, all connections to the compressor, and turbine housing for oil.
→NOTE:
If oil is present, make sure it is not coming from a leak at the oil supply or return line.
Internal Center Housing

LEGEND:
A Oil Return Hole
Checking Shaft and Bearings
[1] - Using a flashlight, look through the oil return hole (A), to check the condition of the shaft and/or bearings. There should
not be excess carbon deposits on the shaft or in the housing.
[2] -
Checking for Oil “Coking” on Shaft

Excessive “blueing” or “coking” of oil along the complete length of the shaft indicates a possible lack of lubrication caused by
an engine failure, or improper operation, such as hot shutdowns.
Turbocharger Bench Test
Checking Shaft Rotation and Clearance
[1] - Mount the turbocharger in a vise.
[2] - Rotate the shaft, using both hands, to check rotation and clearance. The shaft should turn freely, however, there may be
a slight amount of drag.
[3] -
IMPORTANT:
Use only moderate hand force of 0.7—0.9 N (3—4 lb-force) on each end of shaft.

Section 04 - ENGINE Group 0417: Cooling System
Checking for Contact of Compressor and Turbine Wheels

Next, pull up on the compressor end of the shaft and press down on the turbine end while rotating shaft. Neither the
compressor wheel nor the turbine wheel should contact the housing at any point.
→NOTE:
There will be some “play” because the bearings inside the center housing are free floating.
[4] -
Checking Shaft End Play

Next, check shaft endplay by moving the shaft back and forth while rotating. There will be some endplay but not to the extent
that the wheels contact the housings.
→NOTE:
These diagnostic procedures will allow you to determine the condition of the turbocharger. If the
turbocharger has failed, analysis of your inspection notes should direct you to the specific areas of the
engine to correct the problems causing the turbocharger failure. It is not unusual to find that a
turbocharger has not failed. If your turbocharger passes all the inspections, the problem lies somewhere
else.
IMPORTANT:
Before you finalize your conclusion that the turbocharger has not failed, it is strongly recommended that
the following procedures of checking radial bearing clearance and axial bearing endplay with a dial
indicator be performed. These procedures are not required if a failure mode has already been identified.


Water Pump
Remove and Install
[1] -
Remove and Install Coolant Pump

LEGEND:
1 Water Pump
2 Gasket
3 Cap Screw (9 Used)
4 Gasket
6 Adapter Pipe
7 Fill Hose
8 Heater Hose
9 Belt
11 Pulley
12 Thermostat (2 used)
Remove and Install Thermostats and Housing (See Group 0418.)
[2] - Loosen belt (9) and remove from pulley (11).
[3] - Remove cap screws (5) and disconnect adapter pipe (6) from water pump (1).
[4] - Remove pulley (11).
[5] - Remove cap screws (3) and remove water pump.
[6] - Repair or replace as required.
[7] - Install water pump using a new gasket (2) and cap screws (3). Tighten to specification.

Remove and Install Water Pump

Water Pump Cap Screws Torque 25 N˙m (221 lb-in.)
[8] - Install pulley (11). Tighten cap screws to specification.


Water Pump Pulley Cap Screws Torque 25 N˙m (221 lb-in.)
[9] - Connect adapter pipe (6) with cap screws (5). Tighten to specification.

Adapter Pipe-to-Water Pump Cap Screws Torque 50 N˙m (37 lb-ft)
[10] - Install belt.
[11] - Install thermostat housing. See Remove and Install Thermostats and Housing . (See Group 0418.)
[1] -
LEGEND:
2 Water Pump Pulley
Water Pump Pulley

Remove water pump from engine. (See Water Pump in this group.)
[2] - Remove thermostats and housing. (See Remove and Install Thermostats and Housing in Group 0418.)
[3] - Remove cap screws (1) to remove water pump pulley (2).
[4] -

LEGEND:
3 Water Pump Pulley Hub
Water Pump Pulley Hub

Remove water pump pulley hub (3) with a gear puller.
[5] -
LEGEND:
4 Snap Ring
Remove Water Pump Snap Ring

Remove snap ring (4) from front bore of water pump housing with snap ring pliers.
[6] -
LEGEND:
5 Water Pump Impeller
Water Pump Impeller

Support water pump housing and press water pump shaft through water pump impeller (5) until shaft and bearing are removed
from impeller. Discard impeller, shaft and bearing.
[7] -
LEGEND:
6 Ceramic Seal
Ceramic Seal
Remove and discard ceramic seal (6).
[8] - Inspect water pump housing for cracks or damage. Inspect parts for wear or damage.
[9] -
LEGEND:
A Impeller Shaft OD and Impeller ID
B Bearing OD and Housing ID
C Hub Shaft OD and Hub ID
D Impeller-to-Housing Clearance
E Hub OD
F Impeller OD
Water Pump Specification

Measure water pump housing and parts. Measurements must be within specification.
Water Pump

Water Pump Impeller Shaft OD 15.045—15.056 mm (0.5923—0.5928 in.)
Water Pump Impeller ID 15.000—15.018 mm (0.5905—0.5913 in.)
Water Pump Bearing OD 54.981—54.994 mm (2.1646—2.1651 in.)
Water Pump Housing ID 54.940—54.970 mm (2.1630—2.1642 in.)
Water Pump Hub Shaft OD 25.048—25.061 mm (0.9861—0.9867 in.)
Water Pump Hub ID 25.000—25.021 mm (0.9842—0.9851 in.)
Water Pump Impeller-to-Housing Clearance 0.6—1.0 mm (0.023—0.039 in.)
Water Pump Hub OD 55.940—55.970 mm (2.2024—2.2035 in.)
Water Pump Impeller OD 125 mm (4.9 in.)
[10] -
→NOTE:
Oil leakage indicates a damaged sealed bearing. Coolant leakage indicates a damaged housing seal.
Inspect weep holes for oil or coolant leakage.
[11] - Remove gasket material from housing and clean with suitable solvent. Dry thoroughly.
[12] -
IMPORTANT:
DO NOT press against end of bearing shaft. Only press against outer race when installing bearing and
shaft into housing.
LEGEND:
7 Shaft and Bearing
8 Pulley Hub
Install Pump Shaft and Bearing

Water Pump Hub

Install water pump shaft and bearing (7) into water pump housing using a bearing driver.
[13] - Install internal snap ring with snap ring pliers.
[14] - Heat water pump pulley hub (8) and install on shaft flush with the bearing.
[15] -
LEGEND:
9 Ceramic Seal
Ceramic Seal
Put new ceramic seal (9) over the water pump shaft.
[16] -
Install Ceramic Seal

Installed Ceramic Seal

Install dry ceramic seal onto water pump shaft and into water pump housing until firmly seated using a seal driver.
[17] -
LEGEND:
10 Impeller
Water Pump Impeller
Impeller Clearance
Support front of water pump housing and shaft.

Section 04 - ENGINE Group 0418: Thermostats, Housing and Water Piping
Install water pump impeller (10) on shaft using a driver.
[18] - Push impeller on the shaft to the specify clearance. Measure clearance using feeler gauge.
Water Pump
Water Pump Impeller-to-Housing Clearance 0.6—1.0 mm (0.023—0.039 in.)
[19] - Turn water pump shaft to check that it turn freely with minimal resistance.
[20] - Install water pump pulley. Tighten cap screws to specification.

Water Pump Pulley Cap Screw Torque 25 N˙m (221 lb-in.)

ENGINE AUXILIARY SYSTEM (g) by Belgreen v2.0
Group 0418 - Thermostats, Housing and Water Piping

Remove and Install Thermostats and Housing
[1] -
LEGEND:
2 Thermostat Housing
3 O-Ring (2 used)
4 Thermostat (2 used)
5 Upper Radiator Hose
Remove Thermostat Housing

Drain coolant from engine. See Change Engine Coolant . (See Operator′s Manual, Section 3-9.)
[2] - Disconnect upper radiator hose (5) from thermostat housing (2).
[4] - Remove thermostat housing, O-rings (3) and thermostats (4).
[5] -
IMPORTANT:
Bleed hole in thermostats must be to the top for cooling system to properly purge itself of all trapped air.
Install thermostats in thermostat housing so bleed hole is to the top.
[6] - Install new O-rings (4).
[7] - Install thermostat housing and cap screws. Tighten cap screws to specification.
Thermostat Housing
Cap Screws Torque 25 N˙m (221 lb-in.)
[8] - Fill engine coolant. See Change Engine Coolant . (See Operator′s Manual, Section 3-9.)

Section 05 - ENGINE AUXILIARY SYSTEM

Table of contents
Group 0510 - Cooling System ................................................................................................................. 1
Fan Belt ................................................................................................................................................ 1
Remove and Install Radiator ................................................................................................................ 1
Group 0520 - Intake System ................................................................................................................... 2
Air Intake System Leakage Check ........................................................................................................ 2
Remove and Install Charge Air Aftercooler ........................................................................................... 4
Group 0530 - External Exhaust Systems .............................................................................................. 7
Remove and Install Muffler and Exhaust Pipes ..................................................................................... 7
Remove and Install Exhaust Brake Valve Flapper ................................................................................ 9
Body Heater Pipes .............................................................................................................................. 10
Group 0540 - Engine Mounting ............................................................................................................ 14
Remove and Install Engine and Transmission Rubber Mounts ........................................................... 14
Group 0560 - External Fuel Supply Systems ..................................................................................... 17
Remove and Install Hand Primer Pump .............................................................................................. 17
Remove and Install Primary Fuel Filter (Water Separator) ................................................................. 17
Remove and Install Fuel Tank ............................................................................................................. 19

Section 05 - ENGINE AUXILIARY SYSTEM Group 0520: Intake System

Fan Belt
Remove and Install
[1] -
LEGEND:
1 Tensioner Lever
2 Tensioner Pulley
Shown with Cooling Systems Removed for Illustration

Purposes
Pry tensioner lever (1) counterclockwise. Remove belt from tensioner pulley (2). Remove belt from other pulleys.
[2] -
→NOTE:
Belt must be moved between fan and fan shroud for removal and installation.
Remove belt from machine.
[3] - Install belt on machine. Ensure belt is correctly seated on all pulleys.
[4] - Pry tensioner lever counterclockwise and install belt on tensioner pulley.
Remove and Install Radiator

See Remove and Install Charge Air Aftercooler (Group 0520).

Group 0520 - Intake System

Air Intake System Leakage Check
LEGEND:
1 Air Pressure Regulator
2 Fitting
Plastic Bag Over Primary Air Filter Element
Air Intake System Test
[1] - Remove air cleaner cover. Remove primary air filter element.
[2] - Install large plastic bag on primary air filter element as shown.
[3] - Install primary air filter element. Install air cleaner cover.
[4] - Remove air restriction indicator. Connect air pressure regulator (1) to air cleaner using hose and fitting (2) from JDE147
Manifold Pressure Tester.
Manifold Pressure Tester
JDE147
To check for air intake system leakage
[5] - Pressurize air intake system to specifications. Turn engine slightly to close valves, if necessary.
Air Intake System

Leakage Test Pressure 14—34.5 kPa (0.14—0.345 bar) (2—5 psi)
[6] - Spray a soap solution over all connections from the air cleaner to turbochargers. Check for air leaks.

[7] - Tighten clamps or replace parts as needed.
[8] - Remove test assembly. Install air restriction indicator.
[9] - Remove plastic bag from primary air filter element. Assemble air cleaner.

Remove and Install Charge Air Aftercooler

[1] - Remove Hood (Group 1910).
[2] - Remove grille.
[3] -
LEGEND:
1 Condenser Inlet Line
2 Condenser Outlet Line
3 Condenser with Mounting Frame and Seal Plates
7 Lower Seal Plate (2 used)
9 Bottom Seal Plate
10 Condenser Line Bracket (5 used)
12 Aftercooler Lifting Flange (2 used)
13 Radiator
14 Fan Shroud
15 Charge Air Flexible Hose (2 used)
16 Radiator Upper Hose
17 Radiator Overflow Hose
18 Radiator Lower Hose
Condenser
Condenser Hose Brackets

Aftercooler and Radiator

Disconnect condenser inlet line (1) and outlet line (2). See Remove and Install Condenser (Group 1830).
[4] -
CAUTION:


Air Conditioning Condenser with Mounting Frame and Upper Seal Plates Weight 18 kg (40 lb)
Remove cap screws and nuts (4). Remove cap screws (5). Remove condenser with mounting frame and seal plates (3).
[5] - Remove cap screws (6 and 8). Remove bottom seal plate (9) and lower seal plates (7).
[6] - Remove brackets (10) and move inlet line and outlet line aside.
[7] - Drain radiator (13). See Change Engine Coolant (Operator′s Manual, Section 3-9).
[8] - Disconnect charge air flexible hoses (15), radiator overflow hose (17), radiator upper hose (16), and radiator lower hose
(18).
[9] -
CAUTION:


Charge Air Aftercooler and Radiator Weight 45 kg (100 lb)

Section 05 - ENGINE AUXILIARY SYSTEM Group 0530: External Exhaust Systems
Attach a hoist to aftercooler lifting flanges (12). Remove cap screws (11). Remove aftercooler and radiator from machine.
[10] - Remove radiator from aftercooler. Remove fan shroud (14) from radiator.
[11] - Clean, inspect, repair, or replace parts as necessary.
[12] - Install fan shroud on radiator. Install radiator on aftercooler.
[13] - Install radiator and aftercooler in machine. Install cap screws.
[14] - Connect radiator lower hose, radiator upper hose, radiator overflow hose, and charge air flexible hoses.
[15] - Fill radiator. See Change Engine Coolant (Operator′s Manual, Section 3-9).
[16] - Install lower and bottom seal plates. Install cap screws.
[17] - Install condenser with mounting frame and seal plates. Install cap screws. Install cap screws and nuts.
[18] - Install brackets on inlet and outlet lines. Connect lines. See Remove and Install Condenser (Group 1830).
[19] - Install grille.
[20] - Install hood. See Hood (Group 1910).

Group 0530 - External Exhaust Systems

Remove and Install Muffler and Exhaust Pipes
[1] - Tilt Cab (Operator′s Manual, Section 3-2).
[2] -
Exhaust Shields

LEGEND:
2 Washer (9 used)
3 Bushing (2 used)
4 Bracket
5 Cap Screw
6 Washer (5 used)
8 Shield
9 Washer (19 used)
12 Shield
13 Shield
14 Cap Screw
15 Shield
16 Washer (8 used)
18 Nut (2 used)
19 Bracket (2 used)
20 Shield
21 Clamp
22 Nut (11 used)
23 Bracket
Remove parts (1—24) as necessary to access muffler and exhaust pipes.
[3] -

Exhaust Pipes
LEGEND:
1 Cap Screw
2 Washer (5 used)
3 Nut
4 Clamp
5 Exhaust Manifold
6 Clamp
7 Flex Pipe
8 Exhaust Stack
9 Clamp (5 used)
11 Washer (2 used)
12 Bracket
14 Washer (2 used)
15 Nut (11 used)
16 Mounting Band (2 used)
17 Muffler
18 Pipe
19 Bracket (2 used)
20 Nut (4 used)
21 Washer (4 used)
Repair or replace parts (1—22) as necessary.
Remove and Install Exhaust Brake Valve Flapper

[1] - Relieve Pneumatic Pressure (Operator′s Manual, Section 3-2).
[3] -
LEGEND:
1 Exhaust Shield
2 Air Line
3 Valve Assembly
Exhaust Brake
Remove exhaust shield (1).
[4] - Disconnect air line (2).
[5] - Remove valve assembly (3) from machine. Cover turbocharger exhaust port.
[7] - Install valve assembly on machine.
[8] - Connect air line.
[9] - Install exhaust shield.
[10] - Perform Exhaust Brake Adjustment (Group 9010-20).

Body Heater Pipes

Remove and Install
Body Heater Pipes

Swivel Joint
LEGEND:
1 Swivel Joint
2 Swivel Joint
3 Swivel Joint
4 Flexible Exhaust Tube
5 U-Bolt (2 used)
6 Mid-Section Exhaust Pipe
7 Seal Clamp (1 used per swivel joint)
8 Seal Ring (2 used per swivel joint)
9 Swivel Ball (1 used per swivel joint)
10 Swivel Ball Spring Assembly (3 used per swivel joint)
[1] -
CAUTION:
Prevent personal injury from unexpected machine movement. Always install the dump body prop and
articulation safety lock bar before working with the body raised and in the articulation joint area.
Install Articulation Safety Lock Bar (Operator′s Manual, Section 3-2).
[2] - Install Dump Body Prop (Operator′s Manual, Section 3-2).
[3] -
CAUTION:
Exhaust pipes and muffler can be hot.
Allow the exhaust parts to cool before servicing.
[4] - Remove swivel ball spring assembles (10) from swivel joints (2 and 3). Remove flexible exhaust tube (4).
[5] - Remove swivel ball spring assemblies from swivel joint (1). Remove U-bolts (5). Remove mid-section exhaust pipe (6).
[6] - Repair or replace parts as necessary.
[7] - Tighten cap screws and nuts in all seal clamps (7). Compress springs to specification.
Body Heater Pipes

Swivel Joint Spring Compressing Length 43 mm (1.7 in.)

[8] - Adjust body heater exhaust collar, if necessary.
[9] - Install mid-section exhaust pipe. Install U-bolts. Install swivel ball spring assemblies.
[10] - Install flexible exhaust tube. Install swivel ball spring assemblies.
[11] - Tighten all swivel ball spring assemblies. Tighten only enough to compress springs. Ensure that swivel balls (9) turn
freely against seal rings (8) when machine frames articulate and oscillate.
Adjust Body Heater Exhaust Collar
Exhaust Collar
LEGEND:
1 Exhaust Collar
2 Spring Retaining Cap Screw (5 used)
3 Mounting Cap Screw (4 used)
4 Mounting Plate
[1] - Remove flexible exhaust tube.
[2] - Tighten spring retaining cap screws (2).
[3] - Loosen mounting cap screws (3). Move exhaust collar so mounting plate (4) is centered on frame bracket holes.
[4] - Put hardwood blocks approximately 40 mm (1.6 in.) thick on each side of rear frame under front rubber dump body pads.
Lower dump body onto blocks.
[5] - Check alignment and adjust position of exhaust collar, if necessary.
[6] - Remove hardwood blocks and float dump body down until at rest. Raise dump body and install dump body prop.
[7] - Tighten mounting cap screws.

Section 05 - ENGINE AUXILIARY SYSTEM Group 0540: Engine Mounting
[8] - Install flexible exhaust tube.

Group 0540 - Engine Mounting

Remove and Install Engine and Transmission Rubber Mounts
[1] -
Engine Mount

Transmission Mount
LEGEND:
2 Engine Rubber Mount Spacer, Upper (2 used)
3 Engine Rubber Mount, Upper (2 used)
4 Engine Rubber Mount, Lower (2 used)
5 Engine Rubber Mount Spacer, Lower (2 used)
6 Washer (6 used)
7 Nut (6 used)
8 Engine Mounting Bracket (2 used)
9 Transmission Rubber Mount Spacer, Upper (4 used)
10 Transmission Rubber Mount, Upper (4 used)
11 Transmission Rubber Mount, Lower (4 used)
12 Transmission Rubber Mount Spacer, Lower (4 used)
13 Transmission Mounting Bracket (2 used)
Remove nuts (7), washers (6), cap screws (1), upper spacers, (2 and 9), and upper rubber mounts (3 and 10).
[2] - Write down the number of lower spacers (5 and 12) used for each mount.
[3] -

Section 05 - ENGINE AUXILIARY SYSTEM Group 0560: External Fuel Supply Systems
CAUTION:
The approximate weight of engine and transmission is 1475 kg (3250 lb).


Engine and Transmission Weight 1475 kg (3250 lb)
IMPORTANT:
The recommended method for lifting the engine is using the JDG23 Lifting Sling or JT07336 6000-lb Load
Rotor. The lifting force must be at 90° at the lifting points.
Lift the engine and transmission just enough to relieve pressure on lower mounts (4 and 11), using the JDG23 Lifting Sling or
JT07336 6000-lb Load Rotor and a hoist. Connect to the lifting brackets at the front and rear of engine.
Lifting Sling
JDG23
To lift the engine and transmission to change rubber mounts.
6000 lb Load Rotor
JT07336
To lift the engine and transmission to change rubber mounts.
[4] - Remove brackets (8 and 13) if necessary. Replace lower mounts (4 and 11) and lower spacers (5 and 12) as necessary.
[5] - Install brackets, if removed. Apply rigid form-in-place gasket to cap screw threads. Tighten hardware to specifications.
Number Name Use

• T43514 (us)
Apply to braket-to-engine and bracket-to-transmission cap screw
threads.

Bracket-to-Engine Cap Screw Torque 120 N˙m (90 lb-ft)
Bracket-to-Transmission Cap Screw Torque 196 N˙m (145 lb-ft)
[6] - Install upper mounts, upper spacers, cap screws, washers, and nuts. Lower engine and transmission so full weight rests
on rubber mounts.
[7] - Tighten cap screws and nuts to specification.


Rubber Mount Cap Screw and Nut Torque 410 N˙m (300 lb-ft)

Group 0560 - External Fuel Supply Systems

Remove and Install Hand Primer Pump
[1] - Relieve pressure in fuel system.
[2] -
LEGEND:
1 Inlet Line
2 Outlet Line
3 Cap Screw, Washers, and Nut (2 used)
4 Spacer
5 Primer
Primer
Disconnect inlet line (1) and outlet line (2).
[3] - Remove cap screws, washers, and nuts (3).
[4] - Remove primer (5) and spacer (4).
[5] - Clean, repair, or replace parts as necessary. See Clean Fuel Screen (Operator′s Manual, Section 4-1).
[6] - Install spacer, primer, cap screws, washers, and nuts.
[7] - Connect inlet line and outlet line.
[8] - Prime Fuel System (Operator′s Manual, Section 4-1).
Remove and Install Primary Fuel Filter (Water Separator)

LEGEND:
1 Outlet Line
3 Heater Wire (If Equipped)
4 Inlet Line
Primary Fuel Filter
[1] - Drain Primary Fuel Filter (Water Separator) until empty. Close drain screw. (Operator′s Manual, Section 3-3).
[2] - Disconnect heater wire (3), if equipped.
[3] - Disconnect inlet line (4) and outlet line (1).
[4] - Remove cap screws, nuts (2), and filter assembly.
[5] - Repair or replace parts as necessary. See Replace Primary Fuel Filter (Water Separator) (Operator′s Manual, Section 3-6).
[6] - Install filter assembly, nuts, and cap screws.
[7] - Connect outlet line and inlet line.
[8] - Connect heater wire, if equipped.

[9] - Fill filter housing with clean fuel.

Remove and Install Fuel Tank

[1] - Drain fuel from fuel tank.

Fuel Tank Capacity 400 L (106 gal)
[2] -
LEGEND:
1 Air Cleaner
2 Air Horn
3 Plate
4 Fuel Level Sender
Top of Fuel Tank

Remove air cleaner (1). Remove pneumatic line from air horn (2). Disconnect pneumatic lines from fuel tank. Remove plate (3)
and disconnect wiring harness from fuel level sender (4).
[3] -
LEGEND:
1 Headlight
2 Housing
Headlight
Remove headlight (1) and headlight housing (2).
[4] -
LEGEND:
1 Suction Line
2 Return Line
Suction and Return Lines

Disconnect fuel suction line (1) and return line (2) from fuel tank. Close openings using caps and plugs.

[5] -
CAUTION:


Fuel Tank Weight 290 kg (640 lb) approximate
Support fuel tank with hoist.
[6] -

Fuel Tank
LEGEND:
1 Fuel Tank
2 Plug
3 Lid
4 Plate
5 Gasket
6 Fill Cap
CONNECTOR DRIVE (FLEXPLATE) (g) by Belgreen v2.0
7 Nipple
8 Drain Valve
9 Tread Pad
10 Plug (2 used)
12 Washer (8 used)
14 Washer (10 used)
15 Nut (5 used)
Remove cap screws (16), washers (14) and nuts (15). Remove fuel tank.
[8] - Install fuel tank. Install cap screws, washers, and nuts.
[9] - Connect suction and return lines.
[10] - Install headlight housing and headlight.
[11] - Connect wiring harness to fuel level sender and install plate. Connect pneumatic lines to fuel tank. Install pneumatic line
on air horn. Install air cleaner.
[12] - Fill tank with fuel.

Section 07 - CONNECTOR DRIVE (FLEXPLATE)

Table of contents
Group 0752 - Elements ............................................................................................................................ 1
Remove and Install Connector Drive (Flexplate) .................................................................................. 1

Section 07 - CONNECTOR DRIVE (FLEXPLATE) Group 0752: Elements
Group 0752 - Elements

Remove and Install Connector Drive (Flexplate)
Connector Drive (Flexplate)

LEGEND:
1 Disks-to-Adapter Cap Screw (12 used)
2 Disk
3 Disk (3 used)
4 Plate
5 Adapter-to-Torque Converter Cap Screw (12 used)
6 Adapter
7 Plate and Disks-to-Flywheel Cap Screw (12 used)
[1] - Check crankshaft end play. (See Crankshaft in Group 0401.)
[2] - Remove the engine and transmission. (See Engine in Group 0400.)
[3] - Remove cap screws (5 and 7) to remove parts (2, 3, 4, and 6).
[5] - Install adapter (6).
[6] - Apply medium strength thread lock and sealer to threads of cap screws (5). Tighten cap screws to specification.
Number Name Use

• T43512 (us)
Medium strength thread lock and Apply to the adapter-to-torque converter cap screw
sealer threads.

Adapter-to-Torque Converter Cap Screw Torque 35 N˙m (25 lb-ft)
[7] - Apply rigid form-in-place gasket to threads of cap screws (7) and fasten disks (2 and 3) and plate (4) to the flywheel.
Tighten the cap screws to specification.

TRANSFER DRIVE (g) by Belgreen v2.0

Flexplate Disks-to-Flywheel Cap Screw Torque 110 N˙m (81 lb-ft)
Number Name Use

• T43514 (us)
Apply to flexplate disks-to-adapter and flexplate-to-flywheel cap
screw threads.
[8] - Apply anti-seize to center hub of torque converter.
Number Name Use

• PT569 (us)
Never-seize Apply to center hub of torque converter
• NEVER-SEEZ ™ (us)
[9] - After transmission is installed to flywheel housing, apply rigid form-in-place gasket
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to flywheel housing cap screws
to threads of cap screws (1). Install cap screws through opening in flywheel housing to fasten the disks to adapter. Tighten cap
screws to specification.

Flexplate Disks-to-Adapter Cap Screw Torque 35 N˙m (25 lb-ft)

Section 08 - TRANSFER DRIVE

Table of contents
Transfer Case Remove and Install ........................................................................................................ 1
Transfer Case Alignment .................................................................................................................... 12
Drive Shaft Alignment ........................................................................................................................ 14
Group 0851 - Gear Shafts and Bearings ............................................................................................. 30
Transfer Case Disassemble ................................................................................................................ 30
Front Output Housing and Inter-axle Lock Disassemble and Assemble .............................................. 37
Input Shaft Disassemble and Assemble .............................................................................................. 41
Idler Shaft Disassemble and Assemble ............................................................................................... 44
Rear Output Shaft Disassemble and Assemble .................................................................................. 45
Planetary Gear Disassemble and Assemble ....................................................................................... 47
Transfer Case Assemble ..................................................................................................................... 52
Inter-axle Lock Coupler Adjustment ................................................................................................... 64

Section 08 - TRANSFER DRIVE Group 0800: Removal and Installation

Transfer Case Remove and Install
[1] - Install articulation lock bar. See Install Articulation Locking Bar . (Operator′s Manual.) Install chock at wheels. Relieve
hydraulic pressure. See Prepare Machine for Maintenance . (Operator′s Manual.)
[2] - Relieve brake accumulator pressure. See Brake Accumulators Remove and Install . (Group 1060.)
[3] - Relieve pneumatic pressure. See Relieve Pneumatic Pressure . (Operator′s Manual.)
[4] - Tilt the cab. See Tilt Cab . (Operator′s Manual.)
[5] - Drain wet brake reservoir. See Change Wet Disk Brake Cooling Oil—If Equipped . (Operator′s Manual.)
[6] -
LEGEND:
1 Bin Heater Pipe
2 Transmission Cooler Inlet
3 Transmission Cooler Outlet
4 Hydraulic Cooler Outlet
5 Front Wet Brake Cooler Inlet
6 Rear Wet Brake Cooler Inlet
7 Rear Wet Brake Cooler Outlet
9 Hydraulic Cooler Inlet
Cooler Assembly
Disconnect lines (2—6). Close all openings using caps and plugs.
[7] - Disconnect hoses (7—9).
[8] -
LEGEND:
1 Bracket
2 Transmission Cooling Line Support
Transmission Cooling Line Support and Bracket

Remove cap screws from transmission cooling line support (2) and bracket (1) on front of cooler housing.

[9] -
CAUTION:
Remove cooler and housing from machine using appropriate lifting device.
Cooler and Housing Weight (approximate) 188 kg
415 lb
[10] - Remove bin heater pipe. See Bin Heater Pipes Remove and Install . (Group 0530.)
[11] -
LEGEND:
1 Muffler Shield
2 Rear Wet Brake Cooling Return
3 Front Wet Brake Cooling Return
4 Clamp
5 Bypass Check Valve (2 used)
6 To Wet Disk Brake Cooling Oil Pump
Wet Disk Brake Cooling Oil Reservoir and Muffler

Remove clamp (4) from reservoir.
[12] - Install identification tags.
[13] - Disconnect wet brake reservoir hoses with check valves (5).
[14] - Remove hand rail on rear of cab.
[15] - Remove muffler shield (1).
[16] - Disconnect muffler.
[17] - Remove wet disk brake cooling reservoir and muffler using appropriate lifting device.
Wet Disk Brake Cooling Oil Reservoir and Muffler Weight (approximate) 143 kg
315 lb
[18] -

LEGEND:
1 Brake Accumulator
2 Rear Brake Supply Hose
3 Front Brake Supply Hose
4 Front Brake Accumulator Hose
5 Rear Brake Accumulator Hose
Hydraulic System Manifold

Disconnect hoses (2—5) from hydraulic system manifold.
[19] -
CAUTION:
LEGEND:
1 JT01748 Lifting Bracket

Attach JT01748 Lifting Bracket (1) to hydraulic system manifold.
Lifting Bracket
JT01748
Lift hydraulic system manifold
[20] - Attach lifting device to lifting bracket.
[21] -

LEGEND:
2 Secondary Steering Pump
3 Inter-Axle Lock Actuator Air Line
5 Hydraulic System Manifold Cap Screw (4 used)
7 Cross Frame-To-Front Frame Cap Screw (4 used)
Secondary Steering Pump

Remove cross frame-to-front frame cap screws (7).
[22] - Lift and move cross frame and hydraulic system manifold to the side.
[23] - Remove secondary steering pump (2). See Secondary Steering Pump Remove and Install . (Group 0930.)
[24] - Disconnect air line (3).
[25] -
Drive Shafts
LEGEND:
3 Park Brake Disk

Disconnect transfer case-to-oscillation joint drive shaft (5). See Transfer Case-to-Front Axle Drive Shaft or Transfer Case-to-
Oscillation Joint Drive Shaft Remove and Install . (Group 0225.)
[26] - Disconnect transfer case-to-front axle drive shaft (6). See Transfer Case-to-Front Axle Drive Shaft or Transfer Case-to-
Oscillation Joint Drive Shaft Remove and Install . (Group 0225.)
[27] - Disconnect transmission-to-transfer case drive shaft (7). See Transmission-to-Transfer Case Drive Shaft Remove and
Install . (Group 0325.)
[28] -
CAUTION:
Connect appropriate lifting device to eyebolt in transfer case.

Transfer Case Weight (approximate) 218 kg
480 lb
[29] - Remove heat shield over transfer case upper mount.
[30] -
IMPORTANT:
Location and quantity of transfer case shims must be noted to maintain correct drive line alignment.

Transfer Case
LEGEND:
2 Nut (6 used)
3 Washer (12 used)
4 Spacer (6 used)
5 Rubber Mount Pads (12 used)
6 Breather
7 Transfer Case
Remove nuts (2), cap screws (1), and washers (3).
[31] -
CAUTION:
Avoid possible crushing injury. Heavy component; use appropriate lifting device.
Remove transfer case from frame.

480 lb
[32] - Inspect, repair, and replace parts as necessary. See Transfer Case Housing Disassemble . (Group 0851.)
[33] - Install transfer case into frame.

480 lb
[34] -
IMPORTANT:
Install shims as removed. If transfer case housing has been replaced or shim location unknown, transfer
case alignment must be done.
Install nuts (2), cap screws (1), and washers (3).
[35] - Install shims as removed.
[36] - Tighten to specification. If transfer case housing has been replaced or shim location unknown, transfer case alignment
must be done. See Drive Shaft Alignment . (Group 0800.)
Transfer Case Cap Screw and Nuts Torque 320 lb-ft
434 N·m
[37] - Install heat shield over transfer case upper mount.
[38] -
LEGEND:
5 Hydraulic System Manifold Cap Screw (4 used)
7 Cross Frame-To-Front Frame Cap Screw (4 used)

Cross Frame and Drive Shafts

Connect air line (3).
[39] - Install secondary steering pump (2). See Secondary Steering Pump Remove and Install . (Group 0930.)
[40] -
Drive Shafts
LEGEND:
3 Park Brake Disk
Connect transmission-to-transfer case drive shaft (7). See Transmission-to-Transfer Case Drive Shaft Remove and Install .
(Group 0325.)
Transmission-to-Transfer Case Drive Shaft Torque 210 N·m
154 lb-ft
[41] - Install transfer case-to-front axle drive shaft (6). Connect transfer case-to-oscillation joint drive shaft (5). See Transfer
Case-to-Front Axle Drive Shaft or Transfer Case-to-Oscillation Joint Drive Shaft Remove and Install . (Group 0225.)
Transfer Case-to-Front Axle Drive Shaft Torque 142 N·m
104 lb-ft
Transfer Case-to-Oscillation Joint Drive Shaft Torque 142 N·m

104 lb-ft
[42] -
LEGEND:
1 JT01748 Lifting Bracket

Install hydraulic system manifold and cross frame into position. Remove lifting bracket.
[43] -
LEGEND:
4 Transmission-toTransfer Case Drive Shaft
5 Hydraulic System Manifold Cap Screws (4 used)
7 Cross Frame-To-Frame Cap Screw (4 used)
Cross Frame
Install frame-to-front frame cap screws (7), and hydraulic system manifold cap screws (5).
[44] -

LEGEND:
1 Brake Accumulator
2 Rear Brake Supply
3 Front Brake Supply
4 Front Brake Accumulator Hose
5 Rear Brake Accumulator Hose

Connect hoses (2—5) to hydraulic system manifold.
[45] -
LEGEND:
1 Muffler Shield
2 Rear Wet Brake Cooling Return
3 Front Wet Brake Cooling Return
4 Hose Pack Mount Clamp
5 Bypass Check Valves
6 To Wet Brake Cooling Pump
Wet Disk Brake Cooling Reservoir and Muffler

Install wet disk brake cooling reservoir and muffler.
[46] - Connect muffler.
[47] - Install muffler shield (1).
[48] - Install hand rail on rear of cab.
[49] - Connect hoses (6) and bypass check valves (5).
[50] - Install clamp (4) to reservoir.
[51] - Install bin heater pipes, if equipped. See Bin Heater Pipes Remove and Install . (Group 0530).
[52] -

LEGEND:
1 Bin Heater Pipe
2 Transmission Cooler Inlet
3 Transmission Cooler Outlet
4 Hydraulic Cooler Outlet
6 Rear Wet Brake Cooler Inlet
7 Rear Wet Brake Cooler Outlet
9 Hydraulic Cooler Inlet
Cooler Assembly
Install cooler and housing.
[53] - Connect lines (2—6).
[54] - Connect hoses (7—9).
[55] - Install cap screws for transmission cooling line support and bracket on front of cooler housing.
[56] - Fill wet brake reservoir. See Change Wet Disk Brake Cooling Oil—If Equipped . (Operator′s Manual.)
[57] - Lower cab. See Tilt Cab . (Operator′s Manual.)

Transfer Case Alignment

[1] -
Transfer Case Alignment

LEGEND:
1 Upper Mount Cushion Shim Location
2 Lower Mount Cushion Shim Location
3 Side View
4 Top View
5 JDG10747 Transfer Case Alignment Tool
Install JDG10747 Transfer Case Alignment Tool (5) on transfer case rear output yoke and oscillation tube through shaft input
yoke.
Transfer Case Alignment Tool
JDG10747
Align transfer case rear output yoke to oscillation tube through shaft input yoke.
[2] -

→NOTE:
Check alignment with all hardware tightened to specifications.
Check alignment using JDG10747 Transfer Case Alignment Tool. Pointers must be in alignment.
[3] - Add or remove shims at location (1) to adjust vertical position of output shaft.
[4] - Add or remove shims at location (2) to adjust centerline angle of output shaft.
[5] - Tighten all transfer case mounting hardware to specifications.
[6] - Remove JDG10747 Transfer Case Alignment Tools.

Drive Shaft Alignment

IMPORTANT:
Drive shaft alignment procedure must be done whenever the engine, transfer case or front frame is
removed and installed or replaced or damage may occur to drive line assembly.
Drive Shafts
LEGEND:
3 Park Brake Disk
A vibration free drive line with multiple drive shafts requires precision alignment of all connected components. To provide a
smooth running drive line each drive shaft must be installed in such a manner that the angles of each universal joint are equal.
This procedure will describe a method to accomplish this “equal angle” approach on each of the two most difficult drive shafts
on an articulated dump truck (ADT):
transfer case-to-oscillation joint drive shaft (5)

transmission-to-transfer case drive shaft (7)

Alignment Tools
LEGEND:
1 JDG10812 Driveline Laser Alignment Tool
2 Adaptor (2 used)
3 Clamp (4 used)
4 Ruler Plate (2 used)
5 Laser Pointer (2 used)
6 JDG10747 Transfer Case Alignment Tool
7 Pointer Base (2 used)
8 Pointer (2 used)
9 JDG10948 Driveline Digital Protractor
[1] - Transfer Case-to-Oscillation Joint Drive Shaft Alignment— For proper alignment of the transfer case drive shaft
yoke and the oscillation joint drive shaft yoke, the machine must be parked on a level surface. See Park And Prepare For
Service Safely . (Group 0001.)
[2] - Use JDG10747 Transfer Case Alignment Tool (6) and JDG10812 Driveline Laser Alignment Tool (1) to do the alignment
procedure.
Transfer Case Alignment Tool
JDG10747
Driveline aligment.
Driveline Laser Alignment Tool
JDG10812
Driveline aligment.
[3] -
CAUTION:
Prevent possible crushing injury from heavy component, use appropriate lifting device.

LEGEND:
2 Park Brake Disc
Front Yoke On The Park Brake to Middle Axle Drive

Shaft
Support park brake-to-middle axle drive shaft (3) with an appropriate lifting device. Remove cap screws (1) from yoke behind
park brake disc (2).
Park Brake-to-Middle Axle Drive Shaft Weight (approximate) 40 kg
87 lb
[4] - This drive shaft is a two piece assembly that can slide apart at the splines. To prevent this, once cap screws are removed,
the loose end should be raised to ensure the shaft stays together.
[5] -
Transfer Case-to-Oscillation Joint Drive Shaft

LEGEND:
Support transfer case-to-oscillation joint drive shaft (2) with appropriate lifting device.
[6] - Remove cap screws (1) to remove drive shaft.
[7] - Release park brake. See Mechanically Releasing Park Brake . (Operator′s Manual.)
[8] - The transfer case vertical angle can now be checked.
[9] - Clean and remove all rust and debris from yokes.
[10] -
Transfer Case Vertical Angle

LEGEND:
1 Oscillation Joint Drive Shaft Yoke
3 Transfer Case
Place JDG10948 Driveline Digital Protractor (2) on the flat surface of the oscillation joint drive shaft yoke (1).
Driveline Digital Protractor
JDG10948
Measure oscillation joint drive shaft runout.
[11] - Make sure the yoke and JDG10948 Driveline Digital Protractor are in a vertical position.
[12] - Push button to zero JDG10948 Driveline Digital Protractor.
[13] - Rotate the yoke and JDG10948 Driveline Digital Protractor through 1/2 turn (180°), record angle.
If angle is greater than specification, adjust oscillation joint end play. See Oscillation Joint Repair . (Group 1740.) If yoke or drive
shaft is bent it must be replaced.
Oscillation Joint Drive Shaft Yoke Runout -0.1—1.0°
[14] -

Transfer Case Vertical Angle

LEGEND:
1 Oscillation Joint Drive Shaft Yoke
3 Transfer Case Rear Yoke
4 Transfer Case
Place JDG10948 Driveline Digital Protractor (2) on the flat surface of the transfer case rear yoke (3).
[15] - Make sure the yoke and JDG10948 Driveline Digital Protractor are in a vertical position.
[16] - Push button to zero JDG10948 Driveline Digital Protractor.
[17] - Rotate the yoke and JDG10948 Driveline Digital Protractor through 1/2 turn (180°), record angle.
If angle is greater than specification, yoke or transfer case rear output shaft is bent and must be replaced. See Transfer Case
Housing Disassemble . (Group 0851.)
Transfer Case Rear Yoke Runout -0.1—1.0°
[18] - Place JDG 10948 Driveline Digital Protractor on oscillation joint drive shaft yoke (1). Push button to zero JDG 10948
Driveline Digital Protractor.
[19] - Move JDG 10948 Driveline Digital Protractor to transfer case rear yoke rotating it on its vertical axis so the same surface
that contacted the oscillation joint drive shaft yoke contacts the transfer case rear yoke. Do not push button to zero JDG 10948
Driveline Digital Protractor.
[20] -

Shim Location
LEGEND:
1 Transfer Case Mount (3 used)
2 Shim Location
3 Transfer Case
4 Frame
The measurement must be within specification, if it is not transfer case must be shimmed between transfer case mounts (1)
and frame (4) at shim location (2).
[21] -
→NOTE:
The JDG10747 Transfer Case Alignment Tool consists of items (1, 3 and 5).

JDG10747 Transfer Case Alignment Tool Installation

LEGEND:
1 Pointer Base
4 Transfer Case Output Yoke
5 Pointer
6 Oscillation Joint-to-Transfer Case Yoke
Transfer Case Position— Install one pointer base (1) from alignment tool kit on transfer case output yoke (4) and one on
oscillation joint-to-transfer case yoke (6) using cap screws (2).
[22] - Install a pointer (5) in each pointer base. Do not tighten cap screws (3) so pointers can slide in pointer base.
[23] - Extend the pointers towards each other.
[24] - Hand tighten cap screws.
[25] - Pointer tips must align within specification both horizontally and vertically.
Transfer Case to Oscillation Joint Drive Shaft Yoke Vertical and Horizontal Offset Distance 2 mm
0.08 in.
[26] -

Oscillation Through Drive

LEGEND:
1 Straight Edge
2 Right Angle Square
3 Transfer Case
4 Oscillation Joint
5 Articulation Pivot Point
Use a right angle square (2) to determine articulation pivot point (5).
[27] - Keep the right angle square horizontally flat on the upper surface of the articulation pin, after establishing center point
of pin.
[28] - Adjust pointer to articulation pivot point and tighten cap screw to hold adjustable pointer in place.
[29] - Measure the distance A and record.
[30] - Measure the distance B and record.
[31] - Compare measurements, the difference must be within specification.

Articulation Pivot Point Distance 2 mm
0.08 in.
[32] -

Transfer Case Adjustment

LEGEND:
1 Transfer Case Mounts
2 Articulation Pivot
3 Transfer Case
4 Alignment Side View
5 Alignment Top View
6 Alignment Shim
7 Frame
Adjust the transfer case position on it′s mountings in the chassis to achieve equal distance and horizontal and vertical
alignment of pointers. This is done by adding or removing shims on the top and or bottom transfer case mounts, or moving the
transfer case as a whole in the mounting holes. Shim transfer case (3) using alignment shims (6).
[33] -
→NOTE:
The JDG10812 Driveline Laser Alignment Tool consists of items (1 and 2).

JDG10812 Driveline Laser Alignment Tool Installation

LEGEND:
1 Clamp (4 used)
2 Laser Pointer (2 used)
3 Transfer Case
4 Transmission
Transmission to Transfer Case Alignment— Clean and remove all rust and debris from yokes.
[34] - Remove ruler plate from laser pointer base.
[35] -
IMPORTANT:
If laser pointers are not mounted flush on yokes a misalignment will occur.
Install laser pointer (2) without ruler plate on the transfer case top input yoke using clamps (1).
[36] - Install laser pointer without ruler plate on the transmission output yoke using clamps.
[37] - Ensure that each laser pointer′s base is seated flat on the yokes.
[38] -

Laser Pointer Adjustable Body

LEGEND:
2 Laser Beam Point
3 Card
5 Before Adjusting
6 After Adjusted
Switch on the first laser pointer.
[39] - Rotate the laser pointer body by hand and watch laser beam point (2). If laser beam points makes a circle, adjust the
cap screws (4) until the rotating laser beam point makes a single point and not a circle on the opposing laser pointer base.
[40] - Repeat this laser point adjusting procedure for the laser pointer on the opposite yoke.
[41] -

Ruler Plate
LEGEND:
2 Cap Screw
3 50 mm Mark
4 Drive Line Center Point
5 Cap Screws (4 used)
6 50 mm Position
7 Ruler
Before installing the ruler plate, align the 50 mm mark on the ruler (7) to the 50 mm mark (3) on the ruler plate (1).
[42] -
LEGEND:
1 Laser Pointer Base (2 used)
4 Clamp (4 used)
Fitting Ruler Plate

Install one ruler plate (2) on each laser pointer base (1) using the two cap screws (3).
[43] -

Transmission to Transfer Case Vertical Alignment

LEGEND:
2 Ruler Plate
3 0° Ground Level
Transmission to Transfer Case Vertical Alignment— Use the JDG10948 Driveline Digital Protractor (1) on each ruler plate
(2) to ensure that each ruler plate points down vertically.
[44] -
Vertical Distance Measurement

LEGEND:
1 Laser Beam Point
2 Ruler
X1 Measurement
X2 Measurement
With both lasers on read the vertical distance indicated on each opposing ruler (2). X1 and X2 show measurement locations.
To get the drive shaft cross and roller angles on either side equal, these vertical distances must be equal.
The maximum allowable vertical difference of these vertical distances are shown below. If maximum allowable vertical
difference is exceeded the engine and transmission must be shimmed to correct misalignment.
The engine and transmission can be shimmed as one to raise or lower or they can be shimmed separately to change the angle.
250D and 300D

Maximum Allowable Vertical Difference Distance 6 mm
.236 in
350D and 400D

Maximum Allowable Vertical Difference Distance 6 mm
.236 in
→NOTE:
To save time and prevent duplication of work, both vertical and horizontal alignment are checked,
adjustment calculated and the required shimming is done simultaneously. To check the alignment
readings after adjustment, the transmission mounts must be fully fastened.
For example: If one laser beam point indicates a vertical distance of 57 mm (2.24 in) on the laser ruler, and the other indicates
46 mm (1.8 in), this means there is an 11 mm (.43 in) difference. Use a shim, half the difference, e.g. 5 mm (.20 in) (added or
removed, depending if the transmission must be raised or lowered) to reduce this difference to 1 mm (.039 in).
[45] -
Horizontal Alignment
LEGEND:
1 Laser Beam Point
2 Ruler
3 Measurement Location
4 Center Of Drive Line
Transmission to Transfer Case Horizontal Alignment— Notice the position of the one laser beam point (1) on the
opposing ruler (2). The right hand edge (when looking at it) of the ruler indicates the center line of the yoke. The laser beam
points should strike the edge of the opposing ruler, this will indicate the two yokes are parallel and directly opposite to each

other in the horizontal plane.
[46] -
→NOTE:
The maximum allowable distance off the edge of the ruler is per side.
Laser beam points offset to either side of the ruler edge indicates horizontal misalignment. The maximum allowable horizontal
distance is as specified. If maximum allowable horizontal difference is exceeded the engine and transmission must be shimmed
to correct misalignment.
250D and 300D

Maximum Allowable Horizontal Distance Distance 1 mm
.039 in
350D and 400D

Maximum Allowable Horizontal Distance Distance 3 mm
.12 in

Section 08 - TRANSFER DRIVE Group 0851: Gear Shafts and Bearings
Transmission Shimming
LEGEND:
1 350D and 400D Transmission Shim Location
2 350D and 400D Engine Shim Location
3 250D and 300D Transmission Shim Location
4 250D and 300D Engine Shim Location
[47] - Install shims beneath bottom mount and rubber onto chassis.

Group 0851 - Gear Shafts and Bearings

Transfer Case Disassemble
[1] - Clean outside of transfer case.
[2] - Mount transfer case in D05223ST Engine Repair Stand with DFT1223 Transfer Case Mounting Bracket .
Engine Repair Stand
D05223ST
Support transfer case during repair.
Transfer Case Mounting Bracket
DFT1223
Install transfer case in repair stand.
[3] -
Input Yoke and Front Output Housing

LEGEND:

1 Input Yoke
2 Input Shaft
3 Front Output Housing
6 Retainer
7 O-Ring
Remove input yoke (1).
[4] - Remove cap screws (4) and separate front output housing (3) from transfer case housing with jack screws.
[5] -
Planetary and Output Gear

LEGEND:
1 Planetary and Output gear Assembly
2 Transfer Case Housing
Use Remove planetary and output gear assembly (1) with jack screws.
[6] -

Input and Idler Shaft Housings

LEGEND:
2 Input Shaft Bearing Housing
3 Input Gear Cap Screw (12 used)
4 Idler Gear Cap Screw (12 used)
5 Idler Shaft Bearing Housing
Remove input shaft bearing housing (2) with jack screws.
[7] - Remove idler shaft bearing housing (5) with jack screws.
[8] - Remove cap screws (3 and 4) securing input and idler gears.
[9] - Rotate transfer case so rear of case is face-up.
[10] -

Input Shaft
LEGEND:
1 Input Gear
2 Input Shaft
3 Input Shaft Bearing Housing
4 Cover
Remove cover (4) and O-ring.
[11] - Remove input shaft bearing housing (3) with jack screws.
[12] - Tap input shaft with soft faced hammer to remove shaft from input gear (1).
[13] -

Idler Shaft
LEGEND:
1 Idler Gear
3 Idler Shaft Bearing Housing
5 Cover
Remove cover (5) and O-ring.
[14] - Remove idler shaft bearing housing (3) with jack screws.
[15] - Tap idler shaft with soft faced hammer to remove idler shaft from gear (1).
[16] -

Output Shaft and Housing

LEGEND:
1 O-Ring
2 Rear Output Housing
Remove rear output housing (2) with jack screws.
[17] - Rotate transfer case 180 , making sure top of case moves down. Ensure gears do not fall from case.
[18] -

Input and Idler Gears

LEGEND:
1 Idler Gear
2 Input Gear
Remove idler gear (1) and input gear (2).

Front Output Housing and Inter-axle Lock Disassemble and Assemble

[1] -
Front Output Housing

LEGEND:
2 Cover
3 O-Ring
4 Piston Seal
5 Piston
6 Spring
8 Cover
9 Cap Screw
10 Fork
11 Coupler Slide Collar
13 Front Output Shaft
14 Yoke
16 Retainer
17 O-Ring
18 Pin, Spring
19 Button
Remove covers (2 and 8) and O-ring (3).
[2] - Loosen cap screw (9). Using an adjustable two-pin spanner wrench or similar tool, remove piston (5). Remove seal (4),
spring (6), and fork (10).
[3] - Remove parts (14—17).
[4] -

Front Output Shaft and Housing

LEGEND:
1 Seal
3 Bearing
4 Snap Ring
6 Bushing
Remove seal (1).
[5] - Press shaft (5) from housing (2), using an appropriate driver from D01045AA Bushing, Bearing and Seal Driver Set.
Bushing, Bearing and Seal Driver Set
D01045AA
Remove and install bearings and races in transfer case.
[6] - Remove snap ring (4) from housing.
[7] - Press bearing (3) from housing.
[8] - Clean, inspect, and replace parts as necessary. Replace bushing (6) if worn or damaged.
[9] - Heat housing (2) to 85 °C (185 °F), and install bearing (3) and snap ring (4).
[10] - Heat bearing (3) and housing (2) to 85 °C (185 °F), and install shaft (5). Allow assembly to cool.
[11] - Apply a thin layer of petroleum jelly to lip of seal (1). Apply flexible form-in-place gasket to outer diameter of seal. Install
seal.
Number Name Use

• PM38657 (us)
• PM38657 (canadian) Flexible Form-In-Place Gasket Apply to outer diameter of seal.
[12] -

Front Output Housing

LEGEND:
2 Cover
3 O-Ring
4 Piston Seal
5 Piston
6 Spring
8 Cover
9 Cap Screw
10 Fork
11 Coupler Slide Collar
14 Yoke
16 Retainer
17 O-Ring
18 Pin, Spring
19 Button
Install coupler slide collar (11) over shaft (13). Collar must move freely over splined area of shaft.
[13] - Install cap screw (9) and piston (5) in fork (10). Tighten cap screw until clearance is removed, but piston rotation is still
possible. Maintain setting and remove fork from piston.
[14] - Install fork (10) in housing (12) and on collar (11).
[15] - Apply a thin layer of petroleum jelly to lip of seal (4). Lip must face away from piston.
[16] - Apply a thin layer of petroleum jelly to piston bore and piston journals.
[17] -
→NOTE:
Fork adjustment must be done after front output housing assembly is installed.

Using an adjustable two-pin spanner wrench, install piston (5) spring (6). Do not tighten cap screw at this time.
[18] - Apply 641 (Medium Strength) retaining compound to splines of shaft. Install yoke (14), O-ring (17), and retainer (16).
Apply 270 (Maximum Strength) thread lock sealer to cap screws. Tighten cap screws (15) to specification.
Front Output Yoke Cap Screw Torque 156 N˙m
115 lb-ft
Number Name Use

• N/A (us)
• N/A (canadian) Retaining Compound Apply to splines of shaft.
Number Name Use
• EPL279236 (us)
• EPL279236 (canadian) Thread locker Apply to cap screws.

Input Shaft Disassemble and Assemble

[1] -
Transfer Case Input Shaft
Transfer Case Input Cross Section

LEGEND:
1 Seal
3 Input Shaft Front Bearing Housing

4 Bearing
5 O-Ring
6 Inner Race
7 Thrust Bearing
8 Gear
9 Thrust Bearing
10 O-Ring
11 Input Shaft
12 Input Shaft Rear Bearing Housing
13 Inner Race
14 Bearing
15 Inner Race
16 Bearing
17 Inner Race
18 Retainer Plate
Remove cap screws (2), input shaft front bearing housing (3), and O-ring (5).
[2] - Remove seal (1).
[3] - Remove bearing (4) from housing (3), using a bearing puller.
[5] - Remove inner race (6) from input shaft (11), using a bearing puller.
[6] - Remove cap screws (19) and retainer plate (18).
[7] - Remove input shaft bearing rear housing (12) and O-ring (10).
[8] - Remove bearing (14), inner race (15), bearing (16), and inner race (17) from housing (12), using a bearing puller.
[9] - Remove shaft (11), using a press.
[10] - Remove inner race (13) from input shaft (11), using a bearing puller.
[13] - Heat housings (3 and 12) to 85°C (185°F).
[14] - Apply a thin layer of 638 Retaining Compound (maximum strength) to outer race of bearings (4, 14, and 16).
Number Name Use

• 638 LOCTITE ™ (loctite) Retaining Compound (maximum strength) Apply to outer race of bearing.
[15] - Install bearings (4, 14, and 16).
[16] - Install inner race (13) on input shaft (11), using a press.
[17] - Install thrust bearing (9) and shaft (11), using a press.
[18] - Install inner race (15), bearing (16), inner race (17), O-ring (10), and housing (12).
[19] - Install retainer plate (18) and cap screws (19).

Input Shaft Retainer Cap Screw Torque 88 N˙m
65 lb-ft
[21] - Install thrust bearing (7).
[22] - Heat inner race of bearing (6) to 85°C (185°F) and install input shaft (11).
[23] - Install bearing (4), O-ring (5), housing (3), and cap screws (2).

[24] - Apply flexible form-in-place gasket to outer circumference of seal (1) and install seal.
Number Name Use

• TY6304 (us)
• TY9484 (canadian) Flexible Form-In-Place Gasket To retain input shaft seal in input shaft front bearing housing.

Idler Shaft Disassemble and Assemble

[1] -
Idler Shaft Assembly

LEGEND:
1 Housing (2 used)
2 Bearing (2 used)
3 Inner Race
4 Shaft
5 Inner Race
Use a puller to remove inner bearing races (3 and 5) from shaft (4).
[2] - Use a puller to remove bearings (2) from housings (1).
[4] - Heat housings (1) to 85 °C (185 °F). Install bearings (2).
[5] - Heat inner bearing races (3 and 5) to 85 °C (185 °F). Install bearing races on shaft (4).

Rear Output Shaft Disassemble and Assemble

[1] -
Rear Output Shaft Assembly

LEGEND:
1 Bearing
2 Rear Output Shaft
3 Inner Race
4 Snap Ring
5 Bearing
6 Rear Bearing Housing
7 Inner Race
8 Seal
9 Yoke
11 Retainer
12 O-Ring
Remove yoke (9) and seal (8).
[2] - Support rear bearing housing (6) with yoke-side up and tap rear output shaft (2) with soft-faced hammer to remove race
(7) and shaft (2).
[3] - Remove snap ring (4) and remove bearing (5) with press.
[4] - Clean, inspect, and replace parts as needed.
[5] - Heat housing (6) to 85 °C (185 °F). Install bearings (1 and 5) and snap ring (4).
[6] - Heat inner race (3) to 85 °C (185 °F). Use press to push inner race (3) on rear output shaft (2) tight to shoulder.
[7] - Install rear output shaft (2) in housing (6).
[8] - Heat inner race (7) to 85 °C (185 °F). Install inner race.
[9] -

→NOTE:
Allow parts to cool before proceeding.
Apply a thin layer of petroleum jelly to lip of seal (8). Apply flexible form-in-place gasket to outside diameter of seal (8). Install
seal.
Number Name Use

• PM38657 (us)
• PM38657 (canadian) Flexible Form-In-Place Gasket Apply to outer diameter of seal.

Planetary Gear Disassemble and Assemble

[1] -
Output Gear
LEGEND:
1 Snap Ring
2 Bearing
3 Cover
4 Output Gear
Remove snap ring (1). Press output gear (4) from cover (3).
[2] - Press bearing (2) from cover.
[3] -

Planetary Assembly
LEGEND:
2 Carrier
3 Thrust Washer
4 Bushing
5 Sun Gear
6 Thrust Washer
7 Spring Pin (3 used)
8 Ring Gear
9 Thrust Washer
10 Inner Race
11 Output Gear
12 Shaft (3 used)
13 Wear Washer (6 used)
14 Spacer (3 used)
16 Needle Roller (144 used)
17 Planetary Gear (3 used)
Remove cap screws (1) and output gear (11).
[4] - Remove and inspect parts (3 10).
[5] - Remove snap rings (15). Using a press, remove shafts (12).
[6] - Remove planetary gears (17), needle rollers (16), spacers (14) and wear washers (13).
[8] -
IMPORTANT:
Planetary Gears (17) are a matched set, replace all gears when replacing damaged gears.
Apply petroleum jelly to planetary gears (17). Install needle rollers (16), spacer (14) and wear washer (13).
[9] - Heat carrier (2) to 75 °C (167 °F). Put shafts (12) in freezer.
[10] - Position planetary gear and roller assembly with guide pin.
[11] - Press shaft (12) into position with oil hole toward outer edge of planetary housing (2).
[12] - Install snap rings (15) with open end toward outer edge of planetary housing.
[13] - Check to ensure planetary gears rotate freely.
[14] - Apply low air pressure to oil hole in pins to remove petroleum jelly from oil passage.
[15] - Replace bushing (4) if worn or damaged. Install new bushing flush with inner face of carrier.
[16] - Check height of spring pins (7).

Planetary Thrust Washer Locating Spring Pin—Maximum Height 1.3 ± 0.2 mm
0.051 ± 0.008 in.
[17] -
→NOTE:
Metal face of thrust washer (3) must face planetary carrier (2). Metal face of thrust washer (6) must face
ring gear (8). Metal face of thrust washer (9) must face output gear (11).
Apply a thin layer of petroleum jelly to thrust washer (3, 6, and 9) and install with metal face towards planetary carrier, ring
gear, and output gear.
[18] - Install sun gear (5) in carrier (2).

Sun Gear-to-Planetary Gear Backlash 0.154—0.234 mm
0.006—0.009 in.
[19] - Install ring gear (8) on planetary carrier (2). Check for free rotation of planetary gear set.
Planetary Gear-to-Ring Gear Backlash 0.199—0.328 mm
0.008—0.013 in.
[20] - Install output gear (11) on carrier assembly with two equally spaced cap screws without thread lock. Tighten cap screws
to initial torque.
Output Gear Cap Screw—Initial Torque 80 N˙m
59 lb-ft
[21] - Check to ensure planetary gear set rotates freely.
[22] - Apply medium strength threadlock and sealer to cap screws. Torque to specification.
Number Name Use

• PM37418 (us)
Thread Lock and Sealer (Medium Used to lock and seal various cap screws and components
• PM37418 (canadian)
Strength) in transfer case.
Output Gear Cap Screw—Final Torque 156 N˙m
115 lb-ft
[23] -

Bearing
LEGEND:
1 Bearing
2 Cover
Heat bearing cover (2) to 85 °C (185 °F).
[24] - Install bearing (1).
[25] -

Planetary
LEGEND:
3 O-Ring
4 Snap Ring
5 Cover
6 Planetary Housing and Output Gear
7 Bearing
8 O-Ring
Heat inner race of bearing (7) to 85 °C (185 °F). Install bearing and cover on planetary assembly (6). Allow to cool. Install snap
ring (4).
[26] - Install O-rings (3 and 8) in front output housing (2).

Transfer Case Assemble

[1] -
→NOTE:
It is critical to keep housing and components dry and clean from any contaminants during the assembly
procedure. Do not allow any sealants, grease, or any other contaminants on component mounting
surfaces.
Clean transfer case housing thoroughly.
[2] - Inspect transfer case mounting surfaces for flatness and cracks at bolt holes. Remove any nicks or sharp edges using an
oil stone.
[3] - Install plugs with new copper washers and tighten to specification.
Transfer Case Filler Plugs Torque 50 N˙m
37 lb-ft.
[4] -

Input Gear
LEGEND:
1 Input Gear
2 Housing
Install input gear (1) through bottom of housing (2), with ground face towards housing. Secure gear and rotate housing 180 .
[5] -
IMPORTANT:
Input shaft (7) and input gear (5) must be keep clean during assembly.
Input Shaft Assembly

LEGEND:
2 Input Shaft Housing
3 O-Ring (3 used)
5 Input Gear
6 O-Ring
7 Input Shaft
8 Cover
Apply a thin layer of petroleum jelly to O-rings (3 and 6) and install.
[6] - Position input gear (5).
[7] - Install two guide pins in input shaft (7) and two guide pins in housing (10).
[8] -
→NOTE:
Mating surfaces of housing and input shaft must remain dry and clean.
Heat transfer case housing (10) at input shaft opening to 85 °C (185 °F).
[9] -
IMPORTANT:
Openings in transfer case (10) and idler shaft bearing housings (2) must match for proper oil flow to
bearings.
Install input shaft (7) and rear housing (2) matching openings in transfer case (1) and rear housing (2).
[10] - Install cover (8). Tighten cap screws (9) to specification.

Input Shaft Housing and Cover Cap Screw Torque 54 N˙m
40 lb-ft
[11] - Rotate housing in stand 180 so front of housing is up.
[12] - Install O-ring (6).
[13] -
IMPORTANT:
Mating surfaces between gear and input shaft must be dry and clean of foreign material or damage may
occur.
Hold input shaft and gear secure.
[14] - Tighten three equally spaced cap screws (4) alternately in equal increments.
Input Gear Cap Screw Torque 340 N˙m
251 lb-ft
[15] - Apply Loctite ™ PM37509 Cure Primer and Loctite ™ PM37418 Medium Strength Thread Locker and install remaining cap
screws and tighten.
Number Name Use

• PM37509 (us)
• PM37509 (canadian) Cure Primer Apply to input gear cap screws.
• PM37418 (us)
• PM37418 (canadian) Medium Strength Thread Locker Apply to input gear cap screws.
251 lb-ft
[16] - Remove the three cap screws (4) installed in previous steps.

[17] - Apply Loctite ™ PM37509 Cure Primer and Loctite ™ PM37418 Medium Strength Thread Locker to the three cap screws
and tighten.
Number Name Use

• PM37509 (us)
• PM37418 (us)
• PM37418 (canadian) Medium Strength Thread Locker Apply to input gear cap screws.
251 lb-ft
[18] - Measure axial clearance of bearing at input shaft (4).

Input Shaft Bearing—Wobble Axial Runout 0.4—1.2 mm
0.016—0.047 in.
[19] - Install two guide pins in housing (10). Install front bearing housing (2) matching openings in housing and transfer case.
Input Shaft Housing and Cover Torque 54 N˙m
40 lb-ft
[20] -

Idler Gear
LEGEND:
1 Idler Gear
2 Housing
Install idler gear (1), with machined surface of gear towards housing through bottom of housing (2). Slide gear to position and
secure.
[21] -
IMPORTANT:
Housing (12) and idler shaft bearing housing (5 and 9) mounting surfaces must be kept clean.

Idler Shaft Assembly

LEGEND:
2 Cover
3 O-Ring (2 used)
5 Front Housing
7 O-Ring
8 Idler Gear
9 Rear Idler Shaft Bearing Housing
10 Idler Shaft
11 O-Ring
Apply a thin layer of petroleum jelly to O-ring (11) and install on idler housing (9).
[22] - Install guide pins to idler shaft (10) and to housing (12).
[23] -
IMPORTANT:
bearings.
Install idler shaft (10) and bearing housing (9) matching openings in transfer case (12) and housing (9).
[24] - Remove guide pins and install cap screws (4) hand tight at this time.
[25] - Rotate housing 180 degrees in stand so front of housing is up.

[26] -
IMPORTANT:
Clean foreign material from contacting parts and assure that input gear is seated evenly on input shaft or
damage may occur.
Remove guide pins from input shaft.
[27] - Clean threads of cap screws (6) and apply Loctite ™ PM37509 Cure Primer.
Number Name Use

• PM37509 (us)
[28] - Apply one drop of Loctite ™ PM37418 Medium Strength Thread Lock on three of the cap screws (6). Tighten alternately
in equal increments to specification.
Idler Gear Cap Screw Torque 156 N˙m
115 lb-ft
Number Name Use

• PM37418 (us)
• PM37418 (canadian) Medium Strength Thread Locker Apply to three input gear cap screws.
[29] - Apply one drop of Loctite ™ PM37418 Medium Strength Thread Lock to remaining cap screws (6) and tighten to
specification.
Idler Gear Cap Screw Torque 156 N˙m
115 lb-ft
Number Name Use

• PM37418 (us)
• PM37418 (canadian) Medium Strength Thread Locker Apply to nine input gear cap screws.
[30] - Measure axial clearance of bearing at idler shaft (10).

Idler Shaft Bearing—Wobble Axial Runout 0.4—1.2 mm
0.016—0.047 in.
[31] - Apply a thin layer of petroleum jelly to O-ring (7) and install on idler housing (5).
[32] -
IMPORTANT:
bearings.
Use guide pins to install idler shaft bearing housing (5). Make sure to match openings in transfer case (12) and housing (5).
[33] - Remove guide pins from idler shaft bearing.
[34] - Apply one drop of Loctite ™ PM37418 Medium Strength Thread Lock on cap screws (4). Tighten alternately in equal
increments to specification.
Idler Shaft Housing Cap Screw Torque 54 N˙m
40 lb-ft

Number Name Use

• PM37418 (us)
• PM37418 (canadian) Medium Strength Thread Locker Apply to nine input gear cap screws.
[35] - Install O-ring (3) and cover (2). Tighten to specification.

Idler Shaft Housing Cover Cap Screw Torque 88 N˙m
65 lb-ft
[36] - Rotate housing 180 degrees in stand so back of housing is up.

Idler Shaft Housing Cap Screw Torque 54 N˙m
40 lb-ft
[38] - Install O-ring (3) and cover (2). Tighten to specification.

Idler Shaft Housing Cover Cap Screw Torque 88 N˙m
65 lb-ft
[39] - Check backlash between input gear and idler gear.

Input Gear to Idler Gear Backlash 0.25—0.42 mm
0.010—0.017 in
[40] -

Shaft
LEGEND:
2 O-Ring
3 O-Ring
4 Rear Output Housing
Apply a thin layer of petroleum jelly to O-rings (2 and 3). Position O-ring (2) on rear output housing (4) and O-ring (3) on
transfer case housing (1).
[41] - Using two guide pins install rear output housing (1).
Rear Output Housing Cap Screw Torque 54 N˙m
40 lb-ft
[42] - Rotate housing 180 degrees in stand so front of housing is up.
[43] -

Clutch Assembly
LEGEND:
2 Front Output Assembly
3 Inner Race
4 O-Ring
If not previously installed heat inner race (3) to 85 °C (185 °F). Install inner race on front output assembly (2).
[44] -
→NOTE:
Keep mating surfaces dry and clean.
Apply a thin layer of petroleum jelly to O-ring (4) and install.
[45] - Using guide pins, install front output assembly.

Front Output Assembly Cap Screw Torque 54 N˙m
40 lb-ft
[46] - Check backlash between idler gear and output gear.

Output Gear-to-Idler Gear Backlash 0.25—0.42 mm
0.010—0.017 in.
[47] -

Input Flange and Output Yokes

LEGEND:
2 Retainer Plate (3 used)
3 O-Ring (3 used)
4 Yoke (2 used)
5 Mud Shield (2 used)
6 Seal (2 used)
8 Input Shaft Flange
9 Seal
10 Input Shaft
If removed press mud shield (5) onto yoke (4).
[48] - If not previously installed, apply Loctite ™ PM38657 Flexible Form-In-Place Gasket to outer surface of seals (6 and 9) and
press into housing.
Number Name Use

• PM38657 (us)
• PM38657 (canadian) Flexible Form-In-Place Gasket Input flange and output yoke seals.
[49] - Apply Loctite ™ NEVER-SEEZ compound to O-rings (3), splines of yokes (4), and flange (8).
Number Name Use

• PM37617 (us)
• PM37617 (canadian) NEVER-SEEZ ™ Anti-Seize Lubricant Apply to splines and O-rings of yokes and input flange.
• NA LOCTITE ™ (loctite)
[50] - Apply Loctite ™ Cure Primer and Loctite ™ Medium Strength Thread Locker to cap screws and install yokes (4) and input
flange (8).

Number Name Use

• PM37509 (us)
• PM37509 (canadian) Cure Primer Apply to cap screw threads prior to thread lock.
• PM37418 (us)
• PM37418 (canadian) Medium Strength Thread Locker Apply to idler shaft cap screws.
Yoke and Input Flange Cap Screw Torque 156 N˙m
115 lb-ft

Inter-axle Lock Coupler Adjustment

[1] -
LEGEND:
1 Coupler Measurement
Coupler Measurement
Rotate output yoke until teeth of slide coupler and teeth on planetary carrier are positioned to engage.
[2] - Apply air pressure to engage coupler. Coupler teeth must fully engage when air pressure is applied.
Inter-axle Lock Actuator Air Pressure 6—9.1 bar
600—910 kPa
87—132 psi
[3] -
→NOTE:
With coupler released, fork must clear housing.
Apply air pressure several times to engage teeth. Check clearances and function of fork. Check for air leaks.
[4] -
Serial Number Plate

Verify transfer case serial number serial number plate (A).
[5] - With coupler teeth fully engaged, clearance between fork rear face and coupler must be at specification. Adjust by
rotating piston with adjustable two-pin spanner wrench.
Inter-axle Lock Fork-to-Coupler (Transfer Case After S.N. 1421) Clearance (minimum) 0.1 mm
0.004 in.
Inter-axle Lock Fork-to-Coupler (Transfer Case Before S.N. 1420) Clearance (minimum) 0.2 mm
0.008 in.

STEERING SYSTEM (g) by Belgreen v2.0
[6] - With coupler disengaged, check clearance between raised tip of sliding coupler teeth and teeth on planetary carrier.
Inter-axle Lock Coupler Teeth Clearance (minimum) 0.4 mm
0.016 in.
[7] - After adjustment has been completed, remove shift fork cap screw and apply medium strength thread lock and sealer.
Tighten to specification.
Number Name Use

• PM37509 (us)
• PM37509 (canadian) Cure Primer Prepares surface for thread lock.
• PM37477 (us)
• PM37477 (canadian) Thread Lock and Sealer (Medium Strength) Prevents cap screw from working loose.
Shift Fork Cap Screw (Transfer Case After S.N.-857) Torque 30 N˙m
22 lb-ft.
Shift Fork Cap Screw (Transfer Case Before S.N.-858) Torque 18 N·m
159 lb-in.
[8] - Check secureness of fork grip on piston thread.
[9] -
→NOTE:
Check to be sure cover O-ring is in place.
Position O-ring install actuator cover.

Clutch Piston Actuating Cover Cap Screw Torque 54 N˙m
40 lb-ft
[10] - Apply flexible form-in-place gasket and install shift fork cover.
Number Name Use

• PM38655 (us)
• PM38655 (canadian) Flexible Form-In-Place Gasket To seal various components on transfer case.
Coupler Shift Fork Cover Torque 12 N˙m
106 lb-in.

Section 09 - STEERING SYSTEM

Table of contents
Group 0930 - Secondary Steering ......................................................................................................... 1
Secondary Steering Pump .................................................................................................................... 1
Group 0960 - Hydraulic System ............................................................................................................. 5
Steering Valve Remove and Install ....................................................................................................... 5
Steering Valve Disassemble and Assemble .......................................................................................... 8
Steering Cylinder (S.N. —499999) ...................................................................................................... 10
Steering Cylinder (S.N. 500000— ) ..................................................................................................... 15

Section 09 - STEERING SYSTEM Group 0930: Secondary Steering
Group 0930 - Secondary Steering

Remove and Install
[1] -
CAUTION:
Prevent personal injury from unexpected machine movement. Always install articulation locking bar
before working in the articulation joint area.
Install articulation locking bar.
[2] - Mark and disconnect lines.
[3] - Remove pump. Repair or replace as necessary.
[4] - Install pump. Connect lines as marked.
[5] -
IMPORTANT:
Secondary steering pump will be damaged if housing is not filled with oil before moving machine.
Fill pump housing with oil through drain port.
[6] - Adjust residual and compensator valves. Do Secondary Steering Pump Residual and Compensator Valves Test and
Adjustment . (See Group 9025-25.)
[1] - Clean and drain pump.
[2] - Remove anti-cavitation valve.
[3] -
Pump Regulator Valve Cross-Section

LEGEND:
1 Plug
2 Compensator Valve Spool
3 Plug
4 Residual Valve Spool
5 Pump Regulator Valve
6 Orifice
7 Spring Guide
8 Outer Spring
9 Inner Spring
10 Nut (2 used)
11 Cap (2 used)
12 Adjusting Screw
13 Plate
14 Adjusting Screw
16 Plate
17 Spring
18 Spring Guide
19 Orifice
20 O-Ring (3 used)
Remove regulator valve. Disassemble as necessary.
[4] -
IMPORTANT:
The distributor plate may stick to the port plate when removed. The highly machined surface on port
plate, distributor plate, and cylinder block must not be damaged. Lay parts on clean, lint-free towels to
protect the machine surfaces.

LEGEND:
2 Plug
4 O-Ring (3 used)
5 Snap Ring

6 Oil Seal
7 Control Rod
8 Control Piston
9 O-Ring
10 Plug
11 Plug
12 Pump Housing
13 O-Ring
14 Tapered Roller Bearing Cone and Cup
15 Drive Shaft
16 Swash Plate Bearing (2 used)
17 Spring
18 Swash Plate
19 Piston (9 used)
20 Retainer Plate
21 Guide Ball
22 Pin (3 used)
23 Cylinder Block
24 Washer
25 Spring
26 Snap Ring
27 Distributor Plate
28 Spacer
30 O-Ring
31 Dowel Pin
32 Port Plate
Remove port plate (32) and distributor plate (27).
[5] - Remove tapered roller bearing cone (29) and spacer (28).
[6] - Remove the rotary group (19—26) as an assembly.
[7] -
CAUTION:
Spring (25) is under compression. A press must be used to compress spring to remove snap ring (26).
Inspect cylinder block. Remove spring (25) only if replacement is necessary.
[8] - Remove control piston assembly (7—10)
[9] - Remove swash plate (18), drive shaft (15), spring (17), and bearings (16).
[10] - Remove tapered roller bearing cone (14) using a press. Remove bearing only if replacement is necessary.
[11] - Remove snap ring (5) and oil seal (6).
[12] - Clean and inspect all parts for wear and damage. Replace parts as necessary.
[13] -
IMPORTANT:
Replace all oil seals and O-rings. Old seals and O-rings will leak.
Install oil seal (6) with lip facing inside of housing. Press seal into housing just far enough to install snap ring.
Apply petroleum jelly to sealing lip.
[14] - Put pump housing in vise with large opening up, at approximately a 30° angle with control piston port at bottom.
[15] -

Section 09 - STEERING SYSTEM Group 0960: Hydraulic System
IMPORTANT:
Apply clean oil to all internal parts as they are assembled.
Install swash plate bearings and spring.
[16] - Install tapered roller bearing cone on drive shaft tight against shoulder. Bearing cone is a press fit.
[17] - Install drive shaft and swash plate. Position spring (17) on swash plate using a screwdriver.
[18] - Install control rod (7) by pushing the swash plate to one side and moving end of control rod in the opposite direction.
[19] - Install control piston, O-ring, and plug.
[20] - Move pump housing to a horizontal position.
[21] - Assemble rotary group (19—26). A press must be used to install spring (25).
Pins (22) are installed in cylinder block between washer (24) and guide ball (21).
[22] - Install assembled rotary group into pump housing.
[23] - Install spacer (28) and bearing cone (29).
[24] - Install O-rings (13 and 30).
[25] -
LEGEND:
1 Port Plate
2 Notch
3 Dowel Pin
Valve Plate and Port Plate

Apply a small amount of petroleum jelly on the mating surface of distributor plate and port plate (1).
Install the distributor plate on port plate so notch (2) engages the dowel pin (3).
[26] - Install port plate.
[27] - Tighten cap screws to specification using a crisscross pattern.


Port Plate-to-Pump Housing Cap Screw Torque 47 N˙m (35 lb-ft)
[28] - Install pump regulator valve.
[29] - Install anti-cavitation valve.


Steering Valve Remove and Install
[1] - Prepare Machine for Maintenance . (Operator’s Manual.)
[2] -
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. 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 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.
Discharge brake accumulator pressure by pumping service brake pedal (approximately 20 applications). Relieve hydraulic
pressure; turn steering wheel back and forth three times.
[3] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers .
(Operator’s Manual.)
[4] -
LEGEND:
2 Steering Shaft Cap Screw
Instrument Panel

Steering Shaft Coupling

Remove cap screws (1) from instrument panel.
[5] - Remove steering shaft cap screw (2) from steering shaft coupling.
[6] - See Tilt Cab . (Operator’s Manual.)
[7] -
LEGEND:
3 P Port Line
4 T Port Line
5 L Port Line
6 R Port Line
7 LS Port Line
9 Steering Valve
Steering Valve

Steering Valve
Label and disconnect lines (3—7) and close all openings using cap and plugs.
[8] - Remove cap screws (8) from mounting bracket and remove steering valve (9) from cab.
[9] - Remove cap screws (10) and separate steering valve from mounting bracket.
[10] - Repair or replace steering valve as necessary. See Steering Valve Disassemble and Assemble . (Group 0960.)
[11] - Install mounting bracket onto steering valve.
[12] -
IMPORTANT:
To prevent machine damage, ensure hydraulic steering lines are clear between cab and engine bay
before lowering.
Lower cab. See Tilt Cab . (Operator’s Manual.)
[13] -
→NOTE:
To achieve proper alignment of steering valve assembly, connect steering shaft coupling prior to securing
steering valve assembly to cab.
Install steering valve assembly. Align steering shaft coupling and install steering shaft cap screw.
[14] - Install mounting bracket cap screws.
[15] - Install cap screws to instrument panel.
[16] - Raise cab and connect lines (3—7) as marked. See Tilt Cab . (Operator’s Manual.)
[17] - Lower cab. See Tilt Cab . (Operator’s Manual.)
[18] - Check hydraulic oil level. See Check Hydraulic Oil Level . (Operator’s Manual.)
[19] - Operate machine and check for leaks.

Steering Valve Disassemble and Assemble

[1] -
Steering Valve
LEGEND:
1 Snap Ring
2 Seal
3 Retainer
4 O-Ring
5 Seal (three-piece)
6 Bearing Race
7 Thrust Bearing
8 Bearing Race
9 Spring
10 Ball (2 used)
11 Key
12 Drive Shaft
13 O-Ring (2 used)
14 Relief Valve (2 used)
15 O-Ring
16 Wear Plate
17 O-Ring
18 Gerotor Assembly
19 O-Ring
20 End Cap
22 Plug
23 Spool
Remove steering valve. See Steering Valve Remove and Install . (Group 0960.)
[2] - Clean steering valve housing.
[3] - Drain oil from housing.
[4] - Remove relief valves (14) and plug (22).
[5] - Put pump in vise with gerotor end up. Scribe a line across housing to aid in assembling.

[6] - Remove gerotor assembly parts (15—21).
[7] - Remove drive shaft (12).
[8] - Remove snap ring (1), spool (23), and parts (2—11).
[9] -
IMPORTANT:
Spool must be replaced as an assembly.
Clean and inspect parts for wear or damage. Replace as necessary.
[10] -
IMPORTANT:
Replace all seals and O-rings with new.
Apply petroleum jelly to all seals and O-rings.
Apply clean hydraulic oil to all internal parts while assembling.
Install parts (1—5) into housing.
[11] - Install bearing race (6), thrust bearing (7), and bearing race (8).
[12] - Install spool (23).
[13] - Mark splined end of drive shaft (12) to indicate position of slot on opposite end.
[14] - Install drive shaft, O-ring (15), and wear plate (16).
[15] -
IMPORTANT:
Strong steering wheel oscillation can occur if gerotor is not timed. For correct operation, the gerotor
must be installed with two opposing star roots in alignment with slot at opposite end of drive shaft.
Gerotor Timing
Install O-ring (17) and gerotor assembly (18). Gerotor star must be installed on drive shaft with two opposing star roots aligned
with indicator mark on drive shaft.
[16] - Install O-ring (19), end cap, and cap screws. Tighten cap screws in a crisscross pattern to specification.
End Cap-to-Housing Cap Screws Torque 165 N·m
120 lb-ft
[17] - Install plug (22) and relief valves (14).

Steering Cylinder (S.N. —499999)
Steering Cylinder (S.N. —499999)
Remove and Install
[1] - Install articulation safety lock bar. See Install Articulation Safety Lock Bar (Operator′s Manual Section 3-2).
[2] - Relieve hydraulic pressure. See Prepare Machine for Maintenance (Operator’s Manual Section 3-2).
[3] - Drain hydraulic reservoir. See Change Hydraulic Oil (Operator’s Manual Section 3-8).
[4] -
LEGEND:
1 MP1 Test Line
2 MP2 Test Line
3 M4 Test Line
Test Ports
For left-side steering cylinder removal, label and disconnect hydraulic control valve test lines (1—3).
[5] -

Steering Cylinder Pivots

LEGEND:
1 Front of Machine
2 Hydraulic Line—Right Turn Pressure
3 Hydraulic Line—Left Turn Pressure
5 End Plate (8 used)
6 O-Ring (8 used)
7 Cylinder-to-Frame Mount (8 used)
8 Expanding Cone (8 used)
9 V-Ring (4 used)
10 Pin (4 used)
11 Nut (4 used)
13 Washer (2 used)
14 Spacer Ring (2 used)
15 Grease Fitting (4 used)
Label grease lines and disconnect from fittings (15).
[6] - Label and disconnect hydraulic lines (2 and 3).
[7] -

CAUTION:

Steering Cylinder
Steering Cylinder Weight 95 kg (210 lb)
Attach a lifting device to cylinder.
[8] - Disassemble cylinder pivot assemblies (4—14). Lower cylinder from machine.
[10] - Raise cylinder to machine. Assemble pivot assemblies. Pack pivot assemblies with fresh grease.
[11] - Connect hydraulic lines.
[12] - Connect grease lines.
[13] - For left-side steering cylinder removal, connect hydraulic test lines.
[14] - Fill hydraulic reservoir. See Change Hydraulic Oil (Operator’s Manual Section 3-8).
[1] -
CAUTION:

Steering Cylinder
Install cylinder on a cylinder service stand such as JT30043 Cylinder Service Stand.
Cylinder Service Stand
JT30043
To disassemble and assemble hydraulic cylinders.
[2] -

Steering Cylinder
LEGEND:
1 Bushing
2 Rod
3 Barrel Nut
4 Wiper Seal
5 U-Seal
6 Rod Guide
7 O-Ring, Rod Guide Outside
8 Backup Ring
9 O-Ring, Rod Guide Inside
10 Wear Ring (2 used)
11 Piston
12 Seal
13 O-Ring, Piston Inside
14 Nut
15 Cotter Pin
16 Barrel
Unscrew barrel nut (3) from barrel (16) with spanner wrench. Remove barrel nut, rod (2), rod guide assembly (4—9), and piston
assembly (10—15) from barrel.
[3] - Remove and disassemble piston assembly.
[4] - Remove and disassemble rod guide assembly.
[5] - Remove barrel nut.
[6] - Clean, inspect, or replace parts as necessary.
[7] -

IMPORTANT:
Apply clean hydraulic oil to all rod guide and piston components during assembly.
Assemble rod guide assembly.
a. Install U-seal (5) and wiper seal (4) in rod guide (6). U-seal lip must face rod end.
b. Install outside O-ring (7) and backup ring (8) on rod guide.
c. Install inside O-ring (9) in rod guide.
[8] - Install barrel nut on rod.
[9] - Install rod guide assembly on rod.
[10] - Install seal (12) and wear rings (10) on piston (11).
[11] - Install piston on rod.
[12] - Install O-ring (13) on rod. Ensure O-ring is firmly seated on piston.
[13] - Apply rigid form-in-place gasket to threads of nut (3). Tighten nut to specification. Install cotter pin (15).
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to steering cylinder piston retaining nut.
Steering Cylinder
Piston Retaining Nut Torque 400 N˙m (295 lb-ft)
[14] - Install rod in barrel.
[15] - Apply an anti-seize lubricant to threads of barrel nut. Tighten barrel nut.
Number Name Use

• PT569 (us) NEVER-SEEZ ™ Anti-Seize Lubricant Apply to threads of rod guide for steering cylinder.

Steering Cylinder (S.N. 500000— )
Remove and Install
[1] - Install articulation safety lock bar. See Install Articulation Safety Lock Bar . (Operator′s Manual.)
[2] - Relieve hydraulic pressure. See Prepare Machine for Maintenance . (Operator’s Manual.)
[3] - Drain hydraulic reservoir. See Change Hydraulic Oil . (Operator’s Manual.)
[4] -
LEGEND:
1 MP1 Test Line
2 MP2 Test Line
3 M4 Test Line
Test Ports
For left-side steering cylinder removal, label and disconnect hydraulic control valve test lines (1—3).
[5] -

Steering Cylinder Pivots

LEGEND:
1 Front of Machine
2 Hydraulic Line—Right Turn Pressure
3 Hydraulic Line—Left Turn Pressure
5 End Plate (8 used)
6 O-Ring (8 used)
7 Cylinder-to-Frame Mount (8 used)
8 Expanding Cone (8 used)
9 V-Ring (4 used)
10 Pin (4 used)
11 Nut (4 used)
13 Washer (2 used)
14 Spacer Ring (2 used)
15 Grease Fitting (4 used)
Label grease lines and disconnect from fittings (15).
[6] - Label and disconnect hydraulic lines (2 and 3).
[7] -

CAUTION:
Steering Cylinder
Steering Cylinder Weight 95 kg
210 lb.
Attach a lifting device to cylinder.
[8] - Disassemble cylinder pivot assemblies (4—14). Lower cylinder from machine.
[10] - Raise cylinder to machine. Assemble pivot assemblies. Pack pivot assemblies with fresh grease.
[12] - Connect grease lines.
[13] - For left-side steering cylinder removal, connect hydraulic test lines.
[14] - Fill hydraulic reservoir. See Change Hydraulic Oil . (Operator’s Manual.)


LEGEND:
1 Self-Aligning Bushing
2 Snap Ring
3 Hydraulic Cylinder Barrel
4 Nut
5 Scraper Ring
6 Seal

SERVICE BRAKES (g) by Belgreen v2.0
7 Piston
8 Seal
9 Seal
10 O-Ring
11 Backup Ring
12 Snap Ring
13 O-Ring
14 Snap Ring
15 Wear Ring
16 Seal
17 Hydraulic Cylinder Rod Guide
18 Rod
19 Lubrication Fitting
20 Hydraulic Cylinder
21 Rod Seal Kit
22 Bore Seal Kit
23 O-Ring
24 Elbow Fitting
25 O-Ring
For cylinder repair procedures, see see Cylinder Identification . (CTM120519.)

Section 10 - SERVICE BRAKES

Table of contents
Group 1011 - Active Elements ............................................................................................................... 1
Service Brakes—350D .......................................................................................................................... 1
Service Brakes—400D .......................................................................................................................... 7
Group 1060 - Hydraulic System ........................................................................................................... 16
Bleed Service Brake Hydraulic System ............................................................................................... 16
Brake Accumulators ........................................................................................................................... 18
Brake Valve ........................................................................................................................................ 19
Wet Disk Brake Thermal Valve ........................................................................................................... 21
Wet Disk Brake Cooling Oil Pumps ..................................................................................................... 21
Wet Disk Brake Cooling Oil Reservoir ................................................................................................. 23
Wet Disk Brake Cooling Oil Cooler ...................................................................................................... 24

Section 10 - SERVICE BRAKES Group 1011: Active Elements

Service Brakes—350D
Remove and Install Pads
[1] -
LEGEND:
2 Retaining Plate
Brake Pad Cover

Remove wheel. See Remove and Install Wheel (Group 0110).
[2] - Remove four cap screws (1) and retaining plate (2).
[3] -
LEGEND:
1 Brake Pads
Brake Pads
Remove brake pads (1).
[4] - Repeat steps 1—3 for two lower remaining brake pads.
[5] - Retract caliper pistons.
[6] - Install brake pads.
[7] -
→NOTE:
Wear indicator plate is for upper pads only.
Install retaining plate with indicator tabs positioned over brake pads.
[8] - Repeat steps 5—7 for two lower remaining brake pads.
Remove and Install Caliper
[1] -

Service Brake Caliper

LEGEND:
1 Not Used
2 Brake Caliper
5 Cover (2 used)
6 Bleed Screw (6 used)

7 O-Ring (2 used)
8 Scraper Ring (4 used)
9 Seal (4 used)
10 Piston (4 used)
11 Boot (4 used)
12 Cover
13 Cover
15 Cap Screw
16 Rail (2 used)
17 Cover
18 Leaf Spring (2 used)
19 Brake Actuating Disk (4 used)
20 Washer (4 used)
21 Spring Washer (4 used)
25 Seal Kit
26 Kit, Piston
27 Kit, Caliper
Remove brake pads.
[2] - Disconnect brake line from caliper.
[3] - Remove cap screws (23) and lock plates (22).
[4] - Remove bolts (24).
[5] -
CAUTION:

Service Brake Caliper Weight 46 kg (100 lbs) approximate
Remove brake caliper.
[6] - Apply an anti-seize lubricant to bolts (24).
Number Name Use

• PT569 (us)
NEVER-SEEZ ™ Anti-Seize Lubricant Apply to park brake caliper bolts.
[7] - Position the bottom end of caliper on caliper bracket.
[8] - Install bottom mounting cap screw and washer, hand tighten at this time.
[9] - Align top hole of caliper with caliper bracket and install mounting bolt, hand tighten at this time.
[10] - Make sure caliper mounting surface is flush against mounting bracket.
[11] - Tighten caliper mounting bolts to specification.

Caliper Bolt Torque 900 N˙m (664 lb-ft)
[12] - Install brake pads

Disassemble and Assemble Caliper
[1] -
LEGEND:
2 Covers
Brake Caliper Piston Covers

Remove brake caliper.
[2] - Remove cap screws (1) and covers (2).
[3] -
LEGEND:
3 O-Ring (2 used)
4 Piston (4 used)
Brake Caliper Pistons

Remove O-rings (3) and push pistons (4) out of bores using hand pressure.
[4] -
LEGEND:
1 Wood Blocks
2 Piston Ports
Brake Caliper Inner Pistons

Put wood blocks (1) as shown and apply air pressure to ports (2) to remove two remaining pistons.
Wood Block Thickness 51 mm (2 in.)
[5] -

Brake Caliper
LEGEND:
1 Lip Seal
2 Square Cut Seal
3 Dust Boot Seal
Remove lip seal (1), square cut seal (2), and dust boot seal (3) from each piston bore.
[6] - Inspect, repair, and replace parts as necessary.
[7] -
IMPORTANT:
Install lip seal with lip side of seal facing pressure side of bore.
Apply a thin layer of petroleum jelly to seals (1 and 2). Install seals into piston bore.
[8] - Apply a thin layer of petroleum jelly to piston. Install piston in bore.
[9] - Install dust boot seal (3).
[10] -
LEGEND:
1 O-Ring (2 used)
Brake Caliper O-Rings

Install O-rings (1).
[11] -
LEGEND:
2 Cover
Brake Caliper Piston Covers

Install covers (2) and cap screws (1). .
[12] - Install brake caliper.
Remove and Install Brake Disk
Remove axle hub. See Axle Hubs (Group 0250).

Wet Disk Brake Exploded View

LEGEND:
1 Washer (16 used)
3 Face Seal
4 Brake Housing

5 Plug
6 Spacer
7 Separator Plate (10 used)
8 Friction Disk (8 used)
9 Piston
10 Seal (2 used)
11 Seal Spacer
12 Cover Plate (Left Front and Right Middle Axle)
13 Cover Plate (Right Front and Left Middle Axle)
Remove and Install
[1] - Remove wheel. (See Remove and Install Wheel in Group 0110.)
[2] - Drain cooling oil from wet disk brake housing.
[3] -
IMPORTANT:
DO NOT let metal face seals fall to the floor during removal of outboard planetary housing. Damage to
metal face seals will occur.
Remove outboard planetary and housing. (See Axle Outboard Planetaries in Group 0250.)
[4] -
IMPORTANT:
Store face seal set with metal sealing surfaces together. If surfaces are damaged, face seal must be
replaced as a matched set.
Remove face seal assemblies from outboard planetary and wet disk brake housings.
[5] -
CAUTION:

Wet Disk Brake Housing Weight 116 kg (255 lb)

Wet Disk Brake Housing

LEGEND:
1 Brake Housing
2 Cover Plate
Attach lifting sling and hoist to brake housing.
[6] - Remove cap screws and washers. Move brake housing (1) away from cover plate (2).
[7] - Clean and inspect all brake housing parts. Replace parts as necessary. (See Disassemble and Assemble under this
heading.)
[8] -
IMPORTANT:
Silicone gasket must not enter brake housing port holes. If port holes are blocked by gasket, damage to
wet brakes will occur.
Apply a 3.0 mm (0.125 in.) bead of RTV silicone form-in-place gasket on mounting surface of brake housing. Gasket must go
completely around every cap screw hole and port hole. Evenly spread bead around mounting surface making sure gasket does
not enter port holes.
Number Name Use

• TY16135 (us)
ULTRA BLUE ™ RTV Silicone Form-In-Place Apply to mounting surface of brake housing
• NA (canadian)
Gasket before installation.
[9] - Attach lifting sling and hoist to brake housing making sure inlet and bleeder screw ports will line up with correct holes in
cover plate.
[10] - Install two guide studs opposite one another on brake housing.
[11] - Install brake housing onto cover plate making sure port holes are correctly aligned.
[12] - Apply high strength thread lock compound to cap screws. Install cap screws and washers. Replace guide studs with cap
screws and washers. Tighten to specification.
Cover Plate-to-Brake Housing Cap Screw Torque 870 N˙m (640 lb-ft)

[13] -
IMPORTANT:
Install “Matched Set” face seals only. DO NOT mix new and used face seals.
Clean metal and rubber rings of face seal with isopropyl alcohol. If wear or damage is found, replace face seal as a matched
set. A matched set is two new rings or two used rings that have been run together.
[14] - Clean face seal bores of planetary housing and brake housing with isopropyl alcohol. Inspect bores. Remove small marks
or scratches with fine emery cloth or a fine abrasive stone. If marks or scratches cannot be removed, replace housing.
[15] -
IMPORTANT:
Face seal rubber ring and all surfaces that contact the rubber ring must be clean and dry before
installation. If these surfaces are not clean and dry, face seal will leak.
Assembled Face Seals

LEGEND:
1 Lip
2 Rubber Ring
3 Metal Ring
4 Contact Area
Install rubber ring (2) of face seal onto metal ring (3) with lip (1) facing metal ring.
[16] -
IMPORTANT:
Rubber and metal seal rings must be assembled before installing into bore.
Install assembled face seals in planetary housing and brake housing bores until rubber seal contacts bottom of bore. Apply a
light film of brake cooling oil on contact area (4) of the two metal rings.
[17] - Install outboard planetary housing. (See Axle Outboard Planetaries in Group 0250.)
[18] - Check face seal and hub seal for leakage. (See procedure under this heading.)
[19] - Install axle shaft and outboard planetary. (See Axle Outboard Planetaries in Group 0250.)

[20] - Fill brake housing and check wet disk brake cooling oil level. See Check Wet Disk Brake Cooling Oil Level—400D .
(Operator′s Manual, Section 3-4.)
[21] - Bleed wet disk brake cooling system. See Change Wet Disk Brake Cooling Oil—400D . (Operator′s Manual, Section 3-7.)
[22] - Bleed Service Brake Hydraulic System . (See procedure in Group 1060.)
[23] - Install wheel. (See Remove and Install Wheel in Group 0110.)
Face Seal and Hub Seal Leakage Check
[1] -
LEGEND:
1 Gauge
2 Male Quick Coupler
3 Shut-Off Valve
4 Adapter
5 Tee
Face Seal and Hub Seal Leakage Check

Remove brake cooling inlet and outlet lines. Close open fittings using a JT03035 7/8-14F Cap and JT03163 7/8-14M Plug.
7/8-14F Cap
JT03035
Used to check wet disk brake housing face seal and hub seal.
7/8-14M Plug
JT03163
[2] - Remove top brake housing plug. Install a 0—200 kPa (0—2 bar) (0—30 psi) gauge (1), shut-off valve (3), and air supply
male quick coupler (2) using a tee (5) and Parker No. 10-1/4F50G Adapter (4).
Adapter
Parker No. 10-1/4F50G
[3] - Close shut-off valve. Connect a regulated air supply of 100 kPa (1 bar) (15 psi) to male quick coupler.
[4] -
→NOTE:
Rotate planetary housing a few times before doing check to ensure seals are properly seated.
Open shut-off valve to pressurize brake housing. Close shut-off valve and observe gauge for 5 minutes. If pressure drops below
100 kPa (1 bar) (15 psi), inspect and replace face seal and hub seal as necessary.
[1] -

Piston and Seals

LEGEND:
1 Piston
2 Seals
Remove piston (1) and seals (2) by prying under piston as shown.
[2] - Remove separator plates, friction disks, and spacer, maintaining stack order.
[3] -
CAUTION:
Spring force behind return spring plug. A press must be used to retain plug while removing until spring
pressure is relieved.
Return Spring Assemblies

LEGEND:
1 Press
2 Piston Return Spring Assembly (4 used)
Remove piston return spring assemblies (2). Use a press (1) to retain assembly until plug threads are completely disengaged
and spring pressure is relieved.

[4] -
IMPORTANT:
DO NOT use a cleaning solvent or solution to clean friction disks. Wipe with a lint-free shop rag and clean
brake cooling oil.
Replace all O-rings. Used O-rings will leak.
Clean and inspect all parts and replace as necessary.
[5] -
Spring Assembly
LEGEND:
1 Spring Guide (4 used)
2 O-Ring (4 used)
3 Plug (4 used)
4 Spring (4 used)
Install piston return spring assemblies. Using a press apply and keep pressure on spring assembly while turning plug (3).
Tighten plug to specification.
Piston Return Spring Assembly Torque 81-102 N˙m (60-75 lb-ft)
[6] -
→NOTE:
If friction disks and separator plates are reusable, maintain original stack order.
Inspect friction disks for wear, damage, or warpage. If any of these are found the complete stack (friction disks and separator
plates) must be replaced.
Friction Disk Thickness 4.87 mm (0.192 in.) minimum
[7] - Inspect separator plates for wear, damage, or warpage. If any of these are found the complete stack (friction disks and
separator plates) must be replaced.
Separator Plates Thickness 3.07 mm (0.121 in.) minimum
[8] - Install spacer plate in bottom of housing.

[9] -
IMPORTANT:
Apply brake cooling oil on all separator plates and friction disks before installing.
Install a separator plate against spacer plate. Make sure splines on separator plate engage splines in housing and spaces are
over return springs.
[10] - Install a friction disk against separator plate. Continue alternating separator plates and friction disks until stack is
complete. The end of the stack will be two separator plates.
[11] -
IMPORTANT:
Apply hydraulic oil to the outside diameter of the piston, housing bore and seals.
Install piston until seated on guides of return springs.
[12] -
IMPORTANT:
To prevent housing or piston damage, use DFT1222 Wet Disk Brake Piston Seal Installer to install seals
and spacer.
→NOTE:
The sealing arrangement between the piston and the housing consists of one spacer and two seals.
Inner Piston Seal

LEGEND:
1 Inner Piston Seal
Section 10 - SERVICE BRAKES Group 1060: Hydraulic System
2 Correct Seal Installation

Install inner piston seal (1) between piston and housing until contact with piston shoulder is made. Use DFT1222 Wet Disk
Brake Piston Seal Installer for correct installation (2). (See instruction to make tool in Group 9900.)
Wet Disk Brake Piston Seal Installer
DFT1222
Used to install wet disk brake piston seals and spacer.
[13] - Install spacer making sure it is seated against seal.
[14] - Install outer piston seal with rubber part of seal facing spacer. Press seal down until rubber part of seal contacts spacer.
[15] - Install brake housing. (See procedure under this heading.)
[16] - Perform piston seal leakage check. (See procedure under this heading.)
Piston Seal Leakage Check
[1] -
IMPORTANT:
Hand pump must be filled with the same oil used in hydraulic system.
LEGEND:
1 Brake Apply Inlet
Wet Disk Brake Apply Inlet

Install a JT05845 Hand Pump, 0—13 800 kpa (0—138 bar) (0—2000 psi) pressure gauge, and shut-off valve rated for 13 800
kpa (138 bar) (2000 psi) at the brake apply inlet (1) using Parker No. 6-1/4F5OG Adaptor Fitting.
Hand Pump
JT05845
Used to check wet disk brake piston seal for leakage.
Adaptor Fitting
Parker 6-1/4F5OG
Used to check wet disk brake piston seal for leakage.
[2] - Bleed air from brake piston using hand pump.
[3] - Apply 10 000 kPa (100 bar) (1450 psi) pressure to piston and close shut-off valve.
[4] - Observe pressure gauge for two minutes, If pressure drops inspect and replace piston seal as necessary. If pressure does
not drop, continue with check.
[5] - Slowly open shut-off valve and allow pressure to drop to 690 kPa (6.9 bar) (100 psi). Close shut-off valve.
[6] - Observe pressure gauge for two minutes. If pressure drops, inspect and replace piston seal as necessary.


Bleed Service Brake Hydraulic System
Calipers
[1] - Check hydraulic reservoir oil level. Add oil, if necessary.
[2] -
LEGEND:
1 Bleed Screw
Bleed Screw
Attach clear plastic hose to bleed screw (1). Put other end of hose in clear container of hydraulic oil.
[3] - Run engine at slow idle. Apply service brake.
[4] - Loosen bleed screw slowly. Allow air to bleed. Tighten bleed screw to specification when no air bubbles emerge.
Bleed Screw Torque 20-27 N˙m
(15-20 lb-ft)
[5] - Release service brake. Stop engine.
[6] - Repeat bleed procedure for all brake calipers.
Wet Disk
[1] - Check hydraulic reservoir oil level. Add oil, if necessary.
[2] -
LEGEND:
1 Bleed Screw
Bleed Screw
Attach clear plastic hose to bleed screw (1). Put other end of hose in clear container of hydraulic oil.
[3] - Run engine at slow idle. Apply service brake.
[4] - Loosen bleed screw slowly. Allow air to bleed. Tighten bleed screw to specification when no air bubbles emerge.
Bleed Screw Torque 20-27 N˙m

(15-20 lb-ft)
[5] - Release service brake. Stop engine.
[6] - Repeat bleed procedure for all brake housings.

Brake Accumulators
Remove and Install
[1] - Relieve brake accumulator pressure. Pump service brake pedal repeatedly until no oil “hiss” is heard from accumulators.
[2] -
Accumulators
LEGEND:
1 Front Brake Accumulator—350D
2 Rear Brake Accumulator—350D
3 Front Brake Accumulators—400D
4 Rear Brake Accumulators—400D
Disconnect hydraulic lines from accumulators (1—4). Close all openings with caps and plugs.
[3] - Remove accumulators from machine.
[5] - Install accumulators in machine.

Brake Valve
Remove and Install
[1] - Relieve brake accumulator pressure. Pump service brake pedal repeatedly until no oil “hiss” is heard from accumulators.
[2] -
→NOTE:
(S.N. — 200535) machines use a pressure switch located in a pressure line and (S.N. 200536 — ) machines
use a proximity switch located on the brake pedal bracket.
LEGEND:
2 Sensor
3 Brake Valve
(S.N. — 200535) Shown

Disconnect wire leads from sensor (2).
[3] - Disconnect hydraulic lines. Close all openings with caps and plugs.
[5] - Remove brake valve (3).
[6] - Inspect, repair, or replace parts as necessary.
[7] - Install brake valve.
[8] - Install cap screws.
[9] - Install hydraulic lines.
[10] - Install wire leads on sensor.
[1] -

Brake Valve and Pedal Assembly

LEGEND:
1 Piston
2 O-Ring
3 Rear Cap
4 Cap Screw
5 Dust Cover
6 O-Ring
7 Spring
8 Spring
9 Spring Retainer
10 Piston
11 Rear Housing
12 O-Ring
13 Screw (2 used)
14 Front Housing
15 Piston
16 Spring
17 O-Ring
18 Front Plug
Clean brake valve housing before disassembling.
[2] - Remove parts (1—18).
[3] - Inspect all parts for wear or damage. Replace parts as necessary.
[4] -
IMPORTANT:
Replace all O-rings. Used O-rings will leak.
Apply clean hydraulic oil to all internal parts before assembling.
→NOTE:
To ease assembly, tighten rear cap and front plug after all valve parts are installed.
Assemble parts (1—18).

Wet Disk Brake Thermal Valve

Remove and Install
[1] - Relieve hydraulic pressure. See Prepare Machine for Maintenance (Operator′s Manual, Section 3-2).
[2] -
Thermal Valve
LEGEND:
1 Thermal Valve
Disconnect brake cooling oil lines and hydraulic lines from thermal valve (1). Close all openings with caps and plugs.
[3] - Remove thermal valve.
[5] - Install thermal valve.
[6] - Connect hydraulic lines and brake cooling oil lines.

Wet Disk Brake Cooling Oil Pumps

Remove and Install
[1] - Drain wet disk brake cooling oil reservoir. See Change Wet Disk Brake Cooling Oil—400D (Operator′s Manual, Section 3-7).
[3] -
LEGEND:
2 Wet Disk Brake Cooling Oil Pumps
3 Front Axle Pump Inlet Line
4 Middle Axle Pump Inlet Line
5 Front Axle Pump Outlet Line
6 Middle Axle Pump Outlet Line
7 Pump Mounting Bracket
Wet Disk Brake Cooling Oil Pumps
Pump Mounting Bracket

Remove cap screws (8) from bracket (7).
[4] - Label and disconnect inlet lines (3 and 4) and outlet lines (5 and 6). Close all openings with caps and plugs.
[5] - Remove socket head cap screws (1), bracket, and pumps (2).
[6] - Clean, repair, or replace parts as necessary.
[7] - Install pumps, bracket, and socket head cap screws.
[8] - Connect inlet lines and outlet lines.
[9] - Install cap screws in bracket.
[10] - Fill wet disk brake cooling oil reservoir. See Change Wet Disk Brake Cooling Oil—400D (Operator′s Manual, Section 3-7).

Wet Disk Brake Cooling Oil Reservoir

Remove and Install
[1] - Drain brake cooling oil reservoir. See Change Wet Disk Brake Cooling Oil—400D (Operator′s Manual, Section 3-7).
[2] -
LEGEND:
1 Outer Exhaust Shield
Outer Exhaust Shield

Remove outer exhaust shield (1).
[3] - Disconnect hydraulic lines from brake cooling oil reservoir. Close all openings with caps and plugs.
[4] -
LEGEND:
2 Hydraulic Lines Clamp
3 Support Bracket
Hydraulic Lines Clamp and Support Bracket

Remove cap screws, lock nuts, and dump body hydraulic lines clamp (2) from support bracket (3).
[5] -
LEGEND:
4 Wet Disk Brake Cooling Oil Reservoir
5 Muffler
Wet Disk Brake Cooling Oil Reservoir

Remove cap screws securing brake cooling oil reservoir (4) to muffler (5), machine frame and dump body heater pipe, if
equipped.
[6] - Remove brake cooling oil reservoir, using a proper lifting device.
[7] - Install brake cooling oil reservoir to muffler, machine frame and dump body heater pipe, if equipped.

PARK BRAKE (g) by Belgreen v2.0
[8] - Install dump body hydraulic lines clamp, cap screws, and lock nuts to support bracket.
[9] - Connect hydraulic lines to brake cooling oil reservoir.
[10] - Install outer exhaust shield.
[11] - Fill brake cooling oil reservoir. See Change Wet Disk Brake Cooling Oil—400D (Operator′s Manual, Section 3-7).
Wet Disk Brake Cooling Oil Cooler

Remove and Install
[1] - Remove top cover and right side grille from transmission oil cooler housing.
[2] -
LEGEND:
2 Wet Disk Brake Oil Cooler
Wet Disk Brake Oil Cooler

Disconnect lines from brake oil cooler (2). Close all openings with caps and plugs.
[3] - Remove cap screws (1) and brake oil cooler.
[4] - Install brake oil cooler.
[5] - Connect lines to brake oil cooler.
[6] - Install right side grille and top cover to transmission oil cooler housing.

Section 11 - PARK BRAKE

Table of contents
Group 1111 - Active Elements ............................................................................................................... 1
Park Brake ............................................................................................................................................ 1

Section 11 - PARK BRAKE Group 1111: Active Elements

Park Brake
Remove and Install Pads
[1] - Install dump body prop. Install wheel chocks. Relieve pneumatic pressure. See Prepare Machine for Maintenance
(Operator′s Manual Section 3-2).
[2] - Release the park brake. See Mechanically Releasing Park Brake (Operator′s Manual Section 2-2).
[3] -
LEGEND:
1 Backing Plate (2 used)
2 Brake Pad (2 used)
3 Retaining Clip (2 used)
Brake Pads
Move retaining bar aside. Remove brake pads (2).
[4] - Remove backing plates (1) from calipers.
[5] - Remove retaining clips (3) from pads.
[7] -

Adjusting Screw with Key Wrench

Remove plug and washer from socket head adjustment screw. Turn socket head adjustment screw counterclockwise until
resistance is felt. A “clicking” sound is heard as adjusting screw is turned.
[8] - Install retaining clips on pads. Install backing plates. Install pads. Install retaining bar.
[9] - Apply park brake. See Mechanically Releasing Park Brake (Operator′s Manual Section 2-2).
[10] - Turn socket head adjustment screw clockwise until resistance is felt. Turn counterclockwise to specification. Install
washer and plug over socket head adjustment screw.
Adjusting Screw Initial Rotation Clockwise until resistance is felt
Final Rotation Counterclockwise 7 clicks
[11] - Measure actuator rod travel.
a. Start engine. Allow air system to increase to normal operating pressure.

LEGEND:
A Actuator Flange-to-Clevis Pin Distance
b.
Measurement Location
Release park brake. Measure from bottom of park brake actuator to center of clevis on actuator rod. Record
measurement.
c. Apply park brake. Measure from bottom of park brake actuator to center of clevis on actuator rod. Record measurement.
d. Subtract smallest measurement from largest measurement to get actuator rod travel.
e. Compare actuator rod travel to specification.
Actuator Rod Travel Distance 50.8 mm (2.0 in.) maximum
[12] - If actuator rod travel is greater than specification, pneumatically release and apply park brake 20 times to help seat
parts. Repeat actuator rod travel measurements. If travel is still greater than specification, actuator has failed and must be
replaced.
Remove and Install Caliper
[2] - Remove park brake pads.
[3] -

LEGEND:
1 Air Line
Caliper Removal
Disconnect air line (1) from actuator.
[4] -
CAUTION:
→NOTE:
Write down the number of shims (3) removed from each side of caliper mount.
Remove cap screws and washers (2) and shims.
[5] - Remove caliper from machine.
[7] - Install caliper in machine.
[8] -
Park Brake Caliper and Disk

FRAME AND SUPPORTING STRUCTURE (g) by Belgreen v2.0
Shim until the park brake disk is centered. Install cap screws and washers.
[9] - Attach air line.
Remove and Install Disk
[2] - Remove park brake pads.
[3] -
CAUTION:
Components are heavy. Use lifting devices.
Support park brake disk with lifting device. Support oscillation tube-to-middle axle drive shaft with hoist. Disconnect front cross
and bearing assembly from park brake disk and yoke. See Drive Shafts (Group 0225).
[4] - Remove park brake disk from machine.
[5] - Install park brake disk in machine.
[6] - Connect cross and bearing assembly. See Drive Shafts (Group 0225).
[7] - Install park brake pads.

Section 17 - FRAME AND SUPPORTING STRUCTURE

Table of contents
Group 1740 - Frame Installation ........................................................................................................... 1
Welding on Machine ............................................................................................................................. 1
Separate Front and Rear Frames .......................................................................................................... 2
Articulation Frame ................................................................................................................................ 6
Oscillation Joint Bushings Inspect ....................................................................................................... 15
Oscillation Joint ................................................................................................................................... 18

Section 17 - FRAME AND SUPPORTING STRUCTURE Group 1740: Frame Installation
Group 1740 - Frame Installation

Welding on Machine
Use caution when Welding on Machine (Operator′s Manual, Section 4-1).

Separate Front and Rear Frames

[1] - Raise dump body and Install Dump Body Prop (Operator′s Manual, Section 3-2).
[2] - Relieve hydraulic pressure. Install wheel chocks at front and rear of front wheels. See Prepare Machine for Maintenance
(Operator′s Manual, Section 3-2).
[3] - Relieve Pneumatic Pressure (Operator′s Manual, Section 3-2).
[4] - Disconnect electrical harness at articulation joint.
[5] - Label and disconnect air and hydraulic hoses at articulation joint.
[6] - Remove park brake-to-middle axle drive shaft. See Drive Shafts (Group 0225).
[7] - Remove park brake pads, caliper, and disk. See Park Brake (Group 1111).
[8] -
LEGEND:
1 DFT1185 Support (2 used)
Supports
Support front of machine, using DFT1185 Supports (1).
Support
DFT1185
Support front of machine.
[9] -
CAUTION:
Machine may tip backwards when separated.

Jack Stands
Support rear of front half of machine with 10-ton floor stands.
[10] -

Oscillation Joint
LEGEND:
1 Inner Oscillation Tube
2 Seal (2 used)
3 O-Ring (2 used)
4 Bushing (2 used)
5 Oscillation Joint Nut
6 Lock Plate
Remove seals (2) and lock plate (6).
[11] -
CAUTION:
Component is heavy.
Separate Front and Rear Frames

Oscillation Joint Nut Weight 29 kg (63 lb)
Remove oscillation joint nut (5), using DFT1189 Spanner Wrench .

Spanner Wrench
DFT1189
Remove oscillation joint nut.

[12] - Attach an overhead hoist to front of rear half machine.
[13] -
Fork Truck
Attach a forklift to rear of machine.
[14] - Slowly pull rear half of machine away from front half.
[15] - Remove O-rings (3) from flanges of bushings (4).
[16] - Inspect, repair, and replace parts as necessary. See Oscillation Joint .
[17] - Install new O-rings (3) on bushings (4).
[18] - Use a forklift or other machine to push machine together.
[19] - Raise or lower overhead hoist to maintain alignment of inner and outer oscillation tubes as machine comes together.
[20] - Install oscillation joint nut (5) and lock plate (6).
[21] - Adjust oscillation joint end play. See Oscillation Joint .
[22] - Install seals (2).
[23] - install park brake disk, caliper, and pads. See Park Brake (Group 1111).
[24] - Install park brake-to-middle axle drive shaft. See Drive Shafts (Group 0225).
[25] - Connect air and hydraulic hoses.
[26] - Connect electrical harness.

Articulation Frame
Remove and Install
[1] - Separate Front and Rear Frames .
[2] -
CAUTION:

Articulation Frame
Articulation Frame Weight 998 kg (2200 lb)
→NOTE:
Articulation frame angle must be adjusted during removal.
LEGEND:
1 Upper Articulation Pivot Pin
2 Chain
3 Adjustable Lifting Strap
4 Lower Articulation Pivot Pin
5 Steering Cylinder Pin (2 used)
Hoist
Support articulation frame with hoist, using chains at front and adjustable lifting strap at rear.
[3] -
CAUTION:
Components are heavy. Support with chains.

Articulation Frame

Steering Cylinder
Attach chains from steering cylinders to front frame. Remove steering cylinder rod-end pins. Move rods aside. See Steering
Cylinder (Group 0960).
[4] -

Upper and Lower Articulation Sections

LEGEND:
1 Joint Seal (4 used)
3 Lower Pivot Pin
4 Shim (2 used)
5 Upper Pivot Pin
6 Cover Plate
7 Cover (3 used)
8 Retainer
9 Coupling (4 used)
10 Sleeve
11 Bearing (2 used)
12 Seal (2 used)
13 Seal (2 used)
16 Nut (12 used)
18 Washer (4 used)
19 Upper Articulation Section
20 Lower Articulation Section
Remove upper pivot pin (5) by driving downward.
[5] -
IMPORTANT:
Sleeve (10) must be removed before upper articulation joint will separate. Failure to do so will cause
damage to bearing cover or articulation joint.
Remove sleeve (10) by driving upward.
[6] - Remove lower pivot pin (3) by driving upward.
[7] - Move articulation frame away from front frame.
[9] - Apply anti-seize compound to inner bore of bushings.
Number Name Use

NEVER-SEEZ ™ Anti-Seize Lubricant Apply to articulation joint bushing inner bores.
[10] - Install upper pivot pin (5) using a hydraulic jack.
[11] - Install sleeve (10) using a brass hammer.
[12] - Install retainer (8) and cap screws (2). Do not torque at this time.
[13] - Adjust articulation joint bearings.
[14] - Install steering cylinder pins. See Steering Cylinder (Group 0960).
[15] - Assemble front and rear frames. See Separate Front and Rear Frames .
Disassemble and Assemble Upper and Lower Bearings
[1] -

Upper and Lower Articulation Sections

LEGEND:
3 Lower Pivot Pin
4 Shim (2 used)
5 Upper Pivot Pin
6 Cover Plate
7 Cover (3 used)
8 Retainer
9 Coupling (4 used)
10 Sleeve
11 Bearing (2 used)
12 Seal (2 used)
13 Seal (2 used)
16 Nut (12 used)
18 Washer (4 used)
19 Upper Articulation Section
20 Lower Articulation Section
Remove articulation frame.
[2] -
IMPORTANT:
The articulation bearing is a matched set of two bearings and a spacer. Do not mix bearings and spacers
from upper and lower joints. Bearings and spacers must be replaced as a set.
Remove bearing (11) from frame.
[4] - Install bearing (11) in frame centered in bore.
[5] -
IMPORTANT:
Seal (13) is smaller in diameter than seals (12).
For lower bearing, press seal (13) into cover plate (6) using DFT1188 Bearing Driver .
Bearing Driver
DFT1188
Install seal into Articulation Bearing Cover.
[6] - For upper bearing, press seals (12) into covers (7) using DFT1188 Bearing Driver .
Bearing Driver
DFT1188
Install seal into Articulation Bearing Cover.
[7] -
→NOTE:
One cover cap screw (14) is shorter than the rest. If new cap screws are installed, the front cap screw
must be cut off flush with the nut.

Bearing Cover Cap Screw
Articulation Joint
Install cap screws (14) and nuts (16) with shortest cap screw toward front of machine.
[8] - Measure length of front bearing cover cap screw and lock nut (A).
[9] - Measure distance between bosses (B) on frame.
[10] - Shorten cap screw and lock nut (A) so that length is less than distance (B).
[11] - Tighten cap screws (14) and nuts (16) to specification.

Articulation Frame
Bearing Cover Cap Screw Torque 163 N˙m (120 lb-ft)
[12] -
→NOTE:
Install articulation joint seal after installation of hinge articulation frame.
Install articulation joint seal (1), using coupling (9) to assemble.
Adjust Upper and Lower Bearings
[1] -

Articulation Joints
LEGEND:
3 Washer (8 used)
4 Retainer
5 Shim (2 used)
8 Cover (2 used)
9 Rear Frame
10 Lock Nut (6 used)
11 Pin
12 Front Frame
13 Bearing
14 Seal
15 Sleeve
16 Gap
Remove articulation joint seal (6) by pulling apart at coupling.
[2] - Measure gap (16) in upper and lower articulation joints.
[3] - Remove retainer (4).
[4] -
IMPORTANT:
Adding or subtracting shims from upper articulation joint will change gap.
Add or subtract shims (5) until gap measurements are equal.
[5] - Apply medium-strength thread lock and sealer to cap screws (2).
Number Name Use

• T43512 LOCTITE ™ (us) Thread Lock and Sealer (Medium Strength) Apply to upper articulation joint cap screws.

[6] - Install retainer and cap screws (2).
[7] - Apply medium-strength thread lock and sealer to cap screws (1).
Number Name Use

• T43512 LOCTITE ™ (us) Thread Lock and Sealer (Medium Strength) Apply to upper articulation joint pin cap screws.
[8] - Install cap screws and tighten to specification.

Articulation Frame
Upper Pivot Pin Cap Screws Torque 1000 N˙m (795 lb-ft)
[9] - Install articulation joint seal.

Oscillation Joint Bushings Inspect

[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
LEGEND:
1 Grease Seal
2 Oscillation Joint
3 Front of Rear Chassis
Grease Seal
Remove grease seal (1) from between oscillation joint (2) and front of rear chassis (3).
[3] - Install wheel chocks at front of rear wheels.
[4] - Remove oscillation joint drive shaft. See Oscillation Joint-to-Park Brake Drive Shaft Remove and Install . (Group 0225.)
[5] - Start engine and engage inter-axle differential lock (IDL) to ensure front axle is engaged. See Instrument Panel Functions .
(Operator′s Manual.)
[6] -
→NOTE:
Forward pressure must be applied to the oscillation joint to allow separation between the oscillation joint
bushing and oscillation frame before clearance can be checked.
Move machine forward only far enough to allow rear tires to be stopped by the wheel chocks. Stop engine.
[7] -
→NOTE:
A 0.35 mm (0.014 in.) clearance must be present between the oscillation joint bushing and oscillation
frame in order to obtain a correct oscillation joint bushing measurement.
LEGEND:
4 O-Ring
5 Oscillation Frame
6 Oscillation Joint Bushing Flange
7 Feeler Gauge
8 Oscillation Joint Nut Lock Plate
Oscillation Frame-to-Oscillation Joint Bushing Flange

Clearance

Oscillation Joint Nut Lock Plate

Move O-ring (4) to the side. Using a feeler gauge (7), measure clearance between the oscillation frame (5) and oscillation joint
bushing flange (6). Compare to specification.
Oscillation Frame-to-Oscillation Joint Bushing Clearance 0.35 mm
0.014 in.
If clearance is greater than specification: Remove oscillation joint nut lock plate (8) and tighten oscillation joint nut (9)
using DFT1189 Spanner Wrench until specification is obtained. See DFT1189 Spanner Wrench . (Group 9900.)
If clearance is less than specification: Remove oscillation joint nut lock plate (8). Loosen oscillation joint nut (9) using
DFT1189 Spanner Wrench and repeat step 6 until specification is obtained. See DFT1189 Spanner Wrench . (Group 9900.)
Spanner Wrench
DFT1189
To Remove or Install Oscillation Joint Nut
[8] - Raise bin (dump body) and install bin (dump body) prop rod. See Tilt Cab . (Operator′s Manual.)
[9] -
LEGEND:
10 Bin (Dump Body) Heater Mounting Bracket
11 Gauge
12 Top of Oscillation Joint Nut
Dial Indicator Placement

Install dial indicator to bin (dump body) heater mounting bracket (10) with gauge (11) located on the top of the oscillation joint
nut (12) as shown.
[10] - Raise bin (dump body) to the full up position. Note reading on dial indicator gauge. Lower bin (dump body) to bin (dump
body) support rod. Note reading on dial indicator gauge. Repeat this procedure 2 to 3 times to obtain accurate readings.
If reading exceeds specification, the oscillation joint bushings must be replaced. See Oscillation Joint Disassemble and
Assemble . (Group 1740.)

Oscillation Joint Bushing Play 4 mm
0.16 in.
If reading is less than specification, oscillation joint bushing flanges must be checked for correct thickness. If bushing
flange thickness is less than specification, replace bushings.
Oscillation Joint Bushing Flange Thickness 14 mm
0.55 in.
If oscillation joint bushings and flanges are within specifications, adjust oscillation joint end play. See Oscillation Joint
Repair . (Group 1740.)
[11] - Install oscillation joint drive shaft. See Oscillation Joint-to-Park Brake Drive Shaft Remove and Install . (Group 0225.)
[12] - Install grease seal between oscillation joint and front of rear chassis.
[13] - Remove wheel chocks.

Oscillation Joint
[1] - Separate Front and Rear Frames .
[2] -
Oscillation Joint
LEGEND:
2 Seal (2 used)
3 O-Ring (2 used)
4 Bushing (2 used)
6 Lock Plate
Inspect and replace parts (1—6) as necessary.
[3] -
→NOTE:
Replace one bushing at a time.

Bushing Removal
Using a rotary grinder, cut slots through bushing and drive out with a brass drift.
[4] - Clean grease and grinding residue from oscillation tube.
[5] - Install new bushing. Vent passage of front bushing must be aligned at top of tube. Vent passage of rear bushing must be
aligned at bottom of tube.
[6] -
LEGEND:
1 DFT1186 Bushing Driver (2 used)
2 Nut (2 used)
3 Threaded Rod
Bushing Installation
Assemble DFT1186 Bushing Driver (1), threaded rod (3), and nuts (2) on oscillation tube. Tighten nuts to press bushing into
bore.
Bushing Driver
DFT1186
Install oscillation joint bushing.
[7] - Press bushing flush with end of bore.
[8] - Repeat steps 3—7 for other bushing, if necessary.
[9] - Assemble front and rear frames. See Separate Front and Rear Frames .
Adjust End Play
[1] -

OPERATOR′S STATION (g) by Belgreen v2.0
Oscillation Joint
LEGEND:
2 Seal (2 used)
3 O-Ring (2 used)
4 Bushing (2 used)
6 Lock Plate
Tighten oscillation joint nut (5), using DFT1189 Spanner Wrench .
Spanner Wrench
DFT1189
Tighten oscillation joint nut.
[2] - Loosen oscillation joint nut until first set of eight holes in lock plate (6) and nut align.
[3] - Tighten lock plate cap screws to specification.

Oscillation Joint
Lock Plate Cap Screws Torque 150 N˙m (111 lb-ft)

Section 18 - OPERATOR′S STATION

Table of contents
Group 1810 - Operator Enclosure .......................................................................................................... 1
Remove and Install Cab Mounts ........................................................................................................... 1
Remove and Install Cab Tilt Pump and Cylinder ................................................................................... 2
Disassemble and Assemble Cab Tilt Cylinder (S.N. —499999) ............................................................. 4
Disassemble and Assemble Cab Tilt Cylinder (S.N. 500000— ) ............................................................ 5
Windowpanes Remove and Install ........................................................................................................ 8
Cab Door Window Installation ............................................................................................................. 10
Group 1821 - Seat and Seat Belt ......................................................................................................... 13
Operator′s Seat (SN —201517) ........................................................................................................... 13
Operator′s Seat (SN 201518— ) .......................................................................................................... 15
Group 1830 - Heating and Air Conditioning ...................................................................................... 18
Refrigerant Cautions and Proper Handling ......................................................................................... 18
R134a Refrigerant Oil Information ...................................................................................................... 19
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure ........................ 21
Recover R134a Refrigerant ................................................................................................................ 22
Flush and Purge Air Conditioner System ............................................................................................ 23
Evacuate R134a System ..................................................................................................................... 27
Charge R134a System ........................................................................................................................ 27
Remove and Install Air Conditioner Compressor ................................................................................ 28
Disassemble and Assemble Compressor Clutch ................................................................................. 30
Inspect Compressor Manifold ............................................................................................................. 32
Remove and Install Condenser ........................................................................................................... 34
Remove and Install High/Low Pressure Switch ................................................................................... 35
Remove and Install Receiver-Dryer .................................................................................................... 35
Remove and Install Expansion Valve .................................................................................................. 37
Remove and Install Heater Core and Evaporator Core ....................................................................... 39
Remove and Install Freeze Control Switch ......................................................................................... 40

Section 18 - OPERATOR′S STATION Group 1810: Operator Enclosure
Group 1810 - Operator Enclosure

Remove and Install Cab Mounts
[1] -
CAUTION:
Attach hoist to cab.
[2] -
LEGEND:
1 Rubber Mount (4 used)
Cab Mount
Remove all cap screws, washers, and nuts from rubber mounts (1) as necessary.
[3] - Lift cab slightly and remove rubber mount(s).
[4] - Install rubber mount(s).
[5] - Install all cap screws, washers, and nuts. Lower cab onto rubber mounts. Tighten cap screws and nuts.

Remove and Install Cab Tilt Pump and Cylinder

[1] -
Cab Tilt Hydraulics

LEGEND:
1 Pump
2 Support Strut
3 Line to Cylinder Head End
4 Line to Cylinder Rod End
5 Cylinder
Tilt cab. Ensure that support prop is engaged. See Tilt Cab . (Operator′s Manual.)
[2] - Turn pump valve lever clockwise to “Float” position to relieve hydraulic pressure.
[3] - Remove pump, if necessary. Remove lines, if necessary. Remove cylinder, if necessary.
[4] - Inspect, repair, and replace parts as necessary. See Disassemble and Assemble Cab Tilt Cylinder (S.N. —499999) or See
Disassemble and Assemble Cab Tilt Cylinder (S.N. 500000— ) . (Group 1810.)
[5] -
→NOTE:
Fill each component with oil during assembly, working from bottom to top.
Install cylinder, if removed. Install lines, if removed. Install pump, if removed.

[6] - Lower and raise cab several times with pump to move air pockets to top of system.
[7] - With cab lowered, remove plug from fill port on top of pump and add oil as necessary.

Disassemble and Assemble Cab Tilt Cylinder (S.N. —499999)
Cab Tilt Cylinder (S.N. —499999)
[1] -
Cab Tilt Cylinder

LEGEND:
2 Lubrication Fitting (2 used)
3 Rod
4 Nut
5 Rod Guide
6 Piston
7 Hydraulic Cylinder Barrel
8 Bushing
9 Bushing
10 Nut
11 Hydraulic Cylinder Kit
12 Cotter Pin
13 Backup Ring
14 Seal
15 Seal
16 O-Ring
17 Seal
18 O-Ring
Install cylinder in a service stand such as JT30043 Cylinder Service Stand.
JT30043
[2] - Apply rigid form-in-place gasket to threads of nut (4).

Tighten nut to specification. Install cotter pin (12).
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to the hydraulic cylinder piston-to-rod nut.
Cab Tilt Cylinder

Piston-to-Rod Nut Torque 500 N˙m (370 lb-ft)
[3] - Apply clean hydraulic oil to seals (14) and O-rings (16 and 18) before installing piston and rod guide (5) into the barrel.
[4] - Apply an anti-seize lubricant to the threads of nut (10).
Number Name Use

• PT569 (us) NEVER-SEEZ ™ Anti-Seize Lubricant Apply to threads of rod guide-to-cylinder barrel nut of cab tilt cylinder.
Disassemble and Assemble Cab Tilt Cylinder (S.N. 500000— )
Cab Tilt Cylinder (S.N. 500000— )

Cab Tilt Cylinder (S.N. 500000— )

LEGEND:
1 Bushing (2 used)
2 Rod
3 Hydraulic Cylinder
4 Seal
5 Seal
6 Snap Ring
7 O-Ring
8 Snap Ring
9 Washer
10 O-Ring
11 Hydraulic Cylinder Rod Guide
12 Wear Ring
14 Seal Kit
15 O-Ring
16 Piston Ring
17 Piston
18 Elbow
19 Nut
20 Barrel
21 Hydraulic Cylinder Rod Guide Kit
22 Cylinder Bore Seal Kit
23 O-Ring (2 used)
24 Elbow Fitting
25 O-Ring
26 Piston Kit
For cylinder repair procedures, see Cylinder Identification . (CTM120519.)

Windowpanes Remove and Install

The adhesive used to secure windowpanes is a urethane adhesive used on automobile windshields. Urethane adhesive
manufactured by Henkel Corporation or equivalent is recommended. DO NOT use any other type of adhesive. It is
recommended that an auto glass dealer install windowpanes.
IMPORTANT:
Avoid personal injury. Follow manufacturer’s instructions for using activator, primer and adhesive.
Urethane adhesive manufactured by Henkel Corporation or equivalent is recommended. DO NOT use any
other type of adhesive
IMPORTANT:
Windowpanes must include an ultraviolet barrier around edge to prevent adhesive deterioration.
Windowpanes ordered through John Deere Parts include ultraviolet barrier. If windowpane is purchased
through glass dealer, the dealer must incorporate ultraviolet barrier on the glass. DO NOT paint border of
glass.
If auto glass dealer does not install windowpanes, proceed as follows:
[1] -
Cab Windowpanes
LEGEND:
1 Cab
2 Self Adhesive Gasket (as needed)
3 Rubber Seal
4 Windowpane
5 Sliding Window
Remove windowpane (4) from cab (1).
[2] - Remove rubber seal (3).
[3] - Remove self adhesive gasket (2).
[4] - Scrape any broken glass and adhesive from cab flange.

[5] -
IMPORTANT:
Avoid windowpane damage. Adhesive will not bond to dirty surface. Lightly sand flange to clean surface.
Lightly sand flange of cab with sandpaper to clean flange surface.
[6] - Wipe cab windowpane flange to clean any dirt or dust from surface.
[7] -
IMPORTANT:
Avoid windowpane damage. Follow manufacturer’s instructions for using activator. Allow activator to dry.
Apply flex activator to cab windowpane flange using a lint free cloth. Allow flex activator to dry.
Number Name Use

Flex Activator Secure windowpane
[8] - Apply primer to the cab windowpane flange using a lint free cloth.
[9] - Install TT208103 self adhesive gasket (2) to the edge of the cab windowpane flange.
Number Name Use

• TT208103 (us) Self Adhesive Gasket Secure windowpane
[10] - Apply flex activator to edge of the windowpane (4) using a lint free cloth. Allow flex activator to dry.
[11] - Install the rubber seal (3) on windowpane (4).
[12] -
IMPORTANT:
Avoid windowpane damage. Follow manufacturer’s instructions for using adhesive. Allow adhesive to
cure before operating machine.
Apply a bead of adhesive on the windowpane edge.

Adhesive Bead Size 6 mm
0.25 in.
Number Name Use

Urethane Adhesive Secure windowpane
[13] - Position windowpane in cab frame. Use hand pressure to force windowpane down until edges are even with frame.
[14] -
IMPORTANT:
Avoid windowpane damage. Allow adhesive to cure for 8 hours before operating machine.
Secure windowpane with duct tape or tie straps and wood blocks around cab to hold and maintain windowpane position until
adhesive cures. Allow adhesive to cure for 8 hours before operating machine.

Cab Door Window Installation

[1] - Wipe window flange with ethanol (ethyl alcohol) or isopropyl alcohol (isopropanol) using a clean dry cloth. Allow to dry for
5 minutes.
[2] - Apply Terostat ™ 8519P All-in-One Primer to frame flange with wipe-on wipe-off method and allow to dry for a minimum of
10 minutes or a maximum of 2 hours.
[3] - Wipe door flange with ethanol (ethyl alcohol) or isopropyl alcohol (isopropanol). Allow to dry for 5 minutes.
[4] - Apply Terostat® 8519P All-in-One Primer to frame flange with wipe-on wipe-off method and allow to dry for a minimum of
10 minutes or a maximum of 2 hours.
[5] - Using a clean dry cloth, apply Terostat® 8519P All-in-One Primer to F/Glass Flange. Allow to dry for a minimum of 20
minutes or a maximum of 24 hours.
[6] -
Fitting Gasket Roll Stock

Fit gasket roll stock around entire door opening as shown.
[7] -
→NOTE:
Ensure that quantity of Terostat® 9096PL Primerless DGX in gun is sufficient to complete task.
Applying Terostat® 9096PL Primerless DGX to Window Frame

Applying Terostat® 9096PL Primerless DGX to Door Opening

Apply Terostat® 9096PL Primerless DGX using application gun around window frame and around door opening as shown.
[8] -
Fitting Window To Door

Fit window to door starting at the bottom (as shown) and finishing at the top.
[9] - Apply some force to window frame ensuring proper engagement all around door opening.
[10] -
Sealing Around Window with Terostat® 9096PL Primerless DGX.

Section 18 - OPERATOR′S STATION Group 1821: Seat and Seat Belt
Seal around the edge of the window with Terostat® 9096PL Primerless DGX.
[11] -
Removing Excess Terostat® 9096PL Primerless DGX with Terostat® FL+.

Remove any excess Terostat® 9096PL Primerless DGX from window frame and door opening using a clean cloth and Terostat®
FL+ leaving a neat seal with no gaps as shown.
[12] -
Checking Quality of Installation

Ensure door is clean and window is fitted correctly. Allow Terostat® 9096PL Primerless DGX to cure.

Group 1821 - Seat and Seat Belt

Operator′s Seat (SN —201517)
Remove and Install Seat
LEGEND:
1 Air Supply Line
Seat Air Spring Valve
Seat Mounting Hardware
[1] - Relieve pneumatic pressure. See Relieve Pneumatic Pressure (Operator′s Manual Section 3-2).
[2] - Disconnect air supply line (1) at valve. Remove air supply line from seat at rear of boot.
[3] - Remove cap screws and washers (2).
[4] -
CAUTION:

Operator′s Seat Weight 44 kg (97 lb) approximate
Remove seat from cab.
[6] - Install seat in cab.
[7] - Install cap screws and washers.
[8] - Install air supply line through rear of boot.
[9] - Connect air supply line at valve. Ensure boot is properly attached.

Remove and Install Air Spring

LEGEND:
1 Screw
2 Air Line
3 Fitting
4 Bracket
5 Cap Screw
6 Air Spring
Bottom Screw
Air Spring
[1] - Remove seat from cab.
[2] - Operate air spring valve to relieve pneumatic pressure inside air spring.
[3] - Remove screw (1) from bottom of seat.
[4] - Disconnect air line (2) from fitting (3).
[5] - Remove the cap screw (5) and bracket (4). Remove air spring (6) from seat.
[6] - Install air spring in seat. Install bracket and cap screw.
[7] - Connect air line to fitting.
[8] - Install screw in bottom of seat.
[9] - Install seat in cab.

Operator′s Seat (SN 201518— )

[1] -
LEGEND:
1 Storage Cover
2 Air Line
3 Tether Straps
Seat and Storage Cover Removal

Remove and discard existing storage cover (1).
→NOTE:
Replacement seat interferes with storage cover.
[2] - Remove air line (2) from fitting at rear of seat.
CAUTION:
Air reservoir will be discharged after removing air line (2).
[3] - Remove cap screws holding tether straps (3) to seat base brackets.
[4] -
LEGEND:
1 Lock Nuts
Seat Removal
Remove lock nuts (1) holding seat to seat base bracket.
[5] -
LEGEND:
1 19M7868 Cap Screw (6 used)

Cap Screw Installation

Remove seat base brackets from cab floor.
[6] - Install cap screws (1) to threaded inserts in cab floor.
→NOTE:
Cap screws must protrude approximately 6 mm (0.24 in.) above cab floor.
[7] -
LEGEND:
1 Buckle
2 Belt
3 T163962 Cover
Buckle Installation
Belt Installation
Install seat belt buckle (1) to left side of AT187712 seat assembly and torque to specification.
Cap Screw Torque 50 N˙m
37 lb-ft
[8] - Install seat belt (2) to right side of AT187712 seat assembly and torque to specification.
Cap Screw Torque 50 N˙m
37 lb-ft
[9] - Install cover (3) to seat belt (2).
[10] -

Section 18 - OPERATOR′S STATION Group 1830: Heating and Air Conditioning
LEGEND:
1 19M7868 Cap Screws
2 Slot
Seat Assembly-to-Cab Floor Installation

Install seat assembly over cap screws (1) installed in cab floor.
[11] - Slide seat assembly forward to engage cap screws (1) in slots (2).

Seat Assembly Cap Screws Torque 37 N˙m
27 lb-ft
[13] -
LEGEND:
1 Supply Air Line to Seat Air Line Connector
Supply Air Line to Seat Air Line Installation

Connect supply air line to seat air line.

Group 1830 - Heating and Air Conditioning

Refrigerant Cautions and Proper Handling
CAUTION:
DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on
contact. Wear goggles, gloves and protective clothing.
If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on
affected area. Go to a physician or hospital immediately for treatment.
DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric 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 develop high
pressure which can burst the container.
Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear
gloves.
If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or
hospital immediately for treatment.
IMPORTANT:
To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning
system. Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere.
However, it is illegal to discharge any refrigerant into the atmosphere. It must be recovered using the
appropriate recovery stations.
Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings,
components or refrigerant oils.
IMPORTANT:
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause
system damage and contaminate recovery, recycling and charging station equipment. Care must be
taken to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of
system. JT02167A refrigerant test instrument should be used before any testing or repair to system is
preformed.
Prism Pro Refrigerant Identification Instrument

JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems.

R134a Refrigerant Oil Information
CAUTION:
All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22025 (R134a)
refrigerant oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury.
CAUTION:
DO NOT leave system or R134a compressor oil containers open. Refrigerant oil easily absorbs moisture.
DO NOT spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials
rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils.
IMPORTANT:
Do not add any more oil than required or maximum cooling will be reduced.
A new compressor from parts depot contains 190 ± 10 mL (6.42 ± .34 fl oz) of new oil. Oil level visible through suction port
normally is below drive shaft.
Normal operating oil level of a compressor removed from operation is 30 mL (1.0 fl oz). This level cannot be seen through
suction port of compressor.
Compressors can be divided into three categories when determining correct oil for system.
New compressor from parts depot

Used compressor removed from operation
Compressor internally washed with flushing solvent
Determining the amount of system oil prior to installation of compressor on a machine.
[1] - When complete system, lines, and components are flushed add correct amount of oil as described.
New compressor from parts depot contains amount of new oil of 190 ± 10 mL (6.42 ± .34 fl oz). System requires an
additional amount of new oil of 20 mL (1.0 fl oz) of new oil.
Refrigerant Oil Capacity

New Compressor Volume 190 ± 10 mL (6.42 ± .34 fl oz)
Air Conditioning System Additional Oil Volume 20 mL (1.0 fl oz)
Compressor Operating Oil Level Volume 30 mL (1.0 fl oz)
Used compressor removed from operation, oil drained, and system flushed requires 209.6 mL (7.1 fl oz) of new oil.

Used Compressor and System Flushed Oil Volume 209.6 mL (7.1 fl oz)
[2] - When complete system was not flushed add correct amount of oil for compressor plus amount of oil for each component
that was serviced.
New compressor from parts depot, drain and return 30 mL (1 fl oz) of oil to compressor.

New Compressor Operating Oil Level Volume Drain and return 30 mL (1 fl oz)
Used compressor removed from operation and oil drained. Add 30 mL (1 fl oz) of new oil.

Used Compressor Drained-Oil Volume 30 mL (1 fl oz)
Used compressor removed from operation, oil drained, and flushed add 39.6 mL (1.34 fl oz) of new oil.

Used Compressor-Flushed Oil Volume 39.6 mL (1.34 fl oz)
Components listed below which have been removed, drained and flushed, require removal of compressor to determine
correct oil. Use following chart as a guide for adding oil to components:

Evaporator Oil Volume 30 mL (1.0 fl oz)
Condenser Oil Volume 30 mL (1.0 fl oz)
Receiver/Dryer Oil Volume 30 mL (1.0 fl oz)
Flushed Compressor Oil Volume 60 mL (2.0 fl oz)
Hose Oil Volume 3 mL per 30 cm (0.1 fl oz per ft)
Approximate Total Length
→NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft) Approximate total length equals 600 cm (20 ft).
If any section of hose is removed and flushed or replaced, measure length of hose and use formula 3 mL per 30 cm (0.1 fl
oz per ft ) to determine correct amount of oil to be added.
Drain compressor oil into graduated container while rotating compressor shaft and record amount.
If oil drained from a compressor removed from operation is very black or amount of oil is less than 6 mL (0.2 fl oz),
perform the following and discard oil properly:
Determine if R134a leakage was detected, remove component and repair or replace component.
Remove and discard receiver/dryer.
Flush complete system with TY16134 air conditioning flushing solvent.
Number Name Use
▪ TY16134 (us) R134a Flushing Solvent Flush R134a air conditioning system.
[3] - If component is serviceable, pour flushing solvent in ports and internally wash out old oil and discard oil properly.
[4] - Install a new receiver-dryer. (See Remove and Install Receiver-Dryer in this group.)
[5] - Install required amount of TY22025 refrigerant oil in compressor.
Number Name Use

• TY22025 (us) R134a Compressor Oil (8.5 oz) Lubricate R134a air conditioning system.
[6] - Connect all components.
[7] - Evacuate and charge system. (See Evacuate R134a System and Charge R134a System in this group.)

R134a Refrigerant Recovery/Recycling and Charging Station Installation

Procedure
IMPORTANT:
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause
system damage and contaminate recovery/recycling and charging station equipment. Care must be taken
to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type and purity before recovery/recycling or charging of
system. JT02167A refrigerant test instrument should be used before any testing or repair to system is
preformed.
JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C
systems.
IMPORTANT:
Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix
refrigerant, hoses, fittings, components or refrigerant oils.
[1] - Follow refrigerant cautions and proper handling procedures. (See Refrigerant Cautions and Proper Handling in this group.)
[2] -
Charging Station Installation

LEGEND:
1 Refrigerant Recovery/Recycling and Charging Station
2 Blue Hose
3 Red Hose
4 Low Pressure Charge Port

5 High Pressure Charge Port
Close both high-side and low-side valves on refrigerant recovery/recycling and charging station (1).
HFC134a Deluxe Recovery/Recycling and Charging Station
JT02045
Used to remove refrigerant from system.
Charging Station
JT02046
[ Used with JT02050 Recovery and Recycling Station. ]
Servicing air conditioning system using R134a refrigerant.

Recovery and Recycling Station
JT02050
[ Used with JT02046 Charging Station. ]
Servicing air conditioning system using R134a refrigerant.
[3] - Remove cap from low pressure charge port (4) and connect blue hose (2).
[4] - Remove cap high pressure charge port (5) and connect red hose (3).
Recover R134a Refrigerant

IMPORTANT:
Use correct refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.
[2] - Run air conditioning system for three minutes to help in recovery process. Turn air conditioning system off before
proceeding with recovery steps.
[3] - With engine OFF identify refrigerant type using JT02167A refrigerant identification instrument.
JT02167A
[4] - Connect refrigerant recovery system. (See R134a Refrigerant Recovery/Recycling and Charging Station Installation
Procedure in this group.)
[5] - Follow manufacturer′s instructions when using refrigerant recovery/recycling and charging station.

Flush and Purge Air Conditioner System

Add flushing solvent to system with JT02075 Flusher and JT02098 Fitting Kit.
Number Name Use

R134a Flushing Solvent Flush R134a air conditioning system.
Air Conditioning Flusher

JT02075
To be used with air conditioning flushing kit.
Air Conditioning Flushing Kit
JT02098
Flush air conditioner system and adjust expansion valve.
→NOTE:
Flushing can be performed on machine.
[2] - Recover refrigerant. (See Recover R134a Refrigerant in this group.)
[3] - Add flushing solvent to system with JT02075 Flusher and JT02098 Fitting Kit.
Number Name Use

R134a Flushing Solvent Flush R134a air conditioning system.
Air Conditioning Flusher

JT02075
To be used with air conditioning flushing kit.
Air Conditioning Flushing Kit
JT02098
Flush air conditioner system and adjust expansion valve.
[4] - Remove and discard receiver-dryer. (See Remove and Install Receiver-Dryer in this group.)
[5] - Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.
Adapter
JT02102
Connect flusher outlet hose to inlet end of compressor discharge line.
[6] - Fill flusher tank with 4 L (1 gal) of solvent and fasten all connections.
Flush and Purge System

Flusher Tank Capacity 4 L (1 gal)
[7] -
→NOTE:
Air pressure must be at least 620 kPa (90 psi) (6.2 bar) for flushing and purging.

Air Pressure Minimum Pressure 620 kPa (90 psi) (6.2 bar) for flushing and purging
Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve.
[8] - Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional
flushing cycles are required if system is heavily contaminated with burned oil or metal particles.
[9] - Clean compressor as follows:
a. Remove compressor and measure oil drained from both manifold ports.
b. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.
Adapter
JT02102
c. Pour 240 mL (8 fl oz) of flushing solvent into suction port and 120 mL (4 fl oz) into discharge port. Plug both ports in
compressor manifold, using JT02099 and JT03194 Caps.
Flush A/C Compressor

Flushing Solvent in Suction Port Volume 240 mL (8 fl oz)
Flushing Solvent in Discharge Port Volume 120 mL (4 fl oz)
Cap
JT02099
To plug port in compressor manifold.
Cap
JT03194
To plug port in compressor manifold.
d. Turn compressor end for end and roll it side to side.

e. Remove both plugs from manifold ports and drain solvent from compressor.
f. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders.
g. Invert compressor. Roll end for end and side to side. Drain thoroughly.
h. Repeat previous two steps at least three times.
[10] - Divide system into two circuits:
Condenser circuit, including inlet and outlet hoses.

Evaporator circuit, including inlet and outlet hoses.
[11] - Condenser:
IMPORTANT:
DO NOT attempt to flush through compressor or receiver/dryer. Flushing through expansion valve is
acceptable if refrigerant oil has a normal odor and appearance.
Flush/Purge Condenser:
b. Remove and discard receiver/dryer.

c. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.
Adapter
JT02102
d. Fill flusher tank with 4 L (1 gal) of solvent and fasten all connections.


→NOTE:

f. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional
flushing cycles are required if system is heavily contaminated with burned oil or metal particles.
g. Attach a return hose and aerator nozzle to end of receiver/dryer inlet hose using JT03197 Adapter. Put nozzle in container
to collect flushing solvent.
Adapter
JT03197
Attach a return hose and aerator nozzle to outlet end of receiver/dryer inlet hose.
→NOTE:
Purging condenser circuit takes 10—12 minutes to thoroughly remove solvent.
Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard; continue
purging until cardboard is dry.
[12] - See flush evaporator, if evaporator requires flushing.

If system is contaminated with burned refrigerant oil or debris, remove and bench flush evaporator. See following steps to flush
evaporator through expansion valve, if oil appears normal.
[13] - Flush evaporator:
a. Remove evaporator and expansion valve. (See Remove and Install Heater Core and Evaporator Core and also Remove
and Install Expansion Valve in this group.)
b. Force flushing solvent through evaporator inlet with compressed air.
c. Purge system until dry.
d. Install evaporator and expansion valve. (See Remove and Install Heater Core and Evaporator Core and also Remove and
Install Expansion Valve in this group.)
[14] - Flush evaporator through expansion valve:
a. Connect flusher outlet hose to connection of receiver/dryer outlet hose using JT03188 Adapter.
Adapter
JT03188
Connect flusher outlet hose to connection of receiver/dryer outlet hose.
b. Fill flusher tank with 4 L (1 gal) of solvent and fasten all connections.

→NOTE:


d. Attach a hose and aerator nozzle to compressor inlet line using JT02101 Adapter. Put nozzle in a container to collect
solvent.
Adapter
JT02101
Attach a hose and aerator nozzle to compressor inlet line.
[15] -
→NOTE:
Purging evaporator circuit takes 12—15 minutes to thoroughly remove solvent.
Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard and continue purging
until cardboard is dry.
[16] - Install receiver-dryer. (See Remove and Install Receiver-Dryer in this group.)
[17] - Fasten connections and mounting bracket.
[18] - Add required oil. (See R134a Refrigerant Oil Information in this group.)
[19] - Install compressor and connect refrigerant lines to manifold.
[20] - Connect clutch coil wire and install drive belt.

Evacuate R134a System

[2] - Connect refrigerant recovery system. (See R134a Refrigerant Recovery/Recycling and Charging Station Installation
Procedure in this group.)
[3] - Open low-side and high-side valves on refrigerant recovery/recycling and charging station.
[4] - Follow manufacturer′s instructions and evacuate system.
[5] -
→NOTE:
Vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98
kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
Air Conditioning System

Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea
Evacuate System Vacuum
level
Evacuate system until low-side gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum.

Evacuate System Vacuum 98 kPa (980 mbar) (29 in. Hg)
→NOTE:
If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be obtained in 15 minutes, test system for leaks. (See
Refrigerant Leak Test in 9031-25.) Correct any leaks.
[6] - When vacuum is 98 kPa (980 mbar) (29 in. Hg), close low-side and high-side valves. Turn vacuum pump off.
[7] - If vacuum decreases more than 3.4 kPa (34 mbar) (1 in. Hg) in 5 minutes, there is a leak in system.

Evacuate System Vacuum 3.4 kPa (34 mbar) (1 in. Hg)
[8] - Repair leak.
[9] - Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached.)
[10] - Close low-side and high-side valves. Stop evacuation.
[11] - Charge system. (See Charge R134a System in this group.)
Charge R134a System

IMPORTANT:
Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix
refrigerant, hoses, fittings, components or refrigerant oils.
[2] - Identify refrigerant type using JT02167A refrigerant identification instrument.

JT02167A
[3] - Connect R134a Refrigerant Recovery/Recycling and Charging Station. (See R134a Refrigerant Recovery/Recycling and
Charging Station Installation Procedure in this group.)

[4] - Evacuate system. (See Evacuate R134a System in this group.)
[5] -
→NOTE:
Before beginning to charge air conditioning system, the following conditions must exist: Engine
STOPPED, 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 (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.

Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea
Evacuate System Vacuum
level
Follow manufacturer’s instructions and charge system.
[6] - Add 1.8 kg (3.97 lb) refrigerant to system.


Air Conditioning System Refrigerant Refrigerant Quantity 1.8 kg (3.97 lb)
[7] - Check air conditioning for proper function. (See Air Conditioning Operational Checks in 9031-25.)
Remove and Install Air Conditioner Compressor

[1] - Follow refrigerant cautions and proper handling procedures. See Refrigerant Cautions and Proper Handling .
[2] - Recover refrigerant. See Recover R134a Refrigerant .
[3] - Open hood and lower bottom guard.
[4] -
LEGEND:
1 Fan Belt
3 Discharge Port
4 Suction Port
5 Clutch Solenoid Wire Connector
Engine Shown Removed for Clarity of Photo

Remove fan belt (1) from compressor pulley. See Fan Belt (Group 0510).
[5] - Disconnect lines from suction and discharge ports (3 and 4). Close all openings using caps and plugs.
[6] - Disconnect compressor clutch solenoid wire connector (5).
[7] - Remove cap screws (2). Remove compressor.
[8] - Inspect, repair, or replace parts as necessary.
[9] - Before installing compressor, check oil. See R134a Refrigerant Oil Information .
[10] - Install compressor. Install cap screws.
[11] - Connect clutch solenoid wire connector.
[12] - Connect lines to discharge and suction ports.

[13] - Install fan belt. See Fan Belt (Group 0510).
[14] - Evacuate system. See Evacuate R134a System .
[15] - Charge system. See Charge R134a System .

Disassemble and Assemble Compressor Clutch

[2] - Remove compressor. See Remove and Install Air Conditioner Compressor .
[3] - Install compressor on D01006AA Bench Mounted Holding Fixture.

Bench Mounted Holding Fixture
D01006AA
To hold compressor during repair.
[4] - Remove dust cover.
[5] -
JDG747 Compressor Clutch Spanner
Compressor Clutch
LEGEND:
A JDG747 Compressor Clutch Spanner
B Clutch Shaft Bolt
C Clutch Hub
D Pulley Snap Ring

E Pulley
F Clutch Coil Snap Ring
G Clutch Coil
H Shims
Hold clutch hub using JDG747 Compressor Clutch Spanner (A). Remove clutch shaft bolt (B).
Compressor Clutch Spanner
JDG747
Remove compressor clutch.
[6] - Remove clutch hub (C). Remove shims (H) from clutch hub and save for installation.
[7] - Remove and discard snap ring (D). Remove pulley (E) using a plastic hammer or JDG220 Puller, JDG748 Jaws, and JDG771
Hub Protector.
Puller
JDG220
Used with 3-Jaw Puller (D01249AA, OTC 1026, or equivalent) to remove compressor pulley on John Deere air conditioning
compressors.
Jaws
JDG748
Removing compressor pulley (Used with D05277ST Puller).
Hub Protector
JDG771
Used to protect end of shaft on air conditioning when removing hub using D05277ST Hub Puller with JDG748 Jaws or 6000 and
7000-Series Tractors.
[8] - Disconnect clutch coil lead wire. Remove and discard snap ring (F) and remove clutch coil (G).
[9] -
→NOTE:
Bearing in pulley is NOT serviceable.
Check pulley bearing operation. Replace pulley and bearing as required.
[10] - Install clutch coil and new snap ring with flat side of snap ring down. Connect clutch coil lead wire.
[11] - Install pulley with new snap ring flat side down.
[12] - Apply grease to shims (H) and install in clutch hub.
[13] -

Pulley-to-Clutch Hub Clearance

Check pulley-to-clutch hub clearance using a dial indicator. Mount gauge to pulley as illustrated and connect a set of jumper
wires from compressor to a 12V battery.
[14] - Rotate pulley and check clearance in three equally spaced locations around clutch hub. Add or remove shims as
required.
Air Conditioning Compressor

Pulley-to-Clutch Hub Clearance 0.35—0.65 mm (0.014—0.026 in.)
[15] - Install clutch hub and tighten shaft bolt to specification. Install dust cover.

Clutch Hub and Shaft Bolt Torque 14 N˙m (120 lb-in.)
Inspect Compressor Manifold

[1] -
LEGEND:
1 Compressor
2 Manifold Seal
3 Manifold
5 Manifold Tube Assembly
7 Socket Head Cap Screw and Washer
Compressor Manifold Assembly

Remove manifold tube assembly (5) and seal rings (6).
[2] - Remove manifold (3) and manifold seal (2).
[4] - Lubricate and install manifold seal. Install manifold. Install seal rings. Install tube assembly. Tighten cap screws to
specification.


Manifold Cap Screws Torque 26 N˙m (19 lb-ft)

Remove and Install Condenser

[1] -
→NOTE:
It is not necessary to remove condenser to just purge and flush system. See Flush and Purge Air
Conditioner System .
Follow refrigerant cautions and proper handling procedures. See Refrigerant Cautions and Proper Handling .
[3] - Remove grille and open hood.
[4] -
Condenser
LEGEND:
1 Line to Receiver-Dryer
2 Line from Compressor
3 Condenser
4 Condenser Mount
5 Washer
6 Nut
Disconnect lines (1 and 2). Close all openings using caps and plugs.
[5] - Remove nuts and washers (5 and 6). Remove condenser (3).
[7] - Before installing condenser, add refrigerant oil. See R134a Refrigerant Oil Information .
[8] - Install condenser.
Remove and Install High/Low Pressure Switch

[1] -
→NOTE:
A valve prevents system from discharging when switch is removed.
LEGEND:
1 Wire Lead (2 used)
2 High/Low Pressure Switch
High/Low Pressure Switch

Disconnect wire leads (1) and remove pressure switch (2).
Remove and Install Receiver-Dryer

[3] -

LEGEND:
1 Receiver-Dryer
2 Clamps
3 High/Low Pressure Switch
4 Condenser-to-Receiver-Dryer Line
5 Receiver-Dryer-to-Expansion Valve Line
Receiver-Dryer
Disconnect wiring leads from high/low pressure switch (3).
[4] - Disconnect lines (4—5). Close all openings using caps and plugs.
[5] - Loosen clamps (2) to remove receiver-dryer (1).
[6] - Before installing new receiver-dryer, add refrigerant oil. See R134a Refrigerant Oil Information .
[7] - Install new receiver-dryer. Tighten clamp.
[8] - Connect wiring leads and lines.

Remove and Install Expansion Valve

[3] - Remove side panel from air conditioner box.
[4] -
A/C Components
LEGEND:
8 Expansion Valve
9 Heater Control Valve
10 Heater Core
11 Evaporator Core
12 Air Filter
13 Recirculating Damper
14 Blower
15 Floor Vent Actuator
16 Defrost Actuator
17 Freeze Control Switch
18 Relay Box
Disconnect lines and remove expansion valve (8). Close all openings using caps and plugs.
[5] - Install expansion valve and connect lines.
[6] - Install heater and air conditioner module side panel.


Remove and Install Heater Core and Evaporator Core

[1] - Remove air conditioning box from machine.
a. Follow refrigerant cautions and proper handling procedures. See Refrigerant Cautions and Proper Handling . (Group
1830.)
b. Recover refrigerant. See Recover R134a Refrigerant . (Group 1830.)
c. Drain radiator. See Drain, Flush and Refill Engine Cooling System . (Operator′s Manual.)
d. Disconnect wiring connectors and air ducts from air conditioner box.
e. Disconnect refrigerant lines, heater hoses, and drain tubes. Close all openings with caps and plugs.
f. Remove air conditioning box from right-side compartment.
[2] -
A/C Components
LEGEND:
8 Expansion Valve
9 Heater Control Valve
10 Heater Core
11 Evaporator Core
12 Air Filter
13 Recirculating Damper
14 Blower
15 Floor Vent Actuator
16 Defrost Actuator
18 Relay Box

Remove heater core (10) and evaporator core (11) from air conditioner box.
a. Remove side panel from air conditioner box.

b. Remove tray from relay box (18) and disconnect all electrical connectors. Route wiring harness out of relay box.
c. Disconnect freeze control switch (17) from top panel. Remove top panel from air conditioner box.
d. Disconnect evaporator lines from expansion valve (8). Disconnect heater hoses from heater core. Close all openings with
caps and plugs.
e. Remove heater core and evaporator core as an assembly.
f. Remove clips to disconnect evaporator core from heater core.
[4] - Install heater and evaporator cores in air conditioner box.
a. Before installing evaporator core, add refrigerant oil. See R134a Refrigerant Oil Information . (Group 1830.)
b. Install clips to connect evaporator core to heater core.
c. Install heater core and evaporator core in air conditioner box as an assembly.
d. Connect evaporator lines to expansion valve. Connect heater hoses to heater core.
e. Install top panel. Connect freeze control switch to top panel.
f. Install tray in relay box. Connect all electrical connectors.
g. Install side panel on air conditioner box.
[5] - Install air conditioner box in machine.
a. Connect air ducts. Connect electrical connectors.

b. Connect air conditioner lines, heater hoses, and drain tubes.
c. Fill radiator. See Drain, Flush and Refill Engine Cooling System . (Operator′s Manual.)
d. Evacuate system. See Evacuate R134a System . (Group 1830.)
e. Charge system. See Charge R134a System . (Group 1830.)
Remove and Install Freeze Control Switch

[1] - Remove air conditioner box from machine. See Remove and Install Heater Core and Evaporator Core .
[2] - Remove side panel from air conditioner box.
[3] -
LEGEND:
1 Evaporator Core
Freeze Control Switch

Disconnect freeze control switch (2) from top panel. Disconnect wire leads.
[4] - Disconnect top panel from air conditioner box. Lift top panel enough to remove capillary tube from evaporator core (1).

SHEET METAL AND STYLING (g) by Belgreen v2.0
[6] - Install capillary tube in evaporator core.
[7] - Connect wire leads to freeze control switch. Install top panel. Connect freeze control switch to top panel.
[8] - Install side panel.
[9] - Install air conditioner box in machine. See Remove and Install Heater Core and Evaporator Core .

Section 19 - SHEET METAL AND STYLING

Table of contents
Group 1910 - Hood or Engine Enclosure .............................................................................................. 1
Hood ..................................................................................................................................................... 1

Section 19 - SHEET METAL AND STYLING Group 1910: Hood or Engine Enclosure
Group 1910 - Hood or Engine Enclosure

Hood
Remove and Install Hood
[1] -
CAUTION:

Hood
Hood Weight 57 kg (125 lb) approximate
Open hood. Secure hood with hoist.
[2] -
Strut and Strap

Hinge
LEGEND:
1 Strut (2 used)
2 Strap (2 used)
3 Hinge (2 used)
Remove straps (2).
[3] - Remove struts (1).
[4] - Disconnect hinges (3).
[5] - Connect hinges.
[6] - Connect straps and struts.
[7] - Adjust hood latch.
Adjust Hood
[1] -
LEGEND:
1 Catch Pin Assembly
Catch Pin Assembly

Remove catch pin assembly (1) from machine. Clean catch pin and strike plate.
[2] -

Latch Linkage
LEGEND:
1 Linkage Pivot Cap Screw
2 Linkage Rod
3 Latch Arm Pivot Cap Screw
4 Latch Arm
5 Return Spring
6 Catch Pin Tube
7 Linkage Rod
8 Latch Release Lever
Adjust latch linkage.
a. Adjust linkage pivot cap screw (1) and latch arm pivot cap screw (3), if necessary. Pivots should not bind or have excess
free-play.
b. Adjust linkage rods (7 and 2) so latch release lever (8) and latch arm (4) move smoothly through full range of motion.
Ensure latch arm returns to engaged position inside catch pin tube (6) when lever is released. Replace return spring (5), if
necessary. Clean latch arm and catch pin tube.
[3] -
LEGEND:
1 Stopper (2 used)
2 Nut (2 used)
Stopper
Adjust stoppers (1) to initial setup specification.
Hood
Stopper Tip-to-Hood Lower Surface Initial Setup Distance 20 mm (0.8 in.)
[4] -
CAUTION:

Hood
Hood Weight 57 kg (125 lb) approximate

Hinge
LEGEND:
1 Support Plate (2 used)
2 Spacer (as required)
3 Hinge Pivot Cap Screw (2 used)
4 Frame-Mounted Flange (2 used)
5 Hood-Mounted Flange (2 used)
6 Hinge (2 used)
Install support plates (1), spacers (2), and hinges (6) on hood. Lift hood with hoist. Install spacers and hinges to frame. Tighten
hardware enough to eliminate gaps between contact surfaces, but ensure that flanges (4 and 5) are loose enough to allow
adjustment.
[5] -

Strut and Strap

LEGEND:
1 Strut (2 used)
2 Strap (2 used)
Install struts (1) and straps (2).
[6] -
LEGEND:
1 Hood-to-Grille Gap
Hood Left-Right Adjustment

Lower hood. Adjust hood left-to-right alignment. Hood-to-grille gaps (1) should be equal on left and right sides.
[7] - Raise hood slowly. Ensure that hood does not shift left or right. Tighten hood-mounted flanges of hinges.
[8] - Lower hood. Adjust hood front-to-rear alignment. Ensure that weather seal at hood rear edge aligns with mating surface
on front of cab. Front of hood should extend approximately 10 mm (0.4 in.) beyond front bumper surface.
[9] - Lower radiator bottom guard. Tighten frame-mounted flanges of hinges.

MAIN HYDRAULIC SYSTEM (g) by Belgreen v2.0
[10] - Raise hood. Install catch pin assembly. Tighten hardware enough to eliminate gaps between contact surfaces, but
ensure that assembly is loose enough on mounting surface to allow adjustment. Move assembly to centered position.
[11] - Lubricate latch linkage, latch arm, hinges, strike plate, and catch pin with multipurpose grease or dry graphite as
necessary.
[12] - Lower hood. Latch arm should engage catch pin.
[13] - Pull latch release lever. Latch should move smoothly with slight resistance. Latch arm should release catch pin.
[14] - Raise hood slowly. Ensure that catch pin assembly does not shift out of alignment. Tighten catch pin assembly.
[15] - Lower hood and engage latch. Examine hood-to-frame contact. Weather seal surfaces should make even contact.
Stoppers should contact frame, but not be excessively compressed.
[16] - Adjust height of catch pin and stoppers, if necessary, and recheck. Tighten nuts on catch pin and stoppers when
adjustment is complete.

Section 21 - MAIN HYDRAULIC SYSTEM

Table of contents
Main Hydraulic Pump ............................................................................................................................ 1
Hydraulic Pump Power-Takeoff (PTO) Remove and Install .................................................................... 7
Hydraulic Pump Drive Shaft ................................................................................................................ 11
Hydraulic Pump Drive Shaft Damper Coupler Disassemble, Clean, and Assemble ............................. 16
Hydraulic Reservoir ............................................................................................................................ 20
Suction Strainer .................................................................................................................................. 22
Hydraulic System Manifold Assembly ................................................................................................. 23
Hydraulic Fan Motor ........................................................................................................................... 33
Fan Drive Controller ........................................................................................................................... 36

Section 21 - MAIN HYDRAULIC SYSTEM Group 2160: Hydraulic System

Main Hydraulic Pump
Remove and Install
[1] -
LEGEND:
1 Damper Coupler
2 Cap Screw, Washers, and Stop Nut (4 used)
3 Hydraulic Pump
4 Pressure Tube
5 Suction Tube
6 Hydraulic Load Sense Line
7 Case Drain Line
8 Wet Disk Brake Cooling Oil Pump—If Equipped
Wet Disk Brake Machine Shown

Remove wet disk brake cooling oil pumps (8), if equipped. See Wet Disk Brake Cooling Oil Pumps (Group 1060).
[2] - Disconnect damper coupler (1). See Hydraulic Pump Drive Shaft (in this group).
[3] - Disconnect hydraulic load sense line (6), case drain line (7), suction tube (5), and pressure tube (4). Close all openings
using caps and plugs.
[4] -
CAUTION:

Main Hydraulic Pump

Hydraulic Pump Weight 48 kg (105 lb) approximate

LEGEND:
9 DFT1132 Removal and Installation Tool
DFT1132 Removal and Installation Tool

Attach DFT1132 Removal and Installation Tool (9) to hydraulic pump (3) with straps. Attach hoist to tool with a strap.
Removal and Installation Tool
DFT1132
Remove and install main hydraulic pump.
[5] - Remove cap screws, washers, and stop nuts (2). Remove pump from machine.
[7] - Install pump. Install cap screws, washers, and stop nuts loosely.
[8] - Install suction tube and pressure tube.
[9] - Tighten cap screws, washers, and stop nuts.
[10] - Connect damper coupler. See Hydraulic Pump Drive Shaft (in this group).
[11] - Connect hydraulic load sense line and secondary steering load sense line.
[12] - Install wet disk brake cooling oil pumps, if equipped. See Wet Disk Brake Cooling Oil Pumps (Group 1060).
The following procedure should be used for both pumps.
[1] - Clean and drain pump.
[2] -

Pump Regulator Valve Cross-Section

LEGEND:
1 Plug
2 Compensator Valve Spool
3 Plug
4 Residual Valve Spool
6 Orifice
7 Spring Guide
8 Outer Spring
9 Inner Spring
10 Nut (2 used)
11 Cap (2 used)
12 Adjusting Screw
13 Plate
14 Adjusting Screw
16 Plate
17 Spring
18 Spring Guide
19 Orifice Plug
20 O-Ring (3 used)
Remove regulator valve. Disassemble as necessary.
[3] - Remove check valve block. Inspect for wear or damage. Replace block if necessary.
[4] -
IMPORTANT:
protect the machine surfaces.
→NOTE:
The two pumps are joined together by the port plate (32) and the drive shafts are joined by the splined
coupler (34).

Main Hydraulic Pump Exploded View

LEGEND:
2 Plug
4 O-Ring (3 used)
5 Snap Ring
6 Oil Seal
7 Control Rod
8 Control Piston
9 O-Ring
10 Plug
11 Plug
12 Pump Housing
13 O-Ring
15 Drive Shaft
16 Swash Plate Bearing (2 used)
17 Spring
18 Swash Plate
19 Piston (9 used)
20 Retainer Plate
21 Guide Ball
22 Pin (3 used)
23 Cylinder Block
24 Washer
25 Spring
26 Snap Ring
28 Spacer
30 O-Ring
31 Dowel Pin
32 Port Plate
34 Splined Coupler
[6] - Remove the rotary group (19—26) as an assembly.
[7] -
CAUTION:
Inspect cylinder block. Remove spring (25) only if replacement is necessary.
[8] - Remove control piston assembly (7—10).
[9] - Remove swash plate (18), drive shaft (15), spring (17), and bearings (16).
[13] -
IMPORTANT:
Install oil seal with lip facing inside of housing. Press seal into housing just far enough to install snap ring.
[14] - Put pump housing in vise with large opening up, at approximately a 30° angle with control piston port at bottom.
[15] -
IMPORTANT:
Install swash plate bearings and spring.
[16] - Install tapered roller bearing cone on drive shaft tight against shoulder. Bearing cone is a press fit.
[17] - Install drive shaft and swash plate. Position spring (17) on swash plate using a screwdriver.
[18] - Install control rod (7) by pushing the swash plate to one side and moving end of control rod in the opposite direction.
[19] - Install control piston, O-ring, and plug.
[21] - Assemble rotary group (19—26). A press must be used to install spring (25).
[24] - Install O-rings (13 and 30).
[25] - Apply a small amount of petroleum jelly on the mating surface of distributor plate and port plate.
[26] - Install distributor plate onto port plate dowel pin.
[27] - Install splined coupler (34) if removed.

[29] - Tighten cap screws to specification using a crisscross pattern.

Main Hydraulic Pump

Port Plate-to-Pump Housing Cap Screw Torque 225 N˙m (165 lb-ft)
[30] - Install check valve block.
[31] - Install pump regulator valve.

Hydraulic Pump Power-Takeoff (PTO) Remove and Install

The hydraulic pump power-takeoff (PTO) is located in the timing gear case on rear of engine. Removal of this PTO is not
duplicated in engine repair section of this manual.
[1] - Raise cab. See Tilt Cab . (Operator′s Manual.)
[2] -
CAUTION:
Prevent possible burn injury. Hot exhaust pipes; let pipes cool before servicing.

LEGEND:
1 Guard (2 used)
2 Lock Nut (6 used)
4 Drive Shaft
Remove guards (1).
[3] - Remove drive shaft from PTO.
[4] - Remove timing case cover and discard gasket. See Remove and Install Timing Case Cover . (Group 0401.)
[5] -

Hydraulic Pump PTO Drive

LEGEND:
6 Timing Gear Nut
7 Timing Gear
8 O-Ring
9 PTO Housing
10 Bearing
11 Spacer Tube

12 PTO Shaft
13 Bearing
14 Bearing
15 Bearing Inner Race
18 O-Ring
19 Bearing Cover
21 Oil Seal
22 Cover Plate
23 Output Flange
24 Output Shaft Nut
Loosen timing gear nut (6).
[6] - Remove output shaft nut (24), output flange (23), and cover plate (22).
[7] - Remove cap screws (20) and bearing cover (19).
[8] - Remove O-ring (18) and shims (16 and 17).
[9] - Install puller on PTO shaft (12), and pull shaft while backing off timing gear nut. Remove timing gear (7).
[10] - Remove spacer tube (11) from PTO housing (9).
[11] - Replace bearings (10, 13, and 14) as required.
[12] - Install new O-rings and seals.
[13] - Check oil nozzle (not shown), which is in-line with PTO shaft in timing case. Make sure it is firmly in place.
[14] -
→NOTE:
Preheat timing case for ease of installation.
Install PTO housing in timing case.
[15] - Install timing gear in timing case, PTO shaft, and timing gear nut.
[16] - Install bearing cover and shims (16 and 17), and check PTO shaft end play. Adjust shims to meet end play specification.
Tighten cap screws (20) to specification.
PTO Shaft End Play 0.10—0.20 mm
0.004—0.008 in.
Bearing Cover Cap Screw Torque 25 N·m
18 lb.-ft.
[17] - Install output flange on PTO shaft. Tighten timing gear and output shaft nuts to specification.
Timing Gear Nut Torque 300 N·m
220 lb.-ft.
Output Shaft Nut Torque 300 N·m
220 lb.-ft.
[18] - Install new gasket on timing case cover and install cover. See Remove and Install Timing Case Cover . (Group 0401).
[19] -
IMPORTANT:
Assemble drive shaft so yokes on ends of shaft are aligned. If yokes are not aligned, severe vibration and
machine damage may result.
Install drive shaft.

[20] -

LEGEND:
1 Guard (2 used)
2 Lock Nut (6 used)
4 Drive Shaft
Apply PM38655 Rigid Form-In-Place Gasket to threads of cap screws (5 and 3). Install cap screws, washers, and lock nuts.
Tighten hardware to specification.
Number Name Use

• PM38655 (us)
• PM38655 (canadian) Ridgid Form-In-Place Gasket Apply to cap screw threads.
• 518 Loctite ™ (loctite)
Cap Screw and Lock Nut Torque 28 N·m
20 lb.-ft.
[21] - Install guards and lower cab.

Hydraulic Pump Drive Shaft

Remove and Install Shaft
[1] - Tilt the cab. See Tilt Cab (Operator′s Manual, Section 3-2).
[2] -
CAUTION:
Exhaust pipes can be hot.

LEGEND:
1 Guard (2 used)
2 Lock Nut (6 used)
4 Drive Shaft
Remove guards (1).
[3] - Remove lock nuts (2), washers, and cap screws (3).
[5] - Remove drive shaft (4).
[7] -

IMPORTANT:
Assemble drive shaft so yokes on ends of shaft are aligned. If yokes are not aligned, severe vibration and
machine damage may result.
Install drive shaft.
[8] - Apply rigid form-in-place gasket to threads of cap screws (5 and 3). Install cap screws, washers, and lock nuts. Tighten
hardware to specification.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to cap screw threads.
Cap Screw and Lock Nut Torque 28 N˙m (20.5 lb-ft)
[9] - Install guards.
Remove and Install Damper Coupler
Main Hydraulic Pump Drive Shaft Damper Coupler

LEGEND:
1 Damper Coupler
2 Drive Shaft
[1] - Remove drive shaft (2). See Hydraulic Pump Drive Shaft (in this group).
[2] - Remove cap screws (3) and washers.
[3] - Remove damper coupler (1).

[5] - Install damper coupler.
[6] - Apply T43514 Rigid Form-In-Place Gasket to cap screw threads. Install washers and cap screws. Tighten to specification.
Number Name Use

• T43514 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to flange of rear bearing cover.
Cap Screw Torque 28 N˙m (20.5 lb-ft)
[7] - Install drive shaft. See Hydraulic Pump Drive Shaft (in this group).
Disassemble and Assemble Shaft
[1] -

Engine PTO-to-Hydraulic Pump Drive Shaft

LEGEND:
1 Universal Drive Shaft
2 Drive Shaft
3 Cross and Bearing Kit (2 used)
4 Flange (2 used)
Remove snap rings.
[2] - Push on one of the bearing caps to push the opposite bearing cap out of yoke ear as far as possible. Remove the bearing
cap.
[3] - Turn the drive shaft over. Then push on the cross through the yoke ear where the bearing cap was just removed to push
the second bearing cap out as far as possible. Remove the bearing cap.
[4] - Remove the cross from yoke.
[5] - Remove the remaining bearing caps.
[6] - Clean and inspect the yokes for damage. Replace parts as necessary.
[7] -
IMPORTANT:
Assemble drive shaft so yokes on the ends of shaft are aligned. If yokes are not aligned, severe vibration
Install the cross into the yoke for the drive shaft.
[8] - Check that a seal is installed on each bearing cap.
[9] - Install the bearing cap into one of the yoke ears just far enough so snap ring can be installed in its groove. As cap is
pushed into the yoke, check that the cross is aligned with the cap.
Install the snap ring.
[10] - Turn the drive shaft over.

Checking that the cross is aligned with the bearing cap, push the second bearing cap into yoke just far enough so snap ring can
be installed in its groove.
Install the snap ring.
[11] - Install the cross into the yoke for the flange.
[12] - Install the bearing caps. Install the snap rings, checking to be sure they are seated in the groove.

Hydraulic Pump Drive Shaft Damper Coupler Disassemble, Clean, and

Assemble
Damper Coupler Disassemble
[1] -
Removing Inner and Outer Screws

Remove inner and outer screws to access internal components.
[2] -
Removing Friction Disk

Inspect friction disk for residue or rust buildup.
[3] - Remove circlip to allow hub removal.
Removing Circlip
[4] - Remove hub bearings and inspect for any damage or wear.
Removing Hub Bearings
[5] - Remove centering ring and inspect cup spring for any damage.
Removing Centering Ring
Damper Coupler Clean
[1] -
IMPORTANT:
Improper cleaning of elastomer coupling element will cause damage to damper coupler assembly. Use of
benzene, petroleum, or oil based cleaners will damage elastomer element. Use detergent when a
cleaning agent must be used.
Thoroughly clean all parts.
[2] - When a sticky paste or smeared rubber residue is present, a detergent must be used.
[3] - Examine all parts for damage before assembly. Any damaged parts must be replaced.
Damper Coupler Assemble

Damper Coupler Components

LEGEND:
1 Elastomer Coupling Element (2 used)
2 Bearing (2 used)
3 Friction Disk
4 Supporting Journal
5 Hub
6 Spacer Ring
7 Circlip
8 Casing
9 Cup Spring
10 Centering Ring
11 Spigot Hub
12 Outer Cap Screw (6 used)
13 Nut (6 used)
14 Inner Cap Screw (6 used)
16 Nut (6 used)
[1] - Push bearing (2) and spacer ring (6) onto supporting journal (4).
[2] - Install elastomer coupling element (1) and casing (8) in position.
[3] - Push hub (5) into center of elastomer coupling element.
[4] - Push second bearing into hub and secure with circlip (7).
[5] - Insert cup spring (9) and cylindrical rollers in centering ring (10), and fit friction disk (3) with second elastomer coupling
element in place.
[6] - Secure components with inner cap screws (14) and outer cap screws (12). Tighten to specification.
Inner Cap Screw Torque 35 N·m
26 lb.-ft.
Outer Cap Screw Torque 14 N·m
10 lb.-ft.

Hydraulic Reservoir
Hydraulic Reservoir
LEGEND:
1 Washer
2 Washer
5 Cap screw (4 used)

6 Bolt
9 Lock Nut
12 Washer (10 used)
15 Washer
16 Screw
17 Plug
19 Nipple
20 O-Ring
22 Cover
24 Cover
25 Cover
26 Door
27 Door
29 Hydraulic Reservoir
32 Bleed Valve
34 Weld Nut
35 Hinge
36 Weld Nut
40 Anti-Skid Pad
41 Anti-Skid Pad
42 Anti -Skid Pad
Remove and Install
[1] -
→NOTE:
The hydraulic reservoir is part of a compartment at the left front of machine that also contains
components for the electrical and hydraulic brake systems.
Drain oil from the reservoir. The approximate capacity of reservoir is 177.6 L (46.9 gal).
[2] - Lower the front bottom guard.
[3] - Turn battery disconnect switch to the OFF position.
[4] - Disconnect and remove batteries.
[5] - Label and disconnect harness wires from relay/circuit breaker box and battery disconnect switch.
[6] - Remove wiring harness and cable from compartment.
[7] - Remove front and rear brake accumulators. (See Brake Accumulators in Group 1060.)
[8] - Remove brake accumulator lines from compartment.
[9] - Remove left headlight and headlight bracket.
[10] - Label and disconnect all hydraulic lines connected to hydraulic reservoir. Close all openings using caps and plugs.
[11] -
CAUTION:
Install JT01748 Lifting Brackets in two holes provided at top of hydraulic reservoir (29). Attach a lifting chain and hoist to
brackets.
Lifting Bracket
JT01748
Used to remove and install hydraulic reservoir.
[12] - Remove cap screws (3), nuts (11), washers (12), and hydraulic reservoir.
[13] - Remove and install components as necessary to repair or replace reservoir.
[14] - Install reservoir on the main frame.
[15] - Connect hydraulic lines to back side of reservoir.
[16] - Install headlight and headlight bracket.
[17] - Install front and rear brake accumulators and lines. (See Brake Accumulators in Group 1060.)
[18] - Connect harness wires to relay/circuit breaker box and battery disconnect switch.
[19] - Install and connect batteries.
[20] - Fill hydraulic reservoir and Check Hydraulic Oil Level . (See Section 3-4 of Operator′s Manual.)
[21] - Install front bottom guard.
Suction Strainer
Remove and Install
[1] - Drain oil from the hydraulic reservoir.

Hydraulic Reservoir (approximate) Capacity 178 L
47 gal.
[2] - Remove top hydraulic reservoir cover.
[3] - Remove suction strainer from fitting.
[4] - Clean or replace suction strainer as necessary.
[5] - Install suction strainer and reservoir cover.

Reservoir Cover Cap Screw Torque 28 N·m
240 lb.-in.
[6] - Fill hydraulic reservoir and Check Hydraulic Oil Level . (See Section 3-4 of Operator′s Manual.)

Hydraulic System Manifold Assembly

Remove and Install Dump Body Control Valve Section
[1] - Fully lower dump body. Install articulation lock bar. Stop engine. Discharge brake accumulator pressure. Relieve
pneumatic pressure. Turn off battery disconnect switch. See Prepare Machine for Maintenance (Operator′s Manual, Section
3-2).
[2] - Tilt cab. See Tilt Cab (Operator′s Manual, Section 3-2).
[3] -
LEGEND:
1 Port XB
2 Port XA
3 Port A
4 Port B
5 Nut (3 used)
6 Port T2
Dump Body Control Valve Section

Disconnect pneumatic lines from port XB (1) and port XA (2). Disconnect hydraulic lines from port A (3), port B (4), and port T2
(6). Close all openings with caps and plugs.
[4] - Remove nuts (5). Loosen cap screws on underside of hydraulic system manifold section, if necessary. Remove dump body
control valve section. Remove shims and O-rings from between valve sections.
[6] - Install O-rings and shims.
[7] - Install dump body control valve section. Install nuts and tighten in sequence to specification.

Valve Section Tie Rod Nut Torque 80 N˙m (59 lb-ft)
[8] - Tighten cap screws on underside of hydraulic system manifold section.
[9] - Connect hydraulic lines on ports T2, B, and A.
[10] - Connect pneumatic lines on ports XA and XB.
Disassemble and Assemble Dump Body Control Valve Section

Dump Body Control Valve Exploded View

LEGEND:
2 Air Cylinder Housing
3 O-Ring
4 Piston
5 O-Ring
6 Piston
7 O-Ring
8 Disk
9 Sleeve
10 Washer
11 Retainer
12 Guide
13 Spring
14 Spring
15 Disk
16 Seat
17 O-Ring
18 Seal
19 Poppet (2 used)
20 Sleeve (2 used)
21 O-Ring (2 used)
22 Cap (2 used)
24 Retainer
25 Wiper
26 Seal
27 Backup Ring
28 O-Ring
29 Plug
30 O-Ring
31 Spring
32 Spool
33 Plug
34 O-Ring
35 Housing
36 Spool (2 used)
37 Plug (2 used)
38 O-Ring (2 used)
39 Spacer (2 used)
[1] - Disassemble valve as shown.
[2] -
IMPORTANT:
Replace all seals and O-rings. Old seals and O-rings will leak.
→NOTE:
Valve housing and main spool are a matched set. If either is found worn or damaged they must be
replaced as a matched set.
[3] -
→NOTE:
Apply petroleum jelly to seals and O-rings before installation.
Assemble parts (1—39).
Remove and Install Fan Drive Valve Section
[1] - Remove dump body control valve section.
[2] -
LEGEND:
1 Port LSFD
2 Port FD
3 Fan Drive Solenoid Y12
Fan Drive Valve Section

Disconnect connector from fan drive solenoid Y12 (3).
[3] - Disconnect hydraulic lines from port LSFD (1) and port FD (2). Close all openings with caps and plugs.
[4] - Loosen cap screws on underside of hydraulic system manifold section, if necessary. Remove fan drive valve section.
Remove shims and O-rings from between valve sections.
[6] - Install O-rings and shims.
[7] - Install fan drive valve section. Connect hydraulic lines on ports FD and LSFD.
[8] - Connect fan drive solenoid Y12 connector.
[9] - Install dump body control valve section.

Disassemble and Assemble Fan Drive Valve Section
Fan Drive Valve Exploded View

LEGEND:
1 Plastic Nut
2 Coil
3 Solenoid Valve
4 O-Ring
5 O-Ring
6 Backup Ring
7 O-Ring
8 Plug
9 Backup Ring
10 O-Ring
11 O-Ring
12 Check Valve
13 Plug
14 O-Ring
15 Backup Ring
16 O-Ring
17 O-Ring
18 Shuttle Valve
19 Backup Ring
20 O-Ring
21 O-Ring
22 Plug
23 O-Ring (3 used)
24 O-Ring (3 used)
[1] - Disassemble valve as shown.
[2] -
IMPORTANT:
Replace all backup rings and O-rings. Old backup rings and O-rings will leak.

[3] -
→NOTE:
Apply petroleum jelly to backup rings and O-rings before installation.
Assemble parts (1—24). Tighten solenoid valve (3), check valve (12), and shuttle valve (18) to specification.
Disassemble and Assemble Fan Drive Valve Section

Solenoid Valve Torque 60 N˙m (44 lb-ft)
Check Valve Torque 30 N˙m (22 lb-ft)
Shuttle Valve Torque 10 N˙m (89 lb-in.)
Remove and Install Hydraulic System Manifold Section
[1] - Remove dump body control valve section.
[2] - Remove fan drive valve section.
[3] -
LEGEND:
1 Hydraulic Temperature Sensor B21
2 Hydraulic Cut-Off Solenoid Y17
3 Service Brake Low Pressure Switch B23
4 Secondary Steering Low Pressure Switch B24
5 Body Float Solenoid Y11
Electrical Connections
Disconnect connectors from service brake low pressure switch B23 (3), secondary steering low pressure switch B24 (4), body
float solenoid Y11 (5), and hydraulic cut-off solenoid Y17 (2). Disconnect wire leads from hydraulic temperature sensor B21 (1).
[4] -

LEGEND:
6 Port L1
7 Port L2
8 Port MP2
9 Port MP1
10 Port P2
11 Port P1
Hydraulic Connections
Disconnect hydraulic lines from port MP1 (9) and port MP2 (8) on top of manifold section.
[5] - Disconnect hydraulic lines from port P2 (10), port L1 (6), port L2 (7), and port P1 (11) on front of manifold section.
[6] -
LEGEND:
12 Port L3
13 Port P3
14 Port M4
15 Port A6
16 Port A5
17 Port B5
18 Port B6
19 Port A4
Shown Removed from Machine for Illustration Purposes

Only
Disconnect hydraulic lines from port L3 (12), port P3 (13), and port M4 (14) on right side of manifold section.
[7] - Remove accumulator from port A4 (19) on rear of manifold section.
[8] - Disconnect hydraulic lines from port B6 (18), port B5 (17), port A5 (16), and port A6 (15) on rear of manifold section.
[9] -
CAUTION:


Manifold Section Weight 36 kg (80 lb) approximate

Remove cap screws from bottom of manifold section. Remove manifold section from machine.
[10] - Install manifold section in machine. Install cap screws in bottom of manifold section, but do not tighten.
[12] - Install accumulator.
[13] - Connect electrical connectors.
[14] - Install fan drive valve section.
[15] - Install dump body control valve section.
Disassemble and Assemble Hydraulic System Manifold Section

Hydraulic System Manifold Section

Hydraulic System Manifold Valves

LEGEND:
1 Main Relief Valve
2 Orifice 2.5 mm
3 Orifice 0.7 mm
4 Shuttle Valve
5 Check Valve
6 Hydraulic Temperature Sensor
7 Priority Valve
8 Shuttle Valve
9 Pressure Switch
10 Solenoid Valve
11 Relief Valve
12 Accumulator Charge Valve
13 Check Valve
14 Check Valve
15 Pressure Switch
16 Check Valve
17 Pressure Reducing Valve
18 Solenoid Valve
19 Check Valve
[1] - Disassemble hydraulic system manifold as shown.
[2] -
IMPORTANT:
Replace all backup rings and O-rings. Old backup rings and O-rings will leak.
[3] -
→NOTE:
Apply petroleum jelly to backup rings and O-rings before installation.
Assemble parts (1—19). Tighten all components to specification.

Disassemble and Assemble Hydraulic System Manifold Section

Main Relief Valve Torque 60 N˙m (44 lb-ft)
Orifice (2) 2.5 mm Torque 3 N˙m (27 lb-in.)
Orifice (3) 0.7 mm Torque 3 N˙m (27 lb-in.)
Shuttle Valve (4 and 8) Torque 10 N˙m (89 lb-in.)
Check Valve (5) Torque 100 N˙m (70 lb-ft)
Priority Valve Torque 140 N˙m (103 lb-ft)
Solenoid Valve (10 and 18) Torque 30 N˙m (22 lb-ft)
Relief Valve Torque 30 N˙m (22 lb-ft)
Accumulator Charge Valve Torque 60 N˙m (44 lb-ft)
Check Valve (13, 14 and 16) Torque 30 N˙m (22 lb-ft)
Pressure Reducing Valve Torque 60 N˙m (44 lb-ft)
Check Valve (19) Torque 65 N˙m (48 lb-ft)

Hydraulic Fan Motor

Remove and Install
[1] - Remove top cover, left side grille, and right side grille from transmission oil cooler housing.
[2] - Support fan motor bracket and shroud with proper lifting device.
[3] - Disconnect lines from fan motor. Close all openings using caps and plugs.
[4] -
→NOTE:
Transmission cooler and wet disk brake cooler shown removed for illurstraion purposes only.
LEGEND:
Hydraulic Cooling Fan

Remove cap screws (1), assembled fan, fan motor, bracket and shroud.
[5] -
LEGEND:
2 Shroud
3 Fan
Assembled Fan, Fan Motor, Bracket and Shroud

Remove shroud (2).
[6] - Remove fan (3).
[7] -
LEGEND:
4 Flange
5 Fan Motor
6 Bracket

Fan Motor and Bracket

Remove flange (4) from fan motor.
[8] - Remove fan motor (5) from fan motor bracket (6).
[9] - Install fan motor to fan motor bracket.
[10] - Install flange to fan motor.
[11] - Install fan.
[12] - Install fan shroud.
[13] - Install assembled fan, fan motor, bracket and shroud.
[14] - Connect lines to fan motor.
[15] - Install top cover and grilles to transmission oil cooler housing.
Hydraulic Fan Motor

LEGEND:
1 Shaft
2 Key
3 Snap Ring
4 Seal
5 Tapered Roller Bearing

6 Retainer Plate
7 Piston (9 used)
8 Pin (3 used)
9 Cylinder Block
10 Spacer
12 O-Ring
13 Tapered Roller Bearing
14 Socket Head Screw (8 used)
15 Port Plate
16 Dowel Pin
17 Snap Ring
18 Spring
19 Washer
20 Guide Ball
21 Swash Plate
22 Dowel Pin
23 Housing
24 Relief Valve
25 Valve Seat
26 Plug
[1] - Clean and drain motor.
[2] -
IMPORTANT:
protect the machined surfaces.
[4] - Remove the rotary group as an assembly.
[5] -
CAUTION:
Inspect cylinder block (9). Remove spring (18) only if replacement is necessary.
[6] - Remove shaft key (2), swash plate (21), shaft (1), and bearings (5).
[9] - Remove valve seat (25) and relief valve (24) only if replacement is necessary.
[11] -
IMPORTANT:
Install oil seal with lip facing inside of housing. Press seal into housing just far enough to install snap ring.
[12] - Put pump housing in vise with large opening up.

PNEUMATIC SYSTEMS (g) by Belgreen v2.0
[13] -
IMPORTANT:
Install tapered roller bearing cone on shaft tight against shoulder. Bearing cone is a press fit.
[14] - Install shaft and swash plate.
[16] - Assemble rotary group. A press must be used to install spring (18).
[19] - Install O-ring (12).
[20] - Apply a small amount of petroleum jelly on the mating surface of distributor plate and port plate (15).
Install the distributor plate on port plate so notch engages the dowel pin (16).
[22] - Tighten socket head screws to specification using a crisscross pattern.

Hydraulic Fan Motor

Port Plate-to-Motor Housing Socket Head Screw Torque 15 N˙m (133 lb-in.)
Fan Drive Controller

LEGEND:
1 LS2 Port Line
2 T Port Line
3 LS Port Line
4 LS1 Port Line (Wet Brake Only)
5 A1 Port Line
6 P Port Line
Fan Drive Controller
Remove and Install
[1] - Disconnect lines (1—6). Close all openings using caps and plugs.
[2] - Remove mounting cap screws and controller.
[3] - Replace controller as necessary.
[4] - Install controller and connect lines.

Section 22 - PNEUMATIC SYSTEMS

Table of contents
Group 2261 - Pumps and Drives ............................................................................................................ 1
Remove and Install Air Compressor ...................................................................................................... 1
Group 2262 - Control Valves ................................................................................................................ 18
Remove and Install Pneumatic Manifold ............................................................................................. 18
Remove and Install Park Brake Control Valve ..................................................................................... 21
Remove and Install Body Tip Control Valve ........................................................................................ 22
Remove and Install Seat Control Valve ............................................................................................... 22
Differential Lock Actuator ................................................................................................................... 24
Remove and Install Park Brake Actuator ............................................................................................ 33
Group 2264 - Reservoir, Filter, and Trap ........................................................................................... 35
Air Unloader Valve with Integral Air Dryer .......................................................................................... 35
Remove and Install Regeneration Air Reservoir ................................................................................. 37
Remove and Install Air Reservoir ........................................................................................................ 37
Group 2265 - Cylinders ......................................................................................................................... 39
Remove and Install Exhaust Brake Air Cylinder .................................................................................. 39

Section 22 - PNEUMATIC SYSTEMS Group 2261: Pumps and Drives
Group 2261 - Pumps and Drives

Remove and Install Air Compressor
[1] - Remove fuel supply pump. See Remove and Install Fuel Supply Pump (Group 0413).
[2] - Remove timing case cover and discard gasket. See Remove and Install Timing Case Cover (Group 0401).
[3] - Remove cylinder head and intermediate plate assemblies.
LEGEND:
34 Coolant Supply Line
35 Coolant Return Line
36 Compressed Air Line
37 Suction Line
a.
Air Compressor Coolant Lines
Disconnect coolant supply line (34) and coolant return line (35). Close all openings with caps and plugs.
b. Disconnect compressed air line (36) and suction line (37).
LEGEND:
1 Cylinder Head-to-Intermediate Plate Cap Screw
2 Cylinder Head-to-Cylinder Liner Cap Screw (4 used)
3 Cylinder Head
10 Intermediate Plate
c.
Cylinder Head
Remove cap screws (1 and 2). Remove cylinder head and intermediate plate assembly (3 and 10).
[4] - Remove cylinder liner.

LEGEND:
13 Cylinder liner
15 Washer (4 used)
38 Scribed Line
a.
Air Compressor Cylinder Removal
Scribe a line (38) to mark position of cylinder (13) relative to engine block.
b. Remove cap screws and washers (14 and 15).
c. Remove cylinder liner (13).
[5] - Remove side cover.
LEGEND:
39 Side Cover
41 Gasket
a.
Air Compressor Side Cover Removal
Remove cap screws (40). Remove side cover (39).
b. Remove and discard gasket (41).
[6] - Remove piston and connecting rod.

LEGEND:
19 Snap ring (2 used)
20 Piston Pin
21 Piston
22 Gasket
39 Side Cover
a.
Air Compressor Piston Removal
Remove snap rings (19) from piston (21).
b. Press out piston pin (20). Remove piston (21) from connecting rod.
c. Remove and discard gasket (22).
LEGEND:
24 Connecting Rod and Connecting Rod Bearing
42 Scribe Line
d.
Air Compressor Connecting Rod Removal
Scribe a line (42) to mark position of connecting rod bearing relative to connecting rod and connecting rod bearing cap
(24).
e. Remove cap screws (23). Remove connecting rod and connecting rod bearing cap (24).
[7] - Remove drive gear.
a. Rotate crankshaft until crank pin points up.

LEGEND:
28 Crankshaft
46 JDG1500-39 Air Compressor Crankshaft Blocker
b.
Air Compressor Crankshaft Blocker
Install JDG1500-39 Air Compressor Crankshaft Blocker (46) over crankshaft (28). Tighten cap screws.
JDG1500-39
To remove and install air compressor drive gear
LEGEND:
32 Drive Gear
33 Cap Screw
47 JDG1500-40 Drive Gear Wrench
c.
Drive Gear Wrench
Remove cap screw (33) on air compressor drive gear (32) using JDG1500-40 Drive Gear Wrench (47).
Drive Gear Wrench
JDG1500-40
d. Remove drive gear.

e. Remove JDG1500-39 Air Compressor Crankshaft Blocker.
[8] - Remove crankshaft and bearings.
IMPORTANT:
When removing the crankshaft, secure roller bearing inner ring in the timing case (arrow), to
prevent it from falling out.

LEGEND:
25 Flange
28 Crankshaft
31 Inner Bearing
Crankshaft Removal
Remove flange (25) and crankshaft (28).
LEGEND:
29 Bearing Flange
31 Inner Bearing
b.
Inner Bearing Cap
Remove cap screws (30) and bearing flange (29).
LEGEND:
31 Inner Bearing
43 Bearing Removal Tool
c.
Inner Bearing Removal
Using a bearing removal tool (43), remove bearing (31).

LEGEND:
25 Flange
48 Bushing Removal Tool
d.
Outer Bushing Removal
Remove O-ring from flange (25). Using a bushing removal tool (48), remove bushing (26) from flange (25).
[9] - Inspect piston head and intermediate plate assembly.
LEGEND:
3 Cylinder Head
4 Intermediate Plate Gasket
9 Valve (3 used)
12 Cylinder Head Gasket
a.
Piston Head and Intermediate Plate
Remove intermediate plate (10) from cylinder head (3).
b. Remove and discard intermediate plate gasket (4).
c. Remove and discard cylinder head gasket (12).
d. Inspect and replace components as necessary.

[10] - Inspect cylinder liner, piston, connecting rod, and crankshaft assemblies.
IMPORTANT:
Pistons and cylinder liners are marked B, C, or D, based on diameter tolerance ranges. Always use
pistons and cylinder liners with matching letter markings.
LEGEND:
16 First Compression Ring
17 Second Compression Ring
18 Oil Ring
21 Piston
49 Piston Ring Expander
Air Compressor Piston Ring Removal

Using a piston ring expander (49), remove rings (16, 17, and 18) from piston (21).
b. Measure cylinder liner bore ID.


Cylinder Liner, Marking B ID 100.000—100.010 mm (3.93700—3.93739 in.)
Cylinder Liner, Marking C ID 100.010—100.020 mm (3.93739—3.93778 in.)
Cylinder Liner, Marking D ID 100.020—100.030 mm (3.93778—3.93818 in.)
c. Measure piston OD 90° from piston pin bore.


Piston, Marking B OD 99.925—99.935 mm (3.93404—3.93444 in.)
Piston, Marking C OD 99.935—99.945 mm (3.93444—3.93483 in.)
Piston, Marking D OD 99.945—99.955 mm (3.93483—3.93522 in.)
d. Measure pin bore ID on piston and pin OD. Subtract OD from ID to obtain clearance measurement.

Piston Pin-to-Pin Bore Clearance 0.003—0.012 mm (0.0001—0.0004 in.)
e. Replace parts as necessary.
[11] - Install crankshaft and bearings.

LEGEND:
25 Flange
26 Bushing
52 Bearing Installation Tool
a.
Outer Bushing Installation
Align oil holes in bushing (26) with holes in bearing flange (25).
b. Using bearing installation tool (52), install bushing (26) into bearing flange (25).
LEGEND:
31 Inner Bearing
c.
Air Compressor Roller Bearing Installation
Install two cupped washers (arrow) on inner bearing (31) to protect bearing.
d. Install bearing so inner ring and collar face fan.
LEGEND:
31 Roller Bearing
53 Bearing Installation Tool
e.
Air Compressor Roller Bearing Installation Tool
Using bearing installation tool (53), install roller bearing (31) into bearing cap.
f. Remove cupped washers from bearing.

LEGEND:
29 Bearing Flange
g.
Bearing Flange Installation
Install bearing flange (29). Tighten cap screws (30) to specification.

Inner Bearing Cap Cap Screw Torque 50 N˙m (37 lb-ft)
LEGEND:
28 Crankshaft
h.
Crankshaft and Bearing Washer
Install bearing washer (arrow) onto crankshaft (28) with chamfer facing crank pin.
LEGEND:
28 Crankshaft
31 Roller Bearing
i.
Air Compressor Crankshaft Installation
Position roller bearing (31) inner ring and install crankshaft (28).

j. Lubricate new O-ring and install O-ring onto bearing flange (25).
k. Lubricate bearing pilot on flange (25).
LEGEND:
25 Flange
27 O-Ring
28 Crankshaft
l.
Flange Installation
Flange Installation
Align oil hole (arrow) on flange (25) to oil hole on housing. Install flange (25) onto crankshaft (28).
m. Tighten cap screws (arrows) evenly to seat bearing flange. Remove cap screws. Install caps screws evenly again.
[12] - Install drive gear.
LEGEND:
32 Drive Gear
33 Cap Screw
a.
Drive Gear Installation
Install drive gear (32). Hand-tighten cap screw (33).

b. Rotate crankshaft until crank pin points up.

LEGEND:
28 Crankshaft
46 JDG1500-39 Air Compressor Crankshaft Blocker
c.
Install JDG1500-39 Air Compressor Crankshaft Blocker (46) over crankshaft (28). Tighten cap screws.
JDG1500-39
→NOTE:
Torque Wrench with Adapter

LEGEND:
A Leverage Distance of Torque Wrench
B Leverage Distance of Adapter
If an adapter is fastened to the square drive of a torque wrench, it adds to the leverage distance of
the wrench. In this case, the real torque applied is greater than the torque indicated by the torque
wrench. Use the formula below to determine the correct torque wrench reading for the intended
torque specification.
Torque Wrench Formula
Torque Reading on Wrench = Torque Specification x ———
A+B
Leverage distance of torque wrench is measured from center of handle to center of square drive.
Leverage distance of wrench with adapter is measured parallel to beam of wrench, from center of
handle to center of adapter head.
Always measure leverage distance parallel to beam of wrench. If wrench and adapter are assembled
at an angle, leverage distance will be shorter. If adapter is assembled at 90° to beam of wrench, it
does not affect leverage distance.

LEGEND:
32 Drive Gear
33 Cap Screw
47 JDG1500-40 Drive Gear Wrench
Drive Gear Wrench

Using a torque wrench and JDG1500-40 Drive Gear Wrench (47), tighten cap screw (33) to specification.

Drive Gear Cap Screw Torque 360 N˙m (266 lb-ft) actual
Drive Gear Wrench

JDG1500-40
e. Remove JDG1500-39 Air Compressor Crankshaft Blocker.
[13] - Install connecting rod and piston.
a.
Connecting Rod Bearing Installation
Lightly coat connecting rod bearings with clean oil. Install bearings into connecting rod bearing cap and connecting rod.
Ensure that oil holes (arrows) in connecting rod bearing and connecting rod align. Ensure the markings on connecting rod
cap and connecting rod align.

LEGEND:
24 Connecting Rod
b.
Connecting Rod Installation
Install connecting rod (24) on crankshaft. Install cap screws (23). Tighten cap screws (23) to specification.

Connecting Rod Cap Screw Torque 30 N˙m (22 lb-ft)
LEGEND:
16 First Compression Ring
17 Second Compression Ring
18 Oil Ring
21 Piston
49 Piston Ring Expander
c.
Piston Ring Installation
Use a piston ring expander (49) to install rings (16, 17, and 18) onto piston (21). Compression rings (16 and 17) must be
installed bevel-side down.
LEGEND:
19 Snap Ring
20 Piston Pin
21 Piston
24 Connecting Rod
d.
Air Compressor Piston Installation
Install piston (21) on connecting rod (24).
e. Lightly coat piston pin (20) with oil. Install pin. Install snap rings (19).

[14] - Install side cover.
LEGEND:
39 Side Cover
41 Gasket
a.
Air Compressor Side Cover Installation
Install new side cover gasket (41).
b. Install side cover (39). Tighten cap screws (40) to specification.

Side Cover Cap Screw Torque 50 N˙m (37 lb-ft)
[15] - Install cylinder liner.
LEGEND:
21 Piston
22 Gasket
a.
Cylinder Liner Gasket Installation
Install new cylinder liner gasket (22) onto timing case.
b. Lightly coat piston (21) with oil. Offset piston ring gaps by 120° (arrows).

LEGEND:
13 Cylinder Liner
21 Piston
55 Ring Compressor Tool
c.
Ring Compressor Tool
Use a ring compressors tool (55) to compress piston rings to OD of piston (21).
d. Lightly coat inside of cylinder liner (13) with clean oil. Push cylinder liner (13) over piston (21). Remove ring compressor
tool (55).
LEGEND:
13 Cylinder Liner
15 Washer (4 used)
21 Piston
e.
Air Compressor Cylinder Liner Cap Screw Installation
Install cap screws and washers (14 and 15). Tighten cap screws to specification.
Air Compressor
Cylinder Liner Cap Screw Torque 40 N˙m (30 lb-ft)
[16] - Install cylinder head and intermediate plate assembly.

LEGEND:
2 Cap Screw
3 Cylinder Head
4 Intermediate Plate Gasket
9 Valve (3 used)
12 Cylinder Head Gasket
a.
Piston Head and Intermediate Plate
Assemble cylinder head (3), intermediate plate gasket (4), intermediate plate (10), and cylinder head gasket (12). Ensure
wording “Top” on head gasket (12) is toward the cylinder head (3).
LEGEND:
1 Cylinder Head-to-Intermediate Plate Cap Screw
2 Cylinder Head-to-Cylinder Liner Cap Screw (4 used)
3 Cylinder Head
b.
Cylinder Head
Install cylinder head and intermediate plate assembly (3 and 10). Tighten cap screws (1 and 2) to specification.

Cylinder Head-to-Cylinder Liner Cap Screw Torque 40 N˙m (30 lb-ft)
Cylinder Head-to-Intermediate Plate Cap Screw Torque 12 N˙m (9 lb-ft)

Section 22 - PNEUMATIC SYSTEMS Group 2262: Control Valves
LEGEND:
34 Coolant Supply Line
35 Coolant Return Line
36 Compressed Air Line
37 Suction Line
c.
Air Compressor Coolant Lines
Connect compressed air line (36). Connect suction line (37).
d. Connect coolant supply line (34) and coolant return line (35).
[17] - Install new timing case cover gasket. Install timing case cover. See Remove and Install Timing Case Cover (Group 0401).
[18] - Install fuel supply pump. See Remove and Install Fuel Supply Pump (Group 0413).

Group 2262 - Control Valves

Remove and Install Pneumatic Manifold
Pneumatic Manifold—Rear
LEGEND:
1 Body Pilot Control Valve Exhaust
2 Park Brake Supply

3 Differential Lock Solenoid

4 Interaxle Lock Solenoid
5 Air Horn Solenoid
6 Park Brake Exhaust
7 System Air Pressure Sensor
8 Seat Valve Supply
9 Body Pilot Control Valve Up
10 Body Pilot Control Valve Supply
11 Exhaust Brake and Exhaust Valve Brake Solenoid
12 Park Brake Solenoid
13 Body Pilot Control Valve Down
14 Park Brake Pressure Switch
15 Park Brake Solenoid Supply
16 Body Up Pressure Switch
17 Inter-Axle Lock Pressure Switch
18 Differential Lock Pressure Switch
[1] - Turn off battery disconnect switch. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator′s Manual).
[2] - Relieve Pneumatic Pressure . (Operator′s Manual.)
[3] - Open cab right-side compartment door.
[4] - Disconnect wiring connectors from solenoids (3—5, 11, 12), sensor (7), and switches (14, 16—18).
[5] - Remove switches (14, 16—18), if necessary.
[6] - Remove socket head cap screws. Push manifold forward through cab wall.
[7] -

Pneumatic Manifold—Front and Sides

LEGEND:
1 Middle and Rear Axle Differential Lock
2 Front Axle Differential Lock
3 Body Pilot Control Valve Exhaust
4 Park Brake Exhaust
5 Inter-Axle Lock
6 Park Brake Check Valve
7 Body Pilot Control Valve Up

8 Park Brake Exhaust Orifice
9 Body Pilot Control Valve Down
10 Park Brake
11 Exhaust Brake and Exhaust Valve Brake
12 Exhaust Brake and Exhaust Valve Brake Exhaust
13 Quick Coupler
14 Pneumatic System Supply
15 Air Horn
Disconnect air lines (1, 2, 5, 7, 9—11, 14, and 15) from sides of manifold.
[8] - Disconnect remaining air lines from rear of manifold.
[10] - Connect air lines to rear of manifold.
[11] - Connect air lines to sides of manifold.
[12] - Install manifold in cab wall and install socket head cap screws.
[13] - Install switches on rear of manifold, if removed.
[14] - Install wiring connectors on rear of manifold.
Remove and Install Park Brake Control Valve

[1] - Turn off battery disconnect switch. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator′s Manual.)
[2] - Relieve pneumatic pressure. See Relieve Pneumatic Pressure (Operator′s Manual.)
[4] -
LEGEND:
1 Transmission Control Panel Wiring Connector
2 Air Line (2 used)
3 Park Brake Control Lever Wiring Connector
4 Park Brake Control Lever
Air and Electrical Connections
Park Brake Control Lever

Disconnect air lines (2) and wiring connectors (1 and 3).
[5] - Remove panel from dashboard.
[6] - Remove park brake control lever (4).

[8] - Install lever.
[9] - Install panel on dashboard.
[10] - Connect wiring connectors and air lines.
Remove and Install Body Tip Control Valve

[4] -
LEGEND:
1 Transmission Control Panel Wiring Connector
2 Air Line (4 used)
3 Body Tip Control Lever Wiring Connector
4 Body Tip Control Lever
Air and Electrical Connections
Body Tip Control Lever

Disconnect air lines (2) and wiring connectors (1 and 3).
[5] - Remove panel from dashboard.
[6] - Remove body tip control lever (4).
[8] - Install lever.
[9] - Install panel on dashboard.
[10] - Connect wiring connectors and air lines.
Remove and Install Seat Control Valve

[1] - Relieve Pneumatic Pressure (Operator′s Manual Section 3-2).
[2] -
LEGEND:
1 Knob
2 Set Screw
3 Nut
4 Washer
5 Air Inlet Line
6 Air Spring Line
Seat Control Valve

Disconnect air inlet line (5) and air spring line (6).
[3] - Loosen set screw (2) and remove knob (1).
[4] - Remove nut (3) and washer (4). Remove valve.
[5] - Replace components as necessary.
[6] - Install valve, washer, and nut.
[7] - Install knob. Tighten set screw.
[8] - Connect lines.

Differential Lock Actuator

Remove and Install
[1] - Relieve Pneumatic Pressure . (Operator′s Manual Section 3-2).
[2] -
LEGEND:
1 Air Supply Line
2 Nut (2 used)
3 Differential Lock Actuator
4 Sight Plug

Disconnect air supply line (1).
[3] -
→NOTE:
Oil will drain from differential lock actuator when removed.
Remove nuts (2). Remove differential lock actuator (3).
[4] -

LEGEND:
2 Threaded Stud (2 used)
5 Shift Fork
Top View
Push shift fork (5) toward the outside (arrow), away from differential. Install differential lock actuator (3). Install nuts onto
threaded stud (2).
[5] - Tighten nuts to specification.


Differential Lock Actuator Nuts Torque 74—82 N˙m (55—61 lb-ft)
[6] - Remove sight plug (4). Fill actuator (3) to bottom of sight hole with SAE 10 oil or automatic transmission fluid.
[7] - Install sight plug (4). Tighten sight plug (4).
[8] - Connect air supply line (1).
[1] - Clean differential lock actuator to prevent contamination.
[2] -


LEGEND:
2 Sight Plug
4 Washer (7 used)
5 Cover
6 Gasket
7 Bearing

8 Pin
9 Lever
10 Plug
11 O-Ring
12 Housing
13 Stop
14 Spring
15 Pin
16 Bearing
19 Cover
20 O-Ring
21 Lock Nut
22 Washer
23 Oiler (2 used)
24 Piston
25 O-Ring
26 Push Rod
27 O-Ring
Remove cap screws and washer (3 and 4). Remove cover (5).
[3] - Remove cap screws and lock nuts (17 and 18). Remove cover (19).
[4] -
CAUTION:
Piston is under spring pressure. Actuator housing must be properly aligned in press to prevent possible
injury or damage to parts.
LEGEND:
15 Pin
Piston Pin Removal

Install housing assembly in press and apply pressure until pin (15) can be removed. Slowly release press and remove piston
with push rod.
[5] -

Actuator Piston
LEGEND:
21 Lock Nut
22 Washer
23 Oiler (2 used)
24 Piston
25 O-Ring
26 Push Rod
27 O-Ring
Remove O-ring (27) and oilers (23) from piston (24).
[6] - Remove parts (21, 22, 24, and 25) from push rod (26).
[7] -

Actuator Spring Removal

LEGEND:
12 Housing
13 Stop
14 Spring
Remove spring (14) and stop (13) from housing (12).
[8] -
IMPORTANT:
Do not disassemble actuating lever (9).
LEGEND:
8 Pin
9 Lever
12 Housing
Lever Removal
Remove pin (8) and lever (9) from housing (12).

[10] - Install pin (8) and lever (9) into housing (12).
[11] - Soak oilers (23) in SAE 10 oil for one hour before assembly.
Lubricate O-ring (27) with high-viscosity silicone oil or barium grease O-ring lubricant.
IMPORTANT:
Piston (24) must be installed on push rod (26) with wording “nut side” facing toward the lock nut (21).
[12] -
Actuator Piston
LEGEND:
21 Lock Nut
22 Washer
23 Oiler (2 used)
24 Piston
25 O-Ring
26 Push Rod
27 O-Ring
Install parts (25, 24, 22, and 21) onto push rod (26). Tighten lock nut (21) to specification.

Push Rod Lock Nut Torque 14—17 N˙m (10.5—12.5 lb-ft)
[13] - Install oilers (23) and O-ring (27) onto piston (24).
[14] -

Actuator Spring Removal

LEGEND:
12 Housing
13 Stop
14 Spring
Install stop (13) and spring (14) into housing (12)
[15] - Install piston and push rod assembly through spring (14).
[16] -
CAUTION:
Actuator housing must be properly aligned in press to prevent possible injury or damage to parts.

LEGEND:
9 Lever
12 Housing
14 Spring
24 Piston
Push Rod Assembly

Install housing (12) in press and apply pressure until lever (9) is in alignment with push rod (26).
[17] -
LEGEND:
15 Pin
Clevis Pin Installation

Install pin (15) and release press.
[18] -
LEGEND:
6 Gasket
12 Housing
Gasket Installation
Install gasket (6) on housing (12).
[19] - Install cover (5). Apply medium strength thread lock compound to threads of cap screws. Install cap screws and washers
(3 and 4). Tighten cap screws to specification.
Number Name Use
• 242 LOCTITE ™ (loctite) Medium Strength Thread Lock Compound Apply to threads of differential lock actuator housing cover cap screws.


Housing Cover Cap Screw Torque 12—15 N˙m (9—11 lb-ft)
[20] -
LEGEND:
12 Housing
20 O-Ring
O-ring Installation
Install O-ring (20) into groove on housing (12).
[21] -
LEGEND:
19 Cover
Piston Cover
Install cover (19). Install cap screws and washers (17 and 18). Tighten to specification.

Piston Cover Cap Screw and Nut Torque 12—15 N˙m (9—11 lb-ft)
Remove and Install Park Brake Actuator

[1] - Install Dump Body Prop (Operator′s Manual Section 3-2).
[3] - Release park brake. See Mechanically Releasing Park Brake (Operator′s Manual Section 2-2).
[4] -

Section 22 - PNEUMATIC SYSTEMS Group 2264: Reservoir, Filter, and Trap
LEGEND:
1 Air Line
2 Actuator
3 Pin
Park Brake Actuator

Disconnect air line (1).
[5] - Remove pin (3).
[6] - Remove nuts and washers. Remove actuator (2).
[8] - Install actuator. Install washers and nuts.
[9] - Install pin.
[11] - Release park brake. See Mechanically Releasing Park Brake (Operator′s Manual Section 2-2).

Group 2264 - Reservoir, Filter, and Trap

Air Unloader Valve with Integral Air Dryer
Remove and Install
[3] -
LEGEND:
1 Reservoir Air Line
2 Regeneration Reservoir Air Line
3 Compressor Air Line
4 Heater Wire
5 Unloader Valve Assembly
Unloader Removal
Disconnect heater wire (4).
[4] - Disconnect air lines (1—3).
[5] - Loosen cap screws (6).
[6] - Remove unloader valve assembly (5) from machine.
[8] - Install unloader valve assembly.
[9] - Tighten cap screws.
[10] - Connect air lines.
[11] - Connect heater wire.
[1] -
LEGEND:
1 Heater and Screw
2 Plug and Sealing Ring
3 Unloader Valve Spring Assembly
4 O-Ring
5 Element
Unloader and Element

Remove element (5) and O-ring (4).
[2] - Remove heater and screw (1), if necessary.
[3] - Remove plug and sealing ring (2), if necessary.
[4] -
CAUTION:
Spring is under load. Hold component securely while removing snap ring.
Remove snap ring and unloader valve spring assembly (3), if necessary.
[5] -
LEGEND:
6 Retaining Ring
8 Drain Port
Retaining Ring and Drain Port

Remove cap screws (7), retaining ring (6), and drain port (8).
[6] -
LEGEND:
9 Drain Cover
10 Sleeve (3 used)
Drain Cover
Remove drain cover (9) and sleeves (10).
[7] -
LEGEND:
11 Retaining Plate
Retaining Plate
Remove cap screws 12) and retaining plate (11).

[8] -
LEGEND:
13 Valve Base
14 Purging Valve and Spring
15 Check Valve and Spring
16 O-Ring (2 used)
Valve Base and Valves

Remove valve base (13). Remove purging valve and spring (14), check valve and spring (15), and O-rings (16) from valve base.
[10] - Install O-rings, check valve and spring, and purging valve and spring on valve base. Install valve base.
[11] - Install retaining plate and cap screws.
[12] - Install drain cover and sleeves.
[13] - Install drain port, retaining ring, and cap screws.
[14] - Install unloader valve spring assembly and snap ring, if removed.
[15] - Install sealing ring and plug, if removed.
[16] - Install heater and screw, if removed.
[17] - Install O-ring and element.
Remove and Install Regeneration Air Reservoir

[2] -
LEGEND:
1 Reservoir
2 U-Bolt and Nuts
3 Air Line
Regeneration Air Reservoir

[3] - Remove U-bolt and nuts (2).
[4] - Remove reservoir (1).
[6] - Install reservoir, U-bolt, and nuts.

Section 22 - PNEUMATIC SYSTEMS Group 2265: Cylinders
Remove and Install Air Reservoir

[2] -
LEGEND:
1 Auto-Drain Air Line
2 Inlet Line
3 Outlet Line
4 U-Bolt and Nuts (2 used)
5 Reservoir
Air Reservoir
Disconnect air lines (1—3).
[3] - Remove U-bolts and nuts (4).
[4] - Remove reservoir (5).
[6] - Install reservoir, U-bolts, and nuts.
[7] - Connect air lines.

HAULAGE DEVICE (g) by Belgreen v2.0
Group 2265 - Cylinders

Remove and Install Exhaust Brake Air Cylinder
[2] -
LEGEND:
1 Air Line
2 Cylinder
3 Ball Joint
Exhaust Brake Air Cylinder

[3] - Disconnect ball joint (3)
[4] - Remove cap screw and washer. Remove cylinder (2).
[6] - Install cylinder. Install washer and cap screw.
[7] - Connect ball joint.
[9] - Perform Exhaust Brake Adjustment (Group 9010-20).

Section 35 - HAULAGE DEVICE

Table of contents
Group 3540 - Frames ............................................................................................................................... 1
Body ..................................................................................................................................................... 1
Dump Body Lift Cylinder Repair (S.N. —499999) .................................................................................. 4
Dump Body Lift Cylinder Remove and Install (S.N. 500000—608380) ................................................. 9
Dump Body Lift Cylinder Disassemble and Assemble (S.N. 500000—608380) ................................... 11
Dump Body Lift Cylinder Disassemble and Assemble (S.N. 608380—) ............................................... 17

Section 35 - HAULAGE DEVICE Group 3540: Frames
Group 3540 - Frames

Body
Remove and Install
[1] - Remove rear turn signals and tail and brake lights. See Replace Tail and Brake Light and Rear Turn Signal (Operator′s
Manual Section 4-1).
[2] - Remove wiring harnesses from tail light housings.
[3] -
LEGEND:
1 Sensor Linkage
Tip Angle Sensor

Disconnect tip angle sensor linkage (1).
[4] - Remove body lift cylinders. See Dump Body Lift Cylinder Remove and Install (S.N. 500000—608380) (Group 3560).
[5] -
CAUTION:

Body
350D Dump Body Weight 4361 kg (9614 lb)
400D Dump Body Weight 4601 kg (10,143 lb)
Install lifting device on dump body.
[6] -
IMPORTANT:
Avoid machine damage. Do not crush electrical components and grease lines under rear edge of dump
body.

Section 35 - HAULAGE DEVICE Group 3540: Frames
Pivot Pin Removal

LEGEND:
1 Pin (2 used)
2 Retaining Plate (2 used)
4 Washer (8 used)
Remove pivot pins (1). Remove dump body from machine.
[7] - Inspect, clean, and replace hardware as necessary.
[8] - Grease pivot pins and bores. Install dump body on machine. Install pivot pins.
[9] - Install body lift cylinders. See Dump Body Lift Cylinder Remove and Install (S.N. 500000—608380) (Group 3560).
[10] - Connect tip angle sensor linkage.
[11] - Install wiring harnesses into tail light housings.
[12] - Install rear turn signals and tail and brake lights. See Replace Tail and Brake Light and Rear Turn Signal (Operator′s
Manual Section 4-1).
[13] - Align dump body, if necessary.
Align
[1] -
Section 35 - HAULAGE DEVICE Group 3560: Hydraulic System
Dump Body Pads and Shims

LEGEND:
1 Guide Plate (2 used)
2 Guide Plate Shim, 3 mm (0.12 in.)
3 Guide Plate Shim, 5 mm (0.20 in.)
4 Support Pad (6 used)
5 Support Pad Shim, 1.6 mm (0.06 in.)
6 Support Pad Shim, 4.0 mm (0.16 in.)
Remove support pads (4) and shims (5 and 6) from dump body. Loosen guide plates (1).
[2] - Put steel plates on top of rear frame at all support pad positions.
Body
Steel Plate Thickness 38 mm (1.50 in.)
[3] - Float dump body onto steel plates.
[4] - Check for gaps between dump body and each steel plate. Measure and record all gaps.
[5] - Raise dump body. Remove steel plates. Install support pads. Use shim plates as indicated by measurements. Use an
additional 4 mm (0.16 in.) shim (6) with each of the rear four support pads.
[6] - Float dump body onto frame. Check for gaps. The rear four support pads should have no gaps. The front two support pads
should have slight gaps.
[7] - Add or remove shims (2 and 3) as necessary between body guide plates and frame strike plates, to obtain minimum
possible clearance without interference. Tighten guide plates.


Dump Body Lift Cylinder Repair (S.N. —499999)
IMPORTANT:
Dump Body lift cylinders are interchangeable. Service parts are not, identify which cylinder you have
prior to ordering any service parts.
LEGEND:
1 Lubrication Hose (2 used)
2 Lock Plate and Retainer Plate (2 used)
3 Pin (2 used)
4 Hydraulic Line to Rod End
5 Hydraulic Line to Head End
Dump Body Cylinder (S.N. —499999)
Rod End
Head End
Remove and Install
[1] - Prepare machine for maintenance Perform Prepare Machine for Maintenance (Operator′s Manual Section 3-2). Ensure
excess dirt and debris is removed from exterior of cylinders.
[2] -
CAUTION:
Body Lift Cylinder

Body Lift Cylinder Approximate Weight 325 kg (710 lb)
Support cylinder with appropriate lifting device.
[3] - Disconnect lubrication hoses (1).
[4] - Disconnect hydraulic hoses (4 and 5). Close all openings with caps and plugs.
[5] - Remove lock plates and retainer plates (2).
[6] - Remove pins (3). Remove cylinder from machine.
[7] - Clean, repair, and replace parts as necessary.
[8] -
→NOTE:
Position cylinder so hydraulic fittings are facing up at the cab end.
Lift cylinder into position with appropriate lifting device. Ensure hydraulic fittings are facing up at the cab end.
[9] - Apply a thin layer of grease to pins and install.
[10] - Install retainer plates and lock plates. Tighten cap screws to standard torque for cap screw size. Bend one corner of lock
plate over the head of each cap screw.
[11] - Install hydraulic hoses.
[12] - Connect lubrication hoses.

Lift Cylinder Exploded View

LEGEND:
2 Rod Guide
3 Fitting
4 O-Ring
5 Ring (2 used)
6 Backup Ring
7 O-Ring
8 Valve
9 Fitting
10 Self-Aligning Bushing (2 used)
12 Lubrication Fitting (2 used)
14 Washer (2 used)
15 Clamp (2 used)
17 Washer (8 used)
18 Clamp (2 used)
20 Hydraulic Line
21 Cylinder Barrel

22 Cotter Pin
23 Nut
24 Piston
25 Seal (3 used)
26 O-Ring
27 Backup Ring
28 O-Ring
29 Rod
30 Seal
31 Dust Seal
32 Seal
[1] -
CAUTION:
Body Lift Cylinder

Body Lift Cylinder Approximate Weight 325 kg (710 lb)
Install cylinder in a cylinder service stand such as JT30043 Cylinder Service Stand.
JT30043
[2] - Remove snap rings (11), bushings (10), clamps (18), oil line (20), hydraulic fittings (3 and 9), and lubrication fittings (12),
if necessary.
[3] - Remove head cap screws (1).
[4] - Remove rod (29), rod guide assembly (2, 4—8, 27—32), and piston assembly (22—26) from barrel (21).
[5] - Remove and disassemble piston assembly.
[6] - Remove and disassemble rod guide assembly.
[7] - Clean, inspect, or replace parts as necessary. Replace all O-rings and seals.
[8] -
IMPORTANT:
Apply clean hydraulic oil to all rod guide and piston components during assembly.
Assemble rod guide assembly and install on rod. Ensure dust seal (31) is installed with lip facing rod end.
[9] - Assemble piston assembly and install on rod. Apply rigid form-in-place gasket LOCTITE ™ PM38656 to threads of nut.
Number Name Use

• PM38656 (us)
• TY9475 (canadian) Rigid Form-In-Place Gasket Apply to threads of piston-to-rod nut.
Body Lift Cylinder

Piston-to-Rod Nut Torque 500 N˙m (370 lb-ft)
Tighten nut (23) to specification. Install cotter pin (22).

[10] - Install piston assembly, rod guide assembly, and rod in barrel. Align hydraulic fitting port on rod guide with hydraulic
fitting port on head end of barrel. Install cap screws and tighten to specification.

Body Lift Cylinder

Rod Guide-to-Cylinder Barrel Socket Head Cap Screw Torque 308 N˙m (230 lb-ft)
[11] - Install lubrication fittings, hydraulic fittings, oil line, clamps, bushings, and snap rings, if removed.

Dump Body Lift Cylinder Remove and Install (S.N. 500000—608380)
CAUTION:
Prevent possible crushing injury or death from dump body movement. Do not perform this procedure
with dump body raised. Lower dump body to the lowered position.
IMPORTANT:
[2] - Lower dump body.
[3] - Relieve hydraulic pressure in dump body cylinders.
[4] -
CAUTION:
Support cylinder with appropriate lifting device

Dump Body Lift Cylinder Approximate Weight 325 kg
710 lb
.
[5] -
LEGEND:
1 Lubrication Hose (2 used)
2 Lock Plate and Retainer Plate (2 used)
3 Pin (2 used)
4 Hydraulic Hose to Rod End
5 Hydraulic Hose to Head End

Head End
Remove lubrication hoses (1) from both ends of cylinder. Cap and plug all openings
[6] - Remove hydraulic hoses (4 and 5). Cap and plug all openings
[7] - Remove lock plates and retainer plates (2).
[8] - Remove pins (3). Remove cylinder from machine.
[9] - Clean, repair, and replace parts as necessary.
[10] -
→NOTE:
Position cylinder so hydraulic fittings are facing up at the cab end.
Lift cylinder into position with appropriate lifting device. Ensure hydraulic fittings are facing up at the cab end.
710 lb
[11] - Apply a thin layer of grease to pins and install.
[12] - Install retainer plates and lock plates. Tighten cap screws to standard torque for cap screw size. Bend one corner of lock
plate over the head of each cap screw.
[13] - Connect hydraulic hoses.
[14] - Connect lubrication hoses.
[15] - Operate cylinders through full range of motion to ensure system is in proper working order. Adjust as necessary.

Dump Body Lift Cylinder Disassemble and Assemble (S.N.

500000—608380)
Dump Body Lift Cylinder - Exploded View (S.N. 500000 — 608380)

LEGEND:
2 Bearing

3 Bin Cylinder
4 Piston Nut
6 Piston Seal
7 Piston
8 O-Ring
10 Bearing
11 Cylinder Rod
12 Wiper Seal
14 Cylinder Rod Seal
15 Head
16 O-Ring
17 Backup Ring
18 O-Ring
19 Buffer Seal
Cylinder Disassemble
IMPORTANT:
[1] - Clean cylinder thoroughly prior to disassembly.
[2] - Drain hydraulic oil from cylinder.
[3] -
CAUTION:
Install cylinder in cylinder service stand JT30043A or other suitable fixture for disassembly.
710 lb

JT30043A
Disassembly and assembly of hydraulic cylinders
[4] - Remove head assembly (4-8)
[5] - Using appropriate lifting device remove rod (11) from barrel (3). Taking care not to damage rod or barrel.
[6] - Install rod in service stand JT30043A or other suitable fixture.
[7] -
IMPORTANT:
Avoid damage to cylinder rod. Use only hand tools to remove and install piston nut. Do not use impact
wrench or power air tools.
Remove piston nut.
[8] - Remove piston (12-19).
[9] - Remove stroke limiter if equipped (not shown).

Head Assembly
LEGEND:
12 Wiper Seal
14 Cylinder Rod Seal
15 Head
16 O-Ring
17 Backup Ring
18 O-Ring
19 Buffer Seal
Head Assembly
[1] -
IMPORTANT:
Carefully remove rings and seals as to not damage head assembly surfaces.
Remove all rings and seals taking care to not damage head assembly. Discard old seals.
[2] - Inspect head assembly for damage and wear, replace as necessary.
[3] - Clean head assembly with proper solvent and wipe clean with link free cloth. Allow head to air dry.
[4] - Immerse seals and rings, except wiper seal, in new, clean hydraulic oil prior to installation
[5] -
→NOTE:
Wiper seal will be installed last.
Install new rings and seals in head assembly. Starting at the center and working towards the edges.
[6] - Prior to installing wiper seal clean mating surfaces of head assembly and seal with LOCTITE ™
Number Name Use

• PM37509 (us)
• CXTY16285 (canadian) Cure Primer Clean mating surfaces of head assembly and seal prior to installation
PM37509 cure primer.

[7] - Partially install wiper seal in head assembly to specified depth.
Seal in Head Assembly Depth 1.5 mm
.06 in.
[8] - Apply LOCTITE ™
Number Name Use

• TY15969 (us)
• TY9479 (canadian) Retaining Compound (Maximum Strength) Retain wiper seal in head assembly.
PM38626 retaining compound to wiper seal mating surface.
[9] - Press wiper seal evenly into head assembly until seated.
[10] - Wipe off excess retaining compound with link free cloth.
[11] - Apply oil to inner lips of wiper seal.
Piston Assembly
LEGEND:
5 Wiper Seal
6 Piston Seal
7 Piston
8 O-Ring
Piston Assembly
[1] -

IMPORTANT:
Carefully remove rings and seals to prevent damage head assembly surfaces.
Remove all rings and seals. Discard old parts.
[2] - Inspect piston assembly for damage and wear, replace as necessary.
[3] - Clean piston assembly with proper solvent and wipe clean with link free cloth. Allow piston to air dry.
[4] - Immerse all seals and rings in new, clean hydraulic oil prior to installation
[5] - Install new rings and seals in piston assembly. Starting at the center and working towards the edges.
Cylinder Assembly
[1] -
IMPORTANT:
Hydraulic system leakage or failure will occur if contamination, damage, and wear are ignored. Clean
thoroughly, and carefully inspect all components, especially threaded components, for contamination,
damage and wear prior to assembly.
Clean and inspect all components, for contamination, damage and wear. Clean or replace as required.
[2] -
JT30043A
Disassemble and assemble hydraulic cylinders
With rod mounted in service stand JT30043A or other suitable fixture. Apply liberal amounts of clean, new hydraulic oil to all
sealing surfaces on head assembly and rod.
Carefully install head assembly on rod taking care to not damage wiper seal while sliding it past the rod stem shoulder.
Slide head assembly approximately half way up the rod.
[3] - Carefully install stroke limiter if equipped.
[4] - Apply liberal amounts of clean, new hydraulic oil to all sealing and threaded surfaces on piston assembly. Carefully install
the piston onto the rod until it is against rod stem shoulder
[5] -
IMPORTANT:
Cylinder rod damage will occur. Do not use impact wrench or other power tools during assembly of
cylinder.
Apply liberal amounts of clean, new hydraulic oil to rod threads. Install the piston nut and torque to specification. Use hand
tools only, do not use impact wrench or other power tools during assembly of cylinder.
Piston Nut Torque 2195 — 2685 N·m
1620 — 1980 lb-ft
[6] -
CAUTION:
Install barrel in cylinder service stand JT30043A or other suitable fixture.
[7] - Apply liberal amounts of clean, new hydraulic oil to all sealing surfaces on piston and head assembly. Install rod 3/4 of the
length into barrel taking care to not damage seals or o-rings on threaded area of barrel.
[8] - Carefully install head assembly into barrel and torque to specifications.
Hydraulic Cylinder Head Assembly Torque 405—670 N·m
300—500 lb-ft
[9] - Install head assembly lock screw. If holes do not line up drill a new hole in the head with a 3.57 mm (9/64 in.) diameter
drill, 6.35 mm (1/4 in.) deep. Install self tapping cap screw in new hole.
[10] - Clean excess hydraulic oil from exterior of cylinder and test.
Testing
[1] - Install hydraulic hoses to extend and retract ports on cylinder
[2] - Using specified pressure, pressurize retract port to fill cylinder with hydraulic oil. Pressurize extend port until cylinder is
fully extended.
Hydraulic Cylinder Test Pressure 1725 — 2760 kPa
1 725 — 2 760 bar
250 — 400 psi
[3] - Cycle cylinder through full retract and full extend three times
[4] - With cylinder pressurized check for leaks.

Dump Body Lift Cylinder Disassemble and Assemble (S.N. 608380—)
Dump Body Lift Cylinder - Exploded View (S.N. 608380-- )

LEGEND:
1 Cylinder Barrel
2 Cylinder Rod
3 Piston Nut
4 Seal

DEALER FABRICATED TOOLS (g) by Belgreen v2.0
5 Seal
6 Seal
7 Seal
8 Wear Ring
9 Piston
10 V-Ring Seal
11 O-Ring
12 Cylinder Rod Guide
13 Seal
14 Seal
15 Wear Ring
16 O-Ring
17 O-Ring
18 Seal
19 O-Ring
20 Seal
21 Seal
23 Self-Aligning Bushing (2 used)
24 Pipe Plug (2 used)
25 O-Ring
26 Adapter Fitting
27 O-Ring
30 Washer (8 used)
32 Clamp (2 used)
33 Pipe
34 Adapter Fitting
35 O-Ring (2 used)
IMPORTANT:
[2] - For procedure see Cylinder Identification . (CTM120519.)

Section 99 - DEALER FABRICATED TOOLS

Table of contents
Group 9900 - Dealer Fabricated Tools .................................................................................................. 1
DF1002 Rolling Drag Torque Bar .......................................................................................................... 1
DFT1132 Removal and Installation Tool ............................................................................................... 3
DFT1178 Lifting Tool ............................................................................................................................ 4
DFT1181 Bushing Driver ....................................................................................................................... 5
DFT1185 Supports ................................................................................................................................ 6
DFT1186 Bushing Driver ....................................................................................................................... 8
DFT1187 Bearing Driver ....................................................................................................................... 9
DFT1188 Bearing Driver ..................................................................................................................... 10
DFT1189 Spanner Wrench .................................................................................................................. 11
DFT1194 Bearing Puller ...................................................................................................................... 13
DFT1195 Planetary Alignment Stud .................................................................................................... 14
DFT1196 Bushing Driver ..................................................................................................................... 15
DFT1199 Bushing Pusher .................................................................................................................... 18
DFT1222 Wet Disk Brake Piston Seal Installer .................................................................................... 20
DFT1223 Transfer Case Mounting Bracket ......................................................................................... 21
DFT1224 Engine Mounting Adapter .................................................................................................... 22

Section 99 - DEALER FABRICATED TOOLS Group 9900: Dealer Fabricated Tools
Group 9900 - Dealer Fabricated Tools

DF1002 Rolling Drag Torque Bar
DF1002 Rolling Drag Torque Bar

LEGEND:
A 19 mm (0.75 in.)
B 38 mm (1.50 in.)
C 584 mm (23.00 in.)
D 261.9 mm (10.31 in.)
E 236 mm (9.29 in.)
F 212.7 mm (8.37 in.)
G 185.7 mm (7.31 in.)
H 167.4 mm (6.59 in.)
I 102 mm (4.02 in.)
J 53.5 mm (2.11 in.)
K 43.5 mm (1.71 in.)
M 11 mm (0.43 in.)
N 11 mm (0.43 in.)
1 1/2-13 UNC x 8 in. Ready Rod (2 pieces)
2 1/2-UNC Cap Screw and Nut
3 9.7 mm (0.382 in.) (2 holes)
4 15 mm (0.590 in.) (15 holes)
Rolling Drag Torque Bar is used with a torque wrench to measure rolling drag torque.
Material required:
10 x 38 x 584 mm (0.38 x 1.50 x 23.00 in.) mild steel (1020) flat

1/2 in.—13 UNC x 8.00 in. ready rod (2 used)

1/2 in.—13 UNC nuts (9 used)

12.7 x 25.4 x 1.5 mm (0.50 x 1.00 x 0.06 in.) washers (8 used)
1/2 in.—13 UNC x 1.00 in. cap screw

DFT1132 Removal and Installation Tool
DFT1132 Removal And Installation Tool

LEGEND:
A M30 (1 in.) Nut
B 2.134 m (7 ft) Length of Pipe
C 457 mm (18 in.) Length of Pipe
D 25 mm (1 in.) ID Heavy Wall Pipe
E Pipe
F Fillet Weld
G Pipe
Removal and installation tool is used to remove and install the main hydraulic pump.
Material required:
2.591 m (8 ft x 6 in.) length of 25 mm (1 in.) ID heavy wall steel pipe

Fillet weld

DFT1178 Lifting Tool
DFT1178 Lifting Tool

LEGEND:
1 3/8 in. x 7.5 in. Round Bar (2 used)
2 1.0 in. OD x 0.75 in. ID x 24 in. Pipe
3 M12 x 25 mm Cap Screw
4 M14 x 25 mm Cap Screw
Lifting tool is used to remove and install axle planetary cover.
Material required:
3/8 in. x 7.5 in. Round Bar (2 used)

1.0 in. OD x 0.75 in. ID x 24 in. Pipe
M12 x 25 mm Cap Screw
M14 x 25 mm Cap Screw
Weld cap screws to ends of pipe.

Weld round bars to pipe as shown.

DFT1181 Bushing Driver
Bushing Driver
Used to install bushings in axle suspension struts, drag links and stabilizer bars.
Material required:
Steel pipe 114 mm (4.50 in.) O.D. 101.6 mm (4.00 in.) I.D. 89 mm (3.50 in.) Long.

DFT1185 Supports
DFT 1185 Supports

LEGEND:
1 Square Tube (2 used)
2 Steel Pin (2 used)
DFT 185 Supports are used to support front of truck when separating frames.

Material required:
6.00 x 6.00 x 0.375 in. Steel Square Tube

68.6 mm (2.75 in.) Bar Stock

Oscillation Bushing Driver

LEGEND:
1 Radius 457 mm (18.0 in.) Flame Cut Okay
2 Drill Diameter 17/32 in. Hole Through (4 places)
3 Radius 305 mm (12.0 in.)
4 Drill Diameter 17/32 in. Hole Through (4 places)
5 Radius 305 mm (12.0 in.)
6 32.0 mm (1.25 in.) Flame Cut Okay
7 Radius 381 mm (15.0 in.) Flame Cut Okay
8 32.0 mm (1.25 in.) Flame Cut Okay
9 1 in. x 60 in. Threaded Rod
Used to install oscillation joint bushings in machine frame.
→NOTE:
JDG902 Excavator Boom Bushing Installer Kit may be used in place of 1 in. x 60 in. threaded rod. If
JDG902 is used the center hole diameter in disks must be 1.75 in.
Material required:
Steel plate 19.1 mm (0.75 in.) thick, 457 mm (18.0 in.) diameter (2 pieces)
Steel plate 12.7 mm (0.50 in.) thick, 381 mm (15 in.) diameter (2 pieces)
Cap screws 12 mm (0.50 in.) x 45 mm (1.75 in.) (8 used)
Hex nuts 12 mm (0.50 in.) (8 used)
1.0 in. x 60.0 in. Threaded Rod
1.0 in. Flat Washer (2 used)

1.0 in. Nut (2 used)
Attach a small plate to a large plate using 4 cap screws and nuts.
DFT1187 Bearing Driver

Used to install bearings on oscillation joint-to-park brake drive shaft.
Material required:
Steel pipe 89 mm (3.50 in.) O.D. 76 mm (3.0 in.) I. D. 127 mm (5.0 in.) long.

Bearing Driver
Used to install bearings in articulation joint bearing cover
Material required:
Steel pipe 127 mm (5.00 in.) O. D.180 mm (4.25 in.) I. D.89 mm (3.50 in.) long.

DFT1189 Spanner Wrench
Oscillation Joint Nut Spanner Wrench

LEGEND:
1 Flame Cut
2 Weld
A 212.7 mm (8.375 in.)
B 193.7 mm (7.625 in.)
C Steel Plate
D Steel Flat.
E Steel Rod (2 used)
Spanner wrench is used to remove, install and adjust oscillation joint nut.
Material required:
244.5 mm (9.625 in.) x 244.5 mm (9.625 in.) x 6.3 mm (0.250 in.) steel plate
38.1 mm (1.50 in.) x 6.3 mm (0.250 in.) x 711.2 (28 in.) steel flat.
32 mm (1.25 in.) long x 22.2 mm (0.875 in.) diameter steel rod (2 used)
Weld rods (E) to plate (C) on front side or drill 19 mm (0.75 in.) holes in plate and weld rods to plate from the back side.

Weld steel flat (D) to plate (C).

DFT1194 Bearing Puller
Bearing Puller
LEGEND:
A Threaded rod (2 used)
B Pipe (2 used)
C Weld
Bearing puller is used to separate differential housing from axle.
Material required:
Threaded rod 5/8-11 X 229 mm (11.0 in.) (2 pieces)

Pipe 3/4 in. OD x 1/2 in. ID x 1.5 in. (2 pieces)
Hex nut 1/2-13 (2 used)
Flat washer 1/2 in. ID (2 used)
H-bar from push-puller

DFT1195 Planetary Alignment Stud
DFT1195 Stud
Stud is used to remove and install axle planetary cover.

Material required:
M14 x 170 mm cap screw (19M8243) (2 used)
Remove head from cap screw and grind taper per drawing.


LEGEND:
1 19.05 mm (0.75 in.) x 84.13 mm (3.312 in.) Round Steel
2 120.7 mm (4.75 in.) OD x 69.9 mm (2.75 in.) ID x 76.2 mm (3.0 in.) Steel Pipe
3 171.5 mm (6.75 in.) OD x 50.8 mm (2.0 in.) Steel
Bushing driver is used to install front axle pivot bushing.
Material required:
19.05 mm (0.75 in.) x 84.13 mm (3.312 in.) Round Steel

120.7 mm (4.75 in.) OD x 69.9 mm (2.75 in.) ID x 76.2 mm (3.0 in.) Steel Pipe
171.5 mm (6.75 in.) OD x 50.8 mm (2.0 in.) Steel


LEGEND:
1 69.2—70.8 mm (2.724—2.787 in.)
2 3D Isometric View of Component (Not to Scale).
3 114.2—115.8 mm (4.496—4.559 in.)
4 Surface Should Be Polished to 60Ra MAX. Roughness Finish to Prevent Damage to Bushings During Use.
5 2.8—3.2 mm (0.110—0.126 in.)
6 64.2—65.8 mm (2.528—2.591 in.)
7 35°
Material required:
Tool steel.
Bushing driver is used to install bushings in axle drag links, stabilizers, and struts.

DFT1199 Bushing Pusher
DFT1199 Bushing Pusher

LEGEND:
1 20 mm Hex Nut (3 used)
2 20 mm Threaded Rod (3 used)
Bushing pusher is used to push the walking beam bushings off the pivot tube.
Material required:
20 mm threaded rod 152 mm (6.0 in.) long (3 pieces)

20 mm hex nut (3 used)

Walking Beam Bushing Driver
Bushing driver is used to install bushings into walking beams.

Material required:
248 mm (9.75 in.) O.D. 222.3 mm (8.75 in.) I. D. 100mm (4.0 in) long steel pipe.

DFT1222 Wet Disk Brake Piston Seal Installer
DFT1222 Wet Disk Brake Piston Seal Installer

LEGEND:
1 Break Edges
DFT1222 Wet Disk Brake Piston Seal Installer is used to install inner seal between wet disk brake piston and wet disk brake
housing.
Material Required:
32.00 mm x 152.00 mm x 7.00 mm (1.25 in x 6.00 in. x 0.250 in.) Plexiglass

DFT1223 Transfer Case Mounting Bracket
DFT 1223 Transfer Case Mounting Bracket
DFT 1223 Transfer Case Mounting Bracket is used to mount the transfer case to D05223ST Repair Stand.
Material required:
13.00 x 152.00 x 559.00 mm (0.50 x 6.00 x 22.00 in.) Mild Steel (1020) Flat

DFT1224 Engine Mounting Adapter
DFT1224 Engine Mounting Adapter (1 of 3)

LEGEND:
A Part A
C Part C
D Part D
E Part E

F Part F
1 16.0 mm (0.625 in.) x 28.2 mm (1.12 in.) (2 Places)
2 12.7 mm (0.5 in.) Steel Plate
3 Cut Slot Through Outer Edge As Shown
4 Full Radius At Both Ends
5 Steel Tube
6 15.9 mm (0.625 in.) Diameter Hole Through (4 Places)
7 15.87 (0.625 in.) Steel Plate
8 Drill and Tap 2, 12.7 mm (0.5 in.) Diameter Holes Through
9 4.0 x 4.0 x 0.25 in. Steel Tube
10 Detail-A
11 Detail-B

LEGEND:
A Part A
C Part C
D Part D
E Part E
F Part F
12 114.4 mm (4.5 in.) x 152.4 mm (6.00 in.) x 6.35 mm (0.25 in.) x Plate
13 990.6 mm (39.0 in.) (Reference)
14 101.6 mm (4.00 in.) x 101.6 mm (4.00 in.) x 6.35 mm (0.25 in.)
15 527.0 mm (20.75 in.) (Reference)
16 Align Surfaces
17 304.8 mm (12.00 in.)
18 76.2 mm (3.00 in.) (Reference)
19 Assembled View
20 Align Corners (Horizontal Plane)
21 114.4 mm (4.5 in.) x 152.4 mm (6.00 in.) x 12.7 mm (0.5 in.) Plate

22 114.4 mm (4.5 in.) x 152.4 mm (6.00 in.) x 6.35 mm (0.25 in.) Plate

LEGEND:
A Plate A
B Plate B
C Plate C
24 19.05 mm (0.75 in.) Hole Through
25 15.9 mm (0.625 in.) Hole Through

28 Assembled View
DFT1224 Engine Mounting Adapter is used to mount the six-cylinder engine to D05223ST Engine Repair Stand.
Materials required:
2286 mm x 102 mm x 6 mm (90 x 4 x 0.25 in.) Tube

229 mm x 152 mm x 6 mm (9 x 6 x 0.25 in.) Plate

TM1941 (Manual de Taller Jhon Deere 350 y 400D

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350D and 400D Articulated

REPAIR TECHNICAL MANUAL

Articulated Dump models 350D, 400D Bell-(200311—201811) DW-

For complete service information also see:

John Deere Construction and Forestry

Group 1810 - Operator Enclosure

<- Go to Global Table of contents TM1941-REPAIR TECHNICAL MANUAL

<- Go to Global Table of contents TM1941-REPAIR TECHNICAL MANUAL

Technical Information Feedback Form

Technical Manual Fax

SEND TO: John Deere Dubuque Works

18600 South John Deere Road

Attn: Publications, Dept. 324

FAX NUMBER: 1-563-589-5800 (USA)

<- Go to Section TOC Section 00 page 1 TM1941-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

<- Go to Global Table of contents TM1941-REPAIR TECHNICAL MANUAL

Group 0001 - Safety

Safety Alert Symbols

Safety Alert Symbols

Follow Safety Instructions

Follow Safety Instructions

Operate Only If Qualiﬁed

<- Go to Section TOC Section 00 page 1 TM1941-REPAIR TECHNICAL MANUAL

training and instruction.

<- Go to Section TOC Section 00 page 2 TM1941-REPAIR TECHNICAL MANUAL

Wear Protective Equipment

Avoid Unauthorized Machine Modiﬁcations

<- Go to Section TOC Section 00 page 3 TM1941-REPAIR TECHNICAL MANUAL

Inspect machine carefully each day by walking around it before starting.

Stay Clear of Moving Parts

Stay Clear Of Moving Parts

Entanglements in moving parts can cause serious injury.

Avoid High-Pressure Oils

Avoid High Pressure Oils

Avoid High-Pressure Oils

Moline, Illinois, U.S.A.

Beware of Exhaust Fumes

Beware Of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

Handle Fuel Safely

Clean Machine Regularly

Carry A Fire Extinguisher

<- Go to Section TOC Section 00 page 5 TM1941-REPAIR TECHNICAL MANUAL

Prevent Battery Explosions

Handle Chemical Products Safely

Handle Chemical Products Safely

Dispose of Waste Properly

<- Go to Section TOC Section 00 page 6 TM1941-REPAIR TECHNICAL MANUAL

Dispose Of Waste Properly

Prepare for Emergencies

First Aid Kit

Be prepared if an emergency occurs or a ﬁre starts.

Use Steps and Handholds Correctly

Use Handholds and Steps

Start Only From Operator′s Seat

Operate Only From Operators Seat

Use and Maintain Seat Belt

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Park Brake Control

<- Go to Section TOC Section 00 page 8 TM1941-REPAIR TECHNICAL MANUAL

Be careful not to accidentally actuate controls when co-workers are present.

Avoid Work Site Hazards