Complete Repair Service Technical Manual for John Deere 8R BM Tractors 8245R, 8270R, 8295R, 8320R, 8335R, 8345R, 8370R & 8400R (S.N.: 090001-119999, Russia 055001-058000, Brazil 000100-), with workshop information to maintain, repair, and rebuild like professional mechanics.

John Deere 8245R, 8270R, 8295R, 8320R, 8335R, 8345R, 8370R, 8400R Tractors workshop technical manual (repair) 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.
* 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.

tm119119 - 8R Tractors (S. N. 090001—119999) & (Russia S. N. 055001—058000)(Brazil S. N. 000100—) Repair Technical Manual.pdf
tm119119 - 8R Tractors (S. N. 090001—119999) & (Russia S. N. 055001—058000)(Brazil S. N. 000100—) Repair Technical Manual.epub

Total Pages: 2,968 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   Dealer Predelivery Information Form
   General Information
      Safety
      General References
   Engine
      Component Removal and Installation
      Engine Repair
   Fuel, Air Intake, Exhaust, and Cooling
      Diesel Fuel System
      Air Intake System
      Auxiliary Drive System
      Radiator and Coolers
      Exhaust System
   Electrical
      Connectors
      Charging Circuit
      Starting Circuit
      Relays, Fuses, Solenoids, and Switches
      Monitoring System
      CommandARM™
      Implement and Accessory Connectors
      Convenience and Accessory
   Infinitely Variable Transmission (IVT™)
      Component Removal and Installation
      In Tractor Repair
      Transmission Repair
      Assemble Transmission
   e23™ Transmission (e23™)
      Component Removal and Installation
      In Tractor Repair
      Transmission Repair
      Assemble Transmission
   16-Speed PowerShift Transmission (PST)
      Component Removal and Installation
      In Tractor Repair
      Transmission Repair
      Assemble Transmission
   Drive Train
      Component Removal and Installation
      Hydraulic Pump Drive
      Rear Differential and Input Quill
      Rear Final Drives
      Rear PTO
      Front PTO
   1300 Series MFWD
      Component Removal And Installation
      Final Drives
      Axle Housing
      Differential
      Input Gear Train
      Oscillation
   1500 Series MFWD
      Component Removal And Installation
      Final Drives
      Axle Housing
      Differential
      Input Gear Train
      Oscillation
   Independent Link Suspension (ILS™)
      Component Removal And Installation
      Final Drives
      Drive Shafts
      Differential
      Suspension Components
      Steering
      Front Brakes
   Brakes
      Service Brakes
      Hydraulic Trailer Brakes
      Air Trailer Brakes
   Steering
      Steering Column
      Steering Valves
      Steering Cylinders
   Hydraulics
      Component Removal and Installation
      Hydraulic System
      Integrated Hydraulic Pump
      Hitch Valve, Selective Control Valves, and Couplers
      Rear Hitch
      Front Hitch
   Miscellaneous
      Hood and Side Panels
      Wagon and Pick-Up Hitch
   Cab and Open Operator’s Station
      Component Removal and Installation
      Heating, Ventilating, and Air Conditioning (HVAC)
      ComfortCommand™ Seat
      ComfortCommand™ Seat with HCS Plus
      ActiveSeat™
      Cab Door and Windshield
      Cab Suspension
   Dealer Tools
      Dealer Fabricated Tools

tm119119 - 8R Tractors Repair(S. N. 090001—119999)(Russia S. N. 055001—058000)(Brazil S. N. 000100—)

Table of Contents

Foreword

Dealer Predelivery Information Form

Section 10: General Information

Group 05A: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Prevent Machine Runaway

Avoid Backover Accidents

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Handling Batteries Safely

Handle Agricultural Chemicals Safely

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Clean Vehicle of Hazardous Pesticides

Service Machines Safely

Stay Clear of Rotating Drivelines

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Wait Before Opening High-Pressure Fuel System

Service Accumulator Systems Safely

Protect Against High Pressure Spray

Service Cooling System Safely

Avoid High-Pressure Fluids

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Handle Starting Fluid Safely

In Case of Fire

Avoid Static Electricity Risk When Refueling

Avoid Hot Exhaust

Clean Exhaust Filter Safely

Prevent Acid Burns

Keep ROPS Installed Properly

Instructional Seat

Use Steps and Handholds Correctly

Service Front-Wheel Drive Tractor Safely

Transport Tractor Safely

Follow Tire Recommendations

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Construct Dealer-Made Tools Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Install All Guards

Live With Safety

Group 05B: General References

List of References

Trademarks

Sealants and Adhesives Cross-Reference Chart

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Face Seal Fittings Assembly and Installation—All Pressure Applications

Metric Face Seal And O-ring Stud End Fitting Torque Chart—Standard Pressures

Metric Face Seal and O-ring Stud End Fitting Torque Chart—High Pressure Applications

SAE Face Seal and O-ring Stud End Fitting Torque Chart—Standard Pressures

SAE Face Seal and O-ring Stud End Fitting Torque Chart—High Pressure Applications

Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications

External Hexagon Port Plug Torque Chart

Prevent Hydraulic System Contamination

Check Oil Lines and Fittings

Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems

Identify Zinc-Flake Coated Fasteners

Use Torque Wrench Adapter

Servicing and Connecting Snap to Connect STC™ Fittings

Use Special Wrench

Install Hydraulic Fittings

Glossary of Terms

Aftertreatment Indicators Overview

Changing Diesel Exhaust Fluid (DEF) Dosing Unit Filter

Cleaning Diesel Exhaust Fluid (DEF) Tank

Section 20: Engine

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 20—00

Other Material 20—00

Specifications 20—00

Remove Engine

Install Engine

Remove Front Frame

Install Front Frame

Group 05: Engine Repair

List of References

Essential, Recommended, and Fabricated Tools 20—05

Specifications 20—05

Replace Torsional Damper

Engine Repair—Use CTM

Section 30: Fuel, Air Intake, Exhaust, and Cooling

Group 05: Diesel Fuel System

List of References

Specifications 30—05

Remove and Install Fuel Tank

Replace Fuel Filter, Electric Fuel Pump, and Bleed Fuel System

Group 10: Air Intake System

List of References

Specifications 30—10

Air Intake Pipe Connections

Remove and Install Air Cleaner Pipe

Remove and Install Aspirator Pipe

Remove and Install Charge Air Cooler Pipes

Group 15: Auxiliary Drive System

List of References

Essential, Recommended, and Fabricated Tools 30—15

Specifications 30—15

Auxiliary Drive Belt Routing

Belt Tensioner Location

Inspect Belt Tensioner

Replace Idler Pulleys and Belt Tensioner

Remove and Install Vari-Cool™ Fan Belt

Replace Auxiliary Drive Pulley

Replace Auxiliary Drive Shaft Seal

Group 20: Radiator and Coolers

List of References

Essential, Recommended, and Fabricated Tools 30—20

Other Material 30—20

Specifications 30—20

Draining, Flushing, and Refilling Cooling System

Test Radiator and Deaeration Tank

Test Radiator Cap

Remove and Install Radiator

Check and Fill Vari-Cool™ Fan Sheaves

Remove and Install Vari-Cool™ Drive Assembly

Remove and Install Vari-Cool™ Fan Driven Assembly

Repair Vari-Cool™ Fan Drive Assembly

Repair Vari-Cool™ Fan Driven Assembly

Remove and Install Vari-Cool™ Control Valve

Repair Vari-Cool™ Control Valve

Remove and Install Air Conditioning Condenser

Remove and Install Fuel Cooler—Hydraulic Oil Cooler

Leak Test Hydraulic Oil Cooler

Group 25: Exhaust System

List of References

Specifications 30—25

Service Exhaust System

Replace NOx Sensor

Remove and Install DEF Tank

Replace Header Assembly

Replace DEF Dosing Unit

Replace DEF Dosing Injector

Section 40: Electrical

Group 05: Connectors

List of References

Essential, Recommended, and Fabricated Tools 40—05

Other Material 40—05

Use Electrical Insulating Compound

Using High-Pressure Washers

Installation of Repair Wire Assembly (RWA)

Repair AMP™ Connector

Repair AMPSEAL 16™ Connectors

Bosch™ Connectors

Remove Connector Body from Blade Terminals

CINCH™ Control Unit Connectors

Exploded View—CINCH™ FlexBox Connectors

CINCH™ FlexBox Connectors

Repair CPC™ Blade Type Connectors

Repair CPC™, Large Mate-N-Loc™, and Metrimate™ Pin Type Connectors

Repair DEUTSCH™ Connectors

Repair DEUTSCH™ Implement Connectors

Repair ITT Connector

Repair Small Mate-N-Loc™ Socket Connector

Repair Small Mate-N-Loc™ Pin Connector

Repair (Pull Type) Metri-Pack™ Connectors

Repair (Push Type) Metri-Pack™ Connectors

Repair Molex™ Control Unit Connectors

Repair Molex™ Connector

Repair SUMITOMO™ Connectors

Repair Tyco™ Fuel Injector Connector

Repair WEATHER PACK™ Connector

Repair YAZAKI™ Connectors

Group 10: Charging Circuit

List of References

Specifications 40—10

Repair Alternator—Use CTM

Replace Alternator

Replace Alternator and Battery Fuse

Group 15: Starting Circuit

List of References

Essential, Recommended, and Fabricated Tools 40—15

Specifications 40—15

Repair Starter—Use CTM

Remove and Install Starter Motor

Replace Starter Circuit Relay

Replace Master Fuse

Group 20: Relays, Fuses, Solenoids, and Switches

List of References

Essential, Recommended, and Fabricated Tools 40—20

Specifications 40—20

General Repair Procedures 40—20

Replace Hydraulic Backup Pump Fuse

Replace Hydraulic Backup Pump Relay

Replace Starting Aid Solenoid

Replace Sensors e23™ Transmission

Replace Solenoids e23™ Transmission

Replace Park Supply Solenoid (e23™)

Replace Park Sump Block Solenoid (e23™)

Replace MFWD Solenoid (e23™)

Replace Range Clutch R1 and R2 Solenoids (e23™)

Replace Oil Cooler Bypass Solenoid (e23™)

Replace Lube Prioritization Valve Solenoid (e23™)

Replace Sensors and Solenoids PST Transmission

Replace Electrohydraulic Shift Valve Solenoids (PST)

Replace Park Brake Release Solenoid (PST)

Replace MFWD Solenoid (PST)

Replace Sensors IVT™ Transmission

Replace Solenoids IVT™ Transmission

Replace Clutch Enable Solenoid (IVT™)

Replace MFWD Solenoid (IVT™)

Replace Park Supply Solenoid

Replace Park Sump Block Solenoid (IVT™)

Replace Hydro Clutch Unit Solenoid (IVT™)

Replace Ring Unit Hydro Control Solenoid (IVT™)

Replace Loop Flush Cut Off Solenoid (IVT™)

Replace PTO Solenoid

Replace Differential Lock Solenoid

Replace Engine Oil Pressure Switch

Replace Differential Lock Switch

Replace Cab Door Light Switch

Replace Starting Aid Switch

Replace Ignition Switch

Replace Key Immobilizer

Replace Seat Raise-Lower Switch

Replace Seat Firmness Switch—ActiveSeat™

Replace Heated Seat Switch

Replace Operator Presence Seat Switch

Replace Hydraulic Oil Filter Restriction Switch

Replace Ethernet Switch

Replace Battery Disconnect Switch

Replace External Hitch Raise-Lower Switches

Replace Air Conditioning Dual Pressure Sensor

Replace Air Conditioning Temperature Sensor

Replace Air Conditioning Motor Speed Control

Group 25: Monitoring System

List of References

Essential, Recommended, and Fabricated Tools 40—25

Specifications 40—25

Other Material 40—25

General Information 40—25

Disconnect Electrical Circuit

Control Units Identification

Replace Control Units

Replace Navigation Bar

Replace Engine Coolant Temperature Sensor

Replace Engine Coolant Level Sensor

Replace Engine Coolant Loss Sensor

Replace Engine Crank Speed Sensor

Replace Fuel Level Sensor

Replace Foot Throttle Sensor

Replace Wheel Angle Sensor

Replace Wheel Angle Sensor—ILS™

Replace Steering Column Module

Replace Steering Input Device

Replace Primary Transmission Speed Sensor

Replace Secondary Transmission Speed Sensor

Replace PTO Speed Sensor

Replace Radar Sensor

Replace Hydraulic Charge Pump Pressure Sensor

Replace Hydraulic Oil Temperature Sensor

Replace INDEPENDENT LINK SUSPENSION™ Cylinder Position Sensor

Replace Hitch Position Sensor

Replace Draft Sensing Sensor

Adjust Draft Sensing Sensor

Replace Gyroscope Sensor

Replace CommandCenter™ Processor

Group 30: CommandARM™

List of References

Specifications 40—30

Armrest Test Procedures

Remove and Install CommandARM™ Assembly

Replace Armrest Interface Control Unit (AIC)

Replace Throttle Control Module

Replace Transmission Lever Control Module

Replace SCV Control Lever Module

Replace Rear Hitch Control Lever and SCV I Control Lever Module

Replace Hitch Controls Module

Replace Rear PTO Switch

Replace Front PTO Switch

Replace Secondary Brake Switch

Replace Cab Controls Module

Replace SCV Lock Module

Replace Joystick Module

Group 35: Implement and Accessory Connectors

List of References

Specifications 40—35

Replace Seven-Terminal Outlet Socket

Replace GreenStar™ Terminal Connector

Replace Auxiliary Power Strip

Replace Three-Pin Accessory Outlet

Replace Three-Pin Accessory Outlet—Storage Box

Replace and Adjust Field Lights

Group 40: Convenience and Accessory

List of References

Specifications 40—40

Replace Wiper Motor

Replace Windshield Washer Pumps

Replace Circulation Blower Motor

Replace HVAC Pressurizer Blower Motor

Replace Air Flow Mode Motor

Remove Radio and Speakers

Replace Refrigerator

Replace Refrigerator Tray

Replace Refrigerator Top Cover

Replace Refrigerator Door

Replace Refrigerator Thermostat

Replace Refrigerator Module

Section 50A: Infinitely Variable Transmission (IVT™)

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 50A—00

Other Material 50A—00

Specifications 50A—00

Remove Transmission—IVT™

Install Transmission—IVT™

Remove and Install Scavenge Pump—IVT™

Group 05: In Tractor Repair

List of References

Essential, Recommended, and Fabricated Tools 50A—05

Other Material 50A—05

Specifications 50A—05

Replace Input Shaft Front Seal—IVT™

Replace Auxiliary Drive Shaft Seal—IVT™

Synchronizer/Shift Assembly Repair—In Chassis—IVT™

Service Hydrostatic Jumper Tubes—IVT™

Group 10: Transmission Repair

List of References

Essential, Recommended, and Fabricated Tools 50A—10

Other Material 50A—10

Specifications 50A—10

General Repair Procedures 50A—10

Hydrostatic Module Replacement—IVT™

Install Transmission Onto Repair Stand—IVT™

Disassemble Transmission—IVT™

Exploded View—Valve Manifold—IVT™

Repair Valve Manifold—IVT™

Repair Synchronizer—IVT™

Cross Sectional View—C1-C2 Shift Assembly—IVT™

Repair C1-C2 Shift Assembly—IVT™

Repair Accumulator—IVT™

Exploded View—Hydrostatic Module Assembly—IVT™

Multi-Function Valves—IVT™

Test Multi-Function Valves—IVT™

Hydrostatic Module Loop Flush Valve—IVT™

Repair Hydrostatic Module Assembly—IVT™

Exploded View—Reverse Brake—IVT™

Repair Reverse Brake Housing—IVT™

Cross Sectional View—High-Low Clutch Assembly—IVT™

Repair High-Low Clutch Assembly—IVT™

Cross Sectional View—Planetary Input Assembly—IVT™

Repair Planetary Input—IVT™

Exploded View—Planetary Assembly—IVT™

Repair Planetary Assembly—IVT™

Cross Sectional View—Park Brake—IVT™

Repair Park Brake—IVT™

Cross Sectional View—MFWD/ILS™ Clutch—IVT™

Repair MFWD/ILS™ Clutch—IVT™

Repair Output Housing-to-MFWD—IVT™

Repair Output Housing-to-ILS™—IVT™

Repair Scavenge Pump—IVT™

Group 15: Assemble Transmission

List of References

Essential, Recommended, and Dealer Fabricated Tools 50A—15

Other Material 50A—15

Specifications 50A—15

Install Bearing Cups—IVT™

Install CU Idler—IVT™

Install Planetary Input Gears—IVT™

Install Synchronizer—IVT™

Install PTO Drive Gear—IVT™

Install Front Cover—IVT™

Install Output-to-MFWD Housing—IVT™

Install Planetary Ring Gear and RU Idler—IVT™

Install Hydrostatic Assembly—IVT™

Install Planetary Assembly—IVT™

Install Reverse Brake and High-Low Clutch Assembly—IVT™

Install Transmission Output Shaft—IVT™

Install Rear Cover—IVT™

Install Manifold—IVT™

Install Scavenge Pump—IVT™

Adjust Bearings—IVT™

Install Auxiliary Drive Shaft—IVT™

Clutch Element Leak Check—IVT™

Section 50B: e23™ Transmission (e23™)

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 50B—00

Other Material 50B—00

Specifications 50B—00

Remove Transmission—e23™

Install Transmission—e23™

Group 05: In Tractor Repair

List of References

Essential, Recommended, and Fabricated Tools 50B—05

Other Material 50B—05

Specifications 50B—05

Replace Auxiliary Drive Shaft Seal—e23™

Replace Input Shaft Front Seal—e23™

Replace Rear PTO Drive Shaft Seal—e23™

Replace Output Shaft Seal—e23™

Group 10: Transmission Repair

List of References

Essential, Recommended, and Fabricated Tools 50B—10

Other Material 50B—10

Specifications 50B—10

General Repair Procedures 50B—10

Install Transmission Onto Repair Stand—e23™

Disassemble Transmission—e23™

Repair Upper Manifold Valves—e23™

Repair Lower Manifold Valves—e23™

Cleaning Procedures—Manifold, Rear Cover, and Valves—e23™

Repair Auxiliary Drive—e23™

Repair Park Brake—e23™

Cross-Sectional View—MFWD Clutch Assembly (Without ILS™)—e23™

Cross-Sectional View—MFWD Clutch Assembly (With ILS™)—e23™

Disassemble and Assemble MFWD Clutch—e23™

Repair Rear Cover—e23™

Repair Scavenge Pump—e23™

Clutch Backing Plate Orientation—e23™

Cross Sectional View—9 Disk Cast Clutch Pack—e23™

Repair 9 Disk Cast Clutch Pack—e23™

Cross Sectional View—12 Disk Clutch Pack—e23™

Repair 12 Disk Clutch Pack—e23™

6 Disk Clutch Pack Identification—e23™

Cross Sectional View—6 Disk Clutch Pack—e23™

Repair 6 Disk Clutch Pack—e23™

Cross Sectional View—Output Shaft Assembly—e23™

Repair Output Shaft Assembly—e23™

Cross Sectional View—B Countershaft Assembly—e23™

Repair B Countershaft Assembly—e23™

Cross Sectional View—C Countershaft Assembly—e23™

Repair C Countershaft Assembly—e23™

Cross Sectional View—Input Shaft Assembly—e23™

Repair Input Shaft Assembly—e23™

Exploded View—Rear PTO Drive Shaft Assembly—e23™

Repair Rear PTO Shaft Assembly—e23™

Exploded View—Front PTO Drive Shaft Assembly—e23™

Repair Front PTO Shaft Assembly—e23™

Inspect Clutch Disks—e23™

Group 15: Assemble Transmission

List of References

Essential, Recommended, and Fabricated Tools 50B—15

Other Material 50B—15

Specifications 50B—15

Install Transmission Shaft Assemblies—e23™

Install Rear Cover—e23™

Install Auxiliary Drive—e23™

Remove and Install Upper Manifold—e23™

Remove and Install Lower Manifold—e23™

Section 50C: 16-Speed PowerShift Transmission (PST)

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 50C—00

Other Material 50C—00

Specifications 50C—00

Remove Transmission—PST

Install Transmission—PST

Remove Scavenge Pump—PST

Install Scavenge Pump—PST

Remove MFWD Clutch—PST

Install MFWD Clutch—PST

Group 05: In Tractor Repair

List of References

Essential, Recommended, and Fabricated Tools 50C—05

Other Material 50C—05

Specifications 50C—05

General Repair Procedures 50C—05

Cross-Sectional View—MFWD Clutch Assembly (Without ILS™)—PST

Cross-Sectional View—MFWD Clutch Assembly (With ILS™)—PST

Disassemble MFWD Clutch—PST

Assemble MFWD Clutch—PST

Replace Input Shaft Front Seal—PST

Replace Auxiliary Drive Pulley—PST

Replace Transmission Input Shaft Rear Seal—PST

Group 10: Transmission Repair

List of References

Essential, Recommended, and Fabricated Tools 50C—10

Specifications 50C—10

General Repair Procedures 50C—10

Clutch Cover Plate Orientation—PST

Install Transmission Onto Repair Stand—PST

Cross-Sectional View—Transmission Assembly (MFWD without ILS™)—PST

Disassemble Transmission—PST

Exploded View—Valve Manifold—PST

Manifold and Valves—PST

Cleaning Procedures—Manifold, Rear Cover, and Valves—PST

Remove and Install Electrohydraulic Valves—PST

Inspect and Clean Electrohydraulic Valve—PST

Disassemble and Assemble Manifold—PST

Disassemble and Assemble Transmission Rear Cover—PST

Cross-Sectional View—Transmission Input Shaft—PST

Disassemble Input Shaft—PST

Assemble Input Shaft Gear/Clutch Assemblies—PST

Assemble Input Shaft—PST

Cross-Sectional View—Transmission Countershaft—PST

Disassemble Countershaft—PST

Assemble Countershaft Gear/Clutch Assemblies—PST

Assemble Countershaft—PST

Cross-Sectional View—Transmission Output Shaft Assembly—PST

Service Output Shaft Check Valves—PST

Disassemble Output Shaft Assembly—PST

Disassemble, Inspect, and Assemble Planetary Carrier—PST

Inspect Clutch Disks—PST

Assemble Output Shaft Assembly—PST

Group 15: Assemble Transmission

List of References

Essential, Recommended, and Fabricated Tools 50C—15

Other Material 50C—15

Specifications 50C—15

Install Output Shaft Assembly—PST

Install Reverse Idler Gear—PST

Install Rear Cover—PST

Install Park Brake Assembly—PST

Install Manifold—PST

Adjust Bearings—PST

Install MFWD Clutch Assembly—PST

Install Auxiliary Drive Shaft Seals—PST

Remove Transmission From Repair Stand—PST

Section 50D: Drive Train

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 50D—00

Other Material 50D—00

Specifications 50D—00

General Repair Procedures 50D—00

Remove Pump Drive Housing

Install Pump Drive Housing

Remove Final Drive

Install Final Drive

Remove Differential Case

Install Differential Case

Remove Front PTO

Install Front PTO

Prelubricate Front PTO

Cross-Sectional View—Mid-Frame Drive Shafts

Remove and Install Mid-Frame Auxiliary Drive Shaft

Remove and Install Mid-Frame Output Drive Shaft

Group 05: Hydraulic Pump Drive

List of References

Essential, Recommended, and Fabricated Tools 50D—05

Specifications 50D—05

General Repair Procedures 50D—05

Repair Hydraulic Pump Drive

Cross-Sectional View—Pump Drive Gear Train

Disassemble and Assemble Hydraulic Pump Hypoid Pinion Drive Shaft

Disassemble Hypoid Input Gear Quill Assembly

Assemble Hypoid Input Gear Quill Assembly

Disassemble High Flow Hypoid Input Gear Quill Assembly

Assemble High Flow Hypoid Input Gear Quill Assembly

Set Cone Point—Hypoid Pinion Drive Shaft

Set Cone Point—Hypoid Pinion Drive Gear

Verify Gear Set Backlash

Adjust Hypoid Pinion Drive Shaft End Play

Group 10: Rear Differential and Input Quill

List of References

Essential, Recommended, and Fabricated Tools 50D—10

Other Material 50D—10

Specifications 50D—10

General Repair Procedures 50D—10

Remove Differential

Cross-Sectional View—Rear Differential

Disassemble, Inspect, and Assemble Differential

Remove Input Quill Assembly

Cross-Sectional View—Input Quill

Disassemble, Inspect, and Assemble Input Quill

Determine Differential Drive Shaft Cone Point Shim Pack

Assemble and Install Differential Drive Shaft

Install Input Quill Assembly

Install Differential

Side Quill Adjustment Information

Measure End Play and Adjust Differential Preload

Adjust Differential Backlash

Remove and Install Brake Piston

Remove and Install Brake Piston—With Retractors

Group 15: Rear Final Drives

List of References

Essential, Recommended, and Fabricated Tools 50D—15

Specifications 50D—15

General Repair Procedures 50D—15

Cross-Sectional View—Final Drive

Disassemble Final Drive

Disassemble, Inspect, and Assemble Planet Pinion Carrier

Remove Axle Housing

Disassemble and Assemble Axle Housing

Disassemble, Inspect, and Assemble Axle Shaft

Install Axle Housing

Adjust Axle Bearings

Group 20: Rear PTO

List of References

Essential, Recommended and Fabricated Tools 50D—20

Other Material 50D—20

Specifications 50D—20

General Repair Procedures 50D—20

Remove and Install PTO Output Housing

Cross-Sectional View—PTO Clutch Assembly

Remove PTO Clutch

Disassemble and Assemble PTO Clutch

Install PTO Clutch

Remove, Inspect, and Install PTO Clutch Valve

Cross-Sectional View—Standard PTO Output Assembly

Disassemble and Assemble Standard PTO Output Housing

Cross-Sectional View—Optional PTO Output Assembly

Disassemble Optional PTO Output Housing Assembly

Assemble Optional PTO Output Housing Assembly

Disassemble Optional ECO PTO Output Housing Assembly

Assemble Optional ECO PTO Output Housing Assembly

Remove 540/1000 PTO Adapter Assembly

Disassemble and Assemble 540/1000 PTO Adapter Assembly

Install 540/1000 PTO Adapter Assembly

Group 25: Front PTO

List of References

Essential, Recommended, and Fabricated Tools 50D—25

Other Material 50D—25

Specifications 50D—25

Remove Front PTO Pump

Install Front PTO Pump

Disassemble and Assemble Front PTO Gearcase Housing

Disassemble, Inspect, and Assemble Front PTO Clutch

Remove and Install Front PTO Input Shaft

Remove and Install Front PTO Output Shaft

Remove and Install Modulating Valve

Replace Front PTO Drive Shaft Seals

Disassemble, Inspect, and Assemble Front PTO Drive

Section 50E: 1300 Series MFWD

Group 00: Component Removal And Installation

List of References

Essential, Recommended, and Fabricated Tools 50E—00

Specifications 50E—00

Remove MFWD Axle—1300 Series

Install MFWD Axle—1300 Series

Remove and Install Final Drive Assembly—1300 Series

Group 05: Final Drives

List of References

Essential, Recommended, and Fabricated Tools 50E—05

Other Material 50E—05

Specifications 50E—05

General Repair Procedures 50E—05

Cross-Sectional View—Planetary Carrier and Wheel Hub—1300 Series

Remove and Disassemble Planetary Carrier and Wheel Hub—1300 Series

Assemble and Install Planetary Carrier and Wheel Hub—1300 Series

Cross-Sectional View—Knuckle Spindle Assembly—1300 Series

Disassemble, Inspect, and Assemble Knuckle Spindle Assembly—1300 Series

Replace Kingpin Bearings and Seals—1300 Series

Determine Kingpin Shim Pack—1300 Series

Group 10: Axle Housing

List of References

Essential, Recommended, and Fabricated Tools 50E—10

Specifications 50E—10

Install and Remove MFWD Axle To Rollover Stand—1300 Series

Remove Right-Hand Axle Housing—1300 Series

Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack—1300 Series

Measure Backlash—1300 Series

Adjust Backlash—1300 Series

Backlash Shim Pack Example and Worksheet—1300 Series

Install Left-Hand Axle Housing Bearing Cup and Shim Pack—1300 Series

Disassemble Right-Hand Axle Housing and Determine Shim Pack—1300 Series

Preload Shim Pack Example and Worksheet—1300 Series

Install Right-Hand Axle Housing—1300 Series

Group 15: Differential

List of References

Essential, Recommended, and Fabricated Tools 50E—15

Specifications 50E—15

Remove Differential—1300 Series

Cross-Sectional View—Differential Housing—1300 Series

Repair Differential—1300 Series

Assemble Differential—1300 Series

Group 20: Input Gear Train

List of References

Essential, Recommended, and Fabricated Tools 50E—20

Other Material 50E—20

Specifications 50E—20

Cross-Sectional View—Input Gear Train—1300 Series

Disassemble Input Gear Train—1300 Series

Determine Pinion Shaft Cone Point Shim Pack—1300 Series

Assemble Input Gear Train—1300 Series

Adjust Pinion Shaft—1300 Series

Group 25: Oscillation

List of References

Essential, Recommended, and Fabricated Tools 50E—25

Specifications 50E—25

Cross-Sectional View—Oscillating Supports—1300 Series

Repair Front Support—1300 Series

Repair Rear Support—1300 Series

Section 50F: 1500 Series MFWD

Group 00: Component Removal And Installation

List of References

Essential, Recommended, and Fabricated Tools 50F—00

Specifications 50F—00

Remove and Install MFWD Axle—1500 Series

Remove and Install Final Drive Assembly—1500 Series

Group 05: Final Drives

List of References

Essential, Recommended, and Fabricated Tools 50F—05

Other Material 50F—05

Specifications 50F—05

Cross-Sectional View—Planetary Carrier and Wheel Hub—1500 Series

Remove and Disassemble Planetary Carrier and Wheel Hub—1500 Series

Assemble and Install Planetary Carrier and Wheel Hub—1500 Series

Cross-Sectional View—Knuckle Spindle Assembly—1500 Series

Disassemble, Inspect, and Assemble Knuckle Spindle Assembly—1500 Series

Replace Kingpin Bearings and Seals—1500 Series

Determine Kingpin Shim Pack—1500 Series

Group 10: Axle Housing

List of References

Essential, Recommended, and Fabricated Tools 50F—10

Specifications 50F—10

Other Material 50F—10

Install and Remove MFWD Axle To Rollover Stand—1500 Series

Remove Left-Hand Axle Housing—1500 Series

Disassemble Right-Hand Axle Housing and Determine Bearing Cup Shim Pack—1500 Series

Measure Backlash—1500 Series

Adjust Backlash—1500 Series

Backlash Shim Pack Example and Worksheet—1500 Series

Install Right-Hand Axle Housing Bearing Cup and Shim Pack—1500 Series

Disassemble and Assemble Left-Hand Axle Housing—1500 Series

Determine Preload Shim Pack—1500 Series

Install Left-Hand Axle Housing—1500 Series

Group 15: Differential

List of References

Essential, Recommended, and Fabricated Tools 50F—15

Specifications 50F—15

Remove Differential—1500 Series

Disassemble, Inspect, and Assemble Differential Housing Assembly—1500 Series

Group 20: Input Gear Train

List of References

Essential, Recommended, and Fabricated Tools 50F—20

Other Material 50F—20

Specifications 50F—20

Cross-Sectional View—Input Gear Train—1500 Series

Disassemble Input Gear Train—1500 Series

Determine Pinion Shaft Cone Point Shim Pack—1500 Series

Assemble Input Gear Train—1500 Series

Adjust Pinion Shaft—1500 Series

Group 25: Oscillation

List of References

Essential, Recommended, and Fabricated Tools 50F—25

Specifications 50F—25

Cross-Sectional View—Oscillating Supports—1500 Series

Repair Front Support—1500 Series

Repair Rear Support—1500 Series

Repair Tie Rod—1500 Series

Section 50G: Independent Link Suspension (ILS™)

Group 00: Component Removal And Installation

List of References

Essential, Recommended, and Fabricated Tools 50G—00

Specifications 50G—00

Remove Differential Case—ILS™

Install Differential Case—ILS™

Group 05: Final Drives

List of References

Essential, Recommended, and Fabricated Tools 50G—05

Other Material 50G—05

Specifications 50G—05

Cross-Sectional View—Planetary Carrier and Wheel Hub—ILS™

Remove and Disassemble Planetary Carrier and Wheel Hub—ILS™

Assemble and Install Planetary Carrier and Wheel Hub—ILS™

Group 10: Drive Shafts

List of References

Essential, Recommended, and Fabricated Tools 50G—10

Other Material 50G—10

Specifications 50G—10

Cross-Sectional View—Final Drive Assembly—ILS™

Disassemble, Inspect, and Assemble Knuckle Housing Assembly—ILS™

Remove Drive Shaft—ILS™

Inspect, Disassemble, and Assemble Drive Shaft—ILS™

Cross-Sectional View—Differential Output—ILS™

Repair Output Yoke/Shaft and Outer Housing Cover—ILS™

Group 15: Differential

List of References

Essential, Recommended, and Fabricated Tools 50G—15

Other Material 50G—15

Specifications 50G—15

Cross-Sectional View—MFWD Input Gears—ILS™

Repair or Replace Clutch Drive Gear—ILS™

Repair or Replace Input Pinion Gear—ILS™

Remove and Disassemble Differential Drive Shaft—ILS™

Determine Differential Drive Shaft Cone Point Shim Pack—ILS™

Assemble and Install Differential Drive Shaft—ILS™

Adjust Differential Drive Shaft—ILS™

Remove Differential Housing Assembly—ILS™

Cross-Sectional View—Differential with Hydraulic Differential Lock—ILS™

Disassemble, Inspect, and Assemble Differential Housing Assembly—ILS™

Adjust Differential Housing Bearing Preload—ILS™

Adjust Differential Backlash—ILS™

Install Differential Housing Assembly—ILS™

Group 20: Suspension Components

List of References

Essential, Recommended, and Fabricated Tools 50G—20

Other Material 50G—20

Specifications 50G—20

Relieve System Pressure—ILS™

Remove Valve Housing—ILS™

Install Valve Housing—ILS™

Repair Valve Housing—ILS™

Repair Valve Housing With FPTO—ILS™

Remove and Install Accumulators—ILS™

Check and Charge Accumulators—ILS™

Remove and Install Suspension Cylinder—ILS™

Replace Self-Aligning Bushing—ILS™

Replace Cylinder Assembly Pivot Pins—ILS™

Cross-Sectional View—Suspension Cylinder—ILS™

Disassemble and Assemble Suspension Cylinder—ILS™

Cross-Sectional View—Suspension Cylinder Seals—ILS™

Replace Suspension Cylinder Seals—ILS™

Cross-Sectional View—Upper Control Arm Pivot—ILS™

Remove and Disassemble Upper Control Arm Pivot—ILS™

Assemble and Install Upper Control Arm Pivot—ILS™

Cross-Sectional View—Upper Control Arm Ball Joint

Replace Upper Control Arm Ball Joint—ILS™

Cross-Sectional View—Lower Control Arm Front Pivot—ILS™

Repair Lower Control Arm Front Pivot—ILS™

Cross-Sectional View—Lower Control Arm Rear Pivot—ILS™

Repair Lower Control Arm Rear Pivot—ILS™

Cross-Sectional View—Lower Control Arm Ball Joint—ILS™

Replace Lower Control Arm Ball Joint—ILS™

Group 25: Steering

List of References

Essential, Recommended, and Fabricated Tools 50G—25

Specifications 50G—25

Steering Tie Rod—ILS™

Exploded View—Steering Tie Rod—ILS™

Remove and Disassemble Outer Tie Rod End Assembly—ILS™

Assemble and Install Outer Tie Rod End Assembly—ILS™

Cross-Sectional View—Inner Tie Rod Assembly—ILS™

Remove, Disassemble, Assemble, and Install Inner Tie Rod End Assembly—ILS™

Cross-Sectional View—Steering Cylinder—ILS™

Remove Steering Cylinder Assembly—ILS™

Replace Sealing Rings—ILS™

Install Steering Cylinder Assembly—ILS™

Cross-Sectional View—Steering Rod—ILS™

Remove Steering Rod—ILS™

Replace Steering Rod and Rod Guide Seals—ILS™

Install Steering Rod—ILS™

Group 30: Front Brakes

List of References

Essential, Recommended, and Fabricated Tools 50G—30

Specifications 50G—30

General Repair Procedures 50G—30

Cross-Sectional View—Differential with Brakes—ILS™

Repair Front Brakes—ILS™

Section 60A: Brakes

Group 05: Service Brakes

List of References

Essential, Recommended, and Fabricated Tools 60A—05

Specifications 60A—05

General Repair Procedures 60A—05

Remove and Install Brake Rods

Remove and Install Brake Valve

Repair Brake Valve

Remove and Install Secondary Brake Valve

Repair Secondary Brake Valve

Repair Front Brake Solenoid Valves

Bleed Brakes

Check Brakes

Manually Release Park Brake (IVT™)

Manually Release Park Brake (PST)

Manually Release Park Brake (e23™)

Group 10: Hydraulic Trailer Brakes

List of References

Specifications 60A—10

Hydraulic Trailer Brake System

Remove and Install Hydraulic Trailer Brake Valve

Group 15: Air Trailer Brakes

List of References

Specifications 60A—15

Bleed Air from Air Trailer Brake Reservoir

Air Trailer Brake System

Remove and Install Air Compressor

Repair Air Compressor

Remove and Install Air Trailer Brake Pre-Brake/Secondary Brake Valve

Repair Air Trailer Brake Pre-Brake/Secondary Brake Valve

Remove and Install Air Trailer Brake Park Valve

Remove and Install Air Trailer Brake Control Valve

Remove and Install Air Trailer Brake Dryer Assembly

Remove and Install Banjo Fittings

Repair Banjo Fittings

Remove and Install Air Trailer Brake Pressure Regulating Valve

Replace Air Trailer Brake Dryer Filter

Replace Air Trailer Brake Breather

Remove and Install Air Trailer Brake Purge Tank

Remove and Install Air Trailer Brake Purge Tank Charging Valve

Repair Air Trailer Brake Purge Tank Charging Valve

Section 60B: Steering

Group 05: Steering Column

List of References

Specifications 60B—05

Remove and Install Control Support

Repair Steering Column

Repair Steering Column with ActiveCommand Steering (ACS™)

Group 10: Steering Valves

List of References

Specifications 60B—10

General Repair Procedures 60B—10

Remove and Install Steering Valve

Remove and Install AutoTrac™ Valve

Repair AutoTrac™ Valve

Remove and Install ActiveCommand Steering (ACS™) Valve

Repair ActiveCommand Steering (ACS™) Valve

Remove and Install Load Sense Relief Valve

Repair Load Sense Relief Valve

Repair Park Pump Off Manifold

Repair Priority Valve Steering Assembly

Remove and Install Backup Pump

Bleed Steering System

Group 15: Steering Cylinders

List of References

Specifications 60B—15

Remove and Install Steering Cylinder—1300 Series MFWD

Remove and Install Steering Cylinder—1500 Series MFWD

Repair Steering Cylinder

Section 70: Hydraulics

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 70—00

Specifications 70—00

Remove and Install Transmission Pump

Remove and Install Integrated Hydraulic Pump

Remove and Install Hitch-SCV Valve Stack

Remove and Install Hitch Frame

Remove and Install Auxiliary Hydraulic Pump

Group 05: Hydraulic System

List of References

Essential, Recommended, and Fabricated Tools 70—05

Specifications 70—05

General Repair Procedures 70—05

Install Hydraulic Fittings 70—05

Drain Hydraulic System

Fill Hydraulic System

Prelubricate Pump Drive

Group 10: Integrated Hydraulic Pump

List of References

Specifications 70—10

Other Material 70—10

Remove and Install Hydraulic Compensator Valve

Repair Hydraulic Compensator Valve

Disassemble, Repair, and Assemble Integrated Hydraulic Pump

Group 15: Hitch Valve, Selective Control Valves, and Couplers

List of References

Essential, Recommended, and Fabricated Tools 70—15

Specifications 70—15

Disassemble and Assemble Hitch-SCV Valve Stack

Service Pressure Compensator

Service Pressure Compensating Check Valve

Service Solenoid Pilot Valve

Service Spool Centering Spring Assembly

Service Electronic Control Unit

Test Surge Relief Valve

Service Surge Relief Valve

Service Shuttle Valve

Remove and Install Coupler Housing

Repair Couplers

Remove and Install Motor Return

Remove and Install Motor Return with Power Beyond

Group 20: Rear Hitch

List of References

Essential, Recommended, and Fabricated Tools 70—20

Other Material 70—20

Specifications 70—20

Remove and Install Rear Hitch Lift Cylinders

Disassemble, Inspect, and Assemble Lift Cylinder

Replace Rockshaft Bushings

Repair Draft Sensing

Group 25: Front Hitch

List of References

Essential, Recommended, and Fabricated Tools 70—25

Specifications 70—25

Remove and Install Front 3-Point Hitch

Exploded View—Front Hitch

Remove and Install Front Hitch Valve

Repair Front Hitch Lift Cylinder

Section 80: Miscellaneous

Group 05: Hood and Side Panels

List of References

Essential, Recommended, and Fabricated Tools 80—05

Specifications 80—05

Position Hood Forward

Optional Forward Hood Position

Remove and Install Hood

Remove and Install Grille and Headlight Assembly

Remove and Install Hood Side Panels

Remove and Install Hood Screens

Remove and Install Hood Latch

Group 10: Wagon and Pick-Up Hitch

List of References

Specifications 80—10

Repair Wagon Hitch

Adjust Wagon Hitch Release

Repair Pick-Up Hitch

Adjust Pick-Up Hitch

Section 90: Cab and Open Operator’s Station

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 90—00

Other Material 90—00

Specifications 90—00

Remove Cab

Install Cab

Repair Cab

Remove Inner Roof

Install Inner Roof

Remove and Install Left Hand Armrest

Group 05: Heating, Ventilating, and Air Conditioning (HVAC)

List of References

Essential, Recommended, and Fabricated Tools 90—05

Other Material 90—05

Specifications 90—05

Repair Air Conditioning System—Use CTM

Hose and Tubing O-ring Connection Torques

Discharge Air Conditioning System

Flushing, Purging, and Evacuating Information

Purge Air Conditioning System

Evacuate Air Conditioning System

Charge Air Conditioning System

Refrigerant Oil Information

Check Compressor Oil Charge

Determine Correct Refrigerant Oil Charge

Add Refrigerant Oil to System

Add Refrigerant Oil to Pressurized System

Remove and Install Compressor

Replace Receiver-Dryer

Remove and Install Compressor Relief Valve

Remove and Install Expansion Valve

Remove HVAC Module

Install HVAC Module

Remove and Install Heater Control Valve

Group 10: ComfortCommand™ Seat

List of References

Essential, Recommended, and Fabricated Tools 90—10

Other Material 90—10

Specifications 90—10

Remove and Install Seat—ComfortCommand™

Repair Seat Air System—ComfortCommand™

Repair Seat Suspension—ComfortCommand™

Repair Seat Back—ComfortCommand™

Repair Seat Control Knobs—ComfortCommand™

Group 15: ComfortCommand™ Seat with HCS Plus

List of References

Specifications 90—15

Remove and Install Seat—ComfortCommand™ with HCS Plus

Remove and Install Seat Top—ComfortCommand™ with HCS Plus

Repair Seat Back—ComfortCommand™ with HCS Plus

Repair and Install Seat Control Knobs—ComfortCommand™ with HCS Plus

Group 20: ActiveSeat™

List of References

Essential, Recommended, and Fabricated Tools 90—20

Other Material 90—20

Specifications 90—20

Purging Air from ActiveSeat™ System

Remove and Install ActiveSeat™

Remove and Install ActiveSeat™ Actuator

Remove and Install ActiveSeat™ Actuator Hoses

Remove and Install ActiveSeat™ Control Valve Assembly

ActiveSeat™ Hydraulic Control Valve Block

Remove and Install ActiveSeat™ Accumulator

Checking and Charging Replacement Accumulators—ActiveSeat™

Repair ActiveSeat™ Air System

Repair ActiveSeat™ Suspension

Repair ActiveSeat™ Back

Repair ActiveSeat™ Control Knobs

Group 25: Cab Door and Windshield

List of References

Specifications 90—25

Repair Cab Door Latch

Cab Door Adjustment—Step 1

Cab Door Adjustment—Step 2

Cab Door Adjustment—Step 3

Cab Door Adjustment—Step 4

Preparing Windshield Glass or Side Window For Replacement

Group 30: Cab Suspension

List of References

Specifications 90—30

Depressurize Cab Suspension System

Remove and Install Cab Leveling Control Valve

Repair Cab Leveling Valve

Remove and Install Sensor Ball Joint Rod

Adjust Sensor Rod

Remove and Install Position Sensor

Remove and Install Accumulators

Charging Accumulators

Remove and Install Hydraulic Cylinders

Remove and Install Panhard Rod

Bleeding Suspended Cab System

Section 300: Dealer Tools

Group 05: Dealer Fabricated Tools

List of References

Fabricated Tools

DF1057—Axle Adjusting Tool

DFRW4—Axle Wheel Hub Tool

DFRW30A—Axle Jacking Tool

DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses

DFRW89—Transmission Shaft and Clutch Holding Fixture

DFRW90—Transmission Support Plate

DFRW91—Guide Pins

DFRW94—Rear Axle Support Stand

DFRW95—MFWD Clutch Plate Compressor

DFRW96—Rear Axle Lifting Tool

DFRW97—Transmission Countershaft Rotation Screw

DFRW98—Rear Axle Guide Pin

DFRW99—540/1000 PTO Adapter Assembly Bearing Installer

DFRW106—Front Axle Rear Pivot Pin Tool

DFRW107—Front Axle Front Pivot Pin Tool

DFRW117—Transmission-Hydraulic Flusher

DFRW132—Differential Side Bevel Gear End Play Tool

DFRW148—ActiveSeat™ Control Valve Holding Tool

DFRW150—SCV-Hitch Valve Stack Lifting Bracket

DFRW210—Hole Drilled in JT07201

DFRW211—Transmission Support Plate

DFRW212 Leak Test Assembly

DFRW213—Hydraulic Trailer Brake Test / Bleed Assembly

DFRW219—Wheel Tightening Stand

DFRW220—Clutch Cover Removal Plate

DFRW230—Seal Installer

DFRW231—Guide Pins

DFRW234—Hood Support Rod

DFRW238—Front PTO Support Bracket

DFRW248—Front PTO Output Shaft Holding Tool

DFRW252—Ring Gear Retaining Tool

DFRW262—Wheel Adjustment Tool

John Deere Tractors 8245R, 8270R, 8295R, 8320R, 8335R, 8345R, 8370R, 8400R Repair Service Manual (TM119119)