John Deere HPX 4X2, HPX 4X4 (Gas and Diesel) Repair Service Manual (TM2195)
Complete service repair manual with Electrical Wiring Diagrams for John Deere HPX 4X2, HPX 4X4 (Gas and Diesel, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
John Deere HPX 4X2, HPX 4X4 (Gas and Diesel workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
tm2195 - HPX 4X2, HPX 4X4 Gas and Diesel Technical Manual.pdf
tm2195 - HPX 4X2, HPX 4X4 Gas and Diesel Technical Manual.epub
PRODUCT DETAILS:
Total Pages: 2,012 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
TABLE OF CONTENTS....1
Section 10: Safety....26
Group 10: Safety....26
Recognize Safety Information....28
Understand Signal Words....29
Replace Safety Signs....30
Handle Fluids Safely—Avoid Fires....31
Prepare for Emergencies....32
Prevent Battery Explosions....33
Prevent Acid Burns....34
Wear Protective Clothing....36
Avoid High-Pressure Fluids....37
Avoid Heating Near Pressurized Fluid Lines....38
Service Machines Safely....39
Use Proper Tools....40
Park Machine Safely....41
Support Machine Properly....42
Use Proper Lifting Equipment....43
Work in Clean Area....44
Protect Against High Pressure Spray....45
Illuminate Work Area Safely....46
Work In Ventilated Area....47
Remove Paint Before Welding or Heating....48
Avoid Harmful Asbestos Dust....49
Follow Tire Recommendations....50
Stay Clear of Rotating Drivelines....51
Service Cooling System Safely....53
Dispose of Waste Properly....54
Handle Chemical Products Safely....55
Live With Safety....56
Section 20: Specifications Section 20: Specifications & Information{pgNO}57 Information....57
Group 10: Fastener Torques....57
Metric Bolt and Screw Torque Values....61
Unified Inch Bolt and Screw Torque Values....63
Group 20: O-Ring Seal Service Recommendations....57
Face Seal Fittings With Inch Stud Ends Torque....68
Face Seal Fittings With Metric Stud Ends Torque....70
O-Ring Face Seal Fittings....72
O-Ring Boss Fittings....74
Straight Fitting or Special Nut Torques....76
Metric Cap Screw Torque Values—Grade 7....77
Group 30: General Information....57
Gasoline....80
Gasoline Storage....82
Diesel Fuel....83
Diesel Fuel Lubricity....84
Diesel Fuel Storage....85
4 - Cycle Gasoline Engine Oil....86
Break-In Engine Oil - 4-Cycle Gasoline....87
4 - Cycle Diesel Engine Oil....88
Break-In Engine Oil - Diesel....89
Transaxle and MFWD Differential Oil....90
Alternative Lubricants....91
Synthetic Lubricants....92
Lubricant Storage....93
Mixing of Lubricants....94
Oil Filters....95
Brake Fluid....96
Chassis Grease....97
Group 40: Coolant....57
Recommended Engine Coolant....99
Group 50: Serial Number Locations....57
Product Serial Number....101
Gasoline Engine Serial Number Location....102
Diesel Engine Serial Number Location....103
Section 30: Engine - Gas (Liquid Cooled)....104
Group 10: Specifications and Tools....104
Specifications....1951
Service Equipment and Tools....287
Group 20: Component Location....295
Engine Compartment Location....121
Starting Motor....123
Fuel System Components....125
Coolant System Components....128
Group 30: Diagnostics....326
Engine Troubleshooting Guide....104
Starting Motor Troubleshooting....141
Group 40: Tests and Adjustments....104
Summary of References....1967
Governor: Static Adjustment....146
High Idle Speed Adjustment....148
Slow Idle Mixture and Governed Low Idle Adjustments....150
Throttle Cable Adjustment....153
Choke Cable Adjustment....156
Fuel Pump Pressure Test....158
Fuel Pump Flow Test....160
High Altitude Operation....162
Cylinder Compression Test....163
Valve Clearance Adjustment....165
Crankcase Vacuum Test....168
Oil Pressure Test....170
Radiator Cap Pressure Test....172
Thermostat Test....173
Group 50: Repair....104
Summary of References....1967
Muffler Removal and Installation....177
Engine Removal and Installation....179
Carburetor Repair....184
Intake Manifold Removal and Installation....189
Cylinder Head Removal and Installation....192
Cylinder Head Disassembly and Inspection....195
Crankcase Cover Removal and Installation....199
Crankcase Breather Inspection....202
Oil Pump Inspection....203
Oil Pump Installation....206
Camshaft Removal....208
Camshaft Inspection....209
Governor Removal and Inspection....210
Piston and Cylinder Removal....212
Piston Inspection....214
Piston Ring Installation....219
Cylinder Boring....221
Connecting Rod Bend and Twist Inspection....223
Crankshaft Inspection....225
Crankshaft Installation....228
Connecting Rod Assembly and Installation....229
Tappet and Camshaft Installation....231
Water Pump Removal and Installation....232
Water Pump Parts Inspection....234
Starting Motor Removal and Installation....235
Starting Motor Disassembly and Inspection....237
Section 40: Engine - Diesel....249
Group 10: Specifications—3TNE68....249
Engine Specifications....1951
Fuel System....255
Repair Specifications....1951
Service Equipment and Tools....287
Torque Specifications....1951
Checks Tests and Adjustment Specifications....1951
Other Material....290
Group 15: Specifications—3TNV70....249
Specifications....1951
Service Equipment and Tools....287
Other Material....290
Group 20: Component Location....295
Component Location....295
Group 30: Theory of Operation....249
Cooling System Theory of Operation....301
Lubrication System Theory of Operation....303
Fuel System Theory of Operation....305
Air System Theory of Operation....307
Group 40: Diagnostics....326
Engine Troubleshooting and Diagnostics....326
Engine Oil Diagnostics....326
Excessive Fuel Consumption....312
Incorrect Manifold Pressure....313
Low Engine Compression....314
Engine Starting Problem....315
Engine Operation Poor....318
Coolant Temperature Abnormal....324
Coolant in Oil or Oil in Coolant....325
Diagnostics....326
Group 50: Tests and Adjustments....249
Summary of References....1967
Air Restriction Indicator Test—Diesel....331
Slow Idle Speed Adjustment—Diesel....334
High Idle Speed Adjustment—Diesel....336
Throttle Cable Adjustment—Diesel....338
Valve Clearance Adjustment—Diesel....340
Valve Lift Check—Diesel....344
Cylinder Compression Test—Diesel....346
Water Pump and Alternator Drive Belt Adjustment—Diesel....348
Thermostat Test—Diesel....350
Radiator Bubble Test—Diesel....352
Cooling System Pressure Test—Diesel....353
Radiator Cap Pressure Test—Diesel....354
Engine Oil Pressure Test—Diesel....355
Injection Pump Timing—Diesel....357
Fuel Injection Nozzle Test—Diesel....358
Fuel Injection System Tests—Diesel....361
Injection Pump Static Timing Check—Diesel....364
Fuel System Air Bleeding—Diesel....368
Fuel Transfer Pump Flow Test—Diesel....369
Fuel Transfer Pump Pressure Test—Diesel....371
Group 60: Repair....250
Summary of References....1967
Engine Removal and Installation Diesel....377
Muffler Removal and Installation Diesel....388
Rocker Arm Cover Removal and Installation 3TNE68....390
Rocker Arm Cover Removal and Installation 3TNV70....392
Disassemble, Inspect, and Assemble Rocker Arm Assembly and Push Rods....394
Cylinder Head Removal and Installation Diesel 3TNE68....398
Cylinder Head Removal and Installation Diesel 3TNV70....402
Intake Manifold Removal and Installation Diesel 3TNE68....405
Exhaust Manifold Removal and Installation Diesel....406
Cylinder Head Recondition....408
Crankshaft Rear Oil Seal....421
Crankshaft Front Oil Seal....424
Timing Gear Cover Diesel 3TNE68....426
Timing Gear Cover Diesel 3TNV70....428
Camshaft End Play Check....431
Timing Gear Backlash Check....432
Idler Gear 3TNE68....434
Idler Gear 3TNV70....437
Cam Followers....440
Camshaft 3TNE68....443
Camshaft 3TNV70....451
Oil Pan and Strainer....459
Connecting Rod Side Play Check....460
Crankshaft End Play Check Diesel....461
Connecting Rod Bearing Clearance Check....463
Crankshaft Main Bearing Clearance Check....465
Piston to Cylinder Head Clearance....467
Connecting Rod Repair....469
Pistons....473
Cylinder Bore....482
Crankshaft and Main Bearings....487
Flywheel Removal and Installation....493
Flywheel Plate....495
Timing Gear Housing....497
Oil Pump Removal and Installation Diesel 3TNE68....500
Oil Pump Removal and Installation Diesel 3TNV70....503
Oil Pressure Regulating Valve....507
Coolant Temperature Switch....509
Thermostat Removal and Installation....510
Water Pump Removal and Installation—Diesel....512
Fuel Filter Removal and Installation....514
Fuel Filter Assembly Removal and Installation....516
Fuel Transfer Pump Diesel 3TNE68....518
Fuel Transfer Pump Diesel 3TNV70....519
Fuel Injection Nozzle....521
Fuel Injector Pump Diesel 3TNE68....527
Fuel Injection Pump Diesel 3TNV70....533
Fuel Injection Pump Camshaft 3TNE68....537
Governor 3TNE68....543
Fuel Control and Governor Linkage....546
Fuel Shutoff Solenoid Removal and Installation....549
Starting Motor Removal and Installation Diesel....551
20 Amp Alternator....553
40 Amp Alternator....557
Section 50: Electrical....565
Group 10: General Information....565
Reading Electrical Schematics....577
Theory Of Operation Information....579
Diagnostic Information....580
Wire Color Abbreviation Chart....581
Common Circuit Tests....582
Conductors For 12 Volt Circuits....584
Group 20: Specifications....1951
Gasoline Engine Machines....586
Diesel Engine Machines....587
Fuses....588
Group 30: Component Location (SN -040000)....565
Summary of References....1967
Electrical Components—Gas Engines (SN -040000)....592
Electrical Components—Diesel Engines (SN -040000)....594
Electrical Schematic and Wiring harness Legend (Gas and Diesel Engines SN -040000)....596
Group 35: Component Location (SN 040001-)....565
Summary of References....1967
Electrical Components—Gas Engines (SN 040001-080000)....600
Electrical Components—Gas Engines (SN 080001-)....602
Electrical Components—Diesel Engines (SN 040001-080000)....604
Electrical Components—Diesel Engines (SN 080001-110000)....606
Electrical Components—Diesel Engines (SN 110001-)....608
Electrical Schematic and Wiring Harness Legend (SN 040001-080000)....610
Electrical Schematic and Wiring Harness Legend (Gas Engines SN 080001-)....612
Electrical Schematic and Wiring Harness Legend (Diesel Engines SN 080001-110000)....614
Electrical Schematic and Wiring harness Legend (Diesel Engines SN 110001-)....616
Group 40: Schematics and Harnesses (SN -040000)....565
Summary of References....1967
Main Schematic (Gas Engines SN -040000)....620
Main Wiring Harness (Gas Engines SN -040000)....624
Main Harness Wire Codes (Gas Engines SN -040000)....628
W2 Engine Wiring Harnesses (Gas Engines SN -040000)....631
Main Schematic (Diesel Engines SN -040000)....632
Main Wiring Harness (Diesel Engines SN -040000)....635
Main Harness Wire Color Codes (Diesel Engines SN -040000)....639
Group 41: Schematics and Harnesses (SN 040001-110000)....566
Summary of References....1967
Main Wiring Schematic (Gas Engines SN 040001-080000)....644
Main Wiring Harness (Gas Engines SN 040001-080000)....648
Main Harness Wire Color Codes (Gas Engine SN 040001-080000)....652
Main Wiring Schematic (Gas Engines SN 080001-110000)....655
Main Wiring Harness (Gas Engines SN 080001-110000)....660
Main Harness Wire Color Codes (Gas Engine SN 080001-110000)....665
W2 Engine Wiring Harnesses (Gas Engine SN 040001-)....668
Main Schematic (Diesel Engines SN 040001-080000)....669
Main Wiring Harness (Diesel Engines SN 040001-080000)....672
Main Harness Wire Color Codes (Diesel Engines SN 040001-080000)....676
Main Schematic (Diesel Engines SN 080001-110000)....679
Main Wiring Harness (Diesel Engines SN 080001-110000)....682
Main Harness Wire Color Codes (Diesel Engines SN 080001-110000)....686
Battery Wiring Harness—Diesel (SN 040001-)....689
Group 42: Schematics and Harnesses (SN 110000-)....566
Summary of References....1967
Main Wiring Schematic (Gas Engines SN 110001-120000)....692
Main Wiring Harness (Gas Engines SN 110001-120000)....697
Main Harness Wire Color Codes (Gas Engine SN 110001-120000)....702
Main Wiring Schematic (Gas Engines SN 120001-)....705
Main Wiring Harness (Gas Engines SN 120001-)....711
Main Harness Wire Color Codes (Gas Engine SN 120001-)....716
Main Wiring Schematic (Diesel Engines SN 110001-120000)....720
Main Wiring Harness (Diesel Engines SN 110001-120000)....723
Main Harness Wire Color Codes (Diesel Engines SN 110001-120000)....727
Main Wiring Schematic (Diesel Engines SN 120001-)....730
Main Wiring Harness (Diesel Engines SN 120001-)....734
Main Harness Wire Color Codes (Diesel Engines SN 120001-)....738
Group 55: Operation and Diagnostics....326
Summary of References....1967
Power Circuit Operation, Gas (SN -040000)....745
Power Circuit Schematic, Gas (SN -040000)....747
Power Circuit Diagnosis, Gas (SN -040000)....567
Power Circuit Operation, Gas (SN 040001-)....770
Power Circuit Schematic, Gas (SN 040001-)....772
Power Circuit Diagnosis, Gas (SN 040001-)....567
Power Circuit Schematic, Diesel (SN -040000)....813
Power Circuit Diagnosis, Diesel (SN -040000)....567
Power Circuit Operation, Diesel (SN -080000)....836
Power Circuit Schematic, Diesel (SN 040001-080000)....838
Power Circuit Diagnosis, Diesel (SN 040001-080000)....567
Power Circuit Operation, Diesel (SN 080001-)....863
Power Circuit Schematic, Diesel (SN 080001-110000)....865
Power Circuit Diagnosis, Diesel (SN 080001-110000)....567
Power Circuit Operation, Diesel (SN 110001-)....892
Power Circuit Schematic, Diesel (SN 110001-)....894
Power Circuit Diagnosis, Diesel (SN 110001-)....900
Cranking Circuit Operation, Gas (All), Diesel (SN -080000)....901
Cranking Circuit Schematic, Gas and Diesel (SN -040000)....902
Cranking Circuit Diagnosis, Gas, and Diesel (SN -040000)....567
Cranking Circuit Schematic, Gas (SN 040001-), Diesel (SN 040001-080000)....910
Cranking Circuit Diagnosis, Gas (SN 040001-), Diesel (SN 040001-080000)....567
Cranking Circuit Operation, Diesel (SN 080001-)....921
Seat Belt Circuit Operation, Diesel (SN 080001-)....922
Cranking and Seat Belt Circuit Schematic, Diesel (SN 080001-)....923
Cranking Circuit Diagnosis, Diesel (SN 080001-)....567
Seat Belt Circuit Diagnosis, Diesel (SN 080001-)....567
Ignition Circuit Operation, Gas (All)....935
Ignition Circuit Schematic, Gas (All)....936
Ignition Circuit Diagnosis, Gas (All)....568
Charging Circuit Operation, Gas (All)....945
Charging Circuit Schematic, Gas (All)....946
Charging Circuit Diagnosis, Gas (All)....568
Charging Circuit Operation, Diesel (All)....952
Charging Circuit Schematic, Diesel (SN -080000)....953
Charging Circuit Diagnosis, Diesel (SN -080000)....954
Charging Circuit Schematic, Diesel (SN 080001-)....957
Charging Circuit Diagnosis, Diesel (SN 080001-)....568
Fuel Pump Circuit Operation, Gas (All)....964
Fuel Pump Circuit Schematic, Gas (All)....965
Fuel Pump Circuit Diagnosis, Gas (All)....568
Fuel Shutoff Solenoid Circuit Operation, Gas (All)....971
Fuel Shutoff Solenoid Circuit Schematic, Gas (All)....972
Fuel Shutoff Solenoid Circuit Diagnosis, Gas (All)....568
Fuel Shutoff Circuit Operation, Diesel (All)....978
Fuel Shutoff Circuit Schematic, Diesel (SN -040000)....979
Fuel Shutoff Circuit Diagnosis, Diesel (SN -040000)....568
Fuel Shutoff Circuit Schematic, Diesel (SN 040001-080000)....987
Fuel Shutoff Circuit Diagnosis, Diesel (SN 040001-080000)....568
Fuel Shutoff Circuit Schematic, Diesel (SN 080001-)....991
Fuel Shutoff Circuit Diagnosis, Diesel (SN 080001-)....568
Carburetor Heater Circuit Operation, Gas (All)....997
Carburetor Heater Circuit Schematic Gas, (All)....998
Carburetor Heater Circuit Diagnosis, Gas (All)....568
Glow Plug Circuit Operation, Diesel (All)....1004
Glow Plug Circuit Schematic, Diesel (SN -040000)....1005
Glow Plug Circuit Diagnosis, Diesel (SN -040000)....568
Glow Plug Circuit Schematic, Diesel (SN 040001-080000)....1010
Glow Plug Circuit Diagnosis, Diesel (SN 040001-080000)....568
Glow Plug Circuit Schematic, Diesel (SN 080001-)....1015
Glow Plug Circuit Diagnosis, Diesel (SN 080001-)....568
4WD Clutch Circuit Operation, (All)....1022
4WD Clutch Circuit Schematic, Gas (SN 040001-), Diesel (SN 040001-080000)....1023
4WD Clutch Circuit Diagnosis, Gas (SN 040001-), Diesel (SN 040001-080000)....569
4WD Circuit Schematic, Diesel (SN 080001-)....1031
4WD Circuit Diagnosis, Diesel (SN 080001-)....569
Engine Oil Pressure Light Circuit Operation, Gas (All), Diesel (SN -080000)....1040
Hour Meter Circuit Operation, Gas (All), Diesel (SN -080000)....1041
Engine Oil Pressure Light/Hour Meter Circuit Schematic, Gas (All), Diesel (SN -080000)....1042
Engine Oil Pressure Light Diagnosis, Gas (All), Diesel (SN -080000)....569
Hour Meter Circuit Diagnosis, Gas (All), Diesel (SN -080000)....569
Engine Oil Pressure Light Circuit Operation, Diesel (SN 080001-)....1052
Hour Meter Circuit Operation, Diesel (SN 080001-)....1053
Engine Oil Pressure Light /Hour Meter Circuit Schematic, Diesel (SN 080001-)....1054
Engine Oil Pressure Light Diagnosis, Diesel (SN 080001-)....569
Hour Meter Circuit Diagnosis, Diesel (SN 080001-)....569
Cooling Fan and Temperature Light Circuit Operation, Gas (All), Diesel (SN -080000)....1061
Cooling Fan and Temperature Light Circuit Schematic, Gas (All), Diesel (SN -080000)....1062
Cooling Fan and Temperature Light Circuit Diagnosis, Gas (All), and Diesel (SN -080000)....569
Cooling Fan and Temperature Light Circuit, Diesel (SN 080001-)....1074
Cooling Fan and Temperature Light Circuit Schematic, Diesel (SN 080001-)....1075
Cooling Fan and Temperature Light Circuit Diagnosis, Diesel (SN 080001-)....569
Headlight Circuit Operation Gas, (All), Diesel (SN -080000)....1084
Headlight Circuit Schematic, Gas (All) Diesel (SN -080000)....1085
Headlight Circuit Diagnosis, Gas (All), Diesel (SN -080000)....569
Headlight Circuit Operation, Diesel (SN 080001-)....1092
Headlight Circuit Schematic, Diesel (SN 080001-)....1093
Headlight Circuit Diagnosis, Diesel (SN 080001-)....569
Park Brake Circuit Operation, Gas (All), Diesel (SN -080000)....1102
Park Brake Circuit Schematic, Gas (All), Diesel (SN -080000)....1103
Park Brake Circuit Diagnosis, Gas (All), Diesel (SN -080000)....569
Park Brake Circuit Operation, Diesel (SN 080001-)....1110
Park Brake Circuit Schematic, Diesel (SN 080001-)....1111
Park Brake Circuit Diagnosis, Diesel (SN 080001-)....569
Accessory Power Port Circuit Operation, Gas (All), Diesel (SN -080000)....1116
Accessory Power Port Circuit Schematic, Gas (All), Diesel (SN -080000)....1117
Accessory Power Port Circuit Diagnosis Gas (All), Diesel (SN -080000)....570
Accessory Power Port Circuit Operation, Diesel (SN 080001-)....1123
Accessory Power Port Circuit Schematic, Diesel (SN 080001-)....1124
Accessory Power Port Circuit Diagnosis, Diesel (SN 080001-)....1126
Vehicle Control Unit/Relay Module (VCU) Operation (SN 080001-)....1127
Group 60: Tests and Adjustments....570
Summary of References....1967
Ground Circuit Tests....1130
Battery Voltage and Specific Gravity Tests....1131
Battery Charge....1133
Battery Load Test....1135
Clean Battery....1136
Unregulated Voltage Test (Gas Engine)....1137
Stator Resistance Test (Gas Engine)....1139
Alternator Regulated Output Test....1141
Alternator Unregulated Amperage Test....1143
Starting Motor Solenoid Test....1145
Starting Motor Loaded Amperage Draw Test....1147
Starting Motor No-Load Amperage and RPM Tests....1149
Key Switch Test....1151
Headlight Switch Test (2 Position)....1152
Headlight Switch Test (2 Position) (AM144577)....1154
Light Switch Test (3 Position)....1156
Light Switch Test (3 Position) (AM144304)....1158
4WD Switch Test....1160
4WD Switch Test (AM142314)....1161
Turn Signal Lights Switch Test....1163
Hazard Lights Switch Test....1164
Neutral Start Switch Test....1166
Park Brake Switch Test....1168
Fuse Test....1170
Diode Test....1171
Relay Test....1173
Section 60: Power Train....1544
Group 10: Specifications....1951
Specifications....1951
Group 20: Component Location....295
Summary of References....1967
Power Train Components (SN -040000)....1552
Power Train Components (SN 040001-)....1553
Transaxle Control Components....1554
Drive Clutch Components....1555
Driven Clutch....1557
Shift Linkage Components (SN -090000)....1558
Shift Linkage Components (SN 090001-)....1560
Differential Lock Linkage Components....1562
Transaxle Input Components....1563
Transaxle Gear Components....1565
Differential Components....1567
Rear Axle Components....1569
Front Drive Gear Box Components....1570
MFWD Shift Linkage Components....1572
MFWD Driveline Components....1574
MFWD Front Differential Components....1575
EMFWD Front Differential Components....1577
Group 30: Theory of Operation....1544
Summary of References....1967
Power Transfer Operation....1581
Drive Clutch Operation....1589
Clutch Operation....1589
EMFWD Operation....1591
Group 40: Diagnostics....326
Diagnostic Check Points:....1544
Group 50: Tests and Adjustments....1544
Summary of References....1967
Transaxle Shift Adjustments....1603
Differential Lock Adjustments....1606
MFWD Linkage Adjustment....1608
EMFWD Ring and Pinion Backlash Adjustment....1610
Drive to Secondary (Driven) Clutch Adjustment....1611
Checking Drive Belt....1615
Group 60: Repair....1545
Summary of References....1967
Changing MFWD Differential Oil (SN -040000)....1618
Changing EMFWD Differential Oil (SN 040001-)....1619
Changing Transaxle Oil....1620
Removing and Installing Clutch Enclosure Cover—Trail HPX 4x4....1622
Primary Drive Clutch Removal....1625
Primary Drive Clutch Repair....1626
Cleaning Primary Drive Clutch....1629
Driven Clutch Removal and Installation....1632
Driven Clutch Disassembly and Assembly....1634
Transaxle Removal and Installation....1638
Transaxle Disassembly....1643
Transaxle Assembly....1664
Front Drive Gearbox Disassembly and Assembly....1674
MFWD Driveshaft Removal and Installation (SN -040000)....1688
MFWD Driveshaft Removal and Installation (SN 040001-)....1692
Hub Removal....1694
Hub Installation....1696
Front Axle Driveshaft Removal and Installation....1698
Front Differential Removal and Installation (SN -040000)....1701
Front Differential Disassembly (SN -040000)....1705
Front Differential Assembly (SN -040000)....1716
Front Differential Removal and Installation (SN 040001-)....1724
Front Differential Disassembly (SN 040001-)....1727
Front Differential Assembly (SN 040001-)....1737
CV Joint (Front or Rear Axle Drive Shafts) Disassembly and Assembly....1743
Section 70: Steering....1746
Group 10: Specifications....1951
Specifications....1951
Group 20: Component Location....295
Summary of References....1967
Steering System (SN -090000)....1751
Steering System (SN 090001-)....1753
Group 30: Theory of Operation....1746
Steering System Operation....1756
Group 40: Diagnostics....326
System Diagnosis....1773
Group 50: Tests and Adjustments....1746
Summary of References....1967
Toe-Out Adjustment....1791
Group 60: Repair....1746
Summary of References....1967
Steering Wheel Removal and Installation....1968
Tie Rod End Removal and Installation....1797
Steering Rack Removal and Installation....1799
Steering Shaft Removal and Installation....1803
Front Strut/Shock Removal and Installation....1805
Front Wheel Bearing Removal and Installation....1810
Ball Joint Removal and Installation....1816
Front A-Arm Removal and Installation....1820
A-Arm Bushing Removal and Installation....1822
Section 80: Brakes....1823
Group 10: Specifications....1951
Specifications....1951
Group 20: Component Location (SN -040000)....1823
Summary of References....1967
Brake System (SN -040000)....1830
Brake System Components, Front (SN -040000)....1831
Brake System Components, Rear (SN -040000)....1833
Park Brake System (SN -040000)....1834
Two Wheel Drive Park Brake Components (SN -040000)....1835
MFWD Park Brake Components (SN -040000)....1837
Group 25: Component Location (SN 040001-)....1823
Summary of References....1967
Brake System (SN 040001-)....1841
Brake System Components, Front (SN 040001-)....1842
Brake System Components, Rear (SN 040001-)....1844
Park Brake System (SN 040001-)....1846
Group 30: Component Location (SN 090001-)....1823
Summary of References....1967
Brake System (SN 090001-)....1850
Brake System Components (SN 090001-)....1851
Park Brake System (SN 090001-)....1853
Group 35: Theory of Operation....1823
Brake System....1856
Group 40: Diagnostics....326
Brake Pedal....1823
Hydraulic Brakes Checks....1823
Brakes Will Not Engage or Show Poor Response....1823
Brake Effort Excessive....1823
Wheel Brakes Will Not Release....1823
Brake Noisy or Chattering....1823
Excessive Brake Pad Wear....1823
Brake Pedal Travel Excessive....1824
Brakes Pull Left or Right....1824
Pedal Feels Hard With Little Travel....1824
Park Brake Will Not Engage or Hold....1824
Park Brake Will Not Release (SN -040000)....1824
Park Brake Will Not Release (SN 040001-)....1824
Group 45: Tests and Adjustments (SN -040000)....1824
Summary of References....1967
Check Brake Fluid Level (SN -040000)....1886
Master Cylinder Rod Adjustment (SN -040000)....1887
Bleeding Brakes (SN -040000)....1888
Bleeding Master Cylinder (SN -040000)....1890
Two-Wheel Drive Park Brake Adjustment (SN -040000)....1892
MFWD Park Brake Adjustment (SN -040000)....1894
MFWD Park Brake Return Spring Adjustment (SN -040000)....1896
Group 50: Tests and Adjustments (SN 040001-)....1824
Summary of References....1967
Check Brake Fluid Level (SN 040001-)....1899
Master Cylinder Rod Adjustment (SN 040001-)....1900
Bleeding Brakes (SN 040001-)....1901
Bleeding Master Cylinder (SN 040001-)....1903
Burnish Brakes (SN 040001-)....1905
Park Brake Adjustment (SN 040001-)....1906
Group 55: Repair....1824
Summary of References....1967
Brake Pad Replacement....1913
Master Cylinder Removal and Installation....1916
Brake Line Removal and Replacement....1919
Brake Caliper Removal and Installation....1925
MFWD Park Brake Pad Replacement (SN -040000)....1929
MFWD Park Brake Rotor Removal and Installation (SN -040000)....1932
Brake Pedal Removal and Installation....1937
MFWD Park Brake Cable Removal and Installation (SN -040000)....1939
Park Brake Cable Removal and Installation (SN 040001-)....1941
Park Brake Lever Removal and Installation (SN -090000)....1943
Park Brake Lever Removal and Installation (SN 090001-)....1945
Section 90: Miscellaneous....1947
Group 10: Specifications....1951
Specifications....1951
Group 20: Component Location....295
Summary of References....1967
Seat and Seat Support Components (SN -090000)....1955
Seat and Seat Support Components (SN 090001-)....1957
Fuel System Components—Gas....1958
Fuel System Components—Diesel....1961
Coolant System Components—Gas....1964
Coolant System Components—Diesel....1965
Group 30: Repair....1947
Summary of References....1967
Wheel Removal and Installation....1968
Hood Latch Removal and Installation....1969
Hood Removal and Installation....1971
Front Grille Removal and Installation....1973
Front Fender Removal and Installation....1974
Rear Fender Removal and Installation....1977
Dash Panel Removal and Installation....1978
Headlight Removal and Installation....1982
Remove and Install Center Console (SN -090000)....1984
Remove and Install Center Console (SN 090001-)....1985
Remove and Install Transaxle Control Lever Housing (SN -090000)....1986
Remove and Install Transaxle Control Lever Housing (SN 090001-)....1989
Seat Removal and Installation....1991
Seat Base Cover Removal and Installation....1993
Seat Adjuster Removal and Installation....1998
Fuel Tank Removal and Installation....2000
Cargo Box Removal and Installation....2002
Rear Shock Absorber Removal and Installation....2004
Front Bumper/Skid Plate Removal and Installation....2006
Battery Removal and Installation....2008
Radiator Drain Procedure — Gas....2009
Radiator Drain Procedure — Diesel....2013
Radiator Removal and Installation....2017
Cooling Fan Removal and Installation....2020
Radiator Fill and Bleed Procedure — Gas....2021
Radiator Fill and Bleed Procedure — Diesel....2023
Adjust Doors and Door Catch/Locking Bolts....2025
Evaporative Emissions System Operation (SN -130000)....2027
John Deere HPX 4X2, HPX 4X4 (Gas and Diesel) Repair Service Manual (TM2195)
